# US 4,400,426 A · Thermal insulation material comprising a mixture of silk and synthetic fiber staple

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- Number: US 4,400,426 A
- Document ID: US4400426A
- Status: Granted
- Kind: A
- Application number: 06/317,762
- Filed: 1981-11-03
- Granted: 1983-08-23
- Earliest claimed: 1981-11-03
- Assignees: Warnaco Inc.
- Inventors: William E. Aldrich
- Web page: https://patentgrep.com/patent/US4400426A

## CPC

- B68G 1/00: Loose filling materials for upholstery
- A47G 9/0207: {Blankets; Duvets}
- D04H 1/4266: Natural fibres not provided for in group D04H1/425
- D04H 1/435: Polyesters
- D04H 1/43835: {Mixed fibres, e.g. at least two chemically different fibres or fibre blends}
- D04H 1/43914: {hollow fibres}
- D04H 1/43918: {nonlinear fibres, e.g. crimped or coiled fibres}
- D04H 1/64: the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
- B68G 2001/005: {for pillows or duvets}
- Y10T 428/2907: with coating or impregnation
- Y10T 428/2909: Nonlinear [e.g., crimped, coiled, etc.]
- Y10T 428/2975: Tubular or cellular
- Y10T 442/2008: Fabric composed of a fiber or strand which is of specific structural definition
- Y10T 442/2762: Coated or impregnated natural fiber fabric [e.g., cotton, wool, silk, linen, etc.]
- B68G: METHODS, EQUIPMENT, OR MACHINES FOR USE IN UPHOLSTERING; UPHOLSTERY NOT OTHERWISE PROVIDED FOR
- A47G: HOUSEHOLD OR TABLE EQUIPMENT (book-ends A47B5/00; knives B26B)
- 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)
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

An improved thermal insulation material comprising a carded web containing 30 to 80 wt. %, preferably 50 wt. % silk, the balance being crimped, hollow polyester staple or very low denier solid cross section polyester filaments. The carded web is uniformly impregnated with a thermosetting resin to form a bat which is employed as a filler for garments, sleeping bags and the like.

## Claims

### Claim 1

A thermal insulation material comprising a treated batting, said batting being formed from a carded web, said web containing at least 30 wt. % of natural silk fibers and a synthetic fiber staple, said synthetic fiber staple being formed from crimped polyester filaments having a denier per filament in the range of 1 to 6, said batting being formed by uniformly impregnating said carded web with a thermosetting resin capable of forming a relatively rigid, non-tacky structure after curing.

### Claim 2 (depends on 1)

The material of claim 1 wherein said polyester filaments are hollow.

### Claim 3 (depends on 1)

The material of claim 1 wherein said polyester filaments are solid and have a denier per filament in the range of 1 to 3.

### Claim 4 (depends on 1)

The material of claim 1, wherein said thermosetting resin is trimethylol melamine formaldehyde.

### Claim 5 (depends on 1)

The material of claim 1, wherein the resin constitutes 5 to 10 wt. % of the finished material.

### Claim 6

A thermal insulation material comprising a treated batting, said batting being formed from a carded web, said web being a mixture of 30 to 80 wt. % of natural silk fibers and 70 to 20 wt. % of crimped polyester fiber staple having an average length of 11/8th to 21/2 inches, said polyester fiber staple being formed from hollow filaments having a denier of 3 to 6 per filament, said batting being formed by uniformly impregnating said carded web with a thermosetting resin capable of forming a relatively rigid, non-tacky structure after curing.

### Claim 7 (depends on 6)

The insulation material of claim 6, wherein the thermosetting resin is trimethylol melamine formaldehyde.

### Claim 8 (depends on 7)

The insulation material of claim 7, wherein said thermosetting resin is applied to said webbing as a curable aqueous solution.

### Claim 9 (depends on 7)

The insulating material of claim 7, wherein said formaldehyde resin constitutes 8 wt. %, on a solids basis, of the batting.

### Claim 10

A thermal insulation material comprising a treated batting, said batting being formed from a carded web, said web containing at least 30 wt. % of natural silk fibers and a polyester fiber staple, said polyester fiber staple being formed from filaments having a denier of 1 to 6 per filament, said batting being formed by uniformly impregnating said carded web with trimethylol melamine formaldehyde resin.