US20090068397A1 - Convoluted fiber pad - Google Patents
Convoluted fiber pad Download PDFInfo
- Publication number
- US20090068397A1 US20090068397A1 US12/272,601 US27260108A US2009068397A1 US 20090068397 A1 US20090068397 A1 US 20090068397A1 US 27260108 A US27260108 A US 27260108A US 2009068397 A1 US2009068397 A1 US 2009068397A1
- Authority
- US
- United States
- Prior art keywords
- batt
- fibers
- woven fiber
- woven
- fiber batt
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B38/00—Ancillary operations in connection with laminating processes
- B32B38/10—Removing layers, or parts of layers, mechanically or chemically
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- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/22—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with both fibrous and foamed material inlays
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B26—HAND CUTTING TOOLS; CUTTING; SEVERING
- B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
- B26D3/00—Cutting work characterised by the nature of the cut made; Apparatus therefor
- B26D3/28—Splitting layers from work; Mutually separating layers by cutting
- B26D3/281—Splitting layers from work; Mutually separating layers by cutting the work being simultaneously deformed by the application of pressure to obtain profiled workpieces
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
- B29C44/04—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles consisting of at least two parts of chemically or physically different materials, e.g. having different densities
- B29C44/06—Making multilayered articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/34—Auxiliary operations
- B29C44/56—After-treatment of articles, e.g. for altering the shape
- B29C44/5627—After-treatment of articles, e.g. for altering the shape by mechanical deformation, e.g. crushing, embossing, stretching
- B29C44/5654—Subdividing foamed articles to obtain particular surface properties, e.g. on multiple modules
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
- B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
- B32B3/28—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer comprising a deformed thin sheet, i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
- B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
- B32B3/30—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
- B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B68—SADDLERY; UPHOLSTERY
- B68G—METHODS, EQUIPMENT, OR MACHINES FOR USE IN UPHOLSTERING; UPHOLSTERY NOT OTHERWISE PROVIDED FOR
- B68G5/00—Resilient upholstery pads
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B68—SADDLERY; UPHOLSTERY
- B68G—METHODS, EQUIPMENT, OR MACHINES FOR USE IN UPHOLSTERING; UPHOLSTERY NOT OTHERWISE PROVIDED FOR
- B68G5/00—Resilient upholstery pads
- B68G5/02—Resilient upholstery pads of cellular material, e.g. sponge rubber
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/02—Cotton wool; Wadding
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
- D04H1/74—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being orientated, e.g. in parallel (anisotropic fleeces)
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2305/00—Condition, form or state of the layers or laminate
- B32B2305/02—Cellular or porous
- B32B2305/022—Foam
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2305/00—Condition, form or state of the layers or laminate
- B32B2305/10—Fibres of continuous length
- B32B2305/20—Fibres of continuous length in the form of a non-woven mat
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- Y10T428/249955—Void-containing component partially impregnated with adjacent component
- Y10T428/249958—Void-containing component is synthetic resin or natural rubbers
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- Y10T428/249962—Void-containing component has a continuous matrix of fibers only [e.g., porous paper, etc.]
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- Y10T428/249981—Plural void-containing components
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- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
- Y10T428/2913—Rod, strand, filament or fiber
- Y10T428/2929—Bicomponent, conjugate, composite or collateral fibers or filaments [i.e., coextruded sheath-core or side-by-side type]
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- Y10T442/30—Woven fabric [i.e., woven strand or strip material]
- Y10T442/3325—Including a foamed layer or component
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/643—Including parallel strand or fiber material within the nonwoven fabric
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/647—Including a foamed layer or component
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/647—Including a foamed layer or component
- Y10T442/649—Plural foamed layers
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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- Y10T83/00—Cutting
- Y10T83/04—Processes
- Y10T83/0405—With preparatory or simultaneous ancillary treatment of work
- Y10T83/0419—By distorting within elastic limit
- Y10T83/0429—By compressing
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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- Y10T83/04—Processes
- Y10T83/0448—With subsequent handling [i.e., of product]
- Y10T83/0467—By separating products from each other
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T83/00—Cutting
- Y10T83/343—With means to deform work temporarily
Definitions
- the present invention relates to a process of forming a fiber batt and, more particularly, a fiber batt formed to include a surface having a convoluted shape.
- Mattresses and cushions for sofas, loveseats, chairs and other upholstery products generally comprise filler materials, batts, and foams, among other layering materials, for achieving a range of comfort, lot and durability.
- batts from synthetic, staple fiber material for use in mattresses and upholstery cushions.
- Such fibers are inherently lightweight and therefore easy to ship, store and manipulate during fabrication.
- These fibers are also generally less moisture absorbent than natural fibers such as cotton, or cellulosic based synthetic fibers such as rayon. Therefore, products made from these fibers can be maintained in a more hygienic condition and dried with much less expenditure of energy. When subjected to open flame, many of these fibers also tend to melt and drip rather than burn.
- Synthetic fiber batts have been used in mattresses and upholstery cushions since batts maintain their comfort characteristics over time.
- Traditional batts having desired comfort and height characteristics may generally be too stiff to allow a mattress or futon to be easily rolled for storage or folded into a sofa.
- a batt would be required to create a mattress having the desired comfort characteristics.
- an upper surface positioned on top of the general coil structure of a mattress includes a first layer of cover or ticking, a second layer of fiber or filler material, a third layer of a foam having convoluted surface which faces the second layer, and a further layer of backing material. All four layers are stitched together in a quilt pattern.
- Futon furniture in recent years has become a popular alternative to standard upholstered furniture. Futon sofas, loveseats and chairs can be repositioned so that the furniture can be used as a bed.
- polyurethane foam has been combined with other types of cushioning materials such as cotton batting, latex rubber, and various man-made fiber products in order to impart the desired comfort characteristics to a final product.
- the various types and combinations of materials take on different degrees of set as a result of compression from the weight of a human body.
- the final product will take more set over time with continued use. The more set the product takes over time, the more comfort, flexibility and height is lost from the product.
- a futon mattress It is desirable to bend, fold and/or roll up a futon mattress to be used as a sofa or for storage when the futon is not used as a flat sleep surface. Yet, when the futon is used as a sleep surface it must be stiff enough to span slats in a bed frame. Preferably, the material used in making the futon would take on little or no set.
- the convolutions upon the surface of at least one roller compresses the surface of the non-woven fiber batt in frictional engagement therewith to a greater or lesser degree depending on the degree of surface relief of the roller convolutions.
- a heated wire is placed generally parallel to and between the pair of drums so that, as the non-woven fiber batt is drawn between the drums and compressed by the drum convolutions, the heated wire cuts through the non-woven fiber batt to create a cut-pattern generally mirroring the convolutions on the surface of the drum compressing the non-woven fiber batt.
- the present invention is directed to a fiber pad comprised of a non-woven fiber batt having a first, generally flat, surface and a second, convoluted, surface.
- the non-woven fiber batt may further include an unconvoluted base and a number of projections integrally formed with the unconvoluted base.
- the projections may be configured as: (a) free-standing peaks spaced apart from the other peaks; (2) free-standing ridges spaced apart from the other free-standing ridges; or (3) free-standing wavy ridges spaced apart from the other free-standing wavy ridges.
- the fiber pad extends in longitudinal, lateral and transverse dimensions.
- the non-woven fiber batt may be comprised of: (1) fibers oriented substantially horizontally along the longitudinal and transverse dimensions of the fiber pad; (2) fibers oriented substantially horizontally along the longitudinal and transverse dimensions of the fiber pad and substantially vertically along the lateral dimension of the fiber pad; or (3) fibers oriented substantially vertically along the lateral dimension of the fiber pad.
- the non-woven fiber batt may be comprised of: (1) plural fibers spray-bonded to one another by an adhesive; or (2) a first plurality of high-melt fibers and a second plurality of low-melt fibers bonded to one another and to the first plurality of high melt fibers. In either of these aspects, the formation of the second, convoluted, surface does not weaken the bonds between the fibers.
- the fibers may be: (1) a blend of hollow, solid and crimped fibers having varying diameters and deniers; (2) synthetic fibers; or (3) polyester fibers.
- FIG. 1 is a perspective view of a non-woven fiber batt layer.
- FIG. 2 is a perspective view of a foam layer.
- FIG. 3 is a schematic view of a device for separating a batt into first and second convoluted pads.
- FIG. 4 is a schematic view of a device for forming a multi-layer pad having convoluted fiber and convoluted layers from the non-woven fiber batt of FIG. 1 and the foam batt of FIG. 2 .
- FIG. 5 is a perspective view of a drum forming part of the device of either FIG. 3 or FIG. 4 and having alternative embodiments of convoluted surfaces thereon.
- FIG. 6 is a perspective view of a multi-layer pad formed of conforming non-woven fiber and foam batts which is sectioned to show a first type of convoluted surface for the batts.
- FIG. 7 is a perspective view of a multi-layer pad formed of conforming non-woven fiber and foam batts which is sectioned to show a second type of convoluted surface for the batts.
- FIG. 8 is a perspective view of a multi-layer pad formed of conforming non-woven fiber and foam batts sectioned to show a third type of convoluted surface for the bats.
- the non-woven batt 100 may include a blend of different types of fibers 108 having varying diameters and deniers, and fibers which are hollow, solid and crimped. Blending different types of fibers 108 creates dead air spaces which contribute to the resiliency of the convoluted multi-layer pad 500 of FIGS. 6 , 7 and 8 and lends to the integrity of the non-woven batt 100 .
- the fibers 108 of the non-woven batt 100 can be synthetic fibers which are known in the art, for example, polyester and polypropylene.
- the fibers 108 are substantially synthetic fibers having a melting point in the range of about 189°-206° C. (300°-330° F.).
- the fibers 108 are polyester fibers having a melting point substantially in the above specified range.
- other synthetic fibers known in the art also may be used, such as polypropylene, having melt ranges close to or below the above-specified range.
- natural fibers such as camel, llama, wool, cashmere, or cotton can be incorporated with synthetic fibers to form the non-woven batt 100 . Because natural fibers may tend to generate smoke when in contact with a heated cutter, the percentage of natural fiber incorporated into the non-woven batt 100 should be within a range which will not create an environmental or health hazard during a heated cutting operation.
- the fibers 108 of the non-woven batt 100 can also be densified.
- densified fibers hereby refers to fibers having a weight-to-thickness ratio of at least 57 grams (2 ounces) per 3.8 centimeters (1.5 inch) thickness for a 30.5 square centimeter (1 square foot) area of batt.
- the fibers 108 can be oriented substantially horizontally 108 a along the longitudinal dimension 102 and traverse dimension 106 of the non-woven batt 100 .
- the non-woven batt 100 can be comprised of horizontally oriented fibers 108 a, and vertically oriented fibers 108 b along the lateral dimension 104 of the non-woven batt 100 .
- the non-woven batt 100 is formed from substantially vertically oriented fibers 108 b , as vertically oriented fibers 108 b have better convolution retention properties as compared to horizontally oriented fibers 108 a , as discussed below.
- the batt 100 can be formed using one of the several processes for converting a source of fiber into a non-woven batt 100 , as is known in the art.
- the fibers 108 may receive an application of a resin to improve the structural integrity of the non-woven batt 100 , or alternatively may incorporate a portion of low melting fibers which will melt to bond high melt fibers in the non-woven batt 100 on application of heat.
- the ends of the fibers 108 in non-woven batt 100 may be brushed to improve the entwining of individual fibers of one end into adjacent ends. Adjacent ends of fibers 108 may be of substantially the same height, or, in the alternative, may have different heights in a repeating pattern.
- the structure and manufacture of a batt incorporating vertically oriented fibers is described in more detail in U.S. Pat. No. 5,702,801, the entire disclosure of which is incorporated herein by reference.
- the non-woven batt 100 may have an initial thickness of up to about eighteen (18) inches.
- the fibers 108 are spray bonded together with an adhesive and then compressed by rolling the fibers 108 to form the non-woven batt 100 , as is known in the art.
- the fibers 108 are oven-baked together and then rolled and cooled to form the non-woven batt 100 .
- a foam layer 200 has a longitudinal dimension 202 , a lateral dimension 204 and a transverse dimension 206 .
- the foam layer 200 preferably is a cellular foam structure which is resilient along its dimensions 202 , 204 , 206 .
- the foam layer 200 compresses when weight or a load is placed along its dimensions 202 , 204 , 206 and returns generally to its original state when the weight or load is removed.
- the structure of a foam layer having a convoluted surface is described in U.S. Pat. No. 5,317,768, the entire disclosure of which is incorporated herein by reference.
- the lateral dimension 204 of the foam layer 200 can be as large or as small as desired. In one alternate embodiment, the lateral dimension 204 is in the range of one half to three (1 ⁇ 2-3) inches. In another alternate embodiment, the lateral dimension 204 is in the range of one to one and one half (1-11 ⁇ 2) inches. Finally, in the preferred embodiment, the lateral dimension 204 of the foam layer 200 is approximately 11 ⁇ 4 inches.
- the process of forming non-woven batt 100 having a convoluted surface 160 is generally accomplished by transporting the non-woven batt 100 along its longitudinal dimension 102 while compressing the non-woven batt 100 along its lateral dimension 104 . Concomitantly with compression, the non-woven batt 100 is cut transversely along its lateral dimension 104 to separate the non-woven batt 100 into an upper segment 120 and a lower segment 140 to provide conforming convoluted surface 160 of the batt upper and lower segments 120 , 140 .
- the batt upper and lower segments 120 , 140 each have an upper surface 122 , 142 and a lower surface 132 , 152 , respectively.
- the convoluted surface 160 of the batt upper segment 120 is proximate to its lower surface 132 .
- the convoluted surface 160 of the batt lower segment 140 is proximate to its upper surface 152 . Further details of the process for forming a non-woven fiber pad having a convoluted surface are disclosed in U.S. Pat. Nos. 6,500,292 and 6,740,610, both of which were previously incorporated by reference as if reproduced in their entirety.
- the process of forming foam layer 200 having a convoluted surface 260 is generally accomplished by transporting the foam layer 200 along its longitudinal dimension 202 while compressing the foam layer 200 along its lateral dimension 204 . Concomitantly with compression, the foam layer 200 is cut transversely along its lateral dimension 204 to separate the foam layer 200 into an upper segment 220 and a lower segment 240 and to provide conforming convoluted surface 260 of the foam layer upper and lower segments 220 240 , respectively.
- the foam layer upper and lower segments 200 , 240 each have an upper surface 222 , 242 and a lower surface 232 , 262 , respectively.
- the convoluted surface 260 of the foam layer upper segment 220 is proximate to its lower surface 232 .
- the convoluted surface 260 of the foam layer lower segment 240 is proximate to its upper surface 242 .
- the preferred embodiment for transporting the non-woven batt 100 along its longitudinal dimension 102 is accomplished by a conveyor belt (not shown), although it should be clearly understood that alternate embodiments are known in the art.
- Compression of the non-woven batt 100 along its lateral dimension 104 is preferably accomplished by a pair of drums 10 , 12 having opposite rotational directions D, D′. As the conveyor belt introduces the non-woven batt 100 between the drums 10 , 12 , the drums 10 , 12 draw the non-woven batt 100 into compression.
- Drums 10 , 12 each have a convoluted surface 20 with at least one raised pattern thereon.
- the raised pattern is generally comprised of a plurality of upstanding projections and depressions.
- Alternative embodiments of the raised pattern include a plurality of pegs 22 , straight edges 24 or waved edges 26 , although it is to be understood that alternative raised patterns are known in the art.
- the convoluted surface 20 of drum 10 should not intermesh or come in contact with the convoluted surface 20 of opposite drum 12 as the drums 10 , 12 rotate.
- only one of the drums 10 , 12 has a convoluted surface 20 while the other of the drums 10 , 12 does not have a convoluted surface 20 which operates to facilitate the drawing of the batt 100 through the drums 10 , 12 .
- a cutting device 30 is positioned generally parallel to and between drum 10 and drum 12 , and along the lateral dimension 104 of non-woven batt 100 as the non-woven batt 100 is transported between the drums 10 , 12 .
- the cutting device 30 is positioned proximate the location along the longitudinal dimension 102 of the non-woven batt 100 generally where the convoluted surface 20 of drum 10 or drum 12 compresses the non-woven batt 100 .
- the cutting device 30 cuts through the non-woven batt 100 transversely and along the lateral dimension 104 to separate non-woven batt 100 into an upper segment 120 and a lower segment 140 , each segment 120 , 140 having an upper surface 122 , 142 and a lower surface 132 , 152 , respectively.
- the cutting device 30 cuts through the non-woven batt 100 at a point along its lateral dimension 104 either nearer to the upper surface 122 of the batt upper segment 120 or to the lower surface 152 of the batt lower segment 140 , whichever surface 122 or 152 is in contact with the convoluted surface 20 , thus creating convoluted surface 160 of non-woven batt 100 .
- the preferred embodiment for convoluting the foam layer 200 is similar to the process for convoluting the non-woven batt 100 .
- Transportation of the foam layer 200 along its longitudinal dimension 202 is accomplished with a conveyor belt (not shown), although it is to be understood that alternate embodiments are known in the art.
- Compression of the foam layer 202 along its lateral dimension 204 is preferably accomplished by a pair of drums, 50 , 52 having opposite rotational directions E, E′. As the conveyor belt introduces the foam layer 200 between drums 50 , 52 , the drums 50 , 52 draw the foam layer 200 to compression.
- Drums 50 , 52 each have a convoluted surface 20 with at least one raised pattern thereon which corresponds to the raised pattern of drums 10 , 12 .
- the convoluted surface 20 of drum 50 should not intermesh or come in contact with the convoluted surface 20 of opposite drum 52 as the drums 50 , 52 rotate.
- only one of the drums 50 , 52 has a convoluted surface 20 while the other of the drums 50 , 52 does not have a convoluted surface 20 which operates to facilitate the drawing of the foam layer 200 through the drums 50 , 52 .
- a cutting device 70 is positioned generally parallel to and between drum 50 and drum 52 , and along the lateral dimension 204 of foam layer 200 as the foam layer 200 is transported between the drums 50 , 52 .
- the cutting device 70 is positioned proximate the location along the longitudinal dimension 202 of foam layer 200 where the convoluted surface 20 of drums 50 , 52 compresses the foam layer 200 .
- the cutting device 70 cuts through the foam layer 200 transversely and along the lateral dimension 204 to separate foam layer 200 into an upper segment 220 and a lower segment 240 , each segment 220 , 240 having an upper surface 222 , 243 and a lower surface 232 , 252 , respectively.
- the cutting device 70 cuts through the foam layer 200 at a point along its lateral dimension 204 either nearer to the upper surface 222 of the foam layer supper segment 220 or to the lower surface 262 of the foam layer lower segment 240 , whichever upper 222 or 252 is in contact with the convoluted surface 20 .
- drums 10 , 12 may be positioned closer to or further away from each other depending on lateral dimension 104 of the non-woven batt 100 to be convoluted.
- the distance between drums 50 , 52 may be positioned depending on the lateral dimension 204 of the foam layer 200 to be convoluted.
- the convoluted surface 20 of drum 10 does not come into contact with or intermesh with the convoluted surface 20 of drum 12 to prevent the cutting device 30 from cutting through the upper surface 122 of the batt upper segment 120 or the lower surface 152 of the batt lower segment 140 .
- the convoluted surface 20 of drum 50 does not come into contact with or intermesh with the convoluted surface 20 of drum 52 to prevent the cutting device 70 from cutting through the upper surface 222 of the foam upper segment 220 or the lower surface 252 of the foam lower segment 240 .
- the cutting devices 30 , 70 can be heated cutters. In the preferred embodiment, cutting devices 30 , 70 or hot wires.
- the heated cutters of cutting devices 30 , 70 can be heated above the melting point of the fibers 108 of the non-woven batt 100 and of the foam 200 , respectively, in order to speed the cutting process.
- the cutting device 30 should be heated in the range of about 189°-206° C. (300°-330° F.).
- non-woven batt 100 formed from synthetic fibers 108 having a low melting point
- the heated cutter 30 cuts through the non-woven batt 100
- the lower surface 132 of the batt upper segment 120 and the upper surface 142 of the batt lower segment 140 are bonded as fibers 108 lose their original plastic memory and then reform as a skin during cooling.
- convoluted surfaces 160 , 260 of the non-woven batt 100 and foam layer 200 are generally comprised of projections 302 and depressions 402 having different patterns and configurations depending upon the convoluted surface 20 of the drums 10 , 12 , 50 , 52 .
- a plurality of pegs 22 of drum convoluted surface 20 forms a plurality of peaks 304 and basins 404 on convoluted surfaces 160 , 260 of non-woven batt 100 and foam layer 200 .
- a plurality of straight edges 24 on the drum convoluted surface 20 forms ridges 306 and valleys 406 on convoluted surfaces 160 , 260 of non-woven fiber batt 100 and the foam layer 200 .
- Waved ridges 308 and waved valleys 408 on convoluted surfaces 160 , 260 of the fiber batt 100 and foam layer 200 are formed of waved ridges on the convoluted surface 20 of the drum.
- the process for forming a convoluted combination fiber and foam pad includes disposing the convoluted surface 160 of at least one of the batt upper and lower segments 120 , 140 in a conforming relationship to the convoluted surface 260 of at least one of the foam layer upper and lower segments 200 , 240 to form a multi-layer pad of a non-woven fiber batt and foam layer having conforming convoluted surfaces.
- the cohesive nature of the non-woven batt 100 and the foam layer 200 would provide sufficient bonding in some applications.
- the conforming convoluted surfaces 160 , 260 , of the batt 100 and fiber 200 respectively, could be bonded using various boding agents known in the art.
- the preferred embodiment for forming a multi-layer pad comprised of a non-woven batt and a foam layer having conforming convoluted surfaces is accomplished by aligning the pair of drums 10 , 12 substantially above the pair of drums 50 , 52 and convoluting the non-woven batt 100 and the foam layer 200 , respectively, as discussed above.
- the raised pattern of convoluted surface 20 of drums 50 , 52 corresponds to the raised pattern of convoluted surface 20 of drums 10 , 12 .
- the upper and lower segments 120 , 140 of the non-woven batt 100 are transported in relatively opposite and substantially horizontal directions, the lower surface 132 of the batt upper segment 120 facing relatively downward and the upper surface 142 of the batt lower segment 140 facing relatively downward.
- the convoluted surface 160 of the batt upper and lower segment 120 , 140 is facing relatively downward.
- a pair of counter rotating rollers 14 , 16 located generally below drums 10 , 12 assist in transporting the segments 120 , 140 of the non-woven batt 100 in relatively opposite and substantially horizontal directions.
- a conveyor belt (not shown) proximate the surfaces opposite the convoluted surface 160 further assists in transporting the segments 120 , 140 of the non-woven batt 100 in opposite and horizontal directions.
- the upper and lower segments 200 , 240 of the foam layer 200 are transported in relatively opposite and substantially horizontal directions, the lower surface 232 of the foam layer upper segment 220 facing relatively upward and the upper surface 2452 of the foam layer lower segment 140 also facing relatively upward, and the convoluted surface 260 of the foam layer upper and lower segments 220 , 240 facing relatively upward.
- a paid of counter rotating rollers 54 , 56 located generally above drums 50 , 52 assist in transporting the segments 220 , 240 of the foam layer 200 in opposite and substantially horizontal directions.
- a conveyor belt (not shown) proximate the surfaces opposite the convoluted surface 260 further assists in transporting the segments 220 , 240 of the foam layer 200 in opposite and horizontal directions.
- the batt upper segment 120 and the foam upper segment 220 come together laterally.
- the batt lower segment 140 and the foam lower segment 240 laterally come together.
- the distance between conveyer belts (not shown) proximate the non-convoluted surfaces of the non-woven batt 100 and foam layer 200 are adjusted to accomplish the lateral movement.
- the batt convoluted surface 160 and the foam layer convoluted surface 260 are aligned to provide the upstanding projections 302 of the batt convoluted surface 160 to conform with or project into the depressions 402 of the foam convoluted surface 260 , and the depressions 402 of the batt convoluted surface 160 to conform with or project into the upstanding projections 302 of the foam convoluted surface 260 .
- alignment of the convoluted surfaces, 160 , 260 is accomplished by controlling the rotational speeds of drums 10 , 12 and of drums 50 , 52 , and adjusting the horizontal placement of the convoluted surfaces 160 , 260 for proper alignment.
- the peaks 304 of the batt and foam convoluted surfaces 160 , 260 conform with or project into the corresponding basins 404 of the convoluted surfaces 260 , 160 of the batt and foam, respectively.
- the ridges 306 of the batt convoluted surface 160 and the foam convoluted surface 260 conform with or project into the corresponding valleys 406 of the foam convoluted surface 260 and the batt convoluted surface 160 , respectively.
- the waved ridges 308 of the batt and foam convoluted surfaces 160 , 260 conform with or project into the corresponding waved valleys 408 and batt convoluted surfaces 260 , 160 , respectively.
- the convoluted surfaces 160 , 260 of the batt 100 and foam layer 200 can be bonded together with a bonding agent.
- the bonding agent can be applied in various manners and stages throughout the process as is known in the art.
- an apparatus 18 , 20 sprays a bonding agent on at least one of the convoluted surfaces 160 , 260 proximate rollers 14 , 16 or rollers 54 , 56 .
- a multi-layer pad 500 formed from a non-woven fiber batt 162 and a foam layer having conforming convoluted surfaces suitable for use in mattresses and cushions for sofas, loveseats, chairs and other upholstery products is shown.
- the multi-layer pad 500 has convoluted surfaces 160 , 260 generally comprised of projections 302 and depressions 402 in different patterns and configurations depending upon the convoluted surface 20 of the drums 10 , 12 and 50 , 52 .
- the convoluted surfaces 160 , 260 remain integral with unconvoluted thin bases 162 , 262 of the non-woven batt 100 and the foam layer 200 , respectively, to retain stiffness for using the multi-layer pad 500 in items such as sofas, cushions and mattresses.
- convoluted surface 160 and base 162 are formed from the same non-woven batt 100 and convoluted surface 260 and base 262 are formed from the same foam layer 200 .
- the non-woven batt component 100 of the multi-layer pad 500 may be made of either substantially vertically oriented low melt fibers 108 b or substantially horizontally oriented densified low melt fibers 108 b .
- the projections 302 of convoluted surface 160 have a greater ability to retain their shape when cut by the heated cutter 30 , as the vertical orientation of fibers 108 b resists sloughing off portions of the projections 302 during the convolution process.
- projections 302 of the convoluted surfaces 160 , 260 extend in the range of approximately one half to on (1 ⁇ 2-1) inch in a lateral direction from depressions 402 . In the preferred embodiment, projections 302 extend approximately three fourths (3 ⁇ 4) inch in a lateral direction from depressions 402 . In another alternative embodiment, unconvoluted thin bases 162 , 262 extend approximately one half (1 ⁇ 2) inch in the laterally.
- a non-woven fiber batt specifically, one having a first, generally flat, surface and a second, convoluted, surface, which is neither taught nor suggested by the prior art.
- the fibers of the fiber batt are arranged in a generally vertical orientation.
Abstract
resent invention relates to a process of forming a multi-layer pad of a non-woven fiber batt and a foam layer having conforming convoluted surfaces and to a multi-layer pad incorporating a non-woven fiber batt and foam layer. The process of forming a non-woven batt layer and a foam layer having conforming convoluted surfaces comprises transporting each layer along its longitudinal dimension while compressing each layer along its lateral dimension. Concomitantly with compression, each layer is cut transversely along its lateral dimension to separate each layer into an upper segment and a lower segment and to provide conforming convoluted surfaces on the segments of each layer, the convoluted surfaces comprised of upstanding projections and depressions. The convoluted surfaces of the non-woven batt layer and the foam layer are aligned so that the upstanding projections of the batt convoluted surface project into the corresponding depressions of the foam convoluted surface, while the upstanding projections of the foam convoluted surface project into the corresponding depressions of the batt convoluted surface.
Description
- This application is a Continuation Application under 35 USC 120 of and claims priority to co-pending U.S. patent application Ser. No. 11/315,948 (4003-03804) filed Dec. 22, 2005 and entitled “Convoluted Fiber Pad,” which is in turn a Divisional Application of U.S. patent application Ser. No. 10/445,706 filed May 27, 2003, now U.S. Pat. No. 7,008,691, which is in turn a Continuation Application of U.S. patent application Ser. No. 10/068,111 filed Feb. 6, 2002, now U.S. Pat. No. 6,596,387, which is in turn a Divisional Application of U.S. patent application Ser. No. 09/406,366, filed Sep. 28, 1999, now U.S. Pat. No. 6,372,076, all of which are hereby incorporated by reference for all purposes as if reproduced in their entirety. Accordingly, priority is claimed back to the above-listed patents and applications.
- Not applicable.
- Not applicable.
- The present invention relates to a process of forming a fiber batt and, more particularly, a fiber batt formed to include a surface having a convoluted shape.
- Mattresses and cushions for sofas, loveseats, chairs and other upholstery products generally comprise filler materials, batts, and foams, among other layering materials, for achieving a range of comfort, lot and durability. There are a number of advantages to be achieved by the construction of batts from synthetic, staple fiber material for use in mattresses and upholstery cushions. Such fibers are inherently lightweight and therefore easy to ship, store and manipulate during fabrication. These fibers are also generally less moisture absorbent than natural fibers such as cotton, or cellulosic based synthetic fibers such as rayon. Therefore, products made from these fibers can be maintained in a more hygienic condition and dried with much less expenditure of energy. When subjected to open flame, many of these fibers also tend to melt and drip rather than burn. While some of these fibers give off toxic fumes, the escape of such fumes has been avoided or minimized by encapsulating the batt in a fire retardant or relatively air impermeable casing. In contrast, fibers such as cotton burn rapidly at high heat and generate dense smoke.
- Synthetic fiber batts have been used in mattresses and upholstery cushions since batts maintain their comfort characteristics over time. Traditional batts having desired comfort and height characteristics may generally be too stiff to allow a mattress or futon to be easily rolled for storage or folded into a sofa. As disclosed in U.S. Pat. No. 4,668,562, a batt would be required to create a mattress having the desired comfort characteristics.
- Foam materials, in combination with fiber layers, have also been used in the construction of mattresses and upholstery cushions. As disclosed in U.S. Pat. No. 5,317,768, the entire disclosure of which is incorporated herein by reference, an upper surface positioned on top of the general coil structure of a mattress includes a first layer of cover or ticking, a second layer of fiber or filler material, a third layer of a foam having convoluted surface which faces the second layer, and a further layer of backing material. All four layers are stitched together in a quilt pattern.
- Futon furniture in recent years has become a popular alternative to standard upholstered furniture. Futon sofas, loveseats and chairs can be repositioned so that the furniture can be used as a bed. Traditionally, polyurethane foam has been combined with other types of cushioning materials such as cotton batting, latex rubber, and various man-made fiber products in order to impart the desired comfort characteristics to a final product. With time and use, the various types and combinations of materials take on different degrees of set as a result of compression from the weight of a human body. As is often the case with the softer materials, the final product will take more set over time with continued use. The more set the product takes over time, the more comfort, flexibility and height is lost from the product. It is desirable to bend, fold and/or roll up a futon mattress to be used as a sofa or for storage when the futon is not used as a flat sleep surface. Yet, when the futon is used as a sleep surface it must be stiff enough to span slats in a bed frame. Preferably, the material used in making the futon would take on little or no set.
- In our prior U.S. patent application Ser. Nos. 09/363,726 filed Jul. 29, 1999 and 10/124,106 filed Apr. 17, 2002, both entitled “Convoluted Surface Fiber Pad” and since issued as U.S. Pat. Nos. 6,500,292 and 6,40,610, respectively, and hereby incorporated by reference as if reproduced in their entirety, we disclosed a non-woven fiber pad having a convoluted surface and an integral relatively thin but stiff base formed from a non-woven fiber batt. To form the non-woven fiber pad, a non-woven fiber batt is introduced between a pair of counter-rotating drums, at least one of which has a convoluted surface. As the non-woven fiber batt is drawn between the counter-rotating drums, the convolutions upon the surface of at least one roller compresses the surface of the non-woven fiber batt in frictional engagement therewith to a greater or lesser degree depending on the degree of surface relief of the roller convolutions. A heated wire is placed generally parallel to and between the pair of drums so that, as the non-woven fiber batt is drawn between the drums and compressed by the drum convolutions, the heated wire cuts through the non-woven fiber batt to create a cut-pattern generally mirroring the convolutions on the surface of the drum compressing the non-woven fiber batt. The aforementioned cut-pattern results because, whenever a drum convolution compresses the non-woven fiber batt in the vicinity of the heated wire, the wire will pass through the non-woven fiber batt at a point nearer to the batt surface which is in contact with the drum convolution.
- In various embodiments thereof, the present invention is directed to a fiber pad comprised of a non-woven fiber batt having a first, generally flat, surface and a second, convoluted, surface. The non-woven fiber batt may further include an unconvoluted base and a number of projections integrally formed with the unconvoluted base. Variously, the projections may be configured as: (a) free-standing peaks spaced apart from the other peaks; (2) free-standing ridges spaced apart from the other free-standing ridges; or (3) free-standing wavy ridges spaced apart from the other free-standing wavy ridges.
- In further aspects thereof, the fiber pad extends in longitudinal, lateral and transverse dimensions. Variously, the non-woven fiber batt may be comprised of: (1) fibers oriented substantially horizontally along the longitudinal and transverse dimensions of the fiber pad; (2) fibers oriented substantially horizontally along the longitudinal and transverse dimensions of the fiber pad and substantially vertically along the lateral dimension of the fiber pad; or (3) fibers oriented substantially vertically along the lateral dimension of the fiber pad.
- In various further aspects thereof, the non-woven fiber batt may be comprised of: (1) plural fibers spray-bonded to one another by an adhesive; or (2) a first plurality of high-melt fibers and a second plurality of low-melt fibers bonded to one another and to the first plurality of high melt fibers. In either of these aspects, the formation of the second, convoluted, surface does not weaken the bonds between the fibers. Finally, in still further aspects thereof, the fibers may be: (1) a blend of hollow, solid and crimped fibers having varying diameters and deniers; (2) synthetic fibers; or (3) polyester fibers.
- For a more detailed description of the present invention, and for further details and advantages thereof, reference is now made to the Detailed Description which follows, when taken in conjunction with the accompanying drawings, in which:
-
FIG. 1 is a perspective view of a non-woven fiber batt layer. -
FIG. 2 is a perspective view of a foam layer. -
FIG. 3 is a schematic view of a device for separating a batt into first and second convoluted pads. -
FIG. 4 is a schematic view of a device for forming a multi-layer pad having convoluted fiber and convoluted layers from the non-woven fiber batt ofFIG. 1 and the foam batt ofFIG. 2 . -
FIG. 5 is a perspective view of a drum forming part of the device of eitherFIG. 3 orFIG. 4 and having alternative embodiments of convoluted surfaces thereon. -
FIG. 6 is a perspective view of a multi-layer pad formed of conforming non-woven fiber and foam batts which is sectioned to show a first type of convoluted surface for the batts. -
FIG. 7 is a perspective view of a multi-layer pad formed of conforming non-woven fiber and foam batts which is sectioned to show a second type of convoluted surface for the batts. -
FIG. 8 is a perspective view of a multi-layer pad formed of conforming non-woven fiber and foam batts sectioned to show a third type of convoluted surface for the bats. - Referring to
FIG. 1 , anon-woven batt 100 having alongitudinal dimension 102, alateral dimension 104 and atransverse dimension 106 will now be described in greater detail. Thenon-woven batt 100 may include a blend of different types offibers 108 having varying diameters and deniers, and fibers which are hollow, solid and crimped. Blending different types offibers 108 creates dead air spaces which contribute to the resiliency of the convolutedmulti-layer pad 500 ofFIGS. 6 , 7 and 8 and lends to the integrity of thenon-woven batt 100. - The
fibers 108 of thenon-woven batt 100 can be synthetic fibers which are known in the art, for example, polyester and polypropylene. In an alternative embodiment, thefibers 108 are substantially synthetic fibers having a melting point in the range of about 189°-206° C. (300°-330° F.). In the preferred embodiment, thefibers 108 are polyester fibers having a melting point substantially in the above specified range. However, other synthetic fibers known in the art also may be used, such as polypropylene, having melt ranges close to or below the above-specified range. Additionally, natural fibers such as camel, llama, wool, cashmere, or cotton can be incorporated with synthetic fibers to form thenon-woven batt 100. Because natural fibers may tend to generate smoke when in contact with a heated cutter, the percentage of natural fiber incorporated into thenon-woven batt 100 should be within a range which will not create an environmental or health hazard during a heated cutting operation. - The
fibers 108 of thenon-woven batt 100 can also be densified. As used herein, the term “densified fibers” hereby refers to fibers having a weight-to-thickness ratio of at least 57 grams (2 ounces) per 3.8 centimeters (1.5 inch) thickness for a 30.5 square centimeter (1 square foot) area of batt. - The
fibers 108 can be oriented substantially horizontally 108 a along thelongitudinal dimension 102 and traversedimension 106 of thenon-woven batt 100. In an alternative embodiment, thenon-woven batt 100 can be comprised of horizontally orientedfibers 108 a, and vertically orientedfibers 108 b along thelateral dimension 104 of thenon-woven batt 100. In the preferred embodiment, thenon-woven batt 100 is formed from substantially vertically orientedfibers 108 b, as vertically orientedfibers 108 b have better convolution retention properties as compared to horizontally orientedfibers 108 a, as discussed below. - The
batt 100 can be formed using one of the several processes for converting a source of fiber into anon-woven batt 100, as is known in the art. Thefibers 108 may receive an application of a resin to improve the structural integrity of thenon-woven batt 100, or alternatively may incorporate a portion of low melting fibers which will melt to bond high melt fibers in thenon-woven batt 100 on application of heat. The ends of thefibers 108 innon-woven batt 100 may be brushed to improve the entwining of individual fibers of one end into adjacent ends. Adjacent ends offibers 108 may be of substantially the same height, or, in the alternative, may have different heights in a repeating pattern. The structure and manufacture of a batt incorporating vertically oriented fibers is described in more detail in U.S. Pat. No. 5,702,801, the entire disclosure of which is incorporated herein by reference. - In the early stages of forming the
non-woven batt 100 for thefibers 108, thenon-woven batt 100 may have an initial thickness of up to about eighteen (18) inches. Thefibers 108 are spray bonded together with an adhesive and then compressed by rolling thefibers 108 to form thenon-woven batt 100, as is known in the art. In an alternative process, thefibers 108 are oven-baked together and then rolled and cooled to form thenon-woven batt 100. - Referring next to
FIG. 2 , a foam layer 200 has alongitudinal dimension 202, alateral dimension 204 and atransverse dimension 206. The foam layer 200 preferably is a cellular foam structure which is resilient along itsdimensions dimensions - The
lateral dimension 204 of the foam layer 200 can be as large or as small as desired. In one alternate embodiment, thelateral dimension 204 is in the range of one half to three (½-3) inches. In another alternate embodiment, thelateral dimension 204 is in the range of one to one and one half (1-1½) inches. Finally, in the preferred embodiment, thelateral dimension 204 of the foam layer 200 is approximately 1¼ inches. - Referring next to
FIG. 3 , the process of formingnon-woven batt 100 having aconvoluted surface 160 is generally accomplished by transporting thenon-woven batt 100 along itslongitudinal dimension 102 while compressing thenon-woven batt 100 along itslateral dimension 104. Concomitantly with compression, thenon-woven batt 100 is cut transversely along itslateral dimension 104 to separate thenon-woven batt 100 into anupper segment 120 and alower segment 140 to provide conformingconvoluted surface 160 of the batt upper andlower segments lower segments upper surface lower surface convoluted surface 160 of the battupper segment 120 is proximate to itslower surface 132. Conversely, theconvoluted surface 160 of the battlower segment 140 is proximate to itsupper surface 152. Further details of the process for forming a non-woven fiber pad having a convoluted surface are disclosed in U.S. Pat. Nos. 6,500,292 and 6,740,610, both of which were previously incorporated by reference as if reproduced in their entirety. - Referring next to
FIG. 4 , similar to the general process of formingnon-woven batt 100 having aconvoluted surface 160, the process of forming foam layer 200 having aconvoluted surface 260 is generally accomplished by transporting the foam layer 200 along itslongitudinal dimension 202 while compressing the foam layer 200 along itslateral dimension 204. Concomitantly with compression, the foam layer 200 is cut transversely along itslateral dimension 204 to separate the foam layer 200 into an upper segment 220 and alower segment 240 and to provide conformingconvoluted surface 260 of the foam layer upper and lower segments 220 240, respectively. The foam layer upper andlower segments 200, 240 each have anupper surface lower surface 232, 262, respectively. Theconvoluted surface 260 of the foam layer upper segment 220 is proximate to its lower surface 232. Conversely, theconvoluted surface 260 of the foam layerlower segment 240 is proximate to itsupper surface 242. - Referring to
FIGS. 3 and 5 , the preferred embodiment for transporting thenon-woven batt 100 along itslongitudinal dimension 102 is accomplished by a conveyor belt (not shown), although it should be clearly understood that alternate embodiments are known in the art. Compression of thenon-woven batt 100 along itslateral dimension 104 is preferably accomplished by a pair ofdrums non-woven batt 100 between thedrums drums non-woven batt 100 into compression. -
Drums convoluted surface 20 with at least one raised pattern thereon. The raised pattern is generally comprised of a plurality of upstanding projections and depressions. Alternative embodiments of the raised pattern include a plurality ofpegs 22,straight edges 24 or wavededges 26, although it is to be understood that alternative raised patterns are known in the art. Theconvoluted surface 20 ofdrum 10 should not intermesh or come in contact with theconvoluted surface 20 ofopposite drum 12 as thedrums drums convoluted surface 20 while the other of thedrums convoluted surface 20 which operates to facilitate the drawing of thebatt 100 through thedrums - As the
non-woven batt 100 is drawn into frictional engagement with thedrum 10 anddrum 12, theconvoluted surface 20 of either ofdrum 10 or drum 12 compresses thenon-woven batt 100 along itslateral dimension 104 towards theopposite drum device 30, schematically shown as an X, is positioned generally parallel to and betweendrum 10 anddrum 12, and along thelateral dimension 104 ofnon-woven batt 100 as thenon-woven batt 100 is transported between thedrums device 30 is positioned proximate the location along thelongitudinal dimension 102 of thenon-woven batt 100 generally where theconvoluted surface 20 ofdrum 10 or drum 12 compresses thenon-woven batt 100. - As the
non-woven batt 100 encounters the cuttingdevice 30, the cuttingdevice 30 cuts through thenon-woven batt 100 transversely and along thelateral dimension 104 to separatenon-woven batt 100 into anupper segment 120 and alower segment 140, eachsegment upper surface lower surface device 30 cuts through thenon-woven batt 100 at a point along itslateral dimension 104 either nearer to theupper surface 122 of the battupper segment 120 or to thelower surface 152 of the battlower segment 140, whichever surface 122 or 152 is in contact with theconvoluted surface 20, thus creatingconvoluted surface 160 ofnon-woven batt 100. - Returning momentarily to
FIG. 4 , the preferred embodiment for convoluting the foam layer 200 is similar to the process for convoluting thenon-woven batt 100. Transportation of the foam layer 200 along itslongitudinal dimension 202 is accomplished with a conveyor belt (not shown), although it is to be understood that alternate embodiments are known in the art. Compression of thefoam layer 202 along itslateral dimension 204 is preferably accomplished by a pair of drums, 50, 52 having opposite rotational directions E, E′. As the conveyor belt introduces the foam layer 200 betweendrums drums Drums convoluted surface 20 with at least one raised pattern thereon which corresponds to the raised pattern ofdrums convoluted surface 20 ofdrum 50 should not intermesh or come in contact with theconvoluted surface 20 ofopposite drum 52 as thedrums drums convoluted surface 20 while the other of thedrums convoluted surface 20 which operates to facilitate the drawing of the foam layer 200 through thedrums - As the foam layer 200 is drawn into frictional engagement with
drum 50 anddrum 52, theconvoluted surface 20 of eitherdrum 50 or drum 52 compresses the foam layer 200 along itslateral dimension 204 towards theopposite drum device 70, schematically shown as a Y, is positioned generally parallel to and betweendrum 50 anddrum 52, and along thelateral dimension 204 of foam layer 200 as the foam layer 200 is transported between thedrums device 70 is positioned proximate the location along thelongitudinal dimension 202 of foam layer 200 where theconvoluted surface 20 ofdrums device 70, the cuttingdevice 70 cuts through the foam layer 200 transversely and along thelateral dimension 204 to separate foam layer 200 into an upper segment 220 and alower segment 240, eachsegment 220, 240 having anupper surface 222, 243 and alower surface 232, 252, respectively. The cuttingdevice 70 cuts through the foam layer 200 at a point along itslateral dimension 204 either nearer to theupper surface 222 of the foam layer supper segment 220 or to thelower surface 262 of the foam layerlower segment 240, whichever upper 222 or 252 is in contact with theconvoluted surface 20. - It will be understood by those in the art that the
drums lateral dimension 104 of thenon-woven batt 100 to be convoluted. Similarly, the distance betweendrums lateral dimension 204 of the foam layer 200 to be convoluted. In the preferred embodiment, theconvoluted surface 20 ofdrum 10 does not come into contact with or intermesh with theconvoluted surface 20 ofdrum 12 to prevent thecutting device 30 from cutting through theupper surface 122 of the battupper segment 120 or thelower surface 152 of the battlower segment 140. Similarly, in the process for convoluting the foam layer 200, theconvoluted surface 20 ofdrum 50 does not come into contact with or intermesh with theconvoluted surface 20 ofdrum 52 to prevent thecutting device 70 from cutting through theupper surface 222 of the foam upper segment 220 or thelower surface 252 of the foamlower segment 240. - The
cutting devices devices devices fibers 108 of thenon-woven batt 100 and of the foam 200, respectively, in order to speed the cutting process. For polyester fibers of thenon-woven batt 100, the cuttingdevice 30 should be heated in the range of about 189°-206° C. (300°-330° F.). Fornon-woven batt 100 formed fromsynthetic fibers 108 having a low melting point, as theheated cutter 30 cuts through thenon-woven batt 100, thelower surface 132 of the battupper segment 120 and theupper surface 142 of the battlower segment 140 are bonded asfibers 108 lose their original plastic memory and then reform as a skin during cooling. - Referring next to
FIGS. 6 , 7 and 8,convoluted surfaces non-woven batt 100 and foam layer 200, respectively, are generally comprised ofprojections 302 anddepressions 402 having different patterns and configurations depending upon theconvoluted surface 20 of thedrums pegs 22 of drum convolutedsurface 20 forms a plurality ofpeaks 304 andbasins 404 onconvoluted surfaces non-woven batt 100 and foam layer 200. A plurality ofstraight edges 24 on the drum convolutedsurface 20forms ridges 306 andvalleys 406 onconvoluted surfaces non-woven fiber batt 100 and the foam layer 200. Wavedridges 308 and wavedvalleys 408 onconvoluted surfaces fiber batt 100 and foam layer 200 are formed of waved ridges on theconvoluted surface 20 of the drum. - Returning momentarily to
FIG. 4 , generally the process for forming a convoluted combination fiber and foam pad includes disposing theconvoluted surface 160 of at least one of the batt upper andlower segments convoluted surface 260 of at least one of the foam layer upper andlower segments 200, 240 to form a multi-layer pad of a non-woven fiber batt and foam layer having conforming convoluted surfaces. The cohesive nature of thenon-woven batt 100 and the foam layer 200 would provide sufficient bonding in some applications. In alternative embodiments, the conformingconvoluted surfaces batt 100 and fiber 200, respectively, could be bonded using various boding agents known in the art. - The preferred embodiment for forming a multi-layer pad comprised of a non-woven batt and a foam layer having conforming convoluted surfaces is accomplished by aligning the pair of
drums drums non-woven batt 100 and the foam layer 200, respectively, as discussed above. The raised pattern ofconvoluted surface 20 ofdrums convoluted surface 20 ofdrums non-woven batt 100, the upper andlower segments non-woven batt 100 are transported in relatively opposite and substantially horizontal directions, thelower surface 132 of the battupper segment 120 facing relatively downward and theupper surface 142 of the battlower segment 140 facing relatively downward. Thus, theconvoluted surface 160 of the batt upper andlower segment counter rotating rollers 14, 16 located generally below drums 10, 12 assist in transporting thesegments non-woven batt 100 in relatively opposite and substantially horizontal directions. In another alternative embodiment, a conveyor belt (not shown) proximate the surfaces opposite theconvoluted surface 160 further assists in transporting thesegments non-woven batt 100 in opposite and horizontal directions. - Similarly, upon convolution of the foam layer 200 as detailed above, the upper and
lower segments 200, 240 of the foam layer 200 are transported in relatively opposite and substantially horizontal directions, the lower surface 232 of the foam layer upper segment 220 facing relatively upward and the upper surface 2452 of the foam layerlower segment 140 also facing relatively upward, and theconvoluted surface 260 of the foam layer upper andlower segments 220, 240 facing relatively upward. In an alternative embodiment, a paid ofcounter rotating rollers segments 220, 240 of the foam layer 200 in opposite and substantially horizontal directions. In another alternative embodiment, a conveyor belt (not shown) proximate the surfaces opposite theconvoluted surface 260 further assists in transporting thesegments 220, 240 of the foam layer 200 in opposite and horizontal directions. - As the
segments non-woven batt 100, and thesegments 220, 240 of the foam layer 200, are transported in opposite and generally horizontal directions, the battupper segment 120 and the foam upper segment 220 come together laterally. Similarly, the battlower segment 140 and the foamlower segment 240 laterally come together. In an alternative embodiment, the distance between conveyer belts (not shown) proximate the non-convoluted surfaces of thenon-woven batt 100 and foam layer 200 are adjusted to accomplish the lateral movement. The battconvoluted surface 160 and the foam layerconvoluted surface 260 are aligned to provide theupstanding projections 302 of the battconvoluted surface 160 to conform with or project into thedepressions 402 of the foamconvoluted surface 260, and thedepressions 402 of the battconvoluted surface 160 to conform with or project into theupstanding projections 302 of the foamconvoluted surface 260. In the preferred embodiment, alignment of the convoluted surfaces, 160, 260 is accomplished by controlling the rotational speeds ofdrums drums convoluted surfaces - In an alternative embodiment as shown in
FIG. 3 , thepeaks 304 of the batt and foamconvoluted surfaces basins 404 of theconvoluted surfaces FIG. 4 , theridges 306 of the battconvoluted surface 160 and the foamconvoluted surface 260 conform with or project into the correspondingvalleys 406 of the foamconvoluted surface 260 and the battconvoluted surface 160, respectively. In a further alternative embodiment shown inFIG. 5 , the wavedridges 308 of the batt and foamconvoluted surfaces valleys 408 and battconvoluted surfaces - The
convoluted surfaces batt 100 and foam layer 200 can be bonded together with a bonding agent. The bonding agent can be applied in various manners and stages throughout the process as is known in the art. In preferred embodiment, anapparatus convoluted surfaces proximate rollers 14, 16 orrollers - Referring next to
FIGS. 6 , 7 and 8, amulti-layer pad 500 formed from anon-woven fiber batt 162 and a foam layer having conforming convoluted surfaces suitable for use in mattresses and cushions for sofas, loveseats, chairs and other upholstery products is shown. Themulti-layer pad 500 has convolutedsurfaces projections 302 anddepressions 402 in different patterns and configurations depending upon theconvoluted surface 20 of thedrums convoluted surfaces thin bases non-woven batt 100 and the foam layer 200, respectively, to retain stiffness for using themulti-layer pad 500 in items such as sofas, cushions and mattresses. For example,convoluted surface 160 andbase 162 are formed from the samenon-woven batt 100 andconvoluted surface 260 andbase 262 are formed from the same foam layer 200. Thenon-woven batt component 100 of themulti-layer pad 500 may be made of either substantially vertically orientedlow melt fibers 108 b or substantially horizontally oriented densifiedlow melt fibers 108 b. When thenon-woven batt component 100 of themulti-layer pad 500 is made for vertically orientedfibers 108 b, theprojections 302 ofconvoluted surface 160 have a greater ability to retain their shape when cut by theheated cutter 30, as the vertical orientation offibers 108 b resists sloughing off portions of theprojections 302 during the convolution process. - In an alternative embodiment,
projections 302 of theconvoluted surfaces depressions 402. In the preferred embodiment,projections 302 extend approximately three fourths (¾) inch in a lateral direction fromdepressions 402. In another alternative embodiment, unconvolutedthin bases - Thus, there has been described and illustrated herein, a non-woven fiber batt, specifically, one having a first, generally flat, surface and a second, convoluted, surface, which is neither taught nor suggested by the prior art. To enhance the ability of the fiber batt to remain in the convoluted shape, in one aspect of the invention, the fibers of the fiber batt are arranged in a generally vertical orientation. However, those skilled in the art will appreciate that numerous variations and modifications thereof are possible without departing from the spirit and scope of the invention. Accordingly, the invention should not be limited to the specific embodiment or embodiments disclosed herein. Rather, the invention is to be defined solely by the following claims and equivalents thereof.
Claims (20)
1. A fiber pad, comprising:
a non-woven fiber batt having a first surface and a second surface;
said first surface having a generally flat shape and said second surface having a convoluted shape.
2. The fiber pad of claim 1 , wherein said non-woven fiber bat further comprises an unconvoluted base and a plurality of projections integrally formed with said unconvoluted base, each one of said plurality of projections having a free-standing peak spaced apart from said free-standing peaks of adjacent ones of said plurality of projections.
3. The fiber pad of claim 1 , wherein said fiber pad has longitudinal, lateral and transverse dimensions.
4. The fiber pad of claim 3 , wherein said non-woven fiber batt is comprised of fibers oriented substantially horizontally along said longitudinal and transverse dimensions of said fiber pad.
5. The fiber pad of claim 3 , wherein said non-woven fiber batt is comprised of fibers oriented substantially horizontally along said longitudinal and transverse dimensions of said fiber pad and fibers oriented substantially vertically along said lateral dimension of said fiber pad.
6. The fiber pad of claim 3 , wherein said non-woven fiber batt is comprised of fibers oriented substantially vertically along said lateral dimension of said fiber pad.
7. The fiber pad of claim 6 , wherein said non-woven fiber batt is densified.
8. The fiber pad of claim 6 , wherein said non-woven fiber batt is comprised of a plurality of fibers spray-bonded to one another by an adhesive and wherein formation of said second, convoluted, surface does not weaken the bonds between said plurality of fibers.
9. The fiber pad of claim 6 , wherein said non-woven fiber batt is comprised of a first plurality of high-melt fibers and a second plurality of low-melt fibers bonded to one another and to said first plurality of high melt fibers and wherein formation of said second, convoluted, surface does not weaken the bonds between said first and second plurality of fibers.
10. The fiber pad of claim 6 , wherein said fibers are comprised of a blend of hollow, solid and crimped fibers having varying diameters and deniers.
11. The fiber pad of claim 6 , wherein said fibers are synthetic.
12. The fiber pad of claim 11 , wherein said synthetic fibers are polyester fibers.
13 A non-woven fiber batt comprising a plurality of fibers arranged such that a first surface of said non-woven fiber batt has a generally convoluted shape.
14. The non-woven fiber batt of claim 13 , wherein said non-woven fiber batt has longitudinal, lateral and transverse dimensions and wherein said non-woven fiber batt is comprised of fibers oriented substantially horizontally along said longitudinal and transverse dimensions thereof.
15. The non-woven fiber batt of claim 13 , wherein said non-woven fiber batt has longitudinal, lateral and transverse dimensions and wherein said non-woven fiber batt is comprised of fibers oriented substantially horizontally along said longitudinal and transverse dimensions of said non-woven fiber batt and fibers oriented substantially vertically along said lateral dimension of said non-woven fiber batt.
16. The non-woven fiber batt of claim 13 , wherein said non-woven fiber batt has longitudinal, lateral and transverse dimensions and wherein said non-woven fiber batt is comprised of fibers oriented substantially vertically along said lateral dimension of said non-woven fiber batt.
17. The non-woven fiber batt of claim 16 , wherein said non-woven fiber batt further comprises an unconvoluted base and a plurality of projections integrally formed with said unconvoluted base, each one of said plurality of projections including a free-standing peak spaced apart from said free-standing peaks of adjacent ones of said plurality of projections.
18. The non-woven fiber batt of claim 16 , wherein said non-woven fiber batt further comprises an unconvoluted base and a plurality of projections integrally formed with said unconvoluted base, each one of said plurality of projections including a free-standing ridge spaced apart from said free-standing ridges of adjacent ones of said plurality of projections.
19. The non-woven fiber batt of claim 16 , wherein said non-woven fiber batt further comprises an unconvoluted base and a plurality of projections integrally formed with said unconvoluted base, each one of said plurality of projections including a free-standing wavy ridge spaced apart from said free-standing wavy ridges of adjacent ones of said plurality of projections.
20. A fiber pad, comprising:
a non-woven fiber batt formed of a plurality of fibers bonded to one another, said non-woven fiber batt having a first, generally planar, surface and a second, convoluted, surface;
said non-woven fiber batt having a lateral dimension which extends from said first, generally planar, surface to said second, convoluted surface; and
said plurality of fibers forming said non-woven fiber batt being oriented substantially vertically relative to said lateral dimension of said non-woven fiber batt;
wherein said vertically oriented fibers enhance a convolution retention property of said non-woven fiber batt.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US12/272,601 US20090068397A1 (en) | 1999-09-28 | 2008-11-17 | Convoluted fiber pad |
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US09/406,366 US6372076B1 (en) | 1999-09-28 | 1999-09-28 | Convoluted multi-layer pad and process |
US10/068,111 US6596387B2 (en) | 1999-09-28 | 2002-02-06 | Convoluted multi-layer pad and process |
US10/445,706 US7008691B2 (en) | 1999-09-28 | 2003-05-27 | Convoluted multi-layer pad and process |
US11/315,948 US7452589B2 (en) | 1999-09-28 | 2005-12-22 | Convoluted fiber pad |
US12/272,601 US20090068397A1 (en) | 1999-09-28 | 2008-11-17 | Convoluted fiber pad |
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US09/406,366 Expired - Fee Related US6372076B1 (en) | 1999-09-28 | 1999-09-28 | Convoluted multi-layer pad and process |
US10/068,111 Expired - Fee Related US6596387B2 (en) | 1999-09-28 | 2002-02-06 | Convoluted multi-layer pad and process |
US10/445,706 Expired - Fee Related US7008691B2 (en) | 1999-09-28 | 2003-05-27 | Convoluted multi-layer pad and process |
US11/315,948 Expired - Fee Related US7452589B2 (en) | 1999-09-28 | 2005-12-22 | Convoluted fiber pad |
US12/272,601 Abandoned US20090068397A1 (en) | 1999-09-28 | 2008-11-17 | Convoluted fiber pad |
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US09/406,366 Expired - Fee Related US6372076B1 (en) | 1999-09-28 | 1999-09-28 | Convoluted multi-layer pad and process |
US10/068,111 Expired - Fee Related US6596387B2 (en) | 1999-09-28 | 2002-02-06 | Convoluted multi-layer pad and process |
US10/445,706 Expired - Fee Related US7008691B2 (en) | 1999-09-28 | 2003-05-27 | Convoluted multi-layer pad and process |
US11/315,948 Expired - Fee Related US7452589B2 (en) | 1999-09-28 | 2005-12-22 | Convoluted fiber pad |
Country Status (3)
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US (5) | US6372076B1 (en) |
AU (1) | AU7987600A (en) |
WO (1) | WO2001023175A1 (en) |
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2002
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2003
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2005
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WO2013012904A1 (en) * | 2011-07-19 | 2013-01-24 | Kingsdown, Inc. | Foam mattress with progressive support characteristics and method for manufacturing the same |
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Also Published As
Publication number | Publication date |
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AU7987600A (en) | 2001-04-30 |
US7008691B2 (en) | 2006-03-07 |
US20060099869A1 (en) | 2006-05-11 |
US6596387B2 (en) | 2003-07-22 |
US20020069957A1 (en) | 2002-06-13 |
US7452589B2 (en) | 2008-11-18 |
US20030235684A1 (en) | 2003-12-25 |
WO2001023175A1 (en) | 2001-04-05 |
US6372076B1 (en) | 2002-04-16 |
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