Abstract: The present invention is directed to a method of forming a two-sided nonwoven fabric, which exhibits a pronounced three-dimensional image that is durable to both converting and end-use application. In particular, the present invention contemplates that a fabric is formed from a first precursor web comprising a first fibrous matrix and a second precursor web comprising a second fibrous matrix. Between the first and second precursor web, a fluid-pervious support layer or scrim, is interposed and subjected to hydroentanglement on a moveable imaging surface having a three-dimensional image transfer device. By formation of a nonwoven fabric in this fashion, a three-dimensional image that is durable to abrasion and distortion due to elongation is imparted and a product formed which exhibits on its opposite surfaces the unique properties of the respective fibrous matrix used.

Abstract: The present invention is directed to a method of forming a nonwoven cleaning article, which exhibits a first three-dimensional image and a second three-dimensional image whereby the first and second three-dimensional images are dissimilar from one another. In particular, the present invention contemplates a fabric comprised of sequential three-dimensional images that are formed from a pre-entangled precursor web entangled on a first three-dimensional transfer device so as to impart a first image therein, then subjected to hydroentanglement on a second three-dimensional image transfer device wherein a second three-dimensional image is imparted to the web that is different from the first three-dimensional image, the resulting nonwoven cleaning article presenting aesthetic and tactile qualities representative of both imparted images.

Abstract: A nonwoven composite fabric having first and second fibrous layers reinforced by an intermediate scrim layer. The first fibrous layer may be an entangled fabric formed of staple length fibers or continuous filaments, and the second fibrous layer may be a thermally point-bonded fabric formed of staple length fibers or continuous filaments. The second fibrous layer bonds the scrim to the first fibrous layer and will mask the scrim in the finished product. The composite fabric is produced by placing the scrim in face-to-face juxtaposition with the first and second fibrous layers, and subjecting the resulting composite to the forces of high pressure fluid jets to break the bonds in the second fibrous layer and to cause the fibers or filaments of that fibrous layer to pass through the openings in the scrim and become entangled with the fibers or filaments of the first fibrous layer.

Abstract: The present invention is directed to a method of forming a two-sided nonwoven fabric, which exhibits a pronounced three-dimensional image that is durable to both converting and end-use application. In particular, the present invention contemplates that a fabric is formed from a first precursor web comprising a first fibrous matrix and a second precursor web comprising a second fibrous matrix. Between the first and second precursor web, a fluid-pervious support layer or scrim, is interposed and subjected to hydroentanglement on a moveable imaging surface having a three-dimensional image transfer device. By formation of a nonwoven fabric in this fashion, a three-dimensional image that is durable to abrasion and distortion due to elongation is imparted and a product formed which exhibits on its opposite surfaces the unique properties of the respective fibrous matrix used.

Abstract: A nonwoven fabric, and method of production, are disclosed, wherein the nonwoven fabric comprises textile length fibers with a portion being thermally fusible. The fabric exhibits sufficient durability to withstand commercial dyeing processes, with the resultant fabric finding widespread applicability by virtue of its durability and aesthetic appeal.

Abstract: The present invention is directed a nonwoven fabric which is imparted with a three-dimensional image or pattern, and apertures essentially devoid of fiber, during the fabrication stage. The nonwoven fabric exhibits a fibrous extension out of the plane of the material, while apertures are present that have a pronounced uniformity and a significant reduction in fibrous occlusion.

Abstract: A laminated fabric consisting of a relatively lightweight layer formed of dimensionally stable, heat-resistant fibers, and a relatively heavyweight layer formed of one of more plies. The laminate is imaged on a three-dimensional support surface, and the laminate may be treated with a fire-retardant binder to stabilize the image and enhance the flame-retardant properties.

Abstract: A hydroentangled nonwoven fabric exhibiting cross-direction extensibility and recovery comprises a nonwoven web of staple length fibers of about 0.8 to 3.0 denier having a basis weight of about 1.0 to 4.0 ounces per square yard. A polymeric binder composition substantially uniformly applied to the nonwoven web imparts desired elasticity to the web, with the fabric exhibiting at least about 50% extensibility in a cross-direction thereof, and at least about 90% recovery in a cross-direction. The nonwoven web may comprise synthetic fibers, natural fibers, and blends thereof, as well as continuous filaments. Patterned hydroentanglement of the web acts to entangle the fibers to provide the fabric with desired performance characteristics. A method of making the nonwoven fabric is disclosed. The nonwoven fabric is particularly suited for use in a mattress pad assembly, as also disclosed herein.

Abstract: A hydroentangled nonwoven fabric exhibiting cross-direction extensibility and recovery comprises a nonwoven web of staple length fibers of about 0.8 to 3.0 denier having a basis weight of about 1.0 to 4.0 ounces per square yard. A polymeric binder composition substantially uniformly applied to the nonwoven web imparts desired elasticity to the web, with the fabric exhibiting at least about 50% extensibility in a cross-direction thereof, and at least about 90% recovery in a cross-direction. The nonwoven web may comprise synthetic fibers, natural fibers, and blends thereof, as well as continuous filaments. Patterned hydroentanglement of the web acts to entangle the fibers to provide the fabric with desired performance characteristics. A method of making the nonwoven fabric is disclosed. The nonwoven fabric is particularly suited for use in a mattress pad assembly, as also disclosed herein.

Abstract: A nonwoven fabric, and method of production, are disclosed, wherein the nonwoven fabric comprises textile length fibers with a portion being thermally fusible. The fabric exhibits sufficient durability to withstand commercial dyeing processes, with the resultant fabric finding widespread applicability by virtue of its durability and aesthetic appeal.

Abstract: A hydroentangled nonwoven fabric exhibiting cross-direction extensibility and recovery comprises a nonwoven web of staple length fibers of about 0.8 to 3.0 denier having a basis weight of about 1.0 to 4.0 ounces per square yard. A polymeric binder composition substantially uniformly applied to the nonwoven web imparts desired elasticity to the web, with the fabric exhibiting at least about 50% extensibility in a cross-direction thereof, and at least about 90% recovery in a cross-direction. The nonwoven web may comprise synthetic fibers, natural fibers, and blends thereof, as well as continuous filaments. Patterned hydroentanglement of the web acts to entangle the fibers to provide the fabric with desired performance characteristics. A method of making the nonwoven fabric is disclosed. The nonwoven fabric is particularly suited for use in a mattress pad assembly, as also disclosed herein.