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Patent 2080363 Summary

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(12) Patent: (11) CA 2080363
(54) English Title: FILLINGS AND OTHER ASPECTS OF FIBERS
(54) French Title: PRODUITS DE REMPLISSAGE ET AUTRES CARACTERISTIQUES DES FIBRES
Status: Expired and beyond the Period of Reversal
Bibliographic Data
(51) International Patent Classification (IPC):
  • D04H 1/00 (2006.01)
  • D02G 1/00 (2006.01)
(72) Inventors :
  • HALM, WALTER BERNARD (Germany)
  • JONES, WILLIAM JONAS, JR. (United States of America)
  • KIRKBRIDE, JAMES FREDERICK (United States of America)
  • MARCUS, ILAN (Switzerland)
  • SNYDER, ADRIAN CHARLES (United States of America)
(73) Owners :
  • E. I. DU PONT DE NEMOURS AND COMPANY
(71) Applicants :
  • E. I. DU PONT DE NEMOURS AND COMPANY (United States of America)
(74) Agent: BENNETT JONES LLP
(74) Associate agent:
(45) Issued: 2001-06-12
(86) PCT Filing Date: 1991-04-09
(87) Open to Public Inspection: 1991-10-31
Examination requested: 1998-04-03
Availability of licence: N/A
Dedicated to the Public: N/A
(25) Language of filing: English

Patent Cooperation Treaty (PCT): Yes
(86) PCT Filing Number: PCT/US1991/002269
(87) International Publication Number: WO 1991016485
(85) National Entry: 1992-10-09

(30) Application Priority Data:
Application No. Country/Territory Date
07/508,878 (United States of America) 1990-04-12
07/589,960 (United States of America) 1990-09-28

Abstracts

English Abstract


Fiberballs for filling uses have been prepared from mechanically-crimped
fibers having both a primary crimp and a secon-
dary crimp with specific configurations, especially amplitudes and
frequencies. The fiberballs may contain a proportion of other
fibres, particularly binder fibers.


Claims

Note: Claims are shown in the official language in which they were submitted.


32
1. Fiberballs having a random distribution and
entanglement of fibers within each ball, characterized in
that the fiberballs have an average diameter of about 2 to
about 20 mm, and that the individual fibers have a length of
about 10 to about 100mm and are prepared from fibers having
a primary and a secondary crimp, said primary crimp having a
frequency of about 14 to about 40 crimps/10 cm and said
secondary crimp having a frequency of about 4 to about 16
crimps/10 cm, and whereby the average amplitude of the
secondary crimp is at least 4 times the average amplitude of
the primary crimp.
2. Fiberballs according to Claim 1 wherein the
fibers are polyester fibers.
3. Fiberballs according to Claim 2, that are
refluffable.
4. Fiberballs according to any one of Claims 1 to
3, wherein at least 50% by weight of the balls have a cross
section such that the maximum dimension of each ball is not
more than twice the minimum dimension.
5. Fiberballs according to any one of Claims 1 to
3, wherein the fibers are coated with a slickener, which is
a silicone polymer, in amount about 0.01% to about 1% Si by
weight of the fibers.
6. Fiberballs according to any one of Claims 1 to
3, wherein the fibers are coated with about 0.05% to about
1.2% by weight of the fibers of a slickener which consists
essentially of a segmented copolymer of poly(alkyleneoxide)
and of polyethylene terephthalate).
7. Fiberballs having a random distribution and
entanglement of fibers within each ball, said fibers being a
blend of load-bearing fibers and binder fibers which
optionally contain a material capable of being heated when
subjected to microwaves or a high frequency energy source,
characterized in that the fiberballs have an average
diameter of about 2 mm to about 20 mm and the individual

33
fibers have a length of about 10 to about 100 mm, the
load-bearing fibers having primary crimp and a secondary crimp,
said primary crimp having a frequency of about 14 to about
40 crimps/10 cm and said secondary crimp having a frequency
of about 4 to about 16 crimps/10 cm, and whereby the average
amplitude of the secondary crimp is at least 4 times the
average amplitude of the primary crimp.
8. Fiberballs according to Claim 7, wherein the
binder fibers constitute from about 5 to about 30% by weight
of the fiber blend and the load-bearing fibers are polyester
fibers.
9. Fiberballs according to Claim 7 or 8, wherein
the binder fibers are polymeric bicomponent sheath/core or
side-by-side fibers, consisting essentially of a component
polymer with a bonding temperature that is at least 50° C
below the melting temperature of another component polymer.
10. Fiberballs according to Claim 7 or 8, wherein
the binder fibers are polymeric single component binder
fibers having a bonding temperature that is at least 50° C
below the melting temperature of the load-bearing fibers.
11. A process for making fiberballs of any one of
Claims 1 to 8, characterized by tumbling the feed fibers by
air against the wall of a vessel.
12. A process for making fiberballs of any one of
Claims 1 to 8, characterized by passing opened feed fibers
through a roller card.
13. A process for making fiberballs of any one of
Claims 1 to 8, characterized by passing opened feed fibers
through a flat card.
14. A molded structure characterized by
fiberballs of Claim 7 or 8 in a predetermined shape and in
which the binder fibers have been activated by heat.
15. A molded structure characterized by
fiberballs of Claims 7 or 8 in a predetermined shape and in
which the binder fibers have been activated by microwaves or
high frequency energy source.
16. A molded structure characterized by

34
fiberballs of Claim 9 in a predetermined shape and in which
the binder fibers have bean activated by microwaves or high
frequency energy source.
17. A molded structure characterized by
fiberballs of Claim 10 in a predetermined shape and in which
the binder fibers have been activated by microwaves or high
frequency energy source.
18. A molded structure characterized by
fiberballs of Claim 9 in a predetermined shape and in which
the binder fibers have been activated by heat.
19. A molded structure characterized by
fiberballs of Claim 10 in a predetermined shape and in which
the binder fibers have been activated by heat.

Description

Note: Descriptions are shown in the official language in which they were submitted.


CA 02080363 2000-08-14
WO 91/16485 PCT/US91/02269
1
FILLINGS AND OTHER ASPECTS OF FIBERS
10
FIELD OF INVENTION
2o This invention relates to improvements in fiber
filling material, especially polyester fiberfill, and more
particularly fiberfill which is in a fiberball fot~, and
other aspects and uses of these and other libers.
~jACRGROUND OF THE INVENTION
Polyester fiberfill has become widely used and
well accepted as a relatively inexpensive filling material
for pillows, quilts, sleeping bags, apparel, furniture
cushions, mattresses and similar articles. It hae generally
been made of polyethylene tarsphthalate staple (i.s. cut)
fibers that have been cut from filaments crimped in a
stuffer box-type of crimper. The deniers (or dtex) of the
fibers have generally been of the order of 5-6, i.e. a
significantly higher denier par filament (dpf) than cotton
fibers and polyester textile fibers used in apparel. The
fibers may be hollow or solid, and may have a regular round
or another cross section, and are cut to various lengths

WO 91/16485 2 PCT/US91/02269
according to the requirements of the end-use or the process
Polyester fiberfill is often "slickened", i.a.
coated with silicones and more recently with polyethylene
terephthalate/polyether segmented copolymers, to reduce the
fiber/fiber friction. A low fiber/fiber friction improves
the hand of the finished article made from the fiberfill,
producing a slicker and softer hand, and contributes to
reducing a tendency of the fiberfill to mat (or clump
together) in the article during use.
Polyester fiberfill staple has generally been
processed by being opened and then formed into webs which
are cross-lapped to form a wadding (also referred to as a
batty which is used to fill the article. The performance of
articles that have been filled using this technique has
been satisfactory in many end-uses for many years, but could
not fully reproduce the aesthetics of natural fillings such
as down and down/feather blends. Such natural fillings have
a structure that is fundamentally different from carded
polyester fiberfill batts: they are composed of small
2o particles with no continuity of the filling material: this
allows the particles to move around within the ticking and
to adapt the shape of the article to the user's contours or
desires. We believe that the ease with which down and
feather fillings can move around plays a key role in their,
recovery from compression after being compacted, by simple
shaking and patting. This virtue is referred to as
refluffability.
Contrary to down and feather, the carded polyester
fiberfill batts have a layered structure, in which the
fibers are parallelised, and are loosely interconnected
within each web and between the layers so they cannot be
moved around and refluffed in a similar way to down and
feather. Polyester fillings have, however, some advantages
over natural fillings, particularly in regard to washability
and durability. Accordingly, Marcus has developed a
fiberfill product composed of small, soft polyester fiber
clusters or fiberballs which keep their identity during wear

WO 91 / 16485 P~/~~9~/
~j ~,3
and laundering and enable the user to refluff the article
filled with the fiberfill. These clusters combine the good
mechanical properties and washability of polyester fiberfill
with the refluffability of down or down/feather blends.
Although some particulate products had been
produced commercially on modified cards from standard
fiberfill, such products were prepared for different end-
uses, and did not have the properties required for
manufacture of high quality bedding or furniture articles.
Steinruck disclosed one such modified card and process for
making "nubs" in U.S. Patent No. 2,923,980.
Marcus made his new fiberballs using fibers with
specific characteristics as feed for a new fiberball-making
process. U.S. Patents 4,618,531 and 4,783,364 disclose
preferred fiberball products and a process to produce them
from spiral crimp (including omega crimp) feed fibers, which
can be rolled under mild conditions due to their potential
for spontaneous curling. These products have been
commercially successful in the U.S. and Europe, mainly in
bedding and furniture cushions. Marcus demonstrated that
helical crimp was important for achieving the desired
fiberball st~scture, i.e. in providing a desired random
arrangement of the fibers within each fiberball, and in
achieving a desired low cohesion between the surfaces of
neighboring balls. Commercial fibers with standard
mechanical crimp did not produce fiberballs having the
desired fiberball structure which provides good durability,
high filling power and low cohesion, which are key
requirements for refluffable filling products.
To optimize the filling power (i.e. to increase
the bulk) and durability (i.e. to lower the amount of bulk
lost during use), and particularly the durability to
laundering, we believe that the fibers within the fiberball
should be randomly distributed, should have a uniform
density throughout the structure, and should be sufficientlv
entangled to keep the fiberball identity through laundering
or during normal wear. To achieve optimum filling power and

CA 02080363 2000-08-14
WO 91/16485 PCT/US91/02269
4 ,
durability, we believe that it is important that each fiber
within the fiberball should have its bulk fully and
individually developed, so that it can fully contribute (to
the filling power and to the durability). To achieve this
structure, on which depends the performance of the
fiberballs, Marcus used fibers which tend to spontaneously
curl, so that a good, consolidated structure could be
produced under very mild forces. In the aforesaid patents,
Marcus disclosed a preferred way to achieve this desired
fiberball structure and properties by using fibers with
helical crimp as feed fibers and an air tumbling process to
roll the fibers under mild forces. The resulting products
are characterized by a random distribution of the fibers
within the fiberball, by being at least 50~t round (having a
ratio of the largest dimension to the smallest dimension of
less than 2:1) and by having a low cohesion which was not
shown in prior products. Marcus did not produce acceptable
fiberballs under the same conditions using commercial fibers
with standard mechanical crimp.
Ths feed fibers used by Marcus to make his new
fiberballs are relatively unusual, unavailable and/or
expensive in some markets, in which by far the aa;a:ity of
polyester staple fiber is crimped mechanically, generally by
a stuffer box technique. Ever since Marcus disclosed the
value of using fiberfill in the form of a libsrball, rather
than as paralleliasd fibers in a carded batt-type structure,
it has been desirable to find out why standard mechanically
crimped fibers did not make good fiberballs, and to provide
a feed fiber other than what Marcus used. 8nyder et al in
U.S. Patent No. 5,218,740 disclosed
another process and apparatus for making fiber clusters, and
succeeded in processing mechanically crimped feed fiber into
satisfactory fiber clusters. An important object of the
present application is to provide such mechanically crimped
feed fiber that has the capability of being processed into
such clusters, sometimes termed fiberballs. Other objects
will be apparent herein.

WO 91/16485 PCT/US91/02269
Removable, refluffable cushions are now typical in
modern furniture styling . This has created a new need for
refluffable fiberfill, so the cushions can be replumped.
Furniture also requires filling products having more support
5 and filling power than bedding or apparel. This may require
fibers of higher denier. Such fibers may require different
crimping conditions from fibers of the order of 5-6 dtex.
In U.S. Patent No. 4,794,038 to Marcus, there are
disclosed fiberballs from spiral crimp fibers and binder
fibers which can be molded into a consolidated fiber block.
Again, spiral crimped fibers were used to achieve the
desired ball structure. It is desirable to provide
mechanically-crimped fibers capable of making such
fiberballs.
As will be evident herein, the principles of the
invention can also be applied to making clusters from fibers
other than polyester fiberfill.
SUMMARY OF THE INVEN TOrT
Surprisingly, we have now found that fiberballs
with comparable properties can be produced from certain
mechanically crimpea fibezs wi~ic;h have specific crimp
configurations. We believe that an important characteristic
is a potential to curl spontaneously that is similar in this
respect to that of the spiral crimped fibers used as feed
fibers by Marcus. Suitable feed fibers have been used with
combinations of primary and secondary crimp with specific
ranges of frequency and amplitudes. The precise ranges of
values required will depend on various considerations, such
as the denier and configuration of the feed fiber, and the
process technique used to make the balls. The frequency and
amplitude of the secondary crimp, especially, and good heat
setting of this secondary crimp, are believed to be key
requirements for making fiberballs.
~r~r~~rr~i i r~~ tn nrlo syerora n f tho nregen,~ i~,mn"~ 3 ....
s - - _ .. ......~....
there are provided refluffable fiberballs having a uniform
density, and a random distribution and entanglement of

2 ~ ~ ~ ~ ~~ 1~'O 91 / 16485 6
PCT/US91 /02269
fibers within each ball characterized in that the fiberbal:
have an average cross-section dimension of about 2 to about
20 mm, and that the individual fibers have a length in the
range of about 10 to 100 mm and are prepared from fibers
having a primary crimp and a secondary crimp, said primary
crimp having an average frequency of about 14 to about 40
crimps per 10 cm and said secondary crimp having an average
frequency of about 4 to about 16 crimps per 10 cm, and
having an average amplitude from the fiber longitudinal axis
of at least 4 times the average amplitude of the primary
crimps.
Also provided are fiberballe having a random
distribution and entanglement of fibers within each ball,
said fibers being a blend of load bearing fibers and binder
fibers, which optionally contain a material capable of being
heated when subjected to microwaves or a high frequency
energy source, characterized in that the fiberballs have an
average diameter of from about 2 mm to about 20 mm and the
individual fibers have a length of about 10 to about 100 mm,
the load-bearing fibers having primary crimp and a secondary
crimp, said primary crimp having an average frequency of
abazt 1~ to about 40 crimps/10 cm and the said secondary
crimp having an average frequency of from about 4 to about
16 crimps/10 cm, and whereby the average amplitude of the
secondary crimp is at least 4 times the average amplitude of
the primary crimp.
Further provided are processes for making the
aforesaid fiberballs as more fully described herein.
Additionally provided are molded structures
~ prepared from fiberballs which contain binder fibers.
Other aspects of the invention are preferred feed
fibers for making the fiberballs, and processes involved in
making suitable feed fibers.
According to such other aspects of the invention,
processes are provided for mechanically crimping a tow band
of polyester filaments of lower denier (about 4 to about 10
dtex) per filament in a stuffer box crimper at a crimper

CA 02080363 2000-08-14
WO 91/16485 ~ PCT/US91/02269
londing of about 13 to about 26 ktex per inch of crimper
width, and for heat-setting the crimped tow band to provide
crimped filaments hnving a primary crimp with an average
lrsquency of about 14 to about 40 per 10 cm and a secondary
crimp with an average frequency of about 4 to about 16 per
cm, and an average amplitude at least 4X the average
amplitude of the primary crimp and for converting the
resulting crimped tow band into cut fiber to provide feed
fiber for a process for making fiberballs from such feed
10 fiber, and for making such fiberballs by an air-tumbling
process or by using a ball-making machine equipped with card
clothing, s.g. of the modilisd roller-top type, or as
disclosed, e.g., by Snydar st al. in U.S. Patent No.
5,21s,~4o , and preferred mechanically-crimped feed fiber
for use in such ball-making machines and processes. Similnr
processes are provided for polyester filaments of higher
dtsx, with crimper loadings, s.g., up to about 34 ktex per
inch, correspondingly. The invention should not be
considered limited only to inducing the appropriate crimp by
2o use of a mechanical crimpsr of the stuffer box-type, for
example, but alternative methods of inducing the appropriate
structure, are also contemplated.
BRIEF DESCRIPTION OF DRAWINGS
Figures IA, IB, 2A, 2H, 3, 4, and 5 are all
photographs, the details of which are given harelnafter.
Figure 6 is a perspective view, partly cut away,
of a stuffer box-type crimpsr to show the crimping effects
obtained.
DETAILED DESCRIPTION OF THE INVENTION
According to the present invention, certain
mechanically-crimped feed fibers can produce fiberballs with
refluffability and durability characteristics similar to
those produced from spiral crimp fibers (sometimes referred
' to as helical crimped fibers) when submitted to similar
process conditions. A broader range of mechanically crimped

CA 02080363 2000-08-14
WO 91/16485 PCT/US91/02269
8
feed fibers can make satisfactory fiberballs when subjected
to other fiberball making processes_such as the one
described in US Patent No. 5,218,740.
In some cases, the structure of the fiberball is
so similar to the one obtained from spiral crimped fibers .
that it is difficult to distinguish the two products, even
in Electron Scanning Microscope (ESM) photographs of the
fiberballs. Reference is made in this regard to Figures IA,
IB, 2A and ZH, which are all ESM photographs at a
magnification of 20X. Figures IA and IB are photographs of
fiberballs prepared from a mechanically crimped f.ed fiber
as described in Example 1 hereinafter. Figures 2A and 2H
are photographs of commercial fiberballs prepared from a
spirally crimped feed fiber. These are discussed in more
detail hereinafter. Generally, the easiest way to examine
the crimp of the feed fiber from which any fiberball has
been prepared, is to find some of the free ands that usually
extend from the fiberballs, and examine the portions
extending out of the ball, rather than try to disentangle
the fiberballs themBelvss. It i: difficult to provide
an adequate 2-dimensional representation of fiberballs such
as are illustrated in these Figures, but ESM photographs
give a better representation than a photo made with an
ordinary camera. These ESM photographs are provided to show
the structural similarity to the commercial product that is
achievable according to the present invention with
mechanically-crimped feed fiber.
Producing fiberballs with a good structure from
mechanically crimped fibers is of particular practical and
commercial interest for fibers with special cross sections
which are difficult to produce and/or crimp with the spiral
crimp or bicomponent techniques, such as fibers having
multiple channels and/or high void contents and high c~anier
fibers. The technology disclosed herein hakes it possible
to produce fiberballs with a three dimensional structure,

2080~~
WO 91/16485 9 -PCT/US91/02269
low cohesion, and good durability from practically any
source of spun synthetic filaments, by modifying the
crimping conditions and so producing a specific combination
of primary and secondary crimp as disclosed hereinafter. As
will be recognized by those skilled in the art, any crimping
operation must be to some extent empirical, as the expert
will modify the crimping conditions according to the
particular feed fiber, according to the type, dimensions
and/or construction of crimper, and according to what is
l0 desired, experimenting until the results (in fiberballs, in
the present instance) are satisfactory, but guidelines are
given herein.
For filling purposes, fiberballe should preferably
be round and have an average diameter of 2-20 mm, at least
50% by weight of the balls preferably having a cross section
such that the maximum dimension is not more than twice the
minimum dimension. The fiberballs are made up of randomly
arranged, entangled, fibers that have been heat set to
provide both a primary and a secondary crimp with specific
frequency and amplitudes. A suitable primary crimp has an
average frequency of about 14 to about 40 crimps per 10 cm,
preferably shout 18 to about 28 (or for some fibers to about
32j crimps/10 cm, with a suitable secondary crimp having an
average frequency about 4 to about 16 par 10 cm and an
average amplitude of the secondary crimp that is at least 4X
the amplitude of the primary crimp. The crimped polyester
fibers have a cut length of about 20 mm to about 100 mm and
a linear density (for fiberfill purposes) of about 3 to
about 30 dtex. Lower dtex levels will not generally provide
3o good resilience or filling support, but lower dtex polyester
or other fibers may be processed into fiberballs for other
purposes, e.g. for use as nubs in novelty yarns, if desired.
Indeed, it will be understood that the ranges referred to
herein are approximate, and that precise limits for any
fiber will generally depend on various factors, such as
desired end use, other fiber factors, such as denier and
cross-sectional configuration, and the process conditions

PCT/US91/02269
WO 91/16485
i 1~
specifically selected for that particular fiber.
According to specific end-uses, the fiberballs may
contain a proportion, generally up to 30%, of other fibers,
particularly binder fibers. As will be evident to those
skilled in the art, now that we have discovered how to make
mechanically crimped fiber suitable for conversion into
fiberballs, as well ae converting spirally crimped fiber (as
taught by Marcus), it is possible to make fiberballs from
various blends of fibers, particularly blends of spirally
crimped fibers and of mechanically-crimped fibers that are
suitable for making fiberballs. Again, the precise
proportions and crimp configurations of such fibers needed
in such blends will depend on factors such as the technique
to be used to make fiberballs, and the denier and cross-
section of the fibers and, additionally for blends, the
other constituents of the blend. The load-bearing fibers
can be coated with a slickener such as a silicone slickener
or a segmented copolymer consisting essentially of
polyoxyalkylene and polyethylene terephthalate to reduce
fiber/fiber friction. Besides the improved softness in the
end-use product, the lubrication also plays an important
role in the fiberball making process by helping tr~G iii~ars
to slide one on top of the other during the process,
reducing the force required to roll them.
In order to understand the crimp configurations of
the feed fibers of the invention and how to obtain such
crimp configurations, some general discussion of crimping
may be helpful.
In order to process regular synthetic staple
fibers, their precursor filaments are generally treated in
the form of a filamentary tow to mechanically deform the
individual filaments and than set this deformation into
their thermoplastic structure by heating under minimal
tension. The main reasons for this are to provide fiber-
fiber cohesion (to provide continuity and facilitate further
textile processing steps for the cut fibers on cards and
spinning frames) or to provide increased bulk and desirable

WO 91/16485 11 P~i~~l~ ~2~9~
tactile aesthetics. This process is commonly calls ~ ~d
crimping, and will be discussed in relation to Figure 6,
which shows a stuffer box-type of crimper.
Commercial crimpers vary in details (and the
precise practice in any commercial operation may not have
been known publicly) but they are generally composed of at
least the following elements; feed rolls 1 and 2 to feed
fibers into a stuffing chamber 3 where the fiber deformation
takes place, and some means of applying back pressure, for
instance by a pressure loaded gate 4 (or a second set of
rolls) at the exit. There are many other parts but these
are the keys to the ensuing discussion.
Ordinarily, a large number of filaments ie formed
into a tow band 5 of a width that is slightly lass than the
width of the stuffing chamber 3, and fed precisely into the
stuffing chamber 3. This stuffing chamber can be thought of
as a 3-dimensional box; it has a length, which can be
thought of as in-line with the fiber flow through the
process (we show this as a z-dimension), a width, which is
slightly larger than the tow band width (we show this as a
y-dimension), and a depth, which is the other dimension of
the stuffing chamber 3 (we a:cw t:~ia as an x-dimension).
This stuffing chamber provides a transient capacitance or
storage capability for the tow band and, coupled with the
means for back pressure, causes the filaments to buckle in
the y-z plane of the stuffing chamber because there is extra
room for the filaments to so buckle in the y-dimension.
Desirably, the type of crimp generated is called sawtooth or
herringbone. If desired, the crimper can be heated,
3o especially at the entrance, to facilitate crimping, and then
cooled further on to help sat the crimp, somewhat, before
leaving the crimper. If the depth (x) of the stuffing
chamber 3 is large enough and/or the amount of fiber fed
into the stuffing chamber ie low enough, the tow band will
buckle in the x-z plane forming a more sinusoidal geometry.
This crimp is usually of much larger amplitude and lower
frequency than that generated by buckling in the y-z plane.

WO 91 / 16485 12 PCT/US91 /02269
For purposes of understanding the present invention, we
refer to primary crimp as crimp such as is generated in the
y-z plane, and to secondary crimp as crimp such as is
generated in the x-z plane. These crimps are indicated in
the tow band emerging from the crimper at the bottom of
Figure 6, with the secondary crimp indicated at 12 and the
primary crimp at 11.
Both types of crimp can be seen in the photographs
of a crimped tow band in Figures 3, 4 and 5. As can be seen
from the lines on the backing paper (1 cm apart), Figures 4
and 5 are at a greater magnification than Figure 3. The
secondary crimp of the whole tow band is shown more
evidently than the primary crimp, and is shown as
approximately vertical rows with an amplitude generally
perpendicular to the plane of the photograph, except that a
portion of the tow at the top of Figure 3 hae been turned to
show the amplitude in the plane of the photograph. This
secondary crimp corresponds to the depth (in the x-
dimension) of the stuffing chamber. Figure 3 (corresponding
to Example 1, hereinafter) shows a secondary crimp that is
much better set than in Figure 4 (corresponding to
Comparison A1. ~n Figure 5, the heat-setting was
intermediate, being better than Figure 4, but not as good as
Figure 3. The primary crimp can be discerned in the
photographs where some filaments have been pulled apart, and
is of much smaller amplitude than the secondary crimp, and
in a direction generally at right angles to that of the
secondary crimp, as the primary crimp corresponds to the
difference between the widths of the tow band and of the
stuffing chamber (in the y-dimension of the stuffing
chamber).
As noted herein, crimper loading can be an
important factor in obtaining the crimp configuration
desired for making fiberballs. Crimper loadings indicate
the amount of filamentary tow (sometimes referred to as a
rope) that is fed into the crimper, and is herein determined
in terms of ktex per inch of crimper width.

WO 91/16485 13 PCT/US91/02269
An important requirement is that the secondary
crimp be set in the filaments before it is pulled out, for
instance as the tow is advanced from the crimper or during
further processing of the tow. Depending on what has been
used previously in any particular commercial practice,
addition of some post-crimper means for avoiding tension
before the crimp is well set and/or extra heat setting may
be desirable, as prior practices have varied, and may not
have been publicly known. It is the crimp configuration of
the feed fiber at the time of fiberball formation that is
important, rather than any transient crimp configuration
within the crimper, or even shortly thereafter.
It will also be understood that, now we have
explained the importance of a 3-dimensional heat eat
configuration in a feed fiber for making rounded fiber
clusters (or fiberballs), such configurations may be
obtained by other means within the broad ambit of the
present invention. For ease of understanding, we have
explained this in terms of a mechanical crimping process of
the stuffer box-type.
A preferred mechanical crimping process to produce
the feed fibers for making fiberballs esssntial?j~ comprises
crimping the rope under a relatively low crimper loading.
We have used successfully such loadings as 13 to 26 ktex per
inch (crimper width) for round filaments of 4 to 10 dtex,
and somewhat higher loadings, up to 34 ktex per inch, for
higher deniers. As will be understood, any precise crimper
loadings will depend on various considerations apart from
the denier of the fibers, including the technique and
conditions that will be used to convert the feed fiber into
fiber clusters. We have found that a card-type technigue is
more forgiving than when a modified Lorch-type equipment is
used. A low crimper loading helps to generate the secondary
crimp, and affects its frequency and amplitude, and to some
extent improves the heat-setting of the secondary crimp,
which constitutes the memory of the fiber to spontaneously
curl. A low crimper load leaves more space for the rope to

WO 91/16485 14 PCT/US91/02269
fold back and forth, and may cause rotation of the tow
band, which can create variations in the crimping plane of
the secondary crimp, which all help to produce a good three
dimensional fiberball structure, as disclosed hereinafter.
Secondary crimp is essential for the production of the
fiberballs according to the invention, but to produce
optimal results it has to be heat-set as well as possible to
fix the desired crimp configuration.
As indicated, USP 4,618,531 and 4,783,364
disclosed fiberballs produced from feed fibers having a
spiral (or helical) crimp. Such fiberballs have relatively
few fibers sticking out of the fiberball and, as a result, a
low cohesion between the fiberballs. The spiral crimp also
provides optimal contribution of the fibers to the bulk,
resilience and durability of the fiberfill, as well as the
refluffability. The fiberball structure depends in great
part on the spontaneous curling of the fibers due to the
"memory" of the fibers, which results from their bicomponent
structure or from spin stresses imparted during asymmetric
quenching. The spontaneous curling potential allows
fiberballs to be produced from the feed fibers under very
mild conditions, applying ve=-y ?o~~~ forces to achieve a
consolidated fiberball structure. The fiberballs have a
resilient structure with excellent filling power and
durability.
The main difference between such fiberballs and
prior products referred to as "nubs", or similar commercial
products, produced usually on cards, is that the "nubs"
contain a very substantial amount of fibers that are present
in a strongly entangled nucleus and do not contribute any
resilience, but constitute simply a "dead weight". These
nubs can be sufficiently strongly entangled so that they can
resist a carding operation. Nubs are well adapted for
incorporation into slub yarns (for example for
berber carpets, tapestries and other textile uses requiring
different visual and tactile aesthetics), but do not have
the bulk, resilience and durability required for filling

WO 91/16485 PCT/US91/02269
applications.
As indicated, Marcus produced his resilient
fiberballs by using helically crimped fibers, and his air
tumbling process fiber did not produce fiberballs from
5 standard mechanically-crimped fibers. Helically crimped
fibers remain a preferred feed for producing such products
with the desired structure, but we have now discovered that,
contrary to previous experience, fiberballs with a very
similar structure can be produced from modified mechanically
3 crimped fibers having a very specific combination of primary
and secondary crimp. The key is believed to be in providing
the feed fibers with a potential to spontaneously curl.
Although this may not always be as strong as with
bicomponent fibers, this potential to curl allows fiberballs
15 to be produced under mild conditions, resulting in a similar
structure. The crimp configuration of the fiber and the
process conditions used to produce these fibers are
important in regard to fiberball structure. Air tumbling
conditions which did not produce any fiberballs with
standard commercially available mechanically crimped fibers,
may be used according to the present invention to produce a
pro3uct ~~it:: acceptable structure, filling power and
durability from fibers with a modified mechanical crimp.
The key parameter in the making of fiberballs with the
optimal structure from these modified "mechanically crimped
fibers" is the secondary crimp. It is the secondary crimp
of these fibers which is believed to impart their potential
to spontaneously curl, because it provides three-dimensional
crimp configurations.
Thus the key element in the production of fibers
having modified mechanical crimp (such as is required for
the formation of the fiberballs according to the invention)
is believed to be a well set secondary crimp with a
frequency of from about 4 crimps/10 cm to about 16 crimps/10
cm. The primary crimp is believed to be less critical. It
is preferable to have a primary crimp which is below 28
crimps/10 cm, because it helps to better set the primary

WO 91 / 16485 PCT/US91 /02269
16
gimp and makes the ~'olling and fiber entangling in the
fiberball easier; buL some good results are achieved with a
primary crimp frequency as high as about 40 crimps/l0 cm
(Example 1). A simple and proven way that we have used to
achieve a pronounced secondary crimp that is well set is to
reduce the crimper load, but this may also be achieved by
other means e.g. widening the crimper throat, i.e. the x-
dimension.
The polyester rope which is used for the process
is preferably laid down into the crimper at a relatively low
crimper load or density, preferably below 26 ktex per inch,
to allow it to fold back and forth changing direction at a
rate of about 8 to about 32 times within a section of 10 cm
length of rope. Preferably, because of this low crimper
loading, the tow band should not only be folding back and
forth, but also changing the angle of the laydown, so as to
create changes in the plane of the secondary crimp, so the
secondary crimp is not necessarily always at right angles to
the plane of the primary crimp. Secondary crimp, its
frequency, its three-dimensional character, and heat setting
of its configuration are keys to whether mechanically
crimped fiber will form fiberballs, and to their szruczure.
We believe, based on some observations during production,
that in most cases the secondary crimp node serves as a
reversal point for the fiber to go from one side to the
other of the fiberball, creating round smooth loops on the
surface of the fiberball. The resulting structure is very
similar to the structure of fiberballs produced from helical
crimp feed fibers. The indicated frequency and amplitude of
the secondary crimp are not sufficient unless they have been
well set in this configuration. This can be easily
estimated functionally by stretching a bundle and releasing
it, to evaluate the crimp take up. Such a functional
evaluation could be developed into a quantitative
measurement; if desired; as indicated hereinafter; nr; fir
instance by (1) mounting a bundle of known ktex in an
Instron machine, extending to remove secondary crimp, and

PCT/
WO 91 / 16485
then measuring the crimp recovery force from Instron load
cell response, or (2) by fixing one end of a bundle of known
ktex, stretching it under some extension means to achieve
and measure its fully extended length (TL), then removing
the extension means so as to allow the bundle to retract and
measuring the retracted length (RL), and calculating the CTU
as the percentage difference between the two lengths
measured (TL-RL) as a percentage of the fully extended
length (TL). But we have used the functional assessment and
have found it satisfactory for guiding the development of
new products based on the present invention.
Primary crimp also plays a certain minor role in
fiberball formation and structure. It is preferable to have
a relatively low frequency of below 28 crimps/10 cm and
rounded crimp nodes, but these by themselves are not
sufficient to achieve the desired fiberball structure
without the secondary crimp. It has been demonstrated that
merely providing low levels of primary crimp has not been
sufficient to form fiberballs on the modified Lorch
2o equipment mentioned previously.
We have found that feed fibers with a solid cross-
section generally form fiberbaiie~ more easily than hollow
fibers, particularly on the modified Lorch type equipment
disclosed in U.S. Patents 4,618,531, 4,783,364, and
4,794,038. On certain modified cards, differences due to
the secondary crimp may be smaller, as regards an ability
merely to make clusters. But the specific crimp as
disclosed in the invention remains important for the
production of fiberballs with desirably good structure,
durability, filling power (loft/bulk), and low cohesion.
Although solid fibers and relatively low deniers are
generally more easily rolled into fiberballs according to
the invention, the invention can produce fiberballs from
fibers with a high bending modulus such as 13 dtex, 4-hole,
X59_: yni ~7 f~hA_ra ~ spa ~r~_r~ ~11~ RPP_T_ frrnn thA Fsrs~~n~ 1 ~~e _ T~ i
g
believed that the technology used with prior art (modified)
cards did not allow fiberballs to be produced with high bulk

WO 91 / 16485 18 PCT/ US91 /02269
and good durability from such high bending modulus fibers,
or multiple channel fibers. The present invention is
believed to be the bast and perhaps only practical route to
produce fiberballs with the desired structure from high void
and/or multi-channel fibers. These are very difficult to
produce with a helical crimp, via jet quenching. The
bicomponent route would be extremely difficult: to our
knowledge, such bicomponent fibers have not been
commercially produced. The combination of primary and
secondary crimp of the invention allows the manufacturing of
fiberballs from such feed fibers without difficulty,
producing a good and performing filling product for end-uses
requiring high filling power, high support, and good
durability.
The polyester fibers used for the manufacturing of
the fiberballs of the invention can be coated with a
slickener and any conventional slickening agent can be used
for this purpose. Such materials are described in U.S.
patent 4,794,038. Conventional slickeners are normally used
at a level between 0.01 and about 1% Si on the weight of the
fiberball. Silicone polymers are used generally at
concentrations in amounts (approximately) of 0.03% to 0.8% ,
preferably 0.15 to 0.3%, measured as % Si on the weight of
the fiber. The slickener's role here is to reduce the
cohesion between the filaments and allow the formation of a
better structure during the fiberball making operation, to
improve the slickness of the filling material, and to reduce
the cohesion between the fiberballs (improving
refluffability). As disclosed, however, the feed fibers can
be coated with about 0.05% to about 1.2% by weight (of
fiber) of a segmented co(polyalkylene oxide/polyethylene
terephthalate), such as those disclosed in U.S. Patents
3,416,952, 3,557,039, and 3,619,269 to McIntyre et al., and
various other patent specifications disclosing like
segmented copolymers containing polyethylene terephthalate
segments and polyalkylene oxide segments. Other suitable
materials containing grafted polyalkyleneoxide/polyethylene

CA 02080363 2000-08-14
WO 91/16485 PCT/US91/02269
~ 19
oxide can be used. The fiber/fiber friction achieved with
these products is vary similar to those achieved with
silicones, but the fibers slickened with these mnterials do
bond to commercial copolyestsr~binder fibers and this is
essential for the manufacturing of fiberballs for molding
purposes, as disclosed in I.Itaraus~ U.S. Patent Nos.
5,169,580 and 5,294,392 and in U.S. Patent 4,940,502.
Due to the high resilience and support of the
cushions made by molding of the fiberballs, which is about
the same for a Z5 kg/m3 fibsrball block and !or a 45 kg/m3
block batt made from the same fiber bland, an amount of ~ to
30~, preferably 10 to 20~, by weight of binder fiber is
required. Suitable binder fibers, that can be used are
described, s.g. by Marcus in U.B. Patents Numbers 4,794,038
and 4,818,599, and in U.S. Patent No. 5,318,640, relating to
bonded fibrous structures using microwaves as a high
frequency energy source.
The invention is lurther described in the
following Examples in which the fibers were all made =rom
polyethylene terephthnlate. All parts and percentages are
by weight, and are based on the weight of the fibers, unless
otherwise stated. The bulk measurements were made on 80 x
80 cm pillows (1000 g filling weight), and the bulk losses
are given as a ~ after simulated wear tasting. The
qualitative assessment of the structures reflects the
proportion of the fiberballs that were round, the hairiness
of the fiberballs, and how well these fiberballs were formed
(loose structure, well entangled etc.) on a scale of
ls(wOrst) t0 5s(beBt).
Com a~ri,son A
.~ drawn end crisped rope ~~as grega=ed
conventionally from 6.7 dtex solid fiber, using a draw ratio
'-5 of 3.5X, a crimpar loading of 29 ktex par inch, and 0.25

WO 91/16485 PCT/US91/02269
(Si) of a commercial polysiloXane slickener. The resulting
fiber had a primary crimp frequency of 31 crimps/10 cm with
3 poorly set secondary crimps/10 cm. The rope was cut to 32
mm cut length staple and the staple was opened on a
commercial Laroche opening unit and injected into a
modified Lorch machine, as disclosed in U.S. Patents
4,618,531: 4,783,364; and 4,794038. The fibers were
tumbled in the machine for 4 minutes at 450 rpm. No
fiberballs were formed from this feed fiber under these
to conditions.
EXAMPLE 1
This was similar to Comparison A, but the rope
was crimped under reduced pressure and the crimper load was
reduced by 38.:5. The resulting product had.a primary crimp
frequency of 39 crimps/10 cm and a relatively strong
secondary crimp with a frequency of 4 crimps/10 cm which was
much better set, as shown by the crimp pull out force, which
was about 0.6N/ktex (about 4 times that of the secondary
crimp of the feed fiber used in Comparison A). The rope was
cut into 32 min cut length staple which converted easily into
fiberballs, under the conditions described above, with a
good structure and refluffability. Table 1B gives the
properties of these balls from Example 1, and compares them
with a commercial product made from spiral-crimp 5 dtex
(silicone-slickened) feed fiber according to U.S. Patent No.
4,618,531.
Table lA
Crimp Characteristics
Comparison A Example 1
Crimps/l0 cm primary crimp 31 3g
Crimps/10 cm secondary crimp 3 4
f~ri~nn n~ 11-=~t nr~~. I /lrtovl
r -r~__ L_ f___Q ,~, _ _,
- Primary crimp 6.0 5.3
- Secondary crimp 0.14 0.57

WO 91/16485 PCT/US91/02269
Conclusions from comparisons summarized in Table lA.
To produce fiberballs with an acceptable structure
by this technique, a significant frequency of secondary crimp
that is well heat-set is required. Although the forces
required to pull out the primary crimps were comparable for
the feed fibers of Comparison A and Example l, the force
required to pull out the secondary crimp was 4 times higher
in the case of Example 1. This force corresponds directly to
the heat-setting of the secondary crimp, which is related to
the potential of the fiber to spontaneously curl.
As Comparison A did not form fiberballs under the
test conditions, the fiberballs of Example 1 ware compared
with commercial fiberballs.
Table 1B
Fiberball properties
1. Bulk
Commercial Example 1
IH2 228 mm 212 mm
4N 208 mm 190 mm
60N 101 mm 87 mm
200N 44 mm 39 mm
2. Bulk losses
Commercial Example 1
IH2 -25.2% -21.2%
4N -25.0% -20.7%
60N -21.2% -16.4%
200N - 5.7% - 2.6%
3. Cohesion and rating
Commercial Example 1
Cohesion 3.3N 4.3N
Qualitative rating 4-5 4
Conclusions from comparisons summarized in Table 18.

WO 91/16485 PCT/US91/02269
22
These mechanically crimped fibers produced
fiberballs with filling power and durability that were
comparable to those of commercial fiberballs produced from
spiral crimp fibers.
Figures 2A and 2B are photographs taken, through
an Electron Scanning Microscope (ESM) at a magnification of
20X, of the commercial fiberballs (made from 5 dtex spiral
crimp fiber). Figures lA and 18 are similar photographs of
the fiberballs of Example 1. This ESM photographic
comparison shows very similar random arrangements of the
fibers within the fiberballs and similar uniform fiber
densities. The fibers in both products had fully developed
their bulk with no felting. This structure determines the
performance of the fiberball products: bulk, durability and
refluffability. The similarities of structure shown in the
photographs explain the similarities of data in Table 1B.
Figures 3 and 4 are photographs of tow bands from
which were cut feed fibers used as described above. Figure
3 corresponds to Example l, whereas Figure 4 corresponds to
Comparison A. These clearly show the secondary crimp as
rows going from bottom to top of the photographs. The
primary crimp is seen in the cracks formed on the top ~f
these rows by the manipulations made to separate the
individual fibers from the rest of the rope. A bundle of
fibers which was separated from the rope and turned 90
degrees can be seen at the upper part of Figure 3. The
configurations of the secondary and primary crimps can be
observed. The small amplitude, and high frequency of
primary crimp versus the high amplitude and low frequency of
the secondary crimp can be clearly seen.
The difference between the secondary crimps in Figures 3 and
4 are evident from these photographs. Figure 5 shows a tow
band of 6.1 dtex single hole fiber which produced fiberballs
on the modified Lorch machine, but with rather a poor
structure. The secondary crimp is seen to be far bettex
than for Comparison A (Figure 4), but was not adequately
heat set. This could be adjusted, so an improved feed fiber

WO 91/16485 PCT/US91/02269
23
would be obtained.
Comparison B
A drawn and crimped rope was prepared
conventionally from 13 dtex, 4-hole, 24% void fiber, using a
draw ratio of 3.5X, a crimper load of 26 ktex per inch, and
0.5% of a commercial co-polyether/polyester ZELCON* 5126,
available from E.I. du Pont de Nemours and Company. The
resulting fiber had a primary crimp frequency of 22
l0 crimps/10 cm with a poorly set secondary crimp frequency of
2 crimps/10 cm. The rope was cut to 50 mm cut length
staple, and the staple was opened on a carding machine and
then conveyed by air to a roller card, modified to produce
fiberballs of average diameter about 6.5mm. The'fiberballs
were produced at 80 kg/hour and showed substantial hairiness
and a relatively high cohesion of 10.5 N, with a few
elongated bodies. The fiberballs had non-uniform density
with some sections having a high density and showing some
limited felting. This felting reduces the bulk (i.e., the
filling power) and, to a lesser extent, the resilience of
the product (Table 2). The staple fiber did not produce any
fiberballs on the modified Lorch machine under the
conditions used for Example 1.
EXAMPLE 2
A drawn and crimped rope was prepared ae in
Comparison B, but the crimper gate pressure was reduced to
increase the secondary crimp and improve ite heat-setting,
using the same draw ratio 3.5X, crimp load (26 ktex per
inch), and 0.5% of a commercial co-polyether/polyester
ZELCON* 5126, available from E.I. du Pont de Nemours and
Company. The resulting fiber had a primary crimp frequency
of 22 crimps/10 cm with a secondary crimp frequency of about
4 crimps/10 cm. The secondary crimp was well pronounced,
~~rt i tV h~ls~lt V V 1 t 11~ 1~i. 1~A 1~W1~'111 ~V llri Vr/ Vr~j111~~ 11S J
~dgrV~( ~Y
a subjective rating of the recovery force of the stretched
rope. The rope was cut to 50 mm cut length staple and the

PCT/US91/02269
WO 91/16485
24
staple was opened on a carding machine, then conveyed by afi
to a roller card, modified to produce fiberballs. The
fiberballs were produced at 95 kg/hour, under the same
settings as for Comparison H, and showed low hairiness and
well formed fiberballs, having an average diameter of 6.3 mm
with a very significant reduction in the felted area. As a
result, the cohesion dropped to about 6.5N and the bulk
(filling power) also showed a significant improvement (Table
2). This fiber did form fiberballs on the modified Lorch
equipment under the conditions used for Comparison A and
Example l, but their structure was poorer than the
commercial products made on the same equipment, from spiral
crimp feed fibers. The reason is believed to be that the
heat setting of the secondary crimp in this test item was
not adequate; this air-tumbling process requires a feed
fiber with stronger potential for spontaneous curling than
does the modified card.
Table 2
Crimp characteristics Comparison B Example 2
Crimps/10 cm primary crimp 22 22
Crimps/10 cm secondary crimp 2 4
Fiberball properties Comparison H Example 2
.IH2 90 mm 125 mm
7.5N 67 mm 88 mm
60N 41 mm 48 mm
120N 33 mm 37
mmWork Recovery 48.5% 55%
Cohesion 10.5N 6.5N
(Note - although the secondary crimp for Example 2 was
better set than for Comparison H, it did not have a high

WO 91/16485 PCT/US91/02269
recovery force, judged subjec~~vely)
Conclusions from comparisons summarized in Table 2.
The product of Example 2 showed a much higher
filling power with 39% higher initial height and 17% higher
support bulk versus Comparison B. The cohesion was
significantly lower, reflecting much better refluffability.
The product of Example 2 has a high commercial value, while
Comparison H is judged unsatisfactory.
Comparison C
A drawn and crimped rope was prepared as in
Comparison B. This rope was cut to 50 mm together with a
bicomponent 17 dtex sheath/core binder in a weight ratio of
88:22 and the staple was opened on a carding machine, then
conveyed by air to a roller card, modified to produce
fiberballs of average diameter about 6.5 mm. The fiberballs
were produced at 74 kg/hour and showed substantial hairiness
and relatively high cohesion of 12N, with a few elongated
bodies. The fiberballs had non-uniform density with some
sections having a high density and showing some limited
felting. This felting reduced the bulk (i.e. the filling
power) and, to a lesser extent, the resilience of the
product (Table 3).
EXAMPLE 3
A 13 dtex, 4-hole, 24% void, drawn and crimped
rope was prepared as for Example 2. This rope was cut to 50
mm cut length staple together with a 17 dtex bicomponent
sheath/core fiber rope at a weight ratio of 88:22 and the
staple was opened on a carding machine, then conveyed by air
to a roller card, modified to produce fiberballs. The
fiberballs were produced at 87 kg/hour, under the same
bCLt111C~o as for i:c~mparisoii C, anti snowed iow hairiness anti
well formed fiberballs, having an average diameter of 6.5 mm
with a very significant reduction in the felted area. As a

WO 91/16485 PCT/US91/02269
26
result the cohesion dropped to about 7.5 N and the bulk
(filling power) improved significantly over Comparison C, as
can be seen in Table 3.
Table 3
Comparison C Example 3
IH2 93 mm 136 mm
7.5N 68 mm 92 mm
60N 41 mm 48 mm
120N 33 mm 36 mm
Work Recovery 48.6% 55%
Cohesion 12.ON 7.5N
DESCRIPTION OF TEST METHODS USED
Many of the tests used herein have been described
already in the prior patents referred to herein.
Hulk Measurements on Cushions:
Bulk measurements are ma~?s conventionally on an
Instron machine to measure the compression forces and the
height of the cushion. The measurement is made with a foot
of diameter 10 cm attached to the Instron. The sample is
first compressed to the maximum pressure of 60N once, then
released. From the second compression curve are noted the
Initial Height (IH2) of the test material, the support bulk
(SB 7.5N), i.e., the height of the cushion under a force of
7.5N, and the height under a force of 60N (B60N). The
softness is calculated both in absolute terms (AS, i.e.
IH2-SB 7.5N) and in relative terms (RS, i.e., As expressed
as % of IH2). Resilience is measured as Work Recovery
(WR$), i.e., the ratio of the area under the whole recovery
curve, calculated as a percentage of that under the whole
compression curve.

WO 91/16485 PCT/US91/02269
Durability:
2' _2~~a~63
To simulate prolonged normal use, a Fatigue Tester
(FTP) has been designed to alternately mechanically work
(i.e. compress and release) a pillow through about 6,000
cycles over a period of about 18 hours, using a series of
overlapping shearing movements followed by fast compressions
designed to produce the lumping, matting and fiber
interlocking that normally occur during prolonged use with
fiberfill. The amount of fiberfill in the pillow can
greatly affect the results, so each pillow (80 X 80 cm) is
blow-filled with 1000 g of filling material, unless
otherwise stated.
It is important that pillow should retain its
ability to recover ite original shape and volume (height)
during normal use, otherwise the pillow will lose its visual
aesthetics and comfort. So bulk losses are measured, in a
conventional manner, on the pillows both before and after
exposure to the Fatigue Tester, mentioned above. Visual
aesthetics, bulk and softness of a pillow are a matter
of personal and/or traditional preferences, what is
important ie that the change of the properties of the pillow
during wear wi3i be as small as possible (i.e., the
durability of the pillow). Hulk measurements are made on an
"Instron" machine to measure the compression forces and the
height of the pillow, which ie compressed with a foot of
diameter 288 mm attached to the Instron. From the Instron
plot are noted (in cm) the Initial Height (IH2) of the test
material, the Support Bulk (the height under a compression
of 60 N) and the height under a compression of 200 N. The
softness is considered both in absolute terms (IH2-Support
bulk), and in relative terms (as a percentage of IH2).
Both are important, and whether these values are retained
after stomping on the Fatigue Tester.
n~hoc i ~n lvfo~e~tro or~t
._.
This test was designed to test the ability of the
fiberfill to allow a body to pass therethrough, and this

WO 91 / 16485 PCT/ US91 /02269
28
2 ~ ~ ~ ~ ~ ~ correlates with refluffability in the case of fiberballs
made from fibers having comparable properties such as
denier, slickener, etc. In essence, the cohesion is the
force needed to pull a vertical rectangle of metal rods up
through the fiberfill which is retained by 6 stationary
metal rode closely spaced in pairs on either Bide of the
plane of the rectangle. All the metal rods are of 4 mm
diameter, and of stainless steel. The rectangle is made of
rods of length 30 mm (vertical) and 160 mm (horizontal).
The rectangle is attached to an Instron and the lowest rod
of the rectangle is suspended about 3 mm above the bottom of
a plastic transparent cylinder of diameter 180 mm. (The
stationary rods will later be introduced through holes in
the wall of the cylinder and positioned 20 mm apart in pairs
on either side of the rectangle). Before inserting these
rods, however, 50 g of the fiberfill is placed in the
cylinder, and the zero line of the Instron is adjusted to
compensate for the weight of the rectangle and of the
fiberfill. The fiberfill is compressed under a weight of
402 g for 2 minutes. The 6 (stationary) rods are then
introduced horizontally in pairs, as mentioned, 3 rods on
either aide of the rectangle one pair above the other, at
vertical separations of 20 mm with the lowest pair located
at 30 mm from the bottom of the cylinder. The weight is
then removed. Finally, the rectangle is pulled up through
the fiberball between the three pairs of stationary rods, as
the Instron measures the build-up of the force in Newtons.
% Round:
As indicated, tails, i.e., condensed cylinders of
fiberfill, are not desirable since they decrease the
refluffability (and increase the cohesion value) of what
would otherwise be fiberballs of the invention, so the
following method has been devised to determine the
proportions of round and elongated bodies. About 1 g (a
handful) of the fiberfill is extracted for visual
examination and separated into three piles, those obviously
round, those obviously elongated, and those borderline cases

WO 91/16485 29 PCT/US~1~
which are measured individually. All those having a length
to width ratio in cross-section of less than 2:1 are counted
as round.
The dimensions of the fiberballs and denier of the
fibers are important for aesthetic reasons, but it will be
understood that aesthetic preferences can and do change in
the course of time. The cut lengths are preferred for
making the desired fiberballs of low hairiness. As has been
suggested in the art, a mixture of fiber deniers may be
desired for aesthetic reasons.
Determination of Crimp Frequency:
The crimp frequencies are determined using a Crimp
Balance Zweigle S-160 from Zweigle Reutlingen (Germany).
Determination of Primary Crimp Frequency:
The number of primary crimps is counted while the
specimen is under a low tension. Thus, the individual
fibers are fixed on the Crimp Balance and a weight of 2
mg/dtex is placed on the hook and t:a primary crimps are
counted. (The measured length may be recorded as L1.) The
frequency ie calculated based on the specimen's extended
length L2 under high tension. This extended length L2 is
determined under a weight of 45 mg/dtex. The crimp
frequency is then calculated with regard to L2.
Determination of Secondary Crimp Frequency:
The extended length L2 is determined as above and
the specimen is then relaxed completely to 60% of its
extended length. The secondary crimp is then counted and
its frequency calculated with regard to the extended length
L2 under 45 mg/dtex.

CA 02080363 2000-08-14
WO 91/16485 ' PCT/US91/02269
Hsasursmsnt of the Uncrimping stress of the 6econdary Crimp:
The heat-setting of the secondary crimp helps
establish the memory of the fibers to spontaneously curl.
5 The measurement of the force required to uncrimp the
secondary crimp is directly related to the fibers potential
to spontaneously curl. Wenk forces show poor heat-setting.
This may result in poor fibarball structure even when the
frequency and amplitude of the secondary crimp are otherwise
10 adequate.
11 bundle of fibers, cut from a rope of about 0:7
ktex is fixed with clamps on the Instron and the bundle
elongated at a constant rats of extension until the
resulting curve becomes a straight line. The bundle is
15 marked at the clamps level and removed from the Instron.
The bundle is weighed to calculate its exact ktsx and a
weight o! 2 mg/dtsx is suspended to determine its length
between the two marks (i.e. the uncrimping strain for the
secondary crimp). This length is recorded on the stress
20 strain curve, so as to determine the uncrimping stress for
the secondary crimp. Ths uncrimping stress for the primary
crimp can be calculated by continuing the straight line
portion of the stress strain curve until it intersects with
the base line. From the intersection point a perpendicular
25 is drawn up until it intersects the stress strain curve.
Ths stress read at this intersection point corresponds to
the total uncrimping force of the bundle, from which the
uncrimping force of the primary crimp is calculated by the
difference between the total force and the force to uncrimp
30 the secondary crimp. The force required to uncrimp the
primary crimp is generally an order of magnitude higher than
the force required to uncrimp the secondary crimp.
As will readily'be understood, the present
invention is particularly useful as applied to fiberfill,
fQr filling appliaat~,onsr and to polyester fibers having
characteristics suitable for such purposes, but the
invention is not restricted thereto. As can be understood
from U.S. Patent No. 5,218,740,

WO 91/16485 PCT/US91/02269
31 2~~~3~3
fiber clusters may also be made from other fibers, and need
not be restricted to the deniers useful and suitable for
filling purposes. Also, other variations will be evident to
those skilled in the art. For instance, fiber clusters may
be made from blends of different materials, to gain
advantages and enhanced properties. Especially advantageous
results may be obtained by combining in the same cluster
structure different fiber configurations, as regards to
crimp, and/or denier, and/or fiber structure, to maximize
the individual contributions in the whole cluster.
Furthermore, different types of crimp may be combined in the
same fiber with advantage, to give an enhanced cluster
making potential, and/or improved properties in the
resulting cluster. Also, as indicated, those skilled in the
art can devise many ways of generating a three-dimensional
loopy structure in a filament without using a etuffer box
crimper, so that such loopy filaments are suitable for
(cutting into staple and) forming into clusters on
appropriate machines such as modified Lorch equipment or
modified cards. Such alternative crimping means may include
etuffer jet crimping, false twist texturing and air jet
texturing, by way of example. The invention ie not
restricted only to the process or apparatus embodiments set
out specifically herein.

Representative Drawing
A single figure which represents the drawing illustrating the invention.
Administrative Status

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Event History

Description Date
Time Limit for Reversal Expired 2004-04-13
Letter Sent 2003-04-09
Grant by Issuance 2001-06-12
Inactive: Cover page published 2001-06-11
Inactive: Final fee received 2001-01-05
Pre-grant 2001-01-05
Notice of Allowance is Issued 2000-11-16
Letter Sent 2000-11-16
Notice of Allowance is Issued 2000-11-16
Inactive: Approved for allowance (AFA) 2000-10-31
Amendment Received - Voluntary Amendment 2000-08-14
Inactive: S.30(2) Rules - Examiner requisition 2000-04-13
Inactive: Office letter 1999-02-26
Amendment Received - Voluntary Amendment 1998-06-18
Inactive: Application prosecuted on TS as of Log entry date 1998-05-05
Inactive: RFE acknowledged - Prior art enquiry 1998-05-05
Inactive: Status info is complete as of Log entry date 1998-05-05
Request for Examination Requirements Determined Compliant 1998-04-03
All Requirements for Examination Determined Compliant 1998-04-03
Deemed Abandoned - Failure to Respond to Maintenance Fee Notice 1997-04-09
Inactive: Adhoc Request Documented 1997-04-09
Application Published (Open to Public Inspection) 1991-10-31

Abandonment History

Abandonment Date Reason Reinstatement Date
1997-04-09

Maintenance Fee

The last payment was received on 2001-03-28

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  • the reinstatement fee;
  • the late payment fee; or
  • additional fee to reverse deemed expiry.

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Fee History

Fee Type Anniversary Year Due Date Paid Date
MF (application, 7th anniv.) - standard 07 1998-04-09 1998-03-10
Request for examination - standard 1998-04-03
MF (application, 8th anniv.) - standard 08 1999-04-09 1999-04-01
MF (application, 9th anniv.) - standard 09 2000-04-10 2000-03-22
Final fee - standard 2001-01-05
MF (application, 10th anniv.) - standard 10 2001-04-09 2001-03-28
MF (patent, 11th anniv.) - standard 2002-04-09 2002-03-18
Owners on Record

Note: Records showing the ownership history in alphabetical order.

Current Owners on Record
E. I. DU PONT DE NEMOURS AND COMPANY
Past Owners on Record
ADRIAN CHARLES SNYDER
ILAN MARCUS
JAMES FREDERICK KIRKBRIDE
WALTER BERNARD HALM
WILLIAM JONAS, JR. JONES
Past Owners that do not appear in the "Owners on Record" listing will appear in other documentation within the application.
Documents

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Document
Description 
Date
(yyyy-mm-dd) 
Number of pages   Size of Image (KB) 
Description 2000-08-14 31 1,550
Description 1994-05-21 31 1,560
Cover Page 2001-05-17 1 37
Representative drawing 2001-05-17 1 14
Drawings 1994-05-21 5 175
Claims 2000-08-14 3 119
Abstract 1994-05-21 1 45
Claims 1994-05-21 3 123
Cover Page 1994-05-21 1 33
Reminder - Request for Examination 1997-12-09 1 117
Acknowledgement of Request for Examination 1998-05-05 1 173
Commissioner's Notice - Application Found Allowable 2000-11-16 1 165
Maintenance Fee Notice 2003-05-07 1 174
Correspondence 1998-12-08 32 1,385
Correspondence 1999-02-26 2 12
PCT 1992-10-09 12 382
Correspondence 2001-01-05 1 35
Correspondence 2004-04-30 46 2,876
Correspondence 2004-06-16 1 22
Correspondence 2004-07-14 1 28
Fees 1997-04-02 1 86
Fees 1996-03-22 1 86
Fees 1995-03-16 1 83
Fees 1994-03-18 1 77
Fees 1993-03-31 1 89