mid-length air foam

Abstract

It provides lightweight, highly insulating, breathable, and inexpensive insulation. [Solution] A hollow hollow foam

Description

[Technical Field]

[0001] This invention relates to a lightweight padding material that offers excellent heat retention and breathability, and to a method for manufacturing the same. [Background technology]

[0002] Natural down is currently available as a lightweight and insulating material used to enhance warmth in clothing and other garments. However, because it is a natural material, it requires careful handling and care, is susceptible to moisture and water, loses its insulating properties when wet, becomes bulky and restricts movement, is expensive, and its use is becoming increasingly difficult due to the growing trend towards animal-free products. Synthetic fiber padding is inexpensive, water-repellent, durable, easy to sew, and easy to wash, but it has been considered inferior to down in terms of insulation and moisture absorption. In recent years, high-performance padding that overcomes the shortcomings of synthetic fibers has been developed.

[0003] For example, Japanese Patent Publication No. 2022-144473 discloses "a polyester fiber and fibrous spherical body comprising at least two types of single fiber fines blended with a blending uniformity of 15% or less, including polyester fiber A with a single fiber fineness of 0.5 to 1.2 dtex and polyester fiber B with a single fiber fineness of 2.0 to 6.6 dtex and a hollow ratio of 15 to 35%, wherein the ratio of fiber diameters of polyester A to polyester B is 3.5 or less, and polyester fiber A accounts for 20% to 50% by mass." This fibrous spherical body of polyester fiber is soft and has a texture similar to down feathers, has excellent initial bulkiness, and has a small reduction in bulkiness after washing, making it suitable for use as a filling material for cushions, down jackets, etc. [Prior art documents] [Patent Documents]

[0004] [Patent Document 1] Japanese Patent Publication No. 2022-144473 [Disclosure of the Invention] [Problems that the invention aims to solve]

[0005] The batting using fibrous spherical bodies of polyester fibers described in Patent Document 1 has the problem that it is more expensive than general batting because it is a high-performance batting.

[0006] In view of the above problems, the present invention provides a lightweight, highly insulating, and breathable, inexpensive padding. [Means for solving the problem]

[0007] The following is a configuration example that illustrates in detail the features of the present invention for solving the above-mentioned problems. For clarity, the reference numerals used in the drawings of the embodiments described later are also included. In other words, the features of the mid-air foam and its manufacturing method according to the present invention are as follows. [1] The hollow foam (1) comprises a surface layer (2) made of a surface foam sheet (21), a back layer (3) made of a back foam sheet (31), an intermediate layer (4) made of columnar foam (41) sandwiched between the surface foam sheet (21) and the back foam sheet (31), and a hollow tunnel (42) formed by the sandwiching of the columnar foam (41).

[0008] [2] The hollow tunnel (42) is characterized by being in the shape of a rectangular parallelepiped.

[0009] [3] The back padding sheet (31) and the columnar padding (41) are bonded together by a first adhesive (51), and the front padding sheet (21) and the columnar padding (41) are bonded together by a second heat adhesive (52), wherein the materials of the first adhesive (51) and the second adhesive (52) are the same or different.

[0010] [4] The thickness of the air wool (1) is characterized by being 20 mm or more and 50 mm or less.

[0011] [5] The height of the intermediate layer (4) is characterized to be 5.0 mm or more and 30 mm or less.

[0012] 〔6〕 A garment provided with the hollow cotton (1). 〔7〕 A bedding provided with the hollow cotton (1).

[0013] 〔8〕 The manufacturing method of the hollow cotton (1) includes a step of preparing a back middle cotton sheet (21) (step 1), a step of disposing a first adhesive (51) on the back middle cotton sheet (31) and heating it (step 2), a step of disposing a columnar middle cotton (41) on the first adhesive (51’) on the back middle cotton sheet (31) and fixing it (step 3), a step of disposing a second adhesive (52) on the columnar middle cotton (41) and heating it (step 4), and a step of disposing a front middle cotton sheet (21) on the second adhesive (52’) on the columnar middle cotton (41) and heating it to form an integral hollow cotton (1) (step 5).

[0014] The present invention is not limited to the above-described configuration and the configuration of the examples described in the embodiments to be described later, and it is needless to say that various modifications are possible within the scope of the technical idea of the present invention.

Advantages of the Invention

[0015] According to the present invention, it is possible to provide a middle cotton that is lightweight, has high heat retention and breathability, and is inexpensive.

Brief Description of the Drawings

[0016] [Figure 1] FIG. 1 is a perspective view for explaining the whole hollow cotton with a part of the front middle cotton sheet (21) omitted for the purpose of explanation in an embodiment of the hollow cotton according to the present invention. [Figure 2] FIG. 2 is a diagram showing a manufacturing process in an embodiment of the manufacturing method of the hollow cotton according to the present invention. [Figure 3] It is a cross-sectional view for explaining the hollow cotton in an embodiment of the hollow cotton according to the present invention. [Figure 4]This is a photograph of the air-filled foam obtained in the example. [Modes for carrying out the invention]

[0017] Embodiments for implementing the mid-air cotton according to the present invention will be described based on the figures of the examples. Figure 1 is an explanatory perspective view of the entire hollow air foam in an embodiment of the hollow air foam according to the present invention, with the outer foam sheet 21 partially omitted for illustrative purposes. In the figure, 1 is the hollow air foam, 2 is the outer layer, 21 is the outer foam sheet, 3 is the inner layer, 31 is the inner foam sheet, 4 is the intermediate layer, 41 is the columnar foam, and 42 is the hollow tunnel.

[0018] In the overall form of the hollow air foam 1 according to the embodiment of the present invention shown in Figure 1, the hollow air foam 1 comprises a surface layer 2, a back layer 3, and an intermediate layer 4. The surface layer 2 is composed of a surface foam sheet 21, and the back layer 3 is composed of a back foam sheet 31. The intermediate layer 4 is positioned between the surface layer 2 and the back layer 3 and consists of columnar foam 41 sandwiched between the surface foam sheet 21 and the back foam sheet 31, and a hollow tunnel 42 formed by the sandwiching of the columnar foam 41. The surface foam sheet 21 of the surface layer 2 and the back foam sheet 31 of the back layer 3 are connected by the columnar foam 41 of the intermediate layer 4, forming an integrated hollow air foam 1.

[0019] The weight of the medium-weighted air-filled cotton 1 is not particularly limited, but considering ease of wear, for example, 30g / m 2 More than 150g / m 2 The following is preferable: 50g / m 2 More than 110g / m 2 The following are preferable. The thickness of the mid-layer air-filled cotton 1 should preferably be between 20mm and 50mm. If it is less than 20mm, the heat retention may decrease, and if it exceeds 50mm, it may become unnecessarily bulky and restrict movement.

[0020] Because the hollow structure of the hollow-walled cotton 1 has an intermediate layer 4 composed of columnar cotton 41 and hollow tunnels 42, it can be thicker and contain more air than ordinary sheet-type cotton, even if it has the same weight, thus improving heat retention. The hollow structure of the mid-layer 1, in which the intermediate layer 4 is composed of columnar padding 41 and hollow tunnels 42, improves breathability and makes it easier to release moisture when sweating.

[0021] (Padding) The padding used as a material in this invention is a material that is stuffed into bedding, winter clothing, etc., to enhance heat retention. Examples of synthetic fibers that make up the padding include polyester, acrylic, polyamide, polypropylene, and polyurethane, while examples of regenerated fibers include rayon and cupro. Examples of natural fibers include cotton, wool, and kapok. The padding may be composed of one type of fiber alone or a mixture of two or more types. From the viewpoint of ease of manufacture and cost, it is preferable that the padding includes synthetic fibers. Furthermore, the cross-section of the fibers constituting the padding can be either a normal cross-section or an irregular cross-section. Even when using padding with fibers of a normal cross-section, it is possible to provide lightweight padding with high heat retention at a low cost.

[0022] (Outer padding sheet) The outer padding sheet 21 that constitutes the surface layer of the mid-air foam 1 is composed of padding processed into a sheet. The fibers that make up the padding that constitutes the outer padding sheet 21 are not particularly limited, but are preferably the fibers described above for padding. As for the basis weight, for example, 30 g / m 2 More than 150g / m 2 The following is preferable: 50g / m 2 More than 110g / m 2 The following are preferable. The thickness of the outer padding sheet is preferably 3 mm or more and 15 mm or less, more preferably 5 mm or more and 12 mm or less.

[0023] (Insulated lining) The back middle cotton sheet 31 that constitutes the back layer of the hollow middle cotton 1 is composed of middle cotton processed into a sheet shape. The fibers that constitute the middle cotton that constitutes the back middle cotton sheet 31 are not particularly limited, but are preferably the fibers described for the above middle cotton. Also, for the basis weight, for example, 30 g / m 2 or more, and 150 g / m 2 or less is preferable. 50 g / m 2 or more, and 110 g / m 2 or less is more preferable. The thickness of the front middle cotton sheet is preferably 3 mm or more and 15 mm or less, more preferably 5 mm or more and 12 mm or less. The back middle cotton sheet 31 may be the same as or different from the front middle cotton sheet 21.

[0024] (Columnar middle cotton) The columnar middle cotton 41 is columnar middle cotton, and a plurality of columnar middle cottons 41 are sandwiched between the front middle cotton sheet 21 and the back middle cotton sheet 31. The columnar middle cotton 41 constitutes the intermediate layer of the hollow middle cotton 1 together with the hollow tunnel 42 described later. The columnar middle cotton 41 is an elongated rectangular parallelepiped, and the length of the surface in contact with the front middle cotton sheet 21 and the back middle cotton sheet 31 is appropriately selected according to the purpose of use. Also, the width X in FIG. 3 is preferably 10 mm or more and 60 mm or less, and the height Z in FIG. 3 is preferably 5.0 mm or more and 30 mm or less. The height of the intermediate layer configured in this way is the same as the height Z of the columnar middle cotton 41. The columnar middle cotton 41 can be formed by cutting a sheet-shaped middle cotton.

[0025] The fibers that constitute the columnar middle cotton 41 are not particularly limited, but are preferably the same as those of the front middle cotton sheet 21 and the back middle cotton sheet 31, but different fibers may also be used. The interval Y at which the columnar middle cotton 41 is arranged on the back middle cotton sheet 31 is not particularly limited, but is preferably 10 mm or more and 60 mm or less, and an equal interval is preferable. If the interval Y is less than 10 mm, it tends to be heavy, and if it exceeds 60 mm, it is likely to be crushed by its own weight and it may be difficult to form a tunnel. The width X, height Z, and arrangement interval Y of the columnar middle cotton 41 are shown in FIG. 3.

[0026] (Hollow tunnel) The hollow tunnel 42 is a tunnel-shaped space formed when multiple columnar batting sheets 41 are sandwiched between the outer batting sheet 21 and the inner batting sheet 31. It is surrounded by two adjacent columnar batting sheets 41, the outer batting sheet 21, and the inner batting sheet 31, and together with the columnar batting sheets 41, it constitutes the intermediate layer of the hollow batting sheet 1. The hollow tunnel 42 is rectangular in shape. The length of the hollow tunnel 42 is the same as the width of the front and back padding sheets, the width is the same as the spacing between the columnar padding sheets 31, and the height is the same as the height Z of the columnar padding sheets 41.

[0027] (First adhesive) The first adhesive 51 adheres the backing padding sheet 31 and the columnar padding 41. The first adhesive 51 is not particularly limited as long as it can bond the backing batting sheet 31 and the columnar batting 41, and examples include hot melt type, solvent emission type, heat curing type, ultraviolet curing type, and pressure sensitive type adhesives. However, a thermoplastic adhesive (hot melt type adhesive) that is solid at room temperature, melts when heated and becomes liquid, and forms a bond with the adherend by cooling and solidifying is preferred, and examples of thermoplastic adhesives include ethylene vinyl acetate type, polyurethane type, acrylic type, synthetic rubber type, polyamide type, and polyolefin type.

[0028] Examples of the form of the first adhesive 51 include sticks, pellets, blocks, powders, films, and nonwoven fabric sheets in which fibers made of thermoplastic resin are intertwined in a spiderweb or mesh-like manner. If the nonwoven fabric sheet made of thermoplastic resin has a sparse structure in which the fibers are intertwined and overlapped in a spiderweb or mesh-like manner, it will have excellent heat retention and drape without impairing breathability.

[0029] The melting point of the first adhesive 51 is preferably 170°C to 190°C (for example, 180°C), and more preferably 130°C to 210°C. If the melting point of the thermoplastic resin is too low, the thermoplastic resin may remelt due to heating during use or drying after washing, which may cause the backing padding sheet 31 and columnar padding 41 to separate. If the melting point is too high, it may be difficult to handle during processing, and the backing padding sheet 31 and columnar padding 41 may undergo thermal degradation or shrinkage, resulting in a hard texture.

[0030] (Second adhesive) The second adhesive 52 adheres the columnar batting 41 to the outer batting sheet 21. The second adhesive 52 is not particularly limited as long as it can bond the columnar batting 41 and the outer batting sheet 21, but it can be selected from the above-mentioned options for the first adhesive 51. The first adhesive and the second adhesive may be the same or different, but it is preferable that they be the same.

[0031] (Method for manufacturing air foam 1) The method for manufacturing the hollow air foam 1 includes the steps of: preparing a backing foam sheet 31 (step 1); placing a first adhesive 51 on the backing foam sheet 31 and heating it (step 2); placing a columnar foam 41 on the first adhesive 51 on the backing foam sheet 31 and fixing it (step 3); placing a second adhesive 52 on the columnar foam 41 and heating it (step 5); and placing a front foam sheet 21 on the second adhesive 52 on the columnar foam 41 and heating it to form a single hollow air foam 1 (step 5).

[0032] (Step 1) As shown in S1 of Figure 2, the padded sheet 31 is unfolded on a designated table.

[0033] (Step 2) As shown in S2 of Figure 2, the first adhesive 51 is placed on the backing padding sheet 31 at the location where the columnar padding 41 will be placed. Next, the backing padding sheet 31 on which the first adhesive 51 is placed is heated in a high-temperature device to melt the first adhesive 51 and fix it to the backing padding sheet 31. The heating temperature is not particularly limited as long as it is the temperature at which the first adhesive 51 melts. In the description of the manufacturing method, the melted and solidified first adhesive is referred to as the first adhesive 51', as shown in Figure 2.

[0034] (Step 3) As shown in S3 of Figure 2, the columnar batting 41 is placed on the first adhesive 51' on the backing batting sheet 31. Next, the laminate, which consists of the backing batting sheet 31, the first adhesive 51, and the columnar batting 41, is heated again in a high-temperature device to melt the first adhesive 51 and bond the columnar batting 41 to the backing batting sheet 31.

[0035] (Step 4) As shown in S4 of Figure 2, the second adhesive 52 is placed on top of the columnar batting 41. Next, the laminate, which consists of the backing batting sheet 31, the first adhesive 51, the columnar batting 41, and the second adhesive 52, is heated again in a high-temperature device to melt the second adhesive 52 and fix it to the columnar batting 41. The heating temperature is not particularly limited as long as it is the temperature at which the second adhesive 52 melts. The second adhesive, which melted and solidified in the same way as the first adhesive, is indicated with a different designation, "Second Adhesive 52'".

[0036] As shown in S5 of Figure 2, the outer padding sheet 21 is placed on the second adhesive 52' on the columnar padding 41 to complete the final structure. The laminate (final structure) formed by layering the inner padding sheet 31, the first adhesive 51, the columnar padding 41, the second adhesive 52, and the outer padding sheet 21 is heated in a high-temperature device to melt the second adhesive 52, bonding the columnar padding 41 and the outer padding sheet 21 together to form a single piece of air-filled foam. [Examples]

[0037] Padded sheet (weight 80g / m²) 2A 22mm thick, 100% polyester sheet was cut parallel to the width direction at predetermined positions to create multiple rectangular columnar batting pieces, each 30m wide and 22mm thick (height). The padding sheet that makes up the inner padding sheet (weight 80g / m²) 2 A sheet of 100% polyester, 8mm thick, was spread out on a table. Next, a sheet of hot-melt adhesive (melting point: 120°C) was placed on the padding sheet in a straight line parallel to the width of the padding sheet, with a spacing of 30mm between sheets. The padding sheet with the sheet of adhesive was heated to 180°C in a high-temperature device to melt the sheet of adhesive and fix the adhesive to the back padding sheet. The columnar padding was placed on top of the adhesive fixed to the back padding sheet, heated to 180°C in a high-temperature device to melt the adhesive and bond the padding sheet and the columnar padding. The same sheet of adhesive as before was placed on top of the columnar padding bonded to the padding sheet, heated to 180°C in a high-temperature device to melt the sheet of adhesive and fix the adhesive to the columnar padding. On top of the adhesive fixed to the columnar padding, a front padding sheet (weight 80g / m²) of the same size as the back padding sheet was placed. 2 A sheet of 100% polyester, 8 mm thick, was placed so that it overlapped with the padding sheet when viewed vertically on a stand. The sheet was then heated at 180°C for 60 seconds in a high-temperature device to melt the adhesive, bonding the columnar padding and the padding sheet together to form a single, integrated air-filled core. The basis weight of the formed mid-air cotton is 80g / m². 2 The thickness was 30 mm. A photograph of the obtained hollow air foam is shown in Figure 4.

[0038] (Comparison of thicknesses) The examples show the air-filled foam obtained in the examples, the foam sheet used to create the air-filled foam, and commercially available high-performance foam Thinsulate HL80 (manufactured by 3M Japan Ltd., basis weight 80g / m²). 2 ) was compared with [another factor]. The results are shown in Table 1.

[0039] [Table 1]

[0040] The hollow air foam of the present invention has the same basis weight as the foam sheet and high-performance foam Thinsulate HL80 used in its manufacture, but its thickness is approximately 3.7 times that of the foam sheet and approximately 3 times that of the high-performance foam Thinsulate HL80. Because the hollow air foam of the present invention is thicker even with the same basis weight, when used in clothing, it is lightweight, highly insulating, and has high breathability due to the hollow tunnels in the middle layer, making it easy to release moisture when sweating. Therefore, it is suitable for use in clothing worn during winter sports and outdoor activities, where the body often warms up and sweats as it moves, even if it is cold at the start. Furthermore, when the hollow air foam of the present invention is used in bedding, it can result in lightweight bedding with high heat retention. [Industrial applicability]

[0041] The padding according to the present invention is lightweight, highly insulating, breathable, and inexpensive, making it extremely useful in the field of materials used to enhance heat retention. [Explanation of Symbols]

[0042] 1. Medium-sized air cotton 2 Surface layer 21 Outer padding sheet 3. Underlayer 31. Padded lining 4. Middle Class 41 Columnar padding 42 Hollow tunnel 51 First Adhesive 51' The first adhesive that melted and solidified. 52 Second adhesive 52' Melted and solidified second adhesive

Claims

1. The surface layer consists of a surface padding sheet, The back layer consists of a padded sheet, An intermediate layer comprising columnar batting sandwiched between the aforementioned outer batting sheet and the aforementioned inner batting sheet, and a hollow tunnel formed by the sandwiching of the columnar batting, A medium-sized air-filled cotton, The aforementioned hollow tunnel has a rectangular parallelepiped shape with an opening only in the direction of the tunnel. The width of the hollow tunnel is 10 mm or more and 60 mm or less. The aforementioned mid-air cotton has a thickness of 20 mm or more and 50 mm or less, and is intended for use in clothing or bedding.

2. The aforementioned backing sheet and the columnar padding are bonded together with the first adhesive. The aforementioned surface padding sheet and the columnar padding are bonded together with a second adhesive. The materials of the first adhesive and the second adhesive are the same or different, as described in claim 1.

3. The mid-air cotton according to claim 1, wherein the height of the intermediate layer is 5.0 mm or more and 30 mm or less.

4. A garment comprising air-filled cotton according to any one of claims 1 to 3.

5. Bedding comprising the air-filled cotton described in any one of claims 1 to 3.

6. Step 1: Prepare the padding sheet for the backing, Step 2 involves placing the first adhesive on the aforementioned backing pad sheet and heating it, Step 3 involves placing columnar batting on the first adhesive on the backing batting sheet and fixing it in place. Step 4 involves placing the second adhesive on top of the columnar cotton and heating it, By placing the outer padding sheet on the second adhesive on the columnar padding and heating it, A method for producing a hollow air batting, comprising the step of forming a single hollow air batting (step 5), The columnar batting is sandwiched between the outer batting sheet and the inner batting sheet to form a hollow tunnel. The aforementioned hollow tunnel has a rectangular parallelepiped shape with an opening only in the direction of the tunnel. The width of the hollow tunnel is 10 mm or more and 60 mm or less. The thickness of the aforementioned mid-air foam is 20 mm or more and 50 mm or less. A method for manufacturing mid-air cotton for clothing or bedding.

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