Thermal-insulating nonwoven bulky product

Claim 2

A thermal insulating nonwoven bulky product comprising a multiplicity of substantially continuous single filaments having an average fineness of from about 0.01 to about 2 deniers, and a specific volume of not less than about 40 ml/g as calculated by the equation Specific volume (ml/g)=(20×20×h)/A wherein A is the weight of the sample having a length and width of 20 cm and 20 cm, respectively, and h is the average height of the sample measured under the load of 0.125 g/cm 2 ; said filaments having random crimps in the range of from about 1 to about 20% as calculated by the equation percentage crimp (%)=((l.sub.1 -l.sub.0)/l.sub.1)×100 wherein l 0 is the distance between arbitrarily chosen points in the filament measured under the load of 2 mg/d, and l 1 is the distance between the same points measured under the load of 300 mg/d; said filaments being stabilized together and in layers by a surface binder of low molecular weight on the filaments in the range of from about 0.5 to about 20% by weight of the filaments.

Claim 3

A thermal insulating nonwoven accumulated layered product characterized by substantially continuous single filaments having an average fineness of from about 0.01 to about 2 deniers, and a specific volume of not less than about 40 ml/g as calculated by the equation Specific volume (ml/g)=(20×20×h)/A wherein A is the weight of the sample having a length and width of 20 cm and 20 cm, respectively, and h is the average height of the product measured under the load of 0.125 g/cm 2 ; said filaments having random crimps, uneven in form and in number between the filaments, in the range of from about 1 to about 20% calculated by the formula Percentage crimp (%)=((l.sub.1 -l.sub.0)/l.sub.1)×100 wherein l 1 is the distance between arbitrarily chosen points in the filament measured under the load of 2 mg/d, and l 0 is the distance between the same points measured under the load of 300 mg/d; said accumulation of filaments being stabilized together, and in repeated folds at both surfaces by a surface binder of low molecular weight on the filaments in the range of from about 0.5 to about 20% by weight of the filaments.

Claim 4

A thermal insulating nonwoven accumulated layered product characterized by substantially continuous single filaments having an average fineness of from about 0.01 to about 2 deniers, and a specific volume of not less than about 40 ml/g as calculated by the equation Specific volume (ml/g)=(20×20×h)/A wherein A is the weight of the sample having a length and width of 20 cm and 20 cm, respectively, and h is the average height of the product measured under the load of 0.125 g/cm 2 ; said filaments having random crimps, uneven in form and in number between the filaments, in the range of from about 1 to about 20% calculated by the formula Percentage crimp (%)=((l.sub.1 -l.sub.0)/l.sub.1)×100 wherein l 1 is the distance between arbitrarily chosen points in the filament measured under the load of 2 mg/d, and l 0 is the distance between the same points measured under the load of 300 mg/d; said accumulation of filaments being stabilized together, and in repeated folds at both surfaces by a surface binder of low molecular weight on the filaments in the range of from about 0.5 to about 20% by weight of the filaments.

Claim 5

The product of claims 1 or 2 in which the single filaments are derived from multifilament whose total fineness is not less than 10 deniers.

Claim 6

The product of claim 3 in which the multifilament have a total fineness in the range of from about 30 to about 3000 deniers.

Claim 7

The product of claims 1 or 2 in which the filaments are of mixed denier.

Claim 8

The product of claims 1 or 2 in which the filaments are composed of polyesters.

Claim 9

The product of claim 6 in which the filaments are composed of polyethylene terephthalate.

Claim 10

The product of claim 6 in which the filaments are composed of butylene terephthalate.

Claim 11

The product of claims 1 or 2 in which the binder is a thermoplastic resin selected from the group consisting of polyvinylalcohol, polyvinylpyrrolidone, polyurethane, synthetic latexes and polyacrylic esters.

Claim 12

The product of claim 9 in which the binder has a softening temperature of less than that of the filaments.

Claim 13

The product of claim 9 in which the binder is polyvinylalcohol having a molecular weight of from about 100 to about 10,000 and a saponification extent of not less than 98%.

Claim 14

The product of claims 1 or 2 in which the single filaments are spread out in a nonhorizontal direction.

Claim 15

The product of claims 1 or 2 having a specific volume in the range of from about 50 to about 500 ml/g.

Claim 16

The product of claims 1 or 2 having filaments which are finished with a lubricant in an amount of 0.01 to 0.5% by weight of the filaments.

Claim 17

The product of claim 14 in which the lubricant contains polyorganosiloxane.

Claim 18

The product of claim 10 in which the binder is polyvinylalcohol having a molecular weight of from about 100 to about 10,000 and a saponification extent of not less than 98%.

Claim 19

The product of claims 1 or 2 in which the percentage crimp is in the range of 2 to 10%.

Claim 20

The product of claims 1 or 2 in which the average fineness of the single filaments is 0.1 to 1 denier.

Claim 21

The product of claim 9 in which the binder is polyvinylalcohol.

Claim 22

The product of claims 1 or 2 in which the minute particles of the binder are distributed uniformly.

Claim 23

The product of claim 9 in which the binder is polyacrylic ester.

Claim 24

The product of claims 1 or 2 in which the product is additionally finished by surface treatment with a binder.

Claim 25

The product of claim 22 in which the additional binder is polyacrylic ester.