For a process for producing a motor vehicle interior trim material including or consisting at least essentially of a needlefelt which includes a fibre blend including 25-35 wt % of polyamide (PA) fibres and 65-75 wt % of polyester (PES) fibres, preferably without other, bonding fibres, and is consolidated mechanically by needling and via adhesive bonding, it shall be achieved to provide a needlefelt material, in particular a motor vehicle interior trim material, which has a visually appealing surface finish even after thermoforming in the temperature range between 150 C. and 250 C.

For a process for producing a motor vehicle interior trim material including or consisting at least essentially of a needlefelt which includes a fibre blend including 25-35 wt % of polyamide (PA) fibres and 65-75 wt % of polyester (PES) fibres, preferably without other, bonding fibres, and is consolidated mechanically by needling and via adhesive bonding, it shall be achieved to provide a needlefelt material, in particular a motor vehicle interior trim material, which has a visually appealing surface finish even after thermoforming in the temperature range between 150 C. and 250 C.

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 refers to a composite material developed for manufacturing thermoformed products with applications in furniture making, automotive industry, etc., a method and machinery for the manufacturing of the material in unwoven form. The composite material for thermoforming is made of a thermoplastic fibrous component consisting of 4-60 mm long and 7-16 DEN fine polypropylene fibers representing 40% to 50% of the total material weight and a plant fiber component which can be hemp, jute, sisal, coconut, etc., or a mix of natural fibers which is 70-80 DEN fine and 5 to 100 mm in length and represents 60% to 50% of the total material weight. The process for manufacturing the claimed composite material consists in taking and proportioning the components, followed by their mixing and coarse defibering and then a fine mixing in a four-chamber module which also opens the natural fibers to 70 . . . 80 DEN fine, followed by the consolidation of the fibers and, finally, the rolling of the resulting fabric in a roll. The machinery for the manufacturing of the claimed composite material has a modular structure, comprising two modules (1 and 2) for feeding the components, two modules (3 and 4) for weighing and proportioning the components, a primary mixing and coarse defibering module (5), a module (7) for the fine mixing and fibre opening, an interlacing module (8) and a module (9) for pulling and rolling the final fabric.

A thermal insulation batt is created from recycled carpet fibers and fire resistant cotton shoddy bonded by staples of bi-component fiber having a polyester core and low melting polymeric sheath. The low melting polymeric sheath melts at a temperature well below the melting or degradation temperature of any of the carpet fibers from the recycled carpets. Since the sheath has a small thickness, the amount of melt created is small and bonding occurs only between the bi-component staple fiber and adjacent carpet fiber or fire resistant cotton shoddy without melt overflow. The rigidized thermal insulation batt can be used in a building between studs and may be used in an automobile door for sound proofing. This product is particularly well suited for use as acoustic and thermal insulation in buildings as non-load bearing partitions in interior offices of commercial buildings. This bonded low density composite fibrous structure has fire retarding constituents incorporated within the batt to retard propagation of building fire. These stated uses are non-limiting; and other uses are contemplated, including automobile interior structures.

A thermal insulation batt is created from recycled carpet fibers and fire resistant cotton shoddy bonded by staples of bi-component fiber having a polyester core and low melting polymeric sheath. The low melting polymeric sheath melts at a temperature well below the melting or degradation temperature of any of the carpet fibers from the recycled carpets. Since the sheath has a small thickness, the amount of melt created is small and bonding occurs only between the bi-component staple fiber and adjacent carpet fiber or fire resistant cotton shoddy without melt overflow. The rigidized thermal insulation batt can be used in a building between studs and may be used in an automobile door for sound proofing. This product is particularly well suited for use as acoustic and thermal insulation in buildings as non-load bearing partitions in interior offices of commercial buildings. This bonded low density composite fibrous structure has fire retarding constituents incorporated within the batt to retard propagation of building fire. These stated uses are non-limiting; and other uses are contemplated, including automobile interior structures.

A thermally insulating sheet formed by a down core structure which is comprised solely of down feather material mixed with binding material which is heat fused together to form a homogeneous sheet core. The method of fabricating the homogeneous thermally insulating sheet to form the down core structure is described. This novel method restrains the down clusters and binding material during the process of mixing, depositing, conveying and heat fusing to form a homogeneous down core sheet. The down core structure is subjected to two separate heat treatments which produces a down core sheet having at least some of its outer surfaces being of higher bond density than the inside of the core.

A structured fiber product is constructed with fibers oriented primarily in a vertical direction. Fibers made from recycled materials are combined with binder fibers which have a lower transition temperature than the recycled fibers. A three dimensional web is formed from the fibers oriented in a horizontal direction. The web is heated to bind the fibers and cooled to fix the web in a predetermined thickness. Sections of the web are stacked while maintaining substantially parallel orientation of the fibers in the horizontal direction, heated to bind the fibers and cooled to fix a predetermined thickness of the structured fiber product. The structured fiber product is rotated so that the fibers are oriented in the vertical direction. One or more slabs of the structured fiber product with vertically oriented fibers may be configured to form a resilient structure such as a mattress core.

A structured fiber product is constructed with fibers oriented primarily in a vertical direction. Fibers made from recycled materials are combined with binder fibers which have a lower transition temperature than the recycled fibers. A three dimensional web is formed from the fibers oriented in a horizontal direction. The web is heated to bind the fibers and cooled to fix the web in a predetermined thickness. Sections of the web are stacked while maintaining substantially parallel orientation of the fibers in the horizontal direction, heated to bind the fibers and cooled to fix a predetermined thickness of the structured fiber product. The structured fiber product is rotated so that the fibers are oriented in the vertical direction. One or more slabs of the structured fiber product with vertically oriented fibers may be configured to form a resilient structure such as a mattress core.