Thermal insulation sheet and its uses

Abstract

To provide a heat-retaining sheet having excellent flexibility, bulkiness and compression recovery. [Solution] The present invention relates to a thermal insulation sheet and its application. The thermal insulation sheet includes two or more layers of nonwoven fabric webs and a filler, the filler being distributed between the nonwoven fabric webs and consisting only of non-low melting point fibers, which suppresses melt adhesion of the low melting point fibers and greatly improves the compression recovery, flexibility and bulkiness of the thermal insulation sheet, and is particularly suitable for use in the production of apparel, bedding, outdoor products, bags and decorative materials, etc.

Description

[Technical field]

[0001] The present invention relates to a heat-retaining sheet and its uses. [Background technology]

[0002] With the continuous improvement of living standards, people's expectations for thermal clothing are increasing. In order to obtain excellent thermal insulation and wearing comfort, people are making efforts to explore and research thermal sheets used in thermal clothing. For example, Patent Document 1 (Chinese Patent CN108474155A) discloses a thermal insulation sheet material and its manufacturing method, as well as a thermal insulation product. Specifically, the thermal insulation sheet material contains a plurality of monofilament webs and spherical fiber aggregates, the spherical fiber aggregates are distributed at least between a part of the adjacent monofilament webs, at least a part of the fibers constituting the monofilament webs are low-melting point fibers, and at least a part of the fibers constituting the spherical fiber aggregates are low-melting point fibers, and has excellent compression elasticity and (thermal insulation) washing durability. However, since both the spherical fiber aggregates and the monofilament webs contain low-melting point fibers, the low-melting point fibers are fused after heat treatment, and the obtained thermal insulation sheet material has a hard texture and insufficient bulkiness.

[0003] Also, Patent Document 2 (Japanese Patent No. 6669755) discloses a fiber ball filler and a product containing the filler. Specifically, the filler contains a nonwoven web and fiber balls, both of which are composed of a fiber mixture, and the fiber mixture contains 40 to 95% by weight of synthetic fiber and 5 to 40% by weight of binder fiber, and the binder fiber has an adhesive melting temperature lower than the softening temperature of the synthetic fiber, and the resulting filler is characterized by good softness and moldability, but since the fiber mixture constituting the nonwoven web and the fiber balls contains binder fiber, the binder fiber melts and adheres after heat treatment, affecting the bulkiness and texture of the product.

[0004] In addition, Patent Document 3 (China CN106906571A) discloses an elastic and breathable multi-layer fiber composite structure and its application. Specifically, the elastic and breathable structure is mainly composed of a multi-layer fiber web layer and a fiber ball layer sandwiched between the fiber webs, both of which are composed of short fibers, and low-melting short fibers and three-dimensionally crimped hollow short fibers are used as short fibers, which are light, soft, breathable, and have good shape retention after compression. However, there is a problem that the bulkiness is poor, and the low-melting fiber melted in the fiber ball layer inhibits the crimp state of the hollow short fibers, which adversely affects the compression recovery of the product. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] China patent CN108474155A [Patent Document 2] Japanese Patent No. 6669755 [Patent Document 3] China patent CN106906571A Summary of the Invention [Problem to be solved by the invention]

[0006] An object of the present invention is to provide a heat-retaining sheet having excellent flexibility, bulkiness and compression recovery.

[0007] Another object of the present invention is to provide uses for the heat-retaining sheet. [Means for solving the problem]

[0008] The means for solving the problems of the present invention are as follows. (1) A thermal insulation sheet, comprising two or more layers of nonwoven fabric webs and a filler, the filler being distributed between the nonwoven fabric webs, and the filler being composed only of non-low melting point fibers. (2) In the thermal insulation sheet of (1) above, the nonwoven fabric web and the filling are fixed by fixing points, and the distance between any adjacent fixing points is 4 mm or more. (3) In the heat-retaining sheet of (1) or (2), the nonwoven fabric web is 1 cm thick on the surface that comes into contact with the filling. 2 There is at least one fiber per area that is 10 mm or longer. (4) In the heat-retaining sheet according to (3), the nonwoven fabric web has a basis weight of 8 to 25 g / m 2 It is. (5) In the thermal insulation sheet of (3) above, the nonwoven web is composed of low melting point fibers and non-low melting point fibers, and the melting point of the low melting point fibers is 140° C. or lower. (6) In the thermal insulation sheet of (5), the low melting point fiber is one or more of polyester fiber, polyamide fiber, polyethylene fiber, polypropylene fiber, polyethylene / polypropylene composite fiber, polyester / polyethylene composite fiber, and polyester / polypropylene composite fiber. (7) In the heat-retaining sheet of (5) above, the non-low melting point fiber is one or more of polyester fiber, polyamide fiber, and cellulose fiber. (8) In the heat-retaining sheet of (3) above, the filler is a fiber ball. (9) In the thermal insulation sheet of (3) above, the filling material is spread cotton. (10) In the thermal insulation sheet of (3) above, the nonwoven web and the filling are fixed together by fixing points formed by a quilting method. (11) In the thermal insulation sheet of (3) above, the nonwoven web and the filling are fixed together by fixing points formed by a heat press method. (12) In the heat-retaining sheet of (3) above, the nonwoven web and the filling are fixed together by fixing points formed by an adhesive bonding method. (13) Application of the thermal insulation sheets of (1) to (12) in apparel, bedding, outdoor supplies, bags and decorative materials. Effect of the Invention

[0009] The thermal insulation sheet of the present invention comprises two or more layers of nonwoven fabric webs and a filler, the filler being distributed between the nonwoven fabric webs and consisting only of non-low melting point fibers, thereby suppressing melt adhesion of the low melting point fibers and significantly improving the compression recovery, flexibility and bulkiness of the thermal insulation sheet, and is particularly suitable for use in the production of apparel, bedding (e.g., futons, mattresses, rugs, etc.), outdoor products (e.g., tents, etc.), bags and decorative materials (e.g., thermal insulation materials, sound insulation materials, etc.), etc. [Brief description of the drawings]

[0010] [Figure 1] Fig. 1 is a structural diagram of a thermal insulation sheet made by the linear quilting method of the present invention, in which 1 and 2 are the nonwoven web, 3 is the filling, 4 is the fixing point, 5 is the exposed fiber at the contact surface where the nonwoven web contacts the filling, and 6 is the distance between adjacent fixing points. [Diagram 2] Figure 2 shows the structure of the thermal insulation sheet produced by the ultrasonic heat pressing method of the present invention, in which 1 and 2 are the nonwoven web, 3 is the filling material, 4 is the fixing point, 5 is the exposed fiber at the contact surface where the nonwoven web contacts the filling material, and 7 is the distance between adjacent fixing points. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] In the thermal insulation sheet of the present invention, the placement of the nonwoven web, the distribution of the filler, and the composition of the filler are all very important. First, if the nonwoven web is not provided, problems such as uneven filling, entanglement, and clumping during washing will occur. Therefore, the placement of the nonwoven web is very necessary. The number of layers of the nonwoven web is not particularly limited, but at least two layers are required. The problem of the filler being easily displaced due to the distribution of the filler between the two layers of the nonwoven web is solved, while not adversely affecting the thermal insulation properties of the sheet. Next, if low-melting point fibers are contained in the filler, the low-melting point fibers are melted by heat treatment and fixed to the surrounding non-low-melting point fibers to form adhesive points, and the freedom of movement of the fibers constituting the filler is suppressed, which affects the flexibility, bulkiness, and compression recovery of the thermal insulation sheet. Therefore, it is required that the filler of the present invention is composed only of non-low-melting point fibers.

[0012] Preferably, the nonwoven web and the filling in the thermal insulation sheet are fixed by fixing points. Since the nonwoven web and the filling are partially fixed, the space in which the filling in the thermal insulation sheet can move freely is small, which is thought to improve uneven washing. However, if the distance between any adjacent fixing points is less than 4 mm, the bulkiness and texture of the thermal insulation sheet tend to decrease, although the free movement of the filling is sufficiently suppressed.

[0013] Preferably, the nonwoven web is 1 cm thick at the contact surface where the nonwoven web contacts the filling. 2 The number of fibers in the nonwoven web having an area length of 10 mm or more per unit area is 1 or more. It is considered that the fibers of the nonwoven web having an area length of 10 mm or more effectively intertwine with the fibers on the surface of the packing, thereby suppressing the displacement of the packing. More preferably, the fibers of the nonwoven web having an area length of 1 cm or more on the contact surface where the nonwoven web contacts the packing are intertwined with the fibers on the surface of the packing. 2 More preferably, the number of fibers having a length of 10 mm or more per square centimeter is 5 or more. 2 The number of fibers with a length of 10 mm or more within an area per unit is 5 to 15.

[0014] Here, it is preferable that the fibers having a length of 10 mm or more have a crimped structure. The higher the crimp rate of the fibers, the stronger the entanglement strength between the fibers. The fibers having a crimped structure and a length of 10 mm or more in the present invention can be effectively entangled with the fibers exposed on the surface of the filler, and can suppress unevenness and clumping of the filler, and the crimped fibers can effectively improve the bulkiness of the nonwoven web.

[0015] The method of forming the crimped structure is not particularly limited, and any of the following methods can be used. (1) Using the thermoplasticity of the fiber, the tow is continuously sent to a crimping device, and a crimped structure is imparted to the tow by a crimper roller at a certain pressure and temperature, and then cut to obtain short fibers, the number of crimps of which is preferably 3 to 18 / 25 mm and the crimp rate is preferably 3 to 14%. (2) Using a spinneret with an asymmetrical modified cross section, spinning is performed by a rapid cooling method, and a spiral crimped structure is formed in each single fiber due to the shrinkage stress remaining in the fiber, and after stretching and setting, a three-dimensionally crimped hollow fiber is obtained. The number of crimps is preferably 3 to 18 / 25 mm and the crimp rate is preferably 5 to 15%. (3) Different component polymers are extruded from the same spinning nozzle to form a single fiber, and the shrinkage rate of each component is different, resulting in a three-dimensional spiral crimped fiber with good bulkiness and crimpability. The number of crimps is preferably 3 to 20 per 25 mm, and the crimp rate is preferably 6 to 18%.

[0016] Preferably, the nonwoven fabric web has a basis weight of 8 to 25 g / m 2 The weight of the nonwoven web is 8 g / m 2 If the nonwoven web is less than 25 g / m2, the nonwoven web will be thin and have low strength, and the strength of the intertwining of the fibers in the filling will be weak, and the washing durability of the heat-retaining sheet will tend to decrease. 2 If the filling weight exceeds this range, the amount of filler in a thermal insulation sheet product of the same basis weight will be relatively small, and the flexibility and bulkiness of the thermal insulation sheet will tend to decrease.

[0017] Preferably, the fibers forming the nonwoven web are low melting point fibers and non-low melting point fibers. The melting point of the low melting point fibers is 140°C or less, preferably 110°C to 140°C. If the melting point of the low melting point fibers exceeds 140°C, the energy consumption of the hot air processing process is large, and if the melting point of the low melting point fibers is less than 110°C, there is a concern about the stability of production. Non-low melting point fibers are fibers other than those having a melting point of 140°C or less, that is, all fibers other than low melting point fibers.

[0018] Preferably, the content of low melting point fibers in the nonwoven web is 10 to 50% by weight. If the content of low melting point fibers is less than 10% by weight under the same conditions, there will be fewer fusion points after heat treatment, the adhesive strength between the nonwoven web and the filler will be weak, and washing durability will tend to decrease, whereas if the content of low melting point fibers exceeds 50% by weight, there will be more fusion points after heat treatment, and the texture of the thermal insulation sheet will tend to become harder.

[0019] In the present invention, the type of low melting point fiber is not particularly limited, and may be a single component fiber, a bicomponent composite fiber, or the like. The low melting point fiber may be a fiber having a crimped structure, or may be a normal fiber having no crimped structure. It is preferably one or more of polyester fibers, polyamide fibers, polyethylene fibers, polypropylene fibers, polyethylene / polypropylene bicomponent composite fibers, polyester / polyethylene bicomponent composite fibers, and polyester / polypropylene bicomponent composite fibers. Here, the low melting point polyester fibers and low melting point polyamide fibers are modified by adding a third component during the polymerization reaction. The polyester / polyethylene bicomponent composite fibers are more preferable because they can be heat fused under relatively low heating conditions and have little effect on the texture of the nonwoven web.

[0020] If the fineness of the low melting point fiber is too low, the tensile strength of the nonwoven web tends to decrease, and if the fineness of the low melting point fiber is too high, the number of bonding points per unit area of ​​the nonwoven web after heat treatment tends to decrease, so the fineness of the low melting point fiber is preferably 1.0 to 3.0 denier (D). In addition, in consideration of the uniformity of the web, the length of the low melting point fiber used in the present invention is preferably 32 to 64 mm, more preferably 38 to 51 mm.

[0021] In the present invention, the type of non-low melting point fiber is not particularly limited, but is preferably one or more of polyester fiber, polyamide fiber, and regenerated cellulose fiber. The polyester fiber here is preferably three-dimensionally crimped hollow polyester fiber. Considering that the higher the content of three-dimensionally crimped hollow polyester fiber, the better the bulkiness and compression recovery of the nonwoven fabric web, the content of three-dimensionally crimped hollow polyester fiber is preferably 20 to 70% by weight. The regenerated cellulose fiber here is not particularly limited, but examples thereof include rayon, modal, bamboo fiber, etc.

[0022] In the present invention, the filler is preferably fiber balls. The fiber balls here may be obtained by known techniques or may be self-produced. They are preferably composed of fibers having two or more different crimp numbers and crimp rates, and due to the difference in crimp between the fibers, the fiber balls can be softer and have better bulkiness as well as better compression recovery, making it possible to achieve the objective of being washable. In the present invention, the bulkiness (FP value) of the fiber balls is 300 to 600 inches. 3 / 30g is preferred.

[0023] In the present invention, the filling material is preferably spread cotton. Specifically, spread cotton refers to cotton obtained in a fluffy state by spreading raw cotton with a cotton spreader. Spread cotton reduces the weight per unit volume of the fiber raw material, and the filling material has better bulkiness. At the same time, there are many fine fibers on the surface of the spread fiber raw material, which are entangled with the exposed fibers on the nonwoven web, effectively suppressing the problem of lump formation due to displacement of the filling material. In addition, the production process of spread cotton is short and the cost is relatively low. In the present invention, the bulkiness (FP value) of spread cotton is 400 to 800 inches. 3 / 30g is preferred.

[0024] Preferably, in the thermal insulation sheet of the present invention, the fixed points are formed by a quilting method to fix the nonwoven web and the filling. The quilting method generally uses a quilting machine, which is easy to handle and can maintain the bulkiness of the thermal insulation sheet. In the present invention, if the distance between any adjacent fixed points is less than 4 mm, the production efficiency of the thermal insulation sheet tends to decrease and the texture of the thermal insulation sheet may be adversely affected. If the distance between any adjacent fixed points is greater than 20 mm, the movement space of the filling is large, and there is a problem that the uniformity due to the movement of the filling and the washing bias of the filling are deteriorated. Therefore, when the fixed points are formed by the quilting method, the distance between any adjacent fixed points is preferably 4 to 20 mm, and more preferably 4 to 10 mm. In addition, in the present invention, the stitches are not particularly limited and may be straight or curved in the longitudinal direction of the sheet, or may be latticed, circular or other irregular shapes. Of course, the seams may be continuous or discontinuous. When the stitches are straight, if the pitch between two adjacent stitches is too narrow, the bulkiness of the thermal insulation sheet tends to decrease, and if the pitch is too wide, the effect of fixing the filling tends to decrease. Therefore, in the present invention, the width of adjacent quilt pitches is preferably 50 to 200 mm, and more preferably 50 to 100 mm.

[0025] Preferably, in the thermal insulation sheet of the present invention, the fixed points are formed by a heat press method to fix the nonwoven fabric web and the filler. The heat press method is preferably an ultrasonic bonding method, and specific processing conditions are preferably an air pressure of 0.1 to 0.3 MPa, a current of 0.4 to 0.8 A, a pattern roller pressure of 1.5 to 3 kg, and an ultrasonic power of 1400 to 1600 W.

[0026] Preferably, in the heat-retaining sheet of the present invention, the fixed points are formed by an adhesive bonding method to fix the nonwoven fabric web and the filler. Specifically, the adhesive bonding method involves applying an adhesive to the nonwoven fabric web by roll coating, knife coating, spraying, or other methods, cooling and solidifying the adhesive, and then forming the fixed points. The adhesive is not particularly limited, and may be a polyethyl acetate-based adhesive, an acrylic acid-based adhesive, or the like.

[0027] The heat pressing method and the adhesive bonding method have higher production efficiency than the quilting method, and the fixed points formed are stronger. In the present invention, when the fixed points are formed by the heat pressing method or the adhesive bonding method, the distance between any adjacent fixed points is preferably 50 to 200 mm, and more preferably 50 to 100 mm.

[0028] In the present invention, the nonwoven web and the filler may be fixed by a method such as needle punching or spunlace, which is not particularly limited and may be selected as necessary. The fiber raw materials used for the nonwoven web and the filler may be the same or different, and are not particularly limited.

[0029] The method for producing the thermal insulation sheet of the present invention is not particularly limited, and the thermal insulation sheet can be obtained by the following method. First, several nonwoven fabric webs and fillers are prepared, then the nonwoven fabric web 1 as the back layer is fed into the lower feed roller of the sheet processing equipment, and a sheet of the filler is laid on top of it, then the nonwoven fabric web 2 as the surface layer is fed into the upper feed roller, the filler is distributed between the nonwoven fabric webs 1 and 2, and finally the nonwoven fabric webs 1 and 2 and the filler are fixed, thereby obtaining the thermal insulation sheet of the present invention. The nonwoven fabric web may be a single layer or a multi-layer, and may be selected as necessary. EXAMPLES

[0030] The present invention will be further described below with reference to examples and comparative examples.

[0031] The method for measuring each parameter according to the present invention is as follows.

[0032] (1) Distance between adjacent fixed points Prepare a sample measuring 50cm x 50cm and place it flat on a desk without tension. Select two adjacent fixed points on the sample, set the center of the fixed points as the end points, measure the distance between both ends with a ruler, and then measure 10 more points. Calculate the average value for a total of 10 sets of data, which is the distance between adjacent fixed points in this invention.

[0033] (2) Number of fibers with a length of 10 mm or more on the contact surface of the nonwoven web Sampling After gently disassembling the nonwoven web from the heat-insulating sheet under no tension, a test piece measuring 1 cm in length and 1 cm in width is cut from the nonwoven web.

[0034] b. Preparation for measurement The test specimen is attached to a black mount with the nonwoven web contacting surface in contact with the filling facing up, and fixed on a test table.

[0035] c. Measurement The fibers exposed on the contact surface of the nonwoven web are gently stretched with tweezers, their lengths are measured with a ruler, and the number of fibers having a length of more than 10 mm is counted.

[0036] d. Calculation The above procedure is repeated to obtain a total of 10 test pieces, and the number of fibers having a length of 10 mm or more is counted. The calculated average value is the number of fibers having a length of 10 mm or more in the nonwoven fabric web of the present invention.

[0037] (3) Fiber melting point A measurement sample is obtained by separating 2 to 3 g of short fibers from the nonwoven web or filler. Measurement is performed using a differential scanning calorimeter (DSC) at a starting temperature of 30°C, a heating rate of 20°C / min, and a final temperature of 300°C. The extreme (maximum) temperature of the obtained melting endothermic curve is taken as the melting point of the fiber.

[0038] (4) Type of fiber raw material The judgment is made according to "JIS L1030-1:2012 Standard Part 1: Fiber Identification". Refer to 6.1 Flammability Test Method in the standard to judge whether the fiber raw material belongs to natural fiber or chemical fiber. Furthermore, refer to 6.4 Microscope Test Method and 6.8 Infrared Absorption Spectroscopy Test Method in the standard to identify which natural fiber or chemical fiber the fiber raw material specifically belongs to.

[0039] (5) Washing bias rate of filling Prepare one thermal insulation sheet test piece measuring 30cm x 30cm and two pieces of standard white cotton cloth as specified in the JIS L0803:2011 standard, sandwich the test piece between the two pieces of white cotton cloth, sew two threads of stitches at 10cm intervals along the weft direction of the white cotton cloth so that the warp direction of the test piece is parallel to the warp direction of the white cotton cloth, and then sew the four sides with an overlock to obtain a square cushion. Make a total of three cushions in the same way.

[0040] b. One of the cushions is washed according to the washing cycle specified in ISO 6330:2012(E)4M, and after washing, it is dried according to the drying cycle "A-line drying". The dried cushion is disassembled to obtain a thermal insulation sheet test piece after the washing test. It is laid flat on a transparent glass plate with a D65 light source attached below, and a watermark photo of the test piece is taken with a digital camera (the camera and the test piece should be as horizontal as possible). The photo is printed, and the areas with and without filling are distinguished by color shades and drawn by hand, then cut out with scissors, and the weights of each are recorded as W1 and W2, and the washing bias rate is calculated using the following formula.

[0041] Washing bias rate = W1 / (W1+W2) x 100%.

[0042] c. Wash and dry the remaining two cushions in the same way, calculate the washing bias rate of the thermal insulation sheet, and use the average value of the three tests as the final result.

[0043] (6) Heat retention rate Measured according to GB / T 35762-2017 plate method. The higher the thermal insulation rate, the better the thermal insulation.

[0044] (7) Metsuke The nonwoven web is lightly separated from the heat-insulating sheet in a tension-free state, and the nonwoven web measuring 50 cm x 50 cm is weighed and the weight is m. The basis weight (g / m 2 ) = m × 4. Two pieces of nonwoven fabric web are taken and measured using the above procedure, and the average of the three results is the final result.

[0045] (8) Bulkiness of the insulation sheet Measure according to the standard FZ / T 64003-2011 (Appendix A).

[0046] (9) Compression recovery rate Measure according to the standard FZ / T 64003-2011 (Appendix A).

[0047] (10) Texture The texture of the thermal insulation sheet is evaluated by 10 people and judged into one of four levels: excellent (soft), good, average, and poor (hard). If eight or more people judge the texture to be good, it is judged as having an "excellent" level. If six to seven people judge the texture to be good, it is judged as having a "good" level. If three to five people judge the texture to be good, it is judged as having an "average" level. If two or fewer people judge the texture to be good, it is judged as having a "poor" level.

[0048] (11) Bulkiness of fiber balls and spread cotton (FP value) a. Take 30g of fiber balls (or spread cotton) as a sample from the decomposed heat-retaining sheet.

[0049] b. Measure using a fill power (FP) tester based on IDFB standards. First, shake the sample lightly and slowly put it into the measuring tube, then stir it five times with a wooden stirring rod and slowly place the load disk on it. When the load disk and the sample come into contact, release your hand. After one minute, read the height of the cotton and record the data as H1 (measurement accuracy is 0.1 cm). Next, remove the load disk and stir it five times with a stirring rod to restore the bulkiness. Repeat the above test procedure three times, and the data read in the measurement are H2 and H3, respectively, and the average of the three times is H.

[0050] c. Calculation: Bulkiness FP value = 39.73*H (unit: inch 3 / 30g). The higher the FP value, the better the bulkiness.

[0051] The present invention will be further described below with reference to examples and comparative examples.

[0052] The fiber materials used in the examples and comparative examples are as follows: Low melting point fiber 1: low melting point polyester fiber, melting point 120℃, fineness 2.0D, length 51mm, manufactured by Toray Industries, Inc.; Low melting point fiber 2: low melting point polyester fiber, melting point 120℃, fineness 2.0D, length 38mm, manufactured by Toray Industries, Inc.; Low melting point fiber 3: low melting point polyethylene fiber, melting point 110℃, fineness 3.0D, length 51mm, manufactured by Toray Industries, Inc.; Low melting point fiber 4: low melting point polyester / polyethylene composite fiber, melting point 110°C, fineness 2.0D, length 51mm, manufactured by Toray Industries, Inc.; Low melting point fiber 5: low melting point polyethylene fiber, melting point 110°C, fineness 1.0D, length 32mm, manufactured by Toray Industries, Inc.; Non-low melting point fiber 1: 3D crimped hollow polyester fiber treated with silicone oil, melting point 260℃, fineness 3.0D, length 38mm, number of crimps 8 / 25mm, crimp rate 10%, hollow rate 20%, manufactured by Toray Industries, Inc.; Non-low melting point fiber 2: 3D crimped hollow polyamide fiber treated with silicone oil, melting point 230℃, fineness 2.0D, length 38mm, number of crimps 8 / 25mm, crimp rate 13%, hollow rate 20%, manufactured by Toray Industries, Inc.; Non-low melting point fiber 3: rayon fiber, fineness 1.0D, length 51 mm, number of crimps 4 / 25 mm, crimp rate 8%, manufactured by Nippon Daiwabo Co., Ltd.

[0053] Example 1 The non-low melting point fiber 1 is fed into the raw cotton supply port of the fiber ball production equipment, and through the processes of opening, carding, and spherical body formation, the bulkiness (FP value) is 450 inches 3 / 30g of fiber balls were obtained.

[0054] 15 kg of low melting point fiber 1 and 35 kg of non-low melting point fiber 1 were fed into a cotton blending machine at the same time. The two types of fibers were mixed at a feed rate of 20 m / min, output speed of 20 m / min, and passed through the processes of blending, opening, carding, hot air cross web (press roll pressure 50 N), heat fusion (oven temperature 150°C), and winding to produce a fiber with a basis weight of 15 g / m. 2 A nonwoven web 1 and a nonwoven web 2 were obtained. 2 There were eight fibers with a length of 10 mm or more per area.

[0055] The nonwoven fabric web 1 as the backing layer was fed to the lower feed roller of the heat-retaining sheet processing equipment, and the fiber balls were fed onto the nonwoven fabric web in a uniform sheet form (the fiber ball sheet had a basis weight of 70 g / m 2 ), then the nonwoven fabric web 2 as the surface layer was fed to the upper feed roller, the fiber ball sheet was sandwiched between the nonwoven fabric webs 1 and 2, and the thermal insulation sheet was linearly fixed in the length direction by a quilting machine, with the distance between any adjacent fixing points being 6 mm, to obtain the thermal insulation sheet of the present invention. Specific parameters and evaluation results are shown in Table 1.

[0056] Example 2 A heat-retaining sheet of the present invention was obtained in the same manner as in Example 1, except that the distance between any adjacent fixing points was changed to 3 mm when fixing by the quilting method. Specific parameters and evaluation results are shown in Table 1.

[0057] Example 3 When producing the nonwoven webs 1 and 2, 15 kg of low melting point fiber 2 and 35 kg of non-low melting point fiber 1 were used as raw materials, the press roll pressure in the cross-web process was set to 90 N, and a 1 cm 2 The number of fibers having a length of 10 mm or more per unit area was set to 0, and the rest was the same as in Example 1, to obtain a heat-retaining sheet of the present invention. Specific parameters and evaluation results are shown in Table 1.

[0058] Example 4 In the cotton blending machine, the feed speed was 10 m / min and the output speed was 20 m / min. The basis weight of the obtained nonwoven fabric webs 1 and 2 was 5 g / m 2 The heat-retaining sheet of the present invention was obtained in the same manner as in Example 1, except for the above. Specific parameters and evaluation results are shown in Table 1.

[0059] Example 5 Using 50 kg of non-low melting point fiber 1, the spunlace method (spunlace pressure 30 × 10 5 Nonwoven webs 1 and 2 were prepared at 100 Pa, and 1 cm of fibers with a length of 10 mm or more were laid on one side of the webs. 2 A heat-retaining sheet of the present invention was obtained by using 8 pieces per sheet and otherwise following the same procedures as in Example 1. Specific parameters and evaluation results are shown in Table 1.

[0060] Example 6 A heat-retaining sheet of the present invention was obtained by using down as a filling material and sandwiching it between the nonwoven fabric webs 1 and 2, in the same manner as in Example 1 except for the above. Specific parameters and evaluation results are shown in Table 1.

[0061] Example 7 The nonwoven web and the fiber balls were fixed together by needle punching at a speed of 10 m / min, and the rest of the process was the same as in Example 1 to obtain a heat-retaining sheet of the present invention. Specific parameters and evaluation results are shown in Table 1.

[0062] Example 8 Using non-low melting point fiber 1, the bulkiness (FP value) is 620 inches after the fiber opening process. 3 The heat-retaining sheet of the present invention was obtained by using the above-mentioned spread cotton as a filler and otherwise following the same procedures as in Example 1. Specific parameters and evaluation results are shown in Table 1.

[0063] Example 9 In the cotton blending machine, the fibers were processed at a feed speed of 15 m / min and an output speed of 20 m / min. The weight of the resulting nonwoven fabric webs 1 and 2 was 8 g / m 2 The heat-retaining sheet of the present invention was obtained in the same manner as in Example 1, except for the above. Specific parameters and evaluation results are shown in Table 1.

[0064] Example 10 The non-low melting point fiber 2 is fed into the raw cotton supply port of the fiber ball production equipment, and through the processing steps of opening and forming spherical bodies, the bulkiness (FP value) is 470 inches. 3 / 30g of fiber balls were obtained.

[0065] 17.5 kg of low melting point fiber 3 and 32.5 kg of non-low melting point fiber 1 were fed into a cotton blending machine at the same time. The two types of fibers were processed at a feed rate of 18 m / min and an output rate of 20 m / min through processes such as blending, opening, carding, cross-web (press roll pressure 50 N), and melt bonding (oven temperature 150°C) to produce a fiber with a basis weight of 10 g / m 2 Nonwoven webs 1 and 2 were obtained. 2 There were eight fibers with a length of 10 mm or more within the area per unit area.

[0066] The nonwoven fabric web 1 was fed as a backing layer to the lower feed roller of the heat-retaining sheet processing equipment, and the above-mentioned fiber balls were fed in a uniform sheet form on top of the nonwoven fabric web 1 (fiber ball sheet basis weight of 70 g / m 2 ), then nonwoven web 2 was fed to the upper feed roller as a surface layer, a fiber ball sheet was sandwiched between nonwoven webs 1 and 2, and nonwoven webs 1 and 2 and the fiber ball sheet were fixed together by ultrasonic heat pressing, with the distance between any adjacent fixed points being 100 mm, to obtain a heat-retaining sheet of the present invention. Specific conditions for the ultrasonic heat pressing were: atmospheric pressure 0.2 MPa, current 0.5 A, pattern roller pressure 1.5 kg, ultrasonic power 1400 W, and distance between any adjacent fixed points being 100 mm. Specific parameters and evaluation results are shown in Table 2.

[0067] Example 11 When producing a hot air nonwoven web, the press roll pressure in the cross-web process was set to 75 N to obtain nonwoven fiber webs 1 and 2. 2 The number of fibers having a length of 10 mm or more per unit area was set to 4, and the rest was the same as in Example 1, to obtain a heat-retaining sheet of the present invention. Specific parameters and evaluation results are shown in Table 2.

[0068] Example 12 As the raw materials for the nonwoven fabric webs 1 and 2, 30 kg of low melting point fiber 1 and 20 kg of non-low melting point fiber 1 were used, and the rest was the same as in Example 8 to obtain a heat-retaining sheet of the present invention. Specific parameters and evaluation results are shown in Table 2.

[0069] Example 13 The raw materials for the nonwoven fabric webs 1 and 2 were 15 kg of low melting point fiber 4 and 35 kg of non-low melting point fiber 1, and the rest were the same as in Example 8 to obtain a heat-retaining sheet of the present invention. Specific parameters and evaluation results are shown in Table 2.

[0070] Example 14 The raw materials for the nonwoven fabric webs 1 and 2 were 17.5 kg of low melting point fiber 5 and 32.5 kg of non-low melting point fiber 1, and the rest were the same as in Example 10 to obtain a heat-retaining sheet of the present invention. Specific parameters and evaluation results are shown in Table 2.

[0071] Example 15 A fiber ball was made using 8 kg of non-low melting point fiber 1 and 2 kg of non-low melting point fiber 3.

[0072] The low melting point fiber 4 was 15 kg, the non-low melting point fiber 1 was 15 kg, and the non-low melting point fiber 3 was 15 kg. The non-woven fiber webs 1 and 2 were prepared by the hot air method, and a 1 cm 2 The number of fibers with a length of 10 mm or more per unit area was set to 6. When producing nonwoven webs 1 and 2, the press roll pressure in the cross-web process was set to 70 N.

[0073] The nonwoven fabric webs 1 and 2 and the fiber ball sheet were sandwiched together and fixed in a wavy manner in the length direction by quilting, with the distance between any adjacent fixing points set to 10 mm, and the rest of the procedure was the same as in Example 1 to obtain a heat-retaining sheet of the present invention. Specific parameters and evaluation results are shown in Table 2.

[0074] (Example 16) The contact surfaces of the nonwoven fabric webs 1 and 2 that come into contact with the fiber balls were coated with an acrylic acid-based adhesive (manufactured by Shandong Huayu Chemical Technology Co., Ltd.) at a rate of 20 m / min at a rate of 10 g / m 2 The coating amount was then dried and cured at a temperature of 150°C, and finally cooled and solidified to form fixed points, with the distance between any adjacent fixed points being 50 mm, and the rest of the procedure was the same as in Example 10 to obtain a heat-retaining sheet of the present invention. Specific parameters and evaluation results are shown in Table 2.

[0075] (Example 17) In the hot air nonwoven web production, the press roll pressure in the cross web process was set to 80 N to obtain nonwoven webs 1 and 2. 2 The number of fibers having a length of 10 mm or more per unit area was set to 2, and the rest was the same as in Example 1, to obtain a heat-retaining sheet of the present invention. Specific parameters and evaluation results are shown in Table 2.

[0076] (Example 18) When producing a nonwoven web using the hot air method, the feed speed was 30 m / min and the output speed was 20 m / min. The basis weight of the obtained nonwoven webs 1 and 2 was 20 g / m 2 The rest of the test was carried out in the same manner as in Example 8 to obtain a heat-retaining sheet of the present invention. Specific parameters and evaluation results are shown in Table 2.

[0077] The thermal insulation sheets of Examples 1-18 are used in the production of apparel, bedding, outdoor goods, bags, or decorative materials.

[0078] Comparative Example 1 3 kg of low melting point fiber 3 and 7 kg of non-low melting point fiber 1 are fed into the raw cotton supply port of the fiber ball production equipment, and through the process of opening and forming spherical bodies, the bulkiness (FP value) is 450 inches. 3 / 30g of fiber balls were obtained.

[0079] A fiber ball was sandwiched between the nonwoven fabric webs 1 and 2, and without quilting, the fiber ball was heated in an oven at a temperature of 150° C. The rest of the process was the same as in Example 1 to obtain a thermal insulation sheet. The specific parameters and evaluation results are shown in Table 2.

[0080] [Table 1]

[0081] [Table 2]

[0082] According to Tables 1 and 2, (1) From Example 1 and Example 2, it was found that the thermal insulation sheet made under the same conditions with the distance between any adjacent fixing points of 6 mm was comparable in washing durability (uneven washing) to the thermal insulation sheet made with the distance between any adjacent fixing points of 3 mm, but the compression recovery and heat retention of the former were slightly better than the latter, and the bulkiness and texture were clearly superior to the latter.

[0083] (2) From Example 17 and Example 3, under the same conditions, the contact surface of the nonwoven fabric web in contact with the filling material was 1 cm 2 A thermal insulation sheet made of two fibers with a length of 10 mm within the area of ​​1 cm2 of the surface that comes into contact with the nonwoven web filling. 2 Compared to a thermal insulation sheet made with zero fibers of 10 mm length within the surface area, the bulk, compression recovery, heat retention, and texture of both sheets were equivalent, but the washing durability of the former was superior to the latter in terms of uneven washing.

[0084] (3) Looking at Example 9 and Example 4, under the same conditions, the basis weight of the nonwoven fabric web was 8 g / m 2 The thermal insulation sheet made of this nonwoven fabric has a basis weight of 5g / m 2 The texture, bulkiness, compression recovery and heat retention of both sheets were equivalent to that of the thermal insulation sheet made from the former, but the washing durability (uneven washing) of the former was superior to that of the latter.

[0085] (4) From Examples 1 and 5, it was found that, under the same conditions, the thermal insulation sheets made of nonwoven webs consisting of low-melting point fibers and non-low-melting point fibers had the same texture as the thermal insulation sheets made of nonwoven webs consisting only of non-low-melting point fibers, but the bulkiness, compression recovery, heat retention, and washing durability (uneven washing) of the former were all superior to the latter.

[0086] (5) From Example 1 and Example 6, it was found that the thermal insulation sheet made with a filling of fiber balls had the same heat retention and texture as the thermal insulation sheet made with a filling of down, both of which were compared under the same conditions. However, the bulkiness, compression recovery, and washing durability (unevenness after washing) of the former were all superior to the latter.

[0087] (6) From Example 1 and Example 7, it was found that the thermal insulation sheets produced by the linear quilting method under the same conditions were comparable in thermal insulation and washing durability (unevenness after washing) to the thermal insulation sheets produced by the needle punching method, but the bulkiness, compression recovery and texture of the former were all clearly superior to the latter.

[0088] (7) From Example 1 and Example 11, under the same conditions, the contact surface of the nonwoven fabric web in contact with the filling material was 1 cm 2 The thermal insulation sheet is made of 8 fibers with a length of 10 mm per unit area, and the contact surface with the nonwoven web filling is 1 cm 2 Compared with a thermal insulation sheet made with four fibers with a length of 10 mm per unit area, the texture of both was the same, but the bulkiness, compression recovery and heat retention of the former were slightly better than the latter, and the washing durability (uneven washing) was clearly superior to the latter.

[0089] (8) From Examples 8 and 12, it was found that a thermal insulation sheet made of a nonwoven fabric web containing 30% by weight of low-melting point fibers under the same conditions was comparable to a thermal insulation sheet made of a nonwoven fabric web containing 60% by weight of low-melting point fibers in bulkiness, washing durability (uneven washing), heat retention, and compression recovery, but the texture of the former was better than that of the latter.

[0090] (9) From Comparative Example 1 and Example 1, it was found that a thermal insulation sheet made of fiber balls consisting of low-melting point fibers and non-low-melting point fibers under the same conditions was inferior in bulkiness, compression recovery, washing durability (uneven washing), thermal insulation, and texture to a thermal insulation sheet made of fiber balls consisting of only non-low-melting point fibers. [Explanation of symbols]

[0091] 1. Nonwoven web 2. Nonwoven web 3 Filling 4 fixed points 5 Fibers exposed at the contact surface of the nonwoven web and the filling 6 Distance between adjacent fixed points 7 Distance between adjacent fixed points

Claims

1. A heat-insulating sheet comprising two or more non-woven fabric webs and a filling material, wherein the filling material is distributed between the non-woven fabric webs, and the filling material consists only of non-low melting point fibers.

2. The heat-insulating sheet according to Claim 1, wherein the non-woven fabric web and the filling material are fixed by fixing points, and the distance between any adjacent fixing points is 4 mm or more.

3. On the contact surface of the non-woven fabric web in contact with the filling material, there is at least one fiber with a length of 10 mm or more per 1 cm 2 range. The heat-insulating sheet according to Claim 1 or 2.

4. The non-woven fabric web has a basis weight of 8 to 25 g / m 2 The heat-insulating sheet according to Claim 3.

5. The non-woven fabric web is composed of low melting point fibers and non-low melting point fibers, and the low melting point fibers have a melting point of 140°C or lower. The heat-insulating sheet according to Claim 3.

6. The low melting point fibers are one or more of polyester fibers, polyamide fibers, polyethylene fibers, polypropylene fibers, polyethylene / polypropylene composite fibers, polyester / polyethylene composite fibers, and polyester / polypropylene composite fibers. The heat-insulating sheet according to Claim 5.

7. The non-low melting point fibers are one or more of polyester fibers, polyamide fibers, and cellulose fibers. The heat-insulating sheet according to Claim 5.

8. The filling material is a fiber ball. The heat-insulating sheet according to Claim 3.

9. The filling material is opened cotton. The heat-insulating sheet according to Claim 3.

10. The heat-insulating sheet according to claim 3, wherein the nonwoven web and the filling material are fixed by fixing points formed by a quilting method.

11. The heat-insulating sheet according to claim 3, wherein the nonwoven web and the filling material are fixed by fixing points formed by a hot pressing method.

12. The heat-insulating sheet according to claim 3, wherein the nonwoven web and the filling material are fixed by fixing points formed by adhesive bonding.

13. The heat-insulating sheet according to claim 1 or 2, which is used in apparel, bedding, outdoor supplies, bags and decorative materials.

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