Insulation material structure having crimped continued filament tow interposed between staple fiber webs

Abstract

An insulation material structure having crimped continued filaments interposed between staple fiber webs. Crimped continued filament web is interposed between an upper and lower natural or synthetic staple fiber webs having low melty fibers therein. After subjecting to cross-laid lamination-forming process and thermal setting, a resilient, composite laminated layered structure is formed. The laminated layer structure is subsequently cut, sewed, and stitched onto the facing and lining fabrics located at the upper and lower layers to form a stretchable insulation material structure having multiple fiber layers.

What is claimed is: 
     
         1 . An insulation material structure comprising an upper staple fiber web, a lower staple fiber web, and a crimped continued filament web interposed between the upper and lower staple fiber webs, the webs being subject to a cross-laid lamination-forming process and a thermal setting treatment, thereby forming a fiber laminate having stretching recovery properties, wherein the fiber layers are capable of resiliently sliding with respect to each other, the fiber laminate being cut, sewed, and stitched onto a facing fabric and a lining fabric located at the top and bottom of the insulation material structure respectively, whereby the insulation material structure is formed to have multiple fiber layers. 
     
     
         2 . The insulation material structure as claimed in  claim 1 , wherein the staple fiber webs comprise multiple low melty fibers, and the surface of each of the fibrous web is optionally sprayed with resin. 
     
     
         3 . The insulation material structure as claimed in  claim 1 , wherein the fiber laminate formed by the cross-laid lamination-forming process is a dual-ply structure, comprising: an upper and a lower crimped continued filament web, an upper and a lower staple fiber web disposed on the top and bottom of the upper crimped continued filament web, and an upper and a lower staple fiber web disposed on the top and bottom of the lower crimped continued filament web; wherein the staple fiber webs disposed between the upper and lower laminate form a staple fiber cross-laid web as a result of the cross-laid relationship, and the crimped continued filament web is interposed between the staple fiber webs or staple fiber cross-laid webs in each laminate. 
     
     
         4 . The insulation material structure as claimed in  claim 3 , wherein the fiber laminate formed by subjecting to the cross-laid lamination-forming process comprises more than two layers having paired layers of crimped continued filament web. 
     
     
         5 . The insulation material structure as claimed in  claim 1 , wherein the fiber laminate formed by subjecting to the cross-laid lamination-forming process comprises wider stitching pattern after being stitched onto a facing and lining fabrics, so that the fibrous webs do not break easily when subject to stretching or laundry. 
     
     
         6 . The insulation material structure as claimed in  claim 1 , wherein the enclosed crimped continued filament web isolates the upper and lower staple fiber webs in which the fibers are in a cohesion state, is due to the property of the crimped continued filament webs, so that an insulation air layer is formed between the upper and lower staple fiber webs. 
     
     
         7 . The insulation material structure as claimed in  claim 1 , wherein the laminate is composed of a single ply of crimped continued filament web, and a single ply of staple fiber web laminated together, and the laminated fibrous webs are subject to a cross-laid lamination-forming process and a thermal setting treatment to form the insulation material structure in which the fibers layers are capable of resiliently sliding with respect to each other. 
     
     
         8 . The insulation material structure as claimed in  claim 7 , wherein in the fiber laminate, the crimped continued filament web is the upper layer and the staple fiber web is the lower layer. 
     
     
         9 . The insulation material structure as claimed in  claim 7 , wherein in the fiber laminate, the crimped continued filament web is the lower layer and the staple fiber web is the upper layer.