Net for down filling, ultra-light down filling and method for manufacturing the same

Abstract

The present invention relates to a web for down filling, a super-light down filling, and a method for manufacturing the same, and more particularly, to a super-light down filling having a thin thickness, excellent warmth retention, and excellent four-way (or multi-way) elasticity, and a web for down filling for manufacturing the same.

Description

TECHNICAL FIELD

[0001] The present application relates to an ultra-light down filling material having excellent warmth retention and four-way (or multi-way) elasticity with a thin thickness, a net for down filling material for manufacturing the same, and a manufacturing method thereof. BACKGROUND

[0002] Down products using duck down or goose down have excellent warmth retention due to a large amount of air contained between the down and the down, and as cold-weather clothing for maintaining body temperature during winter outdoor activities, the down products have become a high-end product favored in the market.

[0003] As these down products have become a main product of winter fashion, the popularity of ultra-light down jackets, which are light and easy to carry, has continued to rise, and thus a great deal of development is being made in terms of warmth retention and lightness.

[0004] However, if the down filling material uses down, it lacks resilience and support, and down shedding from the seams and the odor unique to down have become unsatisfactory factors for consumers, and in addition, it has been pointed out that the appearance of the product is poor and washing is difficult due to clumping of the down. In order to prevent down shedding or knotting of the down product, a structure in which a core layer (a net composed of down) of the down filling material is sewn together with a liner and cut into a structure having a plurality of compartment structures, or a down filling material is manufactured by sewing a liner and an outer layer fabric together and filling down into the compartments after cutting into a structure having a plurality of compartment structures, has been used, and the down filling material has been manufactured in a state in which the down is filled into the inside of the plurality of compartment structures, that is, in a state in which the down is filled between the seams (for example, a quilted structure, etc.), however, the down filling material of such a structure has a problem in that the warmth retention performance is reduced due to the generation of cold spots.

[0005] In addition, in recent years, the trend of clothing products has emphasized not only design but also activity, and the elasticity and resilience of the above-mentioned compartment-structured down filling material are poor, and since the thickness of the down filling material is manufactured to be excessively thick in order to secure high thermal insulation and warmth retention, there is also a problem in that it does not conform to the latest fashion trend.

[0006] PRIOR ART DOCUMENT

[0007] PATENT DOCUMENT

[0008] Korean Patent No. 10-1334624 (Notice of Publication: November 25, 2013)

[0009] Korean Patent No. 10-1669938 (Notice of Publication: October 21, 2016) SUMMARY

[0010] TECHNICAL PROBLEM

[0011] The present application aims to provide a net for down filling and an ultra-light down filling using the same as a filler (or a net layer), which is not only free from a compartment structure causing a cold spot of the down filling, but also manufactured as a non-punctured one-piece sheet, the components of which are optimized, thereby having excellent warmth retention while greatly increasing elasticity and recovery of the down filling.

[0012] Means for solving the problem

[0013] To solve the above problem, the net for down filling according to the present application includes: mixed down including one or more selected from goosedown and duck down; non-stretching low melting sheath-core composite fiber; hollow conjugate stretch (HCT) short fiber; and regular solid siliconized fiber (RSS) short fiber.

[0014] As a preferred embodiment of the present application, the mixed down includes 15 to 30 wt% of feather and 70 to 85 wt% of down.

[0015] As a preferred embodiment of the present application, the sheath of the non-stretching low melting sheath-core composite fiber has a melting point of 100 to 150°C, and the core has a melting point of 250°C or more.

[0016] According to a preferred embodiment of the present application, the non-stretching low melting sheath-core composite fiber has an average denier of 3.0 de to 5.0 de and an average fiber length of 45 to 60 mm.

[0017] According to a preferred embodiment of the present application, the HCT short fiber and the RSS short fiber each have a melting point of 260°C or more.

[0018] According to a preferred embodiment of the present application, the HCT short fiber has an average denier of 2.0 de to 3.5 de, an average fiber length of 45 to 60 mm, and a crimp number of 15 to 23 per inch.

[0019] According to a preferred embodiment of the present application, the RSS short fiber has an average denier of 2.0 de to 3.5 de and an average fiber length of 45 to 60 mm.

[0020] According to one preferred embodiment of the present application, the net for down filling of the present application includes 25.0 to 50.0 wt% of the mixed down, 9.0 to 18.0 wt% of the HCT staple fiber, 13.0 to 21.0 wt% of the RSS staple fiber, and the balance of 100 wt% of the non-stretchable low-melt core-sheath composite fiber.

[0021] According to one preferred embodiment of the present application, the basis weight of the net for down filling of the present application can be 70 g / m 2 to 150 g / m 2 .

[0022] Another object of the present application is to provide a super-light down filling having four-way high elasticity and high warmth, the down filling including: a net layer composed of the above-described net for down filling; and a sheet layer laminated on the upper and lower portions of the net layer and combined with the net layer.

[0023] As one preferred embodiment of the present application, the down filling of the present application is a composite sheet in which the net layer and the sheet layer are integrated, and does not include a compartment structure that generates a cold spot and a pinhole.

[0024] As one preferred embodiment of the present application, the sheet layer can include a multi-directional stretch fabric having a net-like structure woven from high-elastic polyester yarns.

[0025] As one preferred embodiment of the present application, an acrylic resin layer can be included between the net layer and the sheet layer.

[0026] As one preferred embodiment of the present application, when the basis weight of the net layer of the present application is 80 g / m 2 to 100 g / m 2 , the warmth can satisfy 2.00 CLO or more as measured according to the ASTM D1518 method.

[0027] As one preferred embodiment of the present application, when the basis weight of the net layer is 80 g / m 2 to 100 g / m 2 , the air permeability of the down filling of the present application can satisfy 100 cubic feet per minute (CFM) or more as measured according to the ASTM D737 method.

[0028] As one preferred embodiment of the present application, when the basis weight of the down filling of the present application is 80 g / m 2 to 100 g / m 2 , the dryness rate after 1 hour can satisfy 30.0% or more as measured according to the JIS L 1096 method.

[0029] According to one preferred embodiment of the present application, when the basis weight of the web layer is 80 g / m 2 to 100 g / m 2 , the recovery rate of the down filling of the present application can satisfy 83.0% or more.

[0030] According to one preferred embodiment of the present application, when the basis weight of the web layer is 80 g / m 2 to 100 g / m 2 , the residual extension of the down filling of the present application after 30 seconds, measured according to the ASTM D3107 method and calculated by Equation 2, can satisfy 6.5% or less in the longitudinal direction and 8.0% or less in the lateral direction.

[0031] According to one preferred embodiment of the present application, when the basis weight of the web layer is 80 g / m 2 to 100 g / m 2 , the residual extension of the down filling of the present application after 30 minutes, measured according to the ASTM D3107 method and calculated by Equation 2, can satisfy 3.0% or less in the longitudinal direction and 4.5% or less in the lateral direction.

[0032] [Equation 2]

[0033] Residual Extension (%) = [{(Original Length + Unrecovered Length) - Original Length} / Original Length] X 100%

[0034] According to one preferred embodiment of the present application, when the basis weight of the web layer is 80 g / m 2 to 100 g / m 2 , the recovery rate of the down filling of the present application after 30 seconds, measured according to the ASTM D3107 method and calculated by Equation 3, can satisfy 70.0% or more in the longitudinal direction and 65.0% or more in the lateral direction.

[0035] According to one preferred embodiment of the present application, when the basis weight of the web layer is 80 g / m 2 to 100 g / m 2 , the recovery rate of the down filling of the present application after 30 minutes, measured according to the ASTM D3107 method and calculated by Equation 3, can satisfy 75.0% or more in the longitudinal direction and 75.0% or more in the lateral direction.

[0036] [Equation 3]

[0037] Recovery (%) = [{Maximum extension length - (Original length + Unrecovered length)} / (Maximum extension length - Original length)] X 100%

[0038] Another object of the present application relates to a manufacturing method of the four-way high-elastic and high-warmth ultra-light down filling, which can be manufactured by performing the following steps: Step 1, supplying yarns in a bale state to a supply unit; Step 2, performing a bale breaking and an opening process on the yarns supplied to the supply unit, respectively; Step 3, performing a carding process on the opened yarns; Step 4, processing the carded yarns into a web; Step 5, coating an acrylic resin on both sides of the web, and then performing a drying process; and Step 6, performing a surface heat treatment on the web on which the acrylic resin is fixed, laminating a sheet on both sides of the web, then rolling with a heating roll, and then packaging.

[0039] Effects of the Invention

[0040] The down filling of the present application is an ultra-light down filling, which has no cold spot, and has excellent warmth, thermal insulation, elasticity, and recovery. In addition, compared to the existing down filling, the down filling of the present application has excellent drying performance, and there is no separation of down. BRIEF DESCRIPTION OF DRAWINGS

[0041] Figure 1 is a cross-sectional structure diagram of the down filling of the present application.

[0042] Figure 2 is a schematic diagram of a manufacturing process of the down filling of the present application.

[0043] Figure 3 A and B parts of are photographs taken of the down filling manufactured in Example 1.

[0044] Figure 4 is a photograph of a device used when measuring elasticity of Experimental Example 2.

[0045] REFERENCE NUMERALS

[0046] 1: Web (layer) for down filling; 100, 100': sheet layer; 10: feather; 20: down; 30: RSS short fiber; 40: HCT short fiber DETAILED DESCRIPTION

[0047] The term "non-stretchability" used in the present specification refers to a very low elongation and recovery rate, and refers to a characteristic that a fiber cannot be restored to the original shape after being stretched by an external force due to low elasticity.

[0048] The term "four-way" used in the present specification refers to two directions in a certain direction in which a down filling is stretched in a two-dimensional plane and two directions perpendicular thereto.

[0049] Hereinafter, the present application will be described in more detail.

[0050] The down filling net of the present application is a cold spot-free net, and is a sheet-shaped net that is free of compartment structures and pinholes.

[0051] The down filling net of the present application can include: a mixed down including one or more selected from goose down and duck down; a non-stretchable low-melting sheath-core composite fiber; a hollow conjugate stretch (HCT) short fiber; and a regular solid siliconized fiber (RSS) short fiber.

[0052] The mixed down includes one or more selected from goose down and duck down. At this time, the mixing in the mixed down refers to the mixing of feathers and down, and not to the mixing of goose down and / or duck down.

[0053] In addition, the mixed down can include 15 to 30% by weight of feathers and 70 to 85% by weight of down, preferably, can include 15 to 25% by weight of feathers and the remaining 100% by weight of down, and more preferably, can include 17.5 to 22.5% by weight of feathers and the remaining 100% by weight of down. At this time, if the feather content is less than 15.0% by weight, there can be a problem in that price competitiveness is greatly reduced due to the excessively high down content; if the feather content exceeds 30.0% by weight, warmth retention can be slightly reduced, and there can be a problem in that the product surface is uneven, and thus it is preferable to use feathers and down within the above range in consideration of warmth retention and commodity properties, etc.

[0054] In addition, the non-stretchable low-melting sheath-core composite fiber is a fiber that functions to bind the mixed down and other fibers in the net together and functions to stabilize the shape of the net, and is a fiber that does not have stretchability (elasticity).

[0055] The sheath of the non-stretchable low-melting point sheath-core composite fiber can be composed of a polyethylene terephthalate (PET) resin having a melting point of 100 to 150°C, preferably a melting point of 105 to 130°C, and more preferably a melting point of 105 to 120°C. In addition, the core of the non-stretchable low-melting point sheath-core composite fiber can be composed of a PET resin having a melting point of 250°C or more, preferably a melting point of 250 to 280°C, and more preferably a melting point of 255 to 275°C.

[0056] At this time, if the melting point of the resin forming the sheath is less than 100°C, there can be a problem of poor fusion, and if the melting point of the resin of the sheath exceeds 150°C, there can be a problem of the product becoming hard. In addition, if the melting point of the resin forming the core is less than 250°C, there can be a problem of loose connection between the yarns, and if the melting point of the resin of the core exceeds 280°C, there can be a problem of the connection site between the yarns becoming hard and hardened.

[0057] In addition, the composite fiber of the non-stretchable low-melting point sheath-core composite fiber can use a fiber having an average denier of 3.0 de to 5.0 de and an average fiber length of 45㎜ to 60㎜, preferably, a fiber having an average denier of 3.5 de to 4.7 de and an average fiber length of 45㎜ to 58㎜, and more preferably, a fiber having an average denier of 3.7 de to 4.5 de and an average fiber length of 48㎜ to 55㎜. At this time, if the average denier of the non-stretchable low-melting point sheath-core composite fiber is less than 3.0 de, there can be a problem of reduced thickness, and if the average denier of the non-stretchable low-melting point sheath-core composite fiber exceeds 5.0 de, there can be a problem of poor touch of the product. In addition, if the average fiber length of the non-stretchable low-melting point sheath-core composite fiber is less than 45㎜, there can be a problem of poor bonding between the yarns, and if the average fiber length exceeds 60.0㎜, there can be a problem of entanglement of the yarns and reduced thickness.

[0058] Second, the RSS staple fiber constituting the web is a fiber that plays a role in improving the strength, flexibility, and softness of the web, and is a non-hot-meltable fiber under the conditions of the web manufacturing process and the process of the down filler using the same. Therefore, the RSS staple fiber is a fiber satisfying a melting point of 260°C or more, and preferably a fiber satisfying a melting point of 260 to 300°C. As one preferred example, the RSS staple fiber can use a polyester fiber coated with silicone to increase miscibility with other fibers, and preferably, for example, a PET fiber mixedly coated with a fatty alcohol, a mixed phosphate mixture, a low-molecular-weight alcohol mixture, and a silicone emulsion on a 100% polyethylene terephthalate (PET) regular staple fiber can be used as the RSS staple fiber.

[0059] In addition, the RSS short fibers can use fibers having an average denier of 2.0 de to 3.5 de, an average fiber length of 45㎜ to 60㎜, and a crimp number of 15 / inch to 23 / inch, preferably, fibers having an average denier of 2.0 de to 3.0 de, an average fiber length of 45㎜ to 58㎜, and a crimp number of 17 / inch to 23 / inch, more preferably, fibers having an average denier of 2.2 de to 2.8 de, an average fiber length of 48㎜ to 55㎜, and a crimp number of 18 / inch to 22 / inch. At this time, if the average denier of the RSS short fibers is less than 2.0 de, there can be a problem of poor bonding due to insufficient yarn strength, and if the average denier of the RSS short fibers exceeds 3.0 de, there can be a problem of a decrease in soft touch of the product. In addition, if the average fiber length of the RSS short fibers is less than 45㎜, there can be a problem of poor bonding between yarns, and if the average fiber length exceeds 60.0㎜, there can be a problem of yarn entanglement and a decrease in thickness. In addition, if the crimp number of the RSS short fibers is less than 15 / inch, there can be a problem of a decrease in restoring force, and if the crimp number exceeds 23 / inch, there can be a problem of a decrease in bonding force between yarns.

[0060] Second, the HCT short fibers constituting the web are fibers that play a role of providing elasticity and restoring force to the web, and the HCT short fibers are fibers having a melting point satisfying 260℃ or more, preferably a melting point satisfying 265℃ or more. As a preferred example, the HCT short fibers can use polyester fibers satisfying the above-mentioned melting point, and more preferably, polyethylene terephthalate (PET) fibers.

[0061] In addition, the HCT short fibers can use fibers having an average denier of 2.0 de to 3.5 de and an average fiber length of 45㎜ to 60㎜, preferably, fibers having an average denier of 2.0 de to 3.0 de and an average fiber length of 45㎜ to 58㎜, more preferably, fibers having an average denier of 2.2 de to 2.8 de and an average fiber length of 48㎜ to 55㎜. At this time, if the average denier of the HCT short fibers is less than 2.0 de, there can be a problem of a decrease in elasticity, and if the average denier of the HCT short fibers exceeds 3.0 de, there can be a problem of a decrease in restoring force after elasticity. In addition, if the average fiber length of the HCT short fibers is less than 45㎜, there can be a problem of a decrease in bonding force, and if the average fiber length exceeds 60.0㎜, there can be a problem of yarn entanglement and a decrease in thickness.

[0062] The net for down filling of the present application composed of the above-described fibers can include 25.0 to 50.0% by weight of the mixed down, 9.0 to 18.0% by weight of the HCT staple fiber, 13.0 to 21.0% by weight of the RSS staple fiber, and the balance to 100% by weight of the non-stretchable low-melt sheath-core composite fiber, preferably, can include 28 to 45% by weight of the mixed down, 9.5 to 16.5% by weight of the HCT staple fiber, 14.0 to 21.0% by weight of the RSS staple fiber, and the balance to 100% by weight of the non-stretchable low-melt sheath-core composite fiber, more preferably, can include 29 to 42% by weight of the mixed down, 9.8 to 16.3% by weight of the HCT staple fiber, 14.0 to 20.5% by weight of the RSS staple fiber, and the balance to 100% by weight of the non-stretchable low-melt sheath-core composite fiber. At this time, if the content of the mixed down in the net is less than 25% by weight, the warmth retention can be insufficient, and if it exceeds 50% by weight, the contents of the other fibers can be relatively reduced, and thus can not be suitable for the down filling having high elasticity and recovery force manufactured by applying the net. In addition, if the content of the HCT staple fiber in the net is less than 9% by weight, there can be a problem in that the elasticity and elasticity force, etc. of the net are reduced, and if it exceeds 18% by weight, since higher elasticity cannot be expected, it is preferred to use the HCT staple fiber within the above-described range. In addition, if the content of the RSS staple fiber in the net is less than 13% by weight, the commerciality and processability can be lowered due to insufficient strength and flexibility of the net, and if the amount thereof exceeds 22% by weight, although it is beneficial to increase the strength of the net, the warmth retention can be relatively lowered, and thus it is preferred to use within the above-described range.

[0063] From the viewpoint of securing the properties of the down filling to which the net is applied, such as thinness, ultra-lightness, and high warmth retention, etc., the basis weight of the net for down filling (single-layer net and / or composite net) of the present application is 70 g / m 2 to 150 g / m 2 , preferably 75 g / m 2 to 140 g / m 2 , more preferably 78 g / m 2 to 135 g / m 2 .

[0064] The following describes the ultra-light down filling having high elasticity and high warmth retention of the present application, the down filling of the present application being as follows Figure 1The schematic view of the present application is shown, including: a mesh layer 1, which is composed of a mesh for down filling as described above; and sheet layers 100 and 100', which are laminated on the upper and lower parts of the mesh layer and combined with the mesh layer, the mesh layer and the sheet layer being combined into a composite sheet without cold spots.

[0065] In addition, an acrylic resin layer can be included between the mesh layer and the sheet layer.

[0066] In addition, the sheet layer can be a multidirectional stretch fabric having a net structure woven by high-elastic polyester yarns.

[0067] The down filling of the present application can be manufactured by a method shown in a process schematic view in Figure 2 More specifically, it can be manufactured by performing the following processes: Step 1, supplying yarns in a bale state to a supply unit; Step 2, performing a bale breaking and opening process on the yarns supplied to the supply unit, respectively; Step 3, performing a carding process on the opened yarns; Step 4, processing the carded yarns into a web; Step 5, coating an acrylic resin on both sides of the web, and then performing a drying process; and Step 6, performing a surface heat treatment on the web on which the acrylic resin is fixed, laminating a sheet on both sides of the web, then rolling with a heating roll, and then packaging.

[0068] When the basis weight of the mesh layer of the down filling of the present application as described above is 80 g / m 2 to 100 g / m 2 , the warmth retention force measured according to the ASTM D1518 method can satisfy 2.00 CLO or more, preferably 2.05 CLO to 3.00 CLO, more preferably 2.10 CLO to 2.96 CLO.

[0069] In addition, when the basis weight of the mesh layer of the down filling of the present application is 80 g / m 2 to 100 g / m 2 , the air permeability measured according to the ASTM D737 method can satisfy 100.0 cubic feet per minute (CFM) or more, preferably 120.0 CFM to 150.000 CFM, more preferably 125.0 CFM to 145.000 CFM.

[0070] In addition, when the basis weight of the mesh layer of the down filling of the present application is 80 g / m 2 to 100 g / m 2At this time, the dryness rate after 1 hour measured according to JIS L1096 method can satisfy 30.0% or more, the dryness rate after 1 hour preferably satisfies 31.0% to 40.0%, more preferably can satisfy 31.0% to 38.5%.

[0071] Further, when the basis weight of the web layer of the down filler of the present application is 80 g / m 2 to 100 g / m 2 , the recovery rate can satisfy 83.0% or more, the recovery rate preferably satisfies 85.0% to 92.0%, more preferably can satisfy 85.0% to 90.0%.

[0072] Further, when the basis weight of the web layer of the down filler of the present application is 80 g / m 2 to 100 g / m 2 , the residual extension after 30 seconds measured according to ASTM D3107 method and calculated by the following Formula 2 can satisfy 6.5% or less in the longitudinal direction and 8.0% or less in the lateral direction, preferably satisfy 1.0% to 6.2% in the longitudinal direction and 3.0% to 7.0% in the lateral direction, more preferably can satisfy 1.4% to 6.0% in the longitudinal direction and 3.5% to 6.7% in the lateral direction.

[0073] In addition, when the residual extension after 30 minutes is measured according to the same method, it satisfies 5.0% or less in the longitudinal direction and 4.5% or less in the lateral direction, preferably satisfies 1.0% to 4.8% in the longitudinal direction and 1.2% to 4.5% in the lateral direction, more preferably can satisfy 1.0% to 4.5% in the longitudinal direction and 2.0% to 4.2% in the lateral direction.

[0074] At this time, the longitudinal direction refers to the warp direction of the fabric constituting the sheet layer of the down filler, and the lateral direction refers to the weft direction of the fabric constituting the sheet layer of the down filler.

[0075] [Formula 2]

[0076] Residual Extension (%) = [{(Original Length + Unrecovered Length) - Original Length} / Original Length] X 100%

[0077] Further, when the basis weight of the web layer of the down filler of the present application is 80 g / m 2 to 100 g / m 2At this time, the recovery rate after 30 seconds (Recovery) measured according to the method of ASTM D3107 and calculated by Equation 3 can satisfy 70.0% or more in the longitudinal direction and 65.0% or more in the lateral direction, preferably satisfy 70.0% to 86.0% in the longitudinal direction and 65.0% to 80.0% in the lateral direction, and more preferably can satisfy 65.0% to 85.0% in the longitudinal direction and 66.5% to 80.0% in the lateral direction.

[0078] In addition, when the recovery rate after 30 minutes is measured according to the same method, 75.0% or more in the longitudinal direction and 75.0% or more in the lateral direction are satisfied, preferably 76.0% to 90.0% in the longitudinal direction and 76.5% to 87.5% in the lateral direction are satisfied, and more preferably 77.5% to 89.0% in the longitudinal direction and 77.0% to 87.0% in the lateral direction can be satisfied.

[0079] At this time, the longitudinal direction refers to the warp direction of the fabric constituting the sheet layer of the down filler, and the lateral direction refers to the weft direction of the fabric constituting the sheet layer of the down filler.

[0080] [Equation 3]

[0081] Recovery (%) = [{Maximum extension length - (Original length + Non-recovery length)} / (Maximum extension length - Original length)] X 100%

[0082] The present application will be described in more detail by examples below, but it should be understood that the following examples do not limit the scope of the present application, but are intended to help understand the present application.

[0083] [Example]

[0084] Example 1: Manufacture of Down Filler

[0085] A mixed down containing 20% by weight of duck feathers and 80% by weight of duck down in a bale state was prepared.

[0086] A non-stretching low-melting point sheath-core composite fiber (manufacturer: Huivi, product name: LMF) having an average fineness of 4 de and an average fiber length of 51㎜ was prepared. At this time, the composite fiber is a fiber in which the sheath part is composed of polyethylene terephthalate having a melting point of 110℃ and the core part is composed of a PET resin having a melting point of 250℃, and the ratio of the cross-sectional areas of the core part and the sheath part is 1:1.

[0087] A PET fiber (manufacturer: Hwaseung, product name: ZENTRA) having a melting point of 260°C or more was prepared as a hollow conjugate stretch (HCT) short fiber. The average denier of the HCT fiber was 2.5 de, and the fiber length was 51㎜.

[0088] A PET fiber (manufacturer: Hwaseung, product name: ZENTRA) having a melting point of 260°C or more was prepared as a hollow conjugate stretch (HCT) short fiber. The average denier of the HCT fiber was 2.5 de, and the fiber length was 51㎜.

[0089] The mixed down, the non-stretching low-melting point sheath-core composite fiber, the RSS short fiber, and the HCT short fiber were supplied as yarns, and a down filler was manufactured through the processes shown schematically in FIG. 2. Figure 2

[0090] The yarns were supplied to a supply unit, and a bale breaking and opening process was performed.

[0091] Next, the yarns that had undergone the opening process were transferred using a carding machine and subjected to a carding process.

[0092] Next, the yarns that had undergone the carding process were transferred to a web forming unit and processed into a web, thereby manufacturing a web.

[0093] Next, the web was transferred to a drying unit, and after an acrylic resin (manufacturer: WOLSUNG VINA, product name: MEDIUM RESIN) was sprayed on one surface of the web, a first drying was performed, and after the acrylic resin was sprayed again on the other surface of the web, a second drying was performed, thereby fixing the acrylic resin to the upper and lower portions of the web. At this time, the drying temperature was 145°C to 155°C, and the two sprayings and the first and second dryings were consecutive processes.

[0094] Next, the web on which the acrylic resin layer was formed was transferred to a heat treatment unit and subjected to surface heat treatment at 310°C to 350°C, and then transferred to a sheet supply unit and had a multi-directional stretch fabric (manufacturer: Chargeurs PCC, product name: #6029) woven with high-elasticity polyester yarns laminated on both surface layers of the upper and lower portions of the web.

[0095] ​Next, integration is achieved by using a heating roll press, and then packaged to manufacture an integrated composite sheet-like down filler.

[0096] The manufactured down filler is composed of a single layer of netting and an integrated sheet layer laminated and bonded to the upper and lower portions of the netting, and a photograph of the manufactured down filler is shown in Figure 3

[0097] In addition, the netting is composed of 30 wt% of mixed down, 17 wt% of HCT staple fiber, 17 wt% of RSS staple fiber, and 36 wt% of non-stretchable low-melting point sheath-core composite fiber, and has a basis weight of 100 g / m 2 .

[0098] Examples 2 to 6 and Comparative Examples 1 to 6

[0099] Down fillers were manufactured in the same manner as in Example 1, in which the content of fibers inside the netting or the basis weight was differently set according to Table 1 below, thereby respectively manufacturing down fillers to implement Examples 2 to 6 and Comparative Examples 1 to 6.

[0100] However, in Examples 3 to 6 and Comparative Examples 1 to 6, as a multi-directional stretch fabric constituting a sheet layer on both the upper and lower portions of the netting of the down filler, a stretchable fabric (manufacturer: Picardy, product name: 6029) was used instead of the stretchable fabric (manufacturer: Wonyoung, product name: J30G) of Example 1 and the stretchable fabric (manufacturer: Sejin, product name: 3015F) of Example 2, and down fillers were manufactured.

[0101]

Table 1

[0102]

[0103] Experimental Example 1: Measurement of Warmth Retention, Quick Drying, Air Permeability, Linting, and Recovery

[0104] The tests for evaluating the thermal insulation, quick drying, air permeability, and linting of the down fillers manufactured in the above examples and comparative examples were conducted by commissioning Intertek Testing Services Korea Ltd and ID FL Laboratory and Institute.

[0105] ​In addition, the control group 1 was a 80g / m 2 of a down filling having a basis weight of 80g / m

[0106] In addition, the control group 2 was a 80g / m 2 of a down filling having a basis weight of 80g / m

[0107] In addition, the control group 3 was a 80g / m 2 of a down filling made of 100% polyester (product name: syncloud basic GRS).

[0108] (1) Measurement method of warmth retention

[0109] The test method was measured according to ASTM D1518, and the specific test method was as follows.

[0110] 1) The cover was placed on the bare board (heating body, set to 35℃), and the environmental temperature of the chamber was set to 20℃, and the humidity was set to 65%.

[0111] 2) When the heat exchange between the environmental temperature, humidity, and bare board was stable, the warmth retention (Rct0) of the bare board was measured.

[0112] 3) The test piece was placed on the bare board to prevent wrinkles or tension, and 1) and 2) were sequentially performed. At this time, the test piece was in a mock-up or product (sheet type padding) state, and the size was 550㎜ wide x 550㎜ high.

[0113] 4) When the heat exchange between the environmental temperature, humidity, bare board, and test piece was stable, the warmth retention (Rct) of the test piece was measured.

[0114] 5) The result value of warmth retention (CLO) = (Rct-Rct0) X 6.45 was obtained.

[0115] 1) The warmth retention of CLO is a unit representing thermal resistance, and is a comfortable warmth retention state in which the amount of heat dissipation is 58W / m 2 at a wind speed of 0.1m / s and an environmental temperature of 21℃. 1 gram of clo value is equal to 0.155K·m 2 / W.

[0116] The measurement results of warmth retention are shown in Table 2 below, and the higher the value of warmth retention unit CLO, the more excellent the warmth retention.

[0117] (2) Measurement method of quick-drying property

[0118] The test method was measured according to JIS L 1096:2010, and the specific test method was as follows.

[0119] 1) A test piece of 400㎜ in length x 400㎜ in width in a mock-up state was prepared.

[0120] 2) The test piece was sufficiently immersed in distilled water at 20℃ (±2℃).

[0121] 3) It was taken out of the water, and when water droplets no longer fell, it was installed on the equipment.

[0122] 4) It was placed in a test room under standard conditions, and the time required for natural drying and recovery to the original weight was measured, the average value was expressed in an integer, and the drying rate (%) after 1 hour and the complete drying time were measured.

[0123] (3) Measurement method of air permeability

[0124] The test method was measured according to ASTM D737, and the specific test method was as follows.

[0125] 1) After adjustment, calibration of the equipment was performed.

[0126] 2) After confirming that "0" dl was measured with a reference material, the test piece was installed on the test piece platform, ensuring that there were no wrinkles or folds. At this time, the down filler itself was used as the test piece, and the size was 550㎜ in width x 550㎜ in height.

[0127] 3) The measured result value was recorded, and the average value of 10 repeated tests was taken as the measurement value. In addition, the test area (Test area: 38cm 2 ) and the test pressure (Test pressure: 125pa) of the American standard were used for measurement.

[0128] (4) Measurement method of lint property

[0129] The test method was measured according to FED STD FTMS 5530 International Method (based on Federal Standard 191-5530), and the number of lint was less than 5 to be qualified. The test conditions were the size of tumbling box 45 cm x 45 cm x 45 cm (width, length, height), revolution per minute (RPM) 48 (± 2), and duration of tumbling 30 minutes.

[0130] (5) Measurement method of recovery

[0131] The recovery was measured by the following method.

[0132] 1) Prepare a test piece for measuring recovery.

[0133] 2) After placing the test piece flat, measure the height before starting (Hb) in units of 1 mm.

[0134] 3) Place it in a constant temperature and humidity chamber, and place a 1 kg hammer on it for 1 minute.

[0135] 4) Remove the hammer and measure the height (Ha) after 1 minute of recovery.

[0136] 5) Calculate the recovery rate in percentage using Equation 1 below.

[0137] [Equation 1]

[0138] Recovery rate (Volume recovery rate, %) = Ha / Hb x 100%

[0139] [Table 2]

[0140]

[0141] From the physical property measurement results of Table 2 above, the down fillings of Examples 1 to 6 had warmth of 2.00 CLO or more, air permeability of 100 CFM or more, and good quick-drying properties of 30% or more and no lint. In addition, it could be confirmed that the down fillings of Examples 1 to 6 had excellent recovery rates of more than 83.0%.

[0142] On the other hand, compared to Examples 2 and 3, Comparative Example 1 using a small amount of HCT short fibers had a problem of slightly lower recovery rate. In addition, Comparative Example 2 using HCT short fibers in an amount of more than 18 wt% had good physical properties such as warmth, quick-drying properties, air permeability, etc., but had a problem of relatively rapid decrease in recovery rate compared to Examples 2 and 3.

[0143] Comparative Example 3 using a small amount of 25 wt% mixed down of the filling power, although having other good physical properties, has a problem of having a low warmth retention of less than 2.0 CLO.

[0144] Comparative Example 4 using an excess amount of mixed down and a relatively small amount of sheath-core composite fiber has a problem of linting, and has a problem of decreased quick drying and a significantly decreased recovery rate, compared to other examples and comparative examples in which no linting occurs.

[0145] The basis weight of the net layer was 65 g / m 2 Comparative Example 5 has good physical properties such as warmth retention, quick drying, air permeability, etc., but has a problem of having a warmth retention of less than 2.00 CLO, and the basis weight of the net layer was 160 g / m 2 Comparative Example 6 has good warmth retention, but has a problem of having relatively poor quick drying and air permeability and a recovery rate of 80% or less.

[0146] Experimental Example 2: Measurement of Elasticity

[0147] In terms of elasticity, a high elongation value is interpreted as an excellent product, but it is necessary to consider both the elongation and recovery values to confirm whether durability and appearance are maintained very well. In general, the smaller the residual elongation (or growth, non-recoverable part), the greater the recovery, and the more excellent the performance.

[0148] Elasticity was measured according to the ASTM D3107 method, and the specific measurement method was as follows, and the device used in the test is shown in Figure 4 .

[0149] 1) Six samples of 2.5 inches long x 22 inches wide in the length direction parallel to the stretch direction were taken, the same number of threads were untied from both sides of the test piece to be made to a width of 2.00 (±0.05) inches.

[0150] 2) The stretch was folded by about 1.25 inches using the end portion of the length direction of the test piece, the 1-inch portion was sewn, and it was spread on a flat surface for 30 minutes without external force.

[0151] 3) The test piece was placed under standard conditions of 21 (±1) °C, 65 (±2) % RH for 4 hours.

[0152] 4) A bench mark (minimum length: 10 (±0.

[0153] 05) inches) was marked at the center of the test piece.

[0154] 5) Hang one end of the sewn loop-shaped test specimen on the upper clamp, measure the length of the marked reference portion of the test specimen, and record it in 1mm units.

[0155] 6) Insert a dowel pin into the lower loop of the test specimen, and hang a 4 lbs or 3 lbs hammer.

[0156] 7) Cycle 3 times to apply a load of 0 to 4 lbs (3 lbs) to the test specimen.

[0157] 8) Measure the degree of stretch after 10 seconds or 30 minutes.

[0158] 9) Using the clamp of the tension meter, stretch and fix 85% of the length (H) of the calculated stretch percentage.

[0159] 10) After fixing for 30 minutes in the stretched state, remove the sample from the lower clamp.

[0160] 11) Measure the reference value according to each client time option, and record it in 1mm units.

[0161] The residual extension or growth is calculated by Equation 2, the recovery is calculated by Equation 3, and the stretch is calculated by Equation 4.

[0162] [Equation 2]

[0163] Residual Extension (growth, %) = [{(original length + unrecovered length) - original length} / original length] X 100%

[0164] [Equation 3]

[0165] Recovery (%) = [{maximum extension length - (original length + unrecovered length)} / (maximum extension length - original length)] X 100%

[0166] [Equation 4]

[0167] Stretch (or extension, %) = [{(maximum extension length) - original length} / original length] x 100%

[0168] In Table 3 below, the longitudinal direction refers to the warp direction of the fabric constituting the sheet layer of the down filler, and the transverse direction refers to the weft direction of the fabric constituting the sheet layer of the down filler. In addition, the physical property measurement values in Table 3 represent the average of 3 measurements.

[0169] [Table 3]

[0170]

[0171] [Table 4]

[0172]

[0173] As can be seen from the above Tables 3 and 4, in Examples 1 to 6 showing the down filler of the present application, the overall residual elongation is low and the recovery rate is high, and it is a product having high elasticity.

[0174] In contrast, in Comparative Example 1 using less than 9 wt% of HCT staple fibers and more than 21 wt% of RSS staple fibers, there is a problem of low residual elongation and very low recovery rate.

[0175] In addition, Comparative Example 2 using more than 18 wt% of HCT staple fibers and less than 13 wt% of RSS staple fibers has a problem of high residual elongation and low recovery rate compared to Example 5.

[0176] In addition, in Comparative Example 3 using a small amount of mixed down, as previously confirmed in Experimental Example 1, it has poor warmth retention and shows poor results in terms of residual elongation and recovery rate, which can be a result of using a relatively excessive amount of non-elastic core-sheath composite fibers. In contrast, Comparative Example 4 shows excellent warmth retention compared to Example 6, but a problem of higher residual elongation and relatively lower recovery rate is found.

[0177] In addition, in Comparative Example 5 in which the basis weight of the nonwoven fabric is 65 g / m 2 , the residual elongation and recovery rate are good, but there is a problem of low warmth retention as confirmed in Experimental Example 1, and in Comparative Example 5 in which the basis weight of the nonwoven fabric is 160 g / m 2 compared to Example 6, although the residual elongation is low, there is a problem of extremely low recovery force.

[0178] It is confirmed from the above examples and experimental examples that the down filler of the present application still has excellent warmth retention in the low basis weight range, and the four-way (or multi-way) elasticity is excellent, so the down filler of the present application can provide an ultra-light functional down filler product.

Claims

1. A four-way high-elasticity and high-warmth ultra-light down filling comprising: a layer of netting consisting of a netting with a basis weight of 70 g / m 2 up to 150 g / m 2 of down filling; and a sheet layer laminated on the upper and lower portions of the net layer and combined with the net layer, wherein the sheet layer comprises a multi-directional stretch fabric having a net structure woven from high-elasticity polyester yarns, wherein the net layer and the sheet layer are integrated as a composite sheet in a case where the net layer and the sheet layer are formed in a non-compartment structure, wherein the down filling net comprises: mixed down of 25.0 to 50.0 wt% of at least one selected from the group consisting of goose down and duck down, hollow conjugate stretch short fibers of 9.0 to 18.0 wt%, ordinary solid siliconized short fibers of 13.0 to 21.0 wt%, and a non-stretchable low-melting core-sheath composite fiber to 100 wt%, wherein the non-stretchable low-melting core-sheath composite fiber has an average denier of 3.0 de to 5.0 de and an average fiber length of 45 mm to 60 mm, wherein the hollow conjugate stretch short fiber has an average denier of 2.0 de to 3.5 de and an average fiber length of 45 mm to 60 mm, wherein the ordinary solid siliconized short fiber has an average denier of 2.0 de to 3.5 de and an average fiber length of 45 mm to 60 mm, wherein, when the basis weight of the web layer is 80 g / m 2 to 100 g / m 2 the warmth retention satisfies 2.00 CLO or more as measured according to the ASTM D1518 method, and the air permeability satisfies 100 cubic feet per minute or more as measured according to the ASTM D737 method.

2. The four-way high-elasticity and high-warmth ultra-light down cluster of claim 1, wherein, an acrylic resin layer is included between the net layer and the sheet layer.

3. The four-way high-elasticity and high-warmth ultra-light down filling according to claim 1, wherein, When the basis weight of the net layer is 80 g / m 2 to 100 g / m 2 , the dryness rate after 1 hour measured according to JIS L 1096 method satisfies 30.0% or more, the recovery rate satisfies 83.0% or more.

4. The four-way high-elasticity and high-warmth ultra-light down filling according to claim 1, wherein, When the basis weight of the net layer is 80 g / m 2 to 100 g / m 2 when the basis weight of the net layer is 80 g / m the residual elongation rate after 30 seconds measured according to ASTM D3107 method and calculated by the following formula 2 satisfies 6.5% or less in the longitudinal direction and 8.0% or less in the lateral direction, the recovery rate after 30 seconds measured according to ASTM D3107 method and calculated by formula 3 satisfies 70.0% or more in the longitudinal direction and 65.0% or more in the lateral direction, [Formula 2] Residual Elongation Rate (Residual Elongation Rate = Increase Rate, %) = [{(Original Length + Non-recovered Length) - Original Length} / Original Length] x 100% [Formula 3] Recovery Rate (Recovery, %) = [{Maximum Elongation Length - (Original Length + Non-recovered Length)} / (Maximum Elongation Length - Original Length)] x 100%.

5. A method of manufacturing a four-way high-elasticity and high-warmth ultra-light down and feather filling, wherein, The method includes execution of the following steps: Step 1, supplying yarns in a bale state to a supply unit; Step 2, respectively performing a bale breaking and unloading process on the yarns supplied to the supply unit; Step 3, performing a carding process on the unloading yarns; Step 4, processing the carded yarns into a net; Step 5, applying an acrylic resin to both sides of the net, and then performing a drying process; and Step 6, performing a surface heat treatment on the net to which the acrylic resin is fixed, laminating a sheet on both sides of the net, and then performing a rolling with a heated roller, and then packaging, The net of step 4 includes: mixed down 25.0 to 50.0 wt% of at least one selected from goose down and duck down, hollow conjugate stretch short fiber 9.0 to 18.0 wt%, ordinary solid siliconized fiber short fiber 13.0 to 21.0 wt%, and the rest of non-stretching low-melting point sheath-core composite fiber as down filler net in 100 wt%; The average fiber length of the non-stretching low-melting point sheath-core composite fiber is 45 to 60 mm; The average fiber length of the hollow conjugate stretch short fiber is 45 to 60 mm; The average fiber length of the ordinary solid siliconized fiber short fiber is 45 to 60 mm, wherein the mesh has a basis weight of 70 g / m 2 up to 150 g / m 2 , The sheet of step 6 includes a multi-directional stretch fabric having a net structure woven by high-elasticity polyester yarn, The composite sheet of step 6 includes a net layer and a sheet layer, the sheet layer is laminated on the upper and lower parts of the net layer and combined with the net, wherein the net layer and the sheet layer are integrated without a partition structure, and The average fiber length of the non-stretching low-melting point sheath-core composite fiber is 45 to 60 mm; The average fiber length of the hollow conjugate stretch short fiber is 45 to 60 mm; The average fiber length of the ordinary solid siliconized fiber short fiber is 45 to 60 mm, The sheet of step 6 includes a multi-directional stretch fabric having a net structure woven by high-elasticity polyester yarn, The composite sheet of step 6 includes a net layer and a sheet layer, the sheet layer is laminated on the upper and lower parts of the net layer and combined with the net, wherein the net layer and the sheet layer are integrated without a partition structure, and The average fiber length of the non-stretching low-melting point sheath-core composite fiber is 45 to 60 mm; The average fiber length of the hollow conjugate stretch short fiber is 45 to 60 mm; The average fiber length of the ordinary solid siliconized fiber short fiber is 45 to 60 mm, The sheet of step 6 includes a multi-directional stretch fabric having a net structure woven by high-elasticity polyester yarn, The composite sheet of step 6 includes a net layer and a sheet layer, the sheet layer is laminated on the upper and lower parts of the net layer and combined with the net, wherein the net layer and the sheet layer are integrated without a partition structure, and wherein, in the down filler of step 6, when the basis weight of the net is 80 g / m 2 to 100 g / m 2 , the warmth retention measured according to the method of ASTM D1518 satisfies 2.00 CLO or more, and the air permeability measured according to the method of ASTM D737 satisfies 100 cubic feet per minute or more.

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