Abstract: Disclosed herein a stitch-bonded fabric comprising at least one fibrous web layer having a plurality of the fibers with a first length of more than about 25 mm, oriented substantially in a cross-direction (XD) of the stitch-bonded fabric wherein a density of the at least one fibrous web layer is less than about 0.12 g/cm3. The at least one fibrous web layer is stitch-bonded with yarns following a pattern of linear stitches along a machine direction (MD) spaced from about 1.4 mm to about 4.0 mm along XD, and repeating with a spacing front about 0.8 mm to about 2.5 mm in MD, wherein the plurality of fibers having said first length are captured by multiple stitches. A density of fibers and yarn enclosed within the stitches is above about 0.10 g/cm3 and below about 5.0 g/cm3 and the linear stiches are depressed below exposed the wales between the linear stitches along MD. The stitch-bonded yarns can be heat set to stabilize the stitch-bonded fabric.

Abstract: Disclosed is a stitch-bonded string comprising at least one stitched line extending in a machine direction and fibers emanating from the at least one stitched line. The at least one stitched line comprises a plurality of loops and said plurality of loops enclose substantially all of said fibers. The stitched line is gathered to reduce a dimension of the plurality of loops holding said fibers within the loops. The stitched line's weight is less than 20%, preferably less than 10%, and more preferably less than 5% of the total weight of the stitch-bonded string. The fibers have a basis weight ranging between 30 and 400 grams/meter2, preferably between 40 and 350 g/m2, preferably between 50 and 300 g/m2 or between 100 and 250 g/m2. Methods for making the string are also disclosed.

Abstract: A textile fabric with a three-dimensional contour that blocks fluid penetration at the surface is created by attaching a solid liquid-blocking polymeric layer conforming to the contours of the surface to a fabric layer. The surface includes elevated areas, depressed areas, a plurality of surface fibers and gaps among the plurality the plurality of surface fibers. The liquid-blocking polymeric layer is forced to follow the contours of the surface fibers and gaps using vacuum, heat and forced air. The resulting textile fabric maintains a textile appearance.

Abstract: A planar floor covering is formed having a top face and a bottom face opposite the top face, a length, a width perpendicular to the length, a top surface, a bottom surface opposite the top surface, a height between the top surface and the bottom surface, and physical properties or characteristics that vary across at least one of the length, the width and the height. The physical properties or characteristics include material composition, weight, density, directionality, stiffness, compressibility, elasticity and thickness.

Abstract: Disclosed are the cut edges of an absorbent fabric comprising at least 45% and less than about 90% cellulosic or natural fibers, and a fusible component being stabilized by fusing the fusible component with an arrangement of spaced lines or spaced areas extending from the cut edges, and optionally over the entire absorbent fabric.

Abstract: A textile fabric having improved properties, variously including surface stability, abrasion resistance, resistance to edge fraying, moisture control, and resistance to fluid penetration is created by introducing a polymeric solution or a plurality of low-melting particles suspended in a liquid into the textile fabric while leaving a plurality of surface fibers exposed and maintaining a textile feel on the surface.

Abstract: Disclosed is a stitch-bonded string comprising at least one stitched line extending in a machine direction and fibers emanating from the at least one stitched line. The at least one stitched line comprises a plurality of loops and said plurality of loops enclose substantially all of said fibers. The stitched line is gathered to reduce a dimension of the plurality of loops holding said fibers within the loops. The stitched line's weight is less than 20%, preferably less than 10%, and more preferably less than 5% of the total weight of the stitch-bonded string. The fibers have a basis weight ranging between 30 and 400 grams/meter2, preferably between 40 and 350 g/m2, preferably between 50 and 300 g/m2 or between 100 and 250 g/m2. Methods for making the string are also disclosed.

Abstract: Stabilizing a textile sheet structure was achieved by forming a plurality of discrete fiber tufts extending from a first face of a fibrous layer of the textile sheet structure, through the fibrous layer and beyond a second face opposite the first face. Each discrete fiber tuft included a plurality discrete fibers. Each discrete fiber tuft was anchored to the first face and the second face of the fibrous layer by joining together the plurality of each discrete fiber tuft at the first face and the second face and bonding the joined plurality of discrete fiber tuft to the first face and the second face.

Abstract: Stabilizing a fabric layer and simultaneously laminating a fabric to a bulky and cushioning backing layer using multiple internal adhesive layers placed within the fabric layer forms a composite textile. The melt index, weight and chemical compatibility of the adhesive layers versus the adjacent fabric sub-strata and the backing layer are adjusted to achieve the desired penetration of molten adhesive, mechanical bonding and chemical bonding. An optional external adhesive layer with a low melt index can be added between the fabric layer and the backing layer to facilitate attachment to a highly porous backing.

Abstract: A conformable and optionally elastic weather resistant, comfortable fabric provides wind and rain resistance, plus thermal insulation, along with moisture transfer through the fabric, by combining a hydrophobic and dense outer layer with a bulky absorbent middle layer and a thin hydrophobic inner layer, joined by stitching and optionally subsequently shrinking to bulk the structure and re-adjust the openings formed by stitching. The third hydrophobic layer may be omitted and substituted with hydrophobic underlap yarns formed during the stitching process. The method provides high conformability and optionally elastic fit or inelastic pre-adjustable body fit.

Abstract: A thin highly-open fabric or sleeve is placed over a paint roller cover, allowing the flow of paint in and out of the roller cover and smoother paint films.

Abstract: Disclosed are the cut edges of an absorbent fabric comprising at least 45% and less than about 90% cellulosic or natural fibers, and a fusible component being stabilized by fusing the fusible component with an arrangement of spaced lines or spaced areas extending from the cut edges, and optionally over the entire absorbent fabric.

Abstract: A unitary mattress cover is disclosed. The mattress cover has a top panel and four side panels, which include two end side panels, a left side panel and a right side panel made from a single blank of fabric. Elastic materials are attached to at least a portion of the left and right side panels, and the left and right side panels are longer than the top panel in a longitudinal direction, and wherein free edges of the left and right side panels are attached to one of the two end side panels or to each other. Also disclosed is a method for making this unitary mattress cover in one continuous manufacturing process.

Abstract: Disclosed herein a stitch-bonded fabric comprising at least one fibrous web layer having a plurality of the fibers with a first length of more than about 25 mm, oriented substantially in a cross-direction (XD) of the stitch-bonded fabric wherein a density of the at least one fibrous web layer is less than about 0.12 g/cm3. The at least one fibrous web layer is stitch-bonded with yarns following a pattern of linear stitches along a machine direction (MD) spaced from about 1.4 mm to about 4.0 mm along XD, and repeating with a spacing front about 0.8 mm to about 2.5 mm in MD, wherein the plurality of fibers having said first length are captured by multiple stitches. A density of fibers and yarn enclosed within the stitches is above about 0.10 g/cm3 and below about 5.0 g/cm3 and the linear stiches are depressed below exposed the wales between the linear stitches along MD. The stitch-bonded yarns can be heat set to stabilize the stitch-bonded fabric.

Abstract: A shrinkable material is attached to the backside of a floorcovering tile and allowed to shrink to a controlled extent to produce a backside shrinking that counteracts the tendency of the tile to warp out of plane on the floor as temperature and humidity vary during installation or while in use. The tile assumes a slightly convex shape in one or two directions that can be overcome as it is adhesively attached to the floor. The added material may also serve a secondary function as pressure sensitive adhesive, a friction layer, a fluid barrier, or a cushioning surface.

Abstract: A fabric made of yarns interlooping with each other or passing through an inner layer at looping intervals. The fabric is embossed with a micro-pattern extending into the yarns or into a layer underneath the fabric. The micro-pattern contains a pre-defined pattern of a plurality of binding points attaching the yarns to the inner layer or to the added underlayer. This micro-pattern has an inter-point spacing between adjacent binding points that is less than the interlooping intervals. The fabric can also be embossed with a macro-pattern separate from and coarser than the micro-pattern. The macro-pattern establishes a desired aesthetic in the fabric, and the micro-pattern does not interfere with the desired aesthetic.

Abstract: An adhesive layer carrying a uniform color or a color-scheme is placed within or under a colored or color-printed conformable fabric that is simultaneously or subsequently molded into a three-dimensional shape or embossed with a three-dimensional pattern. The thermoplastic adhesive layer proceeds towards the fabric surface and matches or masks the color gaps opened on the surface by molding or embossing. The fabric can also be laminated to a backing during the molding or embossing process.

Abstract: A surface covering tile has a plurality of edges extending between the face and the back surface. A pressure sensitive adhesive is disposed on the back surface and covers less than 40% of the back along each one of the plurality of edges where the back surface intersects the plurality of edges. For highly porous back surfaces, the pressure sensitive adhesive is selected and applied in a manner limiting penetration into the back surface. The amount of pressure sensitive adhesive required to affix the tile is reduced, and the tile can be optionally constructed in a manner that facilitates lateral movement of the tile during installation.

Abstract: An added layer attached to a textile sheet using polymeric adhesive placed over a textile sheet or between the textile sheet and an added layer is removed by applying heat or a solvent and at least one of an abrasive action, squeezing, or shaving action to remove the adhesive layer or both the added layer and the adhesive sublayer and to prepare the textile sheet for recycling into a new textile structure, preferably into a textile sheet performing the same function as the original textile sheet.

Abstract: A textile fabric with a three-dimensional contour that blocks fluid penetration at the surface is created by attaching a solid liquid-blocking polymeric layer conforming to the contours of the surface to a fabric layer. The surface includes elevated areas, depressed areas, a plurality of surface fibers and gaps among the plurality the plurality of surface fibers. The liquid-blocking polymeric layer is forced to follow the contours of the surface fibers and gaps using vacuum, heat and forced air. The resulting textile fabric maintains a textile appearance.