US 7,588,818 B2
High bulk composite sheets
Dimitri P. Zafiroglu, Wilmington, Del. (US); Jeffrey Allen Chambers, Hockessin, Del. (US); and Geoffrey David Hietpas, Newark, Del. (US)
Assigned to INVISTA North America S.a r.l., Wilmington, Del. (US)
Filed on Sep. 16, 2005, as Appl. No. 11/228,128.
Application 11/228128 is a division of application No. 10/320086, filed on Dec. 16, 2002, granted, now 7,201,816.
Prior Publication US 2006/0068176 A1, Mar. 30, 2006
Int. Cl. B32B 7/02 (2006.01); B32B 27/32 (2006.01); B32B 5/12 (2006.01)
U.S. Cl. 428—212  [428/220; 428/152; 428/198; 428/295.7; 428/297.1; 428/297.4] 20 Claims
OG exemplary drawing
 
1. A multi-layer composite sheet comprising:
a first polymeric layer;
a second polymeric layer bonded to a first side of the first layer with an intermittent pattern of bonds, the bonds being separated by a bond distance of between about 5 and 25 mm in at least one direction, and the second layer being gathered between the bonds;
the multilayer composite sheet having a thickness between about 3 mm and 30 mm and a bulk of at least 50 cc/g;
wherein the first polymeric layer comprises spirally crimped fibers and wherein the spirally crimped fibers comprise a first component and a second component arranged in a configuration selected from the group consisting of side-by-side and eccentric sheath-core.