Washable, carbonized, droplet-free fabric

Abstract

The present invention belongs to the technical field of blended fabrics, and particularly relates to a wash-resistant carbonized film-free fabric. The blended fibers of the fabric of the present invention include polyesteramide fiber, cotton fiber and polyester fiber, the content of polyesteramide fiber is 54.2-62.5% by weight, the polyesteramide fiber is obtained by copolymerizing terephthalic acid, dodecanediol and caprolactam, the ratio of the number of ester bonds to the number of amide bonds in the polyesteramide fiber is (10.2-15.5):1, the final fabric has the characteristics of no droplets in the carbonized film and less scattering of fly ash, and the carbonized film-free function is efficiently maintained even after multiple washings.

Description

[Technical Field]

[0001] The present invention belongs to the technical field of blended fabrics, and in particular to a wash-resistant carbonized film-free fabric. [Background technology]

[0002] After fabrics are burned, they can be divided into droplet and non-droplet fabrics according to the different forms of combustion products. As we know, polyester fibers form droplets after burning, while natural fibers are carbonized after burning and do not form droplets. Many countries around the world are researching, developing, and producing droplet-free fabrics. For example, Japan uses acrylic fibers to produce droplet-free fabrics, and Europe and China also use vinylon to achieve the droplet-free effect.

[0003] In the case of droplet-like fabrics, droplet-like combustion products adhere firmly to the skin, causing serious secondary damage and being extremely dangerous. Therefore, droplet-free fabrics are used in industries and situations such as firefighting of flammable and explosive materials such as petroleum, chemical, and dust, high-temperature work, and emergency training.

[0004] Furthermore, the same droplet-free fabric can be further divided into fly ash droplet-free fabric and carbonized film droplet-free fabric. In the case of fly ash droplet-free fabric, burnt ash scatters into the air, and in dangerous situations such as explosions or fires, although there is no secondary damage from molten drips, the skin will be directly exposed to the high-temperature flame environment.

[0005] Carbonized film-free fabric has a comparatively superior feature: it can be carbonized to form a film, which prevents secondary damage caused by molten droplets in dangerous situations such as explosions and fires, and also has the effect of partially blocking thermal damage to the environment. Summary of the Invention [Problem to be solved by the invention]

[0006] However, conventional research and development of non-melting fabrics has focused mainly on the fabric's ability to burn and melt, and there has been no attention or progress in the field of non-melting carbonized fabrics. Some carbonized fabrics can only withstand one or two washes, after which they lose their carbonized film-forming properties after burning.

[0007] A Chinese patent with publication number CN107177979A and publication date of September 19, 2017, discloses a droplet-free flame-retardant polyester fiber / fabric and a method for producing the same, characterized in that the outer surface of the flame-retardant polyester fiber / fabric is impregnated with an adhesive solution containing a flame retardant and a crosslinking agent, and the flame retardant and crosslinking agent are grafted onto the fabric by electron beam irradiation to form a surface layer material. The fabric is then steamed, soaped, rinsed and dried to obtain the droplet-free flame-retardant polyester fiber / fabric with a weight gain of 5 to 35%.

[0008] However, the droplet-free flame-retardant polyester fiber / fabric in this invention patent uses a large amount of flame retardant to achieve sufficient droplet-free flame-retardant effect, so the fabric feels very uncomfortable when worn next to the skin.

[0009] More importantly, its droplet-free effect is indeed fly ash-free, but it is still very dangerous because the skin is directly exposed after the fabric burns.

[0010] In summary, there is an urgent need for new types of fabrics that have long-lasting, effective, and non-carbonized film formation and non-carbonized film formation properties that do not significantly deteriorate after at least multiple washings. [Means for solving the problem]

[0011] The object of the present invention is to provide a wash-resistant carbonized film-free droplet-free fabric, the blended fibers of which include polyesteramide fiber, cotton fiber, and polyester fiber, the polyesteramide fiber content being 54.2 to 62.5% by weight, the polyesteramide fiber being obtained by copolymerizing terephthalic acid, dodecanediol, and caprolactam, and the ratio of the number of ester bonds to the number of amide bonds in the polyesteramide fiber being (10.2 to 15.5):1, the final fabric having the characteristics of having no droplets in the carbonized film and being less likely to scatter fly ash, and the carbonized film-free droplet function is efficiently maintained even after multiple washings.

[0012] The technical solution adopted by the present invention to solve the above-mentioned problems is a washable, carbonized, droplet-free fabric, the composition of which includes polyesteramide fiber, cotton fiber, and polyester fiber, the polyesteramide fiber content being 54.2-62.5% by weight, the polyesteramide fiber being obtained by copolymerizing terephthalic acid, dodecanediol, and caprolactam, and the ratio of the number of ester bonds to the number of amide bonds in the polyesteramide fiber being (10.2-15.5):1.

[0013] In the present invention, polyester fiber, i.e., polyester, inherently has the advantage of being washable, while cotton fiber is a natural fiber and inherently has the advantage of being droplet-free. By quantitatively introducing polyesteramide fiber of a specific composition, the applicant has achieved the following two objectives:

[0014] First, it improves the normal droplet-free effect to a carbonized film droplet-free effect, so that in dangerous situations such as explosions or fires, secondary damage caused by molten droplets is not caused, and it also has the effect of partially blocking heat damage to the environment, i.e., fly ash is less likely to scatter.

[0015] Secondly, not only is the carbonized film droplet-free, but even after at least 50 water washes, the carbonized film droplet-free function is still efficiently maintained without significant deterioration.

[0016] In a more preferred technical solution, the content of polyesteramide fiber is 56.6% by weight, and the ratio of the number of ester bonds to amide bonds in the polyesteramide fiber is 14.6:1.

[0017] In the present invention, the applicant has woven a fabric using the above-mentioned specific polyesteramide fiber with a content of 56.6% by weight and a ratio of 14.6:1, and has found that the fabric has the advantage of being comprehensively optimal in terms of two indicators: droplet-free carbonized film formation performance and the extent of decline in droplet-free carbonized film formation performance after multiple washings. That is, in the initial stage of wearing the fabric, the post-burning film formation rate is high and the fly ash scattering rate is less than 2%. After 50 washings, the post-burning fly ash scattering rate of the fabric is still less than 3%, that is, the carbonized film-free function is effective for a long period of time.

[0018] In a more preferred technical solution, when the content of polyesteramide fiber is 54.2-56.6 wt% (excluding 56.6 wt%), the ratio of the number of ester bonds to amide bonds in the polyesteramide fiber is (10.2-14.6):1 (excluding 14.6:1), and when the content of polyesteramide fiber is 56.6-62.5 wt%, the ratio of the number of ester bonds to amide bonds in the polyesteramide fiber is (14.6-15.5):1.

[0019] In the present invention, the applicant discovered that when the content of polyesteramide fiber is 54.2 to 56.6 wt % (excluding 56.6 wt %), increasing the ratio of ester bonds to amide bonds in the polyesteramide fiber significantly reduces the droplet-free effect of the carbonized film after multiple washings, and therefore defined the maximum ratio of ester bonds to amide bonds as 14.6:1.

[0020] On the other hand, when the polyesteramide fiber content is 56.6 to 62.5 wt %, by appropriately increasing the ratio of ester bonds to amide bonds, the carbon film formation rate of the initial fabric can be significantly improved, provided that the carbon film formation-free performance and washability are slightly reduced. In particular, the group with a polyesteramide fiber content of 56.6 wt % and an ester bond to amide bond ratio of 14.6:1 has the highest carbon film formation rate. Therefore, in the present invention, improving the carbon film formation rate is given higher priority than extending the effective period of the carbon film formation-free performance.

[0021] In a more preferred technical solution, the polyesteramide fiber has a length of 38 mm and a linear density of 1.33-1.56 dtex. In a more preferred technical solution, the polyesteramide fiber has a breaking elongation of 43-49% and a standard moisture regain of 0.6-0.7%.

[0022] In a more preferred technical solution, the polyesteramide fiber has a melting point of 245-248°C, a melt crystallization temperature of 170-190°C, and a limiting oxygen index LOI of 21.6-22.5%.

[0023] In the present invention, since cotton fiber itself has the basic effect of being droplet-free, and polyesteramide fiber is also required to have at least a relatively basic droplet-free effect, the length and linear density of polyesteramide fiber are defined as above, and ultimately, it is guaranteed that polyesteramide fiber has excellent performance in terms of limit oxygen index (LOI) of 21.6 to 22.5%, which not only does not interfere with the droplet-free effect of cotton fiber, but also further improves the droplet-free effect to a droplet-free carbonized film, and ensures that there is no large amount of fly ash after the fabric is burned.

[0024] In a more preferred technical solution, the fabric is produced by interweaving warp and weft yarns, the weft yarns being made of polyesteramide fibers, cotton fibers, and polyester fibers, and the warp yarns being made of polyesteramide fibers and polyester fibers.

[0025] In a more preferred technical solution, the warp density of the fabric is 390-520 threads / 10cm, and the weft density is 200-280 threads / 10cm.

[0026] In a more preferred technical solution, the initial fly ash scattering rate of the fabric after combustion is less than 2%, and the fly ash scattering rate of the fabric after 50 washes is less than 3%.

[0027] In a more preferred technical solution, the limiting oxygen index of the fabric according to GB / T5455-1997 standard is 22-26%, and there are no droplets during combustion.

[0028] In the present invention, the area of ​​fly ash scattering after the fabric is burned is less than 3% of the total area, so a large amount of fly ash is not generated. [Effects of the Invention]

[0029] The present invention has the following advantages:

[0030] First, the droplet-free effect after burning the fabric is the carbonized film droplet-free effect, and the carbonized film prevents ash from scattering and can still cover the skin and block some of the heat.

[0031] Second, the carbonized film droplet-free performance of the fabric before washing is very good, and even after the fabric has been washed 50 times, the carbonized film droplet-free performance is still relatively good, indicating that the carbonized film droplet-free performance can be effective for a long time.

[0032] Thirdly, the weave of the warp and weft of the fabric is simple and convenient, making it highly useful in the fields of fire fighting and high-temperature work. [Brief explanation of the drawings]

[0033] [Figure 1] 1 is a schematic diagram showing the morphology of a carbonized film formed after combustion of a droplet-free substrate according to the present invention. FIG. [Figure 2] 1 is a schematic diagram showing the morphology of fly ash after combustion of a droplet-free material according to the prior art; FIG. [Figure 3]1 is a schematic diagram showing the morphology of a droplet material after combustion according to the prior art; [Figure 4] 1 is a table showing performance test results of fabrics in examples of the present invention and comparative examples. DETAILED DESCRIPTION OF THE INVENTION

[0034] The following description is merely a preferred embodiment of the present invention and is not intended to limit the scope of the present invention.

[0035] Example 1

[0036] The washable, carbonized, droplet-free fabric contains polyesteramide fiber, cotton fiber, and polyester fiber, with a polyesteramide fiber content of 56.6% by weight. The polyesteramide fiber is obtained by copolymerizing terephthalic acid, dodecanediol, and caprolactam, and the ratio of the number of ester bonds to the number of amide bonds in the polyesteramide fiber is 14.6:1.

[0037] The polyesteramide fiber has a length of 38 mm and a linear density of 1.56 dtex. The elongation at break of the polyesteramide fiber is 44% and the official moisture regain is 0.7%. The polyesteramide fiber has a melting point of 246°C, a melt crystallization temperature of 172°C, and a limiting oxygen index (LOI) of 21.8%.

[0038] The fabric is made by interweaving warp and weft threads, with polyesteramide fiber, cotton fiber, and polyester fiber used for the weft threads, and polyesteramide fiber and polyester fiber used for the warp threads. The warp density of the fabric is 512 threads / 10cm, and the weft density is 275 threads / 10cm.

[0039] Finally, the fabric of this example was tested for the initial fly ash scattering rate (%), the fly ash scattering rate (%) after 50 washes, the limiting oxygen index (%), and the state of combustion droplets. The final test results are shown in Figure 4.

[0040] Example 2

[0041] The washable, carbonized, droplet-free fabric contains polyesteramide fiber, cotton fiber, and polyester fiber, with a polyesteramide fiber content of 54.2% by weight. The polyesteramide fiber is obtained by copolymerizing terephthalic acid, dodecanediol, and caprolactam, and the ratio of the number of ester bonds to the number of amide bonds in the polyesteramide fiber is 10.2:1.

[0042] The polyesteramide fiber has a length of 38 mm and a linear density of 1.56 dtex. The elongation at break of the polyesteramide fiber is 43% and the official moisture regain is 0.6%. The polyesteramide fiber has a melting point of 247°C, a melt crystallization temperature of 171°C, and a limiting oxygen index (LOI) of 21.9%.

[0043] The fabric is made by interweaving warp and weft threads, with polyesteramide fiber, cotton fiber, and polyester fiber used for the weft threads, and polyesteramide fiber and polyester fiber used for the warp threads. The warp density of the fabric is 504 threads / 10cm, and the weft density is 237 threads / 10cm.

[0044] Finally, the fabric of this example was tested for the initial fly ash scattering rate (%), the fly ash scattering rate (%) after 50 washes, the limiting oxygen index (%), and the state of combustion droplets. The final test results are shown in Figure 4.

[0045] Example 3

[0046] The washable, carbonized, droplet-free fabric contains polyesteramide fiber, cotton fiber, and polyester fiber, with a polyesteramide fiber content of 62.5% by weight. The polyesteramide fiber is obtained by copolymerizing terephthalic acid, dodecanediol, and caprolactam, and the ratio of the number of ester bonds to the number of amide bonds in the polyesteramide fiber is 15.5:1.

[0047] The polyesteramide fiber has a length of 38 mm and a linear density of 1.56 dtex. The elongation at break of the polyesteramide fiber is 47% and the official moisture regain is 0.7%. The polyesteramide fiber has a melting point of 248°C, a melt crystallization temperature of 185°C, and a limiting oxygen index (LOI) of 22.2%.

[0048] The fabric is made by interweaving warp and weft threads, with polyesteramide fiber, cotton fiber, and polyester fiber used for the weft threads, and polyesteramide fiber and polyester fiber used for the warp threads. The warp density of the fabric is 394 threads / 10cm, and the weft density is 208 threads / 10cm.

[0049] Finally, the fabric of this example was tested for the initial fly ash scattering rate (%), the fly ash scattering rate (%) after 50 washes, the limiting oxygen index (%), and the state of combustion droplets. The final test results are shown in Figure 4.

[0050] Example 4

[0051] The washable, carbonized, droplet-free fabric contains polyesteramide fiber, cotton fiber, and polyester fiber, with a polyesteramide fiber content of 55.9% by weight. The polyesteramide fiber is obtained by copolymerizing terephthalic acid, dodecanediol, and caprolactam, and the ratio of the number of ester bonds to the number of amide bonds in the polyesteramide fiber is 12.5:1.

[0052] The polyesteramide fiber has a length of 38 mm and a linear density of 1.56 dtex. The elongation at break of the polyesteramide fiber is 49% and the official moisture regain is 0.7%. The polyesteramide fiber has a melting point of 248°C, a melt crystallization temperature of 188°C, and a limiting oxygen index (LOI) of 22.0%.

[0053] The fabric is made by interweaving warp and weft threads, with polyesteramide fiber, cotton fiber, and polyester fiber used for the weft threads, and polyesteramide fiber and polyester fiber used for the warp threads. The warp density of the fabric is 475 threads / 10cm, and the weft density is 236 threads / 10cm.

[0054] Finally, the fabric of this example was tested for the initial fly ash scattering rate (%), the fly ash scattering rate (%) after 50 washes, the limiting oxygen index (%), and the state of combustion droplets. The final test results are shown in Figure 4.

[0055] Example 5

[0056] The washable, carbonized, droplet-free fabric contains polyesteramide fiber, cotton fiber, and polyester fiber, with a polyesteramide fiber content of 58.2% by weight. The polyesteramide fiber is obtained by copolymerizing terephthalic acid, dodecanediol, and caprolactam, and the ratio of the number of ester bonds to the number of amide bonds in the polyesteramide fiber is 14.7:1.

[0057] The polyesteramide fiber has a length of 38 mm and a linear density of 1.33 dtex. The elongation at break of the polyesteramide fiber is 45% and the official moisture regain is 0.7%. The polyesteramide fiber has a melting point of 248°C, a melt crystallization temperature of 188°C, and a limiting oxygen index (LOI) of 22.3%.

[0058] The fabric is made by interweaving warp and weft threads, with polyesteramide fiber, cotton fiber, and polyester fiber used for the weft threads, and polyesteramide fiber and polyester fiber used for the warp threads. The warp density of the fabric is 475 threads / 10cm, and the weft density is 236 threads / 10cm.

[0059] Finally, the fabric of this example was tested for the initial fly ash scattering rate (%), the fly ash scattering rate (%) after 50 washes, the limiting oxygen index (%), and the state of combustion droplets. The final test results are shown in Figure 4.

[0060] Comparative Example 1

[0061] The washable, carbonized, droplet-free fabric comprises polyesteramide fiber, cotton fiber, and polyester fiber, with a polyesteramide fiber content of 53.0% by weight. The polyesteramide fiber is obtained by copolymerizing terephthalic acid, dodecanediol, and caprolactam, and the ratio of the number of ester bonds to the number of amide bonds in the polyesteramide fiber is 9.8:1.

[0062] The polyesteramide fiber has a length of 38 mm and a linear density of 1.56 dtex. The elongation at break of the polyesteramide fiber is 47% and the official moisture regain is 0.7%. The polyesteramide fiber has a melting point of 246°C, a melt crystallization temperature of 182°C, and a limiting oxygen index (LOI) of 22.0%.

[0063] The fabric is made by interweaving warp and weft threads, with polyesteramide fiber, cotton fiber, and polyester fiber used for the weft threads, and polyesteramide fiber and polyester fiber used for the warp threads. The warp density of the fabric is 512 threads / 10cm, and the weft density is 275 threads / 10cm.

[0064] Finally, the fabric of this example was tested for the initial fly ash scattering rate (%), the fly ash scattering rate (%) after 50 washes, the limiting oxygen index (%), and the state of combustion droplets. The final test results are shown in Figure 4.

[0065] Comparative Example 2

[0066] The washable, carbonized, droplet-free fabric contains polyesteramide fiber, cotton fiber, and polyester fiber, with a polyesteramide fiber content of 54.9% by weight. The polyesteramide fiber is obtained by copolymerizing terephthalic acid, dodecanediol, and caprolactam, and the ratio of the number of ester bonds to the number of amide bonds in the polyesteramide fiber is 18.0:1.

[0067] The polyesteramide fiber has a length of 38 mm and a linear density of 1.56 dtex. The elongation at break of the polyesteramide fiber is 48% and the official moisture regain is 0.7%. The polyesteramide fiber has a melting point of 245°C, a melt crystallization temperature of 185°C, and a limiting oxygen index (LOI) of 21.7%.

[0068] The fabric is made by interweaving warp and weft threads, with polyesteramide fiber, cotton fiber, and polyester fiber used for the weft threads, and polyesteramide fiber and polyester fiber used for the warp threads. The warp density of the fabric is 504 threads / 10cm, and the weft density is 237 threads / 10cm.

[0069] Finally, the fabric of this example was tested for the initial fly ash scattering rate (%), the fly ash scattering rate (%) after 50 washes, the limiting oxygen index (%), and the state of combustion droplets. The final test results are shown in Figure 4.

[0070] Comparative Example 3

[0071] The washable, carbonized, droplet-free fabric contains polyesteramide fiber, cotton fiber, and polyester fiber, with a polyesteramide fiber content of 65.1% by weight. The polyesteramide fiber is obtained by copolymerizing terephthalic acid, dodecanediol, and caprolactam, and the ratio of the number of ester bonds to the number of amide bonds in the polyesteramide fiber is 13.4:1.

[0072] The polyesteramide fiber has a length of 38 mm and a linear density of 1.56 dtex. The elongation at break of the polyesteramide fiber is 48% and the official moisture regain is 0.6%. The polyesteramide fiber has a melting point of 248°C, a melt crystallization temperature of 186°C, and a limiting oxygen index (LOI) of 21.9%.

[0073] The fabric is made by interweaving warp and weft threads, with polyesteramide fiber, cotton fiber, and polyester fiber used for the weft threads, and polyesteramide fiber and polyester fiber used for the warp threads. The warp density of the fabric is 394 threads / 10cm, and the weft density is 208 threads / 10cm.

[0074] Finally, the fabric of this example was tested for the initial fly ash scattering rate (%), the fly ash scattering rate (%) after 50 washes, the limiting oxygen index (%), and the state of combustion droplets. The final test results are shown in Figure 4.

[0075] In the combustion test, all fabrics were divided into two, one half was used for the initial combustion test, and the other half was washed and dried 50 times before being used for the combustion test.

[0076] Combining the above five examples, three comparative examples, and four drawings, the following conclusions can be drawn.

[0077] First, of the three comparative examples, in one comparative example, the ratio of ester bonds to amide bonds in the polyesteramide fiber was too low, in the second comparative example, the ratio of ester bonds to amide bonds in the polyesteramide fiber was too high, and in the last comparative example, the content of polyesteramide fiber was too high, which ultimately resulted in an excessively high combustion ash scattering rate for the initial fabric, i.e., the droplet-free performance of the carbonized film did not meet the standard.

[0078] Second, after 50 washes, the carbonized film droplet-free performance of the fabric deteriorates and cannot be improved.

[0079] Third, the fabrics in the five examples meet the standards for both the initial carbonized film no-droplet performance and the carbonized film no-droplet performance after 50 washes, that is, the fly ash scattering rate is 3% or less.

[0080] Fourth, the blended fabrics made of polyesteramide fiber, cotton fiber, and polyester fiber all have the basic effect of being droplet-free.

[0081] Although the embodiments of the present invention have been described in detail above with reference to the accompanying drawings, the present invention is not limited to the above embodiments, and various modifications may be made within the scope of the knowledge of those skilled in the art without departing from the spirit of the present invention. These modifications are all non-inventive and are protected by the Patent Law as long as they fall within the scope of the claims.

Claims

[Claim 1] A washable carbonized film-free fabric containing polyester amide fibers, cotton fibers, and polyester fibers, The content of the polyesteramide fiber is 56.6% by weight, and the ratio of the number of ester bonds to the number of amide bonds in the polyesteramide fiber is 14.6:1; or The content of the polyesteramide fiber is 54.2% by weight, and the ratio of the number of ester bonds to the number of amide bonds in the polyesteramide fiber is 10.2:1; or The content of the polyesteramide fiber is 62.5% by weight, and the ratio of the number of ester bonds to the number of amide bonds in the polyesteramide fiber is 15.5:1; or The content of the polyesteramide fiber is 55.9% by weight, and the ratio of the number of ester bonds to the number of amide bonds in the polyesteramide fiber is 12.5:1; or A wash-resistant, carbonized, droplet-free fabric, characterized in that the content of the polyesteramide fiber is 58.2% by weight, and the ratio of the number of ester bonds to the number of amide bonds in the polyesteramide fiber is 14.7:1.

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