Title:
Flame-Retardant Bedding
Kind Code:
A1


Abstract:
The object of the present invention is to provide a bedding in which polyester having excellent elasticity is used for a batting therein, and which is provided with high-grade flame retardance so as to withstand long-time flaming, even though only a small amount of a halogen-containing fiber is used therein. By configuring the flame-retardant bedding product so that it is composed of a batting and a ticking for covering the batting and that the batting comprises a cellulose fiber (A), a polyester fiber (B), and a halogen-containing fiber (C) as essential components, the bedding product is caused to achieve the above-described object. In addition to the excellent flame retardance, the bedding product of the present invention is allowed to have excellent cushiony properties, since a large amount of a polyester fiber can be used therein because the amount of a halogen-containing fiber used therein is relatively small. Further, with the present invention, even a flame-retardant bedding product in which an easily inflammable fiber such as a polyester fiber or a cellulose fiber is used for a ticking exhibits sufficient flame retardance. Therefore, it is possible to provide a bedding that exhibits excellent feeling and touch as well as flame retardance.



Inventors:
Tanaka, Takeshi (Hyogo, JP)
Mio, Wataru (Hyogo, JP)
Maruyama, Shigeru (Hyogo, JP)
Mihoichi, Masahiko (Hyogo, JP)
Iwade, Susumu (Osaka, JP)
Application Number:
11/920804
Publication Date:
01/29/2009
Filing Date:
05/29/2006
Assignee:
KANEKA CORPORATION (Osaka-shi, JP)
Primary Class:
International Classes:
A47G9/02; D04H1/42
View Patent Images:
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Primary Examiner:
STEELE, JENNIFER A
Attorney, Agent or Firm:
HAMRE, SCHUMANN, MUELLER & LARSON, P.C. (Minneapolis, MN, US)
Claims:
1. A flame-retardant bedding product comprising a batting and a ticking for covering the batting, wherein the batting is formed of fibers comprising 10 wt % to 40 wt % of a cellulose fiber (A), 50 wt % to 80 wt % of a polyester fiber (B), and 10 wt % to 40 wt % of a halogen-containing fiber (C).

2. The flame-retardant bedding product according to claim 1, wherein the cellulose fiber (A) is at least one fiber selected from the group consisting of cotton, hemp, rayon, polynosic, cuprammonium rayon, acetate, and triacetate.

3. The flame-retardant bedding product according to claim 1, wherein the cellulose fiber (A) is a rayon fiber containing 20 wt % to 50 wt % of a flame retardant selected from silicic acid and aluminum silicate.

4. The flame-retardant bedding product according to claim 1, wherein the cellulose fiber (A) is a fiber obtained by adding a flame retardant to a cellulose fiber so that the content of the flame retardant is 6 wt % to 25 wt %, the flame retardant being at least one selected from the group consisting of phosphoric acid ester compounds, halogen-containing phosphoric acid ester compounds, condensed phosphoric acid ester compounds, polyphosphate compounds, red phosphorus, amine compounds, boric acid, halogen compounds such as bromides, urea-formaldehyde compounds, and ammonium sulfate.

5. The flame-retardant bedding product according to claim 1, wherein the polyester fiber (B) is at least one fiber selected from the group consisting of a polyester fiber having a melting point above 200° C., a low-melting-point binder fiber, and a flame-retardant polyester fiber.

6. The flame-retardant bedding product according to claim 5, wherein the low-melting-point binder fiber is at least one fiber selected from the group consisting of a fiber made of a single component of a low-melting-point polyester, a fiber made of a composite of a polyester having a melting point above 200° C. and a low-melting-point polyester, and a fiber made of a composite of a polyester having a melting point above 200° C. and a low-melting-point polyolefin.

7. The flame-retardant bedding product according to claim 5, wherein the flame-retardant polyester fiber is a fiber to which a flame retardant has been added, the flame retardant being at least one selected from the group consisting of phosphorus compounds, phosphoric acid ester compounds, halogen-containing phosphoric acid ester compounds, condensed phosphoric acid ester compounds, polyphosphate compounds, phosphazene compounds, red phosphorus, amine compounds such as hindered amine compounds, boric acid, halogen compounds such as bromides, urea-formaldehyde compounds, ammonium sulfate, hydrated metal compounds, metal oxides, organic metal compounds, and silicone compounds.

8. The flame-retardant bedding product according to claim 1, wherein the halogen-containing fiber (C) is a modacrylic fiber.

9. The flame-retardant bedding product according to claim 1, wherein the ticking contains a cellulose fiber and/or a polyester fiber.

10. The flame-retardant bedding product according to claim 9, wherein the ticking is formed of 20 wt % to 80 wt % of a cellulose fiber, and 80 wt % to 20 wt % of a polyester fiber.

Description:

TECHNICAL FIELD

The present invention relates to bedding products having high-grade flame retardance.

BACKGROUND ART

For fire prevention, it is preferable to impart flame retardance to materials used in bedding products, interior products, furniture, etc. located in doors. Such materials to which the flame retardance has been imparted must be materials that do not impair comfort properties such as good touch and moisture absorption, etc. of bedding products and interior products.

Among bedding products and interior products, there are some products that are required to have cushiony properties, such as mattress pads, comforters, and pillows. In many cases, polyester fibers having excellent elasticity are used as batting in such products so as to exhibit the cushiony properties. For ticking thereof, cotton fibers excellent in moisture absorption, polyester fibers excellent in durability, or the like are used. Various attempts for imparting flame retardance to the above-described products have been made, but most of the attempts related to the flame retardance of tickings.

In order to impart flame retardance to fibers, it is necessary to use fibers containing flame retardants such as antimony compounds or phosphorus compounds, or fibers like glass fibers that are flame-retardant themselves. Such fibers, however, are poor in comfort properties such as feeling or moisture absorption. Therefore, regarding beddings in which batting is used, it is desirable that not ticking but batting is made flame-retardant.

In recent years, bedding and interior fiber products have been required to have high-grade flame retardance. Such flame retardance is mentioned in, for example, Draft of Technical Bulletin 604 (hereinafter referred to as TB604) issued October 2003 by the State of California, the U.S.; therein, a test procedure for the flame retardance of pillows and the like is described. TB604 mentions, as a requirement of the foregoing test, high-grade flame retardance such as not being ignited even if subjected to long-time flaming, e.g., 20 seconds.

Patent Document 1 indicated below proposes a textile product for bedding made of a flame-retardant fiber composite material composed of a halogen-containing fiber to which high-grade flame retardance has been imparted by adding a flame retardant in a large amount; and another fiber such as polyester to which the flame retardance has not been imparted. Patent Document 1 does not disclose that the flame-retardant fiber composite material is used in a batting. It has been found that even if, however, the composite material composed of a halogen-containing fiber and a polyester fiber described in Patent Document 1 is used in a batting, it is necessary to use the flame-retardant halogen-containing fiber in a further larger amount so as to achieve the high-grade flame retardance, for example, the flame retardance according to TB604. If a halogen-containing fiber is used in a large amount, the amount of a polyester fiber used decreases, which causes the elasticity of the batting to decrease.

Patent Document 1: JP 05(1993)-093330 A

DISCLOSURE OF INVENTION

Problem to be Solved by the Invention

It is an object of the present invention to provide a bedding in which polyester, which has excellent elasticity and is inexpensive, and a halogen-containing fiber having excellent flame retardance, are used in a batting thereof, so that the bedding exhibits excellent flame retardance even though only a small amount of a halogen-containing fiber is used.

It is another object of the present invention to provide a bedding that exhibits a high-grade flame retardance even if a fiber that provides comfort properties such as good feeling and high moisture absorption but is easily inflammable, such as a polyester fiber or a cellulose fiber, is used in a ticking.

Means for Solving Problem

The inventors of the present invention have made earnest studies so as to achieve the above-described objects. As a result, they found that it is possible to obtain a flame-retardant bedding product comprising a batting and a ticking covering the batting, by using a cellulose fiber (A), a polyester fiber (B), and a halogen-containing fiber (C) in the batting; this configuration imparts the bedding product high-grade flame retardance, making it withstand long-time flaming even though only a small amount of a halogen-containing fiber is used therein.

More specifically, the present invention is as follows.

(1) A flame-retardant bedding product comprising a batting and a ticking for covering the batting, wherein the batting is formed of fibers comprising 10 wt % to 40 wt % of a cellulose fiber (A), 50 wt % to 80 wt % of a polyester fiber (B), and 10 wt % to 40 wt % of a halogen-containing fiber (C).
(2) The flame-retardant bedding product according to (1), wherein the cellulose fiber (A) is at least one fiber selected from the group consisting of cotton, hemp, rayon, polynosic, cuprammonium rayon, acetate, and triacetate.
(3) The flame-retardant bedding product according to (1) or (2), wherein the cellulose fiber (A) is a rayon fiber containing 20 wt % to 50 wt % of a flame retardant selected from silicic acid and aluminum silicate.
(4) The flame-retardant bedding product according to (1) or (2), wherein the cellulose fiber (A) is a fiber obtained by adding a flame retardant to a cellulose fiber so that the content of the flame retardant is 6 wt % to 25 wt %, the flame retardant being at least one selected from the group consisting of phosphoric acid ester compounds, halogen-containing phosphoric acid ester compounds, condensed phosphoric acid ester compounds, polyphosphate compounds, red phosphorus, amine compounds, boric acid, halogen compounds such as bromides, urea-formaldehyde compounds, and ammonium sulfate.
(5) The flame-retardant bedding product according to any one of (1) to (4), wherein the polyester fiber (B) is at least one fiber selected from the group consisting of a polyester fiber having a melting point above 200° C., a low-melting-point binder fiber, and a flame-retardant polyester fiber.
(6) The flame-retardant bedding product according to (5), wherein the low-melting-point binder fiber is at least one fiber selected from the group consisting of a fiber made of a single component of a low-melting-point polyester, a fiber made of a composite of a polyester having a melting point above 200° C. and a low-melting-point polyester, and a fiber made of a composite of a polyester having a melting point above 200° C. and a low-melting-point polyolefin.
(7) The flame-retardant bedding product according to (5), wherein the flame-retardant polyester fiber is a fiber to which a flame retardant has been added, the flame retardant being at least one selected from the group consisting of phosphorus compounds, phosphoric acid ester compounds, halogen-containing phosphoric acid ester compounds, condensed phosphoric acid ester compounds, polyphosphate compounds, phosphazene compounds, red phosphorus, amine compounds such as hindered amine compounds, boric acid, halogen compounds such as bromides, urea-formaldehyde compounds, ammonium sulfate, hydrated metal compounds, metal oxides, organic metal compounds, and silicone compounds.
(8) The flame-retardant bedding product according to any one of (1) to (7), wherein the halogen-containing fiber (C) is a modacrylic fiber.
(9) The flame-retardant bedding product according to any one of (1) to (8), wherein the ticking contains a cellulose fiber and/or a polyester fiber.
(10) The flame-retardant bedding product according to (9), wherein the ticking is formed of 20 wt % to 80 wt % of a cellulose fiber, and 80 wt % to 20 wt % of a polyester fiber.

EFFECTS OF THE INVENTION

According to the present invention, it is possible to provide a flame-retardant bedding product comprising a batting and a ticking for covering the batting, in which a cellulose fiber (A), a polyester fiber (B), and a halogen-containing fiber (C) are used in the batting, whereby flame retardance is imparted to the bedding product so that the bedding product can withstand long-time flaming even though only a small amount of the halogen-containing fiber is used therein.

Further, according to the present invention, a relatively small amount of a halogen-containing fiber is used in a batting of a bedding, which allows a large amount of a polyester fiber to be used therein. Therefore, it is possible to provide a bedding that exhibits excellent feeling such as cushiony properties and the like. Besides, since a large amount of a polyester fiber is used, the processability of the bedding of the present invention is not impaired, and the bedding is inexpensive.

Still further, according to the present invention, even a flame-retardant bedding product for which a ticking made of an easily inflammable fiber such as a polyester fiber or a cellulose fiber is used can exhibit sufficient flame retardance. Therefore, it is possible to provide a bedding having excellent feeling and touch while having flame retardance.

DESCRIPTION OF THE INVENTION

The batting used in the present invention comprises at least three types of fibers, which are a cellulose fiber (A), a polyester fiber (B), and a halogen-containing fiber (C).

The cellulose fiber (A) is a component that provides comfort properties such as excellent feeling and moisture absorption, while effectively functioning in the formation of a carbonized film upon combustion. Examples of the cellulose fiber (A) used in the present invention include cotton, hemp, rayon, polynosic, cuprammonium rayon, acetate, triacetate, and flame-retardant cellulose fibers. One of these may be used alone, or two or more of these may be used in combination.

As the cellulose fiber (A), a normal cellulose fiber to which flame retardance has not been imparted, or a cellulose fiber to which flame retardance has been imparted, can be used. Examples of the cellulose fibers to which flame retardance has been imparted include silicic-acid-containing cellulose fibers that are cellulose fibers containing silicic acid and/or aluminum silicate as a flame retardant, other flame-retardant cellulose fibers obtained by causing cellulose fibers to contain flame retardants during a manufacturing process, and flame-retardant cellulose fibers to which flame retardance has been imparted by a post-treatment or the like with use of flame retardants. Examples of a cellulose fiber as a substrate for the flame-retardant cellulose fiber (A) include the above-described exemplary cellulose fibers.

As the silicic-acid-containing cellulose fiber, a cellulose fiber containing 20 wt % to 50 wt % of silicic acid and/or aluminum silicate as a flame retardant in the fiber is preferred. The foregoing fiber preferably has a fineness of about 1.7 dtex to 8 dtex, and a cut length of about 38 mm to 128 mm. Specific examples of such a fiber include “Visil” containing about 30 wt % of silicic acid in the fiber, produced by Sateri, and “Visil AP” containing about 33 wt % of aluminum silicate in the fiber, produced by Sateri also. Other examples of the flame-retardant cellulose fiber include “Lenzing FR” produced by Lenzing AG. The flame-retardant cellulose fiber, however, is not limited to these.

A fiber obtained by imparting flame retardance to a cellulose fiber by post-treatment or the like may be used. Examples of the flame retardant that can be usable include: phosphoric acid ester compounds such as triphenyl phosphate, tricresyl phosphate, trixylenyl phosphate, trimethyl phosphate, triethyl phosphate, cresyl phenyl phosphate, xylenyl diphenyl phosphate, resorcinol bis(diphenyl phosphate), 2-ethylhexyl diphenyl phosphate, dimethyl phosphate, triallyl phosphate (“Reofos”), aromatic phosphoric acid ester, phosphonocarboxylic acid amide derivative, tetrakis(hydroxymethyl)phosphonium derivative, and N-methylol dimethyl phosphonopropione amide; halogen-containing phosphoric acid ester compounds, such as tris(chloroethyl) phosphate, trisdichloropropyl phosphate, tris-β-chloropropyl phosphate, chloroalkyl phosphate, tris(tribromoneopentyl) phosphate, diethyl-N,N-bis(2-hydroxyethyl)aminomethyl phosphate, and tris(2,6-dimethylphenyl) phosphate; condensed phosphoric add ester compounds such as aromatic condensed phosphoric add ester, and halogen-containing condensed phosphoric add ester; polyphosphate compounds such as ammonium polyphosphate amide, and polychlorophosphonate; polyphosphoric acid ester compounds such as polyphosphoric acid carbamate; red phosphorus; amine compounds; boric acid; halogen compounds such as bromides; urea-formaldehyde compounds; ammonium sulfate; and guanidine condensate. One of these may be used alone, or two or more of these may be used in combination. An amount of such a flame retardant to be added preferably is not less than 0.5 wt % with respect to the total amount of the batting, so that the flame retardance of the batting should be maintained.

The polyester fiber (B) used in the present invention is a component used for imparting excellent bulk properties and durability to the batting of the present invention. This component is molten upon combustion, and the molten product thus obtained covers a carbonized film. Thus, the component has an effect of increasing the strength of a carbonized film produced. Examples of the polyester fiber (B) include a generally-used polyester fiber having a melting point above 200° C., a low-melting-point binder fiber, and a flame-retardant polyester fiber. One of these may be used alone, or two or more of these may be used in combination.

The low-melting-point binder fiber preferably is at least one fiber selected from the group consisting of a fiber made of a single component of a low-melting-point polyester, a fiber made of a composite of a usual polyester and a low-melting-point polyester, and a fiber made of a composite of a usual polyester and a low-melting-point polyolefin. Generally, the melting point of a low-melting-point polyester is approximately 110° C. to 200° C., the melting point of a low-melting-point polypropylene is approximately 140° C. to 160° C., and the melting point of a low-melting-point polyethylene is approximately 95° C. to 130° C. The low-melting-point binder fiber is not limited particularly as long as it has a melting point of approximately 110° C. to 200° C., and has adhesivity in a molten state. Examples of the low-melting-point binder fiber include “SAFMET” (registered trademark) produced by Toray Industries, Inc. (4.4 dtex×51 mm, melting point: 110° C.).

Examples of the flame-retardant polyester fiber include a fiber obtained by adding a flame retardant to a fiber by post-treatment, a fiber obtained by kneading a flame retardant therein upon spinning, and a fiber into which a flame retardant has been incorporated by copolymerization. The flame-retardant polyester fiber, however, is not limited to these. Typical examples of the flame retardant include halogen compounds and phosphorus compounds, though not being limited to these particularly.

Examples of the phosphorus compound include dimethyl phenylphosphonate, diphenyl phenylphosphonate, [2-(β-hydroxyethoxycarbonyl)ethyl]methyl phosphinic acid, [2-(β-hydroxyethoxycarbonyl)ethyl]phenyl phosphinic acid, (2-carboxyl ethyl)methyl phosphinic acid, (2-carboxylethyl)phenylphosphinic acid, methyl (2-methoxycarboxyl ethyl)phenylphosphinate, methyl (4-methoxycarbonyl phenyl)phenylphosphinate, (1,2-dicarboxyethyl)dimethyl phosphine oxide, (2,3-dicarboxypropyl)dimethylphosphine oxide, (2,3-dimethoxycarbonyl ethyl)dimethylphosphine oxide, and [1,2-di(β-hydroxyethoxycarbonyl)]dimethylphosphine oxide. The phosphorus compound, however, is not limited to these.

The halogen-containing fiber (C) used in the present invention is a component used for improving the flame retardance of the batting; the component has an effect of aiding in the self-extinguishing by generating an oxygen deficient gas upon combustion. Examples of the halogen-containing fiber (C) used in the present invention include fibers made of the following materials: a homopolymer or a copolymer of a halogen-containing monomer such as vinyl chloride or vinylidene chloride; a copolymer of the halogen-containing monomer and a monomer copolymerizable with the same such as acrylonitrile, styrene, vinyl acetate, or acrylic acid ester; or a graft polymer of the halogen-containing monomer grafted with a PVA polymer. The halogen-containing fiber (C), however, is not limited to these. As the halogen-containing fiber (C), a modacrylic fiber that is a fiber made of a copolymer of a halogen-containing monomer and acrylonitrile is preferred. Particularly preferred is a modacrylic fiber made of a copolymer composed of 30 wt % to 70 wt % of acrylonitrile, 70 wt % to 30 wt % of a halogen-containing vinyl monomer, typified by vinyl chloride, and 0 wt % to 10 wt % of vinyl monomer copolymerizable with these.

It is preferable that a flame retardant is added to the foregoing modacrylic fiber so that the flame retardance of the batting is increased. Examples of the flame retardant include the following: antimony compounds such as antimony trioxide, antimony pentoxide, antimonic acid, and antimony oxychloride; Sn compounds such as stannic oxide, metastannic acid, stannous oxyhalide, stannic oxyhalide, stannous hydroxide, and tin tetrachloride; Zn compounds such as zinc oxide; Mg compounds such as magnesium oxide and magnesium hydrochloride; Mo compounds such as molybdenum oxide; Ti compounds such as titanium oxide and barium titanate; N compounds such as melamine sulfate and guanidine sulfamate; P compounds such as ammonium polyphosphate and dibutyl aminophosphate; Al compounds such as aluminum hydroxide, aluminum sulfate, and aluminum silicate; Zr compounds such as zirconium oxide; Si compounds such as silicate and glass; and natural or synthetic metallic mineral compounds such as kaolinite, zeolite, montmorillonite, talc, pearlite, bentonite, vermiculite, diatomaceous earth, and graphite; and halogenated compounds such as paraffin chloride, hexabromobenzene, and hexabromocyclododecane. Alternatively, a composite compound such as magnesium stannate, zinc stannate, or zirconium stannate may be used. One of these may be used alone, or two or more of these may be used in combination.

Among these, an antimony compound is preferred since it reacts with a halogen atom eliminated from a modacrylic fiber upon combustion and generates halogenated antimony, thereby exhibiting considerably high-grade flame retardance. It is preferable that the antimony compound is added to the modacrylic fiber so that the content of the antimony compound is 6 wt % to 50 wt %. Examples of the modacrylic fiber to which the antimony compound has been added include “Kanekalon PBX” manufactured by KANEKA CORPORATION and “SEF” manufactured by Solutia Japan Limited, though not being limited to these.

The contents of the cellulose fiber (A), the polyester fiber (B), and the halogen-containing fiber (C) are 10 wt % to 40 wt %, 50 wt % to 80 wt %, and 10 wt % to 40 wt %, respectively. The contents are determined more specifically with the following taken into consideration: the comfort properties such as texture, moisture absorption, and elasticity, the washing resistance and durability, the degree of formation of the carbonized film, the shape-maintaining performance, and the speed of self-extinguishing.

The cellulose fiber (A) is a principal component that imparts the feeling and the moisture absorption property owing to the cellulose fiber (A) to bedding products, and contributes to the formation of a carbonized film in the batting upon combustion or to the shape maintenance. If the content of the cellulose fiber (A) is less than 10 wt %, the feeling and the moisture absorption property of the cellulose fiber (A) cannot be imparted, while the batting is not given a sufficient capability of forming a carbonized film. If the content of the cellulose fiber (A) in the batting is higher than 40 wt, the elasticity of the batting is impaired or the fire extinguishing property thereof is impaired. Therefore, the content of the cellulose fiber (A) has to be not more than 40 wt %.

The polyester fiber (B) is a principal component that improves the washing resistance, durability, and elasticity of bedding products. Since the polyester fiber (B) easily is melted by combustion, the content thereof above 80 wt %, which means that the content of the melting components is large in the batting, makes the flame retardance insufficient. If the content of the polyester fiber (B) is less than 50 wt %, it does not adversely affect the flame retardance at all. However, it is necessary for the content of the polyester fiber (B) to be not less than 50 wt % so that elasticity should be imparted to batting for bedding products required to have elasticity, such as comforters, mattress pads, pillows, and cushions.

The halogen-containing fiber (C) is a principal component that imparts the self-extinguishing property to the batting. If the content of the halogen-containing fiber (C) exceeds 40 wt %, the feeling or texture owing to the cellulose fiber (A) and the elasticity owing to the polyester fiber (B) cannot be obtained sufficiently, and further, a large amount of gas that adversely affects a human body is generated from the halogen-containing fiber (C) upon combustion of bedding products.

In the batting of the present invention, it is preferable that the cellulose fiber (A), the polyester fiber (B), the halogen-containing fiber (C), and other fibers used as required are intermingled well. The well-intermingled batting may be used in a state of being packed in a ticking of a desired shape. Alternatively, a batting formed in the following manner may be used: like in a manner for forming an unwoven fabric, the blended fibers, after being thus intermingled, may be formed into a web, and the webs thus obtained are stacked so as to form a batting. The batting to which high-grade flame retardance is imparted according to the present invention can be used in bedding products that require battings, such as comforters, mattress pads, pillows, and bed cushions.

As a ticking for covering the batting of the present invention having the high-grade flame retardance, a ticking made of a cellulose fiber and/or a polyester fiber, which is generally used in bedding products and interior furniture, is preferred, but the ticking is not particularly limited. For satisfactorily attaining desired performances of bedding products, interior furniture, etc., such as texture feeling), moisture absorption, and durability, the ticking preferably comprises 20 wt % to 80 wt % of a cellulose fiber, and 80 wt % to 20 wt % of a polyester fiber.

For the batting of the present invention having the high-grade flame retardance, the cellulose fiber (A), the polyester fiber (B), and the halogen-containing fiber (C) are indispensable components. The cellulose fiber (A) has a carbonization promoting effect; it is quickly carbonized, and forms a stable carbonized film that exhibits only little shrinkage upon being subjected to flame. The polyester fiber (B) is capable of imparting excellent elasticity to flame-retardant bedding products of the present invention. The halogen-containing fiber (C) is capable of improving the fire extinguishing property of the batting.

As described above, the present invention makes it possible to obtain bedding products having high-grade flame retardance. Further, the present invention makes it possible to obtain bedding products configured so that the generation of gas that would adversely affect a human body is minimized, while the unique texture and comfort properties of materials for bedding products such as cushions, pillows, mattress pads, comforters, and futons are exhibited fully.

The present invention will be described in further detail by way of example. The present invention however is not limited to the following examples.

EXAMPLES

Production of Batting

As the cellulose fiber (A), “Corona” (registered trademark) (fineness: 1.7 dtex, cut length: 38 mm) manufactured by DAIWABO RAYON Co., Ltd., which is a generally-used cellulose fiber, or “Visil” (registered trademark) (fineness: 3.5 dtex, cut length: 50 mm) manufactured by Sateri, which is a flame-retardant cellulose fiber, was used. As the polyester fiber (B), “Tetron” (registered trademark) (fineness: 6 dtex, cut length: 51 mm) manufactured by Toray Industries, Inc., which is a generally-used polyester fiber, or “Trevira” CS (registered trademark) manufactured by Trevira GmbH, which is a flame-retardant polyester fiber, was used. As the halogen-containing fiber (C), “Kanekalon” PBX (registered trademark) (fineness: 2 dtex, cut length: 51 mm) manufactured by KANEKA CORPORATION containing an antimony compound as a flame retardant was used. These fibers were blended at ratios shown in Table 1 below, and were opened by carding so as to be formed into a web. A plurality of such webs were stacked in a multilayer form, whereby a batting was formed.

TABLE 1
Ratio of Fibers (wt %)
Halogen-containing
Cellulose fiber (A)Polyester fiber (B)fiber (C)Weight of
Production exampleFlame-retardantCellulosePolyesterFlame-retardantHalogen-containingBatting
No.cellulose fiberfiberfiberpolyester fiberfiber(g)
Production example 1405010110.0
Production example 2205030101.0
Production example 320602092.5
Production example 410603093.9
Production example 5105020110.2
Production example 6107020109.0
Production example 720503097.9
Production example 8106030104.8
Production example 910504098.2
Production example 1010094.6
Production example 117030101.1
Production example 12604096.3
Production example 13104050103.3
Production example 1420404094.2
Production example 155050112.3

Production of Ticking

Cotton fiber, 50 wt %, and polyester fiber, 50 wt %, were blended and a spun yarn with a metric count of 34 was obtained. With use of this spun yarn, a plain-woven fabric with a weight per unit area of 120 g/m2 was produced by a known method.

Method for Producing Cushion for Flame Retardance Evaluation

The batting thus obtained was cut into a size of about 30.5 cm (length)×about 30.5 cm (width). The batting was interposed between fabrics (tickings) cut into a size of about 38.1 cm (length)×about 38.1 cm (width). A plate having a weight of 325 g was placed on the cushion so that the height of the cushion was adjusted to not less than 89 mm (3.5 inches) and not more than 102 mm (4.0 inches). Four sides thereof were sewn with a cotton sewing yarn. Thus, a cushion for use in the evaluation of flame retardance was produced.

Method for Evaluating Flame Retardance

The flame retardance was tested according to the test procedure described in Section 2 of Draft of Technical Bulletin 604 (TB604) issued October, 2004 by the State of California, the U.S. To briefly describe the test procedure described in TB604 of the State of California, the U.S., in the case where the test is carried out with respect to pillows and cushions, a corner of the cushion for the flame retardance evaluation, held horizontally, is subjected to a 35 mm high flame rising from a position at ¾ inch below the foregoing corner of the cushion, for 20 seconds. If the weight loss at 6 minutes is not more than 25 wt %, the cushion is considered to pass the criteria. In Table 2, the mark “◯” indicates that the weight loss was not more than 25 wt %, while the mark “x” indicates that the weight loss exceeded 25 wt %.

The burner tube used had an internal diameter of 6.5 mm, an outside diameter of 8.0 mm, and a length of 200 mm. The fuel gas was butane gas with at least 99.0% purity. The flow rate of the butane gas was 45 ml/min, and the flame height was approximately 35 mm.

Method for Evaluating Elasticity

The evaluation of elasticity was carried out with respect to the above-described cushion used for the flame retardance evaluation. The amount of batting was 1000 g/m2. The evaluation of elasticity was performed by visually observing the cushion. The evaluation results are indicated with the following marks: the mark “◯” indicates that the cushion had a sufficient voluminousness as a bedding product (for example, the cushion had a voluminousness at the same level as that of a cushion in which a batting made of polyester fiber is used); the mark “Δ” indicates that the cushion had a voluminousness acceptable as a bedding product; and the mark “x” indicates that the cushion had a voluminousness inferior to the foregoing level (for example, the cushion had a voluminousness at the same level as that of a cushion in which a batting made of rayon fiber is used).

Examples 1 to 9 and Comparative Examples 1 to 9

The cushions for flame retardance evaluation thus formed were evaluated regarding the flame retardance and the elasticity. The evaluation results are shown in Table 2.

TABLE 2
TickingFlame retardance test
configurationProduct configurationRatio of weight
Batting usedWeight perWeight ofHeight ofdecrease
Production Ex.unit areaproductproductat 6 minutesElasticity test
Example No.No.(g/m2)(g)(inch)(%)EvaluationEvaluation
Example 1Prod. Ex. 1120147.53.624.8
Example 2Prod. Ex. 2120137.73.623.6
Example 3Prod. Ex. 3120127.13.721.3
Example 4Prod. Ex. 4120129.53.722.7
Example 5Prod. Ex. 5120146.03.924.9
Example 6Prod. Ex. 6120145.84.024.9
Example 7Prod. Ex. 7120132.93.719.2
Example 8Prod. Ex. 8120140.23.823.4
Example 9Prod. Ex. 9120131.63.624.9
Comp. Ex. 1Prod. Ex. 10120130.03.627.4x
Comp. Ex. 2Prod. Ex. 11120136.33.930.5x
Comp. Ex. 3Prod. Ex. 12120132.34.031.2x
Comp. Ex. 4Prod. Ex. 13120140.04.022.4x
Comp. Ex. 5Prod. Ex. 14120129.23.824.3x
Comp. Ex. 6Prod. Ex. 15120149.33.517.7x

Each of Examples 1 to 9 exhibited excellent flame retardance and excellent condition of a carbonized film in the test for flame retardance. Further, since the polyester fiber (B) was contained at a ratio of 50 wt % to 70 wt % with respect to the total amount of the batting, sufficient elasticity necessary for bedding products such as comforters, mattress pads, pillows, and bed cushions was obtained.

Regarding Comparative Example 1, the flame-retardant polyester fiber has an excellent self-extinguishing property among the polyester fibers (B). However, since no cellulose fiber (A) was contained in the case of the Comparative Example 1, the condition of a carbonized film was insufficient. Therefore, heat generated by molten flame-retardant polyester fiber was transmitted to the inside of the batting, and the heat promoted the melting of the flame-retardant polyester fiber further. As a result, the ratio of weight decrease at 6 minutes after flame was removed exceeded 25 wt %, which means that sufficient flame retardance was not achieved.

Regarding Comparative Examples 2 and 3, the halogen-containing fiber (C) is contained, as compared with Comparative Example 1. However, since no cellulose fiber (A) was contained, the condition of a carbonized film was insufficient. As a result, the fire extinguishing property of the batting was inferior.

Comparative Examples 4 to 6 exhibited excellent flame retardance and excellent condition of a carbonized film, but since the content of the polyester fiber (B) was insufficient, sufficient elasticity was not obtained. Besides, if the content of the halogen-containing fiber (C) was high as is the case with Comparative Example 6, satisfactory feeling as well as sufficient moisture absorption and elasticity could not be achieved, while a large amount of gas that adversely affects a human body is generated upon combustion. Thus, it is difficult to put such a product into actual use.

INDUSTRIAL APPLICABILITY

As described above, the present invention relates to a flame-retardant bedding product in which a cellulose fiber (A), a polyester fiber (B), and a halogen-containing fiber (C) were used as a batting. The bedding product of the present invention has high-grade flame retardance such that combustion can be avoided even in a flame retardance test in which the product is subjected to long-time flaming, in spite of that only a small amount of the halogen-containing fiber (C) is used. Further, the elasticity owing to the polyester fiber (B) is not impaired. Thus, the present invention is industrially applicable in the field of bedding products such as cushions, pillows, mattress pads, comforters, and futons.





 
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