JPH06184900A - Production of padding material - Google Patents

Abstract

PURPOSE:To provide a process for the heat-forming of a padding material having excellent strength, air-permeability and durability without causing the adhesion to the die in heat-forming and the problems such as the lowering of workability and the deterioration of the surface quality of the padding material. CONSTITUTION:A padding material is produced by heating and melting a binder fiber of a fiber aggregate composed of an aggregate of crimped non-elastic polyester short fibers as a matrix and a binder fiber having a melting point lower than the melting point of the polymer constituting the short fiber. The heat-forming is carried out by supporting the aggregate with a non-sticking supporting member.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a shoulder pad material used for adjusting the outer shape of products such as men's clothing and women's clothing, or a pad for clothing materials such as a brassiere pad used to protect a local part of the human body. The present invention relates to a method of manufacturing wood.

[0002]

2. Description of the Related Art Conventionally, the following three materials have been used as pad materials for clothing materials.
Two have been manufactured and put on the market. Most commonly, there are polyurethanes that have been used because of their elasticity. In this case, a curved pad material is produced as an integral structure through steps such as slicing and shaving from a large urethane block, but as is well known, the problem of yellowing inherent to urethane, or the problem of light deterioration, Has a problem of dry cleaning durability, and also has a problem of stuffiness due to lack of breathability inherent to urethane, and a strong improvement has been desired for a long time.

In particular, the problem of yellowing is serious, and therefore, in practical use of the urethane pad, in order to prevent the discoloration due to yellowing from being seen from the outside, it is concealed by covering it with many layers of cloth. It's a reality.

Further, as a pad for a clothing material using fibers, a thin sheet of so-called non-woven fabric is prepared by punching out a number of sheets having different sizes in advance with a die of a predetermined size. There is also a method of obtaining a pad material by laminating 4 to 8 layers to form a curved shape, adhering them to each other with an adhesive, and simultaneously thermoforming them.

However, in this method, the production process is extremely complicated and long, and not only the production efficiency is low, but also the obtained pad material itself has a large change in shape due to the dropping of the adhesive due to washing or the like, which causes a great problem in the mold holding property. is doing.

Further, a method has also been studied in which so-called binder fibers are mixed and laminated with a card web, and the binder fibers are melted and bonded during thermoforming to obtain a pad material.
In this case, there is a problem that the more compressed part of the outer peripheral part of the curved structure is extremely harder than the lightly compressed part of the central part and cannot be used. Since it is fused to the mold, workability is poor and it has not been put to practical use.

[0007]

SUMMARY OF THE INVENTION It is an object of the present invention to provide a method for producing a rational pad material which solves the problems of the prior art and which has high elasticity, high feel, durability and breathability. It is a thing.

[0008]

DETAILED DESCRIPTION OF THE INVENTION The present invention provides: (Claim 1) A fiber assembly comprising a non-elastic polyester crimped short fiber aggregate as a matrix, and a binder fiber having a melting point lower than that of a polymer constituting the short fiber. A method for manufacturing a pad material, which comprises molding the binder fiber by heating and melting the binder fiber through a non-adhesive support. (Claim 2) The method for producing a pad material according to claim 1, wherein the non-adhesive support is made of a fluorocarbon material. (Claim 3) The non-adhesive support has an opening.
Alternatively, the method for manufacturing the pad material according to the item 2. Is.

In the present invention, the non-elastic polyester crimped short fibers constituting the matrix include ordinary polyethylene terephthalate, polybutylene terephthalate, polyhexamethylene terephthalate, polytetramethylene terephthalate, poly-1,4-dimethylcyclohexane terephthalate, It is a short fiber made of polypivalolactone or a copolymerized ester thereof, a cotton blend of these fibers, or a composite fiber made of two or more of the above polymer components. The cross-sectional shape of the short fibers may be circular, flat, atypical or hollow.

Further, the crimps in this case are preferably short fibers having an overt crimp, and these overt crimped fibers are mechanically crimped by a crimper or the like at the time of production, spiral crimped by anisotropic cooling or the like, It can be obtained by heating a side-by-side type or eccentric sheath core type composite fiber. The use of so-called latently crimped fibers has the drawbacks that the feel is poor in elasticity, the dimensional change is large, and the moldability is poor. The single yarn fineness is preferably 0.5 to 10 denier, and particularly 0.8 to 6 denier is recommended. 0.5
If it is less than denier, the structure will be too fine to obtain an appropriate elasticity, and if it is thicker than 10 denier, the texture will be rough and good touch cannot be obtained.

On the other hand, the elastic composite fiber used for forming the heat fixing point which plays an important role in the present invention is formed of a thermoplastic elastomer and a non-elastic polyester. In that case, it is preferable that the former occupy at least 1/2 of the fiber surface. In terms of weight ratio, it is appropriate that the former and the latter are in a composite ratio of 30/70 to 70/30. The form of the elastic composite fiber may be either a side-by-side type or a sheath-core type, but the latter is preferable. In this sheath-core type, the inelastic polyester is of course the core, but the core may be concentric or eccentric. In particular, the eccentric type is more preferable because the coil-shaped elastic crimp is developed.

The thermoplastic elastomer is not particularly limited as long as it is a fiber having a melting point lower than that of the polymer constituting the non-elastic polyester crimped short fiber aggregate matrix, but a polyurethane elastomer or a polyester elastomer is preferable.

As the polyurethane elastomer, a low melting point polyol having a molecular weight of about 500 to 6000, such as dihydroxypolyether, dihydroxypolyester, dihydroxypolycarbonate, dihydroxypolyesteramide, etc., and an organic diisocyanate having a molecular weight of 500 or less, such as p, p '- Diphenylmethane diisocyanate, tolylene diisocyanate, isophorone diisocyanate, hydrogenated diphenylmethane diisocyanate, xylylene diisocyanate, 2,6-diisocyanate methylcaproate, hexamethylene diisocyanate and the like, and a chain extender having a molecular weight of 500 or less, such as glycol, amino alcohol or triol. It is a polymer obtained by the reaction with. Among these polymers, particularly preferred are polyurethanes using polytetramethylene glycol, or poly-ε-caprolactone or polybutylene adipate as a polyol. In this case, as the organic diisocyanate, p,
P'-diphenylmethane diisocyanate is preferred. Further, as the chain extender, p, p'-bishydroxyethoxybenzene and 1,4-butanediol are preferable.

On the other hand, as the polyester elastomer, a polyether ester block copolymer obtained by copolymerizing thermoplastic polyester as a hard segment and poly (alkylene oxide) glycol as a soft segment, more specifically, terephthalic acid, Isophthalic acid, phthalic acid, naphthalene-2,6-dicarboxylic acid, naphthalene-2,7-dicarboxylic acid, diphenyl-4
4'-dicarboxylic acid, diphenoxyethanedicarboxylic acid, aromatic dicarboxylic acid such as sodium 3-sulfoisophthalate, alicyclic dicarboxylic acid such as 1,4-cyclohexanedicarboxylic acid, succinic acid, oxalic acid, adipic acid,
At least one dicarboxylic acid selected from aliphatic dicarboxylic acids such as sebacic acid, dodecanedioic acid, and dimer acid, or ester-forming derivatives thereof, and 1,4-butanediol, ethylene glycol, trimethylene glycol, tetracarboxylic acid, etc. Aliphatic diols such as methylene glycol, pentamethylene glycol, hexamethylene glycol, neopentyl glycol, decamethylene glycol,
Alternatively 1,1-cyclohexanedimethanol, 1,4
-At least one diol component selected from alicyclic diols such as cyclohexanedimethanol and tricyclodecanedimethanol, or ester-forming derivatives thereof, and an average molecular weight of about 400 to 5,000,
Polyethylene glycol, poly (1,2- and 1,3
-Propylene oxide) glycol, poly (tetramethylene oxide) glycol, a copolymer of ethylene oxide and propylene oxide, a copolymer of ethylene oxide and tetrahydrofuran, and the like, composed of at least one kind of poly (alkylene oxide) glycol. It is a terpolymer.

However, in terms of adhesiveness with non-elastic polyester crimped short fibers, temperature characteristics, and strength, polybutylene terephthalate is used as a hard segment,
A block copolymerized polyether polyester having polyoxybutylene glycol as a soft segment is preferable. In this case, the polyester portion constituting the hard segment is polybutylene terephthalate whose main acid component is terephthalic acid and whose main diol component is butylene glycol component. Of course, a part of this acid component (usually 3
0 mol% or less) may be substituted with another dicarboxylic acid component or an oxycarboxylic acid component, and similarly, a part (usually 30 mol% or less) of the glycol component may be substituted with a dioxy component other than the butylene glycol component. May be.

The polyether moiety constituting the soft segment may be a polyether substituted with a dioxy component other than butylene glycol. In the polymer, various stabilizers, ultraviolet absorbers, thickening and branching agents,
A matting agent, a colorant, and other various improving agents may be added as necessary.

Next, the weight ratio of the elastic composite fiber used in the present invention in the fiber assembly is preferably 10 to 50%. If the weight ratio is less than 10%, a sufficient number of heat fixation points cannot be obtained, and there is a problem in durability. On the other hand, if the weight ratio exceeds 50%, the number of heat-fixing points increases too much, resulting in a rough and hard pad material, which is a practical problem. The density of the pad material obtained by the present invention is 0.01 to 0.035 g / cm ³ in the maximum thickness portion of the curved structure. When the density is less than 0.01, the texture is soft, but there is a problem in maintaining dimension stability. Conversely, the density is 0.0
If it exceeds 35 g / cm ³ , only a rough and hard pad material can be obtained.

Next, the present invention will be further described with reference to the drawings.

FIG. 1 shows a conventionally used urethane pad material. (1) is a urethane pad material, which is formed integrally with a curved structure, but it is essential to be covered with a cloth (2) in order to prevent yellowing, which is a drawback of urethane, from being seen. Figure 2 shows an example of a bent structure formed by stacking multiple layers of non-woven fabric sheets.
A curved structure is formed by each layer of the non-woven fabric sheets having different sizes shown in (3-1) to (3-5). An adhesive made of resin may be attached between the layers by spraying, or an adhesive layer made of binder fibers or the like may be provided to fix the layers during thermoforming. Depending on the case, it is possible to integrate them by sewing, though it takes more time.

FIG. 3 shows the shoulder pad material (4) and brassiere pad material (5) obtained according to the invention. All of them are fibrous structures but are composed of a single structure, which shows that the bra pad material of (5) has a slightly curved structure as compared with the shoulder pad material of (4). In the figure, (B) shows the thickest portion of the curved structure (the portion where the compression is small), and (A) shows the strongest degree of compression in the outer peripheral portion of the curved structure, and therefore the thinnest portion. It is important in terms of texture that the (A) part and the (B) part of the pad material are basically equal in hardness and elasticity. In the case of conventional urethane, a structure that has been bent in advance by so-called slicing or carving is mechanically carved out and prepared, and then thermoformed, or in the case of the laminated non-woven fabric shown in FIG. Since it suffices to adjust the portion and the thin portion depending on the number of layers to be laminated, such a change in hardness between the central portion and the outer peripheral portion does not pose a problem. That is, it can be said that, particularly in the case of laminating non-woven fabric as the fibrous structure shown in FIG. 2, this defect is covered due to the complexity of the process. FIG. 3 shows a pad material obtained by the present invention. The greatest feature is that the elastic repulsion force ratio of (A) and (B) is formed with a small elastic force ratio that has not been considered in the past while being formed of a single structure of a fiber structure.

Next, a method for obtaining the pad material of the present invention will be described with reference to FIG. In FIG. 4, (6) represents a mixed raw cotton, C represents, for example, a non-elastic polyester crimped short fiber, and D is a composite fiber containing a thermoplastic elastomer as one component thereof.

These blended cottons are subjected to the card process of (7), laminated in a cross layer of (8) to a necessary basis weight to form a sheet, and then, in the present invention, once subjected to needle punching and / or of (9). Mechanical entanglement is applied by a method such as water needling, and the density is 0.009 to 0.
A sheet of 030 g / cm ³ is used. Subsequently, Em (melting point of thermoplastic elastomer)-
It is pre-fused at a temperature selected between Tm (melting point of non-elastic polyester) and -30 ° C and wound up by the winder (11). In order to obtain the pad material to be subjected to the thermoforming shown in FIG. 5 in a separate step, it is prepared by punching the sheet or the sheet exiting the heat treatment machine (10) is continuously formed into a predetermined shape in some cases. It may be punched out. The punched sheet obtained is passed through the thermoforming process shown in FIG. 5 and is one-shot thermoformed to obtain the pad material shown in FIG. 3, or a particularly thick product (B portion is 10 mm or more). In such a case, a rough structure having a different thickness is once prepared by the shaving process or the chamfering process shown in FIG. 6 and then finally finished by thermoforming.

[0023]

When the punched sheet is directly put into the thermoforming metal frame and molded, it is attributed to the binder fiber constituting the sheet in the heating metal frame. There is a problem that a fusion phenomenon occurs, and if it is forcibly taken out, surface fluff occurs and deformation type collapse occurs.

When the thermoforming method using the non-adhesive support of the present invention is used, an excellent pad material having excellent surface quality and having no loss of shape can be obtained.

The present invention will be specifically described below with reference to examples.

[0026]

Examples 1 to 4 and Comparative Example 1 38% (by weight) of polybutylene-based terephthalate obtained by polymerizing an acid component obtained by mixing terephthalic acid and isophthalic acid at 80/20 (mol%) with butylene glycol was used. Furthermore, it is heated and reacted with 62% (weight) of polybutylene glycol (molecular weight 2000),
A block copolymerized polyether polyester elastomer was obtained. The intrinsic viscosity of this thermoplastic elastomer is 1.
0, melting point 155 ° C, elongation at break in film 1500
%, 300%, elongation stress was 0.3 kg / mm ² , and 300% elongation recovery rate was 75%. This thermoplastic elastomer was spun into a sheath, and polybutylene terephthalate was spun into a core by a conventional method so that the weight ratio of core / sheath was 50/50. This composite fiber is an eccentric sheath / core type composite fiber. This fiber was drawn twice and cut into 64 mm, and then heat-treated with warm water at 95 ° C. to reduce shrinkage and develop crimp, and after drying, an oil agent was applied. The elastic conjugate fiber obtained here was 6 denier. The elastic composite fiber 30% (by weight) and the monofilament obtained by a conventional method have a thickness of 3 denier,
A round cross section polyethylene terephthalate short fiber having a fiber length of 51 mm and a crimping number of 12 / inch (polyethylene terephthalate melting point 259 ° C.) 70% (weight) is mixed with a card to make a web, and then Feller needle punching Machine, using No. 36 regular barb, 40 times / cm ² needling with needle depth of 10 mm, and further 17
Dry heat treatment (pre-fusion) for 60 seconds at 5 ° C without pressurization, basis weight 350g / m ² , thickness 15mm, density 0.02
A fiber aggregate of ³ g / cm ³ was obtained. The fiber assembly was put into a thermoforming pad metal frame and thermoformed at 190 ° C. for 20 seconds through a support to form a curved pad material for clothing.
As a comparative example, a pad material was obtained under the same conditions without using a support.

Table 1 shows the texture and surface quality of the obtained pad material, and the presence or absence of fusion to the mold. Here, ◯ means good, Δ means slightly bad, and × means bad.

[0028]

[Table 1]

As is clear from Table 1, according to the present invention, a pad material excellent in texture and surface quality can be obtained without impairing workability such as fusion with a mold.

[Brief description of drawings]

[Figure 1] Conventional polyurethane pad material

[Fig. 2] Conventional non-woven sheet laminated pad material

FIG. 3 is a pad material of the present invention (4) Shoulder pad material (5) Plastic pad material

FIG. 4 is a manufacturing process diagram of the pad material of the present invention.

FIG. 5 is a side sectional view of a thermoforming machine.

FIG. 6 Thermoforming process diagram

[Explanation of Codes] (1) Polyurethane (2) Fabrics (3-1) to (3-5) Nonwoven sheet A Outer peripheral portion of pad material B Thickest portion of pad material (6) Raw cotton mixed (7) Card ( 8) Cross layer (9) Needle punch (10) Heat treatment machine (11) Winding machine (1 ') Pad material after punching

Claims (3)

[Claims] 1. A pad material is produced by heat-melting binder fibers of a fiber assembly comprising non-elastic polyester crimped short fibers as a matrix and having a melting point lower than that of a polymer forming the short fibers. In this case, a method for producing a pad material, which comprises molding through a non-adhesive support. 2. The method for producing a pad material according to claim 1, wherein the non-adhesive support is made of a fluorocarbon material. 3. The method for producing a pad material according to claim 1, wherein the non-adhesive support has an opening.