JP5303359B2 - Stuffed cotton - Google Patents

Description

  The present invention relates to stuffed cotton including a plurality of loop-like fibers integrated with a core yarn, in which a synthetic resin film is mixed.

  In general, waterfowl feathers are used as feathers filled in feather products such as duvets and feather jackets. Water birds include goose (duck), 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 are limits to capturing 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 pillows, down duvets, down jackets.

  Conventionally, there are many proposals as stuffed cotton instead of feathers. 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. For example, in the examples 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.

  In view of this, the present applicants have proposed, in Patent Document 5, a stuffed cotton having excellent bulkiness and bulk durability by integrating a plurality of loop-like fibers with a core yarn. However, the stuffed cotton of Patent Document 5 tends to be entangled with each other by burrs of the core yarn, curls of the loop-like fibers, and the like, so that the blowing and washing durability are lowered.

JP-A-55-158366 JP 58-146385 A JP-A-6-93513 WO2006 / 104010A1 JP 2009-52183 A

  In order to solve the above-described conventional problems, the present invention is excellent in bulkiness and fluidity by mixing a synthetic resin film piece into stuffed cotton containing a plurality of loop-like fibers integrated with a core yarn. Provide stuffed cotton with excellent washability.

Wadding of the present invention, there is provided a wadding including a plurality of looped fibers integrated with core yarn, to the wad is Ri Contact synthetic resin film pieces are mixed, to 100 wt% the wad On the other hand, the mixing amount of the synthetic resin film piece is 10 to 25% by weight, and the synthetic resin film piece is coated with a silicone resin and has a thickness of 4 to 10 μm .

  The stuffed cotton product of the present invention is obtained by filling the stuffed cotton of the present invention into a container, for example, a dough. Here, the stuffed cotton product means a futon, a blanket, a sleeping bag, a pillow, a cushion, a mat, a stuffed toy, a rug, a neck, a muffler, a jacket, a vest, a coat, a feather suit, and the like.

  The present invention mixes synthetic resin film pieces into stuffed cotton that includes a plurality of loop-like fibers integrated with a core yarn, thereby preventing entanglement between stuffed cotton, improving fluidity, and being excellent in bulkiness. In addition, the present invention provides a stuffed cotton having excellent washing resistance.

FIG. 1A is an explanatory diagram illustrating an example of a manufacturing process for stuffed cotton in the present invention, and FIG. 1B is an explanatory diagram illustrating another example of a manufacturing process for stuffed cotton in the present invention. FIG. 2 is a schematic explanatory diagram of a twisting process in the production of stuffed cotton. FIG. 3 is an enlarged side view of the loop yarn. FIG. 4 is a schematic cross-sectional view of a twisted loop yarn. FIG. 5 is a schematic side view of the loop yarn in a state where the loop fiber is opened in the kneading process. FIG. 6 is a schematic side view of stuffed cotton. FIG. 7A is a schematic explanatory view showing a planar shape of an example synthetic resin film piece in the present invention, and FIG. 7B is a schematic explanatory view showing a three-dimensional shape of the synthetic resin film piece of 7A.

  The stuffed cotton of the present invention is stuffed cotton including a plurality of loop-like fibers integrated with a core yarn, and a synthetic resin film piece is mixed in the stuffed cotton.

(Padded cotton)
In the stuffed cotton, the loop-like fibers are composed of multifilament fibers and opened, and the core yarn is composed of at least two kinds of yarns having different melting points, and is heat-sealed to form the loop-like fibers. Are preferably integrated.

<Loop-like fiber>
The stuffed cotton is composed of a plurality of loop-like fibers (hereinafter also referred to as 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 natural 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 polyesters such as polyethylene terephthalate (PET), synthetic fibers such as nylon, regenerated fibers such as rayon, and natural fibers such as silk. In view 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 from a viewpoint of improving 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 into a back side, a straight fiber will be arranged on the outside, it will become stuffed cotton of a two-layer structure, and a volume feeling will become still higher.

  The average loop length 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 said range, a texture, bulkiness, and bulk durability can further be improved.

  The single fiber fineness of the loop fiber is preferably in the range of 0.1 to 300 dtex (dtex indicates deci tex) and the total fineness is in the range of 10 to 600 dtex. 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 particularly preferably, 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 200 dtex. If the fineness is in 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 fiber and the relatively high-melting core yarn, or for twisting after twisting the flower yarn. . 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.

  The core yarn is not particularly limited. For example, polypropylene fiber (melting point: 160 to 165 ° C.), propylene-ethylene random copolymer fiber (melting point: 135 to 150 ° C.), propylene-ethylene block copolymer fiber (melting point: 160 to 165 ° C.), high density Polyethylene (melting point: 123-135 ° C.), medium density polyethylene (melting point: 120-123 ° C.), low density polyethylene (melting point: 105-120 ° C.), low melting point polyester fiber (melting point: 110-200 ° C.), low melting point nylon fiber (melting point: 110 ~ 120 ° C, Toray's "Elder" and melting point: 95-145 ° C, Unitika's "Flor"), etc., can be used by selecting at least two types of fibers having different melting points. . 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 fibers, it is preferable to use the core-sheath fiber in combination with the low-melting point heat-bonded fiber yarn.

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

  In the stuffed cotton, when the total weight of the loop-like fibers and the core yarn is 100% by weight, the ratio of the loop-like fibers is preferably in the range of 51 to 99% by weight. More preferably, it is in the range of 80 to 98% by weight, particularly preferably in the range of 85 to 97% by weight. If it is the said range, the fixed integration by a core thread will become firm, and a texture will also become favorable.

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

  It is preferable that a silicone treating agent (silicone resin) is further heat-fixed on the filling cotton. Smoothness can be imparted to the stuffed cotton. The fixing amount of the heat-set silicone treatment agent is preferably 0.1 to 10% by weight with respect to the filling cotton. Further, an acrylic resin, a urethane resin or the like may be fixed for adjusting the hardness. The fixed amount of the heat-treated acrylic treatment agent is preferably 0.1 to 5.0% by weight with respect to the filling cotton.

  A method for producing stuffed cotton will be described below with reference to the drawings. In the drawings, the same reference numerals denote the same parts. FIG. 1A is an explanatory view showing an example of a manufacturing process of the stuffed cotton 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 while being rotated or shaken, and at least two types of core yarns 12a and 12b having different melting points are used. It is supplied to the waist gauge 13 so as to be sandwiched. 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 a 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 450 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 obtained loop yarn 14 is unwound from the bobbin 17 and heat treated in a heat treatment step 5 shown in FIG. 1A. The heat treatment temperature is preferably 90 to 200 ° 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 heat treatment, the core yarn having a relatively low melting point is fused, and the loop fiber is twisted. 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 loop yarn is subjected to a fiber opening process in a squeezing 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. Also, 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 bulkiness. In the case where the fiber opening process is not performed after the heat treatment step, the bulkiness is only about 30 mm. In order to open the fiber, in addition to squeezing means, tapping and brushing can be employed. As a squeeze member of mechanical squeezing machine, foams such as neoprene rubber, silicone rubber, urethane rubber, fluorine rubber, urethane foam, silicone rubber foam, ethylene-vinyl alcohol (EVA) foam, cellulose foam, etc. There are body, non-woven fabric, artificial leather and so on. In the case of brushes, there are synthetic fibers such as nylon, polyester, polyolefin, vinyl chloride, acrylic, aramid, and fluororesin, animal hair fibers such as wool, horse hair, deer hair, and pig hair, and brushes such as metal wires.

The loop yarn subjected to the fiber opening process in the kneading process 6 is then processed in a resin processing process 7 with a resin such as a silicone processing agent, for example, a resin dispersion in which a silicone processing agent is dispersed in water. As the silicone treating agent, it is preferable to use a reactive silicone treating agent having a molecular end having a hydrogen group (—H), 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 resin dispersion may further contain an acrylic resin, a urethane resin, or the like. As the acrylic resin, a water-soluble acrylic treating agent and an acrylic resin having a molecular terminal having an ethyl group (—CH ₃ ), a vinyl group (—CH═CH ₂ ), etc. based on a polymer of an acrylic ester or a methacrylic ester. It is preferable to use an emulsion. For example, Nicazole (manufactured by Nippon Carbide Industries Co., Ltd.), primal (manufactured by Rohm and Haas Co., Ltd.) and the like can be used. The content of the silicone treating agent in the resin dispersion is preferably 0.1 to 20% by weight with respect to the entire resin dispersion. Moreover, it is preferable that content of the acrylic processing agent in the said resin dispersion is 0.1 to 20 weight% with respect to the whole resin dispersion. In addition, a processing agent is fixed to a fiber by performing heat processing for about 1 second-about 20 minutes at about 140-180 degreeC, for example. The fixing amount of the heat-set silicone treatment agent is preferably 0.1 to 10% by weight with respect to the filling cotton, and the fixing amount of the heat-set acrylic treatment agent is 0.1 to the filling cotton. It is preferably ˜5.0% by weight.

  The loop yarn subjected to the resin treatment is then cut into a predetermined length in a cutting step 8. The cut length is usually 10 to 50 mm, preferably 20 to 40 mm.

  FIG. 1B is a manufacturing example of another example of stuffed cotton. The difference from FIG. 1A is that the second heat treatment step 41 is first provided after the resin treatment step 7 and the second kneading (opening) step 42 is added after the cutting step 8. Note that the cutting step 8 can be omitted.

(Synthetic resin film piece)
As the synthetic resin film piece, a synthetic resin film cut into a predetermined shape and size can be used. The synthetic resin film is not particularly limited as long as it is a film made of a synthetic resin. For example, a polyester film, a nylon film, a polypropylene film, or the like can be used. A polyester film is preferred from the viewpoint of high heat resistance and hence excellent washing resistance. As said polyester film, a polyethylene terephthalate film (PET), a polyethylene naphthalate film, a polybutylene terephthalate film, a polybutylene naphthalate film, etc. can be used. Moreover, a PET film is preferable from the viewpoint of excellent recyclability.

  The synthetic resin film is preferably coated with a silicone resin from the viewpoint of imparting smoothness to the synthetic resin film and improving the fluidity of stuffed cotton. Among these, a polyester resin coated with a silicone resin is particularly preferable. The silicone resin coating is performed, for example, by impregnating a synthetic resin film with a resin dispersion containing a silicone resin, and then removing the excess resin dispersion and drying. The silicone resin is not particularly limited as long as it is generally used for coating a synthetic resin film. Further, an antistatic function may be imparted to the synthetic resin film by including an antistatic agent in the resin dispersion. The antistatic agent is not particularly limited as long as it is generally used for imparting an antistatic function to a synthetic resin film.

  Although the said synthetic resin film piece is not specifically limited, It is preferable that thickness is 3-14 micrometers, and it is more preferable that it is 4-10 micrometers. When the thickness of the synthetic resin film piece is 4 μm or more, the film is stiff and it is easy to maintain the following three-dimensional shape. Further, when the thickness of the synthetic resin film piece is 10 μm or less, it is easy to maintain light weight while maintaining good fluidity.

  Although the shape of the said synthetic resin film piece is not specifically limited, For example, a rectangle, an ellipse, etc. are mentioned. From the viewpoint of further improving the fluidity, the cross-sectional shape in the longitudinal direction is preferably an uneven shape, more preferably a mountain shape and / or a wave shape, and particularly preferably a mountain shape. In FIG. 7A, the schematic explanatory drawing of the planar shape of the synthetic resin film piece whose cross-sectional shape in a longitudinal direction is a mountain shape is shown. Although the said synthetic resin film piece is not specifically limited, From a viewpoint of improving the ease of entanglement with filling cotton, and a fluidity | liquidity more, length, for example, the length B shown to FIG. 7A, is 50-450 of cut length in filling cotton. % Is preferable, and 100 to 250% is more preferable. Furthermore, it is preferable that it is 100 to 400% of the average length of the loop of the loop-like fiber in stuffed cotton, and it is more preferable that it is 150 to 200%. Specifically, the length is more preferably 10 to 50 mm, particularly preferably 20 to 40 mm. In addition, the synthetic resin film piece is not particularly limited, but from the viewpoint of further improving the ease of entanglement with the filling cotton and the fluidity, the width A, for example, width A shown in FIG. 7A is 10 to 50% of the cut length in the filling cotton. It is preferable that it is 15 to 25%. Furthermore, it is preferable that it is 5-50% of the average length of the loop of the loop-like fiber in stuffed cotton, and it is more preferable that it is 10-30%. Specifically, the width is more preferably 1 to 6 mm, particularly 3 to 5 mm. Further, in the uneven shape, the width of the unevenness, that is, the width of the concave portion or the width of the convex portion, for example, the width D of the concave portion 31a or the width C of the convex portion 31b shown in FIG. , May be different. Further, in the uneven shape, the depth of the unevenness, that is, the difference in height between the top of the convex portion and the bottom point of the concave portion, for example, the depth E shown in FIG. 7A may be the same in each concave portion or convex portion. Well, it can be different.

  The synthetic resin film piece preferably has a three-dimensional shape formed by random squeezing, spiral twisting, wave folding, embossing rolls, etc., and may have a three-dimensional shape formed by random squeezing and wave folding. More preferably, a three-dimensional shape is formed by wave folding. Easily entangled with stuffed cotton, fluidity is improved, and bulkiness can be maintained well. FIG. 7B is a schematic explanatory view of a three-dimensional shape formed by corrugating the synthetic resin film piece shown in FIG. 7A. Specifically, a three-dimensional shape in a crimped state is formed by folding the synthetic resin film piece along the crease 32 and folding it along the crease 33. Note that the crease and the bottom of the recess 31a may or may not coincide.

  When the stuffed cotton is 100% by weight, the mixing amount of the synthetic resin film piece is preferably 1 to 25% by weight. If it is in the said range, it will be excellent in bulkiness and fluidity | liquidity. Moreover, from the viewpoint of making the fluidity and bulkiness better, the mixing amount of the synthetic resin film is more preferably 5 to 20% by weight, and particularly preferably 10 to 15% by weight.

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

(Padded cotton)
<Production Example 1>
As the flower yarn 11 shown in FIG. 2, PET multifilament fiber yarn (“Aerocapsule” manufactured by Teijin, total fineness: 40 dtex, number of filaments: 12, straight yarn) and PET multifilament fiber (“Silmy” manufactured by Unitika), total The fineness: 36 dtex, the number of filaments: 18, and the different shrinkage mixed yarn) were supplied to the waist cage 13 while being rotated or shaken. 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.

  As the core yarn 12a, a low melting point nylon fiber yarn (Unitika "Flor", melting point: 95 to 125 ° C, total fineness: 56 dtex, straight yarn) and PET multifilament fiber yarn (Teijin, melting point: 250 ° C, total fineness: 56 dtex) , Straight yarn) as the core yarn 12b, low melting point nylon fiber yarn ("Flor" manufactured by Unitika, melting point: 95-125 ° C, total fineness: 56dtex, straight yarn) and PET multifilament fiber yarn (Teijin, melting point: 250) C., total fineness: 56 dtex, straight yarn) 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. Next, the flower yarn 11 and the core yarns 12a and 12b were collectively twisted to form a loop yarn 14. The loop yarn 14 was actually twisted by the twisting machine 30. The number of twists was 280 times / m. The obtained loop yarn 14 is shown in FIG.

  The obtained loop yarn 14 was unwound from the bobbin 17 and heat-treated in the heat treatment step 5 shown in FIG. 1A. The heat treatment temperature was 150 ° C. at which the “flor” yarn was fused, and the heat treatment time was 5 seconds. This heat treatment fused the “flor” yarn and the loop fiber was twisted. 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 loop yarn was subjected to a fiber-opening process in the kneading step 6 shown in FIG. 1A. In the kneading process, the loop yarn 21 is passed between the upper kneading member (made of neoprene rubber) and the lower belt material (made of polyvinyl chloride), and the loop kneading force is applied to the loop yarn 21 by the upper kneading member. The yarn 21 was squeezed and opened like a loop fiber 24 shown in FIG.

  The loop yarn was then impregnated with the resin dispersion in the resin treatment step 7. Resin dispersions were 0.5% by weight and 5.0% by weight of silicone treatment agents (“TRON E-722 and E-530” manufactured by Matsumoto Yushi Seiyaku Co., Ltd.), respectively, and acrylic treatment agents (manufactured by Nippon Carbide Industries “ Nicazole FX-586K ") 5.0 wt% and water 89.5 wt%. The excess resin dispersion was removed with a nip roller.

  Next, it heat-processed at 140 degreeC for 10 minute (s), and heat-fixed the silicone processing agent and the acrylic processing agent to the cotton pad. The total fixed amount of the silicone treatment agent and the acrylic treatment agent in the stuffed cotton 10 was 5.0% by weight. 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. The average weight per one stuffed cotton obtained was 4 mg.

  The stuffed cotton 10 obtained was cut into a cut length of about 20 mm by a rotary cutter in the cutting step 8. In addition, in the stuffed cotton 10, the average length of the loop of the loop-shaped fiber was 17.5 mm.

(Synthetic resin film piece)
<Production Example 2>
Polyester film (Toyobo Co., Ltd., thickness: 4.45 μm), silicone resin (Matsumoto Yushi Seiyaku “TERON E-722 and E-530”) 0.5% by weight and 5.0% by weight, respectively, antistatic After impregnation with a resin dispersion containing an agent (“Efcol 301” manufactured by Matsumoto Yushi Seiyaku Co., Ltd., 0.5% by weight), the excess resin dispersion was removed with a nip roller. Subsequently, it was dried at 140 ° C. for 10 minutes to obtain a polyester film coated with a silicone resin. Next, it is cut with a pinking scissors, and as shown in FIG. 7A, the end face shape in the longitudinal direction is a mountain shape, the width A is 4 mm, and the length B is 35 mm. Got. In addition, the length of the obtained film piece is 175% with respect to the cut length of the stuffed cotton 10 in Production Example 1 and 200% with respect to the average length of the loops of the loop-like fibers in the stuffed cotton 10 in Production Example 1. The width of the film piece was 20% with respect to the cut length of the stuffed cotton 10 in Production Example 1 and 23% with respect to the average length of the loops of the loop-like fibers in the stuffed cotton 10 in Production Example 1. .

<Production Example 3>
A synthetic resin film piece of Production Example 3 was obtained in the same manner as Production Example 2 except that a polyester film (Toyobo Co., Ltd.) having a thickness of 7.00 μm was used as the polyester film.

<Production Example 4>
A synthetic resin film piece of Production Example 4 was obtained in the same manner as Production Example 2 except that a polyester film having a thickness of 11.00 μm (Toyobo Co., Ltd.) was used as the polyester film.

(Examples 1 to 4, Reference Example 1 )
Production Example 1 so that the amount of the synthetic resin film piece of Production Example 2 is 25% by weight, 20% by weight, 15% by weight, 10% by weight, and 5% by weight with respect to 100% by weight of the filling cotton. No. 1 and the synthetic resin film piece of Production Example 2 were mixed uniformly to obtain the No. 1 to 4 and Reference Example 1 stuffed cotton. In addition, the synthetic resin film piece of Production Example 2 was used by forming a three-dimensional shape in a crimped state by wave folding as shown in FIG. 7B.

(Examples 6 to 9, Reference Example 2 )
Production Example 1 so that the amount of the synthetic resin film piece of Production Example 3 is 25% by weight, 20% by weight, 15% by weight, 10% by weight, and 5% by weight with respect to 100% by weight of the filling cotton. And the synthetic resin film piece of Production Example 3 were uniformly mixed to obtain the cotton stuffs of Examples 6 to 9 and Reference Example 2 . In addition, the synthetic resin film piece of Production Example 3 was used by forming a three-dimensional shape in a crimped state by wave folding as shown in FIG. 7B.

( Reference Examples 3-7 )
Production Example 1 so that the amount of the synthetic resin film piece of Production Example 4 is 25% by weight, 20% by weight, 15% by weight, 10% by weight, and 5% by weight with respect to 100% by weight of the filling cotton. And the synthetic resin film piece of Production Example 4 were mixed uniformly to obtain stuffed cotton of Reference Examples 3 to 7 . In addition, the synthetic resin film piece of Production Example 4 was used by forming a three-dimensional shape in a crimped state by wave folding as shown in FIG. 7B.

(Comparative Example 1)
A synthetic resin film piece was not mixed, and the stuffed cotton of Production Example 1 was used as Comparative Example 1.

The bulkiness, fluidity and washing resistance of the stuffed cotton of Examples 1 to 4, Reference Example 1, Examples 6 to 9, Reference Examples 2 to 7 and Comparative Example 1 were measured and evaluated as follows. Is shown in Table 1 below. In addition, in Table 1, the manufacture example, thickness, and content rate of the synthetic resin film piece used for Examples 1-4, Reference Example 1, Examples 6-9, and Reference Examples 2-7 were also shown collectively. .

(Bulky)
Put a 5 g sample uniformly in a cylinder with a diameter of 120 mm, then place a 20 g load drop lid (diameter 115 mm), gradually stretch the string connected to the drop lid and drop the drop lid down, When it fell, it was left for 2 minutes, and the height at this time was measured.

(Liquidity)
The sample was lightly pinched with one hand, lightly shaken, and observed to the extent that it dropped and judged as follows.
A: About 1 to 3 stuffed cotton falls as a lump B: About 1 to 10 stuffed cotton falls as a lump C: The whole hardens and falls to 2-3

(Laundry test)
Washing was carried out according to the test method described in Appendix Table 1 (No. 103) of JIS L 0217: 1995. Specifically, a 5 g sample was put in a laundry net, washed in a home automatic washing machine, dehydrated in a dewatering layer, and dried in a hot air dryer set at 65 ° C.

(Wash resistance)
The washing resistance was evaluated by observing bulkiness, sample uniformity and fluidity as follows.

<Bulkyness>
Samples were removed from the laundry net and observed for bulkiness as described above.

<Uniformity>
The washing net was tapped with a palm and the spread of the sample was observed and evaluated as follows.
A: Uniformly spread B: Slightly spread C: Some sample deviation D: Sample deviation

<Fluidity>
Samples were removed from the laundry net and observed for fluidity as described above.

1.0 kg of the stuffed cotton of Examples 1 to 4, Reference Example 1, Examples 6 to 9, and Reference Examples 2 to 7 is filled in the side of the pillow (length: 50 cm, width: 70 cm, cotton 100%). When a practical test was conducted, it had a texture and was bulky, similar to a pillow made of natural feathers. In addition, even when washing was repeated, there was no displacement of the stuffed cotton, no bulkiness, no loss of shape and no texture, and the washing resistance was excellent. Furthermore, although it used continuously for three months, it turned out that there is almost no sag and the stuffed cotton of this invention is excellent in bulk durability.

  The stuffed cotton of the present invention is filled into a storage body, for example, a dough, into a futon, a blanket, a sleeping bag, a pillow, a cushion, a mat, a stuffed animal, a quilt, a neck, a muffler, a jacket, a vest, a coat, a feather clothes, etc. Can be used.

DESCRIPTION OF SYMBOLS 1,11 Flower yarn 2,12a, 12b Core yarn 3,13 Waist gauge 4 Twist yarn process 5 Heat treatment process 6 Stitching process 7 Resin treatment process 8 Cutting process 10 Cotton 14 and 21 Loop yarn 15 Motor 16 Belt 17 Bobbin 18 Ring 19 Traveler 20 Twisting machine 22 Fusion core yarn 23, 24 Loop fiber 30 Synthetic resin film piece 31 Concave shape 31a Convex part 31b Concave part 32, 33 Crease 41 Second heat treatment step 42 Second kneading (opening) step

Claims (6)

A stuffed cotton containing a plurality of looped fibers integrated with a core yarn,
The wad is Ri Contact synthetic resin film pieces are mixed,
The mixing amount of the synthetic resin film piece is 10 to 25% by weight with respect to 100% by weight of the filling cotton,
The synthetic resin film piece is coated with a silicone resin and has a thickness of 4 to 10 μm . Wadding according to 請 Motomeko 1 wherein the synthetic resin film is Ru der polyester film. The stuffed cotton according to claim 1 or 2, wherein the synthetic resin film piece is mixed in an amount of 15 to 25 % by weight with respect to 100% by weight of the stuffed cotton. The stuffed cotton according to any one of claims 1 to 3, wherein the synthetic resin film piece has an uneven shape in cross-section in the longitudinal direction . The said synthetic resin film piece is stuffed cotton in any one of Claims 1-4 which has formed the three-dimensional shape by wave folding .   A stuffed cotton product in which the stuffed cotton according to any one of claims 1 to 5 is filled in a container.

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