Padding structure and method of manufacturing the same

Abstract

To provide a padding structure which has high bulkiness, does not cause the movement of padding, is warm, and has excellent designability such that a flat surface can be worn on the front side or the front and back sides can be reversibly worn, and to provide a method for producing the padding structure.SOLUTION: In the batt structure 1, long fiber batts 2a, 2b, 2c, etc. are filled in a fabric comprising a front fabric 5 and a back fabric 3, the long fiber batts 2a, 2b, 2c, etc. are arranged in a body length direction or a body width direction, and one of the front fabric 5 and the back fabric 3 is quilted by a plurality of quilting yarns 4a, 4b, 4c, etc. in a direction crossing the arrangement direction, and the other of the front fabric 5 or the back fabric 3 is flat without a plurality of parallel quilting yarns in the crossing direction.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a batting structure filled with long fiber batting and a method for producing the same. [Background technology]

[0002] The feathers used to fill feather products such as down comforters and down jackets are generally from waterfowl. Waterfowl include geese, ducks, and wild eiders that live on the coastlines of the Arctic Circle. There are two types of feathers: down, which is similar to chest hair, and feathers, both of which are used in feather products. Feathers are produced in Central Europe, including Poland and Hungary, Northern Europe, including the Scandinavian Peninsula, and China. Feathers are highly voluminous and warm, making them a high-quality material for feather products such as duvets and down jackets. However, natural feathers are dependent on waterfowl, and there is a limit to the supply, and the supply fluctuates depending on natural conditions and harmful diseases (such as avian viruses). From the perspective of nature conservation, there is also a limit to capturing wild birds. Furthermore, natural feathers can cause a foul odor if not washed properly, so it is necessary to remove any foul odor-causing contaminants beforehand and to maintain a certain level of cleanliness and oxygen count, which indicate the degree of feather cleaning. Another fundamental problem is that it is not easy to wash feather products such as down comforters and down jackets. Therefore, many proposals have been made for batting, including long-fiber batting consisting of core yarn and filament yarn. Methods for filling long-fiber batting into thermal insulation structures such as down jackets include a method of providing a gap in the thermal insulation structure into which the long-fiber batting can be inserted and inserting the long-fiber batting, and a method of laying the long-fiber batting on the back fabric, laminating the front fabric, quilting the laminate, and quilting the long-fiber batting between the back fabric and the front fabric. Since these require specialized methods for using long fiber batting, there is a need for a method that allows the use of long fiber batting to be easily applied to existing clothing manufacturing processes.

[0003] Patent Document 1 discloses a thermal insulation material for clothing that is formed by integrating a bulkiness-retaining layer made of synthetic fibers with a microporous membrane layer having a microporous membrane. The bulkiness-retaining layer uses bulky yarn, and the microporous membrane layer uses a microporous membrane, particularly a melt-blown nonwoven fabric, in which 80% or more of the micropores have a pore size of 5.0 μm or less. Patent Document 2 discloses a long-fiber cotton sheet, in which aligned long-fiber cotton sheets are placed on the front and back of a thermal adhesive sheet, and the resulting long-fiber cotton sheet is then re-polymerized (a three-layer structure with the thermal adhesive sheet interposed), passing the re-polymerized long-fiber cotton sheet between a pair of heat rolls to heat-bond the first and second layers of long-fiber cotton sheets to both sides of the thermal adhesive sheet, thereby enhancing the unity of the long-fiber cotton sheet. Patent Document 3 discloses a laminated batting sheet in which long fiber bundles are uniformly and automatically arranged to form a planar laminated batting sheet, and a batting structure using the same. It proposes arranging the batting in a folded state, sandwiching it between two pieces of fabric, and then sewing them together. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Patent Publication No. 2021-046653 [Patent Document 2] Japanese Patent Application Publication No. 2020-063539 [Patent Document 3] Patent No. 7250232 Summary of the Invention [Problem to be solved by the invention]

[0005] However, the above-mentioned prior art has problems with the garment structure, which means that the advantages of the long fiber filling are not fully utilized, and the quilting lines that appear limit the design possibilities.

[0006] To solve the above problems, the present invention provides a padding structure that is bulky, prevents padding from shifting, is warm, and has excellent design, such as being able to be worn with the flat side facing outward or reversibly facing outward and inside out, and a method for manufacturing the same. [Means for solving the problem]

[0007] One embodiment of the present invention is a padding structure in which long fiber padding is filled into a fabric consisting of a surface fabric and a lining fabric, The long fiber filling is arranged in the length direction or width direction, and is quilted with one of the outer fabric or the inner fabric by a plurality of quilting threads in a direction intersecting the arrangement direction, The other of the outer fabric and the inner fabric is a flat padding structure without a plurality of quilting threads parallel to the intersecting direction.

[0008] Another embodiment of the present invention is a method for manufacturing the batting structure, comprising the steps of: A long fiber batting is arranged on the lining in a length direction or width direction, and the lining and the long fiber batting are quilted with a plurality of quilting threads in a direction intersecting with the arrangement direction; The lining quilted with the quilting thread and the long fiber batting are cut according to a paper pattern; The present invention relates to a method for manufacturing a padded structure, which includes sewing together a cut outer fabric, the cut lining fabric, and a long fiber batting, with the long fiber batting on the inside. [Effects of the Invention]

[0009] In the batting structure of the present invention, the long fiber batting is arranged in the length direction or width direction, and is quilted with multiple quilting threads in a direction intersecting the arrangement direction with one of the outer or inner fabrics, and the other of the outer or inner fabric is flat and does not have multiple quilting threads parallel to the intersecting direction, so that the batting structure and its manufacturing method are provided which have high bulk, do not move, are warm, and have excellent design, such as being able to be worn with the flat side facing out or reversibly facing out. [Brief explanation of the drawings]

[0010] [Figure 1] FIG. 1 is a schematic structural diagram of a padded garment according to one embodiment of the present invention. [Figure 2] FIG. 2 is a schematic explanatory diagram showing the relationship between the arrangement direction of the long fiber batting and the quilting thread. [Figure 3] FIG. 3 is a schematic development showing the relationship between the lining and the quilting thread. [Figure 4] FIG. 4 is a schematic front view of the vest. [Figure 5] FIG. 5 is a cross-sectional view taken along line II in FIG. [Figure 6] FIG. 6 is a schematic development view showing the relationship between the lining and quilting threads in another embodiment of the present invention. [Figure 7] FIG. 7 is a schematic front view of the outer fabric. [Figure 8] FIG. 8 is a schematic side view of a continuous fiber yarn according to one embodiment of the present invention. [Figure 9] FIG. 9 is a schematic explanatory diagram showing a method for producing a continuous fiber yarn according to one embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0011] In the batting structure of the present invention, the long fiber batting is arranged in the length direction or width direction and is quilted with one of the outer fabric or the inner fabric with a plurality of quilting threads in a direction intersecting the arrangement direction, while the other of the outer fabric or the inner fabric is flat and does not have a plurality of quilting threads parallel to the intersecting direction. In particular, the long fiber batting is arranged in the length direction and is quilted with one of the outer fabric or the inner fabric with a plurality of quilting threads in the width direction, while the other of the outer fabric or the inner fabric is flat and does not have a quilting thread, and the long fiber batting is filled into a fabric consisting of the outer fabric and the lining. Because the long fiber batting is arranged in the length direction and is quilted with one of the outer fabric or the inner fabric with a plurality of quilting threads in the width direction, there is no movement of the long fiber batting, and the shape will not be lost even after long-term wear or repeated home washing. In addition, the flat side without the parallel quilting lines can be worn as the outer side, or the outer or inner side can be worn as the outer surface depending on the wearer's preference. In other words, it can be worn reversibly with the quilted side or the flat side. Furthermore, the long fiber filling is highly bulky and warm, and this condition remains unchanged even when wet with water such as rain or sweat. Unlike down and feathers, it does not collapse when wet.

[0012] The quilting intervals are usually about 10 to 2000 mm, preferably 30 to 250 mm, and more preferably 40 to 200 mm. This allows the long fiber filling to be quilted efficiently. The quilting intervals may be uniform, or may have a mixture of narrow and wide areas.

[0013] The long fiber yarns constituting the long fiber filling are composed of at least core yarns and filament yarns, which are intertwined and integrated, and it is preferable that a plurality of long fiber yarns are aligned to form a fiber bundle, and that a plurality of fiber bundles are filled in the fabric. The mass per unit length of the fiber bundle formed by aligning a plurality of long fiber yarns is preferably 0.15 to 45 g / m, more preferably 0.3 to 25 g / m. For clothing, 0.3 to 5.0 g / m is particularly preferable. The fiber bundle preferably has 2 to 1,800 long fiber yarns, particularly 10 to 50 long fiber yarns aligned. This results in a warm filling structure.

[0014] The padding structure is preferably padded clothing, sleeping bags, futons, hats, gloves, etc. It is particularly suitable for padded clothing such as jackets, vests, pants, coats, cold weather clothing, work clothes, neck warmers, or parts thereof.

[0015] The method for producing the padding structure of the present invention includes the following steps. (1) The process of arranging long fiber batting in one direction on the surface of the lining. (2) The process of quilting the lining and long fiber batting with multiple quilting threads across the body. Long fiber batting is prone to snagging and is difficult to handle, but once quilted with the lining, it can be handled in the same way as the lining, which is convenient. (3) The process of cutting the lining quilted with multiple quilting threads and the long fiber batting according to the pattern. (4) A process of sewing together the cut outer fabric, the cut lining, and the filament batting so that the filament batting is on the inside.

[0016] The outer and inner linings can be made of commonly used padding structure fabrics, such as polyester (PET) taffeta fabric, nylon taffeta fabric, or any other woven or knitted fabric.

[0017] It is preferable that the long fiber yarns are made into a fiber bundle by plying together 2 to 1800 strands, particularly 10 to 50 strands, which allows for a filling structure ranging from thin to thick.

[0018] The long fiber yarn is preferably a bulky yarn, and is preferably composed of at least two types of core yarn and effect yarn, where the core yarn is relatively short compared to the effect yarn and the core yarn and effect yarn are integrated into a long fiber yarn. While adding fibers other than the core yarn and effect yarn is optional, the total of the core yarn and effect yarn is preferably 70% by mass or more, more preferably 80% by mass or more, when the long fiber yarn is taken as 100% by mass. The core yarn and effect yarn are integrated. Here, "integrated" refers to a state in which the fibers are entangled or wound around each other. The core yarn is relatively short compared to the effect yarn. Bulkiness is achieved by providing a difference in length between the core yarn and the effect yarn. The weight ratio of the effect yarn to the core yarn, when the total of the effect yarn and the core yarn is used as the parameter, is preferably 51 to 99% by mass (wt%). It is more preferably 80 to 98 wt%, and particularly preferably 85 to 97 wt%. Within the above range, both component yarns are firmly fixed and the texture is good. It is preferable that both the core yarn and the filament yarn are continuous fibers (long fibers, filament fibers).

[0019] The mass per unit length of one long fiber yarn is preferably 0.01 to 3 g / m, more preferably 0.02 to 1.5 g / m. 2 to 1,800, preferably 2 to 1,000, more preferably 5 to 250, and particularly preferably 10 to 50, of these long fiber yarns are bundled together, for example, by paralleling them, to form a long fiber bundle. The mass per unit length of one long fiber bundle is preferably 0.15 to 45 g / m, more preferably 0.3 to 25 g / m. For clothing, 0.3 to 5.0 g / m is particularly preferred. This range is convenient for handling when forming a laminated padding sheet. The long fiber bundle can be used singly or by paralleling multiple long fiber bundles. The long fiber bundle can be wound into a yarn body or stored in a carton container. The width of the laminated padding sheet is preferably 0.3 to 3 m, more preferably 0.5 to 2.5 m.

[0020] It is preferable that at least a urethane-based crosslinking agent, an acrylic-based crosslinking agent, or an epoxy resin crosslinking agent is applied to the continuous fiber yarn as a crosslinking agent and fixed by curing. This improves bulkiness and washability. Furthermore, as a surface treatment agent, a resin smoothing agent that improves smoothness is preferably used in combination with the crosslinking agent, for example, a silicone-based resin. In particular, a combination of a silicone-based resin agent and a urethane-based crosslinking agent is preferable. The crosslinking agent and / or smoothing agent is preferably applied in an amount of 0.1 to 10% by mass based on the continuous fiber yarn.

[0021] The core yarn and filament yarns can be made of fibers such as polyester, nylon, and polypropylene, but polyethylene terephthalate (PET) hollow yarn is preferred. Polyethylene terephthalate hollow yarn provides warmth through its insulating effect, while PET is resilient and can maintain high bulkiness. A hollow ratio of approximately 10 to 40% is preferred. Conductive fibers may be added to the core yarn. Examples of conductive fibers include antistatic yarn manufactured by KB Seiren Co., Ltd. and carbon fiber. Adding conductive fibers prevents static electricity buildup when worn, making the garment comfortable to wear and allowing it to be worn safely in open flame-free areas such as gas stations.

[0022] The core yarn and the effect yarn are preferably integrated by at least one process selected from entanglement, air jet processing, winding processing, and processing in which the effect yarn is jetted onto the core yarn. The entanglement process is a process using an air entanglement machine that jets compressed air perpendicular to the running direction of the core yarn and the effect yarn. The air jet processing is a so-called taslan process, in which compressed air is forced into the core yarn and the effect yarn in the direction of travel. The winding process is a process in which the effect yarn is wound onto the core yarn to integrate them. The process in which the effect yarn is jetted onto the core yarn to entangle or rotate the effect yarn.

[0023] The single fiber fineness of the core yarn and the effect yarn is preferably 0.1 to 300 decitex, and the total fineness is preferably in the range of 10 to 600 decitex. More preferably, the single fiber fineness is 1.0 to 50 decitex, and the total fineness is 15 to 250 decitex. If the fineness is in the above range, the yarns are less likely to settling and have a good feel.

[0024] The filling structure of the present invention limits the movement of the long fiber bundles even after repeated washing, resulting in a stuffed product with little bias and high bulk. The filling structure of the present invention may also use other fillings in addition to the long fiber filling. It may also be used in combination with feathers, artificial feathers, or short fiber filling.

[0025] The following description will be given with reference to the drawings, in which the same reference numerals denote the same parts. Figure 1 is a schematic structural diagram of a padded garment (padded structure) 1 according to one embodiment of the present invention. This padded garment (padded structure) 1 has long fiber padding 2 (2a, 2b, 2c, 2d, 2e...) arranged in one direction in a lining 3, quilted with quilting threads 4 (4a, 4b, 4c, 4d...) that cross the long fiber padding 2, and is covered with an outer fabric 5. The periphery is sewn. 2 is a schematic explanatory diagram showing the arrangement direction of the long fiber batting 2 (2a, 2b, 2c, 2d, 2e...) and the relationship between the quilting threads (4a, 4b, 4c, 4d...). The long fiber batting 2 is quilted with the quilting threads 4 so as to cross the batting.

[0026] Figure 3 is a schematic development of the lining 3 of the vest 6, which is formed integrally by sewing together the front body sections 7a, 7b and the back body section 8. Multiple quilting threads 4 (4a, 4b, 4c, 4d, etc.) are quilted in the width direction of the body. Figure 4 is a schematic front view of the vest 6, and the outer fabric 5 is flat and not quilted. When worn with the lining 3 of Figure 3 facing outwards, the multiple quilting threads 4 are visible on the outer side, and when worn with the outer fabric 5 of Figure 4 facing outwards, a flat surface is visible.

[0027] Figure 5 is a cross-sectional view II of Figure 1. This padded garment (padded structure) 1 has long fiber padding 2 arranged in the length direction in a lining 3, quilted with quilting threads 4 (4a, 4b, 4c, 4d...) in the width direction, and is covered with an outer fabric 5. 12a and 12b are the upper and lower sewing points.

[0028] Figure 6 is a schematic development of the lining 3 of jacket 9, which is formed integrally by sewing together front body sections 10a, 10b and back body section 11. Multiple quilting threads 4 (4a, 4b, 4c, 4d, etc.) are quilted in the width direction. Figure 7 is a schematic front view of jacket 9, and the outer fabric 5 is unquilted and flat. When worn with the lining 3 of Figure 6 facing outwards, the multiple quilting threads 4 are visible on the outer side, and when worn with the outer fabric 5 of Figure 7 facing outwards, a flat surface is visible.

[0029] 8 is a side view of a continuous fiber yarn (air-entangled yarn) 31 according to one embodiment of the present invention. In this continuous fiber yarn 31, constituent fibers of a core yarn 32 and an effect yarn 33 are entangled with each other, and the effect yarn 33 is opened to form partially looped fibers.

[0030] Figure 9 is a schematic diagram of a continuous fiber filling manufacturing apparatus according to one embodiment of the present invention. A core yarn 34a is drawn from a yarn wound body 34, and an effect yarn 35a is drawn from a yarn wound body 35. The yarns are passed through two feed rolls 36 and 37 and a yarn guide 38 and then supplied to an air entangling device 40. When compressed air is supplied to the air entangling device 40 from a compressed air line 41, the fibers in the yarn path 39 are opened and rotated, thereby entangling each other. Reference numeral 42 denotes a continuous fiber yarn (air entangled yarn). After a mixed fiber entanglement process is performed using an entanglement nozzle with a core yarn supply speed of 10 to 200 m / min, an effect yarn supply speed of 20 to 10,000 m / min, a winding speed of 10 to 200 m / min, and an air pressure of 0.01 to 1.0 MPa, the yarn passes through a delivery roll 43 and is wound around a yarn wound body 45. Reference numeral 44 denotes a winder roll. This method has the advantage that the yarn can be wound at a high speed of 20 to 1500 m / min, resulting in high productivity. Instead of winding the yarn onto the yarn wound body 45, the yarn may be stored in a can.

[0031] The obtained continuous fiber yarn (air-entangled yarn) is preferably treated with a silicone resin. A reactive silicone treatment agent having a hydrogen group (-OH), a vinyl group (-CH=CH2), or the like at the molecular end is preferably used as the silicone resin. For example, soft silicones such as "TERON E 530" bulky silicone, "TERON E 731," and "TERON E 722" manufactured by Matsumoto Yushi Pharmaceutical Co., Ltd. can be used. The amount of silicone added is preferably 0.1 to 10% by mass of the wadding, on a dry basis. Next, in a heat treatment step, the silicone resin is cured by heat treatment at 140 to 190°C for 1 to 10 minutes. [Example]

[0032] The present invention will be described in more detail below with reference to examples, although the present invention is not limited to the following examples. Example 1 (1) Long-fiber padding The long fiber filling material used was "Air Flake" (a fiber bundle made up of 15 long fiber yarns of approximately 0.12 g / m each; hereafter sometimes abbreviated as "AF") manufactured by Kurabo Industries, Ltd. (2) A process of arranging AF in one direction As shown in Figures 1 and 2, fiber bundles (approximately 1.8 g / m) were arranged in one direction on the lining surface at a rate of one fiber bundle every 3 cm in length. It is preferable to arrange the fiber bundles every 1 cm to 5 cm. The lining material is 100% nylon, the weave is plain (taffeta), and the basis weight is 31 g / m. 2 The lining was cut into a size larger than the pattern. (3) Lining and AF quilting process The roughly cut lining and AF were sewn together with multiple quilting threads in the width direction of the body. The intervals between the quilting threads in the width direction were 5 cm. (4) Cutting process of AF quilted lining The lining, quilted with multiple quilting threads, and AF were cut according to the pattern. (5) Sewing of outer fabric The cut outer fabric, the cut lining, and the long fiber batting were sewn together with the AF facing on the inside. The outer fabric is made of 100% nylon, with a plain weave (taffeta) and a weight of 31 g / m. 2 The fabric used was: (6) Sewing parts The back body, left front body, and right front body parts made from the fabric obtained as described above were sewn together as shown in FIG. 3 to create the vest shown in FIG. This vest was quilted with AF arranged lengthwise and multiple quilting threads in the lining and widthwise directions, and the outer fabric was flat, with no parallel quilting threads. This vest also had high bulk, no movement of the padding, was warm, and had excellent design, allowing it to be worn with the flat side facing outward or reversibly turned inside out, despite being a garment with long fiber padding.

[0033] Example 2 The same procedure as in Example 1 was carried out except that the spacing between the quilting threads in the body width direction in step (3) of Example 1 was set to 15 cm. The jacket obtained in this way had AF arranged in the length direction, quilted with multiple quilting threads in the lining and width direction, and was flat with no parallel quilting threads on the outer fabric. This vest also had high bulk, no movement of the padding, was warm, and had excellent design, such as being able to be worn with the flat side facing out or reversibly facing out, despite being a garment with long fiber padding. [Industrial Applicability]

[0034] The padding structure of the present invention is suitable for padded clothing, sleeping bags, futons, hats, gloves, etc. In particular, it is preferable for it to be used in jackets, vests, pants, coats, cold weather clothing, work clothes, neck warmers, or parts thereof. Garments such as jackets, vests, and pants are suitable for sports. It is also suitable for inner jackets. [Explanation of symbols]

[0035] 1. Padded clothing (padded structure) 2,2a,2b,2c,2d,2e Long fiber filling 3. Lining 4, 4a, 4b, 4c, 4d quilting thread 5 Outer fabric 6 Best 7a, 7b, 10a, 10b Front 8,11 Best time to see 9. Jacket 12a,12b Sewing points 31,42 Long fiber yarn 32,34a Core yarn 33,35a filament 33 Long fiber filling manufacturing equipment 34, 35, 45 Winding body 36,37 Feed roll 38 Thread guide 39 Thread path 40 Air interlacing device 41 Compressed air line 43 Delivery Roll 44 Winder Roll

Claims

1. A padding structure in which long fiber padding is filled in a fabric consisting of a surface fabric and a lining fabric, The long fiber filling is arranged in the length direction or width direction, and is quilted with one of the outer fabric or the inner fabric by a plurality of quilting threads in a direction intersecting the arrangement direction, The other of the outer and inner linings is flat and does not have a plurality of quilting threads parallel to the intersecting direction.

2. The long fiber batting is arranged in the length direction and is quilted with one of the outer fabric or the lining fabric by a plurality of quilting threads in the width direction, 2. The padding structure according to claim 1, wherein the other of the outer fabric and the inner fabric is flat and does not have a plurality of quilting threads parallel to the width direction of the body.

3. 2. The padded structure according to claim 1, wherein the padded garment is a reversible type that can be used with either the quilted surface or the flat surface facing outward.

4. 2. The padding structure according to claim 1, wherein the quilting interval is 30 to 250 mm.

5. The long fiber yarn constituting the long fiber filling is composed of at least a core yarn and an effect yarn, and the two are intertwined and integrated, 2. The padding structure according to claim 1, wherein a plurality of said long fiber yarns are aligned and filled in the fabric as fiber bundles.

6. 2. The padding structure according to claim 1, wherein the fiber bundle formed by arranging a plurality of long fiber yarns has a mass per unit length of 0.15 to 45 g / m.

7. 2. The padding structure according to claim 1, wherein the fiber bundle is made up of 2 to 1,800 long fiber yarns.

8. 2. The padded structure according to claim 1, wherein the padded structure is a padded garment, a sleeping bag, a futon, a hat, or a glove.

9. A method for producing the padding structure according to any one of claims 1 to 8, comprising: A long fiber batting is arranged on the lining in a length direction or width direction, and the lining and the long fiber batting are quilted with a plurality of quilting threads in a direction intersecting the arrangement direction; The lining quilted with the quilting thread and the long fiber batting are cut according to a paper pattern; A method for manufacturing a padded structure, comprising sewing together a cut outer fabric, the cut lining fabric and the long fiber batting, with the long fiber batting on the inside.

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