Artificial feather composite structures and related products

Abstract

This invention provides an artificial feather composite structure comprising a base layer and an artificial feather layer. [Solution] Calculated by the total weight of the artificial down composite structure, the weight of the base layer is 9% to 27% by weight, and the weight of the artificial down layer is 73% to 91% by weight. The base layer and the artificial down layer each contain core-sheath fibers, ultrafine fibers, and three-dimensional curl fibers. The base layer is formed by the intersecting and lamination of the above fibers, and has a density of 14 gsm to 40 gsm. The artificial down layer is located on the base layer, and the above fibers are randomly laminated, with a density of 30 gsm to 400 gsm. The fineness of the ultrafine fibers is 0.1D to 1.5D. The hollowness of the three-dimensional curl fibers is 5% to 30%, and the curl ratio is 2% to 25%. The compression recovery rate of the artificial down composite structure of the present invention is 90% or more. The present invention also provides clothing and supplies made from the above artificial down composite structure.

Description

Technical Field

[0001] The present invention relates to an artificial feather composite structure. The present invention also relates to clothing and supplies made using the above artificial feather composite structure, such as footwear, bedding, sleeping bags, bedding mats, clothing accessories, and the like.

Background Art

[0002] Due to the need for heat preservation, currently, many products made of fabrics filled with batting, such as clothing, futons, etc., are already commercially available. Conventional fabrics filled with batting involve cutting the outer fabric and the inner fabric along a pattern paper, and then sewing a plurality of batting compartments along the pattern paper for each cut piece, stuffing feathers or other fiber materials into the batting compartments, and finally sewing together the cut pieces filled with feathers or fibers as a finished product. Whether it is feathers or fibers, it is necessary to fix the feathers or fibers with these batting compartments. Moreover, when stuffing the batting, it must be stuffed compartment by compartment, and the processing procedure becomes quite complicated.

[0003] Also, in the case of conventional fabrics filled with batting during use, the feathers or fibers stuffed inside may come into contact with moisture in the external environment or moisture emitted from the user's body. In addition, this type of fabric filled with batting is often washed, and the feathers or fibers come into direct contact with water. Whether during use, in the air, in contact with moisture emitted by the human body, or directly washed with water, the feathers or fibers in the batting compartments stick together due to moisture or water, and ultimately shift in position or deform, resulting in a deterioration of the feel, appearance, and heat preservation effect of the fabric filled with batting. Also, the cut pieces of the conventional fabric filled with batting itself require sewing, and since needle holes remain in the fabric, the feathers or fibers stuffed inside also pop out from the gaps between the fibers of the fabric and the needle holes in the sewing (this phenomenon is called cotton leakage), and after long-term use, the content of feathers or fibers in the batting compartments may also decrease.

[0004] To improve upon the shortcomings of conventional padded fabrics, artificial down fiber products are already commercially available. These products have excellent compression recovery and a soft feel, but the need to stuff them into designated areas limits garment design. Furthermore, after washing, the fibers of these products tend to tangle. Currently, padded fabrics made of multiple layers of nonwoven fabric made of insulating fibers are also commercially available. This fabric is a sheet-like material, convenient for cutting and tailoring, has good washability, and is less prone to tangling. However, the fibers in this type of padded fabric are combed into a web-like structure and then layered in a crisscross pattern, and the position of the interlocking points of the surface fibers is fixed with resin to prevent feather shedding, resulting in a less-than-ideal compression recovery rate.

[0005] Therefore, there is currently a need for a sheet-type heat-insulating material that is soft to the touch, does not require cotton stuffing, is resistant to washing, and simultaneously has a good compression recovery rate. [Prior art documents] [Patent Documents]

[0006] [Patent Document 1] Chinese Patent Application Publication No. 115652531 (Published 2023 / 01 / 31) [Patent Document 2] Chinese Patent Application Publication No. 1899814 (Published 2007 / 01 / 24) [Overview of the project] [Problems that the invention aims to solve]

[0007] In view of the shortcomings of the prior art described above, one objective of the present invention is to provide an artificial down composite structure that is a sheet-like material (can be manufactured as a roll material), does not require stuffing with cotton, has excellent heat retention, is resistant to washing, has a low degree of cotton shedding, does not require fixing the position of the interlocking points of the surface fibers with resin to prevent cotton shedding, and has an excellent compression recovery rate.

[0008] Another object of the present invention is to provide clothing and supplies made using the artificial feather composite structure of the present invention, such as footwear, bedding, sleeping bags, bedding mats, clothing accessories, etc. [Means for solving the problem]

[0009] To achieve the above objective, the present invention provides an artificial feather composite structure. Based on the total weight of the above artificial feather composite structure, the weight is calculated to be 9% to 27% by weight, containing 30% to 60% by weight of first core-sheath fibers, 10% to 50% by weight of first ultrafine fibers, and 20% to 30% by weight of first three-dimensional curl fibers. The first core-sheath fibers, first ultrafine fibers, and first three-dimensional curl fibers are mixed and then cross-laminated, and the density is 14 gsm (grams per square meter, g / m²). 2 (This may also be the case) A base layer of ~40 gsm, The artificial feather layer is placed on top of the above-mentioned base layer, and its weight, calculated by the total weight of the above-mentioned artificial feather composite structure, is 73% to 91% by weight, and it contains 10% to 30% by weight of second core-sheath fibers, 30% to 70% by weight of second ultrafine fibers, and 20% to 40% by weight of second three-dimensional curl fibers, and the above-mentioned second core-sheath fibers, second ultrafine fibers, and second three-dimensional curl fibers are mixed and then randomly laminated, and the density is 30 gsm to 400 gsm. Each of the above-mentioned first core-sheath fiber and second core-sheath fiber comprises a core and a sheath, the sheath covering part or all of the outside of the core, the core material being an unused or recycled first polymer material, the sheath material being an unused or recycled second polymer material, the melting point of the second polymer material being lower than the melting point of the first polymer material, and the melting point range of the second polymer material being 100°C to 200°C. The fineness of the first and second ultrafine fibers mentioned above is 0.1D to 1.5D, respectively. The hollow ratios of the first and second three-dimensional curled fibers are 5% to 30%, respectively, and The curl rates of the first and second three-dimensional curl fibers described above are 2% to 25%, respectively.

[0010] In some specific examples, calculated using the total weight of the artificial feather composite structure, the weight of the base layer is 9% by weight and the weight of the artificial feather layer is 91% by weight. In some specific examples, calculated using the total weight of the artificial feather composite structure, the weight of the base layer is 10% by weight and the weight of the artificial feather layer is 90% by weight. In some specific examples, calculated using the total weight of the artificial feather composite structure, the weight of the base layer is 13% by weight and the weight of the artificial feather layer is 87% by weight. In some specific examples, calculated using the total weight of the artificial feather composite structure, the weight of the base layer is 15% by weight and the weight of the artificial feather layer is 85% by weight. In some specific examples, calculated using the total weight of the artificial feather composite structure, the weight of the base layer is 20% by weight and the weight of the artificial feather layer is 80% by weight. In some specific examples, calculated using the total weight of the artificial feather composite structure, the weight of the base layer is 25% by weight and the weight of the artificial feather layer is 75% by weight. In some specific examples, calculated using the total weight of the artificial feather composite structure, the weight of the base layer is 26% by weight and the weight of the artificial feather layer is 74% by weight. In some specific examples, calculated using the total weight of the artificial feather composite structure, the weight of the base layer is 27% by weight and the weight of the artificial feather layer is 73% by weight.

[0011] In some specific examples, the thickness of the base layer is approximately 0.2 cm to 0.3 cm, or approximately 0.25 cm to 0.3 cm. In some specific examples, the thickness of the artificial feather layer is approximately 2.0 cm to 6.0 cm, or approximately 3.0 cm to 5.0 cm, or approximately 4.0 cm to 5.0 cm.

[0012] In some specific embodiments, the ratio of the thickness of the base layer to the thickness of the artificial feather layer is 1:6 to 1:30. In some specific embodiments, the ratio of the thickness of the base layer to the thickness of the artificial feather layer is 1:10 to 1:25, or 1:15 to 1:20.

[0013] In some specific examples, the density of the above-mentioned subsoil is 14gsm to 40gsm, or 15gsm to 35gsm, or 20gsm to 30gsm, or 20gsm to 25gsm.

[0014] In some specific embodiments, the artificial down layer includes the second core-sheath fiber, the second ultrafine fiber, the second three-dimensional curl fiber, and air. In the present invention, the three types of fibers are laminated without being densely packed, and a certain proportion of air is maintained in between to enhance the heat retention effect. In some specific embodiments, the density of the artificial down layer is 30gsm to 400gsm, or 50gsm to 350gsm, or 100gsm to 300gsm, or 150gsm to 200gsm.

[0015] In some specific embodiments, the above-mentioned base layer contains 30% to 60% by weight of first core-sheath fibers, 20% to 40% by weight of first ultrafine fibers, and 20% to 30% by weight of first three-dimensional curl fibers.

[0016] In some specific embodiments, the artificial feather layer contains 10% to 30% by weight of second core sheath fibers, 40% to 60% by weight of second ultrafine fibers, and 20% to 40% by weight of second three-dimensional curl fibers.

[0017] In some specific embodiments, the core portion accounts for 40% to 80% of the total weight of the first core-sheath fiber, and the sheath portion accounts for 60% to 20% of the total weight. In some specific embodiments, the core portion accounts for 40% to 70% of the total weight of the first core-sheath fiber, and the sheath portion accounts for 60% to 30% of the total weight. In some specific embodiments, the core portion accounts for 40% to 60% of the total weight of the first core-sheath fiber, and the sheath portion accounts for 60% to 40% of the total weight. In some specific embodiments, the core portion accounts for 45% to 55% of the total weight of the first core-sheath fiber, and the sheath portion accounts for 55% to 45% of the total weight. In some specific embodiments, the core portion accounts for 48% to 52% of the total weight of the first core-sheath fiber, and the sheath portion accounts for 52% to 48% of the total weight. In some specific embodiments, the core portion accounts for 50% by weight and the sheath portion accounts for 50% by weight of the total weight of the first core-sheath fiber.

[0018] In some specific embodiments, the core portion accounts for 40% to 80% by weight and the sheath portion accounts for 60% to 20% by weight of the total weight of the second core-sheath fiber. In some specific embodiments, the core portion accounts for 40% to 70% by weight and the sheath portion accounts for 60% to 30% by weight of the total weight of the second core-sheath fiber. In some specific embodiments, the core portion accounts for 40% to 60% by weight and the sheath portion accounts for 60% to 40% by weight of the total weight of the second core-sheath fiber. In some specific embodiments, the core portion accounts for 45% to 55% by weight and the sheath portion accounts for 55% to 45% by weight of the total weight of the second core-sheath fiber. In some specific embodiments, the core portion accounts for 48% to 52% by weight and the sheath portion accounts for 52% to 48% by weight of the total weight of the second core-sheath fiber. In some specific embodiments, the core portion accounts for 50% by weight and the sheath portion accounts for 50% by weight of the total weight of the second core-sheath fiber.

[0019] In some specific examples, the first polymer material and the second polymer material are each selected from the group consisting of polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), polyethylene terephthalate copolymer (PET copolymer, coPET), or other similar polymers. In some specific examples, the combination of the first polymer material and the second polymer material is expressed in the form of first polymer material / second polymer material (i.e., core / sheath) and is selected from the group consisting of polyethylene terephthalate / polyethylene (PET / PE), polyethylene terephthalate / polyethylene terephthalate copolymer (PET / coPET), and polypropylene / polyethylene (PP / PE). In some specific examples, the polyethylene terephthalate copolymer is a copolymer polyester of PET and a dicarboxylic acid, and the dicarboxylic acid can be selected from aliphatic dicarboxylic acids and aromatic dicarboxylic acids, of which the aliphatic dicarboxylic acid can be oxalic acid, malonic acid, succinic acid, adipic acid, etc., and the aromatic dicarboxylic acid can be isophthalic acid, sulfoisophthalic acid, etc.

[0020] In some specific embodiments, the melting point of the second polymer material is lower than that of the first polymer material, and the melting point range of the second polymer material is 100°C to 200°C, or 120°C to 180°C, or 140°C to 160°C, or 140°C to 150°C.

[0021] In the present specification, the term "unused" means that this material has not been previously manufactured as any product and is a raw material. In the present specification, the term "reuse" means that this material is a waste of an industrially produced product or a material obtained through resource recycling and is not a raw material. Taking the most common reused polyester material as an example, currently, the main sources of recycled polyester materials that can produce fibers include two types: pre-consumer and post-consumer polyester textiles and post-use PET bottles. However, this type of polyester material is reborn as an environmentally friendly recycled fiber material by physical or chemical methods after collection. In the present specification, the two terms "reuse" and "recycle" can be used interchangeably.

[0022] In some specific embodiments, the recycled component content included in the artificial feather composite structure of the present invention is 20% or more (≧20%) and meets the GRS certification standards. In some specific embodiments, the recycled component content included in the artificial feather composite structure of the present application is 30% or more (≧30%), or 35% or more (≧35%).

[0023] In some specific embodiments, the fineness of the above first core-sheath fiber is 1.5 denier (Denier, D) to 15D, or 1.5D to 10D, or 2D to 5D, or 2D to 4D, or 2D to 3D. In some specific embodiments, the fineness of the above second core-sheath fiber is 1.5 denier (Denier, D) to 15D, or 1.5D to 10D, or 2D to 5D, or 2D to 4D, or 2D to 3D.

[0024] In some specific embodiments, the first core-sheath fiber has a circular or trefoil-shaped cross-section. When the cross-section is circular, the core of the cross-section is located at the center or on one side of the circular cross-section, and the sheath covers the entire outside of the core. When the cross-section is trefoil-shaped, the sheath covers a portion of the outside of the core. In some specific embodiments, the cross-section of the first core-sheath fiber is trefoil-shaped, and the sheath is located at the end of each leaf in the trefoil-shaped cross-section.

[0025] In some specific embodiments, the second core sheath fiber has a circular or trefoil-shaped cross-section. When the cross-section is circular, the core of the cross-section is located at the center or on one side of the circular cross-section, and the sheath covers the entire outside of the core. When the cross-section is trefoil-shaped, the sheath covers a portion of the outside of the core. In some specific embodiments, the cross-section of the second core sheath fiber is trefoil-shaped, and the sheath is located at the end of each leaf in the trefoil-shaped cross-section.

[0026] In some specific embodiments, the first core-sheath fiber is a two-dimensional sawtooth fiber. In some specific embodiments, the second core-sheath fiber is a two-dimensional sawtooth fiber.

[0027] In some specific embodiments, the first core-sheath fiber and the second core-sheath fiber are the same fiber. In some specific embodiments, the first core-sheath fiber and the second core-sheath fiber are different fibers.

[0028] In some specific examples, the material of the first ultrafine fiber is an unused or recycled third polymer material, and the third polymer material is a polymer selected from the group consisting of polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), polybutylene terephthalate (PBT), polyamide (PA: also called nylon), and combinations thereof. In some specific examples, the material of the second ultrafine fiber is an unused or recycled third polymer material, and the third polymer material is a polymer selected from the group consisting of polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), polybutylene terephthalate (PBT), polyamide (PA), and combinations thereof.

[0029] In some specific embodiments, the fineness of the first ultrafine fiber is 0.1D to 1.5D, or 0.5D to 1.5D, or 0.7D to 1.5D, or 0.9D to 1.5D, or 0.9D to 1.4D, or 1.0D to 1.4D. In some specific embodiments, the fineness of the second ultrafine fiber is 0.1D to 1.5D, or 0.5D to 1.5D, or 0.7D to 1.5D, or 0.9D to 1.5D, or 0.9D to 1.4D, or 1.0D to 1.4D.

[0030] In some specific embodiments, the first ultrafine fiber is a solid fiber or a hollow fiber. In some specific embodiments, the second ultrafine fiber is a solid fiber or a hollow fiber.

[0031] In some specific embodiments, the first ultrafine fiber is a hollow fiber, and its hollowness is 3% to 25%, or 5% to 20%, or 10% to 20%. In some specific embodiments, the second ultrafine fiber is a hollow fiber, and its hollowness is 3% to 25%, or 5% to 20%, or 10% to 20%.

[0032] In some specific embodiments, the first ultrafine fiber is a two-dimensional sawtooth fiber. In some specific embodiments, the second ultrafine fiber is a two-dimensional sawtooth fiber.

[0033] In some specific examples, the three-dimensional curled fiber is a two-component fiber.

[0034] In some specific embodiments, the first three-dimensional curled fiber is a parallel two-component fiber, and the parallel two-component fiber includes a first side and a second side that are parallel to each other, the material of the first side being an unused or recycled fourth polymer material, and the material of the second side being an unused or recycled fifth polymer material, the fourth polymer material and the fifth polymer material being selected from the group consisting of polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), polyethylene terephthalate copolymer (coPET), polybutylene terephthalate (PBT), polyamide (PA), and other similar polymers.

[0035] In some specific embodiments, the second stereocurl fiber is a parallel two-component fiber, and the parallel two-component fiber includes a first side and a second side that are parallel to each other, the material of the first side is an unused or recycled fourth polymer material, and the material of the second side is an unused or recycled fifth polymer material, the fourth polymer material and the fifth polymer material are each selected from the group consisting of polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), polyethylene terephthalate copolymer (coPET), polybutylene terephthalate (PBT), polyamide (PA), and other similar polymers.

[0036] In some specific examples, the fourth polymer material and the fifth polymer material are each selected from the group consisting of polyethylene (PE), polypropylene, polyethylene terephthalate, polyethylene terephthalate copolymer (PET copolymer, coPET), or other similar polymers. In some specific examples, the combination of the fourth polymer material and the fifth polymer material is expressed in the form of fourth polymer material / fifth polymer material (i.e., first side / second side) and is selected from the group consisting of polyethylene / polyethylene terephthalate (PE / PET), polyethylene terephthalate / polyethylene terephthalate copolymer (PET / coPET), polyethylene / polypropylene (PE / PP), and polyethylene terephthalate / polyethylene terephthalate (PET / PET). In some specific examples, the polyethylene terephthalate copolymer is a copolymer polyester of PET and a dicarboxylic acid, and the dicarboxylic acid can be selected from aliphatic dicarboxylic acids and aromatic dicarboxylic acids, of which the aliphatic dicarboxylic acid can be oxalic acid, malonic acid, succinic acid, adipic acid, etc., and the aromatic dicarboxylic acid can be isophthalic acid, sulfoisophthalic acid, etc.

[0037] In some specific examples, the combination of the fourth polymer material and the fifth polymer material is expressed in the form of fourth polymer material / fifth polymer material, which is first polyethylene terephthalate / second polyethylene terephthalate (PET / PET), and of these, the first polyethylene terephthalate and the second polyethylene terephthalate have different intrinsic viscosities (inherent viscosity, IV). When the difference in intrinsic viscosity (ΔIV) between the first polyethylene terephthalate and the second polyethylene terephthalate is 0.15 dL / g or more, good steric crimpability is obtained, but preferably ΔIV is 0.25 dL / g or more. If ΔIV is lower than 0.15 dL / g, the degree of curl becomes too low, and sufficient steric crimpability cannot be obtained.

[0038] In some specific embodiments, the first three-dimensional curl fiber is a solid fiber or a hollow fiber. In some specific embodiments, the first three-dimensional curl fiber is a solid fiber with a circular or peanut-shaped cross-section. When the cross-section is circular, the first and second sides of the cross-section are opposite semicircles. When the cross-section is peanut-shaped, the first and second sides of the cross-section touch in the middle of the cross-section and protrude to both sides. In some specific embodiments, the first three-dimensional curl fiber is a hollow fiber with a circular cross-section and a hollow portion in the cross-section. When the hollow portion is in the center of the circular cross-section, the first and second sides have a C-shape that is approximately the same shape. When the hollow portion is on one side of the circular cross-section, the first and second sides have a C-shape that is different in shape.

[0039] In some specific embodiments, the second three-dimensional curl fiber is a solid fiber or a hollow fiber. In some specific embodiments, the second three-dimensional curl fiber is a solid fiber with a circular or peanut-shaped cross-section. When the cross-section is circular, the first and second sides of the cross-section are opposite semicircles. When the cross-section is peanut-shaped, the first and second sides of the cross-section touch in the middle of the cross-section and each protrudes to both sides. In some specific embodiments, the second three-dimensional curl fiber is a hollow fiber with a circular cross-section and a hollow portion in the cross-section. When the hollow portion is in the center of the circular cross-section, the first and second sides have a C-shape that is approximately the same shape. When the hollow portion is on one side of the circular cross-section, the first and second sides have a C-shape with a different shape.

[0040] In some specific embodiments, the diameter of the hollow portion of the cross-section is smaller than the circular shape of the cross-section. In some specific embodiments, the hollow portion is circular.

[0041] In some specific embodiments, the fineness of the first three-dimensional curl fiber is 1D to 15D, or 5D to 12D, or 7D to 10D. In some specific embodiments, the fineness of the second three-dimensional curl fiber is 1D to 15D, or 5D to 12D, or 7D to 10D.

[0042] In some specific examples, the hollowness of the first three-dimensional curl fiber is 5% to 30%, or 10% to 25%, or 15% to 20%, and in some specific examples, the hollowness of the second three-dimensional curl fiber is 5% to 30%, or 10% to 25%, or 15% to 20%.

[0043] In some specific embodiments, the curl rate of the first three-dimensional curl fiber is 2% to 25%, or 5% to 20%, or 7% to 15%, or 7% to 10%. In some specific embodiments, the curl rate of the second three-dimensional curl fiber is 2% to 25%, or 5% to 20%, or 7% to 15%, or 7% to 10%.

[0044] In the present invention, the base layer is formed by mixing the first core-sheath fiber (having a sheath portion made of a second polymer material with a relatively low melting point), the first ultrafine fiber, and the first three-dimensional curl fiber, and then cross-laminating them to form the base layer roll material. Subsequently, the roll material of the base layer is conveyed from the first conveyor belt to below the cotton dropping device, and at the same time, the second core-sheath fibers (having a sheath portion made of a second polymer material with a relatively low melting point), the second ultrafine fibers, and the second three-dimensional curl fibers are mixed and then randomly and irregularly laminated as a temporary artificial feather layer. After the temporary artificial feather layer is placed on top of the base layer, the base layer on which the temporary artificial feather layer is laminated is sent to a heating device and heated to a temperature of 125°C or higher to melt the sheath portions (made of a second polymer material with a relatively low melting point) of the first and second core-sheath fibers in the base layer and the temporary artificial feather layer, bonding them with adjacent fibers and shaping them. After cooling to room temperature, the artificial feather layer, i.e., the artificial feather composite structure of the present invention, is formed from the temporary artificial feather layer, and it can be directly wound as a roll material of the artificial feather composite structure. The first and second core-sheath fibers reinforce the cross-linking structure with the other fibers (the first and second ultrafine fibers and the first and second three-dimensional curled fibers) and maintain the structure of the base layer and the artificial down layer. The first and second core-sheath fibers are each a part of the base layer and the artificial down layer, and even after the sheath portion melts, the core portion still retains a certain level of support performance. Therefore, the melt bonding process does not excessively affect the degree of expansion of the base layer and the artificial down layer.

[0045] In some specific embodiments, the first core-sheath fiber, the first ultrafine fiber, and the first three-dimensional curl fiber are uniformly mixed.

[0046] In some specific embodiments, the second core sheath fiber, the second ultrafine fiber, and the second three-dimensional curl fiber are uniformly mixed.

[0047] In several specific embodiments, the second core sheath fiber, the second ultrafine fiber, and the second three-dimensional curl fiber are mixed and then randomly and irregularly stacked, and the artificial feather temporary fabrication layer is formed by negative pressure suction of a negative pressure device.

[0048] In several specific embodiments, the artificial feather composite structure of the present invention can maintain a certain shape without requiring a separate fixing layer (for example, by spraying resin onto the artificial feather layer to form a fixing layer).

[0049] In some specific embodiments, the first core-sheath fibers of the base layer can be bonded to adjacent first and second core-sheath fibers, first and second ultrafine fibers, and first and second three-dimensional curl fibers by forming multiple binding points through their sheath portion. In some specific embodiments, the second core-sheath fibers of the artificial feather layer can be bonded to adjacent first and second core-sheath fibers, first and second ultrafine fibers, and first and second three-dimensional curl fibers by forming multiple binding points through their sheath portion.

[0050] In some specific embodiments, the compression recovery rate of the artificial feather composite structure of the present invention exceeds 90%, or exceeds 91%, or exceeds 92%, or exceeds 93%, or exceeds 94%, or exceeds 95%.

[0051] In some specific examples, the garments made using the artificial feather composite structure of the present invention include, but are not limited to, jackets, pants, skirts, vests, coats, etc.

[0052] In some specific embodiments, products made using the artificial feather composite structure of the present invention include, but are not limited to, footwear, bedding, sleeping bags, bedding mats, clothing accessories, etc. [Brief explanation of the drawing]

[0053] [Figure 1] This is a three-dimensional schematic diagram of the artificial feather composite structure of the present invention. [Figure 2A]This is a schematic diagram of the core-sheath fiber of the present invention. [Figure 2B] This is a schematic diagram of the ultrafine fibers of the present invention. [Figure 2C] This is a schematic diagram of the three-dimensional curled fiber of the present invention. [Figure 3A] This is a schematic cross-sectional view of the core-sheath fiber of the present invention. [Figure 3B] This is a schematic cross-sectional view of the core-sheath fiber of the present invention. [Figure 3C] This is a schematic cross-sectional view of the core-sheath fiber of the present invention. [Figure 3D] This is a schematic cross-sectional view of the three-dimensional curled fiber of the present invention. [Figure 3E] This is a schematic cross-sectional view of the three-dimensional curled fiber of the present invention. [Figure 3F] This is a schematic cross-sectional view of the three-dimensional curled fiber of the present invention. [Figure 3G] This is a schematic cross-sectional view of the three-dimensional curled fiber of the present invention. [Figure 4] This is a schematic diagram of the manufacturing process for the artificial feather composite structure of the present invention. [Figure 5A] This is a photograph of the multi-layered structure of a currently available padded fabric. [Figure 5B] This is a photograph of the artificial feather composite structure of the present invention. [Modes for carrying out the invention]

[0054] The objectives, advantages, and technical features of the present invention should become clear through the following detailed description of embodiments and accompanying drawings.

[0055] Preparation of the artificial feather composite structure of the present invention

[0056] As shown in Figures 1 and 2A-2C, the artificial feather composite structure 1 of the present invention includes a base layer 10 and an artificial feather layer 11 located on top of the base layer 10. Calculated from the total weight of the artificial feather composite structure 1, the weight of the base layer 10 is 9% to 27% by weight. The base layer 10 contains 30% to 60% by weight of first core-sheath fibers 20, 10% to 50% by weight of first ultrafine fibers 21, and 20% to 30% by weight of first three-dimensional curl fibers 22. After mixing, the first core-sheath fibers 20, first ultrafine fibers 21, and first three-dimensional curl fibers 22 are cross-laminated to form the base layer 10 (not shown). The density of the base layer 10 is 14 gsm to 40 gsm. Calculated from the total weight of the artificial feather composite structure 1, the weight of the artificial feather layer 11 is 73% to 91% by weight. The artificial down layer 11 contains 10% to 30% by weight of second core-sheath fibers 20, 30% to 70% by weight of second ultrafine fibers 21, and 20% to 40% by weight of second three-dimensional curl fibers 22. After mixing, the second core-sheath fibers 20, second ultrafine fibers 21, and second three-dimensional curl fibers 22 are randomly layered to form the artificial down layer 11, and the density of the artificial down layer 11 is 30 gsm to 400 gsm. In Figure 1, when a portion of the artificial down layer 11 is magnified, it can be seen that the fibers have a fluffy, cloud-like appearance after layering. The first and second core-sheath fibers 20 (shown in Figure 2A) and the first and second ultrafine fibers 21 (shown in Figure 2B) are two-dimensional sawtooth fibers, while the first and second three-dimensional curl fibers 22 (shown in Figure 2C) are three-dimensional curl fibers. The second core sheath fibers 20, second ultrafine fibers 21, and second three-dimensional curl fibers 22 of the artificial feather layer 11 are layered without being densely packed, and a certain percentage of air is maintained in between (not shown).

[0057] Of these, the first core-sheath fiber 20 and the second core-sheath fiber 20 each include a core portion 200 and a sheath portion 201, with the sheath portion 201 covering part or all of the outside of the core portion 200. The material of the core portion 200 is an unused or recycled first polymer material, and the material of the sheath portion 201 is an unused or recycled second polymer material, the melting point of the second polymer material being lower than the melting point of the first polymer material, and the melting point range of the second polymer material being 100°C to 200°C. The first polymer material and the second polymer material are each selected from the group consisting of polyethylene, polypropylene, polyethylene terephthalate, polyethylene terephthalate copolymer, and other similar polymers.

[0058] Of the total weight of the first core-sheath fiber 20, the core portion 200 accounts for 50% by weight, and the sheath portion 201 accounts for 50% by weight. Of the total weight of the second core-sheath fiber 20, the core portion 200 accounts for 50% by weight, and the sheath portion 201 accounts for 50% by weight. The cross-sections of the first core-sheath fiber 20 and the second core-sheath fiber 20 can each include one or more shapes. For example, the first core-sheath fiber 20 and the second core-sheath fiber 20 can each have a circular or trefoil-shaped cross-section. When the cross-section is circular, the core portion 200 is located at the center (shown in Figure 3A) or on one side (shown in Figure 3B) of the circular cross-section, and the sheath portion 201 covers the entire outside of the core portion 200. When the cross-section is three-leaf shaped, the sheath portion 201 covers a part of the outside of the core portion 200, and the sheath portion 201 is located at the end of each leaf in the three-leaf cross-section (shown in Figure 3C).

[0059] Of these, the material for the first ultrafine fiber 21 and the material for the second ultrafine fiber 21 are each unused or recycled third polymer materials, and the third polymer material is selected from the group consisting of polyethylene, polypropylene, polyethylene terephthalate, polytrimethylene terephthalate, polybutylene terephthalate, polyamide, and combinations thereof.

[0060] Of these, the fineness of the first ultrafine fiber 21 and the second ultrafine fiber 21 is 0.1D to 1.5D, respectively.

[0061] Of these, the first three-dimensional curl fiber 22 and the second three-dimensional curl fiber 22 are each parallel two-component fibers, and the parallel two-component fibers include a first side portion 220 and a second side portion 221 that are parallel to each other, the material of the first side portion 220 is an unused or recycled fourth polymer material, and the material of the second side portion 221 is an unused or recycled fifth polymer material, and the fourth polymer material and the fifth polymer material are each selected from polyethylene, polypropylene, polyethylene terephthalate, polyethylene terephthalate copolymer, polybutylene terephthalate, polyamide and other similar polymers.

[0062] Of these, the cross-sections of the first three-dimensional curl fiber 22 and the second three-dimensional curl fiber 22 can each include one or more shapes. For example, the first and second three-dimensional curl fibers 22 can each be solid fibers with a circular or peanut-shaped cross-section. When the cross-section is circular, the first side portion 220 and the second side portion 221 of the cross-section are arranged opposite each other, forming a semicircle (shown in Figure 3D). When the cross-section is peanut-shaped, the first side portion 220 and the second side portion 221 of the cross-section are in contact in the middle of the cross-section and protrude to both sides (shown in Figure 3E). Alternatively, the first and second three-dimensional curl fibers 22 can each be hollow fibers with a circular cross-section and a hollow portion in the cross-section. When the hollow portion is at the center of the circular cross-section, the first side portion 220 and the second side portion 221 have roughly the same C-shape (shown in Figure 3F). When the hollow portion is located on one side of the circular cross-section, the first side portion 220 and the second side portion 221 have different C-shapes (as shown in Figure 3G).

[0063] Of these, the hollow ratios of the first and second three-dimensional curled fibers 22 are 5% to 30%, respectively.

[0064] Of these, the curl rates of the first and second three-dimensional curl fibers 22 are 2% to 25%, respectively.

[0065] Figure 4 shows the manufacturing process of the artificial feather composite structure 1 of the present invention. First, the base layer 10 is formed by mixing the first core-sheath fibers 20, the first ultrafine fibers 21, and the first three-dimensional curl fibers 22, and then cross-laminating them to form a roll material. Subsequently, the roll material of the base layer 10 is sent to the cotton dropping device 2 via the first conveyor belt 30. The cotton dropping device 2 includes a hopper 40, a second conveyor belt 50, and a heating device 60. After the second core-sheath fibers 20, second ultrafine fibers 21, and second three-dimensional curl fibers 22 are fed from the hopper 40 into the cotton dropping device 2, the second core-sheath fibers 20, second ultrafine fibers 21, and second three-dimensional curl fibers 22 are mixed and then randomly and irregularly dropped to form a temporary artificial feather layer 12. The temporary artificial feather layer 12 is then transported by the second conveyor belt 50 and loaded onto the base layer 10 transported by the first conveyor belt 30. Finally, the base layer 10 with the temporary artificial feather layer 12 loaded is sent to the heating device 60. The heating device 60 heats to a temperature of 125°C or higher to melt the sheath portion 201 made of low-melting-point polymer material in the first core-sheath fiber 20 in the base layer 10 and the second core-sheath fiber 20 in the artificial feather layer 11, bonding it with adjacent fibers to shape it, and after cooling to room temperature, the artificial feather layer 11, i.e., the artificial feather composite structure 1 of the present invention, is formed from the artificial feather temporary fabrication layer 12, so that it can be directly wound up as a roll material of the artificial feather composite structure 1. Below the second conveyor belt 50, a negative pressure device (not shown) may be provided to generate a slight downward negative pressure to help the artificial feather temporary fabrication layer 12 maintain a constant shape.

[0066] In several specific embodiments, the first core-sheath fiber 20 of the base layer 10 can form multiple adhesion points and bond with adjacent first and second core-sheath fibers 20, first and second ultrafine fibers 21, and first and second three-dimensional curl fibers 22 by its sheath portion 201. Furthermore, the second core-sheath fiber 20 of the artificial feather layer 11 can form multiple adhesion points and bond with adjacent first and second core-sheath fibers 20, first and second ultrafine fibers 21, and first and second three-dimensional curl fibers 22 by its sheath portion 201.

[0067] In the artificial down composite structure 1 of the present invention, a certain shape can be maintained without the need for a separate fixing layer (for example, by spraying resin onto the artificial down layer to fix the position of the interlocking points of the surface fibers and prevent down shedding).

[0068] The photograph in Figure 5A shows that commercially available padded fabrics have a structure formed by laminating multiple layers of nonwoven fabric made of heat-retaining fibers. On the other hand, the photograph of the artificial down composite structure of the present invention is shown in Figure 5B. The structural difference between the two can be seen with the naked eye: the artificial down layer of the artificial down composite structure of the present invention is a fluffy mass of irregularly layered fibers that are uniformly arranged, and its appearance resembles a cloud.

[0069] Characteristics of the artificial feather composite structure of the present invention

[0070] Artificial feather composite structures of Examples 1 to 6 were prepared using the materials listed below. 1. Base layer (1) 30% to 60% by weight of the first core sheath fiber The core / sheath material is recycled PET / recycled coPET, with the core and sheath each accounting for 50% by weight, and the sheath completely covering the outside of the core. The fiber cross-section is circular, and the core is located at the center of the circular cross-section of the first core-sheath fiber. • The fineness ranges from 2D to 4D. (2) 10% to 50% by weight of first ultrafine fibers • The material is recycled PET. The fineness ranges from 0.9D to 1.4D. • Solid fibers, or hollow fibers with a hollowness of 5% to 20%. (3) 20% to 30% by weight of first three-dimensional curl fibers The material of the first side / second side is recycled PET / recycled PET, the intrinsic viscosity difference (ΔIV) between the first polyethylene terephthalate of the first side and the second polyethylene terephthalate of the second side is 0.15 dL / g or more, the material is a solid fiber with a circular cross-section, and the first side and second side are semicircular and opposite each other. • The fineness ranges from 1D to 15D. The hollow ratio is 5% to 30%. The curl rate is 2% to 25%. 2.Artificial feather layer (1) 10% to 30% by weight of the second core sheath fiber The core / sheath material is recycled PET / recycled coPET, with the core and sheath each accounting for 50% by weight, and the sheath completely covering the outside of the core. The fiber cross-section is circular, and the core is located at the center of the circular cross-section of the second core-sheath fiber. • The fineness ranges from 2D to 4D. (2) 30% to 70% by weight of second ultrafine fibers • The material is recycled PET. The fineness ranges from 0.1D to 1.5D. • Solid fibers, or hollow fibers with a hollowness of 5% to 20%. (3) 20% to 40% by weight of second three-dimensional curl fibers The material of the first side / second side is recycled PET / recycled PET, the intrinsic viscosity difference (ΔIV) between the first polyethylene terephthalate of the first side and the second polyethylene terephthalate of the second side is 0.15 dL / g or more, the material is a solid fiber with a circular cross-section, and the first side and second side are semicircular and opposite each other. • The fineness ranges from 1D to 15D. The hollow ratio is 5% to 30%. The curl rate is 2% to 25%.

[0071] First, the heat retention properties of the artificial feather composite structures of Examples 1 to 6 of the present invention were tested. The results are shown in Table 1 below.

[0072] [Table 1]

[0073] As can be seen from Table 1, when the same material is used for both the base layer and the artificial down layer, the density is higher and the heat retention is better. In addition, a general thermal insulation cotton (sheet) was used as Comparative Example 1 (containing 10% to 20% core-sheath fibers with a fineness of 2D to 4D and a low-melting-point sheath material, 20% to 40% ultrafine fibers with a fineness of 0.9D to 1.2D, and 50% to 60% three-dimensional hollow curl fibers with a fineness of 3D to 7D, with a total unit area weight of 200 gsm), and a commercially available conventional artificial down material (filled fabric) was used as Comparative Example 2 (containing 0% to 100% ultrafine fibers with a fineness of 0.9D to 1.2D and 100% to 0% three-dimensional hollow curl fibers with a fineness of 3D to 7D within the sewing area, with a total unit area weight of 200 gsm). Example 5, which had a similar total unit area weight (total unit area weight of 180 gsm), was also selected and compared with Comparative Examples 1 and 2.

[0074] Based on the following standard test methods, each item was tested for Example 5 and Comparative Examples 1 and 2. The results are shown in Table 2 below. 1. Weight per unit area: Tested according to the standard test method ASTM D3776. The unit is grams per square meter (gsm or g / m²). 2 ). 2. Thickness: Tested according to method ASTM D5736-95. 3. Thermal insulation: Tests were conducted according to the standard test method ASTM D1518. The obtained values ​​are CLO values, and the unit is CLO. 4. Water Wash Resistance: Tests were conducted according to the standard test method ASTM D4770. The test results were divided into five levels, with Level 5 indicating the highest level of water wash resistance. Two types of samples were used in the water wash resistance test: 40cm x 40cm (sewing area size 10cm x 10cm) and 30cm x 30cm. (1) Testing of sheets or rolls of thermal insulation material: The sample size was 30cm x 30cm, which is the test sample size for sheets or rolls of thermal insulation material. Comparative Example 2 is a conventional artificial down material (padded fabric) that is not a sheet, and a 30cm x 30cm sample (without sewing sections) was cut directly and tested. In general sheet-type thermal insulation materials, the position of the interlocking points of the surface fibers is fixed using resin, so they usually have good water washing resistance. (2) Testing of padded fabric material: The sample size was 40cm x 40cm (sewing area size 10cm x 10cm), which is the sample size used for testing conventional artificial down materials. Comparative Example 1 is a sheet and not a padded fabric, so a 40cm x 40cm sample (without sewing area) was cut directly and tested. Conventional cotton-filled artificial down materials generally fill the sewing area with down, do not add low-melting-point fibers, and do not fix the position of the interlocking points of the surface fibers with resin, so the down fibers in the sewing area tend to get tangled when washed. Generally, the larger the sewing area size, the lower the level of water washing resistance. 5. Amount of cotton shedding after washing: Tests were conducted according to the standard test method ASTM D4770. The test results were divided into five levels, with level 5 indicating the minimum amount of cotton shedding after washing. 6. Compression recovery rate: Tested according to the standard test method ASTM D6571-01.

[0075] [Table 2]

[0076] The artificial down composite structure of the present invention includes a base layer in which the fibers are flat and orderly, and an artificial down layer in which the fibers are randomly arranged. By combining these two, it is possible to achieve superior loft and compression recovery. The fibers of Comparative Example 1 are flat and orderly arranged, and have high water-wash resistance. The fibers of Comparative Example 2 are randomly arranged, and have good loft. However, neither of the two comparative examples could achieve both loft and water-wash resistance, and both had low compression recovery rates. To achieve high water-wash resistance, the size of the sewing area is limited in the conventional artificial down material of Comparative Example 2. On the other hand, the artificial down composite structure of the present invention and Comparative Example 1 can achieve high water-wash resistance without considering the issue of sewing area.

[0077] As can be seen from the above, the present invention provides a roll-type sheet material that can be directly applied to the design of thermal clothing and accessories (e.g., footwear, bedding, sleeping bags, bedding mats, and clothing accessories), does not require fiber stuffing work, has the soft feel of artificial down material, has good heat retention, is resistant to washing, and has a low degree of fiber shedding, providing an artificial down composite structure. Furthermore, the artificial down composite structure of the present invention does not require the position of the interlocking points of the surface fibers to be fixed with resin to prevent fiber shedding, and has an excellent compression recovery rate. [Explanation of symbols]

[0078] 1 Artificial feather composite structure 2 Cotton dropping device 10 Base layer 11 Artificial feather layer 12. Artificial feather temporary fabrication layer 20 core sheath fibers 21 Ultrafine fibers 22 Three-dimensional curl fibers 30 First conveyor belt 40 hoppers 50 Second conveyor belt 60 Heating device 200 Core 201 Scabbard part 220 First side 221 Second side

Claims

1. The total weight of the artificial feather composite structure is calculated to be 9% to 27% by weight, and it contains 30% to 60% by weight of first core-sheath fibers, 10% to 50% by weight of first ultrafine fibers, and 20% to 30% by weight of first three-dimensional curl fibers, and the above first core-sheath fibers, first ultrafine fibers and first three-dimensional curl fibers are mixed and then cross-laminated, and the density is 14 gsm to 40 gsm, An artificial feather composite structure comprising: an artificial feather layer placed on the above-mentioned base layer, with a total weight of 73% to 91% of the total weight of the artificial feather composite structure, containing 10% to 30% of second core-sheath fibers, 30% to 70% of second ultrafine fibers, and 20% to 40% of second three-dimensional curl fibers, wherein the second core-sheath fibers, second ultrafine fibers, and second three-dimensional curl fibers are mixed and then randomly laminated, and the density is 30 gsm to 400 gsm; The first core-sheath fiber and the second core-sheath fiber each include a core and a sheath, the sheath covering part or all of the outside of the core, the core being made of unused or recycled first polymer material, the sheath being made of unused or recycled second polymer material, the melting point of the second polymer material being lower than that of the first polymer material, and the melting point range of the second polymer material being 100°C to 200°C. The fineness of the first and second ultrafine fibers is 0.1D to 1.5D, respectively. The hollow ratios of the first and second three-dimensional curled fibers are 5% to 30%, respectively, and The curl rates of the first and second three-dimensional curl fibers are 2% to 25%, respectively. A composite structure made of artificial down, characterized by the following features.

2. The artificial feather composite structure according to claim 1, wherein, in the total weight of the first core-sheath fiber, the core portion accounts for 40% to 80% by weight and the sheath portion accounts for 60% to 20% by weight, and in the total weight of the second core-sheath fiber, the core portion accounts for 40% to 80% by weight and the sheath portion accounts for 60% to 20% by weight.

3. The artificial feather composite structure according to claim 1, wherein the first core-sheath fiber and the second core-sheath fiber each have a circular or trefoil-shaped cross-section, and when the cross-section is circular, the core is located at the center or on one side of the circular cross-section, and the sheath covers the entire outside of the core, and when the cross-section is trefoil-shaped, the sheath covers a part of the outside of the core.

4. The artificial feather composite structure according to claim 1, wherein the first polymer material and the second polymer material are each selected from the group consisting of polyethylene, polypropylene, polyethylene terephthalate, polyethylene terephthalate copolymer and other similar polymers.

5. The combination of the first polymer material and the second polymer material described above is expressed in the form of first polymer material / second polymer material, and the first polymer material / second polymer material is selected from the group consisting of polyethylene terephthalate / polyethylene, polyethylene terephthalate / polyethylene terephthalate copolymer, and polypropylene / polyethylene, according to claim 4 of the artificial feather composite structure.

6. The artificial feather composite structure according to claim 1, wherein the material for the first ultrafine fiber and the material for the second ultrafine fiber are each unused or recycled third polymer material, and the third polymer material is independently selected from the group consisting of polyethylene, polypropylene, polyethylene terephthalate, polytrimethylene terephthalate, polybutylene terephthalate, polyamide, and combinations thereof.

7. The artificial feather composite structure according to claim 1, wherein the first three-dimensional curled fiber and the second three-dimensional curled fiber are each parallel two-component fibers, and the parallel two-component fibers include a first side and a second side that are parallel to each other, the material of the first side is an unused or recycled fourth polymer material, the material of the second side is an unused or recycled fifth polymer material, and the fourth polymer material and the fifth polymer material are each selected from the group consisting of polyethylene, polypropylene, polyethylene terephthalate, polyethylene terephthalate copolymer, polybutylene terephthalate, polyamide and other similar polymers.

8. The artificial feather composite structure according to claim 1, wherein the compression recovery rate is 90% or more.

9. An item characterized by being made using an artificial feather composite structure as described in any one of claims 1 to 8.

10. The item according to claim 9, wherein the item is a jacket, pants, skirt, vest, coat, footwear, sleeping bag, or bedding mat.

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