US4288484A — Novel fibrous assembly and process for production…

Claim 1

Independent Claim 127 words

A fibrous assembly of many fibers, the individual constituent fibers being interconnected at random in a spaced-apart relationship so that when spread in a direction at right angles to the longitudinal axes of the fibers, said assembly forms a continuous integral reticulated structure; said individual fibers having asymmetrical irregularly-shaped cross sections of substantially different profiles and sizes from one another when said assembly is cut at right angles to the longitudinal axes of the fibers at an arbitrary point therealong; at least 40% of the entire cross-sectional area of each fiber consisting of at least two different polymer phases which are coalesced side-by-side as at least two irregular blocks; and each of the individual fibers of said assembly having a non-uniform cross-sectional shape along its longitudinal axis.

Claim 2

Dependent Claim 127 words

A fibrous assembly of many fibers, the individual constituent fibers being interconnected at random in a spaced-apart relationship so that when spread in a direction at right angles to the longitudinal axes of the fibers, said assembly forms a continuous integral reticulated structure; said individual fibers having asymmetrical irregularly-shaped cross sections of substantially different profiles and sizes from one another when said assembly is cut at right angles to the longitudinal axes of the fibers at an arbitrary point therealong; at least 40% of the entire cross-sectional area of each fiber consisting of at least two different polymer phases which are coalesced side-by-side as at least two irregular blocks; and each of the individual fibers of said assembly having a non-uniform cross-sectional shape along its longitudinal axis.

Claim 3

Dependent Claim 154 words

A fibrous assembly of many polymeric fibers, the individual constituent fibers being interconnected at random in a spaced-apart relationship so that when spread in a direction at right angles to the longitudinal axes of the fibers, said assembly can form a continuous integral reticulated structure; said individual fibers having asymmetrical irregularly-shaped cross sections of substantially different profiles and sizes from one another when said assembly is cut at right angles to the longitudinal axes of the fibers at an arbitrary point therealong; each of the individual fibers of said assembly having a non-uniform cross-sectional shape along its fiber axis; and said constituent polymeric fibers having (A) a portion having at least two different polymer phases coalesced side-by-side as at least two irregular blocks, and (B) a portion in which at least one of said at least two different polymer phases is separated from the other polymer phase to form at least two finer fibers.

Claim 4

Dependent Claim 154 words

A fibrous assembly of many polymeric fibers, the individual constituent fibers being interconnected at random in a spaced-apart relationship so that when spread in a direction at right angles to the longitudinal axes of the fibers, said assembly can form a continuous integral reticulated structure; said individual fibers having asymmetrical irregularly-shaped cross sections of substantially different profiles and sizes from one another when said assembly is cut at right angles to the longitudinal axes of the fibers at an arbitrary point therealong; each of the individual fibers of said assembly having a non-uniform cross-sectional shape along its fiber axis; and said constituent polymeric fibers having (A) a portion having at least two different polymer phases coalesced side-by-side as at least two irregular blocks, and (B) a portion in which at least one of said at least two different polymer phases is separated from the other polymer phase to form at least two finer fibers.

Claim 5

Dependent Claim 188 words

A fibrous structure comprising a laminate of at least two fibrous assemblies each of which is spread in a direction at right angles to the longitudinal axes of the fibers of said assembly to form a reticulated structure, and in which many fibers are crimped so that the constituent fibers of the laminate are intertwined three-dimensionally; wherein each of said fibrous assembly consists of many fibers, the individual constituent fibers being interconnected at random in a spaced-apart relationship so that when spread in a direction at right angles to the longitudinal axes of the fibers, said assembly can form a continuous integral reticulated structure; said individual fibers having asymmetrical irregularly-shaped cross sections of substantially different profiles and sizes from one another when said assembly is cut at right angles to the longitudinal axes of the fibers at an arbitrary point therealong; at least 40% of the entire cross-sectional area of each fiber consisting of at least two different polymer phases which are coalesced side-by-side as at least two irregular blocks; and each of the individual fibers of said assembly having a non-uniform cross-sectional shape along its longitudinal axis.

Claim 6

Dependent Claim 188 words

A fibrous structure comprising a laminate of at least two fibrous assemblies each of which is spread in a direction at right angles to the longitudinal axes of the fibers of said assembly to form a reticulated structure, and in which many fibers are crimped so that the constituent fibers of the laminate are intertwined three-dimensionally; wherein each of said fibrous assembly consists of many fibers, the individual constituent fibers being interconnected at random in a spaced-apart relationship so that when spread in a direction at right angles to the longitudinal axes of the fibers, said assembly can form a continuous integral reticulated structure; said individual fibers having asymmetrical irregularly-shaped cross sections of substantially different profiles and sizes from one another when said assembly is cut at right angles to the longitudinal axes of the fibers at an arbitrary point therealong; at least 40% of the entire cross-sectional area of each fiber consisting of at least two different polymer phases which are coalesced side-by-side as at least two irregular blocks; and each of the individual fibers of said assembly having a non-uniform cross-sectional shape along its longitudinal axis.

Claim 7

Dependent Claim 212 words

A fibrous structure comprising a laminate of at least two fibrous assemblies each of which is spread in a direction at right angles to the longitudinal axes of the fibers of said assembly to form a reticulated structure, and in which many fibers are crimped so that the constituent fibers of the laminate are intertwined three-dimensionally; wherein each of said fibrous assemblies consists of many fibers, the individual constituent fibers being interconnected at random in a spaced-apart relationship so that when spread in a direction at right angles to the longitudinal axes of the fibers, said assembly can form a continuous integral reticulated structure; said individual fibers having asymmetrical irregularly-shaped cross sections of substantially different profiles and sizes from one another when said assembly is cut at right angles to the longitudinal axes of the fibers at an arbitrary point therealong; each of the individual fibers of said assembly having a non-uniform cross-sectional shape along its fiber axis; and said constituent fibers having (A) a portion having at least two different polymer phases coalesced side-by-side as at least two irregular blocks, and (B) a portion in which at least one of said at least two different polymer phases is separated from the other polymer phase to form at least two finer fibers.

Claim 8

Dependent Claim 212 words

A fibrous structure comprising a laminate of at least two fibrous assemblies each of which is spread in a direction at right angles to the longitudinal axes of the fibers of said assembly to form a reticulated structure, and in which many fibers are crimped so that the constituent fibers of the laminate are intertwined three-dimensionally; wherein each of said fibrous assemblies consists of many fibers, the individual constituent fibers being interconnected at random in a spaced-apart relationship so that when spread in a direction at right angles to the longitudinal axes of the fibers, said assembly can form a continuous integral reticulated structure; said individual fibers having asymmetrical irregularly-shaped cross sections of substantially different profiles and sizes from one another when said assembly is cut at right angles to the longitudinal axes of the fibers at an arbitrary point therealong; each of the individual fibers of said assembly having a non-uniform cross-sectional shape along its fiber axis; and said constituent fibers having (A) a portion having at least two different polymer phases coalesced side-by-side as at least two irregular blocks, and (B) a portion in which at least one of said at least two different polymer phases is separated from the other polymer phase to form at least two finer fibers.

Claim 9

Dependent Claim 42 words

The fibrous structure according to claim 3 or 4 wherein at least some of the fibers are bonded to one another at some of the points of contact of adjoining fibers, whereby at least a part of the laminate is three-dimensionally integrated.

Claim 10

Dependent Claim 28 words

The fibrous structure according to claim 5 wherein said bonding is effected by the heating of the lower-melting polymer phase constituting the fibers to bond the others directly.

Claim 11

Dependent Claim 24 words

The fibrous structure according to claim 5 wherein said bonding is effected by means of an adhesive other than the polymers constituting the fibers.

Claim 12

Dependent Claim 32 words

The fibrous structure according to claim 5 wherein the lower-melting polymer phase constituting the fibers at least contains an elastic polymer component, and the fibers are bonded through the elastic polymer component.

Claim 13

Dependent Claim 17 words

The fibrous structure according to claim 3 which is in the form of a web or sheet.

Claim 14

Dependent Claim 20 words

The fibrous structure according to claim 3 which is in the form of a web or sheet and is embossed.

Claim 15

Dependent Claim 36 words

The fibrous structure according to claim 3 wherein at least one of other woven fabrics, knitted fabrics, nets, non-woven fibrous structures or films is incorporated in an arbitrary position of said laminate of the fibrous assemblies.

Claim 16

Dependent Claim 18 words

The fibrous structure of claim 3 comprising a laminate of from 10 to 10,000 of said fibrous assemblies.

Claim 17

Dependent Claim 17 words

The fibrous structure of claim 4 comprising a laminate of 10 to 10,000 of said fibrous assemblies.

Claim 18

Dependent Claim 212 words

A process for producing a fibrous assembly, the individual constituent fibers being interconnected at random in a spaced-apart relationship so that when spread in a direction at right angles to the longitudinal axes of the fibers, said assembly can form a continuous integral reticulated structure; said individual fibers having asymmetrical irregularly-shaped cross sections of substantially different profiles and sizes from one another when said assembly is cut at right angles to the longitudinal axes of the fibers at an arbitrary point therealong; at least 40% of the entire cross-sectional area of each fiber consisting of at least two different polymer phases which are coalesced side-by-side as at least two irregular blocks; and each of the individual fibers of said assembly having a non-uniform cross-sectional shape along its longitudinal axis; which comprises associating melts of at least two different foamable polymer phases in the form of layers, extruding the associated mass from an elongated slit having a narrow clearance of 30 to 300 microns as superimposed layer-like streams in the direction of the narrow width, simultaneously foaming the polymer phases, and taking up the extrudate at a draft ratio of from 50 to 250 while cooling the extrudate at a location between the slit exit and a point 10 mm below the exit.

Claim 19

Dependent Claim 212 words

A process for producing a fibrous assembly, the individual constituent fibers being interconnected at random in a spaced-apart relationship so that when spread in a direction at right angles to the longitudinal axes of the fibers, said assembly can form a continuous integral reticulated structure; said individual fibers having asymmetrical irregularly-shaped cross sections of substantially different profiles and sizes from one another when said assembly is cut at right angles to the longitudinal axes of the fibers at an arbitrary point therealong; at least 40% of the entire cross-sectional area of each fiber consisting of at least two different polymer phases which are coalesced side-by-side as at least two irregular blocks; and each of the individual fibers of said assembly having a non-uniform cross-sectional shape along its longitudinal axis; which comprises associating melts of at least two different foamable polymer phases in the form of layers, extruding the associated mass from an elongated slit having a narrow clearance of 30 to 300 microns as superimposed layer-like streams in the direction of the narrow width, simultaneously foaming the polymer phases, and taking up the extrudate at a draft ratio of from 50 to 250 while cooling the extrudate at a location between the slit exit and a point 10 mm below the exit.

Claim 20

Dependent Claim 15 words

The process according to claim 14 wherein the draft ratio is from 100 to 200.

Claim 21

Dependent Claim 16 words

The process of claim 14 wherein the slit has a clearance of 30 to 150 microns.

Claim 22

Dependent Claim 25 words

The process of claim 14 wherein the extrudate is cooled at a location between the slit exit and a point 5 mm below the exit.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1984-09-07	1985-03-09	1985-09-08	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1988-09-07	1989-03-09	1989-09-08	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1992-09-07	1993-03-09	1993-09-08	$7700.00	Window Closed / Lapsed

Novel fibrous assembly and process for production thereof

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