JPH0460883B2 - - Google Patents

Description

[Detailed Description of the Invention] [Field of Industrial Application] The present invention relates to a density gradient type high-density filling cotton that has a soft texture and is ideal as a filling cotton for clothing without angularity and no fiber blow-out. It is something.

[Conventional technology and its problems]

Conventionally, padded cotton used in jumpers, ski wear, blousons, etc., was required to have a soft texture, so this was achieved by reducing the amount of resin binder used or making the denier thinner. If the amount of resin binder is small, there is a risk that the fibers will blow out onto the surface of the fabric and the commercial value will be lost, so currently, spunbond nonwoven fabrics are usually laminated together. However, due to the manufacturing process, this spunbond material can only have paper-like characteristics, which is a factor in the loss of flexibility of the nonwoven fabric. Furthermore, conventional manufacturing methods have not been able to provide satisfactory results regarding the angularity of nonwoven fabrics.
The current solution is to increase the thickness of the nonwoven fabric or add stitches. In addition, such nonwoven fabrics have many problems in sewing, such as slippage on sewing machines and workability, and because they pursue softness, their surface strength is low, and they require a spunbond lamination process, which is extremely labor-intensive. be.

[Means for solving problems]

In view of the current situation, the present invention provides a padded cotton that does not have any angularity, is extremely soft, and does not cause fibers to blow out, by simply laminating the fabric and the padded cotton.

That is, the present invention comprises at least a fiber web (layer A) containing at least 50% or more of high shrinkage polyester composite fibers and a highly crimped polyester fiber.
A laminated web with a fiber web (layer B) having a blend of 50% or more is needle punched from the layer A side so that the driving depth is kept within layer A, and the needle punched entanglement is formed. A synthetic resin binder is applied to the front and back surfaces of the fiber mat, and only the A layer is densely shrunk in the thickness direction by heat shrinkage of the high shrinkage polyester composite fiber. do.

In general, the characteristics required for padded cotton are that it be light, soft, and heat-retaining, that it does not have any sharp edges, and that the fibers do not blow out from the surface of the clothing fabric. The high-shrinkage polyester composite fiber used in the product of the present invention is crimped three-dimensionally after shrinkage, which increases entanglement between the fibers and has the advantage of greatly reducing the amount of resin binder used. The three-dimensional crimping of the fibers creates a spring effect and provides stretch, so we focused on the advantage that angularity does not occur. Furthermore, by needle-punching only the web layer containing at least 50% of high-shrinkage polyester composite fibers, the fibers are aligned in the thickness direction, and shrinkage behavior occurs only in the thickness direction, not in the width direction, resulting in higher density. Since we have made it possible, each tension, texture, and
It has been discovered that good results can also be obtained in terms of heat retention. By restricting the shrinkage behavior of high shrinkage polyester composite fibers only in the thickness direction,
It is possible to retain a large amount of air between the fibers without increasing the density of the lower layer of highly crimped polyester fibers, and the high crimped polyester fibers are 50%
Because of the above content, the thickness does not "sag" under repeated loads and can always maintain a predetermined thickness. In this way, the cotton insert of the present invention has an extremely dense structure, and thus has a very soft feel. Furthermore, since the three-dimensional crimp of the highly shrinkable polyester composite fibers is developed in the A layer in contact with the outer fabric, the surface is smooth and strong, and no blow-out occurs on the fabric. A more detailed explanation will be given below based on examples.

〔Example〕

As shown in Figure 2, a cross web with a basis weight of 30 g/m ² is formed by a carding machine from a mixed fiber of high shrinkage polyester composite fiber 2.5 de x 51 mm; 80% and regular polyester fiber 1.5 de x 51 mm; 20%. A
layer) and highly crimped polyester fiber 2.0de×51mm;
After laminating a 100% cross web (layer B) with a basis weight of 60 g/m ² formed by a card machine, needle punch processing 1 is performed from the side containing high shrinkage polyester composite fibers (layer A). In this case, the number of implants is not particularly limited, but it is 10 to 200 P/cm ² , and it is important to keep the implant depth from 1/2 of the thickness of layer A (upper layer) to a level that does not penetrate layer A. It is. If the driving depth is too shallow (for example, about 1/3 of the thickness), the dense layer on the surface of layer A will become too thin during heat shrinkage, resulting in a decrease in heat retention, and even worse, the lower part of layer A will become thinner. To,
Shrinkage occurs in the width and length directions, and along with this, B
The layer (lower layer) also contracts, and the density of layer B increases and becomes empty.
This results in a decrease in heat retention performance. On the other hand, if it is punched too deeply and penetrates the A layer, the coarse and dense structure will disappear due to the intertwining of the A and B layer co-fibers, and the overall thickness will become thinner, making it unable to function as a filler. It becomes something that does not exist.

Next, a resin binder 2 is sprayed and adhered to the front and back surfaces using a resin binder liquid having the following composition.

Spray resin combination Acrylic acid ester emulsion 100 parts Silicone softener (imparts surface lubricity) 10 parts Surfactant (imparts fiber wettability) 0.1 part Concentration 5% liquid, coating amount A layer (upper layer) 2 g/m ² ,
After adjusting and spraying the B layer (lower layer) to 6 g/ ^m2 , it is introduced into a drying machine at 150°C to dry the resin binder and dry the high shrinkage polyester composite fiber of the A layer (upper layer). A three-dimensional crimp is developed to shrink the A layer in the thickness direction, and the density of the A layer is 0.015 g/cm ³ , the density of the B layer is 0.007 g/cm ³ , the basis weight is 98 g/m ² , and the first layer is 10 mm thick.
A density gradient type high-density filled cotton shown in the figure was obtained.

Incidentally, the blending ratio of the high shrinkage polyester composite fiber 3 in the above A layer is implicitly preferably 100%, but
If the content is 50% or more, the purpose will be fully achieved. Also, if it is less than 50%, the density of layer A decreases,
The heat retention effect is weakened, the density difference with the B layer is reduced, angularity occurs, and the surface strength as a padded cotton cannot be obtained unless the amount of resin binder applied is increased, among other problems. This causes points to occur. The constituent fibers of layer B are 100% highly crimped polyester fibers.
However, if it is 50% or more, the bulkiness, stiffness, etc. will be satisfactory.
However, if it falls below 50%, the B layer will sag due to repeated loading, and the sense of thickness and volume will disappear.
This is not preferable because it causes problems such as angularity. In addition, in the above examples, the apparent density of the filling cotton is 0.01 to 0.03 g/cm ³ for layer A, and 0.01 to 0.03 g/cm3 for layer B.
Preferably, the layer thickness is in the range of 0.001 to 0.008 g/cm ³ .

〔Effect of the invention〕

Since the present invention has the above structure, it is possible to increase the density in the thickness direction of the fiber layer on the side in contact with the outer fabric, maintain the bulkiness of the lower layer, and improve the surface smoothness. This invention has excellent and revolutionary effects as a filler cotton in all aspects, such as softening by reducing the amount of resin binder applied, eliminating angularity when folding, and suppressing the blowing of fibers to the fabric side. be.

[Brief explanation of the drawing]

FIG. 1 is a schematic sectional view of the structure of a density gradient type high-density padded cotton according to an embodiment of the present invention, and FIG. 2 is a schematic sectional view of the same needle punch and resin-processed structure. 1...Needle punch processing, 2...Resin binder, 3...High shrinkage polyester composite fiber.

Claims (1)

[Claims] 1 High shrinkage polyester composite fiber at least
A laminated web of a fiber web (layer A) containing 50% or more of high-crimp polyester fibers and a fiber web (layer B) containing at least 50% of highly crimped polyester fibers.
Needle punching is performed from the A layer side so that the driving depth is kept within the A layer, and the fibers on the front and back surfaces of the laminated fiber mat are bonded with a small amount of synthetic resin binder to achieve the high shrinkage. A density gradient type high-density padded cotton characterized in that only the A layer shrinks densely in the thickness direction and is intertwined as a whole due to the appearance of three-dimensional crimp accompanying heat shrinkage of the polyester composite fiber.