JP2016027216A - Woven fabric or knitted fabric made of feathery cotton material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a woven fabric or knitted fabric including a novel feathery cotton material which has a voluminous feeling, is bulky, is without any odor peculiar to an animal, is excellent in washing characteristics, is excellent in heat retaining properties and heat insulation properties, is capable of being formed light-weight, has a new and novel form which has not existed before, and is artificially produced into a form imitating a natural feather.SOLUTION: A woven fabric 150 including as warp 151 and weft 152 a feathery cotton material 1 having 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, in which the down ball-like lump is in an aggregated state with a prescribed diameter and the down ball-like lumps are consecutively arranged with an interval therebetween in a lengthwise direction of the axial yarn 2 to form a cotton-like filament.SELECTED DRAWING: Figure 25

Description

  The present invention does not cause various problems as described below, such as those conventionally found in natural feathers for filling futons, has a sense of volume, is bulky, has no animal-specific odor, is excellent in washability, has heat retention, It is a new and innovative form that has excellent heat insulation, can be made lighter, has never existed before, and relates to a woven or knitted fabric using a new feather-like cotton material artificially manufactured in a form imitating natural feathers It is.

  Conventional woven fabrics and knitted fabrics include knitted fabrics knitted using various known yarn materials such as woven fabrics and knit fabrics woven using various known yarn materials such as synthetic fibers.

  In Patent Document 1, the number of work man-hours at the time of production is small, the base body is not distorted, and is not easily deformed as a fur woven fabric, either as a warp or a weft of a net-like base body made of warp and weft. Disclosed is a textile fabric in which a fur yarn obtained by twisting a minced fur or a minced fur so that the hair surface is exposed is disclosed.

  Patent Document 2 discloses a warp knitted fabric for an air belt cover that forms an inflatable air belt and covers a bag-shaped belt folded into a belt shape, and is inserted into the knitting yarn and the knitting yarn. In the warp knitted fabric for the air belt cover provided with the inserted yarn, the inserted yarn is a relatively thick first inserted yarn that prevents the warp knitting from being stretched in the warp direction, and the warp when the air belt is not expanded. It comprises a relatively thin second insertion thread that prevents the knitting from stretching in the weft direction, and the second insertion thread allows the warp knitting to stretch in the weft direction by tearing when the air belt is expanded. A warp knitted fabric for an air belt cover is disclosed.

  However, in the case of the techniques of Patent Documents 1 and 2 described above, the yarn as the woven material and the yarn as the knitted material are both made of a known yarn material, and in either case, there is a problem with the washability. Therefore, it is impossible to produce a sense of volume and bulk, and it can be inferred that there are also problems with heat retention and heat insulation.

Registered Utility Model No. 3008585 Japanese Patent No. 3849306

  The problems to be solved by the present invention are a novel feather shape artificially produced in a form resembling a feather that is excellent in washability, has a sense of volume, is bulky, has excellent heat retention and heat insulation properties, and can be formed lighter. There is no conventional woven or knitted fabric using cotton material.

  The present invention is a novel woven or knitted fabric using a novel feather-like cotton material that does not exist at all, and has a novel and novel form that does not exist at all in the past. Floating filaments are bundled by special air entanglement in an air scattering atmosphere and entangled together to form a down ball-like lump and are integrated into a single row, the down ball The ball-like lump is a lump having a predetermined diameter, and this down-ball-like lump is formed as cotton-like long fibers continuously arranged at a predetermined interval with respect to the axial direction of the axial yarn. The above-mentioned various problems that natural feathers have for use do not occur, and there is a sense of volume and bulk, no odor peculiar to animals, excellent washability, and excellent heat retention and heat insulation properties. It is a new fabric or knitting made of a unique and new feather-like cotton material that is artificially manufactured in a form imitating that of natural feathers, which can be made lighter and has never existed in the past. Is the main feature.

  According to each of the first to tenth aspects of the present invention, there is a novel and novel form which does not exist at all, and the filaments of the shaft yarn and the float yarn using the polyester base yarn are in an air scattering atmosphere. Are bundled by special air entanglement and are intertwined and integrated while having a downball-shaped lump, which is in a form connected in a row, and the downball-shaped lump is a lump having a predetermined diameter, This downball-shaped lump is formed as cotton-like long fibers that are continuously arranged at a predetermined interval in the longitudinal direction of the axial yarn, and there are various problems such as those of conventional natural feathers for filling futons. It does not occur, has a sense of volume, is bulky, has no odor peculiar to animals, has excellent washability, has excellent heat retention and heat insulation properties, can be made lighter, and does not exist at all In those innovative forms, it is possible to realize a novel woven or knitted to provide made using the novel feathered cotton with specific were artificially prepared in the form that imitates natural feathers.

FIG. 1A shows a feather in a state in which a downball-shaped lump artificially manufactured in a form simulating a feather according to Example 1 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-like 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 Example 1 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 material of the state completed by the form of a diagram. FIG. 2 is an enlarged view showing each shape example of the float used for manufacturing the feather-like cotton material according to the first embodiment. FIG. 3 is a flowchart showing the manufacturing process of the feather-like cotton material according to the first embodiment. FIG. 4 is a schematic explanatory view showing each step of the shaft yarn, the float yarn supplying 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 first 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 first 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 diagram showing the air entanglement unit used in the manufacturing process of the feather-like cotton material according to the first 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 the present Example 1 in a perspective view aspect. FIG. 8 is a schematic partial cross-sectional view showing a venturi of an air entanglement unit used in the manufacturing process of the feather-like cotton material according to the first 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 the first 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 the first embodiment. FIG. 11 is a partial cross-sectional view showing 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 first 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 the first embodiment. FIG. 13 shows the air entanglement unit used in the manufacturing process of the feather-like cotton material according to the first embodiment, the state before the yarn / air supply body is fastened to the unit outer cylinder, and the yarn / air supply body outside the unit. It is explanatory drawing which shows the state fastened by the cylinder. FIG. 14 shows an example of the dimensions of the tip nozzle part of the yarn / air supply body, each part of the venturi, and the angle of the mortar-shaped wall surface part of the venturi in the unit for air entanglement used in the manufacturing process of the feather-like cotton material according to the first embodiment. It is a schematic explanatory drawing which shows an example. 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 air entanglement unit used in the manufacturing process of the feather-like cotton material according to the first embodiment. is there. FIG. 16A shows an outlet of the venturi from the tip surface of the tip nozzle portion of the air entanglement unit, which is used in the air entanglement unit used in the air entanglement step in the manufacturing process of the feather-like cotton material according to the first embodiment. FIG. 16B shows a disturbed state of the floating yarn during the air entanglement of the air entanglement unit used in the air entanglement process in the production process of the feather-like cotton material according to the first embodiment. It is a schematic explanatory drawing. FIG. 17 is an interval 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 first embodiment. It is a schematic explanatory drawing which shows the case where an adjustment 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 the first embodiment. FIG. 19 is an explanatory view showing the heat shrinkage state of the shaft yarn or float yarn according to the first embodiment. FIG. 20 is a diagram showing the conditions of the heat shrink test after the second heating step in the manufacturing process of the feather-like cotton material according to the first embodiment. FIG. 21 is a diagram showing the results of the heat shrinkage test after the second heating step in the manufacturing process of the feather-like cotton material according to the first embodiment. FIG. 22 is an explanatory diagram conceptually showing the size of the downball-shaped lump integrated with the shaft yarn according to the first 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 the first embodiment. 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 floating yarn according to the first embodiment. FIG. 25 is a schematic explanatory view showing, in an enlarged manner, a part of a fabric made of a feather-like cotton material according to this embodiment. FIG. 26 is a schematic explanatory view showing an enlarged part of a knitted fabric made of a feather-like cotton material according to this embodiment.

  The object of the present invention is a novel and novel form that has never existed in the past. Axial yarn / floating filaments using polyester base yarns are specially entangled in an air scattering atmosphere. Are integrated while having a downball-shaped lump by being bound and entangled together, and the downball-shaped lump is a lump having a predetermined diameter, and the downball-shaped lump This is realized by using a unique and novel feather-like cotton material formed as a cotton-like long fiber in which the lump is continuously arranged at a predetermined interval in the axial direction of the axial yarn.

  Hereinafter, a novel woven fabric or knitted fabric made of a novel feather-like cotton material according to an embodiment of the present invention will be described in detail with reference to FIGS.

  First, referring to FIG. 1 to FIG. 24, a feather-like cotton material 1 artificially manufactured in a form imitating a feather constituting a woven fabric 150 (FIG. 25) and a knitted fabric 160 (FIG. 26) according to the present invention, and a manufacturing method thereof. Will be described in detail.

  FIG. 1A shows a feather in a state in which a downball-shaped lump artificially manufactured in a form simulating a feather according to Example 1 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 fabric 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 Example 1 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 by the form of a diagram.

  As shown in FIG. 5 and FIG. 16, which will be described later, the feather-like cotton material 1 according to the first embodiment has a floating yarn 3 Z-twisted with the axial yarn 2 as a core inside the air entanglement unit 21, that is, Z It is twisted while air entangled in the character direction and formed into a downball-like lump shape as shown in FIG. 1, with the axial yarn 2 as the core, spaced from the Z-twisted downball-like lump-like cotton material 1 The three floats are twisted in 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 the first embodiment.

  As shown in FIG. 1, the feather-like cotton material 1 according to the first embodiment includes a shaft yarn 2 and a float 3 that is longer than the shaft yarn 2, and the shaft yarn 2 and the float 3 are feather-shaped. By the air entanglement by the air entanglement unit 21 used in the air entanglement process in the manufacturing process of the cotton material, 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 downball-like lump state and the S-twisted downball-like lump state are continuously formed at intervals, and a cotton-like long fiber is formed as a whole. This is an artificially manufactured model.

  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, which will be described later, the downball-shaped lump in Example 1 is formed by binding the filaments of the shaft yarn 2 and the floating yarn 3 together by tying them together to form a single row. Floating yarn 3 having a diameter φ of approximately 1.0 to 3.5 cm, which is continuously arranged with a spacing of approximately 1 cm to 10 cm, that is, a maximum of approximately 10 cm or less, with respect to the axial yarn 2 in the form of the feather-like cotton material 1 The following description will be given by defining the lump portion as a lump portion.

  As the shape of the floating yarn 3 and the shaft yarn 2, as shown in FIG. 2, for example, a hollow fiber having a hollow rate of 30 to 40% for reducing the weight, a C-shaped cross-sectional yarn, a modified cross-sectional yarn, or the like may be employed. it can.

  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 first embodiment will be described in detail. As the shaft yarn 2 and the float yarn 3 in the first embodiment, for example, a polyester-based yarn is used. Twisted yarn, without interlace processing is used, and the total fineness of each of the axial yarn 2 and the floating yarn 3 is 30 to 200 D (denier), and the total filament number of each of the axial yarn 2 and the floating yarn 3 is 12 to 96 f. Use things.

  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-like cotton raw material 1 which concerns on the present Example 1 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 first embodiment includes a supply process of the shaft yarn 2 and the floating yarn 3, an air entanglement process by the air entanglement unit 21, a winding process, and a silicone resin. It consists of a processing step, a first heating step, a second heating step, and a cooling step.

  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.

  In addition, although the example 1 of the state using the said guide cylinder 14 is shown in the illustration example of FIG. 4, in the present invention, the said guide cylinder 14 is not essential, and even if it implements without using this, it is. good.

  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 first 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. 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 receiving plug 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 first embodiment described above, the size of the downball-shaped lump, the interval between each downball-shaped lump and the lump, and the float density The parameters for adjusting the shaft yarn 2 and the float yarn 3 are the supply magnification, the air volume from the air supply source 91, the air pressure, the presence / absence of an interval adjusting ring disposed between the nozzle portion and the venturi, and the thickness. Various factors such as the adjustment of the distance between the tip nozzle part and the mortar-like wall surface part of the venturi by changing the above can be mentioned, and by combining these factors variously, the size of the downball-shaped lump, each A feather-like cotton material 1 having a downball-shaped lump in a desired form can be produced by variously changing the distance between the downball-shaped lump and the lump and the float density.

(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 the first 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 the present Example 1, 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 first embodiment, and the distance between each downball-shaped lump and lump. The filaments of the floating yarn 3 are bundled and entangled together to be integrated, and the spacing D is about 10 cm or less and the diameter φ is about 1 with respect to the axial yarn 2 in the feather-like cotton material 1 in a row. A lump of floating yarn 3 of 0.0 to 3.5 cm is formed.

  FIG. 23 shows qualitatively the relationship between the shape size of the downball-shaped lump according to the first embodiment and the air pressure during the air entanglement process, and the air pressure decreases as the air pressure changes from high pressure to low pressure. It has been found that the shape size of the ball-like mass increases.

  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 first 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 downball-like lump of Example 1 described above, the downball-like lump is completely different from conventional cotton materials including those of the prior art. Therefore, 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 existing cotton materials).

  That is, the downball-shaped lump in the feather-like cotton material 1 of Example 1 has heat retention as the downball-shaped lump 1 and is formed with a constant interval, so that it has sweating properties and divergence. Good nature.

  With the change of the comforter user of the elderly person, sick person, pregnant woman, child, etc., the comforter etc. in which the density of the material is changed can be formed. Further, the feather-like cotton material 1 of Example 1 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 first 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 It is integrated into a cotton shape by air entanglement in the air scattering atmosphere in the space formed by the mortar-shaped wall portion 72, and the shaft yarn 2 and the floating yarn 3 are entangled and connected to each other, as shown in FIG. Since it has a ball-like lump and is formed as a cotton-like long fiber, it does not have the above-mentioned problem as with a feather for a conventional duvet, and has a unique down-ball-like lump. Newly artificially manufactured in the form of a new and innovative feather that has no volume, bulkiness, no odor peculiar to animals, and is excellent in washability, heat retention and heat insulation. Can be realized.

  In addition, according to the manufacturing method according to the first embodiment, the step of supplying the shaft yarn 2 and the float yarn 3 into the air entanglement unit 21, and the air entanglement step in the air scattering atmosphere in the air entanglement unit 21. In the winding process, a manufacturing method can be realized which can be manufactured simply and can obtain the feather-like cotton material 1 artificially manufactured in a form imitating a feather that exhibits the above effects.

  According to the manufacturing method of the feather-like cotton material 1 according to Example 1 described above, as described above, the filaments of the axial yarn and the floating yarn using the polyester base yarn are special in the air scattering atmosphere. It is formed by bundling and entangled together by air entanglement and integrated with a downball-shaped lump, which is connected in a row, and the downball-shaped lump is a lump having a predetermined diameter. A ball-like lump is formed as a cotton-like long fiber continuously arranged at a predetermined interval in the axial direction of the axial yarn, and the above-mentioned various problems such as those of conventional natural feathers for filling a duvet do not occur. At the same time, it is voluminous, bulky, has no odor peculiar to animals, has excellent washability, has excellent heat retention and heat insulation properties, can be made lighter, and is novel and innovative that has never existed in the past. Intended state, it is possible to realize a feathered cotton 1 is a novel cotton with specific were artificially prepared in the form that imitates natural feathers.

The unique and novel feather-like cotton material 1 described above is used to form a woven fabric 150 (FIG. 25) and a knitted fabric 160 (FIG. 26), which will be described in detail below.
Hereinafter, the woven fabric 150 (FIG. 25) and the knitted fabric 160 (FIG. 26) of the present invention will be described with reference to FIGS.

  The woven fabric 150 or knitted fabric 160 according to the present invention formed with the novel feather-like cotton material 1 described above has the feather-like cotton material 1 as the warp yarn 151 and the weft yarn 152 constituting the woven fabric 150 and the knitting yarn 161 constituting the knitted fabric 160. It is formed as a woven fabric 150 or a knitted fabric 160.

  The means for weaving with the warp 151 and the weft 152 may be a manual operation and may be mechanical weaving by a loom. Of course, the width, length, shape, and the like of the woven fabric 153 can be freely determined.

  Similarly, the means for knitting with the knitting yarn 161 may be manual work and may be machine knitting by a knitting machine. Of course, the width, length, shape, and the like of the knitted fabric 160 can be freely determined.

  In the present invention, the fabric 150 or the knitted fabric 160 using the feather-like cotton material 1 as a single piece, or the fabric 150 or the knitted fabric 160 using two or more feather-like cotton materials 1 may be used. Can also be implemented. That is, the woven fabric 150 or the knitted fabric 160 described above is configured by using a single piece of the feather-like cotton material 1 or by bundling a plurality of the feather-like cotton materials 1 (not shown). The woven fabric 150 or the knitted fabric 160 can also be configured using the above. When a plurality of feather-like cotton materials 1 are bundled, the number and length thereof are not particularly limited and can be variously selected.

  Furthermore, the woven fabric 150 or the knitted fabric 160 can be configured by dyeing the feather-like cotton material 1.

  When each of the woven fabric 150 or the knitted fabric 160 according to this embodiment is woven or knitted by a weaving machine or a knitting machine, the feather-like cotton material 1 is formed on the respective machines of the woven fabric 150 or the knitted fabric 160 to form a sheet-shaped woven fabric or knitted fabric. To do. Then, the formed sheet-like woven fabric or knitted fabric is subjected to silicone processing by applying a silicone agent by the dobbing or spraying, and then enters a drying process to complete the woven fabric or knitted fabric.

  Since the present invention is a new woven fabric 150 or knitted fabric 160 constructed using the novel feather-like cotton material 1 described above, it is excellent in washability, has a sense of volume, is bulky, and has heat retention and heat insulation properties. Further, it is possible to realize a new woven fabric 150 or knitted fabric 160 having a unique texture that is unique and has a peculiarity that the feather-like cotton material 1 constituting the woven fabric or knitted fabric is lightweight.

  As described above, the new woven fabric 150 and the knitted fabric 160 formed of the novel feather-like cotton material 1 that does not exist in the past have a novel and novel form in which the feather-like cotton material 1 itself does not exist at all. Axial yarns and float filaments made of the base yarn of the system are tied together by a special air entanglement in an air scattering atmosphere and entangled together to form a downball-shaped lump and integrated in a row The downball-shaped lump is a lump having a predetermined diameter, and the downball-shaped lump is continuously arranged with a predetermined interval in the longitudinal direction of the axial thread. It is formed as a fiber, and does not cause the above-mentioned various problems that conventional natural feathers for filling a futon, for example, has a sense of volume and is bulky and does not have an animal-specific odor. It is a new material that is excellent in washability, heat retention and heat insulation, can be made lighter, has a novel and novel form that has never existed, and has been artificially manufactured to resemble a natural feather. Therefore, the new woven fabric 150 and knitted fabric 160 formed from the feather-like cotton material 1 exhibit the above-mentioned peculiarities, and the new woven fabric 150 and knitted fabric with a unique texture that has never existed in the past. 160 can be realized.

  The novel woven fabrics and knitted fabrics according to the present invention can be widely applied to woven fabrics and knitted fabrics that exhibit unique properties as described above and have unique materials that do not exist at all. Is possible.

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 the outlet of the venturi through-hole d1 Gap spacing d2 Gap spacing θ Feeding angle θ1 Inclined surface angle φ Diameter 150 Fabric 151 Warp 152 Weft 160 Knitting 161 Knitting yarn

Claims (10)

  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 In this form, 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. A woven or knitted fabric comprising a feather-like cotton material.   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 woven or knitted fabric comprising a feather-like cotton material which is continuously arranged with a spacing of and formed as cotton-like long fibers.   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 woven fabric characterized in that it is formed as a cotton-like long fiber continuously arranged with an interval of, and made of a feather-like cotton material formed by fixing a silicone resin to the cotton-like long fiber and stabilizing the shape by heating. Or knitting. 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 woven or knitted fabric made of a feather-like cotton material formed through the above. 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 woven or knitted fabric made of a feather-like cotton material formed through the above. 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 woven or knitted fabric made of a feather-like cotton material formed through the above.   The heating temperature of the 1st heating process of the said Claim 6 is 100-149 degreeC, It consists of the feather-like cotton raw material formed with the heating temperature of the 2nd heating process 150-200 degreeC. Woven or knitted.   The supply magnification of the axial yarn and the floating yarn according to claim 6 or 7, the air volume and air pressure for air entanglement in the air entanglement unit, the tip nozzle portion and the venturi in the air entanglement unit By combining each factor with the spacing adjustment between the mortar-shaped wall surface portion, the size of the downball-shaped lump, the distance between each downball-shaped lump and lump, and the float density can be changed variously A woven or knitted fabric comprising a feather-like cotton material formed so as to obtain a downball-shaped lump in a desired form.   The feather yarn and shaft yarn according to any one of claims 1 to 8, wherein the float yarn and the shaft yarn are selected from light-weight hollow yarn, C-shaped cross-section yarn having a surface area larger than a circular cross-section yarn, or a modified cross-section yarn. A woven or knitted fabric made of a cotton material.   The feathered cotton according to any one of claims 1 to 9, wherein the woven fabric or the knitted fabric is formed as a woven fabric or a knitted fabric, and then a silicone agent is applied by dobbing or spraying. Weaving or knitting made of materials.

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