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 heat-insulating protective member for skid posts contains a needled blanket of inorganic fibers. At least some of the needled blanket has, disposed therein, an impregnation part where an oxide-precursor-containing liquid is adherent in an undried state. The impregnation part has a water content of 50-400 parts by mass per 100 parts by mass of the inorganic fibers of the impregnation part. The water content of the heat-insulating protective member is 50-400 parts by mass per 100 parts by mass of the inorganic fibers of the heat-insulating protective member. The oxide-precursor-containing liquid contains ingredients that, upon burning, yield a composition containing Al.sub.2O.sub.3 and CaO. The oxide-precursor-containing liquid is adherent in an amount of 2-50 parts by mass in terms of oxide amount per 100 parts by mass of the inorganic fibers of the impregnation part. A molar ratio of Al/Ca, in the whole impregnation part is 10-330.

A hydroformed composite material includes an expanded spun bonded nonwoven layer having a loft of at least about 1.3 times greater than an original loft of an original unexpanded spun bonded nonwoven web from which the expanded spun bonded nonwoven layer was created, and an air permeability of at least about 1.2 times greater than an original air permeability of the original unexpanded spun bonded nonwoven web. The hydroformed composite material includes a formed film layer that includes a plurality of extended cells containing continuous fibers and/or fibrils of the expanded spun bonded nonwoven layer.

A non-woven fabric board for an exterior of a vehicle and a method for manufacturing same are provided. The non-woven fabric board includes a matrix fiber having a non-circular cross-section and an adhesive fiber having a non-circular cross-section, and the matrix fiber is included in an amount of 50 wt % or greater based on the total weight of the non-woven fiber board. Each of the matrix fiber and the adhesive fiber have a linear density of about 6 to 15 denier and a degree of non-circular shape of about 1.3 to 3.0.

The non-woven fabric board for an exterior of a vehicle has a substantially increased specific surface area by using the non-circular cross-section fibers, improved adhesion efficiency between fibers, and substantially improved mechanical properties. In addition, heat moldability thereof is improved, weight thereof is reduced, and the sound-absorbing performance thereof is substantially improved.

A formaldehyde-free and fluorine-free needling additive for the manufacture of needle felts of mineral wool, which contains an aqueous solution or an aqueous dispersion of at least one halogen-free cationic polymer on the basis of azacyclopropane (ethyleneimine). Needle felts of mineral wool that are produced using such needling additive virtually do not emit any aldehydes even in a use of up to 500° C., and are absolutely free of volatile fluorine-containing organic and inorganic compounds, in particular hydrogen fluoride. The needle felts are best suited for heat insulation in household appliances such as ovens, especially those including a high-temperature cleaning program.

A formaldehyde-free and fluorine-free needling additive for the manufacture of needle felts of mineral wool, which contains an aqueous solution or an aqueous dispersion of at least one halogen-free cationic polymer on the basis of azacyclopropane (ethyleneimine). Needle felts of mineral wool that are produced using such needling additive virtually do not emit any aldehydes even in a use of up to 500° C., and are absolutely free of volatile fluorine-containing organic and inorganic compounds, in particular hydrogen fluoride. The needle felts are best suited for heat insulation in household appliances such as ovens, especially those including a high-temperature cleaning program.

Methods for forming a touch fastening material are described as including: providing a lengthwise-incoherent layer of staple fibers supported directly on a bed of bristle tips of a brush; needling the layer of staple fibers by cycling needles through the layer of staple fibers and into the brush; then, while the needled layer of staple fibers remains supported on the brush, fusing portions of the staple fibers by at least partially melting resin of the fibers disposed outside the brush; and then pulling the layer of fibers from the brush as a lengthwise-coherent touch fastening material having exposed fastening loops pulled from between the brush bristles.

Methods for forming a touch fastening material are described as including: providing a lengthwise-incoherent layer of staple fibers supported directly on a bed of bristle tips of a brush; needling the layer of staple fibers by cycling needles through the layer of staple fibers and into the brush; then, while the needled layer of staple fibers remains supported on the brush, fusing portions of the staple fibers by at least partially melting resin of the fibers disposed outside the brush; and then pulling the layer of fibers from the brush as a lengthwise-coherent touch fastening material having exposed fastening loops pulled from between the brush bristles.

Methods of making an artificial leather substrate from leather waste (e.g., shavings, such as wet blue, and/or pulverized trim scrap) and products formed using the artificial leather substrate are disclosed. In one example, the artificial leather substrate comprises a composite web comprising leather waste mixed with a lightweight web, a lightweight web atop the composite web, and another lightweight web atop the first lightweight web. A method of making the artificial leather substrate includes the steps of mixing one or more fiber components, leather shavings, and/or pulverized leather trim scrap to form the composite web; needle punching the composite web; and bonding the composite web.

Methods of making an artificial leather substrate from leather waste (e.g., shavings, such as wet blue, and/or pulverized trim scrap) and products formed using the artificial leather substrate are disclosed. In one example, the artificial leather substrate comprises a composite web comprising leather waste mixed with a lightweight web, a lightweight web atop the composite web, and another lightweight web atop the first lightweight web. A method of making the artificial leather substrate includes the steps of mixing one or more fiber components, leather shavings, and/or pulverized leather trim scrap to form the composite web; needle punching the composite web; and bonding the composite web.