EP3165654A1 - Use of endless filament non-woven fabrics for preventing the escape of down in down- filled textile products - Google Patents

Abstract

The invention relates to the use of a continuous filament nonwoven fabric to prevent feather leakage from a down filled textile product, which nonwoven fabric is obtainable by a spun process wherein composite filaments are laid down to a nonwoven, after which the composite filaments are deposited in continuous filaments having a denier of less than zero , 15 dtex are split and the nonwoven is mechanically bonded to a nonwoven fabric, wherein the nonwoven fabric is not thermally or chemically solidified.

Description

The invention relates to the use of a nonwoven fabric of continuous filaments for preventing the leakage of down from a down filled textile product, wherein the continuous filaments have a titer less than 0.15 dtex. The invention also relates to down-filled textile products and methods for their preparation.

State of the art

Down, also known as lower springs, are feathers with short keel and soft feathered branches. Down is used in textile products, such as bedding, jackets or sleeping bags, as thermal insulation fillers. The downs are contained and enclosed in sheaths of flat textile structures. Down-filled textile products must be "down-proof" when used as intended. This means that the down does not penetrate or even get out of the sheaths. Since quills of down are pointed and hard, the shells must have a high strength. In particular, dense and strong tissues are suitable as casings. Fabrics consist of interwoven weft threads and warp threads. Down quills, which are pointed, but generally much larger than fabric threads and fabric stitches, can not penetrate fabrics because the fibers are not sufficiently slidable. The down density of fabrics can be tested in a standardized method according to DIN 12132-1.

In contrast to fabrics, textile nonwovens are not suitable as sheaths for filling with down. Even thick textile nonwovens are relatively easily penetrated by down. Because the fibers of conventional nonwoven fabrics are disordered and therefore mutually displaceable, down quills can easily penetrate them. The down density of nonwovens can be achieved if they are solidified thermally or chemically. The fibers are then bonded to each other in a similar way as in a tissue and no longer freely displaceable against each other. However, such surface solidification is unacceptable in textile applications, as it leads to unfavorable properties, such as low softness and elasticity, low porosity and associated low air and moisture permeability. Therefore, the prior art generally uses fabric for down fillings.

However, it would also be desirable to make use of nonwovens for such applications, since nonwoven fabrics in particular have many advantageous properties which distinguish them from fabrics, such as high softness, elasticity, stability, porosity, high air and moisture permeability, but also good availability and processability ,

It is therefore proposed in the prior art to use nonwovens for the storage of down as a component of laminates. For example, the JP2008 / 303480A to use a composite material of a fabric with a nonwoven fabric. Also the JP2006 / 291421A discloses down-density laminates containing thermally bonded nonwovens. However, it is disadvantageous that components are included that are currently not ideal nonwovens. Laminates are also relatively expensive to produce, also because the components must be glued or otherwise firmly connected.

The German utility model DE 203 10 279 U1 describes bedding envelopes made of microfiber webs with good air permeability, which provides protection against allergens and mites. The sheaths have characteristic mechanical properties characteristic of nonwoven fabrics, for example in terms of washability and stability. The disclosure also claims that the microfiber web is downproof. For this, however, no proof is provided. The microfiber web according to the embodiment of the DE 203 10 279 U1 is a true nonwoven fabric that has not been thermally consolidated, nor reinforced by other layers in a laminate. Therefore, the fibers in non-solidified areas are mutually displaceable and it is not believable by those skilled in the art that such a conventional nonwoven fabric is down-proof. it is rather to assume that these in the DE 203 10 279 U1 It is simply stated for the reason that a good seal against allergens and mites was found and because down feathers are approximately of a similar size. From the impermeability However, conclusions about the impermeability to down can not be drawn against allergens or mites. While allergens or mites are simply particles, down have a unique hard, sharp, barbed structure that simply drills through nonwovens.

The Applicant of the present application has therefore examined whether the claim of DE 203 10 279 U1 It is true that such fine microfiber nonwovens are downproof. The DE 203 10 279 U1 has an "embodiment", in which, however, no information on the origin or the production of the nonwoven fabric are made. The general information on the nature of the microfiber nonwoven fabric are relatively superficial. However, the microfiber nonwoven fabric described therein essentially corresponds to a commercially available product of the brand Evolon 100 from Freudenberg, DE, which was commercially available in 2003. The Evolon brand product is made from 16 microfiber composite filaments per filament in cupcake form (PIE16). Since the individual fibers are produced from cake-shaped segments, they have an edgy cross-sectional profile, which approximately resembles a triangle. The nonwovens are solidified by water jet treatment, wherein the composite filaments are split into individual filaments of polyethylene terephthalate (PET) and polyamide (PA). The fiber thickness of the composite filament is about 2.4 dtex and that of the individual fibers after splitting about 0.2 dtex and 0.1 dtex. Thus, the nonwoven fabric Evolon 100 with respect to the polyamide fiber component would be even finer than that in the DE 203 10 279 U1 described. But it is to be assumed that in the embodiment of DE 203 10 279 U1 a microfiber nonwoven fabric Evolon 100 Freudenberg was described and investigated. This is supported by the fact that the data in the utility model are essentially identical to the Evolon 100 nonwoven, that the product Evolon 100 was commercially available in 2003, and that in 2003 no comparable third-party product was commercially available. In the utility model there is also no indication that the applicant of the utility model has made the product itself.

To the in the DE 203 10 279 U1 The applicant of the present application has examined whether an Evolon brand microfibre nonwoven fabric covered with a nonwoven fabric from the exemplary embodiment of the present invention has been tested DE 203 10 279 U1 comparable, actually down proof is. As expected, it was found that such a microfiber nonwoven fabric does not have sufficient down resistance. The microfibre nonwoven fabric does not pass the standardized down density leak test according to DIN 12132-1 (see example of the present application: test with Evolon 120, coated with> 15 g / m ² polyurethane or cross-linked polyacrylic binder on the inside of the down), with pure goose down and goose feather Class I made of 90% down and 10% feathers according to EN12934). The test specification actually serves for the investigation of fabrics, but can be used analogously and without substantive modification for nonwovens. A corresponding standard for nonwovens is only not available because in the prior art there was no need for it, since nonwovens are in principle not downproof. Thus, it was possible to confirm the general knowledge that such nonwovens are resistant to allergens, mosquito bites or mites, but not to down.

The Applicant has also microscopically studied the effect of down feathers on such a microfiber nonwoven fabric. The result is in the Fig. 1 to 4 shown. The Fig. 1 and 2 show a typical down feather after penetration of the microfiber nonwoven fabric at different magnifications. In both figures it can be seen that the down quill has a point, with which it can penetrate into the much finer fleece material. The quill has fine barbs that support directional penetration. Fig. 3 shows a down feather in the process of penetration of the nonwoven fabric. Fig. 4 shows a typical hole that has drilled a down through the nonwoven fabric. Overall, it is clear that the down quill a very fine nonwoven according to the DE 10 2014 002232 A1 can easily penetrate by simply pushing the fine individual fibers to the side, the directional penetration is supported by the barbs. Such a fine microfiber nonwoven fabric can not oppose the hard, pointed down keel sufficient resistance.

The lack of down density of the microfiber nonwoven according to DE 203 10 279 U1 is in line with the general knowledge that non-thermally bonded nonwovens, even if made of very fine fibers, are not down-resistant. The DE 203 10 279 U1 contains no teaching to overcome the known disadvantages of nonwovens regarding the lack of down density. Nonwovens known in the prior art were therefore only suitable for the storage of down, if they sufficiently thermally consolidated or combined in laminates with other layers.

Object of the invention

The invention has for its object to provide materials for the storage of down for textile applications, which solve the problems described above. This textile products are to be provided with good mechanical properties to keep down. The textile products should in particular have a high softness and elasticity, porosity, air and moisture permeability, but at the same time be down-proof. The materials should be relatively easily available and the manufacturing process should as far as possible involve no complex processing steps, such as lamination or special post-treatment steps. Overall, the material should be both easily provided by the manufacturer, as well as highly acceptable to the user.

Disclosure of the invention

Surprisingly, the object underlying the invention is achieved by uses, textile products and methods according to the claims.

The invention relates to the use of a continuous filament nonwoven fabric to prevent feather leakage from a down filled textile product, which nonwoven fabric is obtainable by a spun process wherein composite filaments are laid down to a nonwoven, after which the composite filaments are deposited in continuous filaments having a denier of less than 0.15 dtex are split and the nonwoven is mechanically bonded to a nonwoven fabric, wherein the nonwoven fabric is not thermally or chemically solidified surface.

The use according to the invention is carried out with a down filled textile product. The textile product has a sheath enclosing a cavity in which the downs are contained and sealed from the environment. The nonwoven fabric forms the shell of the textile product or a part thereof. Nonwovens are according to the definition of DIN 61 210 (Part 2, 1988) textile fabrics made of loosely deposited fibers by Friction, cohesion or adhesion are interconnected. The nonwoven fabric as a shell and barrier keeps the down from escaping from the textile product.

The nonwoven fabric consists of continuous filaments. The term "filaments" refers to fibers which, in contrast to staple fibers, are produced in a continuous process and are deposited directly into a nonwoven.

For the purposes of this application, the term "down" refers to down feathers (bottom feathers) of birds which are suitable for textile fillings. A definition of down is given in DIN 12934. Down are especially feathers with a very short keel and long, radially arranged spring branches. Down also regularly has fewer hooks than other feathers. Because of their high elasticity and dimensional stability in combination with heat-insulating properties down are used for a variety of textile applications.

The use of the invention is to prevent the escape of down from a down filled textile product. In such textile products, the down filling is contained in a wrapper which separates it from the environment. The term "exit" refers to any movement of the down, in which the shell is penetrated. The down can penetrate the shell only partially or completely. For example, the term "leakage" includes feathers of down only drilling part of the tip through the shell and getting stuck in it, or they can completely penetrate the shell and leave the textile product.

The down density is preferably determined according to the simulated cushion stress test of DIN EN 12132-1, part 1, wherein the nonwoven fabric is used instead of a fabric. Preferably, the nonwoven fabric passes the test according to DIN EN 12132-1, which means that in each direction tested (longitudinal and transverse) not more than 20 particles emerge, ie stuck in the textile material or have penetrated this. An average value is preferably evaluated from a plurality of individual measurements, for example, 5, 10 or 20 individual measurements. In particular, no more than 15 particles, in particular no more than 12 particles, are emitted in the test.

In a preferred embodiment, the nonwoven directly contacts the down filling. This means that there is no additional layer between the nonwoven fabric and the down. The downs touch the nonwoven fabric and would penetrate it if the down density were insufficient. In this case, the nonwoven fabric is preferably used as a textile shell in which the downs are contained. This means that the nonwoven fabric per se forms the shell. He is not part of a laminate with other, other layers. Thus, if the textile product is, for example, a bedding product, the nonwoven fabric would include the down. According to the invention, it has surprisingly been found that a nonwoven fabric per se of fibers with a titre <0.15 dtex, without the need for thermal consolidation or lamination with further layers, in particular fabric layers or stronger nonwoven fabric layers, can prevent the leakage of down.

Composite filaments are filaments of at least two different parallel filaments, which have phase boundary and are splittably interconnected. The composite filaments are split into continuous filaments with a titre of less than 0.15 dtex. Thus, the filaments have a titer <0.15 dtex. This means that the nonwoven fabric has as filament component substantially or exclusively filaments with a corresponding titer. Such nonwovens may have smaller local areas in which composite filaments were not or only partially cleaved. With a sufficient mechanical cleavage, in particular by means of water jet treatment, but nonwovens can be obtained, which consist almost exclusively of single filaments. Preferably at least 80%, in particular at least 90%, at least 95%, at least 98% or about 100% of individual filaments are present, based on the total volume of the fibers. The proportion can be determined microscopically by examining randomly selected sections of a nonwoven fabric.

In a preferred embodiment, the cleavage takes place in continuous filaments with a titre of less than 0.14 dtex, more preferably less than 0.12 dtex or less than 0.11 dtex. The titer is preferably greater than 0.01 dtex or greater than 0.02 5 dtex. In particular, the titre of all continuous filaments is preferably between 0.01 dtex and 0.15 dtex, preferably between 0.02 dtex and 0.12 dtex, or between 0.03 dtex and 0.11 dtex. In particular, the average denier of the continuous filaments is between 0.01 dtex and 0.15 dtex, preferably between 0.025 dtex and 0.125 dtex, in particular between 0.03 dtex and 0.11 dtex.

In a preferred embodiment, the nonwoven fabric contains, as continuous filament component, a filament mixture, in particular of two or three different filament types. For example, it is preferable that two or more continuous filament types having different titers are contained. Preference is given to using composite filaments which contain differently fine continuous filaments of different polymers. In a preferred embodiment, the nonwoven fabric contains at least two components and thereby endless filaments which have a linear density of less than 0.075 dtex, preferably less than 0.065 dtex. The titer of a first fiber component is preferably between 0.80 dtex and 0.15 dtex, preferably between 0.80 dtex and 0.125 dtex, and the titer of a second fiber component is between 0.01 dtex and 0.075 dtex, preferably between 0.02 dtex and 0.065 dtex. The difference between the titers of both components preferably differs by at least 0.02 dtex. In particular, by such an admixture of a second, particularly fine fiber component, an advantageous combination of down-density and stability can be achieved. Preferably, the proportion of the lower denier fibers is at least 5 vol.% Or at least 10 vol.%, In particular at least 20 vol.%. Preferably, the number of fiber strands of the first and second fiber components is the same. If the titer of the first fibers is twice that of the second fibers, volume ratios of about 2: 1 will be obtained, ie about 70:30.

Surprisingly, it has been found that even relatively thin and lightweight nonwovens with a relatively low basis weight can withstand the down. This was unexpected because the down plaits are relatively hard and pointed and in conventional uses exert relatively strong forces on the nonwoven fabric, for example, when pressed into a cushion cover. Without being bound by theory, it is believed that the downs of a densely interlaced nonwoven fabric, upon reaching a threshold fiber fineness, are no longer able to displace the individual filaments and penetrate the nonwoven fabric. When this threshold is reached, even a thin nonwoven fabric is sufficient to effect downproofing. By contrast, above the threshold value, a relatively dense nonwoven fabric is also unsuitable for preventing the leakage of down. Without being tied to a theory It has been assumed that the down-tightness is achieved not only by the fine fibers but also by the special manufacturing process with mechanical splitting of composite filaments, by means of which a particularly dense and homogeneous mixing and intertwining of the filaments is achieved.

In a preferred embodiment, the nonwoven fabric has a basis weight of 70 g / m ² to 200 g / m ² . In a preferred embodiment, the nonwoven fabric has a basis weight of 90 g / m ² to 180 g / m ² , in particular from 100 g / m ² to 160 g / m ² or from 110 g / m ² to 150 g / m ² . Preferably, the basis weight is at least 70 g / m ² or at least 90 g / m ² , more preferably at least 110 g / m ² , in order to ensure a high mechanical stability and down-tightness. Preferably, the basis weight is not greater than 200 g / m ² , not greater than 160 g / m ² or in particular not greater than 160 g / m ² in order to achieve sufficient porosity associated with air and moisture permeability.

Particularly preferred is a nonwoven fabric having two fiber components, preferably split bicomponent fibers, wherein the titer of a first fiber component between 0.08 dtex and 0.15 dtex and the titer of a second fiber component is between 0.01 dtex and 0.075 dtex, wherein the proportion the lower denier fibers are at least 10% by volume combined with a basis weight of from 70 g / m ² to 200 g / m ² , in particular from 90 g / m ² to 180 g / m ² .

The nonwoven fabric is obtainable by a spinning process in which composite filaments are laid down into a nonwoven fabric, after which the composite filaments are split into the continuous filaments and the nonwoven fabric is mechanically consolidated into a nonwoven fabric. With such manufacturing process, a special internal structure of the product is achieved. The filaments have irregular cross-sections, which are due to the cleavage process. The individual filaments are particularly closely intertwined.

Preferably, the composite filaments were prepared by melt spinning. In melt spinning, thermoplastic polymers are melted and spun into fibers. This process enables a particularly simple and reliable production of nonwoven fabrics made of composite filaments.

The composite filaments preferably have two or more different endless filaments. The composite filaments are preferably multicomponent fibers, in particular bicomponent fibers.

Usually, when splitting composite filaments, individual filaments are obtained which have cross sections with corners or edges. This is advantageous because the individual filaments are less mobile to each other. It is believed that this improves the down density.

In a preferred embodiment, the composite filaments, in particular the bicomponent fibers, have a cake-shaped (orange, "PIE") structure. Preferably, the structure 24, 32, 48 or 64 segments, more preferably 32 segments. When splitting the composite filament decomposes into a corresponding number of individual continuous filaments (single filaments). The segments preferably contain alternating polymers. Also suitable are hollow-pie structures that can also have an asymmetrically axially extending cavity. Pie structures, in particular hollow-pie structures, are advantageous because they can be split particularly easily. In addition, the individual filaments have an irregular cross section, which increases the internal strength of the nonwoven fabric. The term "cake" or "pie" actually describes the configuration of the spinneret in such highly fine, split fibers, but the actual cross section of the filaments only approximately.

Preferably, the fiber-forming polymers of the composite polymers are thermoplastic polymers. The composite filaments and / or multicomponent fibers preferably comprise components which are selected from polyesters, polyamides, polyolefins and / or polyurethanes. Particularly preferred are bicomponent fibers with a polyester component and a polyamide component.

In order to obtain easy splittability, it is advantageous if the composite filaments contain endless filaments of at least two thermoplastic polymers (in different components). Preferably, the composite filaments thereby comprise at least two incompatible polymers. Incompatible polymers are to be understood as meaning those polymers which, in combination, give no or only conditionally or poorly adhering pairings. Such a composite filament has a good cleavage in Elementary filaments and allows a favorable ratio of strength to basis weight. As incompatible polymer pairs, polyolefins, polyesters, polyamides and / or polyurethanes are preferably used in a combination that results in no or only partially or heavily adhesive pairings.

Polymer pairs with at least one polyamide or with at least one polyester, in particular polyethylene terephthalate, are preferred because of their conditional bondability. Polymer pairs with at least one polyolefin are preferred because of their poor tackiness.

Combinations of polyesters, preferably polyethylene terephthalate, polylactic acid and / or polybutylene terephthalate, with polyamides, preferably polyamide 6, polyamide 66, polyamide 46 have proved to be particularly preferred, if appropriate in combination with one or more further components to the abovementioned components, preferably selected from polyolefins. These combinations have excellent cleavability. Very particular preference is given to combinations of polyethylene terephthalate and polyamide 6 or of polyethylene terephthalate and polyamide 66.

Also preferred are polymer pairs which contain at least one polyolefin, in particular in combination with at least one polyester or polyamide. Polyamide 6 / polyethylene, polyethylene terephthalate / polyethylene, polypropylene / polyethylene, polyamide 6 / polypropylene or polyethylene terephthalate / polypropylene are preferred.

In a preferred embodiment, the volume ratio of the first to the second continuous filaments is between 90:10 and 10:90, preferably between 80:20 and 20:80.

The average cross-sectional area of the filaments could be less than 15 μm ² or less than 10 μm ² . The cross-sectional area of cut filaments can be determined microscopically. The diameter of the continuous filaments can theoretically be determined from the titers, taking into account the densities, the indication of the fiber diameter being less meaningful for edged filaments.

Suitable composite filaments for producing continuous filaments by means of splits are known in the art. The production of such multicomponent fibers is described inter alia in the FR 2 749 860 A or DE 10 2014 002 232 A1 described. To produce such spunbonded nonwovens, it is possible, for example, to use a Reicofil 4 spunbonded system from Reifenhäuser, DE.

The polymers form the fiber-forming component of the fibers. The fibers may also contain conventional additives. Additives are added regularly to such fiber polymers to modify processability in the production or properties of the fibers. The use of additives also allows adaptation to customer-specific requirements. Suitable additives may, for example, be selected from the group consisting of dyes, antistatic agents, antimicrobial agents such as copper, silver or gold, hydrophilicizing agents or water repellents. These may be present, for example, in an amount of up to 10% by weight, up to 5% by weight or up to 2% by weight, in particular between 150 ppm to 10% by weight.

The nonwoven fabric was mechanically consolidated. In the mechanical consolidation processes, the composite of the fibers is produced by frictional engagement or by a combination of frictional and positive locking. The solidification is preferably carried out by the close mixing of the filaments. Thereby, a nonwoven fabric having an advantageous softness and elasticity combined with good porosity can be obtained. Surprisingly, a sufficient down density is achieved, although the individual fibers are actually mutually displaceable.

The mechanical solidification is preferably carried out under the action of pressure and / or fluids. The solidification can be done by working with pressurized liquids or gases, and / or by pressing, in particular by calendering. At the same time, splitting of the composite filaments takes place during mechanical solidification. The solidification is carried out long enough and with sufficient strength, and / or a suitable combination of different mechanical solidification processes is carried out in order to obtain the Composite filaments completely or at least as far as possible split. At the same time an intimate mixing and intertwining of the individual filaments is achieved.

The solidification preferably comprises a fluid jet solidification, in particular a hydroentanglement. Water is preferred over other fluids because it leaves no residue, is readily available, and allows the nonwoven fabrics to be dried well. In this case, a stored nonwoven is exposed under high pressure to a jet of water, whereby the nonwoven is firstly compacted into a nonwoven fabric, and on the other composite filaments are split into individual filaments. It has been found that hydroentanglement is particularly suitable for achieving intimate intertwining of the continuous filaments, thereby achieving good mechanical properties and also improving down-density. In this case, the mechanical solidification, in particular the hydroentanglement, is carried out so that the microfilaments are not or not too severely impaired. If too much water-jet solidification of such fine filaments, the mechanical stability, and in particular the tear strength (tear propagation force), decrease. The nonwoven fabric preferably has a tear propagation resistance according to DIN EN 13937-2 of 4 to 12 N, in particular of 5 to 12 N or of 6 to 10 N.

As an alternative or in addition to fluid jet solidification and in particular hydroentanglement, further mechanical consolidation steps can be carried out. Thus, a solidification can be done for example by needling and / or calendering. In a preferred embodiment, pre-consolidation takes place by needling and / or calendering, followed by hydroentanglement. The calendering is carried out at a sufficiently low temperature, so that no thermal solidification takes place while bonding the fibers.

The nonwoven fabric was not thermally consolidated surface. This means that it was not consistently, so over the entire nonwoven fabric surface, subjected to a temperature treatment in which fibers or a hot melt adhesive were softened so much that fibers stick together. The thermal bonding of fibers occurs by material bonding, whereby the fibers are connected by adhesion or cohesion. A nonwoven without thermal consolidation is advantageous because the softness and elasticity preserved. On the other hand, upon thermal consolidation, the mechanical properties change significantly and in a manner that is unfavorable to textile applications. In particular, the nonwoven fabric becomes more rigid, that is less elastic and soft, and less porous, so that the air and moisture permeability decreases.

The nonwoven fabric was not chemically solidified surface. This means that the fibers were not bonded together by a chemical reaction and in particular were not crosslinked with a binder. No covalent bonds were created between fibers.

In one embodiment, the nonwoven fabric could only be thermally and / or chemically consolidated in partial areas (locally). A local consolidation in sub-areas that are evenly distributed over the nonwoven surface, could increase the stability. The solidification can be done for example in the form of a dot pattern. In order to obtain the advantageous typical nonwoven properties, however, at most a small portion of the nonwoven fabric should be solidified, for example less than 30%, less than 10% or less than 5% of the total area. The down-density is also given in the non-solidified areas. Local thermal consolidation is not useful and is not required to achieve down-density. However, it is preferred according to the invention that the nonwoven fabric is not thermally or chemically solidified at all. This means that no thermal or chemical consolidation took place to improve the stability of the nonwoven material per se in the area. As a result, the advantageous nonwoven fabric properties are completely retained. Of course, this is not precluded by the fact that the nonwoven fabric has sealed seams, adhesive seams or similar areas which serve for processing into a textile product.

The nonwoven fabric may be post-treated after solidification by conventional methods, for example by drying and / or shrinking. The nonwoven fabric is then formed into an envelope into which the downs are incorporated and entrapped.

In a preferred embodiment, the composite filaments have a cake-like (orange) structure and are cleaved into continuous filaments having a denier of less than 0.12 dtex, wherein the mechanical strengthening comprises hydroentanglement and wherein the nonwoven fabric has a basis weight of from 70 g / ^m2 to 200 g / m ² . In this case, bicomponent fibers, in particular of a polyester component and a polyamide component, are preferably used.

In a preferred embodiment, the nonwoven fabric has an average pore size of 5 .mu.m to 20 .mu.m and / or a maximum pore size of 10 .mu.m to 50 .mu.m, measured with a pore size meter PSM 165 TOPAS, DE, according to the manufacturer's instructions in accordance with ASTM E 1294-89 and ASTM F 316-03.

The thickness of the nonwoven fabric is preferably between 0.20 mm and 0.60 mm, in particular between 0.25 mm and 0.50 mm, measured according to DIN EN 964-1.

The maximum tensile strength (maximum tensile strength) in all directions is preferably at least 150 N / 5 cm, measured according to EN 13934-1. Preferably, the maximum tensile strain in all directions is at least 20%, preferably at least 30%, measured according to DIN EN 13934-1.

The nonwoven fabric is preferably characterized by a very good water absorption. This is preferably at least 250 ml / m ² , in particular more than 350 ml / m ² measured according to DIN 53923 in analogy for nonwovens.

Preferably, the down density is maintained even with prolonged use and conventional mechanical stress. It has been found that the down density is maintained when the nonwoven fabric is washed more often. Preferably, the nonwoven fabric is also down after 5, 10 or 20 household washes according to DIN EN ISO 6330 in the sense of DIN EN 12132-1.

The air permeability according to EN ISO 9237: 1995-12A is preferably at least 20 mm / s, preferably at least 30 mm / s, measured at a test area of 20 cm ² and a differential pressure of 200 Pa, preferably at an average of 10 or 50 individual measurements.

Particularly preferably, the nonwoven fabric has a basis weight of 90 g / m ² to 160 g / m ² , an air permeability according to EN ISO 9237: 1995-12A of at least 20 mm / s and a tear strength according to DIN EN 13937-2 of 4 to 12 N. on.

As stated above, the nonwoven fabric per se is suitable for use in accordance with the invention. Nevertheless, it is conceivable to reinforce the nonwoven fabric with additional textile layers. Thus, the use according to the invention can be carried out, for example, from a laminate of the nonwoven fabric with at least one further layer, for example one or two further layers. It is preferred that the nonwoven fabric directly adjacent to the down and thereby forms a barrier. The nonwoven fabric could be provided on the outside facing away from the down with at least one further layer, which gives the laminate further desired properties, such as moisture protection or increased mechanical strength. Even in such a laminate, however, the purpose of use, that is, the achievement of down density, is achieved by the non-woven fabric per se, which forms the physical barrier for the down. Additional layers, especially on the outside, are preferably applied for a different purpose, that is, they do not improve the down density or only slightly.

The invention also provides a down filled textile product, in particular selected from bedding, jacket, upholstery, mattress or sleeping bag, comprising a textile cover and down contained therein. The sheath comprises a continuous filament nonwoven fabric to prevent feather leakage, which nonwoven fabric is obtainable by a spun process wherein composite filaments are laid down to a nonwoven, after which the composite filaments are split into continuous filaments having a titer of less than 0.15 dtex and the nonwoven fabric mechanically solidified into a nonwoven fabric, wherein the nonwoven fabric is not thermally or chemically solidified.

The wrapper is a textile ply having a suitable shape for keeping down in it. The textile shell could consist essentially of the nonwoven fabric. This means that the nonwoven fabric forms at least the part of the textile casing, through which the storage of the down and separation from the environment takes place. In addition, the textile cover may be modified for other purposes, for example, with decorative elements or closure means, such as buttons or zippers, be equipped.

The textile product is preferably a bedding, jacket, a cushion, a mattress or a sleeping bag. Particularly preferably, the textile product is a bedding product. Because of the

Downproofness combined with good mechanical properties, and especially high softness and elasticity, make the nonwovens particularly well suited as body pads or pads, such as comforters, pillows or mattress pads.

In a preferred embodiment, the down are goose down. These penetrate textile casings because of their hardness and shape particularly easily. It has been found that the use according to the invention with the special nonwovens makes it possible to store even goose down down.

In addition to down, the filling may also contain other customary fillers, such as feathers or synthetic fillers. Down is often used for textile applications as blends with feathers. The proportion of down on the filling is preferably at least 30% by weight or at least 50% by weight, in particular at least 70% by weight.

1. (a) Bereitstellen der textilen Hülle, die den Vliesstoff aus Endlosfilamenten umfasst,
2. (b) Füllen der textilen Hülle mit den Daunen, und
3. (c) daunendichtes Verschließen der textilen Hülle.

The invention also provides a process for producing the down-filled textile product, comprising the steps:

1. (a) providing the textile sheath comprising the continuous filament nonwoven fabric,
2. (b) filling the textile casing with the down, and
3. (c) down-tight sealing of the textile casing.

The down-proof sealing may be accomplished, for example, by thermal sealing, stitching, gluing or other conventional methods. Since in particular spinnable and thus thermoplastically processable polymers are used, sealing thermal joining methods such as ultrasonic sewing or welding are particularly preferred.

The nonwoven fabrics according to the invention are highly advantageous because they are not only down-proof, but also regularly offer high protection against allergens, such as pollen or house dust, or mosquito bites. The latter is particularly advantageous because tissues generally do not provide protection against mosquito bites. The inventively usable nonwovens thus provide an overall high protection against disturbing environmental influences.

Overall, the nonwoven fabric is characterized by an advantageous combination of properties. The mechanical properties, for example with regard to maximum tensile strength, maximum tensile elongation, isotropy, expansion modulus or tear propagation resistance, are excellent and readily allow conventional applications in the textile sector. In addition, the nonwoven fabric has advantageous properties especially for typical textile applications such as absorption, wash shrinkage or pore size. Overall, it was surprising that a combination of advantageous properties in conjunction with high down density can be achieved without thermal or chemical bonding and even with low basis weight. In addition, it is advantageous that the nonwoven fabric can be produced in a simple manner and no special processing steps, such as lamination, or chemical aftertreatment, are required. The materials for its production, in particular composite filaments and corresponding continuous filaments, are easily accessible and processable.

The nonwoven fabric according to the invention has a very good down density, while comparable nonwoven fabrics with somewhat thicker fibers have no down density. It was surprising that the down density does not increase in proportion to the fiber fineness, but that nonwovens with fibers of a certain fiber thickness are unsuitable for storing down, while fibers with higher fineness suddenly have a high down density. It was not to be expected that especially with very fine fibers the down density would suddenly be reached. Rather, one would have expected that very fine fibers could no longer provide the hard and pointed down quills with sufficient mechanical strength. Thus, the invention makes it possible to use only mechanically consolidated nonwoven fabrics for the storage of down. The invention thereby solves the problems described in the introduction.

pictures:

• Abbildung 1 zeigt einen typischen harten, spitzen Daunenkiel mit Widerhaken, der einen Vliesstoff gemäß dem Stand der Technik durchbohrt, in 100-facher Vergrößerung.
• Abbildung 2 zeigt einen typischen Daunenkiel mit Widerhaken in 2000-facher Vergrößerung. Der Radius der Spitze beträgt etwa 3,6 µm und der Durchmesser unterhalb der Spitze etwa 19,1 µm.
• Abbildung 3 zeigt einen Vliesstoff gemäß dem Stand der Technik, der von einem Daunenkiel durchbohrt wird, in 100-facher Vergrößerung.
• Abbildung 4 zeigt das Loch in dem Vliesstoff gemäß dem Stand der Technik aus Abbildung 3, der von einem Daunenkiel durchbohrt wurde, in 100-facher Vergrößerung.

Figures 1 to 4 are micrographs of a prior art nonwoven fabric pierced by a down feather.

• illustration 1 shows a typical hard, pointed barbed down keel piercing a prior art nonwoven fabric at 100x magnification.
• Figure 2 shows a typical barbed down feather in 2000x magnification. The radius of the tip is about 3.6 microns and the diameter below the tip about 19.1 microns.
• Figure 3 shows a nonwoven fabric according to the prior art, which is pierced by a down keel, in 100-fold magnification.
• Figure 4 shows the hole in the nonwoven fabric according to the prior art Figure 3 , which was pierced by a down keel, in 100x magnification.

embodiments Examples 1 to 4: Production of nonwovens

The production of nonwovens with a bicomponent spunbonded web of bicomponent fibers having a cake form cross section is described below by way of example. Two nonwovens which can be used according to the invention were prepared with 32 individual filaments (type "PIE 32") and basis weights of about 100 g / m ² and 130 g / m ² (examples 2 and 4). For comparison with the prior art of DE 203 10 279 U1 Two nonwovens from bicomponent fibers having 16 individual filaments (type "PIE16") and basis weights of about 100 g / m ² and 130 g / m ^{2 was} produced (Examples 1 and 3). The components and manufacturing conditions are summarized below. Raw materials: shares Polyester, INVISTA, DE 70 Polyamide 6, BASF, DE 30 Hydrophilic, CLARIANT, CH 0.05 in PET TiO ₂ , CLARIANT, CH, Renol Weiss ™ 0.05 in PET Antistatic, CLARIANT, CH, Hostatstat ™ 0.05 in PA6 extruder: PET, zones 1-7 270-295 ° C PA6, zones 1-7 260-275 ° C Spinning pumps: Volume, speed, throughput PET: 2x10cm ³ / U, 16.56 rpm, 0.923g / L per min Volume, speed, throughput PA6: 2x3cm ³ / U, 26.25 rpm, 0.377 g / L per min Total throughput: 1.3 g / L per minute (71/29) jets: Nozzle Type: PIE16 or PIE 32, pneumatic stretching

interpretation:

On a preset belt at a preset speed, which gives a nonwoven basis weight of 100 or 130g / m ² .

consolidation:

Pre-consolidation by needling with 35 stitches / cm ² and subsequent calendering with steel rollers smooth / smooth, at 160-170 ° C and 65-85N line pressure.

Final consolidation and splitting of the bicomponent filaments in single filaments by hydroentanglement with 4 to 6 alternating passages on the upper side A and lower side B of the nonwoven fabric in the order ABAB (AB) at 220-250 bar, with nozzle strip hole diameter 130 μm on a 80 mesh deposit belt.

After treatment:

Subsequently, the nonwoven fabric is dried with a cylindrical through-air dryer at 190 ° C and partially shrunk to ensure a possible washing shrinkage of <3% in the first cooking wash.

The production speeds in the process steps after discharge from the nozzles depend on the desired basis weight.

Example 5: Properties of the nonwovens

Properties of the nonwovens produced according to Examples 1 to 4, which are of importance for typical textile applications, were investigated by suitable measuring methods. The tests are based on the following standards in the versions valid on the filing date, unless otherwise stated: property unit standard grammage g / m ² EN 965 thickness mm EN 964-1 ultimate tensile strength N / 5 cm EN 13934-1 maximum stress % EN 13934-1 module N EN 13934-1 porosity microns ISO 2942 / DIN 58355-2 Tear strength N EN 13937-2 Abrasion Martindale (9kPa) tour EN 12947 pilling grade based on DIN 53867 water absorption based on DIN 53923 Household linen (shrinkage% at 95 ° C) DIN EN ISO 6330 Air permeability (air flow measurement method) mm / s DIN EN ISO 9237: 1995-12A

The results are summarized in the following table: example 1 (comparison) 2 3 (comparison) 4 Type PIE16 PIE32 PIE16 PIE32 grammage (g / m ² ) 99 97 130 127 thickness (Mm) 0.37 0.33 0.44 0.41 Titre single filaments dtex 0.2 / 0.1 0.1 / 0.05 0.2 / 0.1 0.1 / 0.05 Textile physical tests carried out at 20 ° C, 400mm / min ultimate tensile along (N) 320 275 424 292 crosswise (N) 290 237 388 192 isotropy 1.1 1.16 1.09 1.52 maximum stress along (%) 48 40 42 35.5 crosswise (%) 51 51.5 46 39 Module / 3% along (N) 73 76 84 84 crosswise (N) 36 31 43 26 Module / 5% along (N) 89 93 110 104 crosswise (N) 48 40 59 35 Module / 15% along (N) 150 154 209 175 crosswise (N) 102 77 134 75 Module / 40% along (N) 285 276 417 crosswise (N) 240 190 333 206 Tear strength along (N) 8.5 7 8.6 5.5 before the wash crosswise (N) 9.8 10 11.4 10.2 pilling down up 4,5 / 4,5 4.5 / 5 3.5 / 3.5 5+ / 5+ absorption (l / m ² ) 350 400 490 467 Abrasion Martindale 9 kPa holing 12000 20000 16000 35000 after 95 ° C wash aspect 2.5 1.5 2 1.5 wash shrinkage along (%) 4.8 2.4 3 2.6 crosswise (%) 3 3.1 2.4 1 After 3 washes aspect 2.5 1.5 2.5 1.5 permeability Pore size on average 25 12 18 8th Maximum pore size 75 37 59 21 Air permeability (Mm / s) 71 37

The results show that all four nonwovens have good textile properties. At the same basis weight, the nonwoven fabrics of the type PIE32 (Examples 2 and 4) which can be used according to the invention show improved wash resistance, allergen tightness and mosquito puncture resistance in comparison to the comparative nonwoven fabrics of the type PIE16 (Examples 1 and 3).

Example 6: Downproof

The down-density test was carried out using the simulated cushion stress test in accordance with DIN EN 12132-1. This standard is used to test the down density of fabrics and is applicable analogously to nonwovens. According to Part 1, a simulated pad stress was performed. The test was carried out on two pillows whose dimensions were 120 mm x 170 mm. For pillow 1, the longer side runs in the direction of 1. For pillow 2, the longer side runs in direction 2. The filling material used was white, new, pure goose down and feathers class I, 90% down / 10% feathers. The test material complies with EN 12934 - marking the composition of finished feathers and down. As a result, the number of down / feathers or parts penetrated after 2700 revolutions was determined. According to the definition, a sample that yields a result in all directions of 20 or less is down-down.

For the nonwoven fabric according to Example 2 (PIE32, 97 g / m ² basis weight), in the direction 1 a result of 16 (one particle stuck in the fabric, 15 particles in the plastic bag) and in the direction 2 a result of 34 (2 particles stuck in the fabric , 32 particles in the plastic bag). For the nonwoven fabric according to Example 4 (PIE32, 127 g / m ² ), a result in direction 1 of 9 (2 particles stuck in fabric, 7 particles in plastic bag) and in direction 2 of 3 (0 particles stuck in fabric, 3 particles in plastic bag). The results show that the nonwoven fabric of the present invention has excellent down-tightness. Even the down density of a nonwoven fabric according to the invention having a basis weight of 100 g / m ² is high, while the down density at 130 g / m ² completely corresponds to the requirements for bedding products.

For comparison, a nonwoven fabric was tested from a mixture of continuous filaments with a linear density of 0.1 dtex and 0.2 dtex. The nonwoven fabric was prepared analogously to Example 1, but had a basis weight of 120 g / m ² and was additionally equipped with a stabilizing coating of polyurethane (15 g / m ² ). After a household wash, the result in the simulated cushion stress test in accordance with DIN EN 12132-1 was 1 in 42 (5 particles stuck in the textile material, 37 particles in the plastic bag) and in the direction 2 of 35 (3 particles stuck in the textile material, 32 particles in the plastic bag) receive. The nonwoven thus has no down density, which is suitable for textile applications.

Microscopic examination showed that feather quills readily penetrate such comparative nonwovens ( Fig. 1 to 4 ). The monofilaments of 0.2 and 0.1 dtex monofilaments can not provide sufficient strength to the hard, pointed, barbed quills.

The results show that the comparative nonwovens are not expected to be down-proof. It was surprising, however, that a slightly finer nonwoven fabric is downproof. Fig. 2 shows a typical pointed quill with a tip that is about 3.6 microns wide. The circumference of the tip is significantly smaller than the average pore sizes between 8 and 25 microns of all four nonwovens of Examples 1 to 4. Therefore, it would be expected that the quills would drilled through all four nonwovens. In addition, it would have been expected that the finer fibers would provide even less resistance to a hard and pointed object. Without being bound by theory, the particular down density of the inventively employable nonwoven fabrics could be caused by the internal structure of closely interlaced filaments.

Claims (15)

Use of a continuous filament nonwoven fabric to prevent feather leakage from a down filled textile product, which nonwoven fabric is obtainable by a spun process wherein composite filaments are laid down to a nonwoven, after which the composite filaments are split into continuous filaments having a titer of less than 0.15 dtex and the nonwoven is mechanically bonded to a nonwoven fabric, wherein the nonwoven fabric is not thermally or chemically solidified surface. Use according to claim 1, wherein the composite filaments are split into continuous filaments having a titer of less than 0.12 dtex. Use according to any one of the preceding claims, wherein the nonwoven fabric contains continuous filaments having a denier of less than 0.075 dtex. Use according to at least one of the preceding claims, wherein the nonwoven fabric has a basis weight of from 70 g / m ² to 200 g / m ² , preferably from 90 g / m ² to 150 g / m ² . Use according to at least one of the preceding claims, wherein the composite filaments are multicomponent fibers, in particular bicomponent fibers. Use according to claim 5, wherein the multicomponent fibers comprise components selected from polyesters, polyamides, polyolefins and / or polyurethanes. Use according to any one of claims 5 to 6, wherein the multicomponent fibers are bicomponent fibers of a polyester and a polyamide component. Use according to any one of the preceding claims, wherein the composite filaments have a cake-like (orange) structure which preferably has 24, 32, 48 or 64 segments. Use according to any one of the preceding claims, wherein the mechanical consolidation comprises hydroentanglement. Use according to at least one of the preceding claims, wherein the nonwoven fabric has a maximum pore size of 5 .mu.m to 20 .mu.m and / or a maximum pore size of 10 .mu.m to 50 .mu.m, measured on the basis of ASTM E 1294-89 and ASTM F 316-03 with a pore meter PSM 165 from Topas, DE. Use according to at least one of the preceding claims, wherein the nonwoven fabric has an air permeability of at least 20 mm / s, preferably at least 30 mm / s, measured according to EN ISO 9237: 1995-12A at a test area of 20 cm ² and a differential pressure of 200 Pa. Use according to any one of the preceding claims, wherein the composite filaments have a cake-like (orange) structure and are split into continuous filaments having a titer of less than 0.12 dtex, the mechanical strengthening comprising hydroentanglement and wherein the nonwoven fabric has a basis weight of 70 g / m ² to 200 g / m ² . Use according to any one of the preceding claims, wherein the nonwoven fabric is down-proof in a simulated cushion stress test according to DIN EN 12132-1, part 1, with a mixture of 90% goose down and 10% goose feather. Down filled textile product, in particular selected from bedding, jacket, upholstery, mattress or sleeping bag, comprising a textile cover and down included therein,
the sheath comprising a continuous filament nonwoven fabric for preventing feather leakage, the nonwoven fabric being obtainable by a spinning process the composite filaments are laid down to a nonwoven fabric, after which the composite filaments are split into continuous filaments with a titre of less than 0.15 dtex and the nonwoven is mechanically consolidated to a nonwoven fabric, wherein the nonwoven fabric is not thermally or chemically solidified. A method of making the down-filled textile product according to claim 13, comprising the steps of: (a) providing the textile sheath comprising the continuous filament nonwoven fabric, (b) filling the envelope with the down, and (c) down-tight sealing of the envelope.

Images