JPH09262167A - Bedding - Google Patents

Abstract

PROBLEM TO BE SOLVED: To allow an easy recycle and provide a deodorizing and comfortable feeling of use by forming all of the stuffing cotton, side cloth, sewing thread and accessories of bedding, out of a fabric made of the same polymer. SOLUTION: Polygthylene terephthalate chips having a fusion point at 255 deg.C are used and subjected to asymmetrical cooling treatment immediately below a spinneret, thereby spinning the un-drawn yarn of cotton stuffed fabric. Also, a fabric woven to eight satin textures and print finished using polyester staple of anti-pill type is utilized as a bedding side cloth. Furthermore, sewing thread to be used is three-twisted thread of high strength polyester filament yarn. Also, a handling indication label or the like as an accessory is as well made of polyester unwoven fabric. According to this construction, an easy recycle is ensured and a deodorizing and comfortable feeling of use can be provided.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a quilt such as a comforter, a quilt, a skin comforter, and a cushion, and more particularly to a quilt which is easy to recycle and has deodorant properties.

[0002]

2. Description of the Related Art In recent years, due to two needs, that is, environmental protection of the earth and efficient use of resources, the problem of treatment and reuse of industrial waste and general household waste has been increasing in importance. In many areas, many people are interested. However, in the field of futons, most used futons have been incinerated or landfilled so far, and recycling technology is still in the development stage.

Conventionally, recycling technologies proposed for textile products are roughly classified into the following three types. The first is thermal recycling. In this method, products are cut into appropriate forms, burned, and reused as in-house power generation and various types of heat energy. However, this method is not preferable from the viewpoint of resource reuse.

[0004] The second is material recycling. This method differs from the following chemical recycling in that it is pelletized physically and mechanically. When this recycled pellet is reused, it is divided into two cases. One is to develop a product as a new material in consideration of the fact that various materials are mixed, such as flower beds, pots for bonsai, and decorative piles for sidewalks. The other is disclosed in Japanese Unexamined Patent Publication Nos. Hei 5-212935 and Hei 6-123052.
In this case, it is composed of 0% of the same material, collected, pelletized, melted and reused.

[0005] The third is chemical recycling. The chemical recycling that best matches the basic concept of recycling is chemical recycling, which collects products, decomposes them, and returns them to their original raw materials. However, since few fiber products are generally made from a single material and the material composition is diverse, it takes some time to develop an economical depolymerization system. Means for solving this problem, for example, in the case of carpet products, is described in Japanese Patent Application Laid-Open No. 5-117441. As an auxiliary means for improving the efficiency of depolymerization, the carpet is fragmented, separated into small pieces containing nylon 6 which is a pile material and other small pieces by a separator, and the small pieces containing nylon 6 are supplied to a depolymerization system. This is a method of recovering ε-caprolactam as a raw material. However, even if the fiber product is made into small pieces and separated by mechanical means, for example, due to the difference in specific gravity due to a cyclone, nylon 6
The substance other than Nylon 6 is still contained in the small pieces containing, and the difficulty of purification of depolymerization has not been solved at all.

On the other hand, polyester-based synthetic fiber stuffed cotton exhibits excellent bulkiness, is lightweight, and has excellent heat retention.
It is often used in the above-mentioned purpose products. This polyester-based synthetic fiber stuffed cotton is made to have three-dimensional crimps by composite spinning, asymmetric cooling, etc. to make it excellent in bulkiness,
For example, as described in Japanese Examined Patent Publication No. 6-51076, a mixture of forward type three-dimensional crimped fibers and inverted three-dimensional crimped fibers can be used in combination to provide excellent bulkiness under no load or under load, There are also fibers with different shapes such as hollow, or those with improved bulkiness and texture by optimizing fiber fineness, fiber length or oil. Further, in order to obtain a soft texture by adding silicone resin, for example, Japanese Patent Publication No.
The inventions described in Japanese Patent Publication No. 28426, Japanese Utility Model Publication No. 53-5353, Japanese Examined Patent Publication No. 4-34435, etc. have been proposed. However, a satisfactory deodorant futon for the sick and elderly has not been disclosed, and development is desired.

That is, a futon which is easy to recycle, has deodorant properties, and has a comfortable feeling has not been disclosed.

[0008]

SUMMARY OF THE INVENTION An object of the present invention is to provide a futon which is easy to recycle and has a deodorant and comfortable feeling.

[0009]

The futon of the present invention has the following constitution in order to solve the above-mentioned problems.

That is, it is a futon characterized in that the wadding, the side cloth of the futon, the sewing thread, and the accessories which compose the futon are all made of fibers made of the same type of polymer.

[0011]

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, the present invention will be described in detail with reference to Examples.

The futon of the present invention is easy to recycle since the quilt, the side cloth, the sewing thread and the accessories of the futon are all made of the same type of polymer.

The conventional futon is made of cotton, which is excellent in touch, hygroscopicity, cotton wicking resistance and pill resistance.
In addition, fibers having a chemical composition different from that of the stuffed cotton fibers such as embroidery thread for side cloth, side sewing thread, and label for indicating kind or handling are often used. Therefore, in the case of recovering and reusing, it is possible to cut the side ground and take out only the stuffed cotton fiber for reuse, but it takes time and becomes a major obstacle. Therefore, according to the present invention, the quilted cotton, the side cloth, the side sewing thread, and the accessories such as the type and the handling display label of the futon are all made of the same type of fiber to make the futon easy to recycle.

In the futon of the present invention, when the constituent fibers are all polyester fibers, it is preferable because the used futon is opened by a fiber-opening machine, melted and pelletized, and then melt spinning can be performed again.

Further, if all the fibers composing the futon of the present invention are nylon 6 type fibers, both material recycling, chemical recycling and thermal recycling are possible.
For example, by supplying the depolymerization system for depolymerization and purification by the method described in JP-B-42-18476, ε-
Caprolactam is more preferable because it can be chemically recycled.

Furthermore, it is preferable that the futon-constituting fibers are nylon 6 fibers, because they can impart use comfort by absorbing moisture.

In the futon of the present invention, it is also preferable that deodorant properties are imparted by using deodorant fibers in the cotton stuffing of the futon. In order to obtain the deodorant property, the deodorant fiber contained in the cotton cot is preferably 40% by weight or more, and more preferably 100% by weight. If it is less than 40% by weight, the ratio of deodorant fibers is small and sufficient deodorant properties may not be obtained.

The deodorant fiber may be one in which a deodorant component is kneaded into a polymer as described in JP-A-3-124809, or a deodorant fiber as described in JP-A-62-6978. The odor component may be added by post-processing. The deodorant fiber can also be obtained by, for example, grafting a free acidic group by graft polymerization as a method of applying a deodorant component in a post-process. The acidic group in this method means a carboxyl group or a sulfonic acid group, and the content of the acidic group is 3. to impart durable deodorant performance.
It is preferably 2 × 10 ⁻⁴ gram equivalent / g fiber or more, more preferably 9.3 × 10 ⁻⁴ gram equivalent / g fiber or more. From the viewpoint of processing cost, the content of the acidic group is preferably 15 × 10 ⁻⁴ gram equivalent / g fiber or less. Incidentally, the end of the introduced acidic group by graft polymerization -COOH or is most preferred state of -SO ₃ H, partially alkali metals or alkaline earth metals, more generally of metal or a quaternary ammonium, It may be substituted by an ionic organic substance such as a salt. It is preferable to distribute a large amount of acidic groups to the surface of the fiber by such graft polymerization, because malodor such as ammonia, hydrogen sulfide, and mercaptans, which are said to be the source of malodor, can be efficiently absorbed.

The cross-sectional shape of the deodorant fiber may be not only a round cross-section but also a modified cross-section such as a polygon, a multileaf or an ellipse, or a hollow cross section thereof. The hollow cross section is a more preferable example because it improves the bulkiness of the futon.

Next, the deodorant fiber used in the present invention is imparted with bulkiness and softness, improves recovery property against compression, and at the same time improves cotton making property. Therefore, the deodorant fiber has a mechanical crimp. Is preferred. The number of crimps may be appropriately selected, but the number of crimps is 3 to 10 peaks / 25 mm and the crimping degree is 5
It is preferably set to -30%. In order to impart further bulkiness, this crimp is derived from, for example, side-by-side composite fibers of polymers of the same system but different properties,
A three-dimensional crimp that develops due to asymmetric cooling during spinning is more preferable.

The deodorant fiber constituting the stuffed cotton has a fineness of 0. from the viewpoint of softness, bulkiness, elasticity and cotton-making property.
Short fibers having a denier of 5 to 30 and a fiber length of 10 to 100 mm are preferably used.

The stuffed cotton may be 100% by weight of the deodorant fiber, but in order to more effectively exert the deodorant property of the futon, at least 40% by weight or more is preferably mixed.

In addition, it is also preferable to add various antioxidants, anti-coloring agents, light-proofing agents, antistatic agents, etc. to the wadding, if necessary, in addition to pigments such as titanium oxide and carbon black.

Further, in order to impart deodorant properties, it is preferable to include deodorant fibers in the cotton stuffing that constitutes the futon, but it is also preferable to impart deodorant properties to the side of the futon and the like. .

[0025]

Next, the present invention will be described more specifically with reference to examples. The measuring methods of various characteristics described in the present invention are as follows.

[Deodorizing Property] Method A: Ammonia gas detector tube method was used to open a carpet of a carpet in a glass column, and 3 g of the carpet cushion was filled.
A gas with a concentration of ammonia gas of ppm is passed at a ventilation rate of 3.3 cm / sec, and the breakthrough time and the amount of breakthrough adsorption are measured (as the breakthrough adsorption amount, after washing with domestic water to exhibit deodorant properties). It is desirable that it is 12 mg / g or more.

Method B: 3 × 6 cm of about 5% ammonia water
After impregnating 0.25 ml of the filter paper of No. 1 into a glass container of 150 ml, 0.5 g of the fiber whose carpet cushion has been opened is placed at the same time and sealed with a stopper, and the odor change after left for 4 hours is subjected to a sensory evaluation. (No odor, slightly odor, odor, and strong odor were evaluated.) [Fineness] The fineness was measured according to the method of JIS L1015-7-51A.

[Average Fiber Length (Cut Length)] JIS L1
The measurement was performed according to the 015A method (staple diagram method).

[Number of Crimps and Degree of Crimp] The number of crimps and the degree of crimp are JIS L1015-7-12-1 and JIS.
It measured according to the method of L1015-7-12-2.

Example 1 A polyethylene terephthalate chip having a normal melting point of 255 ° C. was used, and the spinning temperature was 280.
C., a take-up speed of 1350 m / min, and a hollow cross-section structure with a hollow ratio of 30% were subjected to a usual asymmetric cooling treatment immediately below the spinneret, and an undrawn yarn of stuffed cotton fiber was spun. Then, the undrawn yarn is drawn at a draw ratio of 3.0 times and a drawing bath temperature of 80 ° C., a mechanical crimp is applied by a crimper, a finishing oil agent is applied and cut, and then set by a heat setter at 145 ° C. and dried. Then, a stuffed cotton fiber having a fineness of about 6 denier and a cut length of 51 mm is obtained, and further opened with a roller card to form a web,
A laminated web was made with a cotton-making machine. As the futon side, we use a woven and print-finished fabric with 8 satin weaves using anti-pill type polyester staple (2 denier, 51 mm), and the sewing thread is a triple yarn of high-strength type polyester filament thread. 1. Using a twisted yarn as the futon side, and the laminated web of the stuffed cotton fibers
Packed in 8 kg, the product type and the label for handling were made of a quilt using polyester non-woven fabric. This comforter was a good comforter rich in bulkiness. This futon was used for 6 months, and the side fabric was defibrated with a fluffing machine, and the defibrated fibers were melted and pelletized, melt-spun and stretched again to obtain a 3 denier, 51 mm polyester staple. The obtained staple was a gray-colored polyester staple, which was slightly lower in strength than the commercially available polyester staple, but was sufficiently usable as a polyester staple.

[Examples 2 to 4] First, an ordinary nylon 6 chip was melt-spun and stretched to obtain a circular hollow having a melting point of 215 ° C, a fineness of 7 denier, and a cut length of 51 mm (hollow ratio 17
%) Nylon 6 staple, this staple was used under the conditions of acrylic acid 19% owf, methacrylic acid 30% owf, ammonium persulfate 1% owf, Superlite C (manufactured by Mitsubishi Gas Chemical Co., Inc.) 3% owf, and a bath ratio of 1:14. The temperature is raised from room temperature to 80 ° C at a rate of 1 ° C / min, and then 60 ° C at 80 ° C.
Graft-polymerization processing was performed for a minute to obtain a deodorant fiber.

The graft ratio of methacrylic acid on 100% of this deodorant fiber was determined from the rate of weight increase, and the amount of carboxyl groups was determined to be 3.27 × 10 ^-2 gram equivalent / gram.
Fiber. When the cross section of the deodorant fiber was cut and dyed with a cationic dye, and the distribution state of carboxyl groups was examined, it was confirmed that a large amount of the deodorant fiber was present on the surface of the fiber. The deodorant property of 100% of this deodorant fiber was 34.6 mg / g before washing, 31.2 mg / g after washing, and B in accordance with the breakthrough adsorption amount of Method A.
According to the method, it was odorless both before and after washing, and exhibited extremely high deodorant properties. The breakthrough time before washing in Method A was 46 minutes.

100% by weight of the above deodorant fiber, and deodorant fiber and a non-deodorant melting point of 215 ° C., a fineness of 7 denier, and a circular hollow (hollow ratio 17%) nylon 6 staple fiber having a cut length of 51 mm were mixed and mixed. A roller card was used to further mix and open the fibers into a web, and a cotton molding machine was used to form a laminated web.

On the other hand, as the futon side, nylon 6 staple 2 denier, 51 mm was used to weave into a plain weave structure,
A woven fabric which had been dyed to a skin color and finished was used, and a sewing thread was a triple-twisted yarn of spun yarn using nylon 6 staple to form a futon side. Nylon 6 filament taffeta was used for the type and handling label, and the fiber laminated web for stuffed cotton was packed in nylon 6 side fabric to make a summer comforter.

Further, the mattress is made of commercially available cotton, the pillow is made of commercially available ordinary polyester chips, and the cotton summer pajamas are actually worn in a room controlled at a temperature of 27 ° C. and 70% RH. A sleep experiment was conducted (the results were evaluated in 7 grades from comfortable (⊚) to extremely damp (×)).

Table 1 shows the ratio of stuffed cotton, the deodorizing property, and the results of sleep tests of these futons.

In Examples 2, 3, 4 and 5, 100 to 38% by weight of deodorant fiber was used as the stuffed cotton, and although the deodorant property after washing in Example 4 was slightly low, the entire deodorant property was obtained. Was good and comfort as a comforter was also good.

The comforters of Examples 2 to 5 were used for 3 months and then collected and defibrated by using an anti-fluffing machine. The defibrated fibers were depolymerized and purified by the method described in JP-B-42-18476, and recovered as ε-caprolactam.

[0039]

[Table 1]

[0040]

According to the present invention, it is possible to provide a futon which is easy to recycle and has a deodorant and comfortable feeling.

Claims (10)

[Claims] 1. A quilt characterized in that a quilt, a side material of the quilt, a sewing thread, and an accessory constituting the quilt are all made of fibers made of the same type of polymer. 2. The futon according to claim 1, wherein the fibers constituting the stuffed cotton are hollow fibers. 3. The fineness of the fibers constituting the stuffed cotton is 0.5 to 3.
The futon according to claim 1 or 2, which has a denier of 0 and a fiber length of 10 to 100 mm. 4. The fibers constituting the batting are at least 3 piles /
The futon according to any one of claims 1 to 3, which has a crimp number of 25 mm and a crimp degree of at least 5%. 5. The futon according to claim 4, wherein the fibers constituting the batting are short fibers having a three-dimensional crimp. 6. The futon according to any one of claims 1 to 5, wherein all the fibers constituting the futon are polyester. 7. The fibers constituting the futon are all nylon 6
The futon according to any one of claims 1 to 5, wherein 8. The futon according to claim 1, wherein the stuffed cotton contains deodorant fibers. 9. The futon according to claim 8, wherein the proportion of the deodorant fiber contained in the stuffed cotton is 40% by weight or more. 10. The deodorant fiber has a free carboxyl group.
The futon according to claim 8 or 9, which is a nylon 6 fiber containing 2 × 10 ^-4 gram equivalent / g fiber or more.