U.S. patent application number 15/955932 was filed with the patent office on 2018-08-23 for wadding.
This patent application is currently assigned to Mitsubishi Chemical Corporation. The applicant listed for this patent is Mitsubishi Chemical Corporation. Invention is credited to Tatsuhiko INAGAKI, Hideaki KOBAYASHI, Shima NAKANISHI, Yukio ONOHARA.
Application Number | 20180237966 15/955932 |
Document ID | / |
Family ID | 58557141 |
Filed Date | 2018-08-23 |
United States Patent
Application |
20180237966 |
Kind Code |
A1 |
NAKANISHI; Shima ; et
al. |
August 23, 2018 |
WADDING
Abstract
Wadding of the present invention is obtained by mixing 20% by
mass or more and 95% by mass or less of an acrylic fiber and 5% by
mass or more and 80% by mass or less of a polyester fiber, in which
a down power is 140 cm.sup.3/g or more and 300 cm.sup.3/g or less,
and a warmth retention property (Clo value) is 3.7 or more and 5 or
less.
Inventors: |
NAKANISHI; Shima; (Tokyo,
JP) ; ONOHARA; Yukio; (Tokyo, JP) ; INAGAKI;
Tatsuhiko; (Tokyo, JP) ; KOBAYASHI; Hideaki;
(Tokyo, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Mitsubishi Chemical Corporation |
Tokyo |
|
JP |
|
|
Assignee: |
Mitsubishi Chemical
Corporation
Tokyo
JP
|
Family ID: |
58557141 |
Appl. No.: |
15/955932 |
Filed: |
April 18, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
PCT/JP2016/081078 |
Oct 20, 2016 |
|
|
|
15955932 |
|
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D02G 1/12 20130101; D04H
1/435 20130101; D01D 5/24 20130101; D01D 5/26 20130101; D01F 6/38
20130101; D01F 6/62 20130101; D04H 1/02 20130101; D04H 1/43
20130101; D01D 5/22 20130101 |
International
Class: |
D04H 1/02 20060101
D04H001/02; D04H 1/43 20060101 D04H001/43; D04H 1/435 20060101
D04H001/435 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 20, 2015 |
JP |
2015-206232 |
Oct 20, 2015 |
JP |
2015-206233 |
Claims
1. A wadding that is obtained by mixing 20% by mass or more and 95%
by mass or less of an acrylic fiber and 5% by mass or more and 80%
by mass or less of a polyester fiber, wherein a down power is 140
cm.sup.3/g or more and 300 cm.sup.3/g or less, and a Clo value is
3.7 or more and 5 or less.
2. The wadding according to claim 1, wherein single fiber fineness
of the acrylic fiber is 0.1 dtex or more and 10 dtex or less, and
single fiber fineness of the polyester fiber is 1.0 dtex or more
and 10 dtex or less.
3. The wadding according to claim 1, wherein the polyester fiber is
a hollow fiber, and a hollow ratio of the hollow fiber is 10% or
more and 30% or less.
4. The wadding according to claim 1, wherein the down power is 150
cm.sup.3/g or more and 280 cm.sup.3/g or less.
5. The wadding according to claim 1, wherein the down power is 160
cm.sup.3/g or more and 200 cm.sup.3/g or less.
6. The wadding according to claim 1, wherein the Clo value is 3.8
or more and 4.8 or less.
7. The wadding according to claim 1, wherein the Clo value is 4 or
more and 4.7 or less.
8. The wadding according to claim 1, wherein the single fiber
fineness of the acrylic fiber is 0.5 dtex or more and 2.2 dtex or
less, and the single fiber fineness of the polyester fiber is 1.7
dtex or more and 2.2 dtex or less.
9. The wadding according to claim 1, wherein a fiber length of the
acrylic fiber is 15 mm or more and 40 mm or less, and a fiber
length of the polyester fiber is 10 mm or more and 40 mm or
less.
10. The wadding according to claim 1, wherein a mixing ratio of a
heat-bonding short fiber with respect to the wadding is 5% by mass
or more and 30% by mass or less, and at least a part of the
heat-bonding short fiber is bonded to the acrylic fiber or the
polyester fiber.
11. The wadding according to claim 1, wherein 30% by mass or more
and 70% by mass or less of the acrylic fiber and 30% by mass or
more and 70% by mass or less of the polyester fiber are mixed, and
the wadding is granular wadding in which one or a plurality of
fibers are intertwined.
12. The wadding according to claim 11, wherein the polyester fiber
is a conjugate fiber and has a coil-like form in a no-load
state.
13. The wadding according to claim 11, wherein the maximum length
of the granular wadding is 2 mm or more and 20 mm or less.
14. The wadding according to claim 1, wherein the number of crimps
of the acrylic fiber is 3 peaks/25 mm or more and 20 peaks/25 mm or
less.
15. The wadding according to claim 1, wherein a decreasing rate of
the down power after washing 10 times is 30% or lower.
Description
[0001] The present application is a continuation application of
International Application No. PCT/JP2016/081078, filed on Oct. 20,
2016, which claims priority to Japanese Patent Application Nos.
2015-206232 and 2015-206233, filed on Oct. 20, 2015, the contents
of which are incorporated herein by reference.
TECHNICAL FIELD
[0002] The present invention relates to a wadding used for an
application such as a down jacket or bedding such as a
comforter.
BACKGROUND ART
[0003] It is known that down mainly used as a wadding for
bedclothes and bedding, down jackets, and the like has a rich
texture and is lightweight, has excellent warmth retention property
and bulkiness, and further has a high recovery rate after
compression. However, in order to obtain the down, not only is it
necessary to breed a lot of waterfowl and a large amount of a feed
is required, but also there are problems of water contamination due
to excreta of the waterfowl, occurrence of infection, and spread of
the infection. In addition, in order to enable the down to be used
as a wadding, it is necessary to go through many steps of plucking
of down, selection, disinfection, and fat removal. Further, since
the down is blown up during the steps, working becomes complicated.
Accordingly, a cost of bedclothes and bedding using the down as a
wadding is high.
[0004] In addition, as a material of the wadding, it is also
possible to use a polyester fiber. The polyester fiber is low-cost
but there are problems in that lightweightness and bulkiness are
not sufficient and the warmth retention property is low.
[0005] Therefore, it has been attempted to impart bulkiness to a
synthetic fiber such as the polyester fiber.
[0006] For example, in PTL 1, it is proposed that a certain amount
of a surface treatment agent including a polyether-ester based
block copolymer as a main component be attached to surfaces of both
fibers of a matrix forming a fiber structure body and a
heat-bonding short fiber to obtain a hard cotton structure body in
which stiffness and elasticity are improved. However, in the hard
cotton structure body disclosed in PTL 1, stiffness is high but,
accordingly, there is lack of flexibility, and it is not suitable
for applications where good body-fit is required such as a
comforter or a jacket.
[0007] In addition, PTL 2 proposes the wadding formed by laminating
a layer including a fiber having single fiber fineness of 1.5
denier or less and a layer including a fiber having single fiber
fineness of 2.5 to 15 denier. However, in the wadding disclosed in
PTL 2, the layer (web) of a fiber having small single fiber
fineness and the layer (web) of a fiber having large single fiber
fineness are just laminated and a fiber having different fineness
is not intertwined. Therefore, even when using fibers having two
different fibers, there is almost no effect of increasing the
bulkiness. Here, "web" means a sheet-like object formed by
superimposing fibers.
[0008] Further. PTL 3 proposes the wadding formed by mixing a short
fiber having single fiber fineness of 0.5 dtex or more and less
than 3 dtex, a hollow fiber of 5 dtex or more and less than 10
dtex, a hollow fiber of 10 dtex or more and less than 30 dtex, and
a heat-bonding short fiber of 1 dtex or more and less than 5 dtex.
In the wadding of PTL 3, warmth retention property is imparted by a
short fiber of 0.5 dtex or more and less than 3 dtex and warmth
retention property and bulkiness are imparted by a short fiber of 5
dtex or more. However, even in the wadding described in PTL 3, the
bulkiness was not sufficient.
[0009] PTL 4 proposes ball-like cotton in which single fiber
fineness is 1.1 to 15.0 dtex, an average diameter obtained by
intertwining fibers of which lengths are 3 to 64 mm is 3 to 10 mm,
and polyester fibers having different melting points include two or
more kinds of heat-bonding fibers.
[0010] In the ball-like cotton of PTL 4, the fibers are partially
bonded to each other by heat-bonding fibers, thereby maintaining
the shape and preventing the wadding from biasing. However, even in
the ball-like cotton disclosed in PTL 4, the bulkiness and the
warmth retention property were not sufficient.
CITATION LIST
Patent Literature
[0011] [PTL 1] Japanese Unexamined Patent Application, First
Publication No. 2006-207110
[0012] [PTL 2] Japanese Unexamined Patent Application First
Publication No. S56-143188
[0013] [PTL 3] Japanese Unexamined Patent Application. First
Publication No. 2013-177701
[0014] [PTL 4] Japanese Unexamined Patent Application First
Publication No. 2002-30555
SUMMARY OF INVENTION
Technical Problem
[0015] The present invention solves the problems in the related art
described above, and provides the wadding which has excellent
bulkiness and flexibility and can be appropriately used for an
application such as a down jacket or bedding such as a
comforter.
Solution to Problem
[0016] A wadding of the present invention is obtained by mixing 20%
by mass or more and 95% by mass or less of an acrylic fiber and 5%
by mass or more and 80% by mass or less of a polyester fiber, in
which a down power is 140 cm.sup.3/g or more and 300 cm.sup.3/g or
less, and a Clo value is 3.7 or more and 5.0 or less.
[0017] In the wadding of the present invention, it is preferable
that single fiber fineness of the acrylic fiber be 0.1 dtex or more
and 10 dtex or less, and single fiber fineness of the polyester
fiber is 1 dtex or more and 10 dtex or less.
[0018] In the wadding of the present invention, it is preferable
that the polyester fiber be a hollow fiber.
[0019] In the wadding of the present invention, it is preferable
that a hollow ratio of the hollow fiber be 10% or more and 30% or
less.
[0020] In the wadding of the present invention, it is preferable
that the down power be 140 cm.sup.3/g or more and 220 cm.sup.3/g or
less.
[0021] In the wadding of the present invention, it is preferable
that the down power be 160 cm.sup.3/g or more and 200 cm.sup.3/g or
less.
[0022] In the wadding of the present invention, it is preferable
that the Clo value be 3.8 or more and 4.8 or less.
[0023] In the wadding of the present invention, it is preferable
that the Clo value be 4 or more and 4.7 or less.
[0024] In the wadding of the present invention, it is preferable
that the single fiber fineness of the acrylic fiber be 0.5 dtex or
more and 2.2 dtex or less and the single fiber fineness of the
polyester fiber be 1.7 dtex or more and 2.2 dtex or less.
[0025] In the wadding of the present invention, it is preferable
that a fiber length of the acrylic fiber be 15 mm or more and 40 mm
or less and a fiber length of the polyester fiber be 10 mm or more
and 40 mm or less.
[0026] In the wadding of the present invention, it is preferable
that a mixing ratio of a heat-bonding short fiber with respect to
the wadding be 5% by mass or more and 30% by mass or less, and at
least a part of the heat-bonding short fiber be bonded to the
acrylic fiber or the polyester fiber.
[0027] In the wadding of the present invention, it is preferable
that 30% by mass or more and 70% by mass or less of the acrylic
fiber having the single fiber fineness of 0.1 dtex or more ans 10
dtex or less be included, and the wadding be granular wadding in
which one or a plurality of fibers are intertwined.
[0028] In the wadding of the present invention, it is preferable
that 30% by mass or more and 70% by mass or less of the polyester
fiber having the single fiber fineness of 1 dtex or more and 10
dtex or less be included.
[0029] In the wadding of the present invention, it is preferable
that the polyester fiber be a conjugate fiber and has a coil-like
form in a no-load state.
[0030] In the wadding of the present invention, it is preferable
that the maximum length of the granular wadding be 2 mm or more and
20 mm or less.
[0031] In the wadding of the present invention, it is preferable
that the number of crimps of the acrylic fiber be 3 peaks/25 mm or
more and 20 peaks/25 mm or less.
[0032] In the wadding of the present invention, it is preferable
that a decreasing rate of the down power after washing 10 times be
30% or lower.
Advantageous Effects of Invention
[0033] According to the present invention, it is possible to
provide a wadding which has excellent bulkiness, flexibility, and
warmth retention property and can be appropriately used for an
application such as a down jacket or bedding such as a
comforter.
DESCRIPTION OF EMBODIMENTS
[0034] Hereinafter, the present invention will be described in
detail.
[0035] The wadding of the present invention is obtained by mixing
20% by mass or more and 95% by mass or less of an acrylic fiber and
5% by mass or more and 80% by mass or less of a polyester fiber, in
which a down power is 120 cm.sup.3/g or more and 300 cm.sup.3/g or
less, and a Clo value is 3.7 or more and 5 or less.
[0036] In terms down quality, a down power grade is used as an
index of bulkiness. In the Japan down products corporative
association, the grade is classified into four ranks from a premium
gold label of the highest quality, a royal gold label, an excel
gold label, and a new gold label. The term "down power" indicates a
volume per unit mass and represents that the larger the value
thereof, the higher the bulk. Examples of a method for measuring
the down power include a method in accordance with JIS L1903.
[0037] The wadding of the present invention makes it possible to
provide warmth, lightness, and a similar texture to down by
including the acrylic fiber, and has excellent recovery after
compression by including the polyester fiber. The acrylic fiber and
the polyester fiber are mixed, thereby increasing the bulkiness. It
becomes possible to achieve both improvement of warmth retention
property and improvement of recoverability after compression.
[0038] That is, when 20% by mass or more and 95% by mass or less of
the acrylic fiber and 5% by mass or more and 80% by mass or less of
the polyester fiber combine, it is possible to obtain a down power
of 140 cm.sup.3/g or more.
[0039] When the acrylic fiber is included in an amount of 20% by
mass or more with respect to the entire wadding, it is possible to
further increase the down power compared with a polyester 100%
product and the warmth retention property is improved. When the
acrylic fiber is 95% by mass or less, the polyester fiber is
included in an amount of 5% by mass or more with respect to the
entire wadding. Therefore, the recoverability after compression is
further improved compared with an acrylic fiber 100% product.
[0040] From this viewpoint, the mixing ratio of the acrylic fiber
to the wadding is more preferably 30% by mass or more and 90% by
mass or less and further preferably 50% by mass or more and 85% by
mass or less.
[0041] The wadding of the present invention can be mixed with other
fibers in addition to the acrylic fiber and the polyester fiber, as
long as the down power and the Clo value satisfy the specified
ranges.
[0042] From the viewpoints of the down power and the Clo value, a
total amount of the acrylic fiber and the polyester fiber is
preferably 90% by mass or more and more preferably 100% by mass,
with respect to the total amount of the wadding.
[0043] In addition, in the wadding of the present invention, it is
preferable that, when the down power is 140 cm.sup.3/g or more, the
wadding be bulkier than inner wadding formed of 100% by mass of a
polyester fiber so that the warmth retention property increases. In
addition, when the down power is 300 cm.sup.3/g or less, the
bulkiness is sufficient and the volume per mass can be reduced.
Therefore, it is advantageous in terms of transportation cost.
[0044] From the viewpoint of the warmth retention property, the
down power is more preferably 150 cm.sup.3/g or more and 280
cm.sup.3/g or less, and further preferably 160 cm.sup.3/g or more
and 200 cm.sup.3/g or less.
[0045] In the wadding of the present invention, a Clo value
measured by the method described in Examples which will be
described later is 3.7 or more and 5 or less.
[0046] When the Clo value is 3.7 or more, the wadding can be used
as the wadding with good warmth retention property. When the Clo
value is 5 or less, the warmth retention property equivalent to the
down is obtained. Therefore, the Clo value is sufficient.
[0047] From the viewpoint of warmth retention property, the Clo
value is more preferably 3.8 or more and further preferably 4 or
more.
[0048] In the wadding of the present invention, it is preferable
that single fiber fineness of the acrylic fiber be 0.1 dtex or more
and 10 dtex or less, and single fiber fineness of the polyester
fiber be 1 dtex or more and 10 dtex or less.
[0049] It is preferable that the single fiber fineness of the
acrylic fiber be 0.1 dtex or more, from the viewpoint of
processability of the wadding manufacturing, and it is preferable
that the single fiber fineness of the acrylic fiber be 10 dtex or
less, from the viewpoint of increasing warmth retention property
and the texture not being hard. From this viewpoint, the single
fiber fineness is more preferably 0.5 dtex or more and 2.2 dtex or
less and further preferably 0.8 dtex or more and 2.8 dtex or
less.
[0050] In addition, it is preferable that the mixing ratio of the
acrylic fiber to the wadding be 20% by mass or more, from the
viewpoint of improving the warmth retention property, and it is
preferable that the mixing ratio be 95% by mass, from the viewpoint
of improving the recoverability by adding the polyester fiber.
[0051] It is preferable that the single fiber fineness of the
polyester fiber be 1 dtex or more, from the viewpoints that effects
of improving the recoverability and preventing permanent set
(fatigue deformation) from occurring can be obtained and the
bulkiness increases, and it is preferable that the single fiber
fineness be 10 dtex or less, from the viewpoint of increasing the
warmth retention property and the texture not being hard. From this
viewpoint, the single fiber fineness of the polyester fiber is more
preferably 1.7 dtex or more and 2.2 dtex or less.
[0052] The single fiber fineness described in the present
specification can be measured by a method in accordance with 8.5 in
JIS L1015: 2010.
[0053] In addition, it is preferable that the polyester fiber be a
hollow fiber. Since the polyester fiber is inferior in the warmth
retention property compared to the acrylic fiber, when a
cross-sectional shape thereof is formed to be hollow, it is
possible to secure immobile air. Further, when the polyester fiber
is formed to have a hollow cross section, a cross-sectional area
becomes larger than that of a non-hollow fiber. Therefore, effects
are achieved such that the rigidity of the fiber increases, the
recoverability is improved, and permanent set is prevented from
occurring.
[0054] The hollow ratio of the hollow fiber is preferably 10%/o to
30%. It is preferable that the hollow ratio of the hollow fiber be
10% or more, because the heat retention rate is improved. From this
viewpoint, the hollow ratio of the hollow fiber is preferably 10%
or more and more preferably 20% or more.
[0055] In the wadding of the present invention, it is preferable
that the fiber length of the acrylic fiber be 15 mm or more and 40
mm or less and the fiber length of the polyester fiber is 10 mm or
more and 40 mm or less.
[0056] Here, the "fiber length" described in the present
specification indicates a length in a fiber axis direction. The
fiber length described in the present specification can be measured
by a method in accordance with C method of 8.4 of JIS L1015:
2010.
[0057] It is preferable that the fiber length of the acrylic fiber
be 15 mm or more, because processability in the manufacturing
process of the wadding is favorable and the bulkiness is improved,
and it is preferable that the fiber length be 40 mm or less,
because the fibers are suppressed from intertwining with each other
and the wadding can be prevented from biasing. Further, from this
viewpoint, the fiber length of the acrylic fiber is more preferably
25 mm or more and 38 mm or less.
[0058] It is preferable that the fiber length of the polyester
fiber be 10 mm or more, because it is possible to reduce falling of
the polyester fiber in the manufacturing process or from the
wadding, and it is preferable that the fiber length be 40 mm or
less, because the fibers are suppressed from intertwining with each
other and the wadding can be prevented from biasing. Further, from
this viewpoint, the fiber length of the polyester fiber is
preferably 12 mm or more and 35 mm or less and further preferably
25 mm or more and 30 mm or less.
[0059] The acrylic fiber can be appropriately selected according to
a targeted application or performance. The acrylic fiber may be
obtained by, for example, a method in which side-by-side type
fibers are mixed to develop self-crimpability, thereby improving
the bulkiness of the wadding, a method in which Y-shaped fibers are
mixed so as to improve the bulkiness of the wadding and the warmth
retention property, or a method in which fibers having single fiber
fineness of 0.8 dtex or more and 20 dtex or less are mixed. In
addition, as the acrylic fiber, for example, fibers in which each
function is imparted and the performance is improved by combining
an antibacterial fiber, a deodorant fiber, a hygroscopic
heat-generating fiber, an optothermal fiber, and a flame retardant
fiber. In addition, the fiber may be used alone, and two or more
thereof may be used in combination.
[0060] In addition, it is preferable that the wadding of the
present invention include a heat-bonding short fiber in an amount
of 5% by mass to 30% by mass and at least a part of the
heat-bonding short fiber is bonded to the acrylic fiber or the
polyester fiber, from the viewpoints of bulkiness, compression
recoverability, and easy retention of a formed nep.
[0061] As the heat-bonding short fiber, it is preferable to use a
short fiber formed of low melting point resin having a melting
point of 100.degree. C. to 200.degree. C. As these short fibers,
specifically, it is preferable to use a short fiber using low
melting point polyester obtained by copolymerizing isophthalic
acid, adipic acid, cyclohexane dicarboxylic acid, sebacic acid, or
the like to polyethylene terephthalate or polybutylene
terephthalate, as a raw material. After developing the nep, to be a
core, of the acrylic fiber, the heat-bonding short fiber is
thermally bonded to a part of the acrylic fiber. Accordingly, the
nep can be retained. However, since the acrylic fiber of the
present invention provides effects such that the single fiber
fineness is very small and the formed nep is difficult to unravel,
the heat-bonding short fiber may be used according to an
application requiring durability.
[0062] Next, the wadding of the present invention can have a
configuration in which 30% by mass or more and 70% by mass or less
of the acrylic fiber and 30% by mass or more and 70% by mass or
less of the polyester fiber are mixed, and the wadding is granular
wadding in which one or a plurality of fibers are intertwined.
[0063] Advantageous effects of the down include bulkiness, warmth
retention property, and independence unique to a down ball. Here,
in a case of mixed wadding in which two or more types of wadding
are mixed, when the fiber length is long, entanglement between the
fibers becomes large, which causes the wadding to bias. On the
other hand, since in a case where the fiber length is short, the
entanglement of the fibers becomes small, it is effective for
preventing the wadding from biasing but does not contribute to the
bulkiness between fibers. In addition, in the mixed-wadding type in
which opened wadding is mixed, it is difficult to prevent the
wadding from biasing. However, when the wadding has a granular
form, it is possible to impart independence unique to the down.
Further, since if the single fiber fineness is small, the number of
constituents per unit weight increases, and the warmth retention
property increases.
[0064] In the configuration, it is preferable that the content
ratio of the acrylic fiber with respect to the entire wadding be
30% by mass or more and 70% by mass or less. It is preferable that
the content ratio of the acrylic fiber with respect to the entire
wadding be 30% by mass or more, from the viewpoint of favorable
formability of the granular wadding, and it is preferable that the
content ratio be 70% by mass or less, from the viewpoint of
improvement of the warmth retention property. From these
viewpoints, the content ratio of the acrylic fiber with respect to
the entire wadding is more preferably 40% by mass or more and 60%
by mass or less, and further preferably 45% by mass or more and 55%
by mass or less.
[0065] In addition, in the configuration, it is preferable that the
content ratio of the polyester fiber with respect to the entire
wadding be 30% by mass or more and 700/o by mass or less. The
wadding includes the polyester fiber; accordingly, the formability
of the granular wadding improves and even after compression, a
shape of the granular wadding recovers to a form close to a sphere.
As the shape of the granular wadding is closer to a sphere, the
gaps between the granular wadding become larger. The amount of
immobile air increases as a whole and the warmth retention property
improves.
[0066] It is preferable that the content ratio of the polyester
fiber with respect to the entire wadding be 30% by mass or more,
from the viewpoint of the formability of the granular wadding, and
it is preferable that the content ratio thereof be 70% by mass or
less, from the viewpoint of improvement of the heat retention rate.
From these viewpoints, the content ratio of the polyester fiber
with respect to the entire wadding is more preferably 40% by mass
or more and 60% by mass or less, and further preferably 45% by mass
or more and 55% by mass or less.
[0067] The granular wadding described in the present specification
represents wadding in which one or a plurality of fibers are
intertwined to form a sphere. The sphere may be, for example, a
shape like a rugby ball or the fiber may appear like a whisker, as
long as it is possible to recognize a shape close to a sphere.
[0068] The granular wadding is, for example, a shape close to a
pill generated on a wool sweater.
[0069] It is preferable that the acrylic fiber have crimps, from
the viewpoint of forming granular wadding. The crimp in this case
may be mechanical crimping or may develop self-crimpability as a
side-by-side type composite fiber.
[0070] The acrylic fiber can be appropriately selected according to
a targeted application or performance. For example, the acrylic
fiber may have a cross-sectional shape having a projection portion
on a long side of a flat cross section, Y-shaped cross-sectional
shape, and the like. In addition, for example, antibacterial
property, deodorant property, hygroscopic heat-generating property,
optothermal property, and flame retardancy are imparted to the
acrylic fiber. In addition, the acrylic fiber can be individually
combined. The acrylic fiber may be used alone and two or more
thereof may be used in combination.
[0071] In the wadding formed of the granular wadding having the
configuration, it is preferable that the polyester fiber be a
conjugate fiber, and have a coil-like form in a no-load state.
Here, in order to form the granular wadding, the crimp of the fiber
is important. If there is no crimp, a grain is not formed. The
polyester fiber has a coil-like form, whereby the fibers are
entangled with each other and it is possible to manufacture
granular wadding.
[0072] In addition, in the wadding formed of the granular wadding
having the above described configuration, it is preferable that the
maximum length of the granular wadding be 2 mm or more and 20 mm or
less. It is preferable that the maximum length of the granular
wadding be 2 mm or more, because it is difficult for the user to
feel the tactile sensation of the grain. In addition, it is
preferable that the maximum length of the granular wadding be 20 mm
or less, because it is possible to prevent the wadding from
biasing. Further, the closer the shape of the grain (granular
wadding) to a true sphere, the larger the air gap and the more the
immobile air. Therefore, the warmth retention property
improves.
[0073] From the viewpoints, the maximum length of granular wadding
is preferably 5 mm or more and 15 mm or less, and further
preferably 7 mm or more and 13 mm or less.
[0074] In addition, in the wadding formed of the granular wadding
having the configuration, it is preferable that the number of
crimps of the acrylic fiber be 3 peaks/25 mm or more and 20
peaks/25 mm or less.
[0075] If the number of crimps of the acrylic fiber is 3 peaks/25
mm or more and 20 peaks/25 mm or less, granular wadding is easily
formed and shape-keeping property is also favorable. From these
viewpoints, the number of crimps of the acrylic fiber is more
preferably 7 peaks/25 mm or more and 13 peaks/25 mm or less.
[0076] The unit of "peak" in the number of crimps means the number
of crimping times (a value obtained by dividing a total number of
the mountain and valley by 2). In addition, the number of crimps
described in the present specification can be measured by a method
in accordance with 8.12 of JIS L1015: 2010.
[0077] In the wadding having the configuration formed of the
granular wadding as described above, it is preferable that the down
power (DP) be 120 cm.sup.3/g or more and 270 cm.sup.3/g or less.
The down power of the wadding formed of the granular wadding is
preferably 120 cm.sup.3/g or more, from the viewpoint of securing
sufficient warmth retention property, more preferably 130
cm.sup.3/g or more, and further preferably 140 cm.sup.3/g or
more.
[0078] Further, in the wadding having the configuration formed of
the granular wadding, it is preferable that the decreasing rate of
the down power after washing 10 times be preferably 30% or lower.
In general, the down has restrictions on washing conditions such as
dry cleaning and cannot be washed at home, and is troublesome to
handle. However, according to the granular wadding of the present
invention, the particle shape does not collapse even after washing
and the granular waddings are not entangled with each other.
Therefore, wadding biasing or lowering of the bulkiness is smaller
than mixed wadding.
[0079] That is, in the wadding formed of the granular wadding, it
is preferable that the decreasing rate of the down power after
washing 10 times be 30% or lower because sufficient warmth
retention property can be maintained even after washing.
[0080] Next, the manufacturing method of the wadding of the present
invention will be described.
[0081] The wadding of the present invention can be manufactured by
a method including steps of laminating or mixing an acrylic fiber
having single fiber fineness of 0.1 dtex or more and 10 dtex or
less and a polyester fiber of 1.0 dtex or more and 10 dtex or less
to pass through a spreading machine, and mixing the fibers after
opening with blowing or at least one or more carding machines.
[0082] In addition, in a case where the wadding is formed into the
granular wadding, further, the fibers are put into a device for
manufacturing the granular wadding.
[0083] The method of manufacturing the acrylic fiber having single
fiber fineness of 0.1 dtex to 10 dtex is not particularly limited,
and the acrylic fiber having the single fiber fineness can be
manufactured by a known manufacturing method.
[0084] For example, there is a method including a step (A) in which
after a polyacrylonitrile copolymer is dissolved in
dimethylacetamide to obtain a solution, the solution is discharged
and solidified in an aqueous solution of dimethylacetamide using a
nozzle having a discharge port to obtain a coagulated fiber, and
further including a step (B) in which the coagulated fiber obtained
in the step (A) is subjected to drawing treatment by wet heat
drawing or dry heat drawing, or both methods, is washed in boiling
water, and dried at a temperature of 100.degree. C. to 200.degree.
C. after applying oil, and then mechanical crimping
(two-dimensional mountain-like shape) is imparted to obtain a fiber
(ultra-fine fiber) having a single fiber fineness of from 0.1 dtex
to 10 dtex.
[0085] In the manufacturing method, the ratio of the
polyacrylonitrile copolymer dissolved in dimethylacetamide with
respect to the solution is preferably 10% by mass to 30% by mass
and more preferably 15% by mass to 25% by mass.
[0086] In addition, a pore diameter of the discharge port of the
nozzle is preferably 0.010 mm to 0.080 mm from the viewpoint of
obtaining a fiber having a desired fineness, and more preferably
0.015 mm to 0.060 mm.
[0087] In addition, the concentration of dimethylacetamide in the
dimethylacetamide aqueous solution is preferably 10% by mass to 80%
by mass from the viewpoint of favorable processability, and more
preferably 20% by mass to 60% by mass.
[0088] In addition, a magnification of drawing of the coagulated
fiber is preferably 2 times to 8 times from the viewpoint of
increasing the strength, and more preferably 3 times to 6.5
times.
[0089] Further, examples of method of manufacturing a short fiber
from the ultra-fine fiber obtained in the method include a method
including a crimping step (1) of further imparting mechanical
crimping using a heat relaxation treatment and/or a crimper as
needed and further including step (2) of cutting the acrylic fiber
so that the length thereof is 15 mm to 40 mm after the crimping
step (1).
[0090] The crimping step (1) is preferably machine crimping using a
crimper, and it is preferable that the number of crimps be 3
peaks/25 mm to 20 peaks/25 mm, from the viewpoint of bulkiness.
[0091] It is preferable that the number of crimps of the acrylic
fiber be 3 peaks/25 mm or more, from the viewpoint of maintaining
the shape of the wadding, and it is preferable the number of crimps
thereof be 20 peaks/25 mm or less, from the viewpoint
processability in manufacturing of the wadding.
[0092] Further, in a case where the manufacturing method of the
wadding includes a step of bonding the heat-bonding short fiber to
the acrylic fiber or the polyester fiber, it is preferable that the
acrylic fiber obtained in the step (2) be mixed with the
heat-bonding short fiber to fix the nep by heating to a temperature
of 100.degree. C. to 220.degree. C.
EXAMPLES
[0093] Hereinafter, the present invention will be described in
detail with reference to examples and comparative examples, but the
present invention is not limited to the examples.
(Measurement of Single Fiber Fineness)
[0094] Single fiber fineness of an acrylic fiber and a polyester
fiber was measured in accordance with JIS L 1015: 2010. The results
are shown in Tables 1 and 2 below.
(Measurement Method of Down Power)
[0095] A down power of the wadding was measured in the same manner
as the method specified in JIS L1903, except that the treatment
using the dryer method and the steam method of pretreatment are not
performed. The results are shown in Tables 1 and 2 below.
(Measurement of Maximum Length of Granular Wadding)
[0096] The maximum length of the granular wadding was measured
using a caliper.
[0097] At this time, 30 samples were measured and the average value
thereof was taken as the maximum length thereof. The results are
shown in Tables 1 and 2 below.
(Measurement Method of Clo Value)
[0098] The warmth retention rate (Clo value) of the wadding was
measured using Thermo Labo II and a dry contact method under the
following conditions and procedure. The results are shown in Tables
1 and 2 below.
[0099] 1. The measurement was performed in a test room in which a
room temperature of 22.degree. C. and humidity of 60% were
maintained.
[0100] 2. A sample which is obtained by putting 10 g of the wadding
into a 20 cm square cushion cover (fabric: 100% cotton) was
prepared.
[0101] 3. The sample was set on a heating plate set at 32.degree.
C. using the KES-F7 Thermo Labo 11 Tester (registered trademark)
manufactured by Kato Tech Co., Ltd.
[0102] 4. A heat quantity a (W) dissipated through the sample was
calculated under a windy condition of 30 cm/sec.
[0103] 5. A heat quantity b (W) dissipated in a state where the
sample was not set was calculated, and the Clo value was calculated
by the following equation.
Clo value=0.645/(1/heat quantity a-1/heat quantity b)
This represents that the higher the Clo value, the more warmth
retention property of the wadding. In Tables 1 and 2 below, "-"
indicates non-measured.
[0104] For the Thermo Labo 11 and dry contact method, and Clo
value, refer to the following URL.
[0105] (A) Thermo Labo II Dry contact method (General Foundation
Boken Quality Evaluation Institute)
[0106]
http://www.boken.or.jp/service/clothing/functionality/warmth_keepin-
g.html
[0107] (B) Clo value (General Foundation Kaken Test Center)
[0108]
http://www.kaken.or.jp/guidance/functionality/thermal_mannequin.htm-
l
(Evaluating Method of Permanent Setting Property)
[0109] A height Amm of a loading disk was measured in accordance
with JIS L1903, and the height Bmm of the loading disk after 24
hours was measured.
[0110] Then, a value calculated using this formula
([(A-B)/A].times.100(%)), from respective heights A and B obtained
by the measurement, was assumed as a permanent setting property
(fatigue deformability), and was evaluated according to the
following criteria.
[0111] A (Excellent): Permanent setting property 95% or more
[0112] B (Favorable): Permanent setting property 85% or more and
less than 95%
[0113] C (Inferior): Permanent setting property less than 85%
Example 1
[0114] A copolymer formed of 95% by mass of acrylonitrile and 5% by
mass of vinyl acetate was dissolved in dimethylacetamide such that
the concentration of the copolymer was 20% by mass. Thereafter, the
solution was discharged into an aqueous solution including 50% by
mass of dimethylacetamide using a nozzle having a round discharge
hole with a hole diameter of 0.045 mm and subjected to washing in
boiling water and stretching to 4.5 times. Then, an oil agent was
applied to be dried at a temperature of 150.degree. C. Thereafter,
a thermal relaxation treatment was carried out and mechanical crimp
of 12 peaks/25 mm was imparted using a crimper. A tow was cut such
that a length of the single fiber was 38 mm. Accordingly, an
acrylic short fiber in which a cross-sectional shape was round and
single fiber fineness was 0.8 dtex was obtained.
[0115] Thereafter, 60% by mass of the acrylic short fibers as a
fiber 1 and 40% by mass of the hollow polyester fiber (single fiber
fineness: 2.2 dtex, fiber length: 20 mm, and hollow ratio 6%) as a
fiber 2 were mixed with a cotton mixing machine to pass through a
spreading machine, and further mixed with a carding machine to
obtain the wadding.
[0116] Then, bulkiness evaluation and warmth retention property
evaluation were performed using the wadding obtained by the method.
The evaluation results are shown in Table 1 below.
Example 2
[0117] The wadding was manufactured and evaluated by the same
method as in Example 1 except that the fiber 2 was changed to a
non-hollow regular polyester having single fiber fineness of 1.7
dtex and a fiber length of 15 mm. The results of bulkiness and
warmth retention property obtained in Example 2 are shown in Table
1 below.
Example 3
[0118] The wadding was manufactured and evaluated by the same
method as in Example 1 except that proportions of the fibers 1 and
2 were changed as shown in Table 1 below. The results of bulkiness
and warmth retention property obtained in Example 3 are shown in
Table 1.
Example 4
[0119] A copolymer formed of 93% by mass of acrylonitrile and 7% by
mass of vinyl acetate was dissolved in dimethylacetamide such that
the concentration of the copolymer was 20% by mass. Thereafter, the
solution was discharged into an aqueous solution including 56% by
mass of dimethylacetamide using a nozzle having a round discharge
hole with a hole diameter of 0.060 mm and subjected to washing in
boiling water and stretching to 6 times. Then, an oil agent was
applied to be dried at a temperature of 150.degree. C. Thereafter,
a thermal relaxation treatment was carried out and mechanical crimp
of 12 peaks/25 mm was imparted using a crimper. Then, a tow was cut
such that a length of the single fiber was 20 mm. Accordingly, an
acrylic short fiber in which a cross-sectional shape was
approximately a broad bean shape and single fiber fineness was 1
dtex was obtained.
[0120] Thereafter, as shown in Table 1 below, 20% by mass of the
acrylic fiber in which the cross-sectional shape was a broad bean
shape and 30% by mass of the acrylic fiber in which the
cross-sectional shape was a circular shape, 30% by mass of the
polyester fiber of Example 3 in which the cross-sectional shape was
hollow, and 20% by mass of the polyester fiber of Example 2 in
which the cross-sectional shape was circular were mixed with a
cotton mixing machine to pass through a spreading machine, and
further mixed with a carding machine to obtain the wadding.
[0121] Then, bulkiness evaluation and warmth retention property
evaluation were performed using the obtained wadding by the same
method as above. The evaluation results are shown in Table 1
below.
Comparative Example 1
[0122] The bulkiness and the warmth retention property of another
manufacturer's product (product name: PrimaLoft (registered
trademark), manufactured by Albany International Corp., and
polyester 100%) used for the wadding were evaluated by the same
method as above. The results thereof are shown in Table 1
below.
[0123] The PrimaLoft used in Comparative Example 1 is formed of
polyester having single fiber fineness of 1 dtex. Instead of
several kinds of polyesters having different fineness being mixed
as in the present invention. PrimaLoft is formed of only a fiber
having singular fineness.
Comparative Example 2
[0124] The bulkiness and the warmth retention property of another
manufacturer's product (product name: Air Flake (registered
trademark), manufactured by KURABO INDUSTRIES LTD.) used for the
wadding were evaluated by the same method as above. The results
thereof are shown in Table 1 below.
[0125] The wadding of Comparative Example 2 is formed of a long
fiber and includes a core yarn and a fancy yarn, in which the fancy
yarn is longer than the core yarn, the core yarn and the fancy yarn
are united by interlacing, the fancy yarn is interlacing yarn for
wadding which is opened to form a loop-shaped fiber, the fancy yarn
is hollow fiber, and a hollow ratio is 25%. In addition, in the
wadding material of Comparative Example 2, both the core yarn and
the fancy yarn are 100% by mass of polyester fibers.
Comparative Example 3
[0126] 100% by mass of the polyester fiber having a circular cross
section (single fiber fineness: 1.7 dtex and fiber length: 15 mm)
was passed through a spreading machine and then further wadding was
stirred with air to obtain the wadding. Thereafter, the bulkiness
and the warmth retention property thereof were evaluated by the
same method as above. The evaluation results thereof are shown in
Table 1 below.
[0127] The wadding obtained in Comparative Example 3 was low both
in the bulkiness and the warmth retention property.
Comparative Example 4
[0128] 100% by mass of the polyester fiber having the hollow cross
section (fiber fineness: 2.2 dtex and fiber length: 20 mm) used in
Example 1 was used to pass through the spreading machine and then
further wadding was stirred with air to obtain the wadding. The
evaluation results thereof are shown in Table 1.
[0129] The obtained wadding was low in both bulkiness and the
warmth retention property.
Reference Example 1
[0130] 100% by mass of the acrylic fiber (single fiber fineness:
0.8 dtex and fiber length: 38 mm) used in Example 1 was used to
pass through the spreading machine and then mixed with the carding
machine to obtain the wadding.
[0131] The wadding obtained above was used for performing the
bulkiness evaluation and the warmth retention property evaluation
by the same method as above. The evaluation results are shown in
Table 1 below.
[0132] Reference Example 1 was a wadding of 100% by mass of the
acrylic fiber, in which the down power and the Clo value were
favorable but the permanent setting property was inferior.
TABLE-US-00001 TABLE 1 Compar- Compar- Compar- Compar- Example
Example Example Example ative ative ative ative Reference 1 2 3 4
Example 1 Example 2 Example 3 Example 4 Example 1 <Fiber 1>
Kind of fiber Acryl Acryl Acryl Acryl Polyester Polyester Polyester
Polyester Acryl Cross-sectional Circular Circular Circular Circular
Circular Circular Circular Hollow Circular shape shape shape shape
shape shape shape shape shape shape Fineness (dtex) 0.8 0.8 0.8 1 1
1.2 1.7 2.2 0.8 Fiber length (mm) 38 38 38 20 50 -- 15 20 38 Number
of crimps 12 12 12 12 10 10 10 10 10 (peaks/25 mm) Mixing ratio (%)
60 60 80 30 100 40 100 100 100 <Fiber 2> Kind of fiber
Polyester Polyester Polyester Acryl -- Polyester -- -- --
Cross-sectional Hollow Circular Hollow Broad -- Hollow -- -- --
shape shape shape shape bean shape shape Fineness (dtex) 2.2 1.7
2.2 2.2 -- 1.7 -- -- -- Fiber length (mm) 20 15 20 20 -- 50 -- --
-- Number of crimps 10 10 10 12 -- 10 -- -- -- (peaks/25 min)
Mixing ratio (%) 40 40 20 20 -- 60 -- -- -- <Fiber 3> Kind of
fiber -- -- -- Polyester -- -- -- -- -- Cross-sectional -- -- --
Hollow -- -- -- -- -- shape shape Fineness (dtex) -- -- -- 2.2 --
-- -- -- -- Fiber length (mm) -- -- -- 20 -- -- -- -- -- Number of
crimps -- -- -- 10 -- -- -- -- -- (peaks/25 mm) Mixing ratio (%) --
-- -- 30 -- -- -- -- -- >Fiber 4> Kind of fiber -- -- --
Polyester -- -- -- -- -- Cross-sectional -- -- -- Circular -- -- --
-- -- shape shape Fineness (dtex) -- -- -- 1.7 -- -- -- -- -- Fiber
length (mm) -- -- -- 15.0 -- -- -- -- -- Number of crimps -- -- --
10 -- -- -- -- -- (peaks/25 mm) Mixing ratio (%) -- -- -- 20 -- --
-- -- -- >Wadding> Shape Wadding Wadding Wadding Wadding
Wadding Yarn Wadding Wadding Wadding shape shape shape shape shape
shape shape shape shape Down power (cm.sup.3/g) 191 195 197 179 137
206 99 142 219 clo value 4.07 4.14 4.56 4.28 3.87 3.64 2.6 3.12
4.12 Permanent setting B B B B A A A A C property
Example 5
[0133] A copolymer formed of 93% by mass of acrylonitrile and 7% by
mass of vinyl acetate was dissolved in dimethylacetamide such that
the concentration of the copolymer was 24% by mass. Thereafter, the
solution was discharged into an aqueous solution including 50% by
mass of dimethylacetamide using a nozzle having a round discharge
hole with a hole diameter of 0.060 mm and subjected to washing in
boiling water and stretching to 6 times. Then, an oil agent was
applied to be dried at a temperature of 150.degree. C. Thereafter,
a thermal relaxation treatment was carried out and mechanical crimp
of 12 peaks/25 mm was imparted using a crimper. A tow was cut such
that a length of the single fiber was 20 mm. Accordingly, an
acrylic short fiber in which single fiber fineness was 1.0 dtex and
a cross-sectional shape perpendicular to a fiber axis direction was
a circular shape was obtained.
[0134] Thereafter, 50% by mass of the acrylic short fibers as a
fiber 1 and 50% by mass of the polyester fiber (single fiber
fineness: 2.5 dtex and fiber length: 32 mm) as a fiber 2 were mixed
to pass through a cotton granulator, thereby obtaining granular
wadding.
[0135] Then, bulkiness evaluation and warmth retention property
evaluation were performed using the obtained wadding by the same
method as above. The evaluation results thereof are shown in Table
2 below.
Example 6
[0136] The wadding was manufactured and evaluated by the same
method as in Example 5 except that the acrylic short fiber of the
fiber 1 was changed to those described in Table 2 below.
[0137] The evaluation results of bulkiness and the warmth retention
property of the obtained wadding are shown in Table 2 below.
Comparative Example 5
[0138] The wadding was manufactured and evaluated by the same
method as in Example 5 except that the acrylic short fiber of the
fiber 1 was changed to those described in Table 2 below.
[0139] The evaluation results of the bulkiness and the warmth
retention property of the obtained wadding are shown in Table 2
below.
[0140] The obtained wadding of Comparative Example 5 was low in
down power.
Comparative Example 6
[0141] The granular wadding was manufactured and evaluated by the
same method as in Example 5 except that the acrylic short fiber of
the fiber 1 was changed to a flat acrylic short fiber in which
single fiber fineness was 17 dtex, a cross-sectional shape
perpendicular to the fiber axis direction was a flat shape, and a
flatness ratio was 10.
[0142] The evaluation results of the bulkiness and the warmth
retention property of the obtained wadding are shown in Table 2
below.
[0143] The obtained wadding of Comparative Example 6 was low in the
Clo value.
Comparative Example 7
[0144] The granular wadding was manufactured and evaluated by the
same method as in Example 5 except that the fiber 1 was changed to
the flat acrylic short fiber used in Comparative Example 6 and the
fiber 2 was changed to the acrylic short fiber used in Example
3.
[0145] The evaluation results of the bulkiness and the warmth
retention property of the obtained wadding are shown in Table 2
below.
[0146] The obtained wadding of Comparative Example 7 was low in
down power and Clo value and poor in permanent setting
property.
Comparative Example 8
[0147] The granular wadding was manufactured and evaluated by the
same method as in Example 1 except that the fiber 2 was changed to
the same fiber as fiber 1 used in Example 6.
[0148] The evaluation results of the bulkiness and the warmth
retention property of the obtained wadding are shown in Table 2
below.
[0149] The obtained wadding of Comparative Example 8 was low in Clo
value and poor in permanent setting property.
TABLE-US-00002 TABLE 2 Compar- Compar- Compar- Compar- Example
Example ative ative ative ative 5 6 Example 5 Example 6 Example 7
Example 8 <Fiber 1> Kind of fiber Acryl Acryl Acryl Acryl
Acryl Acryl Cross-sectional Circular Ellipse Broad bean Flat Flat
Circular shape shape shape shape shape shape shape Fineness (dtex)
1 6.6 2.2 17 17 1 Fiber length (mm) 20 32 32 32 32 20 Number of
crimps 12 12 12 12 12 12 (peaks/25 mm) Mixing ratio (%) 50 50 50 50
50 50 <Fiber 2> Kind of fiber Polyester Polyester Polyester
Polyester Acryl Acryl Cross-sectional Circular Circular Circular
Circular Circular Ellipse shape shape shape shape shape shape shape
Fineness (dtex) 2.5 2.5 2.5 2.5 1 6.6 Fiber length (mm) 32 32 32 32
20 32 Number of crimps 10 10 10 10 12 12 (peaks/25 mm) Mixing ratio
(%) 50 50 50 50 50 50 <Fiber 3> Kind of fiber -- -- -- -- --
-- Cross-sectional -- -- -- -- -- -- shape Fineness (dtex) -- -- --
-- -- -- Fiber length (mm) -- -- -- -- -- -- Number of crimps -- --
-- -- -- -- (peaks/25 mm) Mixing ratio (%) -- -- -- -- -- --
<Fiber 4> Kind of fiber -- -- -- -- -- -- Cross-sectional --
-- -- -- -- -- shape Fineness (dex) -- -- -- -- -- -- Fiber length
(mm) -- -- -- -- -- -- Number of crimps -- -- -- -- -- -- (peaks/25
mm) Mixing ratio (%) -- -- -- -- -- -- <Wadding> Shape
Granular Granular Granular Granular Granular Granular wadding
wadding wadding wadding wadding wadding shape shape shape shape
shape shape Maximum length of 10 10 10 10 10 10 granular wadding
(mm) Down power 153 152 126 156 129 134 (cm.sup.3/g) clo value 3.88
3.90 3.79 3.20 3.36 3.81 Permanent setting B B B B C C property
* * * * *
References