# US 4,859,516 A · Mat consisting of filament loop aggregations and method and apparatus for producing the same > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 4,859,516 A - Document ID: US4859516A - Status: Granted - Kind: A - Application number: 07/180,533 - Filed: 1988-04-12 - Granted: 1989-08-22 - Earliest claimed: 1988-02-09 - Assignees: Kabushiki Kaisha Risuron - Inventors: Minoru Yamanaka; Tetsuo Amawa - Web page: https://patentgrep.com/patent/US4859516A ## CPC - B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)} - B32B 5/022: {Non-woven fabric} - B32B 37/153: {at least one layer is extruded and immediately laminated while in semi-molten state} - D04H 3/03: at random - D04H 3/16: with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion - B32B 2307/51: Elastic - B32B 2471/04: Mats - Y10T 428/23957: Particular shape or structure of pile - Y10T 428/23979: Particular backing structure or composition - Y10T 428/23986: With coating, impregnation, or bond - Y10T 428/24992: Density or compression of components - Y10T 428/249922: Embodying intertwined or helical component[s] - Y10T 442/611: Cross-sectional configuration of strand or fiber material is other than circular - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, 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) - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract In this mat consisting of filament loop aggregations, the filament loop aggregations wherein irregular form loops are formed in the upright direction by respectively winding to be coil-like many filaments coarse in the arranging intervals and made of a thermoplastic synthetic resin and are fused in the intersecting parts are overlapped above and below an intermediate filament loop aggregation layer high in the filament density and formed of coiled loops in the partly or all laterally fallen direction. ## Claims ### Claim 1 A mat consisting of filament loop aggregations wherein the filament loop aggregations in which irregular form loops are formed in the upright direction by respectively winding to be coil-like many filaments coarse in the arranging intervals and made of a thermoplastic synthetic resin and are fused in the intersecting parts are overlapped above and below an intermediate filament loop aggregation layer high in the filament density and formed of coiled loops in the partly or all laterally fallen direction. ### Claim 2 (depends on 1) A mat consisting of filament loop aggregations according to claim 1 wherein the diameter of said filament is in the range of 0.3 to 1.5 mm. ### Claim 3 (depends on 1) A mat consisting of filament loop aggregations according to claim 1 wherein the major diameter of said loop is in the range of 3 to 15 mm. ### Claim 4 A method of producing a mat consisting of filament loop aggregations characterized in that, between the first filament loop aggregation forming step wherein many filaments arranged at intervals longitudinally and laterally are continuously molded by extruding a thermoplastic synthetic resin out of a T-die, are present on a cooling water surface boiling as kept by heating at a filament temperature close to the temperature at the time of molding while this filament bundle is vertically lowered toward the cooling water surface and are sunk in the vertical direction as controlled to be at a speed lower than the extruding molding speed of these filaments and the second filament loop aggregation forming step progressing simultaneously with the first step, the aggregation processed in said first step is once pulled up on the water surface, is fed into the filament bundle falling water surface zone in said second step while being heated on one side surface near to the fusing temperature and is formed by making said heated surface a loop forming surface on one side of the filament bundle in said second step. ### Claim 5 (depends on 4) A method of producing a mat consisting of filament loop aggregations according to claim 4 wherein the distance from the lower surface of the T-die to the water surface is in the range of 5 to 10 cm. ### Claim 6 (depends on 4) A method of producing a mat consisting of filament loop aggregations according to claim 4 wherein cooling water held at a temperature of 60.degree. to 80.degree. C. is locally boiled by heating by sinking loops just below the fall of said filaments. ### Claim 7 (depends on 4) A method of producing a mat consisting of filament loop aggregations according to claim 4 wherein about 0.05 to 0.2% surface active agent dialkylsulfosuccinate is added into cooling water. ### Claim 8 (depends on 4) A method of producing a mat consisting of filament loop aggregations according to claim 4 wherein about 0.05 to 0.2% surface active agent dialkylsulfosuccinate is added into cooling water.