JPH0241354B2 - - 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 be made to produce it artificially. For example, attempts have been made to mix polyester fibers with natural down, or to use silicone-treated polyester fibers, but none of these methods are satisfactory, and there are no similar methods other than those that natural down has. At present, a material with excellent properties without oxidation has not yet been realized. Furthermore, these man-made materials tend to sag when used or washed, the materials can tangle with each other, or the materials can break and shift to one side in the fabric, and they are not as light as down. It also has serious practical defects, such as the fact that it does not return to its original state when struck. Conventionally, practically hollow spherical bodies have been described in Japanese Patent Publication No. 53-4456 as materials for padding used in bedding such as futons, winter clothing, etc., but they have become difficult to compress and have a rough and hard texture. It is difficult to obtain so-called down-like physical properties. On the other hand, special public service in the 1970s
Publication No. 30745 proposes a sphere with a diameter of about 5 to 40 mm using thick fibers of about 10 to 300 deniers as a cushion material, but because the fineness of the fibers used is large, it is also difficult to compress and the texture is also poor. It becomes rough and hard. In addition, nylon,
Spherical bodies made of polyester-based, polyacrylonitrile-based, polyvinyl-based, and polyvinylidene chloride-based fiber lumps have been proposed, but the same defects as those described above are inevitable, and no satisfactory product has been obtained. 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 that the cotton wadding is hard to shift in the side fabric, has excellent recovery properties even if it shifts, and is hard to flatten.
Furthermore, it is an object of the present invention to provide a stuffing material whose properties, such as sagging, are less likely to change due to washing. 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 and stored compactly, and that has excellent bulk recovery and can regain its initial properties when reused. The above purpose is to use 90 to 10% by weight of polyester staple fiber A with a fineness of 3 to 10 deniers and a crimp rate of 15% or more, and a synthetic polymer with a fineness of 0.7 to 4 deniers and a crimp rate of less than 15%, which is smaller than the fineness of A. Blend cotton consisting of 10~90% by weight of short polyester fiber B 100%
Based on weight part, than either of the short fibers A and B
100% low melting point synthetic fiber with melting point lower than 20℃
This can be achieved by using a stuffing material containing less than 1 part by weight. As the fiber A, polyester fiber is used.
The fiber length of fiber A is normal, that is, generally
A diameter of 20 to 120 mm can be used, preferably 20 to 100 mm, and more preferably 20 to 80 mm. If the fiber length is outside the above range, carding becomes difficult, especially if it is less than 20 mm, it will not be carded, or
If the fiber length becomes too long, the fibers will become entangled with the clothing, making it impossible to perform the work. The fineness and crimp rate of fiber A affect down-like physical properties such as bulkiness, compact compressibility, and texture of the stuffing material, and from this point of view, the fineness is 3 to 10 deniers, preferably 4 to 7 deniers. If it is thinner than the above range, sufficient bulkiness cannot be obtained, and if it is thicker than the same range, the texture will be hard. Further, the crimp rate is 15% or more, preferably 18% or more. However, the upper limit of the crimp rate is usually about 30% at most due to restrictions from the production side of crimped fibers. Next, as the fiber B, a polyester fiber is used. The fiber length of the fiber B is usually about 20 to 200 mm, preferably 20 to 150 mm,
It is more preferable if it is 20 to 120 mm. If the fiber length is outside the above range, carding becomes difficult, especially
If the fiber length is less than 20 mm, it will not hang on the card, and if the fiber length is too long, the fibers will become entangled with the clothing, making it impossible to work. Further, the fiber length does not need to be uniform, and may vary due to bias cutting, etc., as long as it is within the above range. The fineness and crimp rate of fiber B also affect the physical properties of the stuffing material, as in the case of fiber A.
Therefore, the fineness is particularly smaller than that of fiber A, and is 0.7 to 4 deniers, preferably 1 to 3 deniers. In addition, the crimp rate of fiber B is at most 15% or less, preferably 10% or less, and fibers with a low crimp rate that are not normally used, including those without crimp, that is, zero crimp rate. The effect is fully demonstrated only when using the product, and especially when reusing items that have been stored compactly, applying mechanical stimulation or vibration such as tapping lightly will often restore the bulk. shows. Fibers A and Fibers B include not only fibers made of only one component, but also so-called composite fibers in which different polymers, polymers of the same type with different viscosities, etc. are combined in a concentric, eccentric, or side-by-side manner.
Fibers A and B also include hollow fibers and porous fibers. It is particularly preferable to use a composite hollow fiber as the fiber A because it is easy to crimp, is strong, is lightweight, has excellent bulkiness, and has good heat retention. In this case, the hollowness ratio is usually about 5 to 30%. In the present invention, short fiber A and short fiber B specified as described above are blended, and the blending ratio is 90 to 10% by weight, preferably 80 to 20% by weight, more preferably 80 to 20% by weight of short fiber A. is 70 to 30% by weight, short fiber B
The amount is 10 to 90% by weight, preferably 20 to 80% by weight, and more preferably 30 to 70% by weight. If the fineness, crimp ratio, and blending ratio of short fibers A and B are out of the above range, this is the object of the present invention. It has a high compression ratio, moderate instantaneous elastic recovery and moderate compressive stress, and is easy to store and has a moderate waist, making it comfortable to use, and has excellent texture, drapability, initial bulk, and bulk recovery when reused after storage. Although it is excellent, it is not always possible to obtain one that is bulky and has excellent heat retention when used. In addition, other fibers such as fibers made of different materials, fibers with large or small crimping ratios, etc., may be blended with the fibers A and B in an amount of about 30% by weight or less of the total weight. Various measurements were also carried out on a 3 cm diameter spherical stuffing material made of 80% down by weight and 20% feather. These fibers include synthetic fibers such as polyamide, polyester, and polypropylene, and natural fibers such as wool. The crimp rate referred to in the present invention is (B-A) x 100/B (%), where A is the fiber length when loaded with 2 mg/denier and B is the fiber length when loaded with 50 mg/denier. It is what is expressed. Next, the low melting point synthetic fiber used in the present invention is usually 20°C or higher than the fibers A and B, preferably 30°C.
At least a portion of the component has a melting point as low as 100%. With such a difference in melting point, only the low melting point synthetic fiber can be easily softened and melted during the subsequent heat treatment. That is, in addition to the low-melting point synthetic fibers consisting solely of low-melting point components as mentioned above,
The low melting point component also includes so-called conjugate fibers in which different or homogeneous polymers having a high melting point higher than the above temperature difference are combined side-by-side or concentrically or eccentrically. The above-mentioned low melting point components include polymers such as polyester, polyamide, and polyethylene, as well as various modified or copolycondensed polymers. The fineness of low melting point synthetic fibers is usually 1 to 15 deniers, as the finer the fiber, the higher the bonding density and the thicker the finer, the higher the bonding strength.
Preferably it is 1.5 to 10 deniers. On the other hand, the fiber length is usually 20 to 200 mm, preferably 50 to 100 mm. The low melting point synthetic fiber applicable to the present invention is the fiber A
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 of the blended cotton consisting of B and B are blended in an amount of not more than 100 parts by weight. When the amount of low melting point synthetic fibers 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 A and B of the present invention and the low-melting point synthetic fibers can be blended by a conventional method. The blended stuffing material can be used not only as a wet cloth, but also as a random fiber mass, for example, by disturbing the arrangement of the wet cloth, or by machine, wind power, or human power.
It can be separated into fiber masses of about cm size and further rolled up as needed for use, but in these products, the low melting point synthetic fibers are softened by heating, welded, and the fiber materials etc. are bonded and fixed. In this case, the temperature is fiber A
and B, and higher than the melting point of the low melting point synthetic fiber. The time varies depending on the composition of the low-melting point component, denier, set temperature, etc., but conditions can be selected by testing in advance, and it is generally about 10 minutes at most. When used as a fiber mass, it may be fused in the form of a web 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 reduce the coefficient of static friction between the fibers by, for example, In this case, an elastic polymer, a softener, etc. may be used in combination. In addition, the cotton filling material of the present invention can be wrapped in a suitable side material and used for bedding products such as futons, clothing that requires protection against cold and heat, or various industrial materials that require insulation. The stuffing material of the present invention can be used not only in a single layer or in a laminated form, but also in the case of multi-layer use, on one or both sides of the upper and lower surfaces, or as an intermediate layer. Two effects of the batting material of the present invention are that it exhibits down-like physical properties. That is, the initial bulkiness is mentioned first. Normally, when taking a sample of the same weight, natural down has the highest bulk.Compared to this, general cotton filling materials are generally about half as bulky.
Even good ones are only about 70% bulky. On the other hand, the stuffing material according to the present invention can provide a bulk that is comparable to, if not superior to, natural down. Next, the batting material of the present invention has high compressibility similar to that of natural down. Despite its high bulk, 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. On the other hand, with general cotton filling, it is possible to reduce the compressive stress to the same level or even lower than that of down, but in such cases, the bulkiness usually deteriorates, and if the compressive stress is too small, it will cause stiffness. It is not desirable to become something without. In this way, conventional cotton filling cannot achieve both bulkiness, compressibility, and appropriate elasticity like down. On the other hand, the cotton filling material of the present invention has a compressive stress comparable to that of down, so it can be stored compactly, has a moderate amount of stiffness during use, and, as mentioned above, is bulky. Both of these can be achieved simultaneously. 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 resilience, so conventional cotton wadding has poor bulk recovery. At this point, the bulk after recovery from down is extremely good, together with the initial bulk. In particular, it has excellent recovery properties (beat back properties) when mechanical force is applied, such as by hand tapping, but the cotton stuffing material of the present invention also has excellent bulk recovery properties, including beat back properties, which conventional stuffing materials do not have. There is something. 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, unloaded, left unloaded for 5 minutes, and compressed again. From this measurement, initial bulk: initial load (1.3
Thickness (mm) at g/cm ² ) Compressive stress: Stress immediately after compressing to 5 mm in the initial compression process (g/cm ² ) Initial compression hardness: During the initial compression process, the sample is The stress (g/cm ² ) when compressed by 20 mm was determined from the thickness under load. Next, after applying a high load of 70 g/cm ² to the sample for 24 hours, the weight was removed and the sample was allowed to recover naturally for 5 minutes, and 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 backability after washing: A 50cm square cushion was made and quilted to divide it into thirds. 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. Example 1 Composite hollow fiber obtained by side-by-side composite of polyethylene terephthalate with a relative viscosity (ηrel) of 1.37 and polyethylene terephthalate with a relative viscosity (ηrel) of 1.22 at a ratio of 1:1, hollow ratio 16.1%, fineness 6 denier, crimped. Short fiber A with a ratio of 22.0% and a fiber length of 60 mm.
60 parts, fineness 1.3 denier, crimp rate 7.7%, fiber length 45
A mixture of 40 parts of short polyester fiber B (3 denier, 50 mm) made of polyester with a melting point of 255°C and a melting point of 110°C as shown in Table 1 was carded and rolled to a diameter of about 3 cm. The stuffing material obtained by heating and fusing at 160° C. for 3 minutes was stuffed into the nylon lining, and various measurements were performed. Table 1 shows the results. The above fibers were treated with a smoothing agent. Also, 80% down by weight, feather
Various measurements were also carried out on a spherical stuffing material with a diameter of 3 cm consisting of 20% by weight.

[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 texture. Example 2 Polyester staple fibers A with a fineness of 5 denier, a crimp rate of 19.1%, and a fiber length of 67 mm were mixed with polyester staple fibers B with a fineness of 1.5 denier, a crimp rate of 9.4%, and a fiber length of 50 mm as shown in Table 2. In addition, a composite low melting point synthetic fiber (5.5%
Carded 25 parts of denier (60mm) and heated the fiber mass, which was rolled to a diameter of about 2cm, at 160℃ for 3 minutes.
The stuffing material obtained by fusing is stuffed into the nylon side fabric,
Table 2 shows the results of various measurements. The fiber mass was treated with a smoothing agent after being fused.

[Table] From the above results, it can be seen that fiber materials containing short fibers A and B are superior not only in beat-up properties after washing, but also in initial bulk, compressibility, texture, etc. . Example 3 50 parts of A50 polyester short fibers made of the same composite hollow fiber as in Example 1, having a fineness of 7 denier, a crimp rate of 21.4%, and a fiber length of 76 mm, a fineness of 1 denier, a crimp rate of 6.9%,
Mix 15 parts of a composite low melting point synthetic fiber (3 denier, 65 mm) consisting of polypropylene whose high melting point component is a melting point of 170°C and polyethylene whose melting point is a low melting point component of 125°C with 50 parts of short polyester fiber B with a fiber length of 38 mm, and carding it at 140°C. Various measurements were carried out by stuffing the cotton padding material, which had been heated and fused for 5 minutes, into the cotton lining. (The above fibers were treated with a smoothing agent.) As a result, the initial bulk was 51.5 mm, and the initial compression hardness was 11.0.
g/cm ² , compressive stress 70.5 g/cm ² , and the beet bagginess after washing is excellent.
It can be seen that the bulkiness, compressibility, and texture are all excellent.

Claims (1)

[Claims] 1. 90 to 10% by weight of polyester staple fibers A having a fineness of 3 to 10 deniers and a crimp rate of 15% or more, and a crimp rate of 15 that is smaller than the fineness of A and 0.7 to 4 deniers and a crimp rate of 15%.
100 parts by weight of blended cotton consisting of 10 to 90% by weight of polyester short fibers B consisting of less than 10% by weight of synthetic polymers, a low melting point synthetic fiber having a melting point 20°C or more lower than either of the short fibers A and B. A stuffing material containing 100 parts by weight or less. 2. The stuffing material according to claim 1, wherein the short fibers A have a fineness of 4 to 7 deniers. 3. The cotton filling material according to claim 1, wherein the crimp rate of the short fibers A is 18% or more. 4. The stuffing material according to claim 1, wherein the short fibers B have a fineness of 1 to 3 deniers. 5. The stuffing material according to claim 1, wherein the short fibers B have a crimp degree of 10% or less. 6 The blended cotton contains 80-20% by weight of short fibers A and short fibers.
The stuffing material according to claim 1, comprising 20 to 80% by weight of B. 7. The stuffing material according to claim 1, wherein the low melting point synthetic fiber is made of polyester. 8 A synthetic fiber in which the low melting point synthetic fiber is a composite fiber consisting of a high melting point component and a low melting point component, and the low melting point component has a melting point that is 20°C or more lower than the melting point of either the high melting point component or the fibers A and B. The stuffing material according to claim 1, which is made of a polymer. 9. The stuffing material according to claim 8, wherein the low melting point component comprises polyethylene. 10. The stuffing material according to claim 8, wherein the low melting point component is made of polyester. 11. The stuffing material according to claim 1, which contains 2 to 50 parts by weight of low melting point synthetic fibers.