E.i. Dupont De Nemours and Company

Ilan Marcus

Adrian C Snyder

William J Jones, Jr

James F Kirkbride

Walter B Halm

Gennadii M Lukovkin

Nikolai P Bakeev

John S Ahn

Nikolai A Shitov

Bernhard E Vanissum

Fritz Brakelmann

Alexandr L Volynskii

Anatolii E Mikushev

The present invention relates to surface modified staple fiber, and more particularly, polyester fiberfill and fiber clusters which are made by a completely coupled bulked continuous filament (BCF) process.

Staple fibers produced by a bulked continuous filament process and fiber clusters made from such fibers

A process of preparing new down-like clusters employs a method of point-bonding thermoplastic cut fibers in a stack of webs of carded fibers or continuous filaments in a tow, and then cutting and separating the resulting clusters which have an entirely different structure that is refluffable. Ultrasonic bonding has worked well as the bonding method, but other methods may prove useful.

Fiberfill structure

A process of imbibition drawing is improved by a pretreatment that preferably involves straining an undrawn filament bundle, or other elongated shaped undrawn or partially drawn synthetic polymeric article, while wetted with a cracking agent, before incorporating a desired additive by imbibition drawing, thereby increasing the imbibition capacity of the article, and improved articles incorporating such additives. Alternatively or in addition the pretreatment involves polarizing irradiation, before imbibition drawing.

Imbibition process

Fiberballs have been prepared from mechanically-crimped fibers having both a primary crimp and a secondary crimp with specific configurations, especially amplitudes and frequencies. The fiberballs may contain a proportion of other fibers, particularly binder fibers, and used for making molded structures.

Fillings and other aspects of fibers

Fiberballs are prepared from mechanically-crimped fibers having both a primary crimp and a secondary crimp with specific configurations, especially amplitudes and frequencies. The fiberballs may contain a proportion of other fibers, particularly binder fibers.

Process for preparing fiberballs

In a batch process for repetitive molding of fiberballs into cushions that are required in the same specific shape in large numbers, the molds are filled continuously by means such as a chute.

Method of making bonded non-woven polyester fiber structures using

A batch process and apparatus are provided for molding fiberballs, comprising load-bearing fibers and binder fibers, into shaped articles, preferably using hot air within a perforated mold to allow circulation of the air through the fiberballs. The techniques are particularly adapted to molding cushions of varying shapes and sizes, without excessive wastage of material, using relatively simple flexible equipment.

Bonded non-woven polyester fiber structures

Fiberballs for filling uses have been prepared from mechanically-crimped fibers having both a primary crimp and a secondary crimp with specific configurations, especially amplitudes and frequencies. The fiberballs may contain a proportion of other fibers, particularly binder fibers.

A process is provided with apparatus for molding fiberballs into bonded polyester fiber structures in a continuous line system, whereby novel structures may be economically provided with advantages over bonded batts.

Relating to bonded non-woven polyester fiber structures

Blends of polyester fiberfill and binder fiber, wherein the fiberfill is coated with a hydrophilic poly(alkylene oxide) type finish that cures on to the polyester fibers and so provides improved properties in the eventual bonded product, including combinations of improved durability, soft hand, good bonding, reduced flammability and improved moisture transport.

Polyester fiberfill

Polyester fiberfill having spiral crimp that is randomly-arranged and entangled in the form of fiberballs with binder fibers, preferably with a minimum of hairs extending from the surface of the fiberballs, so as to be air-transportable on account of the low cohesion between the balls. A process for making such fiberballs by repeatedly air-tumbling small tufts of such fiberfill/binder/blend against the wall of a vessel. Improved bonded batts or molded articles or other bonded articles obtained by bonding such fiberballs.

Polyester fiberfill having spiral-crimp that is randomly-arranged and entangled in the form of fiberballs with a minimum of hairs extending from their surface, and having a refluffable characteristic similar to that of down on account of the low cohesion between the balls. A process for making such fiberballs by repeatedly air-tumbling small tufts of such fiberfill against the wall of a vessel.

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Versoix, Switzerland

Ilan Marcus