EP3366822A1

EP3366822A1 - Cotton wadding

Info

Publication number: EP3366822A1
Application number: EP16857503.3A
Authority: EP
Inventors: Shima NAKANISHI; Yukio ONOHARA; Tatsuhiko Inagaki; Hideaki Kobayashi
Original assignee: Mitsubishi Chemical Corp
Current assignee: Mitsubishi Chemical Corp
Priority date: 2015-10-20
Filing date: 2016-10-20
Publication date: 2018-08-29
Also published as: CN108138403A; JP6414228B2; EP3366822A4; US20180237966A1; CN108138403B; WO2017069190A1; JPWO2017069190A1

Abstract

Wadding of the present invention is obtained by mixing 20% by mass or more and 95% by mass or less of an acrylic fiber and 5% by mass or more and 80% by mass or less of a polyester fiber, in which a down power is 140 cm³/g or more and 300 cm³/g or less, and a warmth retention property (Clo value) is 3.7 or more and 5 or less.

Description

Technical Field

The present invention relates to a wadding used for an application such as a down jacket or bedding such as a comforter.
Priority is claimed on Japanese Patent Application Nos. 2015-206232 and 2015-206233, filed on October 20, 2015 , the contents of which are incorporated herein by reference.

Background Art

It is known that down mainly used as a wadding for bedclothes and bedding, down jackets, and the like has a rich texture and is lightweight, has excellent warmth retention property and bulkiness, and further has a high recovery rate after compression. However, in order to obtain the down, not only is it necessary to breed a lot of waterfowl and a large amount of a feed is required, but also there are problems of water contamination due to excreta of the waterfowl, occurrence of infection, and spread of the infection. In addition, in order to enable the down to be used as a wadding, it is necessary to go through many steps of plucking of down, selection, disinfection, and fat removal. Further, since the down is blown up during the steps, working becomes complicated. Accordingly, a cost of bedclothes and bedding using the down as a wadding is high.
In addition, as a material of the wadding, it is also possible to use a polyester fiber. The polyester fiber is low-cost but there are problems in that lightweightness and bulkiness are not sufficient and the warmth retention property is low.
Therefore, it has been attempted to impart bulkiness to a synthetic fiber such as the polyester fiber.
For example, in PTL 1, it is proposed that a certain amount of a surface treatment agent including a polyether-ester based block copolymer as a main component be attached to surfaces of both fibers of a matrix forming a fiber structure body and a heat-bonding short fiber to obtain a hard cotton structure body in which stiffness and elasticity are improved. However, in the hard cotton structure body disclosed in PTL 1, stiffness is high but, accordingly, there is lack of flexibility, and it is not suitable for applications where good body-fit is required such as a comforter or a jacket.
In addition, PTL 2 proposes the wadding formed by laminating a layer including a fiber having single fiber fineness of 1.5 denier or less and a layer including a fiber having single fiber fineness of 2.5 to 15 denier. However, in the wadding disclosed in PTL 2, the layer (web) of a fiber having small single fiber fineness and the layer (web) of a fiber having large single fiber fineness are just laminated and a fiber having different fineness is not intertwined. Therefore, even when using fibers having two different fibers, there is almost no effect of increasing the bulkiness. Here, "web" means a sheet-like object formed by superimposing fibers.
Further, PTL 3 proposes the wadding formed by mixing a short fiber having single fiber fineness of 0.5 dtex or more and less than 3 dtex, a hollow fiber of 5 dtex or more and less than 10 dtex, a hollow fiber of 10 dtex or more and less than 30 dtex, and a heat-bonding short fiber of 1 dtex or more and less than 5 dtex. In the wadding of PTL 3, warmth retention property is imparted by a short fiber of 0.5 dtex or more and less than 3 dtex and warmth retention property and bulkiness are imparted by a short fiber of 5 dtex or more. However, even in the wadding described in PTL 3, the bulkiness was not sufficient.
PTL 4 proposes ball-like cotton in which single fiber fineness is 1.1 to 15.0 dtex, an average diameter obtained by intertwining fibers of which lengths are 3 to 64 mm is 3 to 10 mm, and polyester fibers having different melting points include two or more kinds of heat-bonding fibers.
In the ball-like cotton of PTL 4, the fibers are partially bonded to each other by heat-bonding fibers, thereby maintaining the shape and preventing the wadding from biasing. However, even in the ball-like cotton disclosed in PTL 4, the bulkiness and the warmth retention property were not sufficient.

Citation List

Patent Literature

[PTL 1] Japanese Unexamined Patent Application, First Publication No. 2006-207110
[PTL 2] Japanese Unexamined Patent Application, First Publication No. S56-143188
[PTL 3] Japanese Unexamined Patent Application, First Publication No. 2013-177701
[PTL 4] Japanese Unexamined Patent Application, First Publication No. 2002-30555

Summary of Invention

Technical Problem

The present invention solves the problems in the related art described above, and provides the wadding which has excellent bulkiness and flexibility and can be appropriately used for an application such as a down jacket or bedding such as a comforter.

Solution to Problem

A wadding of the present invention is obtained by mixing 20% by mass or more and 95% by mass or less of an acrylic fiber and 5% by mass or more and 80% by mass or less of a polyester fiber, in which a down power is 140 cm³/g or more and 300 cm³/g or less, and a Clo value is 3.7 or more and 5.0 or less.
In the wadding of the present invention, it is preferable that single fiber fineness of the acrylic fiber be 0.1 dtex or more and 10 dtex or less, and single fiber fineness of the polyester fiber is 1 dtex or more and 10 dtex or less.
In the wadding of the present invention, it is preferable that the polyester fiber be a hollow fiber.
In the wadding of the present invention, it is preferable that a hollow ratio of the hollow fiber be 10% or more and 30% or less.
In the wadding of the present invention, it is preferable that the down power be 140 cm³/g or more and 220 cm³/g or less.
In the wadding of the present invention, it is preferable that the down power be 160 cm³/g or more and 200 cm³/g or less.
In the wadding of the present invention, it is preferable that the Clo value be 3.8 or more and 4.8 or less.
In the wadding of the present invention, it is preferable that the Clo value be 4 or more and 4.7 or less.
In the wadding of the present invention, it is preferable that the single fiber fineness of the acrylic fiber be 0.5 dtex or more and 2.2 dtex or less and the single fiber fineness of the polyester fiber be 1.7 dtex or more and 2.2 dtex or less.
In the wadding of the present invention, it is preferable that a fiber length of the acrylic fiber be 15 mm or more and 40 mm or less and a fiber length of the polyester fiber be 10 mm or more and 40 mm or less.
In the wadding of the present invention, it is preferable that a mixing ratio of a heat-bonding short fiber with respect to the wadding be 5% by mass or more and 30% by mass or less, and at least a part of the heat-bonding short fiber be bonded to the acrylic fiber or the polyester fiber.
In the wadding of the present invention, it is preferable that 30% by mass or more and 70% by mass or less of the acrylic fiber having the single fiber fineness of 0.1 dtex or more ans 10 dtex or less be included, and the wadding be granular wadding in which one or a plurality of fibers are intertwined.
In the wadding of the present invention, it is preferable that 30% by mass or more and 70% by mass or less of the polyester fiber having the single fiber fineness of 1 dtex or more and 10 dtex or less be included.
In the wadding of the present invention, it is preferable that the polyester fiber be a conjugate fiber and has a coil-like form in a no-load state.
In the wadding of the present invention, it is preferable that the maximum length of the granular wadding be 2 mm or more and 20 mm or less.
In the wadding of the present invention, it is preferable that the number of crimps of the acrylic fiber be 3 peaks/25 mm or more and 20 peaks/25 mm or less.
In the wadding of the present invention, it is preferable that a decreasing rate of the down power after washing 10 times be 30% or lower.

Advantageous Effects of Invention

According to the present invention, it is possible to provide a wadding which has excellent bulkiness, flexibility, and warmth retention property and can be appropriately used for an application such as a down jacket or bedding such as a comforter.

Description of Embodiments

Hereinafter, the present invention will be described in detail.
The wadding of the present invention is obtained by mixing 20% by mass or more and 95% by mass or less of an acrylic fiber and 5% by mass or more and 80% by mass or less of a polyester fiber, in which a down power is 120 cm³/g or more and 300 cm³/g or less, and a Clo value is 3.7 or more and 5 or less.
In terms down quality, a down power grade is used as an index of bulkiness. In the Japan down products corporative association, the grade is classified into four ranks from a premium gold label of the highest quality, a royal gold label, an excel gold label, and a new gold label. The term "down power" indicates a volume per unit mass and represents that the larger the value thereof, the higher the bulk. Examples of a method for measuring the down power include a method in accordance with JIS L1903.
The wadding of the present invention makes it possible to provide warmth, lightness, and a similar texture to down by including the acrylic fiber, and has excellent recovery after compression by including the polyester fiber. The acrylic fiber and the polyester fiber are mixed, thereby increasing the bulkiness. It becomes possible to achieve both improvement of warmth retention property and improvement of recoverability after compression.
That is, when 20% by mass or more and 95% by mass or less of the acrylic fiber and 5% by mass or more and 80% by mass or less of the polyester fiber combine, it is possible to obtain a down power of 140 cm³/g or more.
When the acrylic fiber is included in an amount of 20% by mass or more with respect to the entire wadding, it is possible to further increase the down power compared with a polyester 100% product and the warmth retention property is improved. When the acrylic fiber is 95% by mass or less, the polyester fiber is included in an amount of 5% by mass or more with respect to the entire wadding. Therefore, the recoverability after compression is further improved compared with an acrylic fiber 100% product.
From this viewpoint, the mixing ratio of the acrylic fiber to the wadding is more preferably 30% by mass or more and 90% by mass or less and further preferably 50% by mass or more and 85% by mass or less.
The wadding of the present invention can be mixed with other fibers in addition to the acrylic fiber and the polyester fiber, as long as the down power and the Clo value satisfy the specified ranges.
From the viewpoints of the down power and the Clo value, a total amount of the acrylic fiber and the polyester fiber is preferably 90% by mass or more and more preferably 100% by mass, with respect to the total amount of the wadding.
In addition, in the wadding of the present invention, it is preferable that, when the down power is 140 cm³/g or more, the wadding be bulkier than inner wadding formed of 100% by mass of a polyester fiber so that the warmth retention property increases. In addition, when the down power is 300 cm³/g or less, the bulkiness is sufficient and the volume per mass can be reduced. Therefore, it is advantageous in terms of transportation cost.
From the viewpoint of the warmth retention property, the down power is more preferably 150 cm³/g or more and 280 cm³/g or less, and further preferably 160 cm³/g or more and 200 cm³/g or less.
In the wadding of the present invention, a Clo value measured by the method described in Examples which will be described later is 3.7 or more and 5 or less.
When the Clo value is 3.7 or more, the wadding can be used as the wadding with good warmth retention property. When the Clo value is 5 or less, the warmth retention property equivalent to the down is obtained. Therefore, the Clo value is sufficient.
From the viewpoint of warmth retention property, the Clo value is more preferably 3.8 or more and further preferably 4 or more.
In the wadding of the present invention, it is preferable that single fiber fineness of the acrylic fiber be 0.1 dtex or more and 10 dtex or less, and single fiber fineness of the polyester fiber be 1 dtex or more and 10 dtex or less.
It is preferable that the single fiber fineness of the acrylic fiber be 0.1 dtex or more, from the viewpoint of processability of the wadding manufacturing, and it is preferable that the single fiber fineness of the acrylic fiber be 10 dtex or less, from the viewpoint of increasing warmth retention property and the texture not being hard. From this viewpoint, the single fiber fineness is more preferably 0.5 dtex or more and 2.2 dtex or less and further preferably 0.8 dtex or more and 2.8 dtex or less.
In addition, it is preferable that the mixing ratio of the acrylic fiber to the wadding be 20% by mass or more, from the viewpoint of improving the warmth retention property, and it is preferable that the mixing ratio be 95% by mass, from the viewpoint of improving the recoverability by adding the polyester fiber.
It is preferable that the single fiber fineness of the polyester fiber be 1 dtex or more, from the viewpoints that effects of improving the recoverability and preventing permanent set (fatigue deformation) from occurring can be obtained and the bulkiness increases, and it is preferable that the single fiber fineness be 10 dtex or less, from the viewpoint of increasing the warmth retention property and the texture not being hard. From this viewpoint, the single fiber fineness of the polyester fiber is more preferably 1.7 dtex or more and 2.2 dtex or less.
The single fiber fineness described in the present specification can be measured by a method in accordance with 8.5 in JIS L1015: 2010.
In addition, it is preferable that the polyester fiber be a hollow fiber. Since the polyester fiber is inferior in the warmth retention property compared to the acrylic fiber, when a cross-sectional shape thereof is formed to be hollow, it is possible to secure immobile air. Further, when the polyester fiber is formed to have a hollow cross section, a cross-sectional area becomes larger than that of a non-hollow fiber. Therefore, effects are achieved such that the rigidity of the fiber increases, the recoverability is improved, and permanent set is prevented from occurring.
The hollow ratio of the hollow fiber is preferably 10% to 30%. It is preferable that the hollow ratio of the hollow fiber be 10% or more, because the heat retention rate is improved. From this viewpoint, the hollow ratio of the hollow fiber is preferably 10% or more and more preferably 20% or more.
In the wadding of the present invention, it is preferable that the fiber length of the acrylic fiber be 15 mm or more and 40 mm or less and the fiber length of the polyester fiber is 10 mm or more and 40 mm or less.
Here, the "fiber length" described in the present specification indicates a length in a fiber axis direction. The fiber length described in the present specification can be measured by a method in accordance with C method of 8.4 of JIS L1015: 2010.
It is preferable that the fiber length of the acrylic fiber be 15 mm or more, because processability in the manufacturing process of the wadding is favorable and the bulkiness is improved, and it is preferable that the fiber length be 40 mm or less, because the fibers are suppressed from intertwining with each other and the wadding can be prevented from biasing. Further, from this viewpoint, the fiber length of the acrylic fiber is more preferably 25 mm or more and 38 mm or less.
It is preferable that the fiber length of the polyester fiber be 10 mm or more, because it is possible to reduce falling of the polyester fiber in the manufacturing process or from the wadding, and it is preferable that the fiber length be 40 mm or less, because the fibers are suppressed from intertwining with each other and the wadding can be prevented from biasing. Further, from this viewpoint, the fiber length of the polyester fiber is preferably 12 mm or more and 35 mm or less and further preferably 25 mm or more and 30 mm or less.
The acrylic fiber can be appropriately selected according to a targeted application or performance. The acrylic fiber may be obtained by, for example, a method in which side-by-side type fibers are mixed to develop self-crimpability, thereby improving the bulkiness of the wadding, a method in which Y-shaped fibers are mixed so as to improve the bulkiness of the wadding and the warmth retention property, or a method in which fibers having single fiber fineness of 0.8 dtex or more and 20 dtex or less are mixed. In addition, as the acrylic fiber, for example, fibers in which each function is imparted and the performance is improved by combining an antibacterial fiber, a deodorant fiber, a hygroscopic heat-generating fiber, an optothermal fiber, and a flame retardant fiber. In addition, the fiber may be used alone, and two or more thereof may be used in combination.
In addition, it is preferable that the wadding of the present invention include a heat-bonding short fiber in an amount of 5% by mass to 30% by mass and at least a part of the heat-bonding short fiber is bonded to the acrylic fiber or the polyester fiber, from the viewpoints of bulkiness, compression recoverability, and easy retention of a formed nep.
As the heat-bonding short fiber, it is preferable to use a short fiber formed of low melting point resin having a melting point of 100 °C to 200 °C. As these short fibers, specifically, it is preferable to use a short fiber using low melting point polyester obtained by copolymerizing isophthalic acid, adipic acid, cyclohexane dicarboxylic acid, sebacic acid, or the like to polyethylene terephthalate or polybutylene terephthalate, as a raw material. After developing the nep, to be a core, of the acrylic fiber, the heat-bonding short fiber is thermally bonded to a part of the acrylic fiber. Accordingly, the nep can be retained. However, since the acrylic fiber of the present invention provides effects such that the single fiber fineness is very small and the formed nep is difficult to unravel, the heat-bonding short fiber may be used according to an application requiring durability.
Next, the wadding of the present invention can have a configuration in which 30% by mass or more and 70% by mass or less of the acrylic fiber and 30% by mass or more and 70% by mass or less of the polyester fiber are mixed, and the wadding is granular wadding in which one or a plurality of fibers are intertwined.
Advantageous effects of the down include bulkiness, warmth retention property, and independence unique to a down ball. Here, in a case of mixed wadding in which two or more types of wadding are mixed, when the fiber length is long, entanglement between the fibers becomes large, which causes the wadding to bias. On the other hand, since in a case where the fiber length is short, the entanglement of the fibers becomes small, it is effective for preventing the wadding from biasing but does not contribute to the bulkiness between fibers. In addition, in the mixed- wadding type in which opened wadding is mixed, it is difficult to prevent the wadding from biasing. However, when the wadding has a granular form, it is possible to impart independence unique to the down. Further, since if the single fiber fineness is small, the number of constituents per unit weight increases, and the warmth retention property increases.
In the configuration, it is preferable that the content ratio of the acrylic fiber with respect to the entire wadding be 30% by mass or more and 70% by mass or less. It is preferable that the content ratio of the acrylic fiber with respect to the entire wadding be 30% by mass or more, from the viewpoint of favorable formability of the granular wadding, and it is preferable that the content ratio be 70% by mass or less, from the viewpoint of improvement of the warmth retention property. From these viewpoints, the content ratio of the acrylic fiber with respect to the entire wadding is more preferably 40% by mass or more and 60% by mass or less, and further preferably 45% by mass or more and 55% by mass or less.
In addition, in the configuration, it is preferable that the content ratio of the polyester fiber with respect to the entire wadding be 30% by mass or more and 70% by mass or less. The wadding includes the polyester fiber; accordingly, the formability of the granular wadding improves and even after compression, a shape of the granular wadding recovers to a form close to a sphere. As the shape of the granular wadding is closer to a sphere, the gaps between the granular wadding become larger. The amount of immobile air increases as a whole and the warmth retention property improves.
It is preferable that the content ratio of the polyester fiber with respect to the entire wadding be 30% by mass or more, from the viewpoint of the formability of the granular wadding, and it is preferable that the content ratio thereof be 70% by mass or less, from the viewpoint of improvement of the heat retention rate. From these viewpoints, the content ratio of the polyester fiber with respect to the entire wadding is more preferably 40% by mass or more and 60% by mass or less, and further preferably 45% by mass or more and 55% by mass or less.
The granular wadding described in the present specification represents wadding in which one or a plurality of fibers are intertwined to form a sphere. The sphere may be, for example, a shape like a rugby ball or the fiber may appear like a whisker, as long as it is possible to recognize a shape close to a sphere.
The granular wadding is, for example, a shape close to a pill generated on a wool sweater.
It is preferable that the acrylic fiber have crimps, from the viewpoint of forming granular wadding. The crimp in this case may be mechanical crimping or may develop self-crimpability as a side-by-side type composite fiber.
The acrylic fiber can be appropriately selected according to a targeted application or performance. For example, the acrylic fiber may have a cross-sectional shape having a projection portion on a long side of a flat cross section, Y-shaped cross-sectional shape, and the like. In addition, for example, antibacterial property, deodorant property, hygroscopic heat-generating property, optothermal property, and flame retardancy are imparted to the acrylic fiber. In addition, the acrylic fiber can be individually combined. The acrylic fiber may be used alone and two or more thereof may be used in combination.
In the wadding formed of the granular wadding having the configuration, it is preferable that the polyester fiber be a conjugate fiber, and have a coil-like form in a no-load state. Here, in order to form the granular wadding, the crimp of the fiber is important. If there is no crimp, a grain is not formed. The polyester fiber has a coil-like form, whereby the fibers are entangled with each other and it is possible to manufacture granular wadding.
In addition, in the wadding formed of the granular wadding having the above described configuration, it is preferable that the maximum length of the granular wadding be 2 mm or more and 20 mm or less. It is preferable that the maximum length of the granular wadding be 2 mm or more, because it is difficult for the user to feel the tactile sensation of the grain. In addition, it is preferable that the maximum length of the granular wadding be 20 mm or less, because it is possible to prevent the wadding from biasing. Further, the closer the shape of the grain (granular wadding) to a true sphere, the larger the air gap and the more the immobile air. Therefore, the warmth retention property improves.
From the viewpoints, the maximum length of granular wadding is preferably 5 mm or more and 15 mm or less, and further preferably 7 mm or more and 13 mm or less.
In addition, in the wadding formed of the granular wadding having the configuration, it is preferable that the number of crimps of the acrylic fiber be 3 peaks/25 mm or more and 20 peaks/25 mm or less.
If the number of crimps of the acrylic fiber is 3 peaks/25 mm or more and 20 peaks/25 mm or less, granular wadding is easily formed and shape-keeping property is also favorable. From these viewpoints, the number of crimps of the acrylic fiber is more preferably 7 peaks/25 mm or more and 13 peaks/25 mm or less.
The unit of "peak" in the number of crimps means the number of crimping times (a value obtained by dividing a total number of the mountain and valley by 2). In addition, the number of crimps described in the present specification can be measured by a method in accordance with 8.12 of JIS L1015: 2010.
In the wadding having the configuration formed of the granular wadding as described above, it is preferable that the down power (DP) be 120 cm³/g or more and 270 cm³/g or less. The down power of the wadding formed of the granular wadding is preferably 120 cm³/g or more, from the viewpoint of securing sufficient warmth retention property, more preferably 130 cm³/g or more, and further preferably 140cm³/g or more.
Further, in the wadding having the configuration formed of the granular wadding, it is preferable that the decreasing rate of the down power after washing 10 times be preferably 30% or lower. In general, the down has restrictions on washing conditions such as dry cleaning and cannot be washed at home, and is troublesome to handle. However, according to the granular wadding of the present invention, the particle shape does not collapse even after washing and the granular waddings are not entangled with each other. Therefore, wadding biasing or lowering of the bulkiness is smaller than mixed wadding.
That is, in the wadding formed of the granular wadding, it is preferable that the decreasing rate of the down power after washing 10 times be 30% or lower because sufficient warmth retention property can be maintained even after washing.
Next, the manufacturing method of the wadding of the present invention will be described.
The wadding of the present invention can be manufactured by a method including steps of laminating or mixing an acrylic fiber having single fiber fineness of 0.1 dtex or more and 10 dtex or less and a polyester fiber of 1.0 dtex or more and 10 dtex or less to pass through a spreading machine, and mixing the fibers after opening with blowing or at least one or more carding machines.
In addition, in a case where the wadding is formed into the granular wadding, further, the fibers are put into a device for manufacturing the granular wadding.
The method of manufacturing the acrylic fiber having single fiber fineness of 0.1 dtex to 10 dtex is not particularly limited, and the acrylic fiber having the single fiber fineness can be manufactured by a known manufacturing method.
For example, there is a method including a step (A) in which after a polyacrylonitrile copolymer is dissolved in dimethylacetamide to obtain a solution, the solution is discharged and solidified in an aqueous solution of dimethylacetamide using a nozzle having a discharge port to obtain a coagulated fiber, and further including a step (B) in which the coagulated fiber obtained in the step (A) is subjected to drawing treatment by wet heat drawing or dry heat drawing, or both methods, is washed in boiling water, and dried at a temperature of 100 °C to 200 °C after applying oil, and then mechanical crimping (two-dimensional mountain-like shape) is imparted to obtain a fiber (ultra-fine fiber) having a single fiber fineness of from 0.1 dtex to 10 dtex.
In the manufacturing method, the ratio of the polyacrylonitrile copolymer dissolved in dimethylacetamide with respect to the solution is preferably 10% by mass to 30% by mass and more preferably 15% by mass to 25% by mass.
In addition, a pore diameter of the discharge port of the nozzle is preferably 0.010 mm to 0.080 mm from the viewpoint of obtaining a fiber having a desired fineness, and more preferably 0.015 mm to 0.060 mm.
In addition, the concentration of dimethylacetamide in the dimethylacetamide aqueous solution is preferably 10% by mass to 80% by mass from the viewpoint of favorable processability, and more preferably 20% by mass to 60% by mass.
In addition, a magnification of drawing of the coagulated fiber is preferably 2 times to 8 times from the viewpoint of increasing the strength, and more preferably 3 times to 6.5 times.
Further, examples of method of manufacturing a short fiber from the ultra-fine fiber obtained in the method include a method including a crimping step (1) of further imparting mechanical crimping using a heat relaxation treatment and/or a crimper as needed and further including step (2) of cutting the acrylic fiber so that the length thereof is 15 mm to 40 mm after the crimping step (1).
The crimping step (1) is preferably machine crimping using a crimper, and it is preferable that the number of crimps be 3 peaks/25 mm to 20 peaks/25 mm, from the viewpoint of bulkiness.
It is preferable that the number of crimps of the acrylic fiber be 3 peaks/25 mm or more, from the viewpoint of maintaining the shape of the wadding, and it is preferable the number of crimps thereof be 20 peaks/25 mm or less, from the viewpoint processability in manufacturing of the wadding.
Further, in a case where the manufacturing method of the wadding includes a step of bonding the heat-bonding short fiber to the acrylic fiber or the polyester fiber, it is preferable that the acrylic fiber obtained in the step (2) be mixed with the heat-bonding short fiber to fix the nep by heating to a temperature of 100 °C to 220 °C.

Examples

Hereinafter, the present invention will be described in detail with reference to examples and comparative examples, but the present invention is not limited to the examples.

(Measurement of Single Fiber Fineness)

Single fiber fineness of an acrylic fiber and a polyester fiber was measured in accordance with JIS L 1015: 2010. The results are shown in Tables 1 and 2 below.

(Measurement method of Down Power)

A down power of the wadding was measured in the same manner as the method specified in JIS L1903, except that the treatment using the dryer method and the steam method of pretreatment are not performed. The results are shown in Tables 1 and 2 below.

(Measurement of Maximum Length of Granular wadding)

The maximum length of the granular wadding was measured using a caliper.
At this time, 30 samples were measured and the average value thereof was taken as the maximum length thereof. The results are shown in Tables 1 and 2 below.

(Measurement Method of Clo Value)

The warmth retention rate (Clo value) of the wadding was measured using Thermo Labo II and a dry contact method under the following conditions and procedure. The results are shown in Tables 1 and 2 below.

1. The measurement was performed in a test room in which a room temperature of 22 °C and humidity of 60% were maintained.
2. A sample which is obtained by putting 10 g of the wadding into a 20 cm square cushion cover (fabric: 100% cotton) was prepared.
3. The sample was set on a heating plate set at 32 °C using the KES-F7 Thermo Labo II Tester (registered trademark) manufactured by Kato Tech Co.,Ltd.
4. A heat quantity a (W) dissipated through the sample was calculated under a windy condition of 30 cm/sec.
5. A heat quantity b (W) dissipated in a state where the sample was not set was calculated, and the Clo value was calculated by the following equation.

Clo value = 0.645/ (1 / heat quantity a - 1 / heat quantity b)

This represents that the higher the Clo value, the more warmth retention property of the wadding. In Tables 1 and 2 below, "-" indicates non-measured.
For the Thermo Labo II and dry contact method, and Clo value, refer to the following URL.

(A) Thermo Labo II Dry contact method (General Foundation Boken Quality Evaluation Institute) http://www.boken.or.jp/service/clothing/functionality/warmth_keeping.html
(B) Clo value (General Foundation Kaken Test Center) http://www.kaken.or.jp/guidance/functionality/thermal_mannequin.html

(Evaluating Method of Permanent Setting Property)

A height Amm of a loading disk was measured in accordance with JIS L1903, and the height Bmm of the loading disk after 24 hours was measured.
Then, a value calculated using this formula {[(A-B)/A]×100(%)}, from respective heights A and B obtained by the measurement, was assumed as a permanent setting property (fatigue deformability), and was evaluated according to the following criteria.

A (Excellent): Permanent setting property 95% or more
B (Favorable): Permanent setting property 85% or more and less than 95%
C (Inferior): Permanent setting property less than 85%

(Example 1)

A copolymer formed of 95% by mass of acrylonitrile and 5% by mass of vinyl acetate was dissolved in dimethylacetamide such that the concentration of the copolymer was 20% by mass. Thereafter, the solution was discharged into an aqueous solution including 50% by mass of dimethylacetamide using a nozzle having a round discharge hole with a hole diameter of 0.045 mm and subjected to washing in boiling water and stretching to 4.5 times. Then, an oil agent was applied to be dried at a temperature of 150 °C. Thereafter, a thermal relaxation treatment was carried out and mechanical crimp of 12 peaks/25 mm was imparted using a crimper. A tow was cut such that a length of the single fiber was 38 mm. Accordingly, an acrylic short fiber in which a cross-sectional shape was round and single fiber fineness was 0.8 dtex was obtained.
Thereafter, 60% by mass of the acrylic short fibers as a fiber 1 and 40% by mass of the hollow polyester fiber (single fiber fineness: 2.2 dtex, fiber length: 20 mm, and hollow ratio 6%) as a fiber 2 were mixed with a cotton mixing machine to pass through a spreading machine, and further mixed with a carding machine to obtain the wadding.
Then, bulkiness evaluation and warmth retention property evaluation were performed using the wadding obtained by the method. The evaluation results are shown in Table 1 below.

(Example 2)

The wadding was manufactured and evaluated by the same method as in Example 1 except that the fiber 2 was changed to a non-hollow regular polyester having single fiber fineness of 1.7 dtex and a fiber length of 15 mm. The results of bulkiness and warmth retention property obtained in Example 2 are shown in Table 1 below.

(Example 3)

The wadding was manufactured and evaluated by the same method as in Example 1 except that proportions of the fibers 1 and 2 were changed as shown in Table 1 below. The results of bulkiness and warmth retention property obtained in Example 3 are shown in Table 1.

(Example 4)

A copolymer formed of 93% by mass of acrylonitrile and 7% by mass of vinyl acetate was dissolved in dimethylacetamide such that the concentration of the copolymer was 20% by mass. Thereafter, the solution was discharged into an aqueous solution including 56% by mass of dimethylacetamide using a nozzle having a round discharge hole with a hole diameter of 0.060 mm and subjected to washing in boiling water and stretching to 6 times. Then, an oil agent was applied to be dried at a temperature of 150 °C. Thereafter, a thermal relaxation treatment was carried out and mechanical crimp of 12 peaks/25 mm was imparted using a crimper. Then, a tow was cut such that a length of the single fiber was 20 mm. Accordingly, an acrylic short fiber in which a cross-sectional shape was approximately a broad bean shape and single fiber fineness was 1 dtex was obtained.
Thereafter, as shown in Table 1 below, 20% by mass of the acrylic fiber in which the cross-sectional shape was a broad bean shape and 30% by mass of the acrylic fiber in which the cross-sectional shape was a circular shape, 30% by mass of the polyester fiber of Example 3 in which the cross-sectional shape was hollow, and 20% by mass of the polyester fiber of Example 2 in which the cross-sectional shape was circular were mixed with a cotton mixing machine to pass through a spreading machine, and further mixed with a carding machine to obtain the wadding.
Then, bulkiness evaluation and warmth retention property evaluation were performed using the obtained wadding by the same method as above. The evaluation results are shown in Table 1 below.

(Comparative Example 1)

The bulkiness and the warmth retention property of another manufacturer's product (product name: PrimaLoft (registered trademark), manufactured by Albany International Corp., and polyester 100%) used for the wadding were evaluated by the same method as above. The results thereof are shown in Table 1 below.
The PrimaLoft used in Comparative Example 1 is formed of polyester having single fiber fineness of 1 dtex. Instead of several kinds of polyesters having different fineness being mixed as in the present invention, PrimaLoft is formed of only a fiber having singular fineness.

(Comparative Example 2)

The bulkiness and the warmth retention property of another manufacturer's product (product name: Air Flake (registered trademark), manufactured by KURABO INDUSTRIES LTD.) used for the wadding were evaluated by the same method as above. The results thereof are shown in Table 1 below.
The wadding of Comparative Example 2 is formed of a long fiber and includes a core yarn and a fancy yarn, in which the fancy yarn is longer than the core yarn, the core yarn and the fancy yarn are united by interlacing, the fancy yarn is interlacing yarn for wadding which is opened to form a loop-shaped fiber, the fancy yarn is hollow fiber, and a hollow ratio is 25%. In addition, in the wadding material of Comparative Example 2, both the core yarn and the fancy yarn are 100% by mass of polyester fibers.

(Comparative Example 3)

100% by mass of the polyester fiber having a circular cross section (single fiber fineness: 1.7 dtex and fiber length: 15 mm) was passed through a spreading machine and then further wadding was stirred with air to obtain the wadding. Thereafter, the bulkiness and the warmth retention property thereof were evaluated by the same method as above. The evaluation results thereof are shown in Table 1 below.
The wadding obtained in Comparative Example 3 was low both in the bulkiness and the warmth retention property.

(Comparative Example 4)

100% by mass of the polyester fiber having the hollow cross section (fiber fineness: 2.2 dtex and fiber length: 20 mm) used in Example 1 was used to pass through the spreading machine and then further wadding was stirred with air to obtain the wadding. The evaluation results thereof are shown in Table 1.
The obtained wadding was low in both bulkiness and the warmth retention property.

(Reference Example 1)

100% by mass of the acrylic fiber (single fiber fineness: 0.8 dtex and fiber length: 38 mm) used in Example 1 was used to pass through the spreading machine and then mixed with the carding machine to obtain the wadding.
The wadding obtained above was used for performing the bulkiness evaluation and the warmth retention property evaluation by the same method as above. The evaluation results are shown in Table 1 below.

Reference Example 1 was a wadding of 100% by mass of the acrylic fiber, in which the down power and the Clo value were favorable but the permanent setting property was inferior.

[Table 1]

		Example 1	Example 2	Example 3	Example 4	Comparative Example 1	Comparative Example 2	Comparative Example 3	Comparative Example 4	Reference Example 1
<Fiber 1>	Kind of fiber	Acryl	Acryl	Acryl	Acryl	Polyester	Polyester	Polyester	Polyester	Acryl
	Cross-sectional shape	Circular shape	Circular shape	Circular shape	Circular shape	Circular shape	Circular shape	Circular shape	Hollow shape	Circular shape
	Fineness (dtex)	0.8	0.8	0.8	1	1	1.2	1.7	2.2	0.8
	Fiber length (mm)	38	38	38	20	50	-	15	20	38
	Number of crimps (peaks/25 mm)	12	12	12	12	10	10	10	10	10
	Mixing ratio (%)	60	60	80	30	100	40	100	100	100
<Fiber 2>	Kind of fiber	Polyester	Polyester	Polyester	Acryl	-	Polyester	-	-	-
	Cross-sectional shape	Hollow shape	Circular shape	Hollow shape	Broad bean shape	-	Hollow shape	-	-	-
	Fineness (dtex)	2.2	1.7	2.2	2.2	-	1.7	-	-	-
	Fiber length (mm)	20	15	20	20	-	50	-	-	-
	Number of crimps (peaks/25 mm)	10	10	10	12	-	10	-	-	-
	Mixing ratio (%)	40	40	20	20	-	60	-	-	-
<Fiber 3>	Kind of fiber	-	-	-	Polyester	-	-	-	-	-
	Cross-sectional shape	-	-	-	Hollow shape	-	-	-	-	-
	Fineness (dtex)	-	-	-	2.2	-	-	-	-	-
	Fiber length (mm)	-	-	-	20	-	-	-	-	-
	Number of crimps (peaks/25 mm)	-	-	-	10	-	-	-	-	-
	Mixing ratio (%)	-	-	-	30	-	-	-	-	-
<Fiber 4>	Kind of fiber	-	-	-	Polyester	-	-	-	-	-
	Cross-sectional shape	-	-	-	Circular shape	-	-	-	-	-
	Fineness (dtex)	-	-	-	1.7	-	-	-	-	-
	Fiber length (mm)	-	-	-	15.0	-	-	-	-	-
	Number of crimps (peaks/25 mm)	-	-	-	10	-	-	-	-	-
	Mixing ratio (%)	-	-	-	20	-	-	-	-	-
<Wadding>	Shape	Wadding shape	Wadding shape	Wadding shape	Wadding shape	Wadding shape	Yarn shape	Wadding shape	Wadding shape	Wadding shape
	Down power (cm³/g)	191	195	197	179	137	206	99	142	219
	clo value	4.07	4.14	4.56	4.28	3.87	3.64	2.6	3.12	4.12
	Permanent setting property	B	B	B	B	A	A	A	A	C

(Example 5)

A copolymer formed of 93% by mass of acrylonitrile and 7% by mass of vinyl acetate was dissolved in dimethylacetamide such that the concentration of the copolymer was 24% by mass. Thereafter, the solution was discharged into an aqueous solution including 50% by mass of dimethylacetamide using a nozzle having a round discharge hole with a hole diameter of 0.060 mm and subjected to washing in boiling water and stretching to 6 times. Then, an oil agent was applied to be dried at a temperature of 150 °C. Thereafter, a thermal relaxation treatment was carried out and mechanical crimp of 12 peaks/25 mm was imparted using a crimper. A tow was cut such that a length of the single fiber was 20 mm. Accordingly, an acrylic short fiber in which single fiber fineness was 1.0 dtex and a cross-sectional shape perpendicular to a fiber axis direction was a circular shape was obtained.
Thereafter, 50% by mass of the acrylic short fibers as a fiber 1 and 50% by mass of the polyester fiber (single fiber fineness: 2.5 dtex and fiber length: 32 mm) as a fiber 2 were mixed to pass through a cotton granulator, thereby obtaining granular wadding.
Then, bulkiness evaluation and warmth retention property evaluation were performed using the obtained wadding by the same method as above. The evaluation results thereof are shown in Table 2 below.

(Example 6)

The wadding was manufactured and evaluated by the same method as in Example 5 except that the acrylic short fiber of the fiber 1 was changed to those described in Table 2 below.
The evaluation results of bulkiness and the warmth retention property of the obtained wadding are shown in Table 2 below.

(Comparative Example 5)

The wadding was manufactured and evaluated by the same method as in Example 5 except that the acrylic short fiber of the fiber 1 was changed to those described in Table 2 below.
The evaluation results of the bulkiness and the warmth retention property of the obtained wadding are shown in Table 2 below.
The obtained wadding of Comparative Example 5 was low in down power.

(Comparative Example 6)

The granular wadding was manufactured and evaluated by the same method as in Example 5 except that the acrylic short fiber of the fiber 1 was changed to a flat acrylic short fiber in which single fiber fineness was 17 dtex, a cross-sectional shape perpendicular to the fiber axis direction was a flat shape, and a flatness ratio was 10.
The evaluation results of the bulkiness and the warmth retention property of the obtained wadding are shown in Table 2 below.
The obtained wadding of Comparative Example 6 was low in the Clo value.

(Comparative Example 7)

The granular wadding was manufactured and evaluated by the same method as in Example 5 except that the fiber 1 was changed to the flat acrylic short fiber used in Comparative Example 6 and the fiber 2 was changed to the acrylic short fiber used in Example 3.
The evaluation results of the bulkiness and the warmth retention property of the obtained wadding are shown in Table 2 below.
The obtained wadding of Comparative Example 7 was low in down power and Clo value and poor in permanent setting property.

(Comparative Example 8)

The granular wadding was manufactured and evaluated by the same method as in Example 1 except that the fiber 2 was changed to the same fiber as fiber 1 used in Example 6.
The evaluation results of the bulkiness and the warmth retention property of the obtained wadding are shown in Table 2 below.

The obtained wadding of Comparative Example 8 was low in Clo value and poor in permanent setting property.

[Table 2]

		Example 5	Example 6	Comparative Example 5	Comparative Example 6	Comparative Example 7	Comparative Example 8
<Fiber 1>	Kind of fiber	Acryl	Acryl	Acryl	Acryl	Acryl	Acryl
	Cross-sectional shape	Circular shape	Ellipse shape	Broad bean shape	Hat shape	Flat shape	Circular shape
	Fineness (dtex)	1	6.6	2.2	17	17	1
	Fiber length (mm)	20	32	32	32	32	20
	Number of crimps (peaks/25 mm)	12	12	12	12	12	12
	Mixing ratio (%)	50	50	50	50	50	50
<Fiber 2>	Kind of fiber	Polyester	Polyester	Polyester	Polyester	Acryl	Acryl
	Cross-sectional shape	Circular shape	Circular shape	Circular shape	Circular shape	Circular shape	Ellipse shape
	Fineness (dtex)	2.5	2.5	2.5	2.5	1	6.6
	Fiber length (mm)	32	32	32	32	20	32
	Number of crimps (peaks/25 mm)	10	10	10	10	12	12
	Mixing ratio (%)	50	50	50	50	50	50
<Fiber 3>	Kind of fiber	-	-	-	-	-	-
	Cross-sectional shape	-	-	-	-	-	-
	Fineness (dtex)	-	-	-	-	-	-
	Fiber length (mm)	-	-	-	-	-	-
	Number of crimps (peaks/25 mm)	-	-	-	-	-	-
	Mixing ratio (%)	-	-	-	-	-	-
<Fiber 4>	Kind of fiber	-	-	-	-	-	-
	Cross-sectional shape	-	-	-	-	-	-
	Fineness (dtex)	-	-	-	-	-	-
	Fiber length (mm)	-	-	-	-	-	-
	Number of crimps (peaks/25 mm)	-	-	-	-	-	-
	Mixing ratio (%)	-	-	-	-	-	-
<Wadding>	Shape	Granular wadding shape	Granular wadding shape	Granular wadding shape	Granular wadding shape	Granular wadding shape	Granular wadding shape
	Maximum length of granular wadding (mm)	10	10	10	10	10	10
	Down power (cm³/g)	153	152	126	156	129	134
	clo value	3.88	3.90	3.79	3.20	3.36	3.81
	Permanent setting property	B	B	B	B	C	C

Claims

A wadding that is obtained by mixing 20% by mass or more and 95% by mass or less of an acrylic fiber and 5% by mass or more and 80% by mass or less of a polyester fiber,
wherein a down power is 140 cm³/g or more and 300 cm³/g or less, and
a Clo value is 3.7 or more and 5 or less.
The wadding according to Claim 1,
wherein single fiber fineness of the acrylic fiber is 0.1 dtex or more and 10 dtex or less, and
single fiber fineness of the polyester fiber is 1.0 dtex or more and 10 dtex or less.
The wadding according to Claim 3,
wherein the polyester fiber is a hollow fiber, and
a hollow ratio of the hollow fiber is 10% or more and 30% or less.
The wadding according to any one of Claims 1 to 3,
wherein the down power is 150 cm³/g or more and 280 cm³/g or less.
The wadding according to any one of Claims 1 to 4,
wherein the down power is 160 cm³/g or more and 200 cm³/g or less.
The wadding according to any one of Claims 1 to 5,
wherein the Clo value is 3.8 or more and 4.8 or less.
The wadding according to any one of Claims 1 to 5,
wherein the Clo value is 4 or more and 4.7 or less.
The wadding according to any one of Claims 1 to 7,
wherein the single fiber fineness of the acrylic fiber is 0.5 dtex or more and 2.2 dtex or less, and
the single fiber fineness of the polyester fiber is 1.7 dtex or more and 2.2 dtex or less.
The wadding according to any one of Claims 1 to 8,
wherein a fiber length of the acrylic fiber is 15 mm or more and 40 mm or less, and
a fiber length of the polyester fiber is 10 mm or more and 40 mm or less.
The wadding according to any one of Claims 1 to 9,
wherein a mixing ratio of a heat-bonding short fiber with respect to the wadding is 5% by mass or more and 30% by mass or less, and
at least a part of the heat-bonding short fiber is bonded to the acrylic fiber or the polyester fiber.
The wadding according to any one of Claims 1 to 10,
wherein 30% by mass or more and 70% by mass or less of the acrylic fiber and 30% by mass or more and 70% by mass or less of the polyester fiber are mixed, and
the wadding is granular wadding in which one or a plurality of fibers are intertwined.
The wadding according to Claim 11,
wherein the polyester fiber is a conjugate fiber and has a coil-like form in a no-load state.
The wadding according to Claim 11 or 12,
wherein the maximum length of the granular wadding is 2 mm or more and 20 mm or less.
The wadding according to any one of Claims 1 to 13,
wherein the number of crimps of the acrylic fiber is 3 peaks/25 mm or more and 20 peaks/25 mm or less.
The wadding according to any one of Claims 1 to 14,
wherein a decreasing rate of the down power after washing 10 times is 30% or lower.