Filling structure

Abstract

To provide a long fiber sheet, which enables a planar long fiber sheet to be produced by uniformly and automatically aligning long fiber bundles, and an inner cotton structure using the same.SOLUTION: A long fiber sheet 7 includes a long fiber bundle 6 consisting of a plurality of long fiber yarns. The long fiber bundle 6 is continuously arranged in U-shape or wave-form so as to form a planar long fiber sheet 7. An inner cotton structure is the inner cotton structure including the long fiber sheet 7. The long fiber sheet 7 is disposed between a front fabric and a back fabric. The long fiber sheet 7 is aligned in one direction and has a sewing line at least in a direction crossing an end of the long fiber sheet 7. Outer side of the sewing line is cut.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention is a long fiber sheet To Regarding the batting structure used. [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 regarding batting. In Patent Document 1, the present applicant proposes a long-fiber batting in which a core yarn and an effect yarn are intertwined, and proposes wrapping a plurality of long-fiber batting cut to a predetermined length in a film and placing it in the side fabric. Patent Document 2 proposes a long-fiber batting in which an effect yarn is wound around and entangled with a core yarn. Patent Document 3 proposes a bulking process in which yarns having different lengths are swirled with an air jet. Patent Document 4 proposes forming a number of bundle channels in the side fabric as tucks with sewing threads, and placing long-fiber batting cut to a predetermined length in these bundle channels. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2012-067430 [Patent Document 2] Japanese Patent Application Laid-Open No. 2016-027213 [Patent Document 3] Japanese Patent Application Publication No. 2017-122304 [Patent Document 4] Special Publication No. 2017-532458 Summary of the Invention [Problem to be solved by the invention]

[0004] However, it was difficult to uniformly arrange the long fiber filling in the above-mentioned conventional technology.

[0005] In order to solve the above problems, the present invention provides a long fiber sheet that can be formed into a flat long fiber sheet by arranging long fiber bundles uniformly and automatically, and a filling structure using the same. [Means for solving the problem]

[0006] The present invention provides a filling structure containing a long fiber bundle made of a plurality of long fiber yarns as filling, The long fiber yarn is composed of at least two types of long fibers A and B, the long fibers A being relatively shorter than the long fibers B, and the long fibers A and B being an integrated long fiber yarn; the long fiber bundles are continuously arranged in a U-shape or a zigzag shape to form a planar long fiber sheet, the planar long fiber sheet The front and back of The fabric is layered on top of the sheet, and the fabric and the long fiber sheet are integrated by sewing or welding. And, At least three sides are sewn together with thread, and the outer edges are cut. It is a padding structure. [Effects of the Invention]

[0008] The long-fiber sheet of the present invention is formed by arranging long-fiber bundles consisting of a plurality of long-fiber yarns, for example, long-fiber bundles formed by arranging a plurality of aligned long-fiber yarns, in a continuous U-shape or zigzag shape to form a planar long-fiber sheet, and therefore the long-fiber bundles can be uniformly and automatically arranged to form a planar long-fiber sheet. In particular, by arranging the long-fiber bundles in a planar state in a continuous state, a planar long-fiber sheet can be formed efficiently and quickly while maintaining a uniform thickness and uniform density. The padding structure of the present invention includes the above-mentioned long fiber sheet, which is disposed between a front and a backing, and which is oriented in one direction with sewing lines extending across at least the ends of the long fiber sheet, and which is cut outside the sewing lines, thereby enabling automation of sewing and enabling efficient and rapid formation of the padding structure. [Brief explanation of the drawings]

[0009] [Figure 1] FIG. 1 is a schematic perspective view showing a long-fiber sheet forming step according to one embodiment of the present invention. [Figure 2] FIG. 2A is a schematic perspective view showing a state in which the long fiber sheet is sandwiched between a front fabric and a back fabric, and FIG. 2B is a schematic cross-sectional view in the width direction of FIG. 2A. [Figure 3] 3A and 3B are schematic plan views showing a plate having slit holes formed therein that are common to the sewing lines and the cutting lines. [Figure 4] FIG. 4 is a schematic cross-sectional view showing the state in which the laminate is sandwiched between plates, the sewing line is sewn, and the outer cut line is cut. [Figure 5] FIG. 5 is a schematic plan view showing the obtained filling structure. [Figure 6] FIG. 6A is a schematic plan view showing a padding structure according to another embodiment of the present invention, and FIG. 6B is a schematic cross-sectional view of the same. [Figure 7] FIG. 7A is a plan view of a long fiber sheet of a reference example, and FIG. 7B is a schematic plan view showing a filling structure containing the long fiber sheet. [Figure 8]FIG. 8A is a plan view of a long-fiber sheet of another reference example, and FIG. 8B is a schematic plan view showing a filling structure containing the long-fiber sheet. [Figure 9] FIG. 9 is a schematic side view of a continuous fiber yarn according to one embodiment of the present invention. [Figure 10] FIG. 10 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

[0010] The inventors of the present invention have conventionally cut a long fiber yarn or a long fiber bundle formed by arranging a plurality of long fiber yarns (hereinafter collectively referred to as "long fiber batting") to a predetermined length, inserted the plurality of cut pieces of long fiber batting between the outer and inner fabrics, and sewed them together. Problems with this method include the cumbersome process of inserting a plurality of cut pieces of long fiber batting between the outer and inner fabrics, and the fact that the constituent fibers of the long fiber batting are prone to getting caught, making it difficult to maintain a uniform thickness and density. They have therefore conducted various studies. As a result of this investigation, it was found that this problem could be solved by arranging a continuous long-fiber bundle, each of which is composed of a plurality of aligned long-fiber yarns, in a planar state to form a planar long-fiber sheet. It was found that by arranging the continuous long-fiber bundles in a planar state, a planar long-fiber sheet could be formed efficiently and quickly while maintaining a uniform thickness and density.

[0011] The long fiber bundles are arranged in a continuous U-shape (including repetition) or zigzag to form a planar long fiber sheet. In the case of a U-shape or zigzag shape, the long fiber bundles are folded back in a shifted position in a continuous state to form a planar long fiber sheet. The ends of the arranged long fiber bundles are aligned in a straight line. "Straight line" means that the folded back position is roughly a straight line, and is not limited to a strict straight line. This allows the long fiber sheet to be handled as a single object, making it convenient to integrate with fabric.

[0012] The long fiber bundle is preferably folded in order around a plurality of folding tools fixed at intervals to arrange it in one direction, and then the long fiber bundle is removed from the folding tools to form a planar long fiber sheet. When folding it in a U-shape, this is achieved by increasing the diameter of the folding tools (pins) or adjusting the position of the pins. When folding it in a zigzag shape, this is achieved by decreasing the diameter of the folding tools (pins) or adjusting the position of the pins. This makes it possible to arrange the long fiber bundle uniformly and automatically in one direction to form a planar long fiber sheet. Note that the "planar" in the planar long fiber sheet does not limit the arrangement of the long fiber bundles in the height direction. When arranging continuous long fiber bundles in a planar shape, they can be arranged not only in a planar direction but also by stacking them in the height direction.

[0013] The long fiber bundle folded by the folding tool is preferably folded at an angle of more than 0 degrees and not more than 20 degrees. Note that the term "folded long fiber bundle" also includes long fiber bundles that appear to be folded as a result of being arranged. Pins are preferably used as the folding tool, and the long fiber bundle is preferably folded at a slight angle corresponding to the spacing between the pins. This angle is preferably more than 0 degrees and not more than 20 degrees, more preferably more than 0 degrees and not more than 15 degrees, and even more preferably more than 0 degrees and not more than 10 degrees. At this angle, the sheet can be treated as a unidirectional sheet. The angle may also be a symmetric angle.

[0014] In the step of forming the long-fiber sheet, the long-fiber bundles are preferably arranged into a planar sheet by a robot arm or a movable table that moves in the X and Y directions. In particular, it is preferable to form the long-fiber sheet on the fabric by moving a holding device that holds the long-fiber bundles and a table that has a fabric on top of which the long-fiber sheet is to be placed relatively in the X and Y directions.

[0015] The long fiber sheet of the present invention is preferably a long fiber sheet used in a batting structure in which a front fabric and a back fabric are layered together and the fabric and the long fiber sheet are integrated, particularly a planar long fiber sheet for batting. In this configuration, the characteristics of the long fiber sheet of the present invention are utilized. The long fiber sheet and the fabric are integrated by sewing, welding, etc., with sewing being particularly preferred. The fabric may be any fabric, such as a fabric that ultimately forms the exterior or a fabric that is located inside. When integrating the long fiber sheet and the fabric, the order in which the long fiber sheet is formed and the fabric are layered is not limited. This includes cases in which the front fabric is layered on top of a long fiber sheet formed on a back fabric, cases in which the front fabric and the back fabric are placed on the top and bottom surfaces of the long fiber sheet, and cases in which the long fiber sheet is inserted between the back fabric and the front fabric. Cases in which part of the long fiber sheet is exposed are also included. In the case of padded clothing, it is preferable that in the sewing process, a long-fiber sheet is sandwiched between an outer fabric and an inner fabric to form a laminate, the laminate is sandwiched between plates with slit holes, and the laminate is sewn by a sewing machine from the slit holes in a direction across at least the end of the long-fiber sheet, and the outside of the sewn portion is cut. Since the long-fiber sheet is fixed at both ends with sewing thread, it does not become biased. In the cutting process, each end (U-shaped) of the long-fiber bundle is also cut and removed. The plate is then removed, and the padding structure is removed. The sewing method can also be changed to heat welding as appropriate. While the outer fabric and the inner fabric are often fabrics that form the appearance of the final product, in the present invention, they do not have to be fabrics that form the appearance of the final product. Furthermore, while the fabric is usually integrated with the long-fiber sheet as a single-layer fabric, it is not limited to a single-layer fabric and may be a multi-layer fabric. Furthermore, the fabric structure (woven fabric, knitted fabric, nonwoven fabric, etc.) and material are not limited.

[0016] In the case of a futon, it is preferable to place the long fiber sheet between the backing fabric and the front fabric, and sew the four sides so that sewing threads pass over or inside each end (U-shape) of the long fiber sheet, so that the long fiber sheet is fixed at both ends by the sewing threads and does not become biased. In the case of cushions, floor cushions, chair cushions, rugs, etc., it is preferable to arrange the continuous long fiber bundles in a circular or rectangular spiral shape, and then cover and quilt them with fabric, so that the long fiber sheet is fixed at both ends with sewing threads and does not become biased.

[0017] In the sewing step, the outer periphery of three or four sides of the laminate in which the long fiber sheet is sandwiched between the front and back fabrics is preferably sewn with sewing thread. In the case of three sides, the outer periphery is two sides at both ends of the long fiber sheet and one other side. The outer periphery of one side may be sewn with sewing thread, and then the outside of the outer periphery sewing thread may be cut or the part may be connected to another part by sewing. The cut line may be hemmed with a edging fabric such as tape to prevent the long fiber sheet from being exposed.

[0018] The padding structure may be quilted with sewing threads in any direction inside the perimeter sewing thread. This further secures the long fiber sheet and prevents it from becoming misaligned. Furthermore, since the quilting can be done in any direction, it allows for greater design freedom. Quilting can be done horizontally, vertically, diagonally, in curves, circles, or combinations of these. When using inner quilting, it is preferable to first quilt the inner quilting and then sew the perimeter sewing line. This prevents wrinkles from forming on the inside.

[0019] The outer side of the periphery sewing thread can be cut using a laser cutter, ultrasonic cutter, rotary blade cutter, etc., but among these, a laser cutter is preferred. Laser cutting is efficient for cutting a padding structure in which a long fiber sheet is laminated and integrated between the outer fabric and the inner fabric. A carbon dioxide laser is preferred, and an output of 20 to 50 W is preferred.

[0020] The sewing machine is preferably used to sew the lining fabric, the long fiber sheet, and the outer fabric between plates with slits, which are moved in the X and Y directions. This stabilizes the sewing process. An example of such a sewing machine is the "Pattern Seamer PS-800" manufactured by JUKI Corporation.

[0021] The long fiber yarn is preferably a bulky yarn, and is preferably composed of at least two types of long fibers, A and B, where the long fiber A is relatively short compared to the long fiber B and the long fiber A and the long fiber B are integrated into a long fiber yarn. Fibers other than long fibers A and B may be added as desired, but the total amount of long fibers A and B, when the long fiber yarn is taken as 100% by mass, is preferably 70% by mass or more, and more preferably 80% by mass or more. Long fibers A and B are integrated into a long fiber yarn. "Integrated" here 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 fiber A and long fiber B. The weight ratio of long fiber B (effect yarn) to long fiber A (core yarn) is preferably in the range of 51 to 99% by mass (wt%), where the total of long fiber B (effect yarn) and long fiber A (core yarn) is used as the modulus. A more preferable range is 80 to 98 wt %, and an especially preferable range is 85 to 97 wt %.Within this range, the yarns of both components are firmly fixed and the texture is also good.

[0022] The mass per unit length of one of the long fiber yarns 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 500, and particularly preferably 10 to 250, 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 of the long fiber bundles is preferably 0.15 to 45 g / m, more preferably 0.3 to 25 g / m. A mass within this range is convenient for handling when forming a long fiber sheet. The long fiber bundle can be used by paralleling one or more long fiber bundles. The long fiber bundle may be wound into a yarn body or stored in a carton container.

[0023] The mass per unit area of ​​the long fiber sheet (basis weight) is 5 to 1000 g / m 2 In the case of padded clothing, the mass per unit area of ​​the long fiber sheet is preferably 5 to 400 g / m. 2 is preferable, and more preferably, 10 to 120 g / m 2In the case of a futon, for example, the mass per unit area of ​​the long fiber sheet is 10 to 600 g / m 2 is preferable, and more preferably 30 to 400 g / m 2 is.

[0024] The padding structure is preferably clothing, bedding, sleeping bags, or parts thereof. Specifically, it is preferably a futon, blanket, sleeping bag, pillow, cushion, mat, stuffed toy, lap blanket, jacket, shirt, pants, vest, coat, cold weather clothing, work clothes, neck warmer, or parts thereof. Clothing such as jackets, shirts, and pants is suitable for sports. In addition, it has a fit similar to that of an inner jacket and good stretchability.

[0025] 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, it is preferable to use, as a surface treatment agent, a resin smoothing agent that improves smoothness, such as a silicone-based resin, in combination with the crosslinking agent. In particular, it is preferable to use a silicone-based resin agent in combination with a urethane-based crosslinking agent. The crosslinking agent and / or smoothing agent are preferably applied in an amount of 0.1 to 10% by mass relative to the continuous fiber yarn.

[0026] The long fiber bundle preferably has a bulkiness of 140 mm or more as measured in accordance with JIS L 1903-1998 "Testing method for feathers used as filler materials in feather products."

[0027] For the long fibers A and B, fibers such as polyester, nylon, and polypropylene can be used, but polyethylene terephthalate (PET) hollow fibers are preferred. Polyethylene terephthalate hollow fibers are warm due to their insulating effect, and PET has stiffness and can maintain high bulkiness. A hollow ratio of approximately 10 to 40% is preferred.

[0028] It is preferable that long fiber A and long fiber B are integrated by at least one process selected from entanglement, air jet processing, wrapping, and a process in which long fiber B is sprayed onto long fiber A. Entanglement is a process using an air entanglement machine that sprays compressed air perpendicular to the running direction of long fiber A and long fiber B. Air jet processing is a so-called Taslan process in which compressed air is forced into long fiber A and long fiber B in the direction of their travel. Wrapping is a process in which long fiber B is wound around long fiber A to integrate them. Blowing long fiber B onto long fiber A is a process in which long fiber B is sprayed onto long fiber A to entangle or swirl it.

[0029] The single fiber fineness of long fiber A and long fiber B 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 fibers are less likely to become worn out and have a good feel.

[0030] In the filling structure of the present invention, the long fiber bundles are preferably arranged in one direction, both ends of the long fiber bundles are sewn with sewing thread, and the inside is fixed to the outer fabric in any direction with multiple quilting threads. This prevents the length of the long fiber bundles from changing between the fixed points, restricts the movement of the long fiber bundles even after repeated washing, and results in a stuffed product with little bias and high bulk. The filling structure of the present invention may also use other filling materials in addition to the long fiber bundles. They may also be used in combination with feathers, artificial feathers, or staple cotton.

[0031] The following description will be made with reference to the drawings. In each drawing, the same reference numerals indicate the same parts. FIG. 1 is a schematic perspective view showing the process of forming a long-fiber sheet 7 according to one embodiment of the present invention. This long-fiber sheet manufacturing apparatus 1 has a movable table 2 on both sides of which are arranged multiple folding tools (pins) 3a, 3b. A robot arm 4 is used to pull out a long-fiber bundle 6 from a wound yarn body 5, and the long-fiber bundle 6 is folded in order onto the multiple folding tools (pins) 3a, 3b arranged on the upper and lower ends of the movable table 2 to arrange the long-fiber bundle 6, thereby forming the long-fiber sheet 7. The movable table 2 can also be a table that moves in the X and Y directions. Instead of the wound yarn body 5, the long-fiber bundle 6 may be pulled out from a can and supplied to the long-fiber sheet manufacturing apparatus 1.

[0032] FIG. 2A is a schematic perspective view showing a laminate in which a long fiber sheet 7 is sandwiched between a front fabric 9 and a back fabric 8, and FIG. 2B is a schematic cross-sectional view in the width direction of the laminate.

[0033] Fig. 3A is a schematic plan view showing plate 10 with slit hole 11 common to sewing line 12 and cut line 13, and Fig. 3B is a schematic plan view showing plate 10' with slit hole 11' common to sewing line 12 and cut line 13. In this example, slit holes 14a-14d and 14a'-14d' may be provided in the horizontal direction inside sewing line 12a, and quilting 15a-15d may be formed by sewing. Plates 10 and 10' can be made of acrylic plate, polyester film, polypropylene sheet, etc., and their thickness is preferably about 30 μm to 1 mm.

[0034] 4 is a schematic cross-sectional view showing how a laminate, in which a long-fiber sheet 7 is sandwiched between a front fabric 9 and a back fabric 8 and sandwiched between plates 10, 10', is sewn along a sewing line 12 through slit holes 11, 11' and cut along a cut line 13. As a result, the folded-back portion of the long-fiber sheet 7 is cut and removed. The distance between the sewing line 12 and the cut line 13 should be sufficient to prevent fraying, and is preferably about 1 to 10 mm, and more preferably about 2 to 8 mm.

[0035] FIG. 5 is a schematic plan view showing the resulting batting structure 16. This batting structure 16 is an example of the back body of a vest (waistcoat), and at least three sides have circumferential sewing lines 12 sewn with sewing thread, with cut lines 13 on the outside. Four quilting lines 15a-15d are also formed in the width direction of the body. The long fiber sheet is arranged in the same direction as the quilting lines 15a-15d. The sewing order is to first insert the quilting lines 15a-15d, then sew the circumferential sewing lines 12 on the three sides, and then cut the sheets at the cut lines 13 on the outside. 17 indicates the direction of arrangement of the long fiber bundles. For the front body of the vest (waistcoat), batting structures are made in each half in the vertical direction in the same manner as above, and the batting structure 16 shown in FIG. 5 and the sides are sewn together. A zipper, hooks, or buttons and buttonholes are attached to the front body to complete the vest (waistcoat). If the vest (waistcoat) has long sleeves, both sleeves and a collar are then attached. The sleeves and collar can also be made of padding structures similar to those described above. The remaining cut lines are hemmed with a hem fabric such as tape to prevent the long fiber sheet from being exposed.

[0036] Figure 6A is a schematic plan view showing a padding structure according to another embodiment of the present invention, and Figure 6B is a schematic cross-sectional view of the same. This padding structure 18 is an example of a comforter, and the long-fiber sheet is prepared in the same manner as in Figure 1. A backing fabric 20 and a front fabric 21 are placed above and below the long-fiber sheet 7, and the four sides are sewn together so that a peripheral sewing line 19 passes above or inside each end (U-shaped) of the long-fiber sheet 7. As a result, the long-fiber sheet 7 is fixed at both ends with sewing thread, so that the long-fiber sheet does not become biased. 17 indicates the direction in which the long-fiber bundles are arranged. 3 to 5 is that each end (U-shaped) of the continuous fiber sheet 7 is included in the filling structure 18. This allows the continuous fiber sheet 7 to be made into the filling structure 18 with good yield.

[0037] Fig. 7A is a plan view of a long-fiber sheet 22 of a reference example, and Fig. 7B is a schematic plan view of a batting structure 23 containing the same. This long-fiber sheet 22 is formed by arranging long-fiber bundles 6 in a circular spiral pattern to form a surface. It is covered with fabric and has quilting lines 24a-24c. This batting structure 23 is suitable for cushions, floor cushions, chair cushions, rugs, etc. Fig. 8A is a plan view of a long-fiber sheet 25 of another reference example, and Fig. 8B is a schematic plan view of a batting structure 26 containing the same. This long-fiber sheet 25 is formed by arranging long-fiber bundles 6 in a rectangular spiral pattern to form a surface. It is covered with fabric and has quilting lines 27a-274c. This batting structure 26 is also suitable for cushions, floor cushions, chair cushions, rugs, etc.

[0038] 9 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 (continuous fiber A) and an effect yarn 33 (continuous fiber B) are entangled with each other, and the effect yarn 33 is opened to form partially looped fibers.

[0039] 10 is a schematic diagram illustrating a method for producing a continuous fiber yarn (air-entangled yarn) 31 according to one embodiment of the present invention. A core yarn 34a (continuous fiber A) is drawn from a yarn winding body 34, and an effect yarn 35a (continuous fiber B) is drawn from a yarn winding body 35. The core yarn 34a is drawn from the yarn winding body 34, and an effect yarn 35a (continuous fiber B) is drawn from the yarn winding body 35. The core yarn 34a is drawn from the yarn winding body 34, and the effect yarn 35a is drawn from the yarn winding body 35. The core yarn 34a (continuous fiber A) is drawn from the yarn winding body 34, and the effect yarn 35a (continuous fiber B) is drawn from the yarn winding body 35. The core yarn 34a (continuous fiber A) is drawn from the yarn winding body 34, and the effect yarn 35a (continuous fiber B) is drawn from the yarn winding body 35. The core yarn 34a (continuous fiber A) is drawn from the yarn winding body 34, and the effect yarn 35a (continuous fiber B) is drawn from the yarn winding body 35. The core yarn 34a (continuous fiber A) is drawn from the yarn winding body 35 ... effect yarn 35a (continuous fiber B) is drawn from the core yarn 34a (continuous fiber A) and the effect yarn 35a (continuous fiber B) are drawn from the core yarn 34a (continuous fiber A) and the effect yarn 3 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.

[0040] 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) or a vinyl group (-CH=CH2) 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. At this time, the latent crimp-type stretch yarn of the core yarn develops post-crimp. [Example]

[0041] 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.

[0042] Example 1 The long fiber yarn (air-entangled yarn) was manufactured by Kurabo Industries, Ltd. under the trade name "Air Flake." Fifteen fibers with a mass of 0.12 g / m per single fiber length were aligned (total of 1.8 g / m) to prepare a long fiber bundle. These were arranged as shown in Figure 1 to form a long fiber sheet (mass (basis weight): 57 g / m). 2 ) was decided. The backing fabric (made of nylon) was placed on a table, and a U-shaped, flat long fiber sheet was formed on top of it. The front fabric (made of nylon) was then placed on top of the long fiber sheet to create a three-layer laminate of fabric-long fiber sheet-fabric, as shown in Figure 2. Next, the laminate was sandwiched between plates with slit holes that corresponded to the sewing and cutting lines shown in Figures 3A-B, placed on a sewing machine table, and the plates were moved in the XY directions to sew the outer periphery of the three sides of the slit holes with sewing thread as shown in Figure 4. The outer side of the outer sewing thread was cut with a laser cutter to obtain a padding structure. The plates were then opened, and the padding structure was removed. The sewing machine used was a JUKI Corporation model "Pattern Seamer PS-800." As a result, it was confirmed that the process of forming the long fiber sheet and the process of sewing the outer periphery of at least three sides of the laminate with sewing thread and then cutting the outside of the outer periphery sewing thread can be automated, and that a filling structure can be obtained efficiently and rationally.

[0043] Example 2 The long fiber yarn (air-entangled yarn) was manufactured by Kurabo Industries, Ltd. under the trade name "Air Flake." Thirty fibers with a mass of 0.12 g / m per single fiber length (total 3.6 g / m) were aligned to form a long fiber bundle. These were arranged as shown in Figure 1 to form a long fiber sheet (basis weight: 380 g / m 2 ) was decided. This long-fiber sheet was used to create the comforter (2.1 m x 1.5 m: single size) shown in Figure 6. The long-fiber sheet 7 was placed on a backing fabric (made of polyester) 20, and a front fabric (made of polyester) 21 was layered on top of it. The four sides of the long-fiber sheet 7 were sewn so that the perimeter sewing line 19 passed above or inside each end (U-shaped) of the long-fiber sheet 7. As a result, the long-fiber sheet 7 was fixed at both ends with the sewing thread, and the long-fiber sheet did not become uneven. A wear test of this comforter showed no unevenness of the filling even after three months of use, and no unevenness of the filling even after three home washes. [Industrial Applicability]

[0044] The padding structure of the present invention is preferably a futon, blanket, sleeping bag, pillow, cushion, floor cushion, chair cushion, mat, stuffed toy, lap blanket, jacket, shirt, pants, vest, coat, cold weather clothing, work clothes, neck warmer, or parts thereof. [Explanation of symbols]

[0045] 1. Long fiber sheet manufacturing equipment 2 Movable tables 3a, 3b Folding tool (pin) 4. Robotic Arm 5. Wound thread body 6 Long fiber bundles 7,22,25 Long fiber sheet 8,20 Lining 9,21 Outer fabric 10,10' plate 11,11', 14a-14d slit holes 12,19 Sewing line 13 Cut line 15a-15d, 20a-20f, 24a-24c, 27a-27c Quilting lines 16, 18, 23, 26 Filling structure 17 Arrangement direction of long fiber bundles 31,42 Long fiber yarn 32,34a core thread 33,35a filament 34, 35, 45 Winding body 36,37 Feed roller 38 Thread guide 39 Thread path 40 Air interlacing device 41 Compressed air line 43 Deliverable Roller 44 Winder Roller

Claims

1. A filling structure containing a long fiber bundle made of a plurality of long fiber yarns as filling, The long fiber yarn is composed of at least two types of long fibers A and B, the long fibers A being relatively shorter than the long fibers B, and the long fibers A and B being an integrated long fiber yarn; the long fiber bundles are continuously arranged in a U-shape or a zigzag shape to form a planar long fiber sheet, A fabric is laid on the front and back sides of the planar long fiber sheet, and the fabric and the long fiber sheet are integrated by sewing or welding, The padding structure is characterized in that the outer periphery of at least three sides is sewn with sewing thread and the outer side is cut.

2. 2. The padding structure according to claim 1, wherein the inside of a sewing line in a direction crossing the edge of the long fiber sheet is quilted with sewing threads in any direction.

3. The mass per unit area of ​​the long fiber sheet (basis weight) is 5 to 1000 g / m 2 3. The padding structure according to claim 1 or 2,

4. The padding structure according to any one of claims 1 to 3, wherein the padding structure is clothing, a futon, bedding, a sleeping bag, or a part thereof.

5. 5. The padding structure according to claim 1, wherein the ends of the long fiber bundles arranged in a U-shape or zigzag pattern are aligned in a straight line.

6. A padding structure described in any one of claims 1 to 5, wherein the inside of the peripheral sewing lines on at least three sides of the padding structure is fixed to the fabric by multiple quilting threads in any direction.

7. The padding structure according to any one of claims 1 to 6, wherein the mass per unit length of the long fiber yarn is 0.01 to 3 g / m.

8. The padding structure according to any one of claims 1 to 7, wherein the mass per unit length of the long fiber bundle is 0.15 to 45 g / m.

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