# US 4,392,903 A · Process for making a thermal-insulating nonwoven bulky product

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- Number: US 4,392,903 A
- Document ID: US4392903A
- Status: Granted
- Kind: A
- Application number: 06/305,377
- Filed: 1981-09-25
- Granted: 1983-07-12
- Earliest claimed: 1980-05-02
- Assignees: Toray Industries, Inc.
- Inventors: Tadakazu Endo; Hirotsugu Suzuki; Masanori Takahashi
- Web page: https://patentgrep.com/patent/US4392903A

## CPC

- D04H 3/03: at random
- A41D 31/06: Thermally protective, e.g. insulating
- A47G 9/0207: {Blankets; Duvets}
- A62B 17/00: Protective clothing affording protection against heat or harmful chemical agents or for use at high altitudes (protective clothing or garments for work or sport A41D13/00; {e.g. overalls A41D13/02, surgical gowns A41D13/12; materials for protecting clothing A41D31/04}; protecting eyes or ears A61F9/00; composition of materials for protective clothing A62D5/00; life-saving garments for use at sea B63C; diving suits B63C11/02; flight suits B64D10/00; space suits B64G6/00; bullet-proof clothing F41H1/02)
- D04H 3/12: with filaments or yarns secured together by chemical or thermo-activatable bonding agents, e.g. adhesives, applied or incorporated in liquid or solid form
- D04H: MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL (weaving D03; knitting D04B; braiding D04C; net-making D04G; sewing D05B; tufting D05C; finishing non-woven fabrics D06); FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING {; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION}(non-woven fabrics having an intermediate or external layer of a different kind, e.g. of woven fabric, B32B)
- A41D: OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
- A47G: HOUSEHOLD OR TABLE EQUIPMENT (book-ends A47B5/00; knives B26B)
- A62B: DEVICES, APPARATUS OR METHODS FOR LIFE-SAVING (valves specially adapted for medical use A61M39/00; life-saving devices, apparatus or methods specially adapted for use in water B63C9/00; divers' equipment B63C11/00; specially adopted for use with aircraft, e.g. parachutes, ejector seats, {B64D17/00, B64D25/10}; rescue devices peculiar to mining E21F11/00)

## Abstract

A process for producing thermal-insulating nonwoven bulky product characterized by its structural make up of substantially continuous single filaments of from about 0.01 to 2 denier which are stabilized on themselves in the product by a surface binder on the filaments.

## Claims

### Claim 1

A process for producing a thermal insulating nonwoven bulky product the steps which comprise
(a) spinning the filaments of a synthetic polymer under fluid pressure,
(b) releasing the spun filaments together with fluid at high velocity for crimping and separating,
(c) crimping and separating the filaments,
(d) spraying the crimped and separated filaments with a binder,
(e) spreading out and accumulating the separated filaments into layers, and
(f) heating the layered filaments to the final product.

### Claim 2 (depends on 1)

The process of claim 1 including drying of the filaments prior to step (f).

### Claim 3 (depends on 1)

The process of claim 1 including folding the filaments directly after step (e).

### Claim 4 (depends on 1)

The process of claim 1 wherein the filaments of step (a) are multifilament and the fluid is air.

### Claim 5 (depends on 1)

The process of claim 1 in which step (a) is carried out by melt-spinning.