Abstract: A method and apparatus for the descaling of metal surfaces without the use of caustic substances is provided. The apparatus includes a first and second blast heads containing nozzles that spray high velocity jets of media at a scale covered continuous sheet of steel. The continuous sheet of steel is advanced into an abrading station containing a pair of brush assemblies that include stainless steel bristled brushes. The stainless steel brushes engage the surface of the sheet of steel and abrade away the cracked scale, leaving a surface clean of scale. The surface produced is pH neutral and therefore resists additional corrosion and does not require oil coatings, or other protective treatments. Eliminating these steps makes for a faster, more robust process and saves considerable cost.

Abstract: An apparatus and method for imparting a permanent, high resolution pattern to a heat-settable fabric, particularly one having a pile-like surface, using modulated streams of pressurized heated air that are individually controllable and electronically addressable, using a patterning technique capable of extremely fine gauge (i.e., high dots-per-inch or high pixel count) and extremely fine carve depth control (e.g., allowing for multiple finely spaced carve levels, as compared with techniques in the prior art), and which results in the formation of patterns of extraordinary resolution, definition and detail without the harsh hand associated with prior art techniques in which fibers and yarns are melted within patterned areas.

Abstract: A nonwoven fabric with microsponges containing a nonwoven base containing fibers, having a first side and a second side, and having a weight of greater than about 2 oz/yd2. The nonwoven fabric also contains elongated spaced apart rows of stitches with a stitching yarn, where the stitching yarns form a stitching pattern stitch shape factor of greater than 0.54, and where the stitching yarn has a tenacity greater than 1 gf/denier. The nonwoven fabric also contains a plurality of microsponges on the second side of the nonwoven base, the microsponges being bound on at least two sides by the rows of stitches. The microsponges have a microsponge shape factor greater than 0.54, the density of the nonwoven base is between about 10 and 90 percent lower at the midpoint between the rows of stitches compared to the rows of stitches, and the ratio of the distance between the rows of stitches to the average width of the microsponges is from about 3:2 to 5:2.

Abstract: The invention relates to a process of forming a nonwoven fabric with microsponges comprising obtaining a nonwoven base comprising fibers having a first side and a second side and having a weight of greater than about 2 oz/yd2, stitching the nonwoven base with a stitching yarn in elongated spaced apart rows of stitches, the rows of stitching having a stitch shape factor greater than 0.54 wherein the stitching yarn has a tenacity greater than 1 gf/denier. Next, a plurality of microsponges is formed by impinging the first side of the stitched nonwoven fabric with a collimated fluid stream with from about 100 to 200 joules per gram while supporting the stitched nonwoven fabric on a supporting member having areas impervious to the collimated fluid and pores in the supporting member which are pervious to the collimated fluid.

Abstract: The invention relates to a process of forming a nonwoven fabric with microsponges comprising obtaining a nonwoven base comprising fibers having a first side and a second side and having a weight of greater than about 2 oz/yd2, stitching the nonwoven base with a stitching yarn in elongated spaced apart rows of stitches, the rows of stitching having a stitch shape factor greater than 0.54 wherein the stitching yarn has a tenacity greater than 1 gf/denier. Next, a plurality of microsponges is formed by impinging the first side of the stitched nonwoven fabric with a collimated fluid stream with from about 100 to 200 joules per gram while supporting the stitched nonwoven fabric on a supporting member having areas impervious to the collimated fluid and pores in the supporting member which are pervious to the collimated fluid.

Abstract: A method and apparatus for the descaling of metal surfaces without the use of caustic substances is provided. The apparatus includes a first and second blast heads containing fan shaped nozzles that spray high velocity jets of smooth edged, ceramic media at a scale covered continuous sheet of steel. The continuous sheet of steel is advanced into an abrading station containing a pair of brush assemblies that include stainless steel bristled brushes. The stainless steel brushes engage the surface of the sheet of steel and abrade away the cracked scale, leaving a surface clean of scale. The surface produced is pH neutral and therefore resists additional corrosion and does not require oil coatings, or other protective treatments. The metal surface is produced with a roughness that is less than 2.5 microns Ra without stretching, polishing, cold-rolling or the use of acid pickling. Eliminating these steps makes for a faster, more robust process and saves considerable cost.

Abstract: A method and apparatus for the descaling of metal surfaces without the use of caustic substances is provided. The apparatus includes a first and second blast heads containing fan shaped nozzles that spray high velocity jets of smooth edged, ceramic media at a scale covered continuous sheet of steel. The continuous sheet of steel is advanced into an abrading station containing a pair of brush assemblies that include stainless steel bristled brushes. The stainless steel brushes engage the surface of the sheet of steel and abrade away the cracked scale, leaving a surface clean of scale. The surface produced is pH neutral and therefore resists additional corrosion and does not require oil coatings, or other protective treatments. The metal surface is produced with a roughness that is less than 2.5 microns Ra without stretching, polishing, cold-rolling or the use of acid pickling. Eliminating these steps makes for a faster, more robust process and saves considerable cost.