Ultra-bulky fiber aggregate and production method thereof

Stock material or miscellaneous articles – Structurally defined web or sheet – Weight per unit area specified

Patent

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Details

428220, 428288, 428296, 156182, 1562733, 1563082, D04H 158

Patent

active

055695256

DESCRIPTION:

BRIEF SUMMARY
TECHNICAL FIELD

The present invention relates to a method for preparing an ultra-bulky fiber aggregate consisting of polyester fiber aggregate which contains a binder fiber having a low melting point.


BACKGROUND OF THE INVENTION

Various cushion materials made of polyester fiber have been developed. However, no product showing no strain by compression load and having voluminous feel has been prepared.
We have investigated and developed a method for the preparation of a cushion material, which can be used as a bed mat and the like and has a voluminous feel and a high quality, by using a conjugate fiber consisting of polyester (Japanese Laid-Open Patent Publication No. 152050 of 1990).
The method consists of a procedure in which polyester fibers (A) are mixed with core-sheath type composite or conjugate fibers (B) in which a sheath component of a lower melting point than that of the core component is used in a specified ratio and the resultant card web is temporarily melt-adhered with far-infrared ray or with a hot air circulating heater and the temporarily adhered webs are laminated according to the desired density and thickness and then the laminated webs are heated to melt-adhere each layer forming the laminate mutually. The method could prepare a cushion material of approximately 10 cm thick.
However, in the case that the webs are horizontally laminated and continuously heated in dry air, an increased thickness restricts the uniformity of the density and heat transmission. Also, in the case of a batch steaming system, an excessive thickness gives a vertical density gradient by the weight of the fibers themselves and results in an uneven product. Therefore, even the method described in Japanese Laid-Open Patent Publication No. 154050 of 1990 could not prepare stably a cushion material of as high a thickness as 20 cm or 50 cm in a uniform density.
Thus, the object of the present invention is to eliminate the disadvantages of the conventional technologies as mentioned above and to provide a product by using polyester fibers, which is an ultra-bulky block fiber aggregate having a high thickness of at least 20 cm, preferably 100 cm, and a uniform density in all of three directions like a urethane foam and can be used as a cushion material and a shoulder pad when sliced, and also to provide a method for the stable preparation thereof.


SUMMARY OF THE INVENTION

The present invention can provide an ultra-bulky block fiber aggregate, which can be sliced in the same manner as in urethane foam, by devising the material for the fiber aggregate and the heating method.
The product according to the present invention is prepared by blending (A) polyester fibers and (B) core-sheath type composite fibers in which a material having a lower melting point than that of the core component is used as the sheath component. It is characterized in that cubically continued intertwined parts of the fibers are melt-adhered by the fusion of the sheath part of said core-sheath type composite fibers and it has a thickness of at least 200 mm and a density of 0.02 to 0.1 g/cm.sup.3 and the scattering of the density of not wider than .+-.5% in all of the three directions.
The product is prepared by a method in which (A) polyester fibers are blended with (B) core-sheath type composite fibers in which a material having a lower melting point than that of the core component is used as the sheath component and the resultant card web is temporarily melt-adhered with far-infrared ray or with a hot air circulating heater and the temporarily adhered webs are laminated according to the desired density and thickness and then the laminated webs are heated to melt-adhere each layer forming the laminate mutually. The heat treatment is carried out by compressing the laminate between two upper and lower plates, feeding it in a steam oven and introducing steam into the oven. The laminate is heated under a standing condition.


BRIEF DESCRIPTION OF THE DRAWINGS



Detailed Description of the Invention

The present invention provides a fiber aggregate b

REFERENCES:
patent: Re30955 (1982-06-01), Stanistreet
patent: 5141805 (1992-08-01), Nohara et al.

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