JPH0230711B2 - - Google Patents

Description

[Detailed description of the invention]

FIELD OF THE INVENTION The present invention relates to a cotton batting material. Conventionally, natural down has been used as the most preferable filling for cold-weather clothing and bedding. Although down is valued all over the world for its excellent properties, it is extremely expensive because its production is extremely limited. For this reason, attempts have recently begun to try to produce it artificially. For example, attempts have been made to mix natural down with polyester fibers, or to use silicone-treated polyester fibers, but none of these methods are satisfactory. At present, a material with unique and excellent properties has not yet been realized. Furthermore, when these artificial materials are used or washed, they tend to sag, become entangled with each other, or cause cotton to break, causing the material to shift to one side in the side fabric. It also has serious practical defects, such as the fact that it does not return to its original state when struck. On the other hand, regarding futon cotton, a blended cotton made by mixing natural and artificial futon fibers with cut cellophane ribbons is described in Japanese Patent Publication No. 39-6330, but the futon cotton tends to be uneven in the side fabric. Moreover, not only does it lack the ability to recover when it is lopsided, but it also does not sufficiently improve sagging, so it cannot be said to be a so-called down-like product. In particular, when washed, the cotton tends to shift and become stale, and other properties change significantly, making it difficult to use for clothing such as down jackets. The present inventors completed the present invention as a result of intensive research to eliminate such conventional defects. The purpose of the present invention is to prevent the material from shifting in the side area, to have excellent recovery properties even if it becomes lopsided, and to be resistant to deterioration.
An object of the present invention is to provide a stuffing material whose properties such as sag due to washing are less likely to change. Another object of the present invention is to provide a lightweight cotton filling material that is bulky, has a suitable elasticity, is soft to the touch, and has excellent heat retention properties. Still another object is to provide a stuffing material that can be easily folded into a small size for storage, and has excellent bulk recovery when reused, allowing it to regain its initial characteristics. The above purpose is to have a single yarn fineness of 3 to 10 denier and a crimp rate.
15% or more polyester staple fiber (A) 90-10% by weight
and 10 to 90% by weight of polyester staple fibers (B) having a single yarn fineness smaller than that of the polyester staple fibers (A) and having a denier of 0.7 to 4 and a crimp rate of less than 15%. For 100 parts by weight of the mixture with the polyester film-like structural element (C) that has been given bending,
A low melting point synthetic fiber having a melting point 20°C or more lower than either the fiber or the film-like structural element (C) is used.
This can be achieved by using a stuffing material containing 100 parts by weight or less. The fibers applicable to the present invention are polyester fibers which are usually used as batting and heat insulating materials for cold weather clothing and bedding, and polyester fibers are used as the fiber material of the present invention in view of various mechanical properties. It is suitable for In order to maximize the effects of the present invention, it is necessary to use fibers (A) 90 with a fineness of 3 to 10 deniers and a crimp rate of 15% or more as the fiber material to be mixed with the film-like structural element.
~10% by weight, fiber (B) made of a synthetic polymer with a fineness smaller than that of the fiber (A), 0.7 to 4 deniers, and a crimp rate of less than 15%. The fibers (A) and fibers (B) used each contribute to improving the bulkiness of the cotton stuffing material and the beat-back properties and heat retention properties after use. That is, the fiber (A) made of thick yarn has firmness and stiffness, and has strong crimp, so it exhibits strong bulkiness. In addition, the crimp rate of the fiber (B) made of fine yarn is at most 15% or less, preferably 10% or less, and the crimp rate is zero, that is, the crimp rate is zero, that is, the crimp rate is not normally used, including those without crimp. The effect is fully demonstrated only when using fibers with a small shrinkage ratio.In particular, when reusing items that have been stored compactly, applying mechanical stimulation or vibration such as lightly tapping them will damage the fibers. (B) acts as a lubricant at the intertwined parts and exhibits effects such as good bulk recovery. (beat·
Back) In addition, the fibers (B) with a small degree of crimp ratio enter into the voids located between the intertwined parts of the fibers (A),
It also improves heat retention by dividing the air chambers created by the voids and suppressing air convection. In addition, the physical properties of the stuffing material change depending on the blending ratio of fibers (A) and fibers (B), and to obtain the full effect of the present invention, the fiber (A) should be 90 to 10% by weight, preferably 80% by weight. ~20% by weight, more preferably 70-30% by weight, and 10% by weight of fiber (B)
-90% by weight, preferably 20-80% by weight, more preferably 70-30% by weight. By setting such a blending ratio, the effects of the fibers (A) and (B) described above, that is, appropriate bulkiness, beat-back properties, and heat retention properties are exhibited in a well-balanced manner. Even if the fibers (A) and fibers (B) are composed of only one component, the above-mentioned effects can be achieved, but in particular, if the fibers (A) are composite fibers in which polymers of the same type with different viscosities are composited side by side. , a spiral crimp appears, resulting in a three-dimensional structure that contributes to improved bulkiness. Furthermore, it is particularly preferable to use hollow fibers as the fibers (A) because they are easy to crimp, are strong, are lightweight, have excellent bulkiness, and have good heat retention. In this case, the hollowness ratio is usually about 5 to 30%. Next, the film-like structural element (C) referred to in the present invention is:
Generally referred to as flat yarn or lame yarn, it is a flaky material made of polyester, and polyester is particularly preferred because of its excellent mechanical properties. Here, the flaky material is thinner than its length and width, and these dimensions can be selected as appropriate to give the best properties to the stuffing material of the present invention. , typically 5~
It is about 200μ, preferably about 10 to 80μ. These flakes usually have a length to width ratio of 10.
Above, in particular, it is 15 or more, and it goes without saying that the lame yarn and flat yarn are included in this range. These are bent or crimped as appropriate to facilitate carding, which will be described later, and to provide bulkiness, thereby deforming them three-dimensionally. In addition, it is preferable to use these flakes having metal vapor-deposited on the surface because they have an infrared reflective effect and improve heat retention, and those having aluminum vapor-deposited are particularly preferable because they have a high infrared reflectance. The film-like structural element applied to the present invention is blended in an amount of 1 to 50 parts by weight, preferably 2 to 30 parts by weight, more preferably 3 to 25 parts by weight, particularly preferably 4 to 20 parts by weight, based on the fibers. do. A film-like structural element is mainly related to bulkiness and compressibility, so if the blending amount is less than the above range, sufficient bulkiness and compressive stress cannot be obtained, and if the blending amount is too large, the feel will deteriorate. Next, the low melting point synthetic fiber used in the present invention is a component that has a melting point lower than that of the fibers and film-like structural elements by usually 20°C or more, preferably 30°C or more, in order to facilitate the work in the subsequent heat treatment process. At least in part. That is, in addition to the low-melting point synthetic fibers consisting solely of low-melting point components as mentioned above,
It also includes a so-called conjugate fiber, which is a core-sheath type composite of a low melting point component and a different or similar polymer having a high melting point higher than the above temperature difference. The above-mentioned low melting point components include polymers such as polyester, polyamide, polyacrylonitrile, and polyethylene, as well as various modified or copolymerized polymers. The fineness of the low melting point synthetic fiber is usually 1 to 15 deniers, preferably 1.5 to 10 deniers, because the finer the fiber, the higher the adhesive density and the thicker the finer, the higher the adhesive strength when thermally bonding as described below. The low melting point synthetic fiber applied to the present invention contains 100 parts by weight of the mixture of the fiber and the film-like structural element.
100 parts by weight or less, preferably 2 to 50 parts by weight, more preferably 3 to 40 parts by weight, particularly preferably 4 to 30 parts by weight
Mix parts by weight of cotton. The amount of low melting point synthetic fiber is
If it exceeds 100 parts by weight, the stuffing material not only becomes coarse and hard, but also has other physical properties such as bulkiness. The stuffing material containing the fibers, film-like structural elements, and low-melting point synthetic fibers of the present invention can be blended by a conventional method. Furthermore, depending on their size, the film-like structural element and the low-melting point synthetic fiber can be carded together with the fibers, and in some cases, they can be blended after the fiber carding process. In order to use these fibers for the normal carding process, the fiber length is usually about 20 to 200 mm (about the same as cotton to wool).
If the fiber length is within this range, even if the fiber length varies due to bias cutting or the like, cardability etc. will not be impaired. The blended cotton stuffing material is not only formed into a web shape, but also formed into a random fiber mass, for example, by disturbing the arrangement of the web, or by machine, wind power, or human power.
It can be separated into fiber lumps of about cm size and further rolled up as needed for use, but in these cases, the low melting point synthetic fibers are softened and melted by heating, and the fiber materials etc. are bonded and fixed. In this case, the temperature is set lower than the melting point of both the fiber material and the film-like structural element, and higher than the melting point of the low-melting synthetic fiber. The time varies depending on the composition of the low melting point component, denier, set temperature, etc., but conditions can be selected in advance by TET, and it is generally about 10 minutes at most. When used as a fiber mass, the web may be fused and then divided into fiber mass. In addition, the stuffing material of the present invention may be treated with a smoothing agent such as an oil agent, silicone type, fluorine type, etc. before blending some or all of its constituent elements or after heating and fusing the stuffing material. It is preferable to lower the coefficient of static friction between the fibers. In this case, an elastic polymer, a softener, etc. may be used in combination. In addition, when the cotton filling material of the present invention is used, it can be wrapped in a suitable side material and used for sleeping goods such as futons, clothing that requires protection against cold temperatures, or various industrial materials that require insulation. However, in this case, only the stuffing material of the present invention can be used in a single layer or in a layered manner. One of the effects of the cotton filling material of the present invention is excellent wearing performance and washing resistance. That is, the stuffing material of the present invention does not easily set even when washed with water, and even if the stuffing becomes uneven, it easily returns to its original shape like down. Two effects of the cotton filling material of the present invention are that it exhibits down-like physical properties. That is, the initial bulkiness is mentioned first. Normally, when samples of the same weight are taken, the bulkiest material is natural down.
In comparison, general cotton filling materials, even if they are half as good, are only about 70% as bulky. On the other hand, the cotton stuffing material according to the present invention does not have a bulk that is even superior to, or comparable to, natural down. Next, the batting material of the present invention has high compressibility similar to that of natural down. Despite its bulkiness, natural down requires only a small load to compress and can be compressed into a very small volume, so it has the advantage of not taking up much space when stored. The third effect is bulk recovery. After being compactly stored as described above, the bulk must be sufficiently recovered when it is used again. When stored in a compact form for a long time, the cotton wadding gradually becomes distorted and loses its restoring power, so conventional cotton wadding has difficulty recovering its bulk. At this point, the bulk after recovery from down is extremely good in comparison with the initial bulk. Recovery performance (beat back performance) when mechanical force is applied, especially when hitting by hand
However, the wadding material of the present invention also has superior bulk recovery properties including beat-back properties, which are not found in conventional wadding materials. The fourth effect is heat retention. The cotton stuffing material of the present invention has short fibers finely intertwined, and as a result, has many fine voids, which suppresses air convection and provides superior heat retention compared to conventional cotton stuffing materials. The present invention will be specifically described below with reference to Examples, in which "parts" indicate "parts by weight". In addition, various measurements and evaluations were performed using the following methods. A measurement sample was prepared by filling 4 g of cotton stuffing material into a bag made by stacking two 12 cm square pieces of side fabric and sewing the periphery together. The sample was compressed to 5 mm using an Instron, left in this state for 5 minutes, then slowly weighed, left under no load for 5 minutes, and then compressed again. From this measurement, Initial bulk: Thickness (mm) at the initial load (1.3 g/cm ² ) during the initial compression process Compressive stress: Stress immediately after compressing to 5 mm during the initial compression process (g/cm 2 ) ² ) Initial compression hardness: In the initial compression process, the stress (g/
cm ² ) was calculated. Next, a high load of 70 g/cm ² was applied to the sample for 24 hours, the weight was gradually lowered, and the sample was allowed to recover naturally for 5 minutes.Then, the sample was rotated and vibrated for 5 minutes in a tumble dryer to cause it to beat back. The thickness of the object at the time of initial load was taken as the total recovery bulk (mm). Beat back properties after washing: A 50 cm square thread was created and quilted to divide it into three equal parts. This product was washed in a tumbler type washing machine for 10 minutes, rinsed for 3 minutes three times, and then centrifuged and dried. Visually and tactilely judged the resilience of this product when the unevenness of the batting was lightly tapped by hand.
It was evaluated in four stages: good, fair, and poor. Further, the heat retention property was expressed as a heat retention rate (%) measured using a sample with a basis weight of 400 g/m ² by a method based on the JIS-L-1079A method. Incidentally, the coefficient of static friction between fibers was measured by the radar method. Example 1 A composite hollow fiber obtained by side-by-side composite of polyethylene terephthalate with a relative viscosity (ηrel) of 1.38 and polyethylene terephthalate with a relative viscosity (ηrel) of 1.21 at a ratio of 1:1, with a hollowness ratio of 16.5%, a fineness of 5 denier, and crimping. short fibers (A) with a ratio of 22.3% and a fiber length of 65 mm.
50 parts, fineness 1.5 denier, crimp rate 7.0%, fiber length 38
50 parts of polyester short fibers (B) with a diameter of 1.5 mm and a rectangular shape (width 0.04 cm, length 3 cm) with a spread area of 0.12 cm ² are crimped to make an aluminum-deposited polyester film 10
A mixture of 100 parts of polyester with a melting point of 120°C, a fineness of 5 denier, a fiber length of 38 mm, and a low melting point synthetic fiber as shown in Table 1 was carded and divided into fiber lumps with a diameter of about 3 cm. rear,
Table 1 shows the results of various measurements carried out by stuffing the stuffing material obtained by heating and fusing at 160°C for 5 minutes into the polyester lining. The above fibers were treated with a smoothing agent to have a friction coefficient of 0.18.

【table】

[Table] From the above results, it can be seen that if the amount of low melting point fiber is within a specific range, the product will have excellent beat back properties after washing, and will also have good initial bulk, compressibility, and feel. Furthermore, when the heat retention rate of the sample of Experiment No. 1-4 was measured, it was 79.0%, indicating that the heat retention was good. Example 2 Polyester short fibers (A) with a fineness of 4 denier, a crimp rate of 18.3%, and a fiber length of 65 mm and polyester staple fibers (B) with a fineness of 1.5 denier, a crimp rate of 8.3%, and a fiber length of 48 mm are shown in Table 2. Mix as shown and further spread area.
100 parts of a mixture of 5 parts of aluminum vapor-deposited polyester film in the form of a ^0.05cm2 rectangle (width 0.02cm, length 2.5cm), low melting point component is polyethylene (melting point 125℃), high melting point component is polypropylene (melting point
Composite low melting point fiber (3 denier,
64mm), carded 20 parts, rolled the fiber mass to about 2cm in diameter, heated it at 150℃ for 3 minutes, fused it, stuffed the stuffing material into the nylon lining, and performed various measurements. Shown in the table. The fiber mass was treated with a smoothing agent after being fused.

[Table] From the above results, fiber materials containing short fibers (A) and short fibers (B) have excellent initial bulkiness, compressibility, texture, etc. as well as good beat-back properties after washing. I know that there is. Example 3 30 parts of polyester short fiber (A) made of the same composite hollow fiber as in Example 1, having a fineness of 4 denier, a crimp rate of 22.1%, and a fiber length of 65 mm, a fineness of 1.3 denier, a crimp rate of 4.7
%, 70 parts of polyester short fibers (B) with a fiber length of 38 mm, and a polyester film bent into a dogleg shape in a rectangular shape (width 0.1 cm, length 5 cm) with a spread area of 0.5 cm ² are shown in Table 3. A mixture of 15 parts of a composite low melting point fiber (6 denier, 51 mm) consisting of polyester with both a high melting point component (melting point 245°C) and a low melting point component (melting point 110°C) per 100 parts of the blended material was carded. Table 3 shows the results of various measurements carried out by stuffing the stuffing material heat-fused at 170°C for 3 minutes into the polyester/cotton blend side fabric. The above fibers were treated with a smoothing agent to have a coefficient of friction of 0.17.

[Table] From the above results, it can be seen that the products containing polyester film have excellent bulkiness and compressibility as well as beat-back properties after washing. Further, when the heat retention rate of the sample of Experiment No. 3-4 was measured, it was 77.6%, indicating that the heat retention was good.

Claims (1)

[Claims] 1 90 to 10% by weight of polyester short fibers (A) with a single yarn fineness of 3 to 10 deniers and a crimp rate of 15% or more, and a single yarn fineness that is smaller than the fineness of the polyester short fibers (A), and
Mixture 100 of fibers made by blending 10 to 90% by weight of polyester staple fibers (B) with a denier of 0.7 to 4 and a crimp rate of less than 15% and a bent polyester film-like structural element (C) 100 A stuffing material comprising 100 parts by weight or less of a low melting point synthetic fiber having a melting point lower by 20°C or more than either the fibers or the film-like structural element (C).