JPS6119883A - Composite structure - Google Patents

Abstract

PURPOSE:To obtain a flexible composite structure, having a moderate air-permeability, and suitable for thick bedquilts, stuffed with feather, and capable of preventing the slipping out of the feather, by forming a synthetic resin film on a cellulosic fiber base fabric having the sum of covering factors of warps and wefts within a specific range. CONSTITUTION:A composite structure obtained by coating a cloth having 800- 3,000 sum of covering factors (K) of warp and wefts forming a cellulosic fiber cloth with a solution of a synthetic resin, e.g. an acrylic acid ester or polyurethane resin to form a film having 1-30mu thickness. In this case, the permeab ility of the film is set at <=1/2 of the base fabric in the thickness direction to ensure flexible feeling. Micropores having 0.5-5mu diameter are formed in the film to impart moderate air-permeability thereto. The covering factor (K) is expressed by the formula K=DXd<1/2> [D is the density (yarns/inch); d is denier], and the factor is calculated using d=9,000/Nm=9,000/1.69Nec (Nm represents metric count; Nec represents cotton count).

Description

DETAILED DESCRIPTION OF THE INVENTION Field of the Invention The present invention relates to composite structures. More specifically, the present invention relates to a composite structure suitable for down-filled futons, down-filled jackets, and the like.

Conventional technology Futons and jackets filled with feathers, wool, synthetic cotton, etc. have excellent heat retention properties.

However, these products, especially those containing feathers, often have a drawback in that the feathers stuffed inside are easy to pull out from gaps in the fabric structure. In order to compensate for this drawback, measures have been taken to increase the density of the fabric, but when the density is increased, stress is locally concentrated due to shear stress, causing MJWL, making it easier for the feathers to be pulled out. Unable to prevent release. Also, due to high density pressure, the fabric becomes heavy and stiff,
This was not preferable because the air permeability decreased.

In addition, in order to reduce the shedding of feathers, fabrics made of high-density fabrics such as polyester fibers coated with synthetic resin can certainly prevent most of the feathers from being pulled out, but they have a significantly stiffer texture. The woven fabric is heavy and its breathability is significantly reduced, and the elastic recovery of the filling is also reduced.The most important characteristics of feather-filled products, which are light weight and soft texture, are lost, and the product value is extremely poor.

Problems to be Solved by the Invention The present invention has extremely low chance of the feathers and batting stuffed inside coming out, has excellent windproofing and heat retention, maintains appropriate breathability, is extremely flexible and has a smooth texture. It provides a good composite structure.

Means for Solving the Problem The inventors of the present invention have carefully studied the phenomenon of tweezers such as feathers being pulled out and methods for preventing the phenomenon.The inventors have found that increasing the density can prevent feathers from being pulled out to some extent, but the shearing stress As a result, stress is concentrated and gaps are created at the intersections of the warp and weft of the fabric, making it easier for the feathers to be pulled out. Therefore, it has been found that it is better not to increase the density of the fabric to an extreme degree, and furthermore, the inventors have found a fabric that sufficiently prevents the shedding of feathers and the like even in relatively low-density fabrics, and have completed the present invention.

The gist of the present invention is as follows.1.

A composite structure consisting of a synthetic resin coating and a cellulose fiber base fabric, characterized in that the base fabric has a cover factor (the sum of the warp and weft) of 800 to 3000 = DX, a In the formula, K is the cover factor, D is the density (books/inches), and d
is denier. However, in the case of spun yarn, d = 90
00/Nm = 9000/ d by 1.69Nec
Calculate. Nm indicates metric count, and Nec indicates cotton count.

The base fabric used in the present invention is a cellulose fiber base fabric, and by using a wire material, it has a flexible texture and excellent water and sweat absorption performance that cannot be obtained with polyester synthetic fibers, polyamide synthetic fibers, etc. It will be done. The cellulose fibers used in the present invention are cotton, viscose rayon (including polynosic), cuprammonium rayon, and mixtures thereof.

In particular, fibers of other types may be blended or blended within limits that do not impair the characteristics of cellulose fibers, and the allowable limit for other types of fibers is generally 50 wt or less. The yarn may be in the form of long fibers or short fibers, but short fibers may be used for the warp or weft to further improve heat retention and texture.

The present invention is a structure in which feathers are prevented from coming out due to the structure of a coating made of synthetic fibers and a cellulose fiber base fabric, and the thickness of the coating is 1 to 30 μm, preferably 3 to 30 μm.
It is 25μ. If it is less than 1μ, it will not be sufficient to prevent feathers from coming out, and if it is more than 30μ, the texture will be mainly made of synthetic resin.
The unique texture of cellulose fibers is impaired, which is undesirable.

Further, the permeability of the synthetic resin coating is preferably 5 or less, which is 7 mm in the thickness direction of the base fabric; if it exceeds this, there is a risk that the tear strength and flexibility of the fabric will decrease.

Further, the coating made of synthetic resin has micropores of 0.5 to 5 microns, and these countless pores provide appropriate air permeability.

If the pore size is less than 0.5 μm, the air permeability will be insufficient, and if it is more than 5 μm, the prevention of feathers etc. from coming out will not be sufficient.

The synthetic resins of the present invention include acrylic resins such as acrylic acid ester resins, polyurethane resins, vinyl chloride resins, vinyl acetate resins, fluorine resins, polyamino acid resins, polyethylene resins, polyamide resins, etc. Using a solution in which one or more of the synthetic resins is dissolved in a solvent,
Form a film.

If the sum of the cover factors of the warp and weft of the cellulose fiber base fabric used in the present invention is less than 800, it will be difficult to form a uniform coating on the synthetic resin base fabric, and the synthetic resin will not penetrate into the base fabric. increases, and the tear strength of the fabric decreases. If it is 3000 or more, the flexibility of the fabric decreases, the texture becomes rough and hard, and it becomes heavy, resulting in a decrease in breathability. Therefore, the sum of the cover factors of the warp and weft of the base fabric is 800#3000, preferably 1000-2
The composition of the 000 cellulose fiber base fabric and the coating made of synthetic resin makes it possible to obtain a composite structure that is flexible, has very little pull-out of feathers, etc., and has appropriate air permeability.

Next, a method for manufacturing a composite structure according to the present invention will be explained. The present invention is not limited to the method described below. O First Step 2 A solution mainly composed of a synthetic resin is applied to the cellulose fiber base fabric.

In the second step, the synthetic resin is converted into a resin to form a compound 1iI.

Third step: Perform finishing treatment.

That is, in the first step of the present invention, the method of applying a solution mainly composed of synthetic resin to the cellulose fiber base fabric is as follows:
Any method may be used, such as coating the base fabric with the solution, contacting it with a belt-like material containing the solution, or spraying it. In addition, in order to suppress the penetration of solutions mainly composed of synthetic resins, there are methods such as applying a water repellent such as silicone-based, zirconium-based, or fluorine-based to EVA, cellulose fiber base fabric,
There are methods such as applying moisture to the base fabric, and increasing the viscosity of a solution mainly composed of synthetic resin.

The water repellent used in the present invention is o, oi to 1. The amount of the water repellent applied is preferably in the range of 1.0% by weight or more, which is not preferable because the effect of suppressing the penetration of a solution mainly composed of synthetic resin is too large.

Further, the method of applying moisture to the base fabric should be from 15 to 75% by weight based on the absolute dry weight of the base fabric, and if it exceeds 75% by weight, the permeation suppressing effect of the solution will be too large, which is not preferable.

Next, after applying a solution mainly consisting of a synthetic resin to the cellulose fiber base fabric, the synthetic resin is converted into a resin to form a film by a dry method using hot air drying, a wet method using a coagulation bath such as water, or the like. (Second step) The finishing shown in the third step of the present invention is processing using a commonly used finishing agent for cellulose fibers. The finishing agent may be treated while being rubbed in a solution containing a finishing agent (wet condition), or the finishing agent may be applied and then dried and rubbed (dry condition).

The rubbing process is to crush the resinized synthetic resin and give it a rubbing effect, thereby giving it a softer texture and appropriate air permeability. In addition, by adding synthetic resin, -
This restores the tear strength and abrasion strength of the fabric that has been erected to almost the level before applying the synthetic resin.

The rubbing may be carried out in a wet state or in a dry state, but preferably in a wet state. In case of wet condition,
The kneading device may be any device that can knead the fabric, such as a jet dyer, a wince, or a washer. or,
The bath ratio during the rubbing treatment is preferably 1:5 to 100; if it is less than 1:5, the fabric may be seriously damaged, and if it is more than 1:100, a sufficient rubbing effect cannot be obtained. There are things that aren't there. Preferably, the rubbing temperature and time are as follows:
Reed at 15-100°C for 15-90 minutes, the cloth speed during kneading should be 20-120v, more preferably 40-to
on/minute.

If the cloth is rubbed in a dry state, it may be rubbed using a calendar such as felt or paver, an embossing roller, a rubber roller, or the like. Each kneading pressure is 2 to 2.
Preferably, the cloth speed is 5''30 rrt7' minutes at 0 h/ctl.

EXAMPLES The present invention will be explained in more detail with reference to Examples. The sum of the cover factors of the warp and weft of the fabric is 1782.

Asahi Guard AG-710 (manufactured by Kaisei Chemical Co., Ltd.)
・Fluorinated water repellent) After impregnating with 0.5 weight tIb solution and drying, use Crisbon 6868 (manufactured by Dainippon Ink Co., Ltd.)
The polyurethane elastomer was coated with a treatment solution in which 50% by weight of thermoplastic urethane resin was dissolved in NN dimethylformamide, and then immersed in water at 20° C. for 15 minutes to coagulate the polyurethane elastomer and form a film. The coating has a thickness of 1
At 0μ, the degree of penetration into the base fabric was 0.4 of the thickness in the thickness direction of the base fabric.

Next, Softex A-1017 (manufactured by Hana-O Atlas Co., Ltd., a mass softener) was added at 1.5 ow f1 bath ratio i:
50. Softened at 50℃ for 15 minutes using a jet color washer,
Dehydrated and dried. (Method of the Present Invention) For comparison, commercially available down futon materials shown in Table 1 were used.

Table 1 In addition, various physical properties of the fabric were measured according to the following methods.

Flexibility is determined by JIS-L-1096A method (45° cannalev method), air permeability is determined by JIS-L-1096 method, and heat retention is determined by JIS-L-1096 method.
IS-L-1096B method, feather pullability is 15cr
A sample was made by stacking two samples with an n
- Based on pilling test A method of L-io9a method, ICI
The sample was placed in a testing machine together with three hard rubber balls (diameter 4 crn, weight 45 f) and rotated at 60 rpm for 5 hours to examine whether feathers were pulled out from the sample surface.

Table 2 shows the physical properties of the fabric obtained as described above.

Table 2 From the results shown in Table 2, it is clear that the composite structure of the present invention has less feather pullout than the comparative example (compared to the commercially available 7-ton feather material).
It has an extremely flexible texture, is light, has appropriate breathability, and has excellent heat retention.

Example 2 Using No. 40 single yarn cotton for the warp and weft, various fabrics shown in Table 3 were treated with a water repellent in the same manner as in Example 1, and after drying,
It was coated with the polyurethane treatment liquid of Example 1, and then coagulated and softened under the same conditions as in Example 1. Table 3 shows the physical properties of each fabric thus obtained.

The thickness of the coating was 8 to 15 μm, and the degree of penetration into the base fabric was 0.25 to 0.4 of the thickness in the thickness direction of the base fabric.

From Table 3, if the sum of the cover factors of the warp and weft of the base fabric is less than 800, feathers will be pulled out, and if it is more than 3000, the fabric will be heavy, have poor breathability, and have a rough and hard texture. Ta. On the other hand, the sum of the cover factors is 800~3
Magnetic 2 to High 5 within the range of 000 had less feather plucking, were flexible, and had appropriate air permeability.

Example 3 Using viscose and rayon 50d/38f for the warp, and using #40 single yarn viscose and rayon for the weft, warp density 60
A plain woven fabric with a weft density of 86 threads/inch and a weft density of 86 threads/inch (the sum of the warp and weft cover factors of the fabric is 1415) was coated with the following treatment solution in a coach inbre, dried at 60°C for 2 minutes, and then dried at 60°C for 2 minutes. Heat treatment was performed at ℃ for 3 minutes. Next, each fabric was immersed in a 1.0% by weight solution of 2notex BC (manufactured by Takamatsu Yushi Co., Ltd., a fabric softener), squeezed out, dried at 100°C for 3 minutes, and then placed in a vapor calender. and roller pressure 8 K9/
It was treated with LRI at 120° C. at a rate of 7 n/min.

(Treatment liquid) Criscoat p-101880 weight i% (acrylic resin manufactured by Inu Nippon Ink Co., Ltd.) Crisphon CL
-21.6% by weight (crosslinking agent manufactured by Dainippon Ink Co., Ltd.) Toluene
18.4% by weight Table 4 shows the physical properties of each fabric obtained as described above.

In Table 4, the amount of the coating and the coating amount of the solution mainly composed of acrylic resin were adjusted. Further, the degree of penetration of the coating into the base fabric was 0.2 to 0.4.

From Table 4, it can be seen that N[1
Floors 2 to 4 have few feathers pulled out, are flexible, and have appropriate breathability.

Example 4 A plain woven fabric with a warp density of 88 yarns/inch and a weft density of 77 yarns/inch, using copper ammonia rayon yarn of No. 40 single yarn for the warp and weft (the sum of the cover 7 actors of the warp and weft of the fabric is 1898 ) K water was sprayed to obtain base fabrics having various moisture contents shown in Table 5.

The base fabric was coated with the following treatment solution, and then immersed in water at 20° C. for 15 minutes (1) to solidify the polyurethane resin by a wet method to form a film. The thickness of the coating was 8μ.

(Treatment liquid) Crispon 6868 40% by weight N-N dimethylformamide 60% by weight, followed by 2.0% of Softex A-1017. Oowf bath ratio 1:50
．． The fabric was softened at 50°C for 15 minutes using a jet dyeing machine, dehydrated, and then threaded and dried at 120°C.

Table 5 shows the physical properties of each fabric obtained as described above.

From Table 5 below, it can be seen that when the penetration degree of the synthetic resin was less than % of the thickness of the base fabric in the thickness direction, it was particularly soft and there was little removal of feathers, etc.

Effects of the Invention As is clear from the examples above, the composite structure wire of the present invention has very little looseness of feathers, etc., is flexible, lightweight, has appropriate breathability, and has good heat retention. It also has excellent moisture and sweat absorption properties, and is of extremely high industrial value.

Claims (1)

[Claims] A structure consisting of a synthetic resin coating and a cellulose fiber base fabric, the cover factor (K) of the warp and weft of the base fabric being
K = D × √d where K is the cover factor, D is the density (books/inch), and d
is denier. However, in the case of spun yarn, d=9000
d is calculated by /Nm=9000/1.69Nec. Nm is metric number. Nec indicates cotton count.