IP Library › Granted Patent US 10,611,120
Granted Patent B2
US 10,611,120 · App. 15/460,870 · Granted Apr 7, 2020

Multi-layered fabric laminates and methods of making and using the same

Inventors: James D. Small, Jr. (Greensboro, NC); W. Scott Kinlaw (Greensboro, NC); Randell Zane Mitchell (Greensboro, NC)
Assignee: Precision Fabrics Group, Inc.
B32B5/26A47C23/00B32B5/022B32B37/06B32B37/12
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Quick Facts
Patent No.
US 10,611,120
App. No.
15/460,870
Granted
Apr 7, 2020
Kind
B2
Abstract

Multi-layered fabric laminates, such as, for example, those used as filler cloths and/or in manufacturing mattress foundations, are described along with methods of making and/using the same.

Claims (25)

1. A fabric comprising:

a first nonwoven stitchbond fabric layer; and

a second nonwoven fabric layer that is a needlepunched nonwoven fabric and is laminated to a surface of the first nonwoven stitchbond fabric layer,

wherein at least one surface of the needlepunched nonwoven fabric comprises fused fibers and the at least one surface is an outer surface of the fabric,

wherein the first nonwoven stitchbond fabric layer comprises cellulose fibers, viscose fibers, or a combination thereof,

wherein the second nonwoven fabric layer comprises bicomponent fibers in an amount of about 10% to about 50% by weight of the second nonwoven fabric layer, and

wherein the fabric has a bond strength of at least about 50 grams per inch as measured between the first nonwoven stitchbond fabric layer and the second nonwoven fabric layer as measured in the machine direction and/or cross machine direction in accordance with AATCC 136.

2. The fabric of claim 1 , wherein the first nonwoven stitchbond fabric layer further comprises polypropylene fibers, polyester fibers, copolyester fibers, polyethylene fibers, bicomponent fibers, or blends thereof.

3. The fabric of claim 1 , wherein the first and second nonwoven fabric layers are laminated together using a thermal, ultrasonic, and/or adhesive method.

4. The fabric of claim 1 , wherein the first nonwoven stitchbond fabric layer and/or the second nonwoven fabric layer is a single nonwoven layer.

5. The fabric of claim 1 , wherein the fabric has a basis weight in a range of about 3 ounces per square yard (osy) to about 10 osy.

6. The fabric of claim 1 , wherein the second nonwoven fabric layer further comprises polypropylene fibers in an amount of about 10% to about 50% by weight of the second nonwoven fabric layer.

7. The fabric of claim 1 , wherein the fabric has a thickness in a range of about 0.025 to about 0.25 inches.

8. The fabric of claim 1 , wherein the fabric has a bond strength at each adjacent fabric layer that is at least about 85 grams per inch as measured between each adjacent fabric layer in the machine direction and/or cross machine direction in accordance with AATCC 136.

9. The fabric of claim 8 , wherein the bond strength is at least about 200 grams per inch as measured between each adjacent fabric layer in the machine direction and/or cross machine direction in accordance with AATCC 136.

10. The fabric of claim 1 , wherein the first nonwoven stitchbond fabric layer comprises viscose fibers.

11. The fabric of claim 1 , wherein the first nonwoven stitchbond fabric layer further comprises fibers selected from the group consisting of polyester fibers, aramid fibers, bicomponent fibers, and/or silica-modified viscose fibers.

12. The fabric of claim 1 , wherein the first nonwoven stitchbond fabric layer comprises viscose fibers and polyester fibers.

13. The fabric of claim 1 , wherein the first nonwoven stitchbond fabric layer comprises viscose fibers and bicomponent fibers.

14. The fabric of claim 1 , wherein the first nonwoven stitchbond fabric layer further comprises a flame retardant.

15. The fabric of claim 1 , wherein the second nonwoven fabric layer further comprises polypropylene fibers, polyester fibers, copolyester fibers, polyethylene fibers, or blends thereof.

16. The fabric of claim 1 , wherein the first nonwoven stitchbond fabric layer is devoid of a flame retardant.

17. The fabric of claim 1 , wherein the bond strength between the first nonwoven stitchbond fabric layer and the second nonwoven fabric layer is in a range from about 50 grams per inch to about 700 grams per inch as measured between the first nonwoven stitchbond fabric layer and the second nonwoven fabric layer in the machine direction and/or cross machine direction in accordance with AATCC 136.

18. The fabric of claim 8 , wherein the bond strength between each adjacent fabric layer is in a range from about 200 grams per inch to about 700 grams per inch as measured between each adjacent fabric layer in the machine direction and/or cross machine direction in accordance with AATCC 136.

19. A mattress foundation comprising the fabric of claim 1 .

Assignments (3)
SECURITY INTEREST Recorded May 23, 2025
From: PRECISION FABRICS GROUP, INC.
To: PNC BANK, NATIONAL ASSOCIATION
Reel/Frame 071206/0640 →
SECURITY INTEREST Recorded May 23, 2025
From: PRECISION FABRICS GROUP, INC.
To: PNC BANK, NATIONAL ASSOCIATION
Reel/Frame 071206/0660 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Dec 6, 2017
From: SMALL, JAMES D., JR.; KINLAW, W. SCOTT; MITCHELL, RANDELL ZANE
To: PRECISION FABRICS GROUP, INC.
Reel/Frame 044317/0812 →