Inner cotton, bedding including inner cotton and production method of inner cotton

Abstract

To provide inner cotton which has high heat insulation property, can be simplified in its structure, and used for a quilt and blanket, bedding including the same and a production method of the inner cotton.SOLUTION: A quilt 10 as one kind of bedding includes, as shown in the figure 1 (a), an inner cotton layer 1 in which aerogel is kneaded, and an outer material 2 and an inner material 3 respectively provided on a front side and a rear side of the layer 1. A blanket 11 as one kind of bedding includes, as shown in the figure 1 (b), two inner cotton layers 1 in which the aerogel is kneaded, a microfiber outer material 2 provided on a front side of the inner cotton layers, and a microfiber inner material 3 provided on a rear side of the inner cotton layers, and a heat insulation layer, for example, an aluminum layer 4 is provided between the two inner cotton layers 1.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a method for producing filling for use in bedding such as quilts and blankets, bedding containing the filling, and the filling. [Background technology]

[0002] The comforters shown in Patent Documents 1 to 3 are composed of a front and back fabric, and batting, feathers, etc., arranged between the front and back fabrics. In order to increase the heat retention of the comforter, it is necessary to secure many air layers formed between the fibers and feathers that make up the batting. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Utility Model Registration No. 3236318 [Patent Document 2] Patent No. 6584046 [Patent Document 3] Patent No. 6641061 Summary of the Invention [Problem to be solved by the invention]

[0004] It is thought that using aerogel as the filling would improve heat retention, but the manufacturing process for the aerogel filling layer is complicated, making it very difficult to reduce production costs. In addition, aerogel has issues such as low durability, and it is difficult for the aerogel fibers to capture the air in the filling, which may prevent a high level of heat retention and insulation.

[0005] Therefore, the present invention aims to provide a filling for use in bedding such as quilts and blankets that has high heat retention properties and can have a simplified structure, as well as a bedding containing the filling and a method for producing the filling. [Means for solving the problem]

[0006] In order to solve the above problems, the present invention provides a filling comprising short fibers kneaded with aerogel, the weight ratio of the aerogel to the total weight of the short fibers being 0.1% to 10%, the thermal conductivity of the aerogel being 0.01 to 0.03 W / (m·k), and the thermal conductivity of the short fibers being 0.1 to 0.14 W / (m·k). This provides high heat retention and simplifies the structure. The filling of the present invention can be used in bedding such as comforters and blankets to provide bedding with high heat retention, but the use of the filling of the present invention is not limited to bedding. For example, the filling of the present invention can also be used in interior goods such as rugs and cushions.

[0007] The fibers constituting the filling may be only short fibers having the aerogel kneaded therein.

[0008] It is preferable that the filling layer contains a second fiber different from the short fiber, and the weight ratio of the second fiber to the total weight of the filling layer is 0 to 95% (excluding 0%). This prevents any problems in the production of the filling layer.

[0009] It is preferable that the short fibers have a fiber diameter of 0.5 Dtex to 50 Dtex and a length of 20 mm to 100 mm, and the second fibers are short fibers having a fiber diameter of 0.5 Dtex to 50 Dtex and a length of 20 mm to 250 mm, so that no problems occur in the production of the padding layer.

[0010] The present invention also provides bedding comprising a front and back fabric, and a padding layer disposed between the front and back fabric and made of the above-mentioned padding, thereby providing a bedding that is light, thin, has high heat retention, and does not easily lose heat.

[0011] It is preferable that the bedding further comprises a heat insulating layer, the heat insulating layer being sandwiched between two of the padding layers from the front and back sides, and the two padding layers being sandwiched between the front and back fabrics, thereby making it possible to provide a blanket that is light, thin, and has high heat retention and does not easily lose heat.

[0012] The present invention also provides a method for producing a filling material, which includes a melt spinning production process in which aerogel is mixed into a synthetic fiber material, the synthetic fiber material is polymerized to produce chips containing aerogel, and the chips are melt spun into fibers, a staple fiber production process in which the melt spun fibers are stretched and cut to produce staple fibers, and a filling material formation process in which the staple fibers are formed into a filling material, thereby providing high heat retention and simplifying the structure. [Brief description of the drawings]

[0013] [Figure 1] 1 is a cross-sectional view of a bedding item according to an embodiment of the present invention. [Diagram 2] 1 is a flowchart showing a production process of an aerogel-containing polyester staple fiber according to an embodiment of the present invention. [Diagram 3] FIG. 2 is an explanatory diagram of a first production process of the padding sheet according to an embodiment of the present invention. [Figure 4] FIG. 2 is an explanatory diagram of a second production process of the padding sheet according to an embodiment of the present invention. [Diagram 5] FIG. 3 is an explanatory diagram of a third production process of the padding sheet according to an embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0014] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described with reference to the drawings.

[0015] As shown in Fig. 1(a), the comforter 10 as a type of bedding of the present embodiment 1 includes a filling layer 1 containing aerogel kneaded therein, and a surface material 2 and a lining material 3 provided on the front and back surfaces of the filling layer 1. The filling layer 1 has an overall thickness of 2 to 100 mm. The surface material 2 and the lining material 3 each have a thickness of 2 to 30 mm.

[0016] The outer fabric 2 and the inner fabric 3 are made of any material such as cotton, polyester, rayon, lyocell, etc. It is preferable to use a brushed fabric for the outer fabric 2 and the inner fabric 3.

[0017] As shown in FIG. 1(b), the blanket 11 as a kind of bedding of the present embodiment 1 comprises two padding layers 1 in which aerogel is kneaded, a microfiber outer fabric 2 and a microfiber lining 3 provided on the front and back sides of the padding layers 1, respectively, and a heat insulating layer, for example, an aluminum layer 4, is provided between the two padding layers 1. The thickness of the padding layer 1 is 2 to 100 mm, the thickness of the outer fabric 2 and the lining 3 is 2 to 30 mm, and the thickness of the heat insulating layer is 1 to 10 mm. The padding layer 1 of the present embodiment has moisture absorbing heat generating properties, and it can be combined with moisture absorbing heat generating cotton (for example, a mixture of one or more of acrylate and rayon, lyocell, and cotton) or heat storing and retaining cotton (for example, a mixture of one or more of polyester, polypropylene, and acrylic) to further increase the heat retaining properties.

[0018] The filling layer 1 is composed of chemical fiber cotton formed into a sheet shape. Chemical fiber cotton is cotton (wadding) produced from chemical fibers, and examples of chemical fibers for chemical fiber cotton include regenerated fibers, semi-synthetic fibers, synthetic fibers, and inorganic fibers. It is preferable to use synthetic fibers such as polyester, nylon, and polypropylene, and it may be a composite of fibers of multiple materials. In addition, the filling that constitutes the filling layer 1 may contain natural fibers in addition to chemical fibers.

[0019] The filling that constitutes the filling layer 1 contains aerogel-mixed short fibers. The aerogel-mixed short fibers are produced by mixing aerogel into the synthetic fiber raw material of the short fibers, causing a polymerization reaction to produce chips, which are then melt-spun into short fibers.

[0020] Examples of aerogel include silica aerogel, carbon aerogel, alumina aerogel, etc., but silica aerogel is used in this embodiment. Aerogel has an extremely low thermal conductivity and high heat insulating properties.

[0021] In this embodiment, the outer fabric 2 and the lining 3 can be made of any material, such as natural fibers such as cotton, wool, and linen, regenerated fibers such as rayon, synthetic fibers such as polyester, nylon, and acrylic fibers, and natural or synthetic leather. The outer fabric 2 and the lining 3 can be made of the same material or different materials, and materials can be selected appropriately depending on what is to be produced.

[0022] The blanket 11 is breathable and has an aluminum layer 4 that reflects heat from the padding layer 1 containing aerogel, and the high insulating properties of aerogel allow heat to be trapped within the outer layer 2 and the lining 3, ensuring high heat retention.

[0023] In this embodiment, the padding layer 1 is made of padding containing short fibers in which silica aerogel is kneaded into polyester.

[0024] In order to provide synthetic bedding with high thermal insulation properties like down, aerogel with low thermal conductivity can be kneaded into polyester staple fibers to increase the thermal insulation properties of the bedding. The lower the thermal conductivity of the polyester staple fibers, the higher the thermal insulation and heat retention properties.

[0025] As shown in Fig. 1(a) in the comforter 10, a single layer of filling layer 1 is provided between the outer fabric 2 and the inner fabric 3, but multiple layers may also be provided. For example, there may be three or more layers between the outer fabric 2 and the inner fabric 3.

[0026] Depending on the aspect of the embodiment of the present invention, the number of layers may be changed appropriately from one layer shown in Fig. 1(a) to multiple layers (for example, five layers). For example, in the case of one layer, a polyester fiber filling layer kneaded with aerogel is used; in the case of two layers, a polyester fiber filling layer kneaded with aerogel and a moisture-absorbing heat generating filling layer is used; in the case of three layers, a polyester fiber filling layer kneaded with aerogel, a moisture-absorbing heat generating filling layer and a dust mite resistant filling layer is used; in the case of four layers, a polyester fiber filling layer kneaded with aerogel, a moisture-absorbing heat generating filling layer, a dust mite resistant filling layer and a heat storage filling layer is used; in the case of five layers, a polyester fiber filling layer kneaded with aerogel, a moisture-absorbing heat generating filling layer, a dust mite resistant filling layer, a heat storage filling layer and an aluminum nonwoven fabric is used. Other examples include the use of antibacterial, deodorant and deodorant functional cotton. Examples of the moisture-absorbing heat-generating cotton layer include a cotton layer made of a mixture of one or more of acrylate and rayon, lyocell, and cotton; examples of the heat-storing and heat-retaining cotton layer include a cotton layer made of a mixture of one or more of polyester and polypropylene and acrylic; and examples of the anti-mite filling layer include a cotton layer made of polyester with an anti-mite finish.

[0027] The aerogel is mixed in a weight ratio of 0.1% to 10% of the total weight of the polyester short fibers mixed with the aerogel. The polyester short fibers mixed with the aerogel are used in the padding layer 1 in a weight ratio of 5% to 100% of the total weight.

[0028] The polyester short fibers with aerogel mixed in are melt spun into short fibers (also called staples). The fiber diameter is 0.5 to 50 Dtex, and the length is 20 to 100 mm. These short fibers are formed into the padding layer 1 through a carding process or the like.

[0029] The short fibers other than the polyester short fibers kneaded with aerogel contained in the filling layer 1 have a fiber diameter of 0.5 Dtex to 50 Dtex and a length of 20 mm to 250 mm. If the upper and lower limits are exceeded, it becomes difficult to form the filling layer 1.

[0030] The thermal conductivity of the aerogel is preferably 0.01 to 0.03 W / (m·k). The thermal conductivity of the polyester short fibers with the aerogel kneaded therein is preferably 0.1 to 0.14 W / (m·k). The weight of the padding layer 1 is preferably 40 to 700 g / m 2 It is preferable that:

[0031] Table 1 shows the results of a comparison between a synthetic fiber comforter, a feather comforter, and a comforter having a filling layer 1 made of 50% polyester staple fiber mixed with 0.18% of the aerogel of the present invention.

[0032] [Table 1]

[0033] It was confirmed that the embodiment of the present invention, which contains 50% aerogel fiber, has a higher heat retention rate and clo value than a synthetic fiber comforter and a down comforter, which are conventional products that do not contain aerogel. Here, the basis weight of the filling (stuffing) is 400 g / m 2 The "clo value" is a value that can be measured together with thermal conductivity in ASTM D 1518-85. 1clo is the heat retention of clothing that allows a person sitting quietly to maintain an average skin temperature of about 33°C in a room with an air temperature of 21°C, relative humidity of 50%, and air flow of 0.1 m / s. The clo value of the padding layer 1 is preferably 6.0 to 10.0. The "heat retention rate" is a ratio that indicates the difficulty of heat loss according to heat retention tests (JIS L 1096, ASTM D 1518), and this performance of increasing the insulation of clothing and reducing the amount of heat transfer is called heat retention. Representative test methods include ASTM D 1518-1985 and JIS L 1096. The heat retention rate of the padding layer 1 is preferably 89% to 92%.

[0034] Of the methods for producing a comforter according to an embodiment of the present invention, the steps for producing polyester staple fibers having a specific ratio of aerogel kneaded therein will be described with reference to FIG.

[0035] Paraxylene and ethylene are obtained from petroleum. Paraxylene is oxidized to produce terephthalic acid, ethylene is used to produce ethylene glycol, and terephthalic acid and ethylene glycol are polymerized. During the polymerization process, 0.1% to 10% by weight of aerogel raw material (particulate aerogel raw material made of silicon dioxide, particle diameter 50 nm or less) is kneaded into the material to obtain polyester chips kneaded with aerogel. When the polyester raw material is polymerized, it is not a liquid but a highly viscous fluid with a viscosity of 0.6-0.7 dl / g, so the aerogel is added and the aerogel and polyester raw material are stirred and mixed, which is called kneading. Melt spinning is obtained from the polyester chips, which are stretched and shrunk, and the obtained yarn is cut to obtain polyester staple fibers (also called polyester staples). Alternatively, the melt spinning is wound and stretched to form polyester filaments, and polyester staple fibers (also called polyester staples) are obtained from the melt spinning. The aerogel-kneaded polyester staple fibers are used to produce the padding layer 1.

[0036] The fiber diameter of this aerogel-mixed polyester short fiber is 0.5 Dtex to 50 Dtex, and the length is 20 mm to 100 mm. If the upper and lower limits are exceeded, it becomes difficult to form the padding layer 1.

[0037] To form the padding layer 1, short fibers other than the aerogel-mixed polyester short fibers can be mixed, but the fiber diameter is 0.5 Dtex to 50 Dtex and the length is 20 mm to 250 mm. If the upper and lower limits are exceeded, it becomes difficult to form the padding layer 1.

[0038] Hereinafter, a manufacturing process of the padding sheet, which is a sheet-like padding constituting the padding layer 1, will be described with reference to Figs. 3 to 5.

[0039] The padding sheet may be formed only from aerogel-mixed polyester staple fibers (melting point 255-265°C) mixed with 0.1-10% by weight of aerogel, or may be formed by mixing staple fibers other than the aerogel-mixed polyester staple fibers. The aerogel-mixed polyester staple fibers are used in an amount of 5-100% by weight of the total weight of the padding sheet.

[0040] Production process 1, which is a first embodiment of the padding sheet production process, will be described with reference to Fig. 3. It comprises a raw material process, a cotton blending / spreading process, a carding process, a bonding process, a heating process, an inspection process, and a winding process. The heating temperature in the heating process is 110°C to 220°C. The blend ratio of fibers in production process 1 is preferably 5 to 95% by weight of aerogel-mixed polyester staple fibers (melting point 255 to 265°C), 5 to 60% by weight of low-melting-point polyester staple fibers (melting point 100 to 120°C) having a lower melting point than the aerogel-mixed polyester staple fibers, and 5 to 90% by weight of other staple fibers (chemical fibers, natural fibers, etc.). For example, the present invention can be implemented in various forms, such as blending 92% by weight of polyester staple fiber kneaded with aerogel and 8% by weight of low-melting-point polyester staple fiber, blending 50% by weight of polyester staple fiber kneaded with aerogel, 15% by weight of low-melting-point polyester staple fiber, and 35% by weight of polyester staple fiber (melting point 255 to 265°C), blending 50% by weight of polyester staple fiber kneaded with aerogel, 15% by weight of low-melting-point polyester staple fiber, and 35% by weight of rayon staple fiber, blending 30% by weight of polyester staple fiber kneaded with aerogel, 15% by weight of low-melting-point polyester staple fiber, 45% by weight of polyester staple fiber, and 10% by weight of acrylate staple fiber.

[0041] The second embodiment of the padding sheet production process, production process 2, will be described with reference to FIG. 4. It comprises a raw material process, a cotton blending / spreading process, a carding process, a needle punching process, an inspection process, and a winding process. In production process 2, instead of melting the low melting point polyester fiber in the heating process of production process 1, a needle punching process is performed, so there is no need to mix in low melting point polyester fiber. The explanation of production process 1 is used for the common processes. In production process 2, when there is one type of fiber, the raw material is 100% by weight of aerogel-mixed polyester staple fiber, but when there are two or more types of fiber, the fiber blend ratio is preferably 5% by weight to 95% by weight of aerogel-mixed polyester staple fiber (melting point 255-265°C) and 5% by weight to 95% by weight of other staple fibers (chemical fibers, natural fibers, etc.). For example, the present invention can be embodied in various forms, such as a mixture of 100% aerogel-mixed polyester staple fiber, 50% aerogel-mixed polyester staple fiber, and 50% polyester staple fiber (melting point 255 to 265°C), a mixture of 50% aerogel-mixed polyester staple fiber, 15% polyester staple fiber, and 35% rayon staple fiber, and a mixture of 30% aerogel-mixed polyester staple fiber, 60% polyester staple fiber, and 10% acrylate staple fiber.

[0042] The third embodiment of the padding sheet production process, production process 3, will be described with reference to FIG. 5. It consists of a raw material process, a cotton blending / spreading process, a carding process, and a bonding process. In production process 3, the padding sheet production process ends with the bonding process, and the next step is to stuff the padding sheet into the comforter. In production process 3, there is no heating process for melting the low-melting point polyester fiber, so there is no need to mix in low-melting point polyester fiber. The explanation of production process 1 is used for the common steps. In production process 3, when there is one type of fiber, the raw material is 100% by weight of aerogel-mixed polyester staple fiber, but when there are two or more types of fiber, it is preferable that the raw material is 5% by weight to 95% by weight of aerogel-mixed polyester staple fiber (melting point 255-265°C) and 5% by weight to 95% by weight of other staple fibers (chemical fibers, natural fibers, etc.). For example, the present invention can be embodied in various forms, such as a mixture of 100% aerogel-mixed polyester staple fiber, 50% aerogel-mixed polyester staple fiber, and 50% polyester staple fiber (melting point 255 to 265°C), a mixture of 50% aerogel-mixed polyester staple fiber, 15% polyester staple fiber, and 35% rayon staple fiber, and a mixture of 30% aerogel-mixed polyester staple fiber, 60% polyester staple fiber, and 10% acrylate staple fiber.

[0043] According to the present invention, the following effects are achieved. Because aerogel is kneaded into the short fibers, the manufacturing process of the padding layer 1 can be simplified and production costs can be reduced. The production costs are lower than that of the aerogel sheet of Patent Document 1. Because aerogel is kneaded into the short fibers, the durability of the aerogel is increased. The intricately entangled aerogel fibers capture the air in the padding, creating dead air (still air), which provides high heat retention and insulation effects.

[0044] The structure of the filling material and the method of production of the filling material of the present invention are not limited to the above-described embodiment, and various modifications can be made without departing from the spirit of the invention. [Industrial Applicability]

[0045] Since the aerogel is kneaded into the short fibers, it is possible to provide bedding with high heat retention properties, and the range of uses and applications can be expanded, making the product highly applicable industrially. [Explanation of symbols]

[0046] 1. Filling layer 2 Outer material 3. Lining 4 Aluminum layers 10. Comforter 11 Blanket

Claims

1. It contains short fibers with aerogel mixed in. The weight ratio of the aerogel to the total weight of the short fibers is 0.1% to 10%; The filling is characterized in that the thermal conductivity of the aerogel is 0.01 to 0.03 W / (m·k), and the thermal conductivity of the short fibers is 0.1 to 0.14 W / (m·k).

2. The filling according to claim 1, characterized in that the fibers constituting the filling are only short fibers having the aerogel kneaded therein.

3. The filling according to claim 1, characterized in that it contains a second fiber different from the short fiber, and the weight ratio of the second fiber to the total weight of the filling is 0 to 95% (excluding 0%).

4. The filling according to claim 3, characterized in that the short fibers have a fiber diameter of 0.5 Dtex to 50 Dtex and a length of 20 mm to 100 mm, and the second fibers are short fibers having a fiber diameter of 0.5 Dtex to 50 Dtex and a length of 20 mm to 250 mm.

5. The outer and inner linings, A padding layer is provided between the outer fabric and the inner fabric and is made of the padding described in claims 1 to 4. Bedding.

6. Further, it has a heat insulating layer, The two padding layers sandwich the heat insulating layer from the front and back sides, 6. The bedding according to claim 5, wherein the two padding layers are sandwiched between the outer and inner fabrics.

7. a melt spinning production process in which aerogel is kneaded into a synthetic fiber raw material, the synthetic fiber raw material is polymerized to form chips containing aerogel, and the chips are melt spun; a step of producing staple fibers by drawing and cutting the melt-spun yarn; forming the staple fibers into a batting; The present invention is characterized in that How the filling is produced.

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