JP7048033B2 - futon - Google Patents

Description

The present invention relates to a futon.

In feather products such as duvets, it is required to prevent feathers from being blown out from the bag body that fills the feathers. In order to prevent feathers from blowing out, a so-called down-proofed fabric, in which ultrafine fibers are woven at high density, may be used as the fabric constituting the bag body. However, the down-proofed fabric has problems such as extremely low air permeability, hindering the respiration of feathers, and causing discomfort due to stuffiness. Further, since the downproofed fabric has a high density, it has a characteristic that it may feel cold to the touch, and there is also a problem that it is difficult to use it as a fabric for a futon.

Japanese Unexamined Patent Publication No. 2006-89865

The present invention has been made to solve the above-mentioned conventional problems, and a main object thereof is to provide a futon having both blowout prevention performance and breathability of a filling material (for example, feathers).

The futon of the present invention has a bag body in which at least a part thereof is composed of a multi-layer fiber structure, and the multi-layer fiber structure includes a woven or knitted fabric and a fiber nonwoven fabric layer arranged on at least one side of the woven or knitted fabric. The woven and knitted fabric and the fiber non-woven fabric layer are directly arranged.
In one embodiment, at least a portion of the fibers constituting the fiber nonwoven layer and at least a portion of the constituent fibers of the woven or knitted fabric are soluble in the same solvent.
In one embodiment, the solvent is dimethylformamide or dimethylacetamide.
In one embodiment, at least a part of the constituent fibers of the woven or knitted fabric is polyurethane elastic fiber.
In one embodiment, the fiber nonwoven layer comprises polyurethane nanofibers.
In one embodiment, the fibrous nonwoven fabric layer is composed of a plurality of layers having different densities.
In one embodiment, the non-woven fabric layer contains fibers having a melting point of 210 ° C. or lower.
In one embodiment, the duvet has feathers enclosed in the bag.
In one embodiment, the bag body has a sewn portion, and the sewn portion is sealed by heat treatment.

According to the present invention, it is possible to provide a futon having both blowout prevention performance and breathability of a filling material (for example, feathers).

It is a schematic sectional drawing of the multilayer fiber structure in one Embodiment of this invention. FIG. 3 is a schematic cross-sectional view of a multilayer fiber structure according to another embodiment of the present invention.

Hereinafter, preferred embodiments of the present invention will be described, but the present invention is not limited to these embodiments.

A. Multi-layer fiber structure The futon of the present invention has a bag body which is composed of at least a part of the multi-layer fiber structure. FIG. 1 is a schematic cross-sectional view of a multilayer fiber structure according to one embodiment of the present invention. The multilayer fiber structure 100 includes a woven and knitted fabric 10 and a fiber nonwoven fabric layer 20 arranged on at least one side of the woven and knitted fabric 10. The woven and knitted fabric 10 and the fiber non-woven fabric layer 20 are directly arranged. In the present specification, "directly arranged" means another layer between the woven or knitted fabric 10 and the fiber nonwoven fabric layer 20 (a layer containing components other than the components constituting the woven or knitted fabric 10 and the fiber nonwoven fabric layer 20). Means that does not exist. More specifically, in the multilayer fiber structure, the woven and knitted fabric 10 and the nonwoven fabric layer 20 are directly arranged without using an adhesive. In one embodiment, the woven and knitted fabric 10 and the nonwoven fabric layer 20 are fixed by welding (welding with a solvent). The welding is a partial welding in which a part of the constituent fibers of the woven or knitted fabric and a part of the fibers constituting the nonwoven fabric layer are dissolved in a solvent used when forming the nonwoven fabric layer.

In one embodiment, at least a portion of the fibers constituting the fiber nonwoven layer and at least a portion of the constituent fibers of the woven or knitted fabric are soluble in the same solvent. Soluble means that it exhibits a solubility of 5% by weight or more at 20 ° C. In one embodiment, at least a portion of the fibers constituting the fiber nonwoven layer and at least a portion of the constituent fibers of the woven or knit are soluble in dimethylformamide or dimethylacetamide, preferably dimethylformamide. ..

In one embodiment, the woven or knitted fabric comprises polyurethane elastic fibers and the nonwoven fabric layer comprises polyurethane fibers.

The thickness of the multilayer fiber structure is preferably 0.2 mm to 5 mm, more preferably 0.4 mm to 4 mm.

The air permeability of the multilayer fiber structure is preferably 3 cm ³ / cm ² · s or more, and more preferably 5 cm ³ / cm ² · s or more. The higher the air permeability of the multilayer fiber structure, the more preferable, but the upper limit thereof is, for example, 50 cm ³ / cm ² · s. The air permeability can be measured by JIS L1096: 2010 8.26 air permeability A method (Frazil method).

In the present invention, by using a multilayer fiber structure in which a nonwoven fabric layer is arranged on a woven or knitted fabric and these are directly arranged without an adhesive, a filler (for example, feathers) is blown out. It is possible to obtain a futon having excellent breathability. Further, since the multilayer fiber structure may contain other constituent fibers such as cotton yarn, the futon of the present invention is also advantageous in that it has a feature of low contact cold sensitivity.

FIG. 2 is a schematic cross-sectional view of a multilayer fiber structure according to another embodiment of the present invention. In the multilayer fiber structure 200, the fiber nonwoven fabric layer 20 has a two-layer structure, and includes a first fiber nonwoven fabric layer 21 and a second fiber nonwoven fabric layer 22 in order from the woven and knitted fabric 10 side. The first fiber non-woven fabric layer 21 and the second fiber non-woven fabric layer 22 are a low-density fiber non-woven fabric layer (first fiber non-woven fabric layer 21) and a high-density fiber non-woven fabric layer (second fiber non-woven fabric layer 22), respectively. , Microfiber non-woven fabric layer (first fiber non-woven fabric layer 21) and nanofiber non-woven fabric layer (second fiber non-woven fabric layer 22). Details will be described later.

A-1. Woven knits In one embodiment, the woven or knit contains constituent fibers that can be welded (welded with a solvent) to the nonwoven fabric layer. The mixing ratio of the non-woven fabric layer and the weldable constituent fibers is preferably 10% or more, more preferably 15% or more, still more preferably 20% or more, and particularly preferably 30% or more. The mixing ratio can be measured according to JIS L1030.

Examples of the constituent fibers that can be welded to the non-woven layer include polyurethane elastic fibers, polyvinylidene fluoride fibers, polyacrylonitrile fibers, cellulose acetate fibers, polylactic acid fibers, polypropylene fibers, polyester fibers, vinyl chloride fibers, polyamide fibers and the like. .. These constituent fibers may be used alone or in combination of two or more.

In one embodiment, the woven or knit contains constituent fibers having a melting point of 210 ° C. or lower, preferably a constituent fiber having a melting point of 170 ° C. or lower. As the constituent fibers having a melting point of 210 ° C. or lower, polyurethane elastic fibers having a melting point of 210 ° C. or lower can be preferably used. By constructing a woven or knitted fabric using constituent fibers having a low melting point as described above, a multilayer fiber structure having excellent heat-sealing properties can be obtained. By using such a multilayer fiber structure, it is possible to obtain a futon that can be sealed by heat treatment. Constituent fibers having a melting point of 210 ° C. or lower and other constituent fibers may be used in combination. In one embodiment, the mixing ratio of the constituent fibers having a melting point of 210 ° C. or lower (preferably 170 ° C. or lower) is 10% or more, preferably 15% or more, and more preferably 20% or more. More preferably, it is 30% or more.

In one embodiment, at least a part of the constituent fibers of the woven or knitted fabric is polyurethane elastic fiber. In one embodiment, the mixing ratio of the polyurethane elastic fiber is 10% or more, preferably 15% or more, more preferably 20% or more, still more preferably 30% or more.

Any suitable polyurethane is used as the polyurethane constituting the polyurethane elastic fiber. As a method for producing a polyurethane elastic fiber, for example, a polyol is reacted with an excess molar amount of diisocyanate to produce a polyurethane intermediate polymer having isocyanate groups at both ends, which can be easily reacted with the isocyanate groups of the intermediate polymer. A method of producing a polyurethane solution (polymer solution) by reacting a low molecular weight diamine or a low molecular weight diol having active hydrogen in an inert organic solvent and then removing the solvent to form a thread, or a polyol and diisocyanate and low A method in which a polymer reacted with a molecular weight diamine or a low molecular weight diol is solidified and dissolved in a solvent, and then the solvent is removed to form a thread. The solidified polymer is formed into a thread by heating without being dissolved in the solvent. A method of reacting the polyol with a diisocyanate with a low molecular weight diol to form a polymer into threads without solidifying the polymer, and a polymer or polymer solution obtained by each of the above methods. After mixing, there is a method of removing the solvent from the mixed polymer solution and forming into a thread. Preferably, (A) a double-ended isocyanate group prepolymer obtained by reacting a polyol with a diisocyanate (hereinafter referred to as “both-ended NCO group prepolymer”), (B) a polyol, a diisocyanate, and a low molecular weight diol are used. This is a method of melt-spinning a polymer (polymer for spinning) obtained by reacting with a double-ended hydroxyl group prepolymer obtained by reaction (hereinafter referred to as “both-ended OH group prepolymer”) without solidifying.

The polyol is preferably a polymer diol having a number average molecular weight of about 800 to 3,000. Examples of the polymer diol include polyether glycol, polyester glycol, polycarbonate glycol and the like. The polyol constituting the double-ended NCO group prepolymer and the polyol constituting the double-ended OH group prepolymer may be the same or different.

Examples of the polyether glycol include a ring-opening polymer of a cyclic ether such as ethylene oxide, propylene oxide, and tetrahydrofuran; ethylene glycol, propylene glycol, 1,4-butanediol, 1,5-pentanediol, neopentyl glycol, and the like. Examples thereof include polycondensates of glycols such as 1,6-hexanediol and 3-methyl-1,5-pentanediol.

Examples of the polyester glycol include ethylene glycol, propylene glycol, 1,4-butanediol, 1,5-pentanediol, neopentyl glycol, 1,6-hexanediol, 3-methyl-1,5-pentanediol and the like. Polycondensate of at least one selected from glycols of the above and at least one selected from dibasic acids such as adipic acid, sebacic acid, and azelaic acid; ring-opening weight of lactones such as ε-caprolactone and valerolactone. Coalescence and the like can be mentioned.

Examples of the polycarbonate glycol include at least one organic carbonate selected from dialkyl carbonates such as dimethyl carbonate and diethyl carbonate; alkylene carbonates such as ethylene carbonate and propylene carbonate; and diaryl carbonates such as diphenyl carbonate and dinaphthyl carbonate. At least one fat selected from ethylene glycol, propylene glycol, 1,4-butanediol, 1,5-pentanediol, neopentyl glycol, 1,6-hexanediol, 3-methyl-1,5-pentanediol and the like. Examples thereof include carbonate glycol obtained by transesterification reaction with group diol.

As the diisocyanate, any suitable diisocyanate such as an aliphatic type, an alicyclic type, an aromatic type, and an aromatic aliphatic type can be used. Specific examples include 4,4'-diphenylmethane diisocyanate, 2,4-toluene diisocyanate, 1,5-naphthalenedi isocyanate, xylylene diisocyanate, hydrogenated xylylene diisocyanate, isophorone diisocyanate, 1,6-hexamethylene diisocyanate, p. -Phenylene diisocyanate, 4,4'-dicyclohexylmethane diisocyanate, meta-tetramethylxylylene diisocyanate, para-tetramethylxylylene diisocyanate and the like can be mentioned. These may be used alone or in combination of two or more. Of these, 4,4'-diphenylmethane diisocyanate and 4,4'-dicyclohexylmethane diisocyanate are preferably used.

The low molecular weight diols and low molecular weight diamines, which are chain length extenders, are preferably those having an appropriate reaction rate and capable of imparting appropriate heat resistance, and generally have two active hydrogen atoms capable of reacting with isocyanate. A low molecular weight compound having a molecular weight of 500 or less is used.

Examples of the low molecular weight diol include ethylene glycol, propylene glycol, 1,4-butanediol, 1,5-pentanediol, neopentyl glycol, 1,6-hexanediol, and 3-methyl-1,5-pentanediol. Such as aliphatic diols. Trifunctional glycols such as glycerin are also used as long as the spinnability is not impaired. These may be used alone or in combination of two or more. Ethylene glycol and 1,4-butanediol are preferable from the viewpoint of providing workability and appropriate physical properties to the obtained fiber. Examples of the low molecular weight diamine include ethylenediamine, butanediamine, propylenediamine, hexamethylenediamine, xylylenediamine, 4,4-diaminodiphenylmethane, and hydrazine.

In the above reaction, a monofunctional monool such as butanol or a monofunctional monoamine such as diethylamine or dibutylamine may be used as the reaction adjusting agent or the degree of polymerization adjusting agent.

The inert solvent used in the above reaction or as a spinning solution is N, N-dimethylformamide, N, N-dimethylacetamide, N, N, N', N'-tetramethylurea, N-methyl. Examples thereof include polar solvents such as pyrrolidone and dimethylsulfoxide.

The polyurethane elastic fiber may contain optional components such as an ultraviolet absorber, an antioxidant, and a light stabilizer for improving weather resistance, heat oxidation resistance, and yellowing denaturation resistance. The optional component is added at any appropriate timing of the above reaction.

In obtaining the above-mentioned polymer for spinning, the molar ratio of the total molar amount of the total diisocyanate to the total molar amount of the total polyol and the total low molecular weight diol is preferably 1.02 to 1.20. As for the ratio of the bi-terminal NCO group prepolymer to the bi-terminal OH group prepolymer, the NCO group is preferably 0.05 to 1.0% by mass, more preferably 0.10 to 0 in the yarn immediately after spinning. Adjusted to remain at .60% by mass. The content of NCO groups in the spun fiber remains after dissolving the spun fiber (about 1 g) in a dibutylamine / dimethylformamide / toluene solution and then reacting the excess dibutylamine with the NCO group in the sample. It is obtained by titrating dibutylamine with hydrochloric acid.

Examples of commercially available polyurethane elastic fibers include Mobilon (registered trademark) R, RL, KL, R-LL manufactured by Nisshinbo Textile Co., Ltd.

The woven or knitted fabric may contain fibers other than the constituent fibers that can be welded to the non-woven fabric layer. As the other fiber, any suitable fiber may be adopted depending on the application. Examples thereof include natural fibers such as cotton, linen, wool and silk; regenerated fibers such as rayon, cupra and polynosic, semi-regenerated fibers such as acetate, and chemically synthesized fibers such as nylon, polyester, acrylic, polypropylene and vinyl chloride. ..

Constituent fibers that are weldable to the non-woven fabric layer (eg, polyurethane elastic fibers) are included in the woven or knitted fabric in any suitable form. Specific examples thereof include forms such as raw yarn (unprocessed yarn), false twisted yarn, and dyed yarn. Examples thereof include bare yarns; covering yarns (typically, polyurethane elastic fibers are used as core yarns), twisted yarns, and composite yarns with other fibers such as air entangled yarns. Examples of the covering yarn include a single covering yarn (SCY) and a double covering yarn (DCY). These forms are adopted alone or in combination of two or more.

Any suitable structure is adopted for the above-mentioned woven and knitted fabric. Specifically, in the case of a woven fabric, a woven structure such as a plain weave, a twill weave, or a satin weave can be mentioned. Knitting is roughly divided into weft and warp. In the case of weft knitting, knitting structures such as flat knitting, rubber knitting, pearl knitting, and double-sided knitting can be mentioned. In the case of warp, chain, denbi, chord, atlas, etc. can be mentioned.

The multilayer fiber structure may further include another woven or knitted fabric. As constituent fibers of another woven or knitted fabric, for example, natural fibers such as cotton, linen, wool and silk; regenerated fibers such as rayon, cupra and polynosic, semi-regenerated fibers such as acetate, nylon, polyester, acrylic, polypropylene and chloride. Examples thereof include chemically synthesized fibers such as vinyl. Another woven or knitted fabric and a laminate of the woven or knitted fabric obtained as described later and the fiber nonwoven fabric layer can be integrated by any suitable method. Another woven or knitted fabric and the laminated body can be integrated by, for example, a water flow entanglement treatment or the like.

A-2. Fiber non-woven layer As the fiber constituting the fiber non-woven layer, polyurethane fiber, polyvinylidene fluoride fiber, polyacrylonitrile fiber, cellulose acetate fiber, polylactic acid fiber, polypropylene fiber, polyester fiber, vinyl chloride fiber, polyamide fiber, polyimide fiber and the like are used. Can be mentioned. These fibers may be used alone or in combination of two or more. In one embodiment, the fiber nonwoven layer comprises polyurethane fibers. When the polyurethane fiber is used, it is possible to obtain a multilayer fiber structure having excellent adhesive strength between the fiber nonwoven fabric layer and the woven or knitted fabric (particularly, the woven or knitted fabric containing the polyurethane elastic fiber).

In one embodiment, the fibrous nonwoven layer comprises fibers having a melting point of 210 ° C. or lower, preferably fibers having a melting point of 200 ° C. or lower. As the fiber having a melting point of 210 ° C. or lower, a polyurethane fiber having a melting point of 210 ° C. or lower can be preferably used. Further, in one embodiment, polyurethane fibers having a melting point of 210 ° C. or lower can be used in the form of nanofibers. By forming the fiber nonwoven fabric layer using fibers having a low melting point as described above, a multilayer fiber structure having excellent heat-sealing properties can be obtained. By using such a multilayer fiber structure, it is possible to obtain a futon that can be sealed by heat treatment.

The fiber diameter of the fiber is preferably 1 nm to 500 μm, more preferably 10 nm to 300 μm, and further preferably 20 nm to 200 μm. In one embodiment, the fiber nonwoven layer comprises nanofibers (preferably polyurethane nanofibers). The fiber diameter of the nanofiber is preferably 1 nm to 1000 nm, more preferably 50 nm to 900 nm, and further preferably 200 nm to 800 nm. In one embodiment, the fiber nonwoven layer comprises microfibers (preferably polyurethane microfibers). The fiber diameter of the microfiber is preferably 1 μm to 500 μm, more preferably 1 μm to 300 μm, and further preferably 1 μm to 200 μm. Nanofibers and microfibers can be used together. For the fiber diameter of the fiber (nanofiber, microfiber), the fiber diameter at 100 points is measured from a scanning electron micrograph (SEM), and the average value is taken as the average fiber diameter. The fiber diameter can be measured by measuring software such as ImageJ.

The basis weight of the fiber nonwoven fabric layer is preferably 0.1 g / m ² to 20 g / m ² , and more preferably 0.5 g / m ² to 10 g / m ² . Within such a range, it is possible to obtain a futon in which the blowout of the filling material (for example, feathers) is particularly suppressed and the air permeability is excellent. Further, if the basis weight of the fiber nonwoven fabric layer is within the above range, a multilayer fiber structure having excellent puncture resistance is formed, and even when a filler having a core such as a feather is filled, the filling is performed. It is possible to prevent the blowout of objects.

The thickness of the fiber nonwoven fabric layer is preferably 1 μm to 500 μm, more preferably 2 μm to 300 μm, still more preferably 3 μm to 200 μm, and particularly preferably 4 μm to 100 μm. Within such a range, it is possible to obtain a futon in which the blowout of the filling material (for example, feathers) is particularly suppressed and the air permeability is excellent.

In one embodiment, the fibrous nonwoven fabric layer is composed of a plurality of layers having different densities. Preferably, the fiber non-woven fabric layer may have a low-density fiber non-woven fabric layer (first fiber non-woven fabric layer) and a high-density fiber non-woven fabric layer (second fiber non-woven fabric layer) in order from the woven or knitted fabric side. In another embodiment, the fiber nonwoven fabric layer is composed of a plurality of layers having different fiber diameters (average fiber diameters). Preferably, the fiber nonwoven fabric layer is, in order from the woven or knitted fabric side, a microfiber nonwoven fabric layer composed of microfibers (first fiber nonwoven fabric layer) and a nanofiber nonwoven fabric layer composed of nanofibers (second fiber nonwoven fabric). Layer) and may have. Further, in the fiber nonwoven fabric layer, the low density fiber nonwoven fabric layer may be a microfiber nonwoven fabric layer, and the high density fiber nonwoven fabric layer may be a nanofiber nonwoven fabric layer.

As described above, the first fiber non-woven fabric layer (low density fiber non-woven fabric layer or microfiber non-woven fabric layer) is provided directly on the woven or knitted fabric, and the second fiber non-woven fabric layer (high density) is provided on the first fiber non-woven fabric layer. By providing the fiber non-woven fabric layer or the nanofiber non-woven fabric layer), it is possible to obtain a multi-layer fiber structure in which the fiber non-woven fabric layer and the woven or knitted fabric are difficult to peel off and the multi-layer fiber structures have excellent adhesive strength to each other or to another fabric. Can be done. The first fiber non-woven fabric layer and the second fiber non-woven fabric layer may be made of the same resin or may be made of different resins. Preferably, it is composed of the same resin.

The density of the low-density fiber nonwoven fabric layer and the microfiber nonwoven fabric layer is preferably 0.0025 g / cm ³ to 20 g / cm ³ , more preferably 0.003 g / cm ³ to 20 g / cm ³ , and even more preferably. Is 0.005 g / cm ³ to 20 g / cm ³ . Within such a range, the above effect becomes more remarkable.

The thickness of the low-density fiber nonwoven fabric layer and the microfiber nonwoven fabric layer is preferably 1 μm to 40 μm, more preferably 1 μm to 30 μm, and further preferably 1 μm to 20 μm.

The density of the high-density fiber non-woven fabric layer and the nanofiber non-woven fabric layer is preferably 0.0025 g / cm ³ to 200 g / cm ³ , more preferably 0.05 g / cm ³ to 40 g / cm ³ , and even more preferably. Is 0.01 g / cm ³ to 20 g / cm ³ . Within such a range, the above effect becomes more remarkable.

The thickness of the high-density fiber nonwoven fabric layer and the nanofiber nonwoven fabric layer is preferably 0.1 μm to 40 μm, more preferably 0.5 μm to 20 μm, and further preferably 1 μm to 10 μm.

In one embodiment, the nonwoven layer can be formed by electrospinning. As the electrospinning method, a solution type electrospinning method can be preferably used. In the solution-type electrospinning method, a high voltage (for example, 5 kV to 40 kV) is applied to a solution of a resin that is a material of fibers constituting a non-woven fabric layer, the resin solution is sprayed from a nozzle, and the above is performed as a grounded collector. This is a method of collecting resin with a woven or knitted fabric and fiberizing the resin in the process. The resin that is the material of the fibers constituting the non-woven fabric layer is extruded from the nozzles and fiberized to a predetermined fiber diameter by the stretching action by the electric field between the nozzles / collectors (woven and knitted fabrics) and the volatilization of the solvent. The fiber diameter of the fiber can be adjusted by adjusting the concentration of the resin solution, the applied voltage, the nozzle diameter, the distance between the nozzle and the collector, the processing speed, and the like.

In the present invention, it is preferable that the fiber in which the solvent remains in the resin solution reaches the woven or knitted fabric, and then the solvent is volatilized to form a non-woven fabric layer. By doing so, the constituent fibers of the woven or knitted fabric (for example, polyurethane elastic fibers) and the fibers constituting the nonwoven fabric layer can be partially welded, and the adhesive strength between the woven or knitted fabric and the nonwoven fabric layer is excellent. A multilayer fiber structure having excellent breathability can be obtained. The residual amount of the solvent can be adjusted by the distance between the nozzle and the collector (woven or knitted fabric), the concentration of the resin solution, the type of the solvent (boiling point), and the like.

As the solvent used in the resin solution, any suitable solvent can be used as long as the resin that is the material of the fiber constituting the nonwoven fabric layer can be dissolved. Preferably, as the solvent used in the resin solution, a solvent capable of dissolving the resin (for example, polyurethane-based resin) which is the material of the fiber constituting the nonwoven fabric layer and the constituent fiber (for example, polyurethane elastic fiber) of the woven or knitted fabric is used. Be done. If such a solvent is selected, the constituent fibers of the woven or knitted fabric and the fibers constituting the nonwoven fabric layer can be preferably welded, and a multilayer fiber structure having excellent adhesive strength between the woven or knitted fabric and the nonwoven fabric layer can be obtained. can.

When a polyurethane-based resin is used as the resin that is the material of the fibers constituting the nonwoven fabric layer (that is, the nonwoven fabric layer contains polyurethane fibers) and the woven or knitted fabric contains polyurethane elastic fibers, the solvent is, for example, dimethyl. Formamide, dimethylacetamide, methylsulfoxide, N-methylpyrrolidone, methylethylketone, acetone and the like can be used. Of these, dimethylformamide or dimethylacetamide is preferable, and dimethylformamide is more preferable. By using these solvents, it is possible to obtain a multilayer fiber structure having particularly excellent adhesive strength between the woven or knitted fabric and the nonwoven fabric layer. Further, the solvent is a high boiling point solvent, which is advantageous in that it is easy to set the conditions for causing the fiber in the resin solution in which the solvent remains to reach the woven or knitted fabric and welding the woven or knitted fabric and the nonwoven fabric layer. Is.

The resin solution may have an arbitrary appropriate resin concentration depending on the type of resin and solvent contained, the desired fiber diameter, the density of the nonwoven fabric layer, and the like. In one embodiment, the resin concentration of the resin solution is preferably 1 wt% to 30 wt%, more preferably 5 wt% to 20 wt%, based on the total weight of the resin solution.

The weight average molecular weight (Mw) of the resin used as the material of the fiber constituting the nonwoven fabric layer is preferably 10,000 to 1,000,000, more preferably 50,000 to 500,000. A resin having a weight average molecular weight in such a range is advantageous in that it can be preferably fiberized. The weight average molecular weight can be measured by gel permeation chromatography (GPC).

The nozzle diameter of the nozzle is, for example, 0.1 mm to 2.0 mm. The distance from the nozzle to the collector is, for example, 3 cm to 30 cm.

B. Futon As described above, the futon of the present invention has a bag body which is at least partially composed of a multilayer fiber structure. The bag may be entirely composed of the multilayer fiber structure, or a part of the bag may be composed of the multilayer fiber structure. For example, taking advantage of the low contact cold sensitivity (not cold), a multilayer fiber structure is used on the inside (user side), and the outer fabric is any suitable fabric for printing to form the above bag body. You may.

In one embodiment, the futon of the present invention has feathers enclosed in a bag.

In one embodiment, the bag is formed by filling an opening with a filler (eg, feathers) and sewing the opening. Further, the bag body may be sewn so as to provide a plurality of compartments in the bag body. In one embodiment, the bag body has a sewn portion as illustrated above, and the sewn portion is sealed by heat treatment. In the sewn portion, the multilayer fiber structure is heat-sealed and sealed by heat treatment. In this embodiment, the sealing tape is not used for the sealing treatment, and a bag body (as a result, a futon) having no sealing tape can be obtained. As the heat treatment conditions, any appropriate conditions are adopted. Specifically, it may be a dry heat treatment or a wet heat treatment. In the case of dry heat treatment, the treatment temperature is preferably 100 to 200 ° C, more preferably 110 to 190 ° C. The processing time is typically 30 to 120 seconds. On the other hand, in the case of wet heat treatment, the treatment temperature is preferably 90 to 140 ° C, more preferably 95 to 130 ° C. The processing time is typically 10 to 30 seconds. In addition to the above, examples of the heat treatment method include a method in which a multilayer fiber structure is directly pressed against a heat medium such as an iron to perform heat treatment. In this case, the treatment temperature is preferably 80 to 180 ° C, more preferably 80 to 120 ° C. The processing time is typically 5 to 20 seconds.

In another embodiment, the bag body may be formed by heat treatment instead of the above sewing. Specifically, the bag body may be formed by filling a filler (for example, feathers) from the opening and heat-sealing the multi-layer fiber structure in the opening by heat treatment. Further, the plurality of compartments may be provided by fusing the facing fabrics by heat treatment. By forming the bag body by heat treatment instead of sewing, the effect of suppressing the blowout of the filling material can be further enhanced. As the heat treatment conditions, the conditions described above can be adopted.

Hereinafter, the present invention will be specifically described with reference to Examples, but the present invention is not limited to these Examples.

<Example 1>
The warp is cotton yarn (50 count), the warp is cotton yarn (50 count) and polyurethane elastic fiber covering yarn (core yarn Mobilon R110-LL, made by Nisshin Spinning Textile, sheath yarn nylon 33dtex / 10f, Toray), and the surface is cotton yarn. Only, a warp and double woven gauze was obtained by alternately arranging one cotton yarn and one polyurethane elastic fiber covering yarn on the warp and weft on the back surface. Using this cotton fabric (polyurethane elastic fiber (Mobilon) mixing ratio 20%) as a base fabric, a polyurethane solution was directly spun by electrospinning to obtain a multilayer fiber structure. The polyurethane solution for microfiber non-woven fabric was prepared using dimethylformamide as a solvent so that the solid content concentration was 15 wt%. The polyurethane solution for nanofiber non-woven fabric was prepared so as to have a solid content concentration of 13 wt% using a mixed solvent in which dimethylformamide and methyl ethyl ketone were mixed at a ratio of 70:30. ES300 (manufactured by Nafias Co., Ltd.) was used for electrospinning. The ES300 has five spinning nozzles toward the upper metal flat plate collector, and the spinning nozzles are mounted parallel to the longitudinal direction of the spinning chamber. For the microfiber non-woven fabric layer, a base cloth roll having a width of 300 mm was set in ES300, the nozzle was swung in the width direction at a speed of 300 mm and 3 m / min, and the winding speed was 1.88 cm / min. The applied voltage was 10 kV, and the nozzle-collector distance was 8 cm. For the nanofiber non-woven fabric layer, a base cloth roll obtained by processing the microfiber non-woven fabric layer was set in ES300 and processed at a winding speed of 1.88 cm / min. The applied voltage was 10 kV, and the nozzle-collector distance was 6 cm.

<Example 2>
A multilayer fiber structure was obtained in the same manner as in Example 1 except that the spinning speed when the microfiber non-woven fabric layer was provided was doubled.

<Example 3>
A multilayer fiber structure was obtained in the same manner as in Example 1 except that the spinning speed was 0.75 cm / min when the nanofiber layer was provided without the microfiber layer.

<Comparative Example 1>
A porous polytetrafluoroethylene (ePTFE) resin film with a pore diameter of 3 μm, a pore ratio of 91%, and a thickness of 12 μm on one side, based on a cotton satin woven fabric made of cotton yarn (80 count) for both warp and weft (weight:: 2.4 g / m2, air permeability: 4.7 cm ³ / cm ² · s) was bonded at an adhesive area ratio of 15% (adhesive transfer amount: 3.6 g / m ² ) to obtain an ePTFE laminated fabric.

<Comparative Example 2>
A high-density cotton satin woven fabric formed as cotton yarn (80 count) for both warp and weft was subjected to calendar processing to obtain a duvet fabric.

<Comparative Example 3>
Warp yarn is cotton yarn (50 count), warp yarn is cotton yarn (50 count) and polyurethane elastic fiber covering yarn (core yarn: Nisshinbo Textile brand name "Mobilon R110-LL"; sheath yarn: Toray, nylon 33dtex / 10f) Was used to obtain a warp and double woven gauze fabric in which only cotton yarn was arranged on the front surface and one cotton yarn and one polyurethane elastic fiber covering yarn were alternately arranged on the weft on the back surface.

<Evaluation>
The multilayer fiber structures obtained in Examples and Comparative Examples were subjected to the following evaluation. The results are shown in Table 1.
(1) Air permeability JIS L 1096 A method The air permeability was measured by the Frazier method.
(2) Washing test A washing test was conducted at 40 ° C for 30 minutes with 200 ml of water, 20 steel balls and a 10 cm x 10 cm test cloth in a washing tester, and the peeling of the cloth and the air permeability after washing were confirmed. ..
(3) Feather blowout test A feather blowout test was performed according to the Nichibakyo Tumble Dry Method. Specifically, the dough (multilayer fiber structure) obtained in Examples and Comparative Examples is made into a bag shape, and feathers are enclosed in a bag made of the dough to prepare an evaluation sample, and ISO6330 compliant tumble drying is performed. The sample and 10 rubber tubes for ICI type pilling test (JIS L 1076) were placed in the machine and operated at a temperature of 40 ° C. for 60 minutes. After the operation, the blown feathers, the feathers adhering to the product, and the feathers in the middle of the blown out were all collected and judged according to the standards of the Japan Feather Products Cooperative Association.
(4) Contact cold / warm feeling test The test was carried out using the trade name "KES-F7 Thermolab II tester" manufactured by Katou Tech Co., Ltd. The maximum heat absorption rate (q), which is the instantaneous amount of heat transfer when the sensor is placed on the hot plate and the temperature difference (ΔT: 20 ° C.) from the test piece is made constant, and then the sensor is brought into contact with the test piece. -max) was measured.

As is clear from Table 1, the multilayer fiber structure of the present invention has high air permeability, can prevent feathers from blowing out, and has a low contact temperature / cooling feeling, that is, heat retention, stuffiness, and moment of touch. All the evaluation items of warmth are good. The fabric of Comparative Example 1 is a laminated fabric known as Gore-Tex (registered trademark), but the air permeability is extremely low, and the contact temperature / cooling feeling is also a large value close to 0.3. Comparative Example 2 is a down-proofed fabric made of 100% cotton high-density woven fabric, which is generally used as a fabric for duvets. It is a level that feels cold to the touch. Further, in Comparative Example 3 in which the fiber non-woven fabric layer was not laminated on one side, the air permeability was high and the contact temperature and cold feeling were low, so that the warmth at the moment of touching could be felt, but the blowout of feathers could be prevented. It was shown that it could not be done.

Claims (8)

At least a part thereof has a bag body composed of a multilayer fiber structure, and has a bag body.
The multilayer fiber structure is
With woven and knitted fabrics
With a fiber nonwoven layer disposed on at least one side of the woven knit,
The woven or knitted fabric and the fiber non-woven fabric layer are directly arranged ,
At least a part of the fibers constituting the fiber nonwoven fabric layer and at least a part of the constituent fibers of the woven or knitted fabric are soluble in the same solvent.
The fiber nonwoven fabric layer is composed of a plurality of layers having different densities.
futon. The futon according to claim 1 , wherein the solvent is dimethylformamide or dimethylacetamide. The futon according to claim 1 or 2 , wherein at least a part of the constituent fibers of the woven or knitted fabric is polyurethane elastic fiber. The futon according to any one of claims 1 to 3 , wherein the fiber nonwoven fabric layer contains polyurethane nanofibers. The futon according to any one of claims 1 to 4 , wherein the fiber nonwoven fabric layer contains a fiber having a melting point of 210 ° C. or lower. The futon according to any one of claims 1 to 5 , wherein feathers are enclosed in the bag body. The futon according to any one of claims 1 to 6 , wherein the bag body has a sewn portion, and the sewn portion is sealed by heat treatment. The futon according to any one of claims 1 to 7, wherein the fiber nonwoven fabric layer has a low-density fiber nonwoven fabric layer and a high-density fiber nonwoven fabric layer in order from the woven or knitted fabric side.

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