Padding-use nonwoven fabric sheet, method for manufacturing same, and padding structure including same

Abstract

The present invention is a padding-use nonwoven fabric sheet (1), in which fused short fibers that include at least polyester short fibers and a polymer with a melting point lower than that of the polyester short fibers have been blended, wherein: a plurality of layers of fiber webs (3a)–(3f) in which constituent fibers (2) of the padding-use nonwoven fabric sheet (1) are substantially arranged in one direction of the sheet are layered; and at least part of the constituent fibers (2) are partially fused by the fused short fibers. Due to this configuration, provided are: a padding-use nonwoven fabric sheet that has a full and soft texture, has a heat retention property that is unlikely to deteriorate even when wet, and is warm; a method for manufacturing the padding-use nonwoven fabric sheet; and a padding structure that includes the padding-use nonwoven fabric sheet.

Description

Nonwoven fabric sheet for filling, its manufacturing method and filling structure including the same

[0001] The present invention relates to a nonwoven fabric sheet for batting, a method for producing the same, and a batting structure including the same.

[0002] Down is widely used in outerwear, primarily in winter. When used as an insulating material, down offers excellent heat retention and compression recovery, making it suitable for a variety of applications. However, issues include animal welfare concerns, the need for filling equipment during sewing, high cost, and unstable supply. Therefore, synthetic batting is being used as an alternative to down. Synthetic batting is available in the form of granules or shredded cotton, as well as in sheet form. Synthetic batting offers similar heat retention and compression recovery to down and is used in many products. However, washing can cause the batting to shift, impairing not only product quality but also warmth. It also poses manufacturing challenges, such as the need for filling equipment during sewing. Sheet batting is produced by solidifying layered cotton with resin or heat-sealed fibers to create volume, but it can also have challenges such as a stiff texture and increased weight when attempting to increase thickness. Additionally, many products are manufactured and sold using moisture-absorbing, heat-generating fibers to improve warmth.

[0003] As prior art, Patent Document 1 proposes laminating multiple spunbond nonwoven fabric layers and integrating them with a heat calendar. Patent Document 2 proposes producing a lightweight, fluffy laminated fabric by bonding two laminated fiber layers together using a thermoplastic resin to form a front and back fabric. Patent Document 3 proposes a heat-retaining agent in which nonwoven fabrics are laminated on both sides of a meltblown long-fiber nonwoven fabric.

[0004] JP 2022-046702 A JP 2021-095650 A JP 2022-039587 A

[0005] However, Patent Document 1 uses filaments in the nonwoven fabric, which has the problem of not being able to provide sufficient fluffiness, Patent Document 2 has the problem of the texture becoming hard because the mixed fiber layers of each layer are bonded together with resin, and Patent Document 3 uses nanofiber fibers and has a structure in which a fiber laminate is sandwiched between nonwoven fabrics, which has the problem of not being able to provide sufficient fluffiness.

[0006] To solve the above-mentioned conventional problems, the present invention provides a warm nonwoven fabric sheet for padding that has volume and a soft texture and is resistant to loss of heat retention even when wet, a method for manufacturing the same, and a padding structure including the same.

[0007] In one embodiment, the present invention relates to a nonwoven fabric sheet for filling, which is a blend of at least polyester staple fibers and fusible staple fibers containing a polymer having a lower melting point than the polyester staple fibers, wherein the nonwoven fabric sheet for filling is a laminate of multiple layers of fiber webs in which the constituent fibers are arranged substantially in one direction of the sheet, and wherein at least some of the constituent fibers are partially fused by the fusible staple fibers, and the layers of the laminated nonwoven fabric are bonded by entanglement of the constituent fibers.

[0008] In one embodiment, the method for producing a nonwoven fabric sheet for padding of the present invention relates to a method for producing a nonwoven fabric sheet for padding, comprising: (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, and opening the blend to form a fiber web in which the constituent fibers are aligned in a substantially unidirectional manner; (2) a step of folding and stacking 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 (4) a step of cooling and winding the fiber web.

[0009] In one embodiment, the present invention relates to a padding structure using the above-mentioned padding nonwoven fabric sheet as padding.

[0010] The nonwoven fabric sheet for padding of the present invention is a nonwoven fabric sheet for padding that is a blend of at least polyester staple fibers and fused staple fibers containing a polymer with a lower melting point than the polyester staple fibers, and the nonwoven fabric sheet for padding is composed of multiple layers of fiber webs in which the constituent fibers are arranged substantially in one direction of the sheet, and the nonwoven fabric sheet for padding has fluffiness and a soft texture because at least some of the constituent fibers are partially fused by the fused staple fibers, and its heat retention properties are less likely to decrease even when wet, so that a warm nonwoven fabric sheet for padding, a manufacturing method thereof, and a padding structure including the same can be provided.

[0011] Fig. 1A is a schematic perspective view of a nonwoven fabric sheet for batting according to one embodiment of the present invention, and Fig. 1B is a schematic cross-sectional view taken along line I-I in Fig. 1A. Fig. 2 is a photograph of the edge of a nonwoven fabric sheet for batting according to one embodiment of the present invention. Fig. 3 is a schematic explanatory diagram showing the lamination process of a nonwoven fabric sheet for batting according to one embodiment of the present invention. Fig. 4 is a schematic explanatory diagram showing the heating process of a nonwoven fabric sheet for batting according to one embodiment of the present invention.

[0012] The present invention provides a nonwoven fabric sheet for batting, which is a laminate of multiple layers of fiber webs in which at least polyester staple fibers and fusible staple fibers containing a polymer with a lower melting point than the polyester staple fibers are blended, and in which the constituent fibers are aligned substantially in one direction of the sheet, and at least some of the constituent fibers are partially fused with the fusible staple fibers. The polyester staple fibers have high strength and initial modulus of elasticity (Young's modulus), good stiffness, high compression recovery, and a fluffy, soft texture. They are resistant to loss of heat retention even when wet, allowing them to retain warmth. The fusible fibers partially fused at least some of the constituent fibers. This results in a batting sheet that is resistant to deformation, and the batting structure filled with this has good washability. In this specification, "substantially" means 50% by mass or more.

[0013] The blend 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, 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, relative to 100% by mass of the nonwoven fabric sheet for batting. This allows the polyester staple fiber to be partially fused while maintaining a good texture, resulting in a warm nonwoven fabric sheet for batting that has a fluffy and soft texture and is resistant to a decrease in heat retention even when wet.

[0014] The nonwoven fabric padding sheet preferably has a plurality of layers of fiber webs laminated in the same direction as the orientation of the constituent fibers, which allows for a high yield of the nonwoven fabric padding sheet.

[0015] The fusible staple fibers are preferably core-sheath composite fibers having a core component made of polyethylene terephthalate and a sheath component made of a polyester copolymer having a melting point or softening point of 90 to 230° C. After heat treatment, the sheath component of these fusible staple fibers is fused, while the core component maintains its fibrous form, and has the function of softening the texture.

[0016] The nonwoven fabric sheet for padding is preferably further blended with highly cross-linked polyacrylate staple fibers. The highly cross-linked polyacrylate staple fibers are preferably 1 to 50 parts by mass, more preferably 3 to 40 parts by mass, and even more preferably 5 to 30 parts by mass, per 100 parts by mass of the total amount of polyester staple fibers and fusion-bonded staple fibers. The highly cross-linked polyacrylate fibers may also be water-repellent treated. Highly cross-linked polyacrylate fibers inherently have moisture-absorbing heat-generating properties, but when treated with a water-repellent coating, this moisture-absorbing heat-generating properties are maintained even when wet. One example of highly cross-linked polyacrylate fibers is a product sold by the present applicant under the trade name "Breath Thermo." The water-repellent treatment can be carried out using, for example, commercially available products such as the AG series "Asahi Guard AG7000" (trade name), "Asahi Guard AG970" (trade name), and "Asahi Guard AG-E082" (trade name), "Asahi Guard GS10" (trade name) (all manufactured by Asahi Glass Co., Ltd., fluorine-based hydrophobic emulsions), "NK Guard FGN700T" (trade name), and "NK Guard NDN7000" (trade name) (all manufactured by Nicca Chemical Co., Ltd., fluorine-based hydrophobic emulsions), etc. The main components of non-fluorine-based water repellents include silicone-based, urethane-based, acrylic-based, and hydrocarbon-based, and any of these can be used. Modified silicone hydrophobizing agents include epoxy-modified silicone hydrophobizing agents and amino-modified silicone hydrophobizing agents. Commercially available products include "X-22-9002" (trade name, side chain both-end epoxy-modified silicone), "X-22-163A" (trade name, both-end epoxy-modified silicone), and "KF-8012" (trade name, both-end amino-modified silicone), all manufactured by Shin-Etsu Silicones Co., Ltd. Fluorine-containing silicone compounds are commercially available from Nicca Chemical Co., Ltd. under the trade names "NK Guard S-07" and "NK Guard S-09." An example of a hydrocarbon-based compound is a high-melting-point wax emulsion manufactured by Nicca Chemical Co., Ltd. under the trade name "TH-44." These hydrophobizing agents are preferably applied to fibers in a water-dispersed state. The fibers are contacted by immersing them in the treatment solution, spraying them, or padding them, followed by heat treatment with a curing set to fix the agent in place. The amount of the hydrophobizing agent attached is 0.2 to 2.5 mass % (mass % is also called omf %, omf being an abbreviation for on the mass of fiber), and preferably 0.22 to 2.0 omf %.

[0017] In a multi-layered fiber web, the layers are preferably integrated by the entanglement of the constituent fibers. The constituent fibers of the fiber web are uniformly blended, and the fiber direction is aligned in one direction by a carding machine, resulting in a uniform state in both the X direction (the longitudinal direction of the fiber web) and the Y direction (the transverse direction of the fiber web). By laminating these fiber webs, each layer of the nonwoven fabric padding sheet is uniform. With the blend ratio of fusible staple fibers of the present invention, the fiber web is uniformly blended, resulting in satisfactory strength in the plane directions (X and Y directions) during production and use as clothing or bedding. The lamination of each layer is carried out simultaneously with the processing. In other words, the fibers present on the surface of each layer are entangled during lamination, and the layers are integrated by the entanglement of the constituent fibers. When the fiber webs are laminated, the fiber density in the space between adjacent fiber webs in the interlayer direction (Z direction) is lower than the fiber density in the thickness direction (Z direction) of a single fiber web. Therefore, when fiber webs are stacked in the thickness direction (Z direction), the short fibers of adjacent fiber webs are bonded by partial entanglement. A nonwoven fabric sheet with the above structure can be constructed by stacking the fiber webs without applying any external force and placing them in a heater (oven) in an unloaded state.

[0018] In addition to the above, it is preferable that the layers are also integrated by partial fusion with fusible staple fibers. Since the density of fusible staple fibers in the space between adjacent fibrous webs is lower than the density of fusible staple fibers in the thickness direction (Z direction) of a single fibrous web, the proportion of partial fusion with fusible staple fibers is higher within the layer with a higher fiber density than between the layers. The interlayers are partially integrated by entanglement of staple fibers and fusible fibers, which not only allows air to be retained between the constituent fibers within the layer, but also allows a large amount of air to be retained between the layers, thereby improving fluffiness, texture, and heat retention.

[0019] In the present invention, it is preferable to integrate the fibers without using a binder, using only the entanglement of the constituent fibers and partial fusion by the fusion fibers. This results in a uniform structure for the nonwoven fabric sheet of the present invention, and while all of the constituent fiber webs have sufficient tensile strength in the plane direction (X and Y directions), they can also ensure peel strength in the thickness direction (Z direction) to maintain the laminated state, thereby achieving a fluffy feel, soft texture, and heat retention. Examples of binders used when integrating the fiber web and nonwoven fabric sheet with a binder include acrylic, ethylene-vinyl acetate copolymer, polyvinyl acetate, polyvinyl chloride, synthetic rubber, polyurethane, polyester, or any of these with added crosslinking agents. Methods for applying the binder include spraying and padding. When applying the binder by spraying, the binder is applied only to the surface layer. As a result, the surface layer with the binder and the other layers have different fiber configurations, resulting in an overall non-uniform state. The tensile strength of the center layer without the binder is weak, resulting in problems with physical properties. Furthermore, the layer with the binder not only becomes hard in texture, but also loses fluffiness due to the weight increase corresponding to the amount of binder applied. When applying the binder using the padding method, the binder is applied to the entire laminated fiber web, but the amount of binder applied differs between the surface layer and the center layer, resulting in an uneven overall state, as well as a hard texture, and since the entire web is covered with binder, it cannot retain much air, which reduces its heat retention properties.

[0020] It is preferable that the tensile strength of the nonwoven fabric padding sheet in the plane direction (X, Y directions) is at least twice as high as the peel strength between layers (Z direction). This allows for a fluffy and soft texture. In both the plane direction and the interlayer direction, the sheet has sufficient strength for use while also having a soft texture. By making the tensile strength in the plane direction (X, Y directions) stronger in the horizontal direction (Y direction) of the nonwoven fabric padding sheet than in the vertical direction (X direction) of the nonwoven fabric padding sheet, satisfactory strength can be obtained when made into clothing. Rotational movements are common during sports, and a strong tensile strength in the Y direction can prevent the nonwoven fabric sheet in the clothing from tearing.

[0021] By integrating the fibers without using a binder and ensuring that the tensile strength in the plane directions (X and Y directions) of the nonwoven fabric sheet for padding is 0.3 N to 5 N in the longitudinal direction (X direction) of the sheet and that the peel strength in the thickness direction (Z direction) is 0.5 N or less, it is possible to obtain sufficient strength while maintaining a soft texture and high heat retention. If the constituent fibers within a layer are fixed with a resin or if interlayers are bonded with a resin, the resin reduces the void ratio between the constituent fibers, the resin increases the basis weight and reduces fluffiness, and although the strength is high, the texture is reduced, making it impossible to achieve fluffiness and a soft texture.

[0022] The number of layers of the fiber web constituting the nonwoven fabric sheet for padding is preferably 2 to 22 layers, more preferably 4 to 20 layers, and even more preferably 4 to 18 layers. This allows it to be used for a wide range of padded garments, from thin to thick. If there are fewer than two layers, i.e., only one layer, the nonwoven fabric sheet will be a single layer, which will not retain enough air space and will not provide sufficient heat retention. If there are more than 22 layers, the basis weight will be too high, and the thickness and air space will not be able to be maintained due to the sheet's own weight, making it impossible to provide sufficient heat retention. Furthermore, the cotton will tear under its own weight during the manufacturing process of the nonwoven fabric sheet, making it impossible to manufacture.

[0023] The thickness of the nonwoven fabric sheet for filling is 5 to 50 mm in the unloaded and static state, and the mass (basis weight) is 15 to 250 g / m 2 This makes it possible to accommodate a wide range of padded garments, from thin to thick. The thickness and basis weight can be adjusted by changing the processing speed. That is, by slowing down 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 producing a nonwoven fabric sheet for padding of the present invention includes the following steps: (1) 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 blend to form a fiber web in which the constituent fibers are aligned in a substantially unidirectional direction; (2) folding and stacking the fiber web to form a long laminated web; (3) heating the long laminated web to a temperature equal to or higher than the melting point of the low-melting polymer without load; and (4) cooling and winding. The step (1) is preferably performed by carding the fiber web. The step (2) is preferably performed by stacking multiple layers of fiber webs so that the constituent fibers are aligned in a substantially unidirectional direction in the sheet. The step (3) is preferably performed by placing the long fiber web in a heater (oven) without load and heat-treating it. The steps (1) to (4) may be performed continuously or separately, but continuous execution is preferred from the viewpoint of operational efficiency.

[0025] The padding structure of the present invention can be produced by filling the nonwoven fabric sheet for padding between a front and a backing. The nonwoven fabric sheet for padding is easy to handle, can be cut into any shape, and is easy to sew. It also has good flatness, allowing for good clothing design. As clothing, it is suitable for cold weather tops, cold weather bottoms, coveralls, coats, blousons, ski suits, hats, etc. As bedding, it is suitable for comforters, kotatsu futons, gowns, lap blankets, etc.

[0026] The following description will be made with reference to the drawings. In the following drawings, the same reference numerals indicate the same objects. Fig. 1A is a schematic perspective view of a nonwoven fabric sheet 1 for batting made of a nonwoven fabric according to one embodiment of the present invention, and Fig. 1B is a schematic cross-sectional view taken along line I-I in Fig. 1A. In this nonwoven fabric sheet 1 for batting, constituent fibers 2 are aligned in one direction, and multiple layers are laminated in the direction of the alignment of constituent fibers 2. Reference numerals 3a-3f in Fig. 1B represent folded and laminated fiber webs.

[0027] Fig. 2 is a photograph of the edge of a nonwoven fabric sheet for padding according to one embodiment of the present invention, which shows that the constituent fibers are aligned in one direction and that multiple layers are laminated in the direction of the alignment of the constituent fibers.

[0028] 3 is a schematic diagram illustrating the steps of manufacturing a laminated web of nonwoven fabric sheets according to one embodiment of the present invention. Reference numeral 11 denotes a carding machine. Unopened staple fibers 12 are fed from feed rollers 13a and 13b, pass through a stay-in roller 14, are opened by the cooperation of a cylinder 15, workers 16a and 17a, and strippers 16b and 17b, pass through a doffer 18, are stripped by a vibration comb 19, and are taken out as a fibrous web 20. The web is then folded into a long laminated web 22, which is then taken up to the front or rear side. Reference numeral 21 denotes a base of the carding machine, and 23 denotes a device for taking up the fibers to the front or rear side.

[0029] Figure 4 shows a heating device arranged in series with the device shown in Figure 3, in which a long parallel web laminate web 22 passes through a heating chamber 24, is fused with low-melting point polyester fibers, the constituent fibers are integrated, and the thermally bonded nonwoven fabric 1 is wound onto a winding body 25.

[0030] The present invention will be described in more detail below with reference to the following examples. The present invention is not limited to the following examples. <Warmth> Measurements were made using a KES (Kawabata Evaluation System) Thermo Lab II at ΔT = 20°C. The filling was wrapped in a 20 cm x 20 cm polyester fabric, and measurements were made on cushion-shaped samples. Because the basis weight varies depending on the cotton, the measured warmth (clo value) was divided by the basis weight for comparison. <Warmth when wet> The cushion-shaped samples were placed in a constant temperature and humidity chamber at 40°C and 90% RH for 12 hours, after which the warmth was measured. Because the basis weight varies depending on the cotton, the measured warmth (clo value) was divided by the basis weight for comparison. <Bulkiness (Thickness)> Four sheets of cotton cut to a size of 20 cm x 20 cm were stacked, and the thickness of each side was measured and averaged to calculate the thickness per sheet. <Basis Weight> Four sheets of cotton cut to a size of 20 cm x 20 cm were stacked, and the weight was measured to two decimal places using an electronic balance (SHIMADZU, model number: UW4205) to calculate the basis weight per sheet. The measured value was rounded to the nearest integer. <Density> Calculated from the measured thickness and basis weight by (basis weight ÷ thickness). <Tensile strength in the plane direction> Measured using JIS L 1096:2020 Method A (strip method). <Interlayer peel strength> Measured in accordance with JIS L 1066:2004, with the padding peeled 50 mm above and below the center in the thickness direction. All measurements were taken on samples at least 20 cm inside from the edge of the nonwoven fabric sheet.

[0031] Example 1 A long laminated web was prepared by the method shown in Figure 3 from 75% by mass of polyethylene terephthalate staple fibers (fineness 2.8 decitex, fiber length 64 mm), 8% by mass of fusion fibers (core-sheath composite fibers consisting of polyethylene terephthalate as a core component and a polyester copolymer with a melting point of 140°C as a sheath component, fineness 2.2 decitex, fiber length 51 mm), and 17% by mass of highly cross-linked polyacrylate staple fibers ("Breath Thermo," a commercially available product of the present applicant, fineness 2.4 decitex, fiber length 35 mm). This web was then heat-treated at 165°C for 3 minutes at a speed of 3 m / min, cooled, and wound up as shown in Figure 4 to obtain a nonwoven fabric sheet for filling. This nonwoven fabric sheet for filling had a basis weight of 115 g / m. 2and a thickness of 21.67 mm. The nonwoven fabric padding sheet had a tensile strength in the plane directions (X and Y directions) of 1.26 N in the X direction (the longitudinal direction of the nonwoven fabric padding sheet) and 2.89 N in the Y direction (the transverse direction of the nonwoven fabric padding sheet), and an interlayer (Z direction) peel strength of 0.13 N. This nonwoven fabric padding sheet was filled between a nylon outer and inner lining to create an outer coat. This outer coat, a men's size M, weighed 353 g. Wear tests confirmed that it had volume and a soft texture, and its heat retention was not easily reduced even when wet, providing excellent warmth.

[0032] (Example 2) The same procedure as in Example 1 was carried out, except that the fusible fiber content was 13% by mass and the processing speed was 2 m / min. This nonwoven fabric sheet for padding had a basis weight of 200 g / m 2 The nonwoven fabric sheet for filling had a thickness of 36.25 mm. The tensile strength in the plane directions (X and Y directions) of 3.33 N in the X direction (the longitudinal direction of the nonwoven fabric sheet for filling) and 13.95 N in the Y direction (the transverse direction of the nonwoven fabric sheet for filling), and the interlayer peel strength (Z direction) was 0.28 N.

[0033] (Example 3) The same procedure as in Example 2 was carried out, except that the processing speed was set to 2.5 m / min. This nonwoven fabric sheet for filling had a basis weight of 170 g / m 2 The nonwoven fabric sheet for filling had a thickness of 31.50 mm. The tensile strength in the plane directions (X and Y directions) of the sheet was 1.87 N in the X direction (the longitudinal direction of the nonwoven fabric sheet for filling) and 5.22 N in the Y direction (the transverse direction of the nonwoven fabric sheet for filling), and the interlayer peel strength (Z direction) was 0.17 N.

[0034] (Example 4) The same procedure as in Example 1 was carried out, except that the speed was 4 m / min. This nonwoven fabric sheet for filling had a basis weight of 60 g / m 2 The nonwoven fabric sheet for filling had a thickness of 20.00 mm. The tensile strength in the plane directions (X and Y directions) of 0.46 N in the X direction (the longitudinal direction of the nonwoven fabric sheet for filling) and 0.53 N in the Y direction (the transverse direction of the nonwoven fabric sheet for filling), and the interlayer peel strength (Z direction) was 0.10 N.

[0035] (Example 5) The same procedure as in Example 1 was carried out, except that the speed was set to 2 m / min. This nonwoven fabric sheet for filling had a basis weight of 210 g / m 2 The nonwoven fabric sheet for filling had a thickness of 37.5 mm. The tensile strength in the plane directions (X and Y directions) of 1.89 N in the X direction (the longitudinal direction of the nonwoven fabric sheet for filling) and 6.16 N in the Y direction (the transverse direction of the nonwoven fabric sheet for filling), and the interlayer peel strength (Z direction) was 0.19 N.

[0036] Comparative Example 1 The same procedure as in Example 1 was carried out except that no fusible fibers were used. However, the nonwoven fabric sheet was torn during production, and no nonwoven fabric sheet could be obtained.

[0037] Comparative Example 2 The physical properties of a competitor's product, "Primaloft" (filling in the form of a nonwoven fabric sheet), were measured. This is filling held together by a binder.

[0038] Comparative Example 3 The physical properties of a competitor's product "Thermore" (filling in the form of a nonwoven fabric sheet) were measured. This is filling that is integrated with a binder.

[0039] Comparative Example 4 The physical properties of a competitor's product, "Thinsulate" (filling in the form of a nonwoven fabric sheet), were measured. This is filling held together by a binder.

[0040] Comparative Example 5 The physical properties of the applicant's commercially available product "Thermalloft" (filling in the form of a nonwoven fabric sheet) were measured. This is a filling held together by a binder.

[0041] Comparative Example 6 The physical properties of the applicant's commercially available product "Techfill" (filling in the form of torn cotton) were measured. Because it was in the form of torn cotton, measurements of bulkiness and density were not taken into account.

[0042] (Comparative Example 7) The physical properties of a commercially available down product made by the applicant were measured. Because it was down, measurements of bulkiness and density were not included. The results are summarized in Table 1-2.

[0043]

[0044]

[0045] As is clear from the above examples and comparative examples, it has been confirmed that the padded nonwoven fabric sheet of the present invention has a fluffy and soft texture, and its heat retention properties are not easily reduced even when wet, and that it is possible to provide a warm padded nonwoven fabric sheet, a manufacturing method thereof, and clothing including the same.

[0046] The nonwoven fabric sheet for padding of the present invention is suitable for padded clothing worn in cold seasons, such as thermal tops, bottoms, coveralls, coats, blousons, ski suits, hats, and bedding.

[0047] REFERENCE SIGNS LIST 1 Nonwoven fabric sheet for filling 2 Constituent fibers 3a-3f Fiber web 11 Carding machine 12 Unopened short fibers 13a, 13b Feed roller 14 Take-in roller 15 Cylinder 16a, 17a Worker 16b, 17b Stripper 18 Doffer 19 Vibration comb 20 Fiber web 21 Carding machine base 22 Long laminated web 23 Take-up device 24 Heating chamber 25 Winding body

Claims

1. A nonwoven fabric sheet for padding, which is a blend of at least polyester staple fibers and fusible staple fibers containing a polymer having a lower melting point than the polyester staple fibers, wherein the nonwoven fabric sheet for padding is formed by laminating multiple layers of fiber webs in which the constituent fibers are aligned substantially in one direction of the sheet, and wherein the layers of the nonwoven fabric sheet for padding are bonded together by entanglement of the constituent fibers, and further wherein at least a portion of the constituent fibers are partially fused by the fusible staple fibers.

2. A nonwoven fabric sheet for padding as described in claim 1, wherein the polyester staple fibers account for 60 to 99% by mass and the fused staple fibers account for 1 to 40% by mass relative to 100% by mass of the nonwoven fabric sheet for padding.

3. The nonwoven fabric sheet for padding according to claim 1 or 2, wherein the nonwoven fabric sheet for padding is formed by laminating multiple layers of fiber webs in the same direction as the orientation direction of the constituent fibers.

4. A nonwoven fabric sheet for padding according to any one of claims 1 to 3, 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. A nonwoven fabric sheet for padding according to any one of claims 1 to 4, wherein the nonwoven fabric sheet for padding is further blended with highly cross-linked polyacrylate staple fibers, and the highly cross-linked polyacrylate staple fibers are blended in an amount of 1 to 50 parts by mass per 100 parts by mass of the total amount of the polyester staple fibers and the fused staple fibers.

6. The nonwoven fabric sheet for padding according to any one of claims 1 to 5, wherein the highly cross-linked polyacrylate fibers are water-repellent.

7. A nonwoven fabric sheet for padding according to any one of claims 1 to 6, wherein the layers of the laminated fiber web are integrated by entanglement of the constituent fibers.

8. A nonwoven fabric sheet for filling as described in any one of claims 1 to 7, wherein the tensile strength in the plane direction (X, Y directions) is at least twice as high as the peel strength between layers (Z direction).

9. A nonwoven fabric sheet for padding according to any one of claims 1 to 8, wherein the number of layers of the fiber web constituting the nonwoven fabric sheet for padding is 2 to 22.

10. 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 The nonwoven fabric sheet for padding according to any one of claims 1 to 9, 11. A method for producing a nonwoven fabric sheet for padding according to any one of claims 1 to 10, comprising: (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, and opening the blend to form a fiber web in which the constituent fibers are aligned in a substantially unidirectional direction; (2) a step of folding and stacking 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 (4) a step of cooling and winding the fiber web.

12. A padding structure containing the nonwoven fabric sheet for padding according to any one of claims 1 to 10 as padding.

13. The padded structure of claim 12, wherein the padded structure is clothing or bedding.

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