JPWO2018029737A1 - Nonwoven structure and batting and cushioning material containing the structure - Google Patents

Abstract

An object of the present invention is to improve bulkiness when using a moisture absorbing and desorbing fiber for filling for clothing and bedding. In the improvement of bulkiness by modification and crimp, the reduction of bulkiness by repeated use and aging does not improve. Moreover, although the thing which improved the persistence of bulkiness by folding the nonwoven fabric containing moisture absorbing / releasing fiber in accordion shape is also proposed, it is hard and can not be said that texture is favorable. An object of the present invention is to provide a non-woven structure having hygroscopicity and bulkiness, and having a soft texture. A non-woven fabric structure in which non-woven fabric layers are laminated by zigzag folding non-woven fabrics containing moisture-releasing fibers and heat-adhesive fibers is formed, and non-woven fabric layers are adhered to each other. A non-woven fabric structure characterized in that the non-woven fabric layers are bent or curved in the same direction in a body, in which the zigzag shape of the structure is visible. [Selected figure] Figure 1

Description

The present invention relates to a non-woven fabric structure in which a non-woven fabric layer is formed into a laminated structure by zigzag folding a non-woven fabric containing moisture absorbent fibers, and a battling and cushion material containing the structure.

It has been conventionally proposed to use a moisture absorbing and desorbing fiber for filling for clothing and bedding (Patent Document 1). A battling using a moisture absorbing and releasing fiber is expected to have functions such as humidity control by the moisture absorbing and releasing property and heat retention utilizing heat generation accompanying moisture absorption. However, moisture absorbing and desorbing fibers have low bulkiness, low resilience, and the like, and have become a major issue in developing into batting.

With respect to this problem, Patent Document 2 discloses a technique for improving bulkiness by modifying moisture absorbing and desorbing fibers. Moreover, in patent document 3, the technique which improves bulkiness is disclosed by improving the crimp of a moisture absorptive and releasing fiber. In these techniques, although the initial bulkiness can be secured, the bulkiness tends to decrease due to repeated use and aging.

Further, Patent Document 4 discloses a fiber structure in which fiber orientation is aligned in the thickness direction by folding a non-woven fabric composed of an acrylic moisture absorbing and releasing fiber and a heat-adhesive composite short fiber into an accordion shape. The fiber structure is excellent in maintaining bulkiness and bulkiness, but since it is hard, it can not be said that the feel is good in applications such as batting for clothing and bedding.

Japanese Patent Application Laid-Open No. 10-313995 International Publication No. 2013/002367 pamphlet International Publication No. 2015/041275 brochure JP, 2014-080720, A

The present invention has been made in view of the above-mentioned current situation, and the purpose thereof is a non-woven fabric structure having hygroscopicity and bulkiness, soft texture, and suitable for use as a batting for clothing or bedding. It is to provide.

The present inventors diligently studied to achieve the above-mentioned purpose, and as a result, each non-woven fabric containing moisture-absorbing fibers and heat-adhesive fibers was folded in a zigzag and folded to obtain a laminated state. It is found that a hygroscopic non-woven fabric structure having a soft texture and good bulkiness can be obtained by making the non-woven fabric layer not in the upright state but in a bent or curved state in the same direction. did.

That is, the present invention is achieved by the following means.
(1) A non-woven fabric structure in which a non-woven fabric layer is formed into a structure in which non-woven fabric layers are laminated by folding non-woven fabric containing moisture absorbing and releasing fibers and heat adhesive fibers in zigzag. A nonwoven fabric structure characterized in that each nonwoven fabric layer is bent or curved in the same direction on the surface where the zigzag shape of the structure is visible.
(2) It is characterized in that the bending length in the direction perpendicular to the bending line is 7 cm or less when the surface with the bending line is the upper and lower surface measured by the method 6.7.3 a of JIS L 1913. The nonwoven fabric structure as described in (1).
(3) The nonwoven fabric structure according to (1) or (2), wherein the basis weight is 120 to 2000 g / m ² and the thickness is 4 to 40 mm.
(4) The moisture absorbent fiber content in the non-woven fabric is 20 to 80% by mass, and the heat adhesive fiber content is 20 to 80% by mass (1) to (3) The nonwoven fabric structure in any one.
(5) The nonwoven fabric structure according to any one of (1) to (4), wherein the moisture absorbent fiber is a fiber having a crosslinked structure and a carboxyl group.
(6) A battling containing the nonwoven fabric structure according to any one of (1) to (5).
(7) A cushioning material containing the nonwoven fabric structure according to any one of (1) to (5).

The nonwoven fabric structure of the present invention is a material suitable as a batting for clothing or bedding, since it is hygroscopic, high in bulkiness, and soft in texture. Specifically, it can be suitably used for applications such as batting for clothing such as coats, vests and bra cups, batting for bedding such as comforters and mattresses, cushioning materials used for chairs, sofas, cushions and the like.

It is a schematic diagram which shows an example of the nonwoven fabric structure of this invention.

The moisture absorbing and releasing fibers employed in the present invention include cotton, rayon, hemp, wool, animal hair, silk, acetate, nylon, vinylon, polyester modified with moisture absorbing and releasing properties, polyethylene, polypropylene, etc. be able to.

In particular, as the moisture absorbent fiber employed in the present invention, a fiber having a crosslinked structure and a carboxyl group is suitable. As such fibers, a carboxyl group or a hydrophilic group-containing monomer such as an alkali metal base thereof and a hydroxyl group-containing monomer capable of reacting with the carboxyl group to form an ester cross-linked structure are copolymerized, and an ester cross-linking is introduced. The crosslinker is introduced into the cross-linked polyacrylic acid cross-linked fiber, maleic anhydride cross-linked fiber, alginic acid cross-linked fiber, etc. using a cross-linking agent, and then the carboxyl group is introduced by hydrolysis. Crosslinked acrylate fibers and the like. Among these, crosslinked acrylate fibers are preferable as the fibers having a crosslinked structure and a carboxyl group employed in the present invention, since fibers excellent in hygroscopicity can be obtained by controlling crosslinking conditions and hydrolysis conditions with a crosslinking agent. .

The amount of carboxyl groups in the fiber having these cross-linked structures and carboxyl groups is preferably 1 to 10 mmol / g, more preferably 3 to 9 mmol / g, and still more preferably 3 to 8 mmol / g. Most preferably, it is 3 to 6 mmol / g. When the carboxyl group is less than 1 mmol / g, sufficient hygroscopicity may not be expressed in the finally obtained nonwoven fabric structure. When the carboxyl group exceeds 10 mmol / g, the water-swelling property of the fiber becomes too high, and when it contains water, the fiber physical properties become too low, which may make processing or use difficult. The amount of carboxyl groups can be adjusted by the copolymerization amount of monomers having a carboxyl group, the treatment conditions of hydrolysis, and the like.

Moreover, as a counter ion of a carboxyl group, cations, such as hydrogen, ammonium, sodium, potassium, magnesium, calcium, aluminum, manganese, copper, zinc, silver, are mentioned, and multiple types may be mixed. By appropriately selecting these ions, it is possible to adjust the moisture absorption / desorption performance such as the moisture absorption / desorption rate and the saturated moisture absorption amount of the nonwoven fabric structure of the present invention. The nonwoven fabric structure of the present invention can be provided with various known properties derived from carboxyl groups, such as antibacterial performance, antiviral performance, antiallergenic performance, flame retardant performance, and the like.

As a method of adjusting the counter ion of carboxyl group, ion exchange treatment with metal salt such as nitrate, sulfate, hydrochloride and the like to the fiber having a crosslinked structure and carboxyl group, acid by nitric acid, sulfuric acid, hydrochloric acid, formic acid etc. Examples of such a method include treatment or pH adjustment treatment with an alkaline metal compound or the like.

As a preferable example of the fiber which has the crosslinked structure and carboxyl group which were mentioned above, a crosslinked acrylate type fiber is mentioned. Such crosslinked acrylate fibers can be obtained by a conventionally known method. For example, as described in JP-A-2000-314082, the increase in the nitrogen content introduced by the crosslinking treatment with a hydrazine compound to an acrylic fiber having an acrylonitrile content of 85 to 95% by weight is 1.0 A cross-linked acrylic fiber having a content of ~ 5.0% by weight, wherein a part of the remaining nitrile group is converted to an alkali metal salt type carboxyl group of 3.0 to 6.0 meq / g, and further at 20 ° C x 50 The moisture absorptive and desorbable fiber which is 50 weight% or more and 150 weight% or less of the moisture absorption difference of% RH conditions and 20 degreeC * 95% RH conditions can be mentioned.

Moreover, you may use a commercial item as crosslinked acrylate fiber. As a commercial item, for example, EX (registered trademark) made by Toyobo Co., Ltd., Dismel (registered trademark), Mois Fine (registered trademark), Mois Care (registered trademark), Sunburner (registered trademark) manufactured by Toho Textile Co., Ltd. And the like.

The fineness of the moisture absorbent / desorbable fiber employed in the present invention is preferably 0.9 to 9 dtex, more preferably 2 to 7 dtex. When the fineness is less than 0.9 dtex, it may be difficult to obtain a carded web, and when the fineness exceeds 9 dtex, the texture of the obtained nonwoven fabric structure may be too hard. Moreover, as fiber length of this fiber, it is preferable that it is 20-80 mm.

In the non-woven fabric structure of the present invention, the heat-adhesive fiber employed in the present invention maintains the folded structure and the overall shape of the non-woven fabric structure by bonding the moisture-absorbent fibers described above and bonding between the non-woven fabric layers. It is. As such a thermoadhesive fiber, it can be used as long as it has thermoadhesive properties, for example, a low melting point-high melting point such as a heat fusible polyester fiber, polyethylene-polypropylene, polyethylene-polyester, polyester-polyester, etc. The composite fiber which consists of components is mentioned.

As the melting point of such a thermoadhesive fiber (in the case of a thermoadhesive fiber consisting of a low melting point and a high melting point component, the melting point of the low melting point component), it is a temperature which does not adversely affect the physical properties of the moisture absorbable fiber Although it is good, in general, it may be 100 to 190 ° C.

The fineness of the heat-adhesive fiber employed in the present invention is preferably 0.9 to 6.6 dtex, more preferably 1.5 to 6.0 dtex. When the fineness is less than 0.9 dtex, it may be difficult to obtain a carded web, and when the fineness exceeds 6.6 dtex, the texture of the obtained non-woven fabric structure may be too hard. Moreover, as fiber length of this fiber, it is preferable that it is 20-80 mm.

The non-woven fabric employed in the present invention contains the moisture-absorbing and desorbing fibers and the heat-adhesive fibers described above. The content of moisture absorbing and releasing fibers in the nonwoven fabric is preferably 20 to 80 mass%, more preferably 25 to 75 mass%, and still more preferably 30 to 70 mass%, based on the total mass of the nonwoven fabric. It is. The content of the heat-adhesive fiber is preferably 20 to 80% by mass, more preferably 25 to 75% by mass, and still more preferably 30 to 70% by mass, based on the total mass of the nonwoven fabric. is there.

In the non-woven fabric structure of the present invention obtained by using such non-woven fabric, bonding points are formed between the fibers by fusing the heat-adhesive fibers. The bonding points include the bonding point between the heat adhesive fibers and the bonding point between the moisture-absorbent fiber and the heat-adhesive fiber, but the former has stronger adhesion than the latter. In addition, heat-adhesive fibers tend to be harder than moisture-absorbent fibers. For this reason, in the non-woven fabric employed in the present invention, the softness of the non-woven fabric is obtained when the content of moisture-absorbing fibers is less than 20% by mass or the content of heat-adhesive fibers exceeds 80% by mass. Is insufficient, and it becomes difficult to obtain a bent or curved structure to be described later. In addition, when the content of moisture absorbing and releasing fibers exceeds 80% by mass, or when the content of heat adhesive fibers is less than 20% by mass, the number of heat bonding points in the nonwoven fabric decreases, so the nonwoven fabric in practical use The strength may be insufficient or maintenance of the non-woven fabric shape may be difficult.

In the non-woven fabric employed in the present invention, a plurality of types of the above-mentioned moisture-absorbing and desorbing fibers and heat-adhesive fibers may be used, respectively, or fibers other than these fibers and additives may be contained.

The types of non-woven fabrics include those obtained by the needle punching method, the chemical bonding method, the thermal bonding method, the hydroentanglement method, etc. When using a heat treatment machine described later in folding, a card web is adopted. be able to.

The non-woven fabric structure of the present invention is formed by zigzag folding the non-woven fabric containing the moisture absorbable / desorbable fiber and the heat-adhesive fiber described above and bonding the laminated non-woven fabric layers. There is no particular limitation on the method of forming, and any conventionally known method may be adopted. For example, a web obtained by mixing absorbent fibers and heat-adhesive fibers and passing through a roller card may be used as a roller. Heat treatment while folding in a zigzag through a heat treatment machine having a mechanism as shown in FIG. 1 of JP-A-2007-025044 in the same direction as when the card is passed (ie, the direction in which the fibers are oriented); A method of forming a thermal bonding point is preferably exemplified. As such a heat treatment machine, for example, an apparatus disclosed in JP-A-2002-516932, Struto equipment manufactured by Struto, and the like can be mentioned.

Further, the nonwoven fabric structure of the present invention has a structure in which each nonwoven fabric layer is bent or curved in the same direction on the surface where the zigzag shape formed by folding the nonwoven fabric is visible. Such a structure is, for example, a structure as shown in FIG. When the heat treatment machine as described above is used, normally, each non-woven fabric layer is erected, for example, by adjusting the ratio of the moisture-absorbing / desorbable fiber and the heat-adhesive fiber used for the non-woven fabric in the range as described above. It is possible to obtain a structure that is bent or curved in the direction.

The non-woven fabric structure of the present invention having a structure bent or curved in the same direction is bulky and has a small decrease in bulk due to aging or pressure, as compared with a non-folded ordinary non-woven fabric. In addition, the nonwoven fabric structure of the present invention is characterized in that the texture is softer as compared with the conventional foldable nonwoven fabric structure in which the nonwoven fabric layer is upright.

Although the above-mentioned bending or curving may exist in a plurality of places in each non-woven fabric layer, a sufficiently soft feeling can be obtained even at only one place. Also, the bending or bending in the present invention means that the vertical height of the bent or curved nonwoven layer, that is, the height of the nonwoven structure is 90 with respect to the length of the nonwoven layer measured along the bending or bending. % Or less, more preferably 80% or less, and still more preferably 70% or less.

The nonwoven fabric structure of the present invention preferably has a bending length in the direction perpendicular to the bending line, as determined by the method of JIS L 1913, 6.7.3 a, with the surface having the bending line as the upper and lower surfaces. It is desirable that it is 7 cm or less, more preferably 6 cm or less, and further preferably 5 cm or less. When the bending length preferably exceeds 7 cm, a soft texture may not be obtained. Here, the folding line refers to the top of the curved surface where the non-woven fabric is folded, and is the portion illustrated by the dotted line in FIG.

Moreover, as a fabric weight of the nonwoven fabric structure of this invention, Preferably it is 120-2000 g / m < ² >, More preferably, it is 140-1000 g / m < ² >. Moreover, as thickness, Preferably it is 4-40 mm, More preferably, it is 10-30 mm. If the basis weight is less than 120 g / m ² or the thickness is less than 4 mm, the nonwoven fabric structure becomes too soft, resulting in insufficient bulkiness or difficulty in maintaining bulkiness in actual use And may be Here, the thickness of the non-woven fabric structure corresponds to the height when the bending line is the upper and lower surfaces.

Moreover, when the fabric weight of a nonwoven fabric structure exceeds 2000 g / m < ² >, a nonwoven fabric structure may become rigid. Moreover, when the thickness of a nonwoven fabric structure exceeds 40 mm, the folding process mentioned later may become difficult.

The nonwoven fabric structure of the present invention described above is a material suitable as a batting for clothing or bedding because it is hygroscopic, high in bulkiness, excellent in heat retention, and soft in texture. Specifically, it can be suitably used for applications such as batting for clothing such as coats, vests and bra cups, batting for bedding such as comforters and mattresses, cushioning materials used for chairs, sofas, cushions and the like.

Here, it is needless to say that the nonwoven fabric structure of the present invention may be used in combination with other materials as needed, even when used for cotton batting for clothing, batting cotton for bedding, or cushioning material. Moreover, as the hygroscopicity of the nonwoven fabric structure of the present invention in such applications, the lower limit of the saturated moisture absorption rate at 20 ° C. and 65% relative humidity is preferably 9% or more, more preferably 12% or more, from the viewpoint of comfort. More preferably, it is 15% or more. On the other hand, although the upper limit of the saturated moisture absorption rate is not particularly limited, the upper limit is about 70% even when the crosslinked acrylate fiber capable of most enhancing the hygroscopicity is used.

Examples are given below to facilitate understanding of the present invention, but these are merely illustrative, and the scope of the present invention is not limited by these. In the examples, parts and percentages are based on mass unless otherwise specified.

<Measurement of bending length>
Measured according to JIS L 1913, 6.7.3 a method (41.5 ° cantilever method). In the measurement, the folded nonwoven fabric sample is placed on the platform of the cantilever type tester such that the side with the bending line is the upper and lower surfaces, and the longitudinal direction of the platform and the bending line are perpendicular to each other.

<Measurement of Carboxyl Group Amount (mmol / g)>
About 1 g of a sufficiently dried sample is precisely weighed (X g), 200 mL of water is added thereto, and then a titration curve is determined according to a conventional method using 0.1 mol / L aqueous sodium hydroxide solution. The consumption amount (Y cm ³ ) of the aqueous sodium hydroxide solution consumed for the carboxyl group is determined from this titration curve, and the carboxyl group amount (mmol / g) is calculated by the following equation.
Amount of carboxyl group (mmol / g) = 0.1 Y / X

<Measurement of moisture absorption rate>
About 5.0 g of a sample is dried at 105 ° C. for 16 hours in a hot air drier and weighed (W1 [g]). Next, the sample is placed in a thermo-hygrostat kept at 20 ° C. and 65% RH for 24 hours. The weight of the sample absorbed in this manner is measured (W2 [g]). From the above measurement results, the 20 ° C. × 65% RH moisture absorption rate (saturated moisture absorption rate) is calculated by the following equation.
20 ° C × 65% RH moisture absorption rate [%] = (W2-W1) / W1 × 100

<Measurement of the degree of bending and bending>
The height (L1 [mm]) of the non-woven fabric structure and the length (L2 [mm]) of the non-woven fabric layer along the bending and bending of the non-woven fabric structure sample are measured and calculated by the following equation.
Degree of bending and bending [%] = L1 / L2 × 100

<Production example 1 of moisture absorbing and releasing fiber>
A stock solution of spinning solution prepared by dissolving 90% acrylonitrile and 10% methyl acrylate acrylonitrile polymer in a 48% by weight aqueous solution of rhodanate soda according to a conventional method is subjected to spinning, washing with water, stretching, crimping and heat treatment to obtain a raw material fiber. The raw material fiber was subjected to a crosslinking introduction treatment in a 15% aqueous hydrazine solution at 110 ° C. for 3 hours, and washed with water. Next, it was acid-treated in an 8% nitric acid aqueous solution at 110 ° C. for 1 hour, and rinsed. Subsequently, the mixture was hydrolyzed in an 8% aqueous sodium hydroxide solution at 90 ° C. for 2 hours, adjusted to pH 12, washed with pure water, and moisture absorbing and releasing fiber A was obtained. The fiber had a single fiber fineness of 2.0 dtex, a fiber length of 34 mm, a carboxyl group of 5.0 mmol / g, and a saturated moisture absorption of 35%.

Example 1
70% by mass moisture absorbing and releasing fiber A and 30% by mass heat-adhesive fiber a (polyester having a melting point of 155 ° C., a core-sheath structure of polyester having a melting point of 256 ° C. (mass ratio of core component: sheath component) = 30/70), single fiber fineness of 3.3 dtex, and fiber length of 51 mm), and a web was produced with a conventional carding machine. Next, using a Struto facility manufactured by Struto (similar to the apparatus disclosed in JP-A-2002-516932), the web is driven in the fiber orientation direction at a roller surface speed of 2.5 m / min. The sheet was folded into a zigzag by pushing into a hot air suction type heat treatment machine (heat treatment zone length 5 m, moving speed 1 m / min), and treated with hot air at 200 ° C. for 5 minutes to obtain a non-woven fabric structure. In the obtained nonwoven fabric structure, each nonwoven fabric layer was curved in the same direction. The evaluation results of the non-woven fabric structure are shown in Table 1.

Example 2
A non-woven fabric structure was obtained in the same manner as in Example 1 except that the thickness of the non-woven fabric structure was reduced. In the obtained nonwoven fabric structure, each nonwoven fabric layer was curved in the same direction. The evaluation results of the non-woven fabric structure are shown in Table 1.

Example 3
A non-woven fabric structure was obtained in the same manner as in Example 1 except that the proportion of the moisture absorbing and releasing fiber A was 50% by mass and the proportion of the heat-adhesive fiber a was 50% by mass. In the obtained nonwoven fabric structure, each nonwoven fabric layer was curved in the same direction. The evaluation results of the non-woven fabric structure are shown in Table 1.

Example 4
A non-woven fabric structure was obtained in the same manner as in Example 1 except that the proportion of the moisture absorbent fiber A was 50% by mass, the proportion of the heat-adhesive fiber a was 50% by mass, and the fabric weight was increased. In the obtained nonwoven fabric structure, each nonwoven fabric layer was curved in the same direction. The evaluation results of the non-woven fabric structure are shown in Table 1.

Example 5
A nonwoven fabric structure was obtained in the same manner as in Example 1 except that rayon was used instead of the moisture absorbent fiber A. In the obtained nonwoven fabric structure, each nonwoven fabric layer was curved in the same direction. The evaluation results of the non-woven fabric structure are shown in Table 1.

Comparative Example 1
In Example 1, fibers to be blended are 18% by mass moisture-absorbent fibers A, 52% by mass heat-adhesive fibers a and 30% by mass polyester fibers b (single fiber fineness 3.3 dtex, fiber length 51 mm, melting point 256) The nonwoven fabric structure was similarly obtained except setting it as ° C. The obtained non-woven fabric structure was such that each non-woven fabric layer did not have bending or curving. The evaluation results of the non-woven fabric structure are shown in Table 1.

Comparative Example 2
The same procedure as in Example 1 was repeated except that the fibers to be blended were 50% by mass of heat-adhesive fiber a and 50% by mass of high melting point polyester fiber (single fiber fineness 3.3 dtex, fiber length 51 mm, melting point 256 ° C.). The nonwoven fabric structure was obtained. The obtained non-woven fabric structure was such that each non-woven fabric layer did not have bending or curving. The evaluation results of the non-woven fabric structure are shown in Table 1.

As can be seen from Table 1, in the nonwoven fabric structures of Examples 1 to 5 in which the nonwoven fabric layers are curved in the same direction on the surface where the zigzag shape of the nonwoven fabric is visible, the bending length is short and the texture is soft. there were. On the other hand, in the nonwoven fabric structure of Comparative Example 2 which does not contain the fibers of Comparative Example 1 having a small content of moisture absorbing and releasing fibers and the moisture absorbing and releasing fibers, the bending length is long and the softness is poor.

1 Zigzag shape 2 Folded line 3 Non-woven layer curved

Claims (7)

A non-woven fabric structure in which a structure in which non-woven fabric layers are laminated is formed by folding a non-woven fabric containing moisture absorbing and releasing fibers and heat-adhesive fibers in a zigzag manner, and each non-woven fabric layer is bonded A nonwoven fabric structure characterized in that each nonwoven fabric layer is bent or curved in the same direction on the surface where the zigzag shape of the structure is visible. The bending length in the direction perpendicular to the bending line is 7 cm or less when the surface with the bending line is the upper and lower surface measured by the method 6.7.3 a of JIS L 1913. The nonwoven fabric structure as described in 1. The nonwoven fabric structure according to claim 1 or 2, wherein the basis weight is 120 to 2000 g / m2, and the thickness is 4 to 40 mm. The content of the moisture absorbing and releasing fiber in the non-woven fabric is 20 to 80% by mass, and the content of the heat adhesive fiber is 20 to 80% by mass. Nonwoven fabric structure. The nonwoven fabric structure according to any one of claims 1 to 4, wherein the moisture absorbent fiber is a fiber having a crosslinked structure and a carboxyl group. A battling containing the non-woven fabric structure according to any one of claims 1 to 5. The cushioning material containing the nonwoven fabric structure in any one of Claims 1-5.

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