Manufacturing method of stuffed objects

Abstract

To provide a stuffed article which allows product dyeing and is less likely to deteriorate.SOLUTION: The stuffed article comprises a facing fabric, a lining fabric and a cotton pad interposed therebetween. The inner cotton is integrated with the facing fabric and / or the lining fabric and may be dyed relatively darker than the facing fabric and / or the lining fabric. The stuffed article is subjected to product dyeing. It is desirable that the color tone of the dyed cotton pad is seen through the facing fabric and / or the lining fabric to be discriminated. The stuffed article may be dyed partially.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] The present invention relates to a stuffed object in which the filling is made of long fibers. Manufacturing method Regarding. [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 eiders (wild ducks) 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, such as Poland and Hungary, Northern Europe, including the Scandinavian Peninsula, and China. Feathers are bulky and warm, and occupy a position as a luxury material for feather products such as duvets and down jackets.

[0003] However, natural feathers are dependent on waterfowl, and there is a limit to the supply, and the supply fluctuates due to 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 the filth that causes the odor in advance and to maintain a certain level of cleanliness and oxygen count, which indicate the degree to which the feathers have been washed. Another basic problem is that it is not easy to wash feather products such as feather duvets and feather jackets.

[0004] Thus, there have been many proposals for batting. Patent Document 1 proposes shrinking polyester fibers by heat treatment to cause crimping and provide bulk and elasticity. In Patent Documents 2 and 3, the applicant has proposed batting in which a core yarn and an effect yarn are entangled. Patent Document 4 proposes batting in which an effect yarn is wound around a core yarn and entangled. Furthermore, Patent Document 5 proposes bulking processing by rotating yarns having different yarn lengths with an injected air current. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Japanese Patent Application Publication No. 6-93513 [Patent Document 2] JP 2012-067429 A [Patent Document 3] JP 2012-067430 A [Patent Document 4] JP 2016-027213 A [Patent Document 5] JP 2017-122304 A Summary of the Invention [Problem to be solved by the invention]

[0006] However, the stuffing of the prior art has a problem in that the quality of the filling material changes when dyed. In order to solve the above problems, the present invention provides a stuffing material that can be dyed and is less likely to deteriorate. Manufacturing method to provide. [Means for solving the problem]

[0007] The method for producing a stuffed article of the present invention is to insert a cover fabric consisting of a surface fabric and a lining fabric. Long fiber filling 1. A method for producing a filled stuffed object, comprising the steps of: The above Long Fiber The filling is made of core thread and flower thread. Including The effect yarn is relatively long compared to the core yarn, the constituent fibers of the core yarn and the effect yarn are entangled with each other, and the effect yarn is opened to partially form loop-shaped fibers, The long fiber padding is integrated with at least one of the outer and inner fabrics, The above Long Fiber The padding contains nylon fibers, and at least one of the outer and inner linings is made of a polyester fiber fabric; The above Long Fiber The filling is arranged in the length direction and filled into the side fabric to form a stuffing. The stuffing is product dyed with an acid dye; Long FiberThe nylon fiber filling is dyed, and the polyester fiber fabric is not dyed. Effect of the Invention

[0008] The present invention Obtained through manufacturing process In the stuffing, the filling is integrated with at least one of the outer and inner fabrics, so that there are no problems such as shrinkage or unevenness of the filling even when dyed, and there is little or no deterioration. In addition, since the filling is dyed in a relatively dark color compared to at least one of the outer and inner fabrics, even if the product is dyed, the color tone of the filling can be distinguished from the outside in the same way as a stuffing object filled with colored filling. [Brief description of the drawings]

[0009] [Figure 1] FIG. 1 is a side view of an intertwined yarn in one embodiment of the present invention. [Diagram 2] FIG. 2 is a schematic explanatory diagram of a method for producing air-entangled long-fiber yarn in one embodiment of the present invention. [Diagram 3] FIG. 3 is a plan view of the stuffed object according to the first embodiment of the present invention. [Figure 4] FIG. 4 is a plan view of the stuffed object according to the second embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] The present invention is a stuffed object including an outer fabric, a lining, and batting interposed between the outer fabric and the lining. The batting is integrated with at least one of the outer fabric and the lining. The integration is preferably by sewing such as stitching or quilting, but the fabric and the batting can also be integrated via a heat-sealed cloth. Integration by sewing can maintain a good texture. Any sewing method can be used as long as the batting can be integrated with at least one of the outer fabric and the lining, but preferably both ends of the batting are sewn, or an arbitrary position between both ends of the batting is sewn.

[0011] In the stuffing of the present invention, the filling is dyed in a relatively dark color compared to at least one of the outer and inner fabrics. To achieve this, it is preferable to select a fiber that is dyed with a specific dye for the filling, and select a fiber that is resistant to the dye for at least one of the outer and inner fabrics. Alternatively, at least one of the outer and inner fabrics can be treated to be water-repellent to make it less susceptible to dyeing. In other words, it is dye-resistant. Such a technology is described in JP 2018-197406 A.

[0012] The stuffing of the present invention is product dyed. Usually, already dyed components are used to manufacture a product, but product dyeing is a method in which a product is manufactured using undyed components and then dyed after it is shaped into a product. Product dyeing is also called post-dyeing. Product dyeing eliminates the need to prepare batting in many colors, which reduces costs. In the prior art, dyeing of the batting was not considered, and even if the batting was dyed, it was necessary to prepare batting in many colors, and inventory management was also required, resulting in high costs. In addition, when bulky yarn is produced by a method of dyeing filaments in advance, the quality is reduced due to thread breakage and shrinkage during winding, and the bulkiness of the yarn is reduced. Furthermore, when intertwined yarns (bulky yarns) are dyed, there are similar problems, and there is also a problem of uneven dyeing. In contrast, the present invention can solve these problems. The fact that the product is dyed can be determined by the fact that the fabric, sewing thread, interlining, and other auxiliary materials are slightly dyed (contaminated) with the dye that dyed the batting. The dyeing may be done by a normal method.

[0013] The stuffing object may be such that the color tone of the dyed filling can be seen through the fabric when viewed from at least one of the outer and inner fabrics. Any fabric can be used as long as the color tone of the dyed filling can be seen through the fabric. The fabric is preferably thin and colorless. The threads constituting the fabric are preferably thin and densely woven. This configuration can prevent the filling from coming out of the fabric and allows the color tone of the filling to be seen from the outside. For example, when the stuffing object is a padded garment, it is preferable that the color tone of the filling can be seen from the outer fabric, and in the case of a cushion or the like, it is preferable that the color tone of the filling can be seen from either one side or both sides. The stuffing object may also be partially dyed. For example, in the case of a padded garment, only the arm part may be dyed.

[0014] The filling (yarn for stuffing) of the present invention is composed of at least two types of long fibers A and B. Although it is optional to add fibers other than long fibers A and B, when the yarn for stuffing is taken as 100% by mass, the total amount of long fibers A and B is preferably 70% by mass or more, and more preferably 80% by mass or more. Long fibers A and B are integrated. Here, "integrated" refers to a state in which the fibers are entangled or wound around each other. Long fiber A is relatively short compared to long fiber B. Bulkiness is achieved by providing a difference in length between long fibers A and B.

[0015] It is preferable to use polyester hollow fibers with a single fiber fineness of 3 decitex or more for the long fibers B. This will increase bulkiness and heat retention. If the single fiber fineness is less than 3 decitex, bulkiness and heat retention cannot be expected. Note that decitex is also expressed as T.

[0016] It is preferable that the filling (yarn for stuffing) has a bulkiness of 140 mm or more, as measured according to JIS L 1903-1998 "Testing method for feathers for filling materials used in feather products." This improves heat retention.

[0017] It is preferable that the long fibers B have a single fiber fineness of 3 decitex or more and a hollow ratio of more than 30%, which allows the bulkiness and heat retention to be maintained at a high level.

[0018] Stuffing thread Quality The amount is preferably 0.01 to 3 g / m, more preferably 0.02 to 1.5 g / m, because this range makes it easy to handle when processing into stuffing.

[0019] The weight ratio of the effect yarn (long fiber B) to the core yarn (long fiber A) is preferably in the range of 51 to 99% by mass (wt%) when the effect yarn (long fiber B) and the core yarn (long fiber A) are used as the modulus. The ratio of the effect yarn (long fiber B) is more preferably in the range of 80 to 98 wt%, and particularly preferably in the range of 85 to 97 wt%. If it is in the above range, the fixing and integration by the core yarn (long fiber A) will be firm, and the texture will also be good.

[0020] The long fibers B are preferably 1.1 to 100 times, more preferably 2 to 100 times, and even more preferably 4 to 60 times, longer than the long fibers A. Within this range, the long fibers B become loop fibers to the extent that they are longer, and can be made bulky.

[0021] It is preferable that the long fibers A and B are integrated by at least one process selected from the group consisting of entanglement, air jet processing, wrapping, and spraying of long fiber B against long fiber A. The entanglement process is a process using an air entanglement machine that sprays compressed air perpendicular to the running direction of long fibers A and B. The air jet process is a so-called Taslan process, in which compressed air is forced into long fibers A and B in the traveling direction. The wrapping process is a process in which long fiber B is wound around long fiber A to integrate them. The process in which long fiber B is sprayed against long fiber A is a process in which long fiber B is sprayed onto long fiber A to entangle or rotate it.

[0022] The stuffing yarn of the present invention is filled into at least one stuffing object selected from futons, blankets, sleeping bags, pillows, cushions, mats, stuffed toys, lap blankets, jackets, shirts, pants, skirts, vests, coats, cold weather clothing, innerwear, and neck warmers.

[0023] The stuffed object is washable in a washing machine. Because of its washability, bedding is suitable for use in hotels, rentals, disaster relief, hospitals, and elderly care facilities, and clothing is suitable for use in sports.

[0024] The stuffing material of the present invention is preferably filled with long fiber stuffing threads arranged in the length direction of the stuffing, and fixed to the outer fabric by multiple quilt threads sewn in the width direction of the stuffing. As a result, the length of the stuffing threads does not change between the fixed points, and the long fibers A and B are integrated, so that the movement of the stuffing is limited even after repeated washing, resulting in a stuffing product with less unevenness and high volume. The stuffing material of the present invention may use other long fiber stuffing together with the long fiber stuffing thread, or may be a mixture of other long fiber stuffing and the long fiber stuffing thread of the present invention, and fixed to the outer fabric by multiple quilt threads. It may also be used in combination with other feathers, artificial feathers, and short fiber cotton.

[0025] The following description will be given with reference to the drawings. In each drawing, the same reference numerals indicate the same parts. In the following description, the long fiber filling yarn will be described as an example of an intertwined yarn. Figure 1 is a side view of a long fiber filling yarn in one embodiment of the present invention. In this long fiber filling yarn 1, the constituent fibers of a core yarn 2 (long fiber A) and an effect yarn 3 (long fiber B) are intertwined with each other, and the effect yarn 3 (long fiber B) is opened to partially form loop-shaped fibers.

[0026] 2 is a schematic diagram showing a method for producing an air entangled yarn. A core yarn 4a (long fiber A) is drawn from a yarn winding body 4, and an effect yarn 5a (long fiber B) is drawn from the yarn winding body 5, and the core yarn 4a (long fiber B) is passed through two feed rollers 6 and 7 and a yarn guide 8, and is then supplied to an air entanglement device 10. When compressed air 11 is supplied to the air entanglement device 10, the fibers in the yarn path 9 are opened and rotated, and are entangled with each other. 12 is a mixed fiber entangled yarn. The core yarn is supplied at a speed of 10 to 200 m / min, the effect yarn is supplied at a speed of 20 to 10,000 m / min, the winding speed is 10 to 200 m / min, and the mixed fiber entanglement process is performed using an entanglement nozzle with an air pressure of 0.01 to 1.0 MPa. The yarn passes through a delivery roller 13 and a winder roller 14, and is then wound around a yarn winding body 20. This method has the advantage that the yarn winding speed can be increased to 20 to 1,500 m / min, resulting in high productivity.

[0027] The obtained intertwined yarn is given a silicone resin. The silicone resin has a molecular end with a hydrogen group (-OH) or a vinyl group (-CH=CH 2 It is preferable to use a reactive silicone treatment agent having the above properties. For example, bulky silicone "TERON E 530" manufactured by Matsumoto Yushi Seiyaku Co., Ltd., soft silicones such as "TERON E 731" and "TERON E 722" can be used. The amount of the agent applied is preferably 0.1 to 10% by mass based on the dry weight of the filling. Next, in the heat treatment step, the silicone resin is cured by heat treatment at 120 to 190°C for 1 to 18 minutes.

[0028] The relationship between fiber materials and dyes is shown in Table 1, and you can select the fibers you want to dye and the fibers you do not want to dye. The evaluation criteria in Table 1 are as follows. A: It dyes well. B: It dyes normally. C: Not easily stained.

[0029] [Table 1] EXAMPLES

[0030] 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. The measurement method for each physical property will be described below.

[0031] Example 1 <Filling 1: Acid dye-easily dyed fiber> The core yarn was a hollow nylon filament yarn (nylon, hollow ratio 20-30%), with a fineness of 28 decitex and 12 filaments, and the decorative yarn was a hollow nylon filament yarn (nylon, hollow ratio 20-30%), with a fineness of 28 decitex and 12 filaments, to produce the stuffing yarn. The mass of this stuffing yarn was 0.12 g / m. Next, in the silicone resin application process, silicone resin was applied. In the silicone resin application process, 15 of the stuffing threads were bundled together. As the silicone resin, a 0.5% by mass aqueous solution of "Teron E-530" manufactured by Matsumoto Yushi Seiyaku Co., Ltd. was used, and the amount applied was 1.5 to 3.5% by mass based on the dry weight of the wadding. Next, in the heat treatment process, heat treatment was performed at 120 to 170°C for 1 to 18 minutes to thermally cure and fix the silicone resin. <Filling 2: Acid dye resistant fiber used> The core yarn was a polyethylene terephthalate filament yarn with a fineness of 41 decitex and 12 filaments, and the decorative yarn was a polyethylene terephthalate (PET) hollow filament yarn with a hollowness of 35%, a fineness of 41 decitex and 12 filaments, to produce the stuffing yarn. The mass of the stuffing yarn was 0.15 g / m. Silicone resin was added in the same manner as for filling 1. <Side fabric> The outer and inner fabrics are made of 100% polyester filament yarn (fineness 11.1 decitex), with a warp density of 240 threads / inch, weft density of 240 threads / inch, and weight per unit area (basis weight) of 49g / m 2 It is made of ripstop fabric. This fabric was cut to 44 cm length and 30 cm width, folded in half at the center of the long side, and quilted at 3.5 cm intervals parallel to the fold line. Inside, the above-mentioned batting 1 and batting 2 were filled uniformly. The total filling amount was 11.5 g (6.5 g fabric, 5.0 g batting). The horizontal side was then folded in three at 1.5 cm width, and both ends of the batting were sewn together with the outer fabric and lining. <Staining> The fabric was dyed with 1.0% owf acid dye at a bath ratio of 1:15, at 100°C for 60 minutes. After dyeing, the fabric was soaped, washed three times with water, and dried. Figure 3 is a plan view of the dyed batting fabric sample of Example 1. The grey area is batting 1, where the batting is dyed, and the white area is batting 2, where the batting is not dyed.

[0032] Example 2 The same procedure as in Example 1 was carried out, except that no filling 2 was used as the filling, and filling 1 was used entirely to prepare a padded fabric sample. Figure 4 is a flat photograph of the dyed quilted fabric sample of Example 2. The quilted part appears to be dyed gray. A white piece of paper is placed on the bottom of the back of Figure 4.

[0033] Comparative Example 1 The same procedure was carried out as in Example 1, except that polyester fiber batting 2 was used in its entirety as the batting, nylon filament yarn was used as the outer and inner fabrics, and disperse dyes were used to dye the batting. In this dyed product, the batting, outer fabric, and inner fabric were all dyed the same color, so there was no point in dyeing the batting. [Industrial Applicability]

[0034] The stuffed articles of the present invention are useful for futons, blankets, sleeping bags, pillows, cushions, mats, stuffed toys, lap blankets, jackets, shirts, pants, skirts, vests, coats, cold weather clothing, innerwear, work clothes, neck warmers, and the like. [Explanation of symbols]

[0035] 1 Stuffing thread 2,4a Core yarn (long fiber A) 3,5a Flower thread (long fiber B) 4,5,20 Winding thread 6,7 Feed roller 8 Thread guide 9. Yarn path of interlacing machine 10 Air interlacing device 11 Compressed Air 12. Mixed fiber interlaced yarn 13 Deliverables 14 Winder roller

Claims

1. A method for manufacturing a stuffed object in which a cover fabric consisting of a front and a back fabric is filled with long fiber batting, The long fiber filling includes a core yarn and an effect yarn, the effect yarn is relatively long compared to the core yarn, the constituent fibers of the core yarn and the effect yarn are entangled with each other, and the effect yarn is opened to partially form a loop-shaped fiber, The long fiber padding is integrated with at least one of the outer and inner fabrics, The long fiber filling contains nylon fibers, and at least one of the outer and inner linings is made of a polyester fiber fabric; The long fiber filling is arranged in the length direction and filled into the side fabric to form a stuffing. A method for manufacturing a stuffed object, comprising product dyeing the stuffed object with an acid dye, dyeing the nylon fibers of the filamentary batting, and not dyeing the polyester fiber fabric.

2. 2. The method of claim 1, wherein said filamentary batting is dyed throughout.

3. 2. The method of claim 1, wherein said filamentary batting is partially dyed.

4. The method for producing a stuffed object according to any one of claims 1 to 3, wherein the core yarn and the filament yarn of the long fiber filling are integrated by at least one process selected from the group consisting of intertwining process, air jet process, winding process, and process of spraying compressed air against the core yarn and the filament yarn of the long fiber filling.

5. A method for producing a stuffed object according to any one of claims 1 to 4, wherein the mass of the stuffing yarn is in the range of 0.01 to 3 g / m.

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