A manufacturing method includes: a step for producing a batt of fibers, elongated in a longitudinal direction, by batting with interlacing of the fibers, a step for passing the batt of fibers, in the longitudinal direction, through a loop-forming device having a set of rotary discs and stationary loop-forming elements, so as to generate undulations, and, following the passing step, a step for bringing the batt of fibers onto a conveyor equipped with brushes, and accumulating the undulations in the brushes so as to achieve a predetermined density.

Acoustic mediums are disclosed herein. The acoustic mediums can include a plurality of layers. The layers of the acoustic mediums can include fibrous acoustic materials that are entangled throughout the layer. In certain instances, the layers of the acoustic medium can include first portion of acoustic materials disposed along a first plane, and a second portion of acoustic materials disposed along a second plane. Methods of fabricating multi-layer acoustic mediums are also disclosed.

Acoustic mediums are disclosed herein. The acoustic mediums can include a plurality of layers. The layers of the acoustic mediums can include fibrous acoustic materials that are entangled throughout the layer. In certain instances, the layers of the acoustic medium can include first portion of acoustic materials disposed along a first plane, and a second portion of acoustic materials disposed along a second plane. Methods of fabricating multi-layer acoustic mediums are also disclosed.

Disclosed are a method of manufacturing a flame-retardant rayon staple fiber, and a flame-retardant rayon staple fiber laminate made from the same staple fiber. The method includes a step of impregnating a flame-retardant staple fiber web with a flame-retardant solution in which a starch and an inorganic powder are mixed and a step of drying the impregnated staple fiber web. When the flame-retardant rayon staple fiber is manufactured by the method, inorganic particles absorbed by the staple fiber do not easily detach, thereby improving flame retardancy of the fiber. When a staple fiber laminate is made from the staple fiber manufactured by the method, the strength of the laminate is improved due to the presence of the starch, and the workability and moldability of the laminate are also improved due to the increased strength.

A chewable product for oral delivery of a substance. The chewable product is an essentially homogenous portion of nonwoven fabric impregnated with the substance. For example, the chewable product may comprise a nonwoven fabric substrate having a matrix of interleaved fibres. The substance is held within the matrix and releasable therefrom by a chewing action. The nonwoven fabric substrate thus provides a frame for carrying the substance that is both resistant to chewing action (i.e. does not disintegrate when chewed, bitten or sucked) and capable of releasing the substance. The nonwoven fabric substrate may be formed by passing an initial web through a needle loom. The substance may be connected to fibres in the matrix by a binder.

A method and system for the production of a web the fibers of which form a mean angle with respect to the longitudinal direction. The method and system include the passage of the web through a looping system, the passing of the web over a conveyor provided with brushes, the deposition of a first pre-needle-punched layer of fibers over the accumulated undulations, the assembling of the accumulated undulations with the first pre-needle-punched layer by needling, the assembling of the structure with a second pre-needle-punched layer of fibers, so as to obtain a sandwich structure, and the separation of the sandwich structure so as to obtain two symmetrical velour coverings. The web is a card web with a mean angle between 5 and 10° and an area density between 80 and 120 g/m.sup.2. The method includes a longitudinal drawing of the web, with a stretch ratio between 1.5 and 2.

A needled blanket is provided comprising melt-formed inorganic fibres having an overall composition in weight percent SiO.sub.2: 47 to 65% Al.sub.2O.sub.3: 35 to 53%the blanket having a shot content, of shot >45 .Math.m, of less than 51 wt%, a specific surface area (BET) > 0.25 m.sup.2.g.sup.-1.also disclosed are fibres for producing such blankets, and self-supporting products made from such fibres.

A needled blanket is provided comprising melt-formed inorganic fibres having an overall composition in weight percent SiO.sub.2: 47 to 65% Al.sub.2O.sub.3: 35 to 53%the blanket having a shot content, of shot >45 .Math.m, of less than 51 wt%, a specific surface area (BET) > 0.25 m.sup.2.g.sup.-1.also disclosed are fibres for producing such blankets, and self-supporting products made from such fibres.

A method of forming a multi-layer needled non-woven article, comprising forming a web of a fiber base layer, an intermediate film and a fiber top layer, wherein the intermediate film is disposed between the fiber base layer and the fiber top layer; needle punching the web with a plurality of needles; and wherein, during needle punching, fibers of the fiber base layer are carried by the needles, extended through perforations in the intermediate film formed by the needles and entangled with fibers of the fiber top layer.

A method of forming a multi-layer needled non-woven article, comprising forming a web of a fiber base layer, an intermediate film and a fiber top layer, wherein the intermediate film is disposed between the fiber base layer and the fiber top layer; needle punching the web with a plurality of needles; and wherein, during needle punching, fibers of the fiber base layer are carried by the needles, extended through perforations in the intermediate film formed by the needles and entangled with fibers of the fiber top layer.