JP7039049B2 - How to make a comforter - Google Patents

Description

The present invention relates to a comforter middle material and a comforter.

Using a good quality comforter will improve your sleep quality. The comforter is composed of a middle material made of cotton, feathers, etc., and sheets covering the middle material. In particular, down comforters that use feathers as the middle material are popular because they have excellent heat retention and moisture release properties.

Here, Patent Document 1 is provided with an opening for inserting and removing the duvet, and a feather layer containing feathers is contained substantially over one side of the duvet cover, and the feather layer is contained over substantially the entire other side of the duvet cover. A duvet cover is disclosed in which a resin fiber layer containing a three-dimensional structure in which resin fibers are knitted is contained, and a duvet is located between the feather layer and the resin fiber layer.

Utility Model Registration No. 3208977

Feather comforters may be criticized from the viewpoint of animal welfare depending on the method of collecting feathers. Also, people with bird allergies may find it difficult to use a down comforter.
Cited Document 1 describes that the comforter to be put in the comforter cover may be a comforter, but the three-dimensional structure itself is not used as a comforter. Further, as a specific description when used as a comforter, it is only described in Example 5 that the resin fiber layer is eliminated and the comforter is inserted between the feather layers.
Therefore, an object of the present invention is to provide a recyclable comforter medium material and a comforter, which have excellent heat retention and moisture release properties, are easy to wash, and do not use animal-derived materials such as feathers.

In the method for producing a quilt of the present invention according to claim 1 , a plurality of filamentous molten resins 20 are entangled by cooling the molten resin obtained by melting and kneading a thermoplastic resin at a predetermined temperature by flowing it down into a filament. A quilt middle material 1 made of a knitted resin net-like structure having a bulk density of 0.010 g / cm ³ or more and 0.015 g / cm ³ or less partially heat-welded is formed, and the quilt middle material 1 is covered with a quilt cover. It is characterized by covering and quilting .

The present invention according to claim 2 is characterized in that, in the method for manufacturing a comforter according to claim 1, the wire diameter of the knitting resin 21 of the knitting resin net-like structure is 0.3 mm or more and 1.0 mm or less. ..

According to the third aspect of the present invention, in the method for manufacturing a comforter according to the first or second aspect, the knitted resin net-like structure is formed with thermocompression-bonded portions 2 thermocompression-bonded in the thickness direction at predetermined intervals. It is characterized by .

According to the fourth aspect of the present invention, in the method for manufacturing a comforter according to any one of claims 1 to 3, a knitted resin net-like structure covered with a comforter cover is provided with JIS L 1096 (woven fabric and knitted fabric). The amount of air measured according to the Frazier form method of the above-mentioned fabric test method) is 3 cm ³ / cm ² · s or less.

According to the fifth aspect of the present invention, in the method for manufacturing a comforter according to any one of claims 1 to 3, a knitted resin net-like structure covered with a comforter cover is provided with JIS L 1096 (woven fabric and knitted fabric). It is characterized in that the amount of air measured according to the Frazier form method of the dough test method) is 50 cm ³ / cm ² · s or more.

According to the present invention, it is possible to provide a recyclable comforter middle material and a comforter, which are excellent in heat retention and moisture release, easy to wash, and do not use animal-derived materials.

A photograph showing a part of a side surface of a comforter middle material (knitted resin net-like structure) according to an embodiment of the present invention. A photograph showing a part of a comforter middle material (knitted resin net-like structure) according to another embodiment of the present invention. The figure which shows the manufacturing apparatus of the knitting resin net structure of this invention. Photograph showing a part of the side surface of a conventional mattress consisting of a knitted resin mesh structure

In the method for producing a comforter according to the first embodiment of the present invention , a plurality of filamentous molten resins are formed by melting and kneading a thermoplastic resin at a predetermined temperature and cooling the molten resin by flowing it down into threads. An entwined and partially heat-welded bulk density of 0.010 g / cm ³ or more and 0.015 g / cm ³ or less is formed to form a quilt middle material composed of a knitted resin net-like structure, and the quilt middle material is covered with a quilt cover. , Is to be quilted .
According to the present embodiment, it is possible to provide a recyclable comforter medium material that has excellent heat retention and moisture release properties, is easy to wash, and does not use animal-derived materials. In addition, it can be used as a comforter middle material having excellent lightness and flexibility. Further, it is possible to provide a comforter having excellent heat retention and moisture release properties and in which the heat-welded portions of the knitting resins are not easily peeled off.

In the second embodiment of the present invention, in the method for manufacturing a comforter according to the first embodiment, the wire diameter of the knitting resin of the knitting resin net-like structure is 0.3 mm or more and 1.0 mm or less. ..
According to the present embodiment, the comforter middle material can be made lighter and more flexible.

In the third embodiment of the present invention, in the method for manufacturing a comforter according to the first or second embodiment, the knitted resin net-like structure is formed with thermocompression-bonded portions in the thickness direction at predetermined intervals . It is a thing.
According to the present embodiment, the heat-welded portions of the knitting resins are less likely to be peeled off, and the durability is improved .

In the fifth embodiment of the present invention, in the method for manufacturing a comforter according to any one of the first to third embodiments , the knitted resin net-like structure covered with the comforter cover is covered with JIS L 1096 (woven fabric and knitted fabric). The amount of air measured according to the Frazier form method of (Dough test method) is 3 cm ³ / cm ² · s or less.
According to this embodiment, since it has better heat retention, it can be used comfortably when the temperature is low such as winter.

In the sixth embodiment of the present invention, in the method for manufacturing a comforter according to any one of the first to third embodiments , the knitted resin net-like structure covered with the comforter cover is covered with JIS L 1096 (woven fabric and knitted fabric). The amount of air measured according to the Frazier form method of (Dough test method) is 50 cm ³ / cm ² · s or more.
According to this embodiment, since it is more breathable, it can be used comfortably when the temperature is high such as in summer.

Hereinafter, the comforter middle material and the comforter according to the embodiment of the present invention will be described.
FIG. 1 is a photograph showing a part of the side surface of the comforter middle material (knitted resin net-like structure) 1 according to the present embodiment.
The comforter includes a comforter middle material 1 and a comforter cover (not shown) that covers the entire surface of the comforter middle material 1.

The comforter middle material 1 is composed of a knitted resin net-like structure in which a plurality of thread-like molten resins are entangled and partially heat-welded. The knitted resin network structure is formed by melting and kneading a thermoplastic resin at a predetermined temperature and cooling the molten resin by flowing it down in a thread shape.
As the thermoplastic resin, for example, polyethylene, polypropylene, polyvinyl chloride, polystyrene, polyvinyl acetate, polytetrafluoroethylene, acrylonitrile butadiene styrene resin and the like are used alone or in combination of two or more.
The knitted resin network structure produced from these thermoplastic resins as a raw material can be recycled after use and used again as a raw material for the knitted resin network structure.
Further, since the knitted resin net-like structure can be washed with water or the like, it is easy to keep the comforter middle material 1 clean. Furthermore, since it can be washed while it is still in the comforter cover, the trouble of removing and attaching the comforter cover can be saved.
Further, since the knitted resin net-like structure does not use animal-derived materials such as feathers, there is no problem from the viewpoint of animal welfare. In addition, even people with bird allergy symptoms can use it with confidence.

The bulk density of the knitted resin network structure according to this embodiment is preferably 0.005 g / cm ³ or more and 0.030 g / cm ³ or less, and 0.010 g / cm ³ or more and 0.015 g / cm ³ or less. Is even more preferable. As a result, the knitted resin net-like structure has sufficient lightness and softness, and the user feels almost no oppressive feeling or weight, and the comforter can be made to feel good.
Here, FIG. 4 is a photograph showing a part of the side surface of the conventional mattress 100 made of a knitted resin net-like structure. The bulk density of the knitted resin net-like structure used as the mattress 100 is generally at least 0.050 g / cm ³ or more. Therefore, it can be seen that the knitted resin net-like structure of the present embodiment shown in FIG. 1 has more voids than the knitted resin net-like structure for the mattress 100 shown in FIG. The knitted resin network structure according to this embodiment has a porosity of 98% or more.

Further, the wire diameter of the knitting resin 21 of the knitting resin net-like structure is preferably 0.3 mm or more and 1.0 mm or less, and more preferably 0.5 mm or more and 0.6 mm or less.
As a result, the comforter middle material 1 can be made lighter and more flexible.

The vertical and horizontal dimensions of the knitted resin net-like structure are not particularly limited as long as they can function as a comforter middle material. For example, the general vertical and horizontal dimensions of a single-sized comforter are 2100 mm in length and 1500 mm in width. Therefore, when provided for a single-sized comforter, the vertical and horizontal dimensions are used.
Further, the thickness dimension of the knitted resin net-like structure is preferably 10 mm or more and 200 mm or less. When the thickness of the knitted resin net-like structure is reduced, the lightness and flexibility are increased, and when the thickness is increased, the lightness and flexibility are slightly lowered, but the texture is firm. Therefore, by changing the thickness, it is possible to provide the comforter middle material 1 according to the preference of the user.
Table 1 below shows the load when the pressure plate having a diameter of 150 mm is lowered by 10 mm or 20 mm multiple times with respect to the knitted resin network structure at different locations. Two types of knitted resin net-like structures were prepared, one with a thickness of 40 mm and the other with a thickness of 200 mm. In any thickness, the wire diameter of the resin is 0.45 mm to 0.5 mm, and the bulk density is 0.012 g / cm ³ .

Since the knitted resin network structure according to this embodiment has a large porosity as described above, a large number of air layers are formed inside and the moisture release property is also excellent.
In addition, by covering the knitted resin net-like structure with a thick quilt cover or by stacking multiple thin quilt covers, the air warmed by the user's body temperature is retained inside the knitted resin net-like structure, such as in winter. You can comfortably use the comforter when the temperature is low. In particular, the comforter has an air volume of 3 cm ³ / cm ² · s or less measured according to the Frazier form method of JIS L 1096 (fabric test method for woven fabrics and knitted fabrics), so that the comforter has excellent heat retention. can do.
In addition, by covering the knitted resin mesh structure with a thin comforter cover, the air warmed by the user's body temperature escapes from the inside of the knitted resin mesh structure to the outside of the comforter, making it difficult for heat to be trapped, and the temperature such as summer. You can comfortably use the comforter when the temperature is high. In particular, the comforter has an air volume of 50 cm ³ / cm ² · s or less measured according to the Frazier form method of JIS L 1096 (fabric test method for woven fabrics and knitted fabrics), so that the comforter has excellent breathability. can do.

Further, the comforter is quilted by sewing the upper surface and the lower surface of the comforter cover with the knitted resin net-like structure sandwiched between them with threads.
Since the knitted resin net-like structure according to the present embodiment has a smaller bulk density than the knitted resin net-like structure used as the mattress 100 as described above, the knitting resin 21 is used when a force is applied in the direction of tearing the comforter. The heat-welded parts of each other are easily peeled off. However, by applying quilting and sewing the knitted resin mesh structure together with the comforter cover at predetermined intervals, even if a force is applied in the direction of tearing the comforter, the heat-welded parts of the knitted resin 21 are less likely to peel off, and the durability is improved. improves.
Further, as described above, since the knitted resin net-like structure can be washed with water or the like, the entire quilted comforter cover can be washed.

Next, the comforter middle material and the comforter according to another embodiment of the present invention will be described.
FIG. 2 is a photograph showing a part of the comforter middle material (knitted resin net-like structure) 1 according to another embodiment of the present invention.
In the comforter middle material 1 and the comforter in this embodiment, the knitted resin net-like structure has crimping portions 2 thermocompression-bonded in the thickness direction over one surface (upper surface) or the other surface (lower surface) at predetermined intervals. It differs from the above-described embodiment in that a plurality of them are formed. Since the remaining points are the same as those in the above-described embodiment, the description thereof will be omitted.
The crimping portion 2 can be formed linearly by pressing a bar heated to a predetermined temperature from one surface (upper surface) or the other surface (lower surface) side against the knitted resin net-like structure. At the place where the bar material heated to a predetermined temperature is pressed, the knitting resin 21 is softened and crushed by the heat, and the knitting resin 21 is cooled and hardened in a folded state. By providing the crimping portion 2 in this way, even if quilting is not performed, the heat-welded portions of the knitting resins 21 are less likely to be peeled off when a force is applied in the direction of tearing the comforter, and the durability is improved. The crimping portion 2 is preferably formed so as to divide the knitted resin net-like structure into a grid pattern or the like.
In the example shown in FIG. 2, a plurality of crimping portions 2 are diagonally provided so as to intersect each other from one side portion to the other side portion. The width of the crimping portion 2 is about 0.5 mm to 20 mm.
Note that FIG. 2 shows an example in which a plurality of rectangular regions surrounded by the crimping portions 2 are formed by providing the linear crimping portions 2 in a grid pattern on the knitted resin net-like structure. 2 may be provided in a curved shape to form a plurality of circular regions and the like.
Further, if the knitted resin net-like structure in which the crimping portion 2 is formed is covered with a comforter cover and quilted, the heat-welded portions of the knitted resins 21 are more difficult to peel off.

FIG. 3 is a diagram showing a manufacturing apparatus for a knitted resin network structure according to the present embodiment.
In the manufacturing apparatus according to the present embodiment, the thermoplastic resin is melt-kneaded at a predetermined temperature to obtain a molten resin, and the melted resin is extruded at a predetermined extrusion speed. Below the resin pool 30 in which the molten resin flows down from a large number of holes of 31 in a thread shape, the cooling water tank 40 for storing the cooling water, and the knitting resin 21 in which the thread-like molten resin 20 flowing down from the resin pool 30 is cooled by the cooling water. It is equipped with a pick-up machine 50 to pick up the plastic. The take-up machine 50 is provided with a plurality of take-up rollers 51 facing each other, and is arranged in the cooling water tank 40. Further, a guider 70 is provided between the resin pool 30 and the take-up machine 50.
The filamentous molten resin 20 is formed when it flows down from the hole of the bottom surface 31 of the resin pool 30. The knitting resin 21 formed by cooling the filamentous molten resin 20 with cooling water is taken up by the take-up machine 50 toward the bottom plate side of the cooling water tank 40, passes through the take-up machine 50, and then is a pulling member arranged in the cooling water tank 40. While being cooled in the cooling water, the plurality of transport rollers 60 are pulled up diagonally upward and transported to the outside of the cooling water tank 40. After that, it is cooled and cut to a predetermined size to form a knitted resin net-like structure as the comforter middle material 1.

The bulk density of the knitted resin net-like structure is adjusted by setting the number and spacing of holes in the bottom surface 31 of the resin pool 30, setting the pick-up speed of the pick-up machine 50, and the like.
When the crimping portion 2 is provided on the knitting resin net-like structure, the linear crimping portion 2 is formed by pressing a bar heated to a predetermined temperature to a predetermined position on the knitting resin net-like structure.

1 Comforter middle material (knitted resin net-like structure)
2 Crimping part

Claims (5)

By melting and kneading the thermoplastic resin at a predetermined temperature and cooling the molten resin by flowing it down into threads , a plurality of filamentous molten resins are entangled and the bulk density partially heat-welded is 0.010 g /. A method for manufacturing a quilt, which comprises forming a quilt middle material made of a knitted resin net-like structure of cm ³ or more and 0.015 g / cm ³ or less , covering the quilt middle material with a quilt cover, and performing quilting . The method for manufacturing a comforter according to claim 1, wherein the wire diameter of the knitting resin of the knitting resin net-like structure is 0.3 mm or more and 1.0 mm or less. The method for manufacturing a comforter according to claim 1 or 2, wherein crimping portions thermocompression-bonded in the thickness direction are formed on the knitted resin net-like structure at predetermined intervals. The air volume of the knitted resin net-like structure covered with the comforter cover shall be 3 cm ³ / cm ² · s or less measured according to the Frazier form method of JIS L 1096 (fabric test method for woven fabrics and knitted fabrics) . The method for manufacturing a comforter according to any one of claims 1 to 3, wherein the comforter is manufactured . The air volume of the knitted resin net-like structure covered with the comforter cover is 50 cm ³ / cm ² · s or more measured according to the Frazier form method of JIS L 1096 (fabric test method for woven fabrics and knitted fabrics) . The method for manufacturing a comforter according to any one of claims 1 to 3, wherein the comforter is manufactured .

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