JP2005179848A - Bedding material having low air permeability - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a bedding material composed of a high-density woven fabric realizing low air permeability without damaging the texture and appearance under a mild condition of the linear pressure and surface temperature of a blast calender roll in down-proof processing. <P>SOLUTION: The bedding material having low air permeability is a woven fabric made of at least one kind of fiber selected from natural fibers, regenerated fibers, semisynthetic fibers and synthetic fibers and contains a flat cross-section polyester multifilament having a flatness of 3-7 and a single fiber fineness of ≥0.3 dtex and ≤2.0 dtex as at least a part of the warp and/or weft. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to bedding materials, and more particularly to low-breathing fiber materials useful for comforters, mattresses, futon-side fabrics, blanket-side fabrics, sheets, pillowcases, bed covers, etc. Featuring feathers that are widely recognized as fillers, generation of dust due to aging of feathers, high density and low air permeability that suppresses ingress and outflow of ticks, soft touch and mild gloss It relates to bedding materials.

  Many bedding materials have been proposed and put on the market using natural fibers such as cotton, regenerated fibers such as rayon, semi-synthetic fibers such as cellulose acetate, and synthetic fibers such as polyester. In particular, with respect to the futon side fabric, it is desirable to make it a high-density woven fabric in order to suppress the blowing of the filling material, and to carry out down-proof processing (plast calender treatment).

  By down-proofing, the air permeability can be lowered and the blowing of batting can be suppressed, but as a result, artificial surface gloss occurs, the texture becomes flat, paper-like, and the quality deteriorates. There are restrictions on calendar conditions such as linear pressure and temperature.

For this reason, many high-density fabrics using microfibers have been proposed to achieve low air permeability of high-density fabrics under low calender conditions. Among them, high-density fabrics using fibrillated composite fiber filaments have been split. The fiber fibril makes it possible to achieve a low air permeability and to suppress gloss and to be a good bedding material. (For example, see Patent Documents 1 and 2.)
JP-A-9-170137 JP-A-9-176931

  Fibrilized composite fiber filaments become microfibers by splitting, but it is difficult to control the splitting state uniformly, and air permeability unevenness and dyeing differences are likely to occur. Microfibers are stretched because the secondary moment of inertia remains small, resulting in a feeling of poor waist. Furthermore, when splitting or ultrafinening a fibrillated composite fiber filament, it is usually carried out using a combination of physical action and chemical action. However, organic solvents are often used, causing problems such as skin damage due to residual organic solvent. There is. It is produced through a manufacturing process that pays attention to health without using an organic solvent, and can achieve low air permeability even under mild conditions of down-proofing, but the quality and performance decline as before. There is a strong demand for high-density woven materials that do not have any.

  The present invention was made against the background of the problems of the prior art, and realized low air permeability without impairing the texture and appearance quality under mild conditions of the plast calender roll linear pressure and the same surface temperature by down proof processing. The issue is to provide bedding materials.

As a result of intensive studies to solve the above problems, the present inventors have completed the present invention. The flatness is 3 or more and 7 or less, and the single fiber fineness is 0.3 dtex or more and 2.0 or less. By using a polyester multifilament yarn with a flat cross section of decitex or less as at least a part of the warp and / or weft, and reversing the long side of the flat cross-sectional yarn so that the long side of the flat cross-section yarn is substantially parallel to the surface of the fabric by down-proofing We focused on realizing low air permeability. That is, the present invention has the following configuration.
1. It is a woven fabric made of at least one selected from natural fibers, regenerated fibers, semi-synthetic fibers, and synthetic fibers. The warp and / or the wefts have a flatness of 3 to 7 and a single fiber fineness of 0.3 dtex. A low-breathing bedding material comprising a flat cross-sectional polyester multifilament of 2.0 decitex or less.
2. Air permeability by Frazier method initial values 2cm ³ / (cm ² · sec) or less, low according to the first, characterized in that after the washing once is 4cm ³ / (cm ² · sec) or less Breathable bedding material.
3. The low air permeability bedding material according to the first or second aspect, wherein the fabric weight is 80 g / m ² or more and 120 g / m ² or less, and the tear strength is 9.8 N or more.
4). The maximum number of floats of warps and / or wefts in one woven fabric is 4 or less, and the sum of the number of warps and the number of wefts per 1 cm is 115 / cm to 230 / cm The low air permeability bedding material according to any one of the first to third aspects.
5). The warp yarn is a spun yarn including cotton, the weft yarn is a synthetic multifilament yarn, the warp fineness is 50 to 120 in English cotton count display, and the weft is 50 to 200 decitex The low air permeability bedding material according to any one of the first to fourth.

  The low air permeability bedding material according to the present invention exhibits a low air permeability that can be expected to have a tick-proof / dust-proof property and a batting blow-out suppressing effect even when mild down-proof processing conditions are used, and an artificial gloss Low air permeability suitable for applications such as comforters, mattresses, futon-side fabric, blanket-side fabric, sheets, pillowcases, bed covers, etc. Bedding materials can be obtained.

Hereinafter, the present invention will be described in more detail.
The low-breathing bedding material of the present invention is woven using at least one material selected from natural fibers, regenerated fibers, semi-synthetic fibers, and synthetic fibers, and is silk, cotton, rayon, cupra, polynosic, Preferred examples include cellulose acetate, promix, and polyester. The loom used for weaving is not particularly limited, and a known loom can be used. In particular, use of an air jet loom, a rapier room, and a projectile room is preferable.

  In addition, it is effective in achieving low air permeability that at least a part of the warp and / or weft contains a flat cross-sectional polyester multifilament having a flatness of 3 or more and 7 or less. If the flatness of the multi-filament polyester multifilament is less than 3, the air permeability cannot be kept low. If the flatness exceeds 7, the fluff and loops during spinning drawing are likely to occur, which hinders the process operability. The More preferably, the flatness is in the range of 4 or more and 6 or less, and if necessary, crimping such as false twisting, air entanglement treatment, fluid disturbance treatment, twisting yarn or the like can be appropriately combined.

  The flat cross-section polyester multifilament yarn can be usually obtained by a method of producing using a slit nozzle by a melt spinning method. Of course, it is possible to obtain a part by dissolving, swelling, shrinking, and using physical action in combination by a composite spinning method using a multi-component polymer. In view of the health problems and the influence of the treatment waste liquid on the environment, it cannot be said that it is preferable, and the direct melt spinning method is more preferable. The single fiber fineness is preferably 0.3 dtex or more and 2.0 dtex or less, more preferably 0.3 dtex or more and 1.5 dtex or less. Flat cross-section yarns having a single fiber fineness of less than 0.3 dtex are difficult to produce commercially by direct melt spinning, and low air permeability is obtained even with use of flat cross-section yarns at a fineness exceeding 2.0 dtex. I can't.

Further, air permeability by Frazier method initial values 2cm ³ / (cm ² · sec) or less, after one wash 4cm ³ / (cm ² · sec) or less, more preferably an initial value 1cm ³ / (cm ² · sec ) In the following, it is preferably ² cm ³ / (cm ² · sec) or less after one wash. In the range where the air permeability exceeds the initial value of 2 cm ³ / (cm ² · sec), the cotton pad is easily blown out by physical action such as stagnation and distortion during use, and the appearance quality is impaired. This is not a preferable range because it may induce damage to the human body, such as respiratory diseases. In addition, the air permeability of the fabric tends to increase due to the stagnation effect due to washing and use, and if the air permeability after one wash exceeds 4 cm ³ / (cm ² · sec), it will be tick-proof, dust-proof, and batting The preventive properties are deteriorated and it is not preferable for bedding materials.

  Furthermore, in order to satisfy the general consumption performance of the low-breathing bedding material of the present invention, the tear strength is preferably maintained at 9.8 N or more, more preferably 12.0 N or more. When the tear strength is less than 9.8 N, the fabric itself is torn by physical action such as stagnation and distortion during use, causing the batting to blow out. To improve the tear strength, it can be realized by improving the physical properties of the yarn or increasing the fineness of the single yarn. However, according to these methods, the fabric texture becomes coarse and the drape property is poor. In the examples below, the warp direction is the direction to tear the warp, and the weft direction means the direction to tear the weft. In the present application, the tear strength is defined by having the smaller data of both the warp direction and the weft direction data. That is, in this application, when the tear strength is 9.8 N or more, it means that the data in both the longitudinal direction and the lateral direction are both 9.8 N or more.

The fabric weight is in the range of 80 g / m ^{2 to} 120 g / m ² , more preferably 90 g / m ^{2 to} 110 g / m ² . If the fabric basis weight is less than 80 g / m ^{2, the} fabric is thin and drape is poor, and the tear strength is not satisfactory. In the range exceeding 120 g / m ² , the fabric is too thick and too heavy, resulting in a cheap fabric with poor drape. In consideration of aesthetics such as drape, ease of handling as a futon, etc., it is desirable to select appropriately within the range of 80 g / m ^{2 to} 120 g / m ² according to the material and blowing amount of the filling material.

  Further, as the woven fabric structure of the low-breathing bedding material of the present invention, the maximum number of floats of warp and / or weft of the woven fabric is preferably 4 or less, such as five sheets satin and 3/1 broken satin. Examples include satin weaving, 3/1, 3/2, 2/1, etc., plain weaving such as Nanako, Ishime, and plain weaving, and changing structures based on these three primary structures. What is necessary is just to set suitably according to the required characteristic of bedding materials, such as a plain weave structure from a viewpoint of air permeability, and a five-ply satin structure when aiming at refined glossiness. If the maximum number of floats of the warp and / or weft of the above-mentioned single fabric is 5 or more, defects such as pilling, snag and sink are likely to occur, which is not preferable in terms of appearance quality and consumption performance.

  In order to keep the air permeability of the bedding material of the present invention low, the total value of the number of warps and the number of wefts per 1 cm is 115 / cm to 230 / cm, more preferably 150 / cm to 230 / It is desirable to control to cm or less. If the total value is less than 115 / cm, the air permeability remains high, and feather blowing such as feathers and down cannot be particularly suppressed. In addition, in the range where the total value exceeds 230 / cm, the air permeability can be kept low, but the fabric is difficult to bend and drape is poor, which is not preferable as a bedding material.

  The bedding material of the present invention is a combination of a spun yarn containing natural fibers as a warp, a synthetic multi-filament yarn as a weft, and a warp fineness of 50 to 120 in English cotton count display, and a weft of 50 decitex or more. More preferably, it is 200 dtex or less. Spun yarns containing warp natural fibers can be produced by conventional ring spinning, innovative spinning such as OE spinning and jet spinning, and other spinning methods using known techniques. In addition, as a spinning raw material, special spinning in which not only short fibers but also long fibers are combined can be adopted as necessary. It is more effective that the spun yarn used for the warp contains natural fibers in consideration of moisture absorption characteristics and other functions, and silk, cotton, etc. are preferably exemplified.

  The weft yarn is preferably a synthetic fiber multifilament, more preferably a synthetic fiber multifilament including a flat cross-section yarn, and all the weft yarns may be the flat cross-section yarn. Regarding the fineness, the warp fineness is from 50 to 120 in terms of English cotton count, more preferably from 60 to 100 in English cotton count, still more preferably from 80 to 100. The thick cotton yarn with an English cotton count of less than 50 cannot keep the air permeability low, and the fine yarn spun yarn exceeding the 120th has a low tear strength and both can satisfy the consumption performance. Must not. The spun yarn used for the warp may be not only a single spun yarn but also a twin yarn or a triple twist. In particular, twin yarns and triple twists are more effective in terms of fabric quality and strength because the yarn becomes more even.

  In obtaining the low-breathing bedding material of the present invention, it is desirable to perform a calendar process in an optional step of dyeing. The calendering treatment has different crushing conditions depending on the processing conditions such as the linear pressure of the calender roll and the paper roll, the calender roll surface temperature, the calendering time, etc., but if the calender roll surface temperature is excessively high, the color fastness due to dye bleed etc. And surface quality deterioration due to surface glossy glare. The calendering conditions are not particularly limited, and the rough conditions are a linear pressure of 100 to 300 N / cm, a calender roll surface temperature of 120 to 180 ° C., and a fabric treatment speed of about 10 to 30 m / min. What is necessary is just to set suitably according to a constituent material, fabric thickness, etc.

  In particular, because the bedding material of the present invention uses a flat cross-sectional polyester multifilament, the long side of the flat part is easily aligned along the calendar surface by calender pressing, to achieve low air permeability, Calender pressure and temperature conditions can be relaxed in comparison with conventional ones, and it is possible to realize low air permeability, soft touch and moderate drape while suppressing unpleasant gloss and paper-like fabric. The embossing roll is effective in giving a three-dimensional uneven design pattern to differentiate the fabric and giving a high-class feeling, but the uneven portion of the embossed pattern increases the air permeability, and the blowing of the filling material is partially It tends to occur and is not preferable.

  The fabric dyeing method can be carried out using a known technique regardless of plain dyeing or printing. For example, in the case of plain dyeing, in addition to continuous dyeing such as thermosol dyeing, batch dyeing such as liquid dyeing, and in the case of printing, in addition to flat screens and rotary screens, inkjet and the like can also be mentioned as suitable methods. If necessary, antistatic agents, antibacterial agents, antibacterial agents, antifungal agents, flame retardant agents, deodorant agents, and other functional agents can be formulated in any dyeing process. . Preferred examples of the treatment method include a pad steam cure method, a pad dry cure method and the like, which are prescribed after dyeing, or a simultaneous dye exhaust method.

Hereinafter, the present invention will be described in more detail with reference to examples. The characteristic values in the text and in the examples are measured and evaluated by the following methods. Needless to say, the present invention is not limited to the following examples.
(Air permeability) It evaluated according to JIS L-1096 A method (fragile type method).
(Tear Strength) The tear strength was evaluated according to JIS L-1096 D method (pendulum method).
(Fabric basis weight) A fabric sample is cut into a 10 cm × 10 cm square along the warp and weighed to the fourth decimal place using an electronic balance and multiplied by 100 to obtain a fabric basis weight (g / m ² ) And The measured value is determined by averaging the weighing values of five dough samples.
(Flatness) A photograph of the cross section of the flat cross-section fiber sample magnified 1000 times using an optical microscope was taken, and the ratio of the long side / short side of the single yarn cross section was measured and determined. In addition, it was set as the measured value with the average value of 20 single yarns.
(Laundry process) It carried out according to JIS L-0217 103 method.

(Example 1)
Five warp reds (upward to the left 4/1) using a cotton / rayon blended spun yarn with an English surface count of 200 double yarn as the warp and a polyester semi-dal flat cross section 50 dtex 36 filament (flatness 5.0) as the weft. Weaving was carried out 3) to obtain a woven fabric machine. After performing the double-sided gas roasting on the woven fabric machine in an expanded state, scouring, desizing and chlorine bleaching were continuously performed in the expanded state, followed by drying with a cylinder roll and a short loop dryer. Next, an intermediate set was performed while correcting the texture with a heat setter at an atmospheric temperature of 190 ° C. Continue to use a rotary screen printing machine to arrange 16 color prints using reactive dyes and disperse dyes, and after coloring and washing, after drying with a cylinder roll and net conveyor dryer in the expanded state, the dyed fabric is textured And the calendar process was given with the plast calendar apparatus (made by Yuri roller) equipped with the cross guider. Incidentally, the treatment was performed only once on one side so that the back side of the fabric became the calendar roll surface under the conditions of a calender roll surface temperature of 140 ° C., a linear pressure of 120 N / cm, and a dough supply speed of 10 m / min.

The total number of warp yarns per cm of the obtained fabric is 192 / cm, fabric basis weight is 105 g / m ² , the air permeability by the Frazier method is 0.40 cm ³ / (cm ² · sec), the washing After one time, 1.25 cm ³ / (cm ² · sec), tear strength is 14.2 N in the warp direction and 13.7 N in the weft direction, and it has soft touch, moderate drape, and low air permeability. . Using the obtained fabric as a side fabric, a feather comforter was created, and the texture was good and the quality was good and the finish was suitable for bedding materials because it was comfortable to touch and was not confirmed even after repeated use. It was. Incidentally, when the cross-sectional photograph of the weft direction of the woven fabric was confirmed, it was confirmed that the flat filaments constituting the weft were aligned substantially in parallel with the surface of the woven fabric and effectively reduced the air permeability.

(Example 2)
After carrying out double-sided gas roasting in an expanded state using the fabric woven machine obtained in Example 1, continuous scouring, desizing and chlorine bleaching are performed in the expanded state, and drying is performed with a cylinder roll and a short loop dryer. gave. Next, an intermediate set was performed while correcting the texture with a heat setter at an atmospheric temperature of 190 ° C. Continue to dye with reactive dye and disperse dye using a liquid dyeing machine, wash thoroughly with hot water and water, then dry with a cylinder roll and net conveyor drier in the expanded state, Calendar processing was performed with a plast calendar device (manufactured by Yuri Roll Co., Ltd.) equipped with Incidentally, the treatment was performed only once on one side so that the back side of the fabric became the calendar roll surface under the conditions of a calender roll surface temperature of 140 ° C., a linear pressure of 120 N / cm, and a dough supply speed of 10 m / min.

The total number of warp yarns per 1 cm of the obtained fabric is 198 / cm, fabric basis weight is 112 g / m ² , air permeability by Frazier method is 0.35 cm ³ / (cm ² · sec), the same washing After one cycle, 1.00 cm ³ / (cm ² · sec), tear strength is 14.5 N in the warp direction and 13.3 N in the weft direction, and soft touch, moderate drape, and low air permeability are obtained. . Using the obtained fabric as a side fabric, a feather comforter was created, and the texture was good and the quality was good and the finish was suitable for bedding materials because it was comfortable to touch and was not confirmed even after repeated use. It was. Incidentally, when the cross-sectional photograph of the weft direction of the woven fabric was confirmed, it was confirmed that the flat filaments constituting the weft were aligned substantially in parallel with the surface of the woven fabric and effectively reduced the air permeability.

(Comparative Example 1)
A dyed cloth was obtained in the same manner as in Example 1 except that a polyester semidal round cross section 50 dtex 18 filament was used as the weft. The total number of warp yarns per centimeter of the obtained fabric is 192 / cm, fabric weight is 108 g / m ² , the air permeability by the Frazier method is 2.02 cm ³ / (cm ² · sec), the washing After one time, 3.25 cm ³ / (cm ² · sec), tear strength is 14.5N in the warp direction and 13.8N in the weft direction, and it has soft touch and moderate drape, but the air permeability is It greatly hindered mite and dustproof properties and prevention of batting. When we created a feather comforter using the obtained fabric as a side fabric, the texture was well tailored, but it was confirmed that the feathers were blown out by repeated use. It was not suitable. Incidentally, when the cross-sectional photograph of the weft yarn was confirmed, the fibers constituting the weft yarn were round cross-section yarns, and the interfiber gap remained large.

(Comparative Example 2)
A dyed cloth was obtained in the same manner as in Example 1 except that polyester weft flat cross section 50 dtex 24 filament (flatness 8.0) was used for the weft. The total number of warp yarns per 1 cm of the obtained fabric is 190 yarns / cm, the fabric basis weight is 110 g / m ² , the air permeability according to the Frazier method is 2.10 cm ³ / (cm ² · sec), the washing After one time, 3.40 cm ³ / (cm ² · sec), tear strength is 14.1 N in the warp direction and 13.0 N in the weft direction, and it has soft touch and moderate drape, but the air permeability is It greatly hindered mite and dustproof properties and prevention of batting. When a feather comforter was prepared using the obtained fabric as a side fabric, the touch was well tailored, but it was confirmed that the feathers were blown out and was not suitable for use as a bedding material. Incidentally, when the weft cross-sectional photograph was confirmed, since the flatness was extremely high at 8.0, it was difficult to align the fabric surface substantially in parallel, and many portions where the alignment was disturbed were confirmed. In addition, cut fluffs and loops of the flat cross-sectional yarn were confirmed on the surface, and it was not finished with a good quality.

(Comparative Example 3)
A dyed fabric was obtained in the same manner as in Example 1 except that a polyester semidal round section 50 dtex 108 filament was used as the weft. The total number of warp yarns per 1 cm of the obtained fabric is 192 / cm, fabric basis weight 107 g / m ² , air permeability by Frazier method is 0.33 cm ³ / (cm ² · sec), the same washing After one cycle, 1.02 cm ³ / (cm ² · sec), tear strength was 14.1 N in the warp direction and 12.3 N in the weft direction, and the air permeability was low. It showed a texture. When a feather comforter was prepared using the obtained fabric as a side fabric, it showed a very soft touch, but it was not tailored and could not be finished as a suitable material for bedding.

According to the present invention, even if a batting filler that is easy to blow out, such as a waterfowl feather or down, can be prevented from blowing feathers to the surface layer of the fabric or scattering of dust due to aging.
In addition, due to the effect of using a flat cross-section multifilament yarn, calendar pressing and temperature conditions can be more relaxed than conventional conditions, low air permeability, soft tactile feeling while suppressing unpleasant gloss and paper-like fabric, It is possible to provide a low-breathing bedding material having an appropriate drape.

It is a cross-sectional photograph of the weave which shows an example of the embodiment of the present invention. It is the surface photograph of the textile fabric which shows an example of the embodiment of the present invention. It is the back surface photograph of the textile fabric which shows an example of the embodiment of the present invention.

Claims (5)

  It is a woven fabric made of at least one selected from natural fibers, regenerated fibers, semi-synthetic fibers, and synthetic fibers. The warp and / or the wefts have a flatness of 3 to 7 and a single fiber fineness of 0.3 dtex. A low-breathing bedding material comprising a flat cross-sectional polyester multifilament of 2.0 decitex or less. Frazier initial value 2cm ³ / (cm ² · sec) air permeability due form method below, low according to claim 1, after the washing once, characterized in that at 4cm ³ / (cm ² · sec) or less Breathable bedding material. The low-breathing bedding material according to claim 1 or 2, wherein the fabric basis weight is 80 g / m ² or more and 120 g / m ² or less, and the tear strength is 9.8 N or more.   The maximum number of floats of warps and / or wefts in one woven fabric is 4 or less, and the sum of the number of warps and the number of wefts per 1 cm is 115 / cm to 230 / cm The low air permeability bedding material according to any one of claims 1 to 3. The warp is a spun yarn including cotton, the weft is a synthetic fiber multifilament yarn, the warp fineness is 50 to 120 in English cotton count display, and the weft is 50 to 200 decitex. Item 5. The low air permeability bedding material according to any one of Items 1 to 4.