Abstract: In one aspect, a method of forming a linear panel from a thermoformable fibrous material by a continuous process includes continuously drawing an elongate strip of thermoformable fibrous material through a heating station to heat the material, forming the heated material into a desired panel shape, and continuously drawing the material through a cooling unit in order to cool the material after the material has been formed into the desired panel shape.

Abstract: A composite construct comprising a side wall extending at least partially around an interior of the composite construct. At least a portion of the side wall comprises at least one laminate, and the at least one laminate comprises at least one layer of material that comprises a first renewable polymer. The composite construct can also comprise at least one injection-molded element comprising at least a second renewable polymer.

Abstract: An automotive soundproof cover includes a fibrous formed article that exhibits the desired sound insulating properties and high flame retardancy. The automotive soundproof cover includes a fibrous formed article that includes two or more types of fibers, the fibrous formed article including 50 to 80 mass % of organic fibers, 10 to 40 mass % of flame retardant-containing fibers, and 5 to 20 mass % of an organic binder, the ratio of the total mass of the flame retardant included in the flame retardant-containing fibers to the total mass of the fibrous formed article being 0.01 to 1.8 mass %, and the flame retardant being a melt drip regulator.

Abstract: An article comprising hollow ceramic microspheres and multi-component fibers is disclosed. The multi-component fibers are adhered together, and the hollow ceramic microspheres are adhered to external surfaces of the multi-component fibers. A method of making the article and use of the article for insulation are also disclosed.

Abstract: An article including multi-component fibers and particles is disclosed. The multi-component fibers include at least a first polymeric composition and a second polymeric composition, are adhered together, and are non-fusing at a temperature of at least 110° C. At least a portion of the external surfaces of the multi-component fibers includes the first polymeric composition. Particles are adhered or directly attached to the first polymeric composition on the external surfaces of at least some of the multi-component fibers along their lengths. The particles include at least one of activated carbon, superabsorbent polymer particles, and abrasive particles. In some embodiments, the particles are distributed throughout the thickness of a web of the multi-component fibers. A method of making the articles is also disclosed.

Abstract: A nonwoven material suitable for use as a wet wipe substrate is disclosed. The nonwoven material comprises thermoplastic fibers and is provided with a pattern of embossments that join at least a portion of the thermoplastic fibers. When the material is treated with a cleaning lotion to provide a wet wipe, the wet wipe has a wet CD modulus that is greater than about 25 N/m and less than about 80 N/m.

Abstract: A non-woven fabric composite containing coir fibers and a method for producing such composites. The non-woven fabric composite is comprised of coir fibers, which are large diameter, lignin-rich fibers, with a high viscous flow temperature and a high degradation temperature combined with fibers made of a thermoplastic polymer with a lower viscous flow temperature such as polypropylene (“PP”), polyethylene (“PE”), polylactic acid (“PLA”), and polyester (“PET”) or mixtures thereof. A hot-pressed non-woven fabric composite material prepared from the non-woven fabric composite.

Abstract: A composition for the manufacture of a porous, compressible article, the composition comprising a combination of: a plurality of reinforcing fibers; a plurality of polysulfone fibers; and a plurality of polymeric binder fibers; wherein the polymeric binder fibers have a melting point lower than the polysulfone fibers; methods for forming the porous, compressible article; and articles containing the porous, compressible article. An article comprising a thermoformed dual matrix composite is also disclosed, wherein the composite exhibits a time to peak release, as measured by FAR 25.853 (OSU test), a 2 minute total heat release, as measured by FAR 25.853 (OSU test), and an NBS optical smoke density of less than 200 at 4 minutes, determined in accordance with ASTM E-662 (FAR/JAR 25.853).

Abstract: A thermally adhesive laminated nonwoven fabric that is a laminated nonwoven fabric in which nonwoven fabrics of the following (a) layer, (b) layer and (c) layer are integrated by heat contact bonding: (a) layer having at least one filament yarn nonwoven fabric layer composed of a thermoplastic resin; (b) layer having at least one extremely fine yarn nonwoven fabric layer composed of the same type of thermoplastic resin as that of the (a) layer; and (c) layer having at least one composite filament yarn nonwoven fabric layer composed of a thermoplastic resin, and that satisfies the following (1) and (2): (1) a difference between the melting point of the yarn forming the nonwoven fabric of the (a) layer and that of a yarn forming the nonwoven fabric of the (b) layer is 30° C.

Abstract: An acoustic composite containing at least a first acoustically coupled non-woven composite and a second acoustically coupled non-woven composite, each acoustically coupled non-woven composite containing a non-woven layer and a facing layer. The non-woven layer contains a plurality of binder fibers and a plurality of bulking fibers and has a binder zone and a bulking zone. The facing layer of the second acoustically coupled non-woven composite is adjacent the second surface of the non-woven layer of the first acoustically coupled non-woven composite.

Abstract: A non-woven fabric composite containing coir fibers and a method for producing such composites. The non-woven fabric composite is comprised of coir fibers, which are large diameter, lignin-rich fibers, with a high viscous flow temperature and a high degradation temperature combined with fibers made of a thermoplastic polymer with a lower viscous flow temperature such as polypropylene (“PP”), polyethylene (“PE”), polylactic acid (“PLA”), and polyester (“PET”) or mixtures thereof. A hot-pressed non-woven fabric composite material prepared from the non-woven fabric composite.

Abstract: An acoustically coupled non-woven composite containing a non-woven layer and a thermoplastic film. The non-woven layer contains a plurality of binder fibers and a plurality of bulking fibers and has a binder zone and a bulking zone.

Abstract: A composite having a first layer and a second layer. The first layer is a nonwoven layer containing high modulus fibers having a modulus of at least 8 GPa and thermoplastic binder fibers, where at least a portion of the high modulus fibers are connected to the binder fibers, and where the first layer has a solidity of between about 10 and 90%. The second layer is a textile layer selected from the group consisting of a knit layer, a woven layer, bidirectional laminates, and a unidirectional layer. The second layer contains high modulus fibers having a modulus of at least 8 GPa in a thermoplastic matrix.

Abstract: Porous supported articles and methods of making are disclosed. Multicomponent polymeric fibers are introduced into a forming chamber and are infilled at least into the interior void spaces of a support web. At least some of the infilled multi-component component fibers are self-bonded to each other to form a porous web that is embedded within the support web. The porous embedded web may contain particles that are bonded to the multicomponent fibers of the web. The optional particles in the porous embedded web may be e.g. abrasive, absorbent, etc.

Abstract: A stretch nonwoven fabric 10 contains inelastic fibers having a varied thickness along the length and elastic fibers. The nonwoven fabric 10 preferably includes an elastic fiber layer 1 and a substantially inelastic, inelastic fiber layer 2 on at least one side of the elastic fiber layer 1. The fibers with a varied thickness along the length are contained in the inelastic fiber layer 2. The nonwoven fabric 10 is conveniently produced by (a) superposing a web containing low-drawn, inelastic fibers having an elongation of 80% to 800% on at least one side of a web containing elastic fibers, (b) subjecting the webs, while in a non-united state, to through-air technique to obtain a fibrous sheet having the webs united together by thermal bonding the fibers at their intersections, and (c) stretching the fibrous sheet in at least one direction to draw the low-drawn inelastic fibers, followed by releasing the sheet from the stretch.

Abstract: A non-woven fabric composite containing coir fibers and a method for producing such composites. The non-woven fabric composite is comprised of coir fibers, which are large diameter, lignin-rich fibers, with a high viscous flow temperature and a high degradation temperature combined with fibers made of a thermoplastic polymer with a lower viscous flow temperature such as polypropylene (“PP”), polyethylene (“PE”), polylactic acid (“PLA”), and polyester (“PET”) or mixtures thereof. A hot-pressed non-woven fabric composite material prepared from the non-woven fabric composite.

Abstract: A non-woven fabric composite containing coir fibers and a method for producing such composites. The non-woven fabric composite is comprised of coir fibers, which are large diameter, lignin-rich fibers, with a high viscous flow temperature and a high degradation temperature combined with fibers made of a thermoplastic polymer with a lower viscous flow temperature such as polypropylene, polyethylene or a biodegradable thermoplastic polymer fiber such as polylactic acid, or mixture thereof. A hot-pressed non-woven fabric composite material prepared from the non-woven fabric composite.

Abstract: A textile cushioning batting for use in furniture and the like having a high degree of loft and rebound is disclosed comprising: a non-woven blended batting comprising a major portion of a fine denier fiber and a minor portion of a coarse denier fiber. The fibers have increased crimping amplitudes, secondary crimping, sharper crimp and optimized crimps per inch. A low melt binds fiber binding the fine and coarse denier fibers together in the batting; and a sufficient number of the fibers being heat are bonded together at their intersections to provide a high loft resilient batting for cushioning.

Abstract: A fiber mixture according to the invention comprises fibers A comprising a polymer A containing a thermoplastic polyurethane elastomer and fibers B comprising a thermoplastic polymer B other than the thermoplastic polyurethane elastomer, said thermoplastic polyurethane elastomer having a starting temperature for solidifying of 65° C. or above as measured by a differential scanning calorimeter (DSC) and containing 3.00×106 or less polar-solvent-insoluble particles per g counted on a particle size distribution analyzer, which is based on an electrical sensing zone method, equipped with an aperture tube having an orifice of 100 ?m in diameter. An elastic nonwoven fabric comprises the fiber mixture.

Abstract: Provided is a power storage device separator that is realized in the form of a heat-resistant, solvent-resistant, and dimensionally stable thin film. Also provided is a power storage device separator that can be realized in the form of a thin film which has excellent ion permeability and low resistance, which makes short-circuiting between electrodes and self-discharging difficult to occur, and in addition, which has excellent durability even after long periods of use under high temperature environments in the presence of organic solvents and ionic solutions.

Abstract: Provided herein is a non-stratified, or homogeneous, non-woven composite having (a) strength-imparting fibers of a relatively high denier and (b) binder fibers of a lower denier that adhere the composite together and that form a smooth, stiff skin on the outer surfaces of the composite. In one instance, the strength-imparting fibers are staple fibers and the binder fibers are bicomponent fibers having a low melt component. In a variation, the composite also contains a small percentage by weight (that is, less than 20%) of flame retardant fibers that impart flame resistant properties to the composite. Preferably, all of the fibers are comprised of the same polymeric material (e.g., polyester), so that the composite is recyclable. The resulting composite exhibits excellent flame retardance, strength, and stiffness, as well as having a smooth surface for attachment of a decorative fabric or other material. A process for manufacturing such composites is also provided.

Abstract: The instant invention is a hook and loop fastener device. According to the instant invention, the hook and loop fastener device includes a loop component. The loop component includes a binder-free non-woven material having a bottom layer and a top layer. The bottom layer includes a first bicomponent fiber and a first monocomponent fiber. The first bicomponent fiber comprises the majority of the bottom layer based on total weight of the bottom layer, and the first monocomponent fiber comprises the balance thereof. The top layer includes a second bicomponent fiber, and a second monocomponent fiber. The second monocomponent fiber comprises the majority of the top layer based on total weight of the top layer, and the second bicomponent layer comprises the balance thereof. The bottom layer and the top layer may further include interfiber bonding to form the binder-free non-woven material.

Abstract: Provided herein is a non-stratified, or homogeneous, non-woven composite having (a) strength-imparting fibers of a relatively high denier and (b) binder fibers of a lower denier that adhere the composite together and that form a smooth, stiff skin on the outer surfaces of the composite. In one instance, the strength-imparting fibers are staple fibers and the binder fibers are bicomponent fibers having a low melt component. In a variation, the composite also contains a small percentage by weight (that is, less than 20%) of flame retardant fibers that impart flame resistant properties to the composite. Preferably, all of the fibers are comprised of the same polymeric material (e.g., polyester), so that the composite is recyclable. The resulting composite exhibits excellent flame retardance, strength, and stiffness, as well as having a smooth surface for attachment of a decorative fabric or other material. A process for manufacturing such composites is also provided.

Abstract: Disclosed is a nonwoven web material (10) comprising thermoplastic fibers or filaments and a method of manufacture thereof. The web material has properties desirable for use on machinery having conventional heat sealing stations (26). Also, disclosed is a nonwoven infusion web material comprising thermoplastic fibers or filaments and a method of manufacture thereof. The infusion web material has properties desirable for use in making infusion packages.

Abstract: Provided herein is a non-stratified, or homogeneous, non-woven composite having (a) strength-imparting fibers of a relatively high denier and (b) binder fibers of a lower denier that adhere the composite together and that form a smooth, stiff skin on the outer surfaces of the composite. In one instance, the strength-imparting fibers are staple fibers and the binder fibers are bicomponent fibers having a low melt component. In a variation, the composite also contains a small percentage by weight (that is, less than 20%) of flame retardant fibers that impart flame resistant properties to the composite. Preferably, all of the fibers are comprised of the same polymeric material (e.g., polyester), so that the composite is recyclable. The resulting composite exhibits excellent flame retardance, strength, and stiffness, as well as having a smooth surface for attachment of a decorative fabric or other material. A process for manufacturing such composites is also provided.

Abstract: This invention relates to a filter felt and bag filters comprising an intimate staple fiber blend of 20 to 75 parts by weight polymeric staple fiber containing a polymer or copolymer derived from a monomer selected from the group consisting of 4,4?diaminodiphenyl sulfone, 3,3?diaminodiphenyl sulfone, and mixtures thereof; and 25 to 80 parts by weight of a heat resistant staple fiber selected from the group consisting on meta-aramid fiber, acrylic fiber, polyphenylene sulfide fiber, and para-aramid fiber; based on 100 parts by weight of the polymeric fibers and heat resistant fibers in the felt.

Abstract: The invention relates to a conductive nonwoven fabric that is carbonized and/or graphitized and possesses a bending rigidity <8 taber, a density of 0.1 g/m3 to 0.5 g/m3, a thickness of 80 ?m to 500 ?m, and an electrical conductivity of 10 to 300 S/cm in the nonwoven fabric strip and 30 to 220 S/cm2 perpendicular to the nonwoven fabric strip.

Abstract: The invention relates to a nonwoven mat as half-stuff which contains a high performance thermoplast as melt fiber and a reinforcing fiber, and also a method for producing a nonwoven mat of this type and fiber composites produced from the nonwoven mat.

Abstract: A nonwoven fabric having abrasion resistance and absorbency suitable for cleaning printer cylinders, especially textured or rough printer cylinders, is formed by hydroentangling a fibrous nonwoven web formed from higher-melting polyester base fibers and lower-melting binder fibers, and then thermally bonding the fabric.

Abstract: An indoor cleaning tool having a dry fibrous base material is provided. An antigenicity-reducing composition including an antigenicity-reducing component, an oil and a surfactant are applied to the fibrous base material. Preferably, the antigenicity-reducing component is an extract of an olea or a ligustrum plant extracted with water or an organic solvent.

Abstract: The present invention provides a nonwoven web prepared from multicomponent fibers which are partially split. The partially split multicomponent fibers have at least one component of the multicomponent fiber separated from the remaining components of the multicomponent fiber along a first section of the longitudinal length of the multicomponent fibers. Along a second section of the longitudinal length of the multicomponent fibers the components of the multicomponent fibers remain together as a unitary fiber structure. In addition, part of the second section of the multicomponent fibers is bonded to part of a second section of an adjacent multicomponent fiber.

Abstract: Disclosed is a fibrous nonwoven web material and a method of manufacture thereof. The fibrous nonwoven web material includes natural cellulose fibers, manmade cellulose fibers and synthetic fibers. The manmade cellulose fibers are preferably high crystallinity cellulose fibers. The fibrous nonwoven web material has appreciable wet strength yet is capable of dispersing in most aqueous environments with only mild agitation. The fibrous nonwoven web material can be wet laid from an aqueous dispersion of fibers.

Abstract: A method for producing a porous body comprising apatite/collagen composite fibers comprising the steps of gelling a dispersion comprising long apatite/collagen composite fibers having an average length of 10-75 mm, short apatite/collagen composite fibers having an average length of 0.05-1 mm, and a liquid; freezing and drying the resultant gel to form a porous body; and cross-linking collagen in the porous body.

Abstract: A non-woven material including first effect fibers, first binder fibers, second binder fibers, and optionally second effect fibers. The non-woven material has a first planar zone and a second planar zone. The first planar zone includes a greater concentration of first effect fibers and first binder fibers. The second planar zone includes a greater concentration of second effect fibers and second binder fibers. The first planar zone can include a first surface skin associated with the first planar zone on the exterior of the non-woven material, and a second surface skin associated with the second planar zone on the exterior of the non-woven material. The non-woven material has a woven, knitted, or non-woven layer added on either one or both sides of the non-woven material.

Abstract: The inventive cosmetic pad (2) exhibiting an improved effectiveness thereof for make-up removal contains or consists of discontinuous synthetic micro staple fibers whose length is equal to or greater than 7 mm.

Abstract: A non-woven material including first effect fibers, first binder fibers, second binder fibers, and second effect fibers. The non-woven material has a first planar zone and a second planar zone. The first planar zone includes a greater concentration of first effect fibers and first binder fibers. The second planar zone includes a greater concentration of second effect fibers and second binder fibers. The first planar zone can include a first surface skin associated with the first planar zone on the exterior of the non-woven material, and a second surface skin associated with the second planar zone on the exterior of the non-woven material.

Abstract: A process is disclosed of forming cellulose fibers. The process includes extruding an aqueous solution of cellulose and a solvent through a first member to form molten filaments. The first member has multiple rows of first and second openings with a nozzle positioned in each of the first openings. At least one of the nozzles in one row is staggered from at least one of the nozzles in an adjacent row. At least a portion of each of the molten filaments is shrouded in a pressurized gas emitted through each of the first openings. Each of the molten filaments is contacted with a liquid to remove some of the solvent and transform each of the molten filaments into a continuous solid fiber. The continuous solid fibers are then collected on a moving surface to form a non-woven cellulose web.

Abstract: An apparatus and method in which the apparatus includes a first electrospinning device configured to electrospin first fibers of a first substance, a second electrospinning device configured to electrospin second fibers of a second substance such that first and second fibers combine in a mat formation region, and a biasing device configured to bias the first electrospinning device with a first electric polarity and to bias the second electrospinning device with a second electric polarity of opposite polarity to the first electric polarity to promote attraction and coalescence between the first and second fibers. The method electrospins under the first electric polarity first fibers from the first substance, electrospins under the second electric polarity fibers from the second substance, and coalesces the first and second fibers to form the fiber mat.

Abstract: The present invention provides a non-woven felt material that includes a blend of cotton shoddy and synthetic fibers, and a method of making the same. The blend of cotton shoddy and synthetic fibers is carded and needled to form a batt. The batt is compacted and unified into its stable final shape by heating and soft-pressing, which causes at least a portion of the synthetic fibers to soften and/or melt and thereby bond the needled cotton shoddy and synthetic fibers together. The non-woven felt material according to the invention is strong, tear resistant, yet provides a non-slip, cushioned walking surface that readily absorbs and contains spilled oils, water and/or glycols.

Abstract: New nonwoven fibrous webs are taught which comprise a collected mass of a) directly formed fibers disposed within the web in a C-shaped cross-sectional configuration and b) staple fibers having a crimp of at least 15% dispersed among the directly formed fibers in an amount of at least 5% the weight of the directly formed fibers. The web is lofty but free of macrovoids. Preferably, the web has a filling ratio of at least 50 and a light transmittance variation of about 2% or less. Typically, fibers within the web are bonded together at points of fiber intersection, preferably with autogenous bonds, to provide a compression-resistant matrix. The webs are especially useful as acoustic and thermal insulation.

Abstract: A surface material for an absorbent article includes a fibrous web formed by thermally bondable component fibers bonded together under the effect of a hot blast and has a hot blast-exposed surface and a surface opposite to this hot blast-exposed surface. The fibrous web includes, in turn, a first layer lying on the side of the hot blast-exposed surface and having a buffering function to alleviate an influence of the hot blast upon the surface opposite to this hot blast-exposed surface, and a second layer lying on the side opposite to the hot blast-exposed surface.

Abstract: A heat and fire resistant planar unitary shield formed of heat and flame resistant fibers and voluminous bulking fibers. The shield material has a heat and flame resistant zone with a majority of the heat and flame resistant fibers, and a voluminous bulking zone with a majority of the voluminous bulking fibers. The fibers are distributed through the shield material in an manner that the heat and flame resistant fibers collect closest to the outer surface of the shield with the heat and flame resistant zone, and the voluminous bulking fibers collect closest to the outer surface of the shield material with the voluminous bulking zone.

Abstract: A pillow, pillow form, quilt or other household textile article is comprised of a ticking having a fiberfill inserted into an interior space thereof. The fiberfill is comprised of a luxury fiber blend in the form of either loose fibers or a nonwoven fiber batt. The luxury fiber blend is comprised of a first amount, preferably, five percent by weight, of a luxury fiber such as silk or cashmere and a second amount, preferably ninety-five percent by weight, of a non-luxury fiber such as polyester.

Abstract: A ceiling system having panels suspended from a ceiling with a frame and suspension connections. The panels are a non-woven material including first effect fibers, first binder fibers, second binder fibers, and second effect fibers. The non-woven material has a first planar zone and a second planar zone. The first planar zone includes a greater concentration of first effect fibers and first binder fibers. The second planar zone includes a greater concentration of second effect fibers and second binder fibers. The first planar zone can include a first surface skin associated with the first planar zone on the exterior of the non-woven material, and a second surface skin associated with the second planar zone on the exterior of the non-woven material.

Abstract: The present invention relates to a pre-moistened wipe for treating a surface, said pre-moistened wipe comprising: (a) a substrate; wherein said substrate is substantially free of a binder or latex material and said; and (b) a composition applied to said substrate, said composition having (i) a pH of about 7 or less and comprising (ii) at least about one surfactant; and (iii) a polymeric biguanide.

Abstract: Mattress and home furnishing items are made open flame resistant by a fire barrier fabric that includes chlorine-free rayon fiber. The fire barrier fabric at least partially encloses the core of the open flame resistant mattress or home furnishing item. When tested in accordance with the flame resistance test protocols of NFPA 267 or ASTM E 1590, the mattress has a maximum heat release rate of less than 250 kW and a total energy release of less than 40 MJ in the first five minutes of the test. The home furnishing items may be tested under test protocols such as California Technical Bulletin #604 or #117. TEQ of the products of the combustion of chlorine-free fibers, yarns and fabrics is less than or equal to 2 nanograms.

Abstract: A non-woven material including first effect fibers, first binder fibers, second binder fibers, and bulking fibers. The non-woven material has a first planar zone with an exterior skin, and a bulking zone. The first planar zone includes a greater concentration of first effect fibers and first binder fibers. The bulking zone includes a greater concentration of bulking fibers and second binder fibers. The first effect fibers can be fire retardant fibers.

Abstract: A nonwoven web of a wettable fiber matrix, wherein the wettable fiber matrix are thermoplastic polymeric fibers blended with at least one hydrophilic melt additive. In alternate embodiments, the nonwoven web further includes binder fibers which may be wettable or non-wettable or combinations of both.

Abstract: A novel porous fibrous structure containing from 10 to 100% by weight of wet heat bonding fibers, having cellular cavities in the fibrous structure of the fibers, in which a plurality of indefinite cellular cavities are present independently or in a state of partially connected in the inside of the fibrous structure, at least a portion of the fibers constituting the fibrous structure is heat bonding by the wet heat bonding fibers, and a process for producing such porous fibrous structure.

Abstract: The present invention relates to a non-woven web comprising fibers and feathers for use as a substrate for cleaning articles. The non-woven web may be created using a variety of non-woven processing techniques and bonding treatments to bond the fibers. The non-woven web is made by combination of variety of fiber types and feathers in varying proportions which create non-woven webs with varying levels of loft, weight, tensile strength, absorbency and abrasiveness.