Molding nonwoven, needle punched fabrics into three dimensional shapes
AssigneeBrunswick Corporation
InventorJoseph C. Benedyk
Life of this patent
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Abstract
Three dimensional shapes, typically of convex-concave form and having sufficient rigidity to maintain that form are molded from nonwoven, needlepunched fabrics containing certain ethylene-vinyl acetate fibers in admixture with fibers of a higher melting point polymer. Molding is accomplished by heating the fabric to a temperature whereat the ethylene-vinyl acetate fibers soften or melt but below the melting point of the other fibers and thereafter pressing the fabric between the mating faces of a mold pair and allowing the ethylene-vinyl acetate fibers to solidify and cool while in the mold.
Claims29
A method for making a three dimensional fabric shape having sufficient rigidity to maintain that shape which comprises:
- forming a nonwoven, needlepunched fabric containing at least 5% by weight of fibers of ethylene-vinyl acetate in admixture with fibers of a higher melting polymer, said ethylene-vinyl acetate fibers having an elastic modulus in excess of 5,000 psi;
- heating the fabric to a temperature above the softening point of said ethylene-vinyl acetate fibers but below the temperature at which the fibers of said higher melting point polymer begin to soften and melt;
- pressing said heated fabric between the faces of a complementary mold pair, and
- allowing the shaped fabric to cool to a temperature below the softening point of said ethylene-vinyl acetate before removing it from the mold.
The method of 3 wherein said ethylene-vinyl acetate fibers comprise a web needled onto the back of a nonwoven, needlepunched, scrimless fabric of a higher melting point fiber.
A three dimensional shaped fabric having sufficient rigidity to maintain that shape comprising a blend of fused ethylene-vinyl acetate fibers with unfused fibers of a higher melting point polymer, said ethylene-vinyl acetate fibers having an elastic modulus in the range of about 5,000 to 60,000 psi and being needled into the back of a nonwoven, needlepunched, scrimless fabric of said higher melting point fibers.
Dependencies are inferred from the claim text.