US3687759A - Process for producing resilient cushion - Google Patents

Process for producing resilient cushion Download PDF

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Publication number
US3687759A
US3687759A US3687759DA US3687759A US 3687759 A US3687759 A US 3687759A US 3687759D A US3687759D A US 3687759DA US 3687759 A US3687759 A US 3687759A
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Prior art keywords
filaments
bath
loops
cushioning
spinneret
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Expired - Lifetime
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English (en)
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Helmut Werner
Hans Stapp
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Akzona Inc
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Akzona Inc
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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
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/16—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
    • 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
    • Y10T24/00—Buckles, buttons, clasps, etc.
    • Y10T24/27—Buckles, buttons, clasps, etc. including readily dissociable fastener having numerous, protruding, unitary filaments randomly interlocking with, and simultaneously moving towards, mating structure [e.g., hook-loop type fastener]
    • 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
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/26—Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
    • Y10T428/268—Monolayer with structurally defined element
    • 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
    • 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
    • Y10T428/2922—Nonlinear [e.g., crimped, coiled, etc.]
    • Y10T428/2925—Helical or coiled
    • 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
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/68—Melt-blown nonwoven fabric

Definitions

  • This invention relates to a resilient filamentary cushioning unit or pad and a process for its production wherein a plurality of substantially amorphous thermoplastic filaments, e.g. fiber-forming polyamide filaments, are meltspun into a liquid cooling bath in such a manner that they lie in the form of predominately helical to sinuous loops randomly bonded at their points of intersection as the filaments are completely solidified in the bath.
  • the resulting looped and bonded filaments form a cohesive resilient structure which is useful as a spring core or cushioning unit.
  • One object of the present invention is to provide a new cushioning unit which is similar to a spring core having individual coiled or helical springs but which has many advantages by comparison with previously known cushioning constructions.
  • Another object of the invention is to provide a novel process for the production of a resilient filamentary cushioning unit which is essentially composed only of a large number of synthetic melt-spun filaments.
  • a highly useful and unique resilient cushioning unit can be obtained by the steps comprising melt-spinning a plurality of substantially amorphous synthetic thermoplastic polymer filaments having a diameter of from about 0.1 to 1 mm. downwardly onto a liquid cooling medium, preferably water, which initially supports the filaments or exerts a sufiicient buoyant force to cause the individual filaments to extend longitudinally in the form of loops of a helical to sinuous character which spread laterally in overlapping relationship with the loops of the next adjacent filaments as the filaments enter the cooling medium.
  • the freshly spun filaments are completely solidified only after their entry into the cooling medium so as to adhesively bond overlapping loops at their points of intersection on direct contact.
  • the resulting coherent mass of looped and interconnected filaments are withdrawn from the cooling medium as a single continuous unit, preferably without any substantial tension being placed on the filaments as they are spun, looped and bonded or adhered together.
  • spun fiber-forming thermoplastic filaments having a diameter of about 0.3 to 0.5 mm.
  • substantially amorphous as applied to the filaments is employed herein to designate those filaments which have a crystalline proportion which amounts to not more than about 30%, and preferably less than 20%.
  • This amorphous characteristic of the filaments is a well known property which can be easily determined by conventional methods. In the conventional melt-spinning and stretching of thermoplastic filaments, a high degree of molecular orientation is achieved so that the initially amorphous polymer acquires a correspondingly high crystallinity. Since it is preferable to avoid any tension capable of stretching the filaments during the process of the present invention, the amorphous character of the initial polymer is largely retained.
  • buoyant force as used in connection with the liquid cooling medium is intended to include not only the upward force exterted upon an immersed body in a liquid but also surface tension forces which may act to support the body on the surface of the water.
  • the generally helical looping of the freshly spun filaments as they enter the liquid cooling medium can be attributed to one or both of these forces, although the exact mechanism is not fully understood. It is apparent, however, that looping begins at the surface of the cooling liquid, and as the filaments sink below this surface, the individual loops of a filament are most often separated in a continuous helical to sinuous configuration. Thus, relatively few crunodal loops are formed, i.e. where a single filament curves back to cross itself and becomes bonded at the crossing point. Instead, the loops are preponderantly bonded or adhered together as between adjacent filaments.
  • the polymer melt can be extruded with conventional apparatus onto the cooling liquid from at least one multiaperture spinneret, wherein the spinneret apertures are approximately equally spaced from one another at inter vals from about 3 to 10 mm., advantageously about 5 to 7.5 mm.
  • a plurality of such spinnerets can be arranged in juxtaposition to provide additional apertures where desired, it being understood that all apertures must be spaced at intervals sufficiently close to each other to permit the desired overlapping of adjacent loops as they are formed. For practical reasons, one must employ more than just a few filaments, e.g. on the order of at least 30 to or more.
  • the distance between the bottom or lower face of the apertured spinneret and the surface of the cooling liquid should ordinarily amount to about 2 to 30 cm., advantageously about 4 to 20 cm. It is important to avoid any substantial cooling or solidification of the freshly spun filaments before they enter the cooling liquid since otherwise it would not be possible to obtain an adherent meltbonding of the filamentary loops. Thereafter, the freshly spun molten filaments are solidified on entering the cooling liquid as they lie in loop form and cross over one another. After complete solidification into a coherent cushioning unit, the product is continuously withdrawn from the cooling liquid by any suitable means.
  • the filaments forming the cushioning unit can be produced from any melt-spinnable synthetic linear fiber-forming polymer including polyamides, polyesters, polyolefins and the like, preferably non-elastomeric polymers. However, it has been found to be especially advantageous to employ conventional polyamides and especially polycaprolactam.
  • the filaments of a cushioning unit In most instances, it is desirable for all of the filaments of a cushioning unit to have the same diameter within the abovenoted limits, although it is feasible to vary the individual diameters to some extent and still obtain a useful product. With smaller diameter filaments the resulting loops are also smaller while larger diameter filaments produce larger loops, other conditions being equal. Therefore, the interval between spinning apertures is in part dependent upon the diameter of the individual filaments since one must ensure a lateral overlapping of the loops as they are formed by adjacently parallel freshly spun filaments entering the cooling liquid.
  • the temperature of the cooling liquid is not particularly critical and is of relatively lesser significance. Nevertheless, it should be adapted to the particular polymer.
  • bath temperatures between about 20 C. and 45 C. are particularly suitable for polycaprolactam
  • polyhexamethylene adipamide i.e. polyamides of adipic acid and hexamethylene diamine
  • Suitable means such as a heat exchanger are provided for keeping the temperature of the bath constant during the process.
  • Highly turbulent circulation of the bath liquid should be avoided, i.e. it is preferable to employ a relatively deep tank in which agitation or circulation is kept to a minimum.
  • the vertical travel of the spun and looped filaments within the bath until they have been completely solidified and interconnected or adhered to each other.
  • the resulting product can then be turned to one side and withdrawn gradually upwardly until it emerges from the bath.
  • both values are advantageously so adapted to one another such that as far as possible no tension or only a slight tension is exerted on the cushioning unit while it is being formed and While it passes through the bath. If too 'great a tension is exerted, it can be transmitted back to the point where the loops are being formed so as to draw them out completely or at least sutficiently that overlapping of adjacent loops cannot occur. In some instances however, a slight tension can be exerted by increasing the withdrawal speed, e.g. for producing a somewhat less dense product.
  • the external form or shape which is imparted to the cushioning unit depends on the size of the spinnerets, the number thereof and their relative arrangement, and also on the distribution or pattern of the spinneret apertures on the spinneret base plate. It is thus possible to produce cushioning units which have a substantially cylindrical form or an approximatelyrectangular cross-section.
  • the cushioning material with its longitudinally extending fila-. mentary coils or loops is initially withdrawn as an endless unit from the bath and can then without any difiiculty be trimmed or cut in sections to the required size.
  • a plurality of relatively small cushioning units or a single large unit produced to conform to the desired shape can be stuffed; or inserted into the article to be cushioned, such as mattresses, chair upholstery or the like.
  • the padded components such as a fabric or leather coverings filled with the cushioning material according to the invention are extremely light in weight and can be very easily Washed in suitable washing machines.
  • the cushioned articles are extremely resilient and dimensionally stable.
  • FIG. 1 is a schematic representation of a side view of the most essential components of the apparatus employed in the process of the invention
  • FIG. 2 is an enlarged view of that portion of FIG. 1 which includes the spinneret or spinning head and the liquid bath located directly below;
  • FIG. 3 is a bottom plan view or face view of the spinneret or nozzle plate to illustrate one arrangement of spinning apertures therein;
  • FIG. 3a is a cross-sectional view of the final product, e.g. as taken on line AA of FIG. 1, having a circular shape as achieved by the spinneret of FIG. 3;
  • FIG. 4 is a bottom plan view of the spinneret to illustrate another arrangement of spinning apertures therein;
  • IFIG. 4a is a cross-sectional view of the final product, e.g. as taken on line AA of FIG. 1, having an approximately rectangular shape as achieved by the nozzle plate of FIG. 4;
  • FIG. 5 is a side view of an elongated section of the final product approximately as it would appear when using any regular cross-sectional shape
  • FIG. 6 is an enlarged view of a typical individual filament after it has been looped and solidified but shown apart from the remaining filaments of the final product.
  • a conventional extruder 1 equipped with a spinning head 2 conveys the molten polymer to the spinneret or nozzle plate 3 containing a plurality of equidistantly spaced bores 12 emerging as the spinning apertures 13 at the lower face 11 of the nozzle plate.
  • the spun filaments 4 are permitted to fall freely downwardly through an air gap 5 to initially enter the surface 6 of the water bath 7 contained in a suitable vessel.
  • the liquid level in the vessel can be maintained constant by any conventional means.
  • the initially parallel and equidistantly spaced molten or highly softened extruded filaments begin to formloops of a heli cal or sinuous configuration immediately upon entry into the cooling liquid.
  • the overlapping loops solidify, they become adhesively bonded at random points of intersection and the entire mass of filaments tends to continue falling downwardly in the bath of its own weight so that the individual loops are partly drawn out to provide a longitudinally expanded helical or sinuous configuration of each individual filament.
  • the individual filaments are extensively looped or curved laterally back and forth in overlapping relationship with immediately adjacent filaments, each tends to continue in the same longitudinal path as the freshly spun filament.
  • the resulting helical to sinuous loops or coils are formed around parallel vertical or longitudinal axes corresponding approximately to the linear path of the freshly spun filaments.
  • the looped and overlapping filaments become sufli ciently solidified and firmly melt-bonded together after a relatively short distance of vertical travel in the bath 7 so that the coherent product can be continuously drawn around a pin or roller 8 and conveyed out of the bath through the nip rollers 9 and 10 and finally collected as a continuous roll and/ or cut into appropriate lengths.
  • the speed of the rollers 9 and 10 should preferably be adjusted to just take up any slack in the conveyed product, i.e. at about the speed at which the initially solidifying mass of filaments falls vertically down to the roller 8.
  • the spinning velocity is of course more rapid than this falling rate between surface 6 and roller 8. The most desirable spinning velocity can be readily determined by routine tests.
  • FIGS. 3 and 4 the spinning apertures or openings 13 are arranged approximately in the form of a circle or rectangle, respectively, with regard to the outermost cir: cumference of the entire group of openings.
  • Other shapes can also be provided although extremely thin cross-sections are not practical.
  • FIG. 5 merely gives the general appearance from one side of any longitudinal section of the continuous resilient product.
  • FIG. 6 provides an example of atypical filament of the final product when viewed by itself as though no other filaments were bonded thereto.
  • a major proportion of the loops have a generally helical configuration 14 but occasionally the loops have a reverse curve 15 or form a sinuous pattern 16 rather than being strictly helical.
  • the individual filament may also exhibit a crunodal loop 17 where it becomes bonded to itself as at point 18.
  • crunodal loops can be substantially avoided, e.g. by placing a slight tension on the filaments as they form the loops and become bonded to adjacent filaments. In general, such crunodal loops appear to occur in not more than about 5-10% of all of the loops.
  • the finished product of the invention can be generally identified as a resilient cushion material composed of a large number of helically coiled or looped filamentary springs extending longitudinally in approximately parallel positions and interconnected to each other at random points of intersection of immediately adjacent filaments.
  • the product of the invention can be defined as a resilient cushioning unit consisting essen: tially of a plurality of melt-spun filaments of a substantially amorphous synthetic thermoplastic fiber-forming polymer with an individual filament diameter of 0.1 to 1 mm., preferably 0.3 to 0.5 mm, each of the filaments extending longitudinally within the cushioning unit in the form of loops spreading laterally in overlapping relationship with the corresponding loops of the next adjacent filaments with random adhesive or melt bonding of the filaments at their points of intersection.
  • the cushioning unit of the invention provides its greatest compressibility and resiliency in the longitudinal direction corresponding to the axes of the helices.
  • the filamentary cushioning unit of the invention is more apt to bend or be crushed although it still exhibits a large degree of resiliency, depending in part on the density of its structure. For this reason, how ever, all compressibility measurements herein have been taken in the longitudinal direction.
  • EXAMPLE 1 Polycaprolactam with a solution viscosity (1 of 2.6 is extruded at a spinning temperature of 280 C. from a spinneret with 240 apertures.
  • the spinneret apertures have a diameter of 250 millimicrons and are arranged spaced from one another at regular intervals of 6.5 mm. in a pattern similar to that shown in FIG. 3.
  • the diameter of the outer ring of apertures is about mm.
  • the melt is extruded at a speed of 760 g./ min.
  • the extruded filaments having a diameter of about 0.35 mm. strike a water bath, the temperature of which is kept at 40 C.
  • the filaments initiallylie or collect briefly on the surface of the water in loop form, each filament forming approximately helical windings. Adjacent filaments are adhesively bonded'on the surface at the points of intersection. At relatively infrequent intervals, one and the same filament is bonded to itself to form a crunodal loop.
  • the cushioning unit being formed gradually sinks into the water bath and. is withdrawn from the bath at a speed of 2.75 m./ min., practically no tension being exerted on the filamentary material.
  • An approximately cylindrical unit is formed, which is cut or trimmed to the required length.
  • the influence of the dilferent water temperature is apparent from the following Table I.
  • a cushioning unit with a height of 18 cm. was loaded with a weight of 5 kg. as a means of measuring the compressibility of the unit in the present example and also in those which follow.
  • the A1 value shows the change in height under the above noted load and is a standard for the softness, i.e. compressibility of the product.
  • a rather wide range of bath temperature has only a moderate influence on the compressibility.
  • EXAMPLE 3 The process was carried out while maintaining the conditions of Example 1, but with an intervalbetween the spinneret and the bath surface of 6 cm. and using different withdrawal speeds.
  • Table IV shows the results of a series of tests which were carried out according to Example 1, but using a spinneret with an aperture spacing of 7.5 mm. and also a spinneret with an aperture spacing of 5.0 mm. The other variations in the process can be seen from the table.
  • EXAMPLE 5 The following Table V shows the dependency of the properties of the cushioning unit on the withdrawal speed. In these tests, the conditions of Example 1 were maintained, except where other data is set forth in the table.
  • the other processing conditions are set forth in Table VI.
  • EXAMPLE 7 Nine cylindrical padding units, formed in accordance with Example 1, were arranged in rows, each of three units, and while upright, with a conventional upholstery covering material. These upholstered samples were subjected to 10,000 reciprocal loadings with a weight of 75 kg. and thereafter showed a permanent deformation of 10%.
  • a process for the production of a resilient filamentary cushioning unit which comprises melt-spinning a plurality of substantially amorphous synthetic thermoplastic fiber-forming polymer filaments having a diameter of from about 0.1 to 1 mm. to fall freely downwardly over an air gap onto a liquid cooling medium, the liquid surface of said cooling medium being located sufiiciently below the point of melt spinning and said liquid cooling medium exerting a sufficient upward buoyant force to cause the individual filaments to extend longitudinally in the form of loops of a helical to sinuous character which spread laterally in overlapping relationship with the loops of the next adjacent filaments as the filaments enter said cooling medium, completely solidifying the freshly spun filaments only after their entry into said cooling medium to adhesively bond overlapping loops at their points of intersection, and withdrawing the resulting coherent mass of looped and interconnected filaments from the cooling medium.
  • said filaments are melt-spun from at least one multi-aperture spinneret in which the apertures are substantially equally spaced from one another at intervals of from about 3 to 11 mm., and the distance between said apertures at the lower face of said spinneret and the liquid surface of the cooling medium is about 2 to 30 cm.
  • a process as claimed in claim 2 wherein the intervals between said equally spaced apertures is about 5 to 7.5 mm.
  • a process as claimed in claim 1 wherein the polymer being spun is polyhexamethylene adipamide.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)
  • Polyamides (AREA)
  • Artificial Filaments (AREA)
US3687759D 1968-03-21 1969-03-14 Process for producing resilient cushion Expired - Lifetime US3687759A (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE1778026A DE1778026C3 (de) 1968-03-21 1968-03-21 Polstermaterial aus einer Vielzahl von in Schlaufen liegenden, sich überkreuzenden synthetischen Endlosfäden
US80730169A 1969-03-14 1969-03-14
US27135572 US3852152A (en) 1968-03-21 1972-07-13 Resilient cushion

Publications (1)

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US3687759A true US3687759A (en) 1972-08-29

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US3687759D Expired - Lifetime US3687759A (en) 1968-03-21 1969-03-14 Process for producing resilient cushion
US27135572 Expired - Lifetime US3852152A (en) 1968-03-21 1972-07-13 Resilient cushion

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Application Number Title Priority Date Filing Date
US27135572 Expired - Lifetime US3852152A (en) 1968-03-21 1972-07-13 Resilient cushion

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US (2) US3687759A (de)
AT (1) AT308997B (de)
BE (1) BE727924A (de)
CH (1) CH474983A (de)
DE (1) DE1778026C3 (de)
FR (1) FR2004358A1 (de)
GB (1) GB1224451A (de)
LU (1) LU58204A1 (de)
NL (1) NL6904105A (de)

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US9157231B2 (en) 2012-10-05 2015-10-13 Bonar Inc. Sound control mat
WO2015171706A1 (en) 2014-05-06 2015-11-12 Keene James R Protective mat and method for protecting a floor from spillage and debris
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US9763837B2 (en) 2011-12-01 2017-09-19 Sca Hygiene Products Ab Absorbent article having fluid flow control member
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Also Published As

Publication number Publication date
DE1778026A1 (de) 1971-07-15
GB1224451A (en) 1971-03-10
NL6904105A (de) 1969-09-23
FR2004358A1 (de) 1969-11-21
DE1778026C3 (de) 1981-06-11
BE727924A (de) 1969-07-16
US3852152A (en) 1974-12-03
LU58204A1 (de) 1969-07-11
AT308997B (de) 1973-07-25
DE1778026B2 (de) 1980-08-28
CH474983A (de) 1969-07-15

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