Laminated fiber networks
AssigneeHoechst Celanese Corporation
InventorsDai W. Kim, Gerald Peter Rumierz, Clinton Dale Felton
Life of this patent
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Abstract
Laminated fiber network structures having high resilience, good cushioning properties, and excellent impact-resistance include at least one layer of a three-dimensional fiber network material and a second layer, which may be a planar material (e.g. a fabric, film, or sheet) or a second layer of a three-dimensional fiber network material. The surfaces of the two layers face each other and are bonded together at their points of contact. The three-dimensional fiber network material is a fabric made from thermoplastic filaments that are at least 0.1 mm in diameter, where the fabric has an array of projections and optional depressions pushed out of one or both sides of the fabric.
Claims25
A laminated fiber network, comprising:
- (a) a first layer, comprised of a three-dimensional fiber network material;
- wherein said three-dimensional fiber network material is a woven or knit textile fabric having a multiplicity of compressible projections rising above the base plane of said textile fabric, and optionally a multiplicity of compressible depressions extending below the base plane of said textile fabric, said textile fabric comprising thermoplastic filaments having a diameter in the range of about 0.1 mm to about 1.0 mm, said filaments in said fabric crossing over one another at intersections, said filaments at substantially all of said intersections not being bonded to one another in those areas in which said three-dimensional fiber network material is not bonded to other materials;
- wherein said three-dimensional fiber network material has two surfaces, said first surface being defined by the tops of said projections, said second surface being said base plane of said fabric or optionally the surface defined by the tops optional depressions;
- and
- (b) a second layer, comprised of a material selected from the group consisting of a planar material and a three-dimensional fiber network material, which may be the same or different from the three-dimensional fiber network material in said first layer, said second layer having two surfaces;
- wherein one surface of said first layer is bonded to one surface of said second layer at the points at which said surfaces are in contact with each other thereby providing a structure having an increased compression modulus which is also resilient returning substantially to its original height and shape after being compressed to 50% of its height.
A method of making a material having cushioning or impact resistance comprising the steps of:
- (a) making a monofilament having a diameter in the range of about 0.1 mm to about 1 mm from a thermoplastic polymer;
- (b) making said monofilament into a knit, woven, or non-woven textile fabric, said filaments in said fabric crossing over one another at intersections, said filaments at substantially all of said intersections not being bonded to one another;
- (c) making a series of projections and optional depressions in said textile fabric by a thermo-mechanical process to yield a three-dimensional fiber network material;
- and
- (d) bonding a layer of planar material to one or both surfaces of said three-dimensional fiber network material at the points at which said surfaces are in contact with each other,
- thereby providing a structure having an increased compression modulus which is also resilient. returning substantially to its original height and shape after being compressed to 50% of its height.
Dependencies are inferred from the claim text.