RIGID FIBER NETWORK STRUCTURES HAVING IMPROVED POST-YIELD DIMENSIONAL RECOVERY, METHOD OF MAKING SAME, AND ARTICLES INCORPORATING SAME

摘要

A rigid three-dimensionally shaped fiber network structure having improved post-yield dimensional recovery is composed of a deformed sheet-like textile fabric containing: (A) at least one oriented, semi-crystalline monofilament yarn made from a first thermoplastic polymer, the monofilament yarn being disposed in the deformed fabric so as to provide at least one monofilament cross-over points therein; and (B) a second thermoplastic polymer which effects bonding of the monofilament cross-over points. The rigid structure is formed by subjecting a deformable textile fabric formed from the monofilament yarn and the second thermoplastic polymer to an area-enlarging deformation process in a shaping mold at an elevated temperature sufficient to melt the second thermoplastic polymer and permanently deform the first thermoplastic polymer so as to form an initial resilient and self-supporting three-dimensionally shaped fiber network structure having sufficient stiffness that the initial structure can be removed from the mold before the molten second thermoplastic polymer has hardened. The initial network structure is removed from the shaping mold prior to the cooling of the molten second thermoplastic polymer to the hardened state. Hardening of the molten second thermoplastic polymer effects bonding of the monofilament cross-over points and converts the initial network structure into a rigid structure having improved post-yield dimensional recovery.