CONSTRUCTS FOR DISTRIBUTION OF FILL MATERIAL

• US 20180179678A1
• Filed: 11/05/2015
• Published: 06/28/2018
• Est. Priority Date: 11/07/2014
• Status: Active Grant

• Current Assignee: North Face Apparel Corporation (V.F. Corporation)
• Original Assignee: North Face Apparel Corporation (V.F. Corporation)
• Inventors: Dorton, Jeffrey Allen
• Granted Patent: US 10,442,155 B2
• Time in Patent Office: Days
• CPC Class Codes: B32B 1/00 Layered products having a non-planar shape
• CPC Class Codes: B32B 2437/00 Clothing
• CPC Class Codes: B32B 2471/04 Mats
• CPC Class Codes: B32B 2601/00 Upholstery
• CPC Class Codes: B32B 5/00 Layered products characterised by the non- homogeneity or physical structure , i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
• CPC Class Codes: B32B 5/02 characterised by structural features of a fibrous or filamentary layer layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02
• CPC Class Codes: B32B 5/022 Non-woven fabric
• CPC Class Codes: B32B 5/024 Woven fabric
• CPC Class Codes: B32B 5/026 Knitted fabric
• CPC Class Codes: B32B 7/04 Interconnection of layers
• CPC Class Codes: B32B 7/05 the layers not being connected over the whole surface, e.g. discontinuous connection or patterned connection using interposed adhesives or bonding materials applied in spaced arrangements B32B7/14
• CPC Class Codes: B32B 7/08 by mechanical means
• CPC Class Codes: D04H 1/52 by applying or inserting filamentary binding elements
• CPC Class Codes: D04H 1/55 Polyesters
• CPC Class Codes: D04H 3/115 by applying or inserting filamentary binding elements
• CPC Class Codes: D04H 5/06 strengthened or consolidated by welding-together thermoplastic fibres, filaments, or yarns
• CPC Class Codes: D10B 2501/04 Outerwear; Protective garments
• CPC Class Codes: D10B 2503/00 Domestic or personal

Abstract

In some embodiments, the inventive subject matter is directed to an arrangement of discrete elements of fill material on a substrate consisting of a sheet material wherein the discrete elements are fixed relative to the sheet material by pilings, fusion, and/or entanglement to fix the insulating elements in a layered arrangement over the sheet material. A second sheet of material may be used to create a sandwiched assembly of the discrete elements. In some embodiments, the inventive subject matter is generally directed to discrete elements of fill material that are engaged together to form a cohesive sheet-like or layered arrangement of the elements.

Claims

1. A construct, comprising:

a plurality of discrete elements comprising an agglomeration of fibers, the discrete elements arranged in a pliable sheet-like structure; and

the discrete elements being associated with each other in the sheet-like structure by lengths of first interconnecting fibers that engage the discrete elements to help immobilize them in place relative to one another to maintain the sheet-like structure wherein the first interconnecting fibers comprise engaged fibers from a series of different discrete elements that are sufficiently engaged so as to help immobilize the discrete elements in the sheet-like structure;

a first sheet material that is adjacent to the sheet-like structure of discrete elements, the first sheet material supporting the discrete elements wherein the discrete elements interconnect with the first sheet material via second interconnecting fibers, each of the second interconnecting fibers comprising a first fiber portion emanating from a discrete element and a second fiber portion emanating from a supporting sheet material that is adjacent and part of the sheet-like structure of discrete elements; and

wherein the sheet material comprises a non-woven web or scrim comprising a textile of fibers of about 0.5 to about 75 Denier.

2. The construct of claim 1 wherein the first or second interconnecting fibers comprise fused fibers.

3. The construct of claim 2 wherein the agglomerated fibers comprise fibers having secondary structures.

4. The construct of claim 2 wherein the thermoplastic fibers comprise a polyester.

6. The construct of claim 1 wherein the sheet material comprises fusible fibers.

12. The construct of claim 1 wherein the interconnecting fibers comprise a series of neighboring piles that extends from the supporting first sheet material into the arrangement of discrete elements, the piles blocking, entangling, and/or fusing with the discrete fibers to help immobilize them in place relative to supporting sheet material, the piles being discrete structures from the fibers forming the discrete elements and the fibers forming the first sheet material.

14. The construct of claim 12 further comprising a second sheet of material opposite the first sheet of material, the discrete elements being disposed therebetween.

15. The construct of claim 14 wherein the same or a different series of interconnecting piles extend from the second sheet material into the arrangement of discrete elements, the interconnecting piles blocking, entangling, and/or fusing with the fibers on the discrete elements to help immobilize them in place relative to the first and second sheet materials, the piles extending from the second sheet being discrete structures from the fibers forming the discrete elements and the fibers forming the second sheet material.

18. The construct of claim 1 further comprising a second sheet of material opposite the first sheet of material, the discrete elements being disposed therebetween, the first sheet having properties different from the properties, the properties differing in terms of one more of breathability, insulativeness, and wear resistance, the second sheet comprising a knit or woven textile material.

19. The construct of claim 18 wherein the construct comprises a plurality of baffled, integrated compartments, the first sheet material being on a first side of the compartments and the second sheet material being on a second, opposite side of the compartments.

20. The construct of claim 19 wherein the lengths of interconnecting fibers comprise fibers forming part of the first sheet material and fibers forming parts of the discrete elements, the fibers from each type of structure being fused together at one or more points.

24. An assembly according to claim 1, wherein a plurality of the constructs are integrally formed together in a baffled construction.

26. The construct of claim 1 further comprising a supplemental layer of textile or a membrane coextensively joined to the first sheet material.

27. The construct of claim 26 wherein the supplemental layer comprises a heavier textile than the layer it is secured to.

28. The construct of claim 1 wherein the construct comprises an item of apparel, a sleeping bag, a comforter, pillow, or a pad or cushion.

29. The construct of claim 1 wherein the interconnecting fibers are at least 1 DPF or thereabout.

5. (canceled)

7-11. -11. (canceled)

13. (canceled)

16-17. -17. (canceled)

21. (canceled)

22. A construct, comprising:

a first pliable sheet material spaced-apart and opposite to a second pliable sheet material, the space between the sheet materials providing a volume for receiving a loose fill material;

a plurality of piles projecting into the volume of the space, each having a first end fixedly associated with the first sheet material and/or a second end fixedly associated with the second sheet material, the piles being transversely oriented to the first and second sheets of material; and

a loose fill material comprising discrete elements disposed in the volume around the piles.

23. The construct of claim 22 wherein the first sheet material and/or the second sheet material comprise a lightweight fabric such as scrim or taffeta.

25. The construct of claim 22 wherein the piles are oriented generally perpendicular to the first and second sheets of materials.

30. A method of making a construct, comprising:

providing a first layer of a pliable textile sheet material comprising fibers;

placing a plurality of discrete elements comprising an agglomeration of fibers on the pliable sheet material, at least some of the fibers comprising fusible fibers;

causing the fusible fibers to fuse so that the discrete elements are associated with at least the sheet material by lengths of interconnecting fused fibers that immobilize the discrete elements relative to the sheet material and providing for the discrete elements to retain at least 50% of their general volumetric or topological form following the fusion;

wherein the discrete elements interconnect with the sheet material via interconnecting fibers, each of the interconnecting fibers comprising a first fiber portion emanating from a discrete element and a second fiber portion emanating from the sheet material; and

wherein the sheet material comprises a non-woven web or scrim comprising a textile of fibers of about 0.5 to about 75 Denier.