Patent US3908057A successfully refreshed from Google Patents.
US3908057A
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US
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Fabric with thin surface matrix and method for production thereof
Assignee: CHATHAM MANUFACTURING Inc
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Filing: 1973-10-03
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Granted: 1975-09-23
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Expires: 1993-10-03
Abstract
Abstract There is provided a textile fabric having a fiber/polymer surface matrix composed of segments of fibers closely packed together in random arrangement. The surface matrix lies substantially parallel to the face surface of the fabric. Fibers having segments thereof in the surface matrix also have segments which are rooted and bound in the body of the fabric. Segments of fibers in the surface matrix are bonded together by polymeric resin disposed essentially only in the surface matrix and being in an amount such that the surface matrix has a predominately fibrous character. In the preferred method, a textile fabric with upstanding fiber segments is moved relative to a thin blade and a viscous polymeric liquid is applied near the nip between the blade and the fabric. Pressure is applied to the blade to mechanically work the upstanding fibers and remove excess liquid from the fabric. Thereafter, the polymeric liquid is set while pressing the face surface of the fabric. The dense, intensely entangled, fiber network classifies the product as a reticular shoe upper material.
Inventors
- 👤 Ii Alexander M Smith
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-09 01:22
CPC Classifications
D; D04; D04H; D04H1/00; D04H1/40; D04H1/44; D04H1/46; D04H1/48; Y; Y10; Y10T; Y10T428/00; Y10T428/24; Y10T428/24355; Y10T428/24438; Y10T428/24479; Y10T428/24612
Claims Analysis
Total Claims: 53
Claim 1
Independent Claim
182 words
A FRABIC COMPRISING TEXTILE FIBERS FORMING A BODY OF A NEEDLED FABRIC, A FACE SURFACE ON THE BODY OF THE FABRIC HAVING SURFACE FIBERS AND SEGMENTS OF A PLURALITY INDIVIDUAL FIBERS CONTAINED IN A SURFACE MATRIX, THE SURFACE MATRIX BEING DISPOSED ON THE FACE SURFACE AND BEING SUBSTANTIALLY PARALLEL THERETO, THE SEGMENTS OF THE INDIVIDUAL FIBERS IN THE SURFACE MATRIX BEING CLOSELY PACKED TOGETHER AND IN RANDOM ARRANGEMENT SO THAT FIBERS CROSS OVER OTHER FIBERS BUT THE FIBERS ARE IN PLANES SUBSTANTIALLY PARALLEL TO THE PLANE OF THE SURFACE MATRIX, OTHER SEGMENTS OF THE INDIVIDUAL FIBERS BEING ROOTED AND BOND IN THE BODY OF THE FABRIC, THE SEGMENTS OF THE FIBERS CONTAINED IN THE SURFACE MATRIX BEING BONDED TOGETHER, AT LEAST AT CROSS-OVER POINTS, BY A POLYMERIC RESIN WHICH IS DESPOSED ESSENTIALLY ONLY IN THE SURFACE MATRIX AND THE AMOUNT OF THE POLYMERIC RESIN BEING SUCH THAT THE SURFACE MATRIX HAS A PREDOMINATELY FIBROUS CHARACTER, AND WHEREIN THE BODY OF THE TEXTILE FABRIC IS CHARACTERIZED BY HIGHLY ENTANGLED FIBERS AND AN OVERALL BULK DENSITY OF AT LEAST 8 POUNDS OER CUTIC FOOT.
Claim 2
Dependent Claim
182 words
A FRABIC COMPRISING TEXTILE FIBERS FORMING A BODY OF A NEEDLED FABRIC, A FACE SURFACE ON THE BODY OF THE FABRIC HAVING SURFACE FIBERS AND SEGMENTS OF A PLURALITY INDIVIDUAL FIBERS CONTAINED IN A SURFACE MATRIX, THE SURFACE MATRIX BEING DISPOSED ON THE FACE SURFACE AND BEING SUBSTANTIALLY PARALLEL THERETO, THE SEGMENTS OF THE INDIVIDUAL FIBERS IN THE SURFACE MATRIX BEING CLOSELY PACKED TOGETHER AND IN RANDOM ARRANGEMENT SO THAT FIBERS CROSS OVER OTHER FIBERS BUT THE FIBERS ARE IN PLANES SUBSTANTIALLY PARALLEL TO THE PLANE OF THE SURFACE MATRIX, OTHER SEGMENTS OF THE INDIVIDUAL FIBERS BEING ROOTED AND BOND IN THE BODY OF THE FABRIC, THE SEGMENTS OF THE FIBERS CONTAINED IN THE SURFACE MATRIX BEING BONDED TOGETHER, AT LEAST AT CROSS-OVER POINTS, BY A POLYMERIC RESIN WHICH IS DESPOSED ESSENTIALLY ONLY IN THE SURFACE MATRIX AND THE AMOUNT OF THE POLYMERIC RESIN BEING SUCH THAT THE SURFACE MATRIX HAS A PREDOMINATELY FIBROUS CHARACTER, AND WHEREIN THE BODY OF THE TEXTILE FABRIC IS CHARACTERIZED BY HIGHLY ENTANGLED FIBERS AND AN OVERALL BULK DENSITY OF AT LEAST 8 POUNDS OER CUTIC FOOT.
Claim 3
Dependent Claim
22 words
The fabric of claim 1 wherein the segments of the individual fibers and the polymeric resin are fused into the surface matrix.
Claim 4
Dependent Claim
11 words
The fabric of claim 2 wherein the fusion is heat fusion.
Claim 5
Dependent Claim
11 words
The fabric of claim 3 wherein the polymeric resin is cured.
Claim 6
Dependent Claim
15 words
The fabric of claim 4 wherein the resin has become further polymerized or cross linked.
Claim 7
Dependent Claim
14 words
The fabric of claim 1 wherein the surface matrix has a pattern embossed therein.
Claim 8
Dependent Claim
13 words
The fabric of claim 6 wherein a finish is on the surface matrix.
Claim 9
Dependent Claim
12 words
The fabric of claim 7 wherein the finish is a leather finish.
Claim 10
Dependent Claim
16 words
The fabric of claim 1 wherein the surface fibers are at least in part cut fibers.
Claim 11
Dependent Claim
24 words
The fabric of claim 9 wherein the polymeric resin is at least in part disposed in and around the surface of the cut fibers.
Claim 12
Dependent Claim
15 words
The fabric of claim 10 wherein the cut fibers are pressed into the surface matrix.
Claim 13
Dependent Claim
29 words
The fabric of claim 1 wherein the length of the segments of the fibers in the surface matrix is at least equal to the thickness of the surface matrix.
Claim 14
Dependent Claim
22 words
The fabric of claim 12 wherein the said length is at least one and one-half time the thickness of the surface matrix.
Claim 15
Dependent Claim
20 words
The fabric of claim 13 wherein the said length is at least two times the thickness of the surface matrix.
Claim 16
Dependent Claim
22 words
The fabric of claim 1 wherein these are at least 2,000 segments of individual fibers per square centimeter in the surface matrix.
Claim 17
Dependent Claim
29 words
The fabric of claim 15 wherein the surface matrix has a thickness no greater than that equal to the thickness of ten fiber diameters contained in the surface matrix.
Claim 18
Dependent Claim
22 words
The fabric of claim 1 wherein these are at least 4,000 segments of individual fibers per square centimeter in the surface matrix.
Claim 19
Dependent Claim
29 words
The fabric of claim 17 wherein the surface matrix has a thickness no greater than that equal to the thickness of six fibers diameters contained in the surface matrix.
Claim 20
Dependent Claim
25 words
The fabric of claim 1 wherein the majority of the segments of individual fibers cross over the segment of at least one other individual fiber.
Claim 21
Dependent Claim
27 words
The fabric of claim 19 wherein at least 75 percent of the segments of individual fibers cross over the segment of at least one other individual fiber.
Claim 22
Dependent Claim
27 words
The fabric of claim 1 wherein the fabric has a bulk density gradient in which the bulk density increases from the back surface to the face surface.
Claim 23
Dependent Claim
29 words
The fabric of claim 21 wherein the fabric has an axis of flexure which lies within about 0.3 of the distance from the face surface to the back surface.
Claim 24
Dependent Claim
24 words
THE FABRIC OF CLAIM 1 WHEREIN THE BODY OF THE FABRIC HAS FIBERS WHICH ARE ORIENTED INTO CLOSELY SPACED ROWS OF FIBER CHAIN ENTANGLEMENT.
Claim 25
Dependent Claim
21 words
The fabric of claim 1 wherein the overall bulk density of the fabric is at least 8 pounds per cubic foot.
Claim 26
Dependent Claim
21 words
The fabric of claim 1 wherein the overall bulk density of the structure is at least 12 pounds per cubic foot.
Claim 27
Dependent Claim
28 words
The fabric of claim 1 wherein the fabric has open interstices between the fibers in the body of the fabric and the interstices have a filler impregnated therein.
Claim 28
Dependent Claim
17 words
The fabric of claim 26 wherein the filler is an elastomer in the form of solid particles.
Claim 29
Dependent Claim
25 words
The fabric of claim 27 wherein the elastomer particles are in clusters of particles which are predominantly loosely bonded to the fibers of the fabric.
Claim 30
Dependent Claim
26 words
The fabric of claim 28 wherein the impregnated elastomer is in an amount sufficient to fill all of the interstices between the fibers of the structure.
Claim 31
Dependent Claim
21 words
The fabric of claim 29 wherein the bulk density of said fabric is between 20 and 45 pounds per cubic foot.
Claim 32
Independent Claim
316 words
A method for producing a fabric with a fiber/polymer matrix disposed essentially only on a surface of the body of the fabric comprising: a. providing a needled textile fabric having a face surface with a plurality of upper surface fibers and individual fibers wherein a relatively short segment of the individual fibers protrudes and upstands from the body of the fabric, and another segment of the individual fibers is rooted and bound in the body of the fabric; b. causing relating movement between the fabric and a blade in contact with the surface of the fabric; c. applying a viscous liquid with a viscosity of at least 2,000 cp to the surface of the fabric prior to the point of contact between the surface of the fabric and the blade; d. applying a pressure to the surface of the fabrIc by the blade wherein the pressure is at least 1/2 pound per linear inch of the length of the blade and sufficient that the upstanding fibers are mechanically worked and the pressure action of the blade is sufficiently close in time to the application of the viscous liquid as to not allow the viscous liquid to essentially pass through the upstanding fibers and surface fibers and penetrate into the body of the fabric and the viscous liquid is caused to essentially only coat surfaces of the upstanding fibers and surfaces of the upper surface fibers and excess liqiud is removed from the fabric; e. adjusting the point of application of the viscous liquid to the fabric and the rate of movement of the fabric whereby the viscous liquid does not substantially penetrate into the body of the fabric; and f. setting the viscous liquid while pressing the face surface; and wherein the body of the textile fabric is characterized by highly entangled fibers and an overall bulk density of at least 8 pounds per cubic foot.
Claim 33
Independent Claim
316 words
A method for producing a fabric with a fiber/polymer matrix disposed essentially only on a surface of the body of the fabric comprising: a. providing a needled textile fabric having a face surface with a plurality of upper surface fibers and individual fibers wherein a relatively short segment of the individual fibers protrudes and upstands from the body of the fabric, and another segment of the individual fibers is rooted and bound in the body of the fabric; b. causing relating movement between the fabric and a blade in contact with the surface of the fabric; c. applying a viscous liquid with a viscosity of at least 2,000 cp to the surface of the fabric prior to the point of contact between the surface of the fabric and the blade; d. applying a pressure to the surface of the fabrIc by the blade wherein the pressure is at least 1/2 pound per linear inch of the length of the blade and sufficient that the upstanding fibers are mechanically worked and the pressure action of the blade is sufficiently close in time to the application of the viscous liquid as to not allow the viscous liquid to essentially pass through the upstanding fibers and surface fibers and penetrate into the body of the fabric and the viscous liquid is caused to essentially only coat surfaces of the upstanding fibers and surfaces of the upper surface fibers and excess liqiud is removed from the fabric; e. adjusting the point of application of the viscous liquid to the fabric and the rate of movement of the fabric whereby the viscous liquid does not substantially penetrate into the body of the fabric; and f. setting the viscous liquid while pressing the face surface; and wherein the body of the textile fabric is characterized by highly entangled fibers and an overall bulk density of at least 8 pounds per cubic foot.
Claim 34
Dependent Claim
16 words
The method of claim 31 wherein the said surface is provided by cutting the textile fabric.
Claim 35
Dependent Claim
18 words
The method of claim 32 wherein the cutting is substantially parallel to the surface of the textile fabric.
Claim 36
Dependent Claim
10 words
The method of claim 33 wherein the surface is sanded.
Claim 37
Dependent Claim
25 words
The method of claim 31 wherein the body of the textile fabric has an overall bulk density of at least 12 lbs. per cubic foot.
Claim 38
Dependent Claim
13 words
The method of claim 31 wherein the viscous liquid contains a curable resin.
Claim 39
Dependent Claim
28 words
The method of claim 31 wherein the pressure between the blade and the fabric is up to 10 pounds per linear inch of the length of the blade.
Claim 40
Dependent Claim
24 words
The method of claim 31 wherein the blade is also moved in a direction substantially transverse to the direction of movement of the fabric.
Claim 41
Dependent Claim
12 words
The method of claim 31 wherein a plurality of blades are used.
Claim 42
Dependent Claim
29 words
The method of claim 31 wherein a pool of liquid is maintained on the fabric at a depth sufficient to at least inundate the contact tip of the blade.
Claim 43
Dependent Claim
29 words
The method fo claim 31 wherein a resilient pressure support is disposed next to the side of the fabric which is not contacted by the tip of the blade.
Claim 44
Dependent Claim
87 words
The method of claim 31 wherein the textile fabric is characterized by, coherent fiber entanglement, and a controlled axis of flexure and with a face surface and a back surface, said structure having an overall bulk density of at least 8 pounds per cubic foot and a bulk density gradient in which the bulk density increases from the back surface to the face surface and the axis of flexure of the structure lies within about 0.3 of the distance from the face surface to the back surface.
Claim 45
Dependent Claim
34 words
The method of claim 31 wherein the coherent fiber entanglement of said structure includes orienting some of the fibers into closely spaced rows of fiber chain entanglement, the rows extending lengthwise of the structure.
Claim 46
Dependent Claim
21 words
The method of claim 31 wherein the overall bulk density of the structure is at least 12 pounds per cubic foot.
Claim 47
Dependent Claim
23 words
The method of claim 31 wherein the textile fabric has open interstices between the fibers and the interstices have a filler impregnated therein.
Claim 48
Dependent Claim
17 words
The method of claim 45 wherein the filler is an elastomer in the form of solid particles.
Claim 49
Dependent Claim
25 words
The method of claim 46 wherein the elastomer particles are in clusters of particles which are predominantly loosely bonded to the fibers of the fabric.
Claim 50
Dependent Claim
26 words
The method of claim 49 wherein the impregnated elastomer is in an amount insufficient to fill all of the interstices between the fibers of the fabric.
Claim 51
Dependent Claim
21 words
The method of claim 48 wherein the bulk density of said fabric is between 20 and 45 pounds per cubic foot.
Claim 52
Independent Claim
140 words
A method for producing a needled fabric with a fiber/polymer matrix disposed essentially only on the surface of the body of the fabric comprising providing a needled fabric having a face surface with a plurality of fibers wherein a relatively short segment of indivIdual fibers protrudes and upstands from the body of the fabric and another segment of the individual fibers is rooted and bound in the body of the fabric, applying a polymeric liquid to the face surface of the fabric so that the liquid coats surfaces of the upstanding fibers but does not substantially penetrate into the body of the fabric and setting the polymeric liquid while pressing the face surface and wherein the body of the textile fabric is characterized by highly entangled fibers and an overall bulk density of at least 8 pounds per cubic foot.
Claim 53
Independent Claim
140 words
A method for producing a needled fabric with a fiber/polymer matrix disposed essentially only on the surface of the body of the fabric comprising providing a needled fabric having a face surface with a plurality of fibers wherein a relatively short segment of indivIdual fibers protrudes and upstands from the body of the fabric and another segment of the individual fibers is rooted and bound in the body of the fabric, applying a polymeric liquid to the face surface of the fabric so that the liquid coats surfaces of the upstanding fibers but does not substantially penetrate into the body of the fabric and setting the polymeric liquid while pressing the face surface and wherein the body of the textile fabric is characterized by highly entangled fibers and an overall bulk density of at least 8 pounds per cubic foot.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1978-09-22 | 1979-03-24 | 1979-09-23 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1982-09-22 | 1983-03-24 | 1983-09-23 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1986-09-22 | 1987-03-24 | 1987-09-23 | $7700.00 | Window Closed / Lapsed |