Fabric, method for manufacturing same, and fiber product

Abstract

The invention addresses the problem of providing a cloth that is excellent not only in flame retardancy and antistatic properties but also in appearance quality and preferably also has protection performance against electric arcs, a method for producing the same, and a textile product. A means for resolution is a cloth including a meta-type wholly aromatic polyamide fiber and an electrically conductive fiber, wherein both the meta-type wholly aromatic polyamide fiber and the electrically conductive fiber are colored.

Claims

1. A flame-retardant and antistatic cloth, comprising: a meta-type wholly aromatic polyamide fiber, an electrically conductive acrylic fiber, and an additional fiber being at least one selected from the group consisting of para-type wholly aromatic polyamide fibers, polyphenylene sulfide fibers, polyimide fibers, polybenzimidazole fibers, polybenzoxazole fibers, polyamideimide fibers, polyetherimide fibers, and carbon fibers; wherein the meta-type wholly polyamide fiber and the electrically conductive fiber are contained in the form of a blend-spun yarn, wherein the meta-type wholly aromatic polyamide fiber is within the range from 80 to less than 99 mass % relative to the cloth mass; wherein the electrically conductive acrylic fiber is a sheath-core conjugate fiber including a core part containing electrically conductive carbon microparticles and a sheath part not containing any electrically conductive microparticles, wherein the electrically conductive acrylic fiber is within the range of greater than 1 to less than 20 mass % relative to the cloth mass; wherein both the meta-type wholly aromatic polyamide fiber and the electrically conductive acrylic fiber are colored using the same cationic dye, such that a hue difference between the meta-type wholly aromatic polyamide fiber and the electrically conductive acrylic fiber is ΔE 3 or less, wherein the cloth comprises an ATPV value in Arc Resistance Test ASTM F1959-1999 of 8.0 cal/cm2 or more, a frictional charge quantity of 7.0 μC/m2 as measured by a JS L1094-2014, C method, and an afterflame time of 1.0 second or less in a flammability measurement according to JIS L1091-1992,A-4 Method (12-second flame application).

2. The cloth according to claim 1, wherein the range of the electrically conductive fiber is within 5 to 15 mass % relative to the cloth mass.

3. The cloth according to claim 2, wherein the range of the electrically conductive fiber is within 10 to 15 mass % relative to the cloth mass.

4. The cloth according to claim 1, wherein the additional fiber comprises para-type wholly aromatic polyamide fibers, the para-type wholly aromatic polyamide fibers within a range of 1 to 10 mass % relative to the cloth mass.

5. The cloth according to claim 1, wherein the meta-type wholly aromatic polyamide fiber is made of a polymer wherein 85 mol % or more of the repeating unit is m-phenylene isophthalamide.

6. The cloth according to claim 5, wherein the meta-type wholly aromatic polyamide fiber contains an alkylbenzenesulfonic acid onium salt, within a range of 2.5 mol % or more relative to a total amount of m-phenylene isophthalamide units.

7. The cloth according to claim 6, wherein the polymer is a copolymer further comprising an aromatic diamine component or aromatic dicarboxylic acid halide component, different from a main unit, in a range of less than 15 mol % relative to a total amount of repeating structural units in the copolymer.

8. The cloth according to claim 1, wherein the residual solvent content of the meta-type wholly aromatic polyamide fiber is 0.1 mass % or less.

9. The cloth according to claim 1, wherein the meta-type wholly aromatic polyamide fiber has a crystallinity of 5 to 35%.

10. The cloth according to claim 9, wherein the crystallinity is 15 to 25%.

11. The cloth according to claim 10, wherein the crystallinity is 15 to 19%.

12. The cloth according to claim 1, wherein an electrically conductive carbon microparticle content of the core part is 20 to 60 mass % and the electrically conductive acrylic fiber comprises a single-fiber resistivity is 10.sup.1 to 10.sup.6 Ω.Math.cm.

13. The cloth according to claim 1, wherein the cationic dye is azo dye.

14. The cloth according to claim 10, wherein the azo dye is selected from the group consisting of C.I. Basic Blue 54, C.I. Basic Blue 3, C.I. Basic Red 29, and C.I. Basic Yellow 67.

15. The cloth according to claim 1, wherein a fiber length of each fiber of the blend-spun yarn is 25 to 200 mm.

16. The cloth according to claim 1, wherein the blend-spun yarn comprises a fineness being a cotton count (Ecc) of 20 to 80 and comprises a twist coefficient, wherein the twist coefficient is expressed by the following equation:
twist coefficient=number of twists per 2.54 cm/Ecc.sup.1/2 within a range of 3.6 to 4.2.

17. The cloth according to claim 1, wherein the cloth has a weight per unit area within a range of 3.0 to 9.0 yd/oz.sup.2 and a thickness of at least 0.30 mm.

18. The cloth according to claim 1, wherein the cloth comprises a woven structure comprising warp yarns and weft yarns, wherein each of the warp yarns and the weft yarns comprise the blend-spun yarn.

19. The cloth according to claim 18, wherein the woven structure comprises a warp density of 60 to 80 yarns/2.54 cm and a weft density of 60 to 80 yarns/2.54 cm.

20. A wearable textile product comprising the cloth according to claim 1, selected from the group consisting of protective garments, workgarments, fireproof garments, camouflage uniforms, happi coats, and aprons.

Description

EXAMPLES

(1) Hereinafter, the invention will be described in detail with reference to examples, but the invention is not limited thereto. Incidentally, in the examples, the properties were measured by the following methods.

(2) (1) Flame Retardancy of Cloth

(3) The afterflame time was measured by the flammability measurement according to JIS L1091-1992, A-4 Method (12-second flame application).

(4) (2) Residual Solvent Content

(5) About 8.0 g of a raw fiber was collected, dried at 105° C. for 120 minutes, and then allowed to cool in a desiccator, and the fiber mass (M1) was measured. Subsequently, the fiber was subjected to reflux extraction in methanol for 1.5 hours using a Soxhlet extractor to extract the amide-based solvent contained in the fiber. The fiber after extraction was taken out, vacuum-dried at 150° C. for 60 minutes, and then allowed to cool in a desiccator, and the fiber mass (M2) was measured. Using the obtained M1 and M2, the content of residual solvent in the fiber (amide-based solvent mass) was calculated using the following equation.
Residual solvent content (%)=[(M1−M2)/M1]×100
(3) Crystallinity

(6) An about 1 mm-diameter bundle of raw fibers was mounted on a fiber sample table and subjected to measurement of diffraction profile using an X-ray diffraction apparatus (RINT TTRIII manufactured by Rigaku Corporation). The measurement conditions were as follows: Cu—Kα radiation source (50 kV, 300 mA), scanning angle range: 10 to 35°, continuous measurement, measurement width: 0.1°, scanning at 1°/min. From the measured diffraction profile, air scattering and incoherent scattering were corrected by linear approximation to give the total scattering profile. Next, the amorphous scattering profile was subtracted from the total scattering profile to give the crystal scattering profile. The crystallinity was determined from the integrated intensity of the crystal scattering profile (crystal scattering intensity) and the integrated intensity of the total scattering profile (total scattering intensity) using the following equation.
Crystallinity (%)=[crystal scattering intensity/total scattering intensity]×100
(4) Dye Affinity

(7) Color measurement was performed using a Macbeth spectrophotometer (Color-Eye 3100) to determine ΔE.

(8) (5) Antistatic Properties

(9) The frictional charge quantity was measured by JIS L1094-2014, C Method. 7.0 μC/m.sup.2 or less was rated as acceptable.

(10) (6) Weight per Unit

(11) Measurement was performed in accordance with JIS L1096.

(12) (7) ATPV Value

(13) The ATPV value was measured in accordance with Arc Resistance Test ASTM F1959-1999. 8.0 cal/cm.sup.2 or more is rated as acceptable (Level 2 satisfied).

(14) [Production of Meta-Type Wholly Aromatic Polyamide Fiber]

(15) A meta-type wholly aromatic polyamide fiber was prepared by the following method.

(16) 20.0 parts by mass of a polymetaphenylene isophthalamide powder having an intrinsic viscosity (I.V.) of 1.9 produced by an interfacial polymerization method based on the method described in JP-B-47-10863 was suspended in 80.0 parts by mass of N-methyl-2-pyrrolidone (NMP) cooled to −10° C., thereby forming a slurry. Subsequently, the suspension was heated to 60° C. for dissolution to give a transparent polymer solution. A powder of 2-[2H-benzotriazol-2-yl]-4-6-bis(1-methyl-1-phenylethyl)ph enol (solubility in water: 0.01 mg/L) in an amount of 3.0 mass % relative to the polymer was mixed with and dissolved in the polymer solution, and the mixture was defoamed under reduced pressure to give a spinning solution (spinning dope).

(17) [Spinning/Coagulation Step]

(18) The above spinning dope was discharged and spun from a spinneret having 500 0.07-mm-diameter holes into a coagulation bath at a bath temperature of 30° C. The composition of the coagulation liquid was water/NMP=45/55 (parts by mass), and the dope was discharged and spun into the coagulation bath at a yarn speed of 7 m/min.

(19) [Drawing Step in Plastic Drawing Bath]

(20) Subsequently, drawing was performed to a draw ratio of 3.7 in a plastic drawing bath at a temperature of 40° C. having a composition of water/NMP=45/55.

(21) [Washing Step]

(22) After drawing, washing was performed in a bath at 20° C. having water/NMP=70/30 (immersion length: 1.8 m) and then in a water bath at 20° C. (immersion length: 3.6 m), followed by thorough washing through a hot water bath at 60° C. (immersion length: 5.4 m).

(23) [Dry Heat Treatment Step]

(24) The fiber after washing was subjected to a dry heat treatment using a hot roller having a surface temperature of 280° C. to give a meta-type wholly aromatic polyamide fiber.

(25) [Properties of Raw Fiber]

(26) The obtained meta-type wholly aromatic polyamide fiber (meta-aramid fiber) had the following properties: fineness: 1.7 dtex, residual solvent content: 0.08 mass %, crystallinity: 19%. The obtained raw fiber was crimped and cut into short fibers of 51 mm in length (raw cotton).

Example 1

(27) Using the above meta-type wholly aromatic polyamide fiber, a para-type wholly aromatic polyamide fiber having a single-fiber fineness of 1.7 dtex and a fiber length of 50 mm (manufactured by Teijin Aramid, trade name “Twaron”), and an electrically conductive acrylic fiber having a single-fiber fineness of 3.3 dtex and a fiber length of 38 mm (manufactured by Mitsubishi Chemical Corporation, trade name “COREBRID”, eccentric sheath-core electrically conductive acrylic fiber; sheath part: acrylic/core part: electrically conductive carbon-containing polymer), a spun yarn of 1/68 yarn count was formed such that the meta-type wholly aromatic polyamide fiber: 93 mass %, the para-type wholly aromatic polyamide fiber: 5 mass %, and the electrically conductive acrylic fiber: 2 mass %, and a double ply yarn plied yarn was obtained.

(28) Next, the yarn was placed in each of warp and weft yarns, and a plain-structure woven fabric having a warp density of 57 yarns/2.54 cm and a weft density of 50 yarns/2.54 cm was woven.

(29) Using a jet dyeing machine (high-temperature circular dyeing machine manufactured by Hisaka Works, Ltd.), the obtained undyed woven fabric (gray fabric) was treated in a dye bath containing a cationic dye (manufactured by Nippon Kayaku Co., Ltd., Kayacryl Red GL-ED, 15% owf) and a carrier agent (manufactured by Dow Chemical Company, DOWANOL PPH, 40 g/L). The temperature was raised from ambient, and the fabric was dyed at 130° C. for 60 minutes.

(30) The obtained dyed cloth had excellent appearance quality with a deep color and no color non-uniformity. In addition, the meta-type wholly aromatic polyamide fiber and the electrically conductive fiber were colored a same color, and the hue difference ΔE between the two was 3 or less. In addition, the frictional charge quantity was as excellent as 3.3 μC/m.sup.2. In addition, the afterflame time was 0 second, indicating excellent flame retardancy.

Example 2

(31) A dyed cloth was obtained in the same manner as in Example 1, except that a spun yarn of 1/68 yarn count was formed such that the meta-type wholly aromatic polyamide fiber: 80 mass %, the para-type wholly aromatic polyamide fiber: 5 mass %, and the electrically conductive acrylic fiber: 15 mass %.

(32) The obtained dyed cloth had excellent appearance quality with a deep color and no color non-uniformity. In addition, the meta-type wholly aromatic polyamide fiber and the electrically conductive fiber were colored a same color, and the hue difference ΔE between the two was 3 or less. In addition, the frictional charge quantity was as excellent as 1.4 μC/m.sup.2. In addition, the afterflame time was 0 second, indicating excellent flame retardancy.

Comparative Example 1

(33) A dyed cloth was obtained in the same manner as in Example 1, except that an electrically conductive aliphatic polyamide fiber having a single-fiber fineness of 4.5 dtex and a fiber length of 51 mm (eccentric sheath-core electrically conductive nylon fiber; sheath part: Nylon 6/core part: white metal compound) was used as an electrically conductive fiber.

(34) In the obtained dyed cloth, although the frictional charge quantity was as excellent as 2.4 μC/m.sup.2, with respect to the appearance quality, the electrically conductive aliphatic polyamide fiber was not colored, resulting in color non-uniformity. In addition, the afterflame time was 0 second, indicating excellent flame retardancy.

Example 3

(35) Spun yarns (first-twisted in the Z-direction, the number of twists: 800 to 950/m, cotton count: 40/1) each made of a polymetaphenylene isophthalamide fiber (Teijinconex® neo (trade name) manufactured by Teijin Limited, single-fiber fineness: 1.7 dtex, fiber length: 51 mm), an electrically conductive acrylic fiber (COREBRID (trade name) manufactured by Mitsubishi Chemical Corporation), and a para-type wholly aromatic polyamide fiber (Twaron® TW1072 manufactured by Teijin Aramid, single-fiber fineness: 1.7 dtex, fiber length: 51 mm) uniformly blended in a blending ratio of 85/10/5 (mass %) in the above order were combined, twisted using a double twister (900 twists/m in the S-direction), and then, as twist setting, steam-set at 120° C.×30 min, thereby giving a 2-ply yarn.

(36) In addition, a 3-ply yarn formed by adding an electrically conductive yarn (B-TCF U300HX of Teijin Limited, total fineness: 31 dtex/5 fil) to the above combined spun yarns was obtained in the same manner.

(37) Subsequently, using the 2-ply yarn and the 3-ply yarn, the 3-ply yarn was placed at a pitch of 2.02 cm wide (the 3-ply yarn corresponds to about 2 mass % of the warp yarn) and creeled for warping. The obtained warp beam was subjected to sizing, leasing, and threading as warp yarn preparation. In addition, the 2-ply yarn was used as a weft yarn.

(38) Next, a 2/2 twill-structure woven fabric was woven at a warp density of 69 yarns/2.54 cm and a weft density of 62 yarns/2.54 cm.

(39) The obtained gray fabric was unrolled and sewn in the usual manner, and, using an open-width non-tension scouring machine (Sofcer), subjected to desizing, scouring, cylinder drying, singeing, and dyeing, followed by finish setting (180° C.×45 to 90 sec), thereby giving a finished textile having a weight per unit of 5.4 oz/yd.sup.2.

(40) Subsequently, the cloth was subjected to dyeing processing under the following conditions, and the polymetaphenylene isophthalamide fiber and the electrically conductive acrylic fiber contained in the cloth were colored.

(41) (Dyeing Processing Conditions)

(42) Cationic dye: manufactured by Nippon Kayaku, trade name: Kayacryl Red GL-ED, 6.0% owf, 40 g/L swelling agent, 3 cc/L acetic acid, 1 cc/L dispersant, 25 g/L sodium nitrate

(43) Bath ratio: 1:20

(44) Temperature×Time: 130° C.×60 minutes

(45) The ATPV value was 8.7 cal/cm.sup.2, that is, acceptable (Level 2 satisfied).

Example 4

(46) The same procedure as in Example 3 was performed, except that the para-type wholly aromatic polyamide fiber (Twaron® TW1072 manufactured by Teijin Aramid, single-fiber fineness: 1.7 dtex, fiber length: 51 mm) was replaced with a copolyparaphenylene-3,4′ oxydiphenylene terephthalamide (PPODPA) fiber (Technora® manufactured by Teijin Limited). The ATPV value was 8.9 cal/cm.sup.2, that is, acceptable (Level 2 satisfied).

Example 5

(47) The same treatment as in Example 3 was performed, except that the polymetaphenylene isophthalamide fiber (Teijinconex® neo (trade name) manufactured by Teijin Limited, single-fiber fineness: 1.7 dtex, fiber length: 51 mm) was replaced with a polymetaphenylene isophthalamide fiber (Teijinconex® FRNB3 manufactured by Teijin Limited, single-fiber fineness: 1.7 dtex, fiber length: 51 mm). The ATPV value was 8.9 cal/cm.sup.2, that is, acceptable (Level 2 satisfied).

Example 6

(48) The same procedure as in Example 3 was performed, except that a 1/1 plain woven fabric was woven at the following weaving design density: a warp density of 62 yarns/2.54 cm and a weft density of 52 yarns/2.54 cm. A finished textile having a weight per unit of 4.5 oz/yd.sup.2 was thus obtained and evaluated in the same manner. The ATPV value was 6.7 cal/cm.sup.2, that is, unacceptable.

Comparative Example 2

(49) The same treatment and evaluation as in Example 3 were performed, except that the fiber materials and the blending amounts were changed such that the electrically conductive acrylic fiber was 0 wt %. The ATPV value was 7.8 cal/cm.sup.2, that is, unacceptable.

INDUSTRIAL APPLICABILITY

(50) According to the invention, a cloth that is excellent not only in flame retardancy and antistatic properties but also in appearance quality and preferably also has protection performance against electric arcs, a method for producing the same, and a textile product are provided. The industrial value thereof is extremely high.