Intermediate cotton nonwoven fabric sheet, method for producing the same, and intermediate cotton structure including the same

Abstract

A non-woven fabric sheet (1) for batting, in which at least polyester staple fibers and fusible staple fibers containing a polymer having a lower melting point than the polyester staple fibers are blended, wherein fiber webs (3a)-(3f) in which the constituent fibers (2) of the non-woven fabric sheet (1) for batting are substantially arranged in one direction of the sheet are laminated in a plurality of layers, and at least a part of the constituent fibers (2) are partially fused by the fusible staple fibers. This provides a warm batting non-woven fabric sheet having swelling and a soft texture, which is less likely to reduce heat retention even when wet, a method for manufacturing the same, and a batting structure including the same.

Description

Technical Field

[0001] The present invention relates to a non-woven fabric sheet for batting, a method for manufacturing the same, and a batting structure including the same.

Background Art

[0002] Down is widely used as an outer garment mainly worn in winter. When down is used as a heat-insulating material, it is used in various scenarios because of its excellent heat retention and compression recovery properties. However, there are problems such as animal welfare issues, the need for filling equipment during sewing, high prices, and unstable supply. Therefore, chemical fiber batting is used as a heat-insulating material instead of down. As chemical fiber batting, in addition to filled cotton in the form of granules or shredded cotton, cotton formed into a sheet shape is also used. In the case of chemical fiber filled cotton, it has heat retention and compression recovery properties similar to those of down and is used in many products. However, there are also manufacturing problems such as the batting becoming uneven during washing, which not only impairs the product quality but also the warmth, and the need for filling equipment during sewing. In the case of sheet-shaped cotton, the laminated cotton is solidified with resin or heat-fused fibers to give it a bulge, but there are problems such as the texture becoming stiff and the weight of the material increasing when trying to increase the thickness. In addition, many products using moisture-absorbing and heat-generating fibers have been manufactured and sold to improve warmth.

[0003] As a conventional technique, Patent Document 1 proposes laminating a plurality of spunbond non-woven fabric layers and integrating them with a hot calendar. Patent Document 2 proposes manufacturing a lightweight and bulging laminated fabric by adhering the surface fabric and the back fabric of a fiber layer laminated in two layers with a thermoplastic resin. Patent Document 3 proposes a heat-insulating agent in which non-woven fabrics are laminated on both sides of a meltblown long fiber non-woven fabric.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Patent Document 2

[0005] However, Patent Document 1 uses a filament for a non-woven fabric, but there is a problem that sufficient swelling cannot be achieved. Patent Document 2 binds the mixed fiber layers of each layer with a resin, so there is a problem that the texture becomes firm. Patent Document 3 uses nanofiber fibers and has a structure in which a fiber laminate is sandwiched between non-woven fabrics, so there is a problem that sufficient swelling cannot be achieved.

[0006] In order to solve the above conventional problems, the present invention provides a non-woven fabric sheet for batting that has swelling and a soft texture, is less likely to reduce heat retention even when wet, and a batting structure including the same, and a method for manufacturing the same. [Means for Solving the Problems]

[0007] As one embodiment, the present invention is a non-woven fabric sheet for batting in which at least polyester staple fibers, fusible staple fibers containing a polymer having a lower melting point than the polyester staple fibers, and highly crosslinked polyacrylate-based staple fibers are blended, The viaduct polyacrylate short fibers have a hydrophobizing agent attached thereto in an amount of 0.2 to 2.5% by mass, a plurality of fiber webs in which constituent fibers are substantially arranged in one direction of the sheet are laminated in the non-woven fabric sheet for batting, Each layer and the entire layer of the fiber web are not compressed, the layers of the non-woven fabric sheet for batting are bonded by entanglement of the constituent fibers, and further, at least a part of the constituent fibers is partially fused by the fusible staple fibers, the non-woven fabric sheet for batting has a tensile strength in the plane direction (X, Y directions) that is at least twice as high as the peel strength between layers (Z direction), The density of the fused staple fibers in the space between the fiber web and the adjacent fiber web is smaller than the density of the fused staple fibers in the thickness direction (Z direction) of one fiber web. く Regarding the batting nonwoven fabric sheet, the partial fusion ratio by the fused staple fibers is higher in the layer with a higher fiber density than between the layers.

[0008] As one embodiment, the method for manufacturing the batting nonwoven fabric sheet of the present invention is a method for manufacturing the batting nonwoven fabric sheet, (1) A step of blending at least polyester staple fibers, fused staple fibers, with a hydrophobizing agent in an amount of 0.2 to 2.5% by mass attached thereto and crosslinked polyacrylate-based staple fibers, opening the fibers, and forming a fiber web in which the constituent fibers are arranged substantially in one direction. (2) A step of folding and laminating the fiber web to form a long laminated web. (3) A step of heating the long fiber web without load to a temperature equal to or higher than the melting point of the low-melting polymer, and making the tensile strength in the plane direction (X, Y directions) of the batting nonwoven fabric sheet at least twice higher than the peel strength in the layer direction (Z direction). (4) A step of cooling and winding up. including There is no step of compressing each layer and the entire layer of the fiber web relates to a method for manufacturing a batting nonwoven fabric sheet.

[0009] As one embodiment, the present invention relates to a batting structure using the batting nonwoven fabric sheet as batting.

Advantages of the Invention

[0010] The batting nonwoven fabric sheet of the present invention is a batting nonwoven fabric sheet in which at least polyester staple fibers and fused staple fibers containing a polymer having a lower melting point than the polyester staple fibers are blended. The batting nonwoven fabric sheet has a plurality of layers of fiber webs in which the constituent fibers are arranged substantially in one direction of the sheet, and at least a part of the constituent fibers of the batting nonwoven fabric sheet is partially fused by the fused staple fibers, so that it has swelling and a soft texture, and is less likely to have a reduced heat retention property even in a wet state, and can provide a warm batting nonwoven fabric sheet, a method for manufacturing the same, and a batting structure including the same.

Brief Description of the Drawings

[0011]

Figure 1

Figure 2

Figure 3

Figure 4

Embodiments for Carrying Out the Invention

[0012] The present invention is a nonwoven fabric sheet for batting in which at least polyester staple fibers and fusible staple fibers containing a polymer having a melting point lower than that of the polyester staple fibers are blended, a plurality of fiber webs in which constituent fibers are substantially arranged in one direction of the sheet are laminated, and at least a part of the constituent fibers are partially fused by the fusible staple fibers. The polyester staple fibers have high strength, initial elastic modulus (Young's modulus), firmness, high compression recovery, etc., have swelling and a soft texture, are less likely to reduce heat retention even in a wet state, and can maintain warmth. The fusible fibers partially fuse at least some of the constituent fibers. As a result, a batting sheet that is less likely to lose its shape is obtained, and a batting structure filled with this has good washability. In this specification, "substantially" means 50% by mass or more.

[0013] The blending ratio of each fiber is preferably 60 to 99% by mass of polyester staple fiber and 1 to 40% by mass of fusible staple fiber with respect to 100% by mass of the nonwoven fabric sheet for batting, more preferably 70 to 99% by mass of polyester staple fiber and 1 to 30% by mass of fusible staple fiber, and even more preferably 80 to 98% by mass of polyester staple fiber and 2 to 20% by mass of fusible staple fiber. Thereby, the polyester staple fiber can be partially fused while maintaining a good texture, has a swelling and soft texture, is less likely to have a reduced heat retention property even in a wet state, and can be made into a warm nonwoven fabric sheet for batting.

[0014] The nonwoven fabric sheet for batting is preferably laminated in a plurality of layers in the same direction as the arrangement direction of the constituent fibers. Thereby, a nonwoven fabric sheet for batting with good yield can be obtained.

[0015] The fusible staple fiber is preferably a core-sheath composite fiber in which the core component is polyethylene terephthalate and the sheath component is a polyester copolymer having a melting point or softening point of 90 to 230°C. After heat treatment, the sheath component of this fusible staple fiber fuses, and the core component maintains its fibrous form, and it has a function of softening the texture.

[0016] It is preferable that the non-woven fabric sheet for the middle cotton is further mixed with crosslinked polyacrylate short fibers. The crosslinked polyacrylate short fibers are preferably 1 to 50 parts by mass, more preferably 3 to 40 parts by mass, and still more preferably 5 to 30 parts by mass with respect to 100 parts by mass in total of polyester short fibers and fused short fibers. Further, the crosslinked polyacrylate fibers may be water-repellent treated. The crosslinked polyacrylate fibers originally have moisture absorption and heat generation properties, but when water-repellent treated, the moisture absorption and heat generation properties are maintained even when wet. Incidentally, there is a product named "Bress Thermo" commercially available by the applicant for the crosslinked polyacrylate fibers. For the water-repellent treatment, for example, AG series such as commercially available products "Asahi Guard AG7000" (product name), "Asahi Guard AG970" (product name), "Asahi Guard AG-E082" (product name), "Asahi Guard GS10" (product name) (all manufactured by Asahi Glass Co., Ltd., fluorine-based water repellent emulsion), "NK Guard FGN700T" (product name), "NK Guard NDN7000" (product name) (both manufactured by Nihon Kayaku Co., Ltd., fluorine-based water repellent emulsion), etc. are used. The main components of non-fluorine-based water repellents are silicone-based, urethane-based, acrylic-based, hydrocarbon-based, etc., and any of these may be used. Examples of modified silicone-based hydrophobizing agents include epoxy-modified silicone-based hydrophobizing agents and amino-modified silicone-based hydrophobizing agents. Commercially available products include "X-22-9002" (product name, side chain both-end type epoxy-modified silicone), "X-22-163A" (product name, both-end type epoxy-modified silicone), "KF-8012" (product name, both-end amino-modified silicone), all manufactured by Shin-Etsu Silicone Co., Ltd., etc. Examples of fluorine-containing silicone compounds include commercially available products "NK Guard S-07" and "NK Guard S-09" manufactured by Nihon Kayaku Co., Ltd. Examples of hydrocarbon-based compounds include high melting point wax emulsion: "TH-44" (product name) manufactured by Nihon Kayaku Co., Ltd. These hydrophobizing agents are preferably adhered to the fibers in a state of being dispersed in water. They can be brought into contact by methods such as immersing the fibers in the treatment liquid, spraying the fibers, or padding the fibers, and then fixed by heat treatment with a cure set. The adhesion amount of the hydrophobizing agent is 0.2 to 2.5 mass% (mass% is also referred to as omf%, and omf is the abbreviation of on the mass of fiber), preferably 0.22 to 2.0 omf%.

[0017] It is preferable that the fiber webs laminated in multiple layers are integrated between layers by the entanglement of the constituent fibers. In the fiber web, the constituent fibers are uniformly blended, and the fiber direction is arranged in one direction by a carding machine, so that the fiber web becomes uniform in the X direction (the longitudinal direction of the fiber web) and the Y direction (the transverse direction of the fiber web), respectively. In order to laminate this fiber web, all layers of the batting nonwoven fabric sheet are uniform. With the blending ratio of the fused staple fibers in the present invention, by being uniformly blended in the fiber web, it becomes the strength in the satisfactory surface directions (X and Y directions) during the production process and when used as clothing or bedding. The lamination of each layer is performed simultaneously with the progress of processing. That is, since the fibers existing on the surfaces of the respective layers are laminated while being entangled with each other, the layers are integrated by the entanglement of the constituent fibers. When the fiber webs are laminated, in the layer direction (Z direction), the fiber density in the space between the fiber web and the adjacent fiber web is smaller than the fiber density in the thickness direction (Z direction) of a single fiber web. Therefore, the lamination of the fiber webs in the thickness direction (Z direction) is such that the short fibers of the adjacent fiber webs are joined by partial entanglement. By stacking the fiber webs without applying an external force and placing them in a heater (oven) in an unloaded state, a nonwoven fabric sheet having the above structure can be formed. In addition to the above, it is preferable that the layers are also integrated by partial fusion by the fused staple fibers. Since the fused staple fiber density in the space between the fiber web and the adjacent fiber web is smaller than the fused staple fiber density in the thickness direction (Z direction) of a single fiber web, the partial fusion ratio by the fused staple fibers is higher in the layer with a higher fiber density than between the layers.

[0018] Since the layers are partially integrated by the entanglement of the short fibers and the fused fibers, not only can air be retained between the constituent fibers in the layer, but also a large amount of air can be retained between the layers, so that the swelling, texture, and heat retention can be improved. Since the layers are partially integrated by the entanglement of the short fibers and the fused fibers, not only can air be retained between the constituent fibers in the layer, but also a large amount of air can be retained between the layers, so that the swelling, texture, and heat retention can be improved.

[0019] The present invention is preferably integrated only by the entanglement of constituent fibers and partial fusion by fused fibers without using a binder. As a result, the nonwoven fabric sheet of the present invention has a uniform structure, and all of the constituent fiber webs have sufficient tensile strength in the plane directions (X and Y directions), while ensuring the peel strength in the thickness direction (Z direction) to maintain the laminated state, and can achieve both a bulging feeling, a soft texture, and heat retention. Examples of the binder used when integrating the fiber web and the nonwoven fabric sheet with a binder include acrylic-based, ethylene-vinyl acetate copolymer-based, polyvinyl acetate-based, polyvinyl chloride-based, synthetic rubber-based, polyurethane-based, polyester-based, or those with a cross-linking agent added thereto. Also, examples of the method for attaching the binder include the spray method and the padding method. When the binder is attached by the spray method, the binder is attached only to the surface layer. Therefore, the state of the fibers constituting the surface layer with the binder and the other layer is different, and the overall state is non-uniform. The tensile strength of the central layer without the binder is weak, which is a problem in terms of physical properties. Furthermore, not only does the layer with the binder become stiffer in texture, but also the weight increases by the amount of the binder applied, so the bulging is impaired. When the binder is attached by the padding method, the binder is attached to the entire laminated fiber web, but the amount of attachment is different between the surface layer and the central layer. Not only does the overall state become non-uniform, but not only does the texture become stiffer, but also the whole is covered with the binder, so there is also a problem that a large amount of air cannot be retained and the heat retention decreases. Examples include ethylene-vinyl acetate copolymer systems, polyvinyl acetate systems, polyvinyl chloride systems, synthetic rubber systems, polyurethane systems, polyester systems, or those with a cross-linking agent added thereto. Also, examples of the method for attaching the binder include the spray method and the padding method. When the binder is attached by the spray method, the binder is attached only to the surface layer. Therefore, the state of the fibers constituting the surface layer with the binder and the other layer is different, and the overall state is non-uniform. The tensile strength of the central layer without the binder is weak, which is a problem in terms of physical properties. Furthermore, not only does the layer with the binder become stiffer in texture, but also the weight increases by the amount of the binder applied, so the bulging is impaired. When the binder is attached by the padding method, the binder is attached to the entire laminated fiber web, but the amount of attachment is different between the surface layer and the central layer. Not only does the overall state become non-uniform, but not only does the texture become stiffer, but also the whole is covered with the binder, so there is also a problem that a large amount of air cannot be retained and the heat retention decreases.

[0020] For the nonwoven fabric sheet for batting, it is preferable that the tensile strength in the plane directions (X, Y directions) is at least twice as high as the peel strength in the layer direction (Z direction). Thereby, a bulging feeling and a soft texture can be obtained. In any direction, whether it is the surface direction or the interlayer direction, it has sufficient strength when in use, yet has a soft texture. By making the tensile strength in the transverse direction (Y direction) of the batting non-woven fabric sheet stronger than the longitudinal direction (X direction) of the batting non-woven fabric sheet in the surface direction (X, Y directions), a satisfactory strength can be obtained when made into clothing. During sports, there are many rotational movements, and if the tensile strength in the Y direction is strong, it can prevent the non-woven fabric sheet inside the clothing from tearing.

[0021] Integrated without using a binder, and among the tensile strengths in the surface directions (X, Y directions), the longitudinal direction (X direction) of the batting non-woven fabric sheet is 0.3 N to 5 N, and the peel force in the thickness direction (Z direction) is 0.5 N or less, so that sufficient strength can be obtained while having a soft texture and high heat retention. When the constituent fibers in the layer are fixed by resin or when the layers between the layers are bonded by resin, it is impossible to achieve swelling and a soft texture due to a decrease in the porosity between the constituent fibers by the resin, an increase in basis weight and a decrease in swelling due to the resin, and a decrease in texture although the strength is high.

[0022] The number of laminated fiber webs constituting the batting non-woven fabric sheet is preferably 2 to 22 layers, more preferably 4 to 20 layers, and still more preferably 4 to 18 layers. Thereby, it can correspond from thin batting clothing to thick batting clothing. If it is less than 2 layers, that is, 1 layer, it becomes a single-layer non-woven fabric sheet, so there are few air layers that can be retained, and sufficient heat retention cannot be exhibited. If it is more than 22 layers, the basis weight becomes large, so the thickness and air layer cannot be retained due to its own weight, and sufficient heat retention cannot be exhibited. Also, in the manufacturing process of the non-woven fabric sheet, the cotton will be torn due to its own weight, so it cannot be manufactured.

[0023] The thickness of the batting non-woven fabric sheet is 5 to 50 mm under no load and in a static state, and the mass (basis weight) is preferably 15 to 250 g / m 2 so as to, similarly, from thin batting clothing to thick It can handle up to quilting clothes. By changing the processing speed, the thickness and basis weight can be adjusted. That is, by lowering the processing speed, the thickness and basis weight can be increased, and by increasing the processing speed, the thickness and basis weight can be decreased.

[0024] The method for manufacturing the nonwoven fabric sheet for batting of the present invention includes the following steps. (1) A step of blending at least polyester staple fibers and fusible staple fibers containing a polymer having a melting point lower than that of the polyester staple fibers, opening the fibers, and forming a fiber web in which the constituent fibers are arranged substantially in one direction. (2) A step of folding and laminating the fiber web to form a long laminated web. (3) A step of heating the long laminated web without load to a temperature equal to or higher than the melting point of the low-melting polymer. (4) A step of cooling and winding up. The step (1) is preferably carried out by a carding machine to form a fiber web. In the step (2), it is preferable to laminate a plurality of fiber webs so that the constituent fibers are arranged substantially in one direction of the sheet. In the step (3), it is preferable to put the long fiber web into a heater (oven) in an unloaded state and perform heat treatment. Also, the steps (1) to (4) may be carried out continuously or separately, but continuous implementation is preferable from the viewpoint of working efficiency.

[0025] The batting structure of the present invention can be manufactured by filling the nonwoven fabric sheet for batting between a front fabric and a back fabric. The nonwoven fabric sheet for batting has good handleability, can be cut into any shape, and is easy to sew. It also has good flatness and good designability for clothes. Suitable clothes include cold-proof upper garments, cold-proof lower garments, connecting clothes, coats, blousons, ski clothes, hats, etc. Suitable bedding includes futons, kotatsu futons, gowns, knee covers, etc.

[0026] The following will be described with reference to the accompanying drawings. In the following drawings, the same reference numerals denote the same components. FIG. 1A is a schematic perspective view of a nonwoven fabric sheet 1 for batting made of a nonwoven fabric according to an embodiment of the present invention, and FIG. 1B is a schematic cross-sectional view taken along line I-I of FIG. 1A. In this nonwoven fabric sheet 1 for batting, the constituent fibers 2 are arranged in one direction and are laminated in a plurality of layers in the arrangement direction of the constituent fibers 2. 3a - 3f in FIG. 1B are folded and laminated fiber webs.

[0027] FIG. 2 is a photograph of an end portion of a nonwoven fabric sheet for batting according to an embodiment of the present invention. It can be confirmed that the constituent fibers are arranged in one direction and are laminated in a plurality of layers in the arrangement direction of the constituent fibers.

[0028] FIG. 3 is a schematic explanatory view showing the process of manufacturing a laminated web of a nonwoven fabric sheet according to an embodiment of the present invention. 11 is a carding machine, and the unopened short fibers 12 are supplied from the feed rollers 13a, 13b, pass through the tak-in roller 14, are opened by the cooperation of the cylinder 15 and the workers 16a, 17a, and the strippers 16b, 17b, pass through the doffer 18, are stripped off by the vibrating comb 19, are taken out as a fiber web 20, folded, formed into a long laminated web 22, and pulled out to the front side or the back side. 21 is the base of the carding machine, and 23 is a device for pulling out to the front side or the back side.

[0029] FIG. 4 is a heating device arranged continuously with FIG. 3. The long parallel web laminated web 22 passes through the heating chamber 24, is fused with low-melting-point polyester fibers, and the constituent fibers are integrated and wound around the winding body 25 as a thermal bonded nonwoven fabric 1.

Example

[0030] The present invention will be specifically described by the following examples. Note that the present invention is not limited to the following examples. <Heat retention> KES (Kawabata Evaluation System) Thermo Lab II was measured at ΔT = 20°C. The batting was wrapped with a 20 cm × 20 cm polyester fabric and measured as a futon-shaped sample. Since the basis weight differed depending on the cotton, the measured heat retention (clo value) was divided by the basis weight for comparison. <Heat retention when wet> The futon-shaped sample was placed in a thermo-hygrostat at 40°C and 90% RH for 12 hours, and then the heat retention was measured. Since the basis weight differed depending on the cotton, the measured heat retention (clo value) was divided by the basis weight for comparison. <Bulkiness (thickness)> Four layers of cotton cut to a size of 20 cm × 20 cm were stacked, the thickness of each side was measured, and the thickness per layer was calculated from the average. <Basis weight> Four layers of cotton cut to a size of 20 cm × 20 cm were stacked, and the weight was measured to two decimal places using an electronic balance (SHIMADZU, model number: UW4205), and the basis weight per layer was calculated. The measured value was rounded to an integer by rounding. <Density> It was calculated from the measured thickness and basis weight as (basis weight ÷ thickness). <Tensile strength in the plane direction> Measured according to JIS L 1096:2020 Method A (strip method). <Peel strength between layers> Measured in accordance with JIS L 1066:2004 from a state where the batting was peeled 50 mm up and down from the central part in the thickness direction. For all measurements, samples were measured at a location more than 20 cm inside from the edge of the nonwoven fabric sheet.

[0031] (Example 1) 7 mass% of polyethylene terephthalate staple fiber (fineness 2.8 decitex, fiber length 64 mm) 5 mass% and fusible fiber (core component is polyethylene terephthalate, sheath component is a core-sheath composite fiber made of a polyester copolymer with a melting point of 140°C, fineness 2.2 decitex, fiber length 5 1 mm) 8 mass% and crosslinked polyacrylate staple fiber (commercially available product of the applicant "Bressa Using 17% by mass of a polyester staple fiber (fiber fineness: 2.4 decitex, fiber length: 35 mm), a long laminated web was created by the method shown in Figure 3. Then, by the method shown in Figure 4, it was heat-treated at 165°C for 3 minutes at a speed of 3 m / min, cooled, and wound up to obtain a non-woven fabric sheet for batting. This non-woven fabric sheet for batting had a basis weight of 115 g / m 2 and a thickness of 21.67 mm. Also, the non-woven fabric sheet for batting had a tensile strength in the plane direction (X, Y directions) of 1.26 N in the X direction (the warp direction of the non-woven fabric sheet for batting) and 2.89 N in the Y direction (the weft direction of the non-woven fabric sheet for batting), and a peel strength between layers (Z direction) of 0.13 N. This non-woven fabric sheet for batting was filled between the front and back fabrics made of nylon fabric to create an outerwear coat. This outerwear coat was size M for men and weighed 353 g per piece. When a wearing test was conducted, it was confirmed to have a puffy and soft texture, be less likely to have a reduced heat retention property even when wet, and be warm.

[0032] (Example 2) The same procedure as in Example 1 was carried out except that the melt-bonded fiber was 13% by mass and the processing speed was 2 m / min. This non-woven fabric sheet for batting had a basis weight of 200 g / m 2 and a thickness of 36.25 mm. Also, the non-woven fabric sheet for batting had a tensile strength in the plane direction (X, Y directions) of 3.33 N in the X direction (the warp direction of the non-woven fabric sheet for batting) and 13.95 N in the Y direction (the weft direction of the non-woven fabric sheet for batting), and a peel strength between layers (Z direction) of 0.28 N.

[0033] (Example 3) The same procedure as in Example 2 was carried out except that the processing speed was 2.5 m / min. This non-woven fabric sheet for batting had a basis weight of 170 g / m 2 and a thickness of 31.50 mm. Also, the non-woven fabric shee t for batting had a tensile strength in the plane direction (X, Y directions) of 1.87 N in the X direction (the warp direction of the non-woven fabric sheet for batting) and 5.22 N in the Y direction (the weft direction of the non-woven fabric sheet for batting), and a peel strength between layers (Z direction) of 0.17 N.

[0034] (Example 4) It was carried out in the same manner as in Example 1 except that the speed was set to 4 m / min. This non-woven fabric sheet for batting had a basis weight of 60 g / m 2 and a thickness of 20.00 mm. Also, the non-woven fabric sheet for batting had a tensile strength in the plane (X, Y directions) of 0.46 N in the X direction (the vertical direction of the non-woven fabric sheet for batting) and 0.53 N in the Y direction (the horizontal direction of the non-woven fabric sheet for batting), and a peel strength between layers (Z direction) of 0.10 N.

[0035] (Example 5) It was carried out in the same manner as in Example 1 except that the speed was set to 2 m / min. This non-woven fabric sheet for batting had a basis weight of 210 g / m 2 and a thickness of 37.5 mm. Also, the non-woven fabric sheet for batting had a tensile strength in the plane (X, Y directions) of 1.89 N in the X direction (the vertical direction of the non-woven fabric sheet for batting) and 6.16 N in the Y direction (the horizontal direction of the non-woven fabric sheet for batting), and a peel strength between layers (Z direction) of 0.19 N.

[0036] (Comparative Example 1) It was carried out in the same manner as in Example 1 except that no fused fibers were used. However, the non-woven fabric sheet was torn during production and a non-woven fabric sheet could not be obtained.

[0037] (Comparative Example 2) The physical properties of a product "Primaloft" (batting in the form of a non-woven fabric sheet) from another company were measured. This is batting integrated by a binder.

[0038] (Comparative Example 3) The physical properties of a product "Thermore" (batting in the form of a non-woven fabric sheet) from another company were measured. This is batting integrated by a binder.

[0039] (Comparative Example 4) The physical properties of a product "Sinsulate" (batting in the form of a non-woven fabric sheet) from another company were measured. This is batting integrated by a binder.

[0040] (Comparative Example 5) The physical properties of the applicant's commercially available product "Thermal Loft" (batting in the form of a non-woven sheet) were measured. This is a batting integrated by a binder.

[0041] (Comparative Example 6) The physical properties of the applicant's commercially available product "Tech Fill" (batting in the form of shredded cotton) were measured. Due to the shredded cotton form, measurement of bulkiness and density was excluded from the scope.

[0042] (Comparative Example 7) The physical properties of the applicant's commercially available down product were measured. Due to the down, measurement of bulkiness and density was excluded from the scope. The above results are summarized in Table 1-2.

[0043]

Table 1

[0044]

Table 2

[0045] As is clear from the above examples and comparative examples, the batting non-woven sheet of the present invention has swelling and a soft texture, and its heat retention property hardly decreases even when wet. It has been confirmed that a warm batting non-woven sheet, a method for manufacturing the same, and a garment including the same can be provided.

Industrial Applicability

[0046] The batting non-woven sheet of the present invention is suitable as a batting garment to be worn in cold seasons, and is suitable for warm-up jackets, warm-up pants, connecting clothes, coats, blousons, ski clothes, hats, bedding, etc.

Explanation of Reference Numerals

[0047] 1 Batting non-woven sheet 2 Constituent fibers 3a-3f Fiber web 11 Card machine 12 Unopened staple fibers 13a, 13b Feed rollers 14 Take-in roller 15 Cylinder 16a, 17a Worker 16b, 17b Stripper 18 Doffer 19 Oscillating comb 20 Fiber web 21 Base of the card machine 22 Long laminated web 23 Take-up device 24 Heating chamber 25 Take-up body

Claims

1. A nonwoven fabric sheet for filling, which is a blend of at least polyester staple fibers, fusible staple fibers containing a polymer having a lower melting point than the polyester staple fibers, and highly cross-linked polyacrylate staple fibers, The highly cross-linked polyacrylate staple fibers have 0.2 to 2.5% by mass of a hydrophobizing agent attached thereto, The nonwoven fabric sheet for filling is formed by laminating a plurality of layers of fiber webs in which constituent fibers are arranged substantially in one direction of the sheet, and each layer and all layers of the fiber webs are not compressed, In the nonwoven fabric sheet for filling, layers are bonded to each other by entanglement of constituent fibers, and at least a part of the constituent fibers is partially fused by the fusible short fibers, The nonwoven fabric sheet for filling has a tensile strength in the plane direction (X and Y directions) that is at least twice as high as the interlaminar peel strength (Z direction), The nonwoven fabric sheet for padding is characterized in that the density of fused short fibers in the space between adjacent fiber webs is smaller than the density of fused short fibers in the thickness direction (Z direction) of one fiber web, and the proportion of partial fusion by fused short fibers is higher in a layer having a higher fiber density than between layers.

2. 2. The nonwoven fabric sheet for filling according to claim 1, wherein the polyester staple fibers constitute 60 to 99% by mass and the fused staple fibers constitute 1 to 40% by mass with respect to 100% by mass of the nonwoven fabric sheet for filling.

3. 2. The nonwoven fabric sheet for padding according to claim 1, wherein the nonwoven fabric sheet for padding comprises a plurality of layers of fibrous webs laminated in the same direction as the arrangement direction of the constituent fibers.

4. 2. The nonwoven fabric sheet for padding according to claim 1, wherein the fusible staple fibers have a core component of polyethylene terephthalate and a sheath component of composite fibers having a melting point or softening point of 90 to 230°C.

5. The blend ratio of the highly cross-linked polyacrylate staple fiber is 1 to 50 parts by mass per 100 parts by mass of the total amount of the polyester staple fiber and the fused staple fiber.

6. 2. The nonwoven fabric sheet for padding according to claim 1, wherein the number of layers of the fiber web constituting the nonwoven fabric sheet for padding is 2 to 22.

7. The thickness of the nonwoven fabric sheet for filling is 5 to 50 mm in a static state without load, and the mass (basis weight) is 15 to 250 g / m 2 2. The nonwoven fabric sheet for padding according to claim 1,

8. A method for producing the nonwoven fabric sheet for padding according to any one of claims 1 to 7, (1) A process of blending at least polyester staple fibers, fusion staple fibers, and highly cross-linked polyacrylate staple fibers having 0.2 to 2.5 mass% of a hydrophobizing agent attached thereto, and opening the blend to form a fiber web in which the constituent fibers are aligned substantially in one direction; (2) folding and laminating the fiber web to form a long laminated web; (3) heating the long fiber web under no load to a temperature equal to or higher than the melting point of the low-melting point polymer, thereby increasing the tensile strength of the nonwoven fabric sheet for padding in the plane directions (X and Y directions) by at least two times the interlayer peel strength (Z direction); (4) Cooling and winding process The method for producing a nonwoven fabric sheet for padding, comprising the steps of: compressing each layer or all layers of the fiber web;

9. A filling structure comprising the nonwoven fabric sheet for filling according to any one of claims 1 to 7 as filling material.

10. The padding structure according to claim 9, wherein the padding structure is a garment or bedding.

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