JPH10328442A - Fiber forming inner material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a sufficient elasticity and flattening resistance property as a fiber forming inner material and also to obtain excellent work property by providing fiber aggregates where mutual short fibers are partially joined and providing a hairy layer which is constituted of the fibers by which the fiber aggregates is constituted on at least one surface. SOLUTION: This fiber forming inner material to be used for a mattress or a sleeping mat is preferably formed by using the short fibers being 10-20 mm in length, they are the ones provided with cross-sectional shapes such as the hollow one, the different one or the round one, etc., and the fibers provided with crimps is favorably used. The number of crimps in the crimped fibers is favorably adopted as 5-100 piles/25 mm and the thickness of the short fibers is as 2-50 deniers. Then, the hair erecting layer or the hairy layer 2 consisting of the fibers which constitute the fiber aggregates in the inner material is provided on at least one surface of the fiber forming inner material and the hairs for forming the layer 2 are provided with length which is up to the half of the average fiber length of the short fibers or, preferably, the length of 0.5-50 mm.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an intermediate material formed of fibers, and more particularly to an intermediate material for mattresses, mattresses, chair seats, etc., or a sound-insulating intermediate material used for floors and walls. About materials.

[0002]

2. Description of the Related Art Materials and forms of conventionally used fiber molding materials include urethane foam, polyester fiber aggregate, or polyester fiber phase partial adhesive molded product (hereinafter referred to as "polyester molded product"), and These complexes are the mainstream. Among these, urethane foam and polyester molded bodies that generate hardness, elasticity, and sag resistance have poor adhesion to external materials (such as cloth, leather, and wood) when used alone, and do not have a sense of unity. There was a problem.

[0003] On the other hand, polyester fiber aggregates have a sense of unity with external materials, but have poor practicality due to poor hardness, elasticity, sag resistance, and poor handling properties. In many cases, they are used as composites. However, when this composite is used, there are problems such as complicated processing, poor handling, poor sense of unity, and a limit on the thickness of the polyester fiber aggregate layer.

[0004]

SUMMARY OF THE INVENTION In view of the above technical background, the present invention satisfies sufficient elasticity and sag resistance as a material during fiber molding, a sense of unity with an external material, and good workability. It is an object of the present invention to provide a fiber forming material having the following.

[0005]

The present invention employs the following means in order to solve the above-mentioned problems. That is, the fiber forming material according to the present invention is a fiber assembly in which short fibers are partially joined to each other, and a nap layer or a fluff layer formed on at least one surface of the fiber assembly. It is characterized by having.

[0006]

BEST MODE FOR CARRYING OUT THE INVENTION The present invention satisfies the above-mentioned problems, that is, satisfactory elasticity, sag resistance and soft cushioning property as a material during fiber molding, and good workability in addition to a sense of unity with an external material. After a thorough examination of the material, it was determined that the elasticity and sag resistance were satisfactory if a partially joined product of short fiber fiber aggregates was used, but the soft cushioning property and the sense of unity with the outer material could not be realized. Was. Then, when the surface of one surface of the fiber assembly was further made fluffy, it was surprisingly found that the above-mentioned problem was solved all at once.

[0007] The fibers used in the fiber molding material of the present invention are:
Synthetic fibers, natural fibers and the like can be used without any particular limitation, but polyester fibers are most preferred in view of the properties of the material during molding. The fiber aggregate constituting the fiber forming material of the present invention is an aggregate made of short fibers, and the length of the short fibers affects the thickness of the nap layer or the fluff layer, The use of long fibers increases the thickness of the nap layer or the fluff layer, but it is difficult to use the material during fiber molding and may cause inconvenience. As the fiber forming material, short fibers having a fiber length of preferably 10 to 200 mm, more preferably 20 to 100 mm are conveniently used. As such short fibers, fibers having a cross-sectional shape such as hollow, irregular, and round cross sections can be used, and more preferably, fibers having crimps are used. Good from above. Any of the wave forms and the three-dimensional (spiral) warp can be used as the warp form of the warp. Above all, hollow three-dimensional crimped fibers having excellent elasticity and hardness are most preferable. The number of sagging of such a crimped fiber is preferably large in order to generate elasticity, but preferably 5 to 100 crests / 25 mm, more preferably 8 to 70 crests / 25 mm, may be excellent in workability.
The degree of shrinkage of such a crimped fiber is preferably 5 to 5.
50%, more preferably 8 to 30% is used.

The short fibers have a thickness of 1 to 50 denier, more preferably 3 to 20 denier, in order to generate elasticity in the material during molding. Of course, in order to impart a soft feeling, such fibers may be used in combination with ultrafine fibers.

[0009] The intermediate fiber molding material of the present invention is a fiber aggregate in which short fibers are partially joined to each other, and this partial joining is a structure in which elasticity and air permeability are regarded as important.
For the joining, at least one method of adhesive and heat fusion is adopted. As such an adhesive, a rubber-based adhesive or a synthetic resin-based adhesive can be used. In the case of heat fusion, a synthetic resin having a low melting point can be used. The shape of such a joining material may be granular or fibrous, and any of heat, drying, pressure and the like may be employed as the joining process. Most preferably, a method in which ordinary polyester fibers and polyester-based heat bonding fibers (particularly, core-sheath type composite fibers are preferable) are mixed, and a material being molded by heat fusion treatment is produced. The mixing ratio of the joining material is preferably 5 to 60% by weight, more preferably 20 to 50% by weight of the total amount of the fiber aggregate.

[0010] The thickness of the fiber middle material of the present invention depends on the use of the final product and is not particularly limited. 200 mm, more preferably 10
Thicknesses of up to 150 mm are preferred.

The fiber forming material of the present invention has a raised layer or a fluff layer on at least one side, and the single fibers constituting this layer are formed by fluffing from the fiber aggregate. Since the single fibers are not bonded to each other and the fiber direction is oriented in the thickness direction of the material being molded,
The soft cushion property and the crisp texture and the sense of unity with the external material are induced. The bristles constituting the nap layer or the fluff layer may have a length up to half the average fiber length of the short fibers protruding from the surface of the fiber assembly. 5-60m
m, more preferably 1-40 mm long nap or fluff. If the nap or fluff is too long, the nap or fluff tends to fall off. Speaking specifically, the length of the hair, for example, the middle material of the chair, which requires strong elasticity, is made as thin as 1 mm to improve the familiarity with the external material, and the bed material, which requires both softness and elasticity, is as long as 30 mm. It is better to use something.
For example, when the outer material is a cloth on one side and a plate on the other side, the raised layer or the fluffed layer is provided with a fluffed layer so as to be in contact with the cloth, and the one in contact with the plate is defined as a fiber aggregate layer, and the fiber molding layer is formed by fabric. When the entire inner material is foreskinned, a material having a raised layer or a fluff layer on both sides is used.

The portion excluding the raised layer or the fluffed layer constituting the material during fiber molding of the present invention is a fiber aggregate in which fibers are bonded to each other. It affects the brittleness, and is preferably 0.
02 to 0.09 g / cc, more preferably 0.03 to 0.09 g / cc
Those having a range of 0.07 g / cc are preferred. If the fiber density is too low, it is soft and merely a single fiber aggregate. Conversely, if it is too high, it becomes too hard, loses its elasticity and becomes plate-like, making it difficult to put into practical use. The fiber density of the nap layer or the fluff layer is 0.005 to 0.07 g because of having space.
/ Cc.

The fibers constituting the fiber assembly layer of the present invention are as follows:
It may be either a plane arrangement horizontally arranged with respect to a normal plane, or a three-dimensional arrangement arranged substantially at right angles to the plane, but in a three-dimensionally arranged fiber assembly, elasticity and sag resistance are further increased. It is preferable because the property is improved. That is, the fiber axis is oriented in the direction of compression, the buckling of the fiber, there is an advantage that it is possible to utilize the torsional stress, furthermore, it is possible to provide a fiber forming material having excellent bendability like accordion In addition, there is an advantage that good air permeability and water bleeding property can be imparted, and furthermore, it is easy to provide a nap layer or a fluff layer having a long hair.

Such a three-dimensionally arranged fiber assembly can be formed by a method of bending a card web into a waveform or a method of blowing a small fiber assembly by air to deposit. In such a three-dimensional arrangement, it is effective if preferably about 50% or more of the single fibers of the fiber assembly are three-dimensionally arranged.

The material during fiber molding of the present invention may be required to be freely bent depending on the use. For example, mats and reclining chairs used for nursing care beds, which are particularly required to have a soft surface and elasticity of the central layer, as well as a sense of unity with the outer fabric. In the fiber forming material of the present invention, the raised layer or the fluffed layer can expand and contract in accordance with the excellent bending property,
It has the feature of being excellent in unity with external materials.

In the fiber forming material according to the present invention, a fiber forming material sample having a thickness of 5 cm, a width of 10 cm and a length of 50 cm is protruded by 30 cm in the length direction from the test table, and the length of the tip of the material is sagged. When measured and evaluated, it has a bendability of preferably 10 cm or more, more preferably 10 to 30 cm. If the bendability is less than 10 cm, there is a risk of breaking when bent.

The fiber forming material according to the present invention will be described with reference to the drawings. FIG. 1 is a perspective view showing one example of a fiber molding material according to the present invention, and FIG. 2 is a partially enlarged view of FIG. The fiber forming material according to the present invention comprises a fiber aggregate 1 and a nap layer or a fluff layer 2.
It is constituted by. The fibers 4 of the nap layer or the fluff layer 2 are drawn out of the fiber aggregate, and are not bonded to each other, exist in a fluffy state, and the ends are bonded to the fibers 3 of the fiber aggregate. They are united. The fibers 3 are partially joined to each other by a granular or fibrous joining material to form a partially joined portion 5.

Next, the method for producing the fiber forming material of the present invention will be described by way of an example. First, a fiber assembly composed of fibers joined together is made and processed,
A nap layer or a fluff layer is formed to produce a fiber forming material. Specifically, after mixing the fibers with a commonly used cotton-opening mixer, the low-melting fused fibers and the high-melting fibers are mixed, then opened, mixed, and webed with a card machine,
The web is polymerized and laminated. The laminate is sufficiently melted by passing hot air having a melting point of the low melting point fusion fiber or higher,
Next, the melted fibers are cooled and solidified, and the fibers are joined together.

Next, the nap layer or the nap layer is formed by bringing a surface of the fiber assembly into contact with a nap device that rotates a roller, at which high numbers of elastic needles, such as wires, are planted innumerably, at a high speed. The thickness of the nap layer or the fluff layer, that is, the length of the hair, can be adjusted by the contact depth with the roller.

The fiber molding material of the present invention can be further treated with a functional agent, that is, a water repellent or a hydrophilizing agent, to provide a product having desired performance.

[0021]

The present invention will be described below in more detail with reference to Examples and Comparative Examples.

Example 1 70% by weight of a polyester hollow three-dimensional crimped short fiber (13 denier, fiber length 64 mm) was used as a main fiber on the high melting point side constituting a fiber aggregate, and a polyester core-sheath type composite fiber (fused fiber) was used as a joining fiber. A temperature of 110 ° C., 4 denier, fiber length 51 mm) 30% by weight of raw cotton is layered to form an opener 2
After passing through the table and mixing well, the web was made on a card machine. The web was passed through a forming apparatus for laminating the web to form a continuous laminated polymerization zone. Subsequently, hot air of 170 ° C. was passed through with an air-through drier to produce a fiber aggregate having a fiber weight of 2 kg / m ² adhered to each other. Was.

The fiber assembly further has a roller diameter of 2
A 5 cm, 3 cm long wire having a length of about 1 mm was passed through a fluffing roller on which a countless number of wires were planted, and one surface was fluffed to prepare a fiber forming material having a fluffing layer with a fluff length of 5 mm. The thickness of the material during fiber molding is 52m
m, the overall fiber density was 0.0385 g / cc.

Comparative Example 1 In the same manner as in Example 1, a conventionally used polyester fiber aggregate in which fibers having a basis weight of 2 kg / m ² , a thickness of 50 mm, and a fiber density of 0.04 g / cc were bonded to each other was prepared. .

Example 2 Polyester staple fiber (mechanical shrinkage, 18
Denier, fiber length 64 mm) 60% by weight, polyester core-sheath type composite fiber (melting temperature 110 ° C.,
After passing 40% by weight of 4 denier and a fiber length of 51 mm) through a cotton opener and a carding machine in the same manner as in Example 1, the web was disintegrated by an opening and separating machine in which a cylinder wound with a metallic wire rotates at a high speed. After making a fiber mass, blow it with high pressure air, pack it in a frame whose thickness is controlled and compress it.
At a temperature of 70 ° C., the fibers were bonded together to form a fiber assembly. This fiber assembly had a thickness of 80 mm, a basis weight of 3.2 kg / m ² , and a fiber density of 0.04 g / cc.

Further, this fiber assembly was passed through a fluffing roller in the same manner as in Example 1 to form a double-sided fluffing layer, thereby producing a fiber forming material. The length of this fluff is 1
It was 0 mm.

Comparative Example 2 100% polyester hollow short fiber (spiral type three-dimensional crimped fiber, 10 denier, fiber length 64 mm) was passed through a cotton opener / card machine / molding machine to a thickness of about 25 mm and a basis weight of 300 kg / m ^2. A polyester short fiber aggregate was made.
This and the polyester molded article produced in Comparative Example 1 were polymerized in the order of short fiber aggregate / molded article / short fiber aggregate to produce a conventionally used three-layer laminated composite. The size of Example 2 and Comparative Example 2 is 100 cm in width, 200 cm in length and 8 cm in thickness.

In Example 1 and Comparative Example 1, polyester 65 was used.
It was wrapped with a blended plain woven fabric of 35% by weight of cotton and 35% by weight of cotton, and the softness and the sense of unity were compared.

As a result, the softness is determined according to JIS K-64.
01, which is represented by a compression-load curve measured based on No. 01, as shown in FIG.
The thickness deformation under a low load is large, and in a high load region, the same repulsive force as in Comparative Example 1 is felt. When touched by hand, the user feels soft, and when a force is applied, the user feels elasticity. In the case of Comparative Example 1, when touched, there was no sense of unity between the middle material and the outer material, and the feel was separated. On the other hand, in the case of Example 1, there was obtained one having a sense of unity and good feeling and appearance.

The mats for Example 2 and Comparative Example 2 were placed in a circular knitted fabric made of 100% polyester to make a mat for beds.

In the case of Comparative Example 2, it took a lot of time to stack the compact and the short fiber aggregate, and it took a lot of time to require a special machine when putting it into a circular knitted fabric. In addition, even if it bends like a reclining seat, it does not bend and cannot be used as a bed mat for nursing care. On the other hand, in the case of the second embodiment,
Since the middle material is integrated, handling is good, it can be easily put into a circular knitted fabric, and the bendability is 20%.
cm and excellent. Further, in order to compare the sag resistance, the residual compressive residual strain of both was measured.
At 8.2%, that of Example 2 exhibited excellent sag resistance.

The repetitive compression residual strain is represented by the thickness reduction rate immediately after the operation of instantaneously repeating 50% compression of the sample thickness by 80,000 times.

[0033]

According to the present invention, it is possible to provide a product which simultaneously satisfies excellent characteristics such as a feeling of unity with external materials, a feeling of touch, elasticity, workability, and sag resistance. It can be widely used for middle materials such as futons and chair seats used in various fields, and for soundproofing and sound absorbing materials used for floors and walls.

[Brief description of the drawings]

FIG. 1 is an external view showing an example of a fiber forming material according to the present invention.

FIG. 2 is a partial schematic view showing another example of the fiber forming material according to the present invention.

FIG. 3 is a compression-load curve of Example 1 and Comparative Example 2.

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 fiber mutual bonding layer 2 fluffy layer 3 fiber constituting fiber mutual bonding layer 4 fiber of fluffing layer 5 bonding part

 ──────────────────────────────────────────────────の Continued on the front page (72) Inventor Seiichi Kamioka 1-1-1 Sonoyama, Otsu City, Shiga Prefecture Inside Shiga Shokusan Co., Ltd.

Claims (12)

[Claims] 1. A fiber assembly in which short fibers are partially bonded to each other, wherein at least one surface of the fiber assembly has a raised layer or a fluff layer formed of fibers constituting the fiber assembly. During fiber molding. 2. The fiber forming material according to claim 1, wherein the short fibers have a fiber length of 10 to 200 mm. 3. The fiber forming material according to claim 1, wherein the short fibers have a fineness of 1 to 50 denier. 4. The fiber forming material according to claim 1, wherein the short fibers have a shrinkage of 5 to 100 peaks / 25 mm. 5. The fiber forming material according to claim 1, wherein the short fibers include fibers having irregular cross-sections. 6. The fiber forming material according to claim 1, wherein the short fibers include hollow fibers. 7. The fiber forming material according to claim 1, wherein the short fibers include ultrafine fibers. 8. The fiber forming material according to claim 1, wherein the fiber aggregate is composed of single fibers arranged in a direction substantially perpendicular to a plane. 9. The napping layer or the fluffing layer has a thickness of 0.5 to 0.5.
2. The fiber forming material according to claim 1, wherein the material is formed of nap or fluff having a length from the surface of the fiber assembly of 50 mm. 10. The fiber molding material according to claim 1, wherein the partial bonding is performed by at least one method of an adhesive and heat fusion. 11. The fiber forming material has a thickness of 5 cm and a width of 1 cm.
When the length of the sample tip when the fiber forming medium sample having a length of 0 cm and the length of 50 cm is protruded by 30 cm in the length direction from the tip of the test table and the sample tip sags is measured, at least 10 cm is sagged. 2. The fiber forming material according to 1. 12. The fiber forming material according to claim 1, which is used for any of bed mats, bedding, vehicle chairs, boat chairs, office chairs, soundproofing materials for buildings, and soundproofing materials for roads. The material during fiber molding according to any one of items 10 to 10.