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WO2022266463A1 - Amas de fibres de rembourrage et leurs procédés de fabrication - Google Patents

Amas de fibres de rembourrage et leurs procédés de fabrication Download PDF

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Publication number
WO2022266463A1
WO2022266463A1 PCT/US2022/034022 US2022034022W WO2022266463A1 WO 2022266463 A1 WO2022266463 A1 WO 2022266463A1 US 2022034022 W US2022034022 W US 2022034022W WO 2022266463 A1 WO2022266463 A1 WO 2022266463A1
Authority
WO
WIPO (PCT)
Prior art keywords
fibers
fiberfill
bundle
discrete
cluster
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2022/034022
Other languages
English (en)
Inventor
Robert Dempsey
Vanessa Mason
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Primaloft Inc
Original Assignee
Primaloft Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Primaloft Inc filed Critical Primaloft Inc
Priority to CN202280052418.XA priority Critical patent/CN117716080A/zh
Priority to JP2023577559A priority patent/JP2024529239A/ja
Priority to EP22758288.9A priority patent/EP4355941A1/fr
Priority to CA3222998A priority patent/CA3222998A1/fr
Priority to US18/571,486 priority patent/US20240287717A1/en
Priority to KR1020247001710A priority patent/KR20240021962A/ko
Publication of WO2022266463A1 publication Critical patent/WO2022266463A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
    • D04H1/72—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/02—Cotton wool; Wadding
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4326—Condensation or reaction polymers
    • D04H1/435—Polyesters
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/558—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving in combination with mechanical or physical treatments other than embossing
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres

Definitions

  • Tow refers to a large strand of continuous manufactured fiber filaments without definite twist, collected in loose, rope-like form, usually held together by crimp. Tow typically comprises thousands of filaments.
  • the tow used in U.S. Patent No. 5,851,665 had about 122,000 filaments and a total denier of 48.9 ktex (440,100 denier), which would result in a cluster having high fiber density.
  • the plurality of fibers are synthetic polymeric fibers.
  • the plurality of fibers are fibers selected from polyamide, polyester, polypropylene, polylactic acid (also known as polylactide) (PLA), poly(butyl acrylate) (PBA), acrylic, acrylate, acetate, polyolefin, nylon, rayon, lyocell, aramid, spandex, viscose, and modal fibers, or a combination thereof.
  • the plurality of fibers are polyester fibers.
  • the fibers comprise recycled polymeric material.
  • the plurality of fibers comprise siliconized fibers.
  • the plurality of fibers comprise non-siliconized fibers.
  • the plurality of fibers comprise solid fibers.
  • the plurality of fibers comprise hollow fibers.
  • some of the plurality of fibers are entangled together. In some such embodiments, less than about 50% of the plurality of fibers are entangled together. In some such embodiments, less than about 25% of the plurality of fibers are entangled together.
  • the plurality of fibers have a denier of about 0.7 to about 1.7.
  • FIG. 4A illustrates a non-bonded fiber bundle for forming a discrete fiber cluster according to an embodiment of the present invention
  • FIG. 17 is a photograph of a top view of another example of a discrete fiber cluster according to the present invention.
  • the disrupting also acts to twist at least some of the disrupted fibers 12 together.
  • the term “twist” and the like is used herein to refer to fibers that cross and extend about or wrap around each other more than once (i.e., twisted fibers cross and extend about or wrap at least one other fiber more than once).
  • less than about 50% of the disrupted fibers 12 are twisted with at least one other fiber.
  • less than about 25% of the disrupted fibers 12 are twisted with at least one other fiber.
  • the fibers are “longitudinally arranged together” refers to fibers running along the same direction as one another, whether straight, twisted, etc.
  • the term includes texturized and nontexturized fibers, and likewise covers the fibers of filament yarn (including intermingled filament yarn having nip portions therein).
  • the intermingled filament yarn shown in FIGS. 27 and 33A, and the bundle shown in FIG. 29 all have fibers that are longitudinally arranged together.
  • the inventive discrete fiberfill clusters may have a density of 0.08 to 0.70 mg/cm 3 (e.g., 0.08, 0.09, 0.10, 0.11, 0.12, 0.13, 0.14, 0.15, 0.16, 0.17, 0.18, 0.19,
  • FIG. 35 is a drawing of an inventive cluster embodiment from a bundle that was cut with the nip at a far end therefrom.
  • the fiberfill cluster is formed from intermingled filament yarn.
  • the fiberfill cluster is formed from texturized intermingled filament yarn, and thus the plurality of fibers in the cluster are texturized.
  • the fiberfill cluster is formed from non- texturized intermingled filament yam, and thus the plurality of fibers in the cluster are non- texturized.
  • At least 90% of the fiberfill clusters (e g., at least 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, or 99.5%) have the same number of fibers therein, or the same number of fibers within ⁇ 10% of the average number of fibers (e.g., ⁇ 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1% of the average number of fibers in the plurality of fiberfill clusters). In some embodiments of the plurality of fiberfill clusters, 100% of the clusters have the same number of fibers therein, or the same number of fibers within ⁇ 10% of the average number of fibers.
  • disrupting the longitudinal arrangement of at least some of the plurality of fibers of the bundle comprises disrupting the longitudinal arrangement of all of the plurality of fibers of the bundle such that none of the plurality of fibers remain longitudinally arranged together.
  • Clause 6 The method according to clause 5, wherein disrupting the longitudinal arrangement of all of the plurality of fibers of the bundle forms at least one inner relatively densely populated three-dimensional region of fibers, and an outer relatively less densely population region of fibers extending three-dimensionally outwardly from the at least one inner relatively densely populated region.
  • Clause 16 The method according to any one of clauses 1 to 14, further comprising, prior to the disrupting, bonding at least some of the plurality of fibers of the bundle together at at least one point along the longitudinal length of the bundle to form at least one bonding point.
  • Clause 28 The method according to any one of clauses 1-23, wherein the plurality of fibers of the bundle extend non-linearly along their longitudinal length.
  • Clause 35 The method according to any one of the preceding clauses, wherein the fiberfill cluster comprises at least one secondary fiber that was not part of the bundle.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Nonwoven Fabrics (AREA)
  • Artificial Filaments (AREA)
  • Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)
  • Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
  • Footwear And Its Accessory, Manufacturing Method And Apparatuses (AREA)

Abstract

L'invention concerne un amas de fibres de rembourrage distinct qui est constitué de plusieurs fibres qui sont enchevêtrées de manière aléatoire les unes avec les autres. Dans les multiples fibres se trouvent 25 à 3600 fibres ayant un denier de 0,2 à 12,0 et une longueur de 8 à 160 mm. Les multiples fibres sont orientées de manière aléatoire et non uniforme les unes par rapport aux autres. Dans l'amas de fibres de rembourrage distinct, il y a : une ou plusieurs régions de fibres à densité relativement forte ayant un premier degré d'enchevêtrement ; et, à proximité de la ou des régions à densité relativement forte, une ou plusieurs régions de fibres à densité relativement moins forte ayant un second degré d'enchevêtrement qui est inférieur au premier degré d'enchevêtrement.
PCT/US2022/034022 2021-06-17 2022-06-17 Amas de fibres de rembourrage et leurs procédés de fabrication Ceased WO2022266463A1 (fr)

Priority Applications (6)

Application Number Priority Date Filing Date Title
CN202280052418.XA CN117716080A (zh) 2021-06-17 2022-06-17 纤维填充簇及其制造方法
JP2023577559A JP2024529239A (ja) 2021-06-17 2022-06-17 繊維充填材クラスター及び同クラスターを製造する方法
EP22758288.9A EP4355941A1 (fr) 2021-06-17 2022-06-17 Amas de fibres de rembourrage et leurs procédés de fabrication
CA3222998A CA3222998A1 (fr) 2021-06-17 2022-06-17 Amas de fibres de rembourrage et leurs procedes de fabrication
US18/571,486 US20240287717A1 (en) 2021-06-17 2022-06-17 Fiberfill clusters and methods of manufacturing same
KR1020247001710A KR20240021962A (ko) 2021-06-17 2022-06-17 파이버필 클러스터 및 이를 제조하는 방법

Applications Claiming Priority (6)

Application Number Priority Date Filing Date Title
US202163211792P 2021-06-17 2021-06-17
US63/211,792 2021-06-17
US202163264426P 2021-11-22 2021-11-22
US63/264,426 2021-11-22
US202263362484P 2022-04-05 2022-04-05
US63/362,484 2022-04-05

Publications (1)

Publication Number Publication Date
WO2022266463A1 true WO2022266463A1 (fr) 2022-12-22

Family

ID=83049720

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2022/034022 Ceased WO2022266463A1 (fr) 2021-06-17 2022-06-17 Amas de fibres de rembourrage et leurs procédés de fabrication

Country Status (7)

Country Link
US (1) US20240287717A1 (fr)
EP (1) EP4355941A1 (fr)
JP (1) JP2024529239A (fr)
KR (1) KR20240021962A (fr)
CA (1) CA3222998A1 (fr)
TW (1) TW202314076A (fr)
WO (1) WO2022266463A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN116986403A (zh) * 2023-08-19 2023-11-03 东莞雅康宁纤维制品有限公司 一种纤维线间隔结团连续加工设备

Citations (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3454422A (en) 1964-03-13 1969-07-08 Du Pont Organopolysiloxane coated filling materials and the production thereof
JPS5756558A (en) * 1980-09-16 1982-04-05 Kuraray Co Padding material and production thereof
JPS5925786A (ja) * 1982-08-02 1984-02-09 株式会社クラレ 詰物用材料の製造法
US4618531A (en) 1985-05-15 1986-10-21 E. I. Du Pont De Nemours And Company Polyester fiberfill and process
US4794038A (en) 1985-05-15 1988-12-27 E. I. Du Pont De Nemours And Company Polyester fiberfill
US5851665A (en) 1996-06-28 1998-12-22 E. I. Du Pont De Nemours And Company Fiberfill structure
JPH11348160A (ja) * 1998-06-08 1999-12-21 Gifu Prefecture 繊維強化基材及びその製造方法並びに繊維強化材料及びその製造方法
US6329051B1 (en) 1999-04-27 2001-12-11 Albany International Corp. Blowable insulation clusters
US6613431B1 (en) 2002-02-22 2003-09-02 Albany International Corp. Micro denier fiber fill insulation
US20150007924A1 (en) * 2012-02-24 2015-01-08 Larsen Production Aps Method for production of fibre fill
WO2017058986A1 (fr) 2015-09-29 2017-04-06 Primaloft, Inc. Isolation à flocons soufflable et son procédé de préparation
US20180313001A1 (en) 2015-11-17 2018-11-01 Primaloft, Inc. Synthetic fiber containing aerogel and polymer material, and methods of making and articles comprising the same
US20200141029A1 (en) 2017-11-15 2020-05-07 Primaloft, Inc. Reduced density synthetic fiber utilizing hollow microcapsules

Patent Citations (14)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3454422A (en) 1964-03-13 1969-07-08 Du Pont Organopolysiloxane coated filling materials and the production thereof
JPS5756558A (en) * 1980-09-16 1982-04-05 Kuraray Co Padding material and production thereof
JPS5925786A (ja) * 1982-08-02 1984-02-09 株式会社クラレ 詰物用材料の製造法
US4618531A (en) 1985-05-15 1986-10-21 E. I. Du Pont De Nemours And Company Polyester fiberfill and process
US4794038A (en) 1985-05-15 1988-12-27 E. I. Du Pont De Nemours And Company Polyester fiberfill
US5851665A (en) 1996-06-28 1998-12-22 E. I. Du Pont De Nemours And Company Fiberfill structure
JPH11348160A (ja) * 1998-06-08 1999-12-21 Gifu Prefecture 繊維強化基材及びその製造方法並びに繊維強化材料及びその製造方法
US6329051B1 (en) 1999-04-27 2001-12-11 Albany International Corp. Blowable insulation clusters
US6613431B1 (en) 2002-02-22 2003-09-02 Albany International Corp. Micro denier fiber fill insulation
US20150007924A1 (en) * 2012-02-24 2015-01-08 Larsen Production Aps Method for production of fibre fill
WO2017058986A1 (fr) 2015-09-29 2017-04-06 Primaloft, Inc. Isolation à flocons soufflable et son procédé de préparation
US10633244B2 (en) 2015-09-29 2020-04-28 Primaloft, Inc. Blowable floccule insulation and method of making same
US20180313001A1 (en) 2015-11-17 2018-11-01 Primaloft, Inc. Synthetic fiber containing aerogel and polymer material, and methods of making and articles comprising the same
US20200141029A1 (en) 2017-11-15 2020-05-07 Primaloft, Inc. Reduced density synthetic fiber utilizing hollow microcapsules

Non-Patent Citations (2)

* Cited by examiner, † Cited by third party
Title
BAYKAL ET AL.: "The effects of intermingling process parameters and number of filaments on intermingled", THE JOURNAL OF THE TEXTILE INSTITUTE, 2013
MIAO ET AL.: "Air interlaced yarn structure and properties", TEXTILE RESEARCH JOURNAL, vol. 65, 1995, pages 433 - 440

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN116986403A (zh) * 2023-08-19 2023-11-03 东莞雅康宁纤维制品有限公司 一种纤维线间隔结团连续加工设备

Also Published As

Publication number Publication date
US20240287717A1 (en) 2024-08-29
CA3222998A1 (fr) 2022-12-22
JP2024529239A (ja) 2024-08-06
TW202314076A (zh) 2023-04-01
KR20240021962A (ko) 2024-02-19
EP4355941A1 (fr) 2024-04-24

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