# US 8,541,076 B2 · Stretchable high-loft flat-tube structure from continuous filaments

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- Number: US 8,541,076 B2
- Document ID: US8541076B2
- Status: Granted
- Kind: B2
- Application number: 10/751,910
- Filed: 2004-01-07
- Published: 2005-07-07
- Granted: 2013-09-24
- Earliest claimed: 2004-01-07
- Assignees: V.F.T. Inc.
- Applicants: Tomas Jung-Fu Chien
- Inventors: Tomas Jung-Fu Chien
- Web page: https://patentgrep.com/patent/US8541076B2

## CPC

- D04H 3/02: characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
- Y10T 428/13: Hollow or container type article [e.g., tube, vase, etc.]
- Y10T 428/1303: Paper containing [e.g., paperboard, cardboard, fiberboard, etc.]
- Y10T 428/1321: Polymer or resin containing [i.e., natural or synthetic]
- Y10T 428/1352: Polymer or resin containing [i.e., natural or synthetic]
- Y10T 428/1359: Three or more layers [continuous layer]
- Y10T 428/139: Open-ended, self-supporting conduit, cylinder, or tube-type article
- 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

Improved batts for sleeping bags, insulated apparel, bedding, and other uses are made from a tow of crimped continuous filaments by a machine and process which spreads, extends, and wraps the tow into an endless flat-tube structure with desired uniformity, balanced tensile strength, dimensional stability, stretchability, and high loft.

## Claims

### Claim 1

A substantially uniform flat-tube batt structure comprising at least one crimped and widened helically wrapped continuous filaments tow band.

### Claim 2 (depends on 1)

The flat-tube batt structure of claim 1, comprising a single crimped and widened continuous filaments tow band which overlaps on the adjacent wrapped tow band.

### Claim 3 (depends on 2)

The flat-tube structure of claim 2, wherein the widened tow band has a width of 2 meters.

### Claim 4 (depends on 1)

The flat-tube structure of claim 1, wherein the filaments are substantially parallel and at an angle of 30 to 60° with the longitudinal axis of the flat-tube batt.

### Claim 5 (depends on 1)

The flat-tube structure of claim 1, comprising multiple crimped and widened continuous filaments tow bands.

### Claim 6 (depends on 1)

The flat-tube structure of claim 1, comprising multiple widened continuous filaments tow bands which overlap.

### Claim 7 (depends on 6)

The flat-tube structure of claim 6, wherein the filaments in each widened tow band are substantially parallel, and are at an angle of 30 to 60 with the longitudinal axis of the flat-tube and form a fiber orientation between the widened overlapping bands of from 60 to 120°.

### Claim 8 (depends on 7)

The flat-tube structure of claim 7, wherein the angle with the longitudinal axis is about 45° and the fiber orientation between widened overlapping band layers is about 90°.

### Claim 9 (depends on 5)

The flat-tube structure of claim 5, wherein the each tow band has essentially the same thickness, density, and continuity across the width of the tow band.

### Claim 10 (depends on 6)

The flat-tube structure of claim 6, wherein the tow bands contain separated small bundles which form gaps in the flat-tube structure.

### Claim 11 (depends on 7)

The flat-tub structure of claim 7, wherein the tow bands each have 100,000 filaments and a total denier of 600,000.

### Claim 12 (depends on 1)

The flat-tube structure of claim 1, comprising multiple widened continuous filaments tow bands which overlap on the adjacent wrapped tow bands.

### Claim 13 (depends on 1)

The flat-tube structure of claim 1, which is stretchable.