Dimensionally-stable fabric and method of manufacture

Claim 2

An article as defined in claim 2 wherein the filaments comprising said multifilament yarns are at least partially fused together.

Claim 3

An article as defined in claim 1 wherein said filaments are fused together and retain their approximate original fabric-forming appearance and shape.

Claim 4

An article as defined in claim 1 wherein the fabric is a knitted construction.

Claim 5

An article as defined in claim 1 wherein the fabric is a nonwoven construction.

Claim 6

An article as defined in claim 1 wherein the fabric is a woven construction.

Claim 7

An article as defined in claim 1 in which the matrix forming polymeric material is comprised of at least one polymer selected from the group consisting of polyolefins, polyamides and polyesters.

Claim 8

An article as defined in claim 8 in which the dispersed polymeric material is comprised of at least one polymer selected from the group consisting of polyolefins, polyamides, polyesters, polysulfones, polyphenylene oxides and polycarbonates.

Claim 9

An article as defined in claim 9 in which the matrix forming polymeric material is a polyamide.

Claim 10

An article as defined in claim 10 in which said polyamide is polycaproamide.

Claim 11

An article as defined in claim 10 in which said polyamide is a reaction product of hexamethylene diamine and adipic acid.

Claim 12

An article as defined in claim 9 in which said dispersed polymeric material is a polyester.

Claim 13

An article as defined in claim 13 wherein said polyester is polyethylene terephthalate.

Claim 14

An article as defined in claim 9 in which the matrix forming polymeric material has a melting point at least 25* C. lower than the dispersed polymeric material.

Claim 15

An article as defined in claim 9 wherein said matrix forming polymer is a polyolefin.

Claim 16

An article as defined in claim 16 in which said polyolefin is polypropylene.

Claim 17

An article as defined in claim 16 in which said dispersed polymeric material is a polyolefin.

Claim 18

An article as defined in claim 18 in which said polyolefin is polyethylene.

Claim 19

An article as defined in claim 1 in which the dispersed polymeric material is comprised of at least one polymer selected from the group consisting of polyolefins, polyamides, polyesters, polysulfones, polyphenylene oxides and polycarbonates.

Claim 20

An article as defined in claim 1 in which the fabric is heat-treated on only one side thereof.

Claim 21

An article as defined in claim 1 wherein the matrix and fibril dispersions are fused to each other.

Claim 22

An article as defined in claim 1 wherein at least part of the fibrils are bonded together.

Claim 23

An article as defined in claim 1, wherein the textile material has been heat-treated under sufficient pressure that an area of its surface is solid and indistinguishable.

Claim 24

An article as defined in claim 1, in which the textile material is heat-treated on both sides thereof.

Claim 25

The method of manufacturing the dimensionally-stable fabric as defined by claim 1, comprising: a. providing textile material comprised of multiconstituent filaments spun from at least two different polymeric materials such that, in a given filament, a first fiber-forming polymeric material defines a matrix and a second polymeric material is dispersed therein in the form of discontinuous fibrils, said matrix comprising at least about 50 percent by weight of the filament and having a lower melting point than said dispersed fibrils; b. shaping said textile material to the configuration of the fabric desired; c. heat-treating and fusion bonding said textile material at a temperature in the range above the melting point of the matrix but below the melting point of the dispersed fibrils such that the multiconstituent filaments thereof are set and fusion bonded at least at their cross points without substantial polymer flow, disfiguration, and cross-sectional flattening, whereby a textile appearance is retained and the resultant fused textile material is characterized by an enhanced stiffness ranging from a minimum value sufficient that articles shaped thereof maintain their structural rigidity to a maximum value whereat the rigidity of the fused material approaches that of a solid molded plaque of comparable thickness.

Claim 26

A method as defined in claim 26 wherein said matrix material and said dispersed material each is comprised of at least one member selected from the group consisting of polyolefins, polyamides, polyesters, polycarbonates, polysulfones and polyphenylene oxides.

Claim 27

A method as defined in claim 27 wherein said textile material is comprised of a matrix of polyamide and a dispersion of polyester therein and said heat-treating is carried out by subjecting the fabric to approximately 230*-250* C.

Claim 28

A method as defined in claim 27 wherein the textile material is a knitted construction.

Claim 29

A method as defined in claim 27 wherein the textile material is a woven construction.

Claim 30

A method as defined in claim 27 wherein the textile material is a nonwoven.

Claim 31

A method as defined in claim 26 wherein the textile material is heat-treated on one broad surface only.

Claim 32

A method as defined in claim 32 wherein the textile material is simultaneously cooled on the other broad surface.

Claim 33

A method as defined in claim 26 wherein the heat-treating step precedes the shaping of the textile material.

Claim 34

A method as defined in claim 26, wherein the textile material is heat-treated on both broad surfaces thereof.

Claim 35

A method as defined in claim 26, wherein the textile material is heat-treated under sufficient pressure that an area of its surface is rendered solid and indistinguishable.