JP7165964B2 - Stuffed toy manufacturing method - Google Patents

Description

TECHNICAL FIELD The present invention relates to a stuffed toy manufacturing method in which dye is not eluted.

In recent years, advances in artificial fur (fake fur) manufacturing technology have made it possible to produce realistic stuffed animals that can be mistaken for real animals. Such realistic stuffed animals are expected to be used by people in environments where pets such as dogs and cats cannot be kept, households for the elderly, nursing care, and the like. In addition, as a countermeasure against pet loss or as a memory of a pet, a realistic plush toy modeled after a pet that a user has raised is custom-made. However, stuffed animals as toys are assumed to be used by infants, and the Food Sanitation Law of the Ministry of Health, Labor and Welfare imposes strict regulations on the elution of paint components. Dyeing methods that satisfy this regulation include sublimation transfer and boiling dyeing.

Here, in the sublimation transfer, a pattern, picture, etc. is transferred to a cloth or the like using thermal sublimation dye ink, and heated at a temperature of about 180° C. to fix the dye to the fiber. However, there is a problem that the artificial hair cannot withstand the heating temperature at the time of fixation, and the fibers shrink, especially in the faux fur fabric with long hair. In boiling dyeing, the fabric is boiled in a predetermined solution in which the dye is dissolved to fix the dye to the fiber. However, if a perm-curled fake fur fabric is boiled and dyed, the curl of the artificial hair is elongated and the original shape of the artificial hair cannot be maintained. Further, if the fake fur fabric with long hairs is boiled and dyed, the artificial hairs are entangled with each other, and complicated work is required to untangle the entanglements. In other words, the current situation is that no dyeing method that satisfies the above regulations has been established for fake fur fabrics.

Therefore, in order to produce a fake fur fabric that clears the above regulations, it is common to dye the fiber at the point of fiber using boiling dyeing, etc., and process the dyed fiber into a fake fur fabric. . Therefore, in the conventional stuffed toy manufacturing method, fibers and fabrics are dyed in advance by the dyeing method described above, and stuffed animals are produced using the dyed fibers and fabrics. Here, as a patent document using such a conventional plush toy manufacturing method, for example, the following [Patent Document 1] can be cited.

However, a large number of colors are used in realistic stuffed animals, and it is necessary to prepare fibers of a huge number of colors. In addition, depending on the pattern, it is necessary to locally implant fibers of different colors, which is extremely troublesome. Furthermore, the dyeing method described above cannot dye the fibers with a plurality of different colors, and there is a limit to realistic hair reproduction. For these reasons, manufacturing realistic stuffed animals using dyed fibers and fabrics has extremely poor production efficiency and is not realistic. In particular, custom-made stuffed animals need to be produced in different colors and patterns, and it is extremely difficult to manufacture such stuffed animals using dyed fibers and fabrics.

As an alternative method for producing a realistic stuffed toy, there is a method of manufacturing a stuffed toy by sewing a stuffed toy body using colorless faux fur fabric and then finely coloring the stuffed toy by spray painting. However, as described above, a method for fixing dyes to artificial hair has not yet been established, and cannot satisfy legal regulations. Therefore, realistic stuffed animals manufactured by such a method cannot be sold as "stuffed animals", but are currently sold as interior decorations (ornaments).

Japanese Patent Application Laid-Open No. 2009-100968

However, there is a demand to use real stuffed animals not as ornaments, but as "stuffed animals" that can actually be touched, and further improvement is desired in this respect.

SUMMARY OF THE INVENTION It is an object of the present invention to provide a stuffed toy manufacturing method capable of sufficiently fixing artificial hair.

The present invention
(1) Sewing step S102 of sewing the stuffed toy main body 50 using uncolored artificial hair;
a coloring step S106A of spray-coating a predetermined dye ink onto the artificial hair and drying it with warm air as appropriate;
The painted stuffed toy body 50 is placed in the chamber of the vacuum setting machine 12, and saturated steam is introduced into the chamber of the vacuum setting machine 12 at a predetermined processing temperature and degree of vacuum to fix the dye ink to the artificial hair. The above problem is solved by providing a stuffed toy manufacturing method characterized by having a fixing step S108.
(2) The above problem is solved by providing the stuffed animal manufacturing method according to (1), wherein the artificial hair is straight or curled artificial hair.
(3 ) By providing the stuffed toy manufacturing method according to any one of (1) to (3), characterized in that the processing temperature in the vacuum fixing step S108 is 100°C to 135°C. to solve.

According to the method for manufacturing a stuffed toy according to the present invention, by performing vacuum setting, it is possible to fix a precise coating using spray coating at a level that satisfies the legal regulation of paint elution. As a result, a real stuffed toy, which was conventionally sold only as an "ornament", can be sold as a "stuffed toy" that can be touched by a user.

4 is a flow chart of a method for dyeing artificial hair. 4 is a table showing the relationship between processing temperature and dye elution in a vacuum fixing process. 1 is a flow chart of a stuffed toy manufacturing method according to the present invention. It is a figure explaining the manufacturing method of the stuffed toy which concerns on this invention. It is a figure explaining the manufacturing method of the stuffed toy which concerns on this invention. It is another example of the flow chart of the stuffed toy manufacturing method according to the present invention.

A method of manufacturing a stuffed toy according to the present invention will be described with reference to the drawings. Here, FIG. 1 is a flow chart of a method for dyeing artificial hair. This artificial hair dyeing method includes a coloring step S106 of coloring an article having uncolored artificial hair, and a vacuum fixing step S108 of fixing the colored dye to the artificial hair . The synthetic fiber for artificial hair used here is not particularly limited as long as it does not change shape (shrinkage) at the heat treatment temperature in the vacuum fixing process described later, and is polyester, nylon, cationic dyeable polyester. well-known synthetic fibers such as , polyurethane, and aramid. As a treatment for preventing shape change of the synthetic fiber due to heat, for example, heat treatment may be performed in advance at a temperature higher than the processing temperature (preferably higher than the glass transition point) during heating (vacuum fixing step). Therefore, it is preferable that the synthetic fiber used for the artificial hair of the present invention is preliminarily heat-treated at a temperature equal to or higher than the treatment temperature. Further, the synthetic fibers used at this time are colorless and not colored. Therefore, at least the artificial hair portion of the article to be colored in the coloring step S106 is basically colorless (white). Synthetic fibers used for artificial hair may be straight monofilament fibers, curled fibers, or any other synthetic fibers. In addition , any type of yarn such as plied yarn, cross-twisted yarn, etc. may be used. Furthermore, there is no particular limitation on the thickness of the synthetic fiber to be used.

Also, the dye used in the coloring step S106 is not particularly limited, and known dye ink such as transfer sublimation dye ink and disperse dye ink used for general dyeing can be used. As a coloring method in the coloring step S106 , spray coating using an airbrush or the like is used.

The article on which the artificial hair has been colored in the coloring step S106 is then placed in the chamber of the vacuum setting machine. Next, the inside of the vacuum setting machine is decompressed to a degree of vacuum of about 0.1 MPa, for example. Next, a predetermined amount of saturated steam is put into the chamber and the degree of vacuum is set to about 0.11 MPa to 0.16 MPa, and the treatment is performed at 100 ° C. to 135 ° C., preferably 110 ° C. to 125 ° C., more preferably 120 ° C. to 125 ° C. Hold at temperature for 45 min to 90 min. By this vacuum setting process, the colored dye ink is fixed to the artificial hair (vacuum fixing step S108). If the holding time is shorter than 45 minutes, the fixing state will be insufficient, and if it is longer than 90 minutes, it will be excessive. Next, the water vapor in the chamber is exhausted, and the chamber is brought into a vacuum state again. Next, the inside of the storage is opened to release the vacuum state, and the article is taken out from the vacuum set machine.

Here, the relationship between the processing temperature and the elution of the dye ink in the vacuum fixing step S108 is shown. The experiment was conducted as follows. First, a white cloth was made from colorless 75 denier polyester fiber. Next, sublimation dye ink for transfer (KIWA-JET ES-2 (cyan, P-magenta, F-yellow) manufactured by Kiwa Kagaku Kogyo Co., Ltd.) and disperse dye (Dianix AC-E manufactured by DyStar (yellow, red , Blue)) was used for coloring. Next, it was sufficiently dried with warm air.

Next, these samples were placed in a vacuum set machine (SB-300 manufactured by Yasujima Co., Ltd.). Next, the inside of the chamber was evacuated to a degree of vacuum of 0.1 MPa. Next, steam was put into the chamber to set the saturated steam pressure to 0.14 MPa, and the treatment temperature was changed under eight conditions of 100 ° C., 105 ° C., 110 ° C., 115 ° C., 120 ° C., 125 ° C., 130 ° C., and 135 ° C. Hold for 60 min. Next, after the inside of the chamber was evacuated to a degree of vacuum of 0.1 MPa, it was released to normal pressure.

Next, these samples were subjected to color fastness test JIS L 0844 washing test A-2 (temperature 50 ° C, soap concentration 5 g / L, liquid volume 100 ml, time 30 minutes, attached white cloth polyester and cotton). Contamination and liquid contamination were evaluated by visual inspection. The results are shown in FIG. From FIG. 2, discoloration was grade 3 except for grade 2-3 at a treatment temperature of 120°C. In addition, contamination and liquid contamination are grade 4-5 at all temperatures, and the "standards for food and additives" based on the Food Sanitation Act (Ministry of Health and Welfare Notification No. It showed good values suitable for testing. Further, even when the fake fur fabric was subjected to a vacuum setting process, no deformation such as curling, entanglement, or elongation of curls was observed in the artificial hair. Therefore, the processing temperature in the vacuum fixing step S108 can be 100°C to 135°C, preferably 110°C to 125°C, and particularly preferably 120°C to 125°C.

Next, the stuffed toy manufacturing method according to the present invention will be described with reference to the flow chart of FIG. In the stuffed toy manufacturing method according to the present invention, first, non-colored synthetic fibers are mixed or knitted to manufacture a fake fur fabric having a predetermined hair length. Then, as shown in FIG. 4A, the stuffed toy main body 50 is sewn so that the artificial hair of the fake fur fabric becomes the fur of the stuffed toy (sewing step S102). Further, the artificial hair used here is not particularly limited as long as the shape does not change at the treatment temperature in the vacuum fixing process, as in the dyeing method described above. Also, the artificial hair used at this time is colorless and not colored in the same manner as in the dyeing method. Therefore, the stuffed toy main body 50 in the sewing step S102 is basically colorless (white).

Here, in the conventional stuffed toy manufacturing method, it is necessary to cut the fake fur fabric for each color and cut out parts of different colors and sew them, but in the stuffed toy manufacturing method according to the present invention, all are uncolored fake fur fabrics. Since the stuffed toy main body 50 is sewn, it is not necessary to cut out parts for each color, and the number of parts itself is small. Therefore, the stuffed toy main body 50 can be sewn very easily and at a low cost compared to the conventional stuffed toy manufacturing method. Furthermore, by mass-producing non-colored faux fur fabrics, production efficiency can be improved and production costs can be reduced.

Next, the artificial hair of the stuffed toy main body 50 is cut to an appropriate length according to the stuffed toy to be produced. As a result, as shown in FIG. 4B, the appearance of the stuffed toy main body 50 is adjusted (trimming step S104).

Next, as shown in FIG. 4(c), the synthetic hair of the stuffed toy main body 50 is colored with dye ink of a color corresponding to the stuffed toy to be produced using a well-known airbrush or other spraying device 10 (coloring step S106A). At this time, coloring is performed while appropriately drying the dye ink with warm air of about 40°C to 100°C. The back side of the artificial hair is also appropriately colored. The coloring by the spraying device 10 is repeated with a plurality of colors according to the stuffed toy to be produced. By spraying the hair of the stuffed toy body 50 with a plurality of colors using the spraying device 10, it is possible to achieve precise painting that reproduces the shades, patterns, and textures of the hair.

Next, as shown in FIG. 5(a), the stuffed toy main body 50 painted in the coloring step S106A is placed in the chamber of the vacuum setting machine 12. Next, as shown in FIG. Next, the inside of the vacuum setting machine 12 is decompressed to a degree of vacuum of, for example, about 0.1 MPa as described above. Next, a predetermined amount of saturated steam is put into the chamber and the degree of vacuum is set to about 0.11 MPa to 0.16 MPa, and the treatment is performed at 100 ° C. to 135 ° C., preferably 110 ° C. to 125 ° C., more preferably 120 ° C. to 125 ° C. Hold at temperature for 45 min to 90 min. Due to this vacuum setting process, the dye of the dye ink is fixed to the synthetic fibers (vacuum fixing step S108). Next, the water vapor in the chamber is exhausted, and the chamber is brought into a vacuum state again. Next, the interior of the storage is opened to release the vacuum state, and the stuffed toy main body 50 is taken out from the vacuum setting machine 12.例文帳に追加

As described above, the stuffed toy main body 50 to which the dye ink has been fixed by the vacuum fixing step S108 is then subjected to a softening agent treatment for the artificial hair by washing or the like. Next, as shown in FIG. 5(b), the stuffed toy main body 50 is fixed with, for example, plastic eyes, a nose, and other parts 20, so that the color and texture of the hair are realistic. 80 is completed (finishing step S110).

In addition, when the stuffed toy 80 to be produced has a complicated pattern such as a striped pattern, as shown in the flowchart of FIG. The pattern may be painted in the coloring step S206 and fixed in the second vacuum fixing step S208. Further, the second coloring step S206 and the second vacuum fixing step S208 may be performed multiple times for each color. According to this configuration, the base dye ink applied in the coloring step S106A and the pattern dye ink applied in the second coloring step S206 are not mixed with each other, so that a clear and vivid pattern can be reproduced. can be done.

As described above , according to the present invention, artificial hair of fake fur fabric is dyed at a level that satisfies the legal regulation of paint elution by performing so-called vacuum setting in which heat treatment with water vapor is performed under vacuum in the vacuum fixing step S108. , can be established. At this time, the artificial hair does not curl or get tangled. As a result, it is possible to dramatically improve the degree of freedom of the colored pattern of the artificial hair. Moreover, fading and color transfer can be prevented.

Further, according to the stuffed toy manufacturing method of the present invention, by performing vacuum setting in the vacuum fixing step S108, the dye ink of the precise coating using the spraying device 10 is fixed at a level that satisfies the legal regulation of paint elution. be able to. For this reason, realistic stuffed animals, which were conventionally sold only as "figure", can be sold as "stuffed animals" as toys that users can interact with.

In addition, in the stuffed toy manufacturing method according to the present invention, the stuffed toy main body 50 is sewn entirely from non-colored faux fur fabric. It can be carried out. Furthermore, by mass-producing non-colored faux fur fabrics, production efficiency can be improved and production costs can be reduced.

The method of dyeing artificial hair and the method of manufacturing a stuffed animal shown in this example are examples, and therefore, necessary steps can be inserted as appropriate, and the conditions, order, materials used, etc. of each step do not deviate from the gist of the present invention. It is possible to change and implement within the range.

10 spraying device
12 Vacuum setting machine
50 Stuffed toy body
80 stuffed animals
S 106A coloring process
S108 vacuum fixing step

Claims (3)

A sewing process in which uncolored artificial hair is used to sew the stuffed toy body,
a coloring step of spray-coating a predetermined dye ink onto the artificial hair and drying it with warm air as appropriate ;
A vacuum fixing step of putting the painted stuffed toy main body into a chamber of a vacuum setting machine, and adding saturated steam while setting the chamber of the vacuum setting machine to a predetermined processing temperature and degree of vacuum to fix the dye ink to the artificial hair. A method of manufacturing a stuffed toy, comprising: 2. The method of manufacturing a stuffed toy according to claim 1, wherein the artificial hair is artificial hair curled in a perm or straight artificial hair. 3. The method for producing a stuffed toy according to claim 1, wherein the processing temperature in the vacuum fixing process is 100.degree. C. to 135.degree.

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