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 silk felt that comprises an intermediate layer of natural hair and covering layers of silk wadding or oblong. Furthermore, a method for making this silk felt in which an intermediate layer of natural hair is felted together with two covering layers of silk wadding. The textile material according to the invention is distinguished by a high heat and moisture regulation and by low weight.

Abstract: Improved stretchable battings of differentially-shrinkable bicomponent staple fibers are obtained by cross-lapping webs, e.g. from cards, garnets or the like machines, at an angle that determines and controls the degrees of stretch in the machine direction (MD) and cross direction (XD), and then inducing helical crimp in the bicomponent fibers on account of their differential shrinkage. Such batts are especially useful in apparel.

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 reinforced V-belt and method relating to same in which the V-belt comprises bottom, middle and top portions, the bottom portion consisting of a layer of bias cushion fabric and one or more layers of a seamless "fiber-loaded" non-woven fabric which has been impregnated with first and second solvent solutions and a plurality of chopped or staple length fibers generally oriented in the cross-machine direction relative to the longitudinal axis of the non-woven fabric; the middle portion consists of rubberized cord and a layer of non-woven fabric disposed on top of the rubberized cord; the top portion consists of bias cushion fabric.

Abstract: A process is disclosed for manufacturing a high strength composite structure by needling individual webs of initially spunbonded material and then needle-punching a stack of the individual webs to enmesh and entangle filaments across the webs, with little or no loss of the initial filament-related strength.

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.

Abstract: A method and apparatus is set forth to form a flannel-like product. A non-woven web of fibers of two contrasting shades of color are needled twice to form a non-woven fabric with the coloration of woven flannel material. A calendar roll smooths the fabric to remove the appearance of the needling operations and get a non-woven flannel-like product.

Abstract: A stitchbonded fabric with excellent insulating and stretchability characteristics and good laundering durability formed from a bonded fibrous layer stitchbonded with elastic thread under tension, which is then subjected to a relaxed shrinkage treatment to increase its thickness and volume.

Abstract: A moldable fibrous composite having thermal and acoustical insulating characteristics and methods of production thereof are provided. The composite structure comprises a substrate, a middle layer and a non-woven top layer. The substrate may be in the form of a fibrous web or, alternatively, a thermoplastic film. The middle layer comprises mineral fibers of a sufficiently short length to substantially preclude interlocking of any of the mineral fibers with other fibers of the structure and to provide the structure with desired flexibility. The mineral fibers are present in a quantity sufficient to impart desired heat and sound insulating properties to the structure. The top layer may be made of organic fibers or a substantially uniform mixture of organic and inorganic fibers. In making the invention composite structure, the middle layer and the top layer are introduced onto the substrate, respectively. The three layers are thereafter consolidated, such as through needle punching.

Abstract: A nonwoven composite fibrous material adaptable as an insulation medium is formed by a loose layer of inorganic fibers, such as rock wool, glass, ceramic, carbon-graphite or the like, bonded together by at least one carrier web layer positioned on a surface of the inorganic fibrous layer. The carrier web layer is a blend of inorganic fibers and organic fibers with the organic fibers comprising about 1% or less by weight of the total nonwoven composite fibrous material. Both organic and inorganic fibers of the carrier web are advanced into interlocking relation with the fibers of the inorganic layer by needle punching the carrier web.

Abstract: A fiber entanglement is provided which is characterized in that it is a three-dimensional entanglement comprising elastic fibers (A) each being a fine-denier fiber bundle or exhibiting porous fiber structure as seen on a fiber cross section with a number of irregularly-shaped pores extending in the fiber axis direction; nonshrinkable, nonelastic fibers (B); and shrinkable, nonelastic fibers (C); said fibers (A) are at least partially bonded or fused together at various points of contact with one another and, thereby, produce a taut condition; said nonshrinkable, nonelastic fibers (B) are folded several times over by means of the elastic fibers (A) and the shrinkable, nonelastic fibers (C). This fiber entanglement is useful as a base material for leather-like sheet materials.

Abstract: A nonwoven textile fiber panel, useful, for instance, in manufacturing car truck liners, in which synthetic thermoplastic fibers that vary in fiber length, diameter, denier, and/or density are needle-punched to produce a carpeting material, which can then be directly utilized, or thermoformed to retain a desired shape. The fibers that one desires to show up on the face side of the final product are preferentially driven by the needle barbs of a needle loom through the precursor batt material. This preferential needling can also be enhanced through selection of various needle lengths, needle diameters, and barb spacing configurations.

Abstract: A sheet of parallel carbon or carbon-precursor filaments is supported by a carrier sheet of fugitive backing material and needle punched. The fugitive backing material is subsequently destroyed leaving displaced or broken portions of the filaments entangled together to provide a stable sheet for composite manufacture, particularly for reinforcement of a carbon-carbon composite.

Abstract: A non-woven fabric suitable for clothing manufacture, comprising a fiber web substantially formed of a continuous filament of a synthetic fiber, wherein a plurality of weakened portions in a form of a scratch or a crack are distributed on the filament constituting at least one surface of the fiber web. Some of the weakened portions are broken to form free ends, some of which are projected from the fabrice surface to form a short fluff, and some of the remaining ends are embedded in the interior of the fiber web and entangled with the filament. The weakened portions of the filament are provided by nipping the fiber web between a pair of rollers, at least one of which has a rough surface formed of a plurality of prominences of hard particles. A punching treatment of the fiber web after the weakened portions has been imparted is effective for breaking the filament to form short fluffs on the fabric surface and for entangling the filaments with each other.

Abstract: An oriented continuous strand mat of glass fiber filaments is formed by interleaved layers of generally circular or random loops and elongated elliptical loops having their longitudinal axes positioned in the direction of travel of an endless conveyor upon which the glass fibers are deployed to form a mat useable in a stampable glass fiber reinforced thermoplastic resin sheet having increased tensile strength in the length of the sheet. An elongated deflector plate having a planar deflecting surface whose length is aligned with the direction of conveyor travel, and whose face plane is generally perpendicular thereto receives pulled strands which have passed through an air flow nozzle and forms the strands into the elongated elliptical loops used to make the mat.

Abstract: Staple fibers made from crimped, in particular compression crimped, multicomponent filaments of the matrix/segment type, the cross section of which shows, in addition to the matrix, at least 6 peripheral wedge-shaped or lenticular segments, not completely covered by the matrix, are processed into a web, which is then mechanically bonded, preferably by needling. Subsequently, the fabric is subjected to a shrinkage process, by which its density is increased by more than 30%, themulticomponent fibers being completely or partly split up into their components. The difference in shrinkage between the components should be at least 10%. The liquids used for the shrinkage treatment are in particular organic liquids, such as methylene chloride, as well as other liquids producing a difference in shrinkage of at least 20%.

Abstract: The invention relates to a fiber wool in band or pad form, e.g., in the form of steel wool, having a plate-like or band-like support, the fiber wool being able to be joined to the support in a simple manner by forcing portions (15) of the fiber wool (14) through perforations (13) in the support (11) and pressing them flat from the opposite side of the support (11).

Abstract: Disclosed is a nonwoven sheet consisting of undrawn polyethylene terephthalate filaments of which an outer layer portion of a filament section has a higher orientation and higher crystallization than a center of the filament section, and nonwoven sheets produced by using the above-mentioned nonwoven sheet as an intermediate goods.The above-mentioned undrawn polyethylene terephthalate filament are those in which the filaments have an elongation at breakage of at least 100%, a shrinkage in boiling water of at least 15%, the filament section is a circular section having a radius R, and the average refractive index n.parallel.(0) of the central portion of the filament section and the average refractive index n.parallel.(0.8) of the portion apart by 0.8 R from the center satisfy the following requirements:n.parallel.(0).ltoreq.1.640 and [n.parallel.(0.8)-n.parallel.(0)].gtoreq.6.times.10.sup.-3.

Abstract: There is disclosed a fabric made up of short conjugate fusible fibers and longer, base fibers. The conjugate fibers have an exposed low melting point component having a lower melting point than the remainder of said fibers and said base fibers. In the method of the present invention, a web of short conjugate fibers and longer base fibers is passed through an entangling mechanism where the short fusible fibers are concentrated and intertwined in heavily entangled knot areas. The entangled web is heated to thermobond at least the low melting point component of the conjugate fibers to each other and preferably to the surrounding base fibers to reinforce and strengthen the fabric.

Abstract: A laminated nonwoven fabric having excellent bulkiness, softness and strength without cleavage of plys and fluff of fibers on the surface thereof which comprises a web mainly composed of a fiber having a high melting point or being hardly softened or molten (laminate ply A), and one or more webs mainly composed of a thermoplastic fiber which soften or melt more easily than the fiber of the laminate ply A (laminate ply B), said ply B being integrally bound to said ply A by steric entanglement of both fibers composing the plys A and B as well as partial softening or melting of the fibers composing the ply B. The laminated nonwoven fabric is produced by subjecting a laminated web made of different kinds of fibers to a fluid injection entangling treatment and then a dry heat treatment.

Abstract: Nonwoven fabrics of poly(m-phenylene isophthalamide) having a cross-machine modulus greater than 40, and good resistance to abrasion that is useful as a gas filtration substrate, and the process of producing such a fabric by heating an entangled web while stretching the fabric transversely 5 to 15% for a time sufficient to increase the crystallinity index at least about 0.05 units.

Abstract: An entangled fibrous mat comprising an elastic polymer fiber A and a nonelastic polymer fiber B, said fiber A having voids therein and being in a taut condition within the mat; while said fiber B is in a slack condition and is highly elastic and flexible, rich in fullness, and firm-bodied, thus being very suitable for use as a substrate for artificial leather.

Abstract: In spun fleeces of thermoplastics in which the filaments are in approximately random arrangement, which fleeces have been strengthened by needle-punching and which have a higher tensile strength in one direction than in the direction at right angles thereto, the said tensile strengths are approximated to one another by stretching the fleece by 20 to 200% of the original length, in the direction of the lower tensile strength, at a temperature which is 85.degree. to 25.degree. C. below the crystallite melting point, while either maintaining the length in the direction at right angles to the stretching direction, or changing it, beforehand or simultaneously, by an amount within the range of .+-.10% of the original length.

Abstract: An entangled non-woven fabric having a fiber structure which comprises a portion (A) in which ultrafine fiber bundles consisting of ultrafine fibers of a size of not greater than about 0.5 denier are entangled with one another and a portion (B) in which ultrafine fibers to fine bundles of ultrafine fibers branch from the ultrafine fiber bundles and are entangled with one another, and in which portions (A) and (B) are nonuniformly distributed in the direction of fabric thickness. The product of this invention has high flexibility as well as good shape retention.The invention also relates to a grained sheet having on at least one of its surfaces a grain formed by a fiber structure composed of ultrafine fibers to fine bundles of ultrafine fibers and having a distance between the fiber entangling points of not greater than about 200 microns, and a resin in the gap portions of the fiber structure.

Abstract: A method is disclosed wherein a nonwoven fabric composed at least in part of thermally fusible fibers is at least partially fused and then is punched by needles to produce a soft, fluffy fabric that resists mechanical wear.

Abstract: A nonwoven textile fabric laminate comprising at least one layer of nonwoven textile fabric secured by needle punching to an elastic layer such that the nonwoven fabric layer is permanently stretched when the elastic layer is drafted to a condition within its elastic limit and the nonwoven fabric layer exhibits increased bulk when the elastic layer is allowed to relax and return to substantially its condition prior to drafting. One form of the fabric laminate includes a nonwoven textile fabric layer needle punched to each side of the elastic layer. Various methods and apparatus for producing such laminates are also disclosed.

Abstract: A patterned, nonwoven, articulated fabric exhibiting a substantially uniform texture and comprised of a multiplicity of synthetic fiber elements, the opposing free ends of each of said synthetic fiber elements being joined to one another to form substantially continuous loops, said loops being interconnected to one another in a predetermined pattern. Method for producing said nonwoven fabric using specially prepared fiber elements which curl in a predetermined configuration in response to an external stimulus is also disclosed.

Abstract: A laminated non-woven fabric having a stitched core of cellular sheet material and facings of fiber batting needled through the core and partially into the opposite facing, the fibers in the facings dominantly extending transversely to the stitching of the core.

Abstract: A process is described for improving needling efficiency in the preparation of continuous fiber glass strand needled mat involving subjecting the continuous glass strand mat to environmental treatments before and during needling to control mat moisture and temperatures. A low relative humidity and warm temperature environment is maintained during needling and the mat is exposed to similar treatment prior to needling.

Abstract: An improved method of manufacture of a nonwoven fabric wherein a nonwoven fabric web is passed through a needle punching zone wherein the nonwoven fabric web is needle punched in such a manner that the number of needle punches per unit area in the edge portions of the nonwoven fabric web is less than the number of needle punches per unit area in the medial portion of the nonwoven fabric web, and the thus needled nonwoven fabric web is passed through a tentering zone wherein it is stretched transversely relative to its direction of movement to thereby reduce the weight per unit area of the edge portions to approximately the weight per unit area of the medial portion so that a nonwoven fabric of substantially uniform thickness and weight per unit area is produced.

Abstract: 65-99 percent by weight poly(tetrafluoroethylene) fibers and 1-35 percent by weight glass fibers are combined in an intimate blend suitable for the preparation of filter felts having reduced leakage while maintaining high permeability to gas flow.

Abstract: Methods are provided for producing protective and useful wearing apparel, such as work gloves, work boots and aprons, and wearing apparel so produced by such methods. The methods include joining a non-woven fibrous web, such as needled felt to a knitted web, such as a knitted jersey, and utilizing a needled staple fiber preferably from the non-woven web to join the two webs together into a formed laminate. The joining procedure is such that the finished laminate includes the needled staple fiber extending from one surface of the web to form a base surface for a subsequent application of an elastomeric coating. The resulting coated surface is textured to provide a gripping surface, for example, for use in gloves to handle smooth surfaced items with sharp edges, such as glass. The remaining exposed non-woven fibrous web surface forms a soft protective internal surface for the weaving apparel such as gloves or boots.

Abstract: A felt-like layered composite of the following structure:a. a first layer of a predominantly horizontal coplanar superimposed layers of filamentary polytetrafluoroethylene components interrupted by occasional interlayered orientation;b. a thin high density nonwoven layer of fine glass staple fibers;c. a scrim fabric of polytetrafluoroethylene fibers andd. a second predominantly horizontal coplanar superimposed layers of filamentary polytetrafluoroethylene components interrupted by occasional interlayer orientation;wherein the layers are mechanically bonded together by filamentary polytetrafluoroethylene components extending vertically throughout the composite and a process for making this composite; the composite is useful as a filter fabric and is primarily used for bag filters to remove fly ash from the gaseous combustion products of coal fired furnaces and boilers.

Abstract: A nonwoven textile fabric comprising a needled and drawn batt comprising intermixed acrylic fibers and additional fibers selected from the group consisting of polyester fibers, nylon fibers and mixtures of polyester fibers and nylon fibers, with at least a portion of said additional fibers being fused and the acrylic fibers being essentially unfused. The nonwoven textile fabric is produced by forming a batt comprising the acrylic fibers and the additional fibers, drafting and needling the batt and fusing at least a portion of the additional fibers of the needled and drafted batt while allowing the acrylic fibers to remain substantially unfused. Fusing the additional fibers is preferably accomplished by means of infrared radiation.

Abstract: An improved method of manufacture of a nonwoven fabric wherein a nonwoven fabric web is passed through a needle punching zone wherein the nonwoven fabric web is needle punched in such a manner that the number of needle punches per unit area in the edge portions of the nonwoven fabric web is less than the number of needle punches per unit area in the medial portion of the nonwoven fabric web, and the thus needled nonwoven fabric web is passed through a tentering zone wherein it is stretched transversely relative to its direction of movement to thereby reduce the weight per unit area of the edge portions to approximately the weight per unit area of the medical portion so that a nonwoven fabric or substantially uniform thickness and weight per unit area is produced.

Abstract: The specification describes a multi-layered, needle-punched, felt-like cushioning material for a hot-pressing machine. The cushioning material is made of at least two fibrous batts and at least one foundation fabric interposed between the batts and needle-punched with the batts. The specification also describes a method for producing the above cushioning material. The cushioning materials according to this invention have a high density and can maintain high elasticity and excellent cushioning properties over a relatively long period of hot-pressing operation.

Abstract: A papermakers wet felt comprising a three layer fabric having a first or lower layer which defines a machine roll contacting surface, a second or intermediate layer, and a third or top layer which defines a paper-receiving surface. The lower layer is woven of machine direction yarns which are of much greater diameter than the cross machine direction yarns. The intermediate layer is also woven, and adds stability and strength to the felt while providing void areas for drainage. The top layer comprises a batt or fleece of non-woven batting material.Also disclosed is a method of making the papermakers felt wherein the lower and intermediate cloths are separately woven and then associated with each other so that the inner surface of the intermediate layer contacts the outer surface of the bottom layer. The associating of the two layers takes place on a conventional fiber locker or needling machine associated with a conventional stretching device.

Abstract: A papermaking fabric composed of a base having a fibrous batt needled to one surface thereof, the base being formed of interwoven core wrapped yarns, comprising core yarns which are effectively heat infusible and wrapping yarns which are effectively heat fusible, the fibrous batt being either heat fusible or heat infusible, the wrapping yarns of the interwoven base being heat fused to each other at their points of contact with each other on the side of the interwoven base opposite the fibrous batt.

Abstract: A melt bonded fabric is produced by blending particular ethylene-vinyl acetate fibers with fibers of higher melting materials, forming a fabric thereof as by needle punching, and thereafter subjecting the fabric to temperatures above the melting point of ethylene-vinyl acetate but below that of the other fibers in the fabric.

Abstract: Three dimensional shapes, typically of convex-concave form and having sufficient rigidity to maintain that form are molded from nonwoven, needlepunched fabrics containing certain ethylene-vinyl acetate fibers in admixture with fibers of a higher melting point polymer. Molding is accomplished by heating the fabric to a temperature whereat the ethylene-vinyl acetate fibers soften or melt but below the melting point of the other fibers and thereafter pressing the fabric between the mating faces of a mold pair and allowing the ethylene-vinyl acetate fibers to solidify and cool while in the mold.

Abstract: There are disclosed apparatus and methods for incorporating feathers and downs into synthetic fiber. In one embodiment, raw polyester staple is processed into batting by a garnetting machine or the like, after which a quantity of natural feathers and downs is securely implanted in the polyester fiber using an impregnation device. The polyester sheets containing the impregnated plumage may then be folded and cut to the required size and thickness for further use.

Abstract: A plurality of nonflammable, heat sensitive organic fibers are intimately admixed by blending with inorganic fibrous materials such as glass wool, mineral wool and asbestos fibers. The admixture of the organic and inorganic fibers is processed by carding or garnetting to form an insulating composite body of a preselected thickness. The nonflammable, heat sensitive fibers, such as polyester fibers, may be oriented within the composite body by a needling process to interlock the inorganic fibers and compress the composite body to cohesively bind the fibers in a batting. This prevents the composite body from splitting and also serves to decrease the thickness and increase the density of the composite body. The interlocked arrangement of heat sensitive organic fibers and inorganic fibrous material is subjected to a shrinking treatment at a temperature in the range between about 212.degree. to 300.degree. F. for a preselected time interval.

Abstract: A fashion felt of laminar structure comprising two outer layers at least one of which consists essentially of melt fibres, a layer of synthetic fibres, preferably synthetic fibre waste, positioned between the two outer layers, and a layer of surface batt secured to one of the outer layers. The laminar fashion felt possesses a high degree of plasticity and is given the desired shape in heat and compression treatments and the desired outlines in cutting operations. By varying the thickness of the batt layer and by compressing different parts of the product to a larger or lesser extent, the degree of softness or hardness of the product could be chosen in accordance with the end use thereof. The fashion felt is particularly useful for furniture and car interior upholstery and fittings. The invention also concerns a method of producing the felt.

Abstract: A nonwoven fabric is produced from a batt of staple fibers by passing the unneedled batt of staple fibers to at least two needling zones, each needling zone having a plurality of needles which move in a reciprocating motion having a first needling direction and a second needling direction, the needles in a first needling zone having barbs which catch staple fibers of the batt primarily when the needles move only in the first needling direction and the needles in a second needling zone having barbs which catch staple fibers of the batt when the needles move in both the first needling direction and the second needling direction.

Abstract: The disclosure is of decorative panels and the method of their manufacture. The decorative panels are laminates of textile materials, having a decorative fabric surface. The panels of the invention are particularly advantageous in that they are economical to manufacture and exhibit a high degree of structural stability, and resistance to delamination.

Abstract: This invention resides in a flame-resistant nonwoven fabric having an upper and a lower surface and comprising dyeable, flame-resistant fibers and base fibers. In one embodiment the upper surface is substantially, completely comprised of polyvinyl chloride fibers and the lower surface is a blend of adhering base fibers and polyvinyl chloride fibers. The fabric is formed by needling base fibers together to form a batt, needling polyvinyl chloride fibers and the batt together, and heating the lower surface of the fabric to adhere the polyvinyl chloride and base fibers together.

Abstract: In the manufacture of non-woven fabrics waste material is avoided by determining the distribution of the weight per square unit of both border zones of a non-woven and by folding thereafter a part of the thinner border zone toward the inner part so that the resulting non-woven has a uniform distribution of weight per square unit. Especially in the case of non-woven fabrics made from slightly extensile material or having border zones which shall not be stretched, the web is guided at an angle about in the middle of the folding zone, the angle being inclined towards that level towards which the border zone is folded; non-woven fabrics with very uniform distribution of weight per square unit are thereby obtainable.

Abstract: A nonwoven fabric is passed to a compression zone wherein the edge portions of said fabric are compressed to produce a nonwoven fabric with a uniform thickness.

Abstract: Process of producing a nonwoven needled napped fabric, adaptable for use in the formation of blankets and other types of products, characterized by providing superior resistance to pilling and shedding of the napped fabric, as follows. A batt of textile fibers of a desired construction is sequentially needled from a first side to a second side and then from the second side to the first side thereof to form a multiplicity of fiber entanglements for interlocking the fibers of the batt with each other to form an integrated needled fabric. The first and second sides of the needled fabric are napped for producing raised fiber surfaces on each side of the fabric. The needled and napped fabric is then reneedled from the first side to the second side thereof for providing resistance to pilling and shedding of the napped fibers. Preferably, the napped sides of the needled, napped and reneedled fabric are chemically treated for providing further resistance to pilling and shedding of the napped fibers.