A non-woven textile may be formed from a plurality of thermoplastic polymer filaments. The non-woven textile may have a first region and a second region, with the filaments of the first region being fused to a greater degree than the filaments of the second region. A variety of products, including apparel (e.g., shirts, pants, footwear), may incorporate the non-woven textile. In some of these products, the non-woven textile may be joined with another textile element to form a seam. More particularly, an edge area of the non-woven textile may be heatbonded with an edge area of the other textile element at the seam. In other products, the non-woven textile may be joined with another component, whether a textile or a non-textile.

A method of producing flexible polypropylene fabric bags with heat fused seams comprising providing fabric pieces, wherein each fabric piece has a coated side and an uncoated side; positioning fabric pieces so that a coated side of one fabric piece faces a coated side of another fabric piece; selecting an area of fabric to be joined for forming a seam or joint; applying heat to the area to be joined that is less than the melting point of the fabrics, for forming one or more seams or joints and wherein the heat fused seams or joints of a resulting polypropylene bag retains at least 85% of the fabric strength without using sewing machines.

A method of producing flexible polypropylene fabric bags with heat fused seams comprising providing fabric pieces, wherein each fabric piece has a coated side and an uncoated side; positioning fabric pieces so that a coated side of one fabric piece faces a coated side of another fabric piece; selecting an area of fabric to be joined for forming a seam or joint; applying heat to the area to be joined that is less than the melting point of the fabrics, for forming one or more seams or joints and wherein the heat fused seams or joints of a resulting polypropylene bag retains at least 85% of the fabric strength without using sewing machines.

A non-woven textile may be formed from a plurality of thermoplastic polymer filaments. The non-woven textile may have a first region and a second region, with the filaments of the first region being fused to a greater degree than the filaments of the second region. A variety of products, including apparel (e.g., shirts, pants, footwear), may incorporate the non-woven textile. In some of these products, the non-woven textile may be joined with another textile element to form a seam. More particularly, an edge area of the non-woven textile may be heatbonded with an edge area of the other textile element at the seam. In other products, the non-woven textile may be joined with another component, whether a textile or a non-textile.

A non-woven textile may be formed from a plurality of thermoplastic polymer filaments. The non-woven textile may have a first region and a second region, with the filaments of the first region being fused to a greater degree than the filaments of the second region. A variety of products, including apparel (e.g., shirts, pants, footwear), may incorporate the non-woven textile. In some of these products, the non-woven textile may be joined with another textile element to form a seam. More particularly, an edge area of the non-woven textile may be heatbonded with an edge area of the other textile element at the seam. In other products, the non-woven textile may be joined with another component, whether a textile or a non-textile.

The invention relates to ultrasonic welding of industrial fabrics. Specifically, the invention relates to methods for ultrasonically welding the seam area of industrial fabrics using a textured horn and/or anvil. The fabric edges are overlapped as woven or one or both edges can have some warp or weft yarns raveled out. The method involves ultrasonically bonding the overlapped fabric edges, reducing the caliper of the two stacked edges to match the body caliper of the fabric itself. The bonded area can then be perforated using laser or other mechanical means to produce a seam having the same woven texture and permeability (air and/or water) as the body of the fabric.

A non-woven textile may be formed from a plurality of thermoplastic polymer filaments. The non-woven textile may have a first region and a second region, with the filaments of the first region being fused to a greater degree than the filaments of the second region. A variety of products, including apparel (e.g., shirts, pants, footwear), may incorporate the non-woven textile. In some of these products, the non-woven textile may be joined with another textile element to form a seam. More particularly, an edge area of the non-woven textile may be heatbonded with an edge area of the other textile element at the seam. In other products, the non-woven textile may be joined with another component, whether a textile or a non-textile.

A non-woven textile may be formed from a plurality of thermoplastic polymer filaments. The non-woven textile may have a first region and a second region, with the filaments of the first region being fused to a greater degree than the filaments of the second region. A variety of products, including apparel (e.g., shirts, pants, footwear), may incorporate the non-woven textile. In some of these products, the non-woven textile may be joined with another textile element to form a seam. More particularly, an edge area of the non-woven textile may be heatbonded with an edge area of the other textile element at the seam. In other products, the non-woven textile may be joined with another component, whether a textile or a non-textile.

A system and method for welding edge seams at the edges of fabric is presented. A method begins by lowering a fabric pre-fold bar onto a piece of fabric. A pre-aligned portion of the fabric is pushed on top of the pre-fold bar so that the pre-fold bar is between the portion of fabric on top of the fabric pre-fold bar and other fabric below the pre-fold bar. The fabric on top of the fabric pre-fold bar is folded edge fabric and fabric not on top of the fabric pre-fold bar is not folded edge fabric. A folded edge is formed between these two sections of fabric. The method pinches some of the fabric at the folded end and then pulls the folded edge fabric off of the fabric pre-fold bar. After that, the method welds at least some of the folded edge fabric to the not folded edge fabric.

A system and method for welding edge seams at the edges of fabric is presented. A method begins by lowering a fabric pre-fold bar onto a piece of fabric. A pre-aligned portion of the fabric is pushed on top of the pre-fold bar so that the pre-fold bar is between the portion of fabric on top of the fabric pre-fold bar and other fabric below the pre-fold bar. The fabric on top of the fabric pre-fold bar is folded edge fabric and fabric not on top of the fabric pre-fold bar is not folded edge fabric. A folded edge is formed between these two sections of fabric. The method pinches some of the fabric at the folded end and then pulls the folded edge fabric off of the fabric pre-fold bar. After that, the method welds at least some of the folded edge fabric to the not folded edge fabric.