JPH0241356B2 - - Google Patents

Description

[Detailed description of the invention]

The present invention relates to a cotton filling material. Conventionally, natural down has been used as the most preferable filling for cold-weather clothing and bedding. Although down is valued all over the world for its excellent properties, it is extremely expensive because its production is extremely limited. For this reason, attempts have recently begun to be made to produce it artificially. For example, attempts have been made to mix polyester fibers with natural down, or to use silicone-treated polyester fibers, but none of these methods are satisfactory, and there are no similar methods other than those that natural down has. At present, a material with excellent properties without oxidation has not yet been realized. Furthermore, these man-made materials tend to sag when used or washed, the materials can tangle with each other, or the materials can break and shift to one side in the fabric, and they are not as light as down. It also has serious defects in practical use, such as not returning to its original state when struck, or the stuffing material blowing out from the sides. On the other hand, regarding stuffing, Japanese Patent Publication No. 51-39134 describes a method in which a filament or short fiber mass is placed in a specific container, subjected to rotational rubbing motion to form a spherical body, and the shape is fixed with an adhesive component. , it is insufficient to prevent it from sagging or blowing out during use or washing, and it is not so-called down-like in terms of texture and physical properties. The present inventors completed the present invention as a result of intensive research to eliminate such conventional defects. An object of the present invention is to provide a batting material that has excellent recovery properties even if it becomes uneven within the fabric during use and washing, is resistant to deterioration, and exhibits little change in physical properties. Another object is to provide a stuffing material in which the inner fibers do not blow out from the side fabric, and another object is to provide a filling material that is bulky when used, has a moderate stiffness, and has good drapability. To provide a lightweight cotton filling material that is rich in moisture, feels good against the skin, has a soft feel, is lightweight, and has excellent heat retention. Yet another purpose is
To provide a stuffing material that can be easily folded into a small size and stored compactly, has excellent bulk recovery when reused, and can regain its initial characteristics. The above purpose is to have a fineness of 3 to 10 denier and a crimp rate of 15%.
Polyester short fibers A ~ 90 to 10% by weight of
and the fineness is smaller than the fineness of short fiber A and 0.7~
The mixing weight ratio of polyurethane and polyorganosilicon compound to 100 parts by weight of a fiber material made by mixing and blending 10 to 90% by weight of polyester staple fiber B, which is a synthetic polymer of 4 denier and has a crimp rate of less than 15%, is A mixture that is 1:1 to 1:0.01 has a ratio of 0.2 to 20
This is achieved by using a wadding material that is attached by weight. Polyester fibers are suitable as the fibers used in the present invention in view of various mechanical properties. In addition, if so-called hollow fibers and composite fibers are appropriately selected and used, products with excellent heat retention and bulkiness can be obtained. The fineness of these fiber materials is arbitrary, but usually the fineness is 0.1 to 15 denier and the fiber length is 20 to 200 mm.
In this case, it may be bias cut.
The crimp rate is generally less than 30%. It goes without saying that the fibers may have the same fineness, fiber length, crimp ratio, etc., or two or more fibers having different fibers may be blended. In order to maximize the effects of the present invention, the fiber material must have a fineness of 3 to 10 deniers and a crimp rate of 15.
% or more of short fibers A90-10% by weight, and short fibers B10-10 made of a synthetic polymer whose fineness is smaller than that of short fibers A, 0.7 to 4 deniers, and a crimp rate of less than 15%.
It is preferable to use a blend of 90% by weight cotton. The short fiber A may have a normal fiber length, that is, generally 20 to 120 mm, but may have a length of 20 to 100 mm.
It is preferable if it is mm, and it is more preferable if it is 20 to 80 mm. The fineness and crimp rate of short fiber A affect down-like physical properties such as bulkiness, compact compressibility, and texture of the stuffing material, and from this point of view, the fineness should be 3 to 10 deniers, preferably 4 to 7 deniers. The crimp rate is 15% or more, preferably 18% or more. However, the upper limit of the crimp rate is usually about 30% at most due to restrictions from the production side of crimped fibers. The fiber length of short fiber B is usually about 20 to 200 mm, preferably 20 to 150 mm,
It is more preferable if it is 20 to 120 mm. In this case, it may be particularly bias-cut. The fineness and crimp rate of short fiber B also affect the physical properties of the stuffing material, as in the case of short fiber A.
and 0.7 to 4 deniers, preferably 1 to 3 deniers. In addition, the crimp rate of the short fiber B is at most 15% or less, preferably 10% or less. The effect is fully demonstrated only when using fibers, and especially when reusing items that have been stored compactly, applying mechanical stimulation or vibration such as tapping lightly will often restore the bulk. Show effectiveness. Further, it is particularly preferable to use composite hollow fibers as the short fibers A because they are easy to crimp, are strong, are light, have excellent bulkiness, and have good heat retention. In this case, the hollowness ratio is usually about 5 to 30%. The physical properties of the stuffing material change depending on the blending ratio of short fibers A and short fibers B, and in order to fully exhibit the effects of the present invention, short fibers A should be contained in an amount of 90 to 10% by weight, preferably 80 to 10% by weight.
20% by weight, more preferably 70 to 30% by weight, short fiber B 10 to 90% by weight, preferably 20 to 80% by weight,
More preferably, it is blended in an amount of 30 to 70% by weight. In addition, other fibers than the short fibers A and B, such as those made of different materials, those with large or small fineness and crimp ratio, may be blended in an amount of about 30% by weight or less of the total. Further, in the present invention, a film-like structural element C may be added to the fiber material. The film-like structural element C referred to herein is a flaky material made of a synthetic or semi-synthetic polymer. The above-mentioned polymer is preferably a polyester type polymer having excellent mechanical properties. Here, the flaky material is thinner than its length and width, and these dimensions can be selected as appropriate to give the best properties to the stuffing material of the present invention. But generally 5~
It is about 200μ, preferably about 10 to 80μ. The planar shape of the film-like structure may be arbitrary, such as a rectangle or a dendritic shape, but a rectangle is preferred because it is simple and has relatively large effects. Their size can also be selected arbitrarily to bring out the best effect, but in the case of a rectangle, the vertical length is generally 1 to 20 cm, preferably 1.5 to 15 cm,
More preferably 2-10cm, horizontal length 0.01-1cm
degree, preferably 0.01 to 0.8 cm, more preferably
It is 0.02~0.5cm. When expressed in area, ie, spread area, it is 0.01 to 20 cm ² , preferably 0.02 to 10 cm ² ,
More preferably, it is in the range of 0.03 to 5 cm ² . These flakes usually have a ratio of length to width of 10 or more, preferably 15 or more. Of course, so-called flat threads are included in this flaky material. These may be bent or crimped as appropriate to be three-dimensionally deformed. Furthermore, it is possible to use not only a single type having the above-mentioned shape and size, but also a combination of two or more types having different shapes and sizes in any ratio. The film-like structural element applied to the present invention is obtained, for example, by cutting a biaxially stretched polyester film into appropriate widths and lengths. Furthermore, in the present invention, not only such films but also those coated with metal vapor deposition may be used. Among these, infrared reflectance is
Particularly preferred is 50% or more. These include structures in which a reflective material is vapor-deposited, coated, or plated on the surface of a flaky material, or structures in which a reflective material is incorporated into the flaky material by kneading, or structures in which a reflective material is incorporated into the flaky material. This includes a structure sandwiched between two flakes, but a structure on which aluminum is vapor-deposited is particularly suitable because it has a high infrared reflectance. It goes without saying that a mixture of vapor-deposited and undeposited materials can be used. The film-like structural element applied to the present invention is used in an amount of 1 to 50 parts by weight, preferably 2 to 30 parts by weight, more preferably 3 to 25 parts by weight, particularly preferably 4 to 20 parts by weight, based on the fibers. Good to mix. By blending an appropriate amount of the film-like structural element, the effects of the present invention, such as bulkiness, beat-back properties, compressibility, and stiffness, can be best obtained. In the present invention, low melting point synthetic fibers may be further blended. The low melting point synthetic fiber referred to herein is one that at least partially contains a component that has a melting point lower than that of the fibers and film-like structural elements by usually 20° C. or more, preferably 30° C. or more. In other words, in addition to the low melting point component alone as described above, the low melting point synthetic fiber is composed of the low melting point component and a different or homogeneous polymer having a higher melting point than the above temperature difference, in a side-by-side type or concentric type. It also includes so-called conjugate fibers which are compounded in an eccentric manner. As the above-mentioned low melting point component, in addition to commonly used polymers such as polyester, polyamide, and polyethylene, various modified or copolymerized polymers can be used. The fineness of the low melting point synthetic fiber is usually 1 to 15 deniers, preferably 1.5 to 10 deniers, because the finer the fiber, the higher the bonding density and the thicker the finer, the higher the bonding strength during heat fusion as described below. On the other hand, the fiber length is usually 2 to 200 mm, preferably 5 to 100 mm. The low melting point synthetic fiber applied to the present invention is 100 parts by weight or less, preferably 2 to 50 parts by weight, more preferably 3 to 40 parts by weight, based on 100 parts by weight of the fiber or the mixture of the fiber and the film-like structural element. parts, particularly preferably 4 to 30 parts by weight, of blended cotton.
When an appropriate amount of low melting point synthetic fiber is blended, the beatback properties and the ability to prevent fiber blow-out and sag are further improved while maintaining down-like physical properties. The material blended with the fiber or film-like structural element of the present invention or the low-melting point synthetic fiber can be blended into a cotton blend by a conventional method. Depending on their size, film-like structural elements and low-melting point synthetic fibers can be carded together with the fibers, and in some cases, they can be added after the fiber carding step. The compounded material may not only be in the form of a web, but may also be separated into random fiber masses, for example by disarranging the web, or by mechanical, wind, or manual force into relatively small fiber masses. In the present invention, this can be further rolled up using a machine, wind power, or human power. In this fiber mass, the constituent fibers are entangled with each other, and when focusing on one fiber, it intersects or twists with one or more other fibers around it. It is not something that simply overlaps itself like thread wrapped around a spool. When looking at the degree of clogging of the fibers at the surface, middle, and center, there are no particularly dense fibers on the surface or center, and the overall density is spherical. Or it has a shape similar to this, such as an elongated or flat shape. Its diameter is 10-50
mm, preferably 20 to 40 mm, and the density is 0.03 g/
cm ³ or less, preferably 0.02 g/cm ³ or less. If the diameter is too small, the bulk will be reduced, while if it is too large, gaps will be created in the contact area of the fiber mass, resulting in a decrease in heat retention, which is not preferable. Furthermore, if the density is too high, the bulkiness will be poor, it will be difficult to compress, and the feel will be hard, which is not preferable. In addition, in the case of blending low melting point synthetic fibers, the low melting point synthetic fibers are further softened and melted by heating, and the fiber materials etc. are bonded and fixed. In this case, the temperature is set lower than the melting point of both the fiber material and the film-like structural element, and higher than the melting point of the low-melting synthetic fiber. The heating time varies depending on the composition of the low melting point component, denier, set temperature, etc., but the conditions can be selected by testing in advance, and it is generally about 10 minutes at most. Incidentally, after being fused in the form of a web, this may be divided into fiber masses. In the present invention, a mixture of a polyorganosilicon compound and a polyurethane is applied to the above-mentioned fiber layer, separated fiber mass, and the rolled or heat-fused fiber layer. As such polyorganosilicon compounds and polyurethanes, those known as softeners, smoothing agents, etc. can be used. The mixture of polyurethane and polyorganosilicon compound used in the present invention has a weight ratio of 1:1.
-1:0.01, especially 1:05-1:0.02 is preferable. If the amount of the silicon compound deviates from the above range, the slimy feeling will be too strong and the sagging prevention effect will be insufficient. On the other hand, if the polyurethane content is too large, the texture will be hard and undesirable. Further, in the present invention, the solid content of the mixture of polyorganosilicon compound and polyurethane is 0.2 to 20% by weight, preferably 0.5 to 20% by weight, based on the weight of the mixture with the fiber or film-like structural element and low melting point synthetic fiber. It is necessary to apply 15% by weight. If the amount applied is too small, the effect of the mixture will be insufficient and the durability of the effect will also be low. On the other hand, if the amount applied is too large, the texture becomes hard, which is not preferable. There are various application methods, but one example is impregnating the fiber layer or fiber mass in a mixture of a water-soluble or emulsion type polyorganosilicon compound and a water-soluble or emulsion type polyurethane at an appropriate concentration; After removing the liquid or spraying the mixture, the mixture is applied, dried, and further cured if necessary. Drying and curing conditions vary depending on the processing agent used, the amount of the mixed liquid applied, etc., and can be selected in advance through experiments, but in general, drying is carried out at 100 to 140°C for about 10 minutes at a high temperature, followed by curing. may be heated at 130 to 180°C for at most 10 minutes. In this case, the temperature needs to be lower than the melting point of the fibers or film-like structural element C, but in the case of blending low melting point synthetic fibers, it may be fused at the same time as the drying or curing process. The cotton filling material of the present invention can be wrapped in a suitable side material and used for bedding products such as futons, clothing that requires insulation against cold weather, and various industrial materials that require insulation. The batting material of the invention can not only be used alone, but also on one or both of the upper and lower surfaces when used in multiple layers, or as an intermediate layer. One of the effects of the cotton filling material of the present invention is excellent wearing performance and washing resistance. Conventionally, common cotton filling materials have had defects such as becoming sag due to wear and washing, or causing line breaks and causing them to shift to one side. Natural down has similar problems; it is difficult to wash with water at home, and it tends to become uneven. However, if the down is uneven, it can be returned to its original state by tapping it lightly. In this respect, the cotton wadding material of the present invention does not easily set even when washed with water, and even if the wadding material is uneven, it easily returns to its original shape like down. In addition, general cotton stuffing such as natural down blows out through the side fabric, so to prevent this, so-called down-proof fabrics that are coated with high-density fabric or resin coating are used as the side fabric. However, down-proofing is expensive and it is difficult to completely prevent blow-outs. In contrast, the stuffing material of the present invention hardly causes any blow-out. Furthermore, in terms of texture, it is neither too slimy nor harsh, and has a suitable slimy feel, and is soft and feels good when lightly touched. Two effects of the cotton filling material of the present invention are that it exhibits down-like physical properties. That is, first, initial bulkiness is mentioned. Normally, when samples of the same weight are taken, natural down has the highest volume.Compared to this, common cotton filling materials are generally about half as bulky, and even good ones are only about 70% as bulky. On the other hand, the stuffing material according to the present invention has a bulk that is comparable to, if not superior to, natural down. Next, the stuffing material of the present invention has high compressibility similar to that of natural down. Despite its high bulk, natural down requires only a small load to compress and can be compressed into a very small volume, so it has the advantage of not taking up much space when stored. On the other hand, with ordinary cotton padding, it is possible to reduce the compressive stress to the same level as down or even lower.
In such cases, the bulkiness usually deteriorates,
Moreover, if the compressive stress is too small, it will become stiff and undesirable. In this way, conventional cotton filling cannot achieve both bulkiness, compressibility, and appropriate elasticity like down. On the other hand, the cotton filling material of the present invention has a compressive stress comparable to that of down, so it can be stored compactly, has a moderate amount of stiffness during use, and, as mentioned above, is bulky. Both of these can be achieved simultaneously. Yet another effect lies in bulk recovery properties. After being compactly stored as described above, the bulk must be sufficiently recovered when it is used again. If stored in a compact form for a long time, the cotton wadding will gradually become distorted.
Conventional cotton wadding has poor bulk recovery as it loses its restoring power. At this point, the bulk after recovery from down is extremely good, together with the initial bulk. In particular, it has excellent recovery properties (beat back properties) when mechanical force is applied, such as by hand tapping, but the cotton stuffing material of the present invention also has excellent bulk recovery properties, including beat back properties, which conventional stuffing materials do not have. There is something. In addition, futons and clothing that do not drape well and do not conform to the body allow air warmed by body temperature to escape through gaps, but the cotton filling material of the present invention fits well against the skin and does not allow warm air to escape. As mentioned above, in addition to being bulky when in use, it has good heat retention properties. Especially metal,
For example, those containing a film deposited with aluminum can provide particularly excellent heat retention. Furthermore, natural down has a moderately soft texture without being too hard or too soft, and the stuffing material of the present invention also has the same excellent texture and is superior to natural down in every respect. It has comparable performance. Furthermore, although it has various excellent performances as mentioned above, it has a simple structure, so it can be produced economically at extremely low cost, and its industrial utility value is extremely large. The present invention will be specifically described below with reference to Examples, in which "parts" indicate "parts by weight". In addition, various measurements and evaluations were performed using the following methods. Texture: Five texture experts judged the degree of sliminess by holding the side material stuffed with batting material between their fingers and judging the degree of sliminess, which is suitable for padding material.
Those that were not slimy and stiff and undesirable as a stuffing material were rated ×, and those with an intermediate feel were rated △. Softness: Five texture experts judged the softness when lightly pressing the side fabric stuffed with batting material, and the softness that is preferred as a batting material is ○, the softness that is hard and undesirable is ×, and intermediate. △ indicates that Number of blowouts: The side material is stuffed with batting material.
After rubbing together 100 times, the number of fibers blown out from 100 cm ² of the side fabric was measured. Example 1 Hollowness ratio 18.5 made of polyester hollow composite system
%, fineness 7 denier, crimp rate 21.4%, fiber length 68mm
65 parts of short fiber A, fineness 2 denier, crimp rate 9.7
%, 35 parts of polyester staple fiber B with a fiber length of 40 mm,
15 parts of crimped aluminium-deposited polyester film in the form of a rectangular strip with a spread area of 0.12 cm ^{2 and} a melting point of
Made of 130℃ polyester with a fineness of 4 denier.
After carding a mixture of 20 parts of low-melting synthetic fiber with a fiber length of 50 mm, it is divided into fiber lumps, which are rolled and then heated and fused at 150°C for 2 minutes to create a diameter of 25 mm.
A spherical batting material with a density of 0.01 g/cm ³ was produced. Add water-soluble polyurethane (Hydran) to this material.
HW-100) After spraying a mixture of emulsion-type polyorganosilicon compounds (amino-modified siloxane and epoxy-modified siloxane) with varying blending ratios as shown in Table 1 so that the solid content is 2%, the mixture was heated to 130°C. and baked for 2 minutes at 150°C. The results of measuring these things are the first
Shown in the table.

[Table] The stuffing material of the present invention was bulky and easily compressed, and had good recovery properties. From the above results, it can be seen that if the blending ratio of the mixture of polyurethane and polyorganosilicon compound is within a specific range, it will not only exhibit down-like physical properties, but will also have good texture and softness, and will have less blow-out. Example 2 Polyester staple fiber A50 made of hollow decomposed yarn with a hollow ratio of 16.9%, a fineness of 5 denier, a crimp rate of 23.1%, and a fiber length of 60 mm, a polyester short fiber with a fineness of 1.5 denier, a crimp rate of 8.6%, and a fiber length of 48 mm. After blending and carding 50 parts of B, 15 parts of low-melting point synthetic fibers made of polyester composite fibers with a low-melting point component having a melting point of 125°C and a high-melting point component having a melting point of 245°C, the fibers are divided into fiber lumps, which are rolled, and further 160 Heat and fuse at ℃ for 1 minute,
A spherical stuffing material with a diameter of 30 mm and a density of 0.007 g/cm ³ was produced. This product was immersed in a mixture of water-soluble polyurethane (Elastron F-29) and polyorganosilicon compound (Deikku Silicone Softener A-900) at a mixing ratio of 1:0.1, and the amount of solid content adhered to was as shown in Table 2. Remove the liquid using a centrifugal dehydrator and heat at 110℃.
After drying for 5 minutes at 150°C, it was baked for 2 minutes. The results of these measurements are shown in Table 2.

【table】

[Table] The stuffing material of the present invention was bulky and easily compressed, and had good recovery properties. From the above results, it can be seen that if the amount of the mixture of polyurethane and polyorganosilicon compound deposited is within a certain range, it will not only exhibit down-like physical properties, but will also be soft and have little blow-out. Example 3 Polyester staple fiber A40 made of a hollow composite system with a hollow ratio of 17.3%, a fineness of 6 denier, a crimp rate of 20.8%, and a fiber length of 65 mm, a fineness of 1.3 denier, a crimp rate of 7.6%,
Mixed with 60 parts of short polyester fiber B with a fiber length of 50 mm,
After carding, this is laminated, and water-soluble polyurethane (Elastron F-29) and polyorganosilicon compound (Deitsku Silicone Softener) are added to this.
500) was sprayed at a blending ratio of 1:0.05 to give a solid content of 6%, dried at 105°C for 10 minutes, and then baked at 160°C for 3 minutes. As a result of measurements on this product, it was found to be moderately slimy and good with 2 blowouts. Moreover, this material was bulky and showed moderate compressibility and good recovery properties.

Claims (1)

[Claims] 1. 90 to 10% by weight of polyester short fibers A having a fineness of 3 to 10 deniers and a crimp rate of 15% or more, and 90 to 10% by weight of polyester short fibers A having a fineness of 3 to 10 deniers and a crimp rate of 15% to 15% by weight and having a fineness of 0.7 to 4 deniers and a crimp rate of 15% or more. The mixing weight ratio of polyurethane and polyorganosilicon compound is 1:1 to 100 parts by weight of a fiber material made by blending and blending 10 to 90% by weight of polyester short fibers B consisting of less than 10% by weight of synthetic polymers.
A stuffing material prepared by adhering 0.2 to 20 parts by weight of a 1:0.01 mixture. 2 The fiber material is a film-like structural element C and a short fiber A.
and 1 to 50 parts by weight of short fiber B per 100 parts by weight of the short fiber B. 3. The stuffing material according to claim 2, wherein the film-like structural element C has a spread area of 0.01 to 20 ^cm2 . 4. The stuffing material according to claim 2 or 3, wherein the film-like structural element C is a flaky material made of a synthetic polymer or a semi-synthetic polymer. 5. The stuffing material according to claim 2 or 3, wherein the film-like structural element C is made of polyester. 6 Film-like structural element C has a thickness of 5 to 200 μm and a width
0.01~1cm, length 1~20cm, length to width ratio 10
Any one of claims 2 to 5 which is the above
Filling material as described in section. 7 Film-like structural element C has 50% of infrared rays
The stuffing material according to any one of claims 2 to 6, which has the above reflectance. 8. The stuffing material according to any one of claims 2 to 7, wherein the film-like structural element C is vapor-deposited with a metal. 9 The fiber material is a low melting point synthetic fiber having a melting point 20°C or more lower than any of short fibers A, short fibers B, and film-like structural element C, in an amount of 100 parts by weight or less per 100 parts by weight of short fibers A and short fibers B. The stuffing material according to any one of claims 2 to 8, which is a blended material. 10. The stuffing material according to claim 9, wherein the low melting point synthetic fiber is made of polyester. 11 The low melting point synthetic fiber is a composite fiber consisting of a high melting point component and a low melting point component, and the low melting point component has a melting point that is 20°C or more lower than any of short fiber A, short fiber B, and film-like structural element C. The stuffing material according to claim 9 or 10, which is a synthetic polymer. 12. The stuffing material according to claim 11, wherein the low melting point component comprises polyethylene. 13. The stuffing material according to claim 11, wherein the low melting point component comprises polyester. 14. The stuffing material according to any one of claims 1 to 13, wherein the mixing weight ratio of polyurethane and polyorganosilicon compound is 1:0.5 to 1:0.02. 15 Claims 1 to 1 in which the amount of the mixture of polyurethane and polyorganosilicon compound adhered to 100 parts by weight of the fiber material is 0.5 to 15 parts by weight.
4. The stuffing material described in any one of item 4. 16. The stuffing material according to any one of claims 1 to 15, wherein the fiber material is a fiber mass. 17. The stuffing material according to claim 16, wherein the fiber mass has a spherical shape with a diameter of 10 to 50 mm and a substantially uniform density of 0.03 g/cm ³ or less, with the constituent fibers intertwined with each other. .