JPH08512105A - New fiber bat - Google Patents

Abstract

  (57) [Summary] An improved polyester fiber fill bat for use in apparel and other applications made from low dpf polyester fiber and binder fiber sprayed with a soft resin and laminated by a furnace. This invention provides flexibility and drapeability, good thermal insulation performance, low levels of fiber leakage or percolation through the shell, high durability when laundering / washing by dry or dry cleaning, and quilting to small panels. To provide a bonded bat characterized by high structural integrity such that it hangs freely without the need for.

Description

Detailed Description of the Invention                           New fiber bat   The present invention is directed to a bonded polyester fiber fill butt (bonded polyester). fiberfill batts) and related, sometimes battin They are known as battings and are especially improved with desirable aesthetics and practical quality. Bats, and incorporate such improved bats Products.   Specifications of parent patents US Pat. No. 5,225,242 and WO93 / 11292 (disclosure matters) Are incorporated herein by reference), and a bonding bag including the following steps. The manufacturing method of the grate is shown.   That is, the polyester fiber fill in an amount of about 70-96% by weight, About 4 to 3 with a binder material having a melting point below the softening point of the ester fiber fill Intimately mixed with 0% by weight of binder fibers, preferably bicomponent binder fibers And forming a continuous blend having an upper surface and a lower surface from the blend. The step of producing a bat and sending the vat to one or more spray zones, Gives a cured resin with a glass transition temperature (TG) below about 0 degrees Celsius after curing About 10 to 30 times the total amount of the sprayed vat containing the resin selected The amount of resin that occupies the amount% is sprayed on both sides of the vat and sprayed in an oven. The heated batt to harden the resin and soften the binder material, The heated bats on both sides of the bat by feeding them to a heating roll. A step of achieving intimate contact between the resin and the fiber and cooling the wound batt Is a method for manufacturing a bonded bat having a process and such heating rolling (h ot-rolling is a heated roll in the form of a calendar or S-wrap Is used to obtain a favorable effect, and by such a manufacturing method, A bat with improved aesthetics and functionality is obtained. Weight of fiber in the vat (That is, the weight of the blend of polyester fiber fill and binder fiber The amount is said to be the “basis weight” of the bat. However, it is about before the sealing resin is sprayed. It   However, the present invention surprisingly provides a low denier fiber fill. (Various things like sub-denier or micro-denier are referenced) Under the condition that it helps seal at least one or both sides of the , Heating rolling is not always needed to give a proper seal I knew it was. Thus, today it has the following top and bottom surfaces: A laminated bat is provided. That is, the bat is Has a denier of less than about 1 and is calculated based on the base weight of the bat, about 75 From about 4 to about 96%, and calculated from the base weight of the bat Complementarily bonded with a low melting point binder material in an amount of about 25%, It has a polyester fiber fill and the bat has a wash resistance of at least 4. Persistence (defined as WD) and approximately 40 cN / cm²The following bending stiffness (defined as B At least one of the faces has a glass transition of about 0 degrees Celsius or less. Approximately 0.02 oz / yd calculated for the face of the bat with temperature (TG)² From about 0.35 oz / yd²The resin is sealed with an amount of It is characterized in that (defined as SR) is at least 4. Preferred Preferably each of the faces is thus sealed.   Here, both metric units such as decitex (dtex) and denier are 1 decitex is equal to 0.9 in denier per filament (dpf) The same.   Thus, the present invention was first made with a polyester fiber fill (blend 7 5 to 96% by weight) with suitable binder fibers (4 to 25% by weight of the blend) Required to be used in premium clothing by producing a blend of Such a fiber fill bat is provided. This blend is a card or Convert to web with garnet, then layer this web or The bat may be cross lapped to form a top surface (and And preferably sequentially also on this underside) with a suitable latex (eg in more detail below). Acrylic polymer / copolymer colloidal dispersion in water) For example, it is applied by spraying. The sprayed vat can be Conveniently heat it by passing it through an eated oven) to dry the film and polymerize the polymer components. Polymerize in an amount to activate the binder fibers. This is the case in such furnaces, for example, It can be conveniently done by passing it twice, and applying such a coating on each side twice After each such coating is sequentially dried and partially cured. Use the binder fiber to supplement the other threads and prepare for heating rolling. This is to sexualize. There, the bonded bat should be placed around or between the heating rolls. Through (S-wrap or calender treatment) to soften and spread the cured resin (sprea d), ensuring its complete and uniform distribution between the fibers on the two sides of the bat (large surface) To prevent the fibers from leaking through the surface of the bat, and if necessary, the bat It ensures the desired thickness, which is disclosed in U.S. Patent No. 5,225,242. It   However, the fiber fill is 0.2 to 1 denier per filament. And the resin applied to the butt surface has a glass transition temperature (TG) of about 0 degrees Celsius. With about 0.02oz / yd²(0.7 g / m²) To about 0.35 oz / yd² (12 g / m²) In this case when heated to prevent fiber leakage No additional processing like rolling is required. Especially dry fiber fill is used This is the case when it comes to time. The heating roll treatment adjusts the thickness of the bat to an appropriate value to improve bending rigidity. It is applied to ensure reduction.   The resins that can be used here are "soft" and "semi-soft" made by different manufacturers. , Or "extremely soft", the secondary glass transition temperature below about 0 ° C. It is characterized by having a degree (TG). These are used in clothing, for example Sometimes it acts as a barrier against fiber leaks from the bat while still providing flexibility to the bat. Provides both sex and drape suitability. The final bat is 1.5-12o z / yd²(50-400 g / m²) Basis weight and 0.07 to 0.20 inc h / oz / yd²(0.05 to 0.15 mm / g / m²) Thickness. This As described above, the bat of the present invention comprises a polyester fiber fill and a binder fiber. Manufactured from lend, the fibers on both sides are appropriately soft type coating Sealed. Polyester fiber fills are, for example, those mentioned above. All smoothed, and smoothed and unsmoothed It may be a blend of (slickened and unslickened) fibers. Fiber fiber The fiber may be solid, hollow, a blend of solid and hollow fibers, or It is not limited to any type of cross section, ie even circular Cross shape, trilobal, Y-shape, dog bone shape, ska It may be a scalloped oval or other non-circular cross section . Fiberfill has a denier (dpf) per filament in the range of 0.2-10 Having a dpf of about 1.65 is very useful and about 70-96 weight of the above blend. Make up%. As mentioned above, the sub-denier fiber is the surface of the bonded bat. This gives a good sealing effect in the sub-denier Fibers are often preferred. Individual fibers are crimped by conventional means. It has a crimp number of 5 to 15 per inch (cpi), It has a length in the range of 3/4 to 3 inches. The binder fibers are about 4 to 3 in the bat. 0% by weight, sheath / core type (sheath / core) (s / c), side / side type (sid) e / side) (s / s), or single component type. These are, for example, Go) Polyester, polyolefin, polyolefin / polyester, polyami De / polyamide and the like. Useful types of binder fibers and their The functional mode is "Nonwovens World", March / April, 1990, p. 37. Suitable binder fibers in the blend The initial dpf of the class is generally in the range of 2 to 15, and 4 dpf is usually used. To be Useful binder fibers include scott, pamm, fla What is disclosed in the aforementioned patents by Frankosky and Marcus U.S. Pat. No. 4,732,809 to Harris et al., Taniguchi et a U.S. Pat.No. 4,789,592, such as l), U.S. Pat.No. 4,500, such as Tomioka et al. No. 384, Hirose et al., JP-A-57-210,015 (1982). As well as those in the industry that function within the furnace temperatures disclosed herein. Other known ones can be mentioned. The preferred binder fibers are Sales of "Melty 4080" (Unitika Ltd., Japan) and "ES" And "EA" polyolefin (Chisso Japan) Can be   The cured resin coating on both sides of the bat is about 10 ~ 30% by weight, 12 ~ for 1.65 dpf (1.83 dtex) 25% is preferable. If the amount of resin is small, the wash resistance and seal grade tend to decrease. On the other hand, when the amount of resin is large, the rigidity tends to increase and the heat insulating effect tends to decrease. Bag If only one side of the sheet is sealed, half the amount of resin is applied. Low fiber denier Fiber (less than about 1 dpf) is used, fibers can be coated with a small amount of resin. You can control this. Furthermore, the amount of resin on the surface is the basis weight of the bat. A heavy fiber butt, with a smoothed fiber filter Even with respect to the net, the total resin added is at most about 3%. The entire For dried (unsmoothed) fibers, use smoothed fiber Less resin than when using   As mentioned above, suitable resins for coatings have TGs below about 0 ° C. are doing. Useful resins are commercially available acrylic and vinyl latex compositions. , Which include, for example, Rhoplex E-32 (Rhoplex) Rohm and Haas Co., TR-934 (Rohm and Haas Co.), X -4280J (Kanebo, Japan), BF Goodrich (BF Go) odrich) Hicar® latex compositions such as: 26146 , 26171, 26322, 26083, 26092, 2671, 26120, 2679, 26796, National Studio National Starch and Chemical Co. rporation) latex products such as: NACRYLIC X4445, Nacrylic X788-6007, Nacrylic X4483, Nacrylic X4460, Nacrylic Ku X4260, Nacrylic X4425, Nacrylic X4465, Nacrylic X4401, Nacre Rick X78-3990, Nacrylic X78-3997, Nacrylic X78-3905, Nacrylic X4280, Nacrylic X4441, Nacrylic X78-6114, X-LINK 2873, X-Link 2849, X-Link 78-6119, X-Link 2893, X-Link 2833, X- Link 78-6004, X-Link 2813, Resin (RESYN) 2375, Dur-O-Set (DUR -O-SET) E-230, Dur-O-set E-669, and trees with a TG value of about 0 ° C or less Other commercial latte that hardens to fats Cousins can be mentioned. Such commercially available resins and their TG values are , Pamphlets, for example, Hiker Acrylic Latexes (HYCAR) A trademark of Acrylic Latexes) in BF Goodrich in 1989. Binders, Saturants, Lam instars) National Starch and Chemical Corporation It is listed in the above.   The manufacture of bats is accomplished by the conventional opening of polyester fiber fill and binder fiber. It is common to start with the opening and blending, then the carding or Or garnetting to form a web. This web is a system Form other webs and layers from a train of cards and garnets Can be made or cross-wrapped with other webs and combined (combine d), it is also possible to form an unbonded bat. Then of this bat Spray the latex composition on both sides to cure the resin and bond the binder fibers. Introduce into the furnace. The furnace treatment is carried out at 150 to 190 ° C. for 2 to 5 minutes and is described above. As mentioned above, it is convenient to perform the bat three times. Next, 1 butt A heating roll having a surface temperature in the range of 50 to 250 ° C. (preferably at least 2) Between / around the rolls (more than one roll can be used). Bat's The configuration is S-on the roll to give maximum contact with the roll. It may be in the form of a wrap. The latter is 2-5mm depending on the desired final bat thickness It is good to have a clearance of. Instead, heat the bonded vat as described above. It may be passed between the calender rolls. In these processes, if desired, Even when sealing both sides of the bat, it is heated with only one roll, like this If you try to seal both sides on the second time, heat the other side of the bat for the second time. Pass the bat between / above the rolls. The contact time on the roll is 3 to 25 seconds. This Heat roll treatment like softens and spreads the resin, perfect and uniform on the bat surface To ensure good distribution, prevent fiber leakage, and for comfort and aesthetic performance during use Gives a uniform surface without lumps. Bat shows the range of base weight and thickness mentioned above ing.   The bat of this invention has a CLO rating (CLO rating) Desired heat resistance or heat insulation property reported as Japanese Patent No. 4,514,455). Show the bell. The bat of this invention has at least 0.36 CLO / oz / yd², Preferably 0.48 CLO / oz / yd²It is better to show the above CLO values.   Each of the ingredients and methods described herein are selected to provide the bat of the present invention. Please understand that it should be. To choose the combination that gives them Must be careful. For example, on slippers and bats on fibers The latex applied is such that the final vat shows, for example, sufficient wash durability. One should choose one that adheres well.                                 Test method   CLO grades are obtained as described in Wang, supra.   The wash durability ("WD") of the bat of this invention is determined by the method of ASTM D-4770-88. Evaluate. In the example, the panel was 24 inches by 24 inches in size. It was Durability ratings are made in accordance with paragraph 8.6.1. Report the measurement. The bat of this invention has a grade of 3 or higher (paragraph 8. 5 scale).   Fiber leakage through the outer shell fabric, or percolation (per (Collation) is described in US Pat. No. 4,869,771 of LeVan (3 times As a seal grade (SR) by the after 3 wash cycles method Measured and made the seal grade (SR) 5 excellent, and inferior to the seal grade (SR) 1. I shall. The bat of the present invention has a seal grade (SR) of 3 or higher (three wash cycles (After clew). In the table (examples), after one wash (1 W) and three washes (3 The sealing values after washes) (3W) are the same as the values before washing (NEW) for comparison. Both have been reported.   The flexibility or drape suitability of the bat of the present invention is determined by German Industrial Standard 53362 pieces. Measured in accordance with DIN 53362 Cantilever, which is machine direction and machine Bending stiffness (“B”) in the machine and cross machine directions ) Is determined and summed, and the combined result is drapeability and flexibility. It is related. Cut the bat sample into 25 cm and 2.5 cm wide , Machine direction (MD) and cross machine direction (XD). each The test piece is weighed and the weight is recorded as "W". Then the bent sample Slide horizontally on the platform until the tip of the reaches an angle of 41 degrees 30 seconds, Determine the Bend length (“LU”). Next, the following calculation is performed.         B = F1 (LU / 2)³               However, B = CN / cm²Bending stiffness at                       Bending length at LU = cm                       F1 = 9.8 (W ÷ L)                       W = weight of test specimen sample in grams                       Length of sample specimen at L = cm   The bat of this invention is 80 CN / cm²The following bending stiffness ("B" is from the bat Is the sum of the values determined for the MD and XD samples of. ). Low song It is preferable that the rigidity is high.   The invention is further illustrated by the following examples, in which all parts and percents Is weight, unless otherwise stated, "BW" (basic weight, or polyester Fiber filler and binder only, i.e. spray for improved sealing. (Excluding the resin added by-).                                  Example   Various batt samples were prepared, tested and the results are shown in the table. Ba For indah fiber, it is "Melty 4080" (4 dpf) every time. Different bafills were used.   Samples A, B, C and D were 37.5% smoothed 1.65 dpf ( Finished with silicone lubricant) Polyester fiber, 37.5% dry 1.65 dpf (without silicone lubricant) polyester fiber, and 25% It is prepared from a commercially available blend of binder fibers. This blend is unique to the United States A conventional card similar to the device described in Example 1 of Xu 5,225,242 and Processed on a cross-lapper device. The bat obtained is about 1 It is passed through a triple-pass oven maintained at 65 ° C. Bat (A Except for soft resin (glass transition temperature (TG) equal to -10 ° C) on both sides. The amount of resin sprayed and the total amount of resin added based on "BW" is shown in the table. In this case, the basis weight of the fiber in the bat is about 4.5 oz / yd²(150g / M²)Met. One side of the vat is sprayed with resin before the first thread , The other side was sprayed before entering the second pass. The important thing is that the resin Ensuring that the entire bat is adequate to ensure proper curing and binder fiber set Suitable time for high temperature (1 minute after vat reaches 165 ° C To be exposed. Then, the bat is calendered in another operation And the surface is sealed to reduce loft.   From the seal values in the table, under these conditions, 8% resin (Sample B) Cullen to improve the seal of 1.65 dpf fiber even after one wash The effect of Dar was not obtained. Also, with 15% resin (Sample C), wash once The effect of the calendar to improve the seal after cleaning was obtained, but after washing 3 times, It was still insufficient. Surface of sample D under these conditions with 25% resin Had a satisfactory seal rating (after 3 wash cycles).   The bat has a 104 x 84 yarn count and a 0.5 inch water column pressure drop. Loss rate of 13.2 cu ft / min (Frazier air p Fibers are also produced by encasing in a fabric with an ermeability rating. It was also tested.   Samples E and F are 102x84 count and Frazier grade 48 in cloth Identical to samples A and D, respectively, except tested. 0.7 dpf Also tested in a cloth that is more permeable than Samples AD. Therefore, the results of Samples E and F (1.65 dpf) were And samples G-Q are included in the table to connect the data. Resin free Sample E failed in NEW due to opening of the cloth, but was washed three times. After the crew, it is in a fully matted state, which improves leak performance. Did good Sample F had a seal value of 5 at the beginning, which was satisfactory even after three washing cycles. The seal value is shown.   Samples G, H, I and J are approximately 85 pounds of dry polyester fiber ( 0.7 dpf, 0.78 dtex, 1.5 inch cut, 12 cpi, special Blended with 15 pounds of binder fiber Prepared. These samples were resin sprayed, calendered and Samples E and F were tested as well.   Samples K and L are similar 0.7 dpf and finished with silicone lubricant Approximately 55 pounds of slipped fiber, 0.7 dpf dry (not smoothed) Prepared by blending 27 pounds of fiber and 18 pounds of binder fiber It was These samples, as indicated by the two asterisks in the table, Although not calendered, a good seal rating is obtained.   Samples M, O, P and Q are similarly made from the same type of blends as K and L. Although provided, the basis weight is high and low (10 as shown). (Less than%) resin addition, and also uncalendered Nevertheless, it showed a good sealing rating. This uses low dpf fiber It is due to. N is not calendered (unlike others). these A comparison of the results shows that calendering is not necessary to improve the seal rating. Showed (when sub-denier fiber was used with soft resin) There is.   All samples G to L were made with 48 Frazier cloth against fiber leakage Was tested.   Corresponding to the table, samples GI and KQ are all according to the invention. On the other hand, others are comparative examples, some are without resin spray, some are Uses a standard denier fiber fill. The sealing grade of is not satisfactory after washing.

[Procedure of Amendment] Patent Law Article 184-8 [Submission Date] May 2, 1995 [Amendment Content] Claims 1. A laminated bat having an upper surface and a lower surface, wherein the bat has a denier per filament of about 1 or less and an amount of about 75 to about 96% calculated by the basis weight of the bat; and It has a polyester fiber fill, which is laminated throughout with a low melting point binder material in an amount of about 4 to about 25% calculated by basis weight, the bat having a wash durability of at least 4. (Defined as WD) and a flexural rigidity (defined as B) of about 40 cN / cm ² or less, at least one of the faces having a glass transition temperature (TG) of about 0 degrees Celsius or less. Sealed with resin in an amount of about 0.7 g / m ² (0.02 oz / yd ² ) to about 12 g / m ² (0.35 oz / yd ² ) calculated for the face of the bat. Oh , Combined butt bonded seal grade said surface (defined as SR) is characterized in that at least 4. 2. The bonded bat according to claim 1, wherein the amount of resin is about 3.4 to about 8.5 g / m ² (about 0.1 to about 0.25 oz / yd ² ). 3. The bonded bat according to claim 1 or 2, wherein each of the upper surface and the lower surface is sealed with the amount of the resin and has a sealing grade of at least 4.

Claims (1)

[Claims] 1. A laminated bat having an upper surface and a lower surface, wherein the bat has a denier per filament of about 1 or less and an amount of about 75 to about 96% calculated by the basis weight of the bat; and It has a polyester fiber fill, which is laminated throughout with a low melting point binder material in an amount of about 4 to about 25% calculated by basis weight, the bat having a wash durability of at least 4. (Defined as WD) and a flexural rigidity (defined as B) of about 40 cN / cm ² or less, at least one of the faces having a glass transition temperature (TG) of about 0 degrees Celsius or less. It has about 0.02oz / yd is sealed from ² to about 0.35oz / yd ² in an amount of resin, of defining a seal grade (SR of said surface calculated for said surface of said batt Bonded batt, characterized in that that) is at least 4. 2. The laminated bat of claim 1, wherein the amount of resin is about 0.1 to about 0.25 oz / yd ² . 3. The bonded bat according to claim 1 or 2, wherein each of the upper surface and the lower surface is sealed with the amount of the resin and has a sealing grade of at least 4.