JPH09271429A - Production of matting pad - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a smooth touch and bright patterns by laminating cloth having thermal shrinkability, a foamed elastic material, a non-woven fabric and pile cloth formed by using blended yarn of acrylic fibers and low melting fibers as pile yarn and integrating the laminate by quilting, then subjecting the laminate to a heat treatment. SOLUTION: The cloth having the thermal shrinkability, the foamed elastic material, the non-woven fabric and the pile cloth formed by using the blended yarn of the acrylic fibers and the low melting fibers as the pile yarn are laminated in this order and the laminate is integrated by quilting. The laminate is then subjected the heat treatment. Natural fibers and synthetic fibers are used for the stock of the non-woven fabric. Crimped fibers are more preferably used in terms of restoration of compressive elasticity. Hygroscopic fibers are more preferable in terms of absorption of sweat. The foamed elastic material makes up a cushion property and the non-woven fabric is laminated as the human body side on the foamed elastic material. The low melting fibers are usually used by blending the fibers having the m. p. around 120 to 130 deg.C at 20 to 50% therewith for a higher effect in terms of the suppression of fluffing and hand.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a spread pad used for bedding for summer clothes and the like.

[0002]

2. Description of the Related Art Bedding for summer clothes using a loop pile fabric such as a towelette has been widely used. As materials for these summer bedding products, natural fibers such as cotton, which have high hygroscopicity, are generally used. However, as a recent trend, from the viewpoint of dyeability and fashionability, conventional cotton products have been taken away from synthetic fiber products. The new sense by is starting to be used.

[0003]

Synthetic fiber products, especially acrylic fiber products, have good colorability and good dyeing fastness, so that a beautiful printed pattern can be easily provided, and they are useful in terms of fashionability. In terms of the texture of the fabric that affects the life of the product, the slimy feeling peculiar to acrylic fiber is difficult to come off, and it is widely used as winter bedding such as blankets, but it is far behind the dry cotton product as summer bedding. is the current situation. Further, in pile products in which spun yarn of acrylic fiber is used as pile yarn, there is also a basic problem that the print pattern becomes blurred and unclear due to fine fluff on the pile surface.

[0004] The present invention solves such a conventional problem,
An object of the present invention is to provide a method for manufacturing a laying pad using an acrylic fiber pile cloth that can be used as bedding for summer clothes and the like.

[0005]

Means for Solving the Problems The above-mentioned problems are, in the above-mentioned order, a heat-shrinkable cloth, a foamed elastic body, a non-woven fabric, and a pile cloth using a mixed yarn of an acrylic fiber and a low melting point fiber as a pile yarn. This is solved by a method of manufacturing a spread pad, which comprises stacking, integrating the stack by quilting, and then performing heat treatment.

[0006]

BEST MODE FOR CARRYING OUT THE INVENTION The non-woven fabric used in the present invention is intended to impart appropriate cushioning properties, alleviate compression caused by the weight of the human body, and absorb sweat discharged from the human body. Commonly used natural fibers and synthetic fibers are used, but crimped fibers are preferable from the viewpoint of compression elastic recovery, and hygroscopic fibers are preferable from the viewpoint of sweat absorption. As the hygroscopic fiber, any fiber material such as a natural fiber such as cotton or wool or a synthetic fiber modified to have hygroscopicity is used. Even if hydrophobic synthetic fibers are used, it is possible to absorb and retain moisture in the gaps between the constituent fibers if crimped.

The foamed elastic body is for supplementing the cushioning property, and the one normally used for bedding such as mat can be used as it is. The non-woven fabric and the foamed elastic body are laminated with the foamed elastic body so that the non-woven fabric is on the human body side when used. The thickness of the laminate may be determined by arbitrarily selecting the thickness of the nonwoven fabric and the elastic foam according to the purpose of use, but generally, increasing the thickness of the nonwoven fabric is suitable for cushioning. It is preferable because it can impart the property.

[0008] The pile fabric forms the uppermost layer of the spread pad, and since the pile fabric is in direct contact with the human body, the product texture is important and the appearance as a product is also important.
In the present invention, as the pile fabric, a pile fabric in which the pile yarn is composed of a mixed yarn of acrylic fiber and low melting point fiber having a lower melting point than the acrylic fiber is used. In this case, the low-melting point fiber can theoretically be used as long as it has a lower melting point than the acrylic fiber used for general acrylic fiber spun yarns, but it can be used during heat treatment from the viewpoint of maintaining the flexibility of the fabric and process control. The lower the temperature, the better. Therefore, as the low melting point fiber, a low melting point polyester fiber having a melting point of about 130 ° C., a polyolefin fiber, and a split type or core-sheath type composite fiber using a low melting point component as a part of the fiber are preferable. Used for.

The mixing ratio of these low-melting-point fibers can be appropriately set in consideration of the desired product performance and the heat treatment temperature to be used, but heat treatment during the usual dyeing and finishing process is used without any special additional process. Melting point is 12
It is effective from the viewpoint of suppressing fluff and texture to mix the low melting point fibers around 0 to 130 ° C. in the range of 20 to 50%. As the spinning method, the usual acrylic fiber spinning method is used as it is, but the number of the blended yarn is preferably 1/20 to 1/40 English cotton count.

The spun yarn thus obtained is used to make a pile fabric. When the pile fabric is used as the warp knitted fabric, it is possible to prevent the fray of the weft yarn due to the thread breakage or the catch, which is the case in the woven pile. As the warp knitted fabric, a Russell knitted fabric by a Russell knitting machine is preferably used from the viewpoint of pile forming ability, morphological stability and the like. This knitted fabric is generally often used as a pile fabric.

Generally, this pile cloth is exposed or dyed, but in the heat treatment step in this step, the melting point temperature of the low melting point fiber constituting a part of the pile yarn of the pile cloth is close to the melting point temperature. When heated by, the low melting point fibers are fused and the fluff around the low melting point fibers is suppressed, so that the morphological stability of the pile is increased, and at the same time, a dry feeling and a slight coarse and hard feeling are provided.

This heat treatment step can be carried out at any position during the dyeing and finishing step, but it is preferable to carry out the heat treatment step at the same time during the dyeing and finishing drying step from the viewpoint of productivity and economy.
This heat treatment can also be performed in the heat treatment step of the laminated body after being laminated with a nonwoven fabric, a foamed elastic body, and a heat-shrinkable fabric and integrated by quilting as described later. In this pile fabric, it is most effective to print on the pile fabric.

When forming a pattern, the warp knitting machine cannot form a jacquard structure like a flat knitting machine or a loom because of its knitting mechanism, and the pattern formation by force printing is the mainstream. Therefore, in the case of printing a spun yarn pile, the pile causes blurring at the edge of the pattern as described above, and the sharpness of the printed pattern tends to be lacking, but if heat treatment is applied after print printing as described above, it will be low. Due to the shrinkage and fusion caused by the melting point fibers, fine fluff on the surface of the spun yarn is suppressed and the sharpness at the handle is improved. For the print printing, a generally used method may be used as it is, and depending on the low melting point fiber used, the low melting point fiber may be subjected to heat fusion treatment at the time of color development of the print printing.

A heat-shrinkable cloth is laminated under the foamed elastic body to form the lowermost layer of the spread pad. This heat-shrinkable fabric uses a spun yarn obtained by mixing high-shrinkable fibers as a warp or weft of a woven fabric, or both, and is a plain weave in terms of morphological stability as a woven structure. Is preferred. The shrinkage of the cloth is preferably about 20% both in diameter and weft. Such a laminated body is integrally joined by quilting. As a quilting method, a commonly used method is used as it is. Of course, it is also possible to use a heat-shrinkable yarn as the quilting yarn.

Next, the laminated body thus integrated is subjected to a heat treatment to shrink the heat-shrinkable cloth so that the laminated body is tightened and, at the same time, unevenness due to quilting becomes more remarkable. In this case, the low melting point fibers contained in the constituent fibers of the pile fabric used as the uppermost layer can be fused by this heat treatment.

The present invention will be described in more detail with reference to the following examples.

[0017]

[Example] Acrylic fiber (bright, 3d x 51 mm)
70%, low melting point polyester fiber (2
d × 51 mm) 30% was applied to a spinning spinning machine to obtain a blended yarn with 1/20 (English cotton count) and a twist number of 510 T / M. This blended yarn is used as pile yarn, and polyester / cotton blended yarn (1/23 English cotton count) is used as inlay yarn.
A polyester multifilament yarn (100d / 48f) was used as a chain yarn and set on a warp knitting machine to knit a loop pile fabric according to the following standards.

Warp knitting machine; type F manufactured by KARL MAYER
BZ 28G (set a thread on every other knitting needle,
Use as 4G) Pile length: 3mm Number of courses: 11 courses / cm

Next, the knitted pile fabric was printed with a screen printing machine using dyes of six colors, and then finished by coloring with steam treatment, washing with water, treatment with a softening agent, and a tenter dryer. The temperature of the dryer was set to 140 ° C (maximum site temperature). As a result, the fluff formed on the pile yarn due to the partial fusion of the low-melting point polyester fiber was laid down, and the printed fabric pattern was clear, and a pile fabric having a slight rough and hard feeling with a dry feel was obtained.

This printed pile fabric, a non-woven fabric of 10 mm thickness composed of polyester composite fibers (2d × 51 mm), a polyurethane foam elastic body of 6 mm thickness, and a shrinkable acrylic spun yarn (2/32 meter count, Plain fabric woven by using 20% shrinkage with saturated steam for both warp and weft (warp density 22 / inch x weft density 22 /
The bottom layer is a heat-shrinkable plain weave, followed by a foamed elastic body.
The non-woven fabric and the uppermost layer were laminated so as to be a pile fabric, quilted by a quilting sewing machine and quilted, and then the laminated body was passed through a continuous steaming machine for steam treatment. By this steam treatment, the bottom plain weave fabric is quilted and restrained,
Each warp and weft contracted about 20%, and irregularities were formed according to the stitch pattern of the quilting. The thus-obtained laminate had a clear print pattern, the surface of which was covered with a pile fabric having a crispness, and a laying pad having an uneven elastic body was obtained.

[0021]

The floor pad obtained according to the present invention is
It has a light texture and a slight coarse and hard feeling, and when printing is performed on prints, the fluff is suppressed by heat treatment, resulting in a clear pattern with no blur. In addition, since the non-woven fabric is located immediately below the pile fabric, it has an appropriate cushioning property, and perspiration from the human body can be absorbed by this non-woven fabric. Furthermore, due to the unevenness caused by quilting, the breathability of the contact area with the human body is greatly improved.
Great effect as a pad for summer.

Claims (1)

[Claims] 1. A heat-shrinkable cloth, a foamed elastic body, a non-woven fabric, and a pile cloth using a mixed yarn of acrylic fiber and a low melting point fiber as a pile yarn are laminated in the above order, and the laminated body is quilted. A method for manufacturing a spread pad, which comprises subjecting the pad to heat treatment after being integrated.