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: A laminated multilayer textured composite has an embossed fibrous outer layer bonded to one side of an adhesive layer to form a three-dimensional structure defined by all of fibers in depressed areas between elevated areas being fully embedded in the adhesive and most of the fibers in the elevated areas of the elevated areas being free of adhesive. The composite provides an abrasion resistant, surface stable material for covering floors, walls, furniture and the like. An optional backing layer can be simultaneously adhered to the second side of the adhesive layer primarily for improved cushioning and dimensional stability. The composite can be formed by a simultaneous pressure embossing and thermal laminating process.

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 stitched yarn surface structure comprises a backing the entire upper surface of which is covered by a plurality of rows of face yarn underlaps. The face yarn underlaps may be stitched-into the backing, or held to the backing by longitudinally extending overstitches. The yarn underlaps form a yarn surface having a height dimension D. The backing has a thickness dimension T that is at least twice the height dimension D and not less than two millimeters.

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.

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.

Abstract: An improved stitchbonded nonwoven fabric having repeating patterns of stitches in a fibrous layer is prepared with a stitching thread that consists essentially of fiber of partially molecularly oriented synthetic organic polymer. The fabric can be stretched, shrunken, and/or heat set and is particularly suited for thermoforming operations.

Abstract: A fitted mattress cover is provided with a flat top panel and a knitted or woven fabric skirt attached to and depending from the periphery of the top panel. The lower edge of the skirt contains a band of longitudinally extending elastic yarns that were integrally incorporated into the edge during fabrication of the skirt fabric. The yarns of the elastic band provide sufficient tension to pull some of the skirt fabric under the mattress and provide a secure fit when the cover is installed on a mattress.

Abstract: An apparatus for producing a stitched pile surface structure is disclosed. The apparatus has a plurality of transversely spaced needles forming a needle array, with each needle having a predetermined width dimension (142D). The needles in operation being movable to penetrate a backing at a plurality of needle penetration points as the backing is conveyed along a path of travel through the apparatus. A plurality of laterally adjacent sinker fingers extends forwardly in the direction of travel. Each needle is disposed laterally intermediate adjacent fingers. Each finger has a forward end thereon. The sinker fingers extend forwardly in the direction of travel past the needle penetration points, the height dimension of at least that portion of each finger that extends forwardly past the needle penetration points being uniform. In addition, the fingers have a base region, with adjacent fingers being spaced from each other by a lateral spacing distance (132) not greater than 1.

Abstract: A fitted mattress cover has a fabric skirt warp-knit from bulked yarns and elastic yarns. The skirt is elastically stretchable in the longitudinal direction by at least 50%, inelastically stretchable in the transverse direction by at least 60%, and regains its transverse stretch characteristics when laundered and dried in a relaxed condition and possesses important advantages over known stretchable stitchbonded skirts in wash durability, stretch/conformability, and puncture resistance, as well as in economy of manufacture.

Abstract: An abrasion-resistant composite sheet having a surface layer of pile-like fibers immobilized by resin. The surface layer has a thickness of 0.5-3 mm, a pile-like fiber concentration of 0.05 to 0.5 g/cm.sup.3, a resin containing depth of at least 0.5 mm and a density of at least 0.5 g/cm.sup.3. The pile-like fibers can be derived from particular contracted stitchbonded, knit or woven fabrics or from conventional pile fabrics having specific characteristics.

Abstract: An improved stitchbonded nonwoven fabric having repeating patterns of stitches in a fibrous layer is prepared with a stitching thread that consists essentially of fiber of partially molecularly oriented synthetic organic polymer. The fabric can be stretched, shrunken, and/or heat set and is particularly suited for thermoforming operations.

Abstract: An improved composite sheet suited for use as artificial leather is prepared by treating with an elastomeric resin a fabric having an interior yarn network and an outer layer of well separated fibers that loop in and out of the yarn network. The resin completely or partially impregnates the outer layer.