US4062993A — Textile and method of making same

Claim 1

Independent Claim 166 words

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 2

Dependent Claim 166 words

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

Dependent Claim 26 words

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

Dependent Claim 23 words

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

Dependent Claim 19 words

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

Claim 6

Independent Claim 153 words

The method of making a heat dissipating fabric which comprises applying a continuous metallic foil over a web of a fabric base, applying a non-woven batt of fibers over said foil and needle punching the resulting composite with barbed needles from one direction only by successively penetrating first the batt, then the foil and finally the base to form fiber masses on the free side of the fabric base and to force fibers from said batt back and forth through spaced apart needle punched apertures in said foil and through said fabric base, said needle punching operating to densify said composite and forming plural mechanical interlocks to securely interlock said fabric base, said foil and said batt together, while maintaining said foil in a sheet-form condition, whereby said foil forms continuous conductive paths in the fabric to conduct heat away from a point of application to said composition for dissipation throughout the composition.

Claim 7

Independent Claim 153 words

The method of making a heat dissipating fabric which comprises applying a continuous metallic foil over a web of a fabric base, applying a non-woven batt of fibers over said foil and needle punching the resulting composite with barbed needles from one direction only by successively penetrating first the batt, then the foil and finally the base to form fiber masses on the free side of the fabric base and to force fibers from said batt back and forth through spaced apart needle punched apertures in said foil and through said fabric base, said needle punching operating to densify said composite and forming plural mechanical interlocks to securely interlock said fabric base, said foil and said batt together, while maintaining said foil in a sheet-form condition, whereby said foil forms continuous conductive paths in the fabric to conduct heat away from a point of application to said composition for dissipation throughout the composition.

Claim 8

Dependent Claim 25 words

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

Dependent Claim 22 words

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

Dependent Claim 18 words

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

Claim 11

Dependent Claim 14 words

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

Claim 12

Dependent Claim 52 words

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

Dependent Claim 295 words

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

Dependent Claim 295 words

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

Dependent Claim 39 words

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

Dependent Claim 26 words

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.

Claim 17

Independent Claim 236 words

The method of making a composite fire retardant fabric article which includes the steps of interposing a foil part made of a thin initially continuous sheet-form conductive material between a base part made of fabric and a batt part made of loose fibers to form a sandwich laminate initially of many times the thickness of the finished fabric article, mechanically interlocking the laminate by needling the sandwich with successive punching strokes from only one direction, during each said punching stroke successively penetrating first the batt to displace and draw fibers from the batt, then penetrating the foil, and then penetrating the fabric base, throughout said needle punching stroke and during each such successive penetrations continuing to draw the fibers displaced from the batt through a plurality of spaced apart needle punched apertures in the foil to thereby form and leave fiber masses at the fabric base, pulling back a portion of the thus formed fiber masses by retracting a number of fiber strands during a return needle stroke in an opposite direction through said same apertures in the foil to thereby pull some of the displaced fiber strands back through the fabric base, the foil and the loose fiber batt, and spacing the punching strokes sufficiently to leave unbroken thermal conductivity paths extending throughout the composite article, whereby there is formed a mechanically interlocked densified unitary fabric article of conductive foil, fabric base and fiber batt.

Claim 18

Independent Claim 236 words

The method of making a composite fire retardant fabric article which includes the steps of interposing a foil part made of a thin initially continuous sheet-form conductive material between a base part made of fabric and a batt part made of loose fibers to form a sandwich laminate initially of many times the thickness of the finished fabric article, mechanically interlocking the laminate by needling the sandwich with successive punching strokes from only one direction, during each said punching stroke successively penetrating first the batt to displace and draw fibers from the batt, then penetrating the foil, and then penetrating the fabric base, throughout said needle punching stroke and during each such successive penetrations continuing to draw the fibers displaced from the batt through a plurality of spaced apart needle punched apertures in the foil to thereby form and leave fiber masses at the fabric base, pulling back a portion of the thus formed fiber masses by retracting a number of fiber strands during a return needle stroke in an opposite direction through said same apertures in the foil to thereby pull some of the displaced fiber strands back through the fabric base, the foil and the loose fiber batt, and spacing the punching strokes sufficiently to leave unbroken thermal conductivity paths extending throughout the composite article, whereby there is formed a mechanically interlocked densified unitary fabric article of conductive foil, fabric base and fiber batt.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1980-12-12	1981-06-13	1981-12-13	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1984-12-12	1985-06-13	1985-12-13	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1988-12-12	1989-06-13	1989-12-13	$7700.00	Window Closed / Lapsed

Textile and method of making same

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