JP5666830B2 - Packed cotton, method for producing the same, and product using the same - Google Patents

Description

  The present invention relates to stuffed cotton in which fibers are fixed in a loop shape, a method for producing the same, 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. In the patent document 5, the present applicants have proposed a stuffed cotton made of a core yarn and a flower yarn and fused to the core yarn.

  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, it is still easy to sag 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. Moreover, although the stuffed cotton proposed in Patent Document 5 is soft, higher bulk and improved washing resistance have been demanded.

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

  In the present invention, in order to improve the stuffing cotton described in Patent Document 5, a stuffed cotton using a fusion fiber as a loop-like fiber to improve bulkiness and washing resistance, a method for producing the same, and a method for producing the same are used. Provide the products that were there.

  The stuffed cotton of the present invention is a stuffed cotton in which flower yarns are integrated with a core yarn, the flower yarns are composed of fused fibers, opened to form loop-like fibers, and the loop-like fibers are The core yarn includes a fused fiber, the fused fiber is heat-fused to integrate the loop-shaped fibers, and the flower yarn and the core yarn are fused. The fiber is a composite fiber composed of two or more polymers having different melting points.

  The method for producing stuffed cotton according to the present invention is a method for producing stuffed cotton in which a flower yarn is twisted and integrated with a core yarn, the flower yarn is supplied to a waist gauge by rotating or swinging, and the flower yarn is supplied. Supplying to the waist gauge so as to sandwich at least a part thereof, twisting the flower yarn and the core yarn together, forming a loop yarn, and opening the loop-like fiber of the flower yarn, Heating and fusing at least a part of the looped fibers of the flower yarn, and thermally fusing the fused fibers of the core yarn to integrate the looped fibers, It is characterized by manufacturing.

  The stuffed cotton product of the present invention is obtained by filling the stuffed cotton into a dough. Here, the stuffed cotton products include futons, blankets, sleeping bags, pillows, cushions, mats, stuffed animals, rugs, jackets, vests, coats, feather clothes, neck warmers, and the like.

  In the present invention, the flower yarn is composed of fused fibers, opened to form loop-shaped fibers, and includes a portion where the loop-shaped fibers are fused together, thereby improving bulkiness and washing resistance. It is possible to provide an improved stuffed cotton, a manufacturing method thereof, and a product using the same.

FIG. 1 is an explanatory view showing a manufacturing process in one 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 side view of the loop yarn in a state where the loop fiber is opened in the kneading / opening process. FIG. 5 is a schematic side view of the obtained cotton filling.

  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-like fiber is composed of multifilament fibers that are long fibers, opened, and the loop-like fibers are fused together. When the loop-shaped fibers are fused, the bulkiness and the washing resistance can be improved. That is, by fixing the opened loop-like fibers together, the number of fixing points increases, and the texture becomes stiff and difficult to loosen.

  The fused fiber of the flower yarn and the core yarn is a composite fiber composed of two or more polymers having different melting points. The composite fiber is preferably a fiber having a core-sheath structure in which the high melting point polymer is a core and the low melting point polymer is a sheath. This is for fusing the low melting point polymer. Examples of such a core-sheath composite fiber include “Belcouple” manufactured by KB Seiren, “Melset” manufactured by Unitika, and “EZBON” manufactured by Unjin Chemical. These composite fibers have a core made of polyethylene terephthalate (PET) and a sheath made of a low-melting polyester copolymer. It is preferable that the fused fiber of the loop-shaped fiber and the core yarn is a polyester multifilament fused fiber. This is because polyester is difficult to sag. Moreover, it is preferable that the fusion | melting temperature of a fusion fiber is 160-190 degreeC. If it is this range, it will be easy to process.

  The core yarn may further contain non-fusion fibers. As the non-fusion fiber, synthetic fibers such as polyester, nylon, and polypropylene are preferable. The ratio of the fused fiber and the non-fused fiber of the core yarn is preferably 20 to 100% by weight for the fused fiber and 0 to 80% by weight for the non-fused fiber when the core yarn is 100% by weight.

  The average length of the loops of the loop-like fibers is preferably in the range of 1 to 200 mm, and the average length is 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 may include 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 10 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. 1 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. 1, the flower yarn 1 and the core yarn 2 are supplied to the waist gauge 3 and twisted in the twisting step 4. Next, after opening the loop-like fibers of the flower yarn in the kneading / opening step 5, the yarn is heated in the first heat treatment step 6 to fuse at least a part of the loop-like fibers of the flower yarn, and the core yarn The fused fibers are heat fused to integrate the looped fibers. Next, a silicone resin that is a softening agent and a smoothing agent is sprayed in the silicone resin spraying step 7 and cured in the second heat treatment step 8. Next, the cut cotton 9 is obtained by cutting to a predetermined length in the cutting step 9.

  FIG. 2 is a schematic explanatory diagram of an example of the twisting process of the present invention. As shown in FIG. 2, the flower yarn 11 is supplied to the waist gauge 13 by rotating or swinging, and one kind of flower yarn or at least two kinds of core yarns 12 a and 12 b sandwich at least a part of the flower yarn 11. As shown in FIG. 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 subjected to a fiber opening process in the stagnation / fiber opening process 5 shown in FIG. In this step, two pieces of rubber, woven fabric, non-woven fabric, resin sheet, and the like are rubbed together, so that the loop yarn 21 put in between is squeezed and 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 order to open the fiber, it is possible to employ not only a kneading means but also a tapping or brushing process. 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 spread in the kneading / opening process is unwound from the bobbin and heat treated in a first heat treatment process 6 shown in FIG. The heat treatment temperature is preferably 70 to 220 ° C., particularly 140 to 210 ° C. at which the fusion polymer of the loop yarn 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 contact portions of the opened loop-like fibers are fused. Since the loop-like fibers are concentrated on the core portion, they are fused. A schematic cross-sectional view of the obtained loop yarn 21 is shown in FIG. 22 is a core yarn, and 23 is an opened loop-like fiber.

Next, in the silicone resin spraying step, the silicone resin is sprayed. 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. It is preferable that the spraying amount is sprayed in a dry weight of 0.1 to 10 wt% with respect to the filling cotton.

  Next, in the second heat treatment step, for example, heat treatment is performed at 120 to 200 ° C. for about 1 second to 20 minutes to cure the silicone resin. Next, it is cut into a predetermined length in the cutting step. A preferable cut length is 20 to 50 mm. The stuffed cotton 10 thus obtained is composed of looped fibers 23 opened as shown in FIG. 5 and a core portion 25 where the core yarn is heat-sealed. Reference numeral 24 denotes a fused portion between the loop-like fibers 23.

  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, neck warmers, 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, the trade name “EZBON” (Unzin Chemical Co., Ltd.) is a composite multifilament fiber having a PET core and a sheath made of a polyester copolymer, total fineness 78 dtex, 24 filaments, straight yarn. One was used and supplied to the waist cage 13 while being rotated or swung. 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 yarns 12a and 12b, two yarns, one each of the same yarns as the flower yarns 11, were used and 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 subjected to a fiber opening process in the kneading and fiber opening step 5 shown in FIG. In the squeezing / opening step, two pieces of rubber, woven fabric, non-woven fabric, resin sheet, and the like were rubbed together to squeeze the loop yarn 21 put in between, and the fiber was opened like the loop fiber 23 shown in FIG.

  Next, heat treatment was performed in the first heat treatment step 6 shown in FIG. The heat treatment temperature was 140 to 210 ° C., and the heat treatment time was 10 seconds to 10 minutes. By this first heat treatment, the polymer of the sheath portion of the flower yarn 11 and the core yarns 12a and 12b was fused, and the contact point of the loop fiber was fused. The core part was also fused.

  Next, in the silicone resin spraying step 7, the silicone resin was sprayed. As the silicone resin, “TERON E 530” bulky silicone, “TERON E 731”, and “TERON E 722” soft silicone manufactured by Matsumoto Yushi Seiyaku Co., Ltd. were used as a mixed aqueous solution. The spraying amount was 3.0 wt% with respect to the stuffed cotton in dry weight. Next, in the second heat treatment step 8, heat treatment was performed at 140 to 210 ° C. for 1 to 10 minutes to cure the silicone resin. Next, it cut | disconnected in 20-30 mm of cut length by the cutting process 9. FIG.

  The stuffed cotton 10 obtained in this way includes a portion in which the looped fibers 23 opened as shown in FIG. 5 are fused together as a fused portion 24, and the core portion 25 is also fused. It was.

  The bulkiness of the stuffed cotton 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 cylinder with a diameter of 28 cm, and then a drop lid of 120 g of load is placed. This is a method of measuring the height of the padding when it is left for 2 minutes at the time of cutting and then lifting the middle drop lid to remove the load. It was 150 mm when the bulkiness of the obtained stuffed cotton was measured. The texture was slightly hard. Moreover, the initial height of the cushion which filled 40g in the 30cm square side place was 93mm, and the height after 5 times home washing was 74mm. As a result of observing the cushion after washing, it was found that cotton was uniformly filled to the four corners. After washing, there was no unevenness and it was fluffy.

(Example 2)
In Example 1, trade name “EZBON” manufactured by Eunjin Chemical Co., Ltd. (a composite multifilament fiber made of PET and a sheath made of a polyester copolymer, total fineness 33 dtex, 24 filaments, straight yarn) is used as the core yarn. A stuffed cotton was prepared in the same manner as in Example 1 except that two multifilament fibers (total fineness 78 dtex, number of filaments 48, straight yarn) made of polyethylene terephthalate were used.

  The bulkiness of the obtained stuffed cotton was measured in the same manner as in Example 1. As a result, it was 90 mm. Moreover, the initial height of the cushion with 40 g filled in the 30 cm square side ground was 75 mm, and the height after 5 home washings was 65 mm. As a result of observing the cushion after washing, it was found that cotton was uniformly filled to the four corners. After washing, there was no unevenness and it was fluffy.

(Comparative Example 1)
As flower yarn, PET multifilament fiber (total fineness 40 dtex, 12 filaments, straight yarn) and PET multifilament fiber (total fineness 22 dtex, 12 filaments, straight yarn) are rotated or swung into the waist cage. Supplied. In the case of yarn swinging, the reciprocating distance was about 40 mm, and in the case of rotation, the loop on one side when picked up at the center of the loop was about 20 mm. Low melting point thermal bonding fiber yarn (low melting point nylon, melting point 110-113 ° C., trade name “Elder”, 78 dtex, 10 filaments, straight yarn) as core yarn 12a, and PET multifilament as core yarn 12b Fibers (total fineness 78 dtex, 48 filaments, straight yarn) were fed to the waist cage. 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 loop yarn thus obtained was unwound from the bobbin and heat treated in a heat treatment step. The heat treatment temperature was 140 ° C. at which the “elder” yarn was fused, and the heat treatment time was 5 seconds. This heat treatment fused the “elder” yarn and the loop fiber was twisted (temporarily fixed). Next, the twisted (temporarily fixed) loop yarn was subjected to a fiber opening process in a kneading process. 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 in between, and the loop fiber was opened. The loop yarn that was spread in the kneading process was then sprayed with silicone resin in the silicone resin spraying process. As the silicone resin, “TERON E 530” bulky silicone, “TERON E 731”, and “TERON E 722” soft silicone manufactured by Matsumoto Yushi Seiyaku Co., Ltd. were used as a mixed aqueous solution. The spraying amount was 3.0 wt% with respect to the stuffed cotton in dry weight.

  Next, in the second heat treatment step, heat treatment was performed at 140 ° C. for 10 minutes, and the silicone treating agent was heat-fixed on the cotton pad. Next, the cut length was cut to 20 to 30 mm in the cutting step 7. The stuffed cotton thus obtained was formed from the opened loop-like fiber and the core portion in which the core yarn was contracted and heat-sealed.

  The bulkiness of the obtained cotton stuff was measured in the same manner as in Example 1, and it was 75 mm. Moreover, the initial height of the cushions filled with 40 g on a 30 cm square side land was 63 mm, and the height after 5 home washings was 56 mm. Observation of the cushion after washing revealed no padding in the four corners. After washing, the impression was uneven compared to the cushions of Examples 1-2.

  From the above, it was confirmed that the example products of the present invention were improved in bulkiness and washing resistance as compared with conventional cotton filling.

1,11 Flower yarn 2,12a, 12b, 22 Core yarn 3,13 Waist gauge 4 Twist yarn process 5 Kneading and opening process 6 First heat treatment process 7 Silicone resin spraying process 8 Second heat treatment process 9 Cut process 10 Stuffed cotton 14 , 21 Loop yarn 15 Motor 16 Belt 17 Bobbin 18 Ring 19 Traveler 20 Twisting machine 23 Loop fiber 24 Fusion part 25 Core part

Claims (7)

A stuffed cotton in which flower yarn is integrated with a core yarn,
The flower yarn is composed of fused fibers, opened to form loop-shaped fibers, and includes a portion where the loop-shaped fibers are fused together,
The core yarn includes a fused fiber, and the fused fiber is heat-fused to integrate the loop-shaped fibers,
The stuffed cotton characterized in that the fused fiber of the flower yarn and the core yarn is a composite fiber composed of two or more polymers having different melting points.   The stuffed cotton according to claim 1, wherein the core yarn further includes non-fused fibers. The ratio of the fused fiber and the non-fused fiber of the core yarn is such that when the core yarn is 100% by weight, the fused fiber is 20 % by weight or more and less than 100 % by weight, and the non-fused fiber is more than 0 % by weight. The stuffed cotton according to claim 2, which is 80% by weight or less .   The stuffed cotton according to any one of claims 1 to 3, wherein the loop fiber and the fusion fiber of the core yarn are polyester multifilament fusion fibers.   The filling cotton according to any one of claims 1 to 4, wherein a fusion temperature of the fusion fiber is 140 to 210 ° C. A method for producing stuffed cotton in which flower yarn is twisted and integrated with a core yarn,
The flower yarn is supplied to the waist gauge by rotating or swinging the yarn, supplied to the waist gauge so as to sandwich at least a part of the flower yarn, the flower yarn and the core yarn are collectively twisted, and the loop yarn is applied. Forming, and
Opening the looped fiber of the flower yarn;
Heating and fusing at least a part of the looped fibers of the flower yarn, and fusing the fused fibers of the core yarn to integrate the looped fibers,
A method for producing stuffed cotton, comprising producing the stuffed cotton according to any one of claims 1 to 5.   A stuffed cotton product in which the stuffed cotton according to any one of claims 1 to 5 is filled in a dough.

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