U.S. patent application number 10/508888 was filed with the patent office on 2005-06-16 for high flame resistant union fabric.
Invention is credited to Adachi, Masayuki, Matsumoto, Takaharu, Tamura, Masanobu.
Application Number | 20050130535 10/508888 |
Document ID | / |
Family ID | 28449154 |
Filed Date | 2005-06-16 |
United States Patent
Application |
20050130535 |
Kind Code |
A1 |
Adachi, Masayuki ; et
al. |
June 16, 2005 |
High flame resistant union fabric
Abstract
A fabric is provided that has high degree of flame resistance in
the case of a union fabric consisting of a halogen-containing flame
resistant fiber including antimony compounds (A), and a cellulosic
fiber, and the fabric is classified into class M1 of NF P 92-503
combustion test in France. A flame resistant union fabric obtained
by co-weaving: a compound yarn (A) 30% to 70% by weight obtained by
compounding a halogen-containing flame resistant fiber (a-1)
including an antimony compound 25 to 50 parts by weight in an
acrylic based copolymer 100 parts by weight obtained by
polymerizing a monomer mixture including acrylonitrile 30 to 70% by
weight, a halogen containing vinyl based monomer 30 to 70% by
weight, and a vinyl based monomer copolymerizable therewith 0 to
10% by weight, and an other fiber (a-2), the compound yarn (A)
having an elongation percentage less than 5% under a condition of a
load of 300 mg/metric count of No. 17, and of a temperature range
of 100 degrees C. to 500 degrees C.; a cellulosic fiber yarn (B) 70
to 30% by weight.
Inventors: |
Adachi, Masayuki; (Hyogo,
JP) ; Matsumoto, Takaharu; (Hyogo, JP) ;
Tamura, Masanobu; (Osaka, JP) |
Correspondence
Address: |
BRINKS HOFER GILSON & LIONE
P.O. BOX 10395
CHICAGO
IL
60610
US
|
Family ID: |
28449154 |
Appl. No.: |
10/508888 |
Filed: |
September 23, 2004 |
PCT Filed: |
March 20, 2003 |
PCT NO: |
PCT/JP03/03398 |
Current U.S.
Class: |
442/217 |
Current CPC
Class: |
D01F 1/07 20130101; D01F
6/40 20130101; D03D 15/513 20210101; D02G 3/443 20130101; Y10T
442/3293 20150401 |
Class at
Publication: |
442/217 |
International
Class: |
D03D 015/00 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 25, 2002 |
JP |
200282711 |
Claims
1. A flame resistant union fabric obtained by co-weaving: a
compound yarn (A) 30% to 70% by weight obtained by compounding a
halogen-containing flame resistant fiber (a-1) including an
antimony compound 25 to 50 parts by weight in an acrylic based
copolymer 100 parts by weight obtained by polymerizing a monomer
mixture including acrylonitrile 30 to 70% by weight, a halogen
containing vinyl based monomer 30 to 70% by weight, and a vinyl
based monomer copolymerizable therewith 0 to 10% by weight, and an
other fiber (a-2), the compound yarn (A) having an elongation
percentage less than 5% under a condition of a load of 300
mg/metric count of No. 17, and of a temperature range of 100
degrees C. to 500 degrees C.; a cellulosic fiber yarn (B) 70 to 30%
by weight.
2. The flame resistant union fabric according to claim 1, wherein
the cellulosic fiber yarn (B) consists of at least one kind
selected from a group consisting of cotton, hemp, rayon, polynosic,
cupra, acetate, and triacetate.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to a flame resistant union
fabric. Specifically, the present invention relates to a union
fabric having high degree of flame resistance consisting of a
compound yarn having a halogen-containing flame resistant fiber
including an antimony compound as a principal component, and a
cellulosic fiber.
BACKGROUND ART
[0002] In recent years, demand for guarantee of safety of foods,
clothes and housings has become stronger, and necessity for
fire-resistant materials is increasing. In such a situation, a
plurality of methods to give flame resistance to a flammable yarn
by compounding general-purpose flammable fibers and flame resistant
fibers having high degree of flame resistance, while maintaining
characteristics of the flammable yarn, have been proposed. As such
a compound fiber, for example, Japanese Patent No. 2593985
specification and Japanese Patent No. 2593986 specification
disclose a method of using antimony compounds as a flame resistant
agent to be added to the halogen-containing flame resistant fibers
in compounding of halogen-containing flame resistant fibers and
natural fibers.
[0003] Recently, union fabrics using general-purpose cellulosic
fibers as a warp yarn and a halogen-containing flame resistant
fiber including antimony compounds as a weft yarn are often used
for interior design products, such as curtains and chair coverings,
because special features of cellulosic fibers, such as natural
feeling, hygroscopic property, and heat resistance, can be
exhibited. Among them, union fabrics using cellulosic fibers as a
warp yarn and halogen-containing flame resistant fibers including
antimony compounds as a weft yarn, such as jacquard, dobby, and
satin have special feature with many cellulosic fibers disposed on
a surface side of the fabric.
[0004] However, in these union fabrics, uneven existence of
cellulosic fibers and halogen-containing flame resistant fibers in
a fabric makes it very difficult to pass a highest flame resistant
class M1 in NF P 92-503 combustion test in France that requires a
very high degree of flame resistance.
[0005] Only international publication No. 01/32968 pamphlet
proposes a method applying such technique furthermore in which a
union fabric using a cellulosic fiber as a warp yarn and a
halogen-containing fiber having an antimony compound and a zinc
stannate compound added therein in combination as a weft yarn has a
very high flame resistance passing Class M1 of NF P 92-503
combustion test.
[0006] However, since zinc stannate compounds a have higher cost
than that of antimony compounds, the fiber has a cost higher than
that of conventional fibers as compared with independent addition
of the antimony compounds to the halogen-containing fiber, leading
to a problem of higher cost of the union fabric.
[0007] Accordingly, in a union fabric comprising a
halogen-containing fiber by addition of only antimony compounds and
a general-purpose fiber, such as a cellulosic fiber, development of
a union fabric exhibiting high flame resistance and classified in
Class M1 of NF P 92-503 combustion test without combined use of
zinc stannate compounds etc. has been long awaited.
[0008] The present invention aims at providing a fabric having high
degree of flame resistance in case of union fabrics consisting of
halogen-containing flame resistant fibers and cellulosic fibers,
and classified in class M1 of NF P 92-503 combustion test.
SUMMARY OF THE INVENTION
[0009] The present inventors performed repeated investigation about
union fabrics consisting of modacrylic flame resistant fibers as
halogen-containing flame resistant fibers, and cellulosic fibers.
As a result, it was found out that when a compound yarn using a
modacrylic fiber, compounded with other fibers, including antimony
compound as a principal component shows a certain specific thermal
behavior, use of the compound yarn as a warp yarn or a weft yarn
might exhibit high flame resistance in union fabrics, such as
jacquard, dobby, and satin weave.
[0010] That is, the present invention relates to a flame resistant
union fabric obtained by co-weaving: a compound yarn (A) 30% to 70%
by weight obtained by compounding a halogen-containing flame
resistant fiber (a-1) including an antimony compound 25 parts
(hereinafter abbreviated as simply part) to 50 parts into an
acrylic based copolymer 100 parts obtained by copolymerizing a
monomer mixture comprising acrylonitrile 30% to 70% by weight.
(hereinafter abbreviated as simply %), a halogen containing vinyl
based monomer 30% to 70%, and a vinyl based monomer copolymerizable
therewith 0% to 10%, with an other fiber (a-2), the compound yarn
(A) having less than 5% of elongation under a condition of a load
of 300 mg/metric count of No. 17, and of a temperature range of 100
degrees C. to 500 degrees C.; and a cellulosic fiber yarn (B) 70%
to 30% by weight.
[0011] The flame resistant union fabric is preferably of a union
fabric wherein the cellulosic fiber (B) is at least one kind
selected from a group consisting of cotton, hemp, rayon, polynosic,
cupra, acetate, and triacetate.
BEST MODE FOR CARRYING-OUT THE INVENTION
[0012] The present invention relates a flame resistant union fabric
obtained by compounding:
[0013] a compound yarn (A) 30% to 70% by weight obtained by
compounding a halogen-containing flame resistant fiber (a-1)
including an antimony compound 25 parts to 50 parts into an acrylic
based copolymer 100 parts obtained by copolymerizing a monomer
mixture comprising acrylonitrile 30% to 70%, a halogen containing
vinyl based monomer 30% to 70%, and a vinyl based monomer
copolymerizable therewith 0% to 10%, with an other fiber (a-2), the
compound yarn (A) having less than 5% of elongation under a
condition of a load of 300 mg/metric count of No. 17, and of a
temperature range of 100 degrees C. to 500 degrees C.; and a
cellulosic fiber yarn (B) 70% to 30% by weight.
[0014] In the present invention, a fiber yarn including a
halogen-containing flame resistant fiber (a-1) is a fiber used in
order to give flame resistance to a union fabric of the present
invention. The halogen-containing flame resistant fiber (a-1)
consists of a composition including an antimony compound in an
acrylic based copolymer obtained by polymerizing a monomer mixture
including acrylonitrile 30 to 70%, halogen containing vinyl based
monomer 30% to 70%, and a vinyl based monomer copolymerizable with
the acrylonitrile and the halogen containing vinyl based monomer
(hereinafter referred to as copolymerizable vinyl based monomer) 0%
to 10%.
[0015] In the monomer mixture used for obtaining the acrylic based
copolymer, a percentage of the acrylonitrile is not less than 30%,
and preferably not less than 40% (lower limit), and it is not more
than 70%, and preferably not more than 60% (upper limit).
[0016] In the monomer mixture, a percentage of the halogen
containing vinyl based monomer is not less than 30%, and preferably
not less than 40% (lower limit), and it is not more than 70%, and
preferably not more than 60% (upper limit).
[0017] In the monomer mixture, a percentage of the copolymerizable
vinyl based monomer is preferably not less than 1% (lower limit),
and it is not more than 10%, and preferably not more than 5% (upper
limit).
[0018] Of course, a total percentage of the acrylonitrile, the
halogen containing vinyl based monomer, and the copolymerizable
vinyl based monomer is adjusted so as to give 100%.
[0019] In the monomer mixture, a percentage of the acrylonitrile of
less than the lower limit or a percentage exceeding the upper limit
of the halogen containing vinyl based monomer does not allow
demonstration of sufficient heat-resistance, and a percentage
exceeding the upper limit of the acrylonitrile unit or a percentage
of the halogen containing vinyl based monomer of less than the
lower limit gives inadequate flame resistance. In the monomer
mixture, a percentage exceeding the upper limit of the
copolymerizable vinyl based monomer fails to fully exhibit flame
resistance and touch that are special feature of the
halogen-containing flame resistant fiber.
[0020] Any halogen containing vinyl based monomers can be used, as
long as the halogen containing vinyl based monomer is a vinyl based
monomer including halogen atom, preferably bromine atom or chlorine
atom. As examples of the halogen containing vinyl based monomer,
for example, vinyl chloride, vinylidene chloride, vinyl bromide,
etc. may be mentioned. These may be used independently or two or
more kinds may be used in combination.
[0021] As the copolymerizable vinyl based monomer, for example,
there may be mentioned: acrylic acid; acrylic esters, such as ethyl
acrylate, and propyl acrylate; methacrylic acid; methacrylic
esters, such as methyl methacrylate, and ethyl methacrylate; and
furthermore, acrylamide, vinyl acetate, vinyl sulfonic acid, vinyl
sulfonate (sodium vinyl sulfonate etc.), styrene sulfonic acid,
styrene sulfonate (sodium styrene sulfonate etc.) These may be used
independently or two or more kinds may be used in combination.
[0022] As methods of obtaining the acrylic based copolymer by
polymerization of the monomer mixture including the acrylonitrile,
halogen containing monomer, and the monomer copolymerizable
therewith, any methods, such as usual vinyl polymerization methods,
for example, a slurry polymerization method, an emulsion
polymerization method, a solution polymerization method, etc., may
be adopted without special limitation.
[0023] As preferable examples of the antimony compound, for
example, inorganic antimony compounds, such as antimony trioxide,
antimony pentoxide, antimonic acid, and antimony oxychloride may be
mentioned. These may be used independently or two or more kinds may
be used in combination.
[0024] A content of the antimony compound is not less than 25 parts
to the acrylic based copolymers 100 parts, and preferably not less
than 30 parts (lower limit), and it is not more than 50 parts
(upper limit). A content of the antimony compound of less than the
lower limit disables sufficient guarantee of flame resistance of a
compounded flame resistant union fabric. And on the other hand, an
amount the antimony compound exceeding the upper limit reduces
physical properties, such as strength and elongation, of the
halogen-containing flame resistant fiber, leading to problems, such
as nozzle clogging during manufacturing process.
[0025] As methods of adding the antimony compound, as a flame
resistant agent, to the acrylic based copolymer to obtain a
composition (halogen-containing flame resistant fiber), there may
be mentioned: a method of dissolving the acrylic based copolymer in
a solvent that can dissolve the copolymer and then of mixing and
dispersing the flame resistant agent into the obtained solution to
manufacture a fiber; and a method of immersing a fiber obtained
from the acrylic based copolymer into a binder aqueous solution
including a flame resistant agent and then squeezing, drying, and
heat treating to impregnate the flame resistant agent using after
treatment technique etc. Methods for obtaining a halogen-containing
flame resistant fiber are not limited to them, and other well-known
methods may be used.
[0026] As long as a compound yarn (A) obtained by compounding a
halogen-containing flame resistant fiber (a-1) and an other fiber
(a-2) is a compound yarn having less than 5% of elongation
percentage under conditions of a load of 300 mg/metric count of No.
17 and of a temperature range of 100 degrees C. to 500 degrees C.,
the other fiber (a-2) compounded with the halogen-containing flame
resistant fiber (a-1) is not especially limited. An elongation
percentage is more preferably not more than 3%. Since not less than
5% of elongation percentage of the compound yarn (A) reduces heat
resistance and flame resistance, leading to formation of a hole in
a textile fabric when ignited.
[0027] Here, an elongation percentage of the compound yarn (A) is
obtained by measuring a sample length under a fixed load of 300
mg/metric count of No.17, when a temperature is raised from 100
degrees C. to 500 degrees C. at a rate of 100-degree C./minute
using SSC150 (manufactured by Seiko Instruments Inc.) An elongation
percentage is defined as a ratio of a difference between a sample
length at the time of a maximum elongation at 100 degrees C. to 500
degrees C., and an original sample length, with respect to an
original sample length.
[0028] Since a compound yarn (A) having an elongation percentage
less than 5% of thermal behavior under conditions of a load of 300
mg/metric count of No. 17, and of a temperature range of 100
degrees C. to 500 degrees C. may be obtained, cotton, rayon, aramid
fibers, nylon fibers, etc. are preferable as the other fiber (a-2).
Since especially natural touch of the fabric can fully be
exhibited, cotton and rayon are preferable.
[0029] A percentage of the halogen-containing flame resistant fiber
(a-1) is preferably 60 parts to 95 parts in the compound yarn (A),
and more preferably 70 parts to 80 parts. And a percentage of the
other fiber (a-2) is preferably 40 parts to 5 parts in the compound
yarn (A), and more preferably 30 parts to 20 parts. The
halogen-containing flame resistant fiber (a-1) and the other fiber
(a-2) are compounded so as to be 100 parts in total.
[0030] There is shown a tendency for an amount of the
halogen-containing flame resistant fiber (a-1) of less than 60
parts to reduce a content of the halogen-containing fiber
exhibiting flame resistance in the fabric, resulting in decrease in
flame resistance. There is also shown a tendency for an amount
exceeding 95 parts of the halogen-containing flame resistant fiber
(a-1) to melt the compound yarn (A) to easily form a hole in the
fabric during combustion test, also resulting in decrease in flame
resistance.
[0031] Compounding methods of the halogen-containing flame
resistant fiber (a-1) and the other fiber (a-2) are not especially
limited, and blending, twisting, etc. may be mentioned.
[0032] The cellulosic fiber yarn (B) can be used without special
limitation. As examples, in view of fully exhibiting natural touch,
at least one kind of yarns selected from a group consisting of
cotton, hemp, rayon, polynosic, cupra, acetate, and triacetate are
preferable. In view of many advantages, such as washing resistance,
dye affinity, and low cost, especially cotton is preferable among
them.
[0033] A flame resistant union fabric of the present invention is
manufactured by co-weaving of the compound yarn (A) and the
cellulosic fiber yarn (B) for giving heat-resistance and natural
touch.
[0034] The flame resistant union fabric of the present invention is
obtained by co-weaving one of the compound yarn (A) and the
cellulosic fiber yarn (B) for a warp yarn, and another for a weft
yarn, respectively.
[0035] Union fabric itself is a fabric excellent in design having
very characteristic appearance, and especially in co-weaving of the
flame resistant fiber and general non-flame resistant fibers, some
certain weaving methods enable a large amount of disposition on a
fabric surface of non-flame resistant fibers with excellent touch
or hygroscopic property, enabling increase in commercial value of
the fabric. However, union fabrics that dispose much non-flame
resistant fibers to a fabric surface thereof have low flame
resistance in general as compared with that of plain fabrics. A
union fabric of the present invention obtained by co-weaving the
compound yarn (A) and the cellulosic fiber yarn (B) uses the
compound yarn (A) obtained by compounding the halogen-containing
flame resistant fiber (a-1) and the other fiber (a-2), and thereby
while maintaining high degree of flame resistance of class M1 also
in a union fabric, the union fabric allows disposition of a large
amount of cotton (B) in the fabric surface, enabling realization of
a fabric having high design property, excellent touch, and
excellent hygroscopic property. It the union fabric, compounding of
not only the halogen-containing flame resistant fiber but the other
fiber (a-2) as the compound yarn (A) may suppress contraction by
heat, promotes carbonization, and improves flame resistance.
Furthermore, both of special features such as flame resistance of
the compound yarn (A), and touch of the cellulosic fiber yarn (B)
will be maximized.
[0036] In the flame resistant union fabric, a percentage of the
compound yarn (A) is not less than 30%, and preferably not less
than 40% (lower limit), and not more than 70%, and preferably not
more than 60% (upper limit). On the other hand, in the flame
resistant union fabric a percentage of the cellulosic fiber yarn
(B) is not less than 30%, and preferably not less than 40% (lower
limit), and it is not more than 70%, and preferably not more than
60% (upper limit).
[0037] Of course, a total of the compound yarn (A) and the
cellulosic fiber yarn (B) is adjusted to be 100% by weight.
[0038] A percentage of the compound yarn (A) of less than the lower
limit in the flame resistant union fabric fails to provide
sufficient flame resistance, and on the other hand, a percentage
exceeding the upper limit fails to fully exhibit special feature as
a flame resistant fiber of the fiber yarn (B).
[0039] Reasons that a flame resistant fiber union fabric of the
present invention represents high flame resistance of class M1 in
NF P 92-503 combustion test are not yet certain, but for example,
following reasons can be conceivable.
[0040] (1) Use of compound yarn (A) that cannot easily be elongated
under temperatures of 100 degree C. to 500 degrees C. during
heater-heating of combustion test suppresses contraction of the
fabric by heat, and promotes carbonization at the time of contact
to a flame of a heater to improve flame resistance.
[0041] (2) Especially, mixing of fibers having thermal
decomposition temperatures higher than that of the
halogen-containing fiber, such as cotton, rayon, and aramid fibers,
suppresses calorific power at the time of contact to a flame of a
heater.
EXAMPLE
[0042] (Flame Resistance Examination)
[0043] Evaluation of flame resistance of union fabrics was
performed according to French NF P 92-503 method. The French NF P
92-503 combustion test method will be briefly described. Examined
fabric is held horizontally inclined by 30 degrees, an electric
heater with 500 W is brought close to the fabric, and contact with
a burner flame is carried out for 5 seconds at each timing of 20
seconds, 45 seconds, 75 seconds, 105 seconds, 135 seconds, and 165
seconds after heater heating starts. Flame resistance is judged by
a number of seconds in which a flame remains burning, and a
distance of charring. This examination is a very severe combustion
test in which contact with a burner flame is carried out
simultaneously with heating by an electric heater.
[0044] Combustion of a union fabric was carried out in four
directions of: warp surface side, warp reverse side, weft surface
side, and weft reverse side. Judgment was performed according to
following NF P 92-507 criterion.
[0045] Acceptance Criterion
[0046] M1: All flame-remaining periods in 4 directions are not more
than 5 seconds
[0047] M2: In examination in four directions, at least one sheet
has a flame-remaining period exceeding 5 seconds, and an average
distance of charring of not more than 35 cm
[0048] M3: In examination in four directions, at least one sheet
has a flame-remaining period exceeding 5 seconds, and an average
distance of charring of not more than 60 cm
[0049] (Measurement of Elongation Percentage)
[0050] Using SSC150 (manufactured by Seiko Instruments Inc.), a
sample length to the original sample length was measured when a
testing temperature was raised from 100 degrees C. to 500 degrees
C. in a rate of 100-degree C./minute under a fixed load of 300
mg/metric count of No. 17. An elongation percentage is defined as a
ratio of a difference between a sample length at the time of a
maximum elongation at 100 degrees C. to 500 degrees C., and an
original sample length to an original sample length.
Manufacturing Example 1
Manufacture of a Compound Yarn of a Halogen-Containing Flame
Resistant Fiber and Cotton
[0051] Acrylonitrile 52 parts, vinylidene chloride 46.8 parts, and
sodium styrenesulfonate 1.2 parts were copolymerized to obtain an
acrylic based copolymer. The obtained acrylic based copolymer was
dissolved in acetone to obtain a solution with a concentration of
30%. Antimony trioxide 50 parts was added to the obtained copolymer
100 parts to prepare a spinning solution. The obtained spinning
solution was extruded into an aqueous solution of acetone with a
concentration of 38% at 25-degree C. using a nozzle having 0.07 mm
of pore size, and 33000 numbers of holes, and then after washing
with water the obtained filaments were dried for 8 minutes at 120
degrees C. Then the obtained filaments were drawn 3 times at 150
degrees C., and subsequently heat-treated for 30 seconds at 175
degrees C. to obtain a halogen-containing flame resistant fiber
having a size of a fiber of 3 dtex. A finishing oil for spinning
(manufactured by TAKEMOTO OIL & FAT CO., LTD.) were given to
the obtained halogen-containing flame resistant fiber, textured to
form crimps, and subsequently cut into length of 38 mm.
Subsequently, the cut halogen-containing flame resistant fiber 80
parts and cotton 20 parts were mixed in a state of raw fiber so as
to be a total of 100 parts to manufacture a spun yarn having a
metric count of No. 17. Table 1 shows elongation percentage of
obtained compound yarn.
Manufacturing Example 2
Manufacture of a Compound Yarn of a Halogen-Containing Flame
Resistant Fiber and Cotton
[0052] Except for having mixed cotton 30 parts to the
halogen-containing flame resistant fiber 70 parts, a similar method
as in Manufacturing Example 1 was repeated to manufacture a
compound yarn and then a spun yarn having a metric count of No. 17.
Table 1 shows elongation percentage of obtained compound yarn.
Manufacturing Example 3
Manufacture of a Compound Yarn of the Halogen-Containing Flame
Resistant Fiber and Cotton
[0053] Except for having mixed a cotton 40 parts to the
halogen-containing flame resistant fiber 60 parts, a similar method
as in Manufacturing Example 1 was repeated to manufacture a
compound yarn and then a spun yarn having a metric count of No. 17.
Table 1 shows elongation percentage of obtained compound yarn.
Manufacturing Example 4
Manufacture of a Compound Yarn of the Halogen-Containing Flame
Resistant Fiber and Rayon
[0054] Except for having mixed a rayon 20 parts to the
halogen-containing flame resistant fiber 80 parts, a similar method
as in Manufacturing Example 1 was repeated to manufacture a
compound yarn and then a spun yarn having a metric count of No. 17.
Table 1 shows elongation percentage of obtained compound yarn.
Manufacturing Example 5
Manufacture of a Compound Yarn of Halogen-Containing Flame
Resistant Fiber and Rayon
[0055] Except for having mixed a rayon 30 parts to the
halogen-containing flame resistant fiber 70 parts, a similar method
as in Manufacturing Example 1 was repeated to manufacture a
compound yarn and then a spun yarn having a metric count of No. 17.
Table 1 shows elongation percentage of obtained compound yarn.
Manufacturing Example 6
Manufacture of a Compound Yarn of Halogen-Containing Flame
Resistant Fiber and Rayon
[0056] Except for having mixed a rayon 40 parts to the
halogen-containing flame resistant fiber 60 parts, a similar method
as in Manufacturing Example 1 was repeated to manufacture a
compound yarn and then a spun yarn having a metric count of No. 17.
Table 1 shows elongation percentage of obtained compound yarn.
Comparative Manufacturing Example 1
Manufacture of a Halogen-Containing Flame Resistant Fiber
[0057] A halogen-containing flame resistant fiber was manufactured
in a same manner as in Manufacturing Example 1, and a spun yarn
having a metric count of No. 17 was obtained without mixing
cellulosic fiber. Table 1 shows elongation percentage of obtained
compound yarn.
Examples 1 to 6
Manufacture of Union Fabrics
[0058] Using a spun yarn of cotton with a metric count of No. 51
(percentage of the warp yarn 55%) as a warp yarn with a density of
155 units/2.54 cm (1 inch), compound spun yarns manufactured in the
Manufacturing Examples 1 to 6 were woven with a density of 42
units/2.54 cm (1 inch) (percentage of the weft yarn 45%) as weft
yarns into union fabrics having a 5 harness satin weave. The
obtained union fabrics were evaluated for flame resistance. Table 1
shows results.
Comparative Example 1
Manufacture of Union Fabrics
[0059] Except for having used a spun yarn manufactured in the
Comparative Manufacturing Example 1 as a weft yarn, union fabrics
of 5 harness satin weave were manufactured in a same manner as in
Examples 1 to 6. The obtained union fabric was evaluated for flame
resistance. Table 1 shows results.
1 TABLE 1 Compound yarn (A) Mixture ratio Antimony of compound
content in yarn (A)/ Halogen- Mixture Elongation cellulosic
containing Other ratio on fiber yarn EXAMPLE fiber (a-1) fiber
(a-1)/ percentage (B) in a Flame Number (part) (a-2) (a-2) (%)
union fabric resistance 1 50 Cotton 80/20 0 45/55 M1 2 50 Cotton
70/30 0 45/55 M1 3 50 Cotton 60/40 0 45/55 M1 4 50 Rayon 80/20 0
45/55 M1 5 50 Rayon 70/30 0 45/55 M1 6 50 Rayon 60/40 0 45/55 M1
Comparative 50 -- 100/0 35 45/55 M2 Example
[0060] As is clear with reference to Table 1, compound yarns (A) in
Manufacturing Example 1, 2, or 3 using the halogen-containing flame
resistant fiber including antimony trioxide as a flame resistant
agent and cotton have 0% of elongation percentage at 500 degrees C.
And combustion test results of union fabrics in Example 1, 2, or 3
manufactured using the compound yarns (A) and spun yarn (B) of
cotton has class M1, showing high flame resistance. Also in
Examples 4, 5, or 6 using the rayon as a cellulosic fiber,
combustion test results have class M1 to show high flame
resistance.
[0061] On the other hand, the spun yarn using only a
halogen-containing flame resistant fiber manufactured by the
Comparative Manufacturing Example 1, an elongation percentage at a
temperature of 500 degrees C. shows 35%. The union fabric in
Comparative Example 1 manufactured using this compound yarn and a
spun yarn of cotton has flame resistance inferior to that of union
fabrics obtained in Examples 1 to 6, showing class M2.
[0062] As mentioned above, it may be understood that a union fabric
consisting of a compound yarn obtained by compounding a
halogen-containing flame resistant fiber including antimony
trioxide and an other fiber, and a cellulosic fiber yarn can give a
fabric having high flame resistance classified into class M1.
INDUSTRIAL APPLICABILITY
[0063] Since a flame resistant union fabric of the present
invention is a union fabric having high degree of flame resistance
that may passes class M1 of NF P 92-503 combustion test in France,
it can develop high flame resistance also in union fabrics, such as
jacquard, dobby, and satin weave.
* * * * *