JP2022129530A - Wadding and fiber product including the same - Google Patents

Abstract

To provide wadding excellent in heat insulation and comfort and excellent in handleability and long-term performance because of integration property as a blank.SOLUTION: This wadding comprises: a composite layer; and a synthetic fiber cotton layer. The composite layer has a fiber layer including a first synthetic fiber, and a porous material containing organic fiber layer including the first synthetic fiber and a porous material. The synthetic fiber cotton layer includes a second synthetic fiber. The first synthetic fiber is a hollow fiber. The fiber layer and the composite layer in the composite layer at least partially come into contact with each other. The ratio (X/Y) of the thickness X of the fiber layer to the thickness Y of the porous material containing organic fiber layer is 0.05-0.20.SELECTED DRAWING: None

Description

TECHNICAL FIELD The present invention relates to a batting that achieves both heat retention, comfort and handleability, and a textile product containing the same.

BACKGROUND ART Filling used for heat-retaining clothing, bedding such as comforters, sleeping bags, and the like needs to achieve both heat-retaining properties and comfort sensed from touch and the like. For example, down, which is a representative material for filling used in heat-retaining clothing, is bulky, lightweight, and has moderate breathability. . In addition, it has excellent comfort due to deformation recovery and deformation followability due to the movement of each down ball that constitutes the feathers.

Feathers, which are generally used as heat-retaining materials, are composed mostly of down with a small percentage of feathers, and the form is an aggregate of individual down balls. Since it is not integrated as a filling, it is inferior in handleability, and performance such as heat retention and comfort deteriorates in places where the filling amount of feathers has decreased due to movement during use. When feathers are used as a material for clothing or the like, a bag-like structure is made using the side material, and the feathers are blown into the interior of the structure and confined. However, since the feathers can move inside the bag-like structure, the performance is also degraded. Also, product design such as design is restricted. Furthermore, since feathers are natural materials derived from organisms, there is also the issue of supply stability.

Therefore, there is a demand for a batting that has the heat retention and comfort of feathers and also has excellent handleability and supply stability, which are problems of feathers. In recent years, batting using synthetic fibers (hereinafter sometimes referred to as "synthetic fiber cotton") has been studied because of its excellent supply stability.

For example, one layer is a soft layer, and the other layer is a hard layer containing fibers thicker than the fibers that make up the soft layer. We propose insulation for cold weather clothing in which at least two layers with different fiber fineness are directly laminated. (See Patent Document 1, for example).

In addition, a heat and cold insulation material including two resin layers and a resin mass containing a heat buffering substance disposed between the resin layers, and a heat and cold insulation material in which a fiber base material is laminated on this material There have been proposed elastic fabrics and clothing containing these materials or fabrics (see, for example, Patent Document 2).

Furthermore, a non-porous film having a thickness of 5 to 30 microns, having moisture permeability, waterproofness, and stretchability, the main component of which is a polyurethane polymer, and a web having a basis weight of at least 40 g/m ² , A moisture-permeable and waterproof batting has been proposed that is intermittently adhered and has an overall moisture permeability of 3000 g/m ² ·24 hours or more (see, for example, Patent Document 3).

As another technique, an insert cotton is proposed in which hollow bodies are contained in a nonwoven fabric containing fibers having spiral crimps (see, for example, Patent Document 4).

JP 2013-136858 A Japanese Patent Application Laid-Open No. 2004-155113 JP-A-1-121084 JP-A-10-165670

However, the filling disclosed in Patent Document 1 uses fibrous materials for both the hard layer and the soft layer, and even if the breathability is suppressed by the binder resin, the dead air retention is poor, so the heat retention is poor. rice field.

In addition, the heat insulating material disclosed in Patent Document 2 has a thin material thickness and is inferior in heat retaining properties due to dead air in the filling.

The batting disclosed in Patent Document 3 is also not sufficient to exhibit heat retention because it is the web portion made of synthetic fibers that exhibits heat retention.

Patent Literatures 1 to 3 disclose techniques for preliminarily laminating and integrating a plurality of synthetic fibers in order to improve handleability, which is a problem with feathers. However, in mechanical entanglement and integration such as needle punching and water jet punching, the pores for retaining dead air are easily crushed, resulting in a decrease in heat retention. On the other hand, as in the technique disclosed in Patent Document 2, when the surface is smooth, adhesion with a binder or the like is required, which increases the weight of the batting. In addition, the binder may enter the pores for retaining dead air, causing the pores to collapse and the heat retention to decrease. Furthermore, it may be difficult to dry after washing.

On the other hand, the padding disclosed in Patent Document 4 is made of a single material of a hollow body that contributes to heat retention and a non-woven fabric that has excellent texture leading to comfort. Fibers with spiral crimps used for holding hollow bodies are used, and fibers with spiral crimps have a large number of crimps, so it is difficult to increase bulkiness, and dead air is retained. Since there were few voids, the heat-retaining property was inferior. Moreover, there also existed the subject that comfort was easy to fall.

The present invention has been made in view of the above, and an object of the present invention is to provide a filling that is excellent in supply stability, comfort, and heat retention, and a textile product containing the same. Another object of the present invention is to provide an inner cotton pad and a textile product including the same, which maintains heat retention and comfort and is excellent in handleability due to its sense of unity as a material.

In order to solve the above problems, the present invention has the following configurations.
(1) A batting having a composite layer and a synthetic fiber layer, wherein the composite layer is a fiber layer containing a first synthetic fiber and a porous body-containing fiber containing the first synthetic fiber and a porous body wherein the synthetic fiber layer contains second synthetic fibers, the first synthetic fibers are hollow fibers, and at least one of the fiber layer and the porous body-containing fiber layer in the composite layer is a padding in which the ratio (X/Y) of the thickness X of the fiber layer to the thickness Y of the porous body-containing fiber layer is 0.05 to 0.20.
(2) The batting according to (1), wherein the composite layer has a thickness of 5 to 30 mm.
(3) The batting according to (1) or (2), wherein the single filament fineness of the first synthetic fibers is 5 to 20 dtex.
(4) The batting according to any one of (1) to (3), wherein the porous body has an average pore size of 50 to 300 μm.
(5) The batting according to any one of (1) to (4), wherein the composite layer has an apparent density of 0.010 g/cm ³ or less.
(6) The filling according to any one of (1) to (5), wherein the synthetic fiber layer has an apparent density of 0.010 g/cm ³ or less.
(7) The filling according to any one of (1) to (6), wherein the filling is sheet-like.
(8) A textile product containing at least a part of the filling according to any one of (1) to (7).

The batting of the present invention has excellent heat retention and comfort due to softness and the like, and also has excellent handleability. Due to such characteristics, it can be suitably used for various textile products, for example, general clothing such as jackets, pants, cold weather clothing, and sports clothing, and clothing materials such as cushions, futons, sleeping bags, and the like.

FIG. 1 is a schematic diagram showing an example of the batting of the present invention. FIG. 2 is a schematic diagram showing an observation method for determining the thickness of the fiber layer and the porous body-containing fiber layer in the composite layer of the present invention. FIG. 3 is a schematic diagram showing lines used when determining the thickness of the fiber layer and the porous body-containing fiber layer in the composite layer of the present invention. FIG. 4 is a schematic diagram showing an example of the thickness of the fiber layer and the porous body-containing fiber layer and the thickness of the composite layer in the composite layer of the present invention.

The batting of the present invention will be described in detail below.

The batting of the present invention has a composite layer and a synthetic cotton layer. From the point of handleability, the shape is preferably sheet-like. The composite layer of the present invention is preferably formed in a sheet-like structure as described later in terms of productivity, cost, and the like. Further, in order to enhance the integrity of the composite layer and the synthetic fiber layer, it is preferable that the contact surface between the composite layer and the synthetic fiber layer is wide, and the synthetic fiber layer is also preferably in the form of a sheet. From these points of view, it is preferable that the filling is in the form of a sheet. In addition, the sheet form provides excellent washing durability. The composite layer includes a fiber layer made of a first synthetic fiber, a porous material-containing fiber layer having the first synthetic fiber and a porous material, and a synthetic fiber cotton layer including a second synthetic fiber.

The first synthetic fiber and the second synthetic fiber referred to in the present invention are not particularly limited, and known ones can be used. Polyester, polyamide, acrylic, polypropylene and their copolymers, as well as mixtures thereof, are preferred from the viewpoints of availability and balance between performance and price. is more preferred. The single filament fineness of the first synthetic fiber is preferably 5 dtex or more, more preferably 6 dtex or more, and 10 dtex or more in terms of excellent bulkiness and moderate rigidity to withstand deformation such as repeated compression recovery. is more preferable. From the viewpoint of excellent flexibility, it is preferably 20 dtex or less, more preferably 18 dtex or less, and even more preferably 15 dtex or less. Here, the single filament fineness refers to the value obtained by the method described in Examples. In addition, the first synthetic fiber and the second synthetic fiber may be the same, but in order to improve the soft feel of the batting, the second synthetic fiber has a single yarn rather than the first synthetic fiber. It is also a preferred embodiment to use fibers with a small fineness. In this case, the single filament fineness of the second synthetic fiber is preferably less than 5 dtex, more preferably 4 dtex or less, and even more preferably 3 dtex or less. It is preferable that the synthetic fiber cotton layer made of the second synthetic fiber also maintains bulkiness as a batting, and from this point of view, the lower limit of the single yarn fineness that can be practically adopted is 1 dtex.

A first synthetic fiber in the present invention is a hollow fiber having a hollow portion in the cross section of the fiber. As a result, the rigidity per single filament fineness can be increased and the weight can be reduced, so that the bulkiness of the fiber base material that contributes to the soft feel can be increased. In addition, since the hollow portion of the hollow fiber contains air with low thermal conductivity, it is also suitable from the viewpoint of heat retention. Hollow fibers preferably contain more air from the viewpoint of improving heat retention, and the hollowness is preferably 20% or more, more preferably 30% or more. Although the higher the hollowness ratio is, the more preferable it is in terms of heat retention, it is preferable that the hollowness ratio is 50% or less in terms of stable production without collapsing of the hollow portion in the spinning process and the fluid processing process described later. . Here, the hollow ratio is the ratio (%) of the hollow portion in the cross-sectional area, and refers to the value obtained by the method described in the Examples.

Further, the fiber layer containing the first synthetic fibers is a layered material containing the first synthetic fibers, and may be one layer without overlapping. For example, sheet-like, woven fabrics, knitted fabrics, non-woven fabrics, and the like can be exemplified. Among these, a nonwoven fabric is preferable because it can retain a large amount of dead air and improve heat retention.

By including a synthetic fiber in the batting of the present invention, the fiber itself has high rigidity, so that it is excellent in deformation recovery, and it is possible to suppress deterioration in performance over time such as deterioration in physical properties due to repeated washing. Further, other fibers such as vegetable fibers, animal hairs, chemical fibers, inorganic fibers, etc. may be included as long as the effects of the present invention are not impaired. From this point of view, the synthetic fiber content in the batting of the present invention is preferably 60% by weight or more, more preferably 90% by weight or more.

The porous body referred to in the present invention is not particularly limited as long as it has a plurality of pores, and known materials can be used. Here, a hole means a state in which a space formed by a resin exists in at least one of arbitrary cross sections. The space may be formed by a plurality of materials such as fibers other than resin. Also, it does not necessarily have to be a closed space. The resin is not particularly limited and may be a thermoplastic polymer, a thermosetting polymer, or the like, and may be exemplified by polymers such as polyurethane, polyolefin, polyester, polyacrylonitrile, and melamine, and copolymers thereof. Examples of porous bodies include porous bodies formed by wet coagulation of urethane-based resins and polyacrylonitrile-based resins, expanded foams made of polyolefin, polyurethane, melamine resins, etc., and heat-softening resins that can be heat-expanded inside. foamed particles such as thermally expandable microcapsules enclosing a physical substance. Among these, porous bodies and thermally expandable microcapsules formed by wet coagulation are preferable because they can easily form a relatively uniform and large average pore size. In addition, from the viewpoint of comfort due to flexibility, air permeability, etc., the porous body is preferably an open-celled body or a semi-opened-celled body.

The average pore size of the porous body is preferably 50 µm or more, more preferably 70 µm or more, and even more preferably 80 µm or more. Also, it is preferably 300 μm or less, more preferably 200 μm or less, and even more preferably 150 μm or less. By setting it within this range, dead air can be easily formed in the voids inside the porous body, heat transfer through the inside of the batting can be suppressed, heat retention can be improved, and comfort can be improved due to moderate air permeability. can be done. The average pore diameter referred to in the present invention is the average pore diameter of the pores formed by the resin, and refers to the value obtained by the method described in Examples.

The porous body-containing fiber layer in the present invention is a layered material containing the first synthetic fiber and the above-described porous body, and may be one layer without overlapping. A sheet-like fiber base material containing the first synthetic fibers preferably contains a porous material. Due to the reinforcing effect such as the mechanical properties of the first synthetic fiber, even the pores having a large average pore size have flexibility and can maintain a structure with a low apparent density. Especially when the first synthetic fiber is sheet-like, the effect is remarkable. Moreover, it is preferable that the first synthetic fibers contained in the above-mentioned fiber layer and porous-containing fiber layer are integrally continuous from the viewpoint of handleability, manufacturing easiness, and the like. Here, the term "integrally continuous" means that at least one of the first synthetic fibers, preferably 10% or more of the fibers constituting both layers, extends over both the fiber layer and the porous body-containing fiber layer. Refers to the state in which identical fibers exist. By having the porous material-containing fiber layer, the heat retention can be improved compared to the filling with only the fiber layer. In addition, since it has multiple holes, it is possible to control the breathability to an appropriate range, providing comfort by releasing moisture from the skin side and high heat retention by suppressing heat transfer accompanying air movement. can be compatible.

In the composite layer of the present invention, the fiber layer and the porous body-containing fiber layer are in contact with each other at least partially. It is preferable that the fiber layer and the porous-containing fiber layer are in contact with each other on at least one surface so as to be integrated. For example, it is more preferable that the fiber layer has an area of 1 cm ² or more and 50% or more of the area of one surface of the fiber layer is in contact with the porous-containing fiber layer. In addition, it is preferable that both surfaces of the porous body-containing fiber layer are in contact with the fiber layer, in order to further exhibit the fixing effect between the synthetic fiber layer and the composite layer. Here, being in contact means not only a state in which two layers are in contact with each other with a clear space between layers, but also a state in which the first synthetic fiber is continuously present as described above, such as when the space between layers is not clear. There may be. Moreover, the state in which at least one surface is in contact means the state in which the fiber layer exists on the upper side and/or the lower side in the cross section of the composite layer. Identification between layers can be confirmed by the method described in Examples. Also, the number of fiber layers and the number of porous body-containing fiber layers is not particularly limited.

At this time, the ratio (X/Y) between the thickness X of the fiber layer and the thickness Y of the porous body-containing fiber layer is 0.05 to 0.20. By making it 0.05 or more, the fiber layer exerts the effect of fixing the synthetic fiber layer, and the integrity as the filling, that is, the handleability is improved. On the other hand, it is 0.20 or less, preferably 0.15 or less as a range that does not hinder the filling of the synthetic fiber cotton layer into the side fabric. Further, when the synthetic fiber layer is blown and filled, it is preferably 0.10 or less. The thickness ratio refers to the value obtained by the method described in Examples. In the case where there are a plurality of fiber layers and porous body-containing layers, X is the thickness of at least one fiber layer in the outer layer of the composite layer that can be in contact with the synthetic fiber layer, and at least one porous body is in contact with that fiber layer. Assuming that the thickness of the containing fiber layer is Y, the thickness ratio (X/Y) is obtained. When a plurality of thickness ratios (X/Y) are possible, at least one of them is within the scope of the present invention. For example, in the case of a four-layer structure of fiber layer La/porous material-containing fiber layer Lb/fiber layer Lc/porous-containing fiber layer Ld, the thickness of the fiber layer La that can be in contact with the synthetic fiber cotton layer is X, and the porous-containing fiber Let Y be the thickness of the layer Lb. In the present invention, when the composite layer has a three-layer structure of fiber layer Le/porous-containing fiber layer Lf/fiber layer Lg, the fiber layer provides a soft wearing feeling even when there is no synthetic fiber layer as the filling. Therefore, it is preferable. At this time, the thickness of at least one of the fiber layer Le and the fiber layer Lg is set to X. By setting each of the thicknesses to the thickness of the present invention, it is easy to obtain a soft wearing feeling, which is preferable.

It is preferable for the fiber layer to have irregularities in thickness, that is, to improve the effect of holding the synthetic fiber layer.

In the present invention, the composite layer preferably has a thickness of 5 to 30 mm. Even when there are a plurality of composite layers or porous body-containing fiber layers, the sum of all layers is preferably 5 to 30 mm. When the thickness is 5 mm or more, the exposed thickness of the fiber base material becomes large, so that when it is compressed by hand, it becomes easy to feel softness, and sufficient heat retention as a filling can be obtained. On the other hand, the thickness of the composite layer is preferably 30 mm or less, more preferably 20 mm or less, and even more preferably 15 mm or less from the viewpoint of ease of use as a filling. The thickness of the composite layer referred to in the present invention refers to the value obtained by the method described in Examples.

The composite layer in the present invention preferably has an apparent density of 0.010 g/cm ³ or less from the viewpoint of achieving both excellent heat retention and comfort. Since the lower the density, the more comfortable it is, 0.009 g/cm ³ or less is more preferable, and 0.006 g/cm ³ or less is even more preferable. Although the lower limit is not particularly limited, it is 0.001 g/cm ³ or more as a practical range.

In the present invention, by having a composite layer and a synthetic fiber layer, it is possible to provide a filling that has both excellent heat retention of the porous body and comfort due to the soft touch of the synthetic cotton. As the synthetic fiber layer, known ones can be used, examples of which include sheet cotton made of short fiber nonwoven fabric, granulated cotton made of short fibers, sheet molded products made by bonding granulated cotton with a binder or the like, bulky processed yarn of long fibers and its Examples include cut yarn, spunlaid or spunbond nonwoven fabrics. Among these, sheet cotton, granulated cotton, sheet molded products thereof, and long fiber bulky textured yarn are preferable from the viewpoints of low density, high bulkiness, soft touch and recovery from compression. In addition, from the viewpoint of handleability when filling the side fabric and sewing, sheet molded products of sheet cotton and grain cotton are more preferable, and from the viewpoint of suppressing performance deterioration due to repeated washing, etc., sheet cotton is preferable. More preferred.

Since the synthetic fiber layer of the present invention is a portion that mainly exerts an effect in terms of tactile sensation, it is preferable to arrange it evenly over the entire surface of the composite layer. In addition, the apparent density of ordinary cotton is in the range of 0.003 to 0.020 g/cm ³ , but the synthetic fiber layer of the present invention has an apparent density of 0.010 g/cm ³ or less. It is preferable from the viewpoint of comfort. As with the porous material-containing fiber layer, the synthetic fiber layer preferably has a low density, and the apparent density is more preferably 0.009 g/cm ³ or less, further preferably 0.006 g/cm ³ or less. Although the lower limit is not particularly limited, it is 0.001 g/cm ³ or more as a realistic range. The apparent densities of the porous material-containing fiber layer and the synthetic fiber layer referred to in the present invention refer to values obtained by the method described in Examples.

The textile product of the present invention contains at least a part of the above-described filling, and by containing the above-described filling, the textile product can be made excellent in deformation recovery, heat retention, and suppression of performance deterioration. Textile products containing batting include, for example, bag-like structures made of side fabrics filled with batting, side fabrics and batting sewn together, and side fabrics and batting laminated and entangled or bonded together. be done. Examples of textile products include general clothing, sports clothing, materials for clothing, bedding such as quilts, mattresses, and thin blankets, sleeping bags, interior products such as carpets, sofas, curtains, and vehicle interiors such as car seats. be done. Clothing and bedding are particularly suitable.

In the batting of the present invention, the fiber layer and the synthetic fiber layer may be integrated by mechanical entanglement or bonding with a binder or the like, but this is not necessarily required. That is, in the present invention, the composite layer and the synthetic fiber layer can be integrated by arranging them so as to overlap each other or by simultaneously blowing and filling them to mix them. This is preferable in that it is possible to suppress the deterioration of performance over time due to the use of the product and the ease of handling when making it into a textile product. In addition, since there are no restrictions on sewing, etc., the effect of increasing the degree of freedom in design can be expected. It is more preferable to reduce or substantially eliminate mechanical entanglement and integration of binders and the like. In the present invention, since the fiber layer can enhance the integration with the synthetic fiber layer, it becomes a batting in which the porous body-containing fiber layer and the synthetic fiber layer are integrated through the fiber layer. This integration is not necessarily limited to being present at the time of manufacturing the batting, and may be formed, for example, at the time of fabricating the fiber product or during use of the fiber product.

Next, a preferred example of the method for producing the porous material-containing fiber layer in the batting of the present invention will be described, but the method is not limited to this.

Sheet cotton made of short fiber nonwoven fabric, granules made of short fibers, sheet molded products made by bonding granules made of short fibers with a binder, etc., bulky processed yarn of long fibers and cut yarn thereof, spunlaid or spunbond, which are exemplified as synthetic fiber layers Nonwoven fabrics and the like can be produced by known methods.

The porous body-containing fiber layer is preferably produced by impregnating a fiber base material such as a woven fabric, a knitted fabric, or a non-woven fabric with a resin that forms the porous body. A fiber base material can be manufactured by a conventionally well-known method. In addition, as a method for impregnation, a resin solution containing a foaming component is sprayed onto the fiber base material to cause foaming, or after impregnation, heat treatment is performed to foam, or impregnation with a urethane-based resin or polyacrylonitrile-based resin solution. After solidification with a poor solvent, heat treatment is performed to form a porous body.

In the batting of the present invention, the thickness ratio (X/Y) between the thickness X of the fiber layer and the thickness Y of the porous body-containing layer and the thickness of the composite layer are determined by the first synthetic fiber used in the above fiber layer. It can be adjusted by increasing or decreasing the yarn fineness and the apparent density of the fiber base material. Further, the thickness can be increased by reducing the degree of crimping of the first synthetic fibers and the entanglement of the fiber layers.

The apparent density of each layer in the batting of the present invention can be lowered, for example, by lowering the density of the fiber base material described above, or by lowering the concentration of the resin forming the porous body and the content of the resin in the fiber base material. .

The adjustment of the average pore diameter of the porous body in the batting of the present invention varies depending on the method of forming the pores. It can be adjusted by the foaming ratio depending on the heat treatment conditions, etc. The average pore size can also be reduced by gradually solidifying the solvent by gradually decreasing the concentration of the solvent in the solidifying bath. This method can also suppress the formation of coarse pores that are likely to occur due to rapid solidification, so that a porous body having relatively uniform pore diameters can be formed.

In the present invention, the composite layer comprising the fiber layer and the porous body-containing fiber layer is preferably manufactured as one piece. That is, when manufacturing the porous body-containing fibrous layer, it is a preferable manufacturing method to expose the fibers on at least one surface to form the fibrous layer. For example, after a fiber base material is impregnated with a resin solution, it is put in a non-contact state by hanging it, etc., and aggregates inside the fiber base material using the viscosity of the porous body-forming resin. After that, a composite layer can be produced by heat-treating to form a porous body. In the continuous process using wet coagulation, after impregnating the resin solution in an impregnation bath or the like, for example, by providing a section in which the fiber base material is run vertically without contact, coagulation is performed inside the fiber base material, and the porous You can control the placement of the material. When this production method is employed, a fiber base material having an apparent density of 0.009 g/cm ³ or less is preferably employed. As for the resin for forming the porous body, it is preferable to use a resin solution having a viscosity adjusted to a range of 1 to 20 Pa·s.

When manufacturing the composite layer in the batting of the present invention in a continuous process, the higher the viscosity of the resin solution, the more easily the fiber base material loses its shape during the impregnation process. It is also possible to adopt a method of stabilizing the process passability such as sandwiching the fiber base material. In this case, it is preferable to remove the base fabric after impregnating the resin, and then pass through the process of aggregating the resin solution.

The resin-impregnated fibrous base material can be heat-treated to form pores, but it is preferable to appropriately adjust the temperature within a range in which the mechanical properties of the fibers constituting the fibrous base material do not deteriorate. In addition, it is preferable to collect the composite layer after the heat treatment so as not to crush the porous body. A preferred manufacturing method is a method of stacking and recovering.

In order to make a textile product, the composite layer and the synthetic fiber layer are placed one above the other and then sewn after filling, or the composite layer is first filled in the side fabric, and then the synthetic cotton is blown and filled. A method of cutting the composite layer and simultaneously blowing and filling it with granular cotton or the like and sewing can be adopted. After being filled as a batting together with a synthetic fiber layer, it can be sewn to obtain a textile product.

Next, the present invention will be specifically described based on examples. However, the present invention is not limited only to these examples. In the measurement of each physical property, unless otherwise specified, the measurement was performed according to the method described above. However, the present invention is not limited to the description of these examples.

A. Evaluation of Fiber Properties: Single Filament Fineness, Fiber Length, Number of Crimps, Hollow Ratio Various fiber properties of the first synthetic fiber and the second synthetic fiber were measured by the following methods.
・Single yarn fineness (dtex)
It was measured according to the method described in 8.5.1 of JIS L 1015:2010, and the fineness per single yarn was calculated.
・Fiber length (mm)
It was measured according to A method (staple diagram method) described in 8.4.1 of JIS L 1015:2010.
・Number of crimps (peak/25mm)
It was measured according to the method described in 8.12.1 of JIS L 1015:2010.
・Hollowness rate (%)
A cut sample was prepared so that the cross section of the fiber could be observed, and the cross section of the fiber was photographed with an electron microscope (SEM) at such a magnification that the cross section of 10 or more fibers could be observed. 10 randomly selected fibers are extracted from the photographed image, and the equivalent circle diameters of the fibers and the hollow portion are measured using image processing software, from which the area ratio of the hollow portion is calculated and the hollow ratio ( %).

B. The ratio (X/Y) of the thickness X of the fiber layer to the thickness Y of the porous body-containing fiber layer and the thickness of the composite layer , with the cross section facing the observation direction (direction of arrow 7 in FIG. 2). After that, the composite layer was lightly pressed against the vertical surface of the sample table with a finger and left for 30 minutes to restore the shape of the composite layer. This sample was imaged with a microscope SEM manufactured by Keyence Corporation ("VHX-6000", "VHX-D510" built-in) at an observation magnification of 30 times. Select the distance between parallel lines in the measurement mode of the device, draw a line (L0) on the vertical plane of the sample table in the captured image, and project from here to the outermost layer of the fiber layer in the composite layer on the opposite side of the sample table A reference line (L1) was set by drawing a parallel line at the tip (uppermost part in the cross section) of the monofilament. A parallel-shifted line (L2) is set from this reference line (L1) to the surface of the porous material located in the outermost layer (that is, the uppermost part in the cross section), and the distance between the parallel lines of L1 and L2 is the fiber layer. Measured as thickness. The thickness of the fiber layer is measured in the same manner for the other surface, and this operation is performed in the same manner for the five cut surfaces. did. Also, the distance between the parallel lines at the top and bottom of the porous body in the cross section was taken as the thickness of the porous body-containing fiber layer. The average value of the five cut surfaces was calculated and integrated into an integer, which was used as the thickness Y of the porous body-containing fiber layer.

From the thickness X of the fibrous layer and the thickness Y of the porous body-containing fibrous layer obtained in this manner, the ratio of X to Y (X/Y) was calculated and summarized to the second decimal place. Also, the thickness (mm) of the composite layer was determined as an integer.

C. Apparent density of composite layer and synthetic fiber layer For a sample cut into a 10 cm square, the thickness of the composite layer obtained by the measurement method in B and the weight of the sample are measured to obtain the apparent density (g/cm ³ ), and the decimal point The values were summarized up to the third place.

For the sheet-like sample, the synthetic fiber layer is JIS L 1096: 2010 "8.4 Thickness" of "8.4 Thickness" of "a) A method (JIS method)" for the composite layer The thickness (mm) was measured from the side using a vernier caliper so as not to crush the fiber layer and the porous body-containing fiber layer, and used to calculate the apparent density.

When the synthetic cotton layer is an irregular sample such as granular cotton, 5 g of the sample is filled in a φ10 cm acrylic tube, and a disk adjusted to a load of 0.15 g/cm ² is placed on the disc for 1 minute. The height (cm) of the sample after standing was measured to determine the volume (cm ³ ) of the sample, and the apparent density was calculated from the weight and volume of the filled sample.

D. Average Pore Diameter of Porous Body A cross section of the composite layer was cut out and photographed at a magnification of 300 using a Microscope SEM manufactured by KEYENCE CORPORATION ("VHX-6000" and "VHX-D510" built-in). In the obtained cross-sectional photograph, an inscribed circle was drawn by image analysis for the pores surrounded by the resin forming the porous body in the porous body-containing fiber layer, and the diameter of the inscribed circle was obtained. This pore observation was performed at 10 locations per cross section, and this operation was performed on 5 cut surfaces.

E. Heat retention Filling frame made of expanded polystyrene with a thickness of 15 mm with a filling space of 10 cm square and a filling space of 10 cm square (a PET screen gauze was attached to the bottom surface of the filling space). things). After that, a synthetic fiber layer was placed on top, and a PET screen gauze was attached to the top side of the filling space to close it, and a sample for heat retention evaluation was prepared.

Using a "KES-F7 thermolab tester" manufactured by Kato Tech Co., Ltd., the sample was evaluated for heat retention under conditions of a wind tunnel at a wind speed of 30 cm/sec, an ambient temperature of 25°C, and a hot plate temperature of 40°C. Specifically, after placing the filling space portion (10 cm square) of the sample together with the hot plate portion (10 cm square) and leaving it for 15 minutes, the amount of heat (a) dissipated through the sample and the sample The amount of heat dissipated (b) was determined without setting, and the heat retention rate (%) was calculated according to the following formula.
・Insulation rate (%) = (1-a/b) x 100
Subsequently, feathers (down 90%/feather 10%) having a fill power of 640 inches ³ /30 g measured according to ASTM D4522-14 in accordance with the batting weight of each example were weighed and similarly evaluated. In the present invention, the heat retention rate of feathers of the same size and weight is defined as 100% heat retention, and the heat retention (%) is calculated relative to this and summarized in integers.

F. Feeling of batting A 44 dtex nylon taffeta was used as a side material (outer material and lining), and a 10 cm square piece of batting was cut out and sewn to prepare a small cushion. Evaluated in the following three stages from the compression deformation behavior that wraps around the fingers when this small cushion is slowly compressed by hand, and the softness of recovery when the hand is released (slow recovery deformation behavior). did.
◯ (Good): The texture is supple and flexible.
・△ (Possible): The texture is supple and softness can be perceived.
x (impossible): supple and poorly flexible texture (resilience).

G. Handleability of batting (integrity of batting)
Regarding the small cushion used in the evaluation of F above, the integrity of the filling was evaluated from the tactile sensation when touched by rubbing in the horizontal direction while compressing by hand and the appearance of the small cushion after touching. The handleability was evaluated in the following three grades.
・○ (Good): The layers that make up the batting do not feel peeled off or change in appearance, and integrity is maintained.

△ (acceptable): There is no peeling feeling of the layers constituting the filling, and the cotton is biased after being touched, but returns to its original shape.
x (impossible): There is a feeling that the layer constituting the filling is peeled off, and it does not return to its original shape after being touched.

[Example 1]
Using polyethylene terephthalate having an intrinsic viscosity (IV) of 0.65 dl/g, spinning was performed at a spinning temperature of 285° C., a take-up speed of 1350 m/min, and a known asymmetric cooling treatment directly below the spinneret. Subsequently, after drawing, a commercially available silicone resin liquid containing dimethylpolysiloxane as a main component is uniformly applied with a sprayer, heat-treated and fixed to produce fibers imparted with a water-repellent resin, which are cut into short lengths. A fiber (F1) was obtained. The short fibers obtained were hollow fibers having a fiber length of 64 mm and a single filament fineness of 14 dtex (hollow ratio of 34%), and had relatively large crimps of 2 to 3 crimps/25 mm.

After opening the short fibers (F1) with a carding machine, a base material crossed in the length direction of the nonwoven fabric is supplied by a cross layer, and needle punching is performed to obtain short fibers having an apparent density of 0.007 g/cm ³ . A sheet (S1) of fibrous nonwoven fabric was obtained.

As the resin that forms the porous body of the porous body-containing fiber layer, "Samprene LQ-T1508" manufactured by Sanyo Chemical Industries, Ltd. is used, and dimethyl sulfoxide is added to dilute the polyurethane resin concentration to 5 wt%. A resin solution was prepared.

A 20 cm square sample cut from the previously obtained sheet (S1) was immersed in this polyurethane resin solution and impregnated with resin. It was sandwiched between the two and hung for 3 minutes and left to stand. Subsequently, it was immersed in a coagulation solution with a DMF concentration of 30 wt %, and then immersed in water for coagulation.

The sample thus obtained was dried with hot air at 120° C. to produce a composite layer (C1) consisting of a fiber layer and a porous material-containing fiber layer.

The composite layer (C1) had an apparent density of 0.008 g/cm ³ and a thickness of 8 mm, and was bulky and lightweight. The ratio (X/Y) of the thickness X of the fibrous layer to the thickness Y of the porous body-containing fibrous layer was 0.11, and many loop-shaped exposed portions of the fibrous base material were observed on the surface layer. The average pore diameter of the porous body was 115 μm, and semi-open cells were formed.

The sheet (S1) prepared earlier was used as a synthetic fiber layer, and this was combined with the composite layer (C1) to form a filling. The heat retention was 109%, which exceeded that of feathers.

As for the tactile sensation, the texture was supple and had good flexibility. Furthermore, regarding the handleability of the batting, there was no peeling feeling or change in appearance of the layers constituting the batting, and the integrity was maintained, so that the handleability was excellent. Table 1 shows the evaluation results.

[Example 2]
As the synthetic fiber layer, cotton (apparent density 0.006 g/cm ³ ) obtained by passing short fibers having a single filament fineness of 3 dtex and a fiber length of 32 mm through a cotton processing machine is used, and this and the composite layer obtained in Example 1 Combining (C1), a batting was produced and evaluated.

The heat retention was 106%, which exceeded that of feathers. As for the tactile sensation, the tactile sensation was supple and had good flexibility, and the tactile sensation was softer than that of Example 1. Furthermore, regarding the handling of the batting, there was no feeling of peeling of the layers that make up the batting, and although the cotton was biased after touching, it returned to its original shape, and the grainy cotton was on the composite layer (C1). was stably fixed to Table 1 shows the evaluation results.

[Example 3]
In the sheet (S1) of Example 1, hollow fibers (hollow ratio: 32%) having a fiber length of 64 mm and a single filament fineness of 6 dtex were used in place of the staple fibers (F1), and polyethylene terephthalate staple fibers with 4 crimps/25 mm were used. Using (F2), a sheet (S2) made of a staple fiber nonwoven fabric having an apparent density of 0.007 g/cm ³ was obtained. Using this sheet (S2) as the fiber base material of the porous body-containing fiber layer, a composite layer (C2) composed of the fiber layer and the porous body-containing fiber layer was produced in the same manner as in Example 1.

This composite layer (C2) had an apparent density of 0.009 g/cm ³ and a thickness of 6 mm. and semi-open cells were formed. A batting was produced and evaluated in the same manner as in Example 1 except that this composite layer (C2) was used.

The heat retention was 102%, which exceeded that of feathers. As for the tactile sensation, since the thickness of the fiber layer was small, the tactile sensation of the porous material-containing fiber layer was easily felt, but the texture was supple and soft. Furthermore, regarding the handleability of the batting, there was no peeling feeling or change in appearance of the layers constituting the batting, and the integrity was maintained, so that the handleability was excellent. Table 1 shows the evaluation results.

[Example 4]
When the staple fibers (F1) used in Example 1 were opened by a carding machine, the weight of the staple fibers added per hour was reduced to 2/3 that of Example 1, and the cloth layer was used to stretch the length of the nonwoven fabric. A crossed base material was supplied to the sheet and needle-punched to obtain a sheet (S3) of staple fiber nonwoven fabric having an apparent density of 0.004 g/cm ³ . Using this sheet (S3) as the fiber base material of the porous body-containing fiber layer, a composite layer (C3) composed of the fiber layer and the porous body-containing fiber layer was produced in the same manner as in Example 1.

This composite layer (C3) had an apparent density of 0.006 g/cm ³ and a thickness of 10 mm. Moreover, the average pore size of the micropores of the porous body was 144 μm, and semi-open cells were formed. A batting was produced and evaluated in the same manner as in Example 1 except that this composite layer (C3) was used.

The heat retention was 105%, which exceeded that of feathers. As for the tactile sensation, the thickness of the fiber layer was large, and the texture was supple and flexible. Furthermore, regarding the handleability of the batting, there was no peeling feeling or change in appearance of the layers constituting the batting, and the integrity was maintained, so that the handleability was excellent. Table 1 shows the evaluation results.

[Comparative Example 1]
Feathers (down 90%/feather 10%) having a fill power of 640 inches ³ /30 g measured according to ASTM D4522-14 were used as the filling, and each evaluation was performed in the same manner as in Example 1. The heat retention was 100%, and the texture was supple and had good flexibility. Regarding the handleability of the batting, there was no peeling feeling because the batting had no layer, but it did not return to its original shape after being touched and left as it was, so it was evaluated as x. Table 1 shows the evaluation results.

[Comparative Example 2]
Each evaluation was performed in the same manner as in Example 1 except that only the sheet (S1) used for the porous body-containing fiber layer of Example 1 was used as the filling. The heat retention was 76%, which is lower than feathers. On the other hand, as for the tactile sensation, the texture was supple and had good flexibility. In addition, regarding the handleability of the batting, there was no peeling feeling or change in appearance of the layers constituting the batting, and the integrity was maintained, so the handleability was excellent. Table 1 shows the evaluation results.

[Comparative Example 3]
Water-based polyurethane resin emulsion (“Evaphanol HA-107C” manufactured by Nicca Chemical Co., Ltd.) and thermally expandable microcapsules (“Matsumoto Microsphere FN-105D” manufactured by Matsumoto Yushi Co., Ltd.) are added to 2.5 wt%. The mixed resin solution was prepared, and the sheet (S1) obtained in the same manner as in Example 1 was impregnated. Subsequently, heat treatment was performed at 120° C. to fix the thermally expandable microcapsules in the fiber base material, and then heat treatment was performed at 180° C. to foam, thereby producing a porous body-containing fiber layer. At this time, no fibers were exposed from the porous body-containing fiber layer, and no portion corresponding to the fiber layer was observed. Next, each evaluation was performed in the same manner as in Example 1 using a sheet (S1) obtained in the same manner as in Example 1 as the synthetic fiber layer. The insulation of this batting was 101%, which was superior to feathers. As for the tactile feel, although the synthetic fiber layer had flexibility, the porous material-containing fiber layer was hard and had a repulsive feel, giving a feeling of suppleness and poor flexibility as a filling. In addition, regarding the handleability of the batting, there was a feeling that the layers constituting the batting were peeling off, and there was a part where it was peeled off after being touched and did not return to its original shape, and was evaluated as x. Table 1 shows the evaluation results.

[Comparative Example 4]
In the sheet (S1) of Example 1, instead of the short fibers (F1), hollow fibers having a fiber length of 64 mm and a single filament fineness of 3 dtex (hollow ratio of 30%) were used, and polyethylene terephthalate staple fibers having 6 crimps/25 mm were used. Using (F3), a sheet (S4) made of a staple fiber nonwoven fabric having an apparent density of 0.013 g/cm ³ was obtained. Using this sheet (S4) as the fiber base material of the porous body-containing fiber layer, a composite layer (C4) composed of the fiber layer and the porous body-containing fiber layer was produced in the same manner as in Example 1.

This composite layer (C4) had an apparent density of 0.019 g/cm ³ and a thickness of 4 mm. The micropores of the porous body had an average pore diameter of 36 µm, and formed closed cells. In the composite layer (C4), the ratio (X/Y) of the thickness X of the fiber layer to the thickness Y of the porous body-containing fiber layer is as small as 0.03, and most of the composite layer (C4) forms the porous body-containing fiber layer. rice field. A batting was produced and evaluated in the same manner as in Example 1 except that this composite layer (C4) was used.

The heat retention was 69%, which was greatly inferior to feathers. As for the tactile sensation, it was easy to feel the tactile sensation of the porous material-containing fiber layer, and there was a feeling of repulsion. Furthermore, regarding the handleability of the batting, there was a feeling that the layers constituting the batting were peeling off, and there was a part where it was peeled off after being touched and did not return to its original shape, and was evaluated as x. Table 1 shows the evaluation results.

[Comparative Example 5]
In the sheet (S1) of Example 1, instead of the short fibers (F1), hollow fibers having a fiber length of 84 mm and a single filament fineness of 22 dtex (hollow ratio of 34%) were used, and the number of crimps was 1 to 2 crimps/25 mm polyethylene terephthalate. Using the short fibers (F4), a sheet (S5) made of a short fiber nonwoven fabric having an apparent density of 0.010 g/cm ³ was obtained. Using this sheet (S5) as the fiber base material of the porous body-containing fiber layer, a composite layer (C5) composed of the fiber layer and the porous body-containing fiber layer was produced in the same manner as in Example 1.

The composite layer (C5) had an apparent density of 0.012 g/cm ³ and a thickness of 14 mm. Stability was low. The average pore size of the micropores of the porous body was 390 μm, and although semi-open cells were formed, some omissions were observed. The composite layer (C5) had a large ratio (X/Y) of 0.40 between the thickness X of the fiber layer and the thickness Y of the porous body-containing fiber layer. A batting was produced and evaluated in the same manner as in Example 1 except that this composite layer (C5) was used.

The heat retention was 78%, which was significantly inferior to feathers. As for the tactile sensation, the tactile sensation of the fibers constituting the fiber layer was hard, and there was a feeling of repulsion due to this effect, and the texture was supple and lacked flexibility. Furthermore, regarding the handleability of the batting, there was a feeling that the layers constituting the batting were peeled off and a feeling that the composite layer (C5) itself collapsed, and was evaluated as x. Table 1 shows the evaluation results.

[Comparative Example 6]
In the sheet (S1) of Example 1, instead of the short fibers (F1), polyethylene having a fiber length of 64 mm, a single filament fineness of 6 dtex, and a crimp number of 10 crimps/25 mm mechanically crimped with a crimper and having no hollow portion Using terephthalate staple fibers (F5), a sheet (S6) made of staple fiber nonwoven fabric having an apparent density of 0.012 g/cm ³ was obtained. Using this sheet (S6) as the fiber base material of the porous body-containing fiber layer, a composite layer (C6) composed of the fiber layer and the porous body-containing fiber layer was produced in the same manner as in Example 1.

This composite layer (C6) had an apparent density of 0.014 g/cm ³ and a thickness of 6 mm. The micropores of the porous body had an average pore size of 200 μm, and although semi-open cells were formed, the content of the resin was uneven. The composite layer (C6) had a small ratio (X/Y) of 0.02 between the thickness X of the fiber layer and the thickness Y of the porous body-containing fiber layer. A batting was produced and evaluated in the same manner as in Example 1 except that this composite layer (C6) was used.

The heat retention was 80%, which was greatly inferior to feathers. As for the tactile sensation, the tactile sensation was hard, supple and lacking in flexibility because there was almost no fiber layer. Furthermore, regarding the handleability of the batting, there was a feeling that the layers constituting the batting were peeled off, so it was evaluated as x. Table 1 shows the evaluation results.

Reference Signs List 1 Insulation 2 Composite layer 3 Synthetic fiber layer 4 Porous material-containing fiber layer 5 Fiber layer 6 Sample table having a vertical plane 7 Observation direction 8 Line on the vertical plane of the sample table (L0)
9 Reference line of fiber layer surface layer (L1)
10 Porous body surface layer line (L2)
11 Thickness of composite layer composed of fiber layer and porous body-containing fiber layer 12 Thickness X of fiber layer in composite layer
13 Thickness Y of porous material-containing fiber layer in composite layer
14 porous body 15 first fiber

Claims (8)

A batting having a composite layer and a synthetic fiber layer, wherein the composite layer includes a fiber layer containing a first synthetic fiber and a porous body-containing fiber layer containing the first synthetic fiber and a porous body the synthetic fiber layer contains a second synthetic fiber, the first synthetic fiber is a hollow fiber, and the fiber layer and the porous body-containing fiber layer in the composite layer are in contact with each other at least partially and a padding in which the ratio (X/Y) of the thickness X of the fibrous layer to the thickness Y of the porous body-containing fibrous layer is 0.05 to 0.20. The batting according to claim 1, wherein the composite layer has a thickness of 5 to 30 mm. The batting according to claim 1 or 2, wherein the single filament fineness of said first synthetic fibers is 5 to 20 dtex. The batting according to any one of claims 1 to 3, wherein said porous body has an average pore size of 50 to 300 µm. The batting according to any one of claims 1 to 4, wherein the composite layer has an apparent density of 0.010 g/cm ³ or less. The batting according to any one of claims 1 to 5, wherein the synthetic fiber layer has an apparent density of 0.010 g/cm ³ or less. The batting according to any one of claims 1 to 6, wherein the batting is sheet-like. A textile product comprising at least a part of the filling according to any one of claims 1 to 7.

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