JP5197096B2 - Packed cotton, method for producing the same, and product using the same - Google Patents

Description

  The present invention relates to stuffed cotton in which filament fibers are fixed in a loop shape, a manufacturing method thereof, and a product using the same.

  In general, waterfowl feathers are used as feathers filled in feather products such as duvets and feather jackets. Waterbirds include goose (goose), duck (duck), and Eider (wild duck) inhabiting the Arctic coastline. There are two types of feathers: down, which corresponds to the chest, and feathers called feathers, both of which are used in feather products. Feathers are produced in Central Europe such as Poland and Hungary, Northern Europe including the Scandinavian Peninsula, and China. Feathers are highly bulky, warm, and occupy the status of high-quality materials as feather products for comforters and feather jackets.

  However, natural feathers depend on water birds, and the supply amount is limited, and the supply amount fluctuates due to the influence of natural conditions and diseases (for example, bird viruses). Or, from the viewpoint of nature conservation, there is a limit to supplementing wild birds. In addition, natural feathers can cause bad odors if washed insufficiently, so remove the filth that causes bad odors in advance and maintain a certain level of cleanliness and oxygen count to see how much the feathers are washed. Management to keep in In addition, there is a problem that it is not easy to wash down feather products such as down duvets and down jackets.

  Therefore, there have been many proposals for stuffed cotton. Patent Document 1 proposes that a short fiber is bent in a loop shape to fix a concentrated point. Patent Document 2 proposes that an air nozzle is used to melt the core fiber and the loop fiber after air entanglement. Patent Document 3 proposes that polyester fibers are shrunk by heat treatment to develop crimps and have bulkiness and elasticity. Patent Document 4 proposes binding untwisted short fibers with low melting point fibers and fusing them.

However, in the example in which short fibers are used for flower yarns as in Patent Documents 1 and 4, the bulk is easy to sag and there is a problem in the durability of the bulk. In addition, as in Patent Document 2, sufficient bulkiness cannot be obtained by a method in which air is entangled and fused. Even in an example in which the bulkiness is expressed only by crimping of the fiber itself as in Patent Document 3, the bulk is also easily lost, and there is a problem in the durability of the bulk. Therefore, there has been a problem that card spread cotton has been put to practical use up to now.
JP-A-55-158366 JP 58-146385 A JP-A-6-93513 WO2006 / 104010A1

  In order to solve the above-mentioned conventional problems, the present invention uses a filament fiber that is fixed in a loop shape by using a filament fiber, and exhibits a bulkiness and has a bulk durability and a method for producing the same, and a method for producing the same Providing products using

The stuffed cotton of the present invention is a stuffed cotton in which a plurality of loop-like fibers are integrated with a core yarn, wherein the loop-like fiber is composed of a multifilament fiber and opened, and the core yarn has a melting point. Is composed of at least two types of yarns different from each other, and heat-fused to integrate the loop-like fibers, and has a bulkiness of 40 mm or more according to a JIS L 1903: 1998 (7.2) test method .

Another stuffing cotton of the present invention is a stuffing cotton in which a plurality of loop-like fibers are integrated with a core yarn, wherein the loop-like fiber is composed of a multifilament fiber and opened, and the core yarn is , Including at least a composite fiber composed of two or more polymers having different melting points, and heat-sealing to integrate the loop-like fibers, and having a bulkiness of 40 mm or more according to JIS L 1903: 1998 (7.2) test method characterized in that there.

The method for producing stuffed cotton of the present invention is a method for producing stuffed cotton obtained by twisting and integrating a plurality of loop filament fibers with a core yarn,
Supplied by rotating or swinging the yarn to the waist gauge,
At least two types of core yarns having different melting points are supplied to the waist gauge so as to sandwich at least a part of the flower yarn,
A step of collectively twisting the flower yarn and the core yarn to form a loop yarn;
A first heat treatment step of fixing the twist by heat-treating the loop yarn and fusing the lower melting yarn of the core yarn;
Including a second heat treatment step of heat-treating the loop yarn to which the twist is fixed and heat-bonding the yarn having a higher melting point of the core yarn to integrate the loop-shaped fibers, and
A method for producing stuffed cotton, comprising a step of opening the looped fibers of the flower yarn in an arbitrary step after the first heat treatment step.

Another method for producing stuffed cotton of the present invention is a method for producing stuffed cotton obtained by twisting and integrating a plurality of loop filament fibers with a core yarn,
Supplied by rotating or swinging the yarn to the waist gauge,
A core yarn including at least a composite fiber composed of two or more polymers having different melting points is supplied to the waist gauge so as to sandwich at least a part of the flower yarn,
A step of collectively twisting the flower yarn and the core yarn to form a loop yarn;
A first heat treatment step of fixing the twist by heat-treating the loop yarn and fusing the lower melting yarn of the core yarn;
Including a second heat treatment step of heat-treating the loop yarn to which the twist is fixed and heat-bonding the yarn having a higher melting point of the core yarn to integrate the loop-shaped fibers, and
It includes a step of opening the looped fiber of the flower yarn in an arbitrary step after the first heat treatment step.

  The stuffed cotton product of the present invention is obtained by filling the stuffed cotton into a dough. Here, the stuffed cotton product includes a futon, a blanket, a sleeping bag, a pillow, a cushion, a mat, a stuffed animal, a rug, a jacket, a vest, a coat, and a feather suit.

  In the present invention, the multifilament fiber is opened to form a plurality of loop fibers, and the core yarn is twisted into the loop fibers and thermally fused to integrate the loop fibers. It is possible to provide a stuffed cotton that is similar to a feather, is bulky, has little bulkiness, and has a bulk durability, a method for producing the same, and a stuffed cotton product using the same.

  The stuffed cotton of the present invention is composed of a plurality of loop-like fibers (also called flower yarns) and a core yarn. The loop fiber is composed of a multifilament fiber which is a long fiber and is opened. By forming the loop-like fibers with multifilament fibers, which are long fibers, and opening the fibers, the texture resembles feathers, which is bulky, difficult to sag, and can be made into stuffed cotton with high bulk durability. In other words, by using a multifilament fiber to reciprocate a plurality of cores to form a plurality of loops, the structure of the loops themselves can provide bulkiness and difficulty. Moreover, by opening the loop-shaped fibers, the texture becomes soft and the bulkiness can be improved to a practical level. As a result, the whole contains a lot of air, and the texture is similar to natural feathers. Here, the term “opening” refers to opening the converged fiber group so that the single fiber is substantially free. Opening may be performed completely or may be partially opened.

  As long as the loop fiber is a multifilament fiber, any fiber can be used. Examples thereof include synthetic fibers such as polyethylene terephthalate (PET) and nylon, regenerated fibers such as rayon, and natural fibers such as silk. In consideration of elasticity and bulkiness, hollow, W-shaped, star-shaped and other irregular cross-section fibers and high strength fibers, particularly hollow polyester fibers and high strength polyester fibers are preferred. Moreover, you may add a monofilament fiber with a multifilament fiber as an improvement in elasticity and bulkiness.

  The plurality of loop-shaped multifilament fibers may be composed of straight fibers and shrink fibers. If it does in this way, a contraction fiber will enter inside, a straight fiber will be arrange | positioned on the outside, it will become stuffed cotton of a two-layer structure, and a volume feeling will become still higher.

  The average length of the loops of the plurality of loop-like fibers is preferably in the range of 1 to 200 mm, more preferably in the range of 5 to 50 mm, and particularly preferably in the range of 10 to 40 mm. If a loop fiber is the said range, a texture, bulkiness, and bulk durability can further be improved.

  The single fiber fineness of the loop-like fibers is preferably in the range of 0.1 to 300 dtex and the total fineness is in the range of 10 to 600 dtex (dtex indicates deci tex). More preferably, the single fiber fineness is in the range of 1.0 to 50 dtex and the total fineness is in the range of 20 to 250 dtex, and the single fiber fineness is in the range of 2.0 to 25 dtex and the total fineness is in the range of 30 to 100 dtex. If the fineness is within the above range, it is difficult to sag and the texture is good.

  The core yarn is composed of at least two types of yarns having different melting points. Relatively low-melting core yarn is used for heat-sealing to integrate the loop-shaped fiber and relatively high-melting core yarn, or twisting after twisting the flower yarn (temporary fixing) ). The core yarn having a relatively high melting point is used to prevent the core yarn from being broken when the low melting point core yarn is heat-sealed, or is used to integrate the loop-like fibers by heat-sealing. At the time of heat-sealing, the core yarn may be thermally contracted simultaneously. When the core yarn is subjected to heat shrinkage, the core yarn may be heated in a free state. When the core yarn is not subjected to heat shrinkage, the core yarn is heated in a tension or constant length state or heated by pressing with a heating roll.

  Core yarn is polypropylene fiber (melting point 160-165 ° C), propylene-ethylene random copolymer fiber (melting point 135-150 ° C), propylene-ethylene block copolymer fiber (melting point 160-165 ° C), high density polyethylene (melting point 123-135 ° C) ), Medium density polyethylene (melting point 120 to 123 ° C.), low density polyethylene (melting point 105 to 120 ° C.), low melting point polyester fiber (melting point 160 to 190 ° C.), low melting point thermal bonding fiber yarn (low melting point nylon, melting point 110 to 110 ° C.) At least two kinds of fibers having different melting points are selected and used from any fiber not particularly limited such as 113 ° C., trade name “Elder” manufactured by Toray Industries, Inc.). In the present invention, since the fiber opening and the core yarn are subjected to the fiber-spreading process after heat fusion, it is preferable that the flower yarn and the core yarn are more firmly bonded. As the yarn, low-melting polyester fiber and low-melting nylon fiber are preferable. Particularly preferred are low melting point nylon fibers.

  The core yarn may have a configuration including at least a composite fiber composed of two or more polymers having different melting points. Examples of the composite fiber composed of two or more polymers having different melting points include conjugate fibers in which polymers having different melting points are combined in a core-sheath shape, etc., specifically, the high melting point polymer is a polypropylene polymer, Examples thereof include a core-sheath fiber in which the low melting point polymer is made of a polyethylene polymer or a low melting point polypropylene polymer. A composite fiber composed of two or more polymers having different melting points may constitute a core yarn alone or in combination with other core yarns. From the viewpoint of more reliably integrating the loop-like fibers, it is preferable to use the core-sheath fiber in combination with the low-melting point heat-bonding fiber yarn.

  The difference in melting point between at least two types of core yarns having different melting points or two or more polymers having different melting points is preferably 10 to 200 ° C.

  As for the weight ratio of the plurality of loop-shaped fibers and the core yarn, the ratio of the loop-shaped fibers is preferably in the range of 51 to 99 wt% when the loop-shaped fibers and the core yarn are used as a parameter. More preferably, it is the range of 80-98 wt%, Most preferably, it is the range of 85-97 wt%. If it is the said range, the fixed integration by a core thread will become firm, and a texture will also become favorable.

  The average weight per one of the stuffed cotton of the present invention is preferably 0.1 to 1000 mg, more preferably 1 to 100 mg, and particularly preferably 2 to 50 mg. In addition, if average weight is the said range, it will be easy to handle and can exhibit a favorable texture when it is made into feather products, such as a filling. In calculating the average weight per piece in the present invention, first, 30 g of stuffed cotton is collected, and the number of stuffed cotton contained in the 30 g is measured. Thereafter, the average weight (mg) per piece is calculated.

  It is preferable that a silicone treating agent is further heat-set in the stuffed cotton of the present invention. The preferable adhesion amount of the silicone treating agent is in the range of 0.1 to 1.0 wt% with respect to the total amount of the loop fiber (flower yarn) and the core yarn. Further, an acrylic resin, a urethane resin or the like may be fixed for adjusting the hardness.

  The manufacturing method of one Example of the stuffed cotton of this invention is demonstrated using drawing below. In the drawings, the same reference numerals denote the same parts. FIG. 1A is an explanatory view showing a manufacturing process of an example of the present invention, and FIG. 2 is a schematic explanatory view of a twisting process. As shown in FIG. 1A, the flower yarn 1 and the core yarn 2 are supplied to the waist gauge 3 and twisted in the twisting step 4. Specifically, as shown in FIG. 2, the flower yarn 11 is supplied to the waist gauge 13 by rotating or swinging the yarn, and at least two types of core yarns 12 a and 12 b having different melting points are used for at least part of the flower yarn 11. It supplies to the waist gauge 13 so that it may pinch | interpose. Here, the waist gauge is a funnel-shaped instrument, which is an instrument that is capable of temporarily storing the thread, with the upper part being largely open, allowing the thread to be dropped therein, and the lower outlet being narrowed.

  Next, the flower yarn 11 and the core yarns 12 a and 12 b are twisted together to form the loop yarn 14. The loop yarn 14 is formed by actual twisting by the twisting machine 20. That is, the bobbin 17 is rotated via the motor 15 and the belt 16, and a traveler 19 is incorporated in the ring 18 around this, and by rotating behind the rotation of the bobbin 17, the loop yarn 14 passing through the traveler 19 is Real twist is applied. A preferable number of twists is 150 to 350 times / m. An enlarged view of the obtained loop yarn 14 is shown in FIG. The flower yarn 11 forms a loop, and the core yarns 12a and 12b are twisted together to collect the whole.

The loop yarn 14 thus obtained is unwound from the bobbin 17 and heat-treated in the first heat treatment step 5 shown in FIG. 1A. The heat treatment temperature is preferably 90 to 160 ° C. at which the core yarn having a relatively low melting point is fused, and the heat treatment time is preferably about 1 second to 20 minutes. Furthermore, it is more preferable to apply a pressure of 1 kg / cm ² or more. By this first heat treatment, the core yarn having a relatively low melting point is fused, and the loop fiber is twisted (temporarily fixed). A schematic cross-sectional view of the obtained loop yarn 21 is shown in FIG. Reference numeral 22 denotes a fused core yarn.

  Next, the twisted (temporarily fixed) loop yarn is subjected to a fiber opening process in a kneading step 6 shown in FIG. 1A. In the kneading process, two pieces of rubber, woven fabric, non-woven fabric, resin sheet, and the like are rubbed together to squeeze the loop yarn 21 put in between, and the fiber is opened like a loop fiber 24 shown in FIG. By performing such an opening process, bulkiness of 40 mm or more can be obtained. In addition, by selecting the hollow or high-strength polyester fiber as the flower yarn and combining the fiber-opening treatment, or adding a polyester monofilament fiber of 30 dtex or less to the multifilament fiber and combining the fiber-opening treatment, It becomes possible to express sex. In addition, when not performing a fiber opening process after a 1st heat treatment process, bulkiness expresses only about 30 mm. This squeezing step 6 may be performed after the second heat treatment, but the fiber-opening efficiency is better after the first heat treatment step maintaining the yarn shape. In addition, it is more preferable to perform the opening process twice after the first heat treatment step and after the second heat treatment step. Thereby, it is possible to obtain bulkiness of 70 mm to 150 mm. In order to open the fiber, in addition to squeezing means, tapping and brushing can be employed. As a squeeze member of a mechanical squeezing machine, rubber (neoprene rubber, silicone rubber, urethane rubber, fluorine rubber, etc.) foam (urethane foam, silicone rubber foam, ethylene-vinyl alcohol (EVA) foam, cellulose foam) Etc.), non-woven fabric, artificial leather and the like. In the case of brushes, there are synthetic fibers such as nylon, polyester, polyolefin, vinyl chloride, acrylic, aramid, and fluorine resin; animal hair fibers such as wool, horse hair, deer hair, and pig hair, and brushes such as metal wires.

  The loop yarn that has been opened in the kneading process is then cut to a predetermined length in the cutting process 7. A preferable cut length is 20 to 50 mm.

The cut loop yarn is then sprayed with silicone resin in a silicone resin spraying step 8. As the silicone resin, it is preferable to use a reactive silicone treating agent having a molecular end having a hydrogen group (—OH), a vinyl group (—CH═CH ₂ ) or the like. For example, soft silicones such as “TERON E 530” bulky silicon, “TERON E 731”, “TERON E 722” manufactured by Matsumoto Yushi Seiyaku Co., Ltd. can be used. The spraying amount is preferably sprayed in a dry weight of 0.1 to 1.0 wt% with respect to the stuffed cotton.

  Next, in the second heat treatment step 9, for example, heat treatment is performed at 120 to 200 ° C. for about 1 second to 20 minutes, and the yarn having the higher melting point of the core yarn is thermally fused to integrate the looped fibers or the silicone treatment agent And heat-fixed to cotton. The stuffed cotton 10 obtained in this way is composed of a looped fiber 23 opened as shown in FIG. 6 and a core portion 22 where the core yarn is heat-sealed.

  FIG. 1B is an example of manufacturing a filling in another embodiment. The difference from FIG. 1A is that the cutting step 7 is first moved after the second heat treatment step 9 and the second opening (stagnation) step is added after the cutting step 7. The cutting step 7 can be omitted.

  The stuffed cotton of the present invention is suitable for futons, blankets, sleeping bags, pillows, cushions, mats, stuffed animals, rugs, jackets, vests, coats, feather clothes and the like.

  Hereinafter, the present invention will be described more specifically with reference to examples. The present invention is not limited to the following examples.

Example 1
As the flower yarn 11 shown in FIG. 2, PET multifilament fiber (total fineness 280 dtex, 24 filaments, straight yarn) and PET multifilament fiber (total fineness 84 dtex, 12 filaments, high shrinkage yarn) are used as waist. The cage 13 was rotated or threaded and supplied. As an example, in the case of thread swinging, the reciprocating distance is about 40 mm, and in the case of rotation, the loop on one side when picked up at the center of the loop is about 20 mm.

  Low melting point heat-bonded fiber yarn (low melting point nylon, melting point 110-113 ° C., trade name “Elder”, 110 dtex single yarn) as core yarn 12a, and sheath component of polypropylene component (melting point 160) as core yarn 12b A core-sheath type composite fiber yarn (hereinafter referred to as PP / PE composite yarn) having a core part of medium density polyethylene (melting point: 120 to 123 ° C., twin yarn of 380 dtex) was supplied to the waist cage 13. At this time, the core yarns 12a and 12b were supplied so as to sandwich the loop of the flower yarn 11. Subsequently, the flower yarn 11 and the core yarns 12 a and 12 b were twisted together to form a loop yarn 14. The loop yarn 14 was actually twisted by the twisting machine 20. The number of twists was 250 times / m. The obtained loop yarn 14 is shown in FIG.

  The loop yarn 14 thus obtained was unwound from the bobbin 17 and heat-treated in the first heat treatment step 5 shown in FIG. 1A. The heat treatment temperature was 120 ° C. at which the “elder” yarn was fused, and the heat treatment time was 5 seconds. By this first heat treatment, the “elder” yarn was fused and the loop fiber was twisted (temporarily fixed). A schematic cross-sectional view of the obtained loop yarn 21 is shown in FIG. Reference numeral 22 denotes a fused core yarn.

  Next, the twisted (temporarily fixed) loop yarn was subjected to a fiber opening process in the kneading step 6 shown in FIG. 1A. In the squeezing process, two pieces of rubber, woven fabric, non-woven fabric, resin sheet, and the like were rubbed together to squeeze the loop yarn 21 placed between them, and the fiber was opened like the loop fiber 24 shown in FIG.

  The loop yarn that was spread in the kneading process was then cut to a cut length of 20 to 30 mm in the cutting process 7.

  The cut loop yarn was then sprayed with silicone resin in a silicone resin spraying step 8. As the silicone resin, for example, soft silicone such as “TERON E 530” bulky silicone, “TERON E 731”, “TERON E 722” manufactured by Matsumoto Yushi Seiyaku Co., Ltd. was used. The amount of spraying was 0.5 wt% with respect to the stuffed cotton in dry weight.

  Next, in the second heat treatment step 9, heat treatment was performed at 170 ° C. for 10 minutes, and the PP / PE composite yarn having the higher melting point of the core yarn was subjected to heat shrinkage and heat fusion to integrate the loop fibers. In this second heat treatment step, the silicone treatment agent was simultaneously heat-fixed on the cotton pad. The stuffed cotton 10 obtained in this way was formed from the looped fibers 23 opened as shown in FIG. 6 and the core portion 22 in which the core yarn was contracted and heat-sealed.

  When the obtained cotton stuffing was filled with 1.3 kg in the side of a single comforter and subjected to a practical test, it had warmth and texture comparable to natural feathers, and was bulky. Used continuously for 3 months, but almost no settling occurred. From this, it was confirmed that the stuffed cotton had bulk durability.

(Example 2)
As the flower yarn 11 shown in FIG. 2, PET multifilament fiber (total fineness: 140 dtex, number of filaments: 24, product name “Tufrey E” manufactured by Unitika Co., Ltd.) was supplied to the waist cage 13 by rotating or shaking the yarn. As an example, in the case of thread swinging, the reciprocating distance is about 40 mm, and in the case of rotation, the loop on one side when picked up at the center of the loop is about 20 mm.

  Low melting point thermal bonding fiber yarn (low melting point nylon, melting point 110 to 130 ° C., trade name “Elder”, 78 dtex single yarn) as core yarn 12a, and PET monofilament fiber (melting point 250 to 260 ° C.) as core yarn 12b , Fineness 17 dtex) was supplied to the waist cage 13. At this time, the core yarns 12a and 12b were supplied so as to sandwich the loop of the flower yarn 11. Subsequently, the flower yarn 11 and the core yarns 12a and 12b were twisted together to form a loop yarn 14. The loop yarn 14 was actually twisted by the twisting machine 20. The number of twists was 250 times / m. The obtained loop yarn 14 is shown in FIG.

  The loop yarn 14 thus obtained was unwound from the bobbin 17 and heat-treated in the first heat treatment step 5 shown in FIG. 1B. The heat treatment temperature was 170 ° C. at which the “elder” yarn was fused, and the heat treatment time was about 5 seconds. This first heat treatment fused the “elder” yarn and the loop fiber to the core yarn. A schematic cross-sectional view of the obtained loop yarn 21 is shown in FIG. Reference numeral 22 denotes a fused core yarn.

  Next, the twisted (temporarily fixed) loop yarn was subjected to a fiber opening process in the kneading step 6 shown in FIG. In the squeezing process, two pieces of rubber, woven fabric, non-woven fabric, resin sheet, and the like were rubbed together to squeeze the loop yarn 21 placed between them, and the fiber was opened like the loop fiber 24 shown in FIG.

  The resulting fiber opening loop yarn was then sprayed with a silicone resin in a silicone resin spraying step 8. As the silicone resin, for example, soft silicones such as “TERON E 530” bulky silicone, “TERON E 731”, “TERON E 722” manufactured by Matsumoto Yushi Seiyaku Co., Ltd. were used. The amount of spraying was 0.5 wt% with respect to artificial feathers in dry weight.

  Next, in the second heat treatment step 9, heat treatment was performed at 160 ° C. for 10 minutes, and the silicone treating agent was heat-set on the cotton pad. In the stuffed cotton 10 thus obtained, the opened loop-like fibers 23 and the core yarn are heat-sealed, and the difference from Example 1 is that it is not thermally contracted.

  The stuffed cotton treated with silicone was then cut into a cut length of 30 to 40 mm in a cutting step 7. In addition, about partly stuffed cotton, the squeezing process was implemented again.

  When the obtained cotton stuffing was filled with 1.3 kg in the side of a single comforter and subjected to a practical test, it had warmth and texture comparable to natural feathers, and was bulky. Used continuously for 3 months, but almost no settling occurred. From this, it was confirmed that the stuffed cotton had bulk durability.

(Example 3)
A stuffed cotton was prepared under the same conditions as in Example 2 except those shown in Table 1 below. In Table 1, the bulkiness test method was measured according to the test method described in JIS L 1903: 1998 (7.2: bulkiness). In this test method, 30 g of cotton is put in a tube with a diameter of 28 cm, and then a drop lid of 120 g of load is put on, a string connected to the drop lid is gradually extended, and the drop lid is dropped and dropped. At the time of cutting, it was allowed to stand for 2 minutes , and then the height of the stuffed cotton was measured when the drop lid was lifted to remove the load. The reason why the stagnation was performed twice after mechanical stagnation (one time) and the second heat treatment step was because the part that was not completely opened by mechanical stagnation remained. I was able to. The conditions and results are shown in Table 1.

  In Table 1, the average weight per stuffed cotton was about 10 mg for Experimental Examples 1 to 6 and about 3 mg for Experimental Examples 7 to 8.

  Moreover, when the bulkiness of the normal card cotton was measured as a comparative example, the bulkiness of the card cotton was 74 mm. Furthermore, the bulkiness when the fiber opening treatment was not performed in Experiment No. 1 (without mechanical stagnation and twice stagnation process) was 30 mm.

  As apparent from Table 1, the examples of the present invention had high bulkiness.

Example 4
A heat retention test was conducted on the cotton stuffed with mechanical sac obtained in Experiment No. 7 of Example 3 and a general PET short fiber card spread cotton (fineness 18.9 dtex, fiber length 64 mm) as a comparative example. As a reference, an example using no cotton was also tested. A cross-sectional view of the heat retention test is as shown in FIG. 7, and the description is as follows.
Container: 200ml PP sampler cup thermometer: Memory meter SK-L200T Sato Keiki Seisakusho Co., Ltd. Dryer: 44 ℃ Setting cooling / heating device: 15 ℃ Setting procedure:
(1) 5 g of cotton 31 is weighed into a polypropylene container 30 having an outer diameter of 70 mm and a height of 80 mm.
(2) After the padding 31 is inserted, a vial 32 having a glass outer diameter of 25 mm, a height of 50 mm, and a capacity of 20 ml is inserted from above the central portion.
(3) Put 10 ml of warm water 33 into the vial.
(4) The whole upper part is covered with a heat insulating material 34 made of polyurethane resin foam, and the temperature sensor 35 is inserted into the hot water 33 of the vial 32 through a hole formed in the center.
(5) Put two containers containing each sample into the dryer.
(6) Heat at 44 ° C. to 45 ° C. until there is no temperature difference between the hot water in the two containers.
(7) When the temperature difference disappears at about 44 ° C. to 45 ° C., the whole container is replaced with a chiller set at 15 ° C.
(8) Record the temperature of the two samples with a memory meter.
(9) When the equilibrium is reached at 15 ° C to 17 ° C, the recording is terminated.

  The measurement results are shown in Table 2.

  From Table 2, it was confirmed that the product according to the embodiment of the present invention has higher heat retention than the conventional card spread cotton.

FIG. 1A is an explanatory view showing a manufacturing process in one embodiment of the present invention. FIG. 1A is an explanatory view showing a manufacturing process in another embodiment of the present invention. FIG. 2 is a schematic explanatory diagram of a twisting process in one embodiment of the present invention. FIG. 3 is an enlarged side view of the loop yarn in the twisting process. FIG. 4 is a schematic cross-sectional view of a loop yarn that is twisted (temporarily fixed). FIG. 5 is a schematic side view of the loop yarn in a state where the loop fiber is opened in the squeezing step. FIG. 6 is a schematic side view of the obtained cotton filling. FIG. 7 is a cross-sectional view of the heat retention test.

Explanation of symbols

1,11 Flower yarn 2,12a, 12b Core yarn 3,13 Waist gauge 4 Twist yarn process 5 First heat treatment process 6 Wrinkle process 7 Cut process 8 Silicone resin spraying process 9 Second heat treatment process 10 Stuffed cotton 14, 21 Loop yarn 15 Motor 16 Belt 17 Bobbin 18 Ring 19 Traveler 20 Twisting machine 22 Fusion core yarn 23 Loop fiber 30 Packed cotton container 31 Packed cotton 32 Hot water vial 33 Hot water 34 Insulating material 35 Temperature sensor

Claims (14)

A stuffed cotton in which a plurality of looped fibers are integrated with a core yarn,
The loop fiber is composed of a multifilament fiber and is opened,
The core yarn is composed of at least two types of yarns having different melting points, and is heat-sealed to integrate the loop-like fibers ,
JIS L 1903: 1998 (7.2) A stuffed cotton having a bulkiness of 40 mm or more according to a test method . A stuffed cotton in which a plurality of looped fibers are integrated with a core yarn,
The loop fiber is composed of a multifilament fiber and is opened,
The core yarn includes at least a composite fiber composed of two or more polymers having different melting points, and is heat-sealed to integrate the loop-shaped fibers ,
JIS L 1903: 1998 (7.2) A stuffed cotton having a bulkiness of 40 mm or more according to a test method .   The stuffed cotton according to claim 1 or 2, wherein the plurality of loop-like fibers are twisted with a core yarn.   The filling cotton according to any one of claims 1 to 3, wherein an average length of the loops of the plurality of loop-shaped fibers is in a range of 1 to 200 mm.   5. The weight ratio of the plurality of loop fibers and the core yarn is such that the ratio of the loop fibers is in the range of 51 to 99 wt% when the loop fibers and the core yarn are used as a parameter. The stuffed cotton according to item 1.   The stuffed cotton according to any one of claims 1 to 5, wherein the single fiber fineness of the plurality of loop-shaped fibers is in the range of 0.1 to 300 dtex and the total fineness is in the range of 10 to 600 dtex.   The stuffed cotton according to any one of claims 1 to 6, wherein the stuffed cotton is continuous or has an average weight of 0.1 to 1000 mg per piece.   The stuffed cotton according to any one of claims 1 to 7, wherein the plurality of loop-shaped multifilament fibers are composed of straight fibers and shrink fibers.   The stuffed cotton according to any one of claims 1 to 8, wherein a melting point difference between at least two types of core yarns having different melting points or two or more polymers having different melting points is 10 to 200 ° C.   The stuffing cotton according to any one of claims 1 to 9, wherein a silicone treatment agent is further heat-fixed on the stuffing cotton. A method for producing stuffed cotton in which a plurality of loop filament fibers are twisted with a core yarn and integrated,
Supplied by rotating or swinging the yarn to the waist gauge,
At least two types of core yarns having different melting points are supplied to the waist gauge so as to sandwich at least a part of the flower yarn,
A step of collectively twisting the flower yarn and the core yarn to form a loop yarn;
A first heat treatment step of fixing the twist by heat-treating the loop yarn and fusing the lower melting yarn of the core yarn;
Including a second heat treatment step of heat-treating the loop yarn to which the twist is fixed and heat-bonding the yarn having a higher melting point of the core yarn to integrate the loop-shaped fibers, and
A method for producing stuffed cotton, comprising a step of opening the looped fibers of the flower yarn in an arbitrary step after the first heat treatment step. A method for producing stuffed cotton in which a plurality of loop filament fibers are twisted with a core yarn and integrated,
Supplied by rotating or swinging the yarn to the waist gauge,
A core yarn including at least a composite fiber composed of two or more polymers having different melting points is supplied to the waist gauge so as to sandwich at least a part of the flower yarn,
A step of collectively twisting the flower yarn and the core yarn to form a loop yarn;
A first heat treatment step of fixing the twist by heat-treating the loop yarn and fusing the lower melting yarn of the core yarn;
Including a second heat treatment step of heat-treating the loop yarn to which the twist is fixed and heat-bonding the yarn having a higher melting point of the core yarn to integrate the loop-shaped fibers, and
A method for producing stuffed cotton, comprising a step of opening the looped fibers of the flower yarn in an arbitrary step after the first heat treatment step.   13. A step of applying a silicone treatment agent between the first heat treatment step and the second heat treatment step, wherein in the second heat treatment step, the silicone treatment agent is heat-fixed to the filling cotton. A method for producing stuffed cotton according to 1.   A stuffed cotton product in which the stuffed cotton according to any one of claims 1 to 10 is filled in a dough.

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