WO2018113765A1 - 一种填充物体 - Google Patents

一种填充物体 Download PDF

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Publication number
WO2018113765A1
WO2018113765A1 PCT/CN2017/117915 CN2017117915W WO2018113765A1 WO 2018113765 A1 WO2018113765 A1 WO 2018113765A1 CN 2017117915 W CN2017117915 W CN 2017117915W WO 2018113765 A1 WO2018113765 A1 WO 2018113765A1
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WO
WIPO (PCT)
Prior art keywords
filling
fiber
melting point
fluffy
cloth
Prior art date
Application number
PCT/CN2017/117915
Other languages
English (en)
French (fr)
Inventor
景红川
顾金凤
许金碧
铃木英俊
Original Assignee
东丽纤维研究所（中国）有限公司
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
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Application filed by 东丽纤维研究所（中国）有限公司 filed Critical 东丽纤维研究所（中国）有限公司
Priority to CN201780065148.5A priority Critical patent/CN109843785B/zh
Publication of WO2018113765A1 publication Critical patent/WO2018113765A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B68—SADDLERY; UPHOLSTERY
    • B68G—METHODS, EQUIPMENT, OR MACHINES FOR USE IN UPHOLSTERING; UPHOLSTERY NOT OTHERWISE PROVIDED FOR
    • B68G1/00—Loose filling materials for upholstery
    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D23/00—Scarves; Head-scarves; Neckerchiefs
    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D3/00—Overgarments
    • A41D3/02—Overcoats
    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D31/00—Materials specially adapted for outerwear
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
    • A47C27/12—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with fibrous inlays, e.g. made of wool, of cotton
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47G—HOUSEHOLD OR TABLE EQUIPMENT
    • A47G9/00—Bed-covers; Counterpanes; Travelling rugs; Sleeping rugs; Sleeping bags; Pillows
    • A47G9/02—Bed linen; Blankets; Counterpanes
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47G—HOUSEHOLD OR TABLE EQUIPMENT
    • A47G9/00—Bed-covers; Counterpanes; Travelling rugs; Sleeping rugs; Sleeping bags; Pillows
    • A47G9/02—Bed linen; Blankets; Counterpanes
    • A47G9/0207—Blankets; Duvets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B68—SADDLERY; UPHOLSTERY
    • B68G—METHODS, EQUIPMENT, OR MACHINES FOR USE IN UPHOLSTERING; UPHOLSTERY NOT OTHERWISE PROVIDED FOR
    • B68G5/00—Resilient upholstery pads
    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D2400/00—Functions or special features of garments
    • A41D2400/10—Heat retention or warming
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B68—SADDLERY; UPHOLSTERY
    • B68G—METHODS, EQUIPMENT, OR MACHINES FOR USE IN UPHOLSTERING; UPHOLSTERY NOT OTHERWISE PROVIDED FOR
    • B68G1/00—Loose filling materials for upholstery
    • B68G2001/005—Loose filling materials for upholstery for pillows or duvets

Definitions

  • the present invention relates to a filling object provided with a cover cloth, a lining cloth and a filling material.
  • natural feathers come from waterfowl and there are many defects. For example, 1 production cost is high, supply is limited, and its price is subject to large changes in market supply and demand; 2 a large amount of sewage, waste water, etc. are generated in the production process, which causes environmental pollution problems, and if the feathers are insufficiently washed, It will cause bad odor, so it is necessary to remove the dirt that causes malodor in advance; 3 it is difficult to wash, most down products are not suitable for machine washing. Because of the high density of the down fabric, washing clothes with a washing machine will bulge and float on the water surface, resulting in uncleanness. At the same time, the downshift is likely to occur, resulting in poor local warming. Although ordinary cotton fillers do not have the above-mentioned defects of natural down, they are easy to leak and are not widely used for clothing filling because of their heavy weight and poor warmth.
  • Chemical fiber fillers such as pearl cotton, etc., not only have the lightweight style of natural down, but also have the advantages of anti-bacterial and moisture-proof, cost stability, and low price, but their fluffiness is not high enough, and the warmth is far from the down. At the same time, it is not easy to machine wash.
  • Chinese patent CN103097280A discloses a filling object, wherein the inner filling is a long fiber filled cotton which is formed by integrating a fancy wire with a core wire, the fancy wire is opened to form a loop fiber, and the long fiber cotton is at least one. It is woven in multiple directions in the direction and is sewn together with the cover cloth to be integrated with the cover cloth.
  • the application is a filling object formed by sewing long fiber cotton and a cover cloth together, and the phenomenon of leakage may occur at the sewing needle hole.
  • the invention needs to first perform the twisting integration of the core wire and the fancy wire. The process of opening the fancy silk, the process is complicated, and the long fiber filled cotton is lacking in fluffiness, flexibility, and recovery after compression.
  • An object of the present invention is to provide a filled object which is excellent in anti-leaking property, has excellent performances such as bulkiness, light weight, and warmth, and has less concentration of a filler material during use or after washing, is less likely to be displaced, and has a high bulkiness.
  • the filling object of the present invention is provided with a cover cloth, a lining cloth and a filling material, the cover cloth forms at least one filling area, the filling material is long fiber cotton, and the filling material is arranged in the lining cloth and integrated with the lining cloth to form a filling.
  • the unit, the filling unit is filled in the filling area, and the filling unit and the cover cloth are in a non-connected state.
  • the long-fiber cotton as the filling material is preferably a fluffy processed tow formed of N core-sheath type fluffy processed yarns, N is 1 or more; and the sheath-type fluffy processed silk sheath yarn is high a mixed filament formed by a melting point fiber and a low melting point fiber; the core filament is a filament formed of a high melting point fiber, and the fluffy processed tow contains a dispersed molten bond point.
  • the ventilation amount of the cover cloth is 1 to 200 cm 3 /cm 2 /s; when the lining cloth is two layers, the ventilation amount of the lining cloth is preferably 1 to 200 cm 3 /cm 2 /s. .
  • At least one of the near-end position or the intermediate position of the filling material and the lining in the filling unit is sewn together.
  • the weight ratio of the low melting point fiber in the mixed fiber to the mixed fiber is 0.1 to 50% by weight; the total weight of the sheath yarn of the bulky processed tow is 60 in the total amount of the loosely processed tow. ⁇ 99wt%.
  • the difference in melting point between the high melting point fiber and the low melting point fiber in the bulky processed yarn is from 20 ° C to 150 ° C.
  • the high melting point fiber in the fluffy processed yarn is a polyester fiber; and the low melting point fiber is at least one of a modified copolymerized low melting point polyester, polypropylene, polyethylene or nylon fiber.
  • the high-melting-point fiber polyester fiber is a hollow fiber and the hollow ratio is 20 to 50%.
  • the number of the dispersed fusion bonding points contained in the bulky processed tow is 1 to 40 pieces/cm.
  • the fluffy processed tow has a three-dimensionally crimped shape in a natural state, and the curled shape has a radius of curvature of from 3 mm to 15 mm.
  • the preferred filler material used in the present invention is a fluffy processed tow having a bulkiness of 400 to 800 inch 3 / 30 g as measured by IDFB.
  • the problem to be solved by the present invention is to improve the anti-leaking property by adding a lining cloth.
  • the problem of offset and agglomeration of the filling material after washing is improved, and the problem that the filling object is heavy, poor in warmth, and not bulky is solved by using the fluffy processed tow as a filler.
  • Fig. 1 is a schematic view showing a configuration of a filling unit of the present invention. among them,
  • 1 cover cloth
  • 2 lining cloth
  • 3 long fiber cotton
  • 4 sheath fiber of long fiber cotton
  • 5 core wire of long fiber cotton
  • 6 joint of lining cloth and long fiber cotton.
  • Fig. 2 is a side view showing a physical example of the filling object of the present invention.
  • Fig. 3 is a physical diagram of an example of a filler of the present invention.
  • Fig. 4 is a three-dimensional curly shape diagram of long-fiber cotton in a natural state.
  • Fig. 5 is a schematic view showing the measurement of the radius of curvature.
  • the problem to be solved by the present invention is to improve the anti-slip property by adding a lining cloth and to improve the occurrence after washing.
  • the problem of offset, agglomeration, and the use of fluffy processed tow as a filler solves the problem of heavy weight, poor warmth, and no bulkiness.
  • the filling object of the present invention is not particularly limited, and may be a clothing use or a type of filling object for use in home use or the like. Can be listed as winter clothes, quilts, scorpions, sleeping bags, cushions, blankets, coats, bibs, etc.
  • the filling object of the present invention is provided with a cover cloth, a lining cloth and a filling material, the cover cloth forms at least one filling area, the filling material is long fiber cotton, and the filling material is arranged in the lining cloth and integrated with the lining cloth to form a filling unit.
  • the filling unit is filled in the filling area, and the filling unit and the cover cloth are in a non-connected state.
  • the filler material is long-fiber cotton, it can form an integrated connection relationship with the lining cloth.
  • the filling material and the interlining referred to herein form a filling unit, which can be understood as a direct connection between the filling material and the interlining.
  • the term "integration" as used herein refers to a partially overlapping combination of two parts of material having a certain degree of fastness, which can resist the smashing and pulling of a certain external force, so that the two are easily separated. Specifically, it may be directly connected by using an adhesive tape, or may be directly connected by sewing, or may be directly connected by ultrasonic wave or fusion bonding to achieve integration.
  • the engineering is slightly complicated, the cost is slightly higher, and because the tape has a certain width, the insulation at the tape is relatively poor; in addition, the ultrasonic wave and the fusion bonding method will make the filling object The hand feel is slightly hard and the use comfort is slightly poor. Therefore, it is preferable to form the filling unit by integrating the filling material and the lining cloth by a sewing method.
  • the filled object of the present invention has more than one filled area. That is, one filling unit may fill one filling area, or a plurality of filling units may fill a plurality of filling areas.
  • the number of the filling regions is not particularly limited, and the size is not particularly limited.
  • the size of the plurality of filling regions in one filling object may be the same or different. It can be freely set according to the purpose. If the number of filled areas is M, then when the filled object is a cushion, the M number is preferably 1; when the filled object is a quilt, the M number is preferably 4-8; when the filled object is a down jacket, the M number is preferred It is 20 to 50.
  • the form in which the filling material and the lining cloth are integrated in the filling unit is preferably such that at least one of the near end positions or the intermediate positions of the filling material and the lining cloth are sewn together.
  • appropriate adjustments can be made.
  • the bulkiness of the filling material can be maintained, and the filling material can be prevented from leaking out of the surface of the cover cloth through the pinholes of the cover cloth, thereby avoiding the problem of accumulation of the filling material inside the filling object.
  • Even in the case of repeated washing the movement of the filler material is restricted from being displaced, the concentration of the filler is reduced, and the bulkiness is improved.
  • the filling unit and the cover cloth are in a non-connected state, and the filling unit is directly filled in the filling area, so as to satisfy the effect of being neither fluffy nor moving.
  • the cover cloth of the present invention may be a woven or knitted fabric.
  • the fiber raw material used is not particularly limited, and the surface layer and the inner layer may be the same fabric, or different fabrics may be used.
  • the lining cloth of the present invention may be a nonwoven fabric, a woven or a knitted fabric, and the fibrous material used is not particularly limited.
  • the lining of the present invention may be one layer or two layers, that is, it may be directly connected to one side of the filling material or both sides of the filling material.
  • the lining cloth or the lining cloth is preferably a nonwoven fabric, a woven or a knitted fabric having a ventilation amount of 1 to 200 cm 3 /cm 2 /s. More specifically, the following two technical methods are preferred: 1.
  • the lining is a layer and the ventilation of the hood is 1 to 200 cm 3 /cm 2 /s; 2.
  • the lining is two layers and the ventilation of the lining is preferred. It is 1 to 200 cm 3 /cm 2 /s.
  • the design of the lining of the present invention can also bring about operational convenience.
  • the lining cloth and the long-fiber cotton of the filling material are integrated to form a filling unit, the filling unit is filled in the filling area, and the filling unit and the cover cloth are in a non-connected state.
  • the lining cloth is two layers when the lining cloth is two layers. It can also improve the anti-leaking performance itself, so that the filling object is not easy to leak, and it can also be flexibly applied to the filling object for various purposes.
  • the filling material and the interlining of the present invention may be integrally formed by sewing the filling material on the interlining, and the sewing portion is not particularly limited.
  • the filling unit may be formed by integrating at least one of the two ends, the vicinity of the both ends, or the intermediate position to form a filling unit. If the filling object of the present invention is a cushion, a bib, or the like, a filling object having a small size is filled.
  • At least one of the near ends or intermediate positions of the filling material and the lining cloth is sewn to form a filling bag having good bulkiness and low washing offset rate; when the filling object is a size of a winter jacket or a jacket
  • the filling unit is not too long or too wide, and one or both of the near end positions of the filling material and the lining cloth may be selected, or one of the near end positions and The intermediate position is sewn in such a way that a filling unit having a good bulkiness and a low washing offset rate can be obtained; and when the filling object is a large-sized filling object such as a quilt or a sleeping bag, if the filling area is set to be compared In the case of less, considering that the filling unit is relatively long, the form of the filling material and the lining cloth can be integrated with the near end position and the middle of the filling material and the lining cloth.
  • a total of three places are sewn together; and if the filling area is set more, considering that the filling unit is not very long, the filling material and the lining integrated form may be selected only by the filling material and the lining cloth. Two positions at both ends are sewn together.
  • the filling material is sewed together with a layer of interlining cloth, and the filling unit is formed by stitching at the two ends, the position near the two ends or the middle position, and the filling unit is filled in the filling area, the filling unit and the covering cloth. No stitching is required between them to make a filled object;
  • the filling material is filled in the two-layer lining hollow tube which is sewn, and then the filled lining cloth and the filling material are stitched into two ends, near the two ends or in the middle position.
  • a filling unit is formed, and the filling unit is filled in the filling area, and the filling unit and the cover cloth are not required to be stitched, thereby forming a filling object.
  • the filling material is sewn together with a layer of interlining cloth, and the filling unit is formed by stitching at both ends, near the two ends and at the intermediate position, and the filling unit is filled in the filling area, and the filling unit and the cover cloth are filled. No stitching is required between them to make a filled object;
  • the filling material is filled in the two-layer lining hollow tube which is sewn, and then the filled lining cloth and the filling material are carried out at both ends, and the two ends are sewed together in the middle position.
  • a filling unit is formed, and the filling unit is filled in the filling area, and the filling unit and the cover cloth are not required to be stitched, thereby forming a filling object.
  • the long-fiber cotton of the filler material according to the present invention is not particularly limited, and may be a long fiber of DTY or FDY such as ordinary polyester or nylon, or a crimped fiber thereof, in consideration of the bulkiness and warmth of the filled object, preferably
  • the fluffy processed tow formed of the N core-sheath type fluffy processed yarn is used as a filler long fiber cotton, and N is 1 or more. From the viewpoint of heat retention and lightness, N is preferably 6 or more, and more preferably N is 9 or more. A filled object of such a fluffy processed tow is used, and the offset of the internal filling material during washing is small and the bulkiness is good.
  • the preferred filling material core-sheath type fluffy processed tow of the present invention is a fluffy processed yarn comprising N core wires and sheath wires integrated by air entanglement processing. At least one of the core yarn and the sheath yarn of the fluffy processed yarn is a mixed filament formed of a high melting point fiber and a low melting point fiber; and the fluffy processed tow has a dispersed fusion bonding point of 1 or more.
  • the preferred filler material of the present invention is a fluffy processed tow, preferably wherein the sheath filament of the fluffy processed filament is a blended filament formed of a high melting point fiber and a low melting point fiber; the core filament is a filament formed of a high melting point fiber.
  • the preferred filling material of the present invention is a fluffy processed tow, and preferably the low melting point fiber of the mixed fiber formed of the high melting point fiber and the low melting point fiber accounts for 0.1 to 50% by weight of the mixed fiber.
  • the preferred filler material of the present invention is a fluffy processed tow, preferably in a weight ratio of the total amount of sheath filaments to the total amount of fluffy processed tow of from 60 to 99% by weight.
  • the preferred filling material of the present invention is a fluffy processed tow, and preferably the difference between the melting point of the high melting point fiber and the low melting point fiber in the fluffy processed yarn is from 20 ° C to 150 ° C.
  • the high-melting-point fibers described in the present invention are related to the low-melting-point fibers, and do not refer to fibers having a melting point above or below a specific value, but to two fibers having a certain difference in melting point. It can also be expressed as a fiber having a high melting point and a fiber having a low melting point.
  • the melting point difference is preferably in the range of 20 ° C to 150 ° C. If the melting point difference is higher than 20 ° C, the amount of the melt-bonded dots formed by the fluffy processed tow can satisfy the needs of the invention; and below 150 ° C, the resistance of the low-melting fiber Thermal properties are not preferred because they do not affect the processability. It is further preferred that the difference in melting point is from 20 ° C to 100 ° C from the viewpoint of hand feeling and resistance deviation.
  • the preferred filling material core-sheath type fluffy processed tow of the present invention because of the heat treatment, the low-melting fiber in the mixed fiber contained in the tow is partially melted, which is partially melted, partially melted, and partially Adhesive to the fibers having a high melting point such that dispersed melt bonds are formed in the fluffy processed tow.
  • the weight ratio of the low melting point fibers in the mixed filaments to the mixed filaments is preferably from 0.1 to 50% by weight.
  • the content of the low-melting fiber in the mixed filament is in the range of 0.1 to 30% by weight, the number of the fusion bonding points is sufficient, and the washing loss of the finished product is small, which is more preferable.
  • the fusion bonding point is excessive, the bulkiness of the fluffy processed yarn is low, and the hand feel is slightly inferior.
  • the weight ratio of the sheath yarn to the fluffy processed yarn is preferably 60 to 99% by weight, more preferably 80 to 99% by weight.
  • the loft of the processed tow is slightly lower.
  • the core wire and the sheath wire are either alone or both of a high melting point fiber and a mixed fiber composed of a low melting point fiber, after the heat treatment, the low melting point fiber in the mixed fiber is partially melted, which is partially self-melting. Partially fused, partially bonded to the fiber having a high melting point, thereby forming a molten bonding point dispersed in the fluffy processed tow, and achieving the desired effect of the present invention.
  • the fusion bonding point can improve the stability of the loop fiber formed by the opening of the sheath wire, and improve the compression recovery rate.
  • the fusion bonding point can improve the frictional force in contact with the fabric. Thereby, the offset of the insulating filler in many cases, such as washing offset, wearing offset, and the like, is suppressed.
  • the preferred filler material of the present invention is a fluffy processed tow, and preferably the number of dispersed fusion bonding points contained in the tow is from 1 to 40 / cm. These dispersed fusion bonding points have a good effect on the shape fixing of the fluffy processed tow without affecting the bulkiness.
  • the dispersed molten bond points are too small, and the shape fixing effect is insufficient; the dispersed molten bond points are excessive, and although the shape fixing effect is good, the bulkiness, the flexibility, and the like are suppressed.
  • the more the number of points of fusion bonding the better the shape is fixed, that is, the better the resistance to offset, but the handle is relatively hard and the bulkiness is slightly poor. In summary, it is more preferably 1 to 20 pieces/cm. When the melt bonding point is controlled to be 20 pieces/cm or less, the resulting fluffy processed tow has a better hand feeling and a higher bulkiness.
  • a fluffy processed yarn forming a core-sheath type fluffy processed tow preferably a sheath yarn is a mixed filament formed of a high melting point fiber and a low melting point fiber; and the core yarn is a filament formed of a high melting point fiber.
  • the high melting point fiber in the sheath filament and the high melting point fiber in the core yarn may be the same or different, but it is necessary to satisfy the condition that the melting point of the high melting point fiber is higher than the melting point of the low melting point fiber.
  • the difference in melting point between the high melting point fiber and the low melting point fiber in the core-sheath type fluffy processed yarn is from 20 ° C to 150 ° C, preferably from 20 ° C to 100 ° C.
  • Any polymer which satisfies the above conditions can be used as the fiber-forming polymer of the two fibers of the present invention. Specific examples thereof include a conventional melting point polyester fiber and a low melting point modified copolymerized polyester, a conventional melting point polyester fiber and a polypropylene fiber, or a combination of a polypropylene fiber and a polyethylene fiber.
  • the high melting point fiber of the present invention is preferably a polyester fiber
  • the low melting point fiber is a fiber having a slightly lower melting point than the high melting point fiber, preferably at least one of a modified copolymerized low melting point polyester, polypropylene, polyethylene or nylon fiber.
  • the cross section of the high melting point fiber may be one or more of a circle, a hollow, a triangle, a cross, an eight leaf, etc.; preferably a hollow fiber.
  • the high melting point fiber is a main constituent component of the bulky processed tow, and its performance plays a decisive role in the weight of the filled object using the tow of the present invention and the heat retaining property.
  • the hollow fiber is preferred, the lightweight and heat retaining properties of the filled object are greatly improved.
  • the hollow fiber of the high-melting point hollow fiber is preferably 20 to 50%, more preferably 25 to 45%, in view of spinning stability, fiber mechanical properties and the like.
  • the low melting point fiber may be a medium fiber or a hollow fiber.
  • the high-melting-point hollow fiber has a three-dimensionally crimped shape in a natural state.
  • the fluffy processed tow is also preferably a three-dimensionally crimped shape in a natural state, and the curled shape has a radius of curvature of 3 mm to 15 mm. If the radius of curvature is too small, the fluffiness is poor. If it is too large, the three-dimensional effect cannot be reflected, the fluffiness is affected, and the compression recovery rate is low.
  • the radius of curvature is more preferably 4 mm to 12 mm from the fluffy effect and the compression recovery effect.
  • the three-dimensionally crimped shape means that the fiber exhibits an irregular spiral structure in the long direction ( FIG. 4 ), and at the same time, due to the difference in alignment between a part of the monofilaments, the rotation mode and direction of the monofilaments are different. Multi-dimensional three-dimensional shape.
  • the sheath yarn in the bulky processed tow forming the core-sheath type fluffy processed tow is a mixed filament formed of a high melting point fiber and a low melting point fiber; and the core yarn is a filament formed of a high melting point fiber.
  • the sheath wire and the core wire intersect in the fluffy processed yarn, and the sheath fiber formed by the mixed fiber containing the high-melting-point hollow fiber of the preferred form forms a three-dimensional curl having a radius of 3 mm to 15 mm outside the core wire. Ring-shaped.
  • the diameter of the ring formed by the sheath wire is too small, the volume of the formed three-dimensional space is small, the bulkiness of the processed tow is not enough, and the clothes or beddings filled with it are relatively hard, without the fluffiness of the down, and the heat preservation performance is also lowered.
  • the ring formed by the sheath wire is larger, the bulkiness and flexibility of the processed tow are greatly improved, but the compression resistance is deteriorated, that is, the processed tow is permanently formed when pressed by an external force. The deformation causes poor performance.
  • the radius of the ring formed by the sheath wire outside the core wire is more preferably 4 mm to 12 mm.
  • the fineness of the core yarn and the sheath yarn constituting the fluffy processed yarn is preferably 20 to 300 dtex. It is particularly preferable that the core filament fineness is 30 to 250 dtex, and preferably the sheath yarn has a fineness of less than or equal to the fineness of the core filament. If the fineness is too fine, although the softness of the fiber increases, the pressure resistance of the ring formed by the sheath wire or the core wire may decrease. On the contrary, the greater the fineness of the fiber, the higher the rigidity, and the fluffyness obtained. The processed silk will be hard and the hand feel will be worse.
  • the fluffy processed tow of the present invention has a bulkiness of 400 to 800 inch 3 / 30 g as measured by IDFB.
  • the compression ratio is 50 to 95%, and the recovery rate is 50 to 95%.
  • test method involved in the present invention is as follows:
  • the measurement was carried out in accordance with JIS L1096-2010 standard.
  • the measurement was carried out according to the standard of GB/T 14272-2011.
  • the denier test was tested according to the JIS L 1013:2010 standard.
  • the hollow fiber is cut into a thin sheet (ie, a fiber cross section) in the longitudinal direction, and is photographed under a normal optical microscope to a suitable magnification, and the area S 1 of the hollow portion and the area S 2 of the entire fiber (including the hollow portion) are calculated from the photograph. And then calculate:
  • the fluffy processed tow is fixed at both ends, and the middle portion is in a free state, and is enlarged to a suitable magnification (observation magnification 150) under a common optical microscope to take a photograph, and then the sheath monofilament fiber and the core fiber in the fluffy processed tow are photographed according to the photograph.
  • the formed fusion bond points are counted, if the fusion bond points formed by the plurality of sheath fibers and the core fibers are at the same position, counted according to a fusion bond point, and finally converted into a fluffy processed tow unit length by photo magnification.
  • the number of molten bond points on the unit is /cm. The above method was carried out after 5 tests to calculate the average number, which is the number of fusion bonding points of the fluffy processed tow.
  • the yarn is curled by a ruler (for denier measurement) by 10 turns (1 m/turn), and then the sample to be tested is placed (suspended) for 8 h or more in a constant temperature and humidity environment (20 ° C ⁇ 65% RH). Make its state stable ( Figure 4), then select the curved part within 20 cm below the sample to measure the radius, select 20 different places to measure and then average, the obtained data is the radius of curvature.
  • the measuring instrument is a digital microscopy system (VHX-2000C) manufactured by KEYENCE. The magnification is 20 times.
  • the radius of curvature is measured by the calculation function of the radius of curvature in the software (Fig. 5). That is, the radius of curvature of the fiber is measured by crimping the three positions on the fiber.
  • the sample to be tested is placed in an environment of 20 ° C ⁇ 65% RH for 8 hours or more, so that the sample to be tested is stable;
  • the sample to be tested is placed in an environment of 20 ° C ⁇ 65% RH for 8 hours or more, so that the sample to be tested is stable;
  • the two ends of the filling material are sewn on a lining cloth with a length of 50cm*width and 50cm, and then sewed with a hood.
  • the drapes and linings are not stitched, and a sample is obtained, which is then in accordance with JIS standards. Wash 5 times; finally test the area of the filler inside the fabric bag before and after cleaning, and calculate the washing offset rate according to the following formula 3:
  • Washing offset rate (%) (filler area in the sample before washing - filling area in the sample after washing) / filling area in the sample before washing ⁇ 100% (3)
  • the feel style here includes softness and smoothness; the smaller the sample, the better the feel of the sample; when the washing offset rate exceeds 45%, The softness and smoothness of the sample were poor, and the finished product was unqualified.
  • the core wire is a high melting point hollow polyester PET fiber with a fineness of 160.0 dtex;
  • the sheath wire is a mixed fiber composed of the above high melting point hollow polyester PET fiber and low melting medium medium polypropylene PP fiber, and the fineness is 80.0 dtex, and the low melting point
  • the weight ratio of PP to the mixed filaments was 1.0% by weight.
  • the weight ratio of the sheath filament to the processed filament was 91% by weight.
  • the high melting point hollow polyester PET fiber has a three-dimensionally crimped shape in a natural state.
  • the sheath fibers and the core fibers were respectively fed into the coupler through different feeding rollers, the feeding speed of the core fibers was 20 m/min, and the feeding speed of the sheath fibers was 400 m/min.
  • the flow rate of the air in the nozzle was set to 70 L/min, and the sheath fibers and the core fibers were formed into a fluffy processed yarn through an air nozzle.
  • the fluffy processed tow is subjected to a padding coating by a silicon-based aqueous solution prepared by modifying a silicon-based smoothing agent (Zhumoto, DELION SFT-730) having a weight average molecular weight of 2,000 to 6,000 g/mol; and then the processed yarn is passed through a 2 hot box.
  • the silicon-based smoothing agent is fixed, and the obtained fluffy processed tow is finally collected and used.
  • the bulky processed tow has a bulkiness of 500 inch 3 /30 g
  • the amount of the silicone-based smoothing agent is 1.2 wt% of the total amount of the fluffy processed tow
  • the fluffy processed tow forms a three-dimensionally curly shape
  • the curled shape had a radius of curvature of 7.0 mm
  • the melted bonding point dispersed in the fluffy processed tow was 1/cm
  • the compression ratio was 92%
  • the recovery rate was 80%.
  • a polyester-cotton woven fabric (polyester/cotton content ratio of 65/35; gram weight of 110 g/m 2 and a total density of 180 / inch) was used as a cover cloth, and then a machine having a ventilation capacity of 150 cm 3 /cm 2 /s was used.
  • the fabric (polyester/cotton content ratio is 65/35; gram weight is 100g/m 2 , total density is 200/inch) is used as the lining cloth, the lining cloth is two layers, and the fluffy processed tow is used as the filling material, first the filling material is sewed The filling unit is formed on the lining cloth, and the two ends are fixedly integrated to form a filling unit, and then the six filling units are respectively filled in the six filling areas, and the filling unit and the cover cloth are not stitched to obtain a filling object.
  • the performance test results are shown in Table 1.
  • Example 1 The woven fabric of Example 1 with aeration of 150 cm 3 /cm 2 /s (polyester/cotton content ratio of 65/35; gram weight of 100 g/m 2 , total density of 200 / inch) was replaced by aeration.
  • Woven fabric of 250 cm 3 /cm 2 /s (polyester/cotton content ratio of 65/35; gram weight of 100 g/m 2 , total density of 300 / inch), the rest of the same as in Example 1, its performance test results See Table 1.
  • Example 1 The woven fabric of Example 1 with aeration of 150 cm 3 /cm 2 /s (polyester/cotton content ratio of 65/35; gram weight of 100 g/m 2 , total density of 200 / inch) was replaced by aeration.
  • 150cm 3 /cm 2 /s PET non-woven fabric, filling material core-sheath type fluffy processed tow is replaced by ordinary 160dtex-24f-polyester FDY, N 10, and the rest are the same as in the first embodiment, the performance test results See Table 1.
  • Example 1 The woven fabric of Example 1 with aeration of 150 cm 3 /cm 2 /s (polyester/cotton content ratio of 65/35; gram weight of 100 g/m 2 , total density of 200 / inch) was replaced by aeration.
  • the core wire is a high melting point hollow Polyester PET fiber, the fineness is 200.0dtex;
  • the sheath yarn is a mixed fiber composed of high melting point hollow polyester PET fiber and low melting point real copolymerized PET fiber, the fineness is 200.0dtex, and the low melting point copolymerized medium PET fiber accounts for The mass fraction of the mixed filaments was 49.0% by weight.
  • the sheath yarn accounts for 99% by weight of the processed silk.
  • the lining cloth in Example 1 was replaced by two layers, and the ventilation amount was not limited.
  • the woven fabric was limited to a woven fabric having a ventilation capacity of 150 cm 3 /cm 2 /s (polyester/cotton content ratio was 65/35; gram weight) It is 100 g/m 2 and the total density is 200 / inch), and the rest are the same as those in the first embodiment.
  • the performance test results are shown in Table 2.
  • Example 5 The cover cloth of Example 5 was replaced with a woven fabric having a ventilation capacity of 250 cm 3 /cm 2 /s (polyester/cotton content ratio of 65/35; gram weight of 100 g/m 2 , total density of 300 pieces/inch), The performance test results are shown in Table 2.
  • the performance test results are shown in Table 2.
  • the cover cloth of Example 5 was replaced with a PET nonwoven fabric having a ventilation amount of 150 cm 3 /cm 2 /s, and the filling material and the interlining cloth were sewn together, and the integrated method of sewing the cover cloth and the interlining cloth was replaced with
  • the filling material and the lining cloth are glued together, and the cover cloth and the lining cloth are glued together to form an integration;
  • the core wire is a high melting point hollow polyester PET fiber, the fineness is 200.0 dtex;
  • the sheath wire is made of a high melting point hollow polyester PET
  • the mixed fiber composed of fiber and low melting point real copolymerized PET fiber has a fineness of 200.0 dtex, and the low melting point copolymerized medium PET fiber accounts for 49.0 wt% of the mixed fiber.
  • the sheath yarn accounts for 99% by weight of the processed silk.
  • the performance test results are shown in Table 2.
  • the filling material in the embodiment 1 was replaced with pearl cotton, the filling material and the lining cloth were not sewn together, and the cover cloth and the lining cloth were sewn together, and the rest were the same as those in the first embodiment, and the performance test results are shown in Table 1.
  • Example 1 The fluffy processed tow in Example 1 is directly sewn together with the cover cloth to form an integration, and the rest are the same
  • Example 1 the performance test results of which are shown in Table 2.
  • the anti-slip property is better.
  • Example 1 It can be seen from Example 1 and Example 3 that under the same conditions, when a fluffy processed tow is used as a filling material, the bulkiness is superior to that of the non-fluffed yarn.
  • Example 1 the integrated method uses a method in which the hand feel is superior to the tape when sewing.
  • Example 1 It can be seen from Example 1 and Example 5 that under the same conditions, the washing offset ratio using the two-layer interlining is superior to the use of a layer of interlining.
  • Example 5 As is apparent from Example 5 and Comparative Example 2, in the case where the backing cloth, the cover cloth, and the filling material were directly sewn, the anti-slip property was remarkably deteriorated.
  • Example 1 and Comparative Example 1 it can be seen from Example 1 and Comparative Example 1 that when staple fiber cotton is used as the filling material, the filler and the interlining cannot be sewn together, the washing offset is poor, and the bulkiness is lowered.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
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  • Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)

Abstract

一种填充物体，其设置有罩布、衬布和填充材料，所述罩布形成至少一个填充区域，所述填充材料为长纤维棉，填充材料排列在衬布内并与衬布一体化后形成填充单元，填充单元填充在填充区域内，并且填充单元和罩布之间为非连接状态。填充物体能够提高防漏绒性，改善洗涤后填充材料发生偏移、结块的问题。另外填充物体的蓬松性优良，不仅具有轻量保暖的特性，还具有手感柔软滑爽的风格，同时耐机洗性能优越，可以替代羽绒填充制品用途使用。

Description

一种填充物体 技术领域
本发明涉及一种填充物体，其设置有罩布、衬布和填充材料。
背景技术
现今市场上，在众多种类的保温填充物中，羽绒为高级保温填充物。羽毛的蓬松性优异且保温性能高，长期占据着制成被子或羽绒服的羽毛制品的高级材料的地位。
但是，天然的羽毛来自于水禽，存在着诸多缺陷。例如，①生产成本高，供给量有限，并且其价格易受市场供求而发生较大变动；②生产过程中会产生大量污水、废水等，从而带来污染环境的问题，羽毛要是洗涤不充分则会导致恶臭，因此需要事先将导致恶臭的污物除去；③难以洗涤，多数羽绒制品不宜机洗，由于羽绒的面料密度大，用洗衣机洗衣服会鼓起来并漂在水面上导致洗不干净，同时也容易发生羽绒偏移导致局部保暖性变差。虽然普通的纯棉填充物不存在天然羽绒的上述缺陷，但因其厚重、保暖性差，易漏绒而不被广泛用于衣物填充。
化纤填充物如珍珠棉等，既具备了天然羽绒的轻量的风格，又具有防菌防潮、成本安定、价格便宜等的优点，但其蓬松性还不够高，保暖性还与羽绒相差甚远，同时也不易机洗。
中国专利CN103097280A公开了一种填充物体，其内部的填充物是用芯丝将花式丝一体化而成的长纤维填充棉，花式丝被开纤形成环状纤维，长纤维棉在至少一个方向上被多根地并丝，并随罩布一起被缝制而与罩布一体化。该申请为将长纤维棉和罩布缝制在一起后形成的填充物体，缝制针眼处可能发生漏绒现象，另外，此发明需要先进行芯丝和花式丝的加捻一体化再进行花式丝的开纤处理等工序，工艺复杂，且长纤维填充棉蓬松性、柔软性、压缩后的回复性等存在欠缺。
综上所述，为了适应市场需求，迫切需要开发一种防漏绒性好，蓬松、轻量、保暖的填充物体。
发明内容
本发明的目的在于提供一种防漏绒性好，具有蓬松、轻量、保暖等优异性能，且使用中或洗涤后填充材料的集中少，不易发生偏移，蓬松度高的填充物体。
本发明的技术解决方案是：
本发明的填充物体，其设置有罩布、衬布和填充材料，所述罩布形成至少一个填充区域，所述填充材料为长纤维棉，填充材料排列在衬布内并与衬布一体化后形成填充单元，填充单元填充在填充区域内，并且填充单元和罩布之间为非连接状态。
本发明的填充物体，作为填充材料的长纤维棉优选为由N根芯鞘型蓬松加工丝形成的蓬松加工丝束，N为1以上；所述芯鞘型蓬松加工丝的鞘丝是由高熔点纤维和低熔点纤维形成的混纤丝；芯丝为高熔点纤维形成的长丝，并且蓬松加工丝束中含有分散的熔融粘合点。
本发明的填充物体，衬布为一层时，优选罩布的通气量为1～200cm 3/cm 2/s；衬布为两层时，优选衬布的通气量为1～200cm 3/cm 2/s。
本发明的填充物体，优选填充单元中填充材料和衬布的近两端位置或者中间位置的至少一处被缝制在一起。
发明的填充物体，优选混纤丝中的低熔点纤维占混纤丝的重量比为0.1～50wt％；所述蓬松加工丝束的鞘丝总量占蓬松加工丝束总量的重量比为60～99wt％。
发明的填充物体，优选蓬松加工丝中的高熔点纤维与低熔点纤维的熔点差为20℃～150℃。
发明的填充物体，进一步优选蓬松加工丝中的高熔点纤维为聚酯纤维；低熔点纤维为改性共聚合低熔点聚酯、聚丙烯、聚乙烯或尼龙纤维中的至少一种。
发明的填充物体，更进一步优选高熔点纤维聚酯纤维为中空纤维，且中空率为20～50％。
发明的填充物体，优选蓬松加工丝束中含有的分散熔融粘合点的数量为1～40个/cm。
发明的填充物体，优选蓬松加工丝束在自然状态下为三维立体的卷曲形状，且卷曲形状的曲率半径为3mm～15mm。
本发明所使用的优选填充材料蓬松加工丝束，通过IDFB测试的蓬松性为400～800inch3/30g。
综上所述，因为目前填充物体如被子、防寒服、被褥等存在漏绒性差、耐洗涤性差、厚重、不蓬松的问题，所以本发明要解决的问题是通过添加衬布来提高防漏绒性，改善洗涤后填充材料发生偏移、结块的问题，另外，通过使用蓬松加 工丝束作为填充物解决了填充物体厚重、保暖性差、不蓬松的问题。
附图说明
图1是本发明的填充单元的构造示意图例。其中，
1：罩布；2：衬布；3：长纤维棉；4：长纤维棉的鞘丝；5：长纤维棉的芯丝；6：衬布与长纤维棉的连接处。
图2是本发明的填充物体的实物例的侧面图。
图3是本发明的填充材料例的实物图。
图4为长纤维棉在自然状态下的三维立体的卷曲形状图。
图5为曲率半径的测量示意图。
具体实施方式
因为目前填充物体如被子、防寒服，被褥等存在漏绒性差，耐洗涤性差，厚重，不蓬松的问题，所以本发明要解决的问题是通过添加衬布来提高防漏绒性，改善洗涤后发生偏移，结块的问题，另外，通过使用蓬松加工丝束作为填充物解决了填充物体厚重、保暖性差、不蓬松的问题。
本发明的填充物体，没有特别的限定，可以是服装用途，也可以是家居等用途的各类填充物体。可以列举的是防寒服、被子、褥子、睡袋、靠垫、围毯、外套、围脖等等。
本发明的填充物体，设置有罩布、衬布和填充材料，所述罩布形成至少一个填充区域，所述填充材料为长纤维棉，填充材料排列在衬布内并与衬布一体化后形成填充单元，填充单元填充在填充区域内，并且填充单元和罩布之间为非连接状态。
因为填充材料为长纤维棉，所以可以跟衬布形成一体化的连接关系。这里所说的填充材料和衬布一体化后形成填充单元，可以理解为填充材料和衬布之间直接连接。这里所说的一体化，是指两部分材料之间有一定牢度的部分重叠的结合，可以抵挡一定外力的揉搓、拉扯，而不致于两者很轻易地就被分离。具体地说，可以是通过使用胶带进行直接连接，也可以是通过缝制进行直接连接，另外还可以通过超音波、熔融贴合进行直接连接，以达到一体化。当使用胶带的方式进行一体化时，工程稍微复杂，成本稍高，另外因为胶带有一定宽度，胶带处的保温性相对来说变差；另外使用超音波和熔融贴合的方式会使填充物体手感略硬，使用舒适性略差，所以优选通过缝制的方法，将填充材料与衬布一体化后形成填充 单元。
本发明的填充物体，具有一个以上的填充区域。即，可以是一个填充单元填充一个填充区域，也可以是多个填充单元填充多个填充区域。填充区域的个数没有特别限定，尺寸也没有特别的限定，一个填充物体中的多个填充区域的尺寸可以相同，也可以不相同。可以根据用途进行自由设定。如果说填充区域的个数为M的话，那么当填充物体为坐垫时，M数优选为1；当填充物体为被子时，M数优选为4～8；当填充物体为羽绒服时，M数优选为20～50。
另外，本发明中，填充单元中填充材料和衬布一体化的形式优选是填充材料和衬布的近两端位置或者中间位置的至少一处被缝制在一起。根据用途的需要，可以做适当的调整。通过这样的设计，既能保持填充材料的蓬松性，又能避免填充材料透过罩布的针眼等漏出罩布表面，避免填充物体内部填充材料的堆积问题。即便是反复洗涤的情况下，填充材料的移动离位也会受到限制，填充物的集中现象减少，蓬松度提高。而填充单元和罩布之间为非连接状态,填充单元直接填充在填充区域，可以满足既蓬松又不移动的效果。
本发明的罩布，可以是机织或者针织布，所用纤维原料没有特别的限定，表层和里层可以是相同的面料，也可以选用不同的面料。
本发明的衬布，可以是无纺布，机织或者针织布，所用纤维原料没有特别的限定。
本发明的衬布，可以是一层，也可以是两层，也就是说可以在填充材料的一面，也可以在填充材料的两面进行直接连接。
本发明的衬布和罩布，随着通气量的降低，透气性有变差的趋势，随着通气量的增加，漏绒性会有变差的趋势。且如果通气量太小，可能会有闷热的感觉；如果通气量太大，可能会有漏绒现象发生。因此，考虑到透气性以及防漏绒性这两方面的性能，所以衬布或者罩布优选通气量为1～200cm 3/cm 2/s的无纺布、机织或者针织布。更具体的，优选以下两种技术方法：一、衬布为一层且所述罩布的通气量为1～200cm 3/cm 2/s；二、衬布为两层且所述衬布的通气量优选为1～200cm 3/cm 2/s。
本发明衬布的设计，还可以带来操作上的便利性。先将衬布和填充材料长纤维棉进行一体化后形成填充单元，填充单元填充在填充区域内，并且填充单元和罩布之间为非连接状态，这样的方法，一方面衬布为两层时衬布本身也可以提高 防漏绒性能，从而使填充物体不容易发生漏绒现象，另外还可以灵活多变地适用于各种用途的填充物体。
在优选的缝制情况下，本发明的填充材料和衬布一体化可以是将填充材料缝制在衬布上，缝制部位无特别的限制。可以在两端、两端的附近或者中间位置的至少一处进行缝制而将填充材料和衬布进行一体化后形成填充单元，如果本发明的填充物体是靠垫、围脖等填充尺寸较小的填充物体时，一般在填充材料和衬布的近两端或者中间位置的至少一处被缝制就可形成具有蓬松性好，洗涤偏移率低的填充包；当填充物体是防寒服、外套这种尺寸的填充物体时，一般来说，填充单元不是太长也不是太宽，可以选用填充材料和衬布的近两端位置中的一处或者是两处，或者是近两端位置中的一处和中间位置缝制的形式，这样就可得到具有蓬松性好，洗涤偏移率低的填充单元；而当填充物体是被子、睡袋这类尺寸较大的填充物体时，如果是填充区域设置得比较少的情况下，考虑到填充单元比较长，其填充材料和衬布一体化的形式可以选用填充材料和衬布的近两端位置和中间位置共三处全部被缝制在一起；而如果是填充区域设置得比较多的情况下，考虑到填充单元不是很长，其填充材料和衬布一体化的形式可以选用只是填充材料和衬布的近两端位置共两处被缝制在一起。
例如，做靠垫时，具体缝制方法有如下几种：
A.首先将填充材料跟一层衬布缝制在一起，在两端、两端附近位置或者中间位置进行缝制成一体化后形成填充单元，填充单元填充在填充区域内，填充单元和罩布之间无需进行缝合，从而制作成填充物体；
B.先将衬布进行缝合后，将填充材料填充在缝制好的两层衬布空心管中，然后再将填充好的衬布和填充材料进行两端、两端附近或者中间位置进行缝制成一体化后形成填充单元，填充单元填充在填充区域内，填充单元和罩布之间无需进行缝合，从而制作成填充物体。
又如，做被子时，具体缝制方法有如下几种：
A.首先将填充材料跟一层衬布缝制在一起，在两端、两端附近和中间位置进行缝制成一体化后形成填充单元，填充单元填充在填充区域内，填充单元和罩布之间无需进行缝合，从而制作成填充物体；
B.先将衬布进行缝合后，将填充材料填充在缝制好的两层衬布空心管中，然后再将填充好的衬布和填充材料进行两端，两端附近和中间位置进行缝制成一体 化后形成填充单元，填充单元填充在填充区域内，填充单元和罩布之间无需进行缝合，从而制作成填充物体。
本发明所述的填充材料长纤维棉，没有特别的限定，可以选用普通涤纶或尼龙等的DTY或FDY长纤维，也可以选用它们的卷曲纤维，考虑到填充物体的蓬松性和保暖性，优选由N根芯鞘型蓬松加工丝形成的蓬松加工丝束作为填充材料长纤维棉使用，N为1以上，从保暖性和轻量性考虑，优选N为6以上，更优选N为9以上，使用了这样的蓬松加工丝束的填充物体，其洗涤时内部填充材料的偏移会很小，蓬松性很好。
本发明优选的填充材料芯鞘型蓬松加工丝束，是含有N根由芯丝和鞘丝通过空气交络加工一体化而成的蓬松加工丝。所述蓬松加工丝的芯丝和鞘丝至少一种是由高熔点纤维和低熔点纤维形成的混纤丝；所述蓬松加工丝束中含有分散的熔融粘合点为1以上。
本发明优选的填充材料蓬松加工丝束，优选其中的蓬松加工丝的鞘丝是由高熔点纤维和低熔点纤维形成的混纤丝；芯丝为高熔点纤维形成的长丝。
本发明优选的填充材料蓬松加工丝束，优选由高熔点纤维和低熔点纤维形成的混纤丝中的低熔点纤维占混纤丝的重量比为0.1～50wt％。
本发明优选的填充材料蓬松加工丝束，优选鞘丝总量占蓬松加工丝束总量的重量比为60～99wt％。
本发明优选的填充材料蓬松加工丝束，优选蓬松加工丝中的高熔点纤维与低熔点纤维的熔点差为20℃～150℃。
本发明中所述的高熔点纤维和与低熔点纤维是相互关联的，并非是指特定数值以上或以下熔点的纤维，而是指具有一定熔点差的两种纤维。也可以表达为熔点高的纤维和熔点低的纤维。所述的熔点差的范围优选是20℃～150℃，熔点差高于20℃的话，蓬松加工丝束形成熔融粘合点的数量可以满足发明需要；低于150℃的话，低熔点纤维的耐热性不至于影响其加工性，因而成为优选。从手感以及抵抗偏移的角度考虑，进一步优选熔点差为20℃～100℃。
本发明优选的填充材料芯鞘型蓬松加工丝束，因为经过了热处理，丝束中含有的混纤丝中的低熔点纤维发生了部分融化，体现为部分为自身融着，部分融断，部分粘合在熔点高的纤维上，从而使得蓬松加工丝束中形成了分散的熔融粘合点。
本发明的蓬松加工丝束中，混纤丝中的低熔点纤维占混纤丝的重量比范围优 选为0.1～50wt％。混纤丝中的低熔点纤维的含量在0.1～30wt％范围内时，熔融粘合点个数足够，并且制成品的洗涤偏移小，因而成为更优选。而高于30wt％时，虽然也能使用，但是相比而言，熔融粘合点偏多，蓬松加工丝的蓬松度偏低，并且手感稍差。
本发明的芯鞘型蓬松加工丝束中，鞘丝占蓬松加工丝的重量比范围优选是60～99wt％，更优选80～99wt％。鞘丝的重量比低于60wt％时，加工丝束的蓬松度稍低。
形成蓬松加工丝束的芯鞘型蓬松加工丝，其芯丝和鞘丝至少一种是由高熔点纤维和与低熔点纤维组成的混纤丝。当芯丝和鞘丝单独或者都是由高熔点纤维和与低熔点纤维组成的混纤丝时，在热处理后，混纤丝中的低熔点纤维发生了部分融化，体现为部分为自身融着，部分融断，部分粘合在熔点高的纤维上，从而形成了蓬松加工丝束中分散的熔融粘合点，达到本发明所期待的效果。熔融粘合点能够提高鞘丝被开纤形成的环状纤维的稳定性，提高压缩回复率，除此之外，在作为保温填充物时，熔融粘合点可以提高与其面料接触的摩擦力，从而抑制该保温填充物诸多情况下的偏移，比如洗涤偏移、穿着偏移等。
本发明优选的填充材料蓬松加工丝束，优选丝束中含有的分散熔融粘合点的数量为1～40个/cm。这些分散的熔融粘合点在不影响蓬松性的前提下，对蓬松加工丝束的形状固着有良好的作用。分散的熔融粘合点过少，形状固着效果不够；分散的熔融粘合点过多，虽然形状固着效果好，但是蓬松性、柔然性等受到抑制。熔融粘合点数越多，形状固着即抵抗偏移效果越好，但是相对来说手感偏硬，蓬松性略差。综上考虑，更优选1～20个/cm。控制熔融粘合点在20个/cm以下的话，制成的蓬松加工丝束手感更好，蓬松性更高。
形成芯鞘型蓬松加工丝束的蓬松加工丝，优选鞘丝是由高熔点纤维和低熔点纤维形成的混纤丝；芯丝为高熔点纤维形成的长丝。鞘丝的混纤丝中的高熔点纤维和芯丝的高熔点纤维可以相同，也可以不同，但是需要满足高熔点纤维的熔点高于低熔点纤维的熔点的条件。
芯鞘型蓬松加工丝中的高熔点纤维与低熔点纤维的熔点差为20℃～150℃，优选20℃～100℃。只要是满足上述条件的聚合物，就可以作为本发明的两种纤维的成纤聚合物使用。可以具体列举的是常规熔点的聚酯纤维和低熔点的改性共聚合聚酯，常规熔点的聚酯纤维和聚丙烯纤维，或者是聚丙烯纤维和聚乙烯纤维 的组合等。
本发明高熔点纤维优选是聚酯纤维，低熔点纤维是相对于高熔点纤维来说熔点稍低的纤维，优选是改性共聚合低熔点聚酯、聚丙烯、聚乙烯或尼龙纤维中的至少一种。
高熔点纤维的断面可以为圆形、中空、三角、十字、八叶等中的一种或者几种；优选为中空纤维。高熔点纤维作为蓬松加工丝束的主要构成成分，其性能对使用了本发明丝束的填充物体的重量以及保温性能，有决定性的作用。优选为中空纤维的话，填充物体的轻量性和保温性都会有大幅的提高。
高熔点中空纤维的中空度越高加工丝束的轻量感越明显、蓬松度越高。但是中空度过高的话，纤维制造工艺复杂，并且容易变形，品质低下，生产率低下。考虑到纺丝稳定性、纤维力学性能等，优选高熔点中空纤维的中空率为20～50％，更优选25～45％。
低熔点纤维，可以为中实纤维，也可以为中空纤维。
优选高熔点中空纤维在自然状态下为三维立体的卷曲形状。
从而，所述蓬松加工丝束也优选在自然状态下为三维立体的卷曲形状，且卷曲形状的曲率半径为3mm～15mm。曲率半径太小的话，蓬松性差，太大的话，无法体现三维立体效果，影响蓬松性，压缩回复率低下。从蓬松效果以及压缩回复效果来说，曲率半径更优选为4mm～12mm。
所述三维立体的卷曲形状是指纤维在长方向上呈现为不规则的螺旋结构(图4)，同时因为一部分单丝之间存在配向的差异，导致单丝之间旋转方式、方向不同而形成多维度立体形态。
作为本发明的优选形态，形成芯鞘型蓬松加工丝束的蓬松加工丝束中的鞘丝是由高熔点纤维和低熔点纤维形成的混纤丝；芯丝为高熔点纤维形成的长丝。此形态下，蓬松性加工丝中鞘丝和芯丝交叉，且含有了优选形态的高熔点中空纤维的混纤丝所形成的鞘丝纤维在芯丝外形成半径为3mm～15mm三维立体的卷曲圆环状。鞘丝形成的圆环直径过小，形成的立体空间的体积就小，加工丝束的蓬松性不够，用它填充后的衣物或寝具比较硬实，没有羽绒的蓬松感，保温性能也会下降。反之，虽然鞘丝形成的圆环越大加工丝束的蓬松性和柔软性会有很大的提高，但是耐压缩性能会变差，也就是该加工丝束受外力挤压时会形成永久性的变形，导致性能低下。鞘丝在芯丝外所形成的圆环的半径更优选4mm～12mm。
构成蓬松加工丝的芯丝和鞘丝的纤度优选为20～300dtex。特别优选芯丝纤度为30～250dtex，并且优选鞘丝的纤度小于或等于芯丝的纤度。纤度太细的话虽然纤维的柔软性增加，但是鞘丝和或芯丝所形成的圆环的耐压能力反而会下降；反之，纤维的纤度越大所具有的刚性就越高，制得的蓬松加工丝就会偏硬，手感变差。
本发明的蓬松加工丝束，通过IDFB测试的蓬松性为400～800inch 3/30g。
其压缩率为50～95％，回复率为50～95％。
本发明涉及的测试方法如下：
(1)通气量
根据JIS L1096-2010标准进行测定。
(2)漏绒量
根据GB/T 14272-2011法标准进行测定。
(3)纤度的测试方法
纤度的测试根据JIS L 1013:2010标准测试。
(4)中空率
将中空纤维沿纵向切断成薄片(即纤维横截面)，在普通光学显微镜下放大到合适的倍率进行拍照，根据照片计算出中空部分的面积S 1和纤维整体的面积S 2(包括中空部)，然后计算：
中空率＝(S 1/S 2)×100％。
(5)蓬松加工丝束的熔融粘合点个数的测试方法
将蓬松加工丝束两端固定，中间部分成自由状态，在普通光学显微镜下放大到合适的倍率(观察倍率150)进行拍照，然后根据照片对蓬松加工丝束中的鞘单丝纤维和芯纤维所形成的熔融粘合点进行计数，如果多根鞘纤维和芯纤维形成的熔融粘合点在同一位置，按照一个熔融粘合点计数，最后通过照片放大倍率进行换算得到蓬松加工丝束单位长度上的熔融粘合点个数，单位为个/cm。上述方法进行5回测试后算出平均数，即为蓬松加工丝束的熔融粘合点个数。
(6)蓬松加工丝束的曲率半径测试方法
将纱线通过检尺机(纤度测定用)将样品卷曲10圈(1米/圈)，然后将待测试样品在恒温恒湿环境(20℃×65％RH)放置(吊挂)8h或以上使其状态稳定(如图4)，然后选取样品下方20厘米内弯曲部分进行半径测量，选取20个不同地方 测量后取平均，所得数据即为曲率半径。测量仪器为基恩士(KEYENCE)产的数码显微系统(VHX-2000C)，放大倍率为20倍，通过软件中曲率半径的计算功能进行曲率半径的测定(如图5)。即通过卷曲纤维上的三个位置来测量纤维的曲率半径。
(7)蓬松度
根据IDFB方法进行测试：
①首先将待测试样放置在20℃×65％RH的环境中调试8小时或8小时以上，使得待测试样稳定；
②称取试样30g，手动将其抖动到蓬松状态后将其放入测量桶内并盖上盖子；
③将重量盘向下移动至接触试样的最高点，然后放开重量盘使其自由下落，放开重量盘的同时计时，稳定1分钟后读出高度并记录；
④打开盖子取出试样，再次将其抖动至蓬松状态，放入测量桶内盖上盖子，按照步骤③再次测量，同样的方法测试5次；
⑤算出5次的平均高度后通过计算得出蓬松度。
(8)压缩率和回复率的测试方法
①首先将待测试样放置在20℃×65％RH的环境中调试8小时或8小时以上，使得待测试样稳定；
②称取试样30g，手动将其抖动到蓬松状态后将其放入IDFB法中同样的量桶内并盖上盖子；
③将与IDFB法中同样的重量盘W 0向下移动至接触试样的最高点，然后放开重量盘使其自由下落，放开重量盘的同时计时，稳定1分钟后读出高度并记录H 0；
④打开盖子将比原来重量盘W 0重40倍的重量盘W 1，放入测量桶内，重量盘W 1向下移动至接触试样的最高点，然后放开重量盘使其自由下落，放开重量盘的同时计时，稳定1分钟后读出高度并记录H 1；
⑤打开盖子撤掉所有重量，让测试样品在自由状态下回复24h，待其稳定后，按步骤③的方法测试出样品高度并记录为H 2；
⑥根据以上数据通过下公式1和公式2计算出压缩率和回复率：
压缩率(％)＝(H 0－H 1)/H 0×100％            (1)，
回复率(％)＝(H 2－H 1)/(H 0－H 1)×100％      (2)，
⑦重复①～⑥的方法测试5回取平均值。
(9)洗涤偏移率的评价方法
将填充材料两端，两端附近或者中间位置缝制在一层长50cm*宽50cm的衬布上，然后用罩布套起来缝合，罩布跟衬布无需缝合，得到一个样品，再按照JIS标准进行清洗5回；最后测试出清洗前后面料包内部的填充物的面积，根据以下公式3计算出洗涤偏移率：
洗涤偏移率(％)＝(洗涤前样品内填充物面积－洗涤后样品内填充物面积)/洗涤前样品内填充物面积×100％        (3)
其中，洗涤偏移率越大，则说明样品的手感风格越差，这里的手感风格包括柔软性及滑爽感；越小则说明样品的手感风格越好；当洗涤偏移率超过45％时，则样品的柔软性及滑爽感较差，制成的成品不合格。
以下通过实施例来说明本发明的内容，但是本发明并不局限于实施例所列内容。
实施例1：
芯丝是高熔点中空聚酯PET纤维，纤度是160.0dtex；鞘丝是由上述高熔点中空聚酯PET纤维和低熔点中实聚丙烯PP纤维组成的混纤丝，纤度是80.0dtex，低熔点PP占混纤丝的重量比是1.0wt％。鞘丝占加工丝的重量比是91wt％。高熔点中空聚酯PET纤维在自然状态下为三维立体的卷曲形状。
将鞘纤维和芯纤维通过不同的喂入罗拉分别喂入交络器中，芯纤维的喂入速度为20m/min，鞘纤维的喂入速度为400m/min。设置喷嘴内空气的流速为70L/分，鞘纤维和芯纤维通过空气喷嘴形成蓬松加工丝。然后将得到的蓬松加工丝通过1热箱(170℃)进行预热处理，之后将N＝10根蓬松加工丝进行合并成蓬松加工丝束。然后，蓬松加工丝束经过重均分子量2000～6000g/mol的改性硅系平滑剂(竹本，DELION SFT-730)调制成的硅系水溶液进行浸轧涂层；再将加工丝经过2热箱固着硅系平滑剂，最终将得到的蓬松加工丝束进行收集待用。
经测试，所得到的蓬松性加工丝束的蓬松度为500inch 3/30g，硅系平滑剂附着量占蓬松加工丝束总量的1.2wt％，蓬松加工丝束形成三维立体的卷曲形状，且卷曲形状的曲率半径为7.0mm，蓬松加工丝束中分散的熔融粘合点1个/cm，压缩率为92％，回复率为80％。
将涤棉机织物(涤纶/棉含量比为65/35；克重为110g/m 2，总密度为180根/英寸)作为罩布，然后将通气量为150cm 3/cm 2/s的机织物(涤纶/棉含量比为65/35；克重为100g/m 2，总密度为200根/英寸)做衬布，衬布为两层，将蓬松加 工丝束作为填充材料，首先将填充材料缝制在衬布上，两端和中间位置三处进行固定一体化后形成一个填充单元，然后将6个填充单元分别填充在6个填充区域内，填充单元和罩布无需缝合，得到填充物体。其部分形状可参考图2的例。其各项性能测试结果见表1。
实施例2：
将实施例1的通气量为150cm 3/cm 2/s的机织物(涤纶/棉含量比为65/35；克重为100g/m 2，总密度为200根/英寸)替换为通气量为250cm 3/cm 2/s的机织物(涤纶/棉含量比为65/35；克重为100g/m 2，总密度为300根/英寸)，其余同实施例1，其各项性能测试结果见表1。
实施例3：
将实施例1的通气量为150cm 3/cm 2/s的机织物(涤纶/棉含量比为65/35；克重为100g/m 2，总密度为200根/英寸)替换为通气量为150cm 3/cm 2/s的PET无纺布，填充材料芯鞘型蓬松加工丝束替换为普通的160dtex-24f-涤纶FDY，N＝10根，其余同实施例1，其各项性能测试结果见表1。
实施例4：
将实施例1的通气量为150cm 3/cm 2/s的机织物(涤纶/棉含量比为65/35；克重为100g/m 2，总密度为200根/英寸)替换为通气量为150cm 3/cm 2/s的PET无纺布，另外将填充材料和衬布缝制在一起，一体化方法替换为填充材料和衬布用胶带粘在一起形成一体化；另外，芯丝是高熔点中空聚酯PET纤维，纤度是200.0dtex；鞘丝是由高熔点中空聚酯PET纤维和低熔点中实共聚合PET纤维组成的混纤丝，纤度是200.0dtex，低熔点共聚合中实PET纤维占混纤丝的质量分数是49.0wt％。鞘丝占加工丝的质量分数是99wt％。
其余同实施例1，其各项性能测试结果见表1。
实施例5：
将实施例1中的衬布由两层替换为一层，通气量不限定，将罩布限定为通气量150cm 3/cm 2/s的机织物(涤纶/棉含量比为65/35；克重为100g/m 2，总密度为200根/英寸)，其余同实施例1，其各项性能测试结果见表2。
实施例6：
将实施例5的罩布替换为通气量为250cm 3/cm 2/s的机织物(涤纶/棉含量比为65/35；克重为100g/m 2，总密度为300根/英寸)，其各项性能测试结果见表2。
实施例7：
将实施例5的罩布替换为通气量为150cm 3/cm 2/s的PET无纺布，填充材料芯鞘型蓬松加工丝束替换为普通的160dtex-24f-涤纶FDY，N＝10根，其各项性能测试结果见表2。
实施例8：
将实施例5的罩布替换为通气量为150cm 3/cm 2/s的PET无纺布，另外将填充材料和衬布缝制在一起，罩布和衬布缝制在一起的一体化方法替换为填充材料和衬布用胶带粘在一起，罩布和衬布粘在一起，形成一体化；另外，芯丝是高熔点中空聚酯PET纤维，纤度是200.0dtex；鞘丝是由高熔点中空聚酯PET纤维和低熔点中实共聚合PET纤维组成的混纤丝，纤度是200.0dtex，低熔点共聚合中实PET纤维占混纤丝的质量分数是49.0wt％。鞘丝占加工丝的质量分数是99wt％。其各项性能测试结果见表2。
比较例1：
将实施例1中的填充材料替换为珍珠棉，填充材料和衬布不缝制在一起，罩布和衬布缝制在一起，其余同实施例1，其各项性能测试结果见表1。
比较例2：
将实施例1中的蓬松加工丝束直接与罩布缝制在一起，形成一体化，其余同
实施例1，其各项性能测试结果见表2。
根据表1和表2，分析如下。
由实施例1和实施例2可知，同等条件下，衬布的通气量200cm 3/cm 2/s以下时，防漏绒性更好。
由实施例1和实施例3可知，同等条件下，使用蓬松加工丝束作为填充材料时，蓬松度优于非蓬松加工丝。
由实施例1和实施例4可知，一体化方法使用缝制时，手感优于胶带的方法。
由实施例1和实施例5可知，同等条件下，使用两层衬布的洗涤偏移率优于使用一层衬布。
由实施例5和比较例2可知，不加衬布、罩布与填充材料直接缝制的情况下，防漏绒性明显变差。
由实施例1和比较例1可知，使用短纤维棉作为填充材料时，填充材料和衬布不能缝制在一起，洗涤偏移性差，蓬松度降低。
表1
表2
Figure PCTCN2017117915-appb-000002

Claims (11)

  1. 一种填充物体，其特征是：所述填充物体设置有罩布、衬布和填充材料，所述罩布形成至少一个填充区域，所述填充材料为长纤维棉，填充材料排列在衬布内并与衬布一体化后形成填充单元，填充单元填充在填充区域内，并且填充单元和罩布之间为非连接状态。
  2. 根据权利要求1所述的填充物体，其特征是：所述长纤维棉为由N根芯鞘型蓬松加工丝形成的蓬松加工丝束，N为1以上；所述芯鞘型蓬松加工丝的鞘丝是由高熔点纤维和低熔点纤维形成的混纤丝；芯丝为高熔点纤维形成的长丝，并且蓬松加工丝束中含有分散的熔融粘合点。
  3. 根据权利要求1所述的填充物体，其特征是：所述衬布为一层且所述罩布的通气量为1～200cm 3/cm 2/s。
  4. 根据权利要求1所述的填充物体，其特征是：所述衬布为两层且所述衬布的通气量为1～200cm 3/cm 2/s。
  5. 根据权利要求1所述的填充物体，其特征是：所述填充材料与衬布一体化的形式是填充材料和衬布的近两端位置或者中间位置的至少一处被缝制在一起。
  6. 根据权利要求2所述的填充物体，其特征是：所述混纤丝中的低熔点纤维占混纤丝的重量比为0.1～50wt％；所述蓬松加工丝束的鞘丝总量占蓬松加工丝束总量的重量比为60～99wt％。
  7. 根据权利要求2所述的填充物体，其特征是：所述蓬松加工丝中的高熔点纤维与低熔点纤维的熔点差为20℃～150℃。
  8. 根据权利要求6所述的填充物体，其特征是：所述蓬松加工丝中的高熔点纤维为聚酯纤维；低熔点纤维为改性共聚合低熔点聚酯、聚丙烯、聚乙烯或尼龙纤维中的至少一种。
  9. 根据权利要求7所述的填充物体，其特征是：所述高熔点纤维聚酯纤维为中空纤维，且中空率为20～50％。
  10. 根据权利要求2所述的填充物体，其特征是：所述蓬松加工丝束中含有的分散熔融粘合点的数量为1～40个/cm。
  11. 根据权利要求2所述的填充物体，其特征是：所述蓬松加工丝束在自然状态下为三维立体的卷曲形状，且卷曲形状的曲率半径为3mm～15mm。
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