WO2000006379A1 - Insulating material with web strips bonded between layers of batt material and method for producing the same - Google Patents

Insulating material with web strips bonded between layers of batt material and method for producing the same Download PDF

Info

Publication number
WO2000006379A1
WO2000006379A1 PCT/US1999/016858 US9916858W WO0006379A1 WO 2000006379 A1 WO2000006379 A1 WO 2000006379A1 US 9916858 W US9916858 W US 9916858W WO 0006379 A1 WO0006379 A1 WO 0006379A1
Authority
WO
WIPO (PCT)
Prior art keywords
batting
layers
insulating material
strips
insulating
Prior art date
Application number
PCT/US1999/016858
Other languages
French (fr)
Inventor
Robert Ray Yando
Original Assignee
Albany International Corp.
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Albany International Corp. filed Critical Albany International Corp.
Priority to AU52298/99A priority Critical patent/AU5229899A/en
Publication of WO2000006379A1 publication Critical patent/WO2000006379A1/en

Links

Classifications

    • 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 shape; Layered products comprising a layer having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/18—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by an internal layer formed of separate pieces of material which are juxtaposed side-by-side
    • 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 shape; Layered products comprising a layer having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/18—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by an internal layer formed of separate pieces of material which are juxtaposed side-by-side
    • B32B3/22—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by an internal layer formed of separate pieces of material which are juxtaposed side-by-side of spaced pieces
    • 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
    • B32B5/26—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 also being fibrous or filamentary
    • 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
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/559—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving the fibres being within layered webs
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L59/00—Thermal insulation in general
    • F16L59/02—Shape or form of insulating materials, with or without coverings integral with the insulating materials
    • F16L59/029—Shape or form of insulating materials, with or without coverings integral with the insulating materials layered
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating
    • 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
    • B32B2439/00—Containers; Receptacles

Definitions

  • the present invention relates to insulating material for sleeping bags or similar applications wherein web strips are maintained between layers of batt material, and to the method for producing this material. This creates pockets of air within the insulating material resulting in increased insulation.
  • insulating material by the process of first manufacturing a four-layer insulation by carding and sending the insulation through an oven; transporting the resulting roll to a small infrared oven, where strips of insulating material is applied by hand between batting layers using adhesive and slight heat from the oven; then the insulating material is rolled up and transported back to the original oven for final bonding of the strips of insulating material to the batting material.
  • the strips between the layers of batting material create macro air spaces with insulating capability but with only a minimal increase in weight. This process is -relatively slow and labor intensive and it is desirable to improve upon it.
  • the resulting method and product is less costly, provides an improved product which is more durable and stable, avoids the need for adhesive to attach the strips and is less abrasive on the strips.
  • FIG. 1 is a front perspective view of the insulating material produced by the process of the present invention.
  • DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Referring now to the drawing in detail, one sees a front perspective view of the insulating material 10 produced by the process of the present invention.
  • First and second layers of batting material 12, 14, respectively are carded and laid down at a first carding station.
  • First and second layers of batting material 12, 14 are then moved to a second carding station and strips of pre-cut web 16 are laid upon second layer of batting material 14.
  • Web 16 can be a series of substantially parallel strips running in a single direction as shown in Figure 1.
  • the resulting material is then passed to a thi-rd carding station where third and fourth layers of batting material 22, 24 are placed over web 16.
  • the resulting sandwiched product is then passed to an oven for heating and bonding of the entire product .
  • the web 16 causes macro air pockets to form in the insulating material, which increases the insulating capability without a significant increase in weight of the insulating material 10.
  • This process is a single-pass process which results in cost efficiency and further does not require the use of adhesive to attach the strips. Additionally, the sandwiching of the strips 16 between layers stabilizes the position of the strips so that the strips do not abrade against each other. This produces an improved product of increased durability.

Landscapes

  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Laminated Bodies (AREA)
  • Nonwoven Fabrics (AREA)

Abstract

The insulating material (10) includes web strips (16) bonded between first and second batting material. First and second batting material each comprise layer of batting material (12, 14, 22 and 24). This creates macro air pockets which increase the insulating capability of the material without substantially increasing its weight. The process for manufacturing this insulating material (10) includes a series of carding steps to lay down the various materials and then transporting the materials to an oven for heating and bonding.

Description

INSULATING MATERIAL WITH WEB STRIPS BONDED BETWEEN LAYERS OF BATT MATERIAL AND METHOD FOR PRODUCING THE SAME
BACKGROUND OF THE INVENTION Field of Invention
The present invention relates to insulating material for sleeping bags or similar applications wherein web strips are maintained between layers of batt material, and to the method for producing this material. This creates pockets of air within the insulating material resulting in increased insulation. Description of the Prior Art
In the prior art, it is known to use multiple, layers of batt material as thermal insulation. Examples of such material are disclosed in U.S. Patent No. 5,443,893 issued on August 22, 1995 and U.S. Patent No. 5,437,909 issued on August 1, 1995, both entitled "Multilayer Nonwoven Thermal Insulating Batts" with Herzberg as the inventor. However, this insulating and other similar insulating material may have an undesirably high weight. It is also known to create insulating material by the process of first manufacturing a four-layer insulation by carding and sending the insulation through an oven; transporting the resulting roll to a small infrared oven, where strips of insulating material is applied by hand between batting layers using adhesive and slight heat from the oven; then the insulating material is rolled up and transported back to the original oven for final bonding of the strips of insulating material to the batting material. The strips between the layers of batting material create macro air spaces with insulating capability but with only a minimal increase in weight. This process is -relatively slow and labor intensive and it is desirable to improve upon it. OBJECTS AND SUMMARY OF THE INVENTION It is therefore an object of this invention to increase the thermal insulating capability of insulating material made from batting fiber. It is therefore a further object of this invention to increase the thermal insulating capability of insulating material without a substantial increase in weight of the insulating material . It is therefore a still further object of this invention to provide an insulating material of increased durability.
It is therefore a still further object of this invention to provide a method for manufacturing such insulating material which has a reduced number of steps and is less labor intensive than methods used heretofore .
These and other objects are attained by a method in which first, by a two-card process, two layers of batting material are laid down. As the first two layers travel down to the next card, strips of pre- cut web are layered on the second layer. As the resulting material passes under the next card, two more layers of batting material are applied. The resulting sandwiched product is inserted into a large oven for bonding of the entire product .
The resulting method and product is less costly, provides an improved product which is more durable and stable, avoids the need for adhesive to attach the strips and is less abrasive on the strips.
BRIEF DESCRIPTION OF THE DRAWINGS Further objects and advantages of the invention will become apparent from the following description and claims, and from the accompanying drawing, wherein:
Figure 1 is a front perspective view of the insulating material produced by the process of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Referring now to the drawing in detail, one sees a front perspective view of the insulating material 10 produced by the process of the present invention. First and second layers of batting material 12, 14, respectively are carded and laid down at a first carding station.
First and second layers of batting material 12, 14 are then moved to a second carding station and strips of pre-cut web 16 are laid upon second layer of batting material 14. Web 16 can be a series of substantially parallel strips running in a single direction as shown in Figure 1.
The resulting material is then passed to a thi-rd carding station where third and fourth layers of batting material 22, 24 are placed over web 16.
The resulting sandwiched product is then passed to an oven for heating and bonding of the entire product . The web 16 causes macro air pockets to form in the insulating material, which increases the insulating capability without a significant increase in weight of the insulating material 10.
This process is a single-pass process which results in cost efficiency and further does not require the use of adhesive to attach the strips. Additionally, the sandwiching of the strips 16 between layers stabilizes the position of the strips so that the strips do not abrade against each other. This produces an improved product of increased durability.
Thus the several aforementioned objects and advantages are most effectively attained. Although preferred embodiments of the invention have been disclosed and described in detail herein, it should be understood that this invention is in no sense limited thereby and its scope is to be determined by that of the appended claims.

Claims

CLAIMS What is Claimed is:
1. A process for manufacturing insulating material, comprising the steps of: laying down first batting material comprising at least one layer of batting material; laying down a plurality of strips of material on top of said first batting material; laying down second batting material comprising at least one layer of batting material; and heating said first batting material, said plurality of strips, and said second batting material thereby bonding the same together.
2. ^ The process of Claim 1 wherein said first batting material comprises at least two layers of batting material.
3. The process of Claim 2 wherein said second batting material comprises at least two layers of batting material.
4. The process of Claim 3 wherein said plurality of strips of material includes at least one series of substantially parallel strips.
5. An insulating material, comprising: first batting material comprising at least one layer of batting material; a plurality of strips of material bonded on top of said first batting material; and second batting material bonded on top of said plurality of strips.
6. The insulating material of Claim 5 wherein said first batting material comprises at least two layers of batting material.
7. The insulating material of Claim 6 wherein said second batting material comprises at least two layers of batting material.
8. The insulating material of Claim 7 wherein said plurality of strips of material includes at least one series of substantially parallel strips.
PCT/US1999/016858 1998-07-27 1999-07-26 Insulating material with web strips bonded between layers of batt material and method for producing the same WO2000006379A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU52298/99A AU5229899A (en) 1998-07-27 1999-07-26 Insulating material with web strips bonded between layers of batt material and method for producing the same

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US12306198A 1998-07-27 1998-07-27
US09/123,061 1998-07-27

Publications (1)

Publication Number Publication Date
WO2000006379A1 true WO2000006379A1 (en) 2000-02-10

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US1999/016858 WO2000006379A1 (en) 1998-07-27 1999-07-26 Insulating material with web strips bonded between layers of batt material and method for producing the same

Country Status (2)

Country Link
AU (1) AU5229899A (en)
WO (1) WO2000006379A1 (en)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2003059612A1 (en) * 2002-01-04 2003-07-24 Albany International Corp. Insulation material
US10480103B2 (en) 2015-05-22 2019-11-19 Primaloft, Inc. Self-warming insulation
US10633244B2 (en) 2015-09-29 2020-04-28 Primaloft, Inc. Blowable floccule insulation and method of making same
US10954615B2 (en) 2015-01-21 2021-03-23 Primaloft, Inc. Migration resistant batting with stretch and methods of making and articles comprising the same
US11192327B2 (en) * 2017-07-03 2021-12-07 Axel Nickel Voluminous meltblown nonwoven fabric with improved stackability and storability

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4090269A (en) * 1976-03-01 1978-05-23 Alpine Designs, Inc. Insulated covering
US4910055A (en) * 1987-03-23 1990-03-20 Wigutow Jerald N Insulated sleeping bag
US5033135A (en) * 1990-06-11 1991-07-23 Wilson Creek Disposable sleeping bag
US5437909A (en) * 1994-05-20 1995-08-01 Minnesota Mining And Manufacturing Company Multilayer nonwoven thermal insulating batts
US5443893A (en) * 1994-05-20 1995-08-22 Minnesota Mining And Manufacturing Company Multilayer nonwoven thermal insulating batts
US5670238A (en) * 1995-04-13 1997-09-23 Anderson & Middleton Company Laminate sheet material
US5798166A (en) * 1996-08-26 1998-08-25 Albany International Corp. Insulation for sleeping bags and similar items

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4090269A (en) * 1976-03-01 1978-05-23 Alpine Designs, Inc. Insulated covering
US4910055A (en) * 1987-03-23 1990-03-20 Wigutow Jerald N Insulated sleeping bag
US5033135A (en) * 1990-06-11 1991-07-23 Wilson Creek Disposable sleeping bag
US5437909A (en) * 1994-05-20 1995-08-01 Minnesota Mining And Manufacturing Company Multilayer nonwoven thermal insulating batts
US5443893A (en) * 1994-05-20 1995-08-22 Minnesota Mining And Manufacturing Company Multilayer nonwoven thermal insulating batts
US5670238A (en) * 1995-04-13 1997-09-23 Anderson & Middleton Company Laminate sheet material
US5798166A (en) * 1996-08-26 1998-08-25 Albany International Corp. Insulation for sleeping bags and similar items

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2003059612A1 (en) * 2002-01-04 2003-07-24 Albany International Corp. Insulation material
US10954615B2 (en) 2015-01-21 2021-03-23 Primaloft, Inc. Migration resistant batting with stretch and methods of making and articles comprising the same
US10480103B2 (en) 2015-05-22 2019-11-19 Primaloft, Inc. Self-warming insulation
US10633244B2 (en) 2015-09-29 2020-04-28 Primaloft, Inc. Blowable floccule insulation and method of making same
US10870573B2 (en) 2015-09-29 2020-12-22 Primaloft, Inc. Method of making blowable floccule insulation
US11192327B2 (en) * 2017-07-03 2021-12-07 Axel Nickel Voluminous meltblown nonwoven fabric with improved stackability and storability

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