Flame resistant synthetic fiber, flame resistant fiber composite and upholstered furniture products using the same

Abstract

A flame resistant synthetic fiber having advanced flame resistance is provided. Furthermore, the flame resistant synthetic fiber may preferably be used in textiles used for furniture, such as beddings and chairs, such as mattress, and sofa, etc. that need extremely high carbonizability rendered highly flame resistant by flame resistant agents and advanced flame resistance. The present invention also aims at obtaining upholstered furniture products using the flame resistant fiber composite having advanced flame resistance. That is, the present invention relates to a flame resistant fiber composite consisting of a flame resistant synthetic fiber (A) not less than 10 parts by weight, and at least one fiber (B) selected from a natural fiber and/or a chemical fiber (B) not more than 90 parts by weight, the flame resistant synthetic fiber (A) comprising a zinc compound 3 to 50 parts by weight, an antimony compound 0 to 30 parts by weight, and an other inorganic compound 3 to 30 parts by weight, a total amount of these compounds being not less than 15 parts by weight to a polymer containing halogen atom of not less than 17% by weight 100 parts by weight, and also relates to upholstered furniture products using the flame resistant fiber composite.

1 . A flame resistant synthetic fiber, comprising: 
 a zinc compound 3 to 50 parts by weight;    an antimony compound 0 to 30 parts by weight; and    an other inorganic compound 3 to 30 parts by weight,    a total amount of these compounds being not less than 15 parts by weight to a polymer containing halogen atom of not less than 17% by weight 100 parts by weight.    
   
   
       2 . The flame resistant synthetic fiber according to  claim 1 , 
 wherein the polymer containing halogen atom of not less than 17% by weight consists of:    acrylonitrile 30 to 70% by weight;    halogen containing vinyl and/or halogen containing vinylidene monomer 70 to 30 parts by weight; and    a vinyl monomer copolymerizable with the monomers 0 to 10 parts by weight.    
   
   
       3 . The flame resistant synthetic fiber according to any one of  claim 1  and 2, wherein the zinc compound is a compound selected from zinc, zinc oxide, zinc borate, zinc stannate, and zinc carbonate.  
   
   
       4 . The flame resistant synthetic fiber according to  claim 3 , wherein the other inorganic compound is a compound selected from a group consisting of 
 natural or synthetic mineral based compounds, such as kaolin, zeolite, montmorillonite, talc, perlite, bentonite, vermiculite, diatomaceous earth, and graphite;    aluminum based compounds, such as aluminum hydroxide, aluminum sulfate, and aluminum silicate;    magnesium compounds, such as magnesium hydroxide and magnesium oxide; and    silicon compounds, such as silicate and glasses.    
   
   
       5 . The flame resistant synthetic fiber according to  claim 3  comprising: 
 a zinc compound 3 to 30 parts by weight;    an antimony compound 0 to 30 parts by weight; and    kaolin or aluminum hydroxide 3 to 30 parts by weight as the other inorganic compounds,    a total amount of the zinc compound, the antimony compound, and the inorganic compound being 20 to 50 parts by weight to the polymer containing halogen atom of not less than 17% by weight 100 parts by weight.    
   
   
       6 . A flame resistant fiber composite consisting of: 
 a fiber (A) not less than 10 parts by weight,    and a natural fiber and/or a chemical fiber (B) not more than 90 parts by weight,    the flame resistant synthetic fiber (A) comprising:    a zinc compound 3 to 50 parts by weight;    an antimony compound 0 to 30 parts by weight; and    an other inorganic compound 3 to 30 parts by weight,    a total amount of the zinc compound, the antimony compound, and    the inorganic compound being not less than 15 parts by weight to a polymer containing halogen atom of not less than 17% by weight 100 parts by weight.    
   
   
       7 . The flame resistant fiber composite according to  claim 6 , wherein the polymer containing halogen atom of not less than 17% by weight is a copolymer comprising: 
 acrylonitrile 30 to 70% by weight;    a halogen containing vinyl and/or halogen containing vinylidene monomer 70 to 30% by weight; and    a vinyl monomer copolymerizable with therewith 0 to 10% by weight.    
   
   
       8 . The flame resistant fiber composite according to  claim 7 , wherein the zinc compound is a compound selected from a group consisting of zinc, zinc oxide, zinc borate, zinc stannate, and zinc carbonate.  
   
   
       9 . The flame resistant fiber composite according to any one of  claims 6  to  8 , wherein the other inorganic compound is a compound selected from a group consisting of: 
 natural or synthetic mineral based compounds, such as kaolin, zeolite, montmorillonite, talc, perlite, bentonite, vermiculite, diatomaceous earth, and graphite;    aluminum based compounds, such as aluminum hydroxide, aluminum sulfate, and aluminum silicate;    magnesium compounds, such as magnesium hydroxide and magnesium oxide; and    silicon compounds, such as silicate and glasses.    
   
   
       10 . The flame resistant fiber composite according to  claim 9  comprising a polyester fiber as a chemical fiber of at least one kind of fiber in the natural fiber and/or chemical fiber (B) not more than 40 parts by weight.  
   
   
       11 . The flame resistant fiber composite according to  claim 10 , wherein the polyester fiber is a low melting point binder fiber.  
   
   
       12 . A nonwoven fabric comprising the flame resistant fiber composite according to any one of  claims 6  to  8 .  
   
   
       13 . A nonwoven fabric for flame shielding barriers according to  claim 12 .  
   
   
       14 . An upholstered furniture products using the flame resistant fiber composite according to any one of  claims 6  to  8 .  
   
   
       15 . An upholstered furniture products using the nonwoven fabric according to  claim 12 .  
   
   
       16 . An upholstered furniture products using the nonwoven fabric for flame shielding barriers according to  claim 13.