JP4298484B2 - Ball-shaped cotton - Google Patents
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- JP4298484B2 JP4298484B2 JP2003403705A JP2003403705A JP4298484B2 JP 4298484 B2 JP4298484 B2 JP 4298484B2 JP 2003403705 A JP2003403705 A JP 2003403705A JP 2003403705 A JP2003403705 A JP 2003403705A JP 4298484 B2 JP4298484 B2 JP 4298484B2
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Description
本発明は、寝装具、家具用クッション材、シートクッション材等に好適に用いられる玉状綿に関するものである。 The present invention relates to a ball-shaped cotton that is suitably used for bedding, furniture cushion materials, seat cushion materials, and the like.
従来から寝装具、家具用クッション材、シートクッション材等のクッション基材としてポリエステル繊維からなる玉状綿を用いることは良く知られている。例えば、特許文献１にはらせん状に縮れたポリエステル繊維からなる平均寸法１〜１０ｍｍのファイバーボールが提案されている。また、特許文献２には微細なスパイラル捲縮を発現しうる潜在捲縮能を有するポリエステル繊維が結晶融点１００℃以上の共重合ポリエステルをバインダー成分とするバインダー繊維で点接合された玉状綿が提案されている。 2. Description of the Related Art Conventionally, it is well known to use ball-shaped cotton made of polyester fiber as a cushion base material for bedding, furniture cushion materials, seat cushion materials and the like. For example, Patent Document 1 proposes a fiber ball having an average size of 1 to 10 mm made of a polyester fiber shrunk in a spiral shape. Patent Document 2 discloses a ball-like cotton in which a polyester fiber having a latent crimping ability capable of expressing a fine spiral crimp is spot-bonded with a binder fiber containing a copolymer polyester having a crystal melting point of 100 ° C. or higher as a binder component. Proposed.
しかしながら、上記のようなポリエステル繊維等の従来から用いられている一般の合成繊維は、その大部分が石油などの限りある貴重な化石資源を原料としている。またこれらは自然環境下ではほとんど分解されず、廃棄処理が問題となっている。それに対し、ポリ乳酸は、トウモロコシなどの植物資源を原料としており、ポリ乳酸を繊維化したポリ乳酸繊維は種々の製品に加工された後、コンポストまたは土壌中等の自然環境下では最終的に炭酸ガスと水に分解される完全生分解性を持つ。なお、特許文献３には、融点の異なる２種類の生分解性ポリマーを偏心的に接合した潜在捲縮性複合短繊維が提案されている。 However, most of the conventional synthetic fibers conventionally used, such as polyester fibers as described above, are made from precious fossil resources such as petroleum. Also, they are hardly decomposed in the natural environment, and disposal is a problem. Polylactic acid, on the other hand, is made from plant resources such as corn. Polylactic acid fibers made from polylactic acid are processed into various products, and finally carbon dioxide is produced in natural environments such as compost or soil. It is completely biodegradable and decomposes into water. Patent Document 3 proposes a latent crimpable composite short fiber in which two types of biodegradable polymers having different melting points are eccentrically joined.
本発明は、上記の現状を鑑み、吹き込み法にて、嵩高性、圧縮弾性に優れ、さらには吸放湿性に優れたクッションを得るのに適した玉状綿であり、これを用いて製造したクッション材を廃棄する際には、自然界に存在する物質に変換できる玉状綿を提供することを課題とする。 In view of the above-mentioned present situation, the present invention is a ball-shaped cotton suitable for obtaining a cushion excellent in bulkiness, compression elasticity, and also in moisture absorption / release by the blowing method, and manufactured using this. When discarding the cushioning material, an object is to provide a ball-shaped cotton that can be converted into a substance existing in nature.
本発明は、上記の課題を達成するものであり、本発明の第１発明は、メルトフローレート値の異なる２種類のポリ乳酸（ただし、融点の異なる２種類のポリ乳酸の組み合わせは除く。）を偏心的に接合させたポリ乳酸複合繊維を含有する玉状綿であり、前記２種類のポリ乳酸は、メルトフローレート値の差が２０〜５０ｇ／１０分で、メルトフローレート値２０〜３０ｇ／１０分のポリ乳酸とメルトフローレート値５０〜７０ｇ／１０分のポリ乳酸とによって構成され、前記ポリ乳酸複合繊維が三次元的なコイルバネ状の立体捲縮を有していることを特徴とする玉状綿を要旨とするものである。また、本発明の第２発明は、前記した立体捲縮を有するポリ乳酸複合繊維並びに吸水性繊維を含有することを特徴とする玉状綿を要旨とするものである。 The present invention to attain the aforementioned object, the first aspect of the present invention, two kinds of polylactic acid with different melt flow rate value (however, the combination of two different polylactide melting point are excluded.) The two kinds of polylactic acid have a difference in melt flow rate value of 20 to 50 g / 10 minutes and a melt flow rate value of 20 to 30 g. / 10 min of polylactic and a melt flow rate value is constituted by a 50 to 70 g / 10 min of the polylactic acid, and wherein the polylactic acid complex fiber is have a three-dimensional coil spring-like three-dimensional crimps The gadget cotton is the gist. The gist of the second invention of the present invention is a ball-shaped cotton containing the polylactic acid composite fiber having the above-mentioned three-dimensional crimps and a water-absorbing fiber.
本発明の玉状綿は、植物資源を原料とする生分解性のポリ乳酸からなる複合繊維を含有し、また、この複合繊維の形態が、三次元的なコイルバネ状の立体捲縮を有するものであるため、嵩高性、反発弾性に優れ、独立した玉状の形状をしているため吹き込み法に適したものであり、クッション材等を製造するのに好適に用いることができる。また、植物由来原料の生分解性のポリ乳酸を使用するので、石油資源の節約、トータルでの二酸化炭素放出の削減を図ることができ、使用後の廃棄の際に自然界に存在する物質に変換させることが可能である。 The ball-shaped cotton of the present invention contains a composite fiber made of biodegradable polylactic acid made from plant resources, and the form of this composite fiber has a three-dimensional coil spring-like three-dimensional crimp. Therefore, it is excellent in bulkiness and rebound resilience, and has an independent ball shape, so that it is suitable for the blowing method and can be suitably used for producing a cushioning material and the like. In addition, because biodegradable polylactic acid, a plant-derived raw material, is used, it is possible to save petroleum resources and reduce total carbon dioxide emissions, and convert it into a naturally occurring substance when discarded after use. It is possible to make it.
以下、本発明を詳細に説明する。 Hereinafter, the present invention will be described in detail.
本発明の玉状綿は、特定のポリ乳酸からなる立体捲縮を有するポリ乳酸複合繊維を含有する。本発明に用いるポリ乳酸複合繊維を構成するポリ乳酸としては、ポリ（Ｄ−乳酸）、ポリ（Ｌ−乳酸）、ポリ（Ｄ−乳酸）とポリ（Ｌ−乳酸）とのステレオコンプレックス、Ｄ−乳酸とＬ−乳酸との共重合体、Ｄ−乳酸とヒドロキシカルボン酸との共重合体、Ｌ−乳酸とヒドロキシカルボン酸との共重合体、Ｄ−乳酸またはＬ−乳酸と脂肪族ジカルボン酸および脂肪族ジオールとの共重合体あるいはこれらのブレンド体が挙げられる。乳酸とヒドロキシカルボン酸との共重合体である場合におけるヒドロキシカルボン酸の具体例としては、グリコール酸、ヒドロキシ酪酸、ヒドロキシ吉草酸、ヒドロキシカプロン酸、ヒドロキシペンタン酸、ヒドロキシヘプタン酸、ヒドロキシオクタン酸等が挙げられる。中でも、ヒドロキシカプロン酸またはグリコール酸を用いることがコスト面から好ましい。脂肪族ジカルボン酸及び脂肪族ジオールとしては、セバシン酸、アジピン酸、ドデカン二酸、トリメチレングリコール、１，４−ブタンジオール、１，６−ヘキサンジオール等が挙げられる。乳酸にその他の成分を共重合させる場合、乳酸単位を８０モル％以上とするのが好ましい。８０モル％未満であると、融点が低くなりすぎて熱延伸が困難となって、高強度の繊維が得られ難くなるという問題が生じたり、耐熱性、耐摩耗性が低下することがある。 The ball-shaped cotton of the present invention contains a polylactic acid composite fiber having a three-dimensional crimp made of specific polylactic acid. Examples of the polylactic acid constituting the polylactic acid composite fiber used in the present invention include poly (D-lactic acid), poly (L-lactic acid), a stereocomplex of poly (D-lactic acid) and poly (L-lactic acid), D- Copolymer of lactic acid and L-lactic acid, copolymer of D-lactic acid and hydroxycarboxylic acid, copolymer of L-lactic acid and hydroxycarboxylic acid, D-lactic acid or L-lactic acid and aliphatic dicarboxylic acid, and Examples thereof include copolymers with aliphatic diols and blends thereof. Specific examples of hydroxycarboxylic acid in the case of a copolymer of lactic acid and hydroxycarboxylic acid include glycolic acid, hydroxybutyric acid, hydroxyvaleric acid, hydroxycaproic acid, hydroxypentanoic acid, hydroxyheptanoic acid, hydroxyoctanoic acid and the like. Can be mentioned. Among these, it is preferable from the viewpoint of cost to use hydroxycaproic acid or glycolic acid. Examples of the aliphatic dicarboxylic acid and the aliphatic diol include sebacic acid, adipic acid, dodecanedioic acid, trimethylene glycol, 1,4-butanediol, 1,6-hexanediol, and the like. When lactic acid is copolymerized with other components, the lactic acid unit is preferably 80 mol% or more. If it is less than 80 mol%, the melting point becomes too low and heat drawing becomes difficult, and it may be difficult to obtain a high-strength fiber, and heat resistance and wear resistance may be lowered.
ポリ乳酸中には、必要に応じて、例えば、熱安定剤、結晶化核剤、艶消剤、顔料、耐光剤、耐候剤、滑剤、酸化防止剤、抗菌剤、香料、可塑剤、染料、界面活性剤、難燃剤、表面改質剤、各種無機及び有機電解質、その他類似の添加剤を本発明の目的を損なわない範囲で添加することができる。 In the polylactic acid, if necessary, for example, a heat stabilizer, a crystallization nucleating agent, a matting agent, a pigment, a light resistance agent, a weather resistance agent, a lubricant, an antioxidant, an antibacterial agent, a fragrance, a plasticizer, a dye, Surfactants, flame retardants, surface modifiers, various inorganic and organic electrolytes, and other similar additives can be added as long as the object of the present invention is not impaired.
また、ポリ乳酸中にエポキシ化合物、オキサゾリン化合物、オキサジン化合物、アジリジン化合物、カルボジイミド化合物などから選ばれた化合物を添加し、ポリマーの末端カルボキシル基やヒドロキシル基を封鎖することにより耐湿熱分解性を向上させても良い。 In addition, the compound selected from epoxy compounds, oxazoline compounds, oxazine compounds, aziridine compounds, carbodiimide compounds, etc. is added to polylactic acid, and the terminal carboxyl group and hydroxyl group of the polymer are blocked to improve the resistance to moisture and heat degradation. May be.
ポリ乳酸複合繊維は、特定の２種のポリ乳酸からなることにより立体捲縮を有するものであり、２種のポリ乳酸としては、メルトフローレート値の異なる２種のポリ乳酸からなるもの（ただし、融点の異なる２種類のポリ乳酸の組み合わせは除く。）を用いる。 The polylactic acid composite fiber has steric crimps by being composed of two specific types of polylactic acid, and the two types of polylactic acid are composed of two types of polylactic acid having different melt flow rate values (however, , Except for combinations of two types of polylactic acids having different melting points) .
メルトフローレート値の異なるポリ乳酸としては、ＡＳＴＭ Ｄ−１２３８法に準じ、温度２１０℃、荷重２１６０ｇで測定したメルトフローレート値で２０〜５０ｇ／１０分差のあるものを用い、メルトフローレート値２０〜３０ｇ／１０分のポリ乳酸と、メルトフローレート値５０〜７０ｇ／１０分のポリ乳酸とで構成された複合繊維であって立体捲縮を有するものを用いる。メルトフローレート値がこの範囲にあると、強度や耐摩耗性に優れた繊維を生産性良く得ることができる。 Is a different polylactic acid of main belt flow rate value, according to ASTM D-1238 method, temperature 210 ° C., using what 20 to 50 g / 10 min difference melt flow rate value measured under a load 2160 g, the melt are use polylactic acid flow rate value 20 to 30 g / 10 min, a composite fiber composed of a melt flow rate value 50 to 70 g / 10 min polylactic acid having a three-dimensional crimps. When main belt flow rate value is within this range, it is possible to obtain a fiber excellent in strength and wear resistance with good productivity.
なお、本発明において用いる２種のポリ乳酸としては、結晶性の高いものを選択することが好ましい。すなわち、ポリ乳酸のホモポリマーであるポリ（Ｌ−乳酸）やポリ（Ｄ−乳酸）の融点は約１８０℃であり、Ｄ−乳酸とＬ−乳酸との共重合体の場合、いずれかの成分の割合を１０モル％程度とすると、融点はおよそ１３０℃となる。さらに、いずれかの成分の割合を１８モル％以上とすると、融点は１２０℃未満、融解熱は１０Ｊ／ｇ未満となって、ほぼ非晶性の性質となり、熱延伸が困難となって、高強度の繊維が得られ難くなるという問題が生じたり、耐熱性、耐摩耗性が低下することがある。なお、ポリ（Ｄ−乳酸）とポリ（Ｌ−乳酸）とのステレオコンプレックスは融点が２００〜２３０℃と高く、高温染色も可能となるので好ましい。 As the two polylactic acid used in the present invention, it is preferable to select a high crystal property. That is, poly (L-lactic acid) or poly (D-lactic acid), which is a homopolymer of polylactic acid, has a melting point of about 180 ° C., and any component in the case of a copolymer of D-lactic acid and L-lactic acid. When the ratio is about 10 mol%, the melting point is about 130 ° C. Furthermore, when the proportion of any of the components is 18 mol% or more, the melting point is less than 120 ° C., the heat of fusion is less than 10 J / g, which is almost non-crystalline, making heat stretching difficult, There is a problem that it becomes difficult to obtain a strong fiber, and heat resistance and wear resistance may be lowered. A stereocomplex of poly (D-lactic acid) and poly (L-lactic acid) is preferable because it has a high melting point of 200 to 230 ° C. and can be dyed at high temperature.
本発明に用いるポリ乳酸複合繊維を得るには、前記したメルトフローレート値の異なる２種類のポリ乳酸を適宜組み合せて、複合紡糸すればよい。 To obtain a polylactic acid composite fibers used in the present invention, two kinds of polylactic acid with different melt flow rate value the combined may be appropriately composite spinning.
本発明に用いるポリ乳酸複合繊維は、偏心芯鞘あるいはサイドバイサイドといった、メルトフローレート値の異なる２種類のポリ乳酸を偏心的に接合させた繊維である。このような複合形態とすることによって立体捲縮を有する嵩高性に優れたヘタリ難い繊維とすることができる。ここで、立体捲縮とは、２次元の機械捲縮とは異なる態様であって、いわゆる三次元的なコイルバネ状の捲縮のことである。また、このコイルバネ状の捲縮の一部に捩れが加わった形態であってもよい。この繊維の捲縮特性としては、ＪＩＳ Ｌ１０１５に規定の方法で測定した捲縮数が６〜２０個／２５ｍｍ、捲縮率が１０〜２５％であるのが望ましい。このような捲縮特性を有する複合繊維であると、後述する玉状綿の製造に際し、紐状になることなく、きれいな球形状の繊維集合体（玉状綿）を得ることができる。すなわち、捲縮数が６個／２５ｍｍ未満あるいは捲縮率が１０％未満であると、捲縮が大きく、得られる玉状綿がへたりやすい傾向となり、一方、捲縮数が２０個／２５ｍｍを超えるあるいは捲縮率が２５％を超えると、捲縮が微細になって繊維同士が絡みにくく、目的とする球形状の玉状綿を得にくい。 Polylactic acid composite fibers used in the present invention, such as eccentric core-sheath or side-by-side, there are two types of fibers eccentrically to join the polylactic acid with different melt flow rate value. By setting it as such a composite form, it can be set as the fiber which is excellent in the bulkiness which has a three-dimensional crimp, and is hardly sticky. Here, the three-dimensional crimp is a mode different from the two-dimensional mechanical crimp, and is a so-called three-dimensional coil spring-like crimp. Further, a form in which twist is added to a part of the coil spring-like crimp may be used. As the crimp characteristics of this fiber, it is desirable that the number of crimps measured by a method specified in JIS L1015 is 6 to 20 pieces / 25 mm, and the crimp rate is 10 to 25%. When the composite fiber has such crimp characteristics, a clean spherical fiber assembly (ball-shaped cotton) can be obtained without forming a string when the ball-shaped cotton described later is manufactured. That is, if the number of crimps is less than 6 pieces / 25 mm or the crimp rate is less than 10%, the crimps tend to be large and the obtained ball-shaped cotton tends to be loosened, while the number of crimps is 20 pieces / 25 mm. Or the crimp rate exceeds 25%, the crimps become fine and the fibers are less likely to get entangled, making it difficult to obtain the desired spherical ball-shaped cotton.
２種類のポリ乳酸の複合比率は紡糸の操業性考慮し、質量比率で２０／８０〜８０／２０とすることが好ましい。 The composite ratio of the two types of polylactic acid is preferably 20/80 to 80/20 in terms of mass ratio in consideration of spinning operability.
ポリ乳酸複合繊維の断面形状は、特に限定するものではなく丸断面のみでなく、楕円、菱形、Ｔ型、井型、三角あるいはそれ以上の多角形であっても、また外形がこれらのいずれかの断面であって、中空断面であってもよい。中空繊維の場合、特に嵩高性が良好なものが得られるので、より好ましい。 The cross-sectional shape of the polylactic acid composite fiber is not particularly limited, and is not limited to a round cross section, and may be an ellipse, a rhombus, a T-shape, a well-shape, a triangle, or a polygon more than that, and the outer shape is any of these The cross section may be a hollow cross section. In the case of a hollow fiber, a particularly good bulkiness is obtained, which is more preferable.
本発明に用いるポリ乳酸複合繊維の単糸繊度は特に限定されるものではないが、１〜１００デシテックスの範囲とする。単糸繊度が１デシテックスに満たない場合、繊維の生産効率が低く、コストの高いものとなる。一方、１００デシテックスを超えるような場合、通常の紡糸装置では冷却が困難であり、特殊な設備が必要となる。 Although the single yarn fineness of the polylactic acid composite fiber used for this invention is not specifically limited, It is set as the range of 1-100 decitex. When the single yarn fineness is less than 1 dtex, the fiber production efficiency is low and the cost is high. On the other hand, when it exceeds 100 dtex, it is difficult to cool with a normal spinning device, and special equipment is required.
さらに、本発明に用いるポリ乳酸複合繊維にシリコーン系油剤を付与しておくと、非常に良好な、きれいな真球に近い形状の玉状綿とすることができ、また、玉状綿同士がくっつきにくく、より独立したものとなるので好ましい。また、玉状綿の柔軟性も向上するため、柔軟でソフトなクッション体を得ることができる。このようなシリコーン系油剤としては、ジメチルポリシロキサン、ジフェニルポリシロキサン、メチルフェニルポリシロキサン、ポリエーテル変性シリコーンオイル、高級アルコキシ変性シリコーンオイル等が挙げられる。 Furthermore, by adding a silicone-based oil to the polylactic acid composite fiber used in the present invention, it is possible to obtain a ball shape cotton having a very good shape close to a true sphere, and the ball cottons stick to each other. This is preferable because it is difficult and more independent. Moreover, since the softness of ball-shaped cotton is also improved, a soft and soft cushion body can be obtained. Examples of such silicone oils include dimethylpolysiloxane, diphenylpolysiloxane, methylphenylpolysiloxane, polyether-modified silicone oil, and higher alkoxy-modified silicone oil.
本発明に用いるポリ乳酸複合繊維の製造方法について説明する。メルトフローレート値の異なる２種類のポリ乳酸を、通常の偏心芯鞘あるいはサイドバイサイド複合紡糸装置を用いて溶融紡糸し、延伸することなく一旦引き取り、未延伸糸を数十万〜二百万デシテックスのトウに集束する。これを熱延伸した後、リラックスさせ、コイルバネ状の立体捲縮を発現させる。また、前記リラックスさせて立体捲縮を発現させた複合繊維をさらに張力のかからない状態で熱セット（１００℃以上）してコイルバネ状の立体捲縮を発現、熱固定させる。その後、好ましくは１５〜７６ｍｍに、より好ましくは２０〜３８ｍｍにカットして短繊維とする。 The manufacturing method of the polylactic acid composite fiber used for this invention is demonstrated. Two kinds of polylactic acid with different main belt flow rate value, and melt-spun using a conventional eccentric core-sheath or side-by-side composite spinning apparatus, taking over once without stretching hundreds of thousands an undrawn yarn - two million dtex Focus on the tow. This is heat-stretched and then relaxed to develop a coil spring-like three-dimensional crimp. In addition, the composite fiber that has been relaxed to develop the three-dimensional crimp is further heat set (at 100 ° C. or higher) in a state where no tension is applied, so that a coil spring-shaped three-dimensional crimp is developed and heat-fixed. Then, it is preferably cut to 15 to 76 mm, more preferably 20 to 38 mm to obtain short fibers.
本発明の第２発明において、ポリ乳酸複合繊維に併用する吸水性繊維としては、木綿、絹、羊毛、レーヨン、溶剤紡糸セルロース繊維、ビニロン等の天然繊維、再生繊維や合成繊維等であって、公定水分率が５％以上程度の比較的水を吸いやすい繊維や、ポリアクリル酸系の高吸水性繊維と呼ばれるもので、自重の数十倍〜百倍以上の水分を吸収しうるものが挙げられる。ポリアクリル酸系の高吸水性繊維として、具体的には、「ランシール（東洋紡株式会社製 登録商標）」や「ベルオアシス（カネボウ株式会社製 登録商標）」等が挙げられる。 In the second invention of the present invention, the water-absorbing fiber used in combination with the polylactic acid composite fiber is natural fiber such as cotton, silk, wool, rayon, solvent-spun cellulose fiber, vinylon, recycled fiber, synthetic fiber, etc. A fiber that has an official moisture content of about 5% or more and is relatively easy to absorb water, or a polyacrylic acid-based superabsorbent fiber that can absorb water several tens to one hundred times more than its own weight. . Specific examples of the polyacrylic acid-based superabsorbent fibers include “Lanseer (registered trademark) manufactured by Toyobo Co., Ltd.” and “Bel Oasis (registered trademark manufactured by Kanebo Co., Ltd.)”.
これらの吸湿性繊維の中でも、溶剤紡糸セルロース繊維は環境問題に対応した素材であり、クッション材としての調湿性能が優れていることから、より好ましい。溶剤紡糸セルロース繊維について述べる。溶剤紡糸セルロース繊維とは主原料であるパルプを副原料のアミンオキサイド溶剤（閉鎖系で繰り返し使用されるため環境を汚染することがない）で物理的に溶解し、セルロース繊維を極力分断せずに繊維化する画期的な製法によって製造される。そのため、既存のセルロース系の繊維、例えばビスコース法で製造するレーヨン等に比べ乾湿強度が高く繊維収縮率が低い。また、ソフトで肌触りが良く、吸湿性や水拡散性に優れるという特徴を有する。 Among these hygroscopic fibers, solvent-spun cellulose fibers are more preferable because they are materials corresponding to environmental problems and have excellent humidity control performance as a cushioning material. The solvent-spun cellulose fiber will be described. Solvent-spun cellulose fiber is the main raw material pulp that is physically dissolved in the auxiliary raw material amine oxide solvent (which is used repeatedly in a closed system so as not to pollute the environment), and the cellulose fiber is not divided as much as possible. Manufactured by an epoch-making manufacturing method that turns into fiber. Therefore, compared with existing cellulosic fibers, for example, rayon produced by the viscose method, the wet and dry strength is high and the fiber shrinkage is low. In addition, it has the characteristics of being soft and soft to the touch, and excellent in hygroscopicity and water diffusibility.
ポリ乳酸繊維は、平衡水分率が０．５％程度と、殆ど吸水性がないため、汗をかいた場合の水分の吸水、拡散性に乏しいという欠点があるが、溶剤紡糸セルロース繊維等の吸水性繊維を併用することにより、この欠点を効果的に補うことができ、寝装具、クッション材として用いたときの使い心地が格段に良くなるのである。 Polylactic acid fiber has an equilibrium moisture content of about 0.5% and almost no water absorption. Therefore, polylactic acid fiber has the disadvantage of poor water absorption and diffusibility when sweated, but water absorption such as solvent-spun cellulose fiber. By using the synthetic fiber in combination, this drawback can be effectively compensated, and the comfort when used as a bedding or a cushioning material is remarkably improved.
溶剤紡糸セルロース繊維等の吸水性繊維の単糸繊度は、特に限定されるものではないが、一般的には１〜１５デシテックスのものが用いられる。 The single yarn fineness of water-absorbing fibers such as solvent-spun cellulose fibers is not particularly limited, but generally those having 1 to 15 dtex are used.
本発明の玉状綿の製造方法を説明する。まず、好ましくは１５〜７６ｍｍ、より好ましくは２０〜３８ｍｍにカットしたポリ乳酸複合繊維および必要に応じて吸水性繊維を、高速気流下で３０秒〜１０分間攪拌することにより、直径２〜２０ｍｍ程度の球形を呈する柔らかい玉状綿を得ることができる。 The manufacturing method of the ball-shaped cotton of this invention is demonstrated. First, the polylactic acid composite fiber cut into 15 to 76 mm, more preferably 20 to 38 mm, and more preferably, the water-absorbing fiber as needed, is stirred for 30 seconds to 10 minutes under a high-speed air current to have a diameter of about 2 to 20 mm. A soft ball-shaped cotton having a spherical shape can be obtained.
このようにして得られた玉状綿は、枕やクッション、かけ布団、寝袋といった形状に縫製された側地の中へ圧縮空気とともに吹き込むいわゆる吹き込み法によってスムースに入れることができる。 The ball-shaped cotton thus obtained can be smoothly put by a so-called blowing method in which it is blown together with compressed air into a side cloth sewn into a shape such as a pillow, a cushion, a comforter, or a sleeping bag.
また、低融点のポリ乳酸を鞘部、ポリ乳酸ホモポリマーあるいはポリ乳酸ステレオコンプレックスポリマーといった高融点のポリ乳酸を芯部に概ね同心状に配置した、いわゆるバインダー繊維を、全体の１０〜４０質量％程度混合して玉状綿とすることも可能である。この場合には、玉状綿をある型枠や側地の中に吹き込んだ後、バインダー繊維の鞘部のポリ乳酸の融点以上、主体となる立体捲縮を有するポリ乳酸複合繊維のそれぞれのポリマーの融点未満の温度で熱処理することにより、特定の形状に保型することもできる。なお、型枠内で加熱する場合、熱風を片側から吹き込み、もう一方から吸引する、いわゆるサクションタイプの熱処理機を用いるのが、加熱時間が少なくて済み、効率的である。また、型枠内で加熱してから所定の形状にホットプレスあるいはコールドプレスで成形加工してもよい。 Also, 10-40% by mass of a so-called binder fiber in which low melting point polylactic acid is arranged substantially concentrically in the sheath part, and high melting point polylactic acid such as polylactic acid homopolymer or polylactic acid stereocomplex polymer. It is also possible to make a ball-shaped cotton by mixing to some extent. In this case, each polymer of a polylactic acid composite fiber having a three-dimensional crimp that is the main component of the polylactic acid above the melting point of the polylactic acid in the sheath portion of the binder fiber after blowing ball-shaped cotton into a certain formwork or side surface. It is also possible to retain the mold in a specific shape by heat treatment at a temperature lower than the melting point. When heating in the mold, using a so-called suction type heat treatment machine in which hot air is blown from one side and sucked from the other side requires less heating time and is efficient. Further, after being heated in the mold, it may be formed into a predetermined shape by hot pressing or cold pressing.
以下、実施例によって本発明を詳しく説明するが、本発明はこれらによって限定されるものではない。なお、実施例に記述した諸物性の評価法は次のとおりである。
（１）ポリ乳酸のメルトフローレート値（ｇ／１０分）
ＡＳＴＭ Ｄ−１２３８法の記載の方法に準じて測定した。なお、測定条件は温度２１０℃、荷重２１６０ｇとした。
EXAMPLES Hereinafter, although an Example demonstrates this invention in detail, this invention is not limited by these. In addition, the evaluation methods of various physical properties described in the examples are as follows.
(1) Melt flow rate value of polylactic acid (g / 10 min)
The measurement was performed according to the method described in ASTM D-1238. The measurement conditions were a temperature of 210 ° C. and a load of 2160 g.
（２）融点（℃）および融解熱(Ｊ／ｇ)
パーキンエルマー社製の示差走査熱量計ＤＳＣ−２型を使用し、昇温速度２０℃／分の条件で測定した。
(2) Melting point (° C) and heat of fusion (J / g)
A differential scanning calorimeter DSC-2 manufactured by Perkin Elmer was used, and the measurement was performed under the condition of a heating rate of 20 ° C./min.
（３）短繊維の強伸度
ＪＩＳ Ｌ１０１５ 8.7.1標準時試験により、つかみ間隔２０ｍｍ、引張速度２０ｍｍ／分で測定した。
(3) High elongation of short fibers JIS L1015 was measured by a standard time test at a grip interval of 20 mm and a tensile speed of 20 mm / min.
（４）玉状綿の嵩高性
１０００ｃｍ3のメスシリンダーに玉状綿５ｇを少しづつ投入し、投入後、上下逆にひっくり返すことを５回繰り返す。その後、単位面積当たりの質量が０．５ｇ／ｃｍ2のメスシリンダー内壁に沿って水平状態でスムーズに移動できる押さえ板（メスシリンダーの内径とほぼ同形）を玉状綿の上に軽く載せて、玉状綿の占める容積を測定し、嵩高性（ｃｍ3／ｇ）を求める。
(4) Bulkiness of ball-shaped cotton 5 g of ball-shaped cotton is gradually added to a 1000 cm 3 graduated cylinder, and after the charging, it is turned upside down five times. Then, lightly place a pressing plate (almost the same shape as the inner diameter of the graduated cylinder) on the ball-shaped cotton that can move smoothly in a horizontal state along the inner wall of the graduated cylinder with a mass per unit area of 0.5 g / cm 2 . The volume occupied by the ball-shaped cotton is measured to determine bulkiness (cm 3 / g).
（５）玉状綿の圧縮弾性
玉状綿２０ｇを２０ｃｍ四方で厚さ２ｃｍに縫製したミニ布団側地に圧縮空気で吹き込んで、吹き込み口を縫製により閉じてミニ布団を作成した。これを用い、ＪＩＳ Ｋ６４０１に準じて５０％圧縮応力（当初の厚みに対して５０％の厚みになるのに要する力）を測定し圧縮弾性の尺度とした。
(5) Compression Elasticity of Ball-shaped Cotton 20 g of ball-shaped cotton was blown with compressed air into a mini-futon side fabric sewn 20 cm square to a thickness of 2 cm, and the blowing port was closed by sewing to create a mini-futon. Using this, 50% compressive stress (force required to reach 50% of the original thickness) was measured according to JIS K6401, and used as a measure of compression elasticity.
実施例１
融点１７０℃、融解熱３８Ｊ／ｇ、光学純度９８．５％（Ｌ体主体：ラクチドを原料として重合する時のＬ，Ｄ体の仕込み割合によりコントロールされる）で、メルトフローレート値（以後、ＭＦＲと略記する）が２３ｇ／１０分のポリ乳酸（以後、ＰＬＡ１と略記する）チップと、融点１７０℃、融解熱４５Ｊ／ｇ、光学純度９８．５％で、ＭＦＲが５８ｇ／１０分のポリ乳酸（以後、ＰＬＡ２と略記する）のチップとを減圧乾燥した後、紡糸温度２４０℃で通常の中空サイドバイサイド複合溶融紡糸装置を使用して、複合比（容量比）を１／１として複合溶融紡糸した。紡出糸条を冷却風で冷却した後、引取速度１０００ｍ／分で引き取って未延伸糸条を得た。得られた糸条を集束し、３３万ｄｔｅｘのトウにして、延伸倍率３．２倍で延伸し、リラックスしてコイルバネ状の立体捲縮を発現させた後、高級アルキル燐酸エステルＫ塩、エステル型ノニオン、エーテル型ノニオン混合の仕上げ油剤を０．２％付与した。その後１２０℃の乾燥機で熱処理して乾燥および捲縮の熱固定を行った後、長さ３２ｍｍに切断した。得られた短繊維は、単糸繊度６．６ｄｔｅｘ、強度３．３ｃＮ／ｄｔｅｘ、伸度６４％、捲縮数１０．５個／２５ｍｍ、捲縮率２１．４％であった。この短繊維を用いて渦巻き状の高速気流が流れている容器中、常温で５分間攪拌して、本発明の玉状綿を得た。得られた玉状綿の直径は平均５ｍｍであり、玉状の形状は良好で大きさもほぼ揃った均一なものであり、玉状綿の嵩高性は１６５ｃｍ3／ｇ、圧縮応力は６２．７２Ｎ／４００ｃｍ2であった。
Example 1
Melting point 170 ° C., heat of fusion 38 J / g, optical purity 98.5% (mainly L isomer: controlled by charge ratio of L and D isomers when polymerized using lactide as raw material) A polylactic acid (hereinafter abbreviated as PLA1) chip with a melting point of 170 ° C., a melting heat of 45 J / g, an optical purity of 98.5%, and an MFR of 58 g / 10 min. After drying a chip of lactic acid (hereinafter abbreviated as PLA2) under reduced pressure, a composite melt spinning with a composite ratio (volume ratio) of 1/1 at a spinning temperature of 240 ° C. using a normal hollow side-by-side composite melt spinning apparatus did. The spun yarn was cooled with cooling air and then taken at a take-up speed of 1000 m / min to obtain an undrawn yarn. The obtained yarn is converged, made into a tow of 330,000 dtex, drawn at a draw ratio of 3.2 times, relaxed to develop a coil spring-like three-dimensional crimp, and then a higher alkyl phosphate ester K salt, ester 0.2% of a finishing oil mixed with nonionic ether and nonionic ether was added. Thereafter, the mixture was heat-treated with a 120 ° C. dryer and heat-set for drying and crimping, and then cut to a length of 32 mm. The obtained short fibers had a single yarn fineness of 6.6 dtex, a strength of 3.3 cN / dtex, an elongation of 64%, a number of crimps of 10.5 pieces / 25 mm, and a crimp rate of 21.4%. Using the short fibers, a spiral cotton high-velocity airflowed container was stirred at room temperature for 5 minutes to obtain a ball-shaped cotton of the present invention. The obtained ball-shaped cotton has an average diameter of 5 mm, the ball-shaped shape is good and uniform in size, and the ball-shaped cotton has a bulkiness of 165 cm 3 / g and a compressive stress of 62.72 N. / 400 cm 2 .
参考迄に、玉状綿にする前の短繊維（サンプルローラーカードで開繊したカードウエブ）自体の嵩高性をＪＩＳ Ｌ１０９７の５．２比容積（かさ高性）に準じて測定すると、１２７ｃｍ3／ｇであった。 For reference, when the bulkiness of the short fiber (card web opened with a sample roller card) itself before being made into ball-shaped cotton is measured according to 5.2 specific volume (bulk height) of JIS L1097, it is 127 cm 3. / G.
また、同じカードウエブを用い、ＪＩＳ Ｋ６４０１に準じて５０％圧縮応力を測定すると圧縮応力は２６．４６Ｎ／４００ｃｍ2であり、いずれも玉状綿の値に比べて低いものであった。 Further, when 50% compressive stress was measured according to JIS K6401, using the same card web, the compressive stress was 26.46 N / 400 cm 2 , both of which were lower than the value of ball cotton.
参考例
ポリ乳酸複合繊維に替えて、ポリエチレンテレフタレートからなる中空サイドバイサイド型複合繊維（ユニチカファイバー社製＜Ｈ３８Ｆ＞ 単糸繊度６．６ｄｔｅｘ、繊維長３２ｍｍ、捲縮数９．７個／２５ｍｍ、捲縮率２２．３％）を用いたこと以外は、実施例１と同様にして玉状綿を得た。玉状綿の直径は平均５ｍｍであり、また、玉状綿の嵩高性は１６６ｃｍ3／ｇ、圧縮応力は４６．０６Ｎ／４００ｃｍ2であった。
Reference Example A hollow side-by-side type composite fiber made of polyethylene terephthalate instead of polylactic acid composite fiber (Unitika Fiber Co., Ltd. <H38F> single yarn fineness 6.6 dtex, fiber length 32 mm, crimped number 9.7 / 25 mm, crimped A ball-shaped cotton was obtained in the same manner as in Example 1 except that the rate was 22.3%. The diameter of the ball-shaped cotton was 5 mm on average, the bulkiness of the ball-shaped cotton was 166 cm 3 / g, and the compressive stress was 46.06 N / 400 cm 2 .
実施例１と参考例（ポリエチレンテレフタレート繊維からなる玉状綿）とを比較すると、繊維としては同様の形態（単糸繊度、繊維長、捲縮形態）を有するものの、ポリ乳酸繊維は、繊維間摩擦が高いためか、荷重をかけた時に玉状綿が潰れにくく、一定寸法の側地に一定質量の玉状綿を詰めてクッション体を得た場合、ポリ乳酸複合繊維からなる本発明の玉状綿からなるクッション体（実施例１）の方が、ポリエチレンテレフタレート玉状綿（参考例）からなるクッション体よりも圧縮応力が高く、底付き感のないものを得ることができた。 When Example 1 is compared with a reference example (ball-shaped cotton made of polyethylene terephthalate fiber), the fiber has the same form (single yarn fineness, fiber length, crimped form), but the polylactic acid fiber is interfiber The ball of the present invention made of polylactic acid composite fiber when the ball-shaped cotton is hard to be crushed when a load is applied or when a cushion body is obtained by packing ball-shaped cotton of a certain mass into a certain sized side fabric because of high friction. A cushion body made of cotton-like cotton (Example 1) had a higher compressive stress than a cushion body made of polyethylene terephthalate ball-like cotton (Reference Example), and a product without a feeling of bottoming could be obtained.
実施例２
実施例１において用いた仕上げ油剤に代えて、ポリエーテル変性シリコーンオイルおよびアミドタイプカチオン混合の仕上げ油剤を用いること以外は実施例１と同様にして実施した。
Example 2
Instead of the finishing oil used in Example 1, it was carried out in the same manner as in Example 1 except that a polyether-modified silicone oil and an amide type cation mixed finishing oil were used.
得られた玉状綿の直径は平均５ｍｍであり、玉状の形状は良好で大きさもほぼ揃った均一なものであった。玉状綿の風合いは滑らかで、いわゆるフェザータッチといえるものであった。また、玉状綿同士の滑り性が良好であり、吹き込みも極めてスムースに行うことができた。さらに、玉状綿の圧縮弾性の評価にて作成したミニ布団の内部の玉状綿を強制的に片側に片寄せた場合でも、ミニ布団を軽く叩くだけでもとの形状に回復した。 The diameter of the obtained ball-shaped cotton was an average of 5 mm, and the ball-shaped shape was uniform and almost uniform in size. The texture of the ball-shaped cotton was smooth and could be called a so-called feather touch. Further, the slipperiness between the ball cottons was good, and the blowing could be performed very smoothly. Furthermore, even when the ball-shaped cotton inside the mini-futon created by the evaluation of the compression elasticity of the ball-shaped cotton was forcibly moved to one side, it was restored to its original shape simply by tapping the mini-futon.
この玉状綿の嵩高性は１６６ｃｍ3／ｇ、圧縮応力は３５．２８Ｎ／４００ｃｍ2であった。 This bulky cotton had a bulkiness of 166 cm 3 / g and a compressive stress of 35.28 N / 400 cm 2 .
実施例３
実施例２で得られたシリコーン系油剤を付与したポリ乳酸複合繊維７０％に対し溶剤紡糸セルロース繊維であるレンチング社製「レンチングリヨセル」６．６ｄｔｅｘ、３０ｍｍ切断長の短繊維３０％を混合して用いて、渦巻き状の高速気流が流れている容器中、常温で５分間攪拌して、本発明の玉状綿を得た。得られた玉状綿の直径は平均５ｍｍであり、玉状の形状は良好で大きさもほぼ揃った均一なものであった。
Example 3
Mixing 70% polylactic acid composite fiber to which silicone-based oil obtained in Example 2 was applied with solvent-spun cellulose fiber “Lenting Lyyocell” 6.6 dtex, 30 mm short fiber 30% cut length. It was used and stirred for 5 minutes at room temperature in a container in which a spiral high-speed airflow was flowing to obtain the ball-shaped cotton of the present invention. The diameter of the obtained ball-shaped cotton was an average of 5 mm, and the ball-shaped shape was uniform and almost uniform in size.
この玉状綿の嵩高性は１３１ｃｍ3／ｇ、圧縮応力は３１．３６Ｎ／４００ｃｍ2であった。 This bulky cotton had a bulkiness of 131 cm 3 / g and a compressive stress of 31.36 N / 400 cm 2 .
比較例１
実施例１にて用いたＰＬＡ１を用いて通常の溶融紡糸を行い、ＰＬＡ１の単一成分からなる未延伸糸条を得た。得られた糸条を集束し、３３万ｄｔｅｘのトウにして、延伸倍率３．２倍で延伸し、１２０℃のヒートドラムで熱セットしてからクリンパーにて機械的に捲縮を付与した。その後、高級アルキル燐酸エステルＫ塩、エステル型ノニオン、エーテル型ノニオン混合の仕上げ油剤を０．２％付与した後、長さ３２ｍｍに切断した。得られた短繊維は、単糸繊度６．８ｄｔｅｘ、強度３．６ｃＮ／ｄｔｅｘ、伸度６７％、捲縮数９．３個／２５ｍｍ、捲縮率８．７％であった。この短繊維を用いて渦巻き状の高速気流が流れている容器中、常温で５分間攪拌したが、得られた製品は紐状に繊維が集合したような形状で、本発明が目的とする玉状にはならず、吹き込みの試験は行わなかった。
Comparative Example 1
Ordinary melt spinning was performed using PLA 1 used in Example 1 to obtain an undrawn yarn composed of a single component of PLA 1. The obtained yarns were converged to form a tow of 330,000 dtex, drawn at a draw ratio of 3.2 times, heat set with a 120 ° C. heat drum, and mechanically crimped with a crimper. Thereafter, 0.2% of finishing oil mixed with higher alkyl phosphate ester K salt, ester type nonion and ether type nonion was applied, and then cut to a length of 32 mm. The obtained short fiber had a single yarn fineness of 6.8 dtex, a strength of 3.6 cN / dtex, an elongation of 67%, a number of crimps of 9.3 pieces / 25 mm, and a crimp rate of 8.7%. The short fiber was stirred for 5 minutes at room temperature in a container in which a spiral high-speed airflow was flowing, but the resulting product was shaped like a string of fibers gathered, and the ball intended by the present invention. No blow test was performed.
Claims (5)
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| JP6053289B2 (en) * | 2012-01-26 | 2016-12-27 | ユニチカ株式会社 | Polylactic acid long fiber nonwoven fabric |
| JP6158631B2 (en) * | 2013-08-01 | 2017-07-05 | ユニチカ株式会社 | tape |
| JP6492584B2 (en) * | 2014-11-28 | 2019-04-03 | 東レ株式会社 | Short fiber assembly |
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