Abstract: Methods for forming a touch fastening material are described as including: providing a lengthwise-incoherent layer of staple fibers supported directly on a bed of bristle tips of a brush; needling the layer of staple fibers by cycling needles through the layer of staple fibers and into the brush; then, while the needled layer of staple fibers remains supported on the brush, fusing portions of the staple fibers by at least partially melting resin of the fibers disposed outside the brush; and then pulling the layer of fibers from the brush as a lengthwise-coherent touch fastening material having exposed fastening loops pulled from between the brush bristles.

Abstract: Methods for forming a touch fastening material are described as including: providing a lengthwise-incoherent layer of staple fibers supported directly on a bed of bristle tips of a brush; needling the layer of staple fibers by cycling needles through the layer of staple fibers and into the brush; then, while the needled layer of staple fibers remains supported on the brush, fusing portions of the staple fibers by at least partially melting resin of the fibers disposed outside the brush; and then pulling the layer of fibers from the brush as a lengthwise-coherent touch fastening material having exposed fastening loops pulled from between the brush bristles.

Abstract: A mat member includes inorganic fibers, a first surface and a second surface opposite to the first surface. The first surface has a plurality of needle penetration marks and/or a plurality of needle protrusion marks. The second surface has a plurality of needle protrusion marks and/or a plurality of needle penetration marks. A plurality of needle marks are formed in the mat member by needle punching and extend from the needle penetration mark to the needle protrusion mark. An inorganic fiber bundle which includes a plurality of the inorganic fibers oriented in a closed loop configuration is formed at the needle protrusion mark.

Abstract: Apparatuses are disclosed that include forming selected perforation designs and patterns. The perforation designs and patterns can be formed in linear or nonlinear fashion, can extend in the cross direction or the machine direction and can be formed to complement or match an embossed or printed design on the web. The perforation designs and patterns can be formed utilizing various mechanical perforating techniques.

Abstract: The invention relates to an apparatus for producing textiles, nonwoven substances, spun-bonded fabrics or paper materials (5) with the aid of at least one screen drum (1) having openings (4) for transporting away the fluid (6) which is output from a water bar (7) and having numerous outwardly directed elevations (3) which are situated on the outside of the screen drum (1) for the perforation of the nonwoven (5). The invention is based on the object of providing an apparatus which makes it possible, during the water conversion and at the same time as the perforation, also to make patterns in the nonwoven without influencing the strengthening substantially in the process. The object has been achieved in that one or a plurality of regions (8) on the outer side of the screen drum (1) does/do not have any elevations (3) but only openings (4).

Abstract: The invention provides a functional laminate composite fabric which is robust, laundry-durable and adaptable for securing about any three dimensional body, and a method for forming such fabric. The functional laminate fabric is provided with at least one functional element which can conduct electricity, conduct light, provide electromagnetic fields or provide shielding from electromagnetic fields. The functional laminate may include vias through which the functional element may be exposed. Generally, the functional laminate fabric is sufficiently robust for incorporation into garments and for applications in so-called wearable electronics.

Abstract: A method of joining two ends of a fabric for use in a paper machine, carried out using a joining assembly, includes the steps of: placing a first end of the fabric on a first portion of a pin plate, the pins in the first portion of the pin plate extending into the first end; placing a second end of the fabric on a second portion of the pin plate such that the first end and the second end are in close proximity to each other in a join area, the pins in the second portion of the pin plate extending into the second end; and joining the first end and the second end in the join area. The method results in a perforated (and therefore permeable) join area.

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 present invention relates to perforation device for the manufacture of a perforated nonwoven material, whereby a prebonded nonwoven with embossing points is guided to a nonwoven perforation device, needles of a needle roller engage into the prebonded nonwoven and perforate it, and the perforated nonwoven material then undergoes further processing. A ratio is set between the number of needles to the number of embossed points of between 0.15 and 0.25 and a ratio of hole size to embossed point size of between 0.15 and 0.25.

Abstract: A method of preparing a reinforcing structure for use in manufacture a pultruded part where the reinforcing structure is pulled through a pultrusion die in a continuous longitudinal pull direction. The method includes arranging a plurality of first reinforcing fibers in a transverse direction and attaching a permeable transport web of staple fibers to the first reinforcing fibers such that the portion of the first reinforcing fibers oriented in the direction transverse comprises at least 30% of a volume of materials comprising the reinforcing structure.

Abstract: The present invention is directed to a method of forming a nonwoven fabric, which exhibits a plurality of three-dimensional images whereby the fabric is comprised of at least a first and second three-dimensional image that are dissimilar from one another. The three-dimensional images may be imparted into the fabric in a co-planar arrangement, multi-planar arrangement, or by utilizing both arrangements within the same fabric. Further, the present invention contemplates a fabric comprised of a plurality of three-dimensional images which can provide the fabric with various physical and/or aesthetic performances.

Abstract: A method of preparing a reinforcing structure for use in manufacture a pultruded part where the reinforcing structure is pulled through a pultrusion die in a continuous longitudinal pull direction. The method includes arranging a plurality of first reinforcing fibers in a transverse direction and attaching a permeable transport web of staple fibers to the first reinforcing fibers such that the portion of the first reinforcing fibers oriented in the direction transverse comprises at least 40% of a volume of materials comprising the reinforcing structure.

Abstract: A method of making a pultruded part having a uniform cross-section using a novel reinforcing mat. The method comprises orienting a plurality of longitudinal rovings along a longitudinal axis of a pultrusion die; providing a reinforcing structure comprising a permeable transport web of staple fibers attached to a plurality of first reinforcing fibers oriented so that the portion of the first reinforcing fibers oriented in a direction transverse to the longitudinal axis comprises at least 40% of a volume of materials comprising the reinforcing structure; shaping the reinforcing structure to generally conform with a profile of the pultrusion die; combining a resin matrix with the longitudinal rovings and the reinforcing structure in the pultrusion die so that the longitudinal rovings and the reinforcing structure are substantially surrounded by the resin matrix; at least partially curing the resin matrix in the pultrusion die; and pulling the pultruded part from the pultrusion die.

Abstract: The inner circumferential surface of a suction pipe must be periodically cleaned as well as the inner region of the suction slit and especially the webs between the suction holes of the suction pipe. The aim of the invention is to facilitate said cleaning process. To this end, a standard cleaning spray gun is provided with a long cleaning lance comprising a rotor nozzle on the end thereof. In order to clean the suction pipe, said lance can be passed through a hole on the front side of the fixed suction pipe. The dirt released and the remaining suction water can thus be evacuated on the other front side in a problem-free manner.

Abstract: The invention relates to a method for producing a structured, voluminous non-woven web or velourised film from a thermoplastic by producing an unstructured web and subsequently processing this web using a pair of rollers (10a, 10b). The pair of rollers consists of a positive roller (10a) having numerous positive bodies distributed over the roll sleeve surface and a negative roller (10b) having equally as numerous cavities. During the rolling process, the positive bodies engage with the cavities and stretch the unstructured web in the area of the roller engagements in such a way that a deep-drawn web structure with numerous cavities is produced. After the web has passed through a roller gap, the deformed web, still bonded to the positive roller, is brought into contact with a perforating tool and perforated.

Abstract: The present invention is directed to a method of forming a 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 precursor web comprising at least one support layer or scrim, which when subjected to hydroentanglement on a moveable imaging surface of a three-dimensional image transfer device, an enhanced product is achieved. By formation in this fashion, hydroentanglement of the precursor web results in a more pronounced three-dimensional image; an image that is durable to abrasion and distortion due to elongation.

Abstract: The present invention relates generally to a method of making nonwoven fabrics, wherein the fabrics are formed from splittable filaments or staple length fibers having a plurality of sub-components which are at least partially separable. The filaments or fibers are at least partially separated into their sub-components attendant to hydroentanglement, which can be effected on a three-dimensional image transfer device. Improved physical properties, including improved tensile strength, elongation, and Taber Abrasion resistance are achieved.

Abstract: The present invention is directed to a method of forming a nonwoven fabric, 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 sequentially formed 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 fabric presenting aesthetic and tactile qualities representative of both imparted images.

Abstract: The present invention is directed to a method of forming a nonwoven fabric, which exhibits a pronounced durable three-dimensional image, permitting use of the fabric in floor underlayment of laminate floor systems so as to reduce acoustic feedback under normal use (walking) due to sound absorption and leveling of the floating laminate floor system applications. In particular, the present invention contemplates that a fabric is formed from a precursor web comprising at least one support layer or scrim, whereby when subjected to hydroentanglement on a moveable imaging surface of a three-dimensional image transfer device, an enhanced product is achieved. By formation in this fashion, hydroentanglement of the precursor web results in a more pronounced three-dimensional image, an image that is durable to abrasion and distortion.

Abstract: A composite nonwoven fabric is formed by providing a synthetic fiber web comprising staple length polymeric fibers, and a cellulosic fiber web, preferably comprising wood pulp fibers. Prior to integration of the webs, the synthetic fiber web is subjected to hydroentangling to form a partially entangled web, with the cellulosic fiber web thereafter juxtaposed with the partially entangled web for hydroentanglement and integration of the webs. Pre-entanglement of the synthetic fiber web desirably acts to minimize the energy input required for integration of the cellulosic fiber and synthetic fiber webs, and also desirably acts to abate loss of the cellulosic fibers during hydroentanglement and integration of the webs.

Abstract: A non-woven fabric having improved absorbent characteristics. The fabric has three different fiber arrays which are interconnected to produce a unique fiber distribution in the fabric.

Abstract: Method and device for producing perforated nonwovens by hydrodynamic needling. A nonwoven with a basically clean hole structure on a drum with plastic elevations can be produced by energy-rich water jets. Depending on the thickness of the fibers used in the nonwoven, however, certain fibers can nevertheless be stretched transversely across a hole. In order to avoid or eliminate this, the perforated nonwoven is subjected to singeing flames after drying.

Abstract: Method and device for producing perforated nonwovens by hydrodynamic needling. A nonwoven with a basically clean hole structure on a drum with plastic elevations can be produced by energy-rich water jets. Depending on the thickness of the fibers used in the nonwoven, however, certain fibers can nevertheless be stretched transversely across a hole. In order to avoid or eliminate this, the perforated nonwoven is subjected to singeing flames after drying.

Abstract: A method of producing a non-woven fabric having a high recovery after elongation and a substantially uniform surface including the steps of microcrepeing the fabric between about 20% and 35%, and heat setting the fabric to a temperature between its glass transition temperature and its melting temperature. A non-woven fabric having a recovery of at least 40% after five cycles of 35% elongation is made from a microcreped fabric of basis weight from 1-3.5 osy. The non-woven fabric has a uniform surface that is substantially free of bunching, gathering, and that is otherwise substantially flat to the eye and touch.

Abstract: A method of forming durable nonwoven fabrics by hydroentanglement includes providing a precursor web comprising a fibrous matrix of staple length fibers and/or substantially continuous filaments. The precursor web is subjected to hydroentanglement on a three-dimensional image transfer device to create a patterned and imaged fabric. Enhanced imaging is achieved by advancing the precursor web onto the movable imaging surface of the image transfer device at a rate substantially equal to the rate at which the image surface moves relative to one or more associated hydroentangling manifolds. Treatment with a polymeric binder composition enhances the integrity of the fabric, permitting it to exhibit desired physical characteristics, including strength, durability, softness, and drapeability. Mechanical compaction of the imaged and patterned fabric, such as by sanforizing, enhances the desired physical properties.

Abstract: A method and device produce nonwovens by hydrodynamic needling. A nonwoven with a basically clean hole structure on a drum with plastic elevations can be produced by energy-rich water jets. Depending on the thickness of the fibers used in the nonwoven, however, certain fibers can nevertheless be stretched transversely across a hole. In order to avoid or eliminate this, the perforated nonwoven is subjected to singeing flames after drying.

Abstract: A device is known for producing perforated nonwovens by means of hydrodynamic needling, with the perforation consisting primarily of sharply delimited holes in nonwoven of any dimension. The device consists of a smooth drum that supports and transports the nonwoven, said drum being provided with drainage openings to carry away liquid sprayed at high pressure by a nozzle beam from many outlets and having plastic elevations projecting from the plane of the smooth surface for producing the perforations in the nonwoven. The perforated nonwoven that can be produced by this device does not possess uniform strength in all directions. This uniform strength can be achieved simply by distributing the elevations nonuniformly over the drum to produce holes in both dimensions.

Abstract: A method of forming apertured webs is provided comprising the steps of: (a) forming a foraminous member comprising gross foramina and fine foramina wherein the gross foramina define a patterned design superimposed on the fine foramina by means of applying and curing a photosensitive resin onto a foraminous element comprising fine foramina in order to form elevated portions on the fine foramina defining the gross foramina, (b) providing a layer of fibers on said foraminous member; and (c) applying fluid streams to said layer of fibers such that the fibers are randomly entangled in regions interconnected by fibers extending between adjacent entangled regions in a pattern determined by the pattern of the gross foramina of the foraminous member to form an apertured web.

Abstract: An absorbent material and method for making same comprising a fiber web, including a fiber blend comprising from about 50 to about 75 weight percent of a fiber having fineness less than about 3 denier and from about 25 to about 50 weight percent of a fiber having fineness ranging from about 3 to about 5 denier wherein the fiber web is bound together by fiber bundles transverse to the plane of the web. The fiber blend may further comprise from about 3 to about 7 percent by weight of a fiber having fineness greater than about 5 denier. The fibers comprising the fiber blend may be entirely hydrophobic, or the about 3 to about 5 denier fiber may be hydrophilic. The absorbent material exhibits a high degree of absorption and fluid retention and does not wet back even under compression. The transverse fiber bundles formed during the mechanical bonding of the web function as wicks for transferring fluid from the surface of the material to the inner portion of the material.

Abstract: A topographical support member and method of forming a topographical support member for use in producing nonwoven fabrics, especially tricot-like nonwoven fabrics. The topographical support member includes a body having a top surface comprising a pattern of a plurality of peaks and valleys and a plurality of apertures. The apertures have a conical top portion that is surrounded by a cluster of the peaks and valleys. The center line to center line spacing of adjacent apertures is less than the major diameter of the conical top portion of the apertures. The topographical support member is formed by focusing a laser beam so that the focal point is below the top surface of a starting workpiece and drilling with the laser beam the predetermined pattern of tapered apertures. The pattern of tapered apertures forms the cluster of peaks and valleys surrounding each aperture on the top surface of the resulting support member.

Abstract: A topographical support member and a method of forming a topographical support member for use in producing nonwoven fabrics with raised portions, especially intaglio and slub type portions. The topographical support member comprises a body having a top surface including a first micro-sized topographical pattern and a pattern of apertures extending through the body. At least one macro-sized region recessed below the top surface is provided. The micro-sized pattern produces a background portion of the fabric and the macro-sized recessed regions produce the raised portions of the fabric. Multiple levels may be provided in the macro-sized region to produce multiple level raised portions.

Abstract: A technique and apparatus for providing reciprocating hydroenhancement includes a pair of fabric spools with a hydroenhancement process disposed therebetween. The hydroenhancement process is configured to impart a minimal amount of hydroenhancement to the fabric passing therethrough and may comprise only a single vacuum roll and associated single hydroenhancement jet (other arrangements may use two or three of vacuum rolls and jets in order to provide controllable "front side" and "back side" treatments on a per pass basis). The fabric to be treated is loaded onto a first spool, passes through the hydroenhancement process and is thereafter taken up on the second spool. Once the entire length of fabric has been treated and loaded onto the second spool the process is reversed; the fabric is unwound from the second spool, treated a second time and re-loaded onto the first spool. The process is reversed once again, and a second "forward" treatment is imparted to the fabric. This "back and forth" (i.e.

Abstract: A topographical support member and a method of forming a topographical support member for use in producing nonwoven fabrics with raised portions, especially intaglio and slub type portions. The topographical support member comprises a body having a top surface including a first micro-sized topographical pattern and a pattern of apertures extending through the body. At least one macro-sized region recessed below the top surface is provided. The micro-sized pattern produces a background portion of the fabric and the macro-sized recessed regions produce the raised portions of the fabric. Multiple levels may be provided in the macro-sized region to produce multiple level raised portions.

Abstract: A nonwoven fabric of entangled fibers defining a predetermined pattern of openings with the fabric having excellent draping characteristics.

Abstract: An air bag of the type utilized in a vehicle occupant restraint system is constructed of a plurality of panels of uncoated fabric. Respective of the panels have been processed to achieve a selected air permeability with greater accuracy on a lot-to-lot basis than had generally been achieved with uncoated fabrics of the prior art. In one presently preferred methodology, a plurality of fluid jets, preferably water jets, are utilized to impact panels of the uncoated fabric under selected operating conditions. Pores created by the fluid jets may be heat set to achieve a selected permeability. Fluid jet processing may also be utilized to produce a fabric having a selected thread count.

Abstract: This invention relates to a spun-laced fabric having improved water absorbency containing a blend of certain hydrophilic cellulosic and pack resistant fibers with a hydrophobic fiber material layer attached to one side of the blend. The fabric may be used as an absorbent layer in a multilayer or laminated structure.

Abstract: An entangled fibre nonwoven fabric containing irregular sized apertures in a random irregular nonrepeating pattern in disclosed. In the method of the invention, a fibrous web is caused to be displaced out of registry with the forming member between fluid impacts by columnar jets of water.

Abstract: A light weight entangled nonwoven fabric formed by fluid rearrangement/entangling of an oriented web of fibers comprising at least 75% polyolefin staple fibers and displaying excellent machine direction and cross direction strength.

Abstract: A loosely constructed knit or woven fabric is dimensionally stabilized by causing staple length textile fibers to be entangled about the intersections of the yarns comprising the fabric. The stabilized fabric is formed by covering one or both sides of the loosely constructed base fabric with a light web of the staple length fibers, and subjecting the composite material to hydraulic entanglement while supported on a porous forming belt configured to direct and concentrate the staple length fibers at the intersections of the yarns comprising the base fabric.

Abstract: A light weight entangled nonwoven fabric formed by fluid rearrangement/entangling of an oriented web of fibers comprising at least 75% polyester staple fibers, and displaying excellent machine direction and cross direction strength.

Abstract: Ribbed terry cloth-like nonwoven fabric produced by fluid entangling of fibers on a special forming belt.

Abstract: Apertured nonwoven fabrics prepared by hydraulic entanglement of polyethylene terephthalate staple fibers of ribbon cross-section have unusually high resistance to disentanglement when the aspect ratio of the fiber cross-section (i.e., ratio of major to minor axis) is in the range of 1.8 to 3.0.

Abstract: Feminine Hygienic Pads with improved absorption properties for use in the interlabial space in the area of the female urethral meatus and vaginal meatus for absorbing urine and other undesirable exudations comprising an elongated fibrous pad base of cylindrical, elliptical, polygonal or similar regular shape, the surface of the pad base being formed with multiple flutings, a multiplicity of absorptive cells or pin-cushioning or being formed wholly or in part of shaggy material to increase the absorptive surface area of the pad.

Abstract: A soft, non-woven fabric containing no binding agents and composed, at least in part, of thermoplastic fibers bonded to other fibers at their crossing points, which non-woven fabric is produced by a process which comprises passing a mat composed of said thermoplastic fibers over a surface and to said mat applying an uneven heated surface, said heated surface being sufficient to fuse, at least in part, a portion of said thermoplastic fibers to other fibers at some but not all of their crossing points, while at the same time the fusing is effected without any substantial compression of the fabric.

Abstract: Fibrous webs are bonded by passing through a nip comprising an anvil and a hammer vibrating at high frequencies in the presence of uncombined liquid. The liquid is moved within the web causing rearrangement and entanglement of the fibers resulting in improved web properties such as strength, drape, and softness. The nature of the rearrangement and entanglement may be varied to produce random or highly entangled webs having correspondingly varying properties. Other embodiments include the use of additional fibers or other materials in the liquid or in the web and the bonding of multiple layers.

Abstract: A seam of two ends of a rigid screen of interwoven longitudinal and transverse wires is made by butting and fusing together longitudinal wire ends at each end of the screen at the crossovers of the longitudinal wire ends with an adjacent pair of transverse wires forming the seam in one surface of the screen, whereby the seam is not visible from the opposite surface of the screen.

Abstract: A net which comprises an expanded area-bonded non-woven fabric, and method of preparation. The net has a mesh perimeter in the range 1/8 to 12 inches, tear strength of from 5 to 20 lb. per inch per lb. per square yard of net. The process comprises forming numerous, discontinuous parallel and overlapping slits, having lengths from 1/16 to 6 inches in area-bonded non-woven fabric, and then stretching the slit fabric in a direction transverse to the slits to form a net, and preferably heat treating the net.

Abstract: A topographical support member and a method of forming a topographical support member for use in producing nonwoven fabrics with raised portions, especially intaglio and slub type portions. The topographical support member comprises a body having a top surface including a first micro-sized topographical pattern and a pattern of apertures extending through the body. At least one macro-sized region recessed below the top surface is provided. The micro-sized pattern produces a background portion of the fabric and the macro-sized recessed regions produce the raised portions of the fabric. Multiple levels may be provided in the macro-sized region to produce multiple level raised portions.