JPH08170256A - Yarn mixture, molded article of yarn and production of molded article of yarn - Google Patents

Abstract

PURPOSE: To obtain a yarn mixture and a molded article of yarn hardly yielding despite of softness, having a refreshing feeling in use an exerting no bad influence on the environment and to provide a method for producing the molded article of yarn. CONSTITUTION: The characteristic of this yarn mixture is that it comprises 20-60wt.% of conjugated yarn A obtained by bonding thermoplastic polymers R1 and R2 of two different kinds of components in the weight ratio of 30/70-70/30 to form a core part and combining the core part with a thermoplastic polymer R3 having a melting point lower than that of the lower melting point of the thermoplastic materials R1 and R2 in the weight ratio shown by the formula R3/(R1+R2) of 20/80-60/40 as a sheath part and 40-80wt.% of conjugated yarn B prepared by bonding thermoplastic polymers R4 and R5 of two different kinds of components having melting points higher than that of the thermoplastic polymer R3.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a fiber mixture, a fiber molding using the same, and a method for producing the fiber molding.

More specifically, for vehicle seats used in trains and automobiles, pad materials, door trims, sun visors, bedding bed materials, mattresses, kotatsu, sofas for furniture, cushions, other filters, for clothing. The present invention relates to a fiber mixture suitably used as a cushioning material such as a pad material, a fiber molded body, and a method for producing the fiber molded body.

[0003]

2. Description of the Related Art Conventionally, as a cushion material, a resin foam such as polyurethane, Japanese Patent Publication No. 62-2155, Japanese Patent Publication No. 1-18183, and Japanese Patent Publication No. 4-334 are generally used.
No. 78, JP-A-3-140185, etc., a low melting point fiber is used as the thermally adhesive fiber, or a high melting point thermoplastic resin is used as a core portion and a low melting point thermoplastic resin is used as a sheath portion. It has been proposed to use a bicomponent fiber having a core-sheath structure.

[0004]

However, since these cushioning materials are inferior in breathability and moisture permeability and inferior in hygroscopicity, they are apt to be stuffy, and are used for seats installed in places exposed to rain or water splashes. As a result, water accumulates, and there is a problem that the seat is corroded and the water seeps out when the user sits on the seat, which gives the user discomfort.

Further, it has not been disclosed what is soft and hard to be worn, does not use CFC gas or the like in manufacturing, and has no adverse effect on the environment.

An object of the present invention is to provide a fiber mixture which solves the above problems, a fiber molded product using the same, and a method for producing a fiber molded product.

[0007]

The fiber mixture of the present invention comprises:
In order to solve the above-mentioned subject, it has the following composition. That is, two different types of thermoplastic polymers R1 and R2
Are bonded in a weight ratio range of 30/70 to 70/30 to form a core portion, and further, a thermoplastic polymer R having a lower melting point than the thermoplastic polymer R1 or R2 having a lower melting point.
3 is a weight ratio of 20/8 represented by R3 / (R1 + R2)
In the range of 0 to 60/40, 20 to 60% by weight of the composite fiber A which is composited in the sheath portion, and the melting point of the thermoplastic polymer R3 is higher than that of the thermoplastic polymer R3, and the thermoplastic polymer R4 of two different components is used. A fiber mixture comprising 40 to 80% by weight of a composite fiber B in which R5 is joined.

The fiber molding of the present invention has the following constitution.

That is, two different types of thermoplastic polymers R1 and R2 are bonded together in a weight ratio range of 30/70 to 70/30 to form a core portion, and the thermoplastic polymer R is further added.
1 or R2 is a composite in which a thermoplastic polymer R3 having a lower melting point than that having a lower melting point is compounded in the sheath portion in a weight ratio of 20/80 to 60/40 represented by R3 / (R1 + R2). Composite fiber B in which 20 to 60% by weight of the fiber A and the thermoplastic polymers R4 and R5 having a melting point higher than that of the thermoplastic polymer R3 and having two different components are joined.
A fiber molded article, wherein at least a part of contact points between the composite fibers A and between the composite fibers A and the composite fibers B of the fiber mixture composed of 40 to 80% by weight are bonded and molded. Is.

Further, the method for producing a fiber molding of the present invention has the following constitution.

That is, two different types of thermoplastic polymers R1 and R2 are joined in a weight ratio range of 30/70 to 70/30 to form a core portion, and the thermoplastic polymer R is further added.
1 or R2 is a composite in which a thermoplastic polymer R3 having a lower melting point than that having a lower melting point is compounded in the sheath portion in a weight ratio of 20/80 to 60/40 represented by R3 / (R1 + R2). Composite fiber B in which 20 to 60% by weight of the fiber A and the thermoplastic polymers R4 and R5 having a melting point higher than that of the thermoplastic polymer R3 and having two different components are joined.
A fiber mixture consisting of 40 to 80% by weight is opened, and blown into a breathable mold together with gas to obtain a density of 0.02 to 0.
It is a method for producing a fiber molded body, characterized in that a material filled with 10 g / cm ³ is subjected to a heat treatment at 80 to 200 ° C.

The present invention will be described in detail below.

The fiber mixture of the present invention comprises a composite fiber A and a composite fiber B, and the fiber molded body has at least a part of contact points between the composite fibers A and between the composite fibers A and B. It is formed by fusion bonding. 1 to 5 show schematic views of cross sections of the composite fiber A and the composite fiber B. FIG. 1 shows a concentric type, FIGS. 2 and 3 show an eccentric type, and FIG. 4 shows a form in which R3 constitutes a part of the surface of the composite fiber of R1 and R2. FIG. 5 shows the composite fiber B.

The composite fiber A used in the present invention is mainly composed of three components of thermoplastic polymers R1, R2 and R3, and the surface side of the core portion where the two different components of the thermoplastic polymers R1 and R2 are joined. In addition, it has a structure in which the thermoplastic polymer R3 is compounded as a sheath portion.

Further, it is preferable that the composite fiber A has a property of being fused to the composite fiber A or the composite fiber B by heat treatment, that is, a thermal adhesive property.

The combination of two different types of thermoplastic polymers R1 and R2 has a difference in shrinkage ratio after being formed into a fibrous shape by hot water or dry heat treatment from the viewpoint of effectively developing latent crimps by heat treatment. It is desirable that the combination is such that

As the thermoplastic polymer R1, for example, polyethylene terephthalate, polybutylene terephthalate, polyhexamethylene terephthalate, etc. having 2 to 2 carbon atoms can be used.
Aromatic compounds having a metal sulfonate group such as polyalkylene terephthalate having 8 methylene groups, 4-sodium sulfoisophthalic acid or 5-sodium sulfoisophthalic acid, 5-potassium sulfoisophthalic acid, 4-sodium sulfo-2,6-naphthalenedicarboxylic acid Group dicarboxylic acid, isophthalic acid, phthalic acid, 2,6-naphthalenedicarboxylic acid and other aromatic dicarboxylic acids, adipic acid, sebacic acid and other aliphatic dicarboxylic acids and the like polyalkylene terephthalate, propylene glycol, 1,4
-Polyalkylene terephthalate copolymerized with butanediol, glycol such as diethylene glycol, polyalkylene terephthalate copolymerized with polyol such as pentaerythritol, polyalkylene copolymerized with polyalkylene glycol such as polyethylene glycol, polypropylene glycol, polytetramethylene glycol Examples thereof include terephthalate and polyalkylene terephthalate obtained by copolymerizing an oxy acid such as hydroxybenzoic acid. The modification ratio with these copolymerization components is preferably 15 mol% or less. Among the above, a copolymer polyester having an ethylene terephthalate unit as a main constituent unit is more preferably used. More preferred is a polyethylene terephthalate-based copolyester using isophthalic acid, phthalic acid, oxybenzoic acid, bisphenol A or the like as a copolymerization component.

The thermoplastic polymer R2 is not particularly limited as long as it can give a sufficient latent crimp to the fiber in combination with R1. For example, polyethylene terephthalate, nylon-6, nylon-6,6, nylon-6,10, nylon-10,9, nylon-1
1, and polyamides such as nylon-12.

The combination of the thermoplastic polymers R1 and R2 can be arbitrarily selected as long as it can impart a high latent crimp to the fiber. From the viewpoint of imparting excellent morphological fixability and compression characteristics, it is preferable to use a combination of polyesters.

The intrinsic viscosity of the thermoplastic polymers R1 and R2 is not particularly limited, but from the viewpoint of spinning stability, R1 is preferably about 0.45 to 0.65, and R2 is 0.55 to 0.55. About 0.70 is preferable. Thermoplastic polymer R
Examples of 3 include polyethylene, polypropylene,
Polyolefin or olefin copolymer such as ethylene propylene copolymer, ethylene butene copolymer, ethylene butene copolymer, ethylene vinyl acetate copolymer, polyhexamethylene terephthalate, polyhexamethylene butylene terephthalate, polyhexamethylene terephthalate isophthalate And a thermoplastic polymer such as a copolyester. In selecting the thermoplastic polymer R3, the melting point of R3 is made lower than that of the thermoplastic polymers R1 or R2 having a lower melting point. From the viewpoint of thermal adhesiveness, it is preferably 20 ° C. or higher, and more preferably 25 ° C. or higher.

From the viewpoint of the effect of adhesion and prevention of thermal deterioration, the melting point of R3 is preferably in the range of 80 to 170 ° C, more preferably in the range of 100 to 170 ° C.

The weight ratio R1 / R2 of the thermoplastic polymer in the composite fiber A is 30/70 to 70/30. It is preferably 40/60 to 60/40. If either R1 or R2 is less than 30% by weight, R1,
There is a problem that the crimping ability of R2 is lowered, and it becomes difficult to obtain a desired fiber molded body having a low stress loss.

Further, since the viscosity difference between R1 and R2 tends to cause a kneeling phenomenon in which the discharge yarn is bent at the discharge part of the spinneret, the weight ratio R1 / R2 is 45 /.
It is more preferably 55 to 55/45 from the viewpoint of effectively preventing the kneeling phenomenon.

The weight ratio R3 / (R1 + R2) of the thermoplastic polymers R1, R2 and R3 is 20/80 to 60/40. It is preferably 20/80 to 50/50.

If the weight of the thermoplastic polymer R3 is less than 20%, the thermal adhesiveness between the fibers cannot be sufficiently obtained, and there is a problem that the morphological fixability of the produced fiber molding is deteriorated.

On the other hand, if the weight of R3 exceeds 60%, it becomes difficult to obtain a soft feeling of the fiber molding, and at the same time, the residual compression strain becomes large.

The composite form of the thermoplastic polymers R1 and R2 is R
A structure in which 1 and R2 are bonded, particularly a side-by-side structure, is preferable in order to easily develop the three-dimensional crimp. The composite fiber A forms a core portion of R1 and R2 shown in FIG. 1, and has a concentric core-sheath structure having R3 as a sheath, an eccentric core-sheath structure shown in FIGS. 2 and 3, or a thermoplastic heavy fiber shown in FIG. It is possible to adopt a structure in which the united R3 constitutes a part of the surface of the core portion of R1 and R2. It is also preferable to add polymer components other than R1 to R3, pigments, weatherproofing agents and the like to the conjugate fiber A, if necessary, unless the original functions are lost. Such a composite fiber A can be manufactured by an ordinary composite spinning method.

Next, in order to give a soft feeling to the fiber molded article of the present invention and reduce the stress loss due to compression, it is preferable that the conjugate fiber A has a three-dimensional crimp.

The crimp is applied to the composite fiber A at 80 ° C. under no load.
It is preferable to develop it by performing a heat treatment at ˜200 ° C.

The number of crimps in the three-dimensional crimp is at least 30 peaks /
It is desirable that the crimping degree is 25% at 25 mm. It is desirable to make this crimp a latent type.

That is, if strong crimps are developed in the state of the fibers before the fiber molded body is manufactured, the entanglement of the fibers is too strong, and it becomes difficult to obtain the fiber molded body having a uniform density. In order to improve the handleability of fibers in the manufacturing process of the fiber molded body and enhance the latent crimp developability, it is preferable to impart a light mechanical crimp within a certain range before the heat treatment. The number of crimps before heat treatment is preferably 3 to 20 ridges / 25 mm, more preferably 3 to 15 ridges / 25 mm. Such a composite fiber A has a difference in intrinsic viscosity between the thermoplastic polymers R1 and R2, a constant length heat treatment condition in the stretching step, a tow temperature at the time of applying crimp before the heat treatment, pressing, and crimp fixing after the crimp application. It can be obtained by appropriately selecting the relaxation heat treatment conditions and the like.

For example, a polyester having an intrinsic viscosity of 0.65 to 0.69 is used as the thermoplastic polymer R1, and a polyester having an intrinsic viscosity of 0.53 to 0.69 is used as R2.
A polyester having an intrinsic viscosity of 0.50 to 0.60 is used as R3, and these three components are composite-spun, stretched at an appropriate ratio, and then subjected to a fixed length heat treatment at a temperature lower than the melting point of R3 by 20 ° C. or more to cause crimping. Turn into After that, a mechanical crimp is applied using a crimper such as a stuffing box type crimper, and then a relaxation heat treatment is performed at a temperature lower than the melting point of R3 by 20 ° C. or more to fix the crimp.

In order to prevent the latent three-dimensional crimps from being revealed in the relaxation heat treatment step, the tow temperature is set to a temperature range from room temperature to 95 ° C., mechanical crimps are applied, and then the tow It is preferable to perform a relaxation heat treatment so as not to disturb the focusing property.

Further, it is preferable to set the relaxation heat treatment temperature lower than the constant length heat treatment temperature from the viewpoint of enhancing the latent crimp developability in the production of the fiber molded body.

The composite fiber A constituting the fiber mixture has a fineness of 1 to 10 denier and a fiber length of 10 to 100 m.
m short fibers are preferably used.

Next, the conjugate fiber B used in the present invention will be described.

The composite fiber B has a composite fiber structure in which two different thermoplastic polymers R4 and R5 having a melting point higher than that of the thermoplastic polymer R3 are joined.

The melting points of R4 and R5 are 2 more than the melting point of R3.
It is preferably 0 ° C. or higher, and more preferably 25 ° C. or higher.

Further, the composite fiber B preferably has a property of developing latent crimps by heat treatment. The combination of two different types of thermoplastic polymers R4 and R5 shows a shrinkage difference by hot water or dry heat treatment after being formed into a fibrous shape from the viewpoint of effectively developing latent crimps by heat treatment. It is desirable that the combination is

As the thermoplastic polymer R4, for example, polyethylene terephthalate, polybutylene terephthalate, polyhexamethylene terephthalate, etc. having 2 to 2 carbon atoms can be used.
Polyalkylene terephthalate having 8 methylene groups, 4-sodium sulfoisophthalic acid or 5-sodium sulfoisophthalic acid, 5-potassium sulfoisophthalic acid, 4-sodium sulfo-2,6-naphthalenedicarboxylic acid and other metal sulfonate groups Aromatic dicarboxylic acids, isophthalic acid, phthalic acid, 2,6-naphthalenedicarboxylic acid and other aromatic dicarboxylic acids, adipic acid, sebacic acid and other aliphatic dicarboxylic acid copolymerized polyalkylene terephthalate, propylene glycol, 1,
Polyalkylene terephthalate obtained by copolymerizing glycol such as 4-butanediol and diethylene glycol, polyalkylene terephthalate obtained by copolymerizing polyol such as pentaerythritol, and polyalkylene glycol obtained by copolymerizing polyalkylene glycol such as polyethylene glycol, polypropylene glycol and polytetramethylene glycol. Examples thereof include alkylene terephthalate and polyalkylene terephthalate obtained by copolymerizing an oxy acid such as hydroxybenzoic acid. The modification ratio with these copolymerization components is preferably 15 mol% or less.

Among the above, preferably used is a copolyester having an ethylene terephthalate unit as a main constituent unit. More preferred is a polyethylene terephthalate-based copolyester using isophthalic acid, phthalic acid, oxybenzoic acid, bisphenol A or the like as a copolymerization component.

The thermoplastic polymer R5 is not particularly limited as long as it can give a sufficient latent crimp to the fiber by combination with R4. For example, polyethylene terephthalate, nylon-6, nylon-6,6, nylon-
Polyamides such as 6,10, nylon-10, 9, nylon-11, and nylon-12 can be mentioned.

The combination of the thermoplastic polymers R4 and R5 can be arbitrarily selected as long as it can impart a high latent crimp to the fiber. From the viewpoint of imparting excellent morphological fixability and compression characteristics, it is preferable to use a combination of polyesters.

The intrinsic viscosity of the thermoplastic polymers R4 and R5 is not particularly limited, but from the viewpoint of spinning stability, R4 is preferably about 0.45 to 0.65, and R5 is about 0. It is preferably about 55 to 0.70. Further, from the viewpoint of effectively developing crimp, the weight ratio represented by R4 / R5 of the thermoplastic polymer in the composite fiber B is preferably 10/90 to 90/10, and more preferably 40/60 to. It is 60/40.

Further, since the viscosity difference between R4 and R5 tends to cause a kneeling phenomenon in which the discharge yarn is bent at the discharge part of the spinneret, the weight ratio R4 / R5 is 45 /.
From the viewpoint of effectively preventing it, 55 to 55/45 is more preferable.

The composite form of the thermoplastic polymers R4 and R5 is R
A structure in which 4, R5 are bonded, particularly a side-by-side structure shown in FIG. 5, is preferable in order to easily develop the three-dimensional crimp. It is also preferable to add polymer components other than R4 and R5, pigments, weatherproofing agents and the like to the conjugate fiber B, if necessary, unless the original functions are lost. Such a composite fiber B can be manufactured by an ordinary composite spinning method.

Next, in order to impart a soft feeling to the fiber molded article of the present invention and reduce the stress loss due to compression, it is preferable that the composite fiber B has a three-dimensional crimp.

The crimp is 80 to 80 in the composite fiber B under no load.
It is preferable to develop it by performing a heat treatment at 200 ° C.

The number of crimps in the three-dimensional crimp is at least 30 ridges /
It is desirable that the crimping degree is 25% at 25 mm. However, it is desirable to make this crimp a latent type. That is, when strong crimps are developed in the state of the fibers before the fiber molded body is manufactured, the entanglement of the fibers is too strong, and it becomes difficult to obtain the fiber molded body having a uniform density. In order to improve the handleability of the fibers in the manufacturing process of the fiber molded body and enhance the latent crimp developability, it is preferable to apply a light crimp within a certain range before the heat treatment. The number of crimps before heat treatment is preferably 3 to 20 ridges / 25 mm, more preferably 3 to 15 ridges / 25 mm.

The composite fiber B constituting the fiber mixture has a fineness of 0.5 to 30 denier and a fiber length of 10 to 10
Short fibers of 0 mm are preferably used.

In the fiber mixture of the present invention, the weight ratio of the composite fiber A and the composite fiber B expressed by A / B is 20/80 to 6
It is set to 0/40. When the content of the composite fiber A is less than 20% by weight, there is a problem that the thermal adhesiveness between the fibers becomes insufficient and the shape fixability of the manufactured fiber molded product is deteriorated.

Further, if the content of the composite fiber A exceeds 60% by weight, the soft feeling of the fiber molding is deteriorated and the tactile feeling becomes coarse and hard.

In the present invention, the above-mentioned weight ratio of the composite fiber A and the composite fiber B is sufficiently mixed and opened by a cotton feeding machine, a cotton mixing machine and a fiber opening machine used in a usual spinning process. It is possible to obtain a fiber mixture of By sufficiently mixing and opening the fibers, the density and hardness of the fiber molded product produced by using the fiber mixture of the present invention become uniform, and the latent crimp of the composite fiber A is sufficiently expressed to obtain fibers. The softness and compression fatigue resistance of the molded product can be enhanced.

The method for producing the fiber molding of the present invention is as follows.

That is, the fiber mixture of the composite fiber A and the composite fiber B is opened, and the air-permeable mold having a shape suitable for the purpose is blown and filled with a gas such as an air flow from a cotton feeding fan.

In order to blow and fill the mold, it is necessary that the mold has an appropriate air permeability. For example, JIS L 1
The air permeability is 5 to 200 cc / cm ² · when measured by a 079-1966 Frazier type air permeability tester.
The range of sec is preferable.

As such a mold, for example, dies 6 and 7 using a punching metal plate shown in FIG. 6 can be used. The fibers blown into the breathable mold are vertically, horizontally and randomly arranged in the thickness direction.

Next, the filled fiber mixture is compressed to a suitable density according to the intended use of the fiber mixture. The density is 0.02 to 0.10 g / cm ³ . Preferably 0.025-0.095 g /
It is cm ³ . If the density is less than 0.02 g / cm ³ , there is a problem that the fiber mixture becomes too soft and the shape fixability deteriorates, and it becomes difficult to cut and mold it into a desired shape. The density is 0.
If it exceeds 10 g / cm ³ , there is a problem that the softness of the fiber mixture deteriorates.

Further, the filled fiber mixture is heat-treated. The heat treatment temperature is set to 80 to 200 ° C. If the heat treatment temperature is lower than 80 ° C., sufficient thermal adhesion cannot be obtained, and if it exceeds 200 ° C., the fibers constituting the fiber mixture deteriorate. By this heat treatment, the thermoplastic polymer R3 of the composite fiber A has adhesiveness with R1-5,
As a result, at least some of the contact points between the composite fibers A and at least some of the contact points between the composite fibers A and B can be bonded.

The heat treatment time is preferably selected appropriately depending on the density of the fiber mixture and the like.

[0061]

EXAMPLES The present invention will be described in more detail with reference to Examples and Comparative Examples. The methods for measuring various properties described in the present invention are shown below.

[Number of crimps and degree of crimp before heat treatment] 100 g of the short fibers of the composite fiber were opened with an opener and carded with a roller card to make a web, and the web (size: 20 cm × 20 cm, weight) : 25 g), 10 to 20 short fibers are taken out from the center so that the crimps are not stretched. JIS L 1015-7-12
-1 and JIS L 1015-7-12-2.

[Number of crimps and degree of crimp after heat treatment] 100 g of the short fibers of the composite fiber were opened with an opener and carded with a roller card to make a web. The web (size: 20 cm × 20 cm, weight) : 25 g) 18
Heat treatment was performed in an oven at 0 ° C. for 3 minutes. After the heat treatment, 10 to 20 short fibers were taken out from the center of the web so that the crimps would not be stretched, and JIS L 1015-
7-12-1 and JIS L 1015-7-12-
It measured according to the method of 2.

[Intrinsic Viscosity] It was measured in an O-chlorophenol solution at 25 ° C. according to a conventional method.

[Fineness] JIS L 1015-7-51
It measured according to the method of A.

[Average Fiber Length (Cut Length)] JIS L
It was measured according to the 1015A method (staple diagram method). [Shrinkage rate] It was measured according to the method of JIS L 1015-7-15-2.

[Compression Residual Strain] A square test piece having a side of 100 mm and a thickness of 100 mm was compressed by 50% in the thickness direction in a constant temperature bath at a temperature of 70 ± 1 ° C. for 22 hours and then compressed. Was left for 30 minutes at room temperature. Then, the thickness (t ₁ mm) was measured, and the compressive residual strain was determined by the following equation.

Compressive residual strain (%) = [(100-t ₁ ) /
100] × 100 [Density of fiber molding] Test piece (vertical: 20 cm, horizontal:
20 cm, thickness: 20 cm) temperature 20 ° C, humidity 65%
The weight (w) after standing for 24 hours in the atmosphere was measured and calculated by the following formula.

Density (g / cm ³ ) = w / 8000 [Shape fixing / softness] The texture was classified into 6 grades from excellent (⊚) to unacceptable (×).

[Multidirectional cutting property] The test pieces were classified into 6 grades from excellent (⊚) to unacceptable (x) depending on the ease of cutting when cutting in arbitrary directions.

Example 1 Polyethylene terephthalate polyester having an intrinsic viscosity of 0.65 and a melting point of 214 ° C. obtained by copolymerizing 7 mol% of isophthalic acid and 4.5 mol% of bisphenol A as a thermoplastic polymer R1. And polyethylene terephthalate having an intrinsic viscosity of 0.65 and a melting point of 255 ° C. as R2, and an intrinsic viscosity of 0.55 obtained by copolymerizing 40 mol% of isophthalic acid as R3,
Polyethylene terephthalate polyester having a melting point of 110 ° C. is used, and R1 is 40% and R2 is 40% by weight.
%, R3 is 20%, the three-component composite fiber A has a pore number of 24
Was obtained by spinning from a spinneret at a discharge rate of 18.11 g / min, a spinning temperature of 285 ° C. and a take-up speed of 1350 m / min.

Then, the unstretched yarns are combined to obtain a tow denier of 100,000 denier after stretching, and a draw ratio of 3.
It was drawn 0 times at a drawing bath temperature of 80 ° C., and crimped with a crimper so that the number of crimps was 9.4 crests / 25 mm and the crimping degree was 9.1%. Furthermore, after drying with a heat setter at 70 ° C, a finishing oil agent is applied and cut into a cut length of 64 mm, the fineness is 1.9 denier, and the melting point of the surface layer is about 110 ° C.
A composite fiber A of Apart from this, the thermoplastic polymer R
Polyethylene terephthalate polyester having an intrinsic viscosity of 0.65 and a melting point of 214 ° C. obtained by copolymerizing 7 mol% of isophthalic acid and 4.5 mol% of bisphenol A is used as 4, and the intrinsic viscosity of R5 is 0.65. Melting point 2
Using polyethylene terephthalate at 55 ° C., a bicomponent composite fiber B in which R4 is 50% and R5 is 50% by weight is discharged from a spinneret having 24 holes, and a spinning temperature is 28.
It was obtained by spinning at 5 ° C. and a take-off speed of 1350 m / min.

Next, the unstretched yarn was combined with a tow denier of about 100,000 denier after stretching, stretched at a draw ratio of 3.0 times and at a stretching bath temperature of 80 ° C., and crimped with 11 crimps. / 25 mm, crimping was applied so that the crimping degree was 8.2%.

Further, after drying with a heat setter at 70 ° C., a finishing oil agent was applied and cut into a cut length of 64 mm to obtain short fibers having a fineness of 6.1 denier as a composite fiber B. 40% by weight of the composite fiber A and 60% of the composite fiber B were mixed and further mixed and opened with a roller card to obtain a fiber mixture. The fiber mixture was blown through the die inlet port 8 and the inner surface punched on each side was 500 × 500.
It was blown into the lower die 6 mm with the air flow. The fiber mixture 9 blown by the upper die 7 having each surface punched was compressed to a packing density of 0.042 g / cm ³ and fixed at a thickness of 200 mm. The fiber mixture 9 compressed and fixed in the mold is heat set at 130 ° C. for 30 minutes by steam using a heat setter normally used for setting spun yarns, and the contact point between the composite fibers A and the composite fibers B and the composite fibers are set. A fiber molded body was obtained which was heat-bonded at the contact point between A and A.

This fiber molding was hard to settle, was light and soft, and had a comfortable use feeling.

Table 1 shows the characteristics of the composite fiber A and the composite fiber B constituting the fiber molded body.

[0077]

[Table 1] Table 2 shows the characteristics of the fiber molded body.

[0078]

[Table 2] [Example 2] The thermoplastic polymers R1 to R5 used were the same as in Example 1. 25% R1 and 2 R2 by weight
A composite fiber A with 5% and R3 of 50% was obtained by the same method as in Example 1.

Using the conjugate fiber B used in Example 1, 40% by weight of the conjugate fiber A and 60% by weight of the conjugate fiber B were used.
A fiber molded body having the following formula was obtained in the same manner as in Example 1.

This fiber molding was hard to settle down, was light and soft, and had a comfortable use feeling.

Properties of the composite fiber A, the composite fiber B and the fiber molded body are shown in Tables 1 and 2 together.

[Example 3] Thermoplastic polymer R1 used
~ R5 were the same as in Example 1. R1 is 20 by weight
%, R2 was 20%, and R3 was 60% to obtain a composite fiber A by the same method as in Example 1.

Using the composite fiber B used in Example 1, 40% by weight of the composite fiber A and 60% by weight of the composite fiber B were used.
A fiber molded body having the following formula was obtained in the same manner as in Example 1.

This fiber molding was hard to settle, was light and soft, and had a comfortable use feeling.

Properties of the composite fiber A, the composite fiber B and the fiber molded body are shown in Tables 1 and 2 together.

Example 4 Thermoplastic Polymer R1 Used
~ R5 were the same as in Example 1. R1 is 15 by weight
%, R2 35% and R3 50% were obtained in the same manner as in Example 1.

Using the composite fiber B used in Example 1, 40% by weight of the composite fiber A and 60% by weight of the composite fiber B were used.
%, And a packing density of 0.041 g / cm ³ was obtained in the same manner as in Example 1.

This fiber molding was hard to settle, was light and soft, and had a comfortable use feeling.

Properties of the composite fiber A, the composite fiber B and the fiber molded body are shown in Tables 1 and 2 together.

Example 5 Thermoplastic Polymer R1 Used
~ R5 were the same as in Example 1. R1 is 35 by weight
%, R2 15% and R3 50% were obtained by the same method as in Example 1.

Using the conjugate fiber B used in Example 1, 40% by weight of the conjugate fiber A and 60% by weight of the conjugate fiber B were used.
%, And a packing density of 0.041 g / cm ³ was obtained in the same manner as in Example 1.

This fiber molding was hard to settle, was light and soft, and had a comfortable use feeling.

Properties of the composite fiber A, the composite fiber B and the fiber molded body are shown in Tables 1 and 2 together.

Example 6 Thermoplastic Polymer R1 Used
~ R5 were the same as in Example 1. R1 is 25 by weight
%, R2 25% and R3 50% were obtained by the same method as in Example 1.

Using the conjugate fiber B used in Example 1, 20% by weight of the conjugate fiber A and 80% by weight of the conjugate fiber B were used.
%, And a packing density of 0.041 g / cm ³ was obtained in the same manner as in Example 1.

This fiber molding was hard to settle, was light and soft, and had a comfortable use feeling.

Properties of the composite fiber A, the composite fiber B and the fiber molded body are shown in Tables 1 and 2 together.

[Example 7] Thermoplastic polymer R1 used
~ R5 were the same as in Example 1. R1 is 25 by weight
%, R2 25% and R3 50% were obtained by the same method as in Example 1.

Using the composite fiber B used in Example 1, 60% by weight of the composite fiber A and 40% by weight of the composite fiber B were used.
%, And a packing density of 0.042 g / cm ³ was obtained in the same manner as in Example 1.

This fiber molding was hard to settle, was light and soft, and had a comfortable usability.

Properties of the composite fiber A, the composite fiber B and the fiber molded body are shown in Tables 1 and 2 together.

[Example 8] Thermoplastic polymer R1 used
~ R5 were the same as in Example 1. R1 is 25 by weight
%, R2 25% and R3 50% were obtained by the same method as in Example 1.

Using the composite fiber B used in Example 1, 40% by weight of the composite fiber A and 60% of the composite fiber B were used.
%, And a packing density of 0.020 g / cm ³ was obtained in the same manner as in Example 1.

This fiber molding was hard to settle, was light and soft, and had a comfortable use feeling.

Properties of the composite fiber A, the composite fiber B and the fiber molded body are shown in Tables 1 and 2 together.

[Example 9] Thermoplastic polymer R1 used
~ R5 were the same as in Example 1. R1 is 25 by weight
%, R2 25% and R3 50% were obtained by the same method as in Example 1.

Using the composite fiber B used in Example 1, 40% by weight of the composite fiber A and 60% of the composite fiber B were used.
%, And a packing density of 0.051 g / cm ³ was obtained in the same manner as in Example 1.

This fiber molding was hard to settle, was light and soft, and had a comfortable use feeling.

Properties of the composite fiber A, the composite fiber B and the fiber molded product are shown in Tables 1 and 2 together.

[Example 10] Thermoplastic polymer R used
1 to R5 were the same as in Example 1. R1 is 2 by weight
A composite fiber A having 5%, R2 of 25% and R3 of 50% was obtained by the same method as in Example 1.

Using the conjugate fiber B used in Example 1, 40% by weight of the conjugate fiber A and 60% by weight of the conjugate fiber B were used.
%, And a packing density of 0.075 g / cm ³ was obtained in the same manner as in Example 1.

This fiber molding was hard to settle, was light and soft, and had a comfortable use feeling.

Properties of the composite fiber A, the composite fiber B and the fiber molded body are shown in Tables 1 and 2 together.

[Example 11] Thermoplastic polymer R used
1 to R5 were the same as in Example 1. R1 is 2 by weight
A composite fiber A having 5%, R2 of 25% and R3 of 50% was obtained by the same method as in Example 1.

Using the composite fiber B used in Example 1, 40% by weight of the composite fiber A and 60% of the composite fiber B were used.
%, And a packing density of 0.099 g / cm ³ was obtained in the same manner as in Example 1.

The fiber molding was hard to settle, was light and soft, and had a comfortable use feeling.

Properties of the composite fiber A, the composite fiber B and the fiber molded body are shown in Tables 1 and 2 together.

[Example 12] Thermoplastic polymer R used
1 to R5 were the same as in Example 1. R1 is 2 by weight
A composite fiber A having 5%, R2 of 25% and R3 of 50% was obtained by the same method as in Example 1.

Also, R4 is 13% and R5 is 87% by weight.
40% by weight of the composite fiber A and 6% of the composite fiber B were used by using the composite fiber B obtained by the same method as in Example 1 except that
A fiber molding having 0% and a packing density of 0.041 g / cm ³ was obtained in the same manner as in Example 1.

This fiber molding was hard to settle, was light and soft, and had a comfortable use feeling.

Properties of the composite fiber A, the composite fiber B and the fiber molded body are shown in Tables 1 and 2 together.

[Comparative Example 1] Thermoplastic polymer R1 used
5 were the same as in Example 1. R1 is 45 by weight
%, R2 was 45%, and R3 was 10% by the same method as in Example 1.

Also, R4 is 50% and R5 is 50% by weight.
40% by weight of the composite fiber A and 6% of the composite fiber B were used by using the composite fiber B obtained by the same method as in Example 1 except that
A fiber molding having 0% and a packing density of 0.041 g / cm ³ was obtained in the same manner as in Example 1. The composite fiber A of the obtained fiber molding had a weight ratio represented by R3 / (R1 + R2) of 10/90, and the weight ratio of R3 was small, resulting in poor shape fixability of the fiber molding.

Table 3 shows the characteristics of the composite fiber A and the composite fiber B which compose the fiber molded body.

[0125]

[Table 3] Table 4 shows the characteristics of the fiber molded body.

[0126]

[Table 4] [Comparative Example 2] The thermoplastic polymers R1 to R5 used were the same as in Example 1. R1 is 15% and R2 is 1 by weight
A composite fiber A with 5% and R3 of 70% was obtained by the same method as in Example 1.

Also, R4 is 50% and R5 is 50% by weight.
40% by weight of the composite fiber A and 6% of the composite fiber B were used by using the composite fiber B obtained by the same method as in Example 1 except that
A fiber molding having 0% and a packing density of 0.041 g / cm ³ was obtained in the same manner as in Example 1. The composite fiber A of the obtained fiber molding had a weight ratio represented by R3 / (R1 + R2) of 70/30, and the weight ratio of R3 was large, and the softness of the fiber molding was poor.

Properties of the composite fiber A, the composite fiber B and the fiber molded product are shown in Tables 3 and 4 together.

[Comparative Example 3] Thermoplastic polymer R1 used
~ R5 were the same as in Example 1. R1 is 0 by weight
%, R2 was 50%, and R3 was 50% to obtain a composite fiber A by the same method as in Example 1.

Also, R4 is 50% and R5 is 50% by weight.
40% by weight of the composite fiber A and 6% of the composite fiber B were used by using the composite fiber B obtained by the same method as in Example 1 except that
A fiber molding having 0% and a packing density of 0.040 g / cm ³ was obtained in the same manner as in Example 1. The composite fiber A of the obtained fiber molding has a weight ratio represented by R1 / R2 of 0 /
Since the weight ratio of R1 was reduced to 100, the softness of the fiber molding was inferior.

Properties of the composite fiber A, the composite fiber B and the fiber molded product are shown in Tables 3 and 4 together.

[Comparative Example 4] Thermoplastic polymer R1 used
~ R5 were the same as in Example 1. R1 is 10 by weight
%, R2 40% and R3 50% were obtained by the same method as in Example 1.

Further, by weight ratio, R4 is 50% and R5 is 50%.
40% by weight of the composite fiber A and 6% of the composite fiber B were used by using the composite fiber B obtained by the same method as in Example 1 except that
A fiber molding having 0% and a packing density of 0.040 g / cm ³ was obtained in the same manner as in Example 1. The weight ratio represented by R1 / R2 of the composite fiber A of the obtained fiber molding is 20.
/ 80, the weight ratio of R1 was reduced, and the softness of the fiber molded product was inferior.

Properties of the composite fiber A, the composite fiber B and the fiber molded product are shown in Tables 3 and 4 together.

[Comparative Example 5] Thermoplastic polymer R1 used
~ R5 were the same as in Example 1. R1 is 40 by weight
%, R2 was 10%, and R3 was 50% to obtain a composite fiber A by the same method as in Example 1.

Further, R4 is 50% and R5 is 50% by weight.
40% by weight of the composite fiber A and 6% of the composite fiber B were used by using the composite fiber B obtained by the same method as in Example 1 except that
A fiber molding having 0% and a packing density of 0.042 g / cm ³ was obtained in the same manner as in Example 1. The weight ratio represented by R1 / R2 of the composite fiber A of the obtained fiber molding was 80.
Since the weight ratio of R2 was reduced to / 20, the softness of the fiber molded product was inferior.

Properties of the composite fiber A, the composite fiber B and the fiber molded product are shown in Tables 3 and 4 together.

[Comparative Example 6] Thermoplastic polymer R1 used
~ R5 were the same as in Example 1. R1 is 25 by weight
%, R2 25% and R3 50% were obtained by the same method as in Example 1.

Further, by weight ratio, R4 is 50% and R5 is 50%.
Using the composite fiber B obtained in the same manner as in Example 1 except that the composite fiber A is 10% and the composite fiber B is 9% by weight.
A fiber molding having 0% and a packing density of 0.040 g / cm ³ was obtained in the same manner as in Example 1. The obtained fiber molded product was inferior in shape fixing property and multidirectional cutting property because the weight ratio of the composite fiber A was low.

Properties of the composite fiber A, the composite fiber B and the fiber molded product are shown in Tables 3 and 4 together.

[Comparative Example 7] Thermoplastic polymer R1 used
~ R5 were the same as in Example 1. R1 is 25 by weight
%, R2 25% and R3 50% were obtained by the same method as in Example 1.

Also, R4 is 50% and R5 is 50% by weight.
Using the composite fiber B obtained by the same method as in Example 1 except that the composite fiber A is 70% by weight and the composite fiber B is 3% by weight.
A fiber molding having 0% and a packing density of 0.042 g / cm ³ was obtained in the same manner as in Example 1. The obtained fiber molded product was inferior in softness because the weight ratio of the composite fiber A was large.

Properties of the composite fiber A, the composite fiber B and the fiber molded product are shown in Tables 3 and 4 together.

[Comparative Example 8] Thermoplastic polymer R1 used
~ R5 were the same as in Example 1. R1 is 25 by weight
%, R2 25% and R3 50% were obtained by the same method as in Example 1.

Also, R4 is 50% and R5 is 50% by weight.
40% by weight of the composite fiber A and 6% of the composite fiber B were used by using the composite fiber B obtained by the same method as in Example 1 except that
A fiber molding having 0% and a packing density of 0.014 g / cm ³ was obtained in the same manner as in Example 1. The obtained fiber molded product was inferior in shape stability and multidirectional cutting property because of its low packing density.

Properties of the composite fiber A, the composite fiber B and the fiber molded product are shown in Tables 3 and 4 together.

[Comparative Example 9] Thermoplastic polymer R1 used
~ R5 were the same as in Example 1. R1 is 25 by weight
%, R2 25% and R3 50% were obtained by the same method as in Example 1.

Also, R4 is 50% and R5 is 50% by weight.
40% by weight of the composite fiber A and 6% of the composite fiber B were used by using the composite fiber B obtained by the same method as in Example 1 except that
A fiber molding having 0% and a packing density of 0.112 g / cm ³ was obtained in the same manner as in Example 1. The obtained fiber molding had a high packing density and thus was inferior in softness.

Properties of the composite fiber A, the composite fiber B and the fiber molded product are shown in Tables 3 and 4 together.

[Comparative Example 10] Thermoplastic polymer R used
1 and 2 were the same as in Example 1. Example 1 as R3
The polyethylene terephthalate having a melting point of 214 ° C. used in 1. was used. 25% by weight of R1 and 25 by weight of R2
% And R3 of 50% were obtained by the same method as in Example 1. Further, using the conjugate fiber B obtained by the same method as in Example 1 except that R4 is 50% and R5 is 50% by weight, the conjugate fiber A is 40% by weight and the conjugate fiber B is 60% by weight. The fiber mixture of Example 1 was compressed in a mold in the same manner as in Example 1 and set at 220 ° C. for 60 minutes using a dry heat setter to obtain a fiber molded body having a packing density of 0.042 g / cm ^3. It was Since the melting point of R3 was not lower than the melting point of R1, only thermal adhesiveness was poor, and only those having inferior morphological fixability and multidirectional cutting property were obtained.

Properties of the composite fiber A, the composite fiber B and the fiber molded product are shown in Tables 3 and 4 together.

[0152]

According to the fiber mixture of the present invention, the three-dimensional crimp of the composite fiber A and the composite fiber B becomes latent, and the fibers are bonded to each other without being entangled with each other.
It is possible to provide a fiber molded product which has a stable form, is light and soft, is resistant to settling, and has excellent breathability and moisture permeability and is comfortable to use.

Further, since the fibers are randomly arranged in the vertical direction, the horizontal direction, and the thickness direction of the fiber mixture, the difference between the compressibility in the thickness direction and the compressibility in the horizontal direction is reduced, and the obtained fiber molded product is obtained. Is excellent in multidirectional cutting property and can be easily processed according to the purpose of use.

Further, since the fibers can be easily handled in the manufacturing process of the fiber molding, the workability is improved and the fiber molding having a uniform density can be manufactured.

[Brief description of drawings]

FIG. 1 is a schematic cross-sectional view showing an example of a conjugate fiber A of the present invention.

FIG. 2 is a schematic cross-sectional view showing another example of the conjugate fiber A of the present invention.

FIG. 3 is a schematic cross-sectional view showing still another example of the conjugate fiber A of the present invention.

FIG. 4 is a schematic cross-sectional view showing still another example of the conjugate fiber A of the present invention.

FIG. 5 is a schematic cross-sectional view showing an example of the conjugate fiber B of the present invention.

FIG. 6 is a schematic perspective view showing an example of a mold used for producing the fiber molded body of the present invention.

FIG. 7 is a schematic vertical cross-sectional view showing an example of a mold used for producing the fiber molded body of the present invention.

[Explanation of symbols]

 1: Thermoplastic polymer R1 2: Thermoplastic polymer R2 3: Thermoplastic polymer R3 4: Thermoplastic polymer R4 5: Thermoplastic polymer R5 6: Lower mold 7: Upper mold 8: Gas blowing Mouth 9: Fiber mixture

Claims (7)

[Claims] 1. A thermoplastic polymer R1, comprising two different components.
R2 is bonded in a weight ratio range of 30/70 to 70/30 to form a core, and further, a thermoplastic polymer R1 or R
The thermoplastic polymer R3 having a lower melting point than the one having a lower melting point of 2 has a weight ratio of 20 represented by R3 / (R1 + R2).
20 to 60% by weight of the composite fiber A that is composited in the sheath portion in the range of 80/60 to 40/40, and a thermoplastic polymer R4 having a melting point higher than that of the thermoplastic polymer R3 and two different components. , R5 are joined to form a composite fiber B40-80
% Of the fiber mixture. 2. A fiber mixture as claimed in claim 1, characterized in that the thermoplastic polymers R1, R2, R3, R4 and R5 are all polyesters. 3. The composite fiber A and the composite fiber B both have crimps, and the composite fiber A has a number of crimps before heat treatment of 3 to 20 peaks / 2.
A latent crimped conjugate fiber having a size of 5 mm and a crimp number of at least 30 peaks / 25 mm and a crimp degree of at least 25% by heat treatment at 80 to 200 ° C.
Has a crimp number of at least 3 peaks / 25 mm and a crimp degree of at least 5%, and a heat treatment at 80 to 200 ° C. causes a crimp number of at least 30 peaks / 25 mm and a crimp degree of at least 25%. 3. The fiber mixture according to claim 1 or 2, which is a latent crimped conjugate fiber. 4. The composite fiber A is a short fiber having a fineness of 1 to 10 denier and a fiber length of 10 to 100 mm, and the composite fiber B is a short fiber having a fineness of 0.5 to 30 denier and a fiber length of 10 to 100 mm. Fiber mixture according to claim 1, 2 or 3. 5. The composite fibers A of the fiber mixture according to claim 1, 2, 3 or 4 and between the composite fibers A and B.
At least a part of a contact point between the fiber molding and the fiber molding is bonded and molded. 6. The composite fiber A and the composite fiber B are both
At least 30 threads / 25 mm crimp number and at least 25
% Crimp and density of 0.02 to 0.10 g
/ Cm < ³ >, The fiber molded body of Claim 5 characterized by the above-mentioned. 7. The fiber mixture according to claim 1, 2, 3 or 4 is opened and blown into a breathable mold together with gas,
8 for those filled with a density of 0.02 to 0.10 g / cm ^3.
A method for producing a fiber molded body, which comprises performing a heat treatment at 0 to 200 ° C.