Bedding

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 batting used in bedding such as quilts and blankets, bedding containing batting, and batting. [Background technology]

[0002] The quilts shown in Patent Documents 1 to 3 are composed of a surface and a lining, with batting, feathers, etc. placed between the surface and the lining. In order to improve the heat retention of the quilt, it is necessary to ensure many air spaces 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] Using aerogel as the filling may improve heat retention, but the manufacturing process for aerogel filling layers is complicated, making it very difficult to reduce production costs. Furthermore, aerogel has issues such as low durability, and it is difficult for the aerogel fibers to capture the air in the filling, which may result in a lack of effective heat retention and insulation.

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

[0006] To solve the above problems, the present invention provides a filling comprising short fibers kneaded with aerogel, wherein the weight ratio of the aerogel to the total weight of the short fibers is 0.1% to 10%, 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). This allows for high thermal insulation and a simplified structure. The filling of the present invention can be used in bedding such as comforters and blankets to provide bedding with high thermal insulation, 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 items such as rugs and cushions.

[0007] The fibers constituting the filling may be only short fibers in which the aerogel is kneaded.

[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 is 0 to 95% (excluding 0%), thereby preventing 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, thereby preventing any problems in the production of the padding layer.

[0010] The present invention also provides bedding comprising a surface fabric, a lining, and a filling layer formed of the above filling and disposed between the surface fabric and the lining, thereby providing a light, thin bedding that has high heat retention and prevents heat from escaping.

[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 outer and inner fabrics, thereby providing a light, thin blanket with excellent heat retention and heat retention.

[0012] The present invention also provides a method for producing batting, which comprises a melt spinning process in which aerogel is mixed into synthetic fiber raw materials and polymerized to form chips containing aerogel, which are then 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 batting formation process in which the staple fibers are formed into batting, thereby achieving high heat retention and simplifying the structure. [Brief explanation of the drawings]

[0013] [Figure 1] 1 is a cross-sectional view of bedding according to an embodiment of the present invention. [Figure 2] 1 is a flowchart showing a production process of an aerogel-containing polyester staple fiber according to an embodiment of the present invention. [Figure 3] 1 is an explanatory diagram of a first production process of a padded 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. [Figure 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 INVENTION

[0014] An embodiment of the present invention will be described with reference to the drawings.

[0015] As shown in Fig. 1(a), a comforter 10 as a type of bedding product of the present embodiment 1 comprises a filling layer 1 containing aerogel kneaded therein, and a surface fabric 2 and a lining fabric 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 thicknesses of the surface fabric 2 and the lining fabric 3 are each 2 to 30 mm.

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

[0017] As shown in FIG. 1(b), a blanket 11, which is a type of bedding product according to the first embodiment, comprises two aerogel-infused filling layers 1, a microfiber outer layer 2, and a microfiber lining 3, respectively, on the front and back sides of the filling layers 1, and a heat-insulating layer, such as an aluminum layer 4, is provided between the two filling layers 1. The thickness of the filling layers 1 is 2 to 100 mm, the thicknesses of the outer layers 2 and lining 3 are 2 to 30 mm, and the thickness of the heat-insulating layer is 1 to 10 mm. The filling layer 1 according to the first embodiment has moisture-absorbing and heat-generating properties, and can be combined with moisture-absorbing and heat-generating cotton (e.g., a mixture of one or more of acrylate and rayon, lyocell, and cotton) or heat-storing and insulating cotton (e.g., a mixture of one or more of polyester, polypropylene, and acrylic) to further enhance heat retention.

[0018] The filling layer 1 is made of synthetic batting formed into a sheet. Synthetic batting is cotton produced from synthetic fibers, and examples of synthetic fibers include recycled fibers, semi-synthetic fibers, synthetic fibers, and inorganic fibers. Synthetic fibers such as polyester, nylon, and polypropylene are preferably used, and a composite of fibers made from multiple materials may also be used. The batting that makes up the filling layer 1 may also contain natural fibers in addition to synthetic fibers.

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

[0020] Examples of aerogel include silica aerogel, carbon aerogel, and alumina aerogel, but in this embodiment, silica aerogel is used. Aerogel has 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, or linen, regenerated fibers such as rayon, synthetic fibers such as polyester, nylon, or acrylic fibers, or natural or synthetic leather. The outer fabric 2 and the lining 3 may be made of the same material or different materials, and the material can be selected appropriately depending on the product being produced.

[0022] The blanket 11 is breathable and has an aluminum layer 4 that reflects heat from the aerogel-infused padding layer 1, and the high heat insulating properties of the aerogel allow heat to be trapped within the outer layer 2 and lining layer 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] To provide synthetic fiber bedding with high thermal insulation properties, such as down, the low thermal conductivity of aerogel can be incorporated into polyester staple fibers to enhance the thermal insulation properties of the bedding. The lower the thermal conductivity of polyester staple fibers, the higher the thermal insulation and heat retention properties of the bedding.

[0025] As shown in Fig. 1(a), a single filling layer 1 may be provided between a surface 2 and a lining 3, or multiple layers may be provided. For example, there may be three or more layers between the surface 2 and the lining 3.

[0026] Depending on the embodiment of the present invention, the number of layers may be varied appropriately from one shown in Figure 1(a) to multiple layers (e.g., five layers). For example, a single layer may be a polyester fiber batting layer with aerogel kneaded into it; a two-layer may be a polyester fiber batting layer with aerogel kneaded into it and a moisture-absorbing heat-generating batting layer; a three-layer may be a polyester fiber batting layer with aerogel kneaded into it, a moisture-absorbing heat-generating batting layer, and an anti-mite batting layer; a four-layer may be a polyester fiber batting layer with aerogel kneaded into it, a moisture-absorbing heat-generating batting layer, an anti-mite batting layer, and a heat-storing batting layer; and a five-layer may be a polyester fiber batting layer with aerogel kneaded into it, a moisture-absorbing heat-generating batting layer, an anti-mite batting layer, a heat-storing batting layer, and an aluminum nonwoven fabric. Other examples include the use of antibacterial, deodorizing, and deodorizing cotton. Examples of the moisture-absorbing and heat-generating cotton layer include a cotton layer made from 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 from 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 from polyester that has been treated with anti-mite processing.

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

[0028] The polyester short fibers containing aerogel 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 then processed through a carding process to form the filling layer 1.

[0029] The staple fibers other than the polyester staple 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 kneaded with the aerogel 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 short fibers 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 the conventional synthetic fiber comforter and down comforter, which do not contain aerogel. Here, the basis weight of the filling (padding) is 400 g / m 2 The "clo value" is a value that can be measured along with thermal conductivity according to ASTM D 1518-85. 1 clo refers to the heat retention capacity of clothing, such that a person sitting at rest can maintain an average skin temperature of approximately 33°C in a room with a temperature of 21°C, relative humidity of 50%, and airflow 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 the ratio indicating the resistance to heat loss, as determined by heat retention tests (JIS L 1096 and ASTM D 1518). This ability to increase the insulating properties of clothing and reduce heat transfer is called thermal insulation. Typical 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 mixed with a specific proportion of aerogel will be described with reference to FIG.

[0035] Paraxylene and ethylene are obtained from petroleum. Paraxylene is oxidized to produce terephthalic acid, and ethylene is converted to ethylene glycol. Terephthalic acid and ethylene glycol are then polymerized. During the polymerization process, 0.1 to 10% by weight of aerogel raw material (particulate aerogel raw material made of silicon dioxide, with a particle diameter of 50 nm or less) is kneaded into the material to produce 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. Therefore, the process of adding aerogel and stirring and mixing the aerogel and polyester raw material is referred to as kneading. These polyester chips are melt-spun into yarns, which are then stretched and crimped. The resulting yarns are then cut to produce polyester staple fibers (also known as polyester staple). Alternatively, the melt-spun yarns are wound and stretched to form polyester filaments, which are then used to produce polyester staple fibers (also known as polyester staple). The aerogel-kneaded polyester staple fibers are used to produce the padding layer 1.

[0036] The aerogel-mixed polyester short fibers have a fiber diameter of 0.5 Dtex to 50 Dtex and a length of 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 that constitutes the padding layer 1, will be described with reference to FIGS.

[0039] The padding sheet may be formed solely from aerogel-incorporated polyester staple fibers (melting point 255-265°C) in which 0.1-10% by weight of aerogel has been mixed, or may be formed by mixing staple fibers other than the aerogel-incorporated polyester staple fibers. The aerogel-incorporated 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 Figure 3. It consists of a raw material process, a cotton blending / opening 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 fiber blend ratio in production process 1 is preferably 5 to 95 wt% aerogel-incorporated polyester staple fiber (melting point 255 to 265°C), 5 to 60 wt% low-melting-point polyester staple fiber (melting point 100 to 120°C) with a melting point lower than that of the aerogel-incorporated polyester staple fiber, and 5 to 90 wt% other staple fibers (chemical fibers, natural fibers, etc.). For example, various embodiments are possible, such as blending 92% by weight of aerogel-mixed polyester staple fiber with 8% by weight of low-melting-point polyester staple fiber, blending 50% by weight of aerogel-mixed polyester staple fiber with 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 aerogel-mixed polyester staple fiber with 15% by weight of low-melting-point polyester staple fiber and 35% by weight of rayon staple fiber, blending 30% by weight of aerogel-mixed polyester staple fiber with 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, etc.

[0041] Referring to FIG. 4, production process 2, a second embodiment of the padded sheet production process, is described. It consists of a raw material process, a cotton blending / opening process, a carding process, a needle punching process, an inspection process, and a winding process. In production process 2, needle punching is performed instead of the heating process used in production process 1, which melts low-melting-point polyester fibers. Therefore, there is no need to incorporate low-melting-point polyester fibers. The same explanation as for production process 1 applies to the common processes. Regarding the fiber blend ratio in production process 2, when there is one type of fiber, the raw material is 100% aerogel-incorporated polyester staple fiber by weight. However, when there are two or more types of fibers, the blend ratio is preferably 5% to 95% by weight of aerogel-incorporated polyester staple fiber (melting point 255 to 265°C) and 5% to 95% by weight of other staple fibers (such as synthetic fibers or natural fibers). For example, various embodiments are possible, such as a blend 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 blend of 50% aerogel-mixed polyester staple fiber, 15% polyester staple fiber, and 35% rayon staple fiber, and a blend of 30% aerogel-mixed polyester staple fiber, 60% polyester staple fiber, and 10% acrylate staple fiber.

[0042] Referring to Figure 5, Production Process 3, a third example of the padding sheet production process, is described. It consists of a raw material process, a cotton blending / opening process, a carding process, and a bonding process. In Production Process 3, the padding sheet production process ends with the bonding process, followed by the process of stuffing the padding sheet into the comforter. Production Process 3 also does not include a heating process to melt low-melting-point polyester fibers, so there is no need to mix low-melting-point polyester fibers. The explanation for Production Process 1 is used for common processes. Regarding the fiber blend ratio in Production Process 3, when one type of fiber is used, the raw material is 100% aerogel-incorporated polyester staple fiber by weight. However, when two or more types of fiber are used, the preferred blend ratio is 5% to 95% aerogel-incorporated polyester staple fiber (melting point 255 to 265°C) by weight and 5% to 95% other staple fibers (e.g., synthetic fibers, natural fibers, etc.). For example, various embodiments are possible, such as a blend 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 blend of 50% aerogel-mixed polyester staple fiber, 15% polyester staple fiber, and 35% rayon staple fiber, and a blend of 30% aerogel-mixed polyester staple fiber, 60% polyester staple fiber, and 10% acrylate staple fiber.

[0043] The present invention provides the following effects. Because aerogel is kneaded into the short fibers, the manufacturing process for the padding layer 1 is simplified, reducing production costs. The production cost is 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), resulting in high heat retention and insulation effects.

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

[0045] Since the aerogel is kneaded into the short fibers, it is possible to provide bedding products with high heat retention, which can expand the range of uses and applications, and therefore has great industrial applicability. [Explanation of symbols]

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

Claims

1. An outer fabric and a lining, The jacket has a padding layer formed between the outer layer and the inner layer and composed of padding, and a heat insulating layer, The two padding layers sandwich the heat insulating layer from the front and back sides, The two padding layers are sandwiched between the outer fabric and the inner fabric, The filling includes short fibers mixed with aerogel, The weight ratio of the aerogel to the total weight of the short fibers is 0.1% to 10%; 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. 2. The bedding according to claim 1, wherein the fibers constituting the filling are only short fibers mixed with the aerogel.

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

4. The fiber diameter of the short fibers is 0.5 Dtex to 50 Dtex, and the length is 20 mm to 100 mm.

4. The bedding according to claim 3, wherein 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.

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