Textile and method of making same

Claim 2

A fabric composition comprising a fabric base, a heat conductive initially continuous sheet-form metal foil overlying said base, a non-woven batt of fibers overlying said metallic foil, and a plurality of mechanical interlocks joining the base, the foil and the batt and more specifically comprising a plurality of tufts of fibers from said batt extending in one direction through said foil through spaced apart needle punched apertures in the foil without impairing the unbroken thermal conductivity continuity of the foil between the apertures, some of said fibers extending back in an opposite direction through the same apertures in the foil, said batt and said foil being mechanically locked to said base solely by said fibers of said batt which have been pushed through said foil and said base to form fiber masses which are locked against the bottom of said base, said foil forming unbroken continuous conductive paths to conduct heat away from a point of application to said composition for dissipation throughout the fabric composition.

Claim 3

The fabric composition of claim 1 in which the fibers in said batt have an average length in the range from 1/2 inch to 6 inches.

Claim 4

The fabric composition of claim 1 in which the thickness of said metallic foil is in the range from 0.0001 to 0.005 inch.

Claim 5

The fabric composition of claim 1 in which said base has a thickness of from 0.005 to 0.050 inch.

Claim 8

The method of claim 5 in which the fibers in said batt have an average length in the range from 1/2 inch to 6 inches.

Claim 9

The method of claim 5 in which the thickness of said metallic foil is in the range from 0.0001 to 0.005 inch.

Claim 10

The method of claim 5 in which said base has a thickness of from 0.005 to 0.050 inch.

Claim 11

The method of claim 5 in which said metal foil is composed of aluminum.

Claim 12

The method of claim 5 in which the fibers in said batt have an average length in the range from 1/2 inch to 6 inches, the thickness of said metallic foil is in the range from 0.0001 to 0.005 inch, and said base has a thickness of from 0.005 to 0.050 inch.

Claim 13

A flame retardant fabric composition comprising a composite article having, a primary base layer composed of fabric and being in the order of about 0.005 to 0.050 inches, in thickness, a sheet-form metallic foil forming a thermally conductive continuous thermal foil layer having one side completely overlying an adjoining side of said base layer and being in the order of about 0.0001 to 0.005 inches in thickness, a fiber batt corresponding in size to the article and having one side overlying the other side of said thermal foil layer, said batt having fibers of a length in the order of from about one-half inch to six inches, a plurality of mechanical interlocks constituting the sole means of interconnecting the base layer, the foil and the batt and more specifically comprising selected fibers from said batt extending in one direction through spaced apart needle punched apertures in said foil layer and through said base layer and forming fiber masses at the opposite side of said base layer, a number of fiber strands from said fiber masses extending back through said needle punched apertures in said foil in an opposite direction to the exposed side of said batt, said selected fibers at said fiber strands forming interlocks for the layers and being disposed in a uniform array of the article at spaced discreet locations to leave unbroken thermal conductivity paths in the foil which extend throughout the entire article between the interlocks, whereby the base layer and the foil layer and the batt are mechanically interlocked by said selected fibers and said fiber strands to form a densified laminate having a thermally conductive intermediate layer forming unbroken conductive paths to conduct heat away from any point of application to said article for dissipation throughout the composite article.

Claim 14

A flame retardant fabric composition comprising a composite article having, a primary base layer composed of fabric and being in the order of about 0.005 to 0.050 inches, in thickness, a sheet-form metallic foil forming a thermally conductive continuous thermal foil layer having one side completely overlying an adjoining side of said base layer and being in the order of about 0.0001 to 0.005 inches in thickness, a fiber batt corresponding in size to the article and having one side overlying the other side of said thermal foil layer, said batt having fibers of a length in the order of from about one-half inch to six inches, a plurality of mechanical interlocks constituting the sole means of interconnecting the base layer, the foil and the batt and more specifically comprising selected fibers from said batt extending in one direction through spaced apart needle punched apertures in said foil layer and through said base layer and forming fiber masses at the opposite side of said base layer, a number of fiber strands from said fiber masses extending back through said needle punched apertures in said foil in an opposite direction to the exposed side of said batt, said selected fibers at said fiber strands forming interlocks for the layers and being disposed in a uniform array of the article at spaced discreet locations to leave unbroken thermal conductivity paths in the foil which extend throughout the entire article between the interlocks, whereby the base layer and the foil layer and the batt are mechanically interlocked by said selected fibers and said fiber strands to form a densified laminate having a thermally conductive intermediate layer forming unbroken conductive paths to conduct heat away from any point of application to said article for dissipation throughout the composite article.

Claim 15

A composite article as defined in claim 11 and a supplemental backing material bonded thereto which supplemental backing material is selected from the class consisting of latex, foam rubber, foamed flexible polyurethane, foamed polyvinyl chloride, and resilient type material.

Claim 16

A composite article as defined in claim 11 and carpet tufting integrated with said article so that said article forms the primary back for the carpet.