Downy composite structure

Abstract

A down-like composite structure (1) is provided, comprising a base layer (10) and a down-like layer (11) arranged thereon; wherein the base layer (10) and the down-like layer (11) each comprise a core-mantle fiber (20), a microfiber (21) and a 3D crimped fiber (22); the base layer (10) is produced by cross-stacking the above fibers and has a density of 14 g / m³ 2 up to 40 g / m² 2 ; the down-like layer (11) is produced by randomly stacking the above fibers and has a density of 30 g / m³ 2 up to 400 g / m² 2The microfiber (21) has a fineness of 0.1 D to 1.5 D; the 3D crimped fiber (22) has a hollowness of 5% to 30% and a crimp rate of 2% to 25%. The down-like composite structure (1) has a compression recovery rate of 90% or more. Articles and garments made from the down-like composite structure (1) are also provided.

Description

[0001] The present invention relates to a down-like composite structure. Furthermore, the present invention also relates to articles and clothing manufactured using the down-like composite structure, such as shoes, a duvet, a sleeping bag, a sleeping pad, clothing accessories, and the like.

[0002] Currently, many products made from padded fabrics are on the market, such as clothing and comforters, to meet the demand for warmth. With traditional padded fabrics, the outer and lining fabrics are cut into pieces according to a pattern. These pieces are then sewn into multiple grids, which are filled according to a predetermined pattern. The grids are filled with down or other fiber materials, and the down- or fiber-filled pieces are then assembled into the finished products. Regardless of whether down or fibers are used, the grids are necessary to secure the down or fibers in place, and the filling process is quite laborious because each grid must be filled individually.

[0003] The down or fibers contained in conventional upholstery fabrics come into contact with moisture from the external environment or the user's body, and they also come into direct contact with water, as upholstery fabrics are typically cleaned by washing. Whether exposed to moisture from the air or the user's body, or directly washed with water, the down or fibers within the fabric can clump together due to the moisture or water, shifting or becoming deformed, thus deteriorating the feel, appearance, and warmth of the upholstery fabric. Furthermore, the cut pieces of conventional upholstery fabric must be sewn, resulting in needle holes.This allows the down or fibers to move outwards from the gaps between the fabric fibers and these needle holes (known as fiber migration), and the amount of down or fibers packed into the grids may decrease after prolonged use.

[0004] To overcome the shortcomings of traditional padded fabrics, down-like fiber products were developed and marketed. Although these fiber products are soft and have good resilience, they still need to be filled into meshes, which limits garment design. Furthermore, these fibers tend to tangle easily after washing. Padded fabric, created by stacking multiple layers of non-woven fabrics made from heat-insulating fibers, is a sheet material that is easy to cut and use in garment construction and is less prone to knotting, making it easy to wash. However, the fibers in this padded fabric are combed into non-woven sheets and stacked in layers, and resin is required to fix the fiber attachment points to the surface to prevent fiber migration.Therefore, the padded fabric has a poor recovery rate under compression. A heat-insulating foil material must therefore be provided that is soft, does not require padding, and has good washability and a good recovery rate under compression.

[0005] German patent application DE 695 10 050 T2 discloses a multi-layered, heat-insulating nonwoven fabric, the layers of which each contain a mixture of binding staple fibers and filler staple fibers. The length ratio of the filler staple fibers to the binding staple fibers is at least 2:1. The binding staple fibers are bonded to each other and to other binding staple fibers as well as filler staple fibers to reinforce the structural stability of the nonwoven fabric.

[0006] German patent application DE 38 83 088 T2 discloses a heat-insulating nonwoven mat with face layers and an intermediate middle section. The nonwoven mat consists of structural staple fibers and bonding staple fibers. In the face layers, the fibers are interwoven and arranged essentially parallel to the face layers, while in the middle section they are interwoven and arranged essentially perpendicular to the face layers. The bonding staple fibers are bonded to the structural staple fibers and other bonding staple fibers.

[0007] German patent application DE 38 81 230 T2 discloses a synthetic down filling, in particular a heat-insulating material, consisting of 70% to 95% synthetic polymeric microfibers (3 to 12 µm diameter) and 5% to 30% synthetic polymeric macrofibers (12 to 50 µm diameter), wherein the microfibers are bonded to the macrofibers at the contact points.

[0008] Document US 2017 / 0 362 755 A1 discloses a wadding consisting of a nonwoven fabric containing a fiber mixture of synthetic fibers and binder fibers. The binder fibers have a bonding temperature below the softening temperature of the synthetic fibers, and the nonwoven fabric is structurally composed of 50-95% fiber spheres.

[0009] To overcome these shortcomings, an objective of the present invention is to provide a down-like composite structure that is a sheet material (and can be produced as roll material) for which no fiber filling process is required for manufacture. The down-like composite structure of the present invention has a good CLO value, good washability, and low fiber migration. Furthermore, the down-like composite structure of the present invention does not require resin to fix fiber attachment points on the surface to prevent fiber migration, and it exhibits a good recovery rate upon compression.

[0010] Another objective of the present invention is to provide articles and garments manufactured using the down-like composite structure of the present invention, such as shoes, a duvet, a sleeping bag, a sleeping pad, a clothing accessory and the like.

[0011] To achieve these objectives, the present invention provides a down-like composite structure comprising the following: a base layer, based on the total weight of the down-like composite structure, wherein the base layer has a weight of 9 wt% to 27 wt%; wherein the base layer comprises 30 wt% to 60 wt% of a first core-mantle fiber, 10 wt% to 50 wt% of a first microfiber, and 20 wt% to 30 wt% of a first three-dimensional (3D) crimp fiber; the first core-mantle fiber, the first microfiber, and the first 3D crimp fiber are mixed and cross-stacked to obtain the base layer; and the base layer has a density of 14 g / m³ 2 (grams per square meter or gsm) up to 40 g / m² 2 exhibits; and A down-like layer arranged on the base layer, based on the total weight of the down-like composite structure, wherein the down-like layer has a weight of 73 wt.% to 91 wt.%; the down-like layer comprises 10 wt.% to 30 wt.% of a second core-mantle fiber, 30 wt.% to 70 wt.% of a second microfiber, and 20 wt.% to 40 wt.% of a second 3D crimp fiber, wherein the second core-mantle fiber, the second microfiber, and the second 3D crimp fiber are mixed and randomly stacked to obtain the down-like layer, and the down-like layer has a density of 30 g / m³ 2 up to 400 g / m² 2 exhibits; wherein the first core-sheath fiber and the second core-sheath fiber each comprise a core part and a sheath part, and the sheath part covers part or all of the outer surface of the core part; the core part is made from a new or recycled first polymer material, the sheath part is made from a new or recycled second polymer material, the melting point of the second polymer material is lower than the melting point of the first polymer material, and the melting point of the second polymer material is in the range of 100°C to 200°C; The first microfiber and the second microfiber each have a fineness of 0.1 D to 1.5 D; The first 3D crimped fiber and the second 3D crimped fiber each have a hollowness of 5% to 30%; and The first 3D crimp fiber and the second 3D crimp fiber each have a crimp rate of 2% to 25%.

[0012] In some embodiments, the base layer has a weight of 9% by weight and the down-like layer a weight of 91% by weight of the total weight of the down-like composite structure. In some embodiments, the base layer has a weight of 10% by weight and the down-like layer a weight of 90% by weight of the total weight of the down-like composite structure. In some embodiments, the base layer has a weight of 13% by weight and the down-like layer a weight of 87% by weight of the total weight of the down-like composite structure. In some embodiments, the base layer has a weight of 15% by weight and the down-like layer a weight of 85% by weight of the total weight of the down-like composite structure. In some embodiments, the base layer has a weight of 20% by weight and the down-like layer a weight of 80% by weight of the total weight of the down-like composite structure.In some embodiments, the base layer has a weight of 25% by weight and the down-like layer a weight of 75% by weight of the total weight of the down-like composite structure. In some embodiments, the base layer has a weight of 26% by weight and the down-like layer a weight of 74% by weight of the total weight of the down-like composite structure. In some embodiments, the base layer has a weight of 27% by weight and the down-like layer a weight of 73% by weight of the total weight of the down-like composite structure.

[0013] In some embodiments, the base layer has a thickness of approximately 0.2 cm to 0.3 cm or approximately 0.25 cm to 0.3 cm. In some embodiments, the down-like layer has a thickness of 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.

[0014] In some embodiments, the ratio between the thickness of the base layer and the thickness of the down-like layer is 1:6 to 1:30. In some embodiments, the ratio between the thickness of the base layer and the thickness of the down-like layer is 1:10 to 1:25 or 1:15 to 1:20.

[0015] In some embodiments, the base layer has a density of 14 g / m³. 2 up to 40 g / m² 2 , or 15 g / m² 2 up to 35 g / m² 2 , or 20 g / m² 2 up to 30 g / m² 2 , or 20 g / m² 2 up to 25 g / m² 2 .

[0016] In some embodiments, the down-like layer comprises the second core-mantle fiber, the second microfiber, the second 3D crimp fiber, and air. In the present invention, the three fibers mentioned above are not densely stacked, and a certain amount of air is present between them to enhance the heat-insulating effect. In some embodiments, the down-like layer has a density of 30 g / m³. 2 up to 400 g / m² 2 , or 50 g / m² 2 up to 350 g / m² 2 , or 100 g / m² 2 up to 300 g / m² 2 , or 150 g / m² 2 up to 200 g / m² 2 .

[0017] In some embodiments, the base layer consists of 30 to 60 wt.% of the first core-sheath fiber, 20 to 40 wt.% of the first microfiber and 20 to 30 wt.% of the first 3D crimped fiber.

[0018] In some embodiments, the down-like layer comprises 10 to 30 wt.% of the second core mantle fiber, 40 to 60 wt.% of the second microfiber, and 20 to 40 wt.% of the second 3D crimp fiber.

[0019] In some embodiments, the core portion, based on the total weight of the first core-sheath fiber, is between 40 and 80 wt.% and the sheath portion between 60 and 20 wt.%. In some embodiments, the core portion, based on the total weight of the first core-sheath fiber, is between 40 and 70 wt.% and the sheath portion between 60 and 30 wt.%. In some embodiments, the core portion, based on the total weight of the first core-sheath fiber, is between 40 and 60 wt.% and the sheath portion between 60 and 40 wt.%. In some embodiments, based on the total weight of the first core-sheath fiber, the core portion is between 45 and 55 wt.% and the sheath portion is between 55 and 45 wt.%. In some embodiments, the core portion, based on the total weight of the first core-sheath fiber, is between 48 and 52 wt.% and the sheath portion is between 52 and 48 wt.%.In some embodiments, the core part is 50 wt.% and the sheath part is 50 wt.%, based on the total weight of the first core-sheath fiber.

[0020] In some embodiments, the core portion, based on the total weight of the second core-sheath fiber, is between 40 and 80 wt.% and the sheath portion between 60 and 20 wt.%. In some embodiments, the core portion, based on the total weight of the second core-sheath fiber, is between 40 and 70 wt.% and the sheath portion between 60 and 30 wt.%. In some embodiments, the core portion, based on the total weight of the second core-sheath fiber, is between 40 and 60 wt.% and the sheath portion between 60 and 40 wt.%. In some embodiments, based on the total weight of the second core-sheath fiber, the core portion is between 45 and 55 wt.% and the sheath portion is between 55 and 45 wt.%. In some embodiments, the core portion, based on the total weight of the second core-sheath fiber, is between 48 and 52 wt.% and the sheath portion is between 52 and 48 wt.%.In some embodiments, the core part is 50 wt. % and the sheath part is 50 wt. %, based on the total weight of the second core-sheath fiber.

[0021] In some embodiments, the first polymer material and the second polymer material are individually selected from a group consisting of polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), polyethylene terephthalate copolymer (PET copolymer, coPET), or other polymer analogues. In some embodiments, the combination of the first polymer material and the second polymer material is represented as the first polymer material / second polymer material (i.e., core part / shell part), and the combination is selected from a group consisting of polyethylene terephthalate / polyethylene (PET / PE), polyethylene terephthalate / polyethylene terephthalate copolymer (PET / coPET), and polypropylene / polyethylene (PP / PE).In some embodiments, the polyethylene terephthalate copolymer is a co-polyester of PET and a dicarboxylic acid, wherein the dicarboxylic acid can be selected from aliphatic dicarboxylic acids and aromatic dicarboxylic acids; wherein the aliphatic dicarboxylic acids can be oxalic acid, malonic acid, succinic acid, adipic acid and the like; the aromatic dicarboxylic acids can be isophthalic acid, sulfoisophthalic acid and the like.

[0022] In some embodiments, the melting point of the second polymer material is lower than the melting point of the first polymer material, and the melting point of the second polymer material is in the range of 100°C to 200°C, or 120°C to 180°C, or 140°C to 160°C, or 140°C to 150°C.

[0023] Within the scope of the present invention, the term "virgin material" means that the material is a raw material that has not previously been used to manufacture products. Within the scope of the present invention, the term "recycled" means that the material is residue from industrially manufactured products or is a recycled material and not a raw material. Using the most common recycled polyester material as an example, it can be said that the regenerated polyester materials from which fibers can be produced have two main sources: pre-consumer and post-consumer polyester fabrics and post-consumer PET bottles; these polyester materials are recycled and converted into an environmentally friendly regenerated fiber material by physical or chemical processes. Within the scope of the present invention, the terms "recycled" and "regenerated" can be used interchangeably.

[0024] In some embodiments, the down-like composite structure of the present invention comprises a regenerated component in an amount of 20% or more (≥20%) that meets the GRS certification standard. In some embodiments, the down-like composite structure of the present invention comprises a regenerated component in an amount of 30% or more (≥30%), or 35% or more (≥35%).

[0025] In some embodiments, the first core-sheath fiber has a fineness of 1.5 denier (D) to 15 D, or 1.5 D to 10 D, or 2 D to 5 D, or 2 D to 4 D, or 2 D to 3 D. In some embodiments, the second core-sheath fiber has a fineness of 1.5 D to 15 D, or 1.5 D to 10 D, or 2 D to 5 D, or 2 D to 4 D, or 2 D to 3 D.

[0026] In some embodiments, the first core-sheath fiber has a cross-section that is circular or trilobal; if the cross-section is circular, the core portion of the cross-section is located centrally or off-center within the circular cross-section, and the sheath portion covers the entire outer surface of the core portion; if the cross-section is trilobal, the sheath portion covers a portion of the outer surface of the core portion. In some embodiments, the cross-section of the first core-sheath fiber is trilobal, and the sheath portions are located at the end portions of each lobe of the trilobal cross-section.

[0027] In some embodiments, the second core-sheath fiber has a cross-section that is circular or trilobal; if the cross-section is circular, the core portion is located centrally or off-center within the circular cross-section, and the sheath portion covers the entire outer surface of the core portion; if the cross-section is trilobal, the sheath portion covers a portion of the outer surface of the core portion. In some embodiments, the cross-section of the second core-sheath fiber is trilobal, and the sheath portions are located at the end portions of each lobe of the trilobal cross-section.

[0028] In some embodiments, the first core-sheath fiber is a two-dimensional (2D) serrated fiber. In some embodiments, the second core-sheath fiber is a serrated 2D fiber.

[0029] In some embodiments, the first core-sheath fiber and the second core-sheath fiber are the same fiber. In some embodiments, the first core-sheath fiber and the second core-sheath fiber are different fibers.

[0030] In some embodiments, the first microfiber is produced from a new or recycled third polymer material, and the third polymer material is 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 a combination thereof. In some embodiments, the second microfiber is produced from a new or recycled third polymer material, and the third polymer material is selected from the group consisting of polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), polybutylene terephthalate (PBT), polyamide (PA), and a combination thereof.

[0031] In some embodiments, the first microfiber has a fineness of 0.1 D to 1.5 D, or 0.5 D to 1.5 D, or 0.7 D to 1.5 D, or 0.9 D to 1.5 D, or 0.9 D to 1.4 D, or 1.0 D to 1.4 D. In some embodiments, the second microfiber has a fineness of 0.1 D to 1.5 D, or 0.5 D to 1.5 D, or 0.7 D to 1.5 D, or 0.9 D to 1.5 D, or 0.9 D to 1.4 D, or 1.0 D to 1.4 D.

[0032] In some embodiments, the first microfiber is a solid fiber or a hollow fiber. In some embodiments, the second microfiber is a solid fiber or a hollow fiber.

[0033] In some embodiments, the first microfiber is a hollow fiber with a hollowness of 3% to 25%, or 5% to 20%, or 10% to 20%. In some embodiments, the second microfiber is a hollow fiber with a hollowness of 3% to 25%, or 5% to 20%, or 10% to 20%.

[0034] In some embodiments, the first microfiber is a serrated 2D fiber. In some embodiments, the second microfiber is a serrated 2D fiber.

[0035] In some embodiments, the 3D crimped fiber is a bicomponent fiber.

[0036] In some embodiments, the first 3D crimped fiber is a side-by-side bicomponent fiber, and the side-by-side bicomponent fiber comprises a first side part and a second side part arranged parallel to each other; the first side part is made of a new or recycled fourth polymer material, the second side part is made of a new or recycled fifth polymer material, and the fourth and fifth polymer materials are individually selected from a group consisting of polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), polyethylene terephthalate copolymer (coPET), polybutylene terephthalate (PBT), polyamide (PA), and other polymer analogues.

[0037] In some embodiments, the second 3D crimp fiber is a side-by-side bicomponent fiber, and the side-by-side bicomponent fiber comprises a first side part and a second side part arranged parallel to each other, wherein the first side part is made of a new or recycled fourth polymer material, the second side part is made of a new or recycled fifth polymer material, and the fourth and fifth polymer materials are individually selected from a group consisting of polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), polyethylene terephthalate copolymer (coPET), polybutylene terephthalate (PBT), polyamide (PA) and other polymer analogues.

[0038] In some embodiments, the fourth and fifth polymer materials are individually selected from a group consisting of polyethylene (PE), polypropylene, polyethylene terephthalate, polyethylene terephthalate copolymer (PET copolymer, coPET), or other polymer analogues. In some embodiments, the combination of the fourth and fifth polymer materials is represented as fourth / fifth polymer material (i.e., first side part / second side part), and the combination is selected from a 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 embodiments, the polyethylene terephthalate copolymer is a co-polyester of PET and a dicarboxylic acid, wherein the dicarboxylic acid can be selected from aliphatic dicarboxylic acids and aromatic dicarboxylic acids; wherein the aliphatic dicarboxylic acids can be oxalic acid, malonic acid, succinic acid, adipic acid and the like; the aromatic dicarboxylic acids can be isophthalic acid, sulfoisophthalic acid and the like.

[0039] In some embodiments, the combination of the fourth and fifth polymer materials is represented as fourth / fifth polymer material, and the combination is first polyethylene terephthalate / second polyethylene terephthalate (PET / PET), wherein the first and second polyethylene terephthalates have different inherent viscosities (IV). If the first and second polyethylene terephthalates have an inherent viscosity difference (ΔIV) of 0.15 dL / g or more, good 3D crimping can be achieved; preferably, ΔIV is 0.25 dL / g or more. If ΔIV is less than 0.15 dL / g, the curling rate is too low to achieve a sufficient 3D curling rate.

[0040] In some embodiments, the first 3D crimped fiber is a solid fiber or a hollow fiber. In some embodiments, the first 3D crimped fiber is a solid fiber with a cross-section that is either circular or peanut-shaped; if the cross-section is circular, the first and second side parts of the cross-section are semicircular and arranged opposite each other; if the cross-section is peanut-shaped, the first and second side parts of the cross-section join at the center of the cross-section and project individually at both ends.In some embodiments, the first 3D crimped fiber is a hollow fiber with a cross-section that is circular and has a hollow part; if the hollow part is arranged centrally in the circular cross-section, the first side part and the second side part are C-shaped in approximately the same shape; if the hollow part is not arranged centrally in the circular cross-section, the first side part and the second side part are C-shaped in different shapes.

[0041] In some embodiments, the second 3D crimped fiber is a solid fiber or a hollow fiber. In some embodiments, the second 3D crimped fiber is a solid fiber with a cross-section, and the cross-section is circular or peanut-shaped; if the cross-section is circular, the first and second side portions of the cross-section are semicircular and arranged opposite each other; if the cross-section is peanut-shaped, the first and second side portions of the cross-section join at the center of the cross-section and project individually to both ends.In some embodiments, the second 3D crimped fiber is a hollow fiber with a cross-section that is circular and has a hollow part; if the hollow part is arranged centrally in the circular cross-section, the first side part and the second side part are C-shaped in approximately the same shape; if the hollow part is not arranged centrally in the circular cross-section, the first side part and the second side part are C-shaped in different shapes.

[0042] In some embodiments, the hollow part of the cross-section has a smaller diameter than the circular cross-section. In some embodiments, the hollow part is circular.

[0043] In some embodiments, the first 3D crimped fiber has a fineness of 1 D to 15 D, or 5 D to 12 D, or 7 D to 10 D. In some embodiments, the second 3D crimped fiber has a fineness of 1 D to 15 D, or 5 D to 12 D, or 7 D to 10 D.

[0044] In some embodiments, the first 3D crimped fiber has a hollowness of 5% to 30% or 10% to 25% or 15% to 20%; in some embodiments, the second 3D crimped fiber has a hollowness of 5% to 30% or 10% to 25% or 15% to 20%.

[0045] In some embodiments, the first 3D crimped fiber has a crimp rate of 2% to 25%, or 5% to 20%, or 7% to 15%, or 7% to 10%. In some embodiments, the second 3D crimped fiber has a crimp rate of 2% to 25%, or 5% to 20%, or 7% to 15%, or 7% to 10%.

[0046] In the present invention, the first core-sheath fiber (with a sheath portion formed by the second polymer material having a lower melting point), the first microfiber, and the first 3D crimp fiber are mixed and cross-stacked to form a base layer as base layer roll material; then, the base layer roll material is transported directly under a discharge machine by a first conveyor, while the second core-sheath fiber (with a sheath portion formed by the second polymer material having a lower melting point), the second microfiber, and the second 3D crimp fiber are mixed and randomly stacked to form a down-like prepared layer, and the down-like prepared layer is superimposed on the base layer;The base layer, which is overlaid with the down-like prepared layer, is then fed to a heating device and heated to a temperature of 125°C or more in order to melt the sheath parts of the first and second core-sheath fibers (which are formed by the second polymer material with a lower melting point) in the base layer and the down-like prepared layer and to bond the first and second core-sheath fibers to adjacent fibers;After curing and cooling to room temperature, the down-like prepared layer is formed into the down-like layer, thereby obtaining the down-like composite structure of the present invention, which can be directly rolled to produce a down-like composite roll material. The first and second core-sheath fibers can reinforce the cross-linked structure of the first and second core-sheath fibers and other fibers (the first and second microfibers and the first and second 3D crimp fibers) to obtain the structures of the base layer and the down-like layer. The first and second core-sheath fibers are part of the materials of the base layer and the down-like layer, respectively; after the sheath parts melt, the core parts can still provide support, so that the aforementioned melting and bonding steps do not unduly affect the expansion of the base layer and the down-like layer.

[0047] In some embodiments, the first core-sheath fiber, the first microfiber, and the first 3D crimped fiber are evenly mixed.

[0048] In some embodiments, the second core sheath fiber, the second microfiber, and the second 3D crimp fiber are evenly mixed.

[0049] In some embodiments, the second core-mantle fiber, the second microfiber, and the second 3D crimp fiber are mixed and randomly stacked and absorbed by a vacuum from a vacuum device to form the down-like prepared layer.

[0050] In some embodiments, the down-like composite structure of the present invention can maintain a solid form without an additional fixing layer (such as a fixing layer formed by spraying a resin onto the down-like layer).

[0051] In some embodiments, the first core-sheath fiber of the base layer can bind the adjacent first and second core-sheath fibers, the adjacent first and second microfibers, and the adjacent first and second 3D crimp fibers to form multiple binding points across the sheath portion of the first core-sheath fiber. In some embodiments, the second core-sheath fiber of the downy layer can bind the adjacent first and second core-sheath fibers, the adjacent first and second microfibers, and the adjacent first and second 3D crimp fibers to form multiple binding points across the sheath portion of the second core-sheath fiber.

[0052] In some embodiments, the down-like composite structure of the present invention has a compression recovery rate of more than 90% or more than 91% or more than 92% or more than 93% or more than 94% or more than 95%.

[0053] In some embodiments, the clothing produced by the down-like composite structure of the present invention can be, but is not limited to, a shirt, a blouse, trousers, a skirt, a vest or a coat.

[0054] In some embodiments, the object produced by the down-like composite structure of the present invention can be a shoe, a duvet, a sleeping bag, a sleeping pad or a clothing accessory, but is not limited to these.

[0055] In the drawings: Fig. Figure 1 is a three-dimensional schematic representation of the down-like composite structure of the present invention. Fig. Figure 2A is a schematic representation of the core-sheath fiber of the present invention. Fig. Figure 2B is a schematic representation of the microfiber of the present invention. Fig.Figure 2C is a schematic representation of the 3D crimped fiber of the present invention. Fig. Figures 3A to 3C are schematic cross-sectional representations of the core-sheath fiber of the present invention. Fig. Figures 3D to 3G are schematic cross-sectional representations of the 3D crimped fiber of the present invention. Fig. Figure 4 is a schematic diagram of the manufacturing process of the down-like composite structure of the present invention. Fig. 5A is a photograph of the multi-layered structure of commercially available upholstered fabric. Fig. Figure 5B is a photograph of the down-like composite structure of the present invention.

[0056] Further tasks, advantages and new features of the invention will become clearer from the following detailed description in conjunction with the accompanying drawings. Production of the down-like composite structure of the present invention

[0057] As in Fig. 1 and Fig. As shown in Figures 2A to 2C, the down-like composite structure of the present invention 1 comprises a base layer 10 and a down-like layer 11, the down-like layer 11 being arranged on the base layer 10. Based on the total weight of the down-like composite structure 1, the base layer 10 has a weight of 9 wt.% to 27 wt.%; the base layer 10 comprises 30 wt.% to 60 wt.% of a first core-sheath fiber 20, 10 wt.% to 50 wt.% of a first microfiber 21, and 20 wt.% to 30 wt.% of a first 3D crimp fiber 22; the first core-sheath fiber 20, the first microfiber 21, and the first 3D crimp fiber 22 are mixed and cross-stacked to obtain the base layer 10 (not shown in the figures). and the base layer 10 has a density of 14 g / m² 2 up to 40 g / m² 2Furthermore, the down-like layer 11 has a weight of 73 wt.% to 91 wt.% of the total weight of the down-like composite structure 1; the down-like layer 11 comprises 10 wt.% to 30 wt.% of a second core-mantle fiber 20, 30 wt.% to 70 wt.% of a second microfiber 21, and 20 wt.% to 40 wt.% of a second 3D crimp fiber 22; the second core-mantle fiber 20, the second microfiber 21, and the second 3D crimp fiber 22 are mixed and randomly stacked to obtain the down-like layer 11; and the down-like layer 11 has a density of 30 g / m³ 2 up to 400 g / m² 2 exhibits. In Fig. Figure 1 shows the down-like layer 11 locally magnified, and it can be seen that the stacked fibers have a fluffy, cloud-like shape. The first and second core-mantle fibers 20 (as in Fig. 2A shown) and the first and second microfibers 21 (as in Fig.2B) are 2D serrated fibers, and the first and second 3D coiled fibers 22 (as in Fig. 2C shown) are 3D crimp fibers. The second core-mantle fiber 20, the second microfiber 21 and the second 3D crimp fiber 22 of the down-like layer 11 are not intensively stacked on top of each other, and a certain amount of air is contained between them (not shown in the figures).

[0058] The first core-sheath fiber 20 and the second core-sheath fiber 20 each comprise a core part 200 and a sheath part 201, and the sheath part 201 covers part or all of the outer surface of the core part 200; the core part 200 is made of a new or recycled first polymer material, the sheath part 201 is made of a new or recycled second polymer material, and the melting point of the second polymer material is lower than that of the first polymer material and is in the range of 100°C to 200°C. The first polymer material and the second polymer material are individually selected from a group consisting of polyethylene, polypropylene, polyethylene terephthalate, polyethylene terephthalate copolymer, and other polymer analogues.

[0059] Where, with respect to the total weight of the first core-sheath fiber 20, the core part 200 is present in an amount of 50 wt.% and the sheath part 201 in an amount of 50 wt.%; and with respect to the total weight of the second core-sheath fiber 20, the core part 200 is present in an amount of 50 wt.% and the sheath part 201 in an amount of 50 wt.%. The cross-sections of the first core-sheath fiber 20 and the second core-sheath fiber 20 can each comprise one or more configurations, for example, the first core-sheath fiber 20 and the second core-sheath fiber 20 can each have a cross-section, and the cross-section is circular or trilobal; if the cross-section is circular, the core part 200 is central (as in Fig. 3A shown) or not central (as in Fig.(3B shown) in the circular cross-section, and the sheath part 201 covers the entire outer surface of the core part 200; if the cross-section is trilobal, the sheath part 201 covers part of the outer surface of the core part 200, and the sheath parts 201 are arranged at the end parts of each lobe of the trilobal cross-section (as in Fig. 3C shown).

[0060] wherein the first microfiber 21 and the second microfiber 21 are individually manufactured from a new or recycled third polymer material selected from a group consisting of polyethylene, polypropylene, polyethylene terephthalate, polytrimethylene terephthalate, polybutylene terephthalate, polyamide and a combination thereof.

[0061] Where the first microfiber 21 and the second microfiber 21 each have a fineness of 0.1 D to 1.5 D.

[0062] wherein the first 3D crimp fiber 22 and the second 3D crimp fiber 22 are each individually a side-by-side bicomponent fiber, and the side-by-side bicomponent fiber comprises a first side part 220 and a second side part 221 arranged parallel to each other, wherein the first side part 220 is made of a new or recycled fourth polymer material, the second side part 221 is made of a new or recycled fifth polymer material, and the fourth polymer material and the fifth polymer material are individually selected from polyethylene, polypropylene, polyethylene terephthalate, polyethylene terephthalate copolymer, polybutylene terephthalate, polyamide and other polymer analogues.

[0063] The cross-section of the first 3D crimped fiber 22 and the second 3D crimped fiber 22 can each comprise one or more configurations; for example, the first and second 3D crimped fiber 22 can each be a solid fiber with a cross-section that is circular or peanut-shaped; if the cross-section is circular, the first side part 220 and the second side part 221 of the cross-section are semicircular and arranged opposite each other (as in Fig. 3D); if the cross-section is peanut-shaped, the first side part 220 and the second side part 221 of the cross-section join in the middle of the cross-section and project individually to both ends (as in Fig.3E); or the first and second 3D crimp fibers 22 can each be a hollow fiber with a cross-section, the cross-section being circular, and the cross-section having a hollow part; if the hollow part is arranged centrally in the circular cross-section, the first side part 220 and the second side part 221 are C-shaped in approximately the same form (as in Fig. 3F shown); if the hollow part is not arranged centrally in the circular cross-section, the first side part 220 and the second side part 221 are C-shaped in different forms (as shown in Fig. 3G shown).

[0064] Where the first and second 3D crimped fiber 22 each have a hollowness of 5% to 30%.

[0065] The first and second 3D crimp fibers 22 each have a crimp rate of 2% to 25%.

[0066] The manufacturing process of the down-like composite structure of the present invention 1 is described in Fig.Figure 4 illustrates this. First, the first core-sheath fiber 20, the first microfiber 21, and the first 3D crimped fiber 22 were mixed and stacked crosswise to form a base layer 10 as roll material; then, the roll material of the base layer 10 was transported by a first conveyor 30 directly under a discharge machine 2. The discharge machine 2 had a feed hopper 40, a second conveyor 50, and a heating device 60.The second core-sheath fiber 20, the second microfiber 21, and the second 3D crimp fiber 22 were fed from the feed hopper 40 into the discharge machine 2, and the second core-sheath fiber 20, the second microfiber 21, and the second 3D crimp fiber 22 were mixed and dropped randomly to stack and form a down-like prepared layer 12, and the down-like prepared layer 12 was transported by the second conveyor 50 to lay on top of the base layer 10 transported by the first conveyor 30; thereafter, the base layer 10, superimposed with the downward-facing prepared layer 12, was sent to a heating device 60.The heating device 60 could heat to a temperature of 125°C or more to melt the sheath sections 201 (which consist of a polymer material with a lower melting point) of the first core-sheath fiber 20 in the base layer 10 and of the second core-sheath fiber 20 in the downy layer 11, thus bonding adjacent fibers. After curing and cooling to room temperature, the downy prepared layer 12 was formed into the downy layer 11, thereby obtaining the downy composite structure of the present invention 1, which could be directly rolled to produce a roll material of the downy composite structure 1. A vacuum device (not shown in the figures) could be arranged under the second conveyor 50 to create a slight downward vacuum so that the downy prepared layer 12 retains a solid shape.

[0067] In some embodiments, the first core-sheath fiber 20 of the base layer 10 can bind the adjacent first and second core-sheath fibers 20, the adjacent first and second microfibers 21, and the adjacent first and second 3D crimp fibers 22 to form multiple binding points across the sheath portion 201 of the first core-sheath fiber 20. Similarly, the second core-sheath fiber 20 of the down-like layer 11 could bind the adjacent first and second core-sheath fibers 20, the adjacent first and second microfibers 21, and the adjacent first and second 3D crimp fibers 22 to form multiple binding points across the sheath portion 201 of the second core-sheath fiber 20.

[0068] The down-like composite structure of the present invention 1 could maintain a solid form without an additional fixing layer (e.g. a fixing layer formed by spraying a resin onto the down-like layer to fix the fiber attachment points on the surface and thereby prevent fiber migration).

[0069] Fig. Figure 5A is a photograph showing a commercially available upholstered fabric whose structure consists of multiple layers of nonwoven fabrics composed of heat-insulating fibers, and the photograph of the down-like composite structure of the present invention is in Fig. Figure 5B illustrates the structural difference, which can be seen with the naked eye. The down-like composite structure of the present invention has a uniformly distributed down-like layer with irregularly stacked, fluffy fiber masses that resemble clouds. Features of the down-like composite structure of the present invention

[0070] The down-like composite structures of examples 1 to 6 were made with the following materials: 1. The base layer (1) 30 wt.% to 60 wt.% of the first core-sheath fiber: - The core / sheath material is regenerated PET / regenerated coPET, and the core and sheath each comprise 50 wt%; the sheath covers the entire outer surface of the core; the fiber cross-section is circular, with the core part of the cross-section located centrally within the circular cross-section of the first core-sheath fiber; - the fineness ranges from 2 D to 4 D. (2) 10 wt.% to 50 wt.% of the first microfiber: - the material is recycled PET; - the fineness ranges from 0.9 D to 1.4 D; - Solid fibers or hollow fibers with a void content of 5% to 20%. (3) 20 wt.% to 30 wt.% of the first 3D crimp fiber: - the material of the first side part / second side part is regenerated PET / regenerated PET, wherein the inherent viscosity difference (ΔIV) between the first polyethylene terephthalate of the first side part and the second polyethylene terephthalate of the second side part is 0.15 dL / g or more; solid fiber with a circular cross-section, and the first side part and the second side part of the cross-section have a semicircular shape and are arranged opposite each other; - the fineness ranges from 1 D to 15 D; - the void content is 5% to 30%; - the crimp rate is 2% to 25%. 2. The down-like layer (1) 10 wt.% to 30 wt.% of the second core-sheath fiber: - The core / sheath material is regenerated PET / regenerated coPET, and the core and sheath each comprise 50 wt%; the sheath covers the entire outer surface of the core; the fiber cross-section is circular, with the core part of the cross-section located centrally within the circular cross-section of the second core-sheath fiber; - the fineness ranges from 2 D to 4 D. (2) 30 wt.% to 70 wt.% of the second microfiber: - the material is recycled PET; - The fineness ranges from 0.1 D to 1.5 D; - Solid fibers or hollow fibers with a void content of 5% to 20%. (3) 20 wt.% to 40 wt.% of the second 3D crimp fiber: - the material of the first side part / second side part is regenerated PET / regenerated PET, wherein the inherent viscosity difference (ΔIV) between the first polyethylene terephthalate of the first side part and the second polyethylene terephthalate of the second side part is 0.15 dL / g or more; solid fiber with a circular cross-section, and the first side part and the second side part of the cross-section have a semicircular shape and are arranged opposite each other; - the fineness ranges from 1 D to 15 D; - the void content is 5% to 30%; - the crimp rate is 2% to 25%.

[0071] The CLO value of the down-like composite structure of Examples 1 to 6 (E1 to E6) of the present invention was measured. The results are shown in Table 1 below: Table 1 E1 E2 E3 E4 E5 E6 Base layer Density (g / m³) 2 ) 16 16 22 22 30 30 Thickness (cm) 0.1 0.1 0.2 0.2 0.3 0.3 down-like layer Density (g / m³) 2 ) 34 64 78 118 150 190 Thickness (cm) 1.10 1.84 1.15 1.66 2.28 2.49 Down-like composite structure Density (g / m³) 2 ) 60 80 100 140 180 220 Thickness (cm) 1.2 1.94 1.35 1.86 2.58 2.79 CLO value (CLO) 1.27 1.66 2.12 2.74 3.21 3.67

[0072] Table 1 shows that a higher density results in a higher CLO value when the same material is used for the base layer and the down-like layer. Furthermore, a thermal insulation material (foil material) was used as a comparative example 1 (consisting of 10% to 20% of a core-sheath fiber with a fineness of 2D to 4D and a sheath portion of a low-melting-point material, 20% to 40% of a microfiber with a fineness of 0.9D to 1.2D, and 50% to 60% of a 3D crimped hollow fiber with a fineness of 3D to 7D; and with a total weight per unit area of ​​200 g / m²). 2 ); and a commercially available traditional down-like material (upholstery fabric) was used as a comparative example 2 (with fibers in the grids comprising 0% to 100% of a microfiber with a fineness of 0.9 D to 1.2 D and 100% to 0% of a crimped 3D hollow fiber with a fineness of 3 D to 7 D; and with a basis weight of 200 g / m²2 ), and example 5 (with a total basis weight of 180 g / m²) 2 ), which had a similar basis weight, was selected for measurement and comparison with comparison examples 1 and 2.

[0073] Example 5 (E5) and comparison examples 1 and 2 (CE1 and CE2) are measured according to the standard methods below. The results are shown in Table 2 below. 1. Basis weight: measured according to the standard method ASTM D3776 with the unit grams per square meter (abbreviated as gsm or g / m²). 2 ). 2. Thickness: measured according to the standard method ASTM D5736-95. 3. Insulation value of clothing (CLO value): measured according to the standard method ASTM D1518 to obtain the CLO value with one unit of CLO. 4. Washability: measured according to the standard method ASTM D4770. The measurement results are classified into five levels, with level 5 representing the best washability. Two types of samples were used for the washability tests: 40 cm × 40 cm (with a 10 cm × 10 cm grid) and 30 cm × 30 cm. (1) Testing of thermal insulating materials in sheet or roll form: a sample measuring 30 cm × 30 cm, the sample size used for thermal insulating materials in sheet or roll form. In comparison example 2, the material was a traditional down-like material (padded fabric), not a sheet material, so a 30 cm × 30 cm sample was cut directly for measurement (without sewing a grid onto it). Generally, a resin is used to fix the fiber bonding points on the surface of sheet thermal insulation materials, thus improving the washability of these materials. (2) Testing of padded fabrics: a sample measuring 40 cm × 40 cm (with a 10 cm × 10 cm grid) used for conventional down-like materials. In comparison example 1, a layered material was used, not a padded fabric, so a 40 cm × 40 cm sample was cut directly for measurement (without sewing on a grid). In general, in conventional down-like materials, the down is filled into grids, no low-melting-point fibers are added, and no resin is used to fix the fiber bonding points on the surface, so the down fibers easily become entangled in the grids during washing; furthermore, the larger size of the grids results in reduced washability. 5. Fiber migration after washing: measured according to the standard method ASTM D4770. The measurement results have five levels, with level 5 representing the lowest fiber migration after washing. 6. Recovery rate upon compression: measured according to the standard method ASTM D6571-01. Table 2 E5 CE1 CE2 Down-like composite structure Heat-insulating material Traditional down-like material Fiber arrangement Base layer: horizontal and ordered Horizontal and ordered Random number generator Down-like layer: random Total weight per unit area (g / m²) 2 ) 180 200 200 Thickness (cm) 3.2 3.2 3.0 CLO value (CLO) 3.4 3.4 3.2 CLO value / thickness (CLO / cm) 1.06 1.06 1.07 Washability (30x30) 5 washes Level 4 Level 4 Level 1 10 washes Level 4 Level 4 Level 1 Washability (40x40) 5 washes Level 4 Level 4 Level 4 10 times Level 4 Level 4 Level 4 wash Fiber optic migration 3 washes Level 5 Level 5 Level 5 Recovery rate after compression (%) 92.7% 72.0% 83.6% Processability for the processing of clothing Grid Not required Not required Needed Fiber filling process No No Needed

[0074] The down-like composite structure of the present invention comprises a combination of a base layer with horizontally and orderedly arranged fibers and a down-like layer with randomly arranged fibers, such that the down-like composite structure of the present invention exhibits a better expansion and recovery rate upon compression. Comparative example 1 with horizontally and orderedly arranged fibers has good washability; comparative example 2 with randomly arranged fibers has good elongation; however, the two comparative examples cannot exhibit both good elongation and good washability and also have a lower recovery rate upon compression.To achieve good washability, the grid size in the traditional down-like material of Comparative Example 2 must be taken into account; however, the down-like composite structure of the present invention and Comparative Example 1 can exhibit good washability without taking a grid problem into account.

[0075] It is clear from the above that the present invention provides a down-like composite structure, which is a sheet material that can be manufactured as roll material and can be directly applied to the designs of heat-insulating garments and articles (such as shoes, a down comforter, a sleeping bag, a sleeping pad, clothing accessories, etc.). No fiber filling process is required, and the down-like composite structure of the present invention has a soft, downy feel, a good CLO value, good washability, and low fiber migration. Furthermore, the down-like composite structure of the present invention does not require resin to fix fiber attachment points on the surface to prevent fiber migration, and it exhibits a good recovery rate under compression.

[0076] Although numerous features and advantages of the present invention have been set forth in the preceding description, along with details of the invention's structure and features, the disclosure is for illustrative purposes only. Changes may be made in the details, particularly regarding the shape, size, and arrangement of the parts, within the principles of the invention, to the full extent expressed by the broad general meaning of the terms in the accompanying claims.

Claims

[1] Down-like composite structure (1), comprising: a base layer (10) based on the total weight of the down-like composite structure (1), wherein the base layer (10) has a weight of 9 wt.% to 27 wt.%; wherein the base layer (10) comprises 30 wt.% to 60 wt.% of a first core-mantle fiber (20), 10 wt.% to 50 wt.% of a first microfiber (21), and 20 wt.% to 30 wt.% of a first 3D crimp fiber (22); the first core-mantle fiber (20), the first microfiber (21), and the first 3D crimp fiber (22) are mixed and cross-stacked to obtain the base layer (10), and the base layer (10) has a density of 14 g / m³ 2 up to 40 g / m² 2 exhibits; and a down-like layer (11) arranged on the base layer (10) based on the total weight of the down-like composite structure (1), wherein the down-like layer (11) has a weight of 73 wt.% to 91 wt.%; wherein the down-like layer (11) comprises 10 wt.% to 30 wt.% of a second core-mantle fiber (20), 30 wt.% to 70 wt.% of a second microfiber (21), and 20 wt.% to 40 wt.% of a second 3D crimp fiber (22); the second core-mantle fiber (20), the second microfiber (21), and the second 3D crimp fiber (22) are mixed and randomly stacked to obtain the down-like layer (11), and the down-like layer (11) has a density of 30 g / m³ 2 up to 400 g / m² 2 exhibits; wherein the first core-sheath fiber (20) and the second core-sheath fiber (20) each comprise a core part (200) and a sheath part (201), and the sheath part (201) covers part or all of the outer surface of the core part (200); the core part (200) is made of a new or recycled first polymer material, the sheath part (201) is made of a new or recycled second polymer material, the melting point of the second polymer material is lower than the melting point of the first polymer material, and the melting point of the second polymer material is in the range of 100°C to 200°C; the first microfiber (21) and the second microfiber (21) each have a fineness of 0.1 D to 1.5 D; the first 3D crimp fiber (22) and the second 3D crimp fiber (22) each have a hollowness of 5% to 30%; and the first 3D crimp fiber (22) and the second 3D crimp fiber (22) each have a crimp rate of 2% to 25%. [2] Down-like composite structure (1) according to claim 1, wherein, based on the total weight of the first core-sheath fiber (20), the core part (200) is present in an amount of 40 wt.% to 80 wt.% and the sheath part (201) in an amount of 60 wt.% to 20 wt.%; and, based on the total weight of the second core-sheath fiber (20), the core part (200) is present in an amount of 40 wt.% to 80 wt.% and the sheath part (201) in an amount of 60 wt.% to 20 wt.%. [3] Down-like composite structure (1) according to claim 1 or 2, wherein the first core-sheath fiber (20) and the second core-sheath fiber (20) each have a cross-section that is circular or trilobal in shape; if the cross-section is circular, the core part (200) is arranged centrally or non-centrally in the circular cross-section, and the sheath part (201) covers the entire outer surface of the core part (200); if the cross-section is trilobal in shape, the sheath part (201) covers a part of the outer surface of the core part (200). [4] Down-like composite structure (1) according to any one of claims 1 to 3, wherein the first polymer material and the second polymer material are individually selected from a group consisting of polyethylene, polypropylene, polyethylene terephthalate, polyethylene terephthalate copolymer and other polymer analogues. [5] Down-like composite structure (1) according to claim 4, wherein the combination of the first polymer material and the second polymer material is expressed as first polymer material / second polymer material and the first polymer material / second polymer material is selected from a group consisting of polyethylene terephthalate / polyethylene, polyethylene terephthalate / polyethylene terephthalate copolymer and polypropylene / polyethylene. [6] Down-like composite structure (1) according to any one of claims 1 to 5, wherein the first microfiber (21) and the second microfiber (21) are individually produced from a new or recycled third polymer material selected from the group consisting of polyethylene, polypropylene, polyethylene terephthalate, polytrimethylene terephthalate, polybutylene terephthalate, polyamide and a combination thereof. [7] Down-like composite structure (1) according to any one of claims 1 to 6, wherein the first 3D crimp fiber (22) and the second 3D crimp fiber (22) are each a side-by-side bicomponent fiber, and the side-by-side bicomponent fiber comprises a first side part (220) and a second side part (221) arranged parallel to each other, wherein the first side part (220) is made of a new or recycled fourth polymer material, the second side part (221) is made of a new or recycled fifth polymer material, and the fourth polymer material and the fifth polymer material are each individually selected from a group consisting of polyethylene, polypropylene, polyethylene terephthalate, polyethylene terephthalate copolymer, polybutylene terephthalate, polyamide and other polymer analogues. [8] Down-like composite structure (1) according to any one of claims 1 to 7, which has a compression recovery rate of 90% or more. [9] Article or clothing made by the down-like composite structure (1) according to any one of claims 1 to 8. [10] The item or clothing according to claim 9, wherein the item is shoes, a duvet, a sleeping bag, a sleeping pad or a clothing accessory; and the clothing is a shirt, a blouse, trousers, a skirt, a vest or a coat.

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