Abstract: The present invention is directed to a hydroentangled nonwoven fabric with improved flame retardant properties and the making thereof, whereby the nonwoven fabric is differentially entangled to collapse upon itself and self-extinguish upon burning. The self-extinguishing fabric further exhibits favorable tactile and ductile softness while obtaining sufficient physical strength.

Abstract: A fabric including within its construction a first elongated electrical conductor crossed by a second elongated electrical conductor, the conductors being normally biased apart at a crossover point of said fibres with an air gap between them, whereby application of pressure in a direction substantially normal to a plane of the fabric causes the conductors to make contact. The fabric may be woven, knitted, non-woven or plaited. The fabric can be used as a pressure sensor, switch or other sensor.

Abstract: The invention concerns a nonwoven support, in the form of a felt or needle punched product, having a thickness ranging between 0.3 and 1 mm and a surface mass of fibres ranging between 70 and 120 g/m2, and the fibres are embedded in the adhesive over part of the support thickness. The tear strength of the adhesive tape is less than 15 N. The invention is useful for strapping bundles of cables in motor vehicle construction.

Abstract: An elastic composite having a high tearing strength made of an elastomeric material and a consolidated entangled web, wherein the consolidated entangled fabric has at least 2 lbs of tearing strength in the machine direction and the composite has 70-95% elastic recovery from a 100% elongation in the cross direction and greater than 50% elastic recovery from a 150% elongation in the cross direction.

Abstract: A process is described for treating a nonwoven fabric to improve its suitability for use as a primary backing in manufacturing tufted carpets and carpet tiles. The process includes the steps of needle-entangling a nonwoven fabric, preferably a spunbonded polyester web, from one or both sides, heat-setting the needled web, calendering and cooling the web and then saturating with a liquid curable elastomeric binder. The saturated web preferably is treated to remove excess binder, heated to dry the web and cure the binder, and wound up on rolls. The resultant fabric is dimensionally stable and has elastomeric properties similar to a woven fabric which provide improved tuft grip and repairability when used as a backing for tufted carpeting.

Abstract: The present invention relates to a flame-retardant removable cover which may be applied to a mattress. The removable cover, when applied to mattress, may reduce the peak heat release rate and/or total energy released in accordance with 16 CFR 1633 testing protocols. The cover may comprise a non-woven material. The removable cover may also comprise a non-woven type construction and an elastomeric material. The removable cover may therefore be designed with respect to the different requirements of those mattresses to which it may be applied to assist in meeting open flame mattress flammability standards.

Abstract: The invention relates to a flat needle-punched non woven of natural and/or synthetic fibers having a weight per unit area within a range of from 200 to 1600 g/m2, characterized in that one tenth to one hundredth of at least one of the two main surfaces has a surface coating in the form of a pattern.

Abstract: A nonwoven textile assembly, a method for its manufacture, and a spirally wound press felt made from the assembly are disclosed. The nonwoven textile assembly is manufactured by providing a uniform array of parallel yarns having constant height and spacing as a first textile component and which are oriented in a first direction. An adhesive material is applied to a first side of the first component. A second textile component, such as a second array of parallel yarns oriented at an angle of from 2° to 90° to the first, or a nonwoven mesh, or a nonwoven scrim comprising a regenerated cellulosic is then laid over the adhesive material. A lightweight batt layer optionally including a second adhesive preferably located on the side of the batt facing the second side of the second textile component, is overlaid the second textile component.

Abstract: In a clothing support for a card flat covering, the belt-shaped support is made of plastics material, and there is embedded in a base body at least one reinforcing insert which is also belt-shaped and which is arranged in the vicinity of the back of the support. In order to make possible stronger anchoring by simple means and to allow undisrupted oscillation of clothing wires, the base body has at least two layers (bottom layer and top layer) of different plastics materials connected to one another, and the bottom layer incorporates a fabric.

Abstract: A paper makers felt comprising a fibrous outer layer formed of inter-engaged fibers of between 3.0 and 67 dtex inter-engaged preferably by needling, and a web layer formed of fibers which are between 200 and 600 dtex and are inter-engaged preferably by point bonding. The outer layer is engaged with the web layer, preferably by needling, forming a composite paper makers felt.

Abstract: A composite sheet is disclosed. The composite sheet comprises an open random fibrous web having substantially vertical fibers near a top surface, a first binder resin and a second binder resin, wherein the first binder resin has a melting point lower than the melting point of the second binder resin, wherein the melting point of the second resin is lower than the melting point of the web, wherein the resins are activated in situ with the web fibers to form a resin-fiber rich region on the top surface and wherein the abrasion-resistant sheet can withstand at least about 3,000 cycles on the Wyzenbeek abrasion test using 80-grit abrasive paper. An abrasion-resistant sheet comprising a single binder resin and other abrasion-resistant sheets are also disclosed. Processes for making these abrasion-resistant sheets are further disclosed herein.

Abstract: Disclosed is a surface material for an automobile internal trim panel consisting of a fiber sheet, wherein the fiber sheet contains an oil repellent and substantially consists of non-water absorbent fibers; an oil repellency of at least one surface of the surface material is grade 1 or more in an evaluation by an AATCC Test Method 118-1997; and a grade of the oil repellency of one surface of the surface material is different from that of the other surface thereof. Further, an automobile internal trim panel comprising the same is also disclosed.

Abstract: To provide a heat resistant filter of which the reduction of tensile strength and folding endurance is small even when used as a filter material for a filter used at high temperatures, failure of the filter material is difficult even when used at high temperatures, and which is capable of achieving a long life. The heat resistant filter contains: a heat resistant organic fiber base material, and a resin composition which contains an alkaline substance and which adheres to the heat resistant organic fiber base material.

Abstract: The present invention provides non-woven laminate that is not subjected to final consolidation by a binder and the production thereof. The laminate includes at least one non-woven mat containing glass staple fibers pre-consolidated with a resin, and at least one non-woven layer of synthetic fibers. The synthetic non-woven layers and the pre-consolidated non-woven mat of glass fibers are bounded together by needling such that a portion of the fibers of the upper synthetic non-woven layer passes through the non-woven mat of glass fibers possibly through the underlying synthetic non-woven layer. The synthetic fibers are heat shrunken and the laminate is binder free.

Abstract: Interior design structures and lightweight furniture formed from a felted fibrous material such as needle punched felt as the material of construction in replacement for wood. The felted fibrous material is adapted to provide adequate strength to permit construction of three dimensional structures by use of standard joining techniques such as screws, nails, glue and the like. At the same time, the nature of the felted fibrous material affords the opportunity to bend and shape the material thereby allowing additional freedom in construction and use.

Abstract: A base material for a wiping sheet on which powder is to be supported, wherein the ratio of the average pore diameter (D) of the surface of the base material while dry as measured by the mercury penetration method to the average particle diameter (d) of the powder, D/d, ranges from 0.03 to 30, and the base material while dry has a bulk softness of from 0.1 to 5 N/30 mm and a thickness of from 0.3 to 5 mm.

Abstract: A non-woven mat of inorganic fiber is disclosed having a substance which is lower at the edges of the mat than in the remainder of the mat. Apparatus for making such a mat includes: a source of a slurry of inorganic fiber in a liquid; a forming wire disposed to move past the source, the liquid passing through the forming wire to deposit the inorganic fiber on the forming wire; a mask across a part of the width of the forming wire to hinder passage of the liquid through the forming wire over the part, the effectiveness of the mask varying in the direction of movement of the forming wire past the slurry source.

Abstract: Coating compositions, processes for making them and articles for cleaning composed of non-woven fabrics coated with the novel compositions are described.

Abstract: A textured film device formed from at least one layer of gathered textured film. These devices are capable of producing excellent lather when used with a cleanser and are soft to the touch. Other textured film devices include mitts, gloves, washcloths, and the like formed from at least one layer of textured film. Also provided are systems comprised of the textured film devices and at least one active material selected from cleansers; moisturizers, conditioners; sunscreens; shaving foams; tanning agents; anti-acne agents; anti-aging agents; anti-irritant agents; perfumes/fragrances; and mixtures thereof.

Abstract: A neckable nonwoven web is provided with a central region and two edge regions, the central region being selectively easier to neck than the two edge regions. The nonwoven fibers in the central region have a polymer composition and/or physical properties which differ from the nonwoven fibers in the two edge regions. The selectively easier necking in the central region causes the central region to neck to about the same extent as the two edge regions, which otherwise would experience greater necking than the central region if the starting nonwoven web were completely uniform. Necked nonwoven webs and neck-bonded laminates made using the improved neckable nonwoven web, are also provided.

Abstract: A system for utilizing a hazardous apparatus with a pad of fibrous fabric embedded in cement to shield a protectable surface from hazards produced by the hazardous apparatus.

Abstract: Lightweight, non-woven loop products for hook-and-loop fastening are disclosed, as are methods for making them and end products employing them. The products are non-woven webs of entangled fibers of substantial tenacity, the fibers forming both a sheet-form web body and hook-engageable, free-standing loops extending from the web body. The product is stretched and stabilized to produce spaced-apart loop clusters extending from a very thin web of taut fibers. In some embodiments, the fibers include low denier fibers and/or bicomponent fibers.

Abstract: A patterned pile fabric of stitch-bonded construction. The fabric includes a substrate layer with an arrangement of ground yarns extending in stitched relation through the substrate layer so as to define a ground covering across the substrate layer. An arrangement of pile forming yarns extend in stitched relation through the substrate layer such that the pile forming yarns define a patterned arrangement of looped elements projecting away from the ground covering in predefined three dimensional patterned arrays disposed across the fabric.

Abstract: A material to reduce the effects of trauma received from the impact of a projectile. One embodiment is a needle-punched, non-woven material including at least one type of ballistic fibers selected and oriented to provide a cushioning effect and maintain a high compressive restitution constant. A percentage of the fibers are oriented with at least their ends lying approximately perpendicular to the fabric plane and/or oriented to lie in a waveform generally along or parallel to the fabric plane. This enables the ends of the fibers lying perpendicular to the fabric plane to cushion the impact from the projectile by dissipating energy through compressional resistance, and the fibers along the fabric plane to reduce energy through dispersal along fiber lines, thereby reducing the trauma resulting from an impact.

Abstract: A method of making a soft, well cushioned, fabric suitable for use in an automotive interior, furniture and upholstery. The fabric which is formed by depositing a coating of a high temperature adhesive having a viscosity of 6×104 to 75×104 centipoise at its application temperature on one surface of a felt cloth followed by laying down a layer of a second material on top of the adhesive-coated surface of the felt cloth to form a composite. The composite is then passed through a hot pinch point to firmly bond the second layer to the felt cloth.

Abstract: A targeted elastic laminate material is provided having at least one low tension zone with first filaments having a first basis weight and at least one high tension zone having second filaments with a second basis weight greater than the first basis weight. The second basis weight is greater due to increased average thickness of the second filaments and/or increased frequency of second filaments relative to the first filaments. Methods and modifications of those methods are provided to produce a targeted elastic laminate material according to the preferred embodiments of this invention.

Abstract: An improved stitchbonded fabric has a pattern of stitches formed by a multi-needle stitched set of contractible stitching threads in a planar material that comprises a non-fibrous layer of polymer or metal, such as a metallic foil, a polymeric film, or a leather. Contraction of the stitchbonded fabric provides the fabric with unusual tactile, visual and functional effects.

Abstract: A floor cleaning wipe comprising a water insoluble substrate which is impregnated with a floor cleaning composition.

Abstract: The subject invention provides non-woven fabrics having yarns of varying characteristics. In a preferred embodiment the subject invention provides nonwoven fabrics that comprise yarns of different deniers or cross sections. The use of these yarns gives the nonwoven fabric a unique appearance and advantageous properties. The subject invention further pertains to the processes used to produce these fabrics.

Abstract: A method is disclosed for using discarded carpet segments or other recycled textiles to make wood-like material in sheets that are comparable to plywood. The carpet segments or other recycled materials are shredded, then layered across a slow-moving conveyor to form a thick, low-density belt of fibers. This belt is compressed between rollers, and then needle-punched, using needles with surface barbs that pull fibers downward and upward. This needle-punching causes fibers inside the mat to be pulled into vertical alignment (i.e., perpendicular to the top and bottom surfaces of a horizontal mat), to form a needle-punched mat that will hold together without chemical adhesives. A binder material is then applied to at least one and possibly both surfaces of the mat, by means such as spreading or spraying a liquid binder on either or both surfaces of the mat, or stretching a continuous film of the binder material across either or both surfaces of the mat.

Abstract: A composite non-woven needlefelt ink absorber that is particularly suited for use with an ink jet printer to absorb and disperse waste ink utilizes at least two distinct layers. The layer initially contacted by the ink is low density/course denier. The final ink receiving and retaining layer is high density/fine denier. Any intermediate layers are also intermediate in density and denier.

Abstract: The present invention relates to fibrous web materials comprising polymeric material wherein the structure of the polymeric material contains elastic amorphous areas nano-scale-size reinforced with self arranged crystalline domains of nano-crystals.

Abstract: The invention is directed to a composite sheet suitable for use as artificial leather or a precursor to artificial leather, where both surfaces have a napped or brushed appearance. The composite sheet comprises a low-density, lightly bonded non-woven web that is stitch-bonded and bulked such that the stitch-bonding yarns are not visible to the naked eyes without the need of post-processing steps to hide the yarns. The composite sheet may have binder resin(s) dispersed therein and activated.

Abstract: A multiple layer, thermoformable acoustic sheet material useful for manufacturing acoustic absorption, acoustic barrier and/or vibration damping components includes a barrier layer of synthetic fibers having an area weight of from about 40 grams per square foot to about 100 grams per square foot, and an absorber layer of vertically-lapped synthetic fibers, natural fibers or a combination of synthetic and natural fibers. The thermoformable acoustic sheet materials may include additional layers, with certain embodiments including an impermeable polymer film layer disposed between the barrier layer and the absorber layer.

Abstract: Readily-fibrillable fibers of PVA polymer, having good chemical resistance, hydrophilicity, weather resistance and water resistance have a flattened cross-sectional profile and have a mean thickness D (&mgr;m) that satisfies the following formula (1):

Abstract: A fire blocking material is disclosed comprising a nonwoven fabric including para-aramid fibers and pre-oxidized polyacrylonitrile, and optionally, a garnett of recycled polybenzimidazole, para-aramid or meta-aramid, or combinations thereof to form a fire blocking textile meeting Federal Aviation Administration regulation FAR 25.853 and Appendix F to Part 25.

Abstract: Lightweight, non-woven loop products for hook-and-loop fastening are disclosed, as are methods for making them and end products employing them. The products are non-woven webs of entangled fibers of substantial tenacity, the fibers forming both a sheet-form web body and hook-engageable, free-standing loops extending from the web body. The product is stretched and stabilized to produce spaced-apart loop clusters extending from a very thin web of taut fibers. In important cases a binder is added to stabilize the product in its stretched condition. An example of the loop product is produced by needle-punching a batt of staple fibers in multiple needle-punching operations, applying a foamed acrylic binder, and then stretching the needled batt and curing the binder with the batt stretched. Other forming techniques are disclosed and several novel articles and uses employing such loop products are described, such as for filters and fasteners.

Abstract: The suede-finished leather-like sheet of the present invention comprises a fiber-entangled nonwoven fabric comprising a layer (I) made of a microfine fiber (A) having an average fineness of 0.5 dtex or less and a layer (II) made of a microfine fiber (B) having an average fineness equal to or less than that of the microfine fiber (A), and a polymeric elastomer impregnated in the fiber-entangled nonwoven fabric. The layers (I) and (II) are integrated by entanglement such that a ratio of the microfine fiber (A) to the microfine fiber (B) is 10/90 to 90/10 by mass. The surface of the layer (I) is a napped surface made mainly of a raised microfine fiber (A). The microfine fibers (A) and (B) are respectively formed by converting a microfine fiber-forming fiber (a) and a microfine fiber-forming fiber (b), each having an elongation at break and a tenacity of specific ranges, into microfine fibers.

Abstract: Disclosed is a thermoplastic felt structure for an automobile interior substrate, comprising a pair of mat units, each mat unit having a felt layer which is made by a mixture of a jute fiber and a PP fiber mixed in the weight ratio of about 5 to 5˜6 to 4 and a PP foaming fiber adhered to one side of the felt layer, said mat units being coupled each other on the other sides of the felt layers. With this configuration, a thermoplastic felt structure for an automobile interior substrate can prevent a deflection thereof, and have high strength and stiffness, heat-resistance and impact-resistance. Further, the present thermoplastic felt structure can decrease the cost of raw material, enhance the fuel efficiency with a lightweight body, and accomplish a simple manufacturing process.

Abstract: This invention relates to a new nonwoven material which has very high Frazier permeability while having substantial hydrostatic head liquid barrier properties. The material is comprised of fibers which are approximately one denier and finer fibers which have sufficient strength properties so as not to need a support scrim. The fabric is quite comfortable because of its breathability, quite soft because of its construction, and protective from liquids from rain to hazardous chemicals.

Abstract: A composite laminate suitable for use in upholstery, automotive interiors and the like, which is made of a polyester felt substrate, an adhesive coating is contained on said felt substrate which obviates the need for a barrier layer for a vinyl laminate, with a vinyl film overlaying and bonding with said adhesive to said substrate. The method of making the laminate is also disclosed.

Abstract: Dense, highly stable, high performance ballistic material comprises at least one woven layer of ballistic grade fiber (preferably a stack of such layers) and at least one nonwoven layer of fabric which is entangled with the woven or unidirectional layer by needle felting. The resulting core material does not require assembly of individual woven layers during subsequent manufacture of ballistic articles and exhibits excellent ballistic performance at low areal densities and thicknesses.

Abstract: A dispenser for strip materials, e.g. hook and loop fastener material, which automatically finds formations in a continuous fastener strip during its dispensing and, at that point in the dispensing procedure, produces a resistance to the remaining supply, that enables parting of the lead unit from the remaining supply, thus dispensing a discrete unit. The dispenser has a receptacle to hold the supply of fastener strip material; it employs a retarding device to provide light drag against the motion of the strip as the leading strip unit moves from the dispenser in response to pull by a user. A detent downstream of the retarding device engages a corresponding formation in the strip material to resist movement of the remaining strip material, so that the strip ruptures along a line of weakness under a user's tension. Also disclosed are dispensable fastener strips of various forms, some advantageously formed by use of needled bat, and methods of forming the fastening strips.

Abstract: A textile composition having improved structural integrity, thermal stability, and chemical resistance. The textile composition includes a needle-felt material of a high temperature fiber combined with a woven basalt scrim material. The textile composition is preferably formed by needle-felting the high temperature fiber into a layer of woven basalt scrim.

Abstract: A nonwoven fabric includes a cohesively integrated web of hydrodynamically entangled short-staple or “waste cotton” fibers. A batt of waste cotton fibers is hydrodynamically needled by high-pressure streams of water. The hydrodynamic energy of the streams causes the fibers to cohere and to become mutually entangled, which in turn results in a fabric of sufficient strength to be used for, among other things, a bag for a bulk material and particularly a bag or cover for a cotton bale.

Abstract: A resin charged media can be a single or layered construction needled together to provide a graded-density structure of fine fibers intermixed with finer fibers. This resulting media possesses a higher particulate loading retention capability, particularly early in the filtration cycle, relative to other cellulose, spun-bonds, or other similar materials commonly applied to filtration applications where filtration is predominantly a surface-loading phenomenon. The filtration media provides for depth filtration with the multi-layered needled layers, thereby enhancing the overall particulate-holding capacity of the charged media. This results in more resistance to fine particulates and improvements in efficiency due to increased sub-micron particle loading. With the filter media consisting of a graded structure, surface loading phenomenon can be reduced and filter life improved. Since the layers in the media are physically combined using needling technology, they will not separate.

Abstract: Melt processable, flushable polymer fibers and methods of making melt processable, flushable polymer fibers are disclosed. The fibers comprise poly(ethylene oxide). Preferably, the poly(ethylene oxide) is modified by grafting polar vinyl monomers, such as poly(ethylene glycol) methacrylate and 2-hydroxyethyl methacrylate, onto poly(ethylene oxide). The modified poly(ethylene oxide) has improved melt processability and can be used to melt process poly(ethylene oxide) fibers of thinner diameters.

Abstract: A composite sheet has a layer of reinforcing fiber impregnated with a thermoplastic resin. Non-woven fiber is partially impregnated with the thermoplastic resin to provide a bondable surface that can be subsequently bonded to other materials, such as plastics, foam and metal. Such an apparatus may be formed by heating and compressing the thermal plastic resin against the reinforcing fibers of the base layer and against the non-woven fibers, such that the base layer may be fully impregnated while the non-woven fibers may be partially impregnated. A thermal plastic resin must have a melting point less than either the reinforcing fibers of the base layer, or the non-woven fibers.

Abstract: Tuftable primary backings comprise a closed-weave, woven tape fabric to which is affixed a coherent web layer comprising staple fibers with fibers oriented in at least two directions and a plurality of the fibers being fused. The web layer is affixed to the fabric by penetration of fibers from the web into the fabric. The backings have substantial weftline straightness and stability against deformations in the machine, cross and off-axis directions. Improved tufted goods and methods for making the composites and tufted goods are also provided.

Abstract: A nonwoven material which is formed of a blend of fibers diagonally needled together into an integral web for subsequent molded component parts.