E.i. Dupont De Nemours and Company

Wo K Kwok

Michael S Frankosky

Herman H Forsten

James R Vincent

Susan Carol Chamberlin

Donald T Ziesel

Robert Wallace Slavin

A batt, which may be used for a mattress, a seat cushion or a ground pad for a sleeping bag, is compressed so that it has reduced false loft and reduced false support, and is therefore more durable for consumer use. The batt is compressed so that, when subjected to use for an average life cycle (usually six years), it has a thickness reduction of less than 15% and a reduction of load-at-half-height of less than 40%.

Compressed batt having reduced false loft and reduced false support

Lofty battings are prepared by a process involving carding to make one or more webs of fibers, preferably using a blend of mechanically-crimped filling fibers with bicomponent fibers of helical configuration, and that preferably also contains binder fibers, the fiber orientations preferably being randomized in the web(s) before cross-lapping to build up the batt, and preferably followed by spraying with resin and curing, thus providing a bonded batt in which the loft is improved by the presence of the different crimp configurations and/or randomized orientations that are fixed in the fibers in the bonded batt.

Process for lofty battings

An improvement in the sealing of bonded batts of fiberfill is obtained by providing a barrier layer of bonded bicomponent binder fibers on one or both faces of the remainder of the batt to prevent or reduce the tendency of the fiberfill to leak through such faces.

Sealing of bonded batts

Lofty battings are prepared by a process involving carding to make one or more webs of fibers, preferably using a blend of mechanically-crimped filling fibers with bicomponent fibers of helical configuration, and that preferably also contains binder fibers, the fiber orientations preferably being randomized in the web(s) before cross-lapping to build up the batt, and preferably followed by spraying with resin and curing, thus providing a bonded batt in which the loft is improved by the presence or the different crimp configurations and/or randomized orientations that are fixed in the fibers in the bonded batt.

A fire-resistant material used in items such as sleeping bags, comforters, wearing apparel, upholstered furniture and mattress tops comprises a fiberfill batt and a layer of a fire-resistant aramid fiber contacting at least one side of the aramid fiber layer. The fiberfill batt may comprise synthetic fiber, which may be either polyester fiber or polyolefin fiber. Alternatively, the fiberfill batt may comprise natural fiber. The aramid fiber layer may comprise poly(m-phenylene isophthalamide) fiber, poly(p-phenylene terephthalamide) fiber or a blend of poly(m-phenylene isophthalamide) and poly(p-phenylene terephthalamide) fiber. The aramid fiber layer may be needle-punched, hydroentangled, or laminated to the fiberfill batt.

Fire-resistant material comprising a fiberfill batt and at least one

Improved polyester fiberfill batts for apparel and other uses are prepared of polyester fiber and binder fiber, sprayed with a soft resin by oven bonding and hot roll treatment. This provides bonded batting which is characterized by softness and drapability, good insulating performance, low levels of fiber leakage or percolation through shell fabrics, enhanced durability when laundered by washing/drying or by dry cleaning, and enhanced structural integrity whereby it hangs freely without the need for quilting into small size panels.

Bonded polyester fiberfill battings with a sealed outer surface

Method of making a bonded batt with low fiber leakage

A process is disclosed for making spunlaced acrylic/polyester fabrics comprising applying low impact water jet energy to a fabric web and vacuum dewatering the resulting spunlaced fabric. The spunlaced fabrics exhibit very low wet and dry particle counts and high absorbency thereby making them particularly useful in cleanroom wiper applications and as coverstock for sanitary napkins, diapers and the like.

Spunlaced acrylic/polyester fabrics

A blend, a batt, and a process for making the batt from the blend is disclosed. The blend and batt are made from a uniform combination of cotton and copolyester binder fibers wherein the binder fibers have a melting temperature of 230.degree. to 340.degree. F.

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Hockessin, DE, United States of America

Wo K Kwok