A perforated non-woven fabric having at least one fiber layer that has a plurality of through holes. The total area of the through holes accounts for 10˜80% of the total area of the perforated non-woven fabric; the opening of the through holes is flat with the surface of the perforated non-woven fabric; and the density of through holes on the perforated non-woven fabric is 3/cm.sup.2˜100/cm.sup.2. The fiber density at the edge of each through hole is similar to or the same as the fiber density in other areas of the perforated non-woven fabric. The fiber surrounds the through hole, and only the surface of the fiber is bonded to each other.

A perforated non-woven fabric having at least one fiber layer that has a plurality of through holes. The total area of the through holes accounts for 10˜80% of the total area of the perforated non-woven fabric; the opening of the through holes is flat with the surface of the perforated non-woven fabric; and the density of through holes on the perforated non-woven fabric is 3/cm.sup.2˜100/cm.sup.2. The fiber density at the edge of each through hole is similar to or the same as the fiber density in other areas of the perforated non-woven fabric. The fiber surrounds the through hole, and only the surface of the fiber is bonded to each other.

A composite board is made at least partially of a nonwoven composite material. The nonwoven composite material includes unraveled natural fibers and/or glass fibers, plastic fibers, and between 0 and 50% weight of thermoharder. Also, a process for manufacturing the composite board comprises mixing unraveled natural fibers and/or glass fibers with plastic fibers, and with less than 50% weight thermoharder, and thermoforming the mix into a nonwoven composite material layer. Further, the composite board is for use in all applications wherein Particle Board, Medium and High Density Fibreboard, Oriented Strand Board, Laminated Veneer Lumber, Plywood and related materials are used, and in wall panels, separation panels, insulation panels, laminates, flooring, in particular laminate flooring, tiles, furniture, and related applications.

A composite board is made at least partially of a nonwoven composite material. The nonwoven composite material includes unraveled natural fibers and/or glass fibers, plastic fibers, and between 0 and 50% weight of thermoharder. Also, a process for manufacturing the composite board comprises mixing unraveled natural fibers and/or glass fibers with plastic fibers, and with less than 50% weight thermoharder, and thermoforming the mix into a nonwoven composite material layer. Further, the composite board is for use in all applications wherein Particle Board, Medium and High Density Fibreboard, Oriented Strand Board, Laminated Veneer Lumber, Plywood and related materials are used, and in wall panels, separation panels, insulation panels, laminates, flooring, in particular laminate flooring, tiles, furniture, and related applications.

A device for producing a 3 dimensional shaped consolidated product. The device includes a rotary drum, defined as a rotary conveyor with a peripheral surface extending in circumferential direction with at least one product shaping area in the form of a cavity on said peripheral surface, the peripheral surface is pervious to air at least in the product shaping area, at least one material feed device to feed a base material into the at least one cavity, a vacuum device designed to generate a negative pressure at least in the at least one cavity, whereby the generated suction is directed towards the interior of the rotary conveyor, and whereby downstream of the material feed device at least one consolidating device is located such that at least a part of the filled cavity is subjected to a consolidating treatment whereby the base material at least partly will adhere to neighboring material.

A device for producing a 3 dimensional shaped consolidated product. The device includes a rotary drum, defined as a rotary conveyor with a peripheral surface extending in circumferential direction with at least one product shaping area in the form of a cavity on said peripheral surface, the peripheral surface is pervious to air at least in the product shaping area, at least one material feed device to feed a base material into the at least one cavity, a vacuum device designed to generate a negative pressure at least in the at least one cavity, whereby the generated suction is directed towards the interior of the rotary conveyor, and whereby downstream of the material feed device at least one consolidating device is located such that at least a part of the filled cavity is subjected to a consolidating treatment whereby the base material at least partly will adhere to neighboring material.

To prepare a shaped product comprising a thermal adhesive fiber under moisture and having a fiber aggregate nonwoven structure. In the shaped product, the thermal adhesive fibers under moisture are melted to bond to fibers constituting the fiber aggregate nonwoven structure and the bonded fiber ratio is not more than 85%. The shaped product has an apparent density of 0.05 to 0.7 g/cm.sup.3, a maximum bending stress of not less than 0.05 MPa in at least one direction, and a bending stress of not less than ⅕ of the maximum bending stress at 1.5 times as large as the bending deflection at the maximum bending stress. The moistenable-thermal adhesive fiber may be a sheath-core form conjugated fiber comprising a sheath part comprising an ethylene-vinyl alcohol-series copolymer and a core part comprising a polyester-series resin. Such a shaped product can be used for a building board or the like since the shaped product has a high bending stress although the product is light and has a low density.

To prepare a shaped product comprising a thermal adhesive fiber under moisture and having a fiber aggregate nonwoven structure. In the shaped product, the thermal adhesive fibers under moisture are melted to bond to fibers constituting the fiber aggregate nonwoven structure and the bonded fiber ratio is not more than 85%. The shaped product has an apparent density of 0.05 to 0.7 g/cm.sup.3, a maximum bending stress of not less than 0.05 MPa in at least one direction, and a bending stress of not less than ⅕ of the maximum bending stress at 1.5 times as large as the bending deflection at the maximum bending stress. The moistenable-thermal adhesive fiber may be a sheath-core form conjugated fiber comprising a sheath part comprising an ethylene-vinyl alcohol-series copolymer and a core part comprising a polyester-series resin. Such a shaped product can be used for a building board or the like since the shaped product has a high bending stress although the product is light and has a low density.

Provided are a space filling material and a space filling structure capable of filling a predetermined space for various purposes, and method for using those. A space filling material (11) includes reinforcing fibers as an expansion material and a resin. The reinforcing fibers form a plurality of intersections and are bonded with the resin at at least one of the intersections. Heating of the space filling material causes an expansion stress in at least a thickness direction (X) such that the space filling material fills a predetermined space (13). For example, the space filling material may contain the resin at a volume ratio of 15 to 95 vol % based on a total volume of the reinforcing fibers and the resin.

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.