Abstract: A heat stabilized, moldable, consolidated nonwoven panel resistant to shrinkage when molded during a subsequent thermoforming operation, said panel being substantially stiff and comprised of a nonwoven structure of reinforcement fibers admixed throughout and encapsulated by a thermoplastic resin formed from melted and compressed thermoplastic fibers having a melting point less than the melting point of said reinforcement fibers, said reinforcement fibers comprising 60-20 percent per volume of said panel and having a length of from 1-6 inches sufficient to enable said panel to achieve at least about 50 percent elongation during thermoforming.

Abstract: A method of making a moldable, nonwoven composite material. The method includes blending a mix of first fibers and second thermoplastic fibers. The second fibers have a melting point lower than that of the first fibers and comprise approximately 40-80 percent of the blend. The blend is then processed into a fibrous batt. The batt is then consolidated into a nonwoven structure with the first fibers being thoroughly intermixed with the second fibers. The nonwoven structure is then heated to a temperature below the melting point of the first fibers and above the melting point of the second thermoplastic fibers to substantially liquefy the second fibers and form a thermoplastic resin. The heated nonwoven structure is compressed to flow the liquefied resin to displace air voids in the nonwoven structure and encapsulate the first fibers. Finally, the nonwoven structure is cooled to form a composite material having substantially reduced air voids therein with the first fibers thoroughly encapsulated by the resin.

Abstract: A nonwoven fibrous flexible material includes a needled web having a front outer surface and a non-glazed back surface disposed opposite thereof. The web includes interengaged first fibers and second thermoplastic fibers with the outer surface being substantially free of the second thermoplastic fibers. The web also has a plurality of weld joints between the second thermoplastic fibers and at least a portion of the first fibers proximate the back surface.

Abstract: A resilient, low modulus, semirigid shell for use as a component of an article of luggage. The shell comprises a first nonwoven batt of thermoplastic resin fibers and an exterior material attached to the first nonwoven batt. The first batt and exterior material are thermally formed to a predetermined shape. The shell may also include one or more additional component layers selected from a second nonwoven, fibrous batt, a layer of backing material, a water impermeable film, and a lining material. In manufacturing the shell, the exterior material is attached to a first portion of a substrate material which is comprised of the nonwoven batt of thermoplastic resin fibers. A second portion of the substrate material is secured to an apparatus for thermal forming and the exterior material and substrate material are thermally formed to a resilient, low modulus, semirigid shell having a predetermined configuration.

Abstract: A device for attaching thermoformed substrate material having front and back surfaces to a support frame. The device includes a fastener having a base portion and an attachment portion projecting from the base portion for engagement with the support frame. A nonwoven, needle-punched fiber sheet having first and second surfaces sandwiches the base portion between the first surface of the sheet and the back surface of the substrate. The sheet includes a central aperture having a width dimension sufficiently great to permit the attachment portion to project therethrough yet sufficiently narrow to enable the sheet to overlay the base portion. The sheet includes an enriched area of lower melting point fiber disposed proximate the first surface of the sheet and activatable to bond the first surface of the sheet to the back surface of the substrate without material flow and at a temperature utilized to thermoform the substrate material. This secures the base portion to the substrate material.

Abstract: A method for producing a nonwoven fibrous, flexible panel having a textured outer surface, including the steps: of providing a needled web comprised of interengaged first fibers and second thermoplastic fibers; needlepunching the web to produce the textured outer surface; and passing a fluid, at a temperature sufficient to melt at least a portion of the second thermoplastic fibers, through the web in a direction from the textured outer surface to produce a plurality of weld joints of the melted second thermoplastic fibers, the textured outer surface thereafter being substantially free of the second thermoplastic fibers. A nonwoven fibrous panel produced by the methods characterized herein is also described.

Abstract: A composite structural material and a method of making it, which material is thermoformable and capable of being rigidified by application of a resin, and which is useful in certain electronics applications because of a metallic layer incorporated within the structure. A layer of a selected metal is needle punched onto a fibrous batt of selected synthetic thermoplastic fibers, which is then thermoformed to a desired shape and rigidified by contacting with, and being embedded in, a suitable resin. Specific applications of the use of this composite include a parabolic dish-shaped antenna, an electromagnetic interference shield for electronic equipment, and a radioactive emission shield.

Abstract: A carpeting material of nonwoven synthetic thermoplastic resin fibers, capable of being folded so as to fit onto sharply irregular surfaces such as car trunk liners, made by the process of needle-looming a nonwoven carpeting material having higher and lower melting temperature synthetic thermoplastic resin fibers, subjecting the material to sufficient heat to soften and subsequently harden and rigidify one side of the carpeting, and then punching two substantially parallel rows of regularly spaced slots in the back side of the carpeting material. The slots of one row are arranged so that they are staggered in relation to the slots of the parallel row. The arrangement of slots in the back side of the carpeting enables it to be sharply folded while maintaining tear resistance.

Abstract: A nonwoven textile fiber panel, useful, for instance, in manufacturing car truck liners, in which synthetic thermoplastic fibers that vary in fiber length, diameter, denier, and/or density are needle-punched to produce a carpeting material, which can then be directly utilized, or thermoformed to retain a desired shape. The fibers that one desires to show up on the face side of the final product are preferentially driven by the needle barbs of a needle loom through the precursor batt material. This preferential needling can also be enhanced through selection of various needle lengths, needle diameters, and barb spacing configurations.

Abstract: A nonwoven textile panel for use as a fire retardant and sound deadening barrier in the interiors of aircraft, comprised of three layers of nonwoven textile fibers of polyphenylene sulfide fibers and Nomex brand aramid fibers that have been carded, cross-lapped, needle punched and thermally bonded by heating the panel to the temperature softening point of the polyphenylene sulfide fibers. The fibers are capable of being thermoformed and retaining a permanent shape due to the thermoplastic properties of the polyphenylene sulfide fibers.

Abstract: A cargo bed liner system for use in pickup trucks, four-wheel drive vehicles, light utility vehicles and the like, in which rigidified carpeting material made of needle-loomed staple fibers of polypropylene and polyester have been thermoformed to form a floor covering piece, a tail gate covering piece, and two side covering pieces, with flaps on the floor piece being folded upwards to cover the forward panel and any areas of the side panels which have not been covered by the side panel cover pieces. The system is affixed to the vehicle's cargo bed by means of several velcro-type fasteners.

Abstract: A nonwoven textile panel for use as a fire retardant and sound deadening barrier in the interiors of aircraft, comprised of five layers of nonwoven textile fibers of polyphenylene sulfide fibers and Nomex brand aramid fibers that have been carded, cross-lapped, needle punched and thermally bonded by heating the panel to the temperature softening point of the polyphenylene sulfide fibers, whose panel exterior is comprised of a skin of polyvinyl chloride that has been adhered to the outermost fibrous layer. The fibers are capable of being thermoformed and retaining a permanent shape due to the thermoplastic properties of the polyphenylene sulfide fibers. An important alternative embodiment uses a layer of polyester polyurethane foam underneath the vinyl to shield it from the heat radiating properties of the polyphenylene sulfide and prevent puckering of the vinyl material during the processing.

Abstract: The disclosure is of decorative vehicular kick panels e.g. for automobiles, and the method of their manufacture. The decorative panels are laminates of textile materials, having a decorative fabric surface. The panels of the invention are particularly advantageous in that they are economical to manufacture and exhibit resistance to edge fraying.

Abstract: The subject invention relates to methods and materials for making porous resin rigidified shaped articles suitable for filters, surgical trays, and the like, which comprises the steps of impregnating a non-woven fabric with a predetermined amount of thermoplastic or thermosetting water-based epoxy resin; partially curing the resin-impregnated fabric; and, thereafter molding the partially cured fabric into a desired shape with sufficient heat to advance the curing of the resin.