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filingDate 1996-07-02-04:00^^<http://www.w3.org/2001/XMLSchema#date>
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publicationDate 2007-06-06-04:00^^<http://www.w3.org/2001/XMLSchema#date>
publicationNumber EP-0837168-B1
titleOfInvention Process for preparing cushioning structure using fiber assembly and apparatus therefor
abstract A process for preparing a cushioning structure by opening fiber assemblies comprising crimped short matrix fibers and binder fibers, having a melting point below that of the matrix fiber and dispersed therein, packing the opened assemblies into an air-permeable mold cavity by entrainment with a pressurized air system, and thermoforming the same by heating followed by cooling, wherein the matrix fiber is a crimped short inelastic polyethylene terephthalate fiber and the binder fiber is a bicomponent short fiber comprising a thermoplastic elastomer having a melting point at least 40 °C below that of the matrix fiber and an inelastic polyester, the thermoplastic elastomer occupying at least one half of the surface area of the bicomponent fiber. When the mold cavity is defined by (1) a top force comprising a group of split members which are independently vertically movable, (2) a vertically movable bottom force, and (3) a space surrounded by a molding frame, the fiber assemblies within the mold cavity can be partially controlled to have a desired compression density even in the step of packing the same and, at the same time, the fiber assemblies can be uniformly and satisfactorily packed into even a mold cavity having a complicate shape, thereby providing a process and an apparatus for producing a cushioning structure which is more inexpensive and has better performance than cushioning structures produced by the conventional processes in a short time on an actually commercial scale.
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