Classifications

• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/02—Cotton wool; Wadding
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
  • D01D5/00—Formation of filaments, threads, or the like
  • D01D5/22—Formation of filaments, threads, or the like with a crimped or curled structure; with a special structure to simulate wool
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
  • D01D5/00—Formation of filaments, threads, or the like
  • D01D5/24—Formation of filaments, threads, or the like with a hollow structure; Spinnerette packs therefor
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
  • D01D5/00—Formation of filaments, threads, or the like
  • D01D5/26—Formation of staple fibres
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
  • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
  • D01F6/28—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from copolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
  • D01F6/38—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from copolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds comprising unsaturated nitriles as the major constituent
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
  • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
  • D01F6/58—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products
  • D01F6/62—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products from polyesters
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
  • D04H1/4282—Addition polymers
  • D04H1/43—Acrylonitrile series
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
  • D04H1/4326—Condensation or reaction polymers
  • D04H1/435—Polyesters
• • D—TEXTILES; PAPER
  • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
  • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
  • D02G1/00—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics
  • D02G1/12—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics using stuffer boxes

Definitions

• the present invention relates to stuffed cotton used for bedding such as comforters and down jackets.
• This application claims priority based on Japanese Patent Application No. 2015-206232 filed in Japan on October 20, 2015 and Japanese Patent Application No. 2015-206233 filed in Japan on October 20, 2015. And the contents thereof are incorporated herein.
• feathers used as stuffed cotton for bedding, down jackets, etc. are known to have a rich texture, light weight, excellent heat retention and bulkiness, and a high recovery rate after compression.
• it is necessary to raise a large amount of waterfowl, which not only requires a large amount of feed, but also the problem of water pollution due to waterfowl excrement, or the occurrence and spread of infectious diseases. Has occurred.
• feathers in order to be able to use feathers as stuffed cotton, it is necessary to go through many processes, such as hair collection, selection, disinfection, and degreasing.
• the feathers soar during the process the work becomes complicated, and as a result, the price of bedding made of cotton filled with feathers is high.
• polyester fiber can be used as a material for stuffed cotton.
• Polyester fibers are inexpensive, but have a problem that they are not light and bulky and have low heat retention.
• Patent Document 1 discloses that a specific amount of a surface treatment agent mainly composed of a polyether / ester block copolymer is applied to the surface of both the matrix constituting the fiber structure and the heat-adhesive short fibers. It has been proposed to provide a hard cotton structure with improved rigidity and elasticity by adhering. However, the hard cotton structure described in Patent Document 1 lacks flexibility because of its high rigidity, and is unsuitable for uses such as comforters and jackets that require ease along the body.
• Patent Document 2 discloses a stuffed cotton in which a layer made of fibers having a single fiber fineness of 1.5 denier or less and a layer made of fibers having a single fiber fineness of 2.5 to 15 denier are laminated. Proposed.
• the stuffed cotton described in Patent Document 2 is simply formed by laminating a fiber layer (web) having a small single fiber fineness and a fiber layer (web) having a large single fiber fineness, and fibers having different finenesses are intertwined. Therefore, even if fibers having two different finenesses are used, there is almost no effect of increasing the bulkiness.
• the “web” means a sheet formed by overlapping fibers.
• Patent Document 3 discloses a short fiber having a single fiber fineness of 0.5 dtex or more and less than 3 dtex, a hollow fiber of 5 dtex or more and less than 10 dtex, a hollow fiber of 10 dtex or more and less than 30 dtex, and a thermal adhesiveness of 1 dtex or more and less than 5 dtex. Stuffed cotton made by mixing short fibers has been proposed. In the stuffed cotton of Patent Document 3, heat retention is imparted with short fibers of 0.5 dtex or more and less than 3 dtex, and heat retention and bulkiness are imparted with short fibers of 5 dtex or more. However, even the stuffed cotton described in Patent Document 3 is not sufficiently bulky.
• Patent Document 4 discloses a ball-shaped cotton having an average diameter of 3 to 10 mm in which fibers having a single fiber fineness of 1.1 to 15.0 dtex and a fiber length of 3 to 64 mm are intertwined, and 2 polyester fibers having different melting points. Ball-shaped cotton containing more than one kind of heat-bonding fibers has been proposed. In the ball-shaped cotton of Patent Document 4, the shape is maintained by partially adhering the fibers to each other by the heat-bonding fibers, thereby preventing the cotton from being displaced. However, even the ball-shaped cotton described in Patent Document 4 is not sufficient in bulkiness and heat retention.
• the present invention is intended to solve the problems in the prior art described above, and to provide stuffed cotton that is excellent in bulkiness and flexibility, and that is suitably used for bedding such as comforters and down jackets.
• the stuffed cotton of the present invention is a stuffed cotton in which acrylic fiber: 20% by mass to 95% by mass and polyester fiber: 5% by mass to 80% by mass, and the down power is 140 cm 3 / g or more, It is 300 cm ⁇ 3 > / g or less, and Clo value is 3.7 or more and 5.0 or less.
• the single fiber fineness of the acrylic fiber is preferably 0.1 dtex or more and 10 dtex or less, and the single fiber fineness of the polyester fiber is preferably 1 dtex or more and 10 dtex or less.
• the polyester fiber is preferably a hollow fiber.
• the hollow ratio of the hollow fiber is preferably 10% or more and 30% or less.
• the stuffed cotton of the present invention preferably has a down power of 140 cm 3 / g or more and 220 cm 3 / g or less.
• the stuffed cotton of the present invention preferably has a down power of 160 cm 3 / g or more and 200 cm 3 / g or less.
• the stuffed cotton of the present invention preferably has a Clo value of 3.8 or more and 4.8 or less.
• the stuffed cotton of the present invention preferably has a Clo value of 4 or more and 4.7 or less.
• the single fiber fineness of the acrylic fiber is preferably 0.5 dtex or more and 2.2 dtex or less, and the single fiber fineness of the polyester fiber is preferably 1.7 dtex or more and 2.2 dtex or less.
• the fiber length of the acrylic fiber is preferably 15 mm or more and 40 mm or less, and the fiber length of the polyester fiber is preferably 10 mm or more and 40 mm or less.
• the mixing ratio of the heat-bonded short fibers to the stuffed cotton is 5% by mass or more and 30% by mass or less, and at least a part of the heat-bonded short fibers is bonded to the acrylic fiber or the polyester fiber.
• the stuffed cotton of the present invention is a stuffed cotton of granular cotton in which an acrylic fiber having a single fiber fineness of 0.1 dtex or more and 10 dtex or less is contained in an amount of 30% by mass to 70% by mass and one or more fibers are intertwined.
• the stuffed cotton of the present invention preferably further contains a polyester fiber having a single fiber fineness of 1 dtex or more and 10 dtex or less in an amount of 30% by mass or more and 70% by mass or less.
• the polyester is a conjugate fiber and has a coiled form in an unloaded state.
• the maximum length of the granular cotton is preferably 2 mm or more and 20 mm or less.
• the number of crimps of the acrylic fiber is preferably 3/25 mm or more and 20/25 mm or less.
• the stuffed cotton of the present invention preferably has a reduction rate of down power of 30% or less after 10 washings.
• stuffed cotton that is excellent in bulkiness, flexibility, and heat retention, and can be suitably used for bedding such as a comforter and down jackets.
• the stuffed cotton of the present invention is a stuffed cotton in which 20% by mass to 95% by mass of acrylic fiber and 5% by mass to 80% by mass of polyester fiber are mixed, and the down power is 120 cm 3 / g or more and 300 cm 3 / g or less, and the Clo value is 3.7 or more and 5 or less.
• the quality of down is down power grade, which is a bulky indicator, and the Japan Feather Product Cooperative Association ranks it from the highest quality premium gold label into four types: Royal Gold Label, Excel Gold Label, and New Gold Label Has been. “Down power” indicates the volume per unit mass, and the larger this value, the higher the bulk. Examples of the method for measuring the down power include a method based on JIS L1903.
• the stuffed cotton of the present invention can have a texture similar to warmth, lightness, and down due to the acrylic fibers contained therein, and is excellent in recovery after compression due to the polyester fibers contained therein.
• the bulkiness is increased, and it is possible to achieve both improvement in heat retention and improvement in recovery after compression. That is, when acrylic fiber: 20% by mass to 95% by mass and polyester fiber: 5% by mass to 80% by mass are combined, a down power of 140 cm 3 / g or more can be obtained.
• the acrylic fiber is contained in an amount of 20% by mass or more with respect to the entire stuffed cotton, the down power can be further increased as compared with the 100% polyester product, and the heat retention is improved.
• the polyester fiber can be contained in an amount of 5% by mass or more with respect to the entire stuffed cotton, so that the recovery after compression is further improved as compared with the 100% acrylic fiber product.
• the mixing ratio of the acrylic fiber to the stuffed cotton is more preferably 30% by mass or more and 90% by mass or less, and further preferably 50% by mass or more and 85% by mass or less.
• the stuffed cotton of the present invention can be mixed with other fibers in addition to the acrylic fiber and the polyester fiber as long as the down power and the Clo value satisfy the ranges specified above.
• the total amount of the acrylic fiber and the polyester fiber is preferably 90% by mass or more, and more preferably 100% by mass with respect to the total amount of stuffed cotton.
• the down power is 140 cm ⁇ 3 > / g or more
• the stuffed cotton of this invention is preferable since it is bulkier than the batting which consists of 100 mass% of polyester fibers, and heat retention becomes high.
• the down power is 300 cm 3 / g or less, the bulkiness is sufficient and the volume per mass can be reduced, which is advantageous in terms of transportation cost.
• the down power is more preferably 150 cm 3 / g to 280 cm 3 / g, and still more preferably 160 cm 3 / g to 200 cm 3 / g.
• the stuffed cotton of the present invention has a Clo value of 3.7 or more and 5 or less as measured by the method described in Examples described later. If the Clo value is 3.7 or more, it can be used as stuffed cotton with good heat retention, and if it is 5 or less, the heat retention is equivalent to feathers, which is a sufficient value. From the viewpoint of heat retention, the Clo value is more preferably 3.8 or more, and further preferably 4 or more.
• the acrylic fiber preferably has a single fiber fineness of 0.1 dtex or more and 10 dtex or less
• the polyester fiber has a single fiber fineness of 1 dtex or more and 10 dtex or less.
• the single fiber fineness of the acrylic fiber is 0.1 dtex or more, it is preferable from the viewpoint of the processability for producing stuffed cotton, and if it is 10 dtex or less, it is preferable from the viewpoint that the heat retaining property is high and the texture does not become hard. From the above viewpoint, the single fiber fineness is more preferably 0.5 dtex or more and 2.2 dtex or less, and further preferably 0.8 dtex or more and 2.8 dtex or less. Moreover, since the heat retention improves if the mixture ratio of the said acrylic fiber with respect to stuffing cotton is 20 mass% or more, it is preferable at the point which recoverability improves by adding a polyester fiber if it is 95 mass% or less.
• the single fiber fineness of the polyester fiber is 1 dtex or more, the effect of improving the recoverability and preventing sag (fatigue deformation) can be obtained, and it is preferable in terms of enhancing bulkiness, and if it is 10 dtex or less, the heat retention is high. This is preferable in that the texture does not become hard.
• the single fiber fineness of the polyester fiber is more preferably 1.7 dtex or more and 2.2 dtex or less.
• the short fiber fineness demonstrated by this specification can be measured by the method based on JISL1015: 20108.5.
• the said polyester fiber is a hollow fiber. Since polyester fibers are inferior in heat retention compared to acrylic fibers, it is possible to secure immobile air by making the cross-sectional shape hollow. Furthermore, by making the polyester fiber into a hollow cross section, the cross-sectional area becomes larger than that of a non-hollow fiber, so that the rigidity of the fiber is increased, and it is effective in improving recovery and preventing settling.
• the hollow ratio of the hollow fiber is preferably 10% to 30%. If the hollow ratio of the hollow fiber is 10% or more, the heat retention rate is improved, which is preferable. From the above viewpoint, the hollow ratio of the hollow fiber is preferably 10% or more, and more preferably 20% or more.
• the fiber length of the acrylic fiber is preferably 15 mm or more and 40 mm or less
• the fiber length of the polyester fiber is preferably 10 mm or more and 40 mm or less.
• the “fiber length” described in the present specification refers to the length in the fiber axis direction.
• the fiber length demonstrated in this specification can be measured by the method based on JISL1015: 20108.4C method.
• the fiber length of the acrylic fiber is 15 mm or more, it is preferable because the processability of the filling cotton is good and the bulkiness is improved, and if it is 40 mm or less, the entanglement between the fibers is suppressed, and the piece of cotton. This is preferable because it can prevent shifting. Furthermore, from the above viewpoint, the fiber length of the acrylic fiber is more preferably 25 mm or more and 38 mm or less. If the fiber length of the polyester fiber is 10 mm or more, it is preferable because it is possible to reduce the loss of the polyester fibers in the manufacturing process or in the stuffed cotton. Since it can prevent, it is preferable. Furthermore, from the above viewpoint, the fiber length of the polyester fiber is preferably 12 mm or more and 35 mm or less, and more preferably 25 mm or more and 30 mm or less.
• the acrylic fiber can be appropriately selected according to the intended use or performance.
• the acrylic fiber for example, a method of improving the bulkiness of stuffed cotton by mixing side-by-side type fibers to express self-crimping, and the bulkiness of stuffed cotton by mixing Y-shaped fibers. And a method for improving the heat retaining property, or a method obtained by mixing with a fiber having a single fiber fineness of 0.8 dtex or more and 20 dtex or less.
• the acrylic fiber for example, antibacterial fibers, deodorant fibers, hygroscopic heat generating fibers, light heat generating fibers, flame retardant fibers, and the like can be combined to improve the function and performance. .
• these fibers may be used individually by 1 type, and may use 2 or more types together.
• the stuffed cotton of the present invention contains 5% by mass to 30% by mass of heat-adhesive short fibers, and at least a part of the heat-adhesive short fibers are bonded to the acrylic fibers or the polyester fibers.
• the heat-adhesive short fibers it is preferable to use short fibers composed of a low melting point resin having a melting point of 100 ° C. to 200 ° C.
• short fibers specifically, short fibers made from a low melting point polyester obtained by copolymerizing polyethylene terephthalate or polybutylene terephthalate with isophthalic acid, adipic acid, cyclohexanedicarboxylic acid, sebacic acid or the like are used. It is more preferable.
• the thermal adhesive short fiber is heated and bonded to a part of the acrylic fiber, whereby the nep can be held.
• the acrylic fiber according to the present invention has an effect that the single fiber fineness is very small and the formed nep is difficult to unravel, the heat-adhesive short fiber is suitable for applications that require durability. To do.
• the acrylic fiber 30% by mass or more and 70% by mass or less and the polyester fiber: 30% by mass or more and 70% by mass or less are mixed, and one or more fibers are intertwined. It can be set as the structure which is stuffed cotton of granular cotton.
• the down features include bulkiness, heat retention, and the independence unique to downballs.
• the entanglement between the fibers becomes large, which causes the cotton to be offset.
• the fiber length is short, the entanglement of the fibers becomes small, which is effective in preventing the cotton from shifting, but does not contribute to the bulkiness of the fibers.
• the mixed cotton type which mixes the cotton that has been opened, it is difficult to prevent the cotton from shifting.
• the single fiber fineness is thin, the number of components per unit weight increases, so that the heat retaining property is enhanced.
• the content of the acrylic fiber with respect to the entire stuffed cotton is preferably 30% by mass or more and 70% by mass or less. If the content rate of the acrylic fiber with respect to the whole stuffed cotton is 30% by mass or more, it is preferable in terms of good moldability of granular cotton, and if it is 70% by mass or less, it is preferable in terms of improving heat retention. From these viewpoints, the content of the acrylic fiber with respect to the whole stuffed cotton is more preferably 40% by mass or more and 60% by mass or less, and further preferably 45% by mass or more and 55% by mass or less.
• the content of the polyester fiber with respect to the entire filling cotton is preferably 30% by mass or more and 70% by mass or less.
• the formability of the granular cotton is improved, and the shape of the granular cotton is restored to a shape close to a sphere even after compression.
• the gap between the granular cottons becomes larger, the amount of stationary air increases as a whole, and the heat retaining property is improved.
• the content of the polyester fiber relative to the whole stuffed cotton is 30% by mass or more, it is preferable in terms of moldability of the granular cotton, and if it is 70% by mass or less, it is preferable in terms of improving the heat retention rate. From these viewpoints, the content of the polyester fiber with respect to the entire stuffed cotton is more preferably 40% by mass or more and 60% by mass or less, and further preferably 45% by mass or more and 55% by mass or less.
• the granular cotton described in the present specification is one in which one or a plurality of fibers are intertwined to form a sphere.
• a shape like a rugby ball may be used, or a fiber may protrude like a beard, as long as a shape close to a sphere can be recognized.
• Said granular cotton is the shape close
• the acrylic fiber preferably has crimps from the viewpoint of forming granular cotton.
• the crimp in this case may be a mechanical crimp, or may exhibit self-crimpability as a side-by-side type composite fiber.
• the acrylic fiber can be appropriately selected according to the intended use or performance.
• the acrylic fiber may have a cross-sectional shape having a convex portion on the long side of the flat cross section, a Y-shaped cross-sectional shape, or the like.
• antibacterial properties, deodorizing properties, moisture absorption heat generation properties, light heat generation properties, flame retardancy, and the like can be imparted to the acrylic fibers.
• said acrylic fiber can also be combined individually.
• these acrylic fibers may be used individually by 1 type, and may use 2 or more types together.
• the stuffed cotton made of granular cotton having the above-described configuration preferably has a coiled form when the polyester fiber is a conjugate fiber and no load is applied.
• the crimp of a fiber is important, and if there is no crimp, a grain will not be formed. Since the polyester fiber has a coil shape, the fibers are entangled with each other, and granular cotton can be produced.
• the filling cotton which consists of granular cotton of the said structure is 2 mm or more and 20 mm or less in maximum length of granular cotton. If the maximum length of the granular cotton is 2 mm or more, it is preferable because the user hardly feels the feel of the grains even in the case of a thin fabric such as a down jacket. Moreover, if the maximum length of granular cotton is 20 mm or less, it is preferable since the deviation of cotton can be prevented. Further, the closer the shape of the grain (granular cotton) is to a true sphere, the larger the voids and the more immobile air, the better the heat retention rate. From the above viewpoint, the maximum length of the granular cotton is more preferably 5 mm or more and 15 mm or less, and further preferably 7 mm or more and 13 mm or less.
• the stuffed cotton which consists of granular cotton of the said structure is the number of crimps of the said acrylic fiber being 3 mountain / 25 mm or more and 20 mountain / 25 mm or less.
• the number of crimps of the acrylic fiber is 3 crests / 25 mm or more and 20 crests / 25 mm or less, the granular cotton is easy to form and the form maintainability is good.
• the number of crimps of the acrylic fiber is more preferably 7 peaks / 25 mm or more and 13 peaks / 25 mm or less.
• the unit of “mountain” in the number of crimps means the number of crimps (a value obtained by counting all the peaks and valleys and dividing by 2). Moreover, the number of crimps demonstrated in this specification can be measured by the method based on JISL1015: 2010 8.12.
• down power is 120 cm 3 / g or more, is preferably not more than 270m 3 / g. If down power wadding made of granular cotton 120 cm 3 / g or more, preferably from the viewpoint of securing sufficient insulation, more preferably 130 cm 3 / g or more, more preferably 140cm 3 / g or more.
• the reduction rate of the down power after 10 washings is 30% or less.
• down is limited in washing conditions such as dry cleaning, cannot be washed at home, and is difficult to handle.
• the granular cotton of the present invention the grain shape does not collapse even after washing, and the cotton grains do not get entangled with each other. Therefore, the deviation of the cotton and the decrease in bulkiness are small compared to the mixed cotton. That is, in the stuffed cotton made of granular cotton, it is preferable that the decrease rate of the down power after 10 washings is 30% or less because sufficient heat retention can be maintained even after washing.
• an acrylic fiber having a single fiber fineness of 0.1 dtex or more and 10 dtex or less and a polyester fiber of 1.0 dtex or more and 10 dtex or less are laminated or mixed and passed through a fiber opening machine. It can manufacture by the method of including the process which mixes the fiber after fiber sending by an air blow and at least 1 or more card machine.
• the fiber is put into an apparatus for producing granular cotton.
• the method for producing acrylic fibers having a single fiber fineness of 0.1 to 10 dtex is not particularly limited, and can be produced by a known production method. For example, after a polyacrylonitrile copolymer is dissolved in dimethylacetamide to obtain a solution, the solution is discharged and solidified in an aqueous solution of dimethylacedamide using a nozzle having a discharge port to obtain solidified fibers. A solidified fiber obtained in the step (A) is stretched by wet heat stretching, dry heat stretching, or both methods, and washed in boiling water to give an oil agent. And then drying at a temperature of 100 ° C. to 200 ° C., and then applying mechanical crimping (two-dimensional Yamaya shape) to obtain a fiber (ultrafine fiber) having a single fiber fineness of 0.1 to 10 dtex (B) ).
• the ratio of the polyacrylonitrile copolymer dissolved in dimethylacetamide to the solution is preferably 10% by mass to 30% by mass, and more preferably 15% by mass to 25% by mass.
• the hole diameter of the discharge port of the nozzle is preferably 0.010 mm to 0.080 mm from the viewpoint of obtaining fibers having a desired fineness, and more preferably 0.015 mm to 0.060 mm.
• the concentration of dimethylacetamide in the aqueous dimethylacetamide solution is preferably 10% by mass to 80% by mass from the viewpoint of improving process passability, and more preferably 20% by mass to 60% by mass.
• the draw ratio of the coagulated fiber is preferably 2 to 8 times from the viewpoint of increasing the strength, and more preferably 3 to 6.5 times.
• a crimping step for further applying mechanical crimping using a thermal relaxation treatment and / or a crimping machine as necessary ( 1), and further, after the crimping step (1), a method including a step (2) of cutting the acrylic fiber to have a length of 15 mm to 40 mm.
• the crimping step (1) is preferably mechanical crimping using a crimping machine, and the number of crimps is preferably 3/25 mm to 20/25 mm in terms of bulkiness. If the number of crimps of the acrylic fiber is 3 crests / 25 mm or more, it is preferable in terms of maintaining the form of the stuffed cotton, and if it is 20 crests / 25 mm or less, this is preferable in terms of the passability of the stuffed cotton manufacturing process.
• the manufacturing method of stuffed cotton includes the step of adhering the heat-adhesive short fiber to the acrylic fiber or the polyester fiber, the acrylic fiber obtained in the step (2) and the heat-adhesive short fiber are mixed, It is preferable to fix the nep by heating at a temperature of 100 ° C. to 220 ° C.
• thermolab II dry contact method The thermolab II dry contact method was used to measure the heat retention rate (Clo value) of the stuffed cotton under the following conditions and procedures. The results are shown in Tables 1 and 2 below. 1. The measurement was performed in a test room maintained at a room temperature of 22 ° C. and a humidity of 60%. 2. Prepare a sample in which 10 g of cotton is put in a 20 cm square cushion cover (fabric: 100% cotton). 3. The sample is set on a hot plate set at 32 ° C. using a KES-F7 Thermolab II tester (registered trademark) manufactured by Kato Tech Co., Ltd. 4. Calculate the amount of heat a (W) radiated through the sample under a windy condition of 30 cm / sec. 5).
• Clo value 0.645 / (1 / heat quantity a-1 / heat quantity b)
• a higher Clo value indicates that the cotton pad is more excellent in heat retention.
• “-” means not measured.
• Thermolab II dry contact method and Clo value refer to the following URL.
• Clo value (Kaken Test Center) http: // www. kaken. or. jp / guidance / functionality / thermal_mannequin. html
• Example 1 A copolymer composed of 95% by mass of acrylonitrile and 5% by mass of vinyl acetate was dissolved in dimethylacetamide so that the concentration of the copolymer was 20% by mass. Thereafter, using a nozzle having a hole diameter of 0.045 mm and a round discharge hole, the solution was discharged into an aqueous solution of 50% by mass of dimethylacedamide, washed in boiling water, and stretched 4.5 times. Then, an oil agent was applied and dried at a temperature of 150 ° C.
• the tow is cut so that the length of the single fiber is 38 mm, so that the cross-sectional shape is round. Yes, an acrylic short fiber having a single fiber fineness of 0.8 dtex was obtained.
• Example 2 A stuffed cotton was produced in the same manner as in Example 1 except that the fiber 2 was changed to a non-hollow regular polyester having a single fiber fineness of 1.7 dtex and a fiber length of 15 mm.
• the bulkiness and heat retention results of the stuffed cotton obtained in Example 2 are shown in Table 1 below.
• Example 3 Cotton stuffed cotton was produced in the same manner as in Example 1 except that the ratio of fiber 1 and fiber 2 was changed as shown in Table 1 below, and evaluated similarly. Table 1 shows the results of bulkiness and heat retention of the stuffed cotton obtained in Example 3.
• Example 4 A copolymer composed of 93% by mass of acrylonitrile and 7% by mass of vinyl acetate was dissolved in dimethylacetamide so that the concentration of the copolymer was 20% by mass. Thereafter, using a nozzle having a hole diameter of 0.060 mm and a round discharge hole, the solution was discharged into an aqueous solution of 56% by mass of dimethylacedamide, washed in boiling water and stretched 6 times. The oil was applied and dried at a temperature of 150 ° C.
• the cross-sectional shape is a broad bean-shaped acrylic fiber: 20% by mass
• the cross-sectional shape is a circular acrylic fiber: 30% by mass
• the cross-sectional shape of Example 3 is a hollow polyester fiber: 30% by mass and polyester fiber having a circular cross-sectional shape of Example 2: 20% by mass
• Comparative Example 1 The bulkiness and heat-retaining properties of the products of other companies (trade name: PrimaLoft (registered trademark), manufactured by ALBANY, 100% polyester) used for stuffed cotton were evaluated by the same method as described above. The results are shown in Table 1 below.
• the PrimaLoft used in Comparative Example 1 is made of polyester having a short fiber fineness of 1 dtex. As in the present invention, several types of polyesters having different finenesses are not mixed, but only a single fineness fiber.
• the stuffed cotton of Comparative Example 2 is composed of long fibers, has a core yarn and a flower yarn, the flower yarn is longer than the core yarn, the core yarn and the flower yarn are integrated by entanglement, and the flower yarn is opened. It is a entangled yarn for stuffing that is fibrillated to form a loop-like fiber. Further, the flower yarn is a hollow fiber, and the hollow ratio is 25%.
• the stuffed cotton material of Comparative Example 2 is 100% by mass of polyester fiber for both the core yarn and the flower yarn.
• Comparative Example 3 After 100% by mass of a polyester fiber having a circular cross section (single fiber fineness: 1.7 dtex, fiber length: 15 mm) is passed through a fiber opening machine, the cotton is further mixed with air to obtain stuffed cotton. The properties and heat retention were evaluated by the same method as described above. The evaluation results are shown in Table 1 below. The stuffed cotton obtained in Comparative Example 3 was low in both bulkiness and heat retention.
• Example 4 100% by mass of the hollow cross-section polyester (fiber fineness: 2.2 dtex, fiber length: 20 mm) used in Example 1 was passed through a spreader, and cotton was further mixed by air to obtain cotton. The evaluation results are shown in Table 1. The obtained stuffed cotton was low in both bulkiness and heat retention.
• Reference Example 1 Using 100% by mass of the acrylic fiber (single fiber fineness: 0.8 dtex, fiber length: 38 mm) used in Example 1, after passing through a fiber opening machine, it was mixed with a card machine to obtain stuffed cotton. Using the stuffed cotton obtained above, bulkiness evaluation and heat retention evaluation were performed in the same manner as described above. The evaluation results are shown in Table 1 below. Reference Example 1 was a cotton stuffed with 100% by mass of acrylic fiber, which had good down power and Clo value, but was inferior in stickiness.
• Example 5 A copolymer composed of 93% by mass of acrylonitrile and 7% by mass of vinyl acetate was dissolved in dimethylacetamide so that the concentration of the copolymer was 24% by mass. Thereafter, using a nozzle having a hole diameter of 0.060 mm and a round discharge hole, the solution was discharged into an aqueous solution of 50% by mass of dimethylacedamide, washed in boiling water and stretched 6 times. The oil was applied and dried at a temperature of 150 ° C.
• Example 6 Cotton stuffed cotton was produced in the same manner as in Example 5 except that the acrylic short fibers of the fiber 1 were changed to those shown in Table 2 below, and evaluated similarly. Table 2 below shows the evaluation results of the bulkiness and heat retention of the stuffed cotton obtained.
• Example 6 Comparative Example 6 except that the acrylic short fiber of the fiber 1 is changed to a flat acrylic short fiber having a single fiber fineness of 17 dtex, a cross-sectional shape perpendicular to the fiber axis direction, and a flatness ratio of 10.
• Granular stuffed cotton was produced by the method and evaluated in the same manner. Table 2 below shows the evaluation results of the bulkiness and heat retention of the stuffed cotton obtained. The obtained cotton stuff of Comparative Example 6 had a low Clo value.
• Comparative Example 7 In the same manner as in Example 5, except that the fiber 1 was changed to the flat acrylic short fiber used in Comparative Example 6 and the fiber 2 was changed to the acrylic short fiber used in Example 3, a granular stuffed cotton was used. Manufactured and evaluated similarly. Table 2 below shows the evaluation results of the bulkiness and heat retention of the stuffed cotton obtained. The obtained Comparative Example 7 stuffed cotton had a low down power, a low Clo value, and a poor settability.
• Comparative Example 8 Except that the fiber 2 was changed to the same fiber 1 used in Example 6, granular padding was produced in the same manner as in Example 1 and evaluated in the same manner as described above. Table 2 below shows the evaluation results of the bulkiness and heat retention of the stuffed cotton obtained. The stuffed cotton of Comparative Example 8 thus obtained had a low Clo value and poor stickiness.

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