JP2001197968A - Flexible hard cotton - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a flexible hard cotton which hardly wears out even if it is repeatedly used, maintains a soft feeling and further can be used as filling cotton for a mattress without using wound cotton. SOLUTION: This flexible hard cotton comprises short fibers having a fineness of 0.5 to 5 deci tex and binder fibers and has adhesion points due to fusion of the binder fibers, a density of 0.02 g/cm3 or more and a 50% compressive hardness of 20 kg/150 mmϕ or less.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a hard cotton which is used for a mattress, a sheet and the like, has little set even after repeated use, and has a soft texture. further,
When used as a mattress, the present invention relates to a soft hard cotton that can be used as a batting for a mattress without using a roll.

[0002]

2. Description of the Related Art Conventionally, hard cotton used for mattresses and sheets is designed to be hard in order to eliminate a feeling of flooring during use. Specifically, a fiber of 6.6 decitex or more is used as a base material in addition to the binder fiber.
% Compression hardness is high and the texture is poor. In addition to this fiber, as a thermoadhesive fiber, a thermoplastic resin fiber or core having a high melting point as a binder thermoplastic resin,
Including a core / sheath fiber with a binder in the sheath,
It is formed by thermal bonding. However, when these hard cottons are repeatedly used, the point of adhesion is released, and the bulk is lower than the initial bulk. In order to solve this problem, for example, a method of lowering the density of the hard cotton and an improvement of the binder fiber have been proposed. However, the method of reducing the density is insufficient in improving the hand. In addition, a cotton filling material has been proposed which eliminates settling by using fibers of 4.4 dtex or less in some of the constituent fibers, but the texture is insufficient due to the inclusion of fibers thicker than the fibers. It is.

[0003]

SUMMARY OF THE INVENTION The present invention relates to a hard cotton which is used for a mattress or a sheet, has little set even after repeated use, and has a soft texture. Another object of the present invention is to provide a soft hard cotton which can be used as a batting for a mattress without using a roll when used as a mattress.

[0004]

The present invention has the following configuration to solve the above problems. That is, the present invention provides: A structure composed of short fibers having a fineness of 0.5 to 5 decitex and binder fibers, having an adhesion point due to melting of the binder fibers, and having a density of 0.02 g / cm.
³ or more, and 50% compression hardness is 20 kg / 150
Soft hard cotton having a diameter of not more than mmφ. 2. 2. The soft hard cotton according to the above 1, wherein the residual compression set is 8% or less. 3. The soft hard cotton according to any one of the above items 1 to 2, having a structure in which a structure B composed of short fibers having a fineness of 0.5 to 33 decitex and a binder fiber and the fiber structure A described in the above item 1 are laminated. 4. The weight ratio of the structure A to the structure B is 30:70 to 9
The soft hard cotton according to the above item 3, wherein the ratio is 0:10.

[0005]

BEST MODE FOR CARRYING OUT THE INVENTION The hard cotton of the present invention will be described below in detail. The fiber as the base material of the hard cotton of the present invention is a natural fiber, an inorganic fiber, a regenerated fiber or a synthetic fiber, but is preferably a fiber mainly composed of a synthetic fiber such as a polyester fiber or a polyolefin fiber.

Further, as the fiber used in the present invention, a fiber into which titanium oxide, an antibacterial agent, an antifungal agent or the like has been kneaded, or a fiber provided with various functions by post-processing can be used.

The binder fiber of the present invention has a polyolefin fiber or a core-sheath structure, and the melting point or softening point of the sheath component is at least 50 ° C. lower than the melting point of the core component, and the melting point or softening point of the sheath component is from 70 ° C. to 210 ° C. It is a polyester fiber having a temperature of ° C. In addition, 50
All-melting type polyester fibers having a melting point of not lower than ℃ can also be used.

[0008] The content of the binder fiber is not particularly limited, but if it is contained in an amount of 50% by weight or more, the hand becomes hard, which is not preferable. In addition, the bonding point referred to here means that at a point where the base material and the binder fiber or the binder fiber and the binder fiber intersect, the melted portion of the binder fiber is melted or softened by heat, and another fiber is partially or at the intersection. A point that covers all surroundings.

The fiber of 0.5 to 5 dtex used as a base material is important for giving a soft texture even if the density of the hard cotton is increased. 0.5 fineness
5 to 5 dtex, preferably 1.5 to 4 dtex, and contains 60% by weight or more, preferably 70% by weight or more of this fiber. Polyester short fibers having a fiber length of 10 to 100 mm, preferably 50 to 80 mm are suitable. If the fineness is less than 0.5 decitex, the passability of the card during the production of hard cotton becomes poor, and the productivity decreases. If it exceeds 5 dtex, the texture becomes hard and the effect of the present invention is not obtained. In particular, as the density of the hard cotton increases, the hard cotton becomes hard, and as a result, the 50% compression hardness exceeds 15 kg / 150 mmφ. For this reason, a single piece of hard cotton cannot be used as a batting such as a mattress, and a wrapping cotton is required. If the content is less than 20% by weight, it is difficult to obtain a soft texture and an effect of suppressing settling.

On the other hand, if the fiber length is shorter than 10 mm, entanglement between the fibers is poor, and it is difficult to form a structure. If the fiber length is longer than 100 mm, the opening property and the cotton-making property tend to deteriorate. In addition, two or more types of fibers may be used as long as the fibers have a density of 0.5 to 4 dtex.

[0011] The fiber of the base material, in order to improve the cotton production,
It is preferable to give a mechanical crimp, and more preferably a three-dimensional crimp that has been subjected to an asymmetric cooling treatment at the time of spinning of the matrix fiber constituting the structure. The number of crimps is 5 to 30 pieces / inch, preferably 10 to 20 pieces / inch, and the degree of crimp is 5 to 4
It is preferably 0%, preferably 10 to 35%.
When the number of crimps is less than 5 pieces / inch and the degree of crimp is less than 5%, uniform spreading is not performed during the spreading process, and unevenness occurs in the spread web. The number of crimps exceeds 30 pieces / inch and the degree of crimp is 40%
If it exceeds 100, the texture of the product after opening the card tends to deteriorate.

The cross section of the fiber may be a solid fiber, a hollow fiber for giving heat retention, or a modified cross section.

As a method of forming a laminated structure, an air-lay method or a cross-layer method of laminating card webs may be used. In addition, if the fibers are entangled with a needle punch or the like before setting by heat, the effect of suppressing peeling can be obtained. The setting condition by heat can be appropriately set by equipment or the like.

The hard cotton obtained as described above has a thickness of 3 mm.
Or more, preferably 10 mm or more. The density is 0.02
g / cm ³ or more, preferably 0.03 to 0.1 g / c
m ³ , more preferably 0.035 to 0.06 g / cm ³
It is. If the thickness is less than 3 mm, 0.5%
Since the fibers from decitex to 5 decitex are used, the hard cotton becomes too soft. For example, when used for the filling of the mattress, a problem of feeling of flooring occurs at the time of use. Density depends on the method of use. If the thickness is less than 0.02 g / cm ³ , there is no problem as long as it has a thickness. On the other hand, if it is higher than 0.1 g / cm ^3, the efficiency of heat setting at the time of production decreases, or 0.5 dtex to 5 dtex.
Even when decitex fibers are used, the problem that the hard cotton becomes too hard occurs.

The 50% compression hardness of the hard cotton is preferably 20%.
kg / 150mmφ or less, more preferably 15kg / 1
It is 50 mmφ or less. If it is 20 kg / 150 mmφ or more, the texture becomes hard. Further, the residual compression strain is 8% or less, preferably 6% or less.

The hard cotton obtained as described above can be used alone as the filling of the mattress. Conventionally, mattresses are
Using a fiber of 6 decitex or more as a base material, a hard cotton is made using the binder fiber described in the present text, and used as a core of the mattress, and card webs called wrapping cotton are used above and below the hard cotton. Hard cotton alone is hard and has problems during use.
Also, the card web alone is used for a pad, etc., but there is a problem of a floor feeling, and a bed or another mattress is used under the pad. However, the product of the present invention is a hard cotton in which the base fiber is fixed with a binder fiber, does not have a feeling of flooring like a card web alone, and furthermore has a soft texture, so there is a problem when used alone even with a single card web. There is no. Furthermore, the residual compression set is 8%
Since it is as small as the following, it has excellent durability.

[0017]

Next, the present invention will be described in more detail with reference to examples. The measuring methods of various characteristics described in the present invention are as follows. (Density) Measured according to the method of JIS K6401. (Repeated compression residual strain) Measured according to the method of JIS K6401. (50% compression hardness) Measured according to the method of JIS K6401. Each fiber used in the examples will be described.

(Base material polyester fiber A) Polyester fiber of 2.2 decitex, cut length 51 mm, number of crimps 14 / inch, degree of crimp 14%, solid round cross section. (Base material polyester fiber B) 15 decitex, cut length 64 mm, number of crimps 10 / inch, degree of crimp 23%,
Polyester fiber with a hollow ratio of 35%.

(Binder Fiber C) A binder fiber having a core-sheath structure of 4.4 decitex and a cut length of 51 mm and having a sheath component having a melting point of 110 ° C.

Examples 1-2 and Comparative Examples 1-2 Hard cotton having the composition shown in Table 1 was prepared by the air lay method, and heat set was performed at 160 ° C. for about 1.5 minutes. Table 1 shows the evaluation results of the obtained hard cotton.

[0021]

[Table 1]

Example 3 Two layers of different fibrous structures (card webs) having the structure shown in Table 2 were overlapped and entangled with each other by a needle punch, and then subjected to the same heat setting as in Table 1. Table 2 shows the evaluation results of the obtained hard cotton.

[0023]

[Table 2] When the first layer is on the upper side, it can be used as a batting for the bedding.

[0024]

As described above, the hard cotton according to the present invention has little set even after repeated use and has a soft texture. Furthermore, when used as a mattress, it can be used as a batting for the mattress without using the rolled cotton.

Claims (4)

[Claims] 1. A structure composed of short fibers having a fineness of 0.5 to 5 decitex and binder fibers,
It has an adhesion point due to the melting of the binder fiber and has a density of 0.
02 g / cm ³ or more and 50% compression hardness of 20
Soft hard cotton characterized by being not more than kg / 150 mmφ. 2. The soft hard cotton according to claim 1, wherein the residual compression set is 8% or less. 3. A structure in which a structure B composed of short fibers having a fineness of 0.5 to 33 decitex and a binder fiber and the fiber structure A according to claim 1 are laminated.
Soft hard cotton according to any one of claims 1 to 3. 4. The weight ratio of the structure A to the structure B is 30:
4. The soft hard cotton of claim 3, wherein the ratio is from 70 to 90:10.