TW201727007A - Use of continuous filament non-woven fabrics for preventing down leakage from down-filled textile products - Google Patents

Abstract

The invention relates to the use of a nonwoven fabric made of continuous filaments for the preventing of leakage of down from a down filled textile product, whereby a nonwoven fabric is obtained in a spinning process in which multicomponent fibres are deposited into a nonwoven mat, whereafter the multicomponent fibres are split into endless filaments having a titer of less than 0.15 dtex and the nonwoven mat mechanically solidified into a nonwoven fabric, without thermal or chemical solidification of the nonwoven fabric.

Description

Application, method and textile product for preventing the down from drilling a nonwoven fabric composed of continuous filaments from a down-filled textile product

The present invention relates to the use of a nonwoven fabric comprising continuous filaments for preventing the downhole from being dug in a textile product filled with down, wherein the continuous filaments have a titer of less than 0.15 dtex. The invention also relates to a textile product filled with down and a method for its manufacture.

Down [also known as unterfedern] is a feather with short plumes and soft feather branches. In textile products such as bedding, jackets or sleeping bags, down is used as a filler for thermal insulation. Here, the down is contained and enclosed in a cover made of a planar textile formation. In the proposed application, the textile product filled with down must be "anti-down velvet". This means that the down does not penetrate or even extend out of the cover. Down feathers are sharp and hard, and the outer cover must have high strength. A particularly compact and strong fabric is suitable as a cover. The fabric consists of interlaced weft and warp yarns. Despite the sharpness, feather stalks, which are generally significantly larger than fabric yarns and fabric meshes, are not able to penetrate the fabric because the fibers do not move sufficiently to each other. The down-proof pile-down property of the fabric can be checked in a standardized manner according to DIN 12132-1.

Unlike fabrics, woven nonwoven fabrics are not suitable as covers for filling with down. Even thick woven nonwoven fabrics are relatively easily penetrated by down. Since the fibers of the conventional nonwoven fabric are disordered and thus movable relative to each other, the down stem can easily pass through the nonwoven fabric. When the nonwoven fabric is thermally cured or chemically cured in a planar manner, the down comfort of the nonwoven fabric can be achieved. Thus, the fibers are bonded to each other as in the fabric and are no longer free to move relative to each other. However, in textile applications, such planar curing is unacceptable because it reduces softness, elasticity, porosity, breathability and moisture permeability. Therefore, in the prior art, the down is generally filled in the fabric. Since it is considered in the prior art that conventional nonwoven fabrics are not suitable for filling down, there is no standard method for measuring the down-proof pile-down properties of nonwoven fabrics, which corresponds to DIN 12132-1 for fabrics.

However, it is desirable that the nonwoven fabric can also be used for this application because the nonwoven fabric happens to have many advantageous properties which are characterized by a relatively high softness, elasticity, stability, porosity, High gas permeability and moisture permeability, as well as good usability and processability.

Therefore, in the prior art, the down is stored as a portion of the laminate by a non-woven fabric. Thus, for example, Japanese Laid-Open Patent Publication No. 2008303480A proposes the use of a composite material composed of a woven fabric and a non-woven fabric. Japanese Laid-Open Patent Publication No. 2006291421A also discloses a laminate of an anti-down pile, which comprises a heat-cured nonwoven fabric. What is disadvantageous, however, is that it happens to contain parts of the nonwoven fabric that are not ideal. Moreover, because of the necessity to bond or otherwise securely attach to each other, the laminate is relatively costly to manufacture.

German Utility Model Publication No. 20310279 U1 describes a bedding cover composed of a microfiber nonwoven fabric having good gas permeability, and the bedding cover provides protection against allergens and aphids. The outer cover has advantageous mechanical properties characteristic of the nonwoven fabric, for example in terms of washability and stability. Further, it is claimed in the publication that the ultrafine fiber nonwoven fabric is anti-down piled. However, no illustration is given for this. The microfiber nonwoven fabric according to the embodiment of the German Utility Model Publication No. 20310279 U1 is a true nonwoven fabric which is neither thermally cured by the surface nor reinforced by other layers in the laminate. Thus, in the non-cured areas, the fibers can move relative to each other, and it is not plausible to those skilled in the art that such conventional nonwoven fabrics are down-stamped. More specifically, it was determined that the above conclusion was asserted for the reason of this reason because the feathers of the anti-allergens and the mites were found to have good sealing properties and because the down feathers have roughly the same size. However, the impermeability of anti-down can never be inferred from the impermeability of anti-allergens or aphids. Allergens or mites are simply granules, while down has a unique hard and sharp structure with barbs and is easy to drill through the nonwoven fabric.

The applicant of the present application therefore tests whether the assertion of German Utility Model Patent Publication No. 20310279 U1 is realistic, and that the fine microfiber nonwoven fabric is down-tight. German Utility Model Patent No. 20310279 U1 has the following examples, and in this embodiment, of course, no statement is made as to the manufacture or source of the nonwoven fabric. A general statement of the nature of the microfiber nonwoven is also relatively surfaced. However, the microfiber nonwoven fabric described herein substantially corresponds to a commercially available product of the Evolon 100 brand of Freudenberg, Germany (sold in 2003). The Evolon 100 brand product is made of multi-component fibers consisting of 16 filaments per filament in a cake-like arrangement (PIE chart with 16 divisions, PIE16 for short). Since the single fiber is produced by a cake-like section, the cross-sectional profile of the single fiber has an angular shape which approximates a triangle. The nonwoven fabric is cured by a water jet process in which the multicomponent fibers are split into individual filaments composed of polyethylene terephthalate (PET) and polyamine (PA). The fiber strength of the multicomponent fiber is, for example, 2.4 dtex and after splitting, the fiber strength of the single fiber is, for example, 0.1 dtex or 0.2 dtex. Therefore, the nonwoven fabric Evolon 100 is even more slender with respect to the polyurethane fiber component than the nonwoven fabric described in German Utility Model Publication No. 20310279 U1. However, it is considered that the ultrafine fiber nonwoven fabric Evolon 100 of Freudenberg Co., Ltd. is described and studied in the embodiment of German Utility Model Publication No. 20310279 U1. This is illustrated by the fact that the statement in German Utility Model Patent Publication No. 20310279 U1 is substantially identical to the non-woven fabric Evolon 100, which was commercially available in 2003, and in 2003 no other supplier of its kind was Commercially available. It is also not indicated in the German Utility Model Patent Publication No. 20310279 U1 that the applicant of the utility model itself manufactures the product.

In order to examine the down-proof pile-down property claimed in German Utility Model Patent Publication No. 20310279 U1, the applicant of the present application inspects the non-woven fabric in the embodiment of the German Utility Model Publication No. 20310279 U1, which is similar to Evolon 100. Whether the brand of microfiber nonwoven fabric is actually anti-down and down. Here, it is determined according to the invention that such a microfiber nonwoven fabric does not have sufficient down-flushing properties. The microfiber nonwoven fabric is not subjected to the embodiment according to DIN 12132-1 (see embodiment of the present application: Evolon 120, which uses a polyurethane or crosslinked polypropylene cement having a basis weight of more than 15 g/m ² in a down jacket The inner upper coating; a standardized padding test for the down-drilling resistance test with a first goose feather and pure goose down consisting of 90% down and 10% feather according to EN 12934. The test regulations were originally intended for the study of fabrics, but can also be used similarly and without any modification of the nonwoven fabric in terms of content. The corresponding standard for nonwoven fabrics is therefore only not available, since there is still no need in the prior art for this because the nonwoven fabric is in principle not down-proof. Thus, it is possible to confirm general expertise whereby the nonwoven fabric is not sealed relative to the down, although it is sealed against allergens, mosquito bites or mites.

In addition, the Applicant studied the effect of down stems on this microfiber nonwoven fabric in a microscopic manner. According to Figure 1 to Figure 4. Figures 1 and 2 show typical down stems after passing through a microfiber nonwoven at different magnifications. It can be recognized in both of the above figures that the down stem has a tip which can be pierced into the slender nonwoven fabric by the tip. The feather stem has a slender barb that promotes directional penetration. Figure 3 shows the down stems during the process of penetrating the nonwoven fabric. Figure 4 shows a typical hole in which the down is drilled through the nonwoven fabric. In summary, the very fine non-woven fabric can easily push open the slender single fiber, and the down stem can easily penetrate the very slender nonwoven fabric according to the German Patent Publication No. 102014002232A1, in which the orientation is promoted by the barb. through. This slender microfiber nonwoven fabric is resistant to hard and sharp down stems.

According to the German Utility Model Patent Publication No. 20310279U1, the lack of down-filing of the microfiber nonwoven fabric is in accordance with general expertise, whereby the unheated nonwoven fabric cannot prevent the feather from coming out, even if the nonwoven fabric is The same is true for very slim fibers. German Utility Model Patent Publication No. 20310279 U1 does not teach how to overcome the shortcomings of the nonwoven fabric lacking down-proof pile. Therefore, when the nonwoven fabric known in the prior art is sufficiently thermally cured or combined with other layers into a laminated structure, the nonwoven fabric is only suitable for use in preserving down.

World Intellectual Property Organization Patent Publication No. 20018483A1 relates to a pajamas composed of a microfilament nonwoven fabric having a basis weight of 60 g/m ² to 200 g/m ² , for particles smaller than 0.5 μm and a particle intercepting ability of more than 90%. . In the manufacture of nonwoven fabrics, at least no more than 80% of the multicomponent continuous filaments are split into microcontinuous filaments having a titer of from 0.1 dtex to 0.8 dtex and cured.

The World Intellectual Property Organization Patent Publication No. 20018483A1 does not address the problem of preventing such sharp feathers from piercing the nonwoven fabric. "Particles" are very fine nanoparticles, more specifically, dust and their segregants in houses. Instead, the down is sharp and has a length in the range of centimeter sizes. A good fiber barrier for the good interception of nanoparticles requires no special mechanical stability. It is therefore recognized that very fine fibrous formations composed of fibers that can move with each other are not suitable for preventing the piercing of thin, sharp and relatively large objects such as needles, down stems or mosquito thorns. Therefore, it is generally believed in the prior art that particularly stable fibrous products, such as fabrics, only prevent the penetration of relatively large, sharp objects.

It has also been experimentally confirmed within the scope of the invention that nonwoven fabrics composed of multicomponent fibers are not themselves susceptible to down-filing, wherein the multicomponent fibers have a significant fraction of the fineness after splitting, for example 0.1 dtex. A single filament (see the embodiment and examples of German Utility Model Patent No. 20310279 U1). In general, those skilled in the art will therefore not consider that the nonwoven fabric described in the World Intellectual Property Organization Patent Publication No. 20018483A1 is resistant to down velvet.

In view of the above problems, it is an object of the present invention to provide a material for textile applications that can be used to preserve down, which solves the problems of the prior art and provides a textile product having good mechanical properties in order to preserve down. Moreover, the present invention has high softness, elasticity, porosity, gas permeability and moisture permeability of the textile product, and can simultaneously prevent down and down. Furthermore, the materials used in the present invention are relatively easy to provide, and the manufacturing process may not include costly processing steps such as lamination or post-treatment, especially post-treatment steps. In general, the material should be readily available from the manufacturer and highly accepted by the user.

Surprisingly, the object on which the invention is based is achieved by the application according to the claims, the textile product and the method.

In order to achieve the above object, the subject of the invention is the use of a nonwoven fabric for the prevention of the development of down from a textile product filled with down, consisting of continuous filaments, wherein a nonwoven fabric is obtained by a spinning process, wherein the multicomponent fibres Disposed into a nonwoven fabric, whereby the multicomponent fibers are split into continuous filaments having a fineness of less than 0.15 dtex, and the nonwoven fabric is cured into a nonwoven fabric by mechanical curing including fluid jet curing, wherein the nonwoven fabric is not Surface geothermal curing or chemical curing.

The application according to the invention is achieved by means of a textile product filled with down. The textile product has a cover that encloses a cavity in which the down is contained and isolated from the environment. The nonwoven fabric forms the outer cover of the textile product or a portion thereof. According to DIN 61 210 (1988, part 2), a nonwoven fabric is a woven, woven fabric composed of loosely laid fibers which are joined to each other by friction, cohesion or adhesion. A nonwoven fabric as a cover or barrier blocks the down from being drilled from the textile product.

The nonwoven fabric is composed of continuous filaments. The term "filament" is used to denote a fiber which, in contrast to a staple fiber, is produced in a continuous manner and is directly laid down as a nonwoven fabric.

In the context of the present application, the term "down" is used to mean the unterfedern of birds, which is suitable for textile filling. The definition of down is provided in DIN 12934. Downs are especially feathers with very short stems and long, radial branches. Down usually has fewer hooks than other feathers. Due to its high elasticity, shape stability and thermal insulation properties, down is used in a wide range of textile applications.

According to the application of the invention, it is possible to prevent the downing from being drilled from a textile product filled with down. In such textile products, the down filling is contained in a housing that separates the down filling from the environment. The term "drilled out" is used to mean any movement of the down through the outer cover. Here, the down can penetrate the outer cover partially or completely. Thus, the term "drilling out" includes that the feathered down stem only drills through the outer cover with a sharp portion and remains inserted therein, or the feathered stem can pass completely through the outer cover and exit the textile product.

It is preferred to determine the anti-down pile-down property according to the analog pad stress test of Part 1 according to DIN EN 12132-1, wherein a nonwoven fabric is used instead of the fabric. Preferably, the nonwoven fabric is subjected to the test according to DIN EN 12132-1, which means that no more than 20 particles are drilled in the direction of each test (longitudinal and transverse), ie inserted in or through the textile material material. Preferably, here, an average value consisting of a plurality of single measurements, for example 5, 10 or 20 single measurements, is evaluated. In particular, no more than 15 particles, in particular no more than 12 particles, are drilled during the test.

In a preferred embodiment, the nonwoven fabric is in direct contact with the down filling. This means that there are no other layers between the nonwoven fabric and the down. The down contact is in contact with the nonwoven fabric and penetrates the nonwoven fabric when the down-proof pile is insufficient. Here, the nonwoven fabric is preferably used as a woven outer cover in which the down is contained. This means that the nonwoven fabric itself forms a cover. The nonwoven fabric is not a laminated structure having other different layers. Therefore, when the textile product is, for example, a bedding article, then the nonwoven fabric includes down. According to the present invention, it has been found that, surprisingly, the nonwoven fabric itself is capable of preventing down-drilling, which is composed of fibers having a fineness of less than 0.15 dtex, does not require heat curing or has other layers, especially A laminate of a fabric layer or a stronger nonwoven layer.

The multicomponent fiber is a filament composed of at least two different parallel continuous filaments having phase boundaries and being separably joined to each other. The multicomponent fibers are split into continuous filaments having a titer of less than 0.15 dtex. Thus, the continuous filaments have a titer of less than 0.15 dtex. This means that the nonwoven fabric as a filament component has substantially or only filaments of corresponding denier. Such a nonwoven fabric can have a smaller localized area in which the multicomponent fibers do not split or only incompletely split. However, a nonwoven fabric can be obtained by means of sufficient mechanical splitting, in particular by means of a water jet treatment, which consists almost exclusively of a single filament. Preferably, there is a single filament comprising at least 80%, especially at least 90%, at least 95%, at least 98% or about 100% by total volume of the fibers. This fraction can be determined microscopically by studying randomly selected fragments of the nonwoven fabric.

In a preferred embodiment, the filaments are split into filaments having a titer of less than 0.14 dtex, still more preferably less than 0.12 dtex or less than 0.11 dtex. The fineness is preferably greater than 0.01 dtex or greater than 0.025 dtex. In particular, the fineness 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 fineness 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 as a continuous filament component comprises a filament mixture consisting in particular of two or three different filament types. For example, it is preferred to include two or more continuous filament types having different deniers. Preference is given to using multicomponent fibers comprising different fine continuous filaments composed of different polymers. In a preferred embodiment, the nonwoven fabric comprises at least two components and here comprises a continuous filament having a titer of less than 0.075 decitex, preferably less than 0.065 decitex. Preferably, the first fiber component has a titre between 0.80 dtex and 0.15 dtex, preferably between 0.80 dtex and 0.125 dtex, and the second fiber component has a titer of 0.01 dtex and 0.075 dtex. Preferably, it is between 0.02 dtex and 0.065 dtex. Preferably, the densities of the two components differ by at least 0.02 dtex, respectively. In particular, an advantageous combination of anti-down feathering and stability can be achieved by incorporating such a particularly fine second fiber component. Preferably, the proportion of fibers of low denier is at least 5% by volume or at least 10% by volume, in particular at least 20% by volume. Preferably, the number of fiber bundles of the first fiber component and the second fiber component are equal. When the fineness of the first fiber is twice the fineness of the second fiber, a volume ratio of about 2:1, that is, about 70:30 is obtained.

Surprisingly, it has been found that a relatively thin and light nonwoven fabric having a relatively small basis weight also withstands down. This is unexpected because the down stem is relatively stiff and sharp and applies relatively strong forces to the nonwoven in everyday applications, such as when the force is pressed into the pillowcase. Without guessing the theory, it is assumed that in the tightly interlaced nonwoven fabric, from the threshold of fiber fineness, the down is no longer able to move the individual filaments relative to each other and through the nonwoven fabric. When this threshold is reached, a thin nonwoven fabric is also sufficient to cause down-proof velvet. In contrast, above the threshold, relatively tight nonwoven fabrics are also not suitable to prevent down-drilling. Without considering the theory, it is considered that the anti-down velvet property is achieved not only by the fine fibers but also by the special manufacturing method of mechanically splitting the multi-component fibers, by which the filaments are particularly tight and uniform. Mix and interweave.

In a preferred embodiment, the nonwoven fabric has a basis weight of from 70 g/m ² to 200 g/m ² . In a preferred embodiment, the nonwoven fabric has a unit area of from 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 weight. Preferably, the basis weight is at least 70 g/m ² or at least 90 g/m ² , particularly preferably at least 110 g/m ² , in order to ensure high mechanical stability and down-proof velvet. Preferably, the basis weight is not more than 200 g/m ² , not more than 160 g/m ² or especially not more than 160 g/m ² in order to achieve sufficient porosity, both gas permeability and moisture permeability.

Preference is given to nonwoven fabrics having in particular two fiber components, which preferably consist of split bicomponent fibers, wherein the first fiber component has a titre between 0.08 dtex and 0.15 dtex and a second fiber component The denier is between 0.01 dtex and 0.075 dtex, wherein the fraction of fibers having a lower denier is at least 10% by volume, and from 70 g/m ² to 200 g/m ² , especially from 90 g/m ² to 180 g /m ² unit area weight.

A nonwoven fabric is obtained in the spinning method in which the multicomponent fibers are laid into a nonwoven fabric, whereby the multicomponent fibers are split into continuous filaments and the nonwoven fabric is mechanically cured into a nonwoven fabric. A particularly internal structure of the product is achieved by means of this manufacturing method. The continuous filament has an irregular cross section which depends on the splitting process. The individual filaments are especially intertwined with each other.

Preferably, the multicomponent fibers are produced by melt spinning. Upon melt spinning, the thermoplastic polymer is melted and spun into fibers. This method makes it possible to produce a nonwoven fabric composed of multicomponent fibers in a particularly simple and reliable manner.

Preferably, the multicomponent fibers have two, three or more different continuous filaments. Particularly preferably, the multicomponent fiber is a bicomponent fiber.

A single fiber is usually obtained when the multicomponent fiber is split, and the single fiber has a cross section with a corner or an edge. This is advantageous because a single filament is less likely to move relative to each other. Therefore, it is possible to improve the down-proof pile.

In a preferred embodiment, the multicomponent fibers, especially the bicomponent fibers, have a cake-like (willow, PIE, pie) structure. Preferably, the structure has 24, 32, 48 or 64 segments. Upon splitting, the multicomponent fibers are split into a corresponding number of individual continuous filaments (single filaments). The segments here preferably comprise alternating polymers. Also suitable is a hollow pie structure which can also have an asymmetrical axially extending cavity. A pie structure, in particular a hollow pie structure, is advantageous because the structure can be particularly easily split. Furthermore, the individual filaments have an irregular cross section which increases the internal strength of the nonwoven fabric. The term "cake" or "pie" truly describes the design of the spinning nozzle in such very fine, split fibers, but only describes the actual cross section of the filament. Particularly preferably, the multicomponent fibers are in the shape of a cake composed of at least 32 segments, and in particular exactly 32 segments, wherein no other fiber components are added. Such a structure is available in the prior art and can be processed uniformly and in a simple manner. Preferably, the basis weight here is at least 110 g/m ² .

Preferably, the fiber-forming polymer of the multicomponent fiber is a thermoplastic polymer. Preferably, the multicomponent fiber has a component selected from the group consisting of polyester, polyamide, polyolefin and/or polyurethane. Preference is given in particular to bicomponent fibers having a polyester component and a polyamide component.

In order to obtain easy cleavability, it is advantageous if the multicomponent fiber comprises a continuous filament composed of at least two thermoplastic polymers (in different compositions). Preferably, the multicomponent fibers herein comprise at least two incompatible polymers. Incompatible polymers are understood to be polymers which, in a combined manner, do not produce an adhesive pair, or a pair that is only conditionally or difficult to produce a bond. Such multicomponent fibers have good splitting properties that split into primary filaments and achieve a favorable ratio of strength to basis weight. Preferably, the polyolefin, polyester, polyamine and/or polyurethane are used in combination as an incompatible polymer pair such that no or only conditional or difficult pairing of the bond is produced.

Polymers having at least one polyamine or having at least one polyester, in particular polyethylene terephthalate, are preferred for their conditional adhesion. Polymers having at least one polyolefin are preferably used because of their difficult adhesion.

Polyester, preferably polyethylene terephthalate, polylactic acid and/or polybutylene terephthalate, in combination with polyamine, preferably polyamine 6, polyamide 66, polyamine 46 It has proven to be especially preferred, if desired in combination with one or more other components mentioned above, preferably selected from the group consisting of polyolefins. These combinations have excellent cleavability. More particularly preferred is a combination of polyethylene terephthalate and polyamido 6 or a combination of polyethylene terephthalate and polyamine 66.

Polymer pairs comprising at least one polyolefin, especially in combination with at least one polyester or polyamine, are also preferred. Here, for example, polyamide 6/polyethylene, polyethylene terephthalate/polyethylene, polypropylene/polyethylene, polyamine 6/polypropylene or polyethylene terephthalate/poly Propylene is preferred.

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

The average cross-sectional area of the filaments can be less than 15 μm ² or less than 10 μm ² . The cross-sectional area of the split filaments can be determined microscopically. In the case of density considerations, it is theoretically possible to determine the diameter of the continuous filament from the denier, wherein the description of the fiber diameter in the angular filaments is less convincing.

Suitable multicomponent fibers for producing continuous filaments by splitting (dispersion) are known in the prior art. Further, the manufacture of such a multicomponent fiber is described in French Patent Publication No. 2749860A1 or German Patent Publication No. 102014002232A1. This spun nonwoven fabric was produced using a Reicofil 4 brand of spun nonwoven fabric equipment from Reifenhäuser, Germany.

The polymer forms the fiber-forming component of the fiber. The fibers can furthermore comprise customary additives. Additives are regularly added to the fiber polymer in order to modify the properties of the fiber or the processability at the time of manufacture. The use of additives also allows matching of customer specific requirements. Suitable additives can, for example, be selected from pigments, antistatic agents, antibacterially active substances such as copper, silver or gold, hydrophilic additives or hydrophobic additives. For example, the additive can be included 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 and 10% by weight.

The nonwoven fabric is mechanically cured. Mechanical curing includes fluid jet curing. In mechanical curing methods, such as fluid jet curing, the composite of fibers is made by a friction fit or by a combination of friction fit and form fit. Curing is preferably carried out by intimate mixing of the filaments. Thereby, a nonwoven fabric having favorable softness and elasticity combined with good porosity can be obtained. Surprisingly, although the individual fibers can actually move relative to each other, sufficient down-proof velvet is achieved. Preferably, the multicomponent filaments also split into continuous filaments upon mechanical cure.

The fluid jet is solidified under pressure and fluid action. Here, the curing is carried out by using a fluid under pressure, in particular a liquid or a gas. Mechanical curing can additionally be carried out by other methods, such as extrusion, in particular by calendering. Preferably, the splitting of the multicomponent fibers is performed simultaneously in the solidification of the fluid jet. Here, the curing is performed sufficiently long and with sufficient strength. Preferably, the multicomponent filaments are split into continuous filaments during solidification of the fluid jet. It can also be carried out in a suitable combination with other mechanical curing methods so that the multicomponent fibers are completely or at least split as much as possible. At the same time, the tight mixing and interweaving of the individual filaments is achieved.

Curing includes fluid jet curing. Preferably, the fluid is a liquid, especially water. Therefore, water jet curing is especially preferred. In contrast to other fluids, water is preferred because it leaves no residue and is therefore simple to use and the nonwoven fabric can be well dried. Here, the laid nonwoven fabric is subjected to a water jet under high pressure, whereby on the one hand the nonwoven fabric is compressed into a nonwoven fabric and on the other hand the multicomponent fibers are split into individual filaments. It has been found that water jet curing is particularly suitable in order to achieve a tight interweaving of the continuous filaments, thereby achieving good mechanical properties and also improving down-proof velvet. Here, mechanical curing, in particular water jet curing, is carried out so that the microfilaments are not damaged or not strongly damaged. In the case of excessive water jet solidification of such slender filaments, mechanical stability can be reduced, and in particular the re-breaking strength (rebreaking force) is reduced. Preferably, the nonwoven fabric has a re-break strength of from 4 N to 12 N, in particular from 5 N to 12 N or from 6 N to 10 N according to DIN EN 13937-2.

In addition to the fluid jet solidification and in particular the water jet solidification, other mechanical curing steps can be performed. Thus, for example, curing can be carried out by needling and/or calendering. In a preferred embodiment, the pre-cure is completed by means of needling and/or calendering, which is followed by a water jet solidification. Calendering is carried out at a sufficiently low temperature that no thermal curing takes place in the case of pasting the fibers.

The nonwoven fabric is not cured by surface heat. This means that the nonwoven fabric is not subjected to temperature treatment generally, i.e., over the entire nonwoven fabric surface, wherein the fibers or hot melt adhesive soften such that the fibers adhere to each other. Thermal curing of the fibers is carried out by material compounding, wherein the fibers are joined by adhesion or cohesion. A nonwoven fabric without heat curing is advantageous because it maintains softness and elasticity. In contrast, it is significant in thermal curing and changes in mechanical properties in a manner that is not beneficial for textile applications. In particular, the nonwoven fabric becomes stiffer, that is, less elastic and soft, and less porous, resulting in a decrease in gas permeability and moisture permeability.

The nonwoven fabric is not chemically cured in a planar manner. This means that the fibers are not connected to one another by chemical reaction and are in particular not crosslinked by means of a bonding agent. No covalent bond is produced between the fibers.

In an embodiment, the nonwoven fabric can be thermally and/or chemically cured only in the sub-region (partially). Localized solidification in sub-regions uniformly distributed over the nonwoven web surface can improve stability. The curing can be carried out, for example, in the form of a dot pattern. In order to obtain advantageous typical nonwoven properties, at least a small portion of the nonwoven fabric should be cured, for example less than 30%, 10% or 5% of the total area. Here, anti-down velvet is also provided in the uncured area. Partial thermal curing is not required and is not required in order to achieve down-proof velvet. However, it is preferred according to the invention that the nonwoven fabric is not thermally cured or chemically cured at all. This means that no thermal or chemical curing is carried out in order to improve the stability of the nonwoven material itself in the face. Thereby, advantageous nonwoven fabric properties are completely maintained. Of course this does not obstruct: the nonwoven fabric has sealing seams, adhesive seams or the like which are used for processing into textile products.

After curing, the nonwoven fabric can be processed by a usual method, for example, by drying and/or shrinking. The nonwoven fabric is then formed into a cover into which the down is added and enclosed.

In a preferred embodiment, the multicomponent fiber has a cake-like (wille-like) structure and is split into continuous filaments having a titer of less than 0.12 dtex, wherein mechanical curing comprises water jet solidification and wherein the nonwoven fabric has 70 g/ m ² to 200 g/m ² basis weight. Preferably, here, bicomponent fibers consisting in particular of a polyester component and a polyamide component are used.

In a preferred embodiment, the nonwoven fabric has an average pore size of from 5 μm to 20 μm and/or a maximum pore size of from 10 μm to 50 μm, which is determined by means of an aperture measuring instrument from TOPAS, Germany (Model: PSM 165) The manufacturer was measured according to ASTM E 1294-89 and ASTM F 316-03 as set forth by the American Society for Testing and Materials (ASTM).

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

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

The nonwoven fabric is preferably characterized by very good water absorption. This water absorption, which is similarly measured for textiles according to DIN 53923, is preferably at least 250 ml/m ² , in particular in excess of 350 ml/m ² .

Preferably, the down-proof velvet is also maintained under prolonged use and common mechanical loads. It has been found that anti-down and down-drilling properties are maintained when the nonwoven fabric is washed more frequently. Preferably, the nonwoven fabric is also anti-down velvet for DIN EN 12132-1 after 5, 10 or 20 times of household washing according to DIN EN ISO 6330.

Preferably, measured at a test area of 20 cm ² and a pressure difference of 200 Pa, preferably in an average value consisting of 10 or 50 single measurements, the gas permeability according to EN ISO 9237:1995-12A is a minimum of 20 Mm/s, preferably a minimum of 30 mm/s.

Particularly preferably, the nonwoven fabric has a basis weight of from 90 g/m ² to 160 g/m ² , a minimum of 20 mm/s of gas permeability according to EN ISO 9237:1995-12A and a pressure of 4 N to 12 N according to DIN EN 13937 -2 breaking strength. According to the invention, it is advantageous to achieve down-proof pile-deepening properties by means of very fine fibers and a relatively low basis weight, so that sufficient gas permeability for textile applications is achieved.

Preferably, the nonwoven fabric has a minimum of 12000 km/m ² individual filaments per unit area weight, particularly preferably a minimum of 13500 km/m ² individual filaments or a minimum of 15000 km/m ² individual filaments. The number of individual filaments per unit area weight can be calculated from the determined basis weight and the fineness (expressed in decitex) of a single filament, wherein it is considered that the multicomponent fibers are completely dispersed. It has been found that a high degree of down-proof velvet can be achieved by adjusting the relatively high number of filaments per unit area with very fine fibers.

In general, it is especially preferred to coordinate the following properties of the nonwoven fabric: a basis weight of from 90 g/m ² to 160 g/m ² , preferably from 110 g/m ² to 160 g/m ² , the minimum 20 mm/s, preferably minimum 30 mm/s, according to EN ISO 9237:1995-12A, gas permeability and a weight per unit area of at least 12,000 km/m ² , preferably a minimum of 13500 km/m ² individual filaments. Preferably, the nonwoven fabric here comprises or consists of a continuous filament having a fineness of less than 0.075 dtex. Particularly preferably, the nonwoven fabric here consists of or comprises 32 PIE multicomponent fibers.

As detailed above, the nonwoven fabric itself is suitable for use in accordance with the present invention. Nevertheless, it is conceivable to reinforce the nonwoven fabric with other textile layers. Thus, the application according to the invention can be realized, for example, by a laminate of non-woven fabrics having at least one further layer, for example one or two further layers. Here, it is preferred that the nonwoven fabric is directly adjacent to the down and thereby forms a barrier. The nonwoven fabric can be provided with at least one other layer on the outside facing away from the down, which layer imparts other desired properties such as moisture permeability or increased mechanical strength to the laminate. However, in such a laminate, the application purpose is achieved by the nonwoven fabric itself, i.e., anti-down, which forms a physical barrier to down. Preferably, for another purpose, an additional layer is applied, in particular on the outside, that is to say that the layer does not improve or significantly improve the down-proof pile.

The subject of the invention is also a down-filled textile product, in particular selected from the group consisting of a bedding, a jacket, a mat, a mattress or a sleeping bag, the textile product comprising a textile outer cover and a covered down. The outer cover includes a nonwoven fabric for preventing the downhole from being composed of a continuous filament, the multicomponent fiber being split into a continuous filament having a fineness of less than 0.15 decitex to be mechanically cured into the nonwoven fabric, the nonwoven fabric being not subjected to surface heat Cured or chemically cured.

The outer cover is a woven layer that has a suitable shape so that the preserved down is in it. The woven outer cover can consist essentially of a nonwoven fabric. This means that the nonwoven fabric forms at least a part of the woven outer cover, by which the down is preserved and separated from the environment. Furthermore, for other purposes, it is possible to modify the outer cover of the textile, for example with decorative elements or closure mechanisms such as buttons or zippers.

The textile product is preferably a bedding, a jacket, a mat, a mattress or a sleeping bag. Particularly preferably, the textile product is a bedding product. Non-woven fabrics are particularly well suited as coverings or underlays, such as bedspreads, needles or mattress pads, due to their combination of good mechanical properties, and in particular a combination of high softness and elasticity.

In a preferred embodiment, the down is goose down. The goose down is particularly easy to penetrate through the textile cover due to its hardness and shape. It has been found that the application according to the invention is achieved with a special nonwoven fabric, and even the goose down is preserved in a manner that prevents down-filing.

In addition to down, the filler can also contain other commonly used filler materials such as feathers or synthetic filler materials. For textile applications, down is often used as a mixture with feathers. Preferably, the proportion of the downfill to the filler is at least 30% by weight or at least 50% by weight, in particular at least 70% by weight.

The subject matter of the present invention is also a method for manufacturing comprising the steps of: (a) providing a woven outer cover comprising (b) filling the outer cover with a down (c) preventing the down velvet from the outer cover.

The closure of the down-proof pile can be carried out, for example, by heat sealing, stitching, pasting or other conventional methods. Thermal bonding methods for sealing, such as ultrasonic stitching or ultrasonic welding, are especially preferred because of the use of particularly spinnable, thermoplastically processible polymers.

The nonwoven fabric according to the present invention is highly advantageous because the nonwoven fabric is down-proof and has a high degree of protection against allergens such as pollen or house dust, or mosquito bites. The latter is particularly advantageous because the fabric generally does not provide protection against mosquito bites. The nonwoven fabrics which can be used in accordance with the invention thus provide, in their entirety, an unusually high degree of protection against disturbing environmental influences.

The nonwoven fabric as a whole is characterized by a combination of properties. Mechanical properties, for example with respect to maximum tensile strength, maximum elongation, isotropy, tensile modulus of elasticity or re-breaking strength, are outstanding and easily achieve applications commonly used in the textile field. In addition, nonwoven fabrics have advantageous properties particularly for typical textile applications, such as adsorption, wash shrinkage or pore size. Overall, it is surprising that a combination that does not require thermal or chemical cure and that achieves advantageous properties even at low basis weights combines high down-proof velvet. Furthermore, it is advantageous if the nonwoven fabric can be produced in a simple manner and does not require special processing steps such as lamination or chemical post-treatment. The materials used for their manufacture, in particular the multicomponent fibers and the corresponding continuous filaments, are also simple to use and are processable.

The nonwoven fabric according to the present invention has very good down-proof pile-down properties, while a similar nonwoven fabric having substantially thicker fibers does not have down-proof pile-down properties. Here, it is surprising that the down-proof pile-down property does not increase proportionally with the fiber fineness, but the nonwoven fabric having fibers is not suitable for preserving down, but has a higher fiber thickness from a specific fineness. The fineness of the fiber suddenly has a high down-proof pile. Unexpectedly, it was suddenly achieved in the case of extremely fine fibers that it was down-proof. It was originally expected that very fine fibers would no longer have sufficient mechanical strength to withstand hard and sharp down stems. Thus, it is achieved by the present invention that only mechanically cured nonwoven fabrics are used to preserve the down. The present invention thus solves the problems initially described as a whole.

Example 1 to 4 :Manufacture of non-woven fabrics

The following exemplary description manufactures a nonwoven fabric using a bicomponent spun nonwoven fabric apparatus composed of bicomponent fibers having a cake-like cross section. Two nonwoven fabrics (Examples 2 and 4) which can be used according to the invention are produced having 32 individual filaments (PIE32 type) and basis weights of, for example, 100 g/m ² and 130 g/m ² . In order to compare with the prior art of German Utility Model Patent Publication No. 20310279 U1, a two-component having a basis weight of 16 individual filaments (PIE16 type) and, for example, 100 g/m ² and 130 g/m ² is produced. Two nonwoven fabrics composed of fibers (Examples 1 and 3). Next, the components and manufacturing conditions are summarized. Nozzle: Nozzle type: PIE16 or PIE32, pneumatic stretch laying: laid on the laying belt at a preset speed, which gives a basis weight of 100 g/m ² or 130 g/m ² of non-woven fabric. Curing: Pre-cure by means of needle punching at 35 needles/cm ² and smoothing by means of steel roll calendering at a linear pressure of 160 ° C to 170 ° C and 65 N to 85 N. At 220 bar to 250 bar, the nozzle hole diameter of 130 μm is applied to the 80 mesh, and 4 to 6 are performed in the order of ABAB (AB) on the upper side A and the lower side B of the nonwoven fabric. The alternate jet of water jet solidifies the bicomponent filaments to final cure and split into individual filaments. Post-treatment: Immediately thereafter, the nonwoven fabric was dried at 190 ° C with a cylindrical through-air dryer and partially shrunk to ensure as little as 3% washing shrinkage as possible during the first boil washing. The production speed in the method step after dispensing from the nozzle is suitable for the unit weight to be achieved.

Test case 1 : Characteristics of non-woven fabrics

The properties of the nonwoven fabrics produced according to Examples 1 to 4 were investigated by suitable measurement methods which are important for typical textile applications. Unless otherwise stated, the trial is based on the following criteria in a valid version on the filing date:

The results are summarized in Table 1 below. Table 1: Characteristics of the nonwoven fabric according to Test Example 1

The results show that all four non-woven fabrics have good textile properties. In the case of equal basis weight, compared to the comparative nonwoven fabric of the PIE 16 type (Examples 1 and 3), the nonwoven fabric of the PIE 32 type which can be used according to the invention (Examples 2 and 4) shows an improvement. Washing resistance, allergen impermeability and resistance to mosquito puncture.

Test Example 2: Down-proof pile-down property

The inspection of the down-proof pile-down property is carried out by means of a simulated cushion stress test according to DIN EN 12132-1. This standard is used to check the down-proof pileability of fabrics and can be similarly applied to nonwoven fabrics. According to Part 1, an analog pad stress test is performed. The inspection was carried out on two mats with dimensions of 120 mm x 170 mm. In the pad 1, the longer side extends in the direction 1. In the pad 2, the longer side extends in the direction 2. White, new, pure goose down grade I, 90% down//10% feather is used as the filling material. The test material corresponds to EN 12934 (a sign of the finished feather and down composition). The number of down/feathers or parts that were transmitted after 2700 rotations was determined as a result. By definition, samples that achieve 20 or fewer results in all directions are down-proof.

For the nonwoven fabric according to Example 2 (PIE32, basis weight of 97 g/m ² ), 16 results were obtained in the direction 1 (1 particle was inserted into the textile material, 15 particles were inserted into the plastic bag) And in the direction 2, 34 results (2 particles inserted in the textile material and 32 particles inserted in the plastic bag) were obtained. For the nonwoven fabric according to Example 4 (PIE32, 127 g/m ² basis weight), 9 was obtained in the direction 1 (2 particles were inserted into the textile material, 7 particles were inserted into the plastic bag) And the result of 3 (0 particles inserted in the textile material and 3 particles inserted in the plastic bag) was obtained in the direction 2. The results show that the nonwoven fabric according to the present invention has outstanding anti-down feathering properties. The down-proof pile-down property of the nonwoven fabric according to the present invention having a basis weight of 100 g/m ² is already high, and the down-proof pile-down property in 130 g/m ² completely corresponds to the requirements of bedding products. .

For comparison, a nonwoven fabric composed of a mixture of continuous filaments having a fineness of 0.1 dtex and 0.2 dtex was studied. A nonwoven fabric was produced similarly to Example 1, but the nonwoven fabric had a basis weight of 120 g/m ² , and more specifically, a stable coating composed of polyurethane (15 g/m ² ) was additionally provided. Floor. After household washing, in the simulated mat stress test according to DIN EN 12132-1, the result of 42 (5 particles inserted in the textile material and 37 particles inserted in the plastic bag) is obtained in direction 1 and in direction 2 The result was obtained on 35 (3 particles inserted in the textile material and 32 particles inserted in the plastic bag). Therefore, the nonwoven fabric does not have anti-down feathering properties suitable for textile applications.

It has been shown in microscopic studies that the feathered plume easily penetrates this comparative nonwoven fabric (see Figures 1 to 4). A nonwoven fabric composed of a single filament having a fineness of 0.2 dtex and 0.1 dtex does not have sufficient strength to resist barbed, hard, sharp plumes.

The results show that the comparative nonwoven fabric is not expected to be down-proof and velvet as expected. Contrary to this, it is surprising that the substantially finer nonwoven fabric is anti-down and down. Figure 2 shows a typical sharp plume with a tip having a width of about 3.6 μm. The circumference of the tip was significantly smaller than the average pore size between 8 μm and 25 μm of all four nonwoven fabrics of Examples 1 to 4. Here, it is expected that the plume will pierce all four nonwoven fabrics. Furthermore, it is expected that the finer fibers will have less resistance to resist hard and sharp objects. Without being bound by theory, the internal structure consisting of closely interwoven continuous filaments can result in a particularly down-proof pile-down property of the nonwoven fabric that can be used in accordance with the present invention.

Test Example 3: Importance of unit area weight and fiber quantity

A nonwoven fabric composed of PIE32 bicomponent fibers or a nonwoven fabric composed of a mixture of 50% PIE16 bicomponent fibers and PIE32 bicomponent fibers having different basis weights was produced. As described in Test Example 2, the down-proof pile-down property of the nonwoven fabric was determined in a manner similar to DIN EN 12132-1 by means of a simulated pad stress test for fabrics. From the fiber fineness of a single filament, it is calculated how many individual filaments exist per unit area of the nonwoven fabric (1 dtex corresponds to 10 g/km).

The fibers and split filaments have the following characteristics: Material: Polyethylene terephthalate/polyamide 6 (PET/PA6) in a ratio of about 70/30.

Next, the results and the properties of the nonwoven fabric are summarized in Table 2. Table 2: Characteristics of the nonwoven fabric according to Test Example 3 (MD stands for machine direction, CD stands for machine direction)

As detailed in Test Example 2 above, it is considered that the sample is down-proof and velvet when the result of penetration of 20 or less is achieved in all directions. According to DIN EN 12132-1, nonwoven fabrics B, C, F, G and H are therefore anti-down velvet. Nonwoven fabrics also have good breathability and are suitable for use in textile applications, for example as bedding. The results show that it is advantageous that the filament fineness and the basis weight are coordinated with each other such that a sufficiently high number of fibers per unit area exists. Here, it can be advantageous to adjust the basis weight to a desired fine gas permeability when a relatively fine filament is applied.

no

Figure 1 shows a barbed, typical, hard, sharp down stalk at a magnification of 100 times, drilling through a nonwoven fabric according to the prior art. Figure 2 shows, at 2000 magnification, a typically barbed, tipped tip having a radius of about 3.6 μm and a diameter below the tip of about 19.1 μm. Fig. 3 shows that the nonwoven fabric according to the prior art is drilled by a feathered stem at a magnification of 100 times. Fig. 4 is a view showing the hole in the nonwoven fabric of Fig. 3 drilled by the feathered stem at a magnification of 100 times.

Claims (16)

A use of a nonwoven fabric composed of continuous filaments for preventing duvets from being dug-filled in a textile product, wherein the nonwoven fabric is obtained in a spinning method, wherein the multicomponent fibers are laid a nonwoven fabric according to which the multicomponent fiber is split into continuous filaments having a fineness of less than 0.15 dtex and the nonwoven fabric is mechanically cured into the nonwoven fabric by mechanical curing, the curing comprising fluid jet curing Wherein the nonwoven fabric is not thermally cured or chemically cured in a planar manner. The application of claim 1, wherein the multicomponent fiber is split into continuous filaments having a titer of less than 0.12 dtex. The use according to at least one of the preceding claims, wherein the nonwoven fabric comprises continuous filaments having a denier of less than 0.075 dtex. The 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 . The use according to at least one of the preceding claims, wherein the multicomponent fiber is a bicomponent fiber. The use according to at least one of the preceding claims, wherein the multicomponent fiber has a component selected from the group consisting of polyester, polyamide, polyolefin and/or polyurethane. The use according to at least one of the preceding claims, wherein the multicomponent fiber is a bicomponent fiber composed of a polyester component and a polyamide component. The use according to at least one of the preceding claims, wherein the multicomponent fiber has a cake-like (wille-like) structure having preferably 24, 32, 48 or 64 segments, and It is especially preferred to have at least 32 segments. The use according to at least one of the preceding claims, wherein the nonwoven fabric has an average pore size of from 5 mm to 20 mm and/or a maximum pore size of from 10 mm to 50 mm, the pore size according to ASTM E 1294-89 and ASTM F 316-03 is measured with the POM 165, an aperture measuring instrument from TOPAS, Germany. The use according to at least one of the preceding claims, wherein the nonwoven fabric has a gas permeability of at least 20 mm/s, preferably a minimum of 30 mm/s, said gas permeability according to EN ISO 9237:1995-12A at 20 cm ² The test area was measured under a pressure difference of 200 Pa. According to the request of at least one of the items of application, wherein said non-woven fabric having a minimum 12000km / m ² of single filaments, preferably a minimum 13500km / m ² single filament. The use according to at least one of the preceding claims, wherein the nonwoven fabric has a basis weight of from 90 g/m ² to 160 g/m ² and a gas permeability of at least 20 m/s according to EN ISO 9237:1995-12A , and a minimum of 12000km / m ² single filament. The use according to at least one of the preceding claims, wherein the multicomponent fiber has a cake-like (wille-like) structure and is split into continuous filaments having a fineness of less than 0.12 dtex, wherein the mechanical curing comprises water The jet is cured, and wherein the nonwoven fabric has a basis weight of from 70 g/m ² to 200 g/m ² . The use according to at least one of the preceding claims, wherein the nonwoven fabric is in a simulated pad stress test according to DIN EN 12132-1, part 1, by means of a mixture of 90% goose down and 10% goose feathers It is anti-down and down. a textile product filled with a down, in particular selected from the group consisting of a bedding, a jacket, a mat, a mattress or a sleeping bag, the textile product comprising a textile outer cover and a downhole comprising the same, wherein the outer cover comprises a a nonwoven fabric composed of continuous filaments, wherein the nonwoven fabric can be obtained in a spinning method, wherein the multicomponent fibers are laid into a nonwoven fabric, according to which the multicomponent fibers are split into A continuous filament having a denier of less than 0.15 dtex and curing the nonwoven fabric into the nonwoven fabric by mechanical curing, the mechanical curing comprising fluid jet curing, wherein the nonwoven fabric is not thermally cured or chemically cured. A method for manufacturing a down-filled textile product according to claim 15, the method comprising the steps of: (a) providing a woven outer cover, the outer cover comprising a nonwoven fabric composed of continuous filaments, (b) The outer cover is filled with down, and (c) the down cover is closed to prevent the down cover.