JPH024681B2 - - Google Patents

Description

[Detailed description of the invention]

The present invention relates to a method for manufacturing shoulder pad materials, and in particular to a method for efficiently manufacturing shoulder pad materials that have uniform density and excellent texture throughout, and are highly resistant to washing. . Conventionally, various methods are known for producing shoulder pad materials. For example, in Japanese Patent Publication No. 49-36661, opened fibers are deposited on a bowl-shaped net container placed on a conveyor, resin is sprayed from above and below the fiber layer, and then a circular foam sheet is crimped. A method of manufacturing a part is shown. Furthermore, Japanese Patent Application Laid-open No. 143360/1983 describes a method for producing a patch in which fibers opened into a cylinder are heated and dropped, and resin is sprayed while suction depositing and fixing the fibers onto a dish-shaped screen. It is shown. However, in these manufacturing methods, fibers are blown vertically into a net-like dish or bowl-shaped container, as shown in FIG. At this time, a phenomenon occurs in which fibers accumulate faster in the center of the dish or bowl-shaped container, causing the center to collapse and cover the periphery. Furthermore, since the way the particles collapse is not constant, the density of the deposited particles is also not uniform. Therefore, we have no choice but to use a method of suctioning from the bottom of the net-shaped container.
As the deposition progresses, the ventilation resistance also increases.
There was a drawback in the manufacturing process that it was difficult to control suction pressure, etc. Furthermore, in order to increase the strength of the entire patch material, resin is sprayed, but the resin only sticks to the surface of the patch material and does not penetrate sufficiently into the inside.
Furthermore, the amount of resin deposited on the thin peripheral portion is higher than that on the thick center string portion, which is not desirable in terms of texture. Further, when drying the sprayed resin, it takes a long time to completely and uniformly dry the inside of the thick string section. At that time, a resin film was formed on the surface due to so-called binder migration development in which the internal resin migrated from the inside to the surface, which was unfavorable in terms of quality. Furthermore, the materials obtained by these shoulder pad manufacturing methods are cut in half at the center to create a pair of shoulder pad materials. However, it is necessary to create a shape that blends well with the shoulders by cutting the shoulder pad material in the direction of the cut surface of the thick chord part, as shown by the diagonal lines in Figure 2. Ta. In this process, a considerable amount of scrap was produced, resulting in a poor yield of raw materials and problems in terms of workability as well. Therefore, the inventor of the present invention made extensive studies to solve these drawbacks, and as a result, discovered a method for manufacturing a shoulder pad material that does not have these drawbacks. Referring to the drawings, FIG. 1 shows a cross-sectional view of a bowl in which fibers are deposited in a conventional manner, and FIG. 2 shows a perspective view of a conventional halved shoulder pad material. FIG. 3 shows an example of two breathable skin materials of the present invention, and FIG. 4 shows another example. FIG. 5 shows a perspective view of a generally half-moon shaped bag of the present invention. FIG. 6 is a cross-sectional view of an apparatus showing an example of the method for manufacturing the shoulder pad material of the present invention. In the present invention, a bag 5 having a substantially half-moon shape is formed using breathable skin materials 1 and 1' so that string parts 2 and 2' serve as an opening 4, and then the bag is opened from the opening 4. The group of fibers 6 is blown into the bag 5 with a fluid stream 7.
This method of manufacturing a shoulder pad material is characterized by filling the fiber group 6 into the material. In other words, in the method of the present invention, the fiber group 6 is filled not from the thickness direction of the shoulder pad material, but from substantially perpendicular to the thickness direction as shown in FIG. 6, that is, from the direction of the opening 4 in FIG. . Therefore, since the fiber group 6 is sequentially deposited from the back of the bag toward the opening, the airflow resistance around the bag is not affected, and a shoulder pad material with uniform fiber density can be obtained. In the present invention, the breathable skin materials 1 and 1' are fabrics,
If it is a breathable fabric such as knitted fabric or non-woven fabric,
It can be any material, but especially if it is a non-woven fabric,
The type of material, density, thickness, etc. can be selected as desired, and the fibers do not fray from the cut ends, and they are compatible with the filled fiber group and are easily intertwined and integrated, which is preferable. Stitchbond nonwoven fabric is particularly suitable in terms of feel and shape retention. Furthermore, if this skin material contains heat-adhesive fibers, for example, two pieces of air-permeable skin material 1, 1' having substantially similar shapes may be overlapped to form a chord part 2 which becomes an opening 4 as shown in FIG. , 2' except for the peripheral edges 3, 3' to form a substantially half-moon-shaped bag 5 is more preferable because the bag can be easily obtained by heat fusion using ultrasonic waves, high frequency waves, etc. . In addition, although the same material is generally used for both breathable skin materials, it is possible to provide a unique texture and shape retention by using different materials for each. In this way, the breathable skin material that becomes the bag is not limited to two sheets that are polymerized, but a single sheet with a part of the peripheral edge part integrated as shown in FIG. 4 may be used. Needless to say, it is also possible to use a bag that has been molded. Note that the formed bags include not only those whose peripheral edges are necessarily joined, but also those whose peripheral edges are simply overlapped. Therefore, when blowing and filling the fiber group, the bag is secured using a porous holder 8 having the shape of a shoulder pad material made of wire mesh, punched metal, expanded metal, etc. that does not deform or change in quality due to the pressure or heat of the fluid flow. It is also preferable to hold the entire bag, and as long as the peripheral edge of the bag is joined, a simple frame-shaped holder that can grip only the opening 4 may be used. In other words, such a frame-only one has the advantage that it is inexpensive and can be easily replaced depending on the size and shape of the shoulder pad. The fiber group 6 to be filled into the bag in the present invention may be made of any fiber such as natural fiber, synthetic fiber, or recycled fiber, and it is possible to use a mixture of these fibers. Not even. And these fibers are filament, tow,
The fibers may be either slivers, staples, etc., and are opened by a known fiber opening device to form a fiber group, which is then filled. Therefore, if the fibers are filled without being opened, the density tends to be non-uniform, which is not preferable. Furthermore, since the direction in which the fiber groups are packed is completely different from the conventional method, a more uniform density can be achieved in the present invention. As shown in FIG. 6, these fibers 6 are blown together with a fluid stream 7 to fill the bag 5 with the fibers, preferably if the fibers contain 3 to 50% by weight of thermobondable fibers. . For example, when hot air is used as a fluid stream, less than 3% by weight of heat-adhesive fibers is preferable in terms of feel and flexibility, but is inferior in terms of shape retention, and if it exceeds 50% by weight, shoulder pads Although it has a high shape retention property as a material, it is not preferable because it has the disadvantage of losing its texture and flexibility. Room-temperature air streams are used as the fluid streams 7 and 7', but hot air, in some cases moist heat air streams, inert gas streams, liquid streams, etc., may be used at different times for one of the fluid streams 7, 7'. You can also do it. Depending on the amount of heat-adhesive fibers, etc., the temperature, wind speed, air volume, etc. of the hot air must be selected appropriately. It is also possible to fill the bag with suction from outside the bag. In this way, the fiber group filled with the heated air flow is retained in the shape of a shoulder patch and is also integrated with the bag. Therefore, there is no need for a separate molding process or cutting process, which is extremely advantageous in terms of the manufacturing process. The present invention will be explained by examples, but it goes without saying that the present invention is not limited to these examples. Example Stitchbond nonwoven fabric (100g/m ² ) made of 100% polyester fiber was used as a breathable skin material.
It was cut into approximately similar shapes as shown in Figure 3. This 2
The sheets of breathable skin material were stacked one on top of the other, and their peripheral edges were joined in a staggered manner with an ultrasonic welder, excluding the opening, to form a bag, and this bag was held in a shoulder pad-shaped stainless steel wire mesh. A fiber group with a fiber length of 38 mm, which is a mixture of 60% by weight of 3-denier polyester fiber, 35% by weight of 15-denier polyester fiber, and 5% by weight of 3-denier bonded polyester composite fiber, is opened and opened through the opening of the bag. The fibers are blown into a bag in 10 seconds with an air flow of 18 to 20 m/s.
It was filled with 13g. At this time, a heated air stream at 230° C. was passed through for 7 seconds to obtain a total of 16 g of shoulder pad material. Here, a shoulder pad material of an example of the present invention was compared with a shoulder pad material made by a conventional method having almost the same composition and no skin material, and the results are tabulated.

【table】

[Table] Notes (1) Press resistance characteristics: Press temperature 120℃, surface pressure 0.4
Press at Kg/ ^cm2 for 10 seconds and then steam blow at 120℃
(2) Washing resistance: Washed 6 times according to JIS 1085 (3) Workability: Misalignment with the outer material when sewing 100 mm in a straight line (4) Flexibility: Wrinkles when reversed and folded (5) Uniformity of texture: Comparison of overall uniform texture by touch As described above, the shoulder pad material obtained by the present invention had far superior properties and uniformity compared to conventional products. . In this way, the present invention fills the bag with fibers from a direction substantially perpendicular to the thickness of the shoulder pad material, so it has uniform density and excellent texture throughout, and is resistant to washing, etc. This is an extremely useful material that can efficiently produce a material for shoulder pads with a high degree of stability, excellent shape retention and workability.

[Brief explanation of drawings]

FIG. 1 is a cross-sectional view of a bowl-shaped container in which fibers are deposited according to a conventional method, and FIG. 2 is a perspective view of shoulder pad material cut in half according to a conventional method. FIGS. 3 and 4 are plan views showing an example of the breathable skin material of the present invention, and FIG. 5 is a perspective view of a substantially half-moon-shaped bag of the present invention. FIG. 6 is a cross-sectional view of an apparatus showing an example of the method for manufacturing the shoulder pad material of the present invention. 1, 1'... Breathable skin material, 2, 2'... String part,
3, 3'...periphery, 4...opening, 5...bag,
6...Fiber group, 7,7'...Fluid flow.

Claims (1)

[Claims] 1. Using a breathable skin material, a substantially half-moon-shaped bag is formed with the string section serving as an opening, and then the opened fiber group is filled through the opening. A method of manufacturing a shoulder pad material, characterized in that: 2. The method for producing a shoulder pad material according to claim 1, wherein the fiber group contains 3 to 50% by weight of heat-adhesive fibers.