Woven fabric and fiber product

Abstract

The present invention addresses the problem of providing a woven fabric and a fiber product which are extremely excellent in heat resistance, flame resistance, stretchability, and dynamic physical properties, and which have favorable appearance quality. The solution is a woven fabric obtained by using a flame-retardant yarn containing flame-retardant fibers and using a composite yarn containing flame-retardant fibers and composite fibers obtained by bonding two components in a side-by-side manner or an eccentric core-sheath manner. The flame-retardant yarn is disposed on either one of the warp and the weft of the woven fabric, and a yarn A comprising the composite yarn and a yarn B comprising the flame-retardant yarn are arranged on the other of the warp and the weft. In the yarn A, the weight ratio of the composite fibers is 20-60 wt% of the yarn weight, and the yarn B is a twisted yarn in which two or more of the flame-retardant yarns are twisted together and the twist coefficient is 440 or less. In the woven fabric, the basis weight is 190 g / m2 or more. The woven fabric has an elongation percentage of 14% or more and a tensile strength of 300N or more in at least one of a warp direction and a weft direction, and the woven fabric satisfies flame retardancy as defined by ISO 15025-B.

Description

Textiles and Fiber Products

[0001] The present invention relates to woven fabrics and textile products that are extremely excellent in heat resistance, flame resistance, stretchability and mechanical properties, and also have good appearance quality.

[0002] Flame-retardant fabrics are used in work clothes worn by people engaged in work that may expose them to flames, such as firefighters, electric power companies, and chemical companies. These flame-retardant fabrics are primarily made of flame-retardant fibers such as meta-type wholly aromatic polyamide fibers and para-type wholly aromatic polyamide fibers, and generally tend to have poor stretchability.

[0003] As a countermeasure, for example, Patent Document 1 proposes a woven fabric which is woven using a composite yarn obtained by plying and twisting a flame-retardant yarn with a composite fiber yarn in which two components are bonded together in a side-by-side or eccentric core-sheath configuration as a weft yarn, and which is imparted with stretchability by heat shrinkage.

[0004] JP 2014-240532 A

[0005] The woven fabric described in Patent Document 1 is still not satisfactory in terms of flame retardancy. On the other hand, if the weight ratio of the composite fiber is reduced in order to increase the flame retardancy of the woven fabric, the stretchability of the woven fabric tends to decrease. Furthermore, if the ratio of weft yarns to warp yarns is drastically reduced to reduce the blend ratio of composite fibers in order to achieve both flame retardancy and stretchability, this may result in a decrease in the tensile strength in the weft direction.

[0006] It is also possible to arrange flame-retardant fiber yarns and twisted yarns of the above-mentioned composite fiber yarns and flame-retardant yarns alternately in the weft. In this case, the blending ratio of the composite fiber yarns can be reduced, but when the composite yarn shrinks due to heating, the flame-retardant fiber yarns do not shrink and therefore float in loops, which may result in wrinkles on the surface and impair the smooth appearance.

[0007] The present invention has been made in view of the above problems, and has as its object to provide a woven fabric and a textile product which are extremely excellent in heat resistance, flame resistance, stretchability and mechanical properties, and which also have good appearance quality.

[0008] The present inventors have conducted extensive research to achieve the above-mentioned objects, and have completed the present invention. Thus, the present invention provides the following: 1. A woven fabric made using a flame-retardant yarn containing a flame-retardant fiber and a composite yarn containing the flame-retardant fiber and a composite fiber in which two components are bonded together in a side-by-side or eccentric core-sheath configuration, wherein the flame-retardant yarn is arranged in one of the warp and weft of the woven fabric, and a yarn A made of the composite yarn and a yarn B made of the flame-retardant yarn are arranged in the other, in which the weight ratio of the composite fiber in yarn A is 20 to 60% by weight relative to the weight of the yarn, and yarn B is a ply-twisted yarn in which two or more of the flame-retardant yarns are ply-twisted and has a twist coefficient of 440 or less as defined below, and the woven fabric has a basis weight of 190 g / m ２or more, and has an elongation of 14% or more and a tensile strength of 300N or more in at least one of the warp and weft directions of the fabric, and the fabric has no flame spread, no flaming debris, an afterglow of 2 seconds or less, and an afterflame of 2 seconds or less in both the warp and weft directions, as measured according to ISO 15025 B. Twist coefficient K = T x √D where T is the number of twists (turns / 2.54 cm) and D is the total fineness (dtex) of the plied yarn. 2. A woven fabric according to 1 above, wherein the twist coefficient of yarn B is 330 or less, and the tensile strength is 400N or more in at least one of the warp and weft directions of the fabric. 3. 3. A woven fabric according to any one of 1 to 2 above, wherein the ratio of the cover factor CFweft of the weft to the cover factor CFwarp of the warp, CFweft / CFwarp, is within the range of 0.3 to 1.2. 4. A woven fabric according to any one of 1 to 3 above, wherein the weight ratio of the composite fiber is 16% by weight or less relative to the weight of the woven fabric. 5. A woven fabric according to any one of 1 to 4 above, wherein the woven fabric has an afterflame of 1 second or less, a residual flame of 1 second or less, and a char distance of 10 cm or less, measured in both the warp and weft directions according to JIS L 1091-1992A-4 method. 6. 6. The woven fabric according to any one of 1 to 5 above, wherein the flame-retardant fiber is one or more fibers selected from the group consisting of meta-type wholly aromatic polyamide fiber, para-type wholly aromatic polyamide fiber, polyparaphenylene benzoxazole fiber, polybenzimidazole fiber, polyimide fiber, polyetherimide fiber, polyamideimide fiber, carbon fiber, polyphenylene sulfide fiber, polyvinyl chloride fiber, flame-retardant rayon, modacrylic fiber, flame-retardant acrylic fiber, flame-retardant polyester fiber, flame-retardant vinylon fiber, melamine fiber, fluorine fiber, flame-retardant wool, and flame-retardant cotton. 7. The woven fabric according to any one of 1 to 6 above, wherein the composite fiber is contained in a composite yarn as a multifilament having a single fiber fineness of 0.5 to 10.0 dtex and a total fineness of 20 to 200 dtex. 8. The woven fabric according to any one of 1 to 7 above, wherein at least one component constituting the composite fiber is derived from recycled or plant sources.9. A textile product made using the fabric described in any one of 1 to 8 above, and selected from the group consisting of firefighting clothing, fire-resistant clothing, office uniforms, racing suits for motorsports, work clothes, gloves, hats, vests, seats, tents, membrane materials, hoods, building materials, housing materials, and vehicle interior materials.

[0009] According to the present invention, it is possible to obtain woven fabrics and textile products which are excellent in heat resistance, flame resistance, stretchability and mechanical properties and have good appearance quality.

[0010] FIG. 1 is a weave structure diagram used in Comparative Examples 2 and 4. FIG. 2 is a weave structure diagram used in Example 1 and Comparative Example 1. FIG. 3 is a weave structure diagram used in Comparative Examples 3 and 5. FIG. 4 is a weave structure diagram used in Example 2 and Examples 4 to 6. FIG. 5 is a weave structure diagram used in Example 3.

[0011] Embodiments of the present invention are described in detail below. The woven fabric of the present invention is a woven fabric made using a flame-retardant yarn containing a flame-retardant fiber and a composite yarn containing the flame-retardant fiber and a composite fiber in which two components are bonded together in a side-by-side or eccentric core-sheath configuration. (Regarding the Flame-Retardant Fiber) Examples of flame-retardant fibers include meta-type wholly aromatic polyamide fibers (meta-aramid fibers), para-type wholly aromatic polyamide fibers (para-aramid fibers), polyparaphenylene benzoxazole fibers, polybenzimidazole fibers, polyimide fibers, polyetherimide fibers, polyamideimide fibers, carbon fibers, polyphenylene sulfide fibers, polyvinyl chloride fibers, flame-retardant rayon, modacrylic fibers, flame-retardant acrylic fibers, flame-retardant polyester fibers, flame-retardant vinylon fibers, melamine fibers, fluorine fibers, flame-retardant wool, and flame-retardant cotton. These flame-retardant fibers can be used alone or in combination.

[0012] Among these, meta-type wholly aromatic polyamide fibers and para-type wholly aromatic polyamide fibers are particularly useful because they exhibit an excellent limiting oxygen index and have excellent mechanical properties.

[0013] Examples of the meta-type wholly aromatic polyamide fiber include metaphenylene isophthalamide fiber (also referred to as polymetaphenylene isophthalamide fiber). Metaphenylene isophthalamide fibers have aromatic rings constituting the main skeleton bonded meta-ally via amide bonds, and 85 mol % or more of the total repeating units of the polymer are metaphenylene isophthalamide units. Polymetaphenylene isophthalamide homopolymers are particularly preferred. The third component, copolymerizable at 15 mol % or less (preferably 5 mol % or less) of the total repeating units, includes diamine components such as paraphenylenediamine, 3,4'-diaminodiphenyl ether, 4,4'-diaminodiphenyl ether, paraxylylenediamine, biphenylenediamine, 3,3'-dichlorobenzidine, 3,3'-dimethylbenzidine, 3,4'-diaminodiphenylmethane, 4,4'-diaminodiphenylmethane, and 1,5-naphthalenediamine. Examples of the acid component include aromatic dicarboxylic acids such as terephthalic acid, naphthalene-2,6-dicarboxylic acid, and naphthalene-2,7-dicarboxylic acid. These aromatic diamines and aromatic dicarboxylic acids may have some of the hydrogen atoms on the aromatic ring substituted with halogen atoms or alkyl groups such as methyl groups. It is preferable that 20% or more of the total polymer terminals are blocked with a monovalent diamine such as aniline or a monovalent carboxylic acid component, since this reduces the decrease in fiber strength when the fiber is kept at high temperatures for a long period of time.

[0014] Such meta-type wholly aromatic polyamides can be produced by known interfacial polymerization methods, and the degree of polymerization of the polymer is preferably such that the intrinsic viscosity (IV) of the polymer measured in an N-methyl-2-pyrrolidone solution having a concentration of 0.5 g / 100 ml is in the range of 1.3 to 1.9 dl / g.

[0015] The meta-type wholly aromatic polyamide may also contain an alkylbenzenesulfonate onium salt. Examples of the alkylbenzenesulfonate onium salt include tetrabutyl phosphonium salt of hexylbenzenesulfonate, tributylbenzyl phosphonium salt of hexylbenzenesulfonate, tetraphenyl phosphonium salt of dodecylbenzenesulfonate, tributyltetradecylphosphonium salt of dodecylbenzenesulfonate, tetrabutyl phosphonium salt of dodecylbenzenesulfonate, and tributylbenzylammonium salt of dodecylbenzenesulfonate. Among these, tetrabutyl phosphonium salt of dodecylbenzenesulfonate and tributylbenzylammonium salt of dodecylbenzenesulfonate are preferred because they are easily available, have good thermal stability, and have high solubility in N-methyl-2-pyrrolidone.

[0016] In order to obtain a sufficient effect of improving dyeability, the content of the alkylbenzenesulfonic acid onium salt is preferably 2.5 mol % or more, more preferably in the range of 3.0 to 7.0 mol %, based on the metaphenylene isophthalamide.

[0017] The method of mixing metaphenylene isophthalamide and alkylbenzene sulfonate onium salt may include mixing and dissolving metaphenylene isophthalamide in a solvent, and then dissolving alkylbenzene sulfonate onium salt in the solvent. The dope thus obtained is formed into fibers by a known method.

[0018] For the purpose of improving dyeability and resistance to fading, the polymer used for meta-type wholly aromatic polyamide fibers may contain an aromatic diamine component or aromatic dicarboxylic acid halide component different from the main structural unit of the repeating structure copolymerized as a third component in an aromatic polyamide skeleton containing the repeating structural unit represented by the following formula (1) in an amount of 1 to 10 mol % based on the total amount of repeating structural units of the aromatic polyamide: -(NH-Ar1-NH-CO-Ar1-CO)-... formula (1), where Ar1 is a divalent aromatic group having a bonding group in a direction other than the meta-coordinated or parallel axial direction.

[0019] As the third component, aromatic diamines or aromatic dicarboxylic acid dichlorides represented by the following formulas (2), (3), (4) and (5) can be copolymerized.

[0020] Specific examples of the aromatic diamines represented by formulas (2) and (3) include p-phenylenediamine, chlorophenylenediamine, methylphenylenediamine, acetylphenylenediamine, aminoanisidine, benzidine, bis(aminophenyl)ether, bis(aminophenyl)sulfone, diaminobenzanilide, diaminoazobenzene, etc. Specific examples of the aromatic dicarboxylic acid dichlorides represented by formulas (4) and (5) include terephthalic acid chloride, 1,4-naphthalenedicarboxylic acid chloride, 2,6-naphthalenedicarboxylic acid chloride, 4,4'-biphenyldicarboxylic acid chloride, 5-chloroisophthalic acid chloride, 5-methoxyisophthalic acid chloride, bis(chlorocarbonylphenyl)ether, etc.

[0021] H ２ N-Ar2-NH ２ ...Formula (2) H ２ N-Ar2-Y-Ar2-NH ２ Formula (3) XOC-Ar3-COX Formula (4) XOC-Ar3-Y-Ar3-COX Formula (5) Ar2 is a divalent aromatic group different from Ar1, Ar3 is a divalent aromatic group different from Ar1, Y is at least one atom or functional group selected from the group consisting of an oxygen atom, a sulfur atom, and an alkylene group, and X is a halogen atom.

[0022] The crystallinity of the meta-type wholly aromatic polyamide fiber is preferably 5 to 35% in view of good dye exhaustion and ease of adjustment to a target color even with a small amount of dye or weak dyeing conditions, etc. Furthermore, it is more preferably 15 to 25% in view of less occurrence of uneven surface distribution of the dye, high resistance to discoloration, and ensuring dimensional stability required for practical use.

[0023] The amount of residual solvent in the meta-type wholly aromatic polyamide fiber is preferably 1.0% by weight or less (more preferably 0.3% by weight or less) from the viewpoints of not impairing the excellent flame retardancy of the meta-type wholly aromatic polyamide fiber, and of preventing uneven distribution of the dye on the surface and ensuring high resistance to discoloration.

[0024] The meta-type wholly aromatic polyamide polymer may be polymerized by the solution polymerization method or interfacial polymerization method described in, for example, Japanese Patent Publication No. 14399 / 1960, US Pat. No. 3,360,595, or Japanese Patent Publication No. 10863 / 1972.

[0025] The spinning solution may be an amide-based solvent containing an aromatic copolyamide polymer obtained by the above-mentioned solution polymerization or interfacial polymerization, or may be a solution obtained by isolating the polymer from the above-mentioned polymerization solution and dissolving it in an amide-based solvent.

[0026] Examples of the amide solvent used in the polymerization include N,N-dimethylformamide, N,N-dimethylacetamide, N-methyl-2-pyrrolidone, dimethyl sulfoxide, etc. Among these, N,N-dimethylacetamide is particularly preferred.

[0027] The obtained copolymerized aromatic polyamide polymer solution is preferably stabilized by further containing an alkali metal salt or alkaline earth metal salt, which allows use at a higher concentration and at a lower temperature. The alkali metal salt or alkaline earth metal salt is preferably 1 wt % or less, more preferably 0.1 wt % or less, based on the total weight of the polymer solution.

[0028] In the spinning and coagulation step, the spinning solution (meta-type wholly aromatic polyamide polymer solution) obtained above is spun into a coagulation solution and coagulated.

[0029] The spinning apparatus is not particularly limited, and known wet spinning apparatuses can be used. Furthermore, the number, arrangement, and shape of the spinning holes in the spinneret need not be particularly limited as long as stable wet spinning is possible. For example, a multi-hole spinneret for staple fibers having 1,000 to 30,000 holes and a spinning hole diameter of 0.05 to 0.2 mm may be used. The temperature at which the spinning solution (meta-type wholly aromatic polyamide polymer solution) obtained above is spun from the spinneret is suitably in the range of 20 to 90°C.

[0030] The coagulation bath used to obtain the fibers is an amide-based solvent that is substantially free of inorganic salts. It is particularly preferable to use an aqueous solution containing 45 to 60% by weight of NMP at a bath temperature in the range of 10 to 50°C. If the concentration of the amide-based solvent (preferably NMP) is less than 45% by weight, the skin will be thick, which may reduce the cleaning efficiency in the cleaning step and make it difficult to reduce the amount of solvent remaining in the fibers. On the other hand, if the concentration of the amide-based solvent (preferably NMP) exceeds 60% by weight, uniform coagulation cannot be achieved even in the interior of the fibers, making it difficult to reduce the amount of solvent remaining in the fibers. The appropriate immersion time for the fibers in the coagulation bath is 0.1 to 30 seconds.

[0031] Stretching is performed in an amide solvent. In particular, it is preferable to perform stretching at a ratio of 3 to 4 in a plastic stretching bath containing an aqueous solution of NMP with a concentration of 45 to 60% by weight and a bath temperature in the range of 10 to 50°C. After stretching, the film is thoroughly washed by passing it through an aqueous solution of NMP with a concentration of 20 to 40% by weight at 10 to 30°C, and then through a warm water bath at 50 to 70°C.

[0032] The washed fibers are subjected to a dry heat treatment at a temperature of 270 to 290°C to obtain meta-type wholly aromatic polyamide fibers that satisfy the above-mentioned ranges of crystallinity and residual solvent content. By using the above-mentioned method, the crystallinity and residual solvent content can be adjusted to the preferred ranges.

[0033] The meta-type wholly aromatic polyamide fiber may be a long fiber (multifilament) or a short fiber. When blended with other fibers, short fibers having a fiber length of 25 to 200 mm are preferred, and a single fiber fineness in the range of 1 to 5 dtex is more preferred.

[0034] Commercially available metaphenylene isophthalamide fibers include "Conex" (trade name) manufactured by Teijin Limited, "Conex Neo" (trade name) manufactured by Teijin Limited, and "Nomex" (trade name) manufactured by DuPont.

[0035] Next, the para-type wholly aromatic polyamide fiber (para-aramid fiber) is preferably a paraphenylene terephthalamide fiber or a coparaphenylene-3,4'-oxydiphenylene terephthalamide fiber. Commercially available products include "Twaron" (trade name) manufactured by Teijin Limited, "Kevlar" (trade name) manufactured by Toray DuPont Co., Ltd., and "Technora" (trade name) manufactured by Teijin Limited.

[0036] Furthermore, these fibers may contain additives such as antioxidants, infrared absorbers, ultraviolet absorbers, heat stabilizers, titanium oxide, colorants, and inert fine particles, as long as the purpose of the present invention is not impaired. However, it is preferable that the fibers do not contain flame retardants.

[0037] Furthermore, flame-retardant yarns containing such flame-retardant fibers may be in the form of continuous fibers, but are generally used in the form of spun yarns. As spun yarns, British cotton counts of 20 to 60 (more preferably 36 to 48) are preferred. Counts of 40 are particularly preferred. (Regarding Composite Fibers) As composite fibers, fibers composed of a single component made of polytrimethylene terephthalate and composite fibers in which two components are bonded in a side-by-side or eccentric core-sheath configuration are preferred. Specific examples of suitable two-component combinations include polytrimethylene terephthalate and polytrimethylene terephthalate, polytrimethylene terephthalate and polyethylene terephthalate, polyethylene terephthalate and polyethylene terephthalate, and polyethylene terephthalate and polybutylene terephthalate.

[0038] Here, polytrimethylene terephthalate refers to a fiber made of polyester containing trimethylene terephthalate units as the main repeating units, and refers to fibers containing trimethylene terephthalate units in an amount of 50 mol% or more, preferably 70 mol% or more, more preferably 80 mol% or more, and particularly preferably 90 mol% or more. Therefore, the polytrimethylene terephthalate fiber contains other acid components and / or glycol components as third components in a total amount of 50 mol% or less, preferably 30 mol% or less, more preferably 20 mol% or less, and particularly preferably 10 mol% or less.

[0039] Polytrimethylene terephthalate is produced by condensing terephthalic acid or a functional derivative thereof with trimethylene glycol or a functional derivative thereof in the presence of a catalyst under suitable reaction conditions.

[0040] Furthermore, these fibers may contain additives such as antioxidants, infrared absorbers, ultraviolet absorbers, heat stabilizers, titanium oxide, colorants, and inert fine particles, as long as the purpose of the present invention is not impaired. However, it is preferable that the fibers do not contain flame retardants.

[0041] The shape of the composite fiber is not particularly limited, and may be a long fiber (multifilament) or a short fiber (spun yarn), but a long fiber (multifilament) is preferred to obtain excellent stretchability. Furthermore, it is preferable that at least one of the components constituting the composite fiber is derived from recycled materials or plants. Examples include recycled polyethylene terephthalate and plant-derived polytrimethylene terephthalate.

[0042] In the multifilament made of the composite fiber, the total fineness, single fiber fineness, and number of filaments of 50 to 200 may be selected appropriately depending on the application, with a total fineness of 20 to 200 dtex, a single fiber fineness of 0.5 to 10.0 dtex, and a number of filaments of 50 to 200 being preferred. (Regarding the composite yarn (yarn A)) In the present invention, the composite yarn contains the flame-retardant yarn and a yarn made of the composite fiber. In this case, it is important that the weight ratio of the yarn made of the composite fiber contained in the composite yarn is within the range of 20 to 60% by weight (more preferably 40 to 55% by weight) of the composite yarn in order to achieve both flame retardancy and stretchability.

[0043] The fineness ratio of the flame-retardant yarn to the composite fiber is preferably 1: (0.8 to 1.2). If the fineness ratio is below this, i.e., if the fineness of the composite fiber is reduced, high stretchability cannot be obtained, and if the fineness of the composite fiber is further increased, there is a risk that the flame retardancy will decrease.

[0044] The composite yarn is preferably a plied / twisted yarn. More specifically, the spun yarn and the composite fiber yarn are preferably plied / twisted using a commercially available up-twister, Italian twister, double twister, or the like. The twisting is preferably performed so that the twist coefficient K is 270 to 400. Here, the twist coefficient K = T × √D, where T is the number of twists (turns / 2.54 cm) and D is the total fineness (dtex) of the composite yarn. If the twist coefficient is below 270, unevenness due to shrinkage of the composite fiber may appear on the surface of the woven fabric, deteriorating the appearance quality and the anti-pilling properties. Conversely, if the twist coefficient is above 400, the thermal shrinkage of the composite yarn may be inhibited, potentially reducing the elongation rate.

[0045] Twist setting may be performed depending on the required quality. The composite yarn (plied yarn) can be twist set using vacuum steam setting, which is used for setting ordinary spun yarns. The temperature during setting of the composite plied yarn is preferably in the range of 50 to 95°C (more preferably 50 to 85°C). If the twist setting temperature of the composite yarn (plied yarn) is too high, the stretchability of the final woven fabric may be impaired. (Regarding conductive fibers) Furthermore, it is preferable that the woven fabric of the present invention contains conductive fibers to prevent static electricity. In this case, the conductive fibers may be contained in the flame-retardant yarn (spun yarn) or composite yarn, or may be contained separately in the woven fabric.

[0046] The conductive fibers preferably contain at least one of the following conductors in the conductive portion: carbon black, metal particles (silver particles, copper particles, aluminum particles, etc.), metal oxides (particles mainly composed of titanium oxide, stannic oxide, zinc oxide, indium oxide, etc.), and conductive particle-containing polymers containing particles coated with a conductive oxide. The conductive fiber may have a structure in which the entire fiber is made of conductive material, or the non-conductive and conductive portions may have a cross-sectional shape such as a core-sheath, sandwich, or eccentric configuration. The resins forming the conductive and non-conductive portions are not particularly limited as long as they have fiber-forming properties. Specific examples of nylon resins include nylon 6, nylon 11, nylon 12, and nylon 66. Examples of polyester resins include polyethylene terephthalate, polytrimethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, polycyclohexane terephthalate, and copolymers thereof, as well as those in which a portion of the acid component (terephthalic acid) is replaced with isophthalic acid. Acrylic resins are also acceptable. It is particularly preferable that the resins be dyeable with cationic dyes.

[0047] Examples of commercially available conductive fibers include "Metarian" (trade name) manufactured by Teijin Limited, "Megana" (trade name) manufactured by Unitika Fibers, "Luana" (trade name) manufactured by Toray Industries, Inc., "Clacarbo" (trade name) manufactured by Kuraray Co., Ltd., "Coabrit ET10" (trade name) manufactured by Mitsubishi Chemical Corporation, and "Belltron" (trade name) manufactured by KB Seiren Co., Ltd. (Regarding Yarn B) Yarn B is a ply-twisted yarn obtained by plying and twisting two or more (preferably 2 to 4, particularly preferably 2) of the flame-retardant yarns described above, and has a twist coefficient defined below of 440 or less (preferably 430 or less, more preferably 330 or less, particularly preferably 200 to 300). By setting the twist coefficient to 440 or less, Yarn B appears as if it were a single yarn pulled together in the woven fabric, making it difficult to see the wrinkles that occur due to shrinkage of the composite fiber. A twist coefficient of more than 440 is undesirable because the wrinkles become more noticeable. Twist coefficient K = T × √D where T is the number of twists (turns / 2.54 cm) and D is the total fineness (dtex) of the plied yarn. (Regarding yarn arrangement) In the woven fabric of the present invention, the flame-retardant yarn is arranged in either the warp or weft of the woven fabric, and Yarn A made of the composite yarn and Yarn B made of the flame-retardant yarn are arranged in the other. It is particularly preferable that the flame-retardant yarn is arranged in the warp and Yarn A made of the composite yarn and Yarn B made of the flame-retardant yarn are arranged in the weft. (Regarding blend ratio) The woven fabric of the present invention is a woven fabric made using the composite yarn. In this case, to achieve excellent flame retardancy, it is preferable that the weight ratio of the flame-retardant fiber is 80% by weight or more (preferably 85 to 99% by weight, particularly preferably 85 to 97% by weight) of the woven fabric. It is also preferable that the weight ratio of the composite fiber is 16% by weight or less (preferably 1 to 15% by weight, particularly preferably 12 to 15% by weight). If the weight ratio of the composite fiber exceeds 16% by weight, there is a risk of a decrease in flame retardancy. (Regarding elongation, tensile strength, and tear strength) In the woven fabric of the present invention, it is important that, as for the stretchability of the woven fabric, the elongation in at least one of the warp and weft directions (preferably the weft direction) is 14% or more (preferably 15 to 25%) and the tensile strength is 300 N or more (preferably 400 N or more, more preferably 650 N or more, particularly preferably 700 to 2000 N).Furthermore, the elongation recovery rate of the woven fabric in at least one of the warp and weft directions (preferably the weft direction) is preferably 70% or more (more preferably 73 to 99%). Note that, in order to achieve the elongation rate and tensile strength in at least one of the warp and weft directions while satisfying the above blend ratio, it is important to arrange yarn B consisting only of the flame-retardant yarn and yarn A in which the flame-retardant yarn and the composite fiber are twisted together.

[0048] In addition, it is preferable that the tear strength as described in ISO 13937-2 is 35 N or more (more preferably 35 to 70 N) in both the warp and weft directions. (Regarding Cover Factor) In the woven fabric of the present invention, it is preferable that the ratio CFweft / CFwarp, which is the cover factor CFweft of the weft yarn to the cover factor CFwarp of the warp yarn, is in the range of 0.3 to 1.2, in order to achieve both high stretchability and flame retardancy.

[0049] CFweft = √ (weft fineness dtex) × (weft density units / inch) CFwarp = √ (warp fineness dtex) × (warp density units / inch) TCF = CFweft + CFwarp Note that 1 inch is 2.54 cm. (Regarding basis weight) The basis weight of the woven fabric is 190 g / m ２ or more (more preferably 200 to 300 g / m ２ ) is important. ２ Fabrics with a basis weight of less than this are not preferred because they have reduced flame retardancy. (Regarding the fabric weave) Examples of fabric weaves include plain weave, twill weave, and satin weave. In particular, plain weave, 2 / 1 twill, and 2 / 2 twill weave are preferred. Weaves with a higher number of floats than this have a high stretchability, but may have poor anti-pilling properties. (Regarding post-processing) Next, by subjecting the fabric to heat treatments such as scouring, relaxation, dyeing, and setting, the yarns made of the composite fiber contained in the fabric take on a three-dimensional coil crimp form, imparting stretchability to the fabric. In particular, during dyeing, it is preferred to heat the fabric to 130°C in a jet dyeing machine and circulate the fabric, as this shrinks the fabric in the width direction and imparts high stretchability.

[0050] In dyeing, meta-type wholly aromatic polyamide fibers may be dyed using a cationic dye in combination with an organic solvent that acts as a carrier, while polyester composite fibers may be dyed using a disperse dye.

[0051] Such a woven fabric may be subjected to various additional treatments such as water absorption, water repellency, nap raising, flame retardancy, ultraviolet shielding, or the addition of antibacterial, deodorizing, insect repellent, luminous agent, retroreflective agent, negative ion generator, etc. (Regarding Effects) The woven fabric thus obtained has the above-mentioned structure and therefore has not only flame retardancy but also excellent stretchability and appearance quality.

[0052] Here, it is important that both the warp and weft directions satisfy all of the following (1) to (4) defined in ISO 15025 B: (1) No flame spread (2) No flaming debris (3) Afterglow 2 seconds or less (4) After flame 2 seconds or less It is also preferable that the woven fabric satisfy all of the following (1) to (3) defined in JIS L 1091-1992A-4 method: (1) Afterglow 1 second or less (2) Afterglow 1 second or less (3) Char distance 10 cm or less In addition, in ISO 15025 Procedure A, it is preferable that the flame does not reach the edge, there is no flaming / melt debris, afterglow lasts 2 seconds or less, and afterflame lasts 2 seconds or less. It is also preferable that the char length is 100 mm or less, the afterflame is 2 seconds or less, there is no melting, and there are no drips as measured by ASTM D6413. It is also preferable that the limiting oxygen index as measured by JIS K7201 is greater than 24 (more preferably 24.5 or greater).

[0053] Next, the textile products of the present invention are made using the above-described woven fabric. Because such textile products use the above-described woven fabric, they have not only flame retardancy but also excellent stretchability and a high-quality appearance. Examples of such textile products include firefighting uniforms, fire-resistant uniforms, office uniforms, racing suits for motorsports, workwear, gloves, hats, vests, and various industrial materials (sheets, tents, membrane materials, hoods, building materials, housing materials, vehicle interior materials, etc.). Examples of such workwear include workwear for steel mills and steel factories, welding workwear, and workwear for explosion-proof areas. Examples of such gloves include work gloves used in industries that handle precision parts, such as the aircraft industry, the information equipment industry, and the precision equipment industry.

[0054] Examples and comparative examples of the present invention are described in detail below, but the present invention is not limited thereto. The measurement items in the examples were measured using the following methods. (1) LOI (Limiting Oxygen Index) The limiting oxygen index (LOI) was measured according to JIS K7201:1999 (Flame Test Method for Polymeric Materials by the Oxygen Index Method). (2) Flame Resistance Test Measured according to ISO 15025 Procedure A and ISO 15025 Procedure B. (3) Stretchability Measured the weft elongation and elongation recovery according to JIS L1096-2010 (Method B, constant load method). (4) Tensile Strength Measured according to ISO 13934-1 strip method. (5) Tear Strength Measured according to ISO 13937-2 single tear method. (6) Appearance quality (presence or absence of crimping) The sunlight from a north window was directed at the front and back of the fabric at an angle of about 45 degrees, and the presence or absence of crimping was judged in two stages: "present" and "absent" when viewed perpendicularly to the surface of the fabric. (7) Fineness Measured according to JIS L1013-2010 correct fineness. (8) Fabric weight Measured according to JIS L 1096-2010 8.3 (g / m ２ ) was measured.

[0055] [Spun yarn 1] In the spinning process, short fibers made of polymetaphenylene isophthalamide fiber ("Conex Neo" (trade name) manufactured by Teijin Limited) having a single fiber fineness of 1.7 dtex, a cut length (fiber length) of 51 mm, and an LOI of 26, and polyparaphenylene terephthalamide (PPTA) fiber (Teijin Limited) having a single fiber fineness of 1.7 dtex, a cut length (fiber length) of 51 mm, and a limiting oxygen index of 25 as defined in E-2 of JIS 1091:1999 were spun. Short fibers consisting of a conductive fiber ("Twaron" (trade name) manufactured by Mitsubishi Chemical Corporation) with a single fiber fineness of 3.3 dtex and a cut length (fiber length) of 38 mm ("Corebrit ET10" (trade name) manufactured by Mitsubishi Chemical Corporation, dyeable with cationic dyes) were blended in this order in a weight ratio of 93:5:2, and the blend was first twisted in the Z direction with 24 twists / 2.54 cm (twist coefficient = 292), to obtain spun yarn 1 of 40 British cotton count single yarn (fineness 147.6 dtex).

[0056] [Spun yarn 2] In the spinning process, staple fibers made of spun-dyed polymetaphenylene isophthalamide fiber ("Conex" (trade name) manufactured by Teijin Limited) having a single fiber fineness of 2.2 dtex, a cut length (fiber length) of 51 mm, and an LOI of 26 were spun, and a first twist was applied in the Z direction with a twist number of 24 turns / 2.54 cm (twist coefficient = 292), to obtain spun yarn 2 having a single yarn count of 40 (fineness 147.6 dtex) in British cotton count.

[0057] [Composite fiber 1] A polyester-based elastic fiber (Solotex Ecohybrid (trade name) manufactured by Teijin Frontier Co., Ltd., a composite fiber in which a polytrimethylene terephthalate component and a polyethylene terephthalate component are bonded side-by-side) with a total fineness of 167 dtex / 72 strands was used.

[0058] [Example 1] Warp yarn: Two spun yarns 1 were combined and twisted in the S direction using a double twister with 24 final twists per 2.54 cm, and then twist-set using a vacuum steam setting machine at a setting temperature of 90°C for a setting time of 30 minutes.

[0059] Weft yarn A: Two strands of spun yarn 1 and two strands of composite fiber 1 were combined and twisted in the S direction using a double twister with 20 twists / 2.54 cm, and then twist-set using a vacuum steam setting machine at a setting temperature of 70°C for a setting time of 20 minutes.

[0060] Weft yarn B: Two spun yarns 1 were combined and twisted in the S direction using a double twister with 15 final twists per 2.54 cm, and then twist-set using a vacuum steam setting machine at a setting temperature of 90°C for a setting time of 30 minutes.

[0061] Next, a plain weave fabric was woven using the warp yarns, weft yarn A, and weft yarn B at a weave density of 51 warp threads / 2.54 cm and 56 weft threads / 2.54 cm. Weft yarns A and B were alternately arranged. The woven fabric was then set by conventional singeing, scouring, and open-weaving (at 160°C for 30 seconds), and then dyed in a jet dyeing machine at 130°C for 60 minutes with a wholly aromatic polyamide fiber dye solution (liquor ratio 1:20) containing 16% owf of a cationic dye (BASF: Basacry Red GL), 10 g / L of a carrier, 3 g / L of acetic acid, 20 g / L of sodium nitrate, and 1 g / L of a dispersant (Meisei Chemicals: Disper VG). The temperature was raised from room temperature to 130°C.

[0062] Next, the fabric was dyed in a jet dyeing machine with 6% owf disperse dye (Kayalon Polyester Blue GL-SF), 5 g / L acetic acid, 20 g / L sodium acetate, 25 g / L sodium nitrate, and 1 g / L dispersant (Meisei Chemicals: Disper VG), and the temperature was raised from room temperature to 130°C for 30 minutes. After dyeing, the fabric was subjected to reduction washing, dried, and set (temperature 180°C x time 30 seconds) at the same width. The evaluation results are shown in Tables 1 and 2.

[0063] [Examples 2, 4 to 6, Comparative Examples 1 to 5] Examples 2, 4 to 6 and Comparative Examples 1 to 5 were the same as Example 1 except that the yarn type, twist coefficient, design, and warp / weft density were changed. The evaluation results are shown in Tables 1 to 4.

[0064] [Example 3] In Example 3, spun yarn was used, and a woven fabric was produced in the same manner as in Example 1, except that the yarn type, twist coefficient, weave, and warp density were changed. The woven fabric was then set by the usual methods of singeing, scouring, and spreading (temperature 180°C x time 30 seconds). The evaluation results are shown in Tables 1 and 2.

[0065]

[0066]

[0067]

[0068]

[0069] According to the present invention, woven fabrics and textile products which are excellent in heat resistance, flame resistance, stretchability and mechanical properties and have good appearance quality are provided, and they are of great industrial value.

Claims

1. A woven fabric made using a flame-retardant yarn containing a flame-retardant fiber and a composite yarn containing the flame-retardant fiber and a composite fiber in which two components are bonded together in a side-by-side or eccentric core-sheath configuration, wherein the flame-retardant yarn is arranged in one of the warp and weft of the fabric, and Yarn A made of the composite yarn and Yarn B made of the flame-retardant yarn are arranged in the other, the weight ratio of the composite fiber in Yarn A is 20 to 60% by weight relative to the weight of the yarn, and Yarn B is a ply-twisted yarn made by plying and twisting two or more of the flame-retardant yarns and has a twist coefficient of 440 or less as defined below, and the woven fabric has a basis weight of 190 g / m ２ or more, and the elongation is 14% or more and the tensile strength is 300 N or more in at least one of the warp and weft directions of the fabric, and the fabric has no flame spread, no flaming debris, an afterglow of 2 seconds or less, and an afterflame of 2 seconds or less in both the warp and weft directions when measured according to ISO 15025 B. Twist factor K = T × √D where T is the number of twists (turns / 2.54 cm) and D is the total fineness (dtex) of the plied and twisted yarn.

2. The woven fabric according to claim 1, wherein the twist coefficient of yarn B is 330 or less and the tensile strength in at least one of the warp and weft directions of the woven fabric is 400 N or more.

3. The woven fabric according to claim 1, wherein the ratio of the cover factor CFweft of the weft yarn to the cover factor CFwarp of the warp yarn, CFweft / CFwarp, is in the range of 0.3 to 1.

2.

4. The woven fabric according to claim 1, wherein the weight ratio of said composite fiber is 16% by weight or less based on the weight of the woven fabric.

5. The woven fabric according to claim 1, wherein the afterflame is 1 second or less, the afterglow is 1 second or less, and the char distance is 10 cm or less, when measured in both the warp and weft directions according to JIS L 1091-1992A-4.

6. The woven fabric according to claim 1, wherein the flame-retardant fiber is one or more fibers selected from the group consisting of meta-type wholly aromatic polyamide fiber, para-type wholly aromatic polyamide fiber, polyparaphenylenebenzoxazole fiber, polybenzimidazole fiber, polyimide fiber, polyetherimide fiber, polyamideimide fiber, carbon fiber, polyphenylene sulfide fiber, polyvinyl chloride fiber, flame-retardant rayon, modacrylic fiber, flame-retardant acrylic fiber, flame-retardant polyester fiber, flame-retardant vinylon fiber, melamine fiber, fluorine fiber, flame-retardant wool, and flame-retardant cotton.

7. The woven fabric according to claim 1, wherein the composite fibers are contained in a composite yarn as multifilaments having a single fiber fineness of 0.5 to 10.0 dtex and a total fineness of 20 to 200 dtex.

8. The woven fabric according to claim 1, wherein at least one of the components constituting the composite fiber is of recycled or plant origin.

9. A textile product made from the fabric according to any one of claims 1 to 8, and selected from the group consisting of firefighting clothing, fire-resistant clothing, office uniforms, racing suits for motorsports, workwear, gloves, hats, vests, seats, tents, membrane materials, hoods, building materials, housing materials, and vehicle interior materials.

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