Patent ID: 6096249
Filing Date: 2000-08-01
Classification: D04H

Abstract:
A method for molding a fiber aggregate composed of a matrix consisting of crimped synthetic staple fibers and binder fibers having a melting point lower than that of the staple fiber and dispersed in the matrix by charging a cavity of an air-permeable mold with loosen fiber aggregate carried on carrier gas flow, compressing the fiber aggregate charged in the mold cavity to a prescribed bulk density, passing hot air through the compressed fiber aggregate to effect the thermal fusion of the binder fibers and the partial welding of the fibers of the fiber aggregate and passing cooling air through the product to effect the solidification and bonding of the welded part to obtain a cushion structure, characterized in that the mold is pressed at least once stepwise or continuously leaving a compression margin before getting the final form of the cushion structure in the heating and/or cooling of the fiber aggregate before converting the aggregate into the cushion structure to relax the thermal shrinkage of the fiber aggregate, and the aggregate is pressed with the mold to an extent corresponding to the compression margin to obtain the final shape of the cushion structure.