JP2018031085A - 布帛の製造方法 - Google Patents
布帛の製造方法 Download PDFInfo
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- JP2018031085A JP2018031085A JP2016162876A JP2016162876A JP2018031085A JP 2018031085 A JP2018031085 A JP 2018031085A JP 2016162876 A JP2016162876 A JP 2016162876A JP 2016162876 A JP2016162876 A JP 2016162876A JP 2018031085 A JP2018031085 A JP 2018031085A
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- fabric
- flame retardant
- fluorine
- water
- coating
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Abstract
Description
特に、自動車等の乗り物は、夏期の日光に長時間さらされた場合、車内の温度が80℃程度まで上昇することがあるが、フッ素系撥水撥油剤の効果として80℃付近の液体に対しては撥水撥油性が低下しやすいため、このような高温下で高い防汚性を維持することは難しいという問題がある。
(a)ポリエステル系布帛を、第1フッ素系撥水撥油剤を含む処理液に浸漬して処理液を含ませた後、当該布帛を乾燥する工程、
(b)第2フッ素系撥水撥油剤及び難燃剤を含有するコーティング用組成物を用いて、前記布帛の一方の面をコーティングする工程、
(c)コーティング層が形成された前記布帛を、65〜90℃の温水で洗浄する工程
を含むことを特徴とする。
これに対し、本発明では、布帛の一方の面(特に、布帛の裏面)に、フッ素系撥水撥油剤及び難燃剤を含有するコーティング層を形成し(工程b)、さらにその後、湯通しを行うこと(工程c)により、優れた防汚性と難燃性を両立することに成功した。
また、難燃コーティング組成物にフッ素系撥水撥油剤を添加して、難燃・防汚コーティング層を形成すると、難燃剤単独使用の場合と比べて防汚性は改善されるものの、安定した防汚性を達成することは依然として難しいという問題がある。
これに対し、本発明では、布帛の一方の面(特に、裏面)に、フッ素系撥水撥油剤と難燃剤を含むコーティング層を形成し、さらにその後湯洗いを行うことにより、防汚性と難燃性の両方に優れ、さらに風合いの良い布帛を提供することが可能である。
本発明において、ポリエステル系布帛とは、ポリエステル繊維を含む布帛を意味し、ポリエステル繊維単独からなる織物、編物、不織布だけでなく、ポリエステル繊維と他の繊維(木綿、羊毛等の天然繊維やポリアミド、レーヨン、アクリル等の化学繊維)を組み合わせて使用した交織品、交編品等のいずれであってもよい。布帛の構成繊維に占めるポリエステル繊維の割合は、60重量%以上が好ましく、70重量%以上がより好ましく、80重量%以上が特に好ましく、90重量%以上がさらに好ましい。特に好ましい布帛は、ポリエステル繊維からなる厚み0.2〜3.0mm(目付100〜700g/m2)、特に厚み0.4〜2.6mm(目付200〜500g/m2)の布帛である。
浸漬処理に使用される第1フッ素系撥水撥油剤は1種類でもよく、複数(例えば2〜3種類)であってもよい。
この防汚加工により布帛に含浸される第1フッ素系撥水撥油剤の量は、処理液中のフッ素系撥水撥油剤の濃度と絞り率から計算できる。乾燥処理後の布帛に含まれる、第1フッ素系撥水撥油剤の含浸量は、布帛の単位面積当たり、2.0g/m2〜8.0g/m2が適切であり、3.0g/m2〜7.0g/m2がより好ましく、4.0g/m2〜6.5g/m2が特に好ましい。
なお、防汚加工後の洗浄工程で還元洗浄と温水洗浄のどちらを選択するかは、布帛の色移りのしやすさを目安に判断できる(高い染料濃度で染色された布帛は色移りしやすく、低い染料濃度で染色された布帛は色移りしにくい)。高い染料濃度で染色された布帛の例として、黒、青、赤、紫、ダークグレー、濃紺、濃緑等の約5%owf以上の染料濃度で染色された布帛が挙げられ、低い染料濃度で染色された布帛の例として、白、ライトグレー、ベージュ、クリーム等の約5%owf未満の染料濃度で染色された布帛が挙げられる。より具体的には、防汚加工後の布帛が、乾燥・湿潤試験の両方で摩擦堅牢度が4.0級以上である場合は還元洗浄は必要無いと判断でき、4.0級未満である場合、還元洗浄が必要と判断できる。摩擦堅牢度の測定は、JIS L0849(摩擦に対する染色堅ろう度試験方法)に準じる。
工程b)で使用される第2フッ素系撥水撥油剤としては、工程a)の第1フッ素系撥水撥油剤として先に述べたものを使用することができ、第1フッ素系撥水撥油剤と同じものを使用しても、異なるものを使用してもよく、1種のみを使用しても、複数の種類を併用してもよい。
特に、各バインダーはソフトなタイプが良く、アクリル系樹脂では、Tg=−30℃〜−45℃のものが良く、ウレタン系樹脂では、最低造膜温度(MFT)が0℃〜5℃のものが良い。
バインダーの含有量が少なすぎる場合は、フッ素系撥水撥油剤・難燃剤を布帛に十分に固定することが難しくなり、含有量が多すぎる場合は、風合が硬くなる可能性がある。
よって、工程c)では、前記布帛を65〜90℃(より好ましくは70〜90℃、特に好ましくは75〜85℃)の温水で洗浄することが好ましい。洗浄時間は、1〜30分程度が適切であり、より好ましくは5〜25分程度、特に好ましくは10〜20分程度洗浄する。
また、染色と難燃を同じ浴中で行ってもよい。その他、染色時に高い染料濃度(約5%owf以上)で布帛を染色した場合は、染色後に還元洗浄を行ってもよい。
ポリエステル布帛(ポリエステル100%:目付け360g/m2)を、表1に示す工程で処理した。
表1の工程において、染色処理時(工程1)には、黒色の分散染料(固形分換算で約9.8%owfとなるように添加)とともに、大京化学株式会社からビゴールFV−6010の商品名で販売されているリン酸アミド系難燃剤を0.84%owf(固形分換算)添加して、染色と同時に浴中難燃加工を行った。
また、dip−nipによる防汚加工(工程4)には、第1フッ素系撥水撥油剤として、旭硝子株式会社からアサヒガードEシリーズの名称で販売されているフッ素系撥水撥油剤及び日華化学株式会社からNKガードSの名称で販売されているフッ素系撥水撥油剤の混合物を使用し、第1フッ素系撥水撥油剤を2.44重量%(固形分換算)含む水分散液に、ポリエステル布帛を浸漬し(150℃・2分30秒)、次いで、マングルで3.0kgf/cm2の圧力で絞った(pic−up率60%)。
コーティングに使用した第2フッ素系撥水撥油剤(工程8)は、日華化学株式会社からNKガードSの名称で販売されているフッ素系撥水撥油剤である。
JIS L0849(摩擦に対する染色堅ろう度試験方法)に準じて、各加工布帛について、乾燥試験(DRY)と湿潤試験(WET)を行った。汚染の判定は、汚染用グレースケール(JIS L0805)を用いて、1〜5級の判定を行った。4級以上を合格と判定とする。
米国連邦自動車安全基準(FMVSS:Federal Motor-Vehicle Safety Standard)に定められている「内装材料の燃焼性」に準じて試験を行い、難燃性能を判定した。
布帛(加工布帛単独又はラミネート複合体)に炎を15秒間あてても着火しなかった場合(N)又は、布帛に炎をあてると着火したが、炎がA標線を越えた後、燃焼距離101mm以内、燃焼時間60秒以内で消火した場合(101mm/分以下)を合格とする。
試験片として、各試料(加工布帛)から約10×10cm角サイズを1枚準備し試験する。トレーにソフトワイプ(エリエール プロワイプ)を敷き、試験片を載せ(コーティングした場合は、コーティング面(裏面)を下にして、ソフトワイプ上に載せる)、試験試料上にスポイトでサラダ油を直径約5mm又は0.05mlで5か所に滴下する。
ギアオーブン83℃の中にトレーを入れ、24時間静置する。24時間後トレーを取り出し、試験片表面においてサラダ油滴下個所が湿潤していないか(油シミが生じていないか)、また、裏面とソフトワイプにサラダ油の油シミがないか観察する。試験試料の表面と裏面、及び下に敷いていたソフトワイプに油ジミがないものを合格とする。
JIS L1092 6.2で定められている装置に、20cm×20cmの大きさにカットした試験片を試験片保持枠にしわが生じないように取り付ける。
蒸留水又はイオン交換水250mlを漏斗に入れ、試験片上へ散布する。
次に試験片を保持枠ごと台上から取り外し、その一遍で水平に持ち、試験片の表側を下向きにして他端を固い物に一度軽く当て、更に180°回し、前と同様に操作して余分な水滴を落とす。
保持枠を取り付けたまま試験片の濡れた状態を採点する。
0点 :表面及び裏面が全体に湿潤を示すもの
50点:表面全体に湿潤を示すもの
70点:表面の半分に湿潤を示し、小さな個々の湿潤が布を浸透する状態を示すもの
80点:表面に小さな個々の水滴状の湿潤を示すもの
90点:表面に湿潤しないが、小さな水滴の付着を示すもの
95点:表面に湿潤が無く、小さな水滴がわずかに付着を示すもの
100点:表面に湿潤や水滴の付着が無いもの
初期95点以上を合格とする。
工程6及び工程11の洗浄が布帛の風合いに与える影響を確認するために、以下の実験を行った。
ブランク、No.1、No.2、No.4及びNo.5の布帛をそれぞれ20cm×20cmの大きさにカットし、縦方向及び横方向に、裏面側(コーティング層形成側)を外側にして半分に折り曲げた時のサンプルの高さh(mm)を測定した(図2参照)。折り曲げ高さhの値が小さいことは、布帛が柔らかくて風合が良好であることを意味し、折り曲げ高さhの値が高いほど、布帛は硬く風合いが悪くなる。測定結果を表3に示す。
2 フッ素系撥水撥油剤及び難燃剤を含有するコーティング層
3 発泡材シート
Claims (7)
- 布帛の製造方法であって、
(a)ポリエステル系布帛を、第1フッ素系撥水撥油剤を含む処理液に浸漬して処理液を含ませた後、当該布帛を乾燥する工程、
(b)第2フッ素系撥水撥油剤及び難燃剤を含有するコーティング用組成物を用いて、前記布帛の一方の面をコーティングする工程、
(c)コーティング層が形成された前記布帛を、65〜90℃の温水で洗浄する工程
を含むことを特徴とする方法。 - 前記布帛の前記一方の面が、布帛の裏面である、請求項1に記載の方法。
- 前記コーティング層に含まれる第2フッ素系撥水撥油剤の布帛の単位面積当たりの含有量が、0.5〜4.0g/m2となり、前記コーティング層に含まれる難燃剤の布帛の単位面積当たりの含有量が、25〜60g/m2となるように、工程(b)のコーティングを行う、請求項1または2に記載の方法。
- 前記コーティング用組成物が、アクリル系樹脂、ウレタン系樹脂及びポリエステル系樹脂から選択されるバインダーを含み、前記コーティング層に含まれるバインダーの布帛の単位面積当たりの含有量が、15〜35g/m2となるように、工程(b)のコーティングを行う、請求項1〜3のいずれか1項に記載の方法。
- 前記難燃剤が、20℃の水への溶解度が4.0%以下であるリン系難燃剤である、請求項1〜4のいずれか1項に記載の方法。
- さらに、前記工程(a)の後、前記工程(b)の前に、前記布帛を洗浄する工程を含む、請求項1〜5のいずれか1項に記載の方法。
- さらに、前記工程(c)の後に、前記布帛の前記一方の面に発泡材シートを固着させる工程を含む、請求項1〜6のいずれか1項に記載の方法。
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CN101736582A (zh) * | 2009-12-31 | 2010-06-16 | 安徽中天印染股份有限公司 | 一种取得多功能性纺织物的整理方法 |
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CN101736582A (zh) * | 2009-12-31 | 2010-06-16 | 安徽中天印染股份有限公司 | 一种取得多功能性纺织物的整理方法 |
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