Note: Descriptions are shown in the official language in which they were submitted.
~30~
-1-
TITLE
POLYESTER FIBERFILL
TECHNICAL PIELD
This invention concerns improvements in polyester fiberfill material, commonly
referred to as polyester fiberfill, and more particularly to providing polyester fiberfill in a
form that is especially adapted for blending with binder fibers, to such blends as can be
thermally bonded to provide useful bonded products having advantageous properties, such as
bonded batts, and to the resulting bonded batts and other products incorporating the same
BACKGROUND OF INVENTION
Polyester fibeffill is used commercially in many garments and other articles, such as
sleeping bags, cushions, comforters and pillows. A particularly useful and desirable form
of polyester fiberfill has a coating of cured polysilo~ane, often referred to as silicone
slickener, e.g. as disclosed in Ho~mann U.S. Patent No. 3,271,189 and Mead et al. U.S.
Patent No. 3,454,422, because certain desirable properties, such as hand, bulk-stability and
fluffability are improved thereby. Despite the widespread commercial use of such silicone-
slickened-polyester fibrefill, it has long been recognized that this coating has an important
disadvantage, together with the desirable qualities. As reported by Pamm U.S. Patent No.
4,281,042 and Frankosky U.S. Patent No. 4,304,817, a silicone coating makes it almost
impossible to bond the polyester flberfill at cross-over points, especially when blends of only
slickened polyester fiberfill and binder fiber are heat-treated, so as to activate the binder
fiber. Any bonds are very poor and seem to be the result of bonding between residues of any
binder fibers that were bicomponent fibers, whose cores remain after bonding.
:
l l,.,~
~L3~6~
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~hus it is not practical to use such silicone-slickened
fiberfill to form a ~hrough-bonded batt or molded article
that is properly bonded and durable, as is desirable in
~ome end-uses.
The main object of the present invention is to
provide a properly through-bonded batt having advantages
of the type that have been obtainable previously only from
unbonded slickened materials, e.g. in hand, in combination
with the improved performance (especially durability) that
has only been attainable previously with bonded batts from
"dry" fiberfill. Another object is to improve the
resilience and struc~ure stabilization of slickened
fiberfill products. Other objects will appear
hereinafter.
Reference is made here to Jayne et al. U.S.
Patent No. 3,702,260. Jayne discloses surface-modified
polyester fiberfill products having improved compressional
recovery and other outstanding properties (see paragraph
from column 2 - column 3) and to a method for providing
such fiberfill products. The coating is co-crystallized
on the surface of the crimped polyester staple ~iber, and
con6ists of a copolyester comprising about 20-95% by
weight of poly(oxyalkylene) units and about B0 5% by
weight of ester uniti identical to those present in the
polyester staple fiber substrate. ~atts of such coated
fibers may be bonded or unbonded and are preferably
unbonded (column 2, lines 57-59). Bonding resins may be
applied to the batt~ to prevent any later fiber leakage
and/or to prevent shifting of the batting in end-use
applications, e.g. by spraying on both sides of the
surface in the form of water emulsions, followed by drying
and curing (column 5, lines 15-21). J~yne does not
mention binder fibers, and Jayne's fiberfill has not been
used commercially, 50 far as is known.
SllMMARY OF TH~ INVENTION
I have found that, by replacing the existing
com~ercial silicone slickeners with a hydrophilic coating
--2--
~3~ 13~
containing poly(alkylene oxide~ chains or segments on the
surface of the polyester fiberfill, i~ is possible to
attain the desired object and other advantages. Thus such
coated polyester fiberfill can be bonded more effectively
than ~ilicone-slickened fiberfill, e.g. from blends with
binder fiber, and has other advantages in reduced
flammability and improved moisture transport, as will be
mentioned hereinafter. It is believed important to ensure
that the hydrophilic coating is "cured" properly onto the
polyester fibers, in other words, that the poly(alkylene
cxide) chains are essentially permanently affixed to the
surface of the polyester fibers, i.e. so that they wi:Ll
not be removed by washing or by other treatments that will
be encountered in normal processing or use.
Accordingly, there is provided an improved
polyester fiberfill blend consisting essentially of, by
weight, ~a) from about 60 to about 95~ of crimped
polyester staple fiber, and (b) complementally, to total
100%, from about 5 to about 40% of crimped staple binder
fiber, comprising a polymer having a binding temperature
lower than the softening temperature of the said polyester
staple fiber, characterized in that the said polyester
staple fiber has a coating cured thereto of a slickener
consistin~ essentially of chains of polylalkylene oxide).
Two commercial poly(alkylene oxide) copolymers,
involving two different mechanisms of "curing" are
described more particularly below. One is a block
copolymer of poly~ethylene oxide) and poly(ethylene
terephthalate) which, when ~pplied to the surface of a
polyester fiber containing repeat units of poly~ethylene
terephthalate), and cured at about 170C, is fixed to the
fiber. The mechanism by which it is cured is not fully
understood, but is suggested to be the co-crystallization
of the polyest2r Eeg~ents on the polyester fiber. Another
curing mechanism is effected by cross-linking
poly(alkylene oxide) chains modified with reactive groups
13~ )2
capable of cross-linking with or without the addition of
catalysts or cross-linking agents. ~oth these routes can
be effected by using commercially available polymers with
large segments of poly(ethylene oxide) and/or
poly(propylene ox1de), poly(ethylene oxide) bei~g
preferred.
; According to one aspect of thle invention,
the~efore, there is provided a polyester fiberfill blend
consisting essentially of, by weight, (a) from about 60 to
about 95%, preferably about 80 to about 90%, of crimped
polyester staple fiber and Ib), complementally to total
100%, from about S to about 40%, preferably about 10 to
about 20%, of crimped staple binder fibers, comprising a
polymer having a melting point lower than that of the
polyester staple fiber, wherein the polyester staple fiber
is coated with a segmented copolymer of poly(ethylene
terephthalate) and poly(ethylene oxide) in amount from
about 0.1 to about 1~ by weight of the polyester staple
fiber.
~ ccordin~ to another aspect of the invention,
there is provided a polyester fiberfill blend consisting
essentially of (a) from about 60 to about 95% by weight of
crimped polyester staple fiber and (b) oomplementally to
total 100~ by wei~ht, from about 5 to about 40% by weight
of crimped staple binder fibers, comprising a polymer
having a melting point lower than that of the polyester
staple fiber, wherein the polyester staple fiber i6 coated
with a modified poly(alkylene oxide) grafted with
functional groups to permit cross-linking, in amo~nt from
about 0.1 to about 1% by weight of the polyester staple
iber.
Use of these blends makes possible the provision
of bonded fiberfill products with advantages over products
that have hitherto been available commercially, as will be
indicated in more detail hereinafter, but can be
summarized as:
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; Improved performance, especially durability, as compared with "dry" (i.e. non-slickened), fiberfill that
has been available commercially.
Soft hand in combination with the 6tructure
stabilization and resilience that results from good
bonding.
Good moisture transport.
Lack of flammability, comparable with that
resulting from "dry" fiberfill, and such as I have not
obtained with prior commercial silicone-slickened
fiberfill.
DETAILED DESCRIPTION OF THE INVENTION
An important element of the present invention is
the use of an appropriate coating material ~o provide the
desired hydrophilic coating of poly(alkylene oxide) chains
on the polyefiter fiberfill. As already indicated, some of
these materials are available commercially.
Coating materials that are suitable for use
according to the invention include segmented copolyesters
consisting essentially of poly(ethylene terephthalate~
segments and of poly~alkylene oxide3 segments, derived
from a poly~oxyalkylene) having a molecular weight of 300
to 6,000. Several such copo~yester~ and dispersions
thereof are disclosed in McIntyre et al. U.S. Patent
Nos. 3,416,952, 3,557,039 and 3,619,269, and in various
other patent specifications disclosing like segmented
copolymers containing poly(ethylene terephthalate)
segments and poly(alkylene oxide) segments. Preferably
the poly~alkylene oxide) will be a polytethylene oxide),
which is al&o of commercial convenience.
one such product is available commercially from ICI
America Inc. as a textile finishing agent and i6 sold
under the trademark ATLAS* G-7264. This product is sold
in Europe by ICI Specialty Chemicals, ~russels. Another
is sold as ZELCON* 4780, by E. I. du Pont de Nemours and
CompanyO Other materials are disclosed in Raynolds U.S.
* denotes trade mark
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~ L3Q6~(~2
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Patent No. 3,981,807. Other suitable materials include modified poly(ethyleneoxide)/poly(propylene oxide~ granted with functional groups to permit cross-linking, e.g. by
treatment with 5 % by weight of citric acid. Such a product is available commercially from
5 Union Carbide as IJCON*3207A. Other materials that may include particularly useful
compositions are disclosed in Teijin EP 159882 and ICI Americas, EP 66994. Further
discussion is given in Canadian application No. 549,792 filed 1987 October 20 and in
Canadian application No. 509,309 filled 1986 May 15.
The coating material can be applied to the polyester fiber either on the crimped staple
10 or, preferably, on the tow, especially after drawing, in the crimping chamber. It is cured
onto the fiber, by a process which is said to involve co-crystallizing or crosslinking,
depending on the nature of the material. The fiberfill can then be blended with the binder
and packed, or can be packed separately and be blended with the binder fiber prior to
processing the product on standard batt manufacturing equipment. In any case the batt is
15 generally processed, e.g. in an oven, to bond the binder to the fiberfill, and to achieve the
special properties of the battings described herein. The coating can also be applied to the
fiberfill staple at the end of the process line, after cutting and prior to packing, without
~a~g, then be blended with the binder fiber. The blend is then processed on the standard
carding equipment and the curing can take place in the oven at the same time as the bonding
20 by the binder. These coating materials, however, generally produce better results when they
are applied prior to or during crimping, as the reduced fiber to fiber friction ~avors the
formation of smoother crimp, which can also contribute to an improved durability and
increased softness, and the bonding appears to be better as a result of the earlier curing. The
binder fiber blend is process on commercial carding
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*denotes trade mark
_7_ ~3Q~2
e~uipment, cross-la~ped, and heat-treated in an oven to
bond the fiberfill and the binder fiber.
~ he binders are preferably heat-activ~ted, i.e.
they ~elt or soften at temperatures some 50C or ~ore
below the melting points of the polyester fiberfill, so
that the bonding does not affect the integrity of the
fiberfill itself. Commercially available sheath/core
S0/50 bicomponent binder fibers with a core of
poly(ethylene terephthalate) homopolymer and sheath of a
copolymer of poly(ethylene terephthalate/i60phthalate)
(60/40), modified to reduce its melting point, have been
used with poly~et~ylene tercphthalate) fiberfill in the
manufacture of the battings of the invention. Although
sheath/core binder fibers are preferred, single component
binders can also be used with an improvement over the
controls made from the same binder and fiberfill without
the coating. The denier of the binder fiber will
generally be between about 3 to about 30 dtex, preferably
less than about 20 dtex. Further information about binder
fibers is given in ~y aforementioned copending Canadian
application No. 506 309, and in U.S. Patent Nos. 4,281,042
and 4,304,817.
The fiberfill can be of ~bout l to about 30
dtex, can be olid or hollow, with single or ~ultiple
voids, and have a round or an odd cross section.
The lower deniers are used mainly in
applications where the thermal insulation is an i~portant
factor, such as apparel, sleeping bags and special bedding
articles for institutional applications. For these
applieations the blends of the invention have shown
~everal advantages over co~mercially-available polyester
~lickened batts or binder fiber blends. The bonded batts
have shown a combination of softness ~nd good bonding with
good thermal insulation. ~he loft and softne~6 h~ve been
maintained after many washings, because of the resistance
of the coating to washing, and the excellent tear
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resistance ~f the batts h~s been shown, as a re6ult of
good bonding with the binder fiber core. The performance
of these bonded batts is very surprising, in view of the
previous difficulty in bonding fiberfill slickened with
prior art silicone slickeners. The batts combine this
desirable softness with a low flammability such as is
characteristic of batts from non-slickened fibers, and
which also contrasts with the flammability of fibers
slickened with silicones.
DESCRIPTION OF TEST MBTHO~S
.
Bulk measurements were made conventionally on an
Instron machine to measure the compression ~orces a~d the
height of each sample pillow or cushion, which was
compressed with a foot of appropriate diameter (10 or
20 cm) attached to the Instron.
Foot B (20 cm diameter) is used for lower
density products (e.g. pillows) with a maximum pressure of
lOON, and suDport bulk (SB) at 30N (representing the
height in cm of the pillow under the weight o~ an average
head). The softness, in this instance, corresponds to the
difference in height (in cm) bet~teen the initial height at
the beginning of the second compression cycle (I~2) and
the support bulk; i.e. the (absolute) softness ~ IH2-SB
~height at 30N). Softness is sometimes expre6sed as
relative softness, i.e. as a percentage of IH2.
Foot A ~10 cm diameter) is used for higher
density products (e.g~ furnishing cushions, mattresses)
with maximum pressure (the same as support bulk, in this
instance) at 60N (corresponding to the pressure exerted by
a sitting person). The 60ftness, in this instance,
corresponds to the difference in height between the
initial height at the beginning of the second compression
cycle (I~2~ and the height under 7.5N; i.e. the (absolute)
softness, in this instance, - IH2-bulk at 7.5N. Again,
60ftne~s is sometimes expressed as relative ~oftness,
relative to IH2. The firmness of a cushion correlates
with a 6trong support bulk, and is inversely related to
~oftness.
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g : L3~6~0Z
Resilience is measured as Work Recovery (WR),
i.e. the ratio of the area under the whole recovery curve
calculated ac a percentage of that under the whole
compression cur~e. The higher the WR, the better the
resilience.
Durability - Several layers of each batting
~50 x 50 cm) were stacked to provide a weight of about
850 g. ~he number of layers was adjusted to provide
pillows with minimal weight differences. These were
covered with a fabric and measured with foot A. The
initial density of the pillows was between 12 and 15 g/l,
depending on the bulk of the individual item. These lower
density "pillows" were repeatedly compressed to a maximum
pressure of 1,225 N at a rate of 1,200 cycles/hour for
10,000 cycles. ~he pillows were remeasured and the bulk
losses calculated.
Another series of cushions was prepared by
~tacking a number of layers to produce cushions with
850 + 15 g. ~he cushions were compressed using buttons to
produce furnishing back cushions with a density of
25 28 g/l (depending if the measurement is done on the
crown or in the vicinity of the bu~tons~. The~e back
cushions were submitted to a ~tomping test u~ing the shape
of a human bottom with an area of 37 x 43 cm and ~
pressure of B.8 kPa. The stomping was repeated at a rate
of about 1,000 cycles/hour for 10,000 cycles. The
cushions were remeasured ater the testing and the bulk
losses calculated.
Fla~mability: Two tests were used:
~ The methanamine pill test is based on the U.S.
; Federal Method, Flammability Standard for Carpets
DOC FF 1-70.
The 45 deg. open flame test DIN 54335.
The area destroyed was measured and recorded in
both case6, and the rate of propagation of the flame also
recorded in the open flame test.
.
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Strength: The grab test DIN 53857 evaluates the
~trength of the bonding. (The results herein are
normalized to a common ba6is of 200 g/sq.m.).
Laundry Tests: one layer (40X40 c~) of each
batting is quilted (in apparel fabric) and ~ewn in the
~iddle. The compression of two layers is mea6ured by
Instro~ (foo~ B-20 cm diameter, maximum pres~ure 240 N).
All the samples are washed together in a wa6hing ~achine
at 40C for three complete cycle~. The ~amples were
remeasured after laundry and the difference in thickness
was calculated.
~ he invention is further illustrated in the
ollowing Example~. All parts ~nd percentage~ are by
weight, unless otherwise indicated. All heights are
measured in cm, and are sometimes expressed as "Bulk".
Example 1
A commercial hollow unslickened polyester
fiberfill (6.1 dtex~ was coated with 0.35~ by weight
(~olids) of a hydrophilic slickener by spraying with an
aqueou~ solution containing 2.~% solids of "ATLAS" G-7264,
obtained by dilutinq the commercial e~ulsion (14~) wi~h 5X
it~ weight of water, and then dried in air at room
temperature. The coated staple was blended ~85~15) with
the above-mentioned sheath/core binder fiber of 4.4 dtex.
This blend was processed to produce a 1 meter wide batt of
density about 180 g/sq. m. by superposing four parallel
layers without ~rosslapping. This batt was heat bonded in
a commercial 3.5 m. wide oven at a temperature of 160C;
this heat treatment had the dual effect of curing the
coating to the polyester fiberfill and of activating the
binder ~heath of the binder fiber ~o as to bond the batt.
Various properties of the bonded batt are measured and
recorded in tests which clearly demonstrate the
superiority of this item of the invention 2 ov¢r control
item 1, which was prepared in exactly ~he same way from
the ~ame basic commercial fiberfill and binder fiber
* denotes trade mark
--10--
'
3~36~
except that no hydrophilic poly(ethylene oxide)-containing
coating was applied. soth products were processed under
otherwise identical conditions, and were bonded by
heat-treating in parallel in the same oven at the same
time.
1 - The test batt 2 was much softer and more
drapable, but very different rom silicone-slickened
products.
2 - Table 1 shows the improved softness and
durability over the control.
3 - sonding to the binder fiber was far bPtter
than with 0.3% silicone-slickener, being 70~ of control's
strength in machine direction and 50% in the transverse
direction, which is not very significant as there was no
cross-lapping in this Example.
4 - Flammability of the test item 2 was very
close to the control 1 with 1.0 second flame duration (-
control) and 8.4 cm destroyed length versus 6.0 for the
control, whereas silicone slickened batting was totally
destroyed with flame duration of 40 seconds.
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a
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a $ ~
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a ~i ~
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--12--
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~13-
Although this coated fiberfill had not been
pre-cured (i.e. had not been heat-treated prior tD the
bonding treatment), the break strength of the batting was
surprisingly high, being about 70% of that of the control,
thereby demonstrating that good bonding of the coating to
the fiberfill had occurred. The following Example shows
the improvements obtained by c~ring the coating, and using
cross-lapped webs.
Example 2
1. This is a oontrol described below.
2. The same 6.1 dtex hollow dry crimped
commercial polyester fiberfill staple substrate is coated
with 0.35% solids following essentially the procedure
described in Example 1, and the coating is then cured onto
the fiber by heating the staple at 170C for 5 minutes.
The cured coated fiberfill is then blended with the same
sheath/core binder fiber as in Example 1 in the same
proportions (85/15). This blend is processed on a card
and cross-lapper to produce a batt of density about
190 g/sq.m., and is bonded in an oven at 160C at a speed
of 1 m/min. The following Tables co~pare the properties
of this bonded batt as item 2 with a control batt (item 1)
prepared from the same substrate polyester fiberfill
without the hydrophilic coating aceording to the
invention, and with other batts made as follows:-
3. The same basic polyester fiberfill substrateis coated with 0.35~ solids by sprayiny with a 20%
solution of UCON 3207A (with the addition of 5% of citric
acid), and cured as for it0m 2 above.
4. This i5 a control, similar to item 1, but
using hollow crimped polyester fiberfill of 13 dtex, with
the same 4.4 dtex binder fiber.
5. ~his is similar to control item 4, excspt
that the polyester fiberfill is coated with 0.35% of
"ATLAS" G-7264 on the 13 dtex fiberfill, and cured as in
i tem 2 .
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6. This is similar to item 2 above, except that
the polyester fiberfill substrate is coated as a tow under
plant conditions, by applying an 8.2~ emul6ion in water of
"ATLAS" G-7264 to produce the same solids coatins of 0.35%
sn the fiber. The tow was then relaxed at a temperature
of 175DC to cure the coating and set the crimp. The
relaxed tow was cut blended to a cut length of 60 mm with
a tow of the ~heath/core binder fiber to produce a blend
of 85/15 fiberfill/binder. The blend W215 converted into a
batt, and the batt was heat bonded under es~entially the
~ same conditions described.
; 7. This item was produced essentially as for
item 6, except that the coating was provided from
UCON 3207A, as in item 3.
To summarize: Items 1 and 4 are controls, :items
2, 5 and 6 are coated with ATLAS G-7264, while items 3 and
7 are coated with UCON 3207A; items 2, 3 and 5 are coated
in staple form, and cured at 170C, whereas items 6 and 7
are coated in tow form, before se~ting the crimp at 175C;
items 1-3, 6 and 7 have fiberfill of dtex 6.1, whereas
items 4 and 5 are of 13 dtex.
~- ' It will be noted that the weights and densities
of the batts were not identical. To get proper
comparisonst where indica~ed, the mea~urements have been
"normalized" by calculating equivalents all at the same
weight of 200 g/m2.
Table 2 gives the compression data for all 7
bonded batts, to show good results, i.e. good bonding
occurred in every case, in contrast with
~ilicone-~lickened fiberfill that cannot be bonded in this
manner.
Tables 3, 4 and 5 give flammability data. It
will be no~ed that none of the items showed fla~mability,
and the area~ destroyed were comparable to control~ 1 and
4, in which unslickened (dry) fiberfill was used, i.e. the
fiberfill coatings have not significantly increased
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~lammability over that of dry fiberfill. In contrast7
flammability tests were made on controls 8 and 9, to show
the well-known flammability associated with
silicone-slickened products. Control 8 was a batt
entirely of commercial silicone-slickened fiberfill,
otherwise as used in Examples 1 and 2 e;~cept for the
silicone-slickener. Control 9 was from a 60/20~20 blend
of 60% unslickened fiberfill, as used in Examples 1 and 2,
with 20% slickened fiberfill, as used in Control 8, and
2G% of the binder used in Examples 1 and 2; this shows
that even the addition of a minor proportion of
silicone- lickened fiberfill causes a very significant
increase in flammability, which is undesirable. The
flammability tests did not warrant normalization.
Table 6 shows the breaking strength
measurements. The top set gives the actual measurements
and the different weights of each batt, while the lower
~et gives calculated measurements all normalized to the
same weight of 200 g/m2, since this is a better comparison
which somewhat favors control 1 ~f lower weight. The
significantly superior breaking strength of preferred item
6 is most impressive. The low figures of i~ems 3 and 7
are speculated to be because of the nature of the coating,
and better results would be expected from an analogous
coating based on poly(ethylene oxide) chains, such as is
preferred, but it is significant that even these coatings
give significant bonding, in contrast to
silicone-slickened fiberfill which gives products having
virtually no bonding (except possibly between the residues
of the bicomponent binder fibers~. These strength tests
are only indirectly related to durability in furnishing,
but demonstrates the strong bonding, which partly explains
the good support bulk figures and durability.
Table 7 ~hows the results of the delamination
test, and again shows the strength of the bonds between
the layers, especially for preerred item 6, which is much
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better than the control. This is a very important test,
since delamination is a major cause of failure in some
constructions in furnishings and mattresses, and is
important also in sleeping bags and sportswear.
Table 8 contains two sets of data; in part A the
trade control is compared with item 6 in condensed
cushions, having a density of 25 to 28 9/l. A comparison
of the data shows that item 6 has a higher height under
relatively low loads (IH2 and 7.5 N), but a lower bulk at
the support bulk level. This reflects the improved
softness of the product which is explained by the reduced
fiber to fiber friction. The test item 6 has a ~uch
better durability at all loads than the commercial
control, although it has a density which is a little
lower. As shown in part B of the Table the difEerences in
bulk are much higher when considering the same items in
the noncondensed deco cushions or pillows. Despite the
considerable differences in density, the test item 6 has
equal bulk losses and maintains after the durability test
a much higher bulk. Item 7 is also showing considerable
improvement in bulk durability versus the commercial item,
particularly in the support bulk range. Items 3 and 7,
made with the Union Carbide 3207A are also the softest,
having the lowest support bulk. This can be of interest
for applications such as sleeping bags, where a high
compressibility is required. Essentially all test items
show an equal to better durability than controls, even if
they have a somewhat lower density. The durability
advantage of the products of the invention versus the
controls is very significant in both densities and at the
whole practical range of loads. The increased softness
and the durability advantage correspond to a real market
need, and the value of the products of the invention is
further increased by the good bonding and nonflammability
of these waddings. These properties are of particular
interest for applications such as furnishing and
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~attresses, but also sportswear, sleeping bags, etc.
These data in Table 8 call for several remarks:
- Bulk and bulk durability are essential in
furnishing and mattresses.
- The advantage of the products of the
invention, particularly item 6, is in reality much bigger
r than one can see from a quick look at the data. It has a
better durability at a much lower density in terms of g/1.
Table 9 shows the change in bulk after 3 home
laundries at 40C. This shows again the good performance
of most products of the invention, as these have the
lowest changes, althouyh items 6 and 7 have a eonsiderably
higher bulk than the control. The only exception is item
3, which may reflect defects in the preparation of this
item.
.~
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Table 2
Item No. 1 2 3 4 5 6 7
Initial_Height (cm)-
1st cycle 8.3 8.910.7 ll.9 11.2 12.9 12.0
~IH )
2nd cycle 7.7 8.49.2 11.6 10.0 12.0 10.9
2nd Cycle - Hei~ht (cm) under indicated loads
2N 7.6 8.3 9.1 11.4 9.9 11.9 10.8
5N 5.6 5.6 6.5 8.5 7.6 10.5 8.8
lON 4.6 4.7 5.2 7.1 6.3 9.3 7.6
(SB) 30N 3.1 3.1 3.1 4.4 4.0 6.7 S.l
60N 2.1 2.2 1;9 2.8 2.6 4.6 3.5
lOON l.S 1.61.4 1.8 1.8 3.2 2.4
160N 1.1 1.2 1.0 1.2 1.3 2.2 1.7
240N 0.9 1.0 0.8 0.9 1.0 1.6 1.3
Int. Compr.
~eight 0.7 0.7 0.8 1.1 1.0 1.7 1.3
To~al Int,
~eight 1.6 1.7 1.6 2.0 2.0 3.3 2.6
Softness:
Abs.(cm) 4.6 5.3 6.1 7.2 6.0 5.3 5.8
Rel.(%) 59.7 63.166.362.1 60.0 44.2 53.2
~ork
Recovery(X): 63.6 70.859.855.6 62.9 67.0 61.8
:' 11eight
g/m2 190.4 234.4 205.0203.4 239.6221.5 199.6
-18-
-19- ~IIL3C~6~
Table 3
FLAMMABILITY TEST @ 45C (DIN 54'335) SHOWING T~E AREA DESTROYED
; (Flame Length = 4.0 cm AND Exposure time = 15 seconds)
Identi- DURATION OF FLAME (IN SECONDS)AREA
fica~ion UHEN EXPOSED DESTROYED
5.0 cm 30.0 cm 55.0 cm Total (cm2)
(sec~
Item 1 0 0 0 0 6.2
Item 2 0 0 0 0 5.8
Item 3 0 0 O 0 5 0
Item 4 0 0 0 0 7.0
Item 5 0 0 0 0 7.4
Item 6 0 0 0 0 8.0
Item 7 0 0 0 0 10.2
Control 8 6.0 55.0 76.0 137.0 504.0
Control 9 10.0 65.0 80.0 155.0 504.0
.
-19-
~3~6~
-20-
Table 4
FLAMMABILITY TEST @ 45C (DIN 54'335) SHOWING THE FLAME VLLOCITY
(Flame Length = 4.0 cm AND Exposure Time = 15 seconds)
; VELOCITY OF FLAME IN (CM/MIN.) SPREAD FOR
Identification 2.0 minutes _ 3.0 minutes
Item 1 0.0 0.0
Item 2 0.0 0.0
:~ Item 3 -
Item 4 0.0 0.0
Item 5 0.0 0.0
I~em 6 0.0 0-0
Item 7 0.0 0.0
Control 8 54.6 72.4
~ Control 9 41.3 46.2
:':
-20-
~3~02
-21-
Table 5
FLAMMABILITY PILL (METHANAMINE) TEST SHO~ING THE AREA DESTROYED
(Ater 15 seconds of exposure)
DESTROYED2 M EA IN COMBUSTION 0~ T~ PILL
Identification _ (cm ) (sec.)
Item 1 12.64 Avg: 1'27
Item 2 14.51 1'30
Item 3 15.54 1'31
Item 4 ll.lS 1'30
Item 5 12.94 1'31
Item 6 14.53 1'31
Item 7 13.53 1'31
Control 8 82.02 1'30
Conttol 9 67.39 1'30
.
-21-
: L3~6~2
; -22-
Table 6
GRAB T~ST IN ~N)
SHOWING THE T2ARING STRENGTH OF THE BATTS
: ~eigh~ Machine Direction Cross Direction
Identification ~g~cm ~lM.D ) (X. D.~
Item 1 190.419.2 70.3
Item 2 234.425.1 67.4
Item 3 205.07.8 29.3
Item 4 203.415.8 48.7
Item 5 239.619.7 43.9
Item 6 221.564.3 186.0
Item 7 199.612.0 53.0
Normalized Strengths for Ueight ~200 ~/m2)
Item 1 20.2 73.8
Item 2 21.4 57.5
Item 3 7.6 28.6
Item 4 15.5 47.9
Item 5 16.4 45.0
Item 6 58.1 167.9
Item 7 12.0 53.1
'~
: ~,
~: :
: ~ `
: -22-
' '
~3(~i6~02
-23-
Table 7
DELAMINATION TEST IN (N)
SHOWING THE BONDING STRENGTH FRO~ LAYER TO LAYER
Machine DirectionCross Direction
Identification ~M.D.) _ (X.D.)
: Item 1 Avg(N): 7.1 7.7
CV (%): 2.7 11.1
Item 2 Avg(N): 7.0 8.3
CV (%): 10.0 7.7
Item 3 Avg(N~: 2.7 3.6
CV ~%): 5.8 2.1
Item 4 A~g(N): 5.4 7.0
CV (%): 8.8 12.2
Item 5 Avg(N): 6.1 7.2
CV (%): 7.~ 4.9
Item 6 Avg~N): 15.9 13.5
CV (%): 10.3 3.5
Item 7 Avg(N): 4.2 4.8
CV (%): 13.2 8.0
'
;
: '
-23-
~3a!6~
-24-
Table 8
DURABILITY DATA SHOWING THE LOSSES IN INITIAL HEIGHT
~ SUPPORT BULK BEFORE AND AFTER STOMPING (60 X 60 CM)
A. Condensed Cushions at 25-28 ~/l
Trade Control Item 6
Initial Hei~ht (cm):
Before Stomping 14.8 16.3
After Stomping 13.28 15.38
Abs. Diff. (cm) 1.52 0.92
Diff. (%) -10.27 -5.64
Bulk at 7.5N (cm):
~efore Stomping 13.53 14.2
After Stomping 11.63 12.7
Abs. Diff. (cm) 1.9 1.5
Diff. (%) -14.0h -10.6
Support Bulk (60N)(cm):
Before Stomping 8.8 7.63
After Stomping 6.05 5.36
Abs. Diff. (cm) 2.75 2.27
Diff. (%) -31.87 -29.75
B. Non-Condensed Pillows of 12 g/l
1 ~ ~ 4 5 6 7Control
Item No. ~ . _
Initial ~ei~ht (cm3:
Before Stomping 13.2015.0513.1 14.22 14.5 17.17 15.4712.4
Af~er Stomping 11.312.8710.72 11.9 12.52 14.52 13.0710.08
Abs Diff. (cm) 1.92.18 2.38 2.32 1.98 2.65 2.42.32
Diff. (%) -14.39-14.49-18.17 -16.32 -13.66 -15.43 -15.51-18.71
Bulk at 7.5N (cm~:
-
Before Stomping 9.0210.45 8.55 10.95 10.7 11.75 10.09.45
After Stomping 7.17 8.3 6.70 8.35 8.07 8.7 7.75 7.0
Abs Diff. ~cm) 1.852~15 1.85 2.6 2.63 3.05 2.252.45
Diff. (%) -20.51-20.57-21.64 -23.74 -24.58 -25.96 -22.54-25.93
Support Bulk (60N) (cm):
Before Stomping 2.553.05 2.32 4.55 3.95 2,75 2.223.60
After 5tomping 2.12.32 1.9 2.85 2.4 1.87 1.752.13
Abs Diff. (cm) 0.450.73 0.42 1.7 1.55 0.88 0.471.47
Diff. (X) -17.65-23.9318.1 -37.36 -39.24 -32.0 -21.17-40.83
-24-
1~31~ 0;~
-25-
TabIe 9
LAUNDRY EFFECT ON BULK DURABILITY
(3 HOME LAUNDRIES AT 45C)
Initial Height Support Bulk
Identif ation ~%) _ (%)_ _
Item 1 + 24.32 + 6.25
Item 2 + 9.52 O.O
Item 3 + 30.75 + 5.88
IteM 4 + 7.55 - 11.54
Item 5 O.O -
Item 6 + 6.55 - 7.69
Item 7 - 3.92 - 5.26
-25-
