Described is a composite made from a woven fabric, a non-woven fabric, or a knitted face fabric and a non-woven fabric. The woven fabric, the non-woven fabric, or the knitted face fabric is needle punched such that fibers protrude into the non-woven fabric. The woven fabric, the non-woven fabric, or the knitted face fabric has a first polymer having a first melting point and a second polymer having a second melting point being higher than the first melting point. The nonwoven backing material comprises a third polymer having a third melting point and a fourth polymer having a fourth melting point being higher than the third melting point. The woven fabric, the non-woven fabric, or the knitted face fabric is further bonded to the nonwoven backing material applying heat to at least partially melt or soften the first polymer and the third polymer such that they bond together.

Described is a composite made from a woven fabric, a non-woven fabric, or a knitted face fabric and a non-woven fabric. The woven fabric, the non-woven fabric, or the knitted face fabric is needle punched such that fibers protrude into the non-woven fabric. The woven fabric, the non-woven fabric, or the knitted face fabric has a first polymer having a first melting point and a second polymer having a second melting point being higher than the first melting point. The nonwoven backing material comprises a third polymer having a third melting point and a fourth polymer having a fourth melting point being higher than the third melting point. The woven fabric, the non-woven fabric, or the knitted face fabric is further bonded to the nonwoven backing material applying heat to at least partially melt or soften the first polymer and the third polymer such that they bond together.

An needling machine and process needle a nonwoven fibrous web (2) fed in a direction of passage (3). A needling unit (5) with oscillatingly moved needles (11) is configured to needle and strengthen the nonwoven fibrous web (2). The needling unit (5) has a lifting drive (6) and parallel, linearly guided driving rods (15, 16) driven reversably thereby. The needling unit (5) has a supporting beam (8) connected to the needles (11) and extending in the direction of passage (3). Driving rods (15), arranged one after another in the direction of passage (3), are each connected to the supporting beam (8) via a respective beam bearing (18, 19) in an articulated manner. One of the beam bearings (18, 19), arranged one after another in the direction of passage (3), has an additional degree of freedom of motion.

An needling machine and process needle a nonwoven fibrous web (2) fed in a direction of passage (3). A needling unit (5) with oscillatingly moved needles (11) is configured to needle and strengthen the nonwoven fibrous web (2). The needling unit (5) has a lifting drive (6) and parallel, linearly guided driving rods (15, 16) driven reversably thereby. The needling unit (5) has a supporting beam (8) connected to the needles (11) and extending in the direction of passage (3). Driving rods (15), arranged one after another in the direction of passage (3), are each connected to the supporting beam (8) via a respective beam bearing (18, 19) in an articulated manner. One of the beam bearings (18, 19), arranged one after another in the direction of passage (3), has an additional degree of freedom of motion.

A control system for controlling a needling machine includes at least one needle plate having an array of needles and drive systems. The control system can include a drive tie-rod that can be coupled to one or more of the needles, the at least one needle plate, and a part rigidly connected to the at least one needle plate. The control system can include a cam shaft and a rod, the cam shaft driving the rod in rotation in an axis of rotation, and the rod being connected to the drive tie-rod by a part forming an intermediate lever. The lever can be a single part or a plurality of parts and is able to pivot in relation to a pivot pin.

A control system for controlling a needling machine includes at least one needle plate having an array of needles and drive systems. The control system can include a drive tie-rod that can be coupled to one or more of the needles, the at least one needle plate, and a part rigidly connected to the at least one needle plate. The control system can include a cam shaft and a rod, the cam shaft driving the rod in rotation in an axis of rotation, and the rod being connected to the drive tie-rod by a part forming an intermediate lever. The lever can be a single part or a plurality of parts and is able to pivot in relation to a pivot pin.

A needle board for fastening to a needle beam of a needle loom, which serves for consolidating a fibrous pile web, comprises a carrier plate having a receiving apparatus in which a plurality of needle modules are received which are arranged in a row. The needle board further comprises a fluid-activatable clamping device which is configured to fix the plurality of needle modules in the receiving apparatus at least in a first direction.

A needle board for fastening to a needle beam of a needle loom, which serves for consolidating a fibrous pile web, comprises a carrier plate having a receiving apparatus in which a plurality of needle modules are received which are arranged in a row. The needle board further comprises a fluid-activatable clamping device which is configured to fix the plurality of needle modules in the receiving apparatus at least in a first direction.

A method of producing a needled product of a selected material or materials of a desired thickness and size. A first carded batt of a selected material or materials is moved from a feed support into a needle loom between a vertically reciprocating needle bed and a support bed located beneath and in spaced relation to the needle bed. The needle bed and/or the support bed are vertically movable to vary the spacing therebetween. The upper surface of the first carded batt is penetrated by the needles in the needle loom so that the needles do not reach an upper surface of the support bed and are able to flex laterally. The needled first batt is then lifted and moved to the feed support or a feed support for another needle loom. Thereafter, a second batt is positioned over the first batt in overlapping relation, the needle bed or support bed is moved to increase the vertical spacing therebetween to accommodate the overlapped batts, and the batts are moved through the needle loom and connected. This method may be repeated to add additional overlapped batts to produce a layered product of any suitable thickness.

A method of producing a needled product of a selected material or materials of a desired thickness and size. A first carded batt of a selected material or materials is moved from a feed support into a needle loom between a vertically reciprocating needle bed and a support bed located beneath and in spaced relation to the needle bed. The needle bed and/or the support bed are vertically movable to vary the spacing therebetween. The upper surface of the first carded batt is penetrated by the needles in the needle loom so that the needles do not reach an upper surface of the support bed and are able to flex laterally. The needled first batt is then lifted and moved to the feed support or a feed support for another needle loom. Thereafter, a second batt is positioned over the first batt in overlapping relation, the needle bed or support bed is moved to increase the vertical spacing therebetween to accommodate the overlapped batts, and the batts are moved through the needle loom and connected. This method may be repeated to add additional overlapped batts to produce a layered product of any suitable thickness.