Filler

Abstract

To provide a filler that enables a bag-like container to retain any shape when the filler is filled in the container.SOLUTION: A filler is a crushed matter of melt-blown fiber aggregate containing a thermoplastic elastomer. The filler has a compression ratio of 30% or more and a recovery ratio of less than 80% in terms of compression recovery based on bulkiness tests.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present invention relates to a filling material filled inside, for example, a clothing member or bedding.

Background Art

[0002] Conventionally, various filling materials have been known as described in Patent Documents 1 and 2. Patent Document 1 describes a melamine / formaldehyde foam material containing a granular filling material made of quartz, glass beads, or the like. This foam material is used for heat insulation or sound insulation, or for imparting cushioning properties. Patent Document 2 describes a filling material for a cushioning material composed of foam particles obtained by foaming foaming beads. These foam particles can be restored to their original shape by heat treatment or the like even after being once deformed.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0004] The filling material is filled inside a container. For example, a predetermined amount of the filling material is stored in a storage bag to form a clothing member or bedding. With conventional filling materials, it has been difficult to keep the storage bag in the intended shape because the structure is easily deformed.

[0005] An object of the present invention is to provide a filling material that gives the storage bag a shape-retaining force when filled in the storage bag.

Means for Solving the Problems

[0006] [1] The filler according to one aspect of the present disclosure is a crushed product of a melt-blown fiber aggregate containing a thermoplastic elastomer, and in terms of compression recovery based on the bulkiness test, the compression rate is 30% or more and the recovery rate is less than 80%.

[0007] [1] By filling the storage bag with the filler of [1], the storage bag can be easily deformed into an arbitrary shape, and its shape is moderately maintained. Therefore, the filler gives the storage bag a shape-retaining force. Also, static electricity is less likely to be generated between the fillers. When the shape of the storage bag is changed, the fillers rub against each other, but the generation of rubbing noise is also suppressed.

[0008] [2] In the filler of the above [1], in terms of compression recovery based on the bulkiness test, the rebound rate may be 120% or more.

[0009] [3] In the filler of the above [1] or [2], the melt-blown fiber aggregate may contain a thermoplastic polyurethane elastomer.

[0010] [4] In any one of the fillers of the above [1] to [3], the melt-blown fiber aggregate may contain a thermoplastic polyester elastomer.

Advantages of the Invention

[0011] The filler according to the present invention gives the storage bag a shape-retaining force when filled in the storage bag.

Brief Description of the Drawings

[0012]

Figure 1

Figure 2

Figure 3

Modes for Carrying Out the Invention

[0013] Hereinafter, embodiments of the present invention will be described with reference to the drawings.

[0014] The filler according to one embodiment of the present invention is a crushed product of a melt-blown fiber aggregate containing a thermoplastic elastomer. That is, the filler according to one embodiment is obtained by crushing a melt-blown fiber aggregate containing a thermoplastic elastomer. The filler is stored, for example, in a storage bag (or a container such as a bag). A storage bag containing a predetermined amount of the filler can be used as a clothing member or bedding. The storage bag is composed of, for example, a stretchable cloth-like member. That is, as another aspect of the present embodiment, a clothing member including a storage bag or container and a predetermined amount of the filler stored in the storage bag or container may be provided. As still another aspect of the present embodiment, bedding including a storage bag or container and a predetermined amount of the filler stored in the storage bag or container may be provided. In these aspects, the storage bag or container has an opening for charging the filler, and the opening may be made openable and closable by a zipper, a fastener, or the like after charging the filler, or may be closed by sewing, adhesion, or the like. In addition, one or more inner bags for storing the filler may be provided.

[0015] Examples of the clothing member to which the filler of the present embodiment is applied include pads inserted into a bra or the like. The clothing member may be a protective pad or the like, or may be a member that covers another part of the wearer's body (hip pad of bottom clothing). The clothing member can also be used for a woman who has had a breast removed (breast pad for post-mastectomy). The clothing member can be appropriately deformed along the shape of a part of the wearer's body. The clothing member has excellent shape retention force in a state along a part of the wearer's body, particularly unless another large external force is applied.

[0016] Examples of the bedding to which the filler of the present embodiment is applied include a pillow, a cushion, a shock absorber, or a packing material. Note that the filler of the present embodiment may be applied to a zabuton or the seating surface of a seat.

[0017] The meltblown fiber aggregate is a fiber aggregate (or fiber laminate) produced by the meltblown method. The meltblown fiber aggregate has a structure in which resin fibers are deposited planar or three-dimensionally. The content of the thermoplastic elastomer in the meltblown fiber aggregate is preferably 70% by mass or more, more preferably 90% by mass or more, based on 100% by mass of the total amount of the filler.

[0018] Examples of the thermoplastic elastomer include thermoplastic polyurethane elastomers and thermoplastic polyester elastomers, and olefin-based and nylon-based thermoplastic elastomers may also be used. A plurality of types of thermoplastic elastomers may be included. Examples of the thermoplastic polyurethane elastomer include Estane (registered trademark), Rezamin (registered trademark), and Fortimo (registered trademark), and examples of the thermoplastic polyester elastomer include Pelprene (registered trademark) and Hytrel (registered trademark).

[0019] The meltblown fiber aggregate is a fiber aggregate containing resin fibers fused to each other. The meltblown fiber aggregate is produced by three-dimensionally depositing resin fibers F on a base material 50 (see FIG. 1) under normal pressure conditions (for example, atmospheric pressure conditions) using the meltblown method. Note that the meltblown fiber aggregate may be produced by the meltblown method while applying a suction pressure.

[0020] The average fiber diameter of the resin fibers in the meltblown fiber aggregate is, for example, 20 μm or more and 100 μm or less. In the meltblown fiber aggregate, since the voids between the resin fibers are maintained, the average fiber diameter of the resin fibers F discharged from the discharge nozzle of the meltblown apparatus 1 (see FIG. 1) is maintained as the average fiber diameter of the resin fibers in the meltblown fiber aggregate. Further, also in the filler of the present embodiment, since the meltblown fiber aggregate is only crushed, the average fiber diameter of the resin fibers in the meltblown fiber aggregate is maintained.

[0021] Next, with reference to FIG. 1, a method for manufacturing a meltblown fiber aggregate will be described. The manufacturing system S forms a nonwoven sheet 200 as a meltblown fiber aggregate by the meltblown method using a resin material as a raw material. The manufacturing system S includes a meltblown device 1 that generates resin fibers F using a resin material as a raw material, and a substrate position control device 40 that holds the substrate 50 so that the nonwoven sheet 200 is formed on the substrate 50 with a desired thickness and shape.

[0022] The meltblown device 1 includes an extrusion part 10 that melts and extrudes the resin material, a discharge part 20 that discharges the resin material, and a blower part 30 that supplies high-temperature air to the discharge part 20. The extrusion part 10 has a tubular screw part 11 that extrudes the resin material in the axial direction, and a motor 12 that gives a rotational driving force to the screw of the screw part 11. At the upstream end (left side in the drawing) of the screw part 11, a hopper 4 for charging the resin material into the screw part 11 is attached. The resin material may be, for example, in the form of pellets or powder. Also, a plurality of two or more types of resins may be simultaneously charged into the hopper 4.

[0023] The screw part 11 is provided with a plurality of heaters 14 at a plurality of positions in the axial direction. Alternatively, one large heater 14 extending in the axial direction may be provided. The heater 14 heats and melts the resin material in the screw part 11. When using a plurality of resins, those that were different types of resin materials before being charged into the hopper 4 are melted and mixed with each other in the screw part 11 and are homogenized (become a mixed resin material). At a plurality of positions in the axial direction of the screw part 11, a plurality of temperature sensors for detecting the temperature of the melted resin material, for example, a first temperature sensor 16, a second temperature sensor 17, a third temperature sensor 18, and a fourth temperature sensor 19 are provided. The discharge part 20 is connected to the downstream end of the screw part 11.

[0024] The discharging unit 20 includes a spinning pump 21, a die 24, and a discharge pipe section 22 that connects the spinning pump 21 and the die 24. The spinning pump 21 receives the resin material pumped through the screw section 11 and discharges it toward the die head 23 on the discharge port side of the die 24. At the center of the lower end of the die head 23, a discharge port 26 for discharging the resin X is formed. This discharge port 26 is a discharge nozzle in the melt blowing device 1 and has a plurality of holes with a predetermined diameter (hole diameter) corresponding to the desired diameter of the resin fiber F. The die head 23 and the discharge port 26 are provided at the lower end of the discharging unit 20 and are provided below to discharge a plurality of resin fibers F. At least one of the discharge pressure and the discharge amount of the resin X in the discharging unit 20 can be adjusted as appropriate.

[0025] The air blowing unit 30 includes an air blowing pipe 31 for circulating air and a blower 33 provided in the air blowing pipe 31. Air is sucked in from the upstream end of the air blowing pipe 31 and pumped by the blower 33. A connection section 32, which is the downstream end of the air blowing pipe 31, is connected to the die 24. The high-temperature air supplied by the air blowing unit 30 flows into the die 24 and continuously ejects the resin fiber F from the discharge port 26. One or more heaters 34 are provided around the air blowing pipe 31. An air temperature sensor 36 for detecting the temperature of the air is provided at an appropriate position of the air blowing pipe 31. Further, an air volume adjustment valve 37 for adjusting the air volume (the flow rate of air) is provided in the air blowing pipe 31 on the discharge side of the blower 33.

[0026] In the manufacturing system S and the melt blowing device 1, various operating conditions (or operating parameters) including the air volume, discharge pressure, and nozzle temperature are set in order to achieve the desired fiber diameter in the resin fiber F and the desired adhesiveness and bulkiness in the nonwoven sheet 200. Further, the manufacturing system S is provided with a controller and an operation unit (both not shown) for inputting the air volume, discharge pressure, the temperature of the resin material in the screw section 11, and / or the temperature of the resin material passing through the discharge nozzle and adjusting these numerical values (operating conditions or operating parameters) to predetermined target values.

[0027] The base material position control device 40 may include a robot arm portion 40A that holds the base material 50 and can freely change the position and posture of the base material 50 below the discharge port 26. The base material position control device 40 can adjust the position and posture of the base material 50 by driving and controlling the arm portions 41 to 43.

[0028] The base material 50 that can be used in the manufacturing system S includes a surface corresponding to the shape of the non-woven sheet 200 to be manufactured. The base material 50 may be made of resin or metal. The non-woven sheet 200 is formed, for example, in a flat plate shape or a flat sheet shape. In that case, the surface of the base material 50 is also flat.

[0029] Subsequently, the operation method of the meltblowing device 1 will be described. First, in the meltblowing device 1, various operating conditions (or operating parameters) including the air volume, discharge pressure, and nozzle temperature are set. The operator who operates the manufacturing system S turns on the power of the meltblowing device 1 and presses the operation start button or the like of the meltblowing device 1. When each heater is turned on, each part of the meltblowing device 1 is heated up. After the operator confirms that the temperature has risen sufficiently, the resin material is put into the hopper 4. The extrusion part 10 melts the resin material and sends it out by the screw part 11. Air at a predetermined temperature is supplied from the air blowing part 30. The air volume may be set appropriately. However, when it is desired to increase (make denser) the fiber density in the non-woven sheet 200, the air volume is set large, and when it is desired to decrease (make coarser) the fiber density in the non-woven sheet 200, the air volume is set small. By setting the air volume, the fiber density or softness in the non-woven sheet 200 can be controlled. Also, regarding the discharge pressure, similar to the air volume, by setting it large or small, the fiber density or softness in the non-woven sheet 200 can be controlled. In the manufacturing system S, the fiber density or softness in the non-woven sheet 200 is adjusted by adjusting the air volume and the distance between the discharge port 26 and the base material 50. The thickness of the non-woven sheet 200 is not particularly limited, but may be appropriately determined, for example, within the range of 1 mm to 10 mm.

[0030] Next, a method for manufacturing a filler based on the nonwoven sheet 200 (meltblown fiber aggregate) will be described. A crusher (or grinder) is used to crush (or grind) the nonwoven sheet. The crusher (or grinder) includes, for example, a feed hopper, a pair of blade portions driven in a housing, and a screen portion. Known equipment suitable for crushing (or grinding) the soft elastomer nonwoven sheet is used. It is desirable that the pair of blade portions and the screen portion can appropriately adjust the size of crushing (or grinding). The size of crushing (or grinding) is desirably adjustable, for example, between 2 mm and 10 mm (for example, in increments of 0.5 mm to 1 mm).

[0031] Regarding the filler manufactured by the above manufacturing method, only the filler having a predetermined compression recovery property can solve the above-described problems. In other words, the resin material content, the average fiber diameter in the meltblown fiber aggregate, the size of crushing, etc. are determined so that the following compression recovery property is satisfied. Those skilled in the art can manufacture the "filler" having the features specified in each claim of the claims by referring to the description of this specification and common general knowledge in the art.

[0032] The compression recovery property is measured according to the bulkiness test of JIS L1903. As shown in Fig. 2(a), a predetermined amount of the filler as a sample is placed in the container 71, and a load plate 72 is placed on its upper surface. The height of the sample at this time is measured as the initial bulk height (mm). Further, as shown in Fig. 2(b), a weight 73 is placed on the load plate 72. The height of the sample 2 minutes after placing the weight 73 is measured as the compressed bulk height (mm). Subsequently, as shown in Fig. 2(c), the weight 73 and the load plate 72 are removed, and after 4 minutes, only the load plate 72 is placed again (see Fig. 2(d)), and the height of the sample at this time is measured as the recovery bulk height (mm). The mass of the load plate 72 is 30 g, and the mass of the weight 73 is 1000 g. Therefore, the total load mass is 1030 g.

[0033] Through the above tests, the compression ratio, recovery ratio, and resilience ratio are obtained based on the following formulas, respectively. Compression ratio (%) = (Initial height - Compressed height) / Initial height × 100 Recovery rate (%) = Recovery height / Initial height × 100 Rebound rate (%) = Recovery height / Compressed height × 100

[0034] In the filler of the present embodiment, the compression ratio is 30% or more and the recovery rate is less than 80%. The compression ratio is preferably 33% or more, more preferably 43% or more. Also, the recovery rate is preferably less than 77%, more preferably less than 75%. Further, in the filler of the present embodiment, for example, the rebound rate is 120% or more. The rebound rate is preferably 125% or more, more preferably 145% or more.

[0035] According to the filler of the present embodiment, by filling a storage bag (a bag-shaped container), the storage bag can be easily deformed into an arbitrary shape. That is, the filler gives the storage bag a shape-retaining force. The storage bag can appropriately maintain its shape unless another large external force is applied to the storage bag. Also, static electricity is less likely to be generated between the fillers. When the shape of the storage bag is changed, the fillers rub against each other, but the generation of rubbing noise is also suppressed. Therefore, even when the filler is applied to a clothing member or bedding, a good wearing feeling or usability can be obtained by maintaining the shape along a part of the wearer's or user's body.

[0036] As described above, the embodiments of the present invention have been described, but the present invention is not limited to the above embodiments. For example, in the above embodiment, the non-woven sheet 200 was crushed to produce the filler, but the object to be crushed is not limited to the non-woven sheet 200. For example, it is also possible to produce a filler by crushing a sheet-like end material generated when a three-dimensional non-woven structure such as a bra cup is manufactured by the meltblowing method.

[0037] Figure 3 shows the test results of the compression recovery tests according to the examples and comparative examples. As shown in the test results of Examples 1 to 5, when TPC or TPU is used as the resin material, the size of the pulverization is in the range of 2 mm to 6 mm, and the above-described compression ratio and recovery ratio are satisfied, even when the container is deformed, the shape of the container could be suitably maintained. As shown in Comparative Examples 1 to 5, even when TPC or TPU is used as the resin material, it was difficult to maintain the shape of the container against the deformation of the container when the above-described compression ratio and recovery ratio were not satisfied. Further, as shown in Comparative Examples 6 to 11, when polypropylene or nylon is used as the resin material, the above-described compression ratio and recovery ratio are not satisfied, and it was difficult to maintain the shape of the container against the deformation of the container.

Explanation of Signs

[0038] 200…Nonwoven sheet (meltblown fiber aggregate).

Claims

1. A crushed material of a melt-blown fiber aggregate containing a thermoplastic elastomer, a filler having a compression ratio of 30% or more and a recovery rate of less than 80% in compression recovery based on a bulkiness test.

2. The filler according to claim 1, having a rebound rate of 120% or more in compression recovery based on a bulkiness test.

3. The filler according to claim 1 or 2, wherein the melt-blown fiber aggregate contains a thermoplastic polyurethane elastomer.

4. The filler according to claim 1 or 2, wherein the melt-blown fiber aggregate contains a thermoplastic polyester elastomer.

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