Ultra-bulky fiber aggregate and production method thereof

摘要

PCT No. PCT/JP93/01583 Sec. 371 Date Jul. 1, 1994 Sec. 102(e) Date Jul. 1, 1994 PCT Filed Oct. 29, 1993 PCT Pub. No. WO94/10366 PCT Pub. Date May 11, 1994This ultra-bulky fiber aggregate is obtained by blending (A) a polyester fiber and (B) a core-sheath type composite fiber wherein a low melting point component lower in melting point than the core is used for the sheath. The interlacing portions of three-dimensionally continuous fibers are fused by melting of the sheath portions of the core-sheath type composite fiber. The fiber aggregate has a thickness of at least 200 mm and a density of 0.02 to 0.1 g/cm3, and varies in density within +/-5% in all of the longitudinal and transverse directions and the direction of height. The fiber aggregate can be used as a shoulder pad and a cushion material when it is cut. The production method of this fiber aggregate comprises blending (A) a polyester fiber and (B) a core-sheath type composite fiber using a low melting point component lower in melting point than the core for the sheath to obtain a card web, temporarily fusing card webs by far infrared rays or a hot air heater to laminate webs as required by a predetermined density and a predetermined thickness, and heat-treating the resulting laminate so as to mutually fuse the layers forming the laminate, wherein the heat-treatment is carried out by placing the laminate into a steam oven while it is compressed and clamped between two upper and lower plates and introducing the steam, the laminate being subjected to the heat-treatment while kept erect.