Abstract: The invention relates to the field of needling processes for forming fibrous preform structures. The invention is particularly useful in forming fibrous preform structures suitable for subsequent processing into high temperature resistant composite structures such as carbon/carbon aircraft brake disks. The process according to the invention compensates for fiber pull back induced by fiber resilience, and for compaction in previously needled layers induced during subsequent needling passes. According to a further aspect of the invention, Z-fiber distribution throughout the thickness of the fibrous preform structure may be manipulated as necessary to achieve a desired distribution.

Abstract: The described apparatus for needling a nonwoven web comprises at least one needle beam carrying a needle board, a rocker for guiding the needle beam, and a slider-crank mechanism for actuating the needle beam. For a first-order mass balancing it is proposed that the slider-crank mechanism comprises two parallel crankshafts or eccentric shafts, which are adapted to be driven to rotate in mutually opposite senses, and associated connecting rods, which are connected by connecting rods to a link, which is pivoted to the rocker, and the arrangement is such that when the slider-crank mechanism is in a mid-position at the middle of its strike the plane of symmetry between the two crankshafts or eccentric shafts is at least approximately at right angles to a plane which contains the instantaneous overall center of gravity of the oscillating masses and the pivotal axis of the rocker.

Abstract: Method of fabricating a multi-ply carbon fibre fabric, preform or composite material from a layer of unidirectionally aligned carbon fibres of ultra-high modulus and a layer of low modulus carbon fibre comprising the steps of: arranging in superimposed relationship the layer of unidirectionally aligned carbon fibres of ultra-high modulus and the layer of low modulus carbon fibres so that at least a substantial number of the fibres of low modulus are disposed transversely of the fibres of the ultra-high modulus fibre layer, and connecting the two layers by interlacing fibres of the layer of low modulus fibres with those of the layer of ultra-high modulus fibres by needle-punching using felting needles orientated and configured so that their barbs snag only the low modulus fibres during passage through the layers.

Abstract: A tufted fabric (1) devoid of external chemical binders is formed by crosslapping a carded web of fibers (10) onto a back side (15) of a tufted primary backing (12), the opposed front side (19) of which having tufts (17) projecting therethrough, while it is transported by a conveyor (46) feeding into a first needle loom (20). Fibers in the primary backing and in the carded web of fibers are then entangled by the first needle loom and by a second needle loom (36), whereby the carded web of fibers meshes with the primary backing to form a carpet backing (58) of sufficient weight and integrity to replace a conventional carpet underpad. The carpet backing is a blend of preferably homogenous fibers wherein the primary backing and the carded web of fibers are indistinguishable from one another.

Abstract: A composite nonwoven fabric and method for making the same includes subjecting a carded web to the action of a cross lapper (B) and then drafting the cross-lapped web by passing the same through a web drafter (C) utilizing a series of wire wound rolls of progressively increased speed. A web of substantially unbonded polymeric fibers is layed from a roll (D) forming a composite web by hydroentanglement utilizing a series of spun bonding steps resulting in a composite web of substantial strength comparison in the machine direction and in cross direction and possessing the characteristics of fabric suitable for use in hospital applications such as surgical gowns.

Abstract: A brush structure for use as a stitch support for a velour needle loom comprises bristle tufts inserted into a carrier plate, with their free ends forming a continuous support surface for supporting thereon a fiber batt to be needled. The foot portions of the bristle tufts are of polygonal cross-section, resulting in a high packing density of the bristle tufts on the carrier plate and optimum bristle-coverage thereof. This enables excellent continuity of the support surface formed by the free bristle ends to be achieved without the bristles having to be provided with a curl or crimp.

Abstract: Tufted carpets which are conformable and stretchable make use of a stretchable carpet backing formed from a composite fabric. The stretchable carpet backing fabric is formed of a stretchable elastic net and at least one nonwoven fibrous layer overlying the stretchable elastic net. The fibers of the fibrous layer extend through said elastic net to mechanically secure the fibrous layer to the elastic net and form a unitary coherent elastic fabric.

Abstract: Flexible base web of a construction covering comprises a main layer extending at least over the greatest part of the thickness of the web and is constituted of a non-woven mineral fiber mat containing predominantly discontinuous mineral fibers. Said mat contains further blend fibers. The mat is manufactured using a dry method by means of an air stream whereby said blend fibers have become blended inside the mat during the dry method forming of the mat. The portion of said blend fibers is greater in the proximity of one of the surfaces of the mat than in the middle due to subsequent needling of the mat.

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: A nonwoven aramid staple fiber batt is needled into a woven aramid scrim which is overlayed with a thin mat of heat resistant microfiber to give marked improvement in hot gas filtration.

Abstract: Multiple filter bags are formed from a layered composite sheet of two, essentially identical fibrous or felt layers by needling a plurality of transverse paths each 0.75 to 1.5 inches wide on the composite sheet, the paths being spaced 4-18 inches apart so as to form a plurality of tubular shaped channels. The needled transverse paths are then slit longitudinally along a central line so as to form separate elongated tubes, which are then cross cut apart transversely to produce segments of any desired length such as 12-36 inches. These segments are each final closed at one end of each segment by needling or stitching to form multiple filter bag structures. The invention also includes the felt filter bags produced by this method of manufacture.

Abstract: Apparatus for tacking a yarn in a predetermined pattern onto a needled fleece, which lies on a support consisting of brushes and which is supported by the free ends of the brush bristles comprising a pressure plate unit which is movable parallely to the support and having a yarn channel extending basically vertically therethrough, yarn supply structure for supplying the yarn along a yarn path from a yarn supply into the yarn channel, a needle having laterally protruberant projections, which are suitable for piercing yarn fibers into the needled fleece, a needle support connected to the pressure plate unit and mounting the needle, and drive structure for moving up and down the needle support in a direction towards and from the pressure plate unit. The device is suitably combined with a needle loom, which pierces the fibers of the yarn tacked to the needled fleece by the device through the needled fleece. (FIG.

Abstract: Duplex layers of carbon fibre each comprising a lower portion of uni-directional filaments and an upper staple fibre portion are laid one on top of the other in an annular form. Needles are reciprocated through the layers to cause the staple fibre to be pushed downwardly to interconnect the layers. The base supporting the layers being assembled is gradually lowered until there comes a time when the bottom of the needle stroke no longer passes through all of the layers. At that time additional layers comprising staple fibre only are added and needled down into the stack to enrich the lower layers. After that enrichment the stack is then built up by adding further duplex layers. When all of the duplex layers have been added, further staple fibres may be added to the stop of the stack and needled in order to enrich the upper layers with interconnecting staple fibres, which upper layers would otherwise be deficient in interconnecting staple fibre.

Abstract: The present invention relates to a flexible nonwoven mat comprising physically entangled shot-free ceramic oxide fibers. The flexible nonwoven mat is useful, for example, as filter material, mounting mat, thermal insulation, and sound insulation.

Abstract: Apparatus for feeding a fiber batt to a needle loom, in which a gusset gap between an upper reversing roller of a pre-compression means and an upper supply roller is filled by an upper slim transmission roller rotatably suspended at its end portions by bracket means. The transmission roller is made from a carbon fiber reinforced resin material. The bracket means are composed each of two parts which may be released from each other. One part of each bracket means is mounted on the axis of the supply roller, whereas the other part is suspended in a stationary frame of the apparatus. By realeasing the parts of each other, an easy disassembly of the supply roller is enabled.

Abstract: A magnetic marker comprising a plurality of magnetized fibers oriented substantially parallel to each other is attached to a fringe of ground fabric for production of felt in the form of an endless belt for detecting the travel of the ground fabric and changing various production parameters according to the number of turns which the ground fabric makes around a series of rolls for causing the movement of the ground fabric. Since the magnetic marker consists of extremely thin magnetized fibers, it can withstand the repeated piercing by needles which is required for the production of felt for the purpose of entangling the fibers of fiber web with the ground fabric.

Abstract: In the process of the present invention, a plurality of synthetic or natural fibers are arranged by type and color and then lightly needle-punched to form a felted section. One or more of these sections can be cut to appropriate shapes and sizes and then lightly tacked to the base carrier. Thereafter the sections are needle-punched with said base to interlock the fibers, base and carrier.

Abstract: A method of producing a shaped fibrous fabric structure is similar to that described in the parent application, in that a continuous filament sheet is subjected to a needle punching action, segments are cut from the sheet and these segments are assembled to form an annulus, and then subjected to rotary motion under a reciprocating needling head and continuing to add segments to build up a stack of layers whilst at the same time continuing the needling action, and lowering the base of the stack relatively to the needling head. However, in a final step, one or more layers of segments are added to the top of the stack, and these are needled into the stack without lowering the stack. Furthermore, these additional layers are preferably made entirely of stapled fibers.

Abstract: Water- and/or oil-tight bentonite sealing sheets or mats are produced which after laying have a water-tight and frictional interconnection or joint in the overlapped part thereof. This is achieved by filling the pore space in the overlapped zone with bentonite and following in situ needle punching of the overlapped zone or with bitumen or synthetic resin systems, optionally filled with bentonite, and later bonding or welding of the overlapped zone. It is also possible to weld the overlapped zone together as "films" and, then to bond or weld such zones.

Abstract: Apparatus for feeding a fiber batt to a needle loom, in which a gusset gap is filled between the reversing roller of an upper pre-compression conveyor band and an upper supply roller by means of a slim transmission roller, which is suspended at its length at several locations, in order to avoid sagging. The suspensions can consist of ribbons, which carry the transmission roller, or they can be formed by holding fingers which are integrally formed with guide fingers of a finger roller and which are located in respective circumferential grooves in the transmission roller. In an alternative the transmission roller is divided into several segments and roller bearings are provided at the connection positions of the segments and are suspended from above (FIG. 1).

Abstract: To permit a change of the needle boards of an apparatus for needling nonwoven webs, a magazine is provided, which supports the needle boards in superposed slide tracks. The needling apparatus comprises an assembling track, which extends on both sides of vertically movable board carriers, which are arranged in a row and to which the needle boards are detachably secured. The assembling track serves to guide the needle boards, which are adapted to be interconnected by tension-resisting coupling means.

Abstract: There is disclosed a process for continuously producing a pitch-based carbon fiber felt which comprises the steps of spinning a pitch by melt blow spinning system; accumulating the spun fibers as a pitch fiber web composed of the aggregate of short fibers; continuously cross lapping the web; subsequently stabilizing the cross lapped web; carbonizing and/or activating the stabilized web; and then felting the resultant web. The above-mentioned process is capable of efficiently producing a pitch-based carbon fiber felt having uniform unit weight and excellent physical properties and well suited for use in high-performance thermal insulator, cushioning thermal insulator, filter media and adsorbent for water purification and solvent recovery, etc.

Abstract: A base fabric for press felts and a press felt incorporating that base fabric which includes an assembly of three or more separately woven fabric layers. Each of the woven fabric layers making up the base fabric assembly is a single or multilayer fabric, and they may be of the same or different weave patterns. The three or more fabric layers are assembled, one above the other and needled together with at least one batt layer on the papermaking surface of the felt. Preferably, the yarns on the top surface of the top fabric will, by virtue of the weave of the fabric, have long floats in the machine and/or cross machine direction to provide good paper web support. The bottom and intermediate fabric layers may also have long cross machine direction floats on their top surfaces to support the fabric or fabrics above.

Abstract: A non-woven fabric of alginate staple fibres, characterized in that the absorbency of the fabric is greater than 25.0 grams of deionised water or 19.0 grams of saline water per gram of fabric as measured with reference to the test method depicted in FIG. 1, is prepared by a modified needle-tacking process. The fabric is useful for the preparation of wound and burn dressings.

Abstract: An infusiblized, or infusiblized and slightly carbonized fiber of optically anisotropic pitch type is combined with a phenolic resin fiber to produce a high bulk density carbon fiber structure in the form of a laminate of mutually entangled carbon fiber sheets with improved handleability of fiber sheets and improved stability of a laminate structure formed through entanglement. A high flexural strength carbon-carbon composite material with a high volume fiber content is produced by impregnation with a precursor of carbon and subsequent carbonization of the carbon fiber structure of the kind as described above or a fiber laminate of mutually entangled sheets of the infusiblized, or infusiblized and slightly carbonized fiber of optically anisotropic pitch type blended with the phenolic resin fiber.

Abstract: The present invention relates to a process for manufacturing a textile product by starting with fibers and/or filaments in which these fibers and/or filaments travel in the form of a web. The technique consists in subjecting the fibers and/or filaments to a transverse looping accompanied by drawing and that the latter are accumulated in the form of loops in which the fibers and/or filaments are parallelised.

Abstract: The installation comprises support tooling having a shape that corresponds to that of the preform to be made and on which superposed layers of a two-dimensional fiber fabric can be draped; a needling head comprising a group of needles, a device for driving the needles lengthwise with reciprocating translation motion, and a bearing plate provided with perforations to pass the needles and suitable for being pressed against a layer draped over the support tooling; an arm carrying the needling head and possessing a plurality of degrees of freedom; and a control device for automatically controlling the displacement of the arm to move the needling head within the range of the arm along predetermined trajectories and with predetermined orientations.

Abstract: Fibrous substrates for the production of carbon and/or ceramic (including mixtures of these) fiber reinforced carbon and/or ceramic (including mixtures of these) composites and to methods of manufacture of same. A shaped filamentary structure comprising at least a first braided filamentary tape layer of a width generally corresponding to that of the filamentary structure to be formed, the first braided filamentary tape layer superposed upon and joined to least one other filamentary layer by needlepunching to produce cross-linking of the layers by filaments displaced out of the layers and extending in a direction generally perpendicular to the faces of the layers, and methods of making same. The structure may include a plurality of hellically wound braided tapes arranged to form a flat, hollow annulus having a plurality of interleaved braided layers. The structure may be used in the production of friction discs.

Abstract: Process for manufacturing needled spunbondeds from thermoplastic fibers wherein, prior to the needling, the as-spun web is thermally sealed at the surfaces and provided with a lubricant.

Abstract: In a portion of the preform to be made in which the preform is to be of reduced thickness by having a recess formed therein, a mask is interposed between pairs of adjacent layers, the mask being made of a thin film of material through which the needles can pass during needling while opposing the passage of significant quantities of fiber taken by the needles, and after it has been needled, each layer is cut out around a line corresponding to the outline of the recess in the preform at the level where the layer is situated in the preform. A mask situated between two cutout layers occupies an area that is not less than the area between the cutout lines of the two layers, such that the portions of the layers that are delimited by the cutout lines are not securely connected to the remainder of the preform by the needling, thereby enabling the recess to be formed after all the layers have been needled by withdrawing the cutout portions of the layers and by peeling off the masks.

Abstract: A papermaking press fabric for use with impulse drying machinery having a base fabric formed of nylon filament machine direction and cross-machine direction yarns. A fiber batt formed of polyetheretherketone (PEEK) fibers secured to at least a support surface in such a manner as to encapsulate and insulate the base fabric. The resulting press fabric is capable of operating in temperatures of up to 700.degree. F. while exhibiting superior resistance to compacting and wear.

Abstract: A mechanism for operating a needle board in a needling machine comprises two reciprocable rods which serve to operate the board and each of which, together with the associated eccentric drive, is mounted in a bearing housing. To permit an adaptation of the rod spacing to a desired board length, the two bearing housings are rigidly interconnected by at least one spacer to form a flexurally stiff structure.

Abstract: A tailorable, flame barrier, puncture-resistant composite fabric sheet material suitable for use for example as an upholstery cover over a urethane or other foam seat cushion and the method of producing the fabric sheet material. The fabric sheet material comprises a thermoplastic polymer layer, such as a vinyl layer, optionally top coated with an abrasion-resistant layer and which thermoplastic layer is bonded to a fibrous, non-woven layer which layer has been needle punched through a metal foil material to fragment and distribute the metal foil material and a knitted, woven sheet material. The method includes needle punching a synthetic fibrous sheet material through adjacent layers of a metal foil material, such as aluminum, and a woven, fibrous sheet, such as a knitted polyester material, and extruding a molten vinyl film onto the fibers of the non-woven layer and optionally topcoating the vinyl film to provide a composite sheet material having high flame and puncture resistance.

Abstract: A unidirectional textile reinforcement fabric for use in laminated articles and a method of making such fabric from conventional warp and weft fabric is shown in which the filament bundles in one of either warp or weft are substantially broken with little or no damage to the other.

Abstract: A sliver piecing device includes a pair of holding members for piling and holding ends of slivers to be pieced, and a plurality of needles extending through the holding members and being inserted into the slivers to force the fibers into the other sliver and to intertwine the fibers with each other. In a further embodiment of the piecing device, pressurized air may be used, along with the needles, to force the fibers of one sliver into the other and to intertwine the fibers with each other.

Abstract: A resilient, low modulus, semirigid shell for use as a component of an article of luggage. The shell comprises a first nonwoven batt of thermoplastic resin fibers and an exterior material attached to the first nonwoven batt. The first batt and exterior material are thermally formed to a predetermined shape. The shell may also include one or more additional component layers selected from a second nonwoven, fibrous batt, a layer of backing material, a water impermeable film, and a lining material. In manufacturing the shell, the exterior material is attached to a first portion of a substrate material which is comprised of the nonwoven batt of thermoplastic resin fibers. A second portion of the substrate material is secured to an apparatus for thermal forming and the exterior material and substrate material are thermally formed to a resilient, low modulus, semirigid shell having a predetermined configuration.

Abstract: In a method of and an apparatus for manufacturing a glass fiber mat, bundles of glass fibers shake down onto a conveyor unit arranged horizontally, to form a non-oriented fiber layer. The non-oriented fiber layer is dried by a drier. Bundles of uni-directional fibers are supplied onto the dried non-oriented fiber layer, by a bundle supply device, to laminate the uni-directional fiber layer onto the dried non-oriented fiber layer. At the laminating, the bundles of uni-directional fibers are guided in parallel relation to each other at regular intervals in a widthwise direction of the conveyor unit. The uni-directional and non-oriented fiber layers, which are laminated one upon the other, are supplied to a needler and are needled thereby, to form the glass fiber mat. The glass fiber mat is carried out by a delivery roller unit.

Abstract: To ensure that a needle board of a needling machine can be detached from the needle beam in a simple manner and without a substantial expenditure of work, the needle beam is provided with spring-biased mechanisms for clamping the needle board and actuators associated with said clamping mechanisms are provided on the machine frame or on the stripper.

Abstract: A process for bleaching domestic laundry in a household wash cycle, comprising prewashing the laundry in an alkaline bath with a pH value between 9 and 13 and at a temperature between about 40.degree. C. and 70.degree. C. in the presence of at least one peroxide bleaching agent and an uncomplexed barium, said barium being present in an amount between about 0.5.times.10.sup.-3 and 250.times.10.sup.-3 gram-atoms per kg of bath.

Abstract: A soft and strong composite sheet for an artificial leather is provided by superimposing a fabric or woven or knitted construction and a non-woven fiber web, anchoring fibers of the non-woven fiber web with the fabric by needle punching to form a composite sheet and thereafter coating or impregnating the composite sheet with a binder solution. The fabric is constructed at least partly from high twist multifilament yarn and the non-woven fiber web is constructed from fibers having an average fiber length of at least 20 mm, the number of fibers being at least 10 fibers/cm.sup.2.

Abstract: A method of producing a shaped fibrous fabric structure is similar to that described in the parent application, in that a continuous filament sheet is subjected to a needle punching action, segments are cut from the sheet and these segments are assembled to form an annulus, and then subjected to rotary motion under a reciprocating needling head and continuing to add segments to build up a stack of layers while at the same time continuing the needling action, and lowering the base of the stack relatively to the needling head. However, in a final step, one or more layers of segments are added to the top of the stack, and these are needled into the stack without lowering the stack. Furthermore, these additional layers are preferably made entirely of stapled fibers.

Abstract: By combining two measures, namely by using rock wool fibers with a particularly low fiber thickness, and by adding an avivage agent with an unusually high viscosity, it is possible to needle a rock wool felt, without adding any other fibers, to produce a needle felt with high strength and good bendability. If the needle felt is subsequently relaxed with heat treatment, and the avivage agent is also expelled during this treatment, the needle felt is then available as a pure rock wool needle felt, free of any organic additives.

Abstract: A method and corresponding product whereby hydrophobic polyolefin-containing nonwoven materials are provided with sustainable hydrophilic properties for rewet purposes by incorporation into the appropriate spin melt composition an effective amount of an alkoxylated fatty amine in optional combination with up to 60% by weight of primary fatty acid amide.

Abstract: The device carries a bundle of fibers between an upper and lower table of a tufting machine. The bundle of fibers is transferred to a tufting machine by a transfer device having a pair of roller driven conveyors. The conveyors are individual drive belts having individual adjustability over the width of the transfer device. Individual tension is provided in each longitudinal region of the width permitting suitable guiding of each belt despite the very short developed length. The transfer device provides for positively driving the fiber bundle toward the interior of the tufting passage.

Abstract: This invention relates to needling of continuous glass yarn mats.The invention consists in subjecting the mat to the action, preferably simultaneous action, of needles of different diameters. Thus perforations of different dimensions, preferably regularly distributed, are made in the mat.This mat is intended to be used as reinforcement in composite materials with a base of thermoplastic resins, in particular in laminates.

Abstract: A process for producing an interlocked fibrous structure useful as a thermal insulating and/or sound absorbing structure comprising at least one batting of non-flammable carbonaceous fibers, by the steps comprising implanting said batting with non-carbonaceous polymeric fibers and then heat treating the structure in an inert atmosphere so as to transform said non-carbonaceous fibers into substantially permanently set carbonaceous fibers.

Abstract: A process of carding several different types of fibers into webs, combining the webs by layering alternate types and needle punching the combined webs into a tightly felted sheet impregnating the sheet on both sides with a synthetic rubber latex and curing the latex in place by baking the impregnated sheet.

Abstract: There is provided an integral textile composite which fabric comprises a substrate portion having at least one organic textile fiber layer and an insulating portion. The insulating portion has at least one inorganic fiber layer which is substantially co-extensive with the organic fiber layer, and at least one insulating layer of insulating material which is substantially less than co-extensive with the inorganic fiber layer. A plurality of first needled stitches composed of organic fibers from said organic fiber layer of said substrate portion are needled in and disposed at least substantially through the insulating portion, while the inorganic fibers of the inorganic fiber layer in the insulating portion are substantially undisturbed.

Abstract: In order to ensure a desirable withdrawal of the felt in an apparatus for needling a felt from one side, the stripper plate (3) is provided on that side which faces the support (2) for the felt with guide ribs (7), which extend between the longitudinal rows of holes (4) and protrude from the underside surface of the plate and have a height amounting to 0.2 to 2 times the diameter of the holes.

Abstract: Alumina fiber structures prepared by (i) preparing precursor fibers by spinning a viscous spinning solution containing compounds of metals including aluminum and an organic polymer compound in which the proportion of alumina in the total metals in the solution is at least 65% by weight of alumina when all metals are calculated as their oxides; (ii) laying the precursor fibers into a mat; (iii) applying a lubricant which is a solution of higher fatty acid ester in a hydrocarbon solvent to the fibers either before or after forming the mat; (iv) needling the lubricated mat; and (v) burning the obtained structure to convert the precursor fibers to alumina fibers, possess high tensile strengths and high peel strengths.