JPS5911886A - New feather-like padding material - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

[Detailed Description of the Invention] This relates to a completely new batting material that is used inside a bag, and its purpose is to have feather-like softness, warmth, lightness, and bulkiness. Our objective is to provide a filling material with extremely excellent heat resistance.

Conventionally, as a method of imparting feather-like properties to batting materials, four-fold techniques have been used to impart a three-dimensional shape to batting fibers. The first method is to give the fibers a crimped or corrugated shape, but when the batting obtained in this way is used repeatedly, the fibers become entangled and become felt, reducing the compression recovery properties of the batting. be.

The second method is to form spherical bodies with low internal density from fibers and use them as batting, but this method has the drawback that the spherical bodies are entangled and destroyed by repeated use of the batting.

Furthermore, a third method is to concentrate and integrate a plurality of short fibers at the bonding site, and use the non-concentrated ends of the short fibers as puffed and diffused tassels for filling. There was a drawback that the tufts became intertwined with each other and the bulkiness of the batting was reduced due to the penetrating nature of the short fibers.

In order to clarify the above-mentioned drawbacks of the prior art in comparison with feathers, the shape of feathers will be described.

Feathers can be divided into two types: feathers and cotton-like feathers. Feathers have a body shaft with barbs on both sides, and small barbules on either side. The cotton style has a nine-shaft axis as its core, with barbs coming out radially from it, and small barbules branching out to the left and right of it. The thickness decreases in the following order: trunk axis, barbules, and barbules. The softness of the feathers is due to its thin barbules and barbs, and its good recovery after compression is due to its thick body shaft.The fit to the body shape is due to the fact that the feathers extend from the body axis or original trunk axis to the barbs and barbs. This is due to the fact that the penetrability between the feathers is hindered due to the fact that the feathers are derived from each other, and they can be moved independently as small pieces.Also, because this penetrability is hindered, the feathers tend to sag after repeated use. small. Warmth is due to the large air retention capacity of a single feather due to the structure of the feathers and the large air retention capacity of the feather as a whole due to the prevention of penetration, and the bulkiness is also due to the same reason. It is inferred.

As mentioned above, attempts have been made to develop batting that has a feather-like condition, but the results have been unsatisfactory because the special morphology of feathers has been ignored. As a result of intensive research to provide a filling material that approximates the unique form of feathers, the present inventors have obtained a novel feather-like filling material that meets the purpose by using carbon fiber as the fiber material used therein. This was particularly successful and led to the present invention.

That is, the present invention consists of a fibrous or cloth-like substrate A1, a branched carbon fiber body B branched from the base A, and an ultrafine branched carbon fiber body C having a single fiber diameter of 2 microns or less, which is further branched from the branched body B. The present invention relates to a batting material having a feather-like branched structure.

The present invention will be explained in more detail below.

The present invention will be explained with reference to the embodiment shown in FIG. 1 of the accompanying drawings. An adhesive 1 is applied to a base A, and one cut surface of a plurality of carbon fibers B is bonded to the base A in a branched manner. The carbon fiber branched body B thus formed has branched ultrafine carbon fiber branched bodies C having a single fiber diameter of 2 microns or less. Thereafter, the substrate A is cut to obtain the batting material of the present invention. Therefore, depending on the morphological type of the substrate and the cutting relationship of the substrate, the substrate A corresponds to the trunk axis or the original trunk axis of the feather. That is, using monofilaments aligned on the base A, the carbon fiber branches C are made without each of the parallel monofilaments coming into contact with the adjacent monofilament, and without each monofilament being bonded with an adhesive. After planting the carbon fiber branches B on both sides of the monofilaments arranged in parallel, the monofilaments are cut to the same length as the blades, so that the base body A corresponds to the trunk axis. On the other hand, in the above method, after flocking only one side, cut the monofilament into a length of several millimeters or less, or use a nonwoven fabric as a base, and after flocking on one side, cut the monofilament into a square shape of several millimeters or less. If cut to a size of , the base body A will be equivalent to the original trunk axis.

In this way, a feather-like batting is obtained in which the carbon fiber branch B is used as a barb and the carbon fiber branch C is used as a barb.

The length of the base body A corresponding to the trunk axis is preferably about 1 to 1 degree since the purpose of the present invention is to approximate the shape of a feather and obtain feather-like compression characteristics and fit to the human body. If the length is longer than this, the different shafts may become entangled with each other when used as filling for futons, etc., which is preferable. Similarly, the length of the carbon fiber branches B corresponding to barbs is preferably in the range of 05 to 3 to 771, and the length of the carbon fiber branches C corresponding to barbs is the phase of feather-like pieces! i0.005 to 0.5 for the purpose of preventing penetration.
Crn position is appropriate. However, in the present invention, the substrate A1
The lengths of the carbon fiber 11 branches B and C are not critical.

This is because, in the present invention, it is possible to obtain feather-like properties by variously changing the length of the constituent fibers, but it does not preclude obtaining properties other than feather-like properties. For the same reason, the denier and flocking density of the fibers used are also not critical. Although the angle formed between the base body A and the carbon fiber branch B is not particularly critical, it is preferably 30 to 80 degrees in order to provide a feather-like feel. This angle can be adjusted after flocking by applying pressure between heated rollers heated to an appropriate temperature. Furthermore,
The angle between the carbon fiber branch body B and the carbon fiber branch body C is also preferably 20 to 80 degrees for the same reason. Note that the fiber diameter of the single yarn of the branched body C must be 2 microns or less. Preferably it is 0.01 to 1 micron.

As the substrate A in the present invention, monofilaments and nonwoven fabrics can be used as described above, as well as spun yarns, multifilaments, woven fabrics, tows spread in a plane, etc. As the substrate A, synthetic fibers such as polyamide yarn, polyester yarn, and polyacrylic yarn, recycled fibers such as rayon, natural fibers such as wool, carbon fiber, graphite fiber, glass fiber, and combinations thereof can be used.

The adhesive for bonding the carbon fiber branch B having the carbon fiber branch C to the substrate A may be a thermosetting resin such as epoxy or urethane, a rubber such as chloroprene or nitrile rubber, or a thermoplastic such as vinyl acetate or polyethylene. Resins and the like can be used, and these adhesives can be applied in the form of whole solution, emul/kyon, or hot melt by methods such as roll or knife coating, spraying, or electrostatic coating. Note that the above adhesives may be mixed with each other, or may be mixed with other treatment agents, chemicals, etc. to impart antistatic properties, smoothness, flexibility, hygroscopicity, water repellency, flame retardancy, etc. May be used.

As a method for flocking the carbon fiber branch B having the carbon fiber branch C on the base A, an electrostatic flocking method, a gravity scattering method, or the like can be used.

Any carbon fiber material may be used as the carbon fiber branch B in the present invention. For example, cellulose rayon carbon fiber, polyacrylonitrile carbon fiber,
Examples include pitch-based carbon fibers and carbon fibers produced by a vapor growth method, which will be described later.

Of course, graphite fibers obtained by graphitizing these carbon fibers can also be used.

As the carbon fiber branch C in the present invention, carbon fiber produced by a vapor phase growth method or graphite fiber obtained by graphitizing it is preferable.

In the present invention, carbon fiber produced by the vapor phase growth method refers to, for example, a hydrocarbon gas such as benzene is sent to an electric furnace at a temperature of 900 to 1300°C together with a carrier gas such as hydrogen, and iron, nickel, or iron is placed in the electric furnace. -2. It is obtained by producing carbon in the form of fibers on a ceramic or graphite substrate to which fine powder such as Kel alloy is adhered (
(See Proceedings of the 8th Annual Meeting of the Carbon Materials Society, pages 66-67).

The carbon fibers thus obtained by the vapor phase growth method or the graphite fibers obtained by graphitizing the carbon fibers are bonded to the carbon fiber branch B using an adhesive or the like, and carbon fibers having the carbon fiber branch C are bonded to the carbon fiber branch B. Branch B can be made.

However, in the present invention, the carbon fiber branch B having the carbon fiber branch C formed by the vapor phase growth method can be advantageously produced by the production method example described below.

That is, using an apparatus as shown in FIG. 2, carbon fibers made of polyacrylonitrile,
A manufacturing method using benzene as a raw material for branched carbon fiber C by vapor phase growth will be described.

(1) From a bottle 3 of carbon fibers (monofilaments) made of polyacrylonitrile, the carbon fibers 2 are continuously introduced into a catalyst liquid bath 5. The bath contains iron, nickel, and iron-2 having a particle size of several hundred times or less.

It contains a suspension 4 of ultrafine metal powder such as Kel alloy.

(2) The carbon fiber 2 with the ultrafine metal powder coming out of the bath is then placed in a cylindrical electric furnace 1 with a furnace temperature of 900 to 1300°C.
Leads to 1. At this time, the speed of carbon fiber is 5-10 cm
A constant speed of 1 minute is preferred.

(3) On the other hand, a mixed gas of benzene gas diluted with hydrogen gas is sent from the gas introduction pipe 6 to the electric furnace.

The flow rate of the mixed gas is preferably 50 to 200 cC for 7 minutes, and the partial pressure of benzene is preferably 0.5 to 500 TOrr.

(4) The benzene partial pressure can be controlled by adjusting the temperature of the bottle 8 storing liquid benzene 7 using a temperature control bath 9 and by controlling the flow rate of the carrier gas (hydrogen).

(5) By doing this, in the electric furnace, the carbon fiber branches 10 are grown on the surface of the carbon fibers 2 by the vapor phase growth method.
is generated. By adjusting the electric furnace temperature, benzene partial pressure, mixing force flow rate, and speed of the carbon fiber 2, the branched body 1
The length and thickness of 0 can be changed arbitrarily, but preferably the length is adjusted to 01-3) gs thickness 0.05-2) 1. The angle between the carbon fiber 2 and the branched body IO can be adjusted by adjusting the mixed gas flow rate or the like, and is preferably adjusted to 20 to 80 degrees.

The branched carbon fiber thus obtained can be used as it is or at a temperature of 2000 to 3500°C, preferably 28°C.
It can be used after graphitization treatment at a temperature of 00 to 3000°C. The carbon fibers or graphite fiber branches obtained by this vapor phase growth method have a structure in which the carbon hexagonal network planes are oriented parallel to the fiber axis and in the form of tree rings, as shown in FIG. Furthermore, according to X-ray diffraction and electron microscopy, the fibers are in the form of hollow cubes of 50 to 200X in diameter, and the size of the hexagonal network plane is about 10X before heat treatment, and 100X after heat treatment. It is also known that it can grow to ``A'' or higher.

In addition to the batting material of the present invention, its excellent heat retention and insulation properties,
It has extremely high heat resistance, as well as unique softness and bending recovery. It is also excellent in terms of lightness and bulk, and furthermore, it solves the problem of static electricity.

Furthermore, the carbon fibers having branches, which are produced by the method of the present invention by the vapor-phase epitaxy method such that the carbon fiber branch C by the vapor-phase epitaxy method is produced on the surface of the carbon fiber B,
and C are made separately, and then glued together using an adhesive, etc., each branch becomes strong and there is no branch breakage, etc., and the thickness is less than 2 microns. Since it is thin and fine, it has a very soft feather-like feel. Further, the ultrafine fibers constituting the branched body C can be mutually cross-linked and branched as necessary.
As a result, the bulkiness of the ultra-fine carbon fibers is well maintained even after repeated use, and when used as feather-like batting, it prevents mutual pawning and prevents pilling. It shows the properties that

Further, the base body can also be composed of carbon fibers formed by the above-mentioned vapor phase growth method or graphite fibers obtained by graphitization treatment.

When the feather-like batting material according to the present invention is composed of base A1, branched body B, and branched body C, all of which are carbon fibers formed by a vapor phase growth method or graphite fibers obtained by graphitizing the carbon fibers, the carbon fibers Alternatively, the characteristics of graphite fibers can be fully exhibited, and an excellent feather-like batting material can be obtained.

Examples are shown below.

Example 1 Carbon fibers having branches were produced in the following manner using the apparatus shown in FIG.

Carbon fiber (monofilament) made from polyacrylonitrile (indicated by 2 in the figure) was pulled out from the pobin 3, and about 10 parts by weight of fine iron powder (manufactured by Vacuum Metallurgy KK) with a grain size of 300X was suspended in about 100 parts by weight of ethanol. Pass it through a bathtub 5 containing liquid 4. Next, the carbon fibers were placed in an electric furnace 11 made of alumina tube with an inner diameter of 6 c1 ns, a length of 15.0 crns, a soaking zone of about 20 cm, and a soaking zone temperature of 1100°C.
, at a linear speed of 5 cm for 1 minute. On the other hand, before raising the temperature of the electric furnace through the gas pipe 6, argon gas is first flowed into the electric furnace, then hydrogen gas is flowed, the temperature is raised while flowing hydrogen gas, and after reaching a predetermined furnace temperature, liquid Hydrogen gas is passed through a trap bottle 8 containing benzene, and the benzene and hydrogen mixed gas is sent to an electric furnace. Note that the mixed gas flow rate and benzene partial pressure are controlled to be constant by using the temperature control bath 9 to maintain the benzene liquid temperature at 6° C. and the hydrogen gas flow rate to 100° C./min. In this way, carbon fiber 2
The carbon fiber branches IO generated on the surface of the carbon fibers flow out of the furnace (
(in the direction of the arrow).

The carbon fibers having these branches have an average length of about 2 mm, an average thickness of 0.5 μ, and a branch angle of 30 to 40 degrees.
Met. The branched carbon fiber was cut into lengths of 14 mm.

On the other hand, a 130 d polyethylene terephthalate fiber consisting of 32 filaments was used as the substrate.

This fiber was false twisted 120 times per meter and arranged in parallel at 15 mm intervals. Water-soluble polyester urethane resin 25
It was continuously impregnated with an adhesive solution containing 1 part of catalyst, 1 part of catalyst, and 74 parts of water, and squeezed with a roller to a liquid content of 8° to a length of 1 cIrL.
The angle between the carbon fiber having the aforementioned branches and profiteering is 6
Fleece was implanted on both sides of the base material so that the angle was 0°. This is 110
After pre-drying at ℃ for 30 minutes, the substrate was cut into a length of 30 mm to obtain a product with a shape similar to a feather.

The structure of the carbon fiber branch 10 was analyzed by electron beam diffraction and
When examined by line diffraction, it was found that the carbon hexagonal network planes were in the form of a tree ring, with the planes aligned in the axial direction, as shown in Figure 3.

[Brief explanation of drawings]

FIG. 1 is a diagram showing an example of the feather-like batting material of the present invention. FIG. 2 is a diagram showing an example of a manufacturing apparatus for manufacturing a carbon fiber branched body having a carbon fiber branched body by the vapor phase growth method of the present invention. FIG. 3 is a sketch diagram showing the cross-sectional form of a carbon fiber or graphite fiber produced by a vapor phase growth method that can be advantageously used in the present invention. A...Base, B...Carbon fiber branch, C...Carbon fiber branch, 1...Adhesive, 2...Carbon fiber, 3...
・Carbon fiber bobbin, 4... Catalyst liquid, 5 ・Bathtub, 6
...Gas feed pipe, 7.. Raw material hydrocarbon, 8.. Trap bottle, 9.. Temperature control path, 10.. Produced carbon fiber branched body produced by vapor phase growth method, 11.. Electric furnace. Patent applicant: Asahi Kasei Industries, Ltd.

Claims (6)

[Claims] (1) Feather composed of a fibrous or cloth-like substrate A, a carbon fiber branch B branched from the substrate A, and an ultrafine carbon fiber branch C with a single fiber diameter of 2 microns or less further branched from the branch B. A filling material with a branched structure. (2) The batting material according to claim 1, wherein the branched body C is composed of carbon fibers formed by a vapor phase growth method or graphite fibers obtained by graphitizing the carbon fibers [7]. (3) The batting material according to claim 2, wherein the substrate A is a spun yarn, a multifilament yarn, or a monochrome filament yarn. (4) The filling material according to claim 2, wherein the substrate A is a woven fabric, a knitted fabric, a nonwoven fabric, or a flat tow. (5) The batting material according to claim 2, wherein the base body A is made of carbon fiber or graphite fiber. (6) The filling material according to claim 2, wherein the base body A and the branch body B are each composed of carbon fibers formed by a vapor growth method or graphite fibers obtained by graphitizing the same.