A nonwoven material is composed of a nonwoven batt of a plurality of bundles formed of carbon fibers. At least some of the bundles have a curved progression that includes a curved vertex area of a first curvature between the bundle ends and at least one bundle end area of a second curvature extending from said one bundle end to the vertex. The first curvature is greater than the second curvature, in particular it is greater by at least 50%.

A method of forming carded fibers of different materials. A feed system has a plurality of separate laterally spaced chambers containing fibers of different materials. The different fibers are fed in separate laterally spaced paths into a carding apparatus having a plurality of rollers and cylinders each having laterally spaced sections in alignment with the laterally spaced paths to receive and maintain the different fibers in the laterally spaced paths thereon as they move through the carding apparatus. The different fibers are combined into a multi-fiber roving or web after they exit the carding apparatus. Depending on the composition of the different fibers, they may be combined by conveying them through a humidifying and heated chamber or chambers.

A method of forming carded fibers of different materials. A feed system has a plurality of separate laterally spaced chambers containing fibers of different materials. The different fibers are fed in separate laterally spaced paths into a carding apparatus having a plurality of rollers and cylinders each having laterally spaced sections in alignment with the laterally spaced paths to receive and maintain the different fibers in the laterally spaced paths thereon as they move through the carding apparatus. The different fibers are combined into a multi-fiber roving or web after they exit the carding apparatus. Depending on the composition of the different fibers, they may be combined by conveying them through a humidifying and heated chamber or chambers.

An article of manufacture making system for making an article of manufacture containing a plurality of dry solid additives, such as fibers, that utilizes a dry solid additive delivery system with a relatively low Stokes Number for the dry solid additives.

An article of manufacture making system for making an article of manufacture containing a plurality of dry solid additives, such as fibers, that utilizes a dry solid additive delivery system with a relatively low Stokes Number for the dry solid additives.

An insulating fill material composition for use in outerwear, sleeping bags, bedding, and the like includes 40.0 to 85.0 wt % alpaca fibers, 10.0 to 20.0 wt % bicomponent fibers, and 5.0 to 40.0 wt % polyester fibers. The alpaca fibers have a length of 40.0 to 70.0 mm. The bicomponent fibers have a length of 40.0 mm to 60.0 mm and a linear mass density of 0.11 to 0.33 mg/m. The polyester fibers have a length of 40.0 mm to 60.0 mm and a linear mass density of 0.22 to 0.44 mg/m. Blending, combing, carding, and lapping of the alpaca fibers, the bicomponent fibers, and the polyester fibers forms a matte, which when needled and heated forms a batting having a weight of 50.0 to 400.0 g/m.sup.2.

An insulating fill material composition for use in outerwear, sleeping bags, bedding, and the like includes 40.0 to 85.0 wt % alpaca fibers, 10.0 to 20.0 wt % bicomponent fibers, and 5.0 to 40.0 wt % polyester fibers. The alpaca fibers have a length of 40.0 to 70.0 mm. The bicomponent fibers have a length of 40.0 mm to 60.0 mm and a linear mass density of 0.11 to 0.33 mg/m. The polyester fibers have a length of 40.0 mm to 60.0 mm and a linear mass density of 0.22 to 0.44 mg/m. Blending, combing, carding, and lapping of the alpaca fibers, the bicomponent fibers, and the polyester fibers forms a matte, which when needled and heated forms a batting having a weight of 50.0 to 400.0 g/m.sup.2.

A method of manufacturing a synthetic bale, including the steps of heating a mixture of a first plurality of fibers with a second plurality of fibers to cause the first plurality of fibers and the second plurality of fibers to thermally bond with one another to create bonded fibers, directing the bonded fibers into a forming chamber, and outputting the bonded fibers into a sheath configured for use as a synthetic ground-based bale.

A method for manufacturing at least one of fibers and yarn from natural fibers includes providing at least one of technical fibers, elementary fibers, meso fibrils, and micro fibrils. Greater than or equal to 80% of the at least one of the technical fibers, the elementary fibers, the meso fibrils, and the micro fibrils are short natural fibers having a length that is less than or equal to 12.7 mm. The method includes creating at least one of a dispersion, a gel, a solution, a paste, and a dough including the at least one of the technical fibers, the elementary fibers, the meso fibrils and the micro fibrils; and spinning filaments of the at least one of fibers and yarn using the at least one of the dispersion, the gel, the solution, the paste, and the dough.

A method for manufacturing at least one of fibers and yarn from natural fibers includes providing at least one of technical fibers, elementary fibers, meso fibrils, and micro fibrils. Greater than or equal to 80% of the at least one of the technical fibers, the elementary fibers, the meso fibrils, and the micro fibrils are short natural fibers having a length that is less than or equal to 12.7 mm. The method includes creating at least one of a dispersion, a gel, a solution, a paste, and a dough including the at least one of the technical fibers, the elementary fibers, the meso fibrils and the micro fibrils; and spinning filaments of the at least one of fibers and yarn using the at least one of the dispersion, the gel, the solution, the paste, and the dough.