Stock material or miscellaneous articles – Structurally defined web or sheet – Including variation in thickness
Reexamination Certificate
1999-02-22
2001-08-21
Morris, Terrel (Department: 1771)
Stock material or miscellaneous articles
Structurally defined web or sheet
Including variation in thickness
C428S172000, C442S361000, C442S381000
Reexamination Certificate
active
06277469
ABSTRACT:
FIELD OF THE INVENTION
The present invention is generally directed to a composite fabric that is particularly well suited for functioning as an insert or lining in an athletic shoe or boot, such as a ski boot. The present invention is also directed to a process for making the composite fabric.
BACKGROUND OF THE INVENTION
Three dimensional fabric substrates are well known in the art. The purpose of these past products has been to provide a composite fabric which will provide insulation and/or cushioning.
For instance, a stitchbonded nonwoven fabric is disclosed in U.S. Pat. No. 4,876,128 to Zafiroglu, which is incorporated herein by reference. In particular, the '128 patent discloses a stitchbonded fabric made to have improved insulating and stretchability characteristics and good laundering durability. The stitchbonded fabric is formed from a bonded fibrous layer stitchbonded with elastic thread under tension, which is then subjected to a relaxed shrinkage treatment to increase its thickness and volume. Alternatively, instead of inserting the yarn into the fibrous layer in an elongated condition, part or all of the retractive force can be supplied by shrinkage of the yarn. The shrinkage can be activated, for example, by heat, steam or a suitable chemical treatment after the yarn has been stitched into the fibrous layer.
In addition to single layer fabrics, multi-layer composite fabrics have also been constructed in the past having specially designed three dimensional conformations. The layers of these composite fabrics, however, were typically laminated together. Consequently, the composite fabrics lacked in durability and cohesiveness.
Although the above-described fabrics have performed satisfactory in several uses, their utility as an insulating fabric could be greatly enhanced, especially if significant increases could be made in the specific volume of the fabrics and in their resistance to deterioration by repeated washing. As such, a need currently exists for an improved three dimensional fabric and method for manufacturing the fabric. In particular, a need exists for a three dimensional fabric that is durable, that can be repeatedly laundered, that has good cushioning properties, that has good moisture management properties, that can be made stretchable, and that can be easily manufactured.
SUMMARY OF THE INVENTION
The present invention recognizes and addresses the foregoing disadvantages, and others of prior art constructions and methods.
Accordingly, it is an object of the present invention to provide an improved composite fabric that is durable in high wear applications and can provide insulation and cushioning where needed.
It is another object of the invention to provide a suitable fabric which is easy to manufacture.
These and other objects of the present invention are achieved by providing a process for producing a composite fabric that is particularly well suited for durability, insulation and cushioning. The process includes, in one embodiment, the steps of providing at least two layers of fabric which have either differing textures, shrinkage characteristics, and/or elasticity characteristics. The layers are connected together preferably using stitchbonding according to a desired pattern. The resulting composite fabric is then relaxed or heat treated so as to cause one layer to contract, thus causing the other layer to gather and form a three dimensional fabric effect.
These and other objects of the present invention are also achieved by providing a three dimensional composite fabric product made from at least two (2) fabric layers. In particular, the composite fabric product can include a first fabric layer and a second fabric layer that are connected together by a plurality of parallel rows of stitches. The second fabric layer can contain shrinkable fibers. In accordance with the present invention, the second fabric layer is shrunk in relation to the first fabric layer after the layers have been connected together. In this manner, a plurality of ridges is formed defined by the second fabric layer. The formed ridges are located in between the parallel rows of stitches.
The second fabric layer containing the shrinkable fibers can be made from various materials according to various constructions. In one embodiment, the second fabric layer can be a stitchbonded fabric containing a nonwoven web with shrinkable fibers and/or a shrinkable stitchbonded yarn. For instance, the shrinkable fibers or yarn can be made from spandex fibers. Preferably, the second fabric layer has been shrunk at least 5% and particularly at least 10% in one direction after the fabric layers have been connected together.
In one embodiment, the three dimensional composite fabric product can further include a fill layer positioned in between the first fabric layer and the second fabric layer. The fill layer can be a fiber fleece made from high bulk fibers. For instance, the high bulk fibers can be siliconized fibers having a denier of at least
6
.
Other objects, features and aspects of the present invention are discussed in greater detail below.
REFERENCES:
patent: 3649428 (1972-03-01), Hughes
patent: 3837943 (1974-09-01), Ploch et al.
patent: 3961107 (1976-06-01), Hammer et al.
patent: 4876128 (1989-10-01), Zafiroglu
patent: 4891957 (1990-01-01), Strack et al.
patent: 5187952 (1993-02-01), Zafiroglu
patent: 5203186 (1993-04-01), Zafiroglu
patent: 5491017 (1996-02-01), Todt
patent: 5527600 (1996-06-01), Frankosky et al.
patent: 5543004 (1996-08-01), Tochacek et al.
patent: 5623812 (1997-04-01), Todt
patent: 5705566 (1998-01-01), Todt
patent: 5712008 (1998-01-01), Todt
patent: 5736231 (1998-04-01), Todt
Dority & Manning P.A.
Morris Terrel
Pratt Christopher C.
Tietex International, Inc.
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