Textile fiber batting substitution for foam structures
AssigneeDavid C. Poole Company, Inc.
InventorRobert Alton Usher, JR.
Life of this patent
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Abstract
A textile cushioning batting for use in furniture and the like having a high degree of loft and rebound is disclosed comprising: a non-woven blended batting comprising a major portion of a fine denier fiber and a minor portion of a coarse denier fiber. The fibers have increased crimping amplitudes, secondary crimping, sharper crimp and optimized crimps per inch. A low melt binds fiber binding the fine and coarse denier fibers together in the batting; and a sufficient number of the fibers being heat are bonded together at their intersections to provide a high loft resilient batting for cushioning.
Claims20
A textile cushioning batting for use in furniture and the like having a high degree of loft and rebound comprising:
- a non-woven blended batting comprising a major portion of a fine denier fiber and a minor portion of a coarse denier fiber,
- said fibers having increased crimping amplitudes, secondary crimping, sharper crimp and optimized crimps per inch,
- a low melt binder fiber binding said fine and coarse denier fibers together in said batting;
- and
- a sufficient number of said fibers being heat bonded together at their intersections to provide a resilient batting.
A textile batting for use as a cushioning material in furniture and the like comprising a fiber blend comprising 20% to 50% coarse fibers and 50% to 80% finer fibers;
- said coarse fibers having denier of 35 to 70 and said finer fibers having a denier of 10 to 20;
- and a low melt fiber melted in said fiber blend for binding and reinforcing said fiber blend.
A process for producing a textile batting of blended non-woven polymeric fibers for use as a cushion in furniture and the like comprising the steps of:
- blending a minor portion of coarse fibers and a major portion of finer fibers;
- blending said coarse fibers with fine denier fibers to form blended fibers;
- crimping the blended fibers;
- carding the crimped blended fibers to form a web;
- layering a plurality of said webs to form a batting;
- introducing low-melt fibers into said batting;
- applying heat to said batting and low-melt fiber to cause heat bonding at a sufficient number of intersections of said blended fibers to reinforce and provide a three-dimensional, resilient textile cushioning batting.
Dependencies are inferred from the claim text.