US4258093A
Expired / Lapsed
US
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Molding nonwoven, needle punched fabrics into three dimensional shapes
Assignee: Brunswick Corp
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Filing: 1979-04-26
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Granted: 1981-03-24
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Expires: 1999-04-26
Abstract
Abstract Three dimensional shapes, typically of convex-concave form and having sufficient rigidity to maintain that form are molded from nonwoven, needlepunched fabrics containing certain ethylene-vinyl acetate fibers in admixture with fibers of a higher melting point polymer. Molding is accomplished by heating the fabric to a temperature whereat the ethylene-vinyl acetate fibers soften or melt but below the melting point of the other fibers and thereafter pressing the fabric between the mating faces of a mold pair and allowing the ethylene-vinyl acetate fibers to solidify and cool while in the mold.
Inventors
- 👤 Joseph C. Benedyk
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-25 08:04
CPC Classifications
D; D06; D06M; D06M23/00; D06M23/14; B; B29; B29C; B29C51/00; B29C51/002; B29C51/004; Y; Y10; Y10S; Y10S428/00; Y10S428/92; Y10S428/921; Y10T; Y10T428/00; Y10T428/23907; Y10T428/23979
Claims Analysis
Total Claims: 32
Claim 1
Independent Claim
126 words
A method for making a three dimensional fabric shape having sufficient rigidity to maintain that shape which comprises: forming a nonwoven, needlepunched fabric containing at least 5% by weight of fibers of ethylene-vinyl acetate in admixture with fibers of a higher melting polymer, said ethylene-vinyl acetate fibers having an elastic modulus in excess of 5,000 psi; heating the fabric to a temperature above the softening point of said ethylene-vinyl acetate fibers but below the temperature at which the fibers of said higher melting point polymer begin to soften and melt; pressing said heated fabric between the faces of a complementary mold pair, and allowing the shaped fabric to cool to a temperature below the softening point of said ethylene-vinyl acetate before removing it from the mold.
Claim 2
Independent Claim
126 words
A method for making a three dimensional fabric shape having sufficient rigidity to maintain that shape which comprises: forming a nonwoven, needlepunched fabric containing at least 5% by weight of fibers of ethylene-vinyl acetate in admixture with fibers of a higher melting polymer, said ethylene-vinyl acetate fibers having an elastic modulus in excess of 5,000 psi; heating the fabric to a temperature above the softening point of said ethylene-vinyl acetate fibers but below the temperature at which the fibers of said higher melting point polymer begin to soften and melt; pressing said heated fabric between the faces of a complementary mold pair, and allowing the shaped fabric to cool to a temperature below the softening point of said ethylene-vinyl acetate before removing it from the mold.
Claim 3
Dependent Claim
14 words
The method of claim 1 wherein said mold pair defines a generally convex-concave shape.
Claim 4
Dependent Claim
22 words
The method of claim 2 wherein the ratio of ethylene-vinyl acetate fibers to higher melting point fibers ranges from 5:95 to 50:50.
Claim 5
Dependent Claim
23 words
The method of claim 3 wherein said higher melting point fibers are selected from the group consisting of polypropylene, polyamide and mixtures thereof.
Claim 6
Dependent Claim
13 words
The method of claim 4 wherein said higher melting point fibers comprise polypropylene.
Claim 7
Dependent Claim
13 words
The method of claim 4 wherein said higher melting point fibers comprise polyamide.
Claim 8
Dependent Claim
32 words
The method of claim 3 wherein said ethylene-vinyl acetate fibers have an elastic modulus in the range of about 5,000 to 60,000 psi and an ultimate tensile strength above about 5,000 psi.
Claim 9
Dependent Claim
22 words
The method of claim 7 wherein the vinyl acetate content of said ethylene-vinyl acetate is in the range of 5% to 20%.
Claim 10
Dependent Claim
36 words
The method of claim 7 wherein said ethylene-vinyl acetate fibers have dispersed therein one or more additives selected from the group consisting of pigments, fillers and fire retardants in an amount up to 20% by weight.
Claim 11
Dependent Claim
14 words
The method of claim 9 wherein said fire retardant comprises finely divided hydrated magnesia.
Claim 12
Independent Claim
28 words
The method of 3 wherein said ethylene-vinyl acetate fibers comprise a web needled onto the back of a nonwoven, needlepunched, scrimless fabric of a higher melting point fiber.
Claim 13
Independent Claim
28 words
The method of 3 wherein said ethylene-vinyl acetate fibers comprise a web needled onto the back of a nonwoven, needlepunched, scrimless fabric of a higher melting point fiber.
Claim 14
Dependent Claim
13 words
The method of claim 11 wherein said higher melting point fiber comprises polyamide.
Claim 15
Dependent Claim
13 words
The method of claim 11 wherein said higher melting point fiber comprises polypropylene.
Claim 16
Dependent Claim
18 words
The method of claim 11 wherein said fabric of a higher melting point fiber has a pile face.
Claim 17
Dependent Claim
33 words
The method of claim 3 wherein staple fibers of ethylene-vinyl acetate are blended with staple fibers of said higher melting point fiber to form a web which is needlepunched to form a fabric.
Claim 18
Dependent Claim
32 words
The method of claim 3 wherein said fabric is heated to a temperature in the range of about 90° C. to 150° C. and is thereafter pressed to a three dimensional shape.
Claim 19
Dependent Claim
64 words
A three dimensional shaped fabric having sufficient rigidity to maintain that shape comprising a blend of fused ethylene-vinyl acetate fibers with unfused fibers of a higher melting point polymer, said ethylene-vinyl acetate fibers having an elastic modulus in the range of about 5,000 to 60,000 psi and being needled into the back of a nonwoven, needlepunched, scrimless fabric of said higher melting point fibers.
Claim 20
Dependent Claim
64 words
A three dimensional shaped fabric having sufficient rigidity to maintain that shape comprising a blend of fused ethylene-vinyl acetate fibers with unfused fibers of a higher melting point polymer, said ethylene-vinyl acetate fibers having an elastic modulus in the range of about 5,000 to 60,000 psi and being needled into the back of a nonwoven, needlepunched, scrimless fabric of said higher melting point fibers.
Claim 21
Dependent Claim
23 words
The shaped fabric of claim 17 wherein the ratio of ethylene-vinyl acetate fibers to higher melting point fibers ranges from 5:95 to 50:50.
Claim 22
Dependent Claim
24 words
The shaped fabric of claim 18 wherein said higher melting point fiber is selected from the group consisting of polyamide, polypropylene and mixtures thereof.
Claim 23
Dependent Claim
14 words
The shaped fabric of claim 18 wherein said higher melting point fiber is polyamide.
Claim 24
Dependent Claim
14 words
The shaped fabric of claim 18 wherein said higher melting point fiber is polypropylene.
Claim 25
Dependent Claim
37 words
The shaped fabric of claim 18 wherein said ethylene-vinyl acetate fibers have dispersed therein one or more additives selected from the group consisting of pigments, fillers, and fire retardants in an amount up to 20% by weight.
Claim 26
Dependent Claim
11 words
The fabric of claim 18 wherein said shape is generally convex-concave.
Claim 27
Dependent Claim
31 words
The shaped fabric of claim 18 wherein said ethylene-vinyl acetate fibers are in the form of a web which is needled into the back of said higher melting point fiber fabric.
Claim 28
Dependent Claim
24 words
The shaped fabric of claim 24 wherein said higher melting point fiber is selected from the group consisting of polypropylene, polyamide and mixtures thereof.
Claim 29
Dependent Claim
14 words
The shaped fabric of claim 24 wherein said higher melting point fiber comprises polypropylene.
Claim 30
Dependent Claim
14 words
The shaped fabric of claim 24 wherein said higher melting point fiber comprises polyamide.
Claim 31
Dependent Claim
19 words
The shaped fabric of claim 24 wherein said fabric of a higher melting point fiber has a pile face.
Claim 32
Dependent Claim
20 words
The shaped fabric of claim 18 wherein the vinyl acetate content of said ethylene-vinyl acetate ranges from 5% to 20%.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1984-03-23 | 1984-09-22 | 1985-03-24 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1988-03-23 | 1988-09-22 | 1989-03-24 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1992-03-23 | 1992-09-22 | 1993-03-24 | $7700.00 | Window Closed / Lapsed |