High pressure high temperature cushioning material

• US 5,691,036 A
• Filed: 02/23/1996
• Issued: 11/25/1997
• Est. Priority Date: 01/30/1996
• Status: Expired due to Term

• Current Assignee: Du Pont Taiwan Limited (Corteva, Inc.), Industrial Technology Research Institute
• Original Assignee: Du Pont Taiwan Limited (Corteva, Inc.), Industrial Technology Research Institute
• Inventors: Hu, Yen-Jung, Lin, Michael Yuan-Chang, Huang, Hsu-Yeh, Luo, Der-Guey
• Primary Examiner(s): CHOI, KATHLEEN L
• Application Number:
  US08/606,142
• Time in Patent Office: 641 Days
• Field of Search: 442/35, 442/36, 442/57, 428/172
• US Class Current: 428/172
• CPC Class Codes: B32B 3/30 characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs apertured layer B32B3/266; layer with cavities or internal voids B32B3/26
• CPC Class Codes: B32B 5/022 Non-woven fabric
• CPC Class Codes: B32B 5/024 Woven fabric
• CPC Class Codes: B32B 5/06 characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
• 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 1/4342 Aromatic polyamides
• CPC Class Codes: D04H 1/4374 using different kinds of webs, e.g. by layering webs
• CPC Class Codes: D04H 1/559 the fibres being within layered webs
• CPC Class Codes: Y10T 428/24612 Composite web or sheet
• CPC Class Codes: Y10T 442/159 Including a nonwoven fabric which is not a scrim
• CPC Class Codes: Y10T 442/16 Two or more nonwoven layers
• CPC Class Codes: Y10T 442/197 Including a nonwoven fabric which is not a scrim

Abstract

A cushioning material is disclosed having at least two layers of unwoven, temperature-resistant staple fibers and layers of reinforcing scrim between the unwoven layers, wherein the entire structure is needlepunched for integrity and one face is embossed with a pattern to increase resiliency.

Claims

1. A cushioning material comprising at least two fibrous batts of staple fibers with adjacent facing surfaces and at least one outer surface and a layer of scrim between the facing surfaces,

characterized in that

the fibrous batts are staple fibers and are from 1.5 to 10 millimeters thick, at least one of the fibrous batts has embossing on an outer surface, in which depressions having a depth of 10 to 40 percent of the thickness of the batt and an average width of 0.5 to 4 millimeters cover, 25 to 70 percent of the total outside surface;

and,

the scrim has a density from 30 to 120 grams per square meter.

2. The cushioning material of claim 1 wherein the fibrous batts are nonwoven and comprise at least 90 weight percent staple fibers.

3. The cushioning material of claim 2 wherein the staple fibers of the fibrous batts are 3 to 14 centimeters long.

4. The cushioning material of claim 1 wherein the staple fibers are aramid.

5. The cushioning material of claim 1 wherein the fibers of the scrim are continuous fibers.

6. The cushioning material of claim 1 wherein the fibers of the scrim are staple fibers.

7. The cushioning material of claim 6 wherein the staple fibers of the scrim are 3 to 14 centimeters long.

8. The cushioning material of claim 5 wherein the scrim is woven.

9. The cushioning material of claim 5 wherein the fibers of the scrim are aramid.

10. The cushioning material of claim 6 wherein the fibers of the scrim are aramid.

11. The cushioning material of claim 4 wherein the aramid fibers in the fibrous batts are selected from the group consisting of poly(m-phenylene isophthalamide) fibers and poly(p-phenylene terephthalamide) fibers.

12. The cushioning material of claim 9 wherein the aramid fibers in the scrim are selected from the group consisting of poly(m-phenylene isophthalamide) fibers and poly(p-phenylene terephthalamide) fibers.

13. The cushioning material of claim 10 wherein the aramid fibers in the scrim are selected from the group consisting of poly(m-phenylene isophthalamide) fibers and poly(p-phenylene terephthalamide) fibers.