JP2016027213A - Feathery cotton material and method for producing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a novel feathery cotton material, without being accompanied with any odor peculiar to an animal, which has a voluminous feeling, is bulky, is excellent in washing characteristics, is excellent in heat retaining properties and heat insulation properties, and is formed in light-weight.SOLUTION: A feathery cotton material 1 has a form in which filaments of an axial yarn 2 and a float yarn 3 made of a polyester-based raw yarn are mutually bound, entangled and connected by an air entanglement in an air scattering atmosphere and integrated so as to have down ball-like lumps connected in a line with an interval therebetween. The down ball-like lumps have a diameter of 1.0-3.5 cm. The down ball-like portions are consecutively arranged with an interval up to about 10 cm in a lengthwise direction of the axial yarn and formed into a cotton-like filament.SELECTED DRAWING: Figure 1

Description

  The present invention does not cause various problems described later, such as those of conventional natural feathers for filling futons, has a sense of volume, is bulky, has no animal-specific odor, has excellent washability, and retains heat. The present invention relates to a feather-like cotton material that is excellent in heat insulation, can be formed lighter, has a novel and novel form that has never existed in the past, and is artificially produced in a form imitating natural feathers, and a method for producing the same.

Conventionally, futon filled with natural feathers is often used as bedding to be used at bedtime.
However, traditionally, natural duvets are not biased unless the quilts are applied, and each feather moves within the squares and fills up the eyes. When you try to wash a duvet, it is not washable because it causes a so-called balloon phenomenon.Furthermore, duck and goose used for duvets are collected from animals, so the climate and the environment It has been pointed out that the supply amount is unstable and the odor peculiar to animals is accompanied.

  Patent Document 1 discloses an entangled yarn for stuffing composed of long fibers, wherein the entangled yarn includes a core yarn and a flower yarn longer than the core yarn, and the core yarn and the flower yarn are entangled by a core yarn. An interlaced yarn for stuffing is disclosed in which the yarn is wound around the core yarn while the yarn and the yarn are mixed.

  Further, in Patent Document 1, long fiber core yarn and long fiber flower yarn are fed to a known simple air entanglement device at different speeds by two feed rollers, and entangled and integrated with each other. In addition, a method of manufacturing an entangled yarn for stuffing having a form in which a core yarn and a flower yarn are mixed and the flower yarn is wound around the core yarn is disclosed.

  However, in the case of the entangled yarn for stuffing of Patent Document 1, the core yarn of the long fiber and the flower yarn of the long fiber are simply air entangled with each other by a known simple air entanglement device, and the core yarn and the flower yarn are mixed. However, it is a form in which the flower yarn is wound around the core yarn to obtain a mere long fiber entangled yarn that is extremely irregularly formed, and no special measures have been taken for the technical elements such as the air entanglement device, For this reason, in the entangled yarn for stuffing of Patent Document 1, it is difficult to obtain a sufficient volume feeling and bulkiness because of excellent washability, heat retention and heat insulation.

JP 2012-67430 A

The problem to be solved by the present invention is that the above-mentioned problem as in the case of conventional feathers for duvets does not occur at all, and a downball-shaped lump unique to the present invention is provided to provide sufficient volume and bulkiness. In addition, it has no odor peculiar to animals, is excellent in washability, heat retention and heat insulation, and has a novel and novel form that has never existed in the past. There is no conventional cotton material and production method.
In addition, in the case of the entangled yarn for stuffing disclosed in Patent Document 1, it is a form in which the flower yarn is simply wound around the core yarn while the core yarn and the flower yarn are mixed very irregularly, as in the present invention. Of course, it does not form a unique downball-like lump that exhibits various useful effects.

  The feather-like cotton material of the present invention is a novel and novel form that has never existed in the past. Axial yarn and float filaments using polyester base yarns are special air in an air scattering atmosphere. Bundled by entanglement and entangled together to have a downball-shaped lump, integrated into a single row, and the downball-shaped lump is a lump having a predetermined diameter. The main feature is that the lump is formed as cotton-like long fibers arranged continuously at a predetermined interval in the axial direction of the axial yarn.

  According to the first to fourth aspects of the present invention, the downball-shaped lump is formed by binding and entangled the filaments of the shaft yarn and the floating yarn using the polyester base yarn by air entanglement in an air scattering atmosphere. The downball-shaped lump is a lump having a predetermined diameter, and the downball-shaped lump has a predetermined interval with respect to the length direction of the shaft yarn. For example, the diameter of the downball-shaped lump is 1.0 to 3.5 cm and the interval is within about 10 cm at the maximum. The above-mentioned problems like natural feathers for duvets are not generated at all, and it has a characteristic downball-shaped lump and has a sufficient volume feeling and bulkiness, and is not accompanied by animal-specific odors.濯性, warmth, excellent insulating properties, those of novel forms in conventional completely nonexistent new, can be provided to achieve fluffy cotton was artificially prepared in the form that imitates natural feathers.

  According to invention of Claims 5 thru | or 11, the feather-like cotton material which concerns on the invention of said Claims 1 thru | or 4 is used for the axial thread, the supply process of a float, the air entanglement process in the air scattering atmosphere, the winding It can be produced simply by the taking process, and furthermore, a feather-like cotton material whose shape is stabilized by fixing of the silicone resin can be produced simply, and the supply magnification of the shaft yarn and the floating yarn, Air volume for air entanglement, air pressure, presence / absence of interval adjustment ring arranged between nozzle part and venturi, each adjustment of interval between tip nozzle part and venturi wall surface part of venturi by changing thickness Depending on the combination of factors, the size of the downball-shaped lump, the distance between each downball-shaped lump and the lump, and the downball-shaped lump comprising a downball-shaped lump that has a desired form by changing the float density. Cotton material It can be provided to achieve the preparation method of fluffy cotton can also.

FIG. 1 (a) is a feather-like state in which a downball-like lump artificially manufactured in a form resembling a feather according to an embodiment of the present invention is relatively large and is formed as a cotton-like long fiber. It is an expansion conceptual diagram which shows a cotton material in the form of a diagram. FIG. 1 (b) shows a downball-shaped lump artificially manufactured in a form resembling a feather according to an embodiment of the present invention, which is smaller than the size of FIG. 1 (a) and formed as cotton-like long fibers. It is an expansion conceptual diagram which shows the feather-like cotton raw material of the state completed in the form of a diagram. FIG. 2 is an enlarged view showing each shape example of the floating yarn used for manufacturing the feather-like cotton material according to this embodiment. FIG. 3 is a flowchart showing the manufacturing process of the feather-like cotton material according to this embodiment. FIG. 4 is a schematic explanatory view showing each step of the shaft yarn, the float yarn supply step, the air entanglement step, and the winding step after the air entanglement step in the production process of the feather-like cotton material according to the present embodiment. FIG. 5 is an enlarged schematic explanatory view showing a state of Z-twisting and S-twisting of the floating yarn with respect to the axial yarn during the air entanglement process in the manufacturing process of the feather-like cotton material according to the present embodiment. More specifically, as shown in FIG. 16B, inside the air entanglement unit, the floating yarn is Z-twisted with the shaft yarn as the core, that is, the ball is twisted while air entangled in the Z-character direction, and the downball as shown in FIG. It is a schematic explanatory view showing a state in which a feather-like cotton material in the form of a lump is formed, and within the air entanglement unit as shown in FIG. FIG. 2 is a schematic explanatory view showing a state in which a floating yarn is twisted in S, that is, twisted while air entangled in the S-character direction to form a downball-shaped lump-like cotton material as in FIG. 1. FIG. 6 is a schematic assembly view showing the air entanglement unit used in the manufacturing process of the feather-like cotton material according to this embodiment in a perspective view. FIG. 7: is a schematic front view which shows the decomposition | disassembly state of the unit for air entanglement used for the manufacturing process of the feather-like cotton raw material which concerns on a present Example in a perspective view aspect. FIG. 8 is a schematic partial sectional view showing a venturi of an air entanglement unit used in the manufacturing process of a feather-like cotton material according to this embodiment. FIG. 9 is a schematic cross-sectional view showing the tip nozzle portion of the air entanglement unit used in the manufacturing process of the feather-like cotton material according to this embodiment. FIG. 10 is a plan view showing a retaining ring in the air entanglement unit used in the manufacturing process of the feather-like cotton material according to this embodiment. FIG. 11 is a partial cross-sectional view illustrating a unit inner cylinder, a unit outer cylinder, and a retaining ring constituting a positioning tightening mechanism portion of an air entanglement unit used in the manufacturing process of a feather-like cotton material according to the present embodiment. FIG. 12 is a schematic front view showing a positioning and tightening mechanism provided on the yarn / air supply body of the air entanglement unit used in the manufacturing process of the feather-like cotton material according to this embodiment. FIG. 13 shows the air entanglement unit used in the manufacturing process of the feather-like cotton material according to the present embodiment, the state before the yarn / air supply body is fastened to the unit outer cylinder, and the yarn / air supply body as the unit outer cylinder. It is explanatory drawing which shows the state fastened to the body. FIG. 14 shows an example of dimensions of the tip nozzle portion of the yarn / air supply body, each part of the venturi, and an angle example of the mortar-like wall surface portion of the venturi in the unit for air entanglement used in the manufacturing process of the feather-like cotton material according to this embodiment. It is a schematic explanatory drawing which shows. FIG. 15 is a schematic explanatory view showing a dimension example from the tip surface of the tip nozzle portion of the yarn / air supply body to the venturi outlet in the unit for air entanglement used in the manufacturing process of the feather-like cotton material according to the present embodiment. . FIG. 16 (a) shows from the tip surface of the tip nozzle portion of the air entanglement unit used in the air entanglement process in the manufacturing process of the feather-like cotton material according to the present embodiment to the outlet of the venturi. FIG. 16 (b) is a schematic illustration showing a disturbed state of floating yarns during air entanglement of an air entanglement unit used in an air entanglement step in the production process of a feather-like cotton material according to the present embodiment. FIG. FIG. 17 is an interval adjustment for adjusting the interval from the tip surface of the tip nozzle portion of the yarn / air supply body to the mortar-like wall surface portion of the venturi in the unit for air entanglement used in the manufacturing process of the feather-like cotton material according to the present embodiment. It is a schematic explanatory drawing which shows the case where a ring is not used and the case where it uses. FIG. 18 is a schematic explanatory view showing a silicone resin processing step in the manufacturing process of the feather-like cotton material according to this example. FIG. 19 is an explanatory view showing the heat shrinkage state of the shaft yarn or float yarn according to the present embodiment. FIG. 20 is a diagram showing the conditions of the heat shrinkage test after the second heating step in the manufacturing process of the feather-like cotton material according to this example. FIG. 21 is a diagram showing the results of the heat shrinkage test after the second heating process in the manufacturing process of the feather-like cotton material according to this example. FIG. 22 is an explanatory view conceptually showing the size of the downball-shaped lump integrated with the shaft yarn according to the present embodiment and the interval between each downball-shaped lump. FIG. 23 is a graph qualitatively showing the relationship between the shape size of the downball-shaped lump and the air pressure during the air entanglement process according to this example. FIG. 24 is a graph qualitatively showing the relationship between the density of the downball-shaped lump and the supply magnification of the axial yarn and the float yarn according to this example.

  The present invention has a novel and novel form which does not exist at all, and does not have the above-described problems such as conventional natural feathers for duvets, and has a specific downball-like lump and has a sufficient volume feeling. The purpose is to realize and provide a feather-like cotton material that is artificially manufactured in a form resembling a feather that is bulky, has no animal-specific odor, and is excellent in washability, heat retention, and heat insulation. Axial yarn / floating yarn filaments using polyester base yarns are bound together by air entanglement in an air scattering atmosphere and entangled together to form a downball-shaped lump with an interval. The down ball-shaped lump has a diameter φ of 1.0 to 3.5 cm, and the down ball-shaped lump is spaced within a maximum of about 10 cm in the axial direction of the shaft yarn. With It was achieved with the configuration formed as connection-arranged length fibers like cotton.

  Hereinafter, a novel and novel feather-like cotton material that has been artificially produced in a form simulating natural feathers according to an embodiment of the present invention and a method for producing the same will be described in detail with reference to FIGS. 1 to 24. To do.

  FIG. 1 (a) is a feather-like state in which a downball-like lump artificially manufactured in a form resembling a feather according to an embodiment of the present invention is relatively large and is formed as a cotton-like long fiber. It is a conceptual diagram which shows the cotton raw material 1 in the form of a diagram. FIG. 1 (b) shows a downball-shaped lump artificially manufactured in a form resembling a feather according to an embodiment of the present invention, which is smaller than the size of FIG. 1 (a) and formed as cotton-like long fibers. It is the conceptual diagram which shows the feather-like cotton raw material 1 of the state completed in the form of a diagram.

As shown in FIGS. 5 and 16 to be described later, the feather-like cotton material 1 according to the present embodiment has a floating yarn 3 Z-twisted with the axial yarn 2 as a core inside the air entanglement unit 21, that is, a Z character. 1 is formed by twisting while entangled with air in the direction to form a downball-like lump shape as shown in FIG. The floating yarn is twisted S, that is, twisted while air entangled in the S-character direction, to form a down-ball-shaped lump-like cotton material 1 as shown in FIG.
The Z-twisted downball-like lump state and the S-twisted downball-like lump state are continuously formed at intervals, and this is the feather-like cotton material 1 according to this embodiment.

  As shown in FIG. 1, the feather-like cotton material 1 according to the present embodiment includes a shaft yarn 2 and a floating yarn 3 longer than the shaft yarn 2, and the shaft yarn 2 and the floating yarn 3 are made of feather-like cotton. By the air entanglement by the air entanglement unit 21 used in the air entanglement process in the raw material production process, the float 3 is opened to form a cotton-like fiber, and the shaft yarn 2 and the float 3 are intertwined and integrated, That is, the Z-twisted down-ball-like lump state and the S-twisted down-ball-like lump state are continuously formed with an interval, and a cotton-like long fiber is formed, so that the feathers as a whole are formed. Simulated and artificially manufactured.

  That is, the feather-like cotton material 1 is formed by arranging the downball-like lumps and lumps, which will be described later in detail, with the shaft yarn 2 and the floating yarn 3 entangled and connected with each other, and the whole is cotton-like. The long fiber is formed.

  As shown in FIG. 1 and FIG. 22 to be described later, the downball-shaped lump in the present embodiment is a form in which filaments of the shaft yarn 2 and the float yarn 3 are bound and entangled and integrated to form a single row. Of the floating yarn 3 having a diameter φ of approximately 1.0 to 3.5 cm, which is continuously arranged with an interval of approximately 1 cm to 10 cm, that is, a maximum of approximately 10 cm or less, relative to the axial yarn 2 of The following description will be given by defining it as a lump portion.

  As the shape of the float 3, as shown in FIG. 2, for example, a hollow fiber having a hollow ratio of 30 to 40% for weight reduction, a C-shaped cross-section thread, a modified cross-section thread, or the like can be employed.

  In the case of hollow fibers and C-shaped cross-section yarns, the surface area is larger than that of circular cross-section yarns of the same weight, and the air receiving area is larger than that of circular cross-section yarns. Becomes larger and is easily scattered and disturbed by an impinging air flow (air flow), thereby promoting air entanglement. There are advantages such as being lighter than yarns of the same surface area.

  In the case of irregular cross-section yarns (the cross-section is not circular, for example, the cross-section is star-shaped, diamond-shaped, quadrangular with irregularities, etc.) There is an advantage that the air receiving area is increased and the air resistance during the air entanglement is further increased. That is, since the surface area is larger than that of the yarn having a circular cross section, it is easily scattered and disturbed by the impinging air flow (air flow), thereby further promoting air entanglement.

  Next, the material and material characteristics of the feather-like cotton material 1 according to the present embodiment will be described in detail. As the shaft yarn 2 and the floating yarn 3 in the present embodiment, for example, a polyester-based yarn is used, Use the one without interlace processing, the total fineness of each of the shaft yarn 2 and the float yarn 3 is 30 to 200D (denier), and the total filament number of each of the shaft yarn 2 and the float yarn 3 is 12 to 96f. use.

Further, the ratio of the length amount of the shaft yarn 2 and the float yarn 3 (the length amount fed to the air entanglement unit 21) is in the range of 1:10 to 1:40, preferably 1:20 to 1:30. And That is, the float 3 having a length of 10 to 40 times (preferably 20 to 30 times) the shaft yarn 2 is fed into the air entanglement unit 21. When the length is 1 to 9 times, the amount of the float 3 for entanglement is small, and when it exceeds 40, the amount of the float 3 is too large to form a good downball-shaped lump.
The relationship between the air pressure in the air entanglement unit 21 and the size of the downball-shaped lump will be described later.

  The unit length weight of the feather-like cotton material 1 is preferably 0.01 to 3 g / m, particularly preferably 0.02 to 1.5 g / m. When converted to count or denier, 90 to 27000 D (denier), particularly 180 to 13500 D is preferable.

  The diameter φ of the downball-shaped lump portion in the float 3 is about 1.0 to 8 cm, and particularly preferably about 1.0 to 3.5 cm or about 1.5 to 4 cm.

  The single yarn fineness of the float 3 is, for example, 0.1 to 300 dtex (deci tex), preferably 1 to 50 dtex, and more preferably 2 to 25 dtex.

  The total fineness is 10 to 600 dtex, preferably 20 to 250 dtex, more preferably 30 to 100 dtex.

  Regarding the weights of the axial yarn 2 and the floating yarn 3 in the feather-like cotton material 1, the ratio of the floating yarn 3 to the total weight (axial yarn 2 + floating yarn 3) is, for example, 100: 51 to 99 wt%, 100: 80 to Examples include 98 wt%, 100: 85 to 97 wt%, and the like.

  The shaft yarn 2 and the float yarn 3 are configured to include fused fibers and non-fused fibers. The fused fiber is composed of two or more polymers (high melting point polymer, low melting point polymer) having different melting points.

  For example, among two or more polymers, a polyester multifilament or a polypropylene polymer is used as the high melting point polymer, and a polyethylene polymer or a low melting point polypropylene polymer is used as the low melting point polymer.

  The fusion temperature is preferably 80 to 200 ° C, and the melting point temperature difference is preferably 10 to 200 ° C.

  The shaft yarn 2 preferably has a core-sheath structure in which a high melting point polymer is a core and a low melting point polymer is a sheath in order to fuse a low melting point polymer.

  In particular, a combination of a sheath fiber and a low-melting-point heat-bonding fiber thread is preferable in order to more reliably integrate the downball-shaped portion into a cotton shape.

  The polyester multifilament has an advantage that it is difficult to stick.

  Examples of the ratio between the fused fiber and the non-fused fiber include 0 to 90%: 10 to 100%.

  On the other hand, specific examples of the non-fused fiber include polyester, nylon, and polypropylene.

  Furthermore, it is preferable that the silicone treatment agent is thermally fixed to the shaft yarn 2 and the float yarn 3. In this case, the preferable adhesion amount of the silicone treating agent is 0.1 to 5.0%, preferably 0.5 to 3.0%, based on the total weight of the shaft yarn 2 and the float yarn 3.

  In addition, acrylic resin and urethane resin may be fixed to the shaft yarn 2 and the floating yarn 3 for adjusting the hardness.

  Furthermore, the weight of the long fiber air entangled yarn is 0.01 to 3 g / m, preferably 0.02 to 1.5 g / m.

  Next, the manufacturing method of the feather-shaped cotton raw material 1 which concerns on a present Example is demonstrated with reference to the flowchart shown in FIG. 3, and FIG. 4 thru | or FIG.

  As shown in FIG. 3, the manufacturing method of the feather-like cotton material 1 according to the present embodiment includes a process of supplying the shaft yarn 2 and the float yarn 3, an air entanglement process by the air entanglement unit 21, a winding process, and a silicone resin processing. It consists of a process, a 1st heating process, a 2nd heating process, and a cooling process.

  Details of the air entanglement unit 21 will be described later.

(1) (Supplying process of shaft yarn 2 and float yarn 3)
First, as shown in FIG. 4, the shaft yarn 2 is fed into the air entanglement unit 21 using the feed roller 11, and the floating yarn 3 previously wound around the supply roller 13 supported by the krill stand 12 is illustrated in the illustrated example. The guide cylinder 14 and the feed roller 15 shown in the example are used to feed into the air entanglement unit 21. At this time, the floating yarn 3 is naturally twisted by using the guide cylinder 14 and the feed roller 15, and the air entanglement unit 21 In order to make it easier to receive the air resistance, the air is entangled in the air entanglement unit 21 while being twisted.
4 shows an embodiment in which the guide cylinder 14 is used. However, in the present invention, the guide cylinder 14 is not essential, and may be implemented without using it. .

In this case, the feeding angle θ of the floating yarn 3 with respect to the air entanglement unit 21 is 30 to 160 degrees, preferably 80 to 120 degrees with respect to the shaft yarn 2.
The feeding angle θ of the floating yarn 3 with respect to the air entanglement unit 21 is used to prevent the shaft yarn 2 and the floating yarn 3 from being entangled before entering the air entanglement unit 21. The angle θ needs to be adjusted according to the type and shape of the float 3 and the shaft yarn 2, the air volume in the air entanglement unit 21, the air flow (air flow), etc., and this angle θ adjustment is eventually formed. It also affects the formation of downball-shaped lumps.
The feeding angle θ of the floating yarn 3 with respect to the shaft yarn 2 can be changed by freely changing the feeding angle θ of the floating yarn 3 with respect to the air entanglement unit 21 in FIG. Further, the feed angle θ of the float yarn 3 with respect to the shaft yarn 2 can also be changed by freely changing the feed angle θ of the shaft yarn 2 and the float yarn 3 with respect to the air entanglement unit 21.

  Further, in order to avoid the influence of the air pressure of the air jetting upward from the inlet of the air entanglement unit 21 to the shaft yarn 2 and the floating yarn 3, the feeding angle θ is adopted, and the air is allowed to escape upward.

  The conveyance speed by the feed rollers 11 and 15 is, for example, 10 m / min to 1500 m / min.

  In the manufacturing method according to the present embodiment, the shaft yarn 2 fed by the feed roller 15 for the shaft yarn 2 is fed at a low speed, and the float yarn 3 fed from the feed roller 11 for the float yarn 3 is fed at a high speed. To do. That is, the feed amount on the floating yarn 3 side is set larger than that on the shaft yarn 2 side.

  Specifically, the float 3 is fed into the air entanglement unit 21 with a length (supply magnification) 10 to 40 times that of the shaft yarn 2. In this case, the rotational speed of the feed roller 15 on the floating yarn 3 side is preferably 20 to 40 times that of the feed roller 15 on the shaft yarn 2 side in order to form a good downball-shaped lump.

(2) (Air entanglement process)
Next, as shown in FIG. 4, an air entanglement process for the shaft yarn 2 and the float yarn 3 is performed by the air entanglement unit 21.

  Here, the air entanglement unit 21 will be described in detail.

  As shown in FIGS. 4, 6, 7, etc., the air entanglement unit 21 includes a yarn / air supply body 31, a unit inner cylinder 51, a unit outer cylinder 61, and a unit inner cylinder 51. A venturi 71 made of, for example, ceramics, a flat plate-like collision plate 81 disposed below the lower end of the venturi 71 at a predetermined interval (about 25 cm), and an air receptacle 64 provided in the air entanglement unit 21. And an air supply source 91 capable of adjusting the air pressure and the air volume to send air for air entanglement (compressed air) through the air pipe 92.

Note that the air entanglement unit 21 in this example is not necessarily provided with a flat plate-like collision plate 81 that is disposed downward from the lower end of the venturi 71 with a predetermined interval (about 25 cm) as shown in the illustrated example. Absent.
Without providing the collision plate 81, the feather-like cotton material 1, which is a downball-shaped lump that is discharged from the lower end of the venturi 71 and formed at predetermined intervals in the lengthwise direction, is taken up via the take-up feed roller 16. You may make it wind up to 17.

  As shown in FIGS. 7, 8 and 9, the air entanglement unit 21 includes a metal-made substantially cylindrical unit outer cylinder 61, and the upper side in the unit outer cylinder 61 is viewed from above. The upper side of the substantially cylindrical unit inner cylinder 51 to be mounted is fixed and held concentrically, and the lower side of the unit inner cylinder 51 is directed downward from the center of the lower end surface of the unit outer cylinder 61. It is configured to protrude.

  Further, a venturi 71, which will be described in detail later, is provided inside the unit inner cylinder 51, and the lower end surface of the venturi 71 is configured to protrude downward from the center of the lower end surface of the unit inner cylinder 51. Yes.

  Furthermore, the unit outer cylindrical body 61 is protruded downward from the center of the lower end of the metallic nozzle cylindrical portion 32 provided on the lower side of the yarn / air supply body 31 mounted in the unit inner cylindrical body 51. The tip nozzle portion 33 faces the venturi 71, and an air scattering atmosphere state is formed in a space between the tip nozzle portion 33 and a mortar-shaped wall portion 72 of the venturi 71 described later.

  The yarn / air supply body 31, the unit inner cylinder 51, the unit outer cylinder 61, and the venturi 71 will be further described in detail.

  As shown in FIGS. 6 and 7, the yarn / air supply body 31 includes a substantially cylindrical nozzle tube portion 32, a tip nozzle portion 33 that protrudes downward from the lower end center of the nozzle tube portion 32, and It has.

  A circular handle part 38 is integrally attached to the upper end side of the nozzle cylinder part 32 via a nozzle receiving cylinder part 38a. On the bottom surface side of the circular handle portion 38, a circular concave portion 38b into which the circular upper portion of the unit outer cylinder 61 enters is provided.

  In addition, a through hole 35 extending from the center portion on the upper end side of the nozzle tube portion 32 to the center portion on the lower end of the nozzle tube portion 32 is provided.

  On the upper side of the through-hole 35, a substantially cylindrical inlet tube portion 36 made of, for example, a synthetic resin material, having a protruding circular portion 37 on the upper portion and having an insertion hole 36a is mounted. The shaft yarn 2 and the float yarn 3 are configured to be fed into the insertion hole 36a of the cylindrical portion 36.

  The nozzle cylinder part 32 is provided with a large-diameter cylinder part 39 that constitutes a positioning and tightening mechanism part 41, which will be described in detail later, and a part from the lower side to the lower end of the large-diameter cylinder part 39 is a small-diameter cylinder part 40. .

  The upper portion of the through hole 35 is formed in a taper shape having a small dimension in the depth direction, and a range from a position immediately below the taper portion to a lower end of the large diameter cylindrical portion 39 is a straight hole 35a. Furthermore, a taper hole 35b is formed that has a diameter reduced from directly below to the lower end of the small-diameter cylindrical portion 40 in the vicinity of the lower end.

  Further, a lower circular step portion 42 is provided at the lower end side central portion of the small diameter cylindrical portion 40, and the upper end portion of the tip nozzle portion 33 is concentrically arranged at the center position of the lower circular step portion 42. It is configured to be fixed.

  As shown in FIG. 9, the tip nozzle portion 33 is also provided with a nozzle taper hole 33a. The diameter of the lowermost end of the taper hole 35b in the through hole 35 is the same as the diameter of the uppermost portion of the nozzle taper hole 33a. In order to eliminate the level difference, the shaft yarn 2 and the float yarn 3 are smoothly fed into the venturi 71 from the through hole 35 through the nozzle taper hole 33a.

  The small-diameter cylindrical portion 40 is further provided with an air receiving recess 43 that is located outside the tapered hole 35b and extends around the center, for example, in the range of 120 degrees. For example, two air holes 43a that communicate with the side circular stepped portion 42 and eject air toward the lower side thereof are provided.

  As shown in FIGS. 6 and 7, the unit inner cylinder 51 is substantially cylindrical as a whole, and is provided with a protruding cylindrical part 52 in a plan view circular shape protruding sideways at the upper part thereof. An insertion tube portion 53 having a diameter smaller than that of the protruding tube portion 52 is provided so as to protrude downward from the protrusion 52 in a concentric arrangement.

  On the upper surface side of the protruding cylindrical portion 52 of the unit inner cylindrical body 51, a circular large diameter cylindrical portion receiving portion 54 into which the lower side of the large diameter cylindrical portion 39 of the yarn / air supply body 31 is inserted is provided. In addition, a unit inner cylinder through-hole 55 extending from the center portion of the large-diameter cylindrical portion receiving step portion 54 to the lower end thereof through the inside of the insertion cylindrical portion 53 is provided.

  A circular protrusion 55a having an inner diameter smaller than the inner diameter of the unit inner cylinder through-hole 55 is provided at the lower end of the unit inner cylinder through-hole 55 so as to protrude inward of the unit inner cylinder through-hole 55, The lower end of the venturi 71 is received.

  When the O-ring 56 is attached to the side wall of the protruding cylindrical portion 52 of the unit inner cylindrical body 51 and the protruding cylindrical portion 52 is attached to the circular receiving hole 62 of the unit outer cylindrical body 61, the O-ring 56 is circular. It is configured to be in close contact with the inner wall surface of the receiving hole portion 62.

  The side wall portion of the insertion cylinder portion 53 in the unit inner cylinder 51 is arranged to correspond to the mounting receiving hole 65 for the air plug 64 when the unit inner cylinder 51 is mounted on the unit outer cylinder 61. An air passage hole 57 is provided.

  As shown in FIGS. 6 and 7, the unit outer cylinder 61 is substantially cylindrical, and a circular receiver in which the protruding cylinder 52 of the unit inner cylinder 51 is mounted on the inner periphery of the circular upper portion 61a. A hole 62 is provided. Further, the hole is formed in a diameter smaller than the circular hole 62 in a penetrating state until reaching the lower end below the circular hole 62 and penetrates the insertion tube 53 of the unit inner cylinder 51. An insertion hole 63 is provided.

  On the side wall portion of the unit outer cylinder 61, a mounting receiving hole 65 for an air receiving plug 64 that communicates with an air supply source 91 via an air pipe 92 is provided.

  Further, a circular recess 61b having an opening on the circular receiving hole 62 side is provided on the inner peripheral portion of the circular upper portion 61a of the unit outer cylinder 61, and a flat C-ring 102 is attached to the circular recess 61b. Yes.

  As shown in FIGS. 8 and 9, the venturi 71 is substantially cylindrical as a whole, and the diameter decreases from the upper end surface side into which the shaft yarn 2 and the floating yarn 3 enter the upper part of the center of the inside, respectively. A tapered venturi through-hole that is provided with a mortar-shaped wall surface portion 72 and expands toward the lower end side so that the shaft yarn 2 and float 3 can pass from the deepest portion to the lower end surface of the mortar-shaped wall surface portion 72. 73 is provided.

  As shown in FIG. 9, the tip nozzle portion 33 has a substantially cylindrical shape as a whole, a nozzle that penetrates from the upper end surface side to the lower end surface, and has a diameter that decreases from the upper end surface side to the lower end surface. A tapered hole 33a is provided.

  Next, the positioning and tightening mechanism 41 will be described in detail with reference to FIGS.

  The positioning and tightening mechanism 41 includes a large-diameter cylindrical portion 39 of the yarn / air supply body 31 and a retaining ring 101 disposed on the unit inner cylinder 51 in the unit outer cylinder 61.

  As shown in FIG. 10, the retaining ring 101 has a circular hole 103 having a slightly larger diameter than the outer diameter of the large-diameter cylindrical portion 39 of the yarn / air supply body 31. A small protrusion 104 that functions as an alignment receiving portion and a contact receiving portion that has a semicircular shape or a trapezoidal shape protruding inward is provided in part.

  Then, as shown in FIG. 11, in a state where the unit inner cylinder 51 is mounted on the unit outer cylinder 61, a flat annular retaining ring 101 is flat on the upper end surface of the protruding cylinder portion 52 of the unit inner cylinder 51. Further, the outer peripheral portion of the C ring 102 disposed on the retaining ring 101 is attached to the circular recess 61b, so that the unit inner cylinder 51 is internally arranged in a fixed arrangement in the unit outer cylinder 61. It is configured.

  As shown in FIG. 12, the yarn / air supply body 31 is blocked by the small protrusion 104 on the lower side of the large diameter cylindrical portion 39 while being aligned with the small protrusion 104 in the large diameter cylindrical portion 39. A semicircular or trapezoidal concave portion 44 that can be inserted into the large diameter cylindrical portion stepped portion 54 of the unit inner cylindrical body 51, and the circumferential direction of the large diameter cylindrical portion 39 from one end side of the concave portion 44. For example, there is provided an inclined outer peripheral portion 45 that forms an inclined groove portion 46 between the lower surface outer peripheral portion of the nozzle receiving cylinder body portion 38a provided up to a position separated by 180 degrees.

  The inclined outer peripheral portion 45 is formed so that the thickness on the concave portion 44 side is thin and the thickness is increased as the distance from the concave portion 44 is increased, whereby the lower surface of the inclined groove portion 46 is configured to exhibit an inclined surface.

  The left column of FIG. 13 shows a state before the thread / air supply body 31 is tightened to the unit outer cylinder 61, and the right column of FIG. 13 rotates the circular handle portion 38 of the yarn / air supply body 31. Then, the state where the yarn / air supply body 31 is fastened and fixed to the unit outer cylinder 61 by the positioning and tightening mechanism 41 is shown.

  That is, after the unit inner cylinder 51 is mounted and fixed in the unit outer cylinder 61, the thread / air supply body 31 is aligned and mounted in the unit inner cylinder 51 as shown in the left column of FIG. Next, by rotating the circular handle portion 38, the lower surface of the inclined groove portion 46 of the positioning tightening mechanism portion 41 is pressed against the lower surface of the small protrusion 104 of the retaining ring 101 as shown in the right column of FIG. As a result, the thread / air supply body 31 can be fastened and fixed to the unit outer cylinder 61.

  At this time, the air receiving recess 43 of the yarn / air supply body 31 faces the side surface of the air passage hole 57 of the unit inner cylinder 51.

  In FIG. 13, the small protrusion 104 is indicated by an imaginary line.

  Here, setting examples of angles, dimensions, and the like of each part of the air entanglement unit 21 will be described with reference to FIGS. 14 and 15.

  The protrusion length H1 (FIG. 14) of the tip nozzle portion 33 is set to, for example, 5.8 mm to 6.5 mm.

  In the venturi 71, the opening portion of the mortar-shaped wall portion 72 is set to have a diameter of φ12 mm and a height dimension of 15.5 mm to 18 mm, for example, and the inclined surface angle θ1 of the mortar-shaped wall portion 72 is set to 60 degrees, for example. doing.

  The inclined surface of the mortar-shaped wall surface portion 72 is finished by polishing so that the unevenness is 10 μm or less, and is set so that the swirling of the float 3 is smooth and air entanglement is easy.

  The dimension H2 (FIG. 14) of the venturi through-hole 73 from the deepest part to the lower end surface of the mortar-shaped wall part 72 is set to 10 mm, for example.

  The clearance gap between the end part of the tip nozzle part 33 and the mortar-like wall surface part 72 of the venturi 71 is set to 2.0 to 4.0 mm (preferably 2.5 to 3.5 mm).

  It was confirmed that when the gap interval is small, the diameter φ of the downball-shaped lump is small, and when it is large, the diameter φ of the downball-shaped lump is large.

  Further, when the gap interval is large, the length and time of the portion where the floating yarn 3 receives the air pressure becomes longer, and the diameter φ of the downball-shaped lump becomes larger because it is more disturbed and more entangled with the shaft yarn 2.

  A dimension H3 (FIG. 15) from the end of the tip nozzle portion 33 to the outlet of the venturi through hole 73 of the venturi 71 is set to 9 to 12.2 mm, for example. However, the dimension H3 from the end of the tip nozzle portion 33 to the outlet of the venturi through hole 73 of the venturi 71 can be freely changed.

  Examples of the air pressure of the air supplied into the air entanglement unit 21 include 3.5 to 4.0 MPa.

  The collision plate 81 of the air entanglement unit 21 shown in FIG. 4 is installed away from the lower end of the air entanglement unit 21 by, for example, 21 to 29 cm (preferably 25 cm).

  If the collision plate 81 is separated by 21 cm or more, there is no problem in forming a downball-shaped lump. If the collision plate 81 is separated by more than 29 cm, the subsequent winding process is hindered.

  By providing the collision plate 81, it is possible to mitigate the fact that the feather-like cotton material 1 is blown out by the air squirting outside from the air entanglement unit 21 after coming out of the air entanglement unit 21. . If the feather-like cotton material 1 is blown too much, the rhythm with the subsequent winding process may be shifted, or the manufacturing process may be hindered by being caught by surrounding mechanical parts or the like. By providing the collision plate 81, the formed feather-like cotton material 1 can be smoothly wound.

  In addition, if the amount of air that bounces the collision plate 81 closer increases, the collision plate 81 rebounds too much from the end of the tip nozzle portion 33 in the yarn traveling direction, and the airflow in the air entanglement unit 21 The air pressure is affected, which may hinder the formation of a downball-shaped lump, and may also hinder the winding of the formed feather-like cotton material 1.

  Further, if the amount of air that bounces the collision plate 81 closer increases, the shaft that is fed through the feed rollers 11 and 15 in response to the pressure of the bounced air in addition to hindering the formation of a downball-shaped lump. There arises a problem that the yarn 2 and the floating yarn 3 do not enter the air entanglement unit 21 and are pushed upward before the unit.

  Needless to say, the setting examples of the angles, dimensions, and the like described above are merely examples, and the present invention is not limited thereto.

  Next, the air entanglement process by the air entanglement unit 21 will be described in detail with reference to FIGS.

  The shaft yarn 2 and float 3 fed into the air entanglement unit 21 through the above-described supply process of the shaft yarn 2 and float 3 are inside the inlet cylinder 36 and the through hole 35 of the yarn / air supply body 31. Then, it enters the mortar-like wall surface portion 72 in the venturi 71 through the tip nozzle portion 33.

On the other hand, the air supplied to the air receptacle 64 reaches the air receiving recess 43 in the air entanglement unit 21 and further supplied to the space formed by the mortar-shaped wall portion 72 through the air hole 43a. Then, it is sprayed on the inclined surface of the mortar-shaped wall portion and scattered as shown in FIG.

  As a result, the float 3 that has entered the space formed by the mortar-shaped wall surface 72 of the venturi 71 is disturbed by the flow of air that has been scattered in the space, and the shaft yarn 2 and the float 3 The filaments are bundled and entangled (air entangled) and connected and integrated, for example, having a downball-shaped lump in a form connected in a row as shown in FIG. 1 (a) and FIG. 1 (b), In addition, a fluffy cotton material 1 in the form of a cotton is formed, a downball-shaped lump in a form in a row is formed, and a fluffy cotton material 1 in the form of a cotton is formed. The

  That is, at the time of air entanglement in the space portion, as shown in FIG. 5, the float 3 is entangled and connected in a form in which the S-twist and Z-twist portions of the float 3 are alternately repeated around the shaft yarn 2, The diameter of the downball-shaped lump is about 1.0 to 8 cm, particularly about 1.5 to 4 cm, preferably 1.0 to 3.5 cm. In this manner, the cotton-like feather-shaped cotton material 1 is formed which is continuously arranged with an interval D (FIG. 22) within about 10 cm.

  Thereafter, the feather-like cotton material 1 passes through the venturi through-hole 73 of the venturi 71, is released below the air entanglement unit 21, reaches the collision plate 81, and from the venturi through-hole 73. Since air is blown toward the collision plate 81, the feather-like cotton material 1 is scattered or sent to the vicinity of or around the collision plate 81.

  FIG. 17 is a plan view showing a structure in which a flat ring-shaped interval adjusting ring 105 is interposed between the lower end of the yarn / air supply body 31 and the upper end surface of the venturi 71 using a flat interval adjusting ring (shim ring) 105. The structure which adjusts the clearance gap between the edge part of the nozzle part 33 and the mortar-shaped wall surface part 72 of the venturi 71 is shown. In the present invention, it goes without saying that the present invention can be carried out regardless of the presence or absence of the interval adjusting ring (shim ring) 105 portion.

  The left column of FIG. 17 shows an example in which the gap adjustment ring 105 is not used, and the gap interval between the end of the tip nozzle portion 33 and the deepest portion of the mortar-shaped wall portion 72 of the venturi 71 is d1, In the case where the interval adjusting ring 105 is used, an example is shown in which the gap interval between the end portion of the tip nozzle portion 33 and the deepest portion of the mortar-shaped wall portion 72 of the venturi 71 is d2 (d2> d1).

  Regardless of whether or not the interval adjusting ring 105 is used, for example, the interval adjusting ring 105 is used to set the gap interval between the end of the tip nozzle portion 33 and the deepest portion of the mortar-shaped wall portion 72 of the venturi 71. It has been found that by adjusting (d1 or d2), the size of the downball-shaped lump of the feather-like cotton material 1, the distance between each downball-shaped lump and the lump, and the float density can be adjusted as appropriate. Although not shown, the gap between the end of the tip nozzle portion 33 and the deepest portion of the mortar-shaped wall portion 72 of the venturi 71 can also be adjusted by changing the thickness of the interval adjusting ring 105. It was found that the size of each lump, the distance between each downball-like lump and lump, and the float density can be adjusted as appropriate.

  In the manufacturing method of the feather-like cotton material 1 provided with the downball-shaped lump according to the present embodiment described above, the size of the downball-shaped lump, the distance between each downball-shaped lump and the lump, and the float density As parameters to be adjusted, the supply magnification of the shaft yarn 2 and the floating yarn 3, the air volume from the air supply source 91, the air pressure, the presence or absence of a spacing adjustment ring arranged between the nozzle portion and the venturi, the thickness Various factors such as the adjustment of the distance between the tip nozzle part and the mortar-shaped wall surface part of the venturi due to the change can be mentioned, and by combining these factors in various ways, the size of the downball-shaped lump, each down A feather-like cotton material 1 having a downball-shaped lump in a desired form by variously changing the distance between the ball-shaped lump and the lump and the float density can be manufactured.

(3) (Winding process)
The feather-like cotton material 1 bent to the side of the collision plate 81 as described above is taken up by the take-up roller 17 through the take-up feed roller 16 as shown in FIG.

(4) (Silicone resin processing step)
Next, the feather-shaped cotton material 1 formed as described above is immersed in the silicone agent in the container 111 as shown in FIG.

  In addition, as shown in FIG. 18, the silicone resin processing step immerses the down-ball-shaped and cotton-like feather-like cotton material 1 or sprays the cotton-like feather material 1 by means such as spraying (not shown). A silicone agent may be attached to the long fibers. In this embodiment, the silicone agent is mainly applied to the long fibers by spraying means such as spray (not shown).

  Since the surface of the shaft yarn 2 and the floating yarn 3 constituting the feather-like cotton material 1 has irregularities, the amount of the silicone agent is the cotton to be opened, that is, the feather-like cotton material 1 (shaft yarn 2). And 0.1 to 5.0%, preferably 0.5 to 3.0%, based on the total amount of float 3).

(5) (First heating process)
Next, a 1st heating process is implemented with respect to the feather-like cotton raw material 1 which finished the silicone resin processing process.

  That is, although not shown, using a dryer, the first heating step is performed under the conditions of a heating time of 1 to 10 minutes (preferably 3 to 5 minutes) and a heating temperature of 100 to 149 ° C. (especially 130 ° C. is preferable). To remove water when the silicone agent is diluted. In order to remove moisture when the silicone agent is diluted, it is necessary to apply a temperature of 100 ° C. or higher. A temperature of 100 to 149 ° C. is appropriate for removing moisture in a short time to increase production efficiency.

  In addition, when the heating time is 1 to 2 minutes, the water at the time of dilution is slightly too small, and when the heating time exceeds 10 minutes, the silicone agent is discolored due to overheating, so 3 minutes to 5 minutes is preferable. is there.

(6) (Second heating process)
Next, the second heating step is performed on the feather-like cotton material 1 that has completed the first heating step.

  That is, although not shown, using a dryer, the second time is performed under the conditions of a heating time of 1 to 10 minutes (preferably 3 to 5 minutes) and a heating temperature of 150 to 200 ° C. (especially 180 ° C. is preferable). A heating process is implemented and curing (silicone agent fixation) and heat shrink with respect to the feather-like cotton raw material 1 are performed. As a result, a film is formed on the feather-like cotton material 1 by the silicone agent, resulting in a smooth slipping feeling, and the adjacent floating yarns 3 are less likely to be entangled with each other by sliding, and a soft feeling is obtained.

  Further, the second heating step causes heat shrinkage of the shaft yarn 2 and the floating yarn 3 constituting the feather-like cotton material 1, and the shape changes (shrinks) as shown in FIG. The later shape is stably maintained. Further, the diameter becomes thicker and harder, the bulkiness is increased, the resilience is increased, and furthermore, it is possible to impart washing resistance (the shape is stable even after washing) (shrink-proofing process).

  FIG. 20 shows the conditions of the heat shrinkage test performed on the feather-like cotton material 1 (six yarns A to F) subjected to the second heating step, and FIG. 21 shows the result of the heat shrinkage test (without tension). The contraction rate is shown in the case of (1) and in the case of tension).

(7) (Cooling process)
The feather-shaped cotton material 1 after the second heating process is cooled to a temperature of 50 to 90 ° C. (especially 70 to 85 ° C. is preferable) using a dryer, for example, to obtain a product.

  By cooling after heat shrinkage, the shape of the feather-like cotton material 1 is prevented from changing during the subsequent work.

  In addition, in the manufacturing method of the feather-like cotton raw material 1 which concerns on a present Example, it can also be set as the manufacturing method which does not implement the silicone resin processing process mentioned above.

  In this case, the feather-like cotton material 1 formed as described above has a heating time of 1 to 10 minutes (preferably 3 to 5 minutes) and a heating temperature of 150 to 200 ° C. (especially 180 ° C. is preferable). The product is heated only once under the conditions, and thereafter, for example, using a dryer, a cooling step is performed at a temperature of 50 to 90 ° C. (especially 70 to 85 ° C. is preferable) to obtain a product.

  FIG. 22 conceptually shows the size of the downball-shaped lump integrated with the axial thread 2 according to the present embodiment, and the interval between each downball-shaped lump and lump. The filaments 3 of the yarn 3 are bundled and entangled together to be integrated, and the axial yarn 2 in the feather-like cotton material 1 in the form of being connected in a row has a distance D of about 10 cm or less and a diameter φ of about 1. A lump of float 3 of 0 to 3.5 cm is formed.

  FIG. 23 qualitatively shows the relationship between the shape size of the downball-shaped lump and the air pressure during the air entanglement process according to the present embodiment, and the downball as the air pressure changes from high pressure to low pressure. It was found that the shape size of the lumps increased.

  FIG. 24 qualitatively shows the relationship between the density of the downball-shaped lump and the supply magnification of the shaft yarn 2 and the float yarn 3 according to the present embodiment. It has been found that the density of the downball-shaped lump increases as the supply magnification of the shaft yarn 2 and the float yarn 3 increases (the higher the supply amount of the float yarn 3 with respect to the shaft yarn 2). That is, it has been found that the more the float yarn 3 is supplied to the shaft yarn 2, the higher the density of the downball-shaped lump.

  According to the feather-like cotton material 1 having the down-ball-like lump of the present embodiment described above, the down-ball-like lump is completely different from conventional cotton materials including those of the prior art. Thus, it is possible to exhibit unique actions and effects that cannot be exhibited by these conventional cotton materials (those that can change the thickness at most in the existing cotton materials).

  That is, the downball-shaped lump in the feather-like cotton material 1 of the present embodiment is formed with regular intervals, so that the downball-like lump is hygroscopic as the feather-like cotton material 1 and is sweating and divergent. Also good.

  A comforter or the like in which the density of the material is changed can be formed by changing the comforter user of the elderly person, a sick person, a pregnant woman, a child, or the like. Moreover, the feather-like cotton material 1 of the present embodiment is completely different from what can be obtained from conventional taslan processing or the like.

  In addition to the above-described case, the feather-like cotton material 1 may be hung on a bag or the like, and wind may be applied to further expel excess water. The wind in this case may be cold or warm.

  Moreover, in order to make the water | moisture content in the feather-like cotton raw material 1 fly firmly, it is preferable to loosen so that a feather-like cotton raw material may be spread with a hand etc. so that a wind may hit evenly.

  At that time, the float 3 that is a lump of a downball shape may be rubbed by hand so that the float 3 is further opened and bulked.

  Such a hand kneading operation is an operation for opening the floating yarn 3 which is a downball-shaped lump to further increase the volume (bulk).

  Further, it is possible to use a machine such as a hand dryer that blows off moisture on the surface by wind pressure and to remove excess moisture as much as possible before entering the heating / cooling machine. The wind in this case may be cold or warm.

  Further, the feather-like cotton material 1 that has been subjected to the above-described processing may be loosened by hand to include air. At this time, it may be rubbed by hand so that the portion of the downball-shaped lump is further opened. By doing in this way, when many feather-like cotton raw materials 1 are arranged, the clearance gap between the feather-like cotton raw materials 1 is lose | eliminated, and the heat retention improvement can be anticipated.

  According to the feather-like cotton material 1 according to the present embodiment described above, the axial yarn 2 and the floating yarn 3 made of a polymer that is not a feather material are used as the raw yarn, and the axial yarn 2 and the floating yarn 3 are the mortar. Down ball as shown in FIG. 1 or the like, which is integrated into a cotton shape by air entanglement in an air scattering atmosphere in the space formed by the wall surface 72, and the shaft yarn 2 and the floating yarn 3 are intertwined with each other. Since it is formed as a cotton-like long fiber with a lump-like lump, the above-mentioned problem as with conventional feather duvets does not occur, and there is a sufficient volume with a peculiar downball-like lump. It has a feeling and bulkiness, has no odor peculiar to animals, is excellent in washability, heat retention and heat insulation, and has been artificially manufactured in a form resembling a novel and novel feather that has never existed in the past Cotton material can be realized.

  Further, according to the manufacturing method according to the present embodiment, the supply process of the shaft yarn 2 and the floating yarn 3 into the air entanglement unit 21, the air entanglement process in the air scattering atmosphere in the air entanglement unit 21, It is possible to realize and provide a manufacturing method that can be simply manufactured by the winding process, and that can obtain the feather-like cotton material 1 artificially manufactured in a form imitating a feather that exhibits the above effects.

  The feather-like cotton material according to the present invention is used not only for storing and filling comforters, but also applicable as a material for textiles and knitting, as well as clothing, blankets and sleeping bags, pillows and cushions, etc. It can be widely applied to various clothing items.

DESCRIPTION OF SYMBOLS 1 Feather-like cotton material 2 Axle thread 3 Float 11 Feed roller 12 Crill stand 13 Supply roller 14 Guide cylinder 15 Feed roller 16 Take-up feed roller 17 Take-up roller 21 Air entanglement unit 31 Yarn / air supply body 32 Nozzle cylinder part 33 Nozzle tip portion 33a Nozzle taper hole 35 Through hole 35a Straight hole 35b Taper hole 36 Inlet tube portion 36a Insertion hole 37 Protruding circular portion 38 Circular handle portion 38a Nozzle receiving tube portion 38b Circular recess portion 39 Large diameter tube portion 40 Small diameter tube Part 41 Positioning and tightening mechanism part 42 Lower circular step part 43 Air receiving recessed part 43a Air hole 44 Recessed part 45 Inclined outer peripheral part 46 Inclined groove part 51 Unit inner cylinder 52 Projecting cylinder part 53 Insertion cylinder part 54 Large diameter cylinder part receiving part 55 Unit inner cylinder through-hole 55a Circular protrusion 56 O-ring 57 D -Passing hole 61 Unit outer cylinder 61a Circular upper part 61b Circular concave part 62 Circular receiving hole part 63 Through insertion hole 64 Air receiving plug 65 Mounting receiving hole 71 Venturi 72 Mortar-shaped wall part 73 Venturi through hole 81 Collision plate 91 Air supply source 92 Air pipe 101 Stop ring 102 C ring 103 Circular hole 104 Small protrusion 105 Space adjustment ring 111 Container D Space between each downball-shaped lump H1 Projection length H2 Venturi through hole dimension H3 End of nozzle section Dimension to venturi through-hole exit d1 Gap spacing d2 Gap spacing θ Feed angle θ1 Inclined surface angle φ Diameter

The present invention does not cause the various problems described later, such as those of conventional natural feathers for filling a futon , and is a downball-shaped lump, that is, a shaft yarn / floating yarn using a polyester or polypropylene polymer raw yarn The filaments are bound and entangled by air entanglement in an air scattering atmosphere, and the floating yarn is integrated into a spherical shape while expanding randomly in the three-dimensional direction around the axial yarn. The lumps having the spherical shape have a predetermined diameter, and the lumps having the spherical shape are continuously formed at predetermined intervals in the length direction of the shaft yarn. a feathered cotton formed as a long fiber-like cotton Te, voluminous, have bulky, without involving animals peculiar odor, excellent washability, warmth, excellent heat insulating properties, further It can be formed on the amount, but the novel forms in the conventional totally nonexistent new, to a feather-like cotton and a method of manufacturing artificial produced typical morphology naturally feathers.

The problem to be solved by the present invention is that the above-mentioned problem as in the case of conventional feathers for natural duvets does not occur at all, and the downball-like mass peculiar to the present invention , that is, a polyester or polypropylene polymer yarn The filaments of the shaft yarn / floating yarn using the yarn are bound and entangled by air entanglement in an air scattering atmosphere, and the floating yarn is randomly expanded in the three-dimensional direction around the shaft yarn The lumps that are integrated into a spherical shape (hereinafter referred to as “down ball shape”) are arranged in a row, and each of the lumps in the spherical form has a predetermined diameter. Each lump is a fluffy cotton material formed continuously as a cotton-like long fiber with a predetermined interval in the length direction of the shaft yarn, and has sufficient volume and bulkiness, and is animal-specific Accompanied by odor In addition, it is excellent in washability, heat retention, and heat insulation, and has a novel and novel form that has never existed in the past. This is a point that does not exist at all.
In addition, in the case of the entangled yarn for stuffing disclosed in Patent Document 1, it is a form in which the flower yarn is simply wound around the core yarn while the core yarn and the flower yarn are mixed very irregularly, Of course, it does not form a unique downball-shaped lump that exhibits various useful effects.

The feather-like cotton material of the present invention has a downball-like lump, that is, filaments of shaft yarn and float yarn using polyester-based or polypropylene polymer yarn are bound together by air entanglement in an air scattering atmosphere. Then, the floats are intertwined and connected together in a single row while the floating yarns are randomly expanded in the three-dimensional direction around the shaft yarns, and the lumps are in a single row, and each of the spherical shapes The most important feature is that the lump has a predetermined diameter, and each lump of this spherical shape is formed continuously as a cotton-like long fiber with a predetermined interval in the axial direction of the shaft yarn. To do.

According to the first to fourth aspects of the present invention, downball-shaped lumps, that is, filaments of shaft yarn and float yarn using a polyester or polypropylene polymer yarn are entangled in an air scattering atmosphere. Thus, the lump that is bundled and entangled and the floating yarns are integrally expanded while being randomly expanded in the three-dimensional direction around the axial yarn, and the spherical shape is formed in a row, and the spherical shape Each lump of form has a predetermined diameter, each lump of this spherical form is formed continuously with a predetermined interval in the length direction of the shaft yarn, and is formed as a cotton-like long fiber , For example, when the diameter φ of the downball-shaped lump is 1.0 to 3.5 cm and the interval is within about 10 cm at the maximum, the above-described problems such as the conventional feather for a natural duvet are not caused at all. No da It has a cardboard-like lump and has sufficient volume and bulkiness, is not accompanied by animal-specific odors, and has excellent washability, heat retention, and heat insulation properties. Therefore, it is possible to realize and provide a feather-like cotton material artificially manufactured in a form imitating natural feathers.

The present invention has a novel and novel form which does not exist at all, and does not have the above-described problems such as conventional natural feathers for duvets, and has a specific downball-like lump and has a sufficient volume feeling. The purpose is to realize and provide a feather-like cotton material that is artificially manufactured in a form resembling a feather that is bulky, has no animal-specific odor, and is excellent in washability, heat retention, and heat insulation. Down ball-shaped lump, that is, filaments of shaft yarn / floating yarn using polyester yarn or polypropylene polymer yarn are bound and entangled by air entanglement in an air scattering atmosphere. Is a form in which lumps that are integrated into a spherical shape are randomly expanded in a three-dimensional direction centering on the axial thread, and the lumps in the spherical form have a predetermined diameter. A feathered cotton formed as a long fiber is formed continuously at predetermined intervals longitudinally shaped cotton each mass the shaft thread of the spherical form, the diameter φ of the mass of the spherical form 1.0 to 3.5 cm, and this spherically shaped lump can be formed as cotton-like long fibers that are continuously arranged at intervals within a maximum of about 10 cm in the axial direction of the axial yarn. It was realized.

Examples of the air pressure of the air supplied into the air entanglement unit 21 include 0.35 to 0.40 MPa .

Claims (11)

  Axel yarns and float filaments using polyester base yarns are bound together by air entanglement in an air scattering atmosphere and entangled together to form a downball-like lump and integrated into a single row The downball-shaped lump has a predetermined diameter, and the downball-shaped lump is continuously arranged at a predetermined interval with respect to the axial direction of the axial yarn to form cotton-like long fibers. Feathery cotton material characterized by that.   Axial yarns and float yarn filaments using polyester yarns are bound together by air entanglement in the air scattering atmosphere in the air entanglement unit and entangled to form a downball-shaped lump with an interval. However, the diameter of the downball-shaped lump is 1.0 to 3.5 cm in a form that is integrated and connected in a row, and this downball-shaped lump is within a maximum of about 10 cm in the axial direction of the axial thread. A feather-like cotton material characterized by being formed as cotton-like long fibers that are continuously arranged at intervals of.   Axial yarns and float yarn filaments using polyester yarns are bound together by air entanglement in the air scattering atmosphere in the air entanglement unit and entangled to form a downball-shaped lump with an interval. However, the diameter of the downball-shaped lump is 1.0 to 3.5 cm in a form that is integrated and connected in a row, and this downball-shaped lump is within a maximum of about 10 cm in the axial direction of the axial thread. A feather-like cotton material, which is formed as cotton-like long fibers that are continuously arranged with an interval of, a silicone resin fixed to the cotton-like long fibers, and the shape stabilized by heating.   The feather cotton according to any one of claims 1 to 3, wherein the floating yarn is selected from a lightweight hollow yarn, a C-shaped cross-sectional yarn having a surface area larger than a circular cross-sectional yarn, or a modified cross-sectional yarn. Material. Supplying each of the shaft yarn and the floating yarn using the polyester base yarn into the air entanglement unit;
By the air entanglement in the air scattering atmosphere in the air entanglement unit, the filaments of the shaft yarn / floating yarn are bundled together, and are entangled and integrated while having a downball-shaped lump, and are connected in a row. The downball-shaped lump has a predetermined diameter, and the downball-shaped lump is a fluffy cotton that is a cotton-like long fiber that is continuously arranged at a predetermined interval with respect to the longitudinal direction of the axial yarn. Air entanglement process as material,
Winding the feather-like cotton material;
A method for producing a feather-like cotton material, comprising: Supplying each of the shaft yarn and the floating yarn using the polyester base yarn into the air entanglement unit;
By the air entanglement in the air scattering atmosphere in the air entanglement unit, the filaments of the shaft yarn / floating yarn are bundled together, and are entangled and integrated while having a downball-shaped lump, and are connected in a row. In the form, the diameter of the downball-shaped lump is 1.0 to 3.5 cm, and the downball-shaped lump is continuously arranged with an interval within a maximum of about 10 cm in the length direction of the axial thread. Air entanglement process with feather-like cotton material that is long fiber,
Winding the cotton-like long fibers;
A method for producing a feather-like cotton material, comprising: Supplying each of the shaft yarn and the floating yarn using the polyester base yarn into the air entanglement unit;
By the air entanglement in the scattering atmosphere of the air supplied from the outside formed between the tip nozzle part of the nozzle cylinder part in the air entanglement unit and the mortar-like wall surface part of the venturi, the shaft yarn / floating yarn Filaments are bundled together, entangled and connected to form a downball-shaped lump, and are integrated into a single row. The diameter of the downball-shaped lump is 1.0 to 3.5 cm. An air entanglement process in which a lump of fluff is a cotton-like long fiber that is continuously arranged with an interval within a maximum of about 10 cm in the axial direction of the axial yarn,
Winding the cotton-like long fibers;
A silicone resin processing step of applying a silicone agent to the feather-like cotton material;
A first heating step of heating the feather-like cotton material with a silicone agent to blow off moisture;
A second heating step of stabilizing the shape by heating and shrinking the feathered cotton material from which moisture has been removed;
A cooling step of cooling the feather-like cotton material after the second heating step,
A method for producing a feather-like cotton material, comprising:   The heating temperature in the first heating step is 100 to 149 ° C, preferably 130 ° C, and the heating temperature in the second heating step is 150 to 200 ° C, preferably 180 ° C. Item 8. A method for producing a feather-like cotton material according to Item 7.   The supply magnification of the shaft yarn and the floating yarn, the air volume and the air pressure of air for air entanglement in the air entanglement unit, the tip nozzle portion in the air entanglement unit and the mortar-shaped wall portion of the venturi Down ball that has a desired shape by variously changing the size of the down ball-like lump, the distance between each down ball-like lump and the lump density, and the float density by combining each factor with the interval adjustment between A method for producing a feather-like cotton material according to claim 7 or 8, wherein a lump-like lump is obtained.   10. The feather-like shape according to claim 5, wherein the floating yarn is selected from a lightweight hollow yarn, a C-shaped cross-sectional yarn having a surface area larger than a circular cross-sectional yarn, or a modified cross-sectional yarn. Cotton material manufacturing method. The air entanglement unit is connected to an air supply source capable of adjusting the air pressure and the air volume to send compressed air for air entanglement to an air receptacle provided in the air entanglement unit via an air pipe,
Thread and air supply,
A cylindrical unit inner cylinder made of metal,
A cylindrical unit outer cylinder made of metal,
Venturi installed inside the unit cylinder,
Comprising
The upper side of the unit inner cylinder mounted from the upper side on the upper side in the unit outer cylinder is fixedly held concentrically, and the lower side of the unit inner cylinder is located at the center of the lower end surface of the unit outer cylinder Configured to protrude downward from
The lower end surface of the venturi, which is housed inside the unit inner cylinder, is configured to protrude downward from the center of the lower end surface of the unit inner cylinder,
A tip nozzle portion protruding downward from a lower end center of a metal nozzle cylinder portion provided on a lower side of a thread / air supply body mounted in the unit inner cylinder from above the unit outer cylinder is the venturi. Facing inside, configured to form an air scattering atmosphere state in the space between the tip nozzle portion and the mortar-shaped wall portion of the venturi,
The yarn / air supply body includes a cylindrical nozzle tube portion and a tip nozzle portion that protrudes downward from the center of the lower end of the nozzle tube portion. The circular handle part is integrally attached via the cylindrical body part, and a circular concave part into which the circular upper part of the unit outer cylindrical body enters is provided on the bottom surface side of the circular handle part, and the nozzle is provided from the central part on the upper end side of the nozzle cylindrical part. A through hole is provided to reach the center of the lower end of the tube portion. The nozzle tube portion is provided with a large-diameter tube portion that constitutes the positioning and tightening mechanism portion, and the portion from the lower side of the large-diameter tube portion to the lower end is the small-diameter tube portion. Configured as
The thread / air supply body has a protruding circular portion on the upper side of the through hole extending from the center portion of the upper end side of the nozzle tube portion to the center portion of the lower end of the nozzle tube portion, and has an insertion hole. A cylindrical inlet tube portion is mounted, and the shaft yarn and the float yarn are fed into the insertion hole of the inlet tube portion, and the upper portion of the through hole is tapered with a small dimension in the depth direction. A range corresponding to the lower end of the large-diameter cylindrical portion is formed as a straight hole from directly below the tapered portion, and further from below to the lower portion in the vicinity of the lower end in the small-diameter cylindrical portion. The diameter of the taper hole is reduced, and a lower circular step portion is provided at a lower central portion of the small diameter cylindrical portion, and an upper end portion of the tip nozzle portion is provided at a central position of the lower circular step portion. It is configured to be mounted and fixed in a concentric arrangement, Nozzle taper hole is also provided in the tip nozzle part, the step diameter is eliminated by setting the hole diameter at the lowest end of the taper hole in the through hole and the hole diameter at the uppermost part of the nozzle taper hole to eliminate the step. Constructed to smoothly feed the shaft yarn and floating yarn into the venturi through the nozzle taper hole,
An air receiving recess that is located outside the tapered hole and is rotatable around the center is provided in the small diameter cylindrical portion of the nozzle cylinder portion of the yarn / air supply body. Two air holes that communicate with the side circular step and eject air toward the lower side thereof are provided,
The inner cylinder of the unit is provided with a protruding cylindrical part in a circular shape in a plan view projecting laterally on the upper part, and an insertion cylindrical part having a smaller diameter than the protruding cylindrical part is provided concentrically below the protruding cylindrical part. A circular large-diameter cylindrical portion stepped portion into which the lower side of the large-diameter cylindrical portion of the yarn / air supply body is inserted is provided on the upper surface side of the protruding cylindrical portion of the inner cylinder of the unit. The unit inner cylinder through-hole is provided from the center of the large-diameter cylinder receiving step part to the lower end through the inside of the insertion cylinder, and the lower end of the unit inner cylinder through-hole of the unit inner cylinder Is provided with a circular protrusion whose inner diameter is smaller than the inner diameter of the unit inner cylinder through-hole and protrudes inward of the unit inner cylinder through-hole to receive the lower end of the small-diameter cylinder of the yarn / air supply body. And an O-ring is attached to the side wall of the protruding cylindrical portion of the unit inner cylindrical body. When the cylindrical portion is attached to the circular receiving hole portion of the unit outer cylindrical body, the O-ring is configured to be in close contact with the inner wall surface of the circular receiving hole portion, and the insertion cylindrical portion of the unit inner cylindrical body In the side wall portion, when the unit inner cylinder is mounted on the unit outer cylinder, an air passage hole is provided so as to correspond to the mounting receiving hole for the air plug, and configured.
The unit outer cylinder has a cylindrical shape, and a circular receiving hole portion on which the protruding cylinder portion of the unit inner cylinder body is mounted is provided on the inner peripheral portion of the circular upper portion, and further, below the circular receiving hole portion. It is formed to have a smaller diameter than the circular receiving hole portion in a penetrating state until reaching the lower end, and is provided with a through insertion hole that penetrates the insertion cylindrical portion of the unit inner cylindrical body, and on the side wall portion of the unit outer cylindrical body Is provided with a mounting receptacle for an air plug that communicates with an air supply source through an air pipe, and a circular recess is formed in the inner periphery of the circular upper portion of the unit outer cylindrical body. Configured to attach a flat C-ring to this circular recess,
The venturi built in the inner cylinder of the unit has a cylindrical shape as a whole, and is provided with a mortar-like wall surface portion whose diameter decreases toward the lower side from the upper end surface side into which the shaft yarn and the floating yarn respectively enter the upper side of the inner center, From the deepest part of this mortar-shaped wall part to the lower end surface, it is configured by providing a tapered Venturi through-hole that expands toward the lower end side through which the shaft yarn and floating yarn can pass,
The nozzle tip hole of the yarn / air supply body is substantially cylindrical as a whole, and penetrates from the upper end surface side to the lower end surface and decreases in diameter from the upper end surface side to the lower end surface. Provided and configured,
The positioning and tightening mechanism portion in the nozzle tube portion of the yarn / air supply body includes a large-diameter tube portion of the yarn / air supply body, and a retaining ring disposed on the unit inner cylinder in the unit outer cylinder. The retaining ring has a circular hole that is slightly larger in diameter than the outer diameter of the large-diameter cylindrical portion of the yarn / air supply body. Provided with a small projection that functions as a contact receiving portion for alignment and a semicircular shape or trapezoidal shape protruding toward the direction,
In a state where the unit inner cylinder is mounted on the unit outer cylinder, a flat annular retaining ring is brought into contact with the upper end surface of the protruding cylindrical portion of the unit inner cylinder, and further, a C ring disposed on the retaining ring. By mounting the outer peripheral part of the unit in the circular recess, the unit inner cylinder is configured to be fixedly arranged inside the unit outer cylinder,
In the thread / air supply body, the large-diameter cylindrical portion receiving portion of the inner cylinder of the unit is not obstructed by the small projections while the large-diameter cylindrical portion is aligned with the small projections. A semicircular or trapezoidal concave portion that can be inserted into the stepped portion, and an outer periphery of the lower surface of the nozzle receiving cylinder portion provided from one end of the concave portion to a position 180 degrees away from the circumferential direction of the large diameter cylindrical portion By providing an inclined outer peripheral portion that forms an inclined groove portion with the portion, the inclined outer peripheral portion is formed such that the thickness on the concave portion side is thin and the thickness is increased as the distance from the concave portion is increased. The lower surface of the inclined groove portion is configured to exhibit an inclined surface, whereby the unit inner cylinder is mounted and fixed in the unit outer cylinder, and then the thread / air supply body is aligned and the unit inner cylinder is positioned inside the unit inner cylinder. By mounting and then rotating the circular handle part, The lower surface of the inclined groove portion of the positioning tightening mechanism portion is pressed against the lower surface of the small protrusion of the retaining ring, and as a result, the yarn / air supply body can be fastened and fixed to the unit outer cylinder, and the yarn / air The air receiving recess of the supply body is configured to face the air passage hole of the unit inner cylinder,
The shaft yarn and float yarn fed into the air entanglement unit through the yarn and air supply process in the yarn / air supply body are the inside of the inlet cylinder portion, the through hole, the tip nozzle of the yarn / air supply body. The air that enters the mortar-shaped wall portion in the venturi through the inside, and the air supplied to the air receiving plug reaches the air receiving recess in the air entanglement unit, and further passes through the air hole to form the mortar-shaped wall surface. The floating yarn that has been supplied to the space portion formed by the portion and sprayed on the inclined surface of the mortar-shaped wall surface portion and scattered to enter the space portion formed by the mortar-shaped wall surface portion of the venturi is scattered within the space portion. It is disturbed by the air flow that has become a state, and the filaments of the shaft yarn and the floating yarn are bundled together and entangled and integrated to form a downball-shaped lump in a row. And, and, together configured so as to form the fluffy cotton form became flocculent,
Supply magnification of shaft yarn and floating yarn fed from the yarn / air supply body, air volume and air pressure from the air supply source of the air entanglement unit, and the end of the nozzle portion at the tip of the yarn / air supply body The size of the downball-shaped lump of the feather-like cotton material, the distance between each downball-shaped lump and lump by variously combining the gap portion and the gap interval to the deepest portion of the mortar-shaped wall surface portion of the venturi The method for producing a feather-like cotton material according to any one of claims 5 to 10, characterized in that the float yarn density can be produced in various ways.

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