A method of making a three-dimensional web is provided. The method comprises spinning continuous filaments from a spinneret, moving the spun continuous filaments along a travel path having an end, and rotating a collection surface at or proximate to the end of the travel path. The collection surface comprises cavities and land areas. The land areas are tangentially planar with an outer surface of the collection surface. The cavities are recessed with respect to the outer surface of the collection surface. The method comprises applying a fluid pressure to the collection surface and collecting the filaments on the collection surface to create an intermediate three-dimensional web having first regions formed in the cavities and second regions formed on the land areas. The first and second regions differ in at least one intensive property. The method comprises bonding the intermediate web using a bonding operation to form a final three-dimensional web.

A system for bonding a first layer having short fibers with a second layer having long fibers into a nonwoven web. The system includes a belt, a headbox, a depositing belt with a delivery strand, a transfer belt with a receiving strand, a device, a pre-bonding unit, and a bonding device. The short fibers are deposited on the depositing belt to form the first layer with the headbox. The transfer belt transfers the first layer to the second layer. The pre-bonding unit has spaced-apart compacting devices which act on the transfer belt to form a lower strand of the transfer belt there between. The bonding device is arranged between the compacting devices. The bonding device bonds the first and second layers. The compacting devices and the bonding device are operatively connected to one another so that they are each always either in an operating state or in a resting state.

A system for bonding a first layer having short fibers with a second layer having long fibers into a nonwoven web. The system includes a belt, a headbox, a depositing belt with a delivery strand, a transfer belt with a receiving strand, a device, a pre-bonding unit, and a bonding device. The short fibers are deposited on the depositing belt to form the first layer with the headbox. The transfer belt transfers the first layer to the second layer. The pre-bonding unit has spaced-apart compacting devices which act on the transfer belt to form a lower strand of the transfer belt there between. The bonding device is arranged between the compacting devices. The bonding device bonds the first and second layers. The compacting devices and the bonding device are operatively connected to one another so that they are each always either in an operating state or in a resting state.

The present invention relates to a method of manufacturing a non-synthetic textile surface structure, and to the non-synthetic textile surface structure itself.

The present invention relates to a method of manufacturing a non-synthetic textile surface structure, and to the non-synthetic textile surface structure itself.

A cross-lapped multilayered batt, and a method of making the same is presented. The batt includes one or more layers of a carded web of staple fibers, and one or more continuous filament fiber layers. At least some of the staple fibers and, in some instances, some of the continuous filament fibers are mechanically entangled through a thickness of the batt. The method includes folding both the carded web and the continuous filament fiber layers together, and subjecting the folded layers to a needle-punching process to impart structural stability and enhance the Z-directional strength of the batt.

A process for making insulating fabric that includes mechanically orienting wool fibers into a batting capable of being used for insulation, and tacking the batting to a scrim with a loom via needles coupled to a needle board of the loom. Each of the needles includes a body having a pointed end and barbed edges, thereby enabling engagement with the batting when stroking in a first direction, and substantial disengagement with the batting when stroking in a second direction, wherein the tacking is performed primarily without the use of an adhesive.

A process for making insulating fabric that includes mechanically orienting wool fibers into a batting capable of being used for insulation, and tacking the batting to a scrim with a loom via needles coupled to a needle board of the loom. Each of the needles includes a body having a pointed end and barbed edges, thereby enabling engagement with the batting when stroking in a first direction, and substantial disengagement with the batting when stroking in a second direction, wherein the tacking is performed primarily without the use of an adhesive.

An installation for consolidating a batt of fibers, for example a nonwoven web, includes a mechanical consolidation workstation using needlepunching from which the fiber batt emerges in a machine or MD direction. A device is provided downstream of the consolidation workstation for stretching in the cross or CD direction which is transverse, in particular perpendicular, to the machine direction, and parallel to the plane of the batt, particularly before it is wound onto a reel. A consolidated nonwoven that can be obtained by the installation is also provided.

An installation for consolidating a batt of fibers, for example a nonwoven web, includes a mechanical consolidation workstation using needlepunching from which the fiber batt emerges in a machine or MD direction. A device is provided downstream of the consolidation workstation for stretching in the cross or CD direction which is transverse, in particular perpendicular, to the machine direction, and parallel to the plane of the batt, particularly before it is wound onto a reel. A consolidated nonwoven that can be obtained by the installation is also provided.