US5600974A
Expired / Lapsed
US
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Stiff fabric composite and method of making
Assignee: Burlington Industries LLC
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Filing: 1994-10-31
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Granted: 1997-02-11
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Expires: 2014-10-31
Abstract
Abstract A woven or non-woven fibrous material has a substrate formed of first and second thermoplastic fibers. The fabric is passed through an oven at a temperature sufficient to melt the first fibers thereby fusing at least some of the first fibers and second fibers one to the other. The second fibers retain their discrete definition within the composite whereby the composite is provided such that, when cut for use, for example, to form a slat of a vertical blind or a wall panel, the composite retains its shape. A foam backing is provided and cured in the oven simultaneously with the melting of the first fibers.
Inventors
- 👤 Julius R. Schnegg
- 👤 Manfred H. K. Hueneke
- 👤 Bobby L. McConnell
- 👤 John Rinderman, deceased
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-04 01:24
CPC Classifications
D; D04; D04B; D04B21/00; D04B21/14; D04B21/16; D04B21/165; A; A47; A47H; A47H23/00; A47H23/02; A47H23/08; B; B32; B32B; B32B37/00; B32B37/06; D04H; D04H13/00; E; E06; E06B; E06B9/00; E06B9/02; E06B9/08; E06B9/24; E06B9/26; E06B9/266; E06B9/38; E06B9/386; B32B2309/00; B32B2309/12; D10; D10B; D10B2403/00; D10B2403/02; D10B2403/024; D10B2403/0241; D10B2403/02412; D10B2403/0243; D10B2503/00; D10B2503/03; Y; Y10; Y10T; Y10T156/00; Y10T156/10; Y10T156/1089; Y10T156/109; Y10T442/00; Y10T442/30; Y10T442/3179; Y10T442/3325; Y10T442/335; Y10T442/3358; Y10T442/3472; Y10T442/3602; Y10T442/3667; Y10T442/3707; Y10T442/3724; Y10T442/40; Y10T442/45; Y10T442/456; Y10T442/463
Claims Analysis
Total Claims: 29
Claim 1
Independent Claim
124 words
A method of forming a stiff fabric having stitch through warp yarns and a substrate comprising the steps of: on a knitting machine, (a) providing a non-woven substrate for movement in the machine direction formed of first and second different fibers with said first fibers formed of thermoplastic material having a predetermined melting temperature, and (b) stitching the warp yarns and substrate each to the other, and thereafter, heating the fabric to a temperature to fuse said first fibers with said second fibers of the substrate to provide a predetermined stiffness to the fabric while simultaneously retaining the definition of said second fibers as fibers in said fabric and with stitch underlaps and loops exposed and defined on opposite sides of the stiff fabric.
Claim 2
Independent Claim
124 words
A method of forming a stiff fabric having stitch through warp yarns and a substrate comprising the steps of: on a knitting machine, (a) providing a non-woven substrate for movement in the machine direction formed of first and second different fibers with said first fibers formed of thermoplastic material having a predetermined melting temperature, and (b) stitching the warp yarns and substrate each to the other, and thereafter, heating the fabric to a temperature to fuse said first fibers with said second fibers of the substrate to provide a predetermined stiffness to the fabric while simultaneously retaining the definition of said second fibers as fibers in said fabric and with stitch underlaps and loops exposed and defined on opposite sides of the stiff fabric.
Claim 3
Independent Claim
152 words
A method of forming a stiff fabric having stitch through warp yarns, a substrate and a foam backing comprising the steps of: on a knitting machine, (a) providing a non-woven substrate for movement in the machine direction formed of first and second different fibers with said first fibers formed of thermoplastic material having a predetermined melting temperature, and (b) stitching the warp yarns and substrate each to the other; applying a foamed or foamable composition of a polymeric material to one side of said substrate; and thereafter, heating the fabric, substrate and foamed or foamable composition simultaneously to a temperature to (i) fuse said first fibers with said second fibers of the substrate to provide a predetermined stiffness to the fabric while retaining the definition of said second fibers as fibers in said fabric and (ii) cure the foamed or foamable composition to form a stiff fabric composite with a foam backing.
Claim 4
Independent Claim
152 words
A method of forming a stiff fabric having stitch through warp yarns, a substrate and a foam backing comprising the steps of: on a knitting machine, (a) providing a non-woven substrate for movement in the machine direction formed of first and second different fibers with said first fibers formed of thermoplastic material having a predetermined melting temperature, and (b) stitching the warp yarns and substrate each to the other; applying a foamed or foamable composition of a polymeric material to one side of said substrate; and thereafter, heating the fabric, substrate and foamed or foamable composition simultaneously to a temperature to (i) fuse said first fibers with said second fibers of the substrate to provide a predetermined stiffness to the fabric while retaining the definition of said second fibers as fibers in said fabric and (ii) cure the foamed or foamable composition to form a stiff fabric composite with a foam backing.
Claim 5
Dependent Claim
15 words
A method according to claim 2 including fusing said first fibers to the warp yarns.
Claim 6
Dependent Claim
41 words
A method according to claim 2 wherein the fabric is a warp-knit, weft-inserted fabric, including the steps of, on said knitting machine, laying in weft yarns in the cross-machine direction and stitching the weft yarns and substrate each to the other.
Claim 7
Dependent Claim
17 words
A method according to claim 2 including the step of laying in warp yarns on the substrate.
Claim 8
Independent Claim
87 words
A method of forming a stiff fabric composite comprising the steps of: needling a non-woven substrate formed of thermoplastic fibers and a woven material one to the other; applying a foamed or foamable composition to one side of the substrate; heating the needled non-woven substrate, woven material and foamed or foamable composition simultaneously to a temperature to (i) fuse at least some of said fibers in said substrate and (ii) cure the foamed or foamable composition to provide a fabric composite with foam backing of predetermined thickness.
Claim 9
Independent Claim
87 words
A method of forming a stiff fabric composite comprising the steps of: needling a non-woven substrate formed of thermoplastic fibers and a woven material one to the other; applying a foamed or foamable composition to one side of the substrate; heating the needled non-woven substrate, woven material and foamed or foamable composition simultaneously to a temperature to (i) fuse at least some of said fibers in said substrate and (ii) cure the foamed or foamable composition to provide a fabric composite with foam backing of predetermined thickness.
Claim 10
Dependent Claim
72 words
A method according to claim 6 including the steps of providing a non-woven substrate formed of first and second thermoplastic fibers wherein said first fiber has a melting temperature lower than the melting temperature of said second fiber and the step of heating includes melting at least some of the first fibers without substantial melting of the second fibers such that some of the first fibers are fused with the second fibers.
Claim 11
Dependent Claim
35 words
A method according to claim 6 including heating the substrate, woven material and foamed or foamable composition to a temperature to fuse at least some of said fibers in said substrate to said woven material.
Claim 12
Independent Claim
65 words
A method of forming a stiff fabric composite comprising the steps of: fusing only a portion of fibers of a substrate, leaving a remaining portion unfused; applying an adhesive to a surface of the partially fused substrate; heating the partially fused substrate with adhesive applied thereto to melt the adhesive; and thereafter adhering a fabric to the substrate with the adhesive forming a bond therebetween.
Claim 13
Independent Claim
65 words
A method of forming a stiff fabric composite comprising the steps of: fusing only a portion of fibers of a substrate, leaving a remaining portion unfused; applying an adhesive to a surface of the partially fused substrate; heating the partially fused substrate with adhesive applied thereto to melt the adhesive; and thereafter adhering a fabric to the substrate with the adhesive forming a bond therebetween.
Claim 14
Dependent Claim
23 words
A method according to claim 9 including applying a foamed or foamable composition to the substrate and curing the foamed or foamable composition.
Claim 15
Independent Claim
98 words
A method of forming a stiff fabric composite comprising the steps of: applying an adhesive to one of a substrate having first and second thermoplastic fibers and a fabric; laminating the substrate and the fabric to one another with the adhesive bonding the substrate and fabric to one another; and heating the laminated substrate and fabric to a predetermined temperature sufficient to melt said first fibers such that said first fibers are fused with said second fibers in the substrate to provide a composite having a predetermined stiffness, with said second fibers remaining substantially wholly unmelted during heating.
Claim 16
Independent Claim
98 words
A method of forming a stiff fabric composite comprising the steps of: applying an adhesive to one of a substrate having first and second thermoplastic fibers and a fabric; laminating the substrate and the fabric to one another with the adhesive bonding the substrate and fabric to one another; and heating the laminated substrate and fabric to a predetermined temperature sufficient to melt said first fibers such that said first fibers are fused with said second fibers in the substrate to provide a composite having a predetermined stiffness, with said second fibers remaining substantially wholly unmelted during heating.
Claim 17
Dependent Claim
23 words
A method according to claim 11 including applying a foamed or foamable composition to the substrate and curing the foamed or foamable composition.
Claim 18
Dependent Claim
21 words
A method according to claim 12 including curing the foamed or foamable composition simultaneously with fusing said first fibers during heating.
Claim 19
Independent Claim
89 words
A method of forming a stiff fabric composite comprising the steps of: disposing a fusible material between a substrate having first and second thermoplastic fibers and a fabric; and laminating said substrate, fusible material and fabric to one another by heating said substrate, fusible material and fabric to a predetermined temperature sufficient to melt said first fibers such that said first fibers are fused with said second fibers in said substrate to provide a composite having a predetermined stiffness, with said second fibers remaining substantially wholly unmelted during heating.
Claim 20
Independent Claim
89 words
A method of forming a stiff fabric composite comprising the steps of: disposing a fusible material between a substrate having first and second thermoplastic fibers and a fabric; and laminating said substrate, fusible material and fabric to one another by heating said substrate, fusible material and fabric to a predetermined temperature sufficient to melt said first fibers such that said first fibers are fused with said second fibers in said substrate to provide a composite having a predetermined stiffness, with said second fibers remaining substantially wholly unmelted during heating.
Claim 21
Dependent Claim
23 words
A method according to claim 14 including applying a foamed or foamable composition to the substrate and curing the foamed or foamable composition.
Claim 22
Dependent Claim
21 words
A method according to claim 15 including curing the foamed or foamable composition simultaneously with fusing said first fibers during heating.
Claim 23
Independent Claim
77 words
A method of forming a stiff fabric composite including the steps of: passing a fabric formed of acetate and rayon yarns, a substrate having thermoplastic fibers and a spunbonded polyester through a heat transfer/warp print machine; heating the fabric to a temperature sufficient to melt certain of the fibers in said substrate for fusing with unmelted fibers in the substrate to provide a composite having a predetermined stiffness with certain fibers remaining substantially wholly unmelted during heating.
Claim 24
Independent Claim
77 words
A method of forming a stiff fabric composite including the steps of: passing a fabric formed of acetate and rayon yarns, a substrate having thermoplastic fibers and a spunbonded polyester through a heat transfer/warp print machine; heating the fabric to a temperature sufficient to melt certain of the fibers in said substrate for fusing with unmelted fibers in the substrate to provide a composite having a predetermined stiffness with certain fibers remaining substantially wholly unmelted during heating.
Claim 25
Independent Claim
127 words
A method of forming a stiff fabric composite comprising the steps of: needling a non-woven substrate formed of first and second thermoplastic fibers, wherein said first fibers have a melting temperature lower than the melting temperature of said second fibers, and a woven material one to the other; and heating the needled non-woven fabric and woven fabric to a temperature within a range of 310°-370° F. to melt the first fibers without substantial melting of the second fibers such that the first fibers are fused with the second fibers and to said woven fabric to provide a fabric composite of predetermined stiffness, the step of heating including passing the needled non-woven fabric and woven fabric through an oven at a speed of about 20-30 yards per minute.
Claim 26
Independent Claim
127 words
A method of forming a stiff fabric composite comprising the steps of: needling a non-woven substrate formed of first and second thermoplastic fibers, wherein said first fibers have a melting temperature lower than the melting temperature of said second fibers, and a woven material one to the other; and heating the needled non-woven fabric and woven fabric to a temperature within a range of 310°-370° F. to melt the first fibers without substantial melting of the second fibers such that the first fibers are fused with the second fibers and to said woven fabric to provide a fabric composite of predetermined stiffness, the step of heating including passing the needled non-woven fabric and woven fabric through an oven at a speed of about 20-30 yards per minute.
Claim 27
Independent Claim
68 words
A method of forming a stiff fabric composite including the steps of: applying a ground polyester powder to a surface of a non-fusible substrate; heating the substrate with ground polyester powder applied such that said ground polyester powder obtains a molten state on said substrate; disposing a fabric on the molten polyester; and laminating the fabric, polyester and substrate to one another to form the stiff fabric composite.
Claim 28
Independent Claim
68 words
A method of forming a stiff fabric composite including the steps of: applying a ground polyester powder to a surface of a non-fusible substrate; heating the substrate with ground polyester powder applied such that said ground polyester powder obtains a molten state on said substrate; disposing a fabric on the molten polyester; and laminating the fabric, polyester and substrate to one another to form the stiff fabric composite.
Claim 29
Dependent Claim
62 words
A method according to claim 14 wherein the step of heating includes heating the polyester powder to a temperature within a range of 220°-375° F. and the step of laminating includes passing the fabric, polyester and substrate through the nip of a pair of rolls to press the fabric, polyester and substrate together to achieve a bond between the fabric and substrate.
References Cited (Backward Citations)
US4565735A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 2000-02-11 | 2000-08-12 | 2001-02-11 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2004-02-11 | 2004-08-12 | 2005-02-11 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2008-02-11 | 2008-08-12 | 2009-02-11 | $7700.00 | Window Closed / Lapsed |