Abstract: A new fiber-forming method, and related apparatus, are taught in which extruded filaments of fiber-forming material are directed through a processing chamber that is defined by two parallel walls, at least one of which is instantaneously movable toward and away from the other wall; preferably both walls are instantaneously movable toward and away from one another. Movement means provide instantaneous movement to the at least one movable wall. In one embodiment, the movement means comprises biasing means for resiliently biasing the wall toward the other wall. Movement of the wall toward and away from the other wall is sufficiently easy and rapid that the wall will move away from the other wall in response to increases in pressure within the chamber but will be quickly returned to its original position by the biasing means upon resumption of the original pressure within the chamber. In another embodiment the movement means comprises oscillating means for oscillating the wall at a rapid rate.

Abstract: Curled decorative grasses and methods for producing same are disclosed wherein the curled decorative grasses have improved bulk and simulate Spanish moss in color and appearance.

Abstract: A stabilized creped nonwoven web and a method for producing the same, wherein a creped nonwoven web is thermally stabilized, for example by through-air-bonding or embossing, to produce the stabilized creped nonwoven web. The stabilized creped nonwoven web having increased tensile strength in the machine direction and an enhanced appearance. The stabilized creped nonwoven web of this invention id capable of withstanding a tensile force or load in a machine direction of at least about 2.0 lbs. at 20% strain and a tensile force or load in the machine direction of at least about 5.0 lbs. at 50% strain.

Abstract: A spunbond nonwoven fabric is provided, formed from a multiplicity of substantially continuous bicomponent filaments randomly arranged and bonded to one another. The bicomponent filaments have a multilobal cross-sectional configuration including a first polymer component formed of a higher-melting composition occupying at least the central portion of the filament cross-section and a second polymer component formed of a lower-melting composition being present in at least one lobe of the multilobal cross-section.

Abstract: A process for making textile staple fibre from polytrimethylene terephthalate (PTT) which comprises: (a) melt extruding PTT polymer at 245 to 253° C., (b) spinning the extruded PTT into yarn using at least one spinneret, (c) moving the spun yarn to a first takeup roll wherein the distance from the spinneret to the roll is from 16 to 20 feet, (d) cooling the spun yarn to less than 31° C. before it reaches the roll, (e) prior to the draw process, preconditioning the yarn under tension at a temperature of at least 60° C., (f) drawing the yarn at a temperature of at least 60° C., (g) allowing the drawn yarn to relax at a temperature of up to 190° C., and (h) crimping the drawn yarn at a temperature of 70 to 120° C., and decreasing the drawn yarn feed denier into the crimper by 10 to 60 percent by denier.

Abstract: A method for applying a fluid filament to a strand useful for bonding elastic strands to an absorbent garment is described. The strand is oscillated as it moves along an isolated path past a fixed fluid filament dispenser. The strand captures substantially all of the fluid filament, and at least partially all sides of the strand are coated with the filament. The filament coated strand may then be bonded to one or more substrates in some embodiments.

Abstract: A crosslinkable cellulosic fibrous product that includes cellulosic fibers and a crosslinking agent is disclosed. The crosslinkable cellulosic fibrous product can be formed as a web or sheet that has structural integrity and sheet strength sufficient to permit the fibrous web to be rolled, transported, and used in rolled form in subsequent processes. The crosslinkable fibrous product can be converted into a crosslinked fibrous product by subjecting the product to conditions sufficient to effect intrafiber crosslinking. Alternatively, the web can be fiberized and the resulting individual crosslinkable fibers combined with other fibers and/or other materials to provide a fibrous web containing crosslinkable cellulosic fibers. Subjecting such a web to crosslinking conditions provides a fibrous web that includes, in addition to other fibers or materials, crosslinked cellulosic fibers.

Abstract: The present invention is directed to a method of making an absorbent composite containing superabsorbent material. The method includes incorporating a superabsorbent material comprising superabsorbent particles into a substrate, wherein the superabsorbent particles have a bimodal particle size distribution. The absorbent composite displays enhanced fluid intake and fluid distribution properties, and is useful in disposable personal care products.

Abstract: A method for producing a film with attached fibrils having a cloth-like look and feel. A flocking or metering device is provided for dispensing a layer of the fibrils. The fibrils are next delivered onto a moving vacuum belt, which has a porous surface for drawing the layer of fibrils thereto. After dispersion, the fibril layer is transported and held by the vacuum conveyor belt to a position under a slot cast extrusion die, where a lower temperature melt polymer is released. Upon release, the lower temperature melt polymer and fibril layer fuse and combine to interlock to create a composite temporary web. In one embodiment, the fibril layer and lower temperature melt polymer are delivered at a first nip point between a pair of nip rollers to create the composite temporary web. The composite temporary web may next be collected on collection rolls, or combined with a higher temperature melt polymer under a second slot cast extrusion die to form a permanent film with fibrils.

Abstract: This invention aims to provide a composite sheet having a layer of inelastically stretchable continuous fibers improved so that a possible unevenness in fiber diameter may be minimized.

Abstract: A method for preparing multiple component spunbond nonwoven fabrics in which the individual polymer components are extruded from separate orifices and contacted and fused after extrusion to form multiple component filaments that are drawn, quenched, and collected to form a spunbond web. The method is especially suitable for forming multiple component spunbond webs in which the different polymeric components have significantly different viscosities, for example in forming nonwoven webs comprising multiple component filaments having three-dimensional helical crimp.

Abstract: A process for making an elastically stretchable composite sheet having a relatively low basis weight. An elastically stretchable second web is placed upon a first web comprising stretchable first continuous fibers and the first and second webs are intermittently bonded together to obtained a first composite web which is stretched under a plastic deformation of the first continuous fibers and then elastically contracted to obtain a second composite web.

Abstract: A method of making a non-woven fibrous media, combining high vapor permeability and low liquid permeability, includes the steps of providing a non-woven fabric formed from fibers that are prematurely crystallized during fabric formation and have a wide heat of fusion range distribution, and calendering the fabric to soften the small polymer crystals therein of low heats of fusion, but not the relatively larger polymer crystals therein of relatively higher heats of fusion, thereby to retain high vapor permeability while providing low liquid permeability. The polymer is preferably isotactic polypropylene.

Abstract: Disclosed is a process for preparing a fibrous web. The fibrous web includes a microencapsulated material, such as a microencapsulated phase change material, adhered to the web. Preferably, the web is prepared in a melt-blowing or spun-bonding process. In the melt-blowing process, cooling water containing the microcapsules is used to cool melt blown fibers prior to collection on a collector. In the spun-bonding process, microcapsules are applied in liquid suspension or in dry form to a heated web, for instance, after the web has been calendared. The fibrous webs thus prepared have numerous uses, and are particularly suited to the manufacture of clothing.

Abstract: A blown micro-fiber filtration unit having multiple overlapping layers of fibrous material and an active material applied over said layers. The fibrous material layers being fused together.

Abstract: A multi-layer absorbent product in a preferred embodiment includes a fibrous nonwoven top sheet, a fibrous nonwoven absorbent core layer, and a fibrous nonwoven substantially water-impervious back sheet. Each component layer or sheet is manufactured at a fiberizing station (i.e., melt spinning) and laminated together at a combining station. The preferred melt spinning apparatus is spunbond for the top sheet, meltblowing for the core layer, and a combination of spunbond and meltblowing for the bottom sheet.

Abstract: A new fiber-forming method, and related apparatus, and webs prepared by the new method and apparatus are taught. In the new method a) a stream of filaments is extruded from a die of known width and thickness; b) the stream of extruded filaments is directed through a processing chamber that is defined by two narrowly separated walls that are parallel to one another, parallel to said width of the die, and parallel to the longitudinal axis of the stream of extruded filaments; c) the stream of filaments passed through the processing chamber is intercepted on a collector where the filaments are collected as a nonwoven fibrous web; and d) a spacing between the walls of the processing chamber is selected that causes the stream of extruded filaments to spread before it reaches the collector and be collected as a web significantly wider in width than the die. Generally the increase in width is sufficient to be economically significant, e.g., to reduce costs of web manufacture.

Abstract: Nonwoven laminates are made by a multi-station line comprising at least one spunbond die assembly and at least one meltblowing die assembly. Each station includes (a) a melt spinning die which can be selectively equipped with a spunbond die insert or a meltblowing die insert and (b) a moveable support structure for adjusting the proper die-to-collector distance, depending on the spunbond or meltblowing mode of operation. The multi-station line permits the selective manufacture of a variety of spunbond (S) and meltblown (M) laminates, including the S-M-S laminate.

Abstract: A method of forming a meltblown web having meltblown fibers and particles is provided. The particles are heated to a temperature approximating that of the meltblown fibers as they are being extruded. As a portion of any heated particle impacts the skin of one or more solidifying meltblown fibers, that portion of any heated particle penetrates into one or more solidifying particles. Although a portion of any particle becomes embedded in and retained by one or more meltblown fibers, such surface penetration is generally slight desirably leaving a substantial amount of surface area of any particle available for interaction with any medium to which a web may be exposed.

Abstract: A method for making a fluid transfer layer has steps of depositing a first non-woven layer on a support, depositing a second non-woven layer on the first layer, with the two layers having a different melting point. The two layers are then thermally bonded to one another in a heated calender nip, during which differential shrinkage occurs because of the two layers' different melting points. A micro-bulked profile results. The composite, micro-bulked web is then mechanically bulked to provide a macro-bulked profile. The resulting non-woven fabric has a high bulk, high resistance to pore structure collapse, high resistance to compression deformation, and is more economical to produce than prior art carded or bicomponent webs. An absorbent article has a porous topsheet, the fluid transfer layer of the invention underlying the topsheet, and an absorbent core.

Abstract: A method of making a non-woven fibrous media, combining high vapor permeability and low liquid permeability, includes the steps of providing a non-woven fabric formed from fibers that are prematurely crystallized during fabric formation and have a wide heat of fusion range distribution, and calendering the fabric to soften the small polymer crystals therein of low heats of fusion, but not the relatively larger polymer crystals therein of relatively higher heats of fusion, thereby to retain high vapor permeability while providing low liquid permeability. The polymer is preferably isotactic polypropylene.

Abstract: Nonwoven fabric is formed from a spunbond process by extruding generally ribbon-shaped fibers 126 through slot-shaped orifices 124 of a spinneret 122. The ribbon-shaped fibers are rapidly quenched after extrusion to achieve a substantially uniform molecular orientation throughout a transverse cross section of the fibers, yielding stronger fibers. The rapid quenching results largely from the relatively high aspect ratio (thinness) of the fibers and the relatively large surface area of the fibers, which permits the fibers to quickly cool throughout the transverse cross section. The ribbon-shaped fibers are drawn longitudinally by an aspirator 128 that exerts a generally downward force produced by an air stream that longitudinally stretches and transversely attenuates the ribbon-shaped fibers in such a manner that the transverse cross-sectional shape of the ribbon-shaped fibers enhances the interaction between the air stream and the ribbon-shaped fibers to maximize the downward force.

Abstract: A filter medium has a function member accommodated between two fiber layers. A production method for manufacturing a filter medium includes the steps of: preparing a first fiber layer having a shape identical to that of a side surface of the filter medium; disposing a function member on a surface of the first fiber layer; and forming a second fiber layer by spinning partially melted fibers onto the function member disposed on the surface of the first fiber layer. Therefore, it is unnecessary to carry out press-forming in a state in which the function member is sandwiched between nonwoven fabrics, and a countermeasure to prevent the function member from falling out and a countermeasure to prevent the nonwoven fabric from being torn by the function member are unnecessary.

Abstract: A method and apparatus for making a fiber, especially a fiber adapted for use in a sectioned array, are provided according to the invention. The method includes a step of supplying a composition into a mold or tubing wherein the composition solidifies in the mold or tubing. The method further includes a step of allowing the composition to solidify and form the fiber. The method further includes a step of placing a predetermined elongation force onto an end of the fiber, the predetermined elongation force causing an elongation and reduction in cross-section of the fiber and causing a separation of the fiber from an interior surface of the mold or tubing. The method further includes a step of substantially maintaining the predetermined elongation force to propagate the separation through the mold or tubing until the fiber is completely separated from the interior surface of the mold or tubing.

Abstract: Robust homofilament fibers are meltspun from a differently shaped dual capillary spinneret design to induce differential fiber morphology to produce crimping. Crimping may further be aided by quenching and drawing of the fibers.

Abstract: Nonwoven laminates are made by a multi-station line comprising at least one spunbond die assembly and at least one meltblowing die assembly. Each station includes (a) a melt spinning die which can be selectively equipped with a spunbond die insert or a meltblowing die insert and (b) a moveable support structure for adjusting the proper die-to-collector distance, depending on the spunbond or meltblowing mode of operation. The multi-station line permits the selective manufacture of a variety of spunbond (S) and meltblown (M) laminates, including the S-M-S laminate.

Abstract: A breathable net-shape microporous membrane structure is created by forming a polymeric solution and electrostatically spinning polymeric fibers from the solution into a microporous membrane structure. The average fiber size ranges from about 0.1 microns to about 1 micron and the average pore size ranges from about 0.4 to about 3.0 microns.

Abstract: An elastomer film laminated cushion includes an elastomer having the physical properties of flexibility and compressibilities in the range of flexibilities and compressibilities of stable elastomer block polymer gels. A film is provided for encapsulating the elastomer with the film having physical properties of flexibility to enable uninhibited flexure compression of the elastomer by a user. A compatibilizing layer is provided for laminating the film to an exterior of the elastomer. The compatibilizing layer also has physical properties of flexibility to enable uninhibited flexure and compression of the elastomer by the user.

Abstract: A method of making a non-woven fibrous media, combining high vapor permeability and low liquid permeability, includes the steps of providing a non-woven fabric formed from fibers that are prematurely crystallized during fabric formation and have a wide heat of fusion range distribution, and calendering the fabric to soften the small polymer crystals therein of low heats of fusion, but not the relatively larger polymer crystals therein of relatively higher heats of fusion, thereby to retain high vapor permeability while providing low liquid permeability. The polymer is preferably isotactic polypropylene.

Abstract: Method and apparatus for producing multi-segmented filaments are provided. In one embodiment a first polymer material is passed into a die, the first polymer material and the die being maintained under predetermined rheological conditions. Next, the first polymer material is extruded through a plurality of die openings in the die, the die openings arranged in a group, the group configured to form at least two elementary filaments. Then, the two elementary filaments are connected to one another by adhesion contact to form a multi-segmented filament. In another embodiment a die for producing multi-segmented filaments is provided. This die comprises a polymer source maintaining a polymer under predetermined rheological conditions.

Abstract: An apparatus for providing a uniform web of filaments comprises tube filament transport means exiting through a confined zone of reduced turbulence, which preferably comprises a delivery slot. The delivery slot is configured with sidewalls substantially parallel to one another and to the transport tubes, so that filaments undergo minimal machine direction deflection in the slot. Charging means within the slot charge the filaments for further cross direction separation. A method of providing a uniform web of filaments comprises transporting filaments through transport tubes, through a tapered transition member, and into a delivery slot. The delivery slot is defined by sidewalls that are substantially parallel to one another and to the transport tubes, so that minimal machine direction deflection of the filaments occurs. The filaments are also charged by electrostatic charging means while they are in the slot for further separation.

Abstract: Nonwoven laminates are made by a multi-station line comprising at least one spunbond die assembly and at least one meltblowing die assembly. Each station includes (a) a melt spinning die which can be selectively equipped with a spunbond die insert or a meltblowing die insert and (b) a moveable support structure for adjusting the proper die-to-collector distance, depending on the spunbond or meltblowing mode of operation. The multi-station line permits the selective manufacture of a variety of spunbond (S) and meltblown (M) laminates, including the S-M-S laminate.

Abstract: A nonwoven fabric from spun fibers wherein the density of the spun fibers in the fabric varies between strips of relatively high density and strips of relatively low density. The strips extend along the length of the fabric in the machine direction in an alternating pattern, with the high density strips separated from each other by low density strips. The alternating high density and low density strips provide the fabric with a higher percent elongation in the cross direction than in the machine direction. The alternating pattern is achieved through use of a pattern screen defining a plurality of elongated air permeable regions separated by elongated substantially or relatively air impermeable regions, the elongated regions extending in the machine direction in an alternating pattern, with the air permeable regions separated from each other by the substantially or relatively air impermeable regions.

Abstract: A composite nonwoven fabric is provided for use as a one-piece topsheet and barrier fabric for disposable absorbent articles including diapers, catamenial products, and adult incontinence products. The fabric is engineered to have a strikethrough region that is normally surfactant treated for receiving insults and transporting them to an absorbent core material for storage. The strikethrough region is bounded by liquid barrier regions that are suitable for defining containment structures, including diaper leg cuff. The barrier and strikethrough regions can be designed to have excellent low rewet characteristics and to have balanced properties comparable to or better than conventional spunbonded topsheet at comparable or lower basis weights.

Abstract: An elastic laminate suitable for use with a nonwoven garment has an elastic film with elastic strands placed thereon. The laminate is particularly suitable for combining with facing materials when making “targeted elastic materials” for placement into the structure of the nonwoven garment. A disposable garment may then utilize the elastic laminate, or the targeted elastic material made therefrom, to include an area of elasticized gathering under tension to better conform to the body of the wearer.

Abstract: A targeted elastic laminate material having different zones of tension across a width of a material roll and methods for making the same. At least two polymers or polymer blends having different set properties are used to produce varying tension zones across the material. The targeted elastic laminate material has elastic properties that provide improved fit characteristics to disposable personal care products, while maintaining a flat roll profile that allows the material to be easily processed at a high speed.

Abstract: A spunbond web formation apparatus includes a spinneret (1) of a spin pack (2) that extrudes an array of fibers (5) that are drawn into an aspirator (6). The attenuated fibers (8) discharged from aspirator (6) are deflected sideways by a Coanda device (7) that entrains the exiting air stream along with the fibers. The fibers are deposited on a vertically moving belt (9) and subsequently bonded by calender rolls (20, 21) to form a non-woven spunbond web. The spinning distance L is adjusted by vertically moving the aspirator (6), while the laydown distance M is adjusted by horizontally moving the belt (9) or aspirator (6) or by adjusting the size of the Coanda device (7). Deflection of the fibers exiting the aspirator permits the spinning distance L to be adjusted independently of the laydown distance M, without having to move the spin beam or adjust the height of the web-forming belt.

Abstract: A main storage apparatus is a synchronous dynamic memory having a plurality of memory banks and a mode register for determining an operation mode, a main storage controller is coupled to a processor and the main storage apparatus, and means to realize controlling of parallel access to a plurality of banks of the memory and controlling of setting of an operation mode to the built-in register is arranged in the main storage controller. Accordingly, the use of a conventional processor of high generality and a conventional memory can be ensured.

Abstract: A nonwoven fabric from spun fibers wherein the density of the spun fibers in the fabric varies between strips of relatively high density and strips of relatively low density. The strips extend along the length of the fabric in the machine direction in an alternating pattern, with the high density strips separated from each other by low density strips. The alternating high density and low density strips provide the fabric with a higher percent elongation in the cross direction than in the machine direction. The alternating pattern is achieved through use of a pattern screen defining a plurality of elongated air permeable regions separated by elongated substantially or relatively air impermeable regions, the elongated regions extending in the machine direction in an alternating pattern, with the air permeable regions separated from each other by the substantially or relatively air impermeable regions.

Abstract: A method of forming a meltblown web having meltblown fibers and particles is provided. The particles are heated to a temperature approximating that of the meltblown fibers as they are being extruded. As a portion of any heated particle impacts the skin of one or more solidifying meltblown fibers, that portion of any heated particle penetrates into one or more solidifying particles. Although a portion of any particle becomes embedded in and retained by one or more meltblown fibers, such surface penetration is generally slight desirably leaving a substantial amount of surface area of any particle available for interaction with any medium to which a web may be exposed.

Abstract: A nonwoven fabric from spun fibers wherein the density of the spun fibers in the fabric varies between strips of relatively high density and strips of relatively low density. The strips extend along the length of the fabric in the machine direction in an alternating pattern, with the high density strips separated from each other by low density strips. The alternating high density and low density strips provide the fabric with a higher percent elongation in the cross direction than in the machine direction. The alternating pattern is achieved through use of a pattern screen defining a plurality of elongated air permeable regions separated by elongated substantially or relatively air impermeable regions, the elongated regions extending in the machine direction in an alternating pattern, with the air permeable regions separated from each other by the substantially or relatively air impermeable regions.

Abstract: The present invention provides a process whereby high quality, well-coalesced spandex can be made by dry-spinning a high-melting thermoplastic polyurethane, bundling the as-spun filaments into a side-by-side relationship, and passing the bundled filaments over or through a guide. The spandex made by this method has high-heat settability, high denier uniformity, good knittability and weavability, and provides fabrics having good surface uniformity.

Abstract: Bulked and liquid-permeable fleeces are used in the hygienic products industry for diapers and bandages. These fleeces have the purpose of rapidly absorbing fluid secreted from the body, storing it, and slowly giving it up to the absorber located beneath, uniformly over the entire surface of the absorber. As a result of the idea according to the invention, a fleece is formed from shrunk and/or crimped fibers together with non-shrinking man-made fibers, and the fleece is then compacted by a hydrodynamic compacting method without using binders, after which the fleece is dried and the shrinking ability present in the shrinking fibers and/or the crimping ability present in the crimping fibers in latent form are triggered immediately and/or subsequently by the action of temperature. This fleece can be manufactured economically and meets all of the requirements imposed upon it.

Abstract: An improved system for forming a three-dimensional object by filament deposition of forming materials includes a crucible for holding a reservoir of the filament forming material, an orifice disposed in the bottom of the crucible through which the forming material passes to form a flow of material filaments, and a flow control apparatus for controlling and selectively depositing the flow of material filaments on the substrate exclusively where required to form the three-dimensional object. In a preferred embodiment, the forming material is ejected from the crucible as a variable-diameter circular liquid jet, which cools to form variable-diameter filaments of semi-molten forming materials.

Abstract: The present invention provides a method for producing multifilament elastomeric yarn of modified cross-sectional shape and surface by hot-pressing a coalesced elastomeric multifilament yarn between rolls, thereby modifying the cross-sectional shape and/or surface of the multifilament.

Abstract: A cylindrical filter which is easily produced and has a high withstand strength, a high filtration accuracy and a long filtration life; a microfine fiber web and a non-woven fabric suitable to a production of such a cylindrical filter; and processes for producing such web, non-woven fabric and cylindrical filter, are provided, the web consisting of microfine mixed fibers spun according to melt-blown process, the mixed fibers consisting of high melting point microfine fibers and low melting point microfine fibers having a melting temperature difference of 10° c. or more, the low melting point microfine fibers being contained in a quantity of 10 to 90% by weight in the mixed fibers; the non-woven fabric being obtained by heat-treating the web; and the cylindrical filter being obtained by winding up the web or the nonwoven fabric, followed by heat-treatment.

Abstract: A method for making loop material for hook and loop fasteners comprising the steps of forming a nonwoven web of randomly deposited nonelastomeric thermoplastic fibers, wherein the nonwoven web has a front side and a back side. Wherein the web is the consolidated by stretching the web in an x direction and then stretching the nonwoven web in a y direction thereby creating looped fibers, a majority of which are in an “x-y” plane. And wherein fluid is passed through the nonwoven web in a “z” direction and then stabilized in the “z” direction.

Abstract: The present invention provides a process whereby high quality, well-coalesced spandex can be made by dry-spinning a high-melting thermoplastic polyurethane, bundling the as-spun filaments into a side-by-side relationship, and passing the bundled filaments over or through a guide. The spandex made by this method has high heat-settability, high denier uniformity, good knittability and weavability, and provides fabrics having good surface uniformity.

Abstract: The disclosure relates to a melt-blown non-woven fabric based on cellulose esters, with fibers of mean diameter less than about 10 microns. The fabric contains 0-10 wt. % extractable softener, has a reflection factor determined according to DIN 53 145 Part I (1992) of more than 60% and the cellulose ester has a degree of substitution DS of about 1.5-3.0. The softener is preferably water-extractable. A melt-blown non-woven fabric is produced with the cellulose ester as follows: a cellulose ester, cellulose acetate, with a DS of about 1.5-3.0, in particular 1.7-2.7, is mixed with softener in a weight ratio of about 2:1 to 1:4 and simultaneously heated and melted. The mixture of softener and cellulose ester has a melting index MFI (210/2.16) according to DIN 53 735 of about 400 to 5 g/10 min., in particular 300 to 50 g/10 min. The melt is worked in a melt-blown spinning device into a melt-blown non-woven fabric and the softener is then extracted with a softener solvent to leave a proportion of 0-10 wt. %.

Abstract: A method of producing a mineral fibre element comprising a mineral fibre base layer having a surface coating in the form of a fibrous netting formed of a thermoplastic polymer material wherein such a surface coating is provided on at least a part of the surface of the base layer, wherein the surface coating is formed directly on the surface of the base layer and wherein the surface coating is formed by heating a thermoplastic polymer material so as to melt it and distributing the polymer melt obtained in the form of fibres and/or filaments on the surface of the base layer and cooling it to form a solid layer.