US6007898A
Expired / Lapsed
US
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Thermoplastic three-dimensional fiber network
Assignee: North Carolina State University
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Filing: 1998-03-23
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Granted: 1999-12-28
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Expires: 2018-03-23
Abstract
Abstract Three dimensional fiber networks which are semi-rigid and dimensionally stable are made from textile fabrics that have projections and optional depressions which are compressible and return to their original shape after being compressed. The fiber networks are made by the thermo-mechanical deformation of textile fabrics that are in turn made from thermoplastic fibers. The fiber networks have particular utility as cushioning and impact absorbing materials.
Inventors
- 👤 Dai W. Kim
- 👤 Joseph Steven Wiley Haas
- 👤 William Edward Bessey
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-02 21:41
CPC Classifications
D; D04; D04H; D04H1/00; B; B29; B29C; B29C51/00; B29C51/002; B29C51/004; D04B; D04B1/00; D04B1/14; D04B1/18; D04H13/00; D04H3/00; D04H3/02; D04H3/07; D10; D10B; D10B2503/00; D10B2503/04; D10B2503/041; D10B2503/06; D10B2505/00; D10B2505/08; D10B2505/10; Y; Y10; Y10T; Y10T428/00; Y10T428/24; Y10T428/24479; Y10T428/2457; Y10T428/24628; Y10T428/24636; Y10T428/24661; Y10T442/00; Y10T442/30; Y10T442/3008; Y10T442/3065; Y10T442/313; Y10T442/40; Y10T442/425
Claims Analysis
Total Claims: 30
Claim 1
Independent Claim
79 words
A method of making a material suitable for cushioning, comprising the steps of (a) making a monofilament having a diameter of at least about 0.1 mm from a thermoplastic polymer; (b) making said monofilament into a knit, woven, or non-woven textile fabric; and (c) making a series of projections and optional depressions in said textile fabric by a thermo-mechanical process; wherein said projections and optional depressions are resilient, returning substantially to their original shape after being compressed by 50%.
Claim 2
Independent Claim
79 words
A method of making a material suitable for cushioning, comprising the steps of (a) making a monofilament having a diameter of at least about 0.1 mm from a thermoplastic polymer; (b) making said monofilament into a knit, woven, or non-woven textile fabric; and (c) making a series of projections and optional depressions in said textile fabric by a thermo-mechanical process; wherein said projections and optional depressions are resilient, returning substantially to their original shape after being compressed by 50%.
Claim 3
Dependent Claim
16 words
The method recited in claim 1, wherein said monofilament is made by a melt spinning process.
Claim 4
Dependent Claim
31 words
The method recited in claim 1, wherein said thermo-mechanical process is carried out by application of a mechanical force at a temperature above the glass transition temperature of said thermoplastic polymer.
Claim 5
Dependent Claim
23 words
The method recited in claim 3, wherein said mechanical force is applied at a temperature below the melting temperature of said thermoplastic polymer.
Claim 6
Dependent Claim
14 words
The method recited in claim 1, wherein said textile fabric is a knit fabric.
Claim 7
Dependent Claim
14 words
The method recited in claim 1, wherein said textile fabric is a woven fabric.
Claim 8
Dependent Claim
40 words
The method recited in claim 1, wherein said projections and optional depressions have a shape selected from the group consisting of cones, truncated cones, pyramids having polygonal bases, truncated pyramids having polygonal bases, cylinders, prisms, spherical elements, and mixtures thereof.
Claim 9
Dependent Claim
25 words
The method recited in claim 1, wherein said projections have apex points or flat tops, and said apex points or flat tops define a surface.
Claim 10
Dependent Claim
27 words
The method recited in claim 1, wherein said filaments in said fabric cross over one another at intersections, wherein said filaments at said intersections are not bonded.
Claim 11
Dependent Claim
25 words
The method recited in claim 1, wherein said thermoplastic polymer has a melting temperature in the range of about 80° C. to about 375° C.
Claim 12
Dependent Claim
26 words
The method recited in claim 1, wherein the apparent density of said fiber network is less than about 10% of the density of said thermoplastic fiber.
Claim 13
Dependent Claim
33 words
The method recited in claim 1, wherein said thermoplastic polymer is selected from the group consisting of polyesters, polyamides, thermoplastic copolyetherester elastomers, poly(arylene sulfides), polyolefins, aliphatic-aromatic polyamides, polyacrylates, and thermotropic liquid crystalline polymers.
Claim 14
Dependent Claim
31 words
The method recited in claim 1, wherein said thermoplastic polymer is a thermoplastic copolyetherester elastomer comprising long chain ether ester units and short chain ester units joined head-to-tail through ester linkages.
Claim 15
Dependent Claim
41 words
The method recited in claim 13, wherein said long chain ether ester units consist essentially of the residues of poly(tetramethylene oxide) glycol and terephthalic acid and said short chain ester units consist essentially of the residues of 1,4-butanediol and terephthalic acid.
Claim 16
Dependent Claim
13 words
The method recited in claim 1, wherein said thermoplastic polymer is poly(ethylene terephthalate).
Claim 17
Dependent Claim
17 words
The method recited in claim 1, wherein said thermoplastic polymer is polypropylene, nylon 6, or nylon 66.
Claim 18
Dependent Claim
12 words
The method recited in claim 1, wherein said network also comprises depressions.
Claim 19
Dependent Claim
25 words
The method recited in claim 7, wherein said depressions have apex points or flat tops, and said apex points or flat tops define a surface.
Claim 20
Dependent Claim
22 words
The method recited in claim 1, said filaments having a diameter in the range of about 0.15 mm to about 0.7 mm.
Claim 21
Dependent Claim
14 words
The method recited in claim 1, wherein said thermoplastic polymer contains a flame retardant.
Claim 22
Dependent Claim
73 words
An article comprising a three-dimensional fiber network structure as a component or sub-component, wherein said three-dimensional fiber network structure comprises a textile fabric having a multiplicity of compressible projections, and optional depressions, wherein said projections and optional projections return substantially to their original shape after being compressed by 50%, said textile fabric comprising thermoplastic filaments which consist essentially of a thermoplastic polymer, said filaments having a diameter of at least about 0.1 mm.
Claim 23
Dependent Claim
73 words
An article comprising a three-dimensional fiber network structure as a component or sub-component, wherein said three-dimensional fiber network structure comprises a textile fabric having a multiplicity of compressible projections, and optional depressions, wherein said projections and optional projections return substantially to their original shape after being compressed by 50%, said textile fabric comprising thermoplastic filaments which consist essentially of a thermoplastic polymer, said filaments having a diameter of at least about 0.1 mm.
Claim 24
Dependent Claim
53 words
The article recited in claim 21, said article being selected from the group consisting of mattresses, mattress accessories, footwear components, pads for protective head gear, cushions, wrappings and liners for medical casts, protective braces, protective helmet liners, space/sound barriers, protective packaging for electronics, automobile headliners, liners for clothing, carpet pads and athletic shoes.
Claim 25
Dependent Claim
12 words
The article of claim 22, wherein said mattress is an infant mattress.
Claim 26
Dependent Claim
22 words
The article of claim 22, wherein said mattress accessory is selected from the group consisting of mattress topper pads and mattress covers.
Claim 27
Dependent Claim
22 words
The article of claim 22, wherein said footwear components are selected from the group consisting of sock liners, collar linings, and midsoles.
Claim 28
Dependent Claim
24 words
The article of claim 22, wherein said cushions are selected from the group consisting of seat cushions, automobile seat cushions, and outdoor furniture cushions.
Claim 29
Dependent Claim
15 words
The article of claim 22, wherein said space/sound barrier is a wall partition or panel.
Claim 30
Dependent Claim
23 words
The article of claim 22, wherein said clothing is selected from the group consisting of athletic clothing, outdoor clothing, brassieres, and athletic supporters.
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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) | 2002-12-27 | 2003-06-28 | 2003-12-28 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2006-12-27 | 2007-06-28 | 2007-12-28 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2010-12-27 | 2011-06-28 | 2011-12-28 | $7700.00 | Window Closed / Lapsed |