Abstract: The present invention concerns a textured floorcovering composite comprising a highly conformable fibrous outer layer 101 and an optional porous and resilient backing layer 102 that are continually, contiguously, or continuously attached to an activated adhesive layer 103 along a three-dimensional, undulating interface. The undulations correspond to depressed and elevated areas on the surface of the composite. Such a composite can be fabricated if its precursor is subjected to heat and pressure for a finite length time, provided that the applied pressure is relatively low, preferably under about 200 psi. The textured composite can be used as a floorcovering that advantageously resists warping and remains insensitive to variations in ambient temperature and humidity, including exposure to water.

Abstract: A cooking pad has a three dimensional surface configuration of peaks and valleys for cooking food. The three dimensional surface configuration elevates the food to a level where it cooks efficiently and evenly. The three dimensional surface configuration rapidly moves liquids expelled from the food during cooking away down depressions and prevents splattering of the liquids back onto the food. The cooking pad may be preformed to the three dimensional surface configuration or may assume this three dimensional surface configuration upon exposure to a cooking environment.

Abstract: The present invention concerns a process for forming a wearable and functional fabric from a composite material comprising a nonwoven face layer containing a plurality of fibers, and at least one thermoplastic binder layer disposed underneath. The fibers are initially arranged in a generally planar web and subsequently needlepunched through at least one binder layer. The fiber layers can also be placed on both sides of one or more centrally-located binder layers, and further reinforced with scrims. In an innovative aspect of the invention, the composite is heated under low and uniform pressure to remove thermal stresses, resulting in at a least one relatively smooth face that can be coated to form a wearable fabric, e.g., artificial leather, odor absorbing fabric, and the like.

Abstract: The present invention is directed to multiple layer composites suitable for use as wall and floor coverings, among other uses, that provide a strong durable structure and a soft textile or fabric face. The composite includes a face layer bonded to an adhesive layer such that the adhesive layer penetrates into the face layer. The face layer can have legs extending there from, and such legs are anchored by the adhesive layer to provide stronger attachment between the adhesive layer and the face layer. A backing layer may also be provided in contact with the adhesive layer such that the adhesive layer also embeds into the backing layer, and the legs extending from the face layer may penetrate into the backing layer.

Abstract: The present invention is directed to multiple layer composites suitable for use as wall and floor coverings, among other uses, that provide a strong durable structure and a soft textile or fabric face. The composite includes a face layer bonded to an adhesive layer such that the adhesive layer penetrates into the face layer. The face layer can have legs extending there from, and such legs are anchored by the adhesive layer to provide stronger attachment between the adhesive layer and the face layer. A backing layer may also be provided in contact with the adhesive layer such that the adhesive layer also embeds into the backing layer, and the legs extending from the face layer may penetrate into the backing layer.

Abstract: The present invention concerns a process for forming a wearable and functional fabric from a composite material comprising a nonwoven face layer containing a plurality of fibers, and at least one thermoplastic binder layer disposed underneath. The fibers are initially arranged in a generally planar web and subsequently needlepunched through at least one binder layer. The fiber layers can also be placed on both sides of one or more centrally-located binder layers, and further reinforced with scrims. In an innovative aspect of the invention, the composite is heated under low and uniform pressure to remove thermal stresses, resulting in at a least one relatively smooth face that can be coated to form a wearable fabric, e.g., artificial leather, odor absorbing fabric, and the like.

Abstract: The present invention concerns a method for recycling used floor covering. Post-consumer or post-industrial fibrous floor coverings are shredded to form a fibrous dispersion. The dispersion is maintained at a content of about 20-65% low-melt thermoplastic. The shredded fibrous dispersion is conveyed into a chute feeder which converts it into a batt that is heated, compressed, and cooled to form a durable backing particularly suitable for flooring applications. The batt comprises vertical layers or strata of fibers to provide additional cushion for the backing. Additionally, a portion of the shredded fibrous dispersion can also be diverted and used to form a face layer and/or adhesive layer for a reconstituted floor covering.

Abstract: A process for making abrasion-resistant composites is disclosed. The process comprises the steps of providing a fibrous sheet containing a high density of relatively short staple fibers having a decitex under 6.6; needle-punching the staple layer and applying an adhesive containing layer; followed by the application of heat and pressure to the composite to form a thin consolidated and abrasion-resistant back-face layer on the composite. Preferably, the adhesive layer is penetrated by the needled fibers during the needling step and the product is shrunk in area by 20-50% before the consolidation step. Also optionally, the consolidated layer is abraded or perforated to create micro-pores that are permeable to gases and capable of containing liquids under low-to-moderate pressures.

Abstract: The present invention concerns a textured floorcovering composite comprising a highly conformable fibrous outer layer 101 and an optional porous and resilient backing layer 102 that are continually, contiguously, or continuously attached to an activated adhesive layer 103 along a three-dimensional, undulating interface. The undulations correspond to depressed and elevated areas on the surface of the composite. Such a composite can be fabricated if its precursor is subjected to heat and pressure for a finite length time, provided that the applied pressure is relatively low, preferably under about 200 psi. The textured composite can be used as a floorcovering that advantageously resists warping and remains insensitive to variations in ambient temperature and humidity, including exposure to water.

Abstract: A floor covering composite made from at least a fibrous outer layer and an adhesive layer is disclosed. These layers are laminated and/or embossed to form elevated areas and depressed areas. Within the depressed areas, fibers from the fibrous outer layer are anchored by the adhesive layer activated by the laminating and/or embossing process. Within the elevated areas, the surface fibers of the fibrous outer layer are substantially free from the activated adhesive, and are movable relative to each other. Transitioning cluster areas are positioned between the depressed areas and the elevated areas. Fibers from the fibrous outer layer are partially bonded by the activated adhesive to provide some structural integrity to the fibers in the elevated areas. The composite may further include a backing layer, a gas permeable, liquid impermeable layer to allow the composite to vent, but prevent liquid from penetrating to the backing layer or to the substrate covered by the composite.

Abstract: A composite sheet is disclosed. The composite sheet comprises an open random fibrous web having substantially vertical fibers near a top surface, a first binder resin and a second binder resin, wherein the first binder resin has a melting point lower than the melting point of the second binder resin, wherein the melting point of the second resin is lower than the melting point of the web, wherein the resins are activated in situ with the web fibers to form a resin-fiber rich region on the top surface and wherein the abrasion-resistant sheet can withstand at least about 3,000 cycles on the Wyzenbeek abrasion test using 80-grit abrasive paper. An abrasion-resistant sheet comprising a single binder resin and other abrasion-resistant sheets are also disclosed. Processes for making these abrasion-resistant sheets are further disclosed herein.

Abstract: Disclosed herein is a composite comprising at least one heat shrinkable adhesive layer stitch-bonded with yarns, which shrink less than the adhesive layer or do not shrink, when the adhesive layer is exposed to heat. The stitch-bonded yarns form loops upstanding from the shrunk adhesive layer and the loops create a textured surface on the composite, and the composite is substantially inelastic after the adhesive layer is shrunk. The composite may further comprise at least one fibrous layer stitch-bonded to the shrinkable adhesive layer, and the fibrous layer is less shrinkable than the adhesive layer or is substantially non-shrinkable.

Abstract: The invention is directed to a composite sheet suitable for use as artificial leather or a precursor to artificial leather, where both surfaces have a napped or brushed appearance. The composite sheet comprises a low-density, lightly bonded non-woven web that is stitch-bonded and bulked such that the stitch-bonding yarns are not visible to the naked eyes without the need of post-processing steps to hide the yarns. The composite sheet may have binder resin(s) dispersed therein and activated.

Abstract: A stretchable stitch-bonded nonwoven fabric is disclosed herein. The fabric includes a nonwoven substrate having basis weight in the range from about 15 to about 150 g/m2, and density in the range from about 0.02 to about 0.12 g/cm3. The nonwoven substrate is bonded with a binder applied to the outer surfaces of the substrate in a liquid form in a sufficiently uniform manner so that no areas greater than the spaces between stitch insertion points are devoid of binder. The binder constitutes from about 2% to about 25% of the total weight of the sum of binder and nonwoven substrate weight. The substrate is stitch-bonded with yarns arranged in a stitch pattern that allows the stitch-bonded fabric to be stretched in at least one direction by a factor of about 2.5 to about 5.0 without forming local ruptures therein, and wherein the stitch-bonded nonwoven fabric can be washed and dried at least twenty times.

Abstract: The present invention is directed to a stitch-bonded elastic polymeric composite comprising a non-fibrous elastically extensible substrate stitched with a substantially inextensible yarn system. The composite may have an optional fibrous layer stitch-bonded to the non-fibrous substrate either over or under the non-fibrous elastic substrate. The composite preferably has a shrinkage during boil-off of less than about 10%. The stitching yarn network preferably allows stretch beyond the as-stitched dimensions of about 10–100% in at least one direction, and the composite can recover from this stretch to within 5% in at least one direction.

Abstract: A stitched pile surface structure and a process and apparatus for producing and finishing the same is disclosed. The stitched pile surface structure includes a backing having a thickness T. A plurality of parallel lines of stitches extends longitudinally along the backing. Each stitch has a predetermined stitch length dimension S. A plurality of rows of pile elements (either as loop pile or cut pile) is formed from one or more pile yarn(s) having an effective predetermined yarn diameter D. The total weight of the yarn used to form the pile loop elements is G grams. Substantially all of the stitches have a thread length DKL that satisfies the relationship: DKL<=D·(1+?/2)+(2·T)+(2·S) A mass of binder material having a weight of less than G grams is disposed on the pile surface structure.

Abstract: Disclosed herein is a composite comprising at least one heat shrinkable adhesive layer stitch-bonded with yarns, which shrink less than the adhesive layer or do not shrink, when the adhesive layer is exposed to heat. The stitch-bonded yarns form loops upstanding from the shrunk adhesive layer and the loops create a textured surface on the composite, and the composite is substantially inelastic after the adhesive layer is shrunk. The composite may further comprise at least one fibrous layer stitch-bonded to the shrinkable adhesive layer, and the fibrous layer is less shrinkable than the adhesive layer or is substantially non-shrinkable.

Abstract: A unitary sinker finger is attached at its first end to a sinker bar. In a first embodiment the second end of the finger is attached to a fixed support member. The sinker finger has a loop formation region and a loop cutting region disposed thereon, with the loop cutting region being disposed intermediate the loop formation region and the second end of the finger. A cutting blade that is operable in the cutting region for cutting pile loops formed on the loop formation region of the finger. In a second embodiment the sinker finger is an arcuate member that cantilevers from the sinker bar. A loop cutter cooperates with the arcuate sinker finger to cut the pile loops formed on the finger at a location adjacent to the free end of the finger. A sensing arrangement for determining operability of the cutting arrangement is also disclosed.

Abstract: A textile laminate for covering diverse substrates includes a backing layer to be placed adjacent to the substrate, a substantially non-shrinkable fibrous layer coextensive with the backing layer and an adhesive component to bind the fibrous layer to the backing layer. The adhesive component is activated to adhere the fibrous and backing layers only at selected bonding points in a pattern bond. The backing layer is a material adapted to irreversibly shrink by at least about 25% such that after the backing layer shrinks, the fibrous layer separates from the backing layer at locations away from the bonding points and forms pile-like loops that protrude in a direction normal to the plane of the textile laminate.

Abstract: The invention is directed to a composite sheet suitable for use as artificial leather or a precursor to artificial leather, where both surfaces have a napped or brushed appearance. The composite sheet comprises a low-density, lightly bonded non-woven web that is stitch-bonded and bulked such that the stitch-bonding yarns are not visible to the naked eyes without the need of post-processing steps to hide the yarns. The composite sheet may have binder resin(s) dispersed therein and activated.