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: The present invention is directed to multiple layer composites (10) suitable for use as wall and floor coverings, among other uses, that provide a strong durable structure and a soft textile or fabric face. The composite includes a face layer (12) bonded to an adhesive layer (22) such that the adhesive layer (22) penetrates into the face layer (12). The face layer (12) can have legs (19, 34) extending there from, and such legs (19, 34) are anchored by the adhesive layer to provide stronger attachment between the adhesive layer and the face layer. A backing layer (26) may also be provided in contact with the adhesive layer (22) such that the adhesive layer also embeds into the backing layer (26), and the legs (19, 34) extending from the face layer may penetrate into the backing layer.

Abstract: A method for preparing stretchable bonded nonwoven fabrics which involves forming a substantially nonbonded nonwoven web of multiple-component continuous filaments or staple fibers which are capable of developing three-dimensional spiral crimp, activating the spiral crimp by heating substantially nonbonded web under free shrinkage conditions during which the nonwoven remains substantially nonbonded, followed by bonding the crimped nonwoven web using an array of discrete mechanical, chemical, or thermal bonds. Nonwoven fabrics prepared according to the method of the current invention have an improved combination of stretch-recovery properties, textile hand and drape compared to multiple-component nonwoven fabrics known in the art.

Abstract: Provided is a process comprising contacting a spun-bonded polypropylene fabric with a layer of fibers that are not polypropylene, point-bonding the layers together to form a bonded layered fabric, exposing the bonded layered fabric to heat under suitable conditions followed by cooling to form a layered elastomeric fabric, the bonded layered fabric being disposed in a manner to permit free-shrinkage in at least one dimension to occur during at least a portion of the heating, and wherein the point-bonds in the bonded layered fabric comprise 5-60% of the total fabric area. A layered elastomeric fabric produced by the process and textile products made of the layered elastomeric fabric are also provided.

Abstract: A process for making abrasion-resistant composites is disclosed. The process comprises the steps of providing a fibrous sheet containing a high density of relatively short staple fibers having a decitex under 6.6; needle-punching the staple layer and applying an adhesive containing layer; followed by the application of heat and pressure to the composite to form a thin consolidated and abrasion-resistant back-face layer on the composite. Preferably, the adhesive layer is penetrated by the needled fibers during the needling step and the product is shrunk in area by 20-50% before the consolidation step. Also optionally, the consolidated layer is abraded or perforated to create micro-pores that are permeable to gases and capable of containing liquids under low-to-moderate pressures.

Abstract: A multi-layer composite sheet comprising a shrinkable layer intermittently bonded a to a gatherable layer with the bonds separated by a specified distance and wherein the shrinkable layer can shrink and at the same time gather the gatherable layer between the bonds. A process for preparing multi-layer composite sheets by intermittently bonding a shrinkable layer to a gatherable layer with the bonds separated by a specified distance and causing the shrinkable layer to shrink while at the same time gathering the gatherable layer between the bonds. Preferably, the shrinkable layer comprises an array of fibers or nonwoven web comprising fibers having latent spiral crimp.

Abstract: A microwavable package has a pad for absorbing fat, grease, oil, moisture, and like liquid exuded from food, primarily meat, during cooking. The pad has a high-melting, liquid-transmissible, stiff, shrink-resistant, preferably foraminous face layer in contact with the food. A body layer is in contact with the face layer opposite the food. During cooking, the food releases liquid that transfers through the face layer where it contacts and is absorbed by the body layer. The face layer resists adhering to the food and therefore can be easily separated from the food after cooking.

Abstract: A stitched yarn surface structure includes a backing having decorative upper surface and a thickness dimension T of at least two (2) millimeters. The backing exhibits a predetermined compressive resistance Rb. Plural rows of face yarn segments cover at least a portion of the decorative upper surface of the backing, with adjacent face yarn segments being spaced apart by a predetermined minimum spacing dimension S. The yarns forming the face yarn segments have a predetermined compressive resistance Ry. The compressive resistance Rb, the compressive resistance Ry, and the spacing S are selected such that a load of up to one hundred (100) pounds per square inch (psi) imposed on the stitched yarn surface structure by a loading member is able to be borne by the stitched yarn surface structure without allowing contact between the member and the decorative upper surface of the backing.

Abstract: Disclosed herein is a composite comprising at least one heat shrinkable adhesive layer stitch-bonded with yarns, which shrink less than the adhesive layer or do not shrink, when the adhesive layer is exposed to heat. The stitch-bonded yarns form loops upstanding from the shrunk adhesive layer and the loops create a textured surface on the composite, and the composite is substantially inelastic after the adhesive layer is shrunk. The composite may further comprise at least one fibrous layer stitch-bonded to the shrinkable adhesive layer, and the fibrous layer is less shrinkable than the adhesive layer or is substantially non-shrinkable.

Abstract: The present invention is directed to a stitch-bonded elastic polymeric composite comprising a non-fibrous elastically extensible substrate stitched with a substantially inextensible yarn system. The composite may have an optional fibrous layer stitch-bonded to the non-fibrous substrate either over or under the non-fibrous elastic substrate. The composite preferably has a shrinkage during boil-off of less than about 10%. The stitching yarn network preferably allows stretch beyond the as-stitched dimensions of about 10-100% in at least one direction, and the composite can recover from this stretch to within 5% in at least one direction.

Abstract: A thermoplastic binder applied in the vicinity of the roots of a pile surface structure, typically before stitching, is raised above its melting point but below the critical exposure temperature that can adversely affect the properties of the material forming the pile elements. While at this elevated temperature the pile surface structure is mechanically flexed, as by repeatedly bending the backing with the pile loops thereon into and out of its plane. This flexing action assists the molten (but not freely flowing) binder to propagate into the roots of the pile elements and into the interstices between the fibers forming the same.

Abstract: A stretchable stitch-bonded nonwoven fabric is disclosed herein. The fabric includes a nonwoven substrate having basis weight in the range from about 15 to about 150 g/m2, and density in the range from about 0.02 to about 0.12 g/cm3. The nonwoven substrate is bonded with a binder applied to the outer surfaces of the substrate in a liquid form in a sufficiently uniform manner so that no areas greater than the spaces between stitch insertion points are devoid of binder. The binder constitutes from about 2% to about 25% of the total weight of the sum of binder and nonwoven substrate weight. The substrate is stitch-bonded with yarns arranged in a stitch pattern that allows the stitch-bonded fabric to be stretched in at least one direction by a factor of about 2.5 to about 5.0 without forming local ruptures therein, and wherein the stitch-bonded nonwoven fabric can be washed and dried at least twenty times.

Abstract: The present invention is directed to multiple layer composites suitable for use as wall and floor coverings, among other uses, that provide a strong durable structure and a soft textile or fabric face. The composite includes a face layer bonded to an adhesive layer such that the adhesive layer penetrates into the face layer. The face layer can have legs extending there from, and such legs are anchored by the adhesive layer to provide stronger attachment between the adhesive layer and the face layer. A backing layer may also be provided in contact with the adhesive layer such that the adhesive layer also embeds into the backing layer, and the legs extending from the face layer may penetrate into the backing layer.

Abstract: Disclosed herein is a composite comprising at least one heat shrinkable adhesive layer stitch-bonded with yarns, which shrink less than the adhesive layer or do not shrink, when the adhesive layer is exposed to heat. The stitch-bonded yarns form loops upstanding from the shrunk adhesive layer and the loops create a textured surface on the composite, and the composite is substantially inelastic after the adhesive layer is shrunk. The composite may further comprise at least one fibrous layer stitch-bonded to the shrinkable adhesive layer, and the fibrous layer is less shrinkable than the adhesive layer or is substantially non-shrinkable.

Abstract: A warp knit fabric having a plurality of stitches formed by overlaps arranged in adjacent, longitudinally extending wales with transverse underlaps connecting the overlaps of adjacent wales and with a binder material extending along the wales is used to produce a chenille yarn having a core and a pile. The pile of the chenille yarn is defined by the slit transverse underlaps and the core is defined by the overlaps of the stitches and the binder. Either before or after slitting, either the fabric or the chenille yarns is(are) heated to activate the binder. A tensile force is imposed either during or after heating.

Abstract: A stitched yarn surface structure includes a backing having decorative upper surface and a thickness dimension T of at least two (2) millimeters. The backing exhibits a predetermined compressive resistance Rb. Plural rows of face yarn segments cover at least a portion of the decorative upper surface of the backing, with adjacent face yarn segments being spaced apart by a predetermined minimum spacing dimension S. The yarns forming the face yarn segments have a predetermined compressive resistance Ry. The compressive resistance Rb, the compressive resistance Ry, and the spacing S are selected such that a load of up to one hundred (100) pounds per square inch (psi) imposed on the stitched yarn surface structure by a loading member is able to be borne by the stitched yarn surface structure without allowing contact between the member and the decorative upper surface of the backing.

Abstract: A warp knit fabric having a plurality of stitches formed by overlaps arranged in adjacent, longitudinally extending wales with transverse underlaps connecting the overlaps of adjacent wales and with a binder material extending along the wales is used to produce a chenille yarn having a core and a pile. The pile of the chenille yarn is defined by the slit transverse underlaps and the core is defined by the overlaps of the stitches and the binder. Either before or after slitting, either the fabric or the chenille yarns is(are) heated to activate the binder. A tensile force is imposed either during or after heating.