Abstract: Apparatus for loosening the needled structure of a textile fabric. A moveable surface having penetrating elements which penetrate the fabric, produce planar forces on the internal fibers of the fabric. A co-operating surface provides an opposite force to that exerted by the moveable surface. The moveable surface moves at a different speed than the cooperating surface and compressive forces are applied to the internal fibers of the fabric at discrete points by the penetrating elements, and internal fibers are moved relative to other fibers.

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: An improved needled fabric structure having superior fiber entanglement and produced by an improved needling method and needle machine. The improved needled fabric structure has fibers coherently oriented throughout the batt from one surface to the other in a plurality of rows of fibers extending in a generally lengthwise direction of the batt with each of the rows of fibers being a continuous chain entanglement of fibers from one surface to the other, and at least some of the rows of chain entanglement of fibers crossing, recrossing, and extending through other of the rows of chain entanglement of fibers.

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 smooth-surfaced textile fabric, suitable for use in artificial leather, is prepared by needling staple fibers into a coherently-entangled structure. The structure has a base layer which carries a major portion of planar loading and a top layer which carries a minor portion of planar loading. Disposed on the top layer is a polymeric finish having a smooth surface. The base layer and the top layer are connected by connecting fibers having segments disposed in each of the said layers and the connecting fibers only loosely connect the top layer to the base layer.

Abstract: There is provided a needled textile fabric having high bulk density, entangled fibers, a controlled axis of flexure and a bulk density gradient wherein the bulk density increases from the back surface to the face surface thereof. The products are made by needling layers of fibers having a needle pick-up gradient into a dense structure, with a bulk density gradient. The needled fabric is coated with a polymeric coating on the face surface of the structure where the thickness of the coating is from 4 to 20 mils. The fabric is suitable for use as an artificial leather.

Abstract: A textile fabric with a dense intensely entangled reticular fibrous structure and process for manufacture thereof are provided wherein staple fibers are needled into a high bulk density structure with a bulk density gradient wherein the bulk density increases from the back surface to the face surface of the structure. The needled structure is impregnated with a liquid phase filler and capillary action preferentially disposes the liquid phase filler toward the more dense face surface. The filler is coagulated and dried, cured, etc., into particles which are at most loosely bonded to the fibers. The preferential disposition of the filler increases the bulk density gradient of the filled fabric.