JP2020056125A - Flakes of long fiber non-woven fabric, and clothing and bedding for filling the same - Google Patents

Abstract

To provide flakes of long fiber non-woven fabric, which are not formed from short fibers or resin foam as materials as in a conventional case, in which the fiber of inner cotton does not escape from side cloth, which are light and have compactness to be filled in a storage bag and made small to be stored, and have irregular wrinkles or irregular three-dimensional shapes.SOLUTION: Flakes 120 of long fiber non-woven fabric, have irregular wrinkles or irregular three-dimensional shapes and have prescribed shapes and prescribed sizes. The maximum bulkiness per prescribed size of the flakes of the long fiber non-woven fabric may be 100 times as much as a thickness (t) of the flakes of the long fiber non-woven fabric. The thickness (t) of the flakes of the long fiber non-woven fabric may be 0.01 mm to 1.0 mm.SELECTED DRAWING: Figure 2B

Description

  TECHNICAL FIELD The present invention relates to a long-fiber nonwoven flake, clothing and bedding filled with the flake.

Patent Literature 1 discloses a garment having a batting in a bag-shaped side material, wherein the batting is obtained by blowing short fibers into the bag-shaped side material, and the short fibers are substantially randomly filled. Is described.
Patent Document 2 discloses that in a garment having a surface material, a lining, and a batting, the batting is made of a granular cotton made of polyester short fibers and regenerated cellulose short fibers, and a small piece made of a synthetic resin film having a random shape and size. A garment composed of a mixture of granular cotton and small pieces made of synthetic resin film is described.
Patent Literature 3 discloses a cushion body formed by assembling a large number of cords formed by punching or cutting a foamed synthetic resin sheet, wherein the foamed synthetic resin sheet has a thick and thin thickness and an apparent density of 10%. ６０60 g / L, the average number of bubbles is 350 / cm ³ or more, the average thickness is 0.1 to 5.0 mm, the width of the string is 0.1 to 5.0 mm, and the length is It describes a cushion body characterized by being 10 mm or more.

JP 2006-307364 A JP-A-2005-203161 JP 2014-180460 A

However, the above-mentioned Patent Document 1 randomly and independently press-fits short fibers, and the above-mentioned Patent Document 2 mixes granular cotton composed of short fiber batting of polyester and regenerated cellulose with small pieces made of a synthetic resin film. The batting fiber comes off from the sewing needle hole of the side fabric or the texture or stitch on the fabric surface. To prevent this, it was necessary to fill the gaps in the texture of the fabric surface, such as applying pressure heat treatment such as silling or resin coating to make the side fabric extremely dense.
In Patent Document 3, the foamed synthetic sheet is cut into a string to be used as a heat insulating material for clothing or the like. However, since it is a polyolefin-based foamed resin, the material itself has a thickness and is packed in a storage bag. There was a difficulty in compactness, such as storing in a small size.

The present invention is not based on the above-described conventionally known short fibers or foamed resin, and unlike independent short fibers or cotton-like batting materials, the fibers do not fall out or come out, and the foaming is not performed. Provide flakes (small pieces) of long-fiber nonwoven fabric with irregular wrinkles or irregular three-dimensional shapes, which are lighter than synthetic sheets and compact when packed in a small bag and compacted, and have the advantage of taking up space. The purpose is to do.
Another object of the present invention is to provide clothing, bedding, and the like in which flakes of long-fiber nonwoven fabric are filled in specific portions.

  The present invention is a flake of long-fiber nonwoven fabric having an irregular wrinkle or an irregular three-dimensional shape, and having a predetermined size.

  The “irregular wrinkles or irregular three-dimensional shapes” of long-fiber nonwoven flakes are formed by processing a flat long-fiber nonwoven so that it becomes three-dimensionally bulky in the thickness direction of the nonwoven, and cutting it. You. Further, as another manufacturing method, a flat long-fiber nonwoven fabric may be cut into a predetermined size and then processed into an irregular wrinkle or an irregular three-dimensional shape. Details will be described later.

  The thickness (t) of the flakes having irregular wrinkles or irregular three-dimensional shapes is 0.01 mm to 1.0 mm. For reasons of bulkiness, the thickness is preferably 0.02 mm to 0.5 mm, more preferably 0.02 mm to 0.3 mm, and even more preferably 0.05 mm to 0.2 mm or 0.05 mm to 0.15 mm. In the present invention, unless otherwise specified, the lower limit to the upper limit of the numerical value range means the upper limit to the lower limit or more including the value.

Basis weight of flakes having an irregular wrinkles or irregular three-dimensional shape ^is a ^{15g / m 2 ~300g / m 2} , preferably less than ^{15g / m 2 ~250g / m 2} , more preferably 15 g / m ² is a to 100 g / ^m less than ² or less than ^{15g / m 2 ~50g / m 2} . In the present invention, the method of measuring the basis weight measures the basis weight of flakes having irregular wrinkles or irregular three-dimensional shapes.
Placing a long-fiber nonwoven fabric or flake having an irregular wrinkle or irregular three-dimensional shape on a flat surface, and calculating an area when the long-fiber nonwoven fabric or flake having an irregular wrinkle or irregular three-dimensional shape is viewed in plan, Obtained by dividing the flake weight by the area.

  The long fibers of the flakes having irregular wrinkles or irregular three-dimensional shapes preferably have a fiber thickness (diameter) of 1 μm to 100 μm, more preferably 2 μm or more and less than 10 μm, and further preferably 2 μm or more and less than 8 μm. The fiber thickness before processing for forming an irregular wrinkle or an irregular three-dimensional shape and the fiber thickness after the processing may be the same or substantially the same, and the fiber thickness may be different.

The flakes (f) having irregular wrinkles or irregular three-dimensional shapes are all sized to fit in a virtual cuboid (VP) (see FIG. 2D). The virtual rectangular parallelepiped (VP) has a first side (for example, vertical) and a second side (for example, horizontal) of the main surface, each of which is 10 mm to 500 mm, preferably 40 mm to 400 mm, more preferably 40 mm to 300 mm, and a specific portion such as clothing. Preferably, the smaller the filling space size, the smaller the flake size. The height is 10 mm or more and 100 mm or less, preferably 10 mm or more and 80 mm or less.
The length of the first side of the main surface is in the range of 40% to 160%, preferably 50% to 150% of the length of the second side.
In the present invention, the “flakes of a long-fiber nonwoven fabric of a predetermined size” may, for example, define the flakes in a virtual rectangular parallelepiped size.

(Production method)
The first method for producing flakes comprises a three-dimensional processing step (A) of forming an irregular wrinkle or an irregular three-dimensional shape on a sheet-shaped long-fiber nonwoven fabric, and forming an irregular wrinkle or an irregular three-dimensional shape. (A) for cutting the long-fiber nonwoven fabric into a predetermined shape and a predetermined size. The first method may further include a re-stereo-processing step of forming an irregular wrinkle or an irregular three-dimensional shape on the cut flakes of the long-fiber nonwoven fabric again.
A second method as another method includes a cutting step (B) of cutting a sheet-like long-fiber nonwoven fabric into a predetermined shape and a predetermined size, and an irregular wrinkle on the cut flakes (small pieces) of the long-fiber nonwoven fabric. Or a three-dimensional processing step (B) for forming an irregular three-dimensional shape.

The “three-dimensional processing step (A)” or “three-dimensional processing step (B)” includes, for example, a step of packing a sheet-like long-fiber nonwoven fabric or flakes in a bag and applying wet heat. Thereby, an irregular wrinkle or an irregular three-dimensional shape is formed in the sheet-shaped long-fiber nonwoven fabric or flake. In order to form irregular wrinkles or irregular three-dimensional shapes, the long-fiber nonwoven fabric or flakes on which they are not formed are randomly (in other words, in a state where they are not folded randomly, randomly, irregularly, Etc.) It is preferable that the bag is packed into the bag. This is because, when folded neatly and packed into a bag, irregular wrinkles or irregular three-dimensional shapes are hardly formed. As the state where the long fiber nonwoven fabric is packed in the bag, the volume ratio of the gap space to the volume of the long fiber nonwoven fabric in the inner volume of the bag is preferably 50:50 to 20:80.
"Re-sterilization" may include a step of packing flakes in a bag and applying moist heat, as described above. In this case, it is preferable that the flakes be randomly packed into the bag body.

The “cutting step (A)” can be adopted, for example, by any of a cutting method such as laser cutting, pull-cutting with a blade, push-cutting, and punching. In the cutting step (A), cutting a long-fiber nonwoven fabric having irregular wrinkles or irregular three-dimensional shapes formed in a flat state (wrinkles or three-dimensional shapes are extended), for example, at least one sheet It is preferable to cut the long-fiber nonwoven fabric in a state where the long-fiber nonwoven fabric does not overlap in the vertical direction with respect to the cut surface. However, the present invention is not limited to this, and the cutting may be performed without wrinkles or the like being stretched.
When the flakes are recovered in a state where wrinkles or the like are stretched, the shape of the cut flakes (<the area of the virtual rectangular frame) becomes smaller than the cutting area (for example, the cutting area of the punching blade) after the shape of the flakes is recovered. The flake area (<the area of the virtual rectangular frame) may be 0.7 to 0.99 times, preferably 0.75 to 0.95 times the cutting area (for example, the cutting area of the punching blade). .
When a wrinkle or the like is cut without being stretched, the cut flake area (<the area of the virtual rectangular frame) is equal to or substantially equal to the cutting area (for example, the cutting area of the punching blade) (for example, the flake area (<the virtual rectangular frame). May be 0.95 times to 1.05 times the cutting area (for example, the cutting area of the punching blade).
Examples of the shape of the punching blade include a rectangle such as a rhombus, a parallelogram, a square, and a rectangle, a polygon, a circle, an ellipse, and an irregular shape. For example, the size of a diamond is represented by two diagonal lines, and the area of the diamond is diagonal line × diagonal line ÷ 2. The size of the parallelogram is represented by the base and height, and the area of the parallelogram is base × height.
In the “cutting step (A)”, the sheet-shaped long-fiber nonwoven fabric may be cut in a state where one or a plurality of sheets are stacked.
In the present invention, the “flakes of long-fiber nonwoven fabric of a predetermined size” may, for example, define the size of the flakes by the cut flake area.

The shape of the flakes of the long-fiber nonwoven fabric having an irregular wrinkle or an irregular three-dimensional shape is, for example, a rhombus shape, a square shape, a triangular shape, a round shape, a cloud shape, or a random shape.
In the "cutting (A)", punching by a press in a state where a plurality of sheets are stacked is preferable from the viewpoint of cutting workability and yield. When a long-fiber nonwoven fabric with irregular wrinkles or irregular three-dimensional shapes is not cut while the wrinkles or three-dimensional shapes are stretched, the shape of the cut end (cut surface) of the flakes (small pieces) may be wrinkles, etc. Since they are formed, they may be jagged.
In the "cutting (B)", punching with a press in a state where a plurality of sheet-shaped long-fiber nonwoven fabrics are stacked is preferable from the viewpoint of cutting workability and yield. The shape of the flake after cutting is, for example, a diamond shape, a square shape, a triangular shape, a round shape, a cloud shape, and a random shape. Here, the “rhombic shape” includes not a perfect rhombus but a shape whose overall appearance looks like a rhombus. The other "-" has the same meaning.

The thickness (t) of the sheet-shaped long-fiber nonwoven fabric or flake before the three-dimensional processing is preferably the same or substantially the same before and after the three-dimensional processing. The thickness (t) is, for example, 0.01 mm to 1.0 mm. For reasons of bulkiness, the thickness is preferably 0.02 mm to 0.5 mm, more preferably 0.02 mm to 0.3 mm, and even more preferably 0.05 mm to 0.2 mm or 0.05 mm to 0.15 mm.
Sheet of long-fiber nonwoven fabric or flakes basis weight before solid processing ^{is 5g / m 2 ~60g / m 2} , preferably less than ^{5g / m 2 ~20g / m 2} , more preferably 6 g / m2 and 10 g / m ² . The smaller the basis weight, the weaker the shape retention after processing, and the larger the basis weight, the more the bulkiness is impaired.
The fiber length of the sheet-shaped long-fiber nonwoven fabric before the three-dimensional processing is, as a lower limit, 100 mm or more, preferably 150 mm or more, and more preferably 200 mm or more. The upper limit of the fiber length is 2,000 mm or less, more preferably 1,000 mm or less.
Alternatively, the average fiber length may be 100 mm or more and 500 mm or less, more preferably 150 mm or more and 500 mm or less, and even more preferably 200 mm or more and 500 mm or less.
It is preferable that the fiber length is long because the fiber waste generated from the cut cross section at the time of the cutting process can be suppressed and irregular wrinkles or irregular three-dimensional shape can be retained for a long time.
In addition to the cut surface or end surface of the flake, the number of ends of the long fibers is 200 or less, preferably 100 or less, more preferably 50 or less, and further preferably 30 or less.

The “predetermined size” of the flake after the three-dimensional processing is such that when the flake (f) is placed on a plane (see the xy plane in FIG. 2B) and viewed from above, a virtual rectangular frame (VF) (see FIG. 2C) ) May be defined as a size in which all of the flakes fit. That is, in the present invention, “flakes of long-fiber nonwoven fabric of a predetermined size” may define the flakes, for example, in the size of a virtual rectangular frame (VF).
More specifically, as shown in FIG. 2C, at least two diagonals of the maximum diagonal (L1) of the flake (f) and the next longest diagonal (L2) intersecting with the maximum diagonal are shown in the virtual rectangular frame (VF). When the condition that at least one end (or an end within 5 mm from one end) of the maximum diagonal line (L1) is in contact with the line of the virtual rectangular frame (VF), the virtual frame line (VF) f) is defined as the size. In the present invention, the size of a flake is a size in a plan view unless otherwise specified. The plan view size corresponds to the size of the main surface of the virtual rectangular parallelepiped.
The size of the flake after the three-dimensional processing (that is, the size defined by the virtual rectangular frame (VF)) is such that a pair of first sides and a pair of second sides orthogonal thereto are respectively 10 mm to 500 mm, preferably 40 mm to 400 mm, More preferably, it is 40 mm to 300 mm.
The length of the first side is in the range of 40% to 160%, preferably 50% to 150% of the length of the second side.
From the flake after the three-dimensional processing, the planar size of the flake in a state where the wrinkles or the three-dimensional shape is stretched and completely flattened is larger than the above-described planar size.
The flake area described above is smaller than the area of the virtual rectangular frame.

Further, in the flakes after the three-dimensional processing, for each predetermined size (for example, two diagonal lines in a diamond shape in a wrinkle-formed state are (1) 10 cm × 10 cm, (2) 5 cm × 12 cm, (3) 18 cm × 27 cm, ( 4) The maximum bulk height (hmax: vertical height from the plane to the top when placed on a plane) of 4 cm x 6 cm) is 100 times or more to 500 times the thickness (t) of the flake, and is preferably The ratio is from 120 to 500 times, more preferably from 150 to 500 times, particularly preferably from 200 to 500 times (see FIG. 2B).
The maximum bulk height (hmax) per 1 m ² of the long-fiber nonwoven fabric (not a flake) after the three-dimensional processing is 100 to 500 times, preferably 120 times, the thickness (t) of the long-fiber nonwoven fabric. The ratio is from 500 to 500 times, more preferably from 150 to 500 times, particularly preferably from 200 to 500 times (see FIG. 1B).
Here, the “predetermined size” is a projection area obtained by projecting the flake placed on a plane from above, and may define the size of the flake, and the “cut area of the flake” defines the size of the flake. Is also good.

Also, per predetermined size of the flakes after the three-dimensional processing (for example, two diagonal lines in a wrinkled rhombic shape are (1) 10 cm × 10 cm, (2) 5 cm × 12 cm, (3) 18 cm × 27 cm, (4 ) As the distribution of the bulk height (h) of 4 cm x 6 cm), the vertical height from the plane is 0 mm or more and less than 10 mm, 5 points (location) or more, 10 mm or more and less than 20 mm, 5 points or more, and 20 mm or more and less than 30 mm, 5 points. It is preferable that one or two or more of the configurations in which 30 mm or more and less than 40 mm are 5 points or more, 40 mm or more and less than 50 mm are 2 points or more, and 50 mm or more are 1 point or more are established.
As a method of measuring bulkiness, the flakes of the measurement sample may be placed on a plane, and the intersection of vertical and horizontal lattices (for example, at intervals of 10 mm) may be set as a point, and the vertical height of the point may be measured with a gauge or the like.
It is preferable that points (locations) having different bulks are present irregularly per predetermined size and are not repeatedly arranged at regular intervals. By not being arranged regularly, when filled in small or narrow spaces, the flakes do not gather in one place or become unevenly distributed, and the flakes can overlap or intertwine appropriately It becomes excellent in heat retention and space shape maintenance. In the case of irregularities formed by continuous embossing using a normal cylinder, only small projections and irregularities are formed on the sheet surface, and the main body (thickness) does not have a shape that is irregularly wavy.
Here, the “predetermined size” may be a “projected flake area” in which flakes placed on a plane are projected from above, and the size of the flakes may be defined. May be specified.

In the flakes of the present invention, many irregular wrinkles were formed while the thickness (t) was kept constant, instead of forming the irregularities on the fabric surface as in embossing and deforming the fabric thickness. Preferably, it is
The flakes of the present invention are characterized in that when the wrinkles are stretched, the area becomes 1.2 times or more larger than the area before the wrinkles are stretched, preferably 1.5 times or more, more preferably 2 times or more. I do.
The range of the area ratio averaged from 2 to 10 flakes is in the range of 1.2 to 2.5 times, preferably in the range of 1.5 to 2.5 times, more preferably 1.7. The range is from 2 to 2.5 times.

(Clothes and bedding filled with flakes)
The shape and size of the flakes and the number of sheets to be packed can be set based on the shape and size of the portion of the garment to be filled.
For example, when used as a batting for heat insulation such as a down jacket of a down batting, a rectangular shape, a rhombus shape, or a parallelogram shape is preferable. When cutting is performed after three-dimensional processing, in a state where wrinkles or three-dimensional shapes are stretched, the shape does not become a perfect rectangle, rhombus, or parallelogram, but does not cause any particular problem.
Also, the flakes taken out after being packed in clothes or bedding may have a wrinkled or three-dimensional shape that has changed from the state before the stuffing, but the above-described virtual rectangular parallelepiped (VP) and / or virtual rectangular frame The size may fit in (VF).
The virtual cuboid (VP) and / or virtual rectangular frame (VF) of the flake before stuffing and the virtual cuboid (VP) and / or virtual rectangular frame (VF) of the extracted flake are the same (or substantially the same) Alternatively, the extracted flakes may have a smaller main surface and a larger height direction.
The “projection flake area (or projection flake shape)” of the flakes before packing and the “projection flake area (projection flake shape)” of the extracted flakes may be different.
The flakes taken out after being packed in clothes or bedding have a bulk (h) distribution of 10 points (points) where the vertical height from the plane is 0 mm or more and less than 10 mm and 10 mm or more and less than 20 mm. At least one type, at least two types, among the configurations of 10 points or more, 20 mm or more and less than 30 mm, 5 points or more, 30 mm or more and less than 40 mm, 5 points or more, 40 mm or more but less than 50 mm, and 5 points or more, and 50 mm or more of 2 points or more , Or three or more types are preferable.
When filling (filling) into a small space or an elongated space, each of the pair of first sides and the pair of second sides of the virtual rectangular frame (VF) is 60 mm to 400 mm, preferably 60 mm to 300 mm, and more preferably. Is from 60 mm to 200 mm. As a virtual rectangular parallelepiped (VP), the length and width of the main surface are each 60 mm to 400 mm, preferably 60 mm to 300 mm, and more preferably 60 mm to 200 mm. The height is 10 mm or more and 60 mm or less.
Here, if the flake size is too small or too large, it is cut into a flake shape from a raw sheet of long-fiber nonwoven fabric having an irregular wrinkle or an irregular three-dimensional shape, and is cut into a specific portion of clothing (eg, side cloth). Since a series of workability such as filling is deteriorated, it is preferable to set the size in consideration of cutting and filling.
The number of flakes to be packed is preferably two or more than one, and may be three or more. It can be set according to the space size to be filled.

Another embodiment of the present invention is a garment having an irregular wrinkle or an irregular three-dimensional shape, and in which one or two or more flakes (small pieces) of a long-fiber nonwoven fabric of a predetermined size are filled in a specific portion.
Another aspect of the present invention is a bedding which has an irregular wrinkle or an irregular three-dimensional shape, and in which one or two or more flakes of a long-fiber nonwoven fabric of a predetermined size are filled in a specific portion.

The flakes to be filled may be flakes of different sizes or flakes obtained in the same cutting step.
In order to regulate the movement of the flakes in the filled state, the space size of the specific portion may be set according to the product specifications.
Further, in the present invention, it is preferable that the flakes filled in the specific portion are not fixed (for example, sewn) to the cloth (side cloth) for forming the space of the specific portion. The flakes are simply packed. Even in a simply packed state, it is possible to suppress unevenness after washing during use.

The “specific portion” is, for example, a small space or an elongated space, a space around a neck, a hood, a collar, or the like, a storage portion for a side cloth, and the like. The flakes of the present invention can be easily and quickly filled even in areas where feathers, cotton, strip-shaped sheets, etc. are difficult to fill.
When the specific part is cylindrical, the cross-sectional diameter is 10 mm to 60 mm, the height is 10 mm to 600 mm, and when the elliptic column is, the long radius is 10 to 60 mm, the short radius is 5 to 50 mm, the height is 10 to 600 mm, and the rectangular parallelepiped In the case of, the vertical length is 10 mm to 60 mm, the horizontal width is 5 mm to 50 mm, and the height is 10 mm to 600 mm.
The end of the specific portion may not be the above-described columnar shape, elliptical columnar shape, or rectangular parallelepiped shape, for example, due to sewing processing.
Packing density of the flakes to be filled to a particular site ^is a ^{30g / m 3 ~600g / m 3} , preferably less than ^{30g / m 3 ~500g / m 3} , more preferably ^30g / m 3 ^~200g / m ^3, or less than ^{30 g} / m 3 is less than to 100 g / ^{m 3.}

Another aspect of the present invention is a garment having an irregular wrinkle or an irregular three-dimensional shape, and entirely filled with flakes (small pieces) of a long-fiber nonwoven fabric of a predetermined size.
Another aspect of the present invention is a bedding having an irregular wrinkle or an irregular three-dimensional shape, and entirely filled with flakes (small pieces) of a predetermined-sized long-fiber nonwoven fabric.
The phrase “entirely filled” means that in a garment having one or more filling portions having a space in which flakes can be filled, all the filling portions are filled with flakes, preferably 80%. It means that the flakes are filled in the above number of filling portions. The filling site may be filled with dough (any shape) other than the flakes of the present invention. Fabrics other than flakes may include long-fiber nonwoven fabric, feathers, cotton, and the like.
The filling site where the flakes are filled may have a partition (sewing process) for regulating the movement of the flakes.
Preferably, the flakes in the filling site are not fixed with the dough that makes up the filling site.
Packing density of the flakes to be entirely ^filled, a ^{30g / m 3 ~600g / m 3} , preferably less than ^{30g / m 3 ~500g / m 3} , more preferably ^30g / m 3 ^~200g / m ^3, or less than ^{30 g} / m 3 is less than to 100 g / ^{m 3.}

In one embodiment of the invention, the long fibers constituting the long-fiber nonwoven fabric and the flakes are one or more of polyester, nylon, polypropylene, vinylon, aramid, acryl, rayon, polyethylene, polyurethane and silk. It is a kind of long fiber or more. Polyester is preferred because of its formation of irregular wrinkles or irregular three-dimensional shapes, long-term shape retention, and shape recovery after shape deformation.
Examples of the polyester include a core-sheath yarn of a polyester (PET) and a modified PET whose melting point is changed by, for example, isophthalic acid.

Further, the garment or bedding of another invention is characterized in that the flakes of the long-fiber nonwoven fabric to be filled in a specific portion and the irregular wrinkles or And a long-fiber nonwoven fabric having an irregular three-dimensional shape.
A long-fiber nonwoven fabric having the irregular wrinkles or irregular three-dimensional shapes formed between a first fabric (front fabric) and a second fabric (back fabric); The long fiber nonwoven flakes are provided in a small space or an elongated space in the fabric. Thereby, the flakes of the long-fiber nonwoven fabric can be filled in a small space or an elongate space that cannot be filled by the large-sized irregular wrinkles or the long-fiber nonwoven fabric having an irregular three-dimensional shape, and the heat insulation in the small space or the elongate space can be achieved. Properties and heat retention can also be improved. The first and second fabrics and the other fabrics are fabrics other than the long-fiber nonwoven fabric.
The flakes of the present invention are filled in specific parts of clothing (or part of clothing) and bedding (or part of bedding) made of long-fiber nonwoven fabric without irregular wrinkles or irregular three-dimensional shapes. May be done.

The clothing is not particularly limited, and examples thereof include a vest type, a short sleeve type, a long sleeve type, a short pants type, a long pants type, a coverall type, a hat, gloves, socks, a balaclava, a shawl, a waistband, and a muffler.
The bedding is not particularly limited, and examples thereof include a sleeping bag, a comforter, a mattress, a pillow, a cushion, and a blanket.

  In the flakes of the above invention, the long fibers before the non-woven fabric processing, the long fiber non-woven fabric before the processing, the long fiber non-woven fabric after the processing, and the flakes are subjected to various processings (for example, moisture permeable waterproof processing, water repellent processing, rebound processing, Antibacterial and deodorant processing, water absorption processing, flame retarding processing, etc.) may be appropriately performed.

In the above invention, the side cloth filled with flakes and / or the long-fiber nonwoven fabric (having a size larger than the flakes) on which irregular wrinkles or irregular three-dimensional shapes are formed are formed into an inner layer (single layer or two or more layers). The first and second fabrics (when the large-sized long-fiber nonwoven fabric is used as the inner layer, the first and second fabrics constitute the outer layers on the front and back sides) of the first and second fabrics to be stored as a good material are particularly limited in thread material and sewing method. Not done.
Further, the inner layer long-fiber nonwoven fabric and the first and second fabrics are appropriately subjected to various processings (for example, moisture permeable waterproof processing, water repellent processing, rebound processing, antibacterial deodorization processing, water absorption processing, flame retardant processing, etc.). May be.
The first and second fabrics (first and second outer layers) may be the same fabric or different fabrics.
The first and second fabrics are, for example, a knitting structure, a woven structure, a nonwoven fabric, and a film. The first and second fabrics may have a single-layer structure or a multi-layer structure, but a single layer is more preferable from the viewpoint of lightness. The first and second fabrics may be, for example, synthetic fibers such as polyester and nylon, or natural fibers. The first and second fabrics may be composed of one type of fiber, or may be composed of a combination of a plurality of types of fibers. In addition, the above-described various kinds of processing may be applied to the original yarns (fibers) of the first and second fabrics.

  In addition, the cloth of the inner layer is disposed between the first outer layer and the second outer layer (the first cloth and the second cloth), but it is not necessary to be disposed between the first cloth and the second cloth. The inner layer is omitted according to clothing (shape of clothing, shape of clothing, necessity of parts, purpose) and bedding (shape of bedding, shape of bedding parts, necessity of parts, purpose). In some cases, another cloth (or member) exists only between the outer layer and the second outer layer, or between the first outer layer and the second outer layer. For example, a rubber material or a fastener that can be freely opened and closed may be provided for fitting or tightening. Fasteners include, for example, regular buttons, point fasteners (e.g., snap buttons), line fasteners (e.g., zippers, chucks) or hook-and-loop fasteners (e.g., Velcro®), which may be used alone. Alternatively, two or more kinds can be used in appropriate combination. Further, the clothing may be provided with a pocket.

  Further, in the above invention, a long-fiber nonwoven fabric having a different three-dimensional shape (or having different bulk wrinkles) may be used depending on a specific portion (part) of clothing or bedding. Examples of the shape of the irregular wrinkle or the irregular three-dimensional shape include a wavy shape, an uneven shape, a grain shape, and a pleated shape.

  Further, as one embodiment of the present invention, the sheet-shaped long-fiber nonwoven fabrics laminated as the inner layer may be sewed to each other at a predetermined interval, and further, the sheet-shaped long-fiber nonwoven fabric on the first fabric side may be used. The first fabric may be partially sewn, and the long-fiber nonwoven fabric on the second fabric side may be partially sewn with the second fabric.

(Sheet-shaped long-fiber nonwoven fabric used as a raw material)
Sheet-shaped long-fiber nonwoven fabric (raw sheet) can be obtained by a wet method (eg, water punch method), a dry method (eg, tow opening method, burst fiber method), a spun bond method (eg, chemical bond method, thermal bond method). Method, needle punch method), melt blow method or cross lamination bonding. From the viewpoint of forming and maintaining a wrinkle shape, a spun bond method, a melt blow method, or a method of manufacturing an orthogonal lamination bond is preferable. As shown in FIG. 1B, the orthogonally laminated nonwoven fabric manufactured by orthogonally laminated bonding has an integrated structure in which aligned warp yarns 1 and aligned weft yarns 2 overlap. This means that the thickness can be reduced and the surface is smooth. Therefore, the orthogonally laminated nonwoven fabric can be made thinner, has dimensional stability, and has a higher tensile strength than a nonwoven fabric produced by a spunbond method. For example, the basis weight is 5 g / m ^{2 to} 60 g / m ² and the thickness is 50 μm to 130 μm. The tensile strength is 25 to 300 [N / 50 mm] in the vertical direction and 10 to 90 [N / 50 mm] in the horizontal direction. Further, as a manufacturing method of the orthogonal lamination bonding, a manufacturing method disclosed in JP-A-2003-213560 is cited as an example.

  The long fibers of the sheet-like long-fiber nonwoven fabric (raw sheet) preferably have a fiber thickness (diameter) of 1 μm to 100 μm, more preferably 2 μm to 50 μm, and still more preferably 5 μm to 30 μm. It is preferable that the fiber thickness of the long fiber is maintained after the processing.

The typical feather as a warming batting material can be freely filled into the space covered with the side cloth, and has the advantage of being very lightweight compared to the bulkiness, but because it is very fine and detailed, the side cloth is Get out of the gap of the weave. In order to prevent this, it was necessary to fill the gaps in the texture on the fabric surface, such as pressurizing heat treatment such as sire processing and resin coating on the side fabric. By filling the gaps in the weave, feathers can be prevented from coming off, but the air permeability of the side fabric is lost, and it is easy to cause stuffiness in clothes or futons. Was. Conventional chemical and natural fibers also have a problem in that the fibers may fall out of the weave as well as the feathers, although the degree of the fineness of the fibers may vary. On the other hand, the flakes of the present invention can be freely filled into the space covered with the side fabric like the feathers, but since the cotton does not come off, it is necessary to fill the gaps in the texture of the side fabric. Therefore, it is possible to use woven fabrics, knitted fabrics, non-woven fabrics, etc. that have a large gap in the side lining, regardless of the type of the lining. It becomes a difficult product.
In addition, a large-sized sheet-shaped long-fiber nonwoven fabric has been developed as a heat-retaining batting material that can use a breathable side fabric. Due to its large size, it is difficult to fill small or elongated spaces. On the other hand, the flakes of the present invention can be freely filled in a small space or an elongated space covered with the side fabric.
In addition, there is a problem that feathers come off through needle holes for sewing the side fabric, similarly to the case where feathers come off from gaps in the texture of the fabric. For this reason, sewing must be performed with great care such as sewing threads for feather products, needle holes, and stitch pitch, and the above problem has not been fundamentally solved. Since the flakes of the present invention do not cause such detachment, there is no need to take measures against feathers, and sewing is easy and detachment does not occur.
In the case of feathers, there is an advantage that a lightweight, bulky, highly heat-retaining and light-weight product can be manufactured, and if the product is packed in a small bag or the like and compressed, the product becomes compact and takes up little space. Even in the case of the flake of the present invention, lightness, bulkiness, and compactness are realized, and there are advantages similar to feathers.
In addition, when the feathers get wet with water, they lose their bulk and lose heat retention. In addition, there is a problem in that when it gets wet, it dries slowly, and even if it dries, its original bulkiness is difficult to recover. On the other hand, the flake of the present invention uses a long-fiber nonwoven fabric as a raw material, does not lose its bulk even when wet, dries quickly, and recovers its original bulk when dried.
Polyester cotton becomes heavy in order to obtain the same bulkiness as feathers. Moreover, the compactness at the time of storage is inferior to feathers. On the other hand, the flake of the present invention is a long-fiber nonwoven fabric using the same polyester raw material, but is much superior to conventional polyester cotton in bulkiness and compactness in storage, like feathers.
In addition, the flakes of the present invention, which can use a highly breathable side fabric, are easier to dry than feathers or cotton (cotton) heat-insulating clothes or futons using low-breathable side fabrics. The subsequent drying time is short.
Moreover, since it is a non-woven fabric, it is difficult for dust to come out, and there is no allergy caused by it.
In addition, it is resistant to mites, molds and insects, and there is no allergy caused by them.
In addition, by using the same material as the side fabric (the side to be filled), complete recycling is possible.

It is a figure showing an example of a sheet-like long fiber nonwoven fabric (raw material). It is a figure for explaining an orthogonal lamination nonwoven fabric. 1 shows a plan view of an example of a long-fiber nonwoven fabric on which irregular wrinkles are formed. It is a figure which shows an example of the bulkiness on the XY plane of the long-fiber nonwoven fabric in which the irregular wrinkle was formed. It is a figure which shows an example of the cutting process of the long fiber nonwoven fabric in which the irregular wrinkle was formed. It is a figure which shows an example of the bulkiness on the xy plane of a flake. It is a figure which shows an example of the virtual rectangular frame which prescribes the planar view size of a flake. It is a figure which shows an example of the virtual rectangular parallelepiped which prescribes the solid size of a flake.

Hereinafter, the present embodiment will be described with reference to the drawings, but is not limited to the following embodiment.
As shown in FIG. 1A, a long long-fiber nonwoven fabric 10 is pulled out from a long-fiber nonwoven fabric (raw material) roll R1, cut by a cutting means 35 in a width direction orthogonal to the longitudinal direction, and cut into a sheet-shaped long-fiber nonwoven fabric 11 of a predetermined size. Get. FIG. 1B shows that the long-fiber nonwoven fabric is an orthogonal laminated nonwoven fabric.

As the orthogonal laminated nonwoven fabric, for example, a core-sheath structured yarn composed of PET and modified PET, a sheet 1 arranged in a longitudinal direction and a sheet 2 arranged in a lateral direction are overlapped, and heat treatment is applied to melt a low melting point sheath portion, This is a nonwoven fabric in which intersections of longitudinally arranged fibers and laterally arranged fibers are fused and integrated. It should be noted that this structure is a one-layer structure in which the warp 1 and the weft 2 are integrated, and is distinguished from a multilayer nonwoven structure.
The long fiber (core-sheath structure yarn) used as the material of the orthogonal laminated nonwoven fabric has a thickness of 10 μm and an average length of the long fiber of 200 mm. Long fibers are different from short fiber filaments.

(Flake production method)
The method of forming an irregular wrinkle or an irregular three-dimensional shape is as follows.
By packing the sheet-shaped long-fiber nonwoven fabric 11 into a bag and applying wet heat (hot water, steam, or the like of 60 ° or more), the long-fiber nonwoven fabric 11 is formed with an irregular wrinkle or an irregular three-dimensional shape. It is preferable that the long-fiber nonwoven fabric 11 be randomly packed into the bag. The time for applying the moist heat is preferably, for example, 10 minutes or more. After the application of moist heat, the long-fiber nonwoven fabric is taken out of the bag and dried with hot air at 40 ° C. FIG. 1C shows a plan view of an example of the long-fiber nonwoven fabric 111 in which an irregular wrinkle or an irregular three-dimensional shape is formed after drying.

FIG. 1D shows an example of bulkiness on the XY plane of the long-fiber nonwoven fabric 111 on which irregular wrinkles are formed. The long fiber nonwoven fabric 111 is placed on the XY plane. The XY plane is a lattice having intersections of X coordinates 0 to 6 and Y coordinates 0 to 5. FIG. 1D is a graph showing, as an example of the bulk height h, a cross-sectional view of the long-fiber nonwoven fabric 111 at each position where X is 2 to 5 and Y is 2 to 4. It turns out that many irregular wrinkles are formed in the long fiber nonwoven fabric 111.
In FIG. 1D, the maximum bulk height (hmax) of the long-fiber nonwoven fabric 111 on which irregular wrinkles are formed is 200 times the thickness (t) of the long-fiber nonwoven fabric 111. The thickness (t) of the long fiber nonwoven fabric 111 is 0.05 mm, and the maximum bulk height (hmax) is 10 mm. The thickness (t) may be an average value at a plurality of locations.

Next, as shown in FIG. 2A, with respect to the long-fiber nonwoven fabric 111 on which the irregular wrinkles are formed, the sheet-like long-fiber nonwoven fabric 111 a in a state where the wrinkles are stretched by slightly extending the wrinkles is formed. On the other hand, in a state where the same long-fiber nonwoven fabrics do not overlap with each other due to wrinkles in the vertical and vertical directions, press cutting is performed with a diamond-shaped cutting blade 36. A plurality of long-fiber nonwoven fabrics 111 on which irregular wrinkles are formed may be pressed and cut.
In the cut flakes 120, the wrinkles stretched before cutting return, and irregular wrinkles appear.

FIG. 2B shows an example of the bulkiness of the flake 120 on the xy plane. The flakes 120 are located in the xy plane. The xy plane is a lattice having intersections of x coordinates 0 to 6 and y coordinates 0 to 5. FIG. 2B is a graph showing, as an example of the bulk height h, a cross-sectional view of the flake 120 at each position where x is 2 to 5 and y is 2 to 4. It can be seen that many irregular wrinkles are formed on the flakes 120.
In FIG. 2B, the maximum bulk (hmax) of the flake 120 on which any one of the irregular wrinkles is formed is 150 times the thickness (t) of the flake 120. The thickness (t) of the flake 120 is 0.05 mm, and the maximum bulk height (hmax) is 7.5 mm. The thickness (t) may be an average value at a plurality of locations. The flakes 120 tend to have a maximum bulk height smaller than that of the long-fiber nonwoven fabric 111 due to the cutting.

In addition, one arbitrary flake 120 has a predetermined size (for example, two diagonal lines in a rhombic shape in a wrinkled state, (1) 10 cm × 10 cm, (2) 5 cm × 12 cm, (3) 18 cm × 27 cm). , (4) the distribution of the height (h) of 4 cm × 6 cm) (the distribution of the intersection points of the xy coordinates) as the vertical height from the xy plane,
0 mm or more and less than 10 mm are 5 points or more,
10 points or more and less than 20 mm are 5 points or more,
20 mm or more and less than 30 mm are 5 points or more,
30 points or more and less than 40 mm are 3 points or more,
At least two types of conditions are satisfied under the condition of 2 points or more when 40 mm or more and less than 50 mm and 1 point or more when 50 mm or more.
All the flakes obtained by cutting one long-fiber nonwoven fabric 111 may satisfy the above relationship, or the average value of the flakes obtained by cutting a plurality of long-fiber nonwoven fabrics 111 may satisfy the above relationship.

  In the flake 120, the area where the wrinkles are stretched becomes 1.1 times to 1.5 times the area before the wrinkles are stretched, and the average area ratio is 1.3 times.

(Another embodiment)
In the above embodiment, the order in which the long-fiber nonwoven fabric 111 on which the irregular wrinkles are formed is cut into a flake shape, but after the long-fiber nonwoven fabric 11 is cut into a flake shape, the cut flakes have an irregular shape. The order in which wrinkles or irregular three-dimensional shapes are formed may be used.
In addition, the wrinkles formed in the long-fiber nonwoven fabric 111 are slightly stretched and press-cut, but the present invention is not limited thereto, and the press-cut may be performed in the state of the long-fiber nonwoven fabric 111.
In the above embodiment, the long-fiber nonwoven fabric 11 before the formation of the wrinkles is not limited to the one manufactured by the orthogonally laminated nonwoven fabric, and may be another manufacturing method exemplified above. In addition, the long fiber used as the material is not limited to the polyester having a thickness of 10 μm, and may have a thickness of 0.1 μm or more and less than 5 μm and 5 μm or more and 10 μm or less.
The above-mentioned materials other than polyester may be used.

  Further, the maximum bulk height (hmax) of the flake 120 may be 50 times or more, preferably 100 times or more, more preferably 150 times or more of its thickness (t).

  The method for forming irregular wrinkles or irregular three-dimensional shapes is not limited to packing long-fiber non-woven fabric in a bag and applying moist heat (for example, hot water or steam having a temperature of 60 ° or more). A pressure higher than the atmospheric pressure may be applied. The time for applying the moist heat is not limited to 10 minutes and is exemplified by 10 minutes to 24 hours. The long-fiber nonwoven fabric taken out of the bag body after applying the moist heat is not limited to drying with hot air of 40 ° C, and naturally at a temperature in the range of 30 ° to 150 ° or room temperature in the range of 18 ° to 28 °. It may be dried. Alternatively, other methods such as a method of forming wrinkles by feeding a long-fiber nonwoven fabric to a roller that has given heat of 90 or more so as to be faster than the rotation speed of the roller so as to be in contact with the roller may be used. Good.

  The step of cutting the long-fiber nonwoven fabric 111 (111a) on which the irregular wrinkles are formed is not limited to the above-described press cutting, and may be, for example, any of a laser cutting method, a cutting method using a cutter, and a cutting method using a cutting die. . The cutting may be performed in a state where one or more long-fiber nonwoven fabrics 111 (or 111a) are stacked.

(Example)
The raw sheet-shaped long fiber nonwoven fabric is an orthogonally laminated nonwoven fabric. As an orthogonal laminated nonwoven fabric, a core-sheath structure yarn composed of PET and modified PET is superposed on a vertically arranged sheet and a horizontally arranged sheet, and heat treatment is applied to melt the low-melting sheath portion, thereby forming a vertically arranged fiber. And an integrated long-fiber nonwoven fabric in which the intersections of the fibers arranged in the horizontal direction were fused.
The thickness of the long fiber of the orthogonally laminated nonwoven fabric is about 10 μm.
The thickness of the orthogonally laminated nonwoven fabric is about 50 μm. (In addition, the longitudinally arranged fibers are not necessarily completely in contact with each other and are not necessarily arranged in parallel, and there may be an overlap. Similarly, the horizontally arranged fibers are not completely in contact with each other and are arranged in parallel. In some cases, there may be overlap, not necessarily in the area.Therefore, the area where the vertical fibers overlap may overlap with the area where the horizontal fibers overlap, and the fabric thickness is directly calculated from the fiber thickness. In some cases, the measurement was made with a digital caliper.)
The basis weight of the orthogonally laminated nonwoven fabric is about 8 g / m ² .

The raw sheet-shaped long-fiber nonwoven fabric was cut into a predetermined size, packed in a bag, and given wet heat (for example, hot water of 60 ° or more, steam, or the like). The time for applying the moist heat was 1 hour. The long-fiber nonwoven fabric taken out of the bag after applying the moist heat was dried with hot air at 40 ° C. Thereby, an irregular wrinkle or an irregular three-dimensional shape was formed in the long-fiber nonwoven fabric.
Thereafter, the long-fiber nonwoven fabric was flattened, a plurality of the nonwoven fabrics were piled, and cut into a rhombus shape with a length of 160 mm and a width of 240 mm by punching with a press machine. After cutting, the flakes were recovered in shape to obtain long fiber nonwoven flakes having irregular wrinkles or irregular three-dimensional shapes.

Irregular wrinkles or irregular distribution of the bulkiness per 1 m ² of the three-dimensional shape is a long fiber nonwoven fabric which is formed, the vertical height 30mm less than 5 points or more 20 mm, 40 mm less than five points more than 30mm from the plane, Three points were 40 mm or more and less than 50 mm, and one point was 50 mm or more.
The average distribution of the bulk of flakes (n = 10) on which irregular wrinkles or irregular three-dimensional shapes are formed is 6 points when the vertical height from the plane is 10 mm or more and less than 20 mm, and 4 points when the vertical height from the plane is 20 mm or more and less than 30 mm. , 30 mm or more and less than 40 mm was 1 point.
The measurement sample was placed on a plane, and the intersection of the vertical and horizontal lattices (for example, at intervals of 10 mm) was taken as a point, and the vertical height of that point was measured with a gauge.

(Evaluation of bulkiness stability)
1. Test equipment washing net (40cm x 50cm square size)
Washing machine (Multi-washer AK-M60 Aluminums Co., Ltd.)
Laundry detergent (Ultra Attack Neo Kao Corporation)
1. 1cm square gridded sheet Test sample Sheet-shaped long-fiber nonwoven fabric (three-dimensional finished) (cut into 50 cm x 50 cm squares)
Flake 1 (size: 180 mm x 270 mm diamond shape (meaning it is not a perfect diamond shape)
Flake 2 (size: 40 mm x 60 mm diamond shape (meaning it is not a perfect diamond shape)
3. Bulk height measuring method (1) A test sample is placed flat on a 1 cm square grid-inserted sheet.
(2) With the intersection of the vertical and horizontal grids (1 cm intervals) as a point, the vertical height at that point is measured with a gauge.
Before the test described later, 20 places of the sheet-shaped long-fiber nonwoven fabric are randomly selected and marked, and then the vertical height of each is measured. In order to evaluate flake 1 and flake 2 at N = 10, respectively, two places are randomly selected from N = 1, marked, and then the vertical height is measured at N = 10 (total 20). Location).
4. Washing test (1) Each test sample is sealed in a washing net.
(2) 5 L of tap water (normal temperature) is put into a washing machine, and a laundry detergent is put to a recommended concentration.
(3) Washing conditions are such that a “standard stirring” and “rinsing for 15 minutes and then rinsing for 5 minutes” courses are performed four times in succession.
(4) Drying is carried out at room temperature and flat.
(5) The bulkiness of each test sample is measured according to the "bulk height measuring method".
5. Immersion test and load recovery test (1) Each test sample is immersed in water at room temperature for 30 minutes.
(2) Dry each test sample at room temperature and flat.
(3) The bulkiness of each test sample is measured according to the “bulk height measurement method”. (Immersion test)
(4) A load is applied to the test sample at a constant weight (3 kg), and the test sample is left for 2 hours.
(5) Leave each test sample for 30 minutes.
(6) The bulkiness of each test sample is measured according to the "bulk height measuring method". (Load recovery test after immersion)

The above evaluation results were as follows.
1. Evaluation of Washing Test Based on the above washing test, the average value of the bulk (mm) of each test sample before and after washing (after drying) was compared. The sheet-like long-fiber nonwoven fabric had an average bulk value of 15.55 mm before washing and 8.45 mm after washing four times, a decrease of about 54%. On the other hand, the average value of bulkiness of flake 1 (180 mm × 270 mm) was 21.55 mm before washing, and 18.4 mm after washing four times, a decrease of about 15%. Flake 2 (40 mm x 60 mm) had an average value of bulkiness of 13.9 mm before washing and 14.45 mm after washing four times, an increase of about 4%.
In the distribution of the total number of measurement points where the bulk height (h) is 0 mm or more and less than 10 mm, the vertical height from a plane is 10 mm or more and less than 20 mm, 20 mm or more and less than 30 mm, and 30 mm or more, the sheet-shaped long-fiber nonwoven fabric is better. The variation in bulk distribution to lower values after washing than before flakes was significantly greater than for flakes.
From this result, it was confirmed that the flakes having a small area had higher form stability and recoverability of the bulkiness in the washing test than the flakes having a larger area or sheet-like flakes.

2. Evaluation of immersion test Based on the immersion test, the average value of the bulk (mm) of each test sample before and after immersion was compared. The sheet-shaped long-fiber nonwoven fabric had an average value of bulkiness of 16.25 mm before immersion and 16.45 mm after immersion and drying, which was almost unchanged. Flake 1 (180 mm x 270 mm) had almost no change in the average bulk height, 15.2 mm before immersion and 16.85 mm after immersion and drying. Flake 2 (40 mm × 60 mm) had almost no change in the average value of bulkiness as 11.7 mm before immersion and 11.95 mm after immersion and drying.
From this result, it is confirmed that the flakes have the same form stability as the sheet-shaped long-fiber nonwoven fabric.

3. Evaluation of Post-Immersion Load Recovery Test Based on the post-immersion load recovery test, each test sample was subjected to a certain load after the immersion test, and then the morphological stability was compared. In the sheet-shaped long-fiber nonwoven fabric, the average value of the bulkiness was 16.45 mm before the load and 12.7 mm after the recovery, which was a decrease of about 22%. Flake 1 (180 mm x 270 mm) had an average value of bulkiness of 16.85 mm before load and 15.35 mm after recovery, a decrease of about 9%. Flake 2 (40 mm × 60 mm) had an average value of bulkiness of 11.95 mm before load and 11.35 mm after recovery, a decrease of about 5%.
From these results, it was confirmed that the flakes having a small area had higher morphological stability and recoverability of the bulk in the load recovery test after immersion than the flakes having a larger area or a sheet.

(Flake-filled clothing, bedding, etc.)
The clothing or bedding of the present embodiment is configured by filling the flakes 120 into a small space or an elongated space. The clothing is not particularly limited, and examples thereof include a vest type, a short sleeve type, a long sleeve type, a short pants type, a long pants type, a coverall type, a hat, gloves, socks, a balaclava, a shawl, a waistband, and a muffler. The bedding is not particularly limited, and examples thereof include a sleeping bag, a comforter, a mattress, a pillow, and a blanket.

(Example)
As a vest filled with flakes, a long-fiber nonwoven fabric 111 on which irregular wrinkles are formed is provided on the front body of the vest, and flakes 120 are filled around the neck. The flakes to be filled are filled in a moderately small size. The number of sheets to be filled is also set according to the space of the storage site.

(Insulation evaluation)
1. Test sample Sheet-shaped long-fiber nonwoven fabric (three-dimensionally processed) (cut into 30 cm x 30 cm squares)
Flake 1 (size: 180 mm x 270 mm diamond shape (meaning it is not a perfect diamond shape)
Flake 2 (size: 40 mm x 60 mm diamond shape (meaning it is not a perfect diamond shape)
2. Test method (1) The test environment temperature is kept at 20 ° C. and 65% RH.
(2) Using a KES-F7 Thermolab II testing machine (Kato Tech Co., Ltd.), set the test piece on a hot plate set at a constant temperature (environmental temperature + 10 ° C.).
(3) The amount of heat (a) dissipated through the test piece is determined.
(4) The amount of heat dissipated (b) without the test piece set is determined, and the heat retention (%) is calculated according to the following equation.
(Formula) Heat retention rate (%) = (1−a / b) × 100
(5) The difference in the heat retention rate between flake 1 and flake 2 was compared. A bag 1 of 30 cm × 30 cm and a flake 1 are filled in a bag 1 of a cushion shape, and a bag 2 of the same shape is filled with 20 g of a flake 2, and the heat retention rate is measured.
(6) The difference in the heat retention rate between the flake 2 and the sheet-shaped long-fiber nonwoven fabric was compared. 24 g of flakes 2 are filled in a cushion 3 having a size of 30 cm × 30 cm, and a bag 4 of the same shape is filled with six sheets (24 g) of sheet-like long-fiber nonwoven fabrics laminated, and the heat retention rate is measured.

以上の結果から、フレークは、シート状の長繊維不織布と同等の保温性を示すことが確認された。

From the above results, it was confirmed that the flakes exhibited heat retention equivalent to that of the sheet-shaped long-fiber nonwoven fabric.

(Evaluation of heat retention: wet conditions)
1. Test sample Sheet-shaped long-fiber nonwoven fabric (three-dimensionally processed) (cut into 30 cm x 30 cm squares)
700 fill power down ("700 fill power" means 1 ounce feathers bulging to a volume of 700 cubic inches; "down" means feathers shaped like dandelion fluff.)
2. Test Method (1) A test sample (5 g) is sufficiently immersed in water (20 ° C.) and dehydrated by a centrifugal dehydrator for 30 seconds.
(2) After the dehydrated test sample is allowed to stand for 30 minutes, the amount of heat consumed is measured using a Thermolab II tester.

消費熱量が高いほど、保温効果が低いことを意味する。よって、湿潤状態では、羽毛よりもシート状の長繊維不織布の方が、保温効果が高いことが確認された。上記表１の結果を参酌することで、羽毛よりもフレークの方が、保温効果が高いことが推察できる。

The higher the heat consumption, the lower the heat retention effect. Therefore, in the wet state, it was confirmed that the sheet-shaped long-fiber nonwoven fabric had a higher heat retaining effect than the feathers. By taking into account the results in Table 1 above, it can be inferred that flakes have a higher heat retaining effect than feathers.

REFERENCE SIGNS LIST 10 raw long-fiber nonwoven fabric 11 sheet-shaped long-fiber nonwoven fabric 111 after cutting 111 long-fiber nonwoven fabric 111 a with irregular wrinkles formed sheet-like long-fiber nonwoven fabric 120 with wrinkles extended 120 flakes of long-fiber nonwoven fabric 36 diamond Punching blade

Claims (12)

  A flake of long-fiber nonwoven fabric having an irregular wrinkle or an irregular three-dimensional shape and having a predetermined size.   The flake of long-fiber nonwoven fabric according to claim 1, wherein a maximum bulk height (hmax) per predetermined size of the flake is 100 times or more of a thickness (t) of the flake.   The flake of a long-fiber nonwoven fabric according to claim 1 or 2, wherein a thickness (t) of the flake is 0.01 mm to 1.0 mm.   Distribution of the bulk height per predetermined size of the flakes, the vertical height from the mounted plane is 0 mm or more and less than 10 mm is 5 points or more, 10 mm or more and less than 20 mm is 5 points or more, 20 mm or more and less than 30 mm is 5 points or more, 4. One or two or more of the configurations in which 30 mm or more and less than 40 mm are 3 points or more, 40 mm or more and less than 50 mm are 2 points or more, and 50 mm or more are 1 point or more are established. A flake of a long-fiber nonwoven fabric according to the above.   The flakes of a long-fiber nonwoven fabric according to any one of claims 1 to 4, wherein the long fibers constituting the flakes have a core-sheath yarn of polyester and modified PET.   The long fibers constituting the flakes are one or two or more long fibers of polyester, nylon, polypropylene, vinylon, aramid, acrylic, rayon, polyethylene, polyurethane and silk. The flakes of a long-fiber nonwoven fabric according to any one of the above items 4.   A garment in which one or more flakes of the long-fiber nonwoven fabric according to any one of claims 1 to 6 are filled in a specific site, or are entirely filled.   The garment according to claim 7, wherein the specific portion is selected from a small space or an elongated space, a neck circumference, a hood, a collar, and a storage portion for a side cloth.   When the specific portion is (1) cylindrical, the cross-sectional diameter is 10 mm to 60 mm, and the height is 10 mm to 600 mm. (2) When the specific portion is elliptical, the long radius is 10 to 60 mm, the short radius is 5 to 50 mm, and the height is 5 mm. 9. The garment according to claim 7, wherein the garment has a length of 10 mm to 60 mm, a width of 5 mm to 50 mm, and a height of 10 mm to 600 mm in the case of (3) a rectangular parallelepiped. In a state of being filled in the specific site, the packing density of the ^flakes, a ^{30g / m 3 ~600g / m 3} , garment according to any one of claims 7-9.   7. Bedding in which one or two or more flakes of the long-fiber nonwoven fabric according to any one of claims 1 to 6 are filled in a specific site, or are completely filled. In a state of being filled in the specific site, the packing density of the ^flakes, a ^{30g / m 3 ~600g / m 3} , bedding according to claim 11.

Images