Method of making high loft nonwoven

Details Method of making high loft nonwoven Method of making high loft nonwoven

2005-11-15

2008-08-12

Hurley, Shaun R (Department: 3765)

Textiles: fiber preparation

Assembling

Formed web

Reexamination Certificate

active

07409748

ABSTRACT:
The present invention relates to a process for making high loft, nonwoven material by providing either natural and/or synthetic fibers, providing a low melt binder fiber, mixing the low melt binder fiber and the natural and/or synthetic fibers to form a web, cross-lapping the web, drafting the web with a drafter, heating the drafted web to a temperature sufficient to melt the low melt binder fibers, and cooling the web thereby forming a structural nonwoven material. The nonwoven batt can be cross-lapped between 2 and 10 layers and when the batt is cooled and has structural rigidity, the tensile strength in the machine direction is at least 50% of the tensile strength in the cross-direction. The batt weight is in a range of 0.25 oz/ft2to 2.0 oz/ft2. The low melt binder fibers comprise 10 to 30 wt. % of the nonwoven batt and the synthetic and/or natural fibers comprise about 70 to 90 wt. %. This product is useful for nonwoven applications in indoor and outdoor furniture, quilting, bed covers and mattresses specifically.

REFERENCES:
patent: 5252386 (1993-10-01), Hughes et al.
patent: 5296289 (1994-03-01), Collins
patent: 5475903 (1995-12-01), Collins
patent: 5873964 (1999-02-01), Kwok
patent: 5928973 (1999-07-01), Daniel et al.
patent: 6375773 (2002-04-01), Andersen
patent: 2007/0202294 (2007-08-01), Ogle et al.

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