Nonwoven sheet for batting, method for manufacturing the same, and batting structure comprising the same

Abstract

A nonwoven fabric sheet is provided, which is a nonwoven fabric sheet (1) for wadding made of at least polyester staple fibers and fused staple fibers containing a polymer with a melting point lower than the polyester staple fibers. The nonwoven fabric sheet (1) for wadding consists of multiple layers of a web (3a)-(3f) formed by the constituent fibers (2) arranged substantially along one direction of the sheet, and at least a portion of the constituent fibers (2) is partially fused together by the fused staple fibers. Thus, a nonwoven fabric sheet for wadding with a full and soft feel, and a temperature feel that does not easily reduce its heat retention even when wet, a method for manufacturing the same, and a wadding structure comprising the same are provided.

Description

Technical Field

[0001] This invention relates to nonwoven fabric sheets for cotton wadding, methods for manufacturing the same, and cotton wadding structures comprising the same. Background Technology

[0002] Down is commonly used in outerwear, primarily worn in winter. When used as insulation, down is widely used due to its excellent insulation and compression recovery properties, but issues arise such as animal welfare concerns, the need for filling equipment during sewing, high price, and unstable supply. Therefore, synthetic fiber fillings are used as alternatives to down. Besides using granulated or shredded cotton fillings, sheet-shaped cotton is also used. Synthetic fiber fillings offer insulation and compression recovery properties close to down and are used in many products, but manufacturing issues include: the filling shifts during washing, affecting both product quality and warmth; and the need for filling equipment during sewing. Sheet-shaped cotton, created by fixing layers with resin and heat-bonded fibers, provides a fuller feel, but this results in a stiffer feel and increased weight if thickness is desired. Furthermore, to improve warmth, products using moisture-wicking and heat-generating fibers are widely manufactured and sold.

[0003] As prior art, Patent Document 1 proposes a method of stacking multiple spunbond nonwoven fabric layers and integrating them using hot calendering. Patent Document 2 proposes a method where two fiber layers are stacked together and the front and back fabrics are bonded using thermoplastic resin to create a lightweight and full-feeling stacked fabric. Patent Document 3 proposes a heat-insulating agent made by stacking nonwoven fabrics on both sides of meltblown long fiber nonwoven fabric.

[0004] Existing technical documents Patent documents Patent Document 1: Japanese Patent Application Publication No. 2022-046702 Patent Document 2: Japanese Patent Application Publication No. 2021-095650 Patent Document 3: Japanese Patent Application Publication No. 2022-039587 Summary of the Invention

[0005] The problem that the invention aims to solve

[0006] However, Patent Document 1 uses filaments in nonwoven fabric, but it has the problem of not having a full enough feel. Patent Document 2 has the problem of hardening of the hand feel because it combines the mixed fiber layers of each layer with resin. Patent Document 3 uses nanofibers, and because it has the structure of fiber layers sandwiched in nonwoven fabric, it also has the problem of not having a full enough feel.

[0007] In order to solve the aforementioned problems, the present invention provides a nonwoven fabric sheet for cotton wadding that has a full and soft feel and whose heat retention is not easily reduced even when wet, a method for manufacturing the same, and a cotton wadding structure comprising the same.

[0008] means for solving problems

[0009] In one embodiment, the present invention relates to a nonwoven fabric sheet for wadding, which is a nonwoven fabric sheet for wadding made by blending at least polyester staple fibers with welded staple fibers containing a polymer having a melting point lower than that of the polyester staple fibers. The nonwoven fabric sheet for wadding is stacked with multiple layers of a web of constituent fibers arranged substantially in one direction of the sheet. At least a portion of the constituent fibers of the nonwoven fabric sheet for wadding are partially fused together by the welded staple fibers, and the layers of the stacked nonwoven fabric are bonded together by the interweaving of the constituent fibers.

[0010] As one embodiment of the method for manufacturing nonwoven fabric sheets for cotton wadding according to the present invention, a method for manufacturing nonwoven fabric sheets for cotton wadding is provided, comprising: (1) A process of mixing at least polyester staple fibers with welded staple fibers containing a polymer having a melting point lower than that of the polyester staple fibers, opening the fibers, and forming a web that consists of fibers substantially arranged in one direction. (2) The process of folding and stacking the fiber web to form a long strip of stacked web; (3) The step of heating the elongated fiber web without load to a temperature above the melting point of the low-melting-point polymer; and (4) Cooling and winding process.

[0011] As one embodiment, the present invention relates to a cotton wadding structure in which a nonwoven fabric sheet is used as the cotton wadding.

[0012] Invention Effects

[0013] The nonwoven fabric sheet for cotton wadding of the present invention is a nonwoven fabric sheet for cotton wadding made by blending at least polyester staple fibers with fused staple fibers containing a polymer having a melting point lower than that of the polyester staple fibers. The nonwoven fabric sheet for cotton wadding has multiple layers of a web formed by the constituent fibers arranged substantially in one direction of the sheet. At least a portion of the constituent fibers of the nonwoven fabric sheet for cotton wadding is partially fused by the fused staple fibers, thereby having a fullness and soft hand feel, and its heat retention is not easily reduced even in a wet state. It can provide a temperature-sensitive nonwoven fabric sheet for cotton wadding, a method for manufacturing the same, and a cotton wadding structure containing the same. Attached Figure Description

[0014] Figure 1 A is a schematic perspective view of a nonwoven fabric sheet for cotton wadding according to one embodiment of the present invention. Figure 1 B is Figure 1 Schematic cross-sectional view of line II of A.

[0015] Figure 2 This is a photograph of the end of a nonwoven fabric sheet for cotton wadding according to one embodiment of the present invention.

[0016] Figure 3 This is a schematic diagram illustrating the layering process of nonwoven fabric sheets for cotton wadding in one embodiment of the present invention.

[0017] Figure 4 This is a schematic diagram illustrating the heating process of a nonwoven fabric sheet for cotton wadding in one embodiment of the present invention. Detailed Implementation

[0018] This invention relates to a nonwoven fabric sheet for making cotton wadding, consisting of at least polyester staple fibers and welded staple fibers comprising a polymer with a melting point lower than the polyester staple fibers. The fabric comprises multiple layers of a fiber web arranged substantially in one direction, and at least a portion of the fibers are partially fused together by the welded staple fibers. The polyester staple fibers have high strength and initial modulus of elasticity (Young's modulus), exhibiting high stiffness and compression recovery, a full feel, and a soft hand feel. Even when wet, their heat retention is not easily reduced, maintaining a comfortable temperature. The welded fibers fuse at least a portion of the fibers together. This results in a cotton wadding sheet that is not easily deformed, and the cotton wadding structure filling the sheet exhibits good wash resistance. In this specification, "substantially" refers to 50% by mass or more.

[0019] The blending ratio of each fiber relative to 100% by mass of the nonwoven fabric sheet for cotton wadding is preferably 60-99% by mass of polyester staple fiber and 1-40% by mass of welded staple fiber, more preferably 70-99% by mass of polyester staple fiber and 1-30% by mass of welded staple fiber, and even more preferably 80-98% by mass of polyester staple fiber and 2-20% by mass of welded staple fiber. This allows for the partial welding of polyester staple fibers while maintaining a good hand feel, resulting in a full and soft hand feel. Even when wet, the heat retention is not easily reduced, enabling the production of a temperature-sensitive nonwoven fabric sheet for cotton wadding.

[0020] The nonwoven fabric sheet for cotton wadding is preferably made by stacking the fiber web in the same direction as the arrangement direction of the fibers constituting the multilayer. This allows for the production of nonwoven fabric sheets for cotton wadding with a high yield.

[0021] The preferred core component of the welded staple fiber is polyethylene terephthalate, and the sheath component is a core-sheath composite fiber composed of a polyester copolymer with a melting or softening point of 90-230℃. After heat treatment, the sheath component of this welded staple fiber is fused together, while the core component retains its fiber shape, resulting in a soft hand feel.

[0022] The nonwoven fabric sheet used for the cotton wadding is preferably further blended with highly cross-linked polyacrylate staple fibers. Relative to 100 parts by weight of the combined amount of polyester staple fibers and welded staple fibers, the highly cross-linked polyacrylate staple fibers are preferably 1 to 50 parts by weight, more preferably 3 to 40 parts by weight, and even more preferably 5 to 30 parts by weight. Furthermore, the highly cross-linked polyacrylate fibers can also be waterproofed. While highly cross-linked polyacrylate fibers inherently possess hygroscopic and heat-generating properties, if waterproofed, these properties persist even when wetted. It should be noted that the highly cross-linked polyacrylate fibers are commercially available under the applicant's trade name "Breath Thermo". Waterproofing treatments can be achieved using commercially available products such as the AG series "AsahiGuard AG7000," "AsahiGuard AG970," "AsahiGuard AG-E082," "AsahiGuard GS10" (all manufactured by Asahi Glass Co., Ltd., fluorinated hydrophobic emulsions), "NK Guard FGN700T," and "NK Guard NDN7000" (all manufactured by Nichika Chemical Co., Ltd., fluorinated hydrophobic emulsions). Non-fluorinated waterproofing agents primarily consist of silicone, carbamate, acrylic, and hydrocarbon-based components; any of these can be used. As modified organosilicon hydrophobic agents, there are epoxy-modified organosilicon hydrophobic agents and amino-modified organosilicon hydrophobic agents, etc. Commercially available products include "X-22-9002" (trade name, two-terminated epoxy-modified organosilicon), "X-22-163A" (trade name, two-terminated epoxy-modified organosilicon), and "KF-8012" (trade name, two-terminated amino-modified organosilicon), all manufactured by Shin-Etsu Silicones Co., Ltd. As fluorinated organosilicon compounds, commercially available products include those manufactured by Nichika Chemical Co., Ltd., under the trade names "NK GuardS-07" and "NK Guard S-09". As hydrocarbon compounds, there are high-melting-point wax emulsions: manufactured by Nichika Chemical Co., Ltd., under the trade name "TH-44". These hydrophobic agents are preferably attached to fibers in a dispersed state in water. They are brought into contact with the fibers by methods such as immersing them in the treatment solution, spraying the fibers, or pad printing, and then fixed by heat treatment of curing set. The amount of hydrophobic agent attached is 0.2~2.5% by mass (omf% is an abbreviation for on the mass of fiber), preferably 0.22~2.0omf.

[0023] Multi-layered fiber webs are preferably integrated between layers by the intertwining of the constituent fibers. The constituent fibers of the fiber web are uniformly blended and aligned in one direction by a carding machine, thereby making the fiber web uniform with respect to the X direction (longitudinal direction of the fiber web) and the Y direction (transverse direction of the fiber web), respectively. For the fiber web to be laminated, any layer of nonwoven fabric sheet is uniform. If it is the blending ratio of fused short fibers in this invention, then by uniformly blending them into the fiber web, a satisfactory strength in the surface direction (X, Y directions) is achieved for both the production process and use as clothing and bedding. The lamination of each layer is carried out simultaneously with the processing. That is, the fibers present on the surface of each layer are intertwined while being laminated, thus integrating the layers by the intertwining of the constituent fibers. When laminating the fiber web, in the interlayer direction (Z direction), the fiber density in the space of the fiber web adjacent to the fiber web is smaller than the fiber density in the thickness direction (Z direction) of a single fiber web sheet. Therefore, the lamination of the fiber webs in the thickness direction (Z direction) is achieved by the partial interweaving of short fibers from adjacent webs. By overlapping the webs without applying external force and placing them in a heater (oven) under no-load conditions, a nonwoven fabric sheet achieving the above structure can be formed.

[0024] In addition to the above, it is also preferable to integrate the layers by partial welding based on welded short fibers. Since the density of welded short fibers in the space of the fiber web adjacent to the fiber web is smaller than the density of welded short fibers in the thickness direction (Z direction) of a single fiber web, the proportion of partial welding formed by welded short fibers is higher in the layer with high fiber density than in the interlayer.

[0025] The layers are partially integrated through the interweaving and fusion of short fibers, which not only keeps air between the constituent fibers within the layers, but also between the layers, thus improving the fullness, feel, and insulation.

[0026] This invention preferably does not use adhesives, but integrates the fibers solely through entanglement and partial fusion based on the welded fibers. As a result, the nonwoven fabric sheet of this invention has a uniform structure, ensuring sufficient tensile strength in the planar directions (X, Y directions) while maintaining peel strength in the thickness direction (Z direction) of the laminated state, thus achieving a balance between fullness, soft hand feel, and heat insulation. Examples of adhesives used in integrating the fiber web and nonwoven fabric sheet using adhesives include acrylic, ethylene-vinyl acetate copolymer, polyvinyl acetate, polyvinyl chloride, synthetic rubber, urethane, polyester, or adhesives containing crosslinking agents. Furthermore, methods for attaching the adhesive include spraying and padding. When attaching the adhesive by spraying, the adhesive only adheres to the surface layer. Therefore, the surface layer with the adhesive differs in fiber state from the other layers, resulting in an overall non-uniform state. The central layer without the adhesive has weak tensile strength, leading to problems in physical properties. Furthermore, the adhesive layer not only feels harder, but the weight of the adhesive coating also increases, thus impairing the fullness. When the adhesive is applied using the padding method, it adheres to the entire laminated fiber web, but the amount of adhesive applied differs between the surface and central layers. This results in an uneven overall state, a harder feel, and the entire surface being covered by adhesive, which also leads to a problem of reduced insulation due to the inability to retain a large amount of air.

[0027] The tensile strength of the nonwoven fabric sheet used for cotton wadding in the planar direction (X and Y directions) is preferably more than twice as high as the peel strength between layers (Z direction). This results in a fuller feel and a softer hand feel.

[0028] It provides sufficient strength in both the planar and interlayer directions while maintaining a soft hand feel. By increasing the tensile strength in the planar (X and Y) directions compared to the longitudinal (X) direction of the nonwoven fabric sheet used for cotton wadding, a satisfactory strength can be obtained when making garments. During movement, most actions involve rotation; if the tensile strength in the Y direction is high, it can prevent the nonwoven fabric sheets inside the garment from tearing.

[0029] By integrating the nonwoven fabric without the use of adhesives, and with a tensile strength of 0.3N to 5N in the longitudinal direction (X direction) and a peel force of less than 0.5N in the thickness direction (Z direction) of the cotton wadding nonwoven fabric sheet in the planar direction (X and Y directions), it is possible to achieve a soft hand feel, high heat insulation and sufficient strength.

[0030] When the constituent fibers within the layer are fixed by resin, or when the layers between layers are bonded together by resin, the porosity between the constituent fibers decreases due to the resin, the weight per unit area increases due to the resin, the fullness decreases, the strength is high but the feel is reduced, and it is impossible to achieve a fullness and a soft feel.

[0031] The number of layers in the nonwoven fabric sheet constituting the cotton wadding is preferably 2 to 22, more preferably 4 to 20, and even more preferably 4 to 18. This allows for the fabric to be used in both thin and thick cotton-wadding garments. With fewer than 2 layers (i.e., 1 layer), the nonwoven fabric sheet becomes a single layer, resulting in insufficient air pockets and inadequate insulation. With more than 22 layers, the weight per unit area increases, making it impossible to maintain thickness and air pockets by weight alone, thus hindering sufficient insulation. Furthermore, the cotton tears due to its own weight during the nonwoven fabric sheet manufacturing process, making manufacturing impossible.

[0032] The thickness of the nonwoven fabric sheet used for cotton wadding is 5-50 mm when unloaded and at rest, and its mass (weight per unit area) is preferably 15-250 g / m². 2 Therefore, it can be used for both thin and thick cotton-padded clothing. By changing the processing speed, the thickness and weight per unit area can be adjusted. That is, by decreasing the processing speed, the thickness and weight per unit area can be increased, and by increasing the processing speed, the thickness and weight per unit area can be decreased.

[0033] The method for manufacturing nonwoven fabric sheets for cotton wadding according to the present invention includes the following steps.

[0034] (1) A process of mixing at least polyester staple fibers with welded staple fibers containing a polymer having a lower melting point than the polyester staple fibers, opening the fibers, and forming a fiber web that constitutes fibers substantially arranged in one direction.

[0035] (2) The process of folding and stacking the fiber web to form a long strip of stacked web.

[0036] (3) The process of heating the long strip-shaped laminated mesh to above the melting point of the low-melting-point polymer under no load.

[0037] (4) Cooling and winding process.

[0038] The process (1) is preferably performed by forming a fiber web using a carding machine. The process (2) is preferably performed by stacking multiple layers of fiber web in such a way that the fibers are substantially arranged along one direction of the sheet. The process (3) is preferably performed by placing the long strip of fiber web into a heater (oven) under no load for heat treatment. In addition, the processes (1) to (4) can be performed continuously or separately, but for the sake of work efficiency, continuous performance is preferred.

[0039] The cotton wadding structure of the present invention can be manufactured by filling the aforementioned cotton wadding into the outer fabric and lining with a non-woven fabric sheet. The non-woven fabric sheet for the cotton wadding is easy to work with, can be cut into any shape, and is easy to sew. Furthermore, it has good flatness, allowing for good garment design. As clothing, it is suitable for thermal tops, thermal bottoms, jumpsuits, coats, jackets, ski suits, hats, etc. As bedding, it is suitable for quilts, blankets, robes, knee covers, etc.

[0040] The following description uses the accompanying drawings. In the following drawings, the same symbols represent the same parts. Figure 1 A is a schematic perspective view of a nonwoven fabric sheet 1 for making cotton wadding, which is made of nonwoven fabric according to one embodiment of the present invention. Figure 1 B is Figure 1 A schematic cross-sectional view of line II of A. The cotton wadding is made of nonwoven fabric sheet 1, the constituent fibers 2 are arranged in one direction, and multiple layers are stacked along the arrangement direction of the constituent fibers 2. Figure 1 B's 3a-3f are folded and stacked fiber webs.

[0041] Figure 2 This is a photograph of the end of a nonwoven fabric sheet for cotton wadding according to one embodiment of the present invention. It can be confirmed that the constituent fibers are arranged in one direction and that multiple layers are stacked in the direction of the arrangement of the constituent fibers.

[0042] Figure 3 This is a schematic diagram illustrating the process of manufacturing a laminated web of a nonwoven fabric sheet according to one embodiment of the present invention. 11 is a carding machine, from which unopened short fibers 12 are supplied from feed rollers 13a and 13b. These fibers are opened by the interaction of the licker-in roller 14, the tin cylinder 15, the work rollers 16a and 17a, and the stripping rollers 16b and 17b. The fibers are then stripped by the doffing roller 18 and the vibrating knife 19, and extracted as a fiber web 20. This web is folded and drawn forward or inward as a long, strip-shaped laminated web sheet 22. 21 is the base of the carding machine, and 23 is the device for drawing the fibers forward or inward.

[0043] Figure 4 Is with Figure 3 A continuously configured heating device is used to weld long strips of parallel fiber web 22 through a heating chamber 24 with low-melting-point polyester fibers to form an integrated fiber lining, which is then wound onto a winding body 25 as a thermally bonded nonwoven fabric 1.

[0044] Example

[0045] The present invention will be specifically described below through embodiments. It should be noted that the present invention is not limited to the following embodiments.

[0046] <Insulation properties> KES (Kawabata Evaluation System) measurements were performed using Thermo Lab II at ΔT=20℃. A 20cm x 20cm polyester fabric was used to wrap cotton fibers, serving as a cushion-type sample for measurement. Since the weight per unit area varies depending on the type of cotton, the measured insulation performance (clo value) was divided by the weight per unit area for comparison.

[0047] <Insulation properties in humid conditions> The cushion-type sample was placed in a constant temperature and humidity bath at 40℃ and 90%RH for 12 hours, and then its thermal insulation performance was measured. Since the weight per unit area varies depending on the type of cotton, the measured thermal insulation performance (clo value) was divided by the weight per unit area for comparison.

[0048] <Loft (Thickness)> Cut the cotton into 20cm x 20cm pieces and stack them into 4 layers. Measure the thickness of each side and calculate the average thickness of each piece.

[0049] <Weight per unit area> Four pieces of cotton, each 20cm x 20cm in size, are stacked together. The weight is measured to two decimal places using an electronic balance (SHIMADZU, model: UW4205). The weight per unit area of ​​each piece is calculated. Note that the measured values ​​are rounded to the nearest integer.

[0050] <Density> Calculate based on the measured thickness and weight per unit area, using (weight per unit area ÷ thickness).

[0051] Tensile strength in the planar direction The determination was performed using JIS L 1096:2020 Method A (strip method).

[0052] <Interlayer peel strength> The measurement was performed according to JIS L 1066:2004, based on the condition of peeling 50 mm up and down from the central part of the cotton wadding in the thickness direction.

[0053] In any measurement, the sample was taken from the inner side of the nonwoven sheet at least 20 cm from the end.

[0054] (Example 1) The composition includes 75% by weight of polyethylene terephthalate short fibers (2.8 decitex, fiber length 64 mm), 8% by weight of welded fibers (core-sheath composite fibers formed by a polyester copolymer with a melting point of 140°C, 2.2 decitex, fiber length 51 mm), and 17% by weight of highly cross-linked polyacrylate short fibers (the applicant's commercially available product "Breath Thermo", 2.4 decitex, fiber length 35 mm). Figure 3 The method shown is used to create long, layered meshes, which are then used... Figure 4 The method shown involves heat treatment at 165°C for 3 minutes at a speed of 3 m / min, followed by cooling and winding to obtain a nonwoven fabric sheet for cotton wadding. The unit area weight of this nonwoven fabric sheet for cotton wadding is 115 g / m². 2 The thickness is 21.67 mm. In addition, the tensile strength of the nonwoven fabric sheet for cotton wadding in the face direction (X and Y directions) is 1.26 N in the X direction (longitudinal direction of the nonwoven fabric sheet for cotton wadding) and 2.89 N in the Y direction (transverse direction of the nonwoven fabric sheet for cotton wadding), and the interlayer (Z direction) peel strength is 0.13 N.

[0055] The cotton wadding was filled with non-woven fabric between the outer and lining of a nylon fabric to make an outer jacket. The jacket weighed 353g per piece in men's size M. Wearing tests were conducted, and the results showed that it had a full and soft feel, and its warmth retention was not easily reduced even when wet, confirming its warmth.

[0056] (Example 2) The fusion-bonded fiber was set to 13% by mass, and the processing speed was set to 2 m / min. Otherwise, the process was carried out in the same manner as in Example 1. The nonwoven fabric sheet used for this cotton wadding had a unit area weight of 200 g / m². 2 The thickness is 36.25 mm. In addition, the tensile strength of the nonwoven fabric sheet for cotton wadding in the face direction (X and Y directions) is 3.33 N in the X direction (longitudinal direction of the nonwoven fabric sheet for cotton wadding) and 13.95 N in the Y direction (transverse direction of the nonwoven fabric sheet for cotton wadding), and the interlayer (Z direction) peel strength is 0.28 N.

[0057] (Example 3) Except that the processing speed was set to 2.5 m / min, the process was carried out in the same manner as in Example 2. The nonwoven fabric sheet used for the cotton wadding had a unit area weight of 170 g / m². 2 The thickness is 31.50 mm. In addition, the tensile strength of the nonwoven fabric sheet for cotton wadding in the face direction (X and Y directions) is 1.87 N in the X direction (longitudinal direction of the nonwoven fabric sheet for cotton wadding) and 5.22 N in the Y direction (transverse direction of the nonwoven fabric sheet for cotton wadding), and the interlayer (Z direction) peel strength is 0.17 N.

[0058] (Example 4) Except for setting the speed to 4 m / min, the procedure was carried out in the same manner as in Example 1. The nonwoven fabric sheet used for the cotton wadding had a unit area weight of 60 g / m². 2 The thickness is 20.00 mm. In addition, the tensile strength of the nonwoven fabric sheet for cotton wadding in the face direction (X and Y directions) is 0.46 N in the X direction (longitudinal direction of the nonwoven fabric sheet for cotton wadding) and 0.53 N in the Y direction (transverse direction of the nonwoven fabric sheet for cotton wadding), and the interlayer (Z direction) peel strength is 0.10 N.

[0059] (Example 5) Except that the speed was set to 2 m / min, it was carried out in the same manner as in Example 1. The nonwoven fabric sheet used for the cotton wadding had a unit area weight of 210 g / m². 2 The thickness is 37.5 mm. In addition, the tensile strength of the nonwoven fabric sheet for cotton wadding in the face direction (X and Y directions) is 1.89 N in the X direction (longitudinal direction of the nonwoven fabric sheet for cotton wadding) and 6.16 N in the Y direction (transverse direction of the nonwoven fabric sheet for cotton wadding), and the interlayer (Z direction) peel strength is 0.19 N.

[0060] (Comparative Example 1) The process was carried out in the same manner as in Example 1, except that fused fibers were not used. However, the nonwoven fabric sheet tore during manufacturing, making it impossible to obtain a nonwoven fabric sheet.

[0061] (Comparative Example 2) The physical properties of another company's product, "PrimaLoft" (a nonwoven sheet-shaped cotton wadding), were measured. This is a cotton wadding integrated through an adhesive.

[0062] (Comparative Example 3) The physical properties of another company's product, "Thermore" (a nonwoven sheet-shaped cotton wadding), were measured. This is a cotton wadding integrated through an adhesive.

[0063] (Comparative Example 4) The physical properties of other companies' "Thinsulate" (non-woven sheet-shaped cotton wadding) products were measured. This is cotton wadding integrated through an adhesive.

[0064] (Comparative Example 5) The physical properties of the applicant's commercially available product, "Thermal Loft" (a non-woven sheet-shaped cotton wadding), were determined. This is a cotton wadding integrated by an adhesive.

[0065] (Comparative Example 6) The physical properties of the applicant's commercially available product, "Techfill" (tear-and-shred cotton-shaped wadding), were determined.

[0066] Since it is in the shape of hand-torn cotton, it is not used as a measurement object for fluffiness and density.

[0067] (Comparative Example 7) The physical properties of the applicant's commercially available down products were determined. Since it is down, loft and density were not the measurement objects.

[0068] The results are summarized in Table 1-2.

[0069]

[0070]

[0071] As can be seen from the above embodiments and comparative examples, the nonwoven fabric sheet for cotton wadding of the present invention has a full and soft feel, and its heat retention is not easily reduced even when wet. It can provide a temperature-sensitive nonwoven fabric sheet for cotton wadding, its manufacturing method, and clothing containing the same.

[0072] Industrial availability The nonwoven fabric sheet for cotton wadding of the present invention is suitable for use as cotton wadding clothing worn in cold weather, and is suitable for cold-proof tops, cold-proof bottoms, jumpsuits, coats, jackets, ski suits, hats, bedding, etc.

[0073] Explanation of reference numerals in the attached figures 1. Non-woven fabric sheet for cotton wadding 2. Constituent fibers 3a-3f fiber mesh 11. Combing machine 12 Unopened short fibers 13a, 13b Yarn feeding rollers 14. Zipper Roller 15 Xilin 16a, 17a work rolls 16b, 17b peeling rollers 18 doffing roller 19 Vibrating knife 20 fiber mesh 21. Base of the carding machine 22. Long, strip-shaped, layered mesh 23 Traction device 24 Heating Chamber 25 coils

Claims

1. A nonwoven fabric sheet for cotton wadding, characterized in that, It is a nonwoven fabric sheet for use as cotton wadding, made by blending at least polyester staple fibers with welded staple fibers containing polymers with melting points lower than the polyester staple fibers. The cotton wadding is made of non-woven fabric sheets with multiple layers forming a fiber web that is essentially arranged along one direction of the sheets. The layers of the nonwoven fabric sheet are bonded together by the interweaving of the constituent fibers, and at least a portion of the constituent fibers are fused together by the fused short fiber portions.

2. The nonwoven fabric sheet for cotton wadding according to claim 1, wherein, Relative to 100% by mass of the nonwoven fabric sheet for cotton wadding, the polyester staple fiber is 60-99% by mass, and the fused staple fiber is 1-40% by mass.

3. The nonwoven fabric sheet for cotton wadding according to claim 1 or 2, wherein, In the nonwoven fabric sheet used for cotton wadding, the fiber web has multiple layers stacked in the same direction as the arrangement direction of the constituent fibers.

4. The nonwoven fabric sheet for cotton wadding according to any one of claims 1 to 3, wherein, The welded short fiber is a composite fiber with a core component of polyethylene terephthalate and a sheath component with a melting or softening point of 90~230℃.

5. The nonwoven fabric sheet for cotton wadding according to any one of claims 1 to 4, wherein, The nonwoven fabric sheet used for the cotton wadding also contains highly cross-linked polyacrylate short fibers. The highly cross-linked polyacrylate short fibers account for 1 to 50 parts by weight relative to 100 parts by weight of the total mass of the polyester short fibers and the welded short fibers.

6. The nonwoven fabric sheet for cotton wadding according to any one of claims 1 to 5, wherein, The highly cross-linked polyacrylate fibers were treated with a waterproof coating.

7. The nonwoven fabric sheet for cotton wadding according to any one of claims 1 to 6, wherein, The multi-layered fiber web achieves interlayer integration through the intertwining of the fibers.

8. The nonwoven fabric sheet for cotton wadding according to any one of claims 1 to 7, wherein, The tensile strength of the nonwoven fabric sheet used for cotton wadding in the planar direction (X, Y direction) is more than twice as high as the peel strength between layers (Z direction).

9. The nonwoven fabric sheet for cotton wadding according to any one of claims 1 to 8, wherein, The number of layers in the nonwoven fabric sheet constituting the cotton wadding is 2 to 22.

10. The nonwoven fabric sheet for cotton wadding according to any one of claims 1 to 9, wherein, The thickness of the nonwoven fabric sheet used for the cotton wadding is 5-50 mm under no load and in a static state, and its mass (weight per unit area) is 15-250 g / m². 2 .

11. A method for manufacturing a nonwoven fabric sheet for cotton wadding, characterized in that, It is a method for manufacturing nonwoven fabric sheets for cotton wadding as described in any one of claims 1 to 10, comprising: (1) A process of mixing at least polyester staple fibers with welded staple fibers containing a polymer having a melting point lower than that of the polyester staple fibers, opening the fibers, and forming a web that consists of fibers substantially arranged in one direction. (2) The process of folding and stacking the fiber web to form a long strip of stacked web; (3) The step of heating the elongated fiber web without load to a temperature above the melting point of the low-melting-point polymer; and (4) Cooling and winding process.

12. A cotton wadding structure, wherein the cotton wadding as described in any one of claims 1 to 10 is made of nonwoven fabric sheet.

13. The cotton wadding structure according to claim 12, wherein, The cotton wadding structure is used for clothing or bedding.

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