KR20170097067A - Fiberball batting and articles comprising the same - Google Patents

Abstract

The present invention provides a quilt web comprising a nonwoven web comprising a specific fiber mixture, wherein the nonwoven web comprises 50 to 95 wt% of a plurality of fiber balls having an average diameter of 3.0 to 8.0 mm; And a portion of a plurality of the nonwoven webs of 5 to 50 wt%, which are close to the one or more fiber balls but which themselves do not comprise one or more fiber balls or any part thereof. The duvet has a density of 2 to 12 kg / m < ^{3 &} gt ;. A method of making an article comprising a quilt web and a quilt web is also provided.

Description

FIELD OF THE INVENTION [0001] The present invention relates to a fiber bag,

Cross reference to related application

This application is a continuation-in-part of U.S. Patent Application, filed December 17, 2014, the entire content of which is incorporated herein by reference. Priority is claimed for provisional application number 62 / 093,293.

Field of the Invention

FIELD OF THE INVENTION The present invention relates generally to fiberglass batting, including synthetic fibers and binder fibers, such as bedding useful as insulation. The present invention also relates to an article comprising a duvet bat, and a method of making the duvet bat.

BACKGROUND OF THE INVENTION

Fiber ball has already been known for some time. While fibrous balls exhibit undesirable manufacturing deficiencies in other applications, such as, for example, carding of a variety of continuous nonwoven materials, such as for blowable applications, .

U.S.A. Patent No. No. 4,618,531 discloses such an inflatable fiber ball. Clearly, U.S.A. No. 4,618,531 discloses a polyester fiber filler having a spiral crimp that is arbitrarily arranged and entangled in the form of an inflatable fiber ball. The fibrous balls are said to be easily transportable, e.g. by blowing, by, for example, jetting.

US Pat. No. 4,794,038 also discloses a fiber ball comprised of preferably spiral-crimped, binder fibers and entangled spiral-crimped fiber pills. The fiber ball can be easily transported, for example, by jetting, and then compressed and bonded together. The above references describe that binder fiber blends are used on a large scale in similar end-uses where fixtures, mattresses, and strong supports are required. However, they are rarely used, for example, in furniture seat cushions, only in this end-use as filling material, and the usual practice is to obtain the desired elasticity and performance in a 100% For this reason it is for the use of fiberfill batts as "rapping" for the foam core, which is necessary to provide such a relatively high density or a very high cost And may not be provided for the preferred implementation. US 4,794,038 provides a solution and its expandable fiber ball is compressed and / or shaped to form a strong support as an alternative to the layer structure, e.g. for use in furniture, matrices, and similar end uses . Consistent with this article, the reference discloses a structure that is strong, relatively dense (20 Kg / m ³ to 50 Kg / m ³ ) bonded, and the best density (50 Kg / m ³ ) Elasticity and most of the support.

US Pat. No. 4,940,502 discloses a bonded structure which is provided in the form of a shaped fiber ball block produced through a process comprising compression. The resulting fiber ball block has a relatively high density (having a general range of densities of about 20 Kg / m ³ to 80 Kg / m ³ ) and has improved elasticity, durability and conformability, for example, .

Previous efforts related to fibrous filler materials have been directed to high density resilient bonded structures containing, for example, conventional batts, inflatable fiber balls, and fiber balls, while improved filler materials There is a continuing need for this.

Certain aspects of conventional techniques are discussed in order to facilitate the subject matter of the present invention and the applicant never gives up on any of these technical aspects and the claimed invention is not limited to the one or more conventional It may also be considered that the technical aspect may be included.

When a document, act or knowledge item is referred to or discussed in the present specification, such reference or discussion refers to a document, action or knowledge item, or any combination thereof, on a priority date, a portion known to the general public, Does not acknowledge that it is publicly available in the case of constituting prior art under the provisions of this Article; Or attempted to solve any problems associated with this specification.

SUMMARY OF THE INVENTION

Briefly, the present invention satisfies the need for an improved fill material. The present invention may address one or more of the problems and drawbacks of the above discussed literature. However, the present invention contemplates demonstrating its usefulness in addressing other problems and drawbacks in a number of technical areas. Accordingly, the claimed invention should not necessarily be construed as limited to solve any particular problems or deficiencies discussed herein.

The presently-disclosed batting, articles comprising quilt webs, and methods for forming quilt webs have some characteristics, and no signal is responsible for their desired characteristics . Without limiting the scope of the duvet coverings, articles and methods as defined by the following claims, their more important features will now be briefly discussed. After considering this discussion, and particularly after reading the portions of this specification referred to as "Detailed Description of the Invention ", it will be appreciated that the features of the various embodiments presented herein provide numerous advantages over the present state of the art .

In one aspect, the present invention provides a quilt web comprising a nonwoven web comprising a fiber mixture having:

40 to 95 wt% synthetic fibers having a denier of 0.5 to 7.0 and a length of 18 to 51 mm; And

- 5 to 40 wt.% Binder fibers having a denier of 1.0 to 5.0 and a length of 18 mm to 71 mm, wherein the binder fibers have a bonding temperature lower than the softening temperature of the synthetic fibers Binder fiber, which is to have.

Structurally, the nonwoven web comprises:

A plurality of fiber balls of 50 to 95 wt% with an average diameter of 3.0 to 8.0 mm; And

5 to 50 wt% of a plurality of the nonwoven webs 5 to 50 wt%, which are close to one or more fiber balls but which themselves do not contain one or more fiber balls or any part thereof of portions of the nonwoven web that are adjacent to one or more fiberballs and that do not contain one or more fiberballs or any portion thereof);

.

The duvet has a density of 2 to 12 kg / m < ^{3 &} gt ;.

In a second aspect, the invention provides an article comprising a creative quilt cover. Non-limiting examples of such articles include, for example, outerwear products (e.g., outer garments such as jackets), clothing, sleeping bags, and bedding (e.g., Futon) and the like.

In a third aspect, the invention provides a method of making a creative bedding, comprising:

Mixing the fibers comprising:

40 to 95 wt% synthetic fibers having a denier of 0.5 to 7.0 and a length of 18 to 51 mm; And

- 5 to 40 wt% of binder fibers having a denier of 1.0 to 5.0 and a length of 18 to 71 mm, said binder fibers having a binding temperature lower than the softening temperature of said synthetic fibers;

Thereby forming a fiber mixture;

- forming a plurality of fiber balls from said fiber mixture;

- forming a nonwoven web from said fiber mixture, said nonwoven web comprising:

A plurality of fiber balls of 50 to 95 wt% with an average diameter of 3.0 to 8.0 mm; And

A portion of a plurality of said nonwoven webs of from 5 to 50 wt%, which are close to one or more fiber balls but which themselves do not comprise one or more fiber balls or any part thereof;

And < / RTI > And

Heating the nonwoven web at or above the binding temperature of the binder fibers, thereby forming a bedding web (heating the nonwoven web to an excess of the binder fibers, batting);

.

These and other features and advantages of the present invention will become apparent from the following detailed description of various aspects of the invention taken in conjunction with the appended claims and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS The invention will be described below with reference to the following drawings, wherein like numerals represent like elements:
BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a top-view photograph of one embodiment of a creative bedding pad.
Figure 2 is a profile-view photograph of one embodiment of a creative bedding pad.

DETAILED DESCRIPTION OF THE INVENTION

The aspects and specific features, advantages and details of the present invention are more fully described below with reference to the non-limiting embodiments illustrated in the accompanying drawings. The description of well-known materials, manufacturing tools, processing techniques, etc. is omitted so as not to unnecessarily obscure the present invention in detail. It should be understood, however, that the description and the specific example (s) show embodiments of the invention, but are not intended to be limiting. Various substitutions, modifications, additions, and / or arrangements within the spirit and / or scope of the concept of the present invention will be apparent to those of ordinary skill in the art from this disclosure.

In one aspect,

40 to 95 wt% of synthetic fibers having a denier of 0.5 to 7.0 and a length of 18 to 51 mm; And

From 5 to 40 wt.% Of binder fibers having a denier of from 1.0 to 5.0 and a length of from 18 mm to 71 mm, said binder fibers having a binding temperature lower than the softening temperature of said synthetic fibers;

≪ RTI ID = 0.0 > a < / RTI > nonwoven web comprising a fiber blend having a web of fibers.

Structurally, the nonwoven web comprises:

A plurality of fiber balls of 50 to 95 wt% with an average diameter of 3.0 to 8.0 mm; And

A portion of a plurality of said nonwoven webs of from 5 to 50 wt%, which are close to one or more fiber balls but which themselves do not comprise one or more fiber balls or any part thereof;

.

A portion of a nonwoven web that is close to a plurality of fiber balls and one or more fiber balls but which themselves does not include one or more fiber balls or any portion thereof includes one or more fibrous balls or any portion thereof And also comprises a fiber mixture of said nonwoven webs. (The majority of fiberglass webbing webbing webbing webbing webbing webbing webbing webbing webbing webbing , also comprising the fiber mixture of the nonwoven web).

The inventive quilt web is typically heat treated, such as by dissolving some or all of the binder fibers, thereby forming a bonded web-type quilt web. Accordingly, one of ordinary skill in the art will recognize that in this embodiment, even though "binder fibers" are quoted in the fiber blend of nonwoven webs, the fibers may be in their original, pre-heat treatment form ), As opposed to the binder fibers, as will be understood by those skilled in the art. Nevertheless, the denier and length description of the binder fibers, as used herein, describes the characteristics of the binder fibers prior to thermal bonding treatment.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a top view photograph of one embodiment of a creative bedding 100. As shown, the duvet is close to one or more fiber balls, which also include a plurality of fiber balls 12, and also a fiber mixture of the nonwoven web 14, (Which may be referred to as "space" for simplicity) of a plurality of the nonwoven webs, but not including a fibrous ball or any portion thereof. The present invention can be distinguished from prior art bonded materials formed from an inflatable fiber ball (e.g., as described in US Patent No. 4,794,038), for example, an inflatable fiber ball, When combined with each other using compression and heat treatments such as the bar, the result is a lack of space 14, as shown in the present invention, by a nonwoven web formed prior to thermal treatment. Figure 2 is a profile-view photograph of an embodiment of a creative quilt 200 that also shows a fiber ball 12 and space 14.

An advantage of the present invention over the state of the art includes the ability of the inventive blanket to form rolled goods. While prior art inflatable fiber balls are engaged, bonding typically occurs only after the fiber ball is introduced into their final destination (e.g., cushion). On the other hand, the inventive futon cotton is dissolved in the binder fiber, the field outside the inventive bedding cotton (the inventive batting ex situ) to be subject to heat treatment to the (outer side of the finished product), and then, a non-woven web which is formed (usually , In the form of a soft, flexible sheet). The inventive bedding may be rolled and purchased to be used as a rounded product. (The inventive batting may then be rolled and used as a rolled good). For example, the rolls of the duvet may later be cut to the desired dimensions, depending on the intended application.

The fiber mixture of quilt cotton comprises 40 to 95 wt% of synthetic fibers, including any and all ranges and subranges therebetween. For example, in some embodiments, the quilted cotton may have a thickness of 40, 41, 42, 43, 44, 45 (for example, 75 to 90 wt.%), Including any and all ranges and subranges therebetween , 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70 , 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 95 wt% of synthetic fibers.

Many synthetic fibers are known in the art, and any desired synthetic fibers may be used in the present invention. Exactly, different fibers have different characteristics and provide themselves for use advantageous in different applications. Such information is well within the purview of those of ordinary skill in the art. In some embodiments, the synthetic fibers may be selected from the group consisting of polyamides, polyesters, acrylics, acetates, polyolefins, nylons, rayon, lyocell, aramid, spandex, , Viscose, and modal fibers, and combinations thereof.

In certain embodiments, the synthetic fibers comprise polyester fibers. In some embodiments, such a polyester fiber may comprise one or more of poly (ethylene terephthalate), poly (hexahydro-p-xylylene terephthalate), poly 1,4-cyclohexelyne dimethylene (PCDT), and terephthalate copolyesters, wherein at least 85 mole percent of the poly (ethylene terephthalate) The ester unit is ethylene terephthalate or hexahydro-p-xylylene terephthalate units. In certain embodiments, the synthetic fibers are polyethylene terephthalate fibers.

Denier is a unit of measurement defined as the weight in grams of fibers or yarns of 9000 meters. This is a common way to specify the weight (or size) of a fiber or yarn. For example, a polyester fiber that is 1.0 denier typically has a diameter of about 10 micrometers. Micro-denier fibers are those having a denier of 1.0 or less, while macro-denier fibers have a denier greater than 1.0.

The synthetic fibers have a denier of from 0.5 to 7.0, including any and all ranges and subranges therebetween. For example, in some embodiments, the denier has a thickness of 0.5, 0.6, 0.7, 0.8 (e.g., 1.0 to 4.0 denier, 1.0 to 2.0 denier, etc.) , 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, , 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8 , 5.9, 6.0, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, or 7.0.

The synthetic fibers have a length of 18 mm to 51 mm, including any and all ranges and subranges therebetween. For example, in some embodiments, the length may be 18, 19, 20, 21, 22, 23, 24, 25 (for example, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, , Or 51 mm.

In some embodiments, the synthetic fibers are siliconized. The term "siliconized" means that the fiber is coated with a silicone-containing composition (e.g., silicone). Siliconization techniques are well known in the art and are described, for example, in U.S. Pat. Patent No. 3,454,422. The silicone-containing composition may be applied using any method known in the art, such as, for example, spraying, mixing, dipping, padding, and the like. The silicone-containing (e. G., Silicone) composition, which may comprise an organosiloxane or polysiloxane, is bonded to the outer portion of the fiber. In some embodiments, the silicone coating is a polysiloxane such as methylhydrogenpolysiloxane, modified methylhydrogenpolysiloxane, polydimethylsiloxane, or amino modified dimethylpolysiloxane. The silicone-containing compositions, such as those known in the art, may be applied directly to the fibers, or may be diluted with a solution or emulsion, e. G., An aqueous emulsion of a polysiloxane, prior to application. After treatment, the coating may be dried and / or cured. As is known in the art, the catalyst may be used to accelerate the curing of a silicone-containing composition (e.g., a polysiloxane containing Si-H bonds), and for the sake of convenience, ≪ / RTI > may be added to the silicone-containing composition emulsion. Suitable catalysts include iron, cobalt, manganese, lead, zinc and tin salts of carboxylic acids such as acetates, octanoates, naphthenates and oleates. In some embodiments, following siliconization, the fibers may be dried to remove residual solvent, and then heated to between 65 ° C and 200 ° C to optionally cure.

In some embodiments, the synthetic fibers are made by the method of U.S. Pat. Patent No. With other segmented copolymers of other slickening agents, such as polyalkylene oxides and other polymers, such as polyesters or polyethylene or polyalkylene polymers, as mentioned in US Patent No. 6,492,020 B1, It is slickened.

Binder fibers are well known in the art, and many binder fibers are commonly available. The binder fiber used in the present invention is a binder fiber having a lower binding strength than the softening temperature of the synthetic fiber, as long as conventional binder fibers (for example, low-melting point polyester binder fibers) or binder fibers are used. If it has a temperature, it may be another binder fiber. The binder fibers are, for example, U.S. Pat. Patent No. 4,794,038, and a general protocol for a specific embodiment of binder fibers is shown in U.S. Pat. Patent No. 4,281,042 and U.S. Pat. Patent No. 4,304,817. In some embodiments, the binder fibers are monocomponent fibers. In some components, the binder fibers may be multi-component fibers (e.g., bicomponent fibers, e.g., sheath-core fibers) Element. In some embodiments, the binder fibers comprise blends of one or more different types of binder fibers.

The fiber mixture of quilt cotton comprises 5 to 40 wt% of binder fibers, including any and all ranges and subranges therebetween. For example, in some embodiments, the duvet cover may have a thickness of 5, 6, 7, 8, 9, 10 (for example, 10 to 25 weight percent) , 11,12,13,14,15,16,17,18,19,20,21,22,23,24,25,26,27,28,29,30,31,32,33,34,35 , 36, 37, 38, 39, or 40 wt% of binder fibers.

The binder fibers have a denier of between 1.0 and 5.0, including any and all ranges and subranges therebetween. For example, in some embodiments, the denier may include any and all subranges (e.g., 1.5 to 3.5 denier, 1.9 to 2.5 denier, etc.), 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, or 5.0 denier.

The binder fibers have a length of between 18 mm and 71 mm, including any and subranges therebetween. For example, in some embodiments, the length is at least one of 18, 19, 20, 21, 20, 30, 40, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 5, 36, 37, 38, 39, 40, 41, 42, 43, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, or 71 mm.

As shown above, the binder fibers have a bonding temperature lower than the softening temperature of the synthetic fibers. In some embodiments, the binder fibers have a bonding temperature of 200 DEG C or less. In some embodiments, the binder fibers have a bonding temperature of 50 to 200, including any and all ranges and subranges therebetween. In some embodiments, the binder fibers have a bonding temperature of 80 ° C to 150 ° C. In some embodiments, the binder fibers have a bonding temperature of 100 占 폚 to 125 占 폚.

In some embodiments, the binder fibers have a melting temperature that is less than the melting temperature of the synthetic fibers of from 15 to 170 占 폚. For example, in some embodiments, the binder fibers have a melting temperature that is less than the melting temperature of the synthetic fibers between 15 and 170 degrees Celsius (e.g., including any and all ranges and subranges therebetween, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 103, 104, 105, 106, 107, 108, 109, 110, 111, 112, 113, 114, 128, 129, 130, 131, 132, 133, 134, 135, 136, 137, 138, 139, 128, 119, 120, 121, 122, 123, 124, 125, 126, 140, 141, 142, 143, 144, 145, 146, 147, 148, 149, 150, 151, 152, 153, 154, 155, 156, 157, 158, 159, 160, 161, 162, 163, 164, 165, 166, 167, 168, 169, or 170 DEG C. For example, some implementations In the state, the synthetic fibers are polyester fibers having a melting point of about 250 ℃, the binder fiber is from 80 to 180 ℃ has a melting point (e.g., about 110 ℃).

In some embodiments, the binder fibers comprise low-melting point polyester fibers.

In some embodiments, the binder fiber is a bicomponent fiber comprising a sheath and a core, wherein the sheath comprises a material having a lower melting point than the core. In some embodiments, the binder fiber is a polyethylene / polypropylene bicomponent fiber.

In some embodiments, the synthetic fibers and / or binder fibers are crimped fibers. A variety of crimps, including helical and standard crimp, are known in the art. The fibers may typically have any crimp. However, in some embodiments, the fibers are not spirally or helically crimped fibers. In some embodiments, the synthetic and / or binder fibers are not crimped.

In some embodiments, the fiber mixture additionally comprises one or more types of natural fibers in addition to the synthetic fibers and binder fibers. For example, in some embodiments, the fiber mixture additionally comprises wool, cotton, tencel, flax, animal hair, silk and down.

Nonwoven webs comprise 50 to 90 wt% of fiber balls, including any and all ranges and subranges therebetween; And between 10 and 50 wt%, including any and all ranges and subranges therebetween. For example, in some embodiments, the quilt / nonwoven web may have a width of 50, 51, 52, 53, 54, 55 (e.g., 70 to 90 wt% , 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80 , 81, 82, 83, 84, 85, 86, 87, 88, 89, or 90 wt% fiber balls. In some embodiments, the quilt / nonwoven web comprises 10, 11, 12, 13, 14, 15, 16, 17 (for example, 10 to 30 wt.%) , 18,19,20,21,22,23,24,25,26,27,28,29,30,31,32,33,34,35,36,37,38,39,40,41,42 , 43, 44, 45, 46, 47, 48, 49, or 50 wt% space.

The fiber ball may have a diameter ranging from 3.0 to 8.0 mm (e.g., 3.0, 3.1, 3.2, 3.3, 3.4 (e.g., 4 to 6 mm, 5 to 6 mm, , 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9 , 6.0, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, 7.0, 7.1, 7.2, 7.3, 7.4, 7.5, 7.6, 7.7, 7.8, 7.9, or 8 mm) .

In some embodiments, the duvet may have a width of 40 mm or less, such as 5 to 40 mm (e.g., 5, 6, 7, 8, 9, 10 , 11,12,13,14,15,16,17,18,19,20,21,22,23,24,25,26,27,28,29,30,31,32,33,34,35 , 36, 37, 38, 39, or 40 mm).

The duvet cover has a density of 2 to 12 kg / m ³ (eg, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9 , 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4 , 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, 7.0, 7.1, 7.2, 7.3, 7.4, 7.5, 7.6, 7.7, 7.8, 7.9 , 8.0, 8.1, 8.2, 8.3, 8.4, 8.5, 8.6, 8.7, 8.8, 8.9, 9.0, 9.1,9.2,9.3,9.4,9.5,9.6,9.7, 9.8,9.9,10.0,10.1,10.2,10.3,10.4 , 10.5, 10.6, 10.7, 10.8, 10.9, 11.0, 11.1, 11.2, 11.3, 11.4, 11.5, 11.6, 11.7, 11.8, and has a 11.9 or 12.0 kg / m ^3). The density of the quilt cotton is therefore relatively low compared to the prior art using compressed fiber balls. Indeed, unlike the prior art, embodiments of the inventive blanket provide very high, soft, and flexible insulation (lofty, soft, and pliable insulation). The inventive comforter, with a density of 2 to 12 kg / m ³ , will not have sufficient structural integrity (and therefore will not be controlled as insulation) to remain intact following treatment and use, Applicants have discovered that embodiments of the present invention achieve all of these objects surprisingly, despite the usual thinking in the art, which suggests that the present invention will not have, and / or will not readily produce. The inventive quilt web comprises a first surface and a second surface, wherein the second surface is parallel to the first surface. In some embodiments, the first and / or second surface of the duvet cover comprises a cross-linked resin. This is the case, for example, where a cross-linking solution comprising a cross-linking compound is applied to the first and / or second surface. The resin is a cross-linked (e.g., through heat treatment) version of the cross-linking solution. In some embodiments, the cross-linked resin comprises a cross-linker that is a cross-linked acrylate (co) polymer. In some embodiments, the cross-linker solution and / or the cross-linker compound exhibits softness and hydrophobicity. In some embodiments, the cross-linker compound has a glass transition temperature (Tg) of less than 0 占 폚.

In some embodiments, the at least one first surface and the second surface comprise a scrim layer. Scrim is well known in the art. The use of a scrim can help alleviate fiber migration in a creative bedding (e.g., during processing of the product).

As discussed above, the inventive quilt web comprises a nonwoven web comprising the fiber mixture. In some embodiments, the fiber content of the nonwoven web is comprised of the fiber mixture.

In some embodiments, the duvet cover comprises a single nonwoven web. In another embodiment, the duvet cover comprises a plurality of nonwoven web layers, and one or more of the layers are formed from a nonwoven web according to the invention (i. E., The specified weight percent of fiber ball and space, will be. In some embodiments, the duvet cover comprises a plurality of nonwoven webs, all of which are nonwoven webs according to the present invention.

In a second aspect, the present invention provides an article comprising a creative bedding. Non-limiting examples of such articles include, for example, outer garments (e.g., outer garments such as jackets), garments, sleeping bags and bedding (e.g., comforters) and the like.

In a third aspect, the present invention provides a method of making a creative bedding, comprising:

Mixing the fibers comprising:

40 to 95 wt% synthetic fibers having a denier of 0.5 to 7.0 and a length of 18 to 51 mm; And

- 5 to 40 wt% of binder fibers having a denier of 1.0 to 5.0 and a length of 18 to 71 mm, said binder fibers having a binding temperature lower than the softening temperature of said synthetic fibers;

Thereby forming a fiber mixture;

- forming a plurality of fiber balls from said fiber mixture;

- forming a nonwoven web from said fiber mixture, said nonwoven web comprising:

A plurality of fiber balls of 50 to 95 wt% with an average diameter of 3.0 to 8.0 mm; And

A portion of a plurality of said nonwoven webs of from 5 to 50 wt%, which are close to one or more fiber balls but which themselves do not comprise one or more fiber balls or any part thereof;

And < / RTI > And

- heating the nonwoven web at or above the binding temperature of the binder fibers, thereby forming a bedding pad;

.

Methods of forming a fiber ball are well known in the art and any known fiber ball forming process (knowledge within the ordinary skill in the art) that helps to form a fiber ball from the fiber blend may be used have. For example, a method of forming a fiber ball is disclosed, for example, in U.S. Pat. Patent Nos. 4,794,038 and 6,613,431. While some fiber ball forming techniques may be used, in some embodiments, the fiber ball may be repeatedly synthesized and / or repeated against the wall of the container to increase the density of the object, round them, and thereby form a fiber ball. The fiber bundles are formed by air-tumbling small bundles of binder fibers (while some fiber bundle formation techniques are used in some embodiments, the fiber bundles are formed by air-tumbling small tufts of the synthetic and binder fibers repeatedly against a wall of a vessel so as to densify the bodies and make them rounder, thereby forming fiberballs). In another embodiment, a fiber ball machine is used to form a fiber ball. In some embodiments, the fiber ball is formed using a ball card (i.e., a carding machine modified for the production of a fiber ball)

In some embodiments, prior to fiber ball formation, the synthetic fibers and / or binder fibers are open (the synthetic fibers, and / or the binder fibers are opened). As is well known in the art, the opening entails separating the fibers to some extent prior to further processing (e.g., using an opener, such as a bale opening system).

The formation of a nonwoven web from the fiber blend may be accomplished using any acceptable web-forming technique (e.g., an airlaid system, or a carding machine). For example, in some embodiments, the fiber mixture (i.e., formed from the mixture, in the form of a fiber ball) is subjected to a flowing air stream to form a nonwoven web. In this embodiment, the space may be formed, for example, from "fallout" fibers separated from a mixture of fiber balls treated through the airlaid system.

In some embodiments, forming a nonwoven web may include forming a fiber mixture (e. G., Any loose fibers remaining after forming the formed fiber ball and fiber ball) with a forming wire And depositing. In some embodiments, this may be performed with vacuum assistance (e.g., the vacuum system is located under the forming wire). In a particular embodiment, loose fiber balls are fed into an air lay system. The airlay system meters the fiber ball through the airflow over a given width and a specified thickness.

After the nonwoven web is formed, it is heated to or above the binding temperature of the binder fibers, thereby forming a creative bedding pad. For example, after the nonwoven fibrous ball web is formed by an airlay system, it may be carried by an apron into a thermal bonding oven of the heat that is activated by the binder fibers, Resulting in a futon bed.

Before heat bonding (to heat to the nonwoven web to a bonding temperature of the binder fiber, or greater than this), the intermediate nonwoven web, if desired (course, by this process is greater than 12 kg / m ³ to have a density (Eg, rollers) to provide a degree of completeness to the web (unless it results in a quilted cotton that will be heated to a non-woven web) the intermediate nonwoven web may be subjected to machining (eg, rollers) to provide a degree of integrity to the web, if desired, result in a batting that would have a density in excess of 12 kg / m ³ ).

The nonwoven web may serve as a bedding pad, or it may be layered with one or more additional layers (in accordance with the present invention or otherwise) to form a layered batting .

Example

The present invention will now be described by reference to the specific embodiments described in the following examples, but it is not limited thereto.

The sample quilt cotton was prepared according to the above method. The fiber mix for this sample comprised 90% 1.4 denier polyester fibers having a major length of 28 mm and 10% low-melt bi-component polyester / polyester binders It is fiber. The fibrous mixture may be a carding machine to obtain a nonwoven web batting pre-cursor, which is heated to < RTI ID = 0.0 > 110 C < / RTI > to form an embodiment of a creative bedding pad. Lt; / RTI > The final duvet cushion structure consists of an 80% fibrous ball having a diameter of 6 mm, and one or more fibrous balls, each of which contains 20% of And a plurality of nonwoven webs. The quilt is cotton, the weight 175 gsm (grams per square meter), and has a density in thickness, and 10 kg / m ³ of 17.5 mm.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms, unless the context clearly dictates otherwise. The terms "comprise" and "comprises" and "any form of comprise", "having" (and "having" and "having" Contain, "" include, "" include, "and" include "(and any form of" inclusive ", such as" Quot; and "containing"), and any other grammatical variations thereof, are open-ended linking verbs. As a result, a method or article that "comprises", "having", "having", "covering", or "containing" one or more steps or elements has one or more steps or elements, Or elements. Likewise, steps or article elements of a method or element of " comprising, "" including," " covering, "or" containing, " one or more features, But are not limited to retaining features.

As used herein, the terms "comprising," "having," "including," "containing," and other grammatical variations thereof shall be construed as consisting essentially of " consisting essentially of. "

As used herein, "consisting essentially of," or grammatical variants thereof, means a feature, integer, step, or configuration that is explicitly stated as not excluding one or more additional features, integers, steps, components, Elements, elements, steps, elements, or groups, unless the additional features, integers, steps, elements, or groups substantially modify the basic and novel features of the claimed composition or method.

All publications cited herein are hereby incorporated by reference as if each individual publication were specifically and individually indicated to be included by reference, such as is fully disclosed.

The subject matter covered by the reference is not to be considered as a substitute for any claimed limitation unless expressly stated otherwise.

Where one or more ranges are referred to throughout this specification, each range is intended to be a shorthand format for indicating information, and the range is to be understood to include a number of different points in the range each discrete point).

While several aspects and embodiments of the present invention have been described and illustrated herein, alternative aspects and embodiments may be affected by the ordinary skill in the art to achieve the same purpose. Accordingly, it is intended that the present disclosure and appended claims be construed to include all such additional and alternative aspects and embodiments as fall within the true spirit and scope of the present invention.

Claims (23)

40 to 95 wt% of synthetic fibers having a denier of 0.5 to 7.0 and a length of 18 to 51 mm; And
Binder fibers having a denier of from 1.0 to 5.0 and a length of from 18 mm to 71 mm, said binder fibers having a binding temperature lower than the softening temperature of said synthetic fibers, the binder fiber having a bonding temperature;
A webbing comprising a nonwoven web comprising a fiber mixture having a plurality of fibers,
Structurally, the nonwoven web comprises:
A plurality of fiber balls of 50 to 95 wt% with an average diameter of 3.0 to 8.0 mm; And
A portion of a plurality of said nonwoven webs of from 5 to 50 wt%, which are close to one or more fiber balls but which themselves do not comprise one or more fiber balls or any part thereof;
Lt; / RTI >
Wherein the duvet has a density of from 2 to 12 kg / m < ³ >.
The method according to claim 1,
Wherein the synthetic fibers comprise polyester fibers.
The method according to claim 1,
Wherein the synthetic fibers have a denier of 1.0 to 2.0.
The method according to claim 1,
Wherein the synthetic fibers have a length of 20 mm to 30 mm.
The method according to claim 1,
Wherein the fiber ball has an average diameter of 4.0 mm to 6.0 mm.
6. The method of claim 5,
Wherein the fiber ball has an average diameter of from 5.0 mm to 6.0 mm.
The method according to claim 1,
Wherein the binder fibers have a denier of 1.5 to 3.5.
8. The method of claim 7,
Wherein the binder fibers have a denier of 1.9 to 2.5.
The method according to claim 1,
Wherein the binder fibers have a length of 18 mm to 51 mm.
The method according to claim 1,
Wherein the binder fibers have a bonding temperature of 200 DEG C or less.
11. The method of claim 10,
Wherein the binder fibers have a binding temperature of 80 < 0 > C to 150 < 0 > C.
12. The method of claim 11,
Wherein the binder fibers have a binding temperature of 100 < 0 > C to 125 < 0 > C.
13. The method according to any one of claims 1 to 12,
Said fiber mixture comprising:
75 to 90 wt% of synthetic fibers; And
10 to 25 wt.% Of binder fibers;
Wherein the backsheet comprises a backsheet.
14. The method of claim 13,
The nonwoven web comprises:
A plurality of fiber balls of 70 to 90 wt%; And
A portion of a plurality of said nonwoven webs of 10 to 30 wt%, which are close to one or more fiber balls but which themselves do not comprise one or more fiber balls or any part thereof;
Wherein the backsheet comprises a backsheet.
13. The method according to any one of claims 1 to 12,
Wherein the synthetic fibers are siliconized.
13. The method according to any one of claims 1 to 12,
Wherein the synthetic fibers are crimped fibers.
17. The method of claim 16,
Wherein the crimped fiber has a spiral crimp or a standard crimp.
13. The method according to any one of claims 1 to 12,
Wherein the duvet cushion does not include spirally crimped fibers.
13. The method according to any one of claims 1 to 12,
Wherein the binder fibers are bicomponent fibers comprising a sheath and a core, the sheath comprising a material having a lower melting point than the core.
13. An article comprising a bed sheet according to any one of claims 1 to 12.
21. The method of claim 20,
Wherein the article is selected from the group consisting of an outerwear product, a clothing, a sleeping bag and a bedding.
13. A method for producing a duvet according to any one of claims 1 to 12,
The method comprising:
Mixing the fibers comprising:
40 to 95 wt% synthetic fibers having a denier of 0.5 to 7.0 and a length of 18 to 51 mm; And
- 5 to 40 wt% of binder fibers having a denier of 1.0 to 5.0 and a length of 18 to 71 mm, said binder fibers having a binding temperature lower than the softening temperature of said synthetic fibers;
Thereby forming a fiber mixture;
- forming a plurality of fiber balls from said fiber mixture;
- forming a nonwoven web from said fiber mixture, said nonwoven web comprising:
A plurality of fiber balls of 50 to 95 wt% with an average diameter of 3.0 to 8.0 mm; And
A portion of a plurality of said nonwoven webs of from 5 to 50 wt%, which are close to one or more fiber balls but which themselves do not comprise one or more fiber balls or any part thereof;
And < / RTI > And
- heating the nonwoven web at or above the binding temperature of the binder fibers, thereby forming a bedding pad;
≪ / RTI >
23. The method of claim 22,
Wherein the nonwoven web is formed using an airlaid system.

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