JP3794560B2 - Molded product - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a molded product. In particular, the present invention relates to a molded product having excellent transpiration and soft touch.
[0002]
[Prior art]
Conventionally, materials such as nonwoven fabric or urethane foam have been used in molded articles such as brassiere cups, shoulder pads, waist pads, and the like. However, in a molded product made of such a nonwoven fabric or foamed urethane, it has been desired to be improved because repeated wear and washing cause sag and lowers the shape retention.
[0003]
In view of this, attempts to improve the decrease in shape retention in a mold cup such as a brassiere have been proposed in Japanese Patent Application Laid-Open Nos. 11-172505 and 2000-226704. These publications describe a two-layer molded clothing article having an outer layer portion made of a knitted fabric and an inner layer portion made of a nonwoven fabric or a synthetic resin foam.
[0004]
[Problems to be solved by the invention]
Certainly, it has been found that mold-processed clothing such as brassiere cups described in the above-mentioned publication can prevent deterioration of mold retention, but is insufficient in transpiration, that is, easily stuffy when worn. Moreover, when a nonwoven fabric was used for the inner layer part which contacts a body, there also existed a problem that the tactile sensation of a brassiere cup was hard when worn.
[0005]
The present invention has been made to solve the above-mentioned problems, and an object of the present invention is to provide a molded product that is excellent in transpiration and soft to the touch when worn.
[0006]
[Means for Solving the Problems]
The present invention is a molded product comprising an inner layer composed of at least a surface material and a lining material and an outer layer containing a nonwoven fabric, wherein the inner layer surface material is formed with irregularities, and the inner layer lining material and the outer layer nonwoven material are pointed. It is characterized by being adhered in a shape.
[0007]
Further, in the present invention, the inner layer of the molded product is composed of an outer stretch made of inelastic stretch yarn, a lining made of elastic stretch yarn, and a batting arranged between the outer fabric and the lining. It is preferable that it is a stretchy quilted fabric integrated by the above.
[0008]
Furthermore, in the present invention, it is preferable that the inner surface of the inner layer forms the body side surface.
[0009]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the molded product of the present invention will be described. FIG. 1 is a schematic cross-sectional view schematically showing a mold cup which is an example of a molded product of the present invention. The mold cup 1 includes an inner layer 2 composed of a front material and a lining material, and an outer layer 3 including a nonwoven fabric.
[0010]
The inner layer used in the molded article of the present invention is composed of at least a surface material and a lining material, and it is necessary that irregularities be formed on the surface material. The shape of the unevenness is not particularly limited, and may be any shape such as a dome shape, a rhombus shape, a turtle shell shape, or a kamaboko shape. Moreover, there is no restriction | limiting in particular also about the structure of a surface material and a lining, Either a woven fabric and a knitted fabric may be sufficient, However, A knitted fabric is preferable from the point of breathability and workability. Furthermore, in the present invention, it is preferable that the outer material is a quilted fabric in order to impart cushioning properties to the obtained molded product and enhance the soft feeling.
[0011]
In the present invention, in order to further improve the soft feeling of the molded product to be obtained, it is particularly preferable that the inner layer is a stretchable quilted fabric. Here, the stretch quilted fabric is composed of an outer fabric made of inelastic elastic yarn, a lining made of elastic elastic yarn, and a batting arranged between the outer material and the outer material, and the outer material, the lining material and the inner cotton material constitute the lining material. Connected and integrated by elastic elastic yarns.
[0012]
The term “elastic stretch yarn” as used herein refers to a core-sheath structure yarn using polyurethane fibers in the core, short fibers in the sheath, polyurethane fibers in the core, and filaments in the sheath, and twisted. , A filament or spun yarn and polyurethane fiber twisted. Moreover, you may use the thread | yarn which wound the filament around the polyurethane fiber instead of the polyurethane fiber. Polyurethane fibers have elastic stretchability and are usually stretched 3 to 4 times to form core-sheath structure yarns and the like. On the other hand, the “non-elastic stretch yarn” referred to here is a yarn that does not contain polyurethane fiber and has a low elastic stretch rate. For example, filaments such as polyester, acrylic, nylon, and rayon, and spun yarns of natural fibers, chemical fibers, and synthetic fibers.
[0013]
Specifically, the surface of the stretchable quilted fabric is preferably knitted from inelastic stretch yarns such as polyester fiber, nylon fiber, and acrylic fiber. From the viewpoint of recycling the molded product, it is particularly preferable to use a polyester fiber as a surface material of the stretchable quilted fabric. In addition, although the surface material comprised from the said inelastic elastic yarn may be either a textile fabric or a knitted fabric, it is preferable that it is a knitted fabric from the point of breathability and workability.
[0014]
On the other hand, the lining of the stretchable quilted fabric is not particularly limited as long as it is composed of elastic stretch yarns, but it is preferable to use elastic stretch yarns having a core-sheath structure. For example, polyurethane fibers (spandex) are used as the core, and short fibers such as polyester are used as the sheath. As with the outer material, the lining made of the elastic elastic yarn may be either a woven fabric or a knitted fabric, but it is preferable that the lining is substantially flat. Moreover, it is preferable that it is a knitted fabric from the point of air permeability and workability. The yarns constituting the lining need not all be elastic stretch yarns, and may be alternately arranged with non-elastic stretch yarns as long as the fabric has elastic stretch properties.
[0015]
In addition, synthetic fibers such as acrylic, nylon, and polyester are suitable for the filling of the stretchable quilted fabric. Here, since it is calculated | required that it is excellent in cushioning properties and air permeability as a batting, it is preferable to use the thing which has bulkiness like spun yarn, wooly processed yarn, or conjugate yarn with a bulky property. From the viewpoint of fluffing and softness, it is preferable to use a filament yarn.
[0016]
As described above, the stretchable quilted fabric is a three-layer structure of the outer material, the lining material, and the batting. At the time of weaving and knitting, the elastic stretch yarns that make up the lining intersect the yarns that make up the outer material, so that the outer material, batting and lining are connected and integrated into a quilted shape.
[0017]
In the stretch quilted fabric, as described above, the elastic material is used for the outer material and the elastic material is used for the inner material. It curves greatly between. Therefore, the stretchable quilted fabric obtained has unevenness on the surface and has a soft cushioning property. Further, by integrating the three-layer structure composed of the outer material, the lining material, and the batting using the elastic elastic yarn constituting the lining material, it becomes possible to maintain a good elasticity, and the joint portion does not become hard. Furthermore, since both the longitudinal direction and the weft direction are stretchable, the workability during molding is very good.
[0018]
Next, the outer layer in the molded product of the present invention is made of a nonwoven fabric. Examples of the fibers constituting the nonwoven fabric include polyester fibers, nylon fibers, and acrylic fibers. In the present invention, among these, polyester fibers are preferably used from the viewpoint of durability and recyclability. Moreover, what is necessary is just to follow the method known conventionally about the manufacturing method of a nonwoven fabric. Moreover, you may mix a small amount of heat-fusible fibers in a nonwoven fabric. The heat-fusible fiber is heated at the time of molding, so that the heat-fusible fiber is fused with the fiber forming the nonwoven fabric, and the shape retention of the molded product can be further improved.
[0019]
Subsequently, in the molded product of the present invention, as shown in FIG. 2, the inner layer lining and the outer layer non-woven fabric are bonded in a dot shape. That is, in FIG. 2, in the molded product 1 using the stretchable quilted fabric 20 composed of the outer fabric 21, the batting 22 and the lining 23 as an inner layer, the backing 23 and the nonwoven fabric 3 of the stretchable quilted fabric 20 are shown. A state in which the adhesive 4 is adhered in a dot shape is schematically shown. Thus, it becomes possible to make air permeability of the molded product obtained favorable by adhering an inner layer and an outer layer in the shape of a spot.
[0020]
Here, as a method of adhering the inner layer lining and the outer layer non-woven fabric in a dot shape, for example, an adhesive is applied to one or both of the inner layer lining and the outer layer non-woven fabric in a dot shape, and both are described later in molding. The method of making it adhere | attach by doing is mentioned. Moreover, the method of making it adhere | attach by spraying a solid adhesive agent to one or both of the inner layer lining or the nonwoven fabric of an outer layer by planar shape, and molding both. In addition, what is necessary is just to use the adhesive agent normally used for clothes as an adhesive agent, and there is no restriction | limiting in particular.
[0021]
As a further method of adhering the inner layer lining and the outer layer non-woven fabric, for example, a mesh-like or web-like thermoplastic fiber sheet is interposed between the inner layer lining and the outer layer non-woven fabric, and heat generated by molding. A method of adhering the inner lining and the outer non-woven fabric in a dot-like manner by melting the plastic fiber sheet may be used.
[0022]
When the molded product of the present invention is used for apparel and the like, if the inner surface of the inner layer where the irregularities are formed is on the body surface side, there is a recess in the quilted part of the molded product A gap is formed between the body surface and the body surface. For this reason, the phenomenon that a molded product adheres over the whole body surface does not occur. Further, heat and moisture emitted from the wearer are emitted through the gap between the molded product and the body surface. Therefore, in the molded product, when the surface having the irregularities is on the body surface side, the air permeability and the transpiration can be improved.
[0023]
Then, the manufacturing method of the molded product of this invention is demonstrated. In the present invention, a molded product having a predetermined shape is manufactured by superposing and molding an inner layer and an outer layer manufactured in advance.
[0024]
Here, before the inner layer and the outer layer are overlapped, it is preferable to perform a pretreatment such that the inner layer lining and the outer layer non-woven fabric adhere to each other in the form of dots. That is, in the present invention, as described above, the adhesive is applied to one or both of the inner layer lining and the outer layer non-woven fabric in a dot-like manner (or the solid adhesive is spread in a planar shape), or the inner layer lining. It is preferable that a thermoplastic fiber sheet is interposed between the outer layer and the nonwoven fabric of the outer layer, and then the inner layer and the outer layer are overlapped and molded. In the present invention, it is also possible to mold using a laminated structure in which the inner layer lining and the outer layer non-woven fabric are already bonded in the form of dots.
[0025]
In the present invention, before the inner layer and the outer layer are superposed, each can be formed into a predetermined shape.
[0026]
The molded product of the present invention can have various shapes such as a cup shape depending on the application. Specific uses include brassiere cups, shoulder pads, waist pads, supporters, shoe base materials, mat materials, and the like.
[0027]
In particular, when the molded product of the present invention is used for apparel applications such as brassiere cups, shoulder pads, waist pads, supporters, etc., if the body surface side is the outer surface of the stretchable quilted fabric, the stretchable quilted fabric Due to its volume and cushioning properties, it is a molded product that is soft to wear and fits comfortably on the skin of the wearer. Moreover, since the molded product of the present invention has a double structure of an inner layer and an outer layer, it also has an effect of having good shape retention.
[0028]
Moreover, the molded product of this invention is very excellent in transpiration | evaporation property by having the structure which adheres a specific inner layer and an outer layer in the shape of a point. Furthermore, the molded product of the present invention has good air permeability and moisture permeability equivalent to that of a conventional molded product made of only a nonwoven fabric.
[0029]
Furthermore, in the molded product of the present invention, among the raw materials constituting the inner layer and the outer layer, all other than the polyurethane fibers constituting the lining can be made into polyester fibers, whereby the molded product obtained It is possible to prevent the yellowing of the resin, and at the same time, it is possible to obtain a molded article having excellent recyclability.
[0030]
【Example】
EXAMPLES Hereinafter, although an Example and a comparative example demonstrate this invention more concretely, this is only a mere illustration and does not restrict | limit this invention.
[0031]
[Example 1]
Polyester 84 dtex filament yarn without elastic stretch is used as the outer material, and the core spun yarn English cotton count 30 (core is spandex 45 dtex and the sheath is polyester short fiber) is used as the backing. Using wooly processed yarn of polyester 84 dtex as batting, it was knitted. The obtained knitted fabric was dyed and processed to obtain an elastic quilted fabric having a thickness of 2.25 mm and a fabric weight of about 490 g / m ² .
After the obtained stretch quilted fabric is used as an inner layer and a non-woven fabric having a thickness of 20 mm and a basis weight of 200 g / m ² using a polyester 6.6 dtex yarn is used as an outer layer, an adhesive is applied to the non-woven fabric in the form of dots. Then, it was superposed on the stretchable quilted fabric, and then put into a mold and molded to obtain a molded product.
[0032]
[Comparative Example 1]
A non-woven fabric having a thickness of 20 mm and a basis weight of 400 g / m ² using a polyester 6.6 decitex yarn was placed in the same mold as in Example 1 to obtain a molded product.
[0033]
[Comparative Example 2]
A urethane foam having a thickness of 20 mm and a basis weight of 23 kg / m ³ was placed in the same mold as in Example 1 and molded to obtain a molded product.
[0034]
The molded products obtained in Example 1 and Comparative Examples 1 and 2 were cut into a predetermined size to obtain a sample for measuring transpiration, and the weight of this sample was measured. Next, a watch glass having a known weight was prepared, 1 cc of water was dropped into the watch glass, and a sample was placed so as to cover the top of the watch glass, and the initial initial weight (Wo) was measured. After that, the sample placed on the top of the watch glass containing water is left in a room at a temperature of 20 ° C. and a humidity of 65%, and the weight (Wt) after a lapse of a certain time (t) is measured as needed. The transpiration rate of moisture from the watch glass was determined by the following formula.
Transpiration rate (%) = [(Wo−W) − (Wt−W)] / (Wo−W) × 100
W: Total weight of sample and watch glass Wo: Total weight of initial sample, watch glass and water Wt: Total weight of sample, watch glass and water after a fixed time (t) 100% transpiration rate It can be said that the sample with a faster time is faster in moisture transpiration and excellent in transpiration (i.e. less stuffy).
[0035]
The results of the transpiration test of Example 1 and Comparative Examples 1 and 2 are shown in FIG. As is apparent from this figure, the molded product of the present invention has very good transpiration compared with a conventional material such as nonwoven fabric or urethane foam.
[0036]
【The invention's effect】
The molded product of the present invention is excellent in transpiration and moisture permeability. In particular, by making the body side of the molded product into a concavo-convex shape with cushioning properties, it is possible to obtain a molded product with soft touch and excellent transpiration, so it is comfortable to wear when used for clothing A feeling is obtained.
[Brief description of the drawings]
FIG. 1 is a schematic sectional view showing an embodiment of a molded product of the present invention.
FIG. 2 is a view schematically showing a state in which an inner layer and an outer layer of a molded product are bonded in a dot shape.
FIG. 3 is a graph showing the transpiration of a molded product.
[Explanation of symbols]
1 Molded product (mold cup)
2 Inner layer 3 Outer layer 4 Adhesive 20 Stretch quilted fabric 21 Outer fabric 22 Filling 23 Lining

Claims (3)

A molded product comprising at least an inner layer composed of a surface and a lining and an outer layer containing a nonwoven fabric, wherein the inner layer is formed with irregularities, and the inner layer lining and the outer layer nonwoven fabric are adhered in a dot-like manner. It is characterized by the above-mentioned. It is a stretchable quilted fabric in which the inner layer is made of an elastic stretch yarn that constitutes the lining, with an outer fabric made of inelastic stretch yarn, a lining made of elastic stretch yarn, and a batting arranged between the outer fabric and the lining. 2. The molded article according to claim 1, wherein The molded product according to claim 1 or 2, wherein the outer layer of the inner layer forms a body-side surface.

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