Polymeric mats having continuous filaments with an asymmetrical

Stock material or miscellaneous articles – Structurally defined web or sheet – Discontinuous or differential coating – impregnation or bond

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428290, 428332, 428338, 428340, 428369, 428375, 428394, 428395, 428397, D04H 158

Patent

active

042923654

ABSTRACT:
A lofted mat of filaments is produced from process and apparatus including: supplying a plurality of streams of molten polymeric material; attenuating said streams of material into continuous filaments through the action of a stream of fluid moving from an attenuation means; said filaments being entrained in said fluid moving from said attenuation means, said filaments having non-uniform residual stresses established therein; moving said stream of fluid and filaments along a first surface positioned intermediate said attenuation means and a foraminous surface; establishing a vacuum at said foraminous surface; directing said stream of fluid and filaments into said foraminous surface obliquely oriented with respect to said first surface such that a first portion of said fluid separates from the filaments and passes through said foraminous surface and a second portion of said fluid moves said filaments along the foraminous surface; collecting said filaments in a randomly dispersed, substantially uniform layer having a first thickness; passing said layer through crimp inducing means adapted to permit said unbalanced, residual stresses to randomly crimp said filaments to form said lofted mat having a second thickness greater than said first thickness wherein said lofted mat is comprised of a lofted mat comprising a plurality of continuous polymeric filaments having an asymmetrical cross-sectional shape, the cross-sectional shape having a major dimension within the range from about 0.00150 inch to about 0.00350 inch, the filaments having a crimp factor within the range from about 0.1 to about 4 waves per inch of filament, said mat having a density within the range from about 0.33 pounds per cubic foot to about 1.74 pounds per cubic foot.

REFERENCES:
patent: 3169899 (1965-02-01), Steuber
patent: 3314122 (1967-04-01), Bundy
patent: 3378398 (1968-04-01), Nottebohn et al.
patent: 3509009 (1970-04-01), Hartmann
patent: 3652753 (1972-03-01), Shemdin
patent: 3716317 (1973-02-01), Williams et al.
patent: 3849241 (1974-11-01), Butin et al.
patent: 4118531 (1978-10-01), Hauser

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