Abstract: An artificial leather sheet material, comprising a layer of permeable fabric made of interlaced multifiber yarns, the lower face of said fabric having an open nap of fibers teased from said yarns and bonded together, and a continuous layer of polymer material on the upper face of said fabric. The bonded nap may be subjected to spaced short cuts to give it a rough appearance.

Abstract: Novel polyester filamentary yarn is provided having (a) a fineness of 0.9 denier per filament or less, (b) an amorphous orientation in the range of 30% to 70% and (c) a negative .epsilon..sub.0.2 where said .epsilon..sub.0.2 is a structural integrity parameter. The yarn possesses ameliorated properties regarding a heat-setting property, a raising property, a dimensional stability and a twist resistance. The yarn finds its wide range of usage, for example, silky fabrics with an excellent fullness, pliability and liveliness, raised fabrics with thermally stabilized fluffs protruding straight-forwardly and an extremely soft hand, and uniformly creped fabrics with an improved surface contour are obtained therefrom.

Abstract: A suede-like sheet material closely resembling natural leathers in feel and nap is produced by temporarily fixing a fibrous mat consisting of "oceano-insular" composite fibers, impregnating said fibrous mat with elastomer (A), smoothing the surface, impregnating the resulting mat with another elastomer (B) which is harder and less swellable than said elastomer (A), removing the sea or matrix component of the composite fiber, and napping the surface of the resulting sheet material.

Abstract: A double knit fabric includes a plurality of courses knitted to form first and second sets of alternating wales. The first set of alternating wales forms the face of the fabric while the second set of alternating wales forms the reverse side of the fabric. The courses are knitted in a preselected pattern to form stitches which join the courses together at selected wales. First yarns are used to form selected courses with the first yarns having a higher shrinkability than second yarns forming the remainder of the courses. Selected second yarns are knit in a pattern which allows portions of the second yarns to float on the face of the fabric. The floating portions are formed by causing the yarn to welt or miss at least two consecutive wales of the first set of alternating wales.

Abstract: Process of producing a nonwoven needled napped fabric, adaptable for use in the formation of blankets and other types of products, characterized by providing superior resistance to pilling and shedding of the napped fabric, as follows. A batt of textile fibers of a desired construction is sequentially needled from a first side to a second side and then from the second side to the first side thereof to form a multiplicity of fiber entanglements for interlocking the fibers of the batt with each other to form an integrated needled fabric. The first and second sides of the needled fabric are napped for producing raised fiber surfaces on each side of the fabric. The needled and napped fabric is then reneedled from the first side to the second side thereof for providing resistance to pilling and shedding of the napped fibers. Preferably, the napped sides of the needled, napped and reneedled fabric are chemically treated for providing further resistance to pilling and shedding of the napped fibers.

Abstract: Synthetic suede leather is produced by casting a mixture containing polyurethane elastomer and a solvent therefor between two sheets of a substrate fabric, immersing the resulting structure in a liquid which is a nonsolvent for polyurethane elastomer but miscible with said solvent, splitting said structure into two sheets at middle of the cast layer before it is fully gelled, and re-immersing the resultant sheets in said nonsolvent to allow complete gelation of said mixture.

Abstract: The disclosure is of an elastomer coated textile garment characterized by a textured or "wrinkle" finish. The disclosure is also of a method of manufacturing an elastomer coated textile garment with a "wrinkle" finish. In a preferred embodiment process, the method comprises forming a glove from a base fabric of a woven or knitted fabric having a fibrous, non-woven bat attached thereto and coating the glove with an elastomer in conventional manner.

Abstract: Pleasing tonality is obtained in a fabric by subjecting a moving, superficially dyed fabric to abrasion. The fabric, while being processed, has a low longitudinal tension and the peripheral velocity of the abrasion means is different than the moving fabric.

Abstract: Natural suede-like artificial leathers are manufactured by subjecting pile fibrous structures wherein at least the pile portion is composed of separatable composite filaments made by bonding different polymers having mutual low adhesive affinity with each other, the cross-section of which is constituted of a radial segment (A) and segments (B) complementing the radial segment or a radial segment (A), segments (B') corresponding to said radial segment and having wedge-shaped concave portions directing to the center and wedge-shaped segments (C) complementing said concave portions, to at least one of a heat treatment and a swelling treatment to shrink said fibrous structure at least 10% in the area, impregnating or coating said fibrous structures with a synthetic polymer solution or emulsion, coagulating said polymer solution or emulsion, drying the thus treated pile fibrous structure and then buffing said piles to raise naps.

Abstract: A nonwoven fabric is produced by forming a batt comprising staple fibers oriented primarily in the fill direction, drafting the batt in the warp direction in a first warp-drafting zone, needling the drafted batt, drafting the needled batt in the warp direction in a second warp-drafting zone, and drafting the warp-drafted, needled batt in the fill direction in a fill-drafting zone. A fabric, apparatus for producing the fabric, and a method for fusing a nonwoven batt are provided.

Abstract: The disclosed foam laminate preferably includes a corrugated paper sheet, a layer of thermosetting resin foam wherein the corrugations extend into and are bonded to the foam layer and a relatively flexible finish sheet bonded to the foam layer. The corrugated sheet preferably includes a corrugated paper sheet bonded to a relatively flat sheet. In the disclosed automotive headliner, the corrugations preferably extend perpendicular to the headliner side edges, providing support for the concave midportion of the headliner and preventing delamination of the paper and foam laminae.

Abstract: A woven synthetic textile, useful as the primary and secondary backing for carpets and as woven cloth to manufacture bags, bale wrap, wall covering, drapes and the like, can be prepared using a heavily fibrillated synthetic ribbon as at least one of the warp and fill members. The textile is characterized by the look and feel of a jute fabric. The fabric may be further treated after weaving to lift the fibril ends above the fabric surface as by brushing and/or needling.

Abstract: Disclosed is a suede-like raised woven fabric of a combination weave having raised extra fine fibers on the surface thereof, which fabric comprises a continuous multifilament yarn used as warp, a yarn of a bundle comprising continuous extra fine filaments used as a first weft and a continuous multifilament yarn used as a second weft. The preparation of the raised fabric comprises weaving a fabric using appropriate material yarns, subjecting the fabric to heat treatment and subjecting the fabric to raising. The yarn constituting the first weft may be produced from a bundle of multi-core composite filaments by removing a component surrounding the cores. The fabric has an excellent suede-like touch, appearance and feel.

Abstract: Process for making a synthetic suede product, two rolls at a time, each roll consisting of a web of fibrous material, to the upper side of which is attached outwardly extending polyurethane fibers. The process consists of continuously feeding two thin films of polyurethane into the nips formed by two rotating heated cylinders wherein the two feed materials are forced into two flexible molding bands provided with a multiplicity of molding cavities by pressing the film against a heated silicone roller. Most of the urethane film fills the cavities and forms a fibrous surface when removed, leaving a very thin layer in molten state which becomes glued to the upper layers of fibrous webs which are passed into a second set of nips formed by two rotating heated cylinders. The fibrous material or fabric may be man-made such preformed woven, knitted, foamed, non-woven, spun bonded, spun laced, etc.

Abstract: An artificial leather sheet material, comprising a layer of permeable fabric made of interlaced multifiber yarns, the lower face of said fabric having an open nap of fibers teased from said yarns and bonded together, and a continuous layer of polymer material on the upper face of said fabric. The bonded nap may be subjected to spaced short cuts to give it a rough appearance.

Abstract: A suede woven fabric comprises a warp yarn selected from the group consisting of polyester textured yarn, polyester filament yarn and polyester spun yarn, and a weft yarn of polyester island filaments whose mean thicknesses in denier are within the range from 0.05 to 0.50 and whose degree of variation of thickness is 15 to 60%; wherein a portion of said island filaments on at least one surface of the fabric is raised to form piles of individual island monofilaments whose mean lengths are from 0.5 to 4.0mm; wherein the number of floating points on said weft yarn, whose number of floats in within the range of 3 to 11, is 100 to 500/cm.sup.2 of woven fabric, and wherein the relation between the shear stiffness G.sub.0.5 at a shear angle of 0.5.degree. and the stiffness G.sub.5 at a shear angle of 5.degree., represented by G.sub.5 /G.sub.0.5, is 1.5 to 15.

Abstract: This application relates to textile sheets which have been coated with polyurethanes and to a process for coating said textile sheets wherein a solution of polyurethane is applied as a top coat to a release substrate and then a bonding coat is applied before application of the textile material. The polyurethane which is used as a top coat is prepared by reacting a dihydroxyl compound with a molecular weight between about 600 and 4000 and a mixture of at least 2 diols with a molecular weight between 62 and 450 with at least one organic diisocyanate. The invention overcomes the difficulty of the top coat being lifted from the release substrate in numerous areas while other areas remain firmly attached giving the so-called "hoar-frost" effect.

Abstract: A suede-like raised woven fabric which comprises: warp yarns; weft yarns, each being a single twist filament yarn or a loopy textured filament yarn consisting of a bundle of fine fibers; and an elastic polymer applied to the fabric. The bundle of fine fibers consists of a raised portion having an average monofilament denier of from 0.05 to 0.4 and an unraised portion having an average monofilament denier of above 0.4 but not exceeding 0.8.

Abstract: A grass-like carpet comprises 1-20 plies of a fibrous web needle-punched into a substrate. The fibrous web is made from a uniaxially oriented polymer film.

Abstract: Disclosed is a suede-like raised woven fabric of a combination weave. A yarn having a thickness in a range between 30 and 300 denier, the thickness of most of individual filaments or fibers thereof being in a range between 1.0 and 8.0 denier, is utilized as the warp; while a spun yarn having a thickness represented by a total denier in a range between 50 and 1000 denier, the thickness of the most of individual component fibers thereof being in a range between 0.0001 and 0.4 denier, is utilized as a first weft, and a yarn having a fineness represented by a total denier in a range between 30 and 300 denier, the thickness of the most of individual filaments or fibers thereof being in a range between 1.0 and 8.0 denier, is utilized as a second weft. At least one of the warp and the second weft does not substantially involve crimped filaments or fibers. A combination woven fabric structure provided with a number of floating points of the first weft upon the warp in a range between three and seven is adopted.

Abstract: The method of this disclosure relates to the application of a foam layer, in fluid form, to either an impervious or a relatively porous substrate and to the formation of a contoured foam laminate using a relatively rigid foam. The method of applying foam to a porous substrate includes heating the substrate prior to the application of the fluid foam. Upon striking the heated substrate, the foam forms a blow barrier to prevent foam bleedthrough. The method also optionally includes forming the laminate in a die prior to completion of foaming.The laminate includes a flexible substrate, preferably a polyurethane foam layer and an optional lattice skrim located between the substrate and the exposed surface of the foam layer.

Abstract: The disclosure is of an elastomer coated textile garment characterized by a textured or "wrinkle" finish. The disclosure is also of a method of manufacturing an elastomer coated textile garment with a "wrinkle" finish. In a preferred embodiment process, the method comprises forming a glove from a base fabric of a woven or knitted fabric having a fibrous, non-woven bat attached thereto and coating the glove with an elastomer in conventional manner.

Abstract: A yarn or fiber is incorporated into the jacket of a long suspended small ameter cable for reducing low velocity current cable strumming in water. The yarn or fiber comprises at least one-quarter of the strands of a braided cable. A nap or mossy cable effect is produced when the jacket is brushed.

Abstract: Natural suede-like artificial leathers are manufactured by subjecting pile fibrous structures wherein at least the pile portion is composed of separatable composite filaments made by bonding different polymers having mutual low adhesive affinity with each other, the cross-section of which is constituted of a radial segment (A) and segments (B) complementing the radial segment or a radial segment (A), segments (B') corresponding to said radial segment and having wedge-shaped concave portions directing to the center and wedge-shaped segments (C) complementing said concave portions, to at least one of a heat treatment and a swelling treatment to shrink said fibrous structure at least 10% in the area, impregnating or coating said fibrous structures with a synthetic polymer solution or emulsion, coagulating said polymer solution or emulsion, drying the thus treated pile fibrous structure and then buffing said piles to raise naps.

Abstract: An electric blanket shell is composed of first and second-needled textile fabrics with a yarn layer disposed in at least one of the needled fabrics. The yarn layer has a plurality of first planar yarns extending generally in a first planar direction. A heat-fusible component is disposed in at least one of the needled fabrics. A plurality of small, discrete sonically or ultra-sonically-produced fusion bonds, spaced from each other, link the needled fabrics to form a blanket shell. The fusion bonds form a series of patterns across a planar dimension of the blanket shell and the patterns define a series of channels, for receiving heating wires, between the needled fabrics. The patterns of fusion bonds are disposed in a direction traverse to the direction of the first planar yarns. The fusion bonds of any one pattern do not engage more than about 50% of the first planar yarns and overlaps of fusion-bond patterns are substantially avoided.

Abstract: A napped fabric is treated to bond the nap fibers together while leaving the nap structure largely open and porous.The surface of the bonded nap is then subjected to a series of spaced short cuts to form spaced clumps of bonded fibers which clumps have free ends projecting from the bonded nap so that they can be brushed from stable upright positions to bent-over positions, giving an attractive rough appearance resembling a split suede leather.

Abstract: A suede-like or deer skin-like raised woven or knitted fabric having at least one raised surface is produced by providing a woven or knitted fabric using a yarn consisting of synthetic hollow composite fibers each composed of two or more fiber-forming polyester constituents and two or more fiber-forming polyamide constituents and having a hollow space surrounded by the polyamide and polyester constituents which are arranged alternately with each other and adhered to each other side-by-side so as to form a tube-shaped body, and raising a surface of the fabric while allowing the hollow composite fibers located in at least the raised surface portion of the fabric to be divided into numerous very fine fibrils consisting of said polyester and polyamide constituents.

Abstract: Process for preparing a synthetic suede product from three or more separate layers of non-fibrous materials welded together: two outer layers with outwardly extending polyurethane fibers and at least one inner layer of polyurethane film, sheet, web, or foam. The process comprises continuously feeding at least three separate films, sheets or webs of the appropriate non-fibrous feed materials into the nip formed by two rotating, heated cylinders wherein the feed materials are contacted under pressure with two heated flexible molding bands provided with a multiplicity of molding cavities whereby outwardly extending fibrous polyurethane surfaces are formed and wherein the separate layers are welded together. The novel synthetic suede product obtained by this process is also disclosed and claimed.

Abstract: A sheet material having leather-like grain, excellent scuffing and abrasion resistance and superior dyeability comprising in combination, a substrate, and intermediate layer of 0.05 to 2.5 mm thickness consisting of a finely napped porous polymer bonded to said substrate and an upper layer consisting of a polymeric coating of thickness ranging from 1-100 microns. In typical embodiments, the upper layer may be a polymeric coating material such as linear or cross-linked polyurethanes, the intermediate layer may be a porous polyester, polyamide, vinyl or elastomeric polymer, e.g. a polyurethane, and the substrate may be a woven or non-woven fabric. In preparation of this sheet material, the intermediate layer is pressed and condensed to about 10 to 90% to a density of from about 0.20 to 0.50 g/cc.

Abstract: Methods for treating or producing original documents to inhibit, if not preclude, the reproduction of such documents by copying processes. The documents so produced favor the visual response of the human eye over the physical response of a copying machine so that the graphical information imprinted on the document background is readily perceptible by the human eye but imperceptible by the sensor and associated processes of a copying machine.

Abstract: The product of the present invention is a fabric woven from oriented polytetrafluoroethylene (PTFE) strands, in which the strands of the weave are interconnected by a multiplicity of fine PTFE fibrils. To produce this fabric, consisting entirely of PTFE, a woven PTFE fabric is heated substantially unrestrained to a temperature above the crystalline melt point of PTFE and stretched. Alternatively, a woven PTFE fabric may be impregnated with other fluorocarbon polymers, heated substantially unrestrained to a temperature above the crystalline melt point of PTFE, and subsequently stretched, thereby generating a multiplicity of fine fibrils interconnecting the weave.

Abstract: The invention contemplates expanded-plastic coated fabric wherein the exposed surface of the expanded plastic is characterized by a random distribution of torn cellular pockets and by a random distribution of projecting free ends of flock elements which are rooted to the plastic at their other ends. Various methods of making the fabric are described, with different "hand" or "feel" depending upon the method and upon the materials and their dimensions.

Abstract: An imitation leather material which comprises in combination: a woven fabric base sheet material, one surface of which is a napped surface and the other surface of which is not napped; the napped surface of the base sheet impregnated with a crosslinked polymeric material; the napped impregnated surface of the base sheet characterized by a smooth, buffed, flesh-like surface; an open-cell flexible polymeric foam layer bonded to the other unnapped surface of the base sheet material; a thin polymeric skin layer bonded to the surface of the foam layer; and the thin polymeric skin layer characterized by an imitation leather-like surface.

Abstract: Tightly woven colored fabrics such as twills, denims, sateens, and poplins are provided with pattern areas thereon simulating the appearance of a printed design and wherein the pattern areas are of a color tone contrasting with the color of adjacent pattern areas and have a discernible softer texture imparting further contrast with the non-pattern areas. The contrasting tone colored pattern areas may either have a lighter color tone appearance than the non-pattern areas or a darker color tone appearance or the pattern areas may appear to change in color tone with respect to the background areas when the fabric is viewed at different angles.

Abstract: A napped fabric is treated to bond the nap fibers together while leaving the nap structure largely open and porous.The surface of the bonded nap is then subjected to a series of spaced short cuts to form spaced clumps of bonded fibers which clumps have free ends projecting from the bonded nap so that they can be brushed from stable upright positions to bent-over positions, giving an attractive rough appearance resembling a split suede leather.

Abstract: A durably soil-resistant pile fabric, such as a carpet, is provided which comprises a plurality of organic fibers having thereon a normally solid coating comprising (a) a first phase of a water-insoluble fluoroaliphatic radical free urethane adduct having at least one major transition temperature higher than about 45.degree. C. and melting to a flowable liquid below about 200.degree. C. and (b) a second phase of waterinsoluble fluoroaliphatic radical containing urethane adduct having at least one major transition temperature higher than about 45.degree. C. and melting to a flowable liquid below about 200.degree. C.

Abstract: A process of forming pile surfaced material comprising drawing fibrils from the surface of a cross-linkable thermoplastic material and cross-linking the thermoplastic while maintaining the fibrils in a self-supporting position.

Abstract: A process for the manufacture of artificial leather which has a napped, suede or nubuck surface finish by contacting a natural, synthetic of semi-synthetic backing member with a polymeric system comprising a mixture of a heat-reactive latex and a carboxylated latex and which contains at least one dyestuff. Each of the latices is cross-linked in sequence while the contacted backing member is dried. The migration of non-polymeric components in the system of latices is suppressed during drying. The backing so treated is mechanically altered on the grain side of the backing member to provide an irregular leather-like surface thereto.

Abstract: A pile-surfaced product is made by feeding a synthetic polymeric material and a backing web to a surface with the synthetic polymeric material between the backing web and the surface under conditions where the polymeric material is filament forming and the polymeric material adheres to the surface and bonds to the backing web, then withdrawing the backing web from that surface so that as the backing web is so withdrawn the synthetic polymeric material adheres thereto and is drawn into fibrils due to its adhesion to the surface but the fibrils remain integral with the remainder of the polymeric material which is laminated to the backing web, rendering the polymeric material non-filament forming, separating the fibrils from the surface and subsequently separating the pilous synthetic polymeric layer from the backing web.

Abstract: An artificial tennis-playing court surface which comprises a flat, woven, fiber-glass, base sheet, one surface of the sheet characterized by a plurality of napped, generally upright, glass fibers and a layer of a cross-linked resin bonded to the upper surface, the resin forming a coating about and between the napped glass fibers to provide a rough, resin, fiber-coated surface, and a backing sheet secured to the opposite surface of the fiber-glass base sheet. A process of manufacturing an artificial tennis court-playing surface, which process comprises: napping the surface of a woven fiber-glass base sheet to provide a napped surface comprising a plurality of fine glass fibers protruding therefrom; coating the napped surface with a thin layer of a cross-linkable resin to coat the napped fibers and between the napped fibers; and securing a backing sheet to the fiber-glass base sheet.

Abstract: An electric blanket shell is composed of first and second-needled textile fabrics with a yarn layer disposed in at least one of the needled fabrics. The yarn layer has a plurality of first planar yarns extending generally in a first planar direction. A heat-fusible component is disposed in at least one of the needled fabrics. A plurality of small, discrete sonically or ultra-sonically-produced fusion bonds, spaced from each other, link the needled fabrics to form a blanket shell. The fusion bonds form a series of patterns across a planar dimension of the blanket shell and the patterns define a series of channels, for receiving heating wires, between the needled fabrics. The patterns of fusion bonds are disposed in a direction transverse to the direction of the first planar yarns. The fusion bonds of any one pattern do not engage more than about 50% of the first planar yarns and overlaps of fusion-bond patterns are substantially avoided.

Abstract: A method for attaching plastic nets to non-woven blankets without use of adhesives is disclosed. The net is positioned adjacent the non-woven blanket and then the strands of the netting are vibrated causing surface fibers of the blanket to surround the strands and hold the net to the blanket without the use of adhesives.

Abstract: Artificial leather is produced by applying a dope comprising urethane prepolymers containing terminal isocyanate groups, an amine catalyst and a foam stabilizer onto a releasing carrier sheet, exposing the resulting coating layer to a moisture-containing gas under controlled conditions, laminating the coating layer onto a backing material and stripping off the releasing carrier sheet. The resulting artificial leather has a cellular structure of polyurethane microfoam in adhesion with the backing material and an adhesion strength of 100 to 10,000 g/cm of width.

Abstract: An aqueous composition containing (A) an aminoplast precondensate, (B) a polymeric ethylene imine, the monomer of which is a reaction product of toluenediisocyanate a fluorinated alkanol and ethylene imine, which polymer is dispersed by means of a dispersant obtained by reacting said fluorinated alkanol, toluenediisocyanate and a polyethylene glycol, (C) a long-chain alkyl urea and (D) a cross-linking catalyst is useful for rendering a velvety suede-like polyurethane structure oil- and water-repellant.

Abstract: A fabric is superficially dyed by stamping and then subjected to abrasion to produce a feltlike appearance and a simultaneous mutation in coloring.

Abstract: .Iadd.The invention is directed to a tennis ball which includes a spherical shaped inner-member made of rubber or similar material and filled with compressed air to give it the desired shape and resiliency. An outer cover made of two pieces of non-woven non-napped, needle-punched fabric cut into the form of a figure eight is applied to the inner-member by an adhesive. The needle-punched fabric is formed by a sheet of fibrous material in which the fibers normally extend in a plane substantially parallel with the upper and lower surfaces of the sheet and in which a large number of the fibers extend substantially perpendicular to the upper and lower surfaces of the material which is needle-punched therefrom. As a result, the fibers which extend perpendicular to the upper and lower surfaces interlock with successive layers of the fibers to form a desirable cover layer. .Iaddend.