JPH0449990A - Manufacturing, transporting, and storing methods of bedquilt (futon) - Google Patents

Abstract

PURPOSE:To reduce the bulk of a bedquilt when it is transported or stored, by a method wherein the bedquilt contains filling consisting of structural fibers and hot-melt fibers, and the structural fibers are substantially combined together by the hot-melt fibers. CONSTITUTION:Filling of a bedquilt consists of structural fibers and hot-melt fibers, and the hot-melt fiber content is preferably within a range of 5-20 wt.%. After heated to a temperature lower than 100 deg.C, and compressed, the filling is cooled down as it is compressed so that its thickness can be reduced to 1/5-1/13 of the original thickness because compressed state is retained by the hot-melt fibers. Thus, the filing is fixed in compressed state by heating and compressing. The bedquilt containing the filling in compressed state has a small bulk and some degree of rigidity as well so that it is not bulky and excellent in the workability in transportation, storage and sewing.

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Application Field] The present invention relates to a futon, a method for manufacturing the same, a method for transporting the same, and a method for storing the same.

[Prior Art] Generally, bulky cotton or feathers containing a large amount of air are used in futons. For this reason, transporting and storing such cotton blankets is like transporting and storing air; This required a considerable amount of space and was extremely disadvantageous in terms of cost.

Furthermore, such bulky futons also have the disadvantage that they are bulky and soft, making them difficult to handle when working at actual sewing sites.

[Problem to be solved by the invention] The present invention has been made in view of the above-mentioned prior art,
The object of the present invention is to provide a futon that can significantly reduce costs by reducing its bulk during transportation and storage. Furthermore, the present invention can improve the workability of sewing by reducing the bulk of the cotton quilt when making the quilt, and can restore the bulk to its original state after making the quilt. The purpose is also to provide futons.

[Means for Solving the Problems] The present invention provides: (1) A quilt having a built-in quilt made of constituent fibers and heat-fusible fibers, wherein the constituent fibers are substantially bonded by the heat-fusible fibers; A futon characterized by: ■ A futon made of constituent fibers and heat-fusible fibers is heated and pressurized to fix it in a compressed state, and the futon cotton fixed in this compressed state is used to form a futon. after,
A method for producing a futon, which is characterized by heating the futon to a temperature higher than the melting point of the heat-fusible fiber to recover the bulk of the futon. The present invention relates to a method for transporting a futon, and (1) a method for storing a futon, characterized in that the futon is heated and pressurized to fix it in a compressed state and then stored.

[Operations and Examples] The quilt of the present invention has a built-in quilt cotton made of constituent fibers and heat-fusible fibers, and is characterized in that the constituent fibers are not substantially bonded by the heat-fusible fibers. That is.

Although there are no particular limitations on the constituent fibers used in the quilt, it is preferable to use fibers that can largely recover bulk when released from the compressed state by melting the heat-fusible fibers. The constituent fibers that greatly restore bulk are:
For example, crimped fibers such as highly crimped fibers can be mentioned, and among the crimped fibers, latent crimped fibers are particularly preferred because they develop large crimps when heated.

When the crimped fibers are reheated to recover their bulk, the temporarily bonded heat-fusible fibers melt and the adhesive strength weakens, causing the previously distorted crimped fibers to return to their original state. This repulsive force acts as a driving force for bulk recovery. Therefore, in the present invention, it is preferable to use fibers having a high crimp rate, residual crimp rate, and crimp elastic modulus as these crimped fibers.

The fibers with a large crimp rate, residual crimp rate, and crimp elastic modulus refer to fibers with a crimp rate of 12 to 70%, a residual crimp rate of 7 to 70%, and a crimp elastic modulus of 30 to 100%. . Among such fibers, those having a crimp rate of 20 to 70%, a residual crimp rate of 15 to 70%, and a crimp elastic modulus of 60 to 100% are particularly preferred. Note that the crimp rate, residual crimp rate, and crimp elastic modulus are the values when the crimp is apparent, and when the crimp is latent, the values are the values when the crimp becomes apparent. represent.

Examples of such fibers include hollow fibers, thick fibers with a fineness of 6 denier or more, fibers with a large crimp radius, and highly crimped fibers that shrink into a three-dimensional spiral structure when heated or humidified. Examples include fibers that can be used.

In addition to these, 4 to 3 crimps are mechanically crimped.
It is also possible to use fibers of about 0 pieces/25 μl.

In the present invention, the crimp rate, residual crimp rate, and crimp elastic modulus are defined as follows.

In other words, the length (a) when an initial load of 2tsgf' per denier is applied to the sample, and the length when a load of 500g' per denier is applied to the sample is #1.
Set. Next, after removing the full load and leaving it for 1 minute, measure the length (C) when the initial load is applied, and calculate the crimp rate (
%) and residual crimp rate (%). The number of tests was 20, and the average value of each test was expressed.

-a Crimp rate (%)-X100 b-c Residual crimp rate (%) - X100 Moreover, the crimp elastic modulus (%) is calculated based on the following formula.

-c Crimp elastic modulus (%) -X100 -a As mentioned above, in addition to hollow fibers, fibers with large fineness, and fibers with large crimp radius, Fibers with a high ratio have good recovery properties, so
It can be suitably used.

In this specification, the expression "highly crimped fibers" mainly refers to fibers with a high crimp rate, residual crimp rate, and crimp elastic modulus as described above, and fibers with a three-dimensional spiral structure. The crimp in the fiber may be manifest or latent.

Examples of fibers that shrink into a three-dimensional spiral structure when heated under dry heat or wet heat include composite fibers with obvious crimp, composite fibers with latent crimp, and single fibers. Examples include fibers that have latent crimp due to their specific thermal history.

Examples of the composite fibers include side-by-side type, core-sheath type, and eccentric type composite fibers each consisting of two components, a low melting point polyester component and a high melting point polyester component, or a low melting point polyamide component and a high melting point polyester component. can give.

Fibers that are a single component and have latent crimp due to a specific thermal history are those that are made by rubbing the fibers against a heating blade under tension, or by rubbing the fibers against a blade in a heated state. A fiber that has been subjected to a thermal history that disrupts the arrangement of molecules in the parts that come into contact with it.

The fibers shrink when heated under dry heat or wet heat to produce crimp in a three-dimensional spiral structure, but in the present invention, the crimp may be latent at the time of completion of the cotton quilt. In the present invention, the fibers in which crimping is latent develop crimping by heating during bulk recovery, and this acts as a restoring force to recover the bulk, so that it improves the bulk recovery rate. It is desirable. Note that as the degree of crimp development increases, the thickness in the bulk direction increases, but shrinkage occurs in the width direction, resulting in a reduction in the area of the cotton quilt. Therefore, especially when dimensional stability is required, it is desirable to use fibers whose crimping is obvious when the cotton quilt is completed.

In addition, in the case where the aforementioned composite fibers with latent crimp or single component fibers with latent crimp due to a specific thermal history are used as fibers with actual crimp, manufacturing of the quilt is not possible. At this time, the fibers may be heated to a temperature that causes crimp to occur.

Further, in the present invention, other natural fibers, synthetic fibers, semi-synthetic fibers, etc. may be appropriately blended into the constituent fibers as long as the degree of expansion is not inhibited.

In the present invention, heat-fusible fibers are used to fix the constituent fibers of the cotton quilt in a compressed state.

The heat-fusible fibers include composite fibers and single-component fibers.

When composite fibers are used in the present invention, only the low melting point components are melted, so there is no excessive melting or adhesion, so the texture is not impaired and handling becomes easier.

Typical examples of the composite fibers include composite fibers made of a combination of a low melting point polyester component and a high melting point polyester component, and a combination of a low melting point polyamide component and a high melting point polyester component. Types include core-sheath type, core-sheath type, and sea-island type. In addition, the low melting point component of these composite fibers is generally 80
It has a melting temperature of ~100℃, so it can be heated and reheated at low temperatures, so it has the advantage of not affecting other constituent fibers, helping to save energy, and improving workability. .

Incidentally, as the content of the heat-fusible fiber in the quilt cotton increases, the quilt cotton becomes harder and at the same time its bulk recovery properties deteriorate. On the other hand, if the content of the heat-fusible fibers in the batting cotton decreases, the dispersion state of the heat-fusible fibers becomes non-uniform. Therefore, the content of the heat-fusible fiber in the cotton quilt is 5 to 40% by weight, especially 5 to 20% by weight.
It is preferable that

As mentioned above, the cotton quilt made of constituent fibers and heat-fusible fibers is heated to a temperature of 100°C or less and pressurized, and then cooled in the pressurized state to cause the heat-fusible fibers to release the compressed state. Therefore, the thickness of the quilt can be made to be about 175 to 1/13 of the initial thickness.

In the present invention, cotton having no bulk recovery properties (but not containing heat-fusible fibers) may be laminated on one or both sides of the cotton quilt. Laminating cotton that does not have bulk recovery properties in this way has the effect of preventing thickness unevenness that occurs when the bulk of the quilt cotton increases or decreases, and preventing molten adhesive components from contaminating the fabric of the quilt. It is played.

Since the futon of the present invention contains the above-mentioned futon cotton, it is fixed in a compressed state by heating and pressurizing, but the futon having the futon cotton fixed in a compressed state in this way
Because its bulk is small and has a certain degree of rigidity,
It is not bulky and has excellent workability in transportation, storage, and sewing. Furthermore, after being transported, stored, sewn, etc., the bulk can be restored to its original state simply by applying heat, so it can be used in the same way as conventional futons.

In the present invention, there is no particular limitation on the fabric constituting the futon side bag into which the futon cotton is placed, and any commonly used fabric may be used. An example of such a fabric is a woven fabric made of cotton or the like.

An example of a method for manufacturing the quilt cotton used in the quilt of the present invention includes, for example, a method of mixing constituent fibers and heat-fusible fibers and forming a fiber web by means such as carding.

The basis weight of the quilt cotton cannot be determined in part because it varies depending on the thickness of the intended quilt, but for example, it is about 500 to 2,500 g4.

Next, the obtained batting cotton is heated and compressed at a temperature higher than the melting temperature of the heat-fusible fibers and lower than the melting temperature of the constituent fibers. This heating melts a portion of the heat-fusible fibers, fixing the quilt in a compressed state.

Examples of heat-compression methods include a roller press method and a flat press method. The roller press method is a preferable method for production because it continuously heats and compresses the batting cotton.

In addition, when the futon cotton leaves the roller press, flat press, or belt press that heats and compresses it, the heat drops and the heat-fusible fibers solidify, so they remain fixed at their compressed thickness. However, in order to more reliably fix the thickness in the compressed state, it is desirable to maintain the compressed state, stop heating and let it cool, or actively cool the cotton quilt. Further, the above-mentioned heating and compression step may be performed by heating and then compressing, as long as compression can be performed while the temperature of the heated cotton quilt does not drop.

Furthermore, in any of the heat compression methods described above, the batting cotton can be compressed on the entire surface or in dots.

The cotton fabric produced as described above is heat-treated at a temperature higher than the melting temperature of the heat-fusible fibers, but lower than the melting temperature of the constituent fibers, so that the constituent fibers are substantially bonded to the heat-fusible fibers. It is no longer physically bound and regains its bulk. Note that, in practice, it is preferable to recover the bulk using hot air or heated steam because it is simple.

In addition, in the case where the bulk of the quilt containing the quilt cotton is to be restored, it is preferable from the viewpoint of workability to recover the bulk at the stage when sewing is completed.

Another method for manufacturing the futon of the present invention is to mix the constituent fibers and heat-fusible fibers to form a fiber web by means such as carding, and then convert this fiber web into a cotton wool that has been used in the past for making futons. Depending on the filling method, there is a method in which the bag on the side of the futon is stuffed with cotton to form the futon. However, in the case of this method, workability is inferior to that of the above-mentioned method for manufacturing the mattress.

When transporting or storing the thus obtained quilt of the present invention, the bulk can be reduced by subjecting it to heat compression in the same manner as the method used to heat and compress cotton quilt. Therefore, it is easy to handle during transportation and storage, and does not take up much space, so transportation and storage costs can be extremely reduced.

In addition, when using this mattress after transportation or storage, the bulk can be recovered by heat-treating it with dry heat or wet heat to melt the heat-fusible fibers and break the bonds between the constituent fibers. It can be used as a bulky futon in its original condition.

Next, the present invention will be explained in more detail based on Examples, but the present invention is not limited to these Examples.

Example 1 Highly crimped polyester fiber (melting point 256°C) as constituent fiber
, fineness 6 denier, fiber length 51 mm) 48% by weight and Egyptian cotton 47% by weight, and as a temporary adhesive low melting point core-sheath type composite polyester fiber (core: polyester (melting point 256°C), sheath: low melting point polyester (melting point 87℃)
, fineness 3 denier, fiber length 51 mm) was carded to obtain a fiber web with a basis weight of 800 g and a weight of 19.

Next, this fibrous web was compression-pressed using a belt-type press device at a temperature of 110° C. and a gauge pressure of 5) cgJ.

The thickness of the fiber web at this time was approximately 11 mm, and since it was not bulky, it was very easy to handle during storage and transportation.

In this way, it can be seen that the cotton quilt, which is fixed in a compressed state by heating and pressurizing, does not take up much space.

Next, I stuffed the resulting futon cotton into a bag on the side of the futon.
Since the batting cotton was in the form of a sheet, it was very easy to handle and had good workability.

After stuffing the futon with cotton, it was sewn to create the futon.

When the resulting futon was heated with steam at 100°C to increase its bulk, its thickness recovered to 8011 mm. The resulting futon had uniform thickness and basis weight, and had a good appearance.

Next, the pillow whose bulk had been recovered was compressed again using a belt-type press machine at a temperature of 110°C at a gauge pressure of 5 kgd, and then heated steam at 100°C was applied to recover the bulk, and the recovery rate was 95%. and the degree of expansion was 8 times higher.

Note that the definitions of the restoration rate and the degree of expansion are as follows.

[Thickness after recovery] [Recovery rate (%) Co x 100 [Initial thickness] [Thickness after recovery Co [Degree of expansion (times) Co [Thickness after pressing]] In this way, the present invention The bulk of the pillow can be reduced by compression pressing and then repeatedly restored to bulk by heating.

Therefore, when the volume of the obtained futon was reduced by compression press, it was very easy to store and transport.

Example 2 First, a pillow was made in the same manner as in Example 1.

Next, the resulting futon was subjected to dry heat treatment at 150° C. to increase its bulk, and its thickness was restored to 8 cII. The resulting futon had uniform thickness and basis weight, and had a good appearance, similar to the futon obtained in Example 1.

The pillow whose bulk had been recovered was compressed and pressed again in the same manner as in Example 1, and then heated steam at 100°C was applied to recover the bulk, and the recovery rate was 95% and the degree of expansion was 8 times higher. Ta.

From the above, the obtained futon was heated and pressurized to fix it in a compressed state to reduce the bulk, and then heated to recover the bulk, similar to the futon obtained in Example 1. It turns out that this can be done repeatedly.

Next, the volume of the resulting futon was reduced using a compression press, and then it was stored and transported, both of which were very convenient.

Example 3 First, fibers having the same composition as in Example 1 were prepared, and the fibers were sufficiently mixed to produce a cotton quilt. Next, the futon side bag is stuffed with this futon cotton, and then sewn to a thickness of 8.
I got a cm-sized futon.

Next, the futon was once compression-pressed using a belt-type press machine at a temperature of 110°C at a gauge pressure of 5 kg/cd, and then heated steam at 100°C was applied to recover the bulk, and the recovery rate was 95%. The degree of expansion was 8 times higher.

As described above, the futon of the present invention, similar to the futon obtained in Example 1, can be heated and pressurized to fix it in a compressed state to reduce its bulk, and then heated to recover the bulk. It is something that can be done in return.

The pillow thus obtained was very easy to store and transport when its volume was reduced by compression press.

[Effect of the Invention J The quilt of the present invention has a built-in quilt cotton made of constituent fibers and heat-fusible fibers, and is fixed in a compressed state by heating and pressurizing, so that the bulk can be reduced. Therefore, the space required for transportation and storage can be reduced.

Furthermore, after the futon of the present invention is fixed in a compressed state by heating and pressurizing, it is restored to its pre-heating shape by being reheated, so its bulk can be adjusted as appropriate depending on the usage situation. It is possible.

Claims (1)

[Scope of Claims] 1. A quilt that incorporates a quilt made of constituent fibers and heat-fusible fibers, characterized in that the constituent fibers are not substantially bonded by heat-fusible fibers. Futon. 2. A quilt consisting of constituent fibers and heat-fusible fibers is heated and pressurized to fix it in a compressed state, and after forming a quilt using the quilt cotton fixed in this compressed state, the melting point of the heat-fusible fiber is A method for producing a futon, which is characterized by heating the futon to a temperature above or above to restore the bulk of the futon. 3. A method for transporting a futon according to claim 1, characterized in that the futon according to claim 1 is fixed in a compressed state by heating and pressurizing it and then transported. 4. A method for storing a futon according to claim 1, which comprises fixing the futon according to claim 1 in a compressed state by applying heat and pressure.