Bond site reinforcement in thermal bonded highloft non-wovens

• US 5,585,161 A
• Filed: 11/12/1993
• Issued: 12/17/1996
• Est. Priority Date: 01/22/1992
• Status: Expired due to Term

• Current Assignee: Donna M. Difloe, Thomas E. Taylor
• Original Assignee: Donna M. Difloe, Thomas E. Taylor
• Inventors: Taylor, Thomas E., Difloe, Donna M.
• Primary Examiner(s): Pal, Asok
• Assistant Examiner(s): Shelborne, Kathryne E.
• Application Number:
  US08/150,761
• Time in Patent Office: 1,131 Days
• Field of Search: 428/247, 428/253, 428/283, 428/284, 428/288, 428/296, 428/109, 428/156, 428/171, 428/255, 428/293, 428/294, 428/297
• US Class Current: 428/109
• CPC Class Codes: B32B 2262/0276 Polyester fibres
• CPC Class Codes: B32B 2262/12 Conjugate fibres, e.g. core/sheath or side-by-side
• CPC Class Codes: B32B 2305/38 Meshes, lattices or nets
• CPC Class Codes: B32B 5/022 Non-woven fabric
• CPC Class Codes: B32B 5/028 Net structure, e.g. spaced apart filaments bonded at the crossing points
• CPC Class Codes: B32B 5/22 characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed layer formed of natural mineral fibres or particles next to a foam layer B32B19/047, next to a layer made of particles B32B19/048, or next to a fibrous or filamentary layer B32B19/06; paper layer or cardboard layer next to a paper layer or cardboard layer B32B29/005, next to a foam layer B32B29/007, next to a fibrous or filamentary layer B32B29/02, or next to a particulate layer B32B29/04
• CPC Class Codes: B32B 5/26 another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: D04H 1/02 Cotton wool; Wadding
• CPC Class Codes: D04H 1/54 by welding together the fibres, e.g. by partially melting or dissolving in combination with needling D04H1/485
• CPC Class Codes: D04H 5/06 strengthened or consolidated by welding-together thermoplastic fibres, filaments, or yarns
• CPC Class Codes: Y10T 428/24091 with additional layer[s]
• CPC Class Codes: Y10T 428/24479 including variation in thickness
• CPC Class Codes: Y10T 428/24603 Fiber containing component
• CPC Class Codes: Y10T 442/159 Including a nonwoven fabric which is not a scrim
• CPC Class Codes: Y10T 442/641 Sheath-core multicomponent strand or fiber material
• CPC Class Codes: Y10T 442/698 Containing polymeric and natural strand or fiber materials

Abstract

Provided is a supplement or additive to thermal bonded highloft nonwoven fiber masses bonded by the fusion of a matrix fiber and a heat reactive binder. The purpose of the supplement or additive is to reinforce and enhance the bonded fiber structure. The supplement is in the form of an embedment or filler.

Claims

1. A highloft nonwoven thermally bonded fiber batting consisting essentially of:

a series of matrix fibers;

at least one binder element comprising at least one low-melt, sheath-core binder fiber and which secures the matrix fibers together to establish a desired textile structure; and

at least one supplemental reinforcing element positioned throughout the established textile structure in a manner that assists in maintaining it'"'"'s structural integrity and loft even after exposure to multiple compressions, wherein the supplemental reinforcing element comprises at least one medially located, planar textile component formed of single or multiple filaments, fibers or yarns.

2. The fiber batting of claim 1 wherein the textile component of the supplemental reinforcing element is formed by interlacing.

3. The fiber batting of claim 2 wherein the textile component of the supplemental reinforcing element has a mesh-like configuration.

4. The fiber batting of claim 1 wherein the textile component of the supplemental reinforcing element is formed by extrusion.

5. The fiber batting of claim 4 wherein the textile component of the supplemental reinforcing element has a mesh-like configuration.

6. The fiber batting of claim 1 wherein the textile component of the supplemental reinforcing element has a lineal orientation.

7. The fiber batting of claim 6 wherein the textile component of the supplemental reinforcing element comprises cut lengths.

8. The fiber batting of claim 6 wherein the textile component of the supplemental reinforcing element is continuous.

9. The fiber batting of claim 1 wherein the textile component of the supplemental reinforcing element is formed by a knitting process.

10. The fiber batting of claim 1 wherein the textile component of the supplemental reinforcing element is a nonwoven fabric.