JPS6247395A - Production of 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 FIELD OF INDUSTRIAL APPLICATION The present invention relates to a method for producing a batting material consisting of fiber spheres.

BACKGROUND OF THE INVENTION Various methods have been developed for producing fiber spheres as batting materials for bedding, winter clothing, and the like. However, for example,
The method of Japanese Patent Publication No. 53-4456 for obtaining hollow spherical stuffing material using multifilaments, and the method of Japanese Patent Publication No. 50-30745 for making spheres with a diameter of about 5 to 40 mm using thick fibers of about 10 to 300 deniers. The method disclosed in Japanese Patent Publication No. 51-39134, which is characterized by continuous filament yarn or short fiber mass, yields only a product that is difficult to compress and has a rough texture, and is not satisfactory. There wasn't.

Therefore, a new cotton filling material formed by combining short fibers with different finenesses was developed, and these materials are disclosed in JP-A-57-56560, JP-A-58-75586, and JP-A-58-81.
It is published as Publication No. 075.

Problems to be Solved by the Invention The batting materials described in each of the above-mentioned publications use extremely thin fibers as some of the short fibers, and the difference in the fineness and crimp rate of the two types of short fibers causes the difference in texture. Although this product has excellent commercial value due to its excellent compressibility and bulkiness, the manufacturing method requires the combined use of heat-adhesive, low-melting synthetic fibers and film-like structural elements. However, in both cases, the carded fibers had to be separated into fiber lumps and rolled into pieces of appropriate size, making them difficult to implement industrially.

An object of the present invention is to provide a method for manufacturing such spherical stuffing material with excellent workability by combining fiber materials without requiring any special equipment.

Means for Solving the Problems In the present invention, 80 to 20% by weight of short fibers (A) with a single yarn fineness of 4 denier or more and 10 denier or less and a single yarn fineness of 0
．． Short fiber (B) 7 denier or more and less than 4 denier 20~
A fiber aggregate consisting of 80% by weight and 20% by weight
100 parts by weight of a fiber aggregate that is a highly shrinkable short fiber with a heat shrinkage rate of 5% or more, and a low melting point synthetic fiber that has a melting point 20°C or more lower than both short fibers (A) and (B). After blending 10 to 100 parts by weight of short fibers (C),
By carding to form sliver rovings, separating the sliver rovings into individual chunks, and then heat-treating them, the latent heat shrinkage force and low melting point of the high-shrinkage short fibers, which are the constituent components of the fiber aggregate, can be improved. A synergistic effect with the fusing strength of the fibers automatically produces a stable stuffing material with a spherical or nearly spherical shape.

The blending ratio of short fibers (A) and (B) may be within the above range, but (A) 70 to 30% by weight and (B) 30 to 70% by weight.
It is preferable to use % by weight; if the amount of (A) is too large, the compressibility will be poor, only a product with a rough and hard feel will be obtained, and the beatback will also be poor. Moreover, if the amount of (B) is too large, only a product with poor bulkiness and stiffness will be obtained, and the beatback will also be poor.

Next, the fineness of (A) and (B) is (A) 4 to 1, respectively.
0 denier, (B) is limited to 0.7 to 4 denier, but if the fineness of (A) is thicker than this, the compressibility of the product will be small and the compressive stress and repulsion force will be too large, making it difficult to compact. Moreover, if the fineness of (B) is too small, only a product with poor bulk, low compressive stress, and no stiffness can be obtained.

The heat-shrinkable highly shrinkable short fibers only need to account for 20% by weight or more of the fiber aggregate consisting of (A) and (B), and (A)
Alternatively, component (B) may be composed of highly shrinkable short fibers, or both components (A) and (B) may be composed of highly shrinkable short fibers. It is particularly preferable that the proportion of highly shrinkable short fibers in the fiber aggregate is 35% by weight or more, and if it is less than 20% by weight, the shape of the product will not be uniform and the fusion strength will be weak. On the other hand, when the proportion of highly shrinkable short fibers increases, the feel of the product becomes hard, but the amount may be arbitrarily selected depending on the purpose, and the upper limit is not particularly limited. The heat shrinkability of the highly shrinkable short fibers may be 5% or more, but preferably 10% or more. If the heat shrinkability is too low, the shrinkage force will be weak and it will be difficult for the product to become spherical.

In addition, the fiber lengths of (A) and (B) are not particularly limited, but
The length is preferably 20 to 100 mm, especially 30 to 80 mm.
It is preferable that If the fiber lengths of (A) and (B) are too long or too short, it is difficult to obtain a spherical product.

The crimp ratios of (A) and (B) may be selected appropriately depending on the purpose, but in order to obtain a product with a soft texture, the crimp ratio of (A) other than high-shrinkable short fibers should be selected. is preferably 18% or more, and the crimp rate of (B) other than high shrinkage short fibers is 10
% or less.

In addition, it is preferable to use (A) or (B) with a smooth surface and a coefficient of friction of 0.2 or less. , it is possible to obtain a product with a very soft texture.

The low melting point synthetic fiber (C) used in combination with such components (A) and (B) is used in a proportion of 10 to 100 parts by weight per 100 parts by weight of components (A) and (B). However, it is preferably about 10 to 50 parts by weight. In particular, when composite fibers are used as component (C), the shrinkage of the composite fibers is higher than that of (A) and/or (B). 10 because it exhibits a synergistic effect with the shrinkage of short fibers and increases shape stability.
A small amount on the order of ~25 parts by weight is sufficient.

The fineness of the low melting point synthetic fiber (C) is not particularly limited □.

After mixing (A), (B), and (C), the carded sliver roving can be separated into chunks by any means that can separate the sliver roving into pieces of, for example, 1 g or less, preferably 0.3 g or less. Any common method can be used, such as negative pressure suction with compressed air. It is preferable for the stuffing material that the size of the separated lumps is somewhat non-uniform.

In the present invention, by simply heating the fiber mass separated in this way without applying any external force, a spherical stuffing material with a stable and good texture is produced by the unique action of the fibers contained therein. It's something you get. The temperature for heat treatment of the fiber mass varies depending on the type of fiber used, but is generally 1.
The temperature is 20°C to 200°C.

Next, examples will be shown, but the present invention is not limited to these examples.

Example (1) A composite hollow fiber made of polyethysanterephthalate having a relative viscosity of η-1.35 and η = 1.20 in a side-by-side ratio of 1:1, with a fineness of 6 denier and a fiber length of 75.
mm, 60 parts by weight of highly shrinkable staple fiber (A) with a heat shrinkage rate of 20% at 150°C and fineness of 3 denier, fiber length 3
40 parts by weight of polyester stable (B) with a 8 mm silicone surface smoothing treatment, and a polyester conjugate fiber with a core-sheath structure consisting of a low melting point component with a melting point of 1) 0°C and a high melting point component with a high melting point of 245°C (fineness 4 denier fiber length 51 mm) ) (
C) After blending and blending 15 parts, carding was performed to obtain 3 g/m sliver roving.

This sliver roving is continuously separated into fiber lumps of approximately 0.12 g in size by negative pressure suction using compressed air, and these fiber lumps are sent onto a conveyor that is irradiated with far-infrared heaters from above and below. The shape stability and fusion strength over temperature and time were evaluated. The results are shown in Table 1.

Table 1 Experiment No. Temperature<"c> Time (sec) Shape Fusion Adhesion 1-1" 100 120 x
xl-2° 120 60 △ ×1
-6° 150 5 x xl-
715010Δ × However, experiments marked with * indicate comparative examples.

Example (2) A composite hollow fiber made of polyethysanterephthalate with a relative viscosity of η-1.37 and η = 1.22 in a side-by-side ratio of 1:1, with a fineness of 4 denier and a fiber length of 5.
1 mm, short fiber with a dry heat shrinkage rate of 20% at 150°C (
A), fineness 1.5 denier, fiber length 38I1m, 150
Polyester short fiber C having a dry heat shrinkage rate of 1) at °C
B) Two types of high shrinkage short fibers are blended in the proportions shown in Table 2, and a polyester composite fiber with a core-sheath structure consisting of both components with melting points of 1) 0°C and 255°C with a fineness of 4 denier. , low melting point fibers (C) each having a fiber length of 51 mm were mixed in the blending ratio shown in Table 2. This is carded into sliver rovings, separated into fiber masses of approximately 0.1 g by negative pressure suction using compressed air, and then passed through a far-infrared heater furnace heated to 150°C. A self-spheroidized stuffing material was obtained by tightening, shrinking or fusing. The results are shown in Table 2.

In Table 2, however, experiments No. 2-1.2, 3, 8.9.10 are comparative examples. These results show that if the blending amount of high-shrinkable staple fibers with different fineness falls within a specific range, bulkiness and compressive stress will be excellent, and the blending of low-melting point components will further promote shrinkage force, resulting in good-shaped stuffing. It can be seen that the material is obtained.

Example (3) Composite hollow fiber made of polyethysanterephthalate with relative viscosity η = 1.37 and v = 1.22 in a side-by-side ratio at a ratio of 1:1, fineness 6 denier, fiber length 63 mm, at 150°C Highly shrinkable staple fiber (A) with a heat shrinkage rate of 15%, fineness of 1.3 denier, and fiber length of 38 m.
The polyester short fibers (B) whose surface has been smoothed are
As shown in the table, 100 parts by weight of the mixture has a melting point of 1)
20 parts by weight of polyester conjugate fiber (C) (4 denier, fiber length 51 mm) with a core-sheath structure consisting of a low melting point component at 0°C and a high melting point component at 255°C are blended and carded to form a sliver roving. This was separated into fiber masses of approximately 0.1 to 0.2 g in size, and passed through a far-infrared heater furnace for 1 minute at an ambient temperature of 150° C. to obtain a fused fiber aggregate. Table 3 shows the shape, fusion properties, softness, and density of the product, and Table 4 shows the evaluation of the product as a stuffing material (results of measuring sublime compressibility by stuffing it into a cotton lining). .

Table 3 However, +1) Experiments 3-1 and 3-9 are comparative examples.

(2) Shape evaluation: ◎=Very good 〇-Good Δ=Slightly bad × = bad Fusion adhesiveness: ◎=Strong △＝Slightly weak ×=weak Softness: ◎=Soft △；Hard × = very hard Table 4 However, experiments 4-1 and 4-9 are comparative examples.

The unit of initial compressive hardness and compressive stress is 87 cm''.

From this result, it can be seen that when the blending ratio of short fibers A and short fibers B is within a specific range, the product has a large initial bulk, moderately low compressive stress, high compressibility, and is compact and easy to handle. . In addition, the initial compression hardness indicates that the texture is soft.

Example (4) Comprising side-by-side type composite hollow fibers, fineness 6 denier, fiber length 51fflI1). For 65 parts by weight of short fibers (AI) with a crimp rate of 19.0%, the yield at 1.50°C was 20 to 22%, and the single yarn fineness was 0.5% as shown in Table 5. 165.3.10 denier and different fiber lengths 38
A blend of 35 parts by weight of high-shrinkage short fibers (Bl) of NUW and polyester composite short fibers (CI>10 parts by weight) having a core-sheath structure with a low melting point component of 1) 0°C and a high melting point component of 255°C. After carding, the fibers were separated into fiber masses of around 0.1 g, subjected to dry heat treatment at 150° C., and fusion molded.Table 5 shows the results of evaluating various properties of the obtained product.

The short fibers (AI) treated with a silicone-based smoothing agent had a static friction coefficient of 0.17.

In addition, Table 6 shows high shrinkage short fibers made of side-by-side composite hollow fibers with a fineness of 6 denier and a fiber length of 51 mm.
Hot water boiled at 100°C 25% - 70 parts by weight of (A2), 30 parts by weight of polyester short fibers (B2) with a fineness different from 0.5.1.3.3.10 denier, and low melting point components Core-sheath type low melting point composite fiber (1) having a melting point of 0°C (
C2) Mix 12 parts by weight of cotton and add 0.1 g as above.
Separate into front and back fiber lumps and heat in continuous high pressure steamer at 130℃
The fibers were sent onto a conveyor, and the fibers were simultaneously fusion-molded and shrunk. The properties of these products are shown in Table 6.

From the results in Tables 5 and 6, whether heat-shrinkable short fibers are used for the component with a large fineness (A2) or the component with a small fineness (B1), the combination of finenesses is appropriate. It can be seen that within this range, it is possible to obtain a product that has excellent initial bulk, moderate compressive stress, can be stored compactly, and has a comfortable and soft feel. In addition, the fusion strength is also sufficient.

Effects of the Invention In the present invention, by using a special combination of fibers, a fiber mass can be formed into a spherical shape by heating only, without applying any external force, by utilizing the fiber's unique heat shrinkability and fusion properties. Spherical batting material can be obtained with high productivity through a labor-saving process.

Furthermore, since the method of the present invention does not require special equipment,
It can be carried out at low cost and in a simple process, and since there is no step of rolling the fibers as in the conventional method, products of arbitrarily different sizes can be obtained at the same time, and the product has a good texture.

Claims (4)

[Claims] (1) 80-20% by weight of short fibers (A) with a single yarn fineness of 4 denier or more and 10 denier or less, and 20-80% by weight of short fibers (B) with a single yarn fineness of 0.7 denier or more and less than 4 denier. Fiber aggregate 10 consisting of 20% by weight or more of highly shrinkable short fibers with a heat shrinkage rate of 5% or more
0 parts by weight, and 2 parts than both short fibers (A) and (B).
After blending 10 to 100 parts by weight of short fibers (C) made of low melting point synthetic fibers having a melting point lower than 0°C, carding is performed to form sliver rovings, the sliver rovings are separated into lumps, and then A method for producing a substantially spherical batting material, the method comprising heating the material. (2) The fiber length of short fibers (A) and short fibers (B) is 2 to 1
The method according to claim 1, wherein the diameter is 00 mm. (3) The method according to claim 1 or 2, wherein a composite fiber is used as the short fiber (C). (4) The method according to any one of claims 1 to 3, wherein the temperature of the heat treatment is 120°C to 200°C.