JPS625640B2 - - Google Patents

Description

[Detailed description of the invention]

The present invention relates to a polyester fiber filling having good softness and compression fatigue resistance for use as stuffing for bedding, pillows, cushions, textured clothing, etc. Conventionally, most of the materials used for stuffing have been sheets made by intertwining fibers in a certain direction, almost parallel to each other, as typified by momen futons. There has been an increasing demand for batting materials with a feather-like texture. Methods of creating a feather-like texture using synthetic fibers include reducing the denier, opening the tow and folding it in parallel or zigzag patterns. Although the cotton stuffing produced by these methods satisfies the characteristics of softness and bulkiness, which are the characteristics of feathers, to a certain extent, it does not meet the characteristics of feathers, which are the most important characteristics, such as resistance to fatigue, that is, the bulkiness due to compression, long-term use, etc. The fact is that even if the shell is destroyed, the initial bulk can be easily restored by applying an external force such as "knocking", which has not been resolved at all. This is due to the fact that the feathers are independent and never intertwine with each other, that is, they are mutually exclusive. Of course, it would be possible to create a structure similar to feathers using synthetic fibers, but it would be nearly impossible to produce it industrially. The purpose of the present invention is to improve the softness, which is the characteristic of the above-mentioned feathers,
The object of the present invention is to provide a polyester fiber filling which has bulkiness and which easily recovers its initial bulk by applying an external force such as "beating", and has the following structure. That is, the present invention provides: ``(1) A fiber filling made of polyester synthetic fibers in which each single fiber is opened and has a lumpy shape with a diameter of 10 to 50 mm and a density of 0.03 g/cm ³ or less. "A polyester fiber filling characterized by a stuffed body." In the present invention, polyester synthetic fibers are:
The target material is polyethylene terephthalate, but any known polyester fiber may be used. Moreover, such fibers are made of short fibers. Furthermore, in the present invention, each single fiber being opened means that the raw cotton is passed through a known opening machine, such as a card machine. By opening the fibers in this manner, the texture and heat retention effect can be improved. Unopened polyester fibers not only cannot exhibit such effects, but are also undesirable because they are heavy and easily sag.
The opening degree of the present invention may be at least 50%, preferably at least 80%, particularly preferably at least 90%. Next, in the present invention, the open fibers have a diameter of 10 to
It is necessary to have a block shape of 50 mm and a density of 0.03/cm ³ or less. With such a configuration, it is possible to exhibit light and warm performance similar to that of feathers, and it is also possible to recover the bulk by just tapping it lightly, thereby improving fatigue resistance. In other words, the fiber filling of the present invention does not have fibers intertwined to form a sheet like conventional web cotton, but rather fibers of a size that is difficult to judge by feel when stuffed. The clumps are gathered together to form the batting base material, and each fiber clump is in a state where it can act independently. The bulk fiber aggregate of the present invention will be explained in further detail. The conventional sheet-like material in which the fibers are arranged almost parallel has strong resistance to compressive loads, and is designed to withstand this load through fiber buckling, twisting, bending stress, etc. I was working on fiber quality design. However, recently, feather-like softness and compression fatigue resistance have become required, and instead of resisting compression, it is necessary to easily deform and recover easily with a small external force. It's coming. That is, it is necessary that the batting base material is organized by clusters of fibrils like feathers, and that the clusters of fibrils have a large degree of freedom and can be easily deformed and moved by external force.
The stuffing material according to the present invention satisfies this requirement. Table 1 shows comparative data with sheet-like stuffing material when the same material is used.

[Table] As can be seen from the results, the fiber filling of the present invention is bulkier and softer, and has better compression fatigue resistance. A necessary condition for the fiber aggregate for stuffing is that the constituent fibers are three-dimensionally intertwined and have a size that is difficult to judge by feel when stuffed. In the present invention, if the size of the lump-like fiber aggregate is less than 10 mm in diameter, it will easily become flat,
The effects of the present invention cannot be exhibited. In addition, if the diameter is less than 10 mm, it will easily deteriorate and the effects of the present invention cannot be exhibited. Also the diameter is 50
If it exceeds mm, the texture becomes rough and uneven, which is undesirable. Also, those with a density exceeding 0.03 g/cm ³ are undesirable because they feel heavy and cause stiff shoulders when worn, and are heavy and uncomfortable when worn as a blanket. Next, the method for manufacturing the fiber filling of the present invention will be explained using the drawings. FIG. 1 is a process schematic diagram showing one example of the method for manufacturing the polyester fiber filling of the present invention. Raw cotton 1 made of short polyester fibers is placed on a feed lattice 2 and fed. The raw cotton to be supplied is preferably a staple, which has been carded and opened to form a sheet. The sheet-like fiber 1 is fed by a feed roller 3 to a cylinder 5 rotating at high speed. The cylinder 5 is equipped with a needle or projection 6,
This strikes the sheet fibers and separates them into certain fiber aggregates. The amount of fibers in the fiber aggregate produced at this time depends on the amount of raw cotton supplied (thickness and speed), the surface speed of the cylinder 5, and the spacing between the protrusions 6. The fiber aggregate separated into a certain amount is conveyed to the lattice 7 while being twisted by the undercasing, the cylinder 5, and the protrusion 6. Although it is possible to use the resulting large number of fiber aggregates 8 as is, each fiber aggregate 8 can be used independently as is, but since it is easy to collapse due to external force, it is desirable to pass through a step of fixing the shape subsequent to this step. That is, in the process of fixing the shape, the group 8 of single aggregates is supplied to the cylinder 10 by the lattice 7. The cylinder 10 is equipped with a protrusion 11 and rotates at high speed. The single assembly 8 includes an under casing 9, a cylinder 10, and a protrusion 11.
The tangle of fibers that are twisted between the fibers to form a single unit of each aggregate is strengthened and sent onto the delivery lattice 12. It is effective that the cylinder protrusion 11 has a rounder tip and a higher density than the cylinder protrusion 6 in the previous step. The size of the unit, the degree of entanglement of the constituent fibers, and the hardness of the unit are controlled by the amount of fibers supplied, the shape and density of the projections 11, the rotational speed of the cylinder, and the distance between the undercasing 9 and the projections 11. However, it is preferable to control the distance between the cylinder 10 and the under casing 11 in view of the difficulty and effect contribution rate. If a stronger intertwining of the fibers constituting the single fiber or a very small single fiber is required, it is more effective to add an additional step for spinning. The stuffing material thus produced has a strong intertwining of the fibers that make up the single fibers, does not easily deform due to external forces, and does not cause entanglement of the single fibers. In order to obtain a cotton stuffing material of even better quality, it is preferable to use the process shown in FIG. 2, row 1 of FIG. That is, in FIG. 2, the fiber sheet 1 is fed by the feed roller 3, the fibers are singulated by the protrusion 6 of the cylinder 5, and then the single fibers are entangled between the protrusion 11 of the cylinder 10 and the under casing 9. Make it bigger. It is then supplied to cylinder 14, which rotates at a relatively low speed compared to cylinders 5 and 10. The surface of the cylinder 14 has no protrusions and is finished smoothly, and the structure is such that the resin liquid 15 is constantly applied in the required amount. The wood grain 15 attached to the cylinder 14 is applied to the supplied single aggregate material 13 between the rotating cylinder 14 and the undercasing 16. The wadding material coated with resin by the air flowing through the cavity 17 is sent onto the lattice 19 passing through the dryer 18, where it is dried, the entanglements of the individual pieces are fixed, and the wadding material is made into a stronger aggregate. The cotton material will be 20. Further, the object can also be sufficiently achieved by the example method shown in FIG. A pair of conveyors 2 carry the stuffing material 13
1 and 22, but since the conveyor 21 rotates at a higher surface speed than the conveyor 22, it is given a kneading effect. At the same time, since the resin 23 is constantly applied to the conveyor 21, the resin is applied to the surface of the stuffing material as it is rolled. A dryer 24 is installed on the delivery side of the conveyor, which dries the applied resin onto the conveyor 25.
A strong aggregate 26 of single entanglements is completed. Any resin can be used at this time that has the effect of fixing the fibers, but it is particularly preferable to use an acrylic resin that has a soft texture. When manufactured using this manufacturing method, the fibers in the cotton material are strongly intertwined, there is no entanglement between the fibers during use, and the density and size of the cotton material can be controlled freely, making it possible to pack in very large quantities and at low cost. Can make cotton. Furthermore, since the stuffing material can be handled in the same way as granular material, it has the advantage that it is extremely easy to fill the sides of futons, pillows, etc. Example 1 Polyethylene terephthalate fiber (6d×76
Create a web with a cotton card using staples of 2.5 mm) and place it on a cylinder with a circumference of 3 m and a width of 1 m.
pcs/ ^100cm2 of blunt protrusions and surface speed
A block separator with a thickness of 5 mm is rotated at 300 m/min.
cm, feed the web at a feeding speed of 20 m/min, and add the resulting fiber mass to a cylinder with a circumference of 3 m and a width of 1 m/min.
40 m blunt protrusions/100cm ² , distance between the undercasing and the tip of the protrusions 10mm, cylinder surface speed
It was passed through the device at a feed rate of 20 m/min. As a result, the diameter of the single piece for stuffing is 10 mm to 25 mm, and the density
One having a weight of 0.020 g/cm ³ to 0.025 g/cm ³ was obtained. When this cotton wadding material was placed in the side of a futon with a width of 1.5 m and a length of 2 m, a futon with good bulk, softness, and compression fatigue resistance was obtained. Furthermore, the single piece of cotton stuffing obtained as described above was cut into a diameter of 30 mm.
cm, width 1 m, and a cylinder rotating at a surface speed of 30 m/min is fed to a resin coating device that constantly coats the surface with acrylic synthetic resin. After coating the resin on the surface of the unit, hot air at 180°C is passed onto the conveyor. It was dried for 10 minutes to obtain a more complete cotton pad. Similarly, when I put it in a side land with a width of 1.5m and a length of 2m,
We were able to obtain a product with even better compression fatigue resistance than the product before applying the resin. Example 2 Using the same process as in Example 1, by changing the fiber supply speed and cylinder rotation speed, fiber aggregates as shown in Table 2 were made, and this was applied to the same futon side as in Example 1. It was stuffed into the ground and made into a cushion.

[Table] As is clear from Table 2, experiment numbers 2, 3, and 5
It was a good product because it was within the scope of the present invention. On the other hand, in Experiment No. 1, the average diameter was smaller than the range of the present invention, and the compression fatigue resistance and heat retention properties were unfavorable. Further, in Experiment No. 4, the average diameter was larger than the range of the present invention, giving an undesirable uneven feel. In addition, Experiment No. 6 had too high a density and poor bulkiness, and was not desirable.

[Brief explanation of the drawing]

FIG. 1, FIG. 2, and FIG. 3 are diagrams showing an embodiment of the manufacturing method of the present invention. 1: Raw cotton, 2: Feed lattice, 3: Feed roller, 4: Under casing, 5: Cylinder,
6: protrusion, 7: lattice, 8: group of incomplete fiber aggregates, 9: undercasing, 10: cylinder, 11: protrusion, 12: lattice, 13: single active type cotton stuffing material, 14: cylinder, 15: resin, 1
6: Under casing, 17: Cavity, 18: Dryer, 19: Lattice, 20: Single active type cotton filling material.

Claims (1)

[Claims] 1 In a fiber filling made of polyester synthetic fiber, each single fiber is opened and has a diameter of 10
50 mm and a density of 0.03 g/cm ³ or less, a polyester fiber filling is filled with a fiber aggregate having a block shape.