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.

Disclosed is a wearable article continuous in a longitudinal direction and a transverse direction comprising a body-facing surface and a garment-facing surface; wherein at least a portion of the garment-facing surface is a nonwoven substrate material made of fibers having a Roughness (standard deviation of the grayscale image) of at least about 16, preferably at least about 18, more preferably at least about 20; and a fiber diameter of no more than about 22 μm, preferably no more than about 17 μm, more preferably no more than about 15 μm, according to the measurements herein.

Disclosed is a wearable article continuous in a longitudinal direction and a transverse direction comprising a body-facing surface and a garment-facing surface; wherein at least a portion of the garment-facing surface is a nonwoven substrate material made of fibers having a Roughness (standard deviation of the grayscale image) of at least about 16, preferably at least about 18, more preferably at least about 20; and a fiber diameter of no more than about 22 μm, preferably no more than about 17 μm, more preferably no more than about 15 μm, according to the measurements herein.

The present invention provides a cloth having different properties depending on regions, a cloth product comprising the cloth, and a method of producing the cloth product. The cloth of the present invention is characterized in that it includes a first region and a second region having a higher degree of fusion than the first region, wherein the first region includes a thermally fusible fiber and a fiber having a higher melting point than the thermally fusible fiber at a predetermined ratio. The cloth product of the present invention is characterized in that it includes the body made of the cloth, and the second region is positioned in a region requiring a greater strength than other regions.

A method for making a high topography nonwoven substrate includes generating a foam including water and synthetic binder fibers; depositing the foam on a planar surface; disposing a template form on the foam opposite the planar surface to create a foam/form assembly; heating the foam/form assembly to dry the foam and bind the synthetic binder fibers; and removing the template from the substrate after heating the foam/form assembly, wherein the substrate includes a planar base layer having an X-Y surface and a backside surface opposite the X-Y surface; and a plurality of projection elements integral with and protruding in a Z-direction from the X-Y surface, wherein the projection elements are distributed in both the X- and Y-directions, and wherein the density of a projection element is the same as the density of the base layer.

A system for thermally bonding nonwoven fibers of assemblages of nonwoven fibers loosely held together may include a processing duct including an inlet end, an outlet end, and an intermediate portion extending between the inlet end and the outlet end. The system also may include one or more heat inlets located in the intermediate portion and configured to facilitate introduction of heat and air flow into the intermediate portion. The system further may include an inlet air feed at the inlet end and configured to separate the assemblages upon entry into the inlet end and propel the assemblages into the intermediate portion. The system also may include one or more heating devices configured to heat the assemblages as the assemblages are conveyed toward the outlet end to form processed assemblages, each of the processed assemblages including at least some nonwoven fibers adhered to one another.

A system for thermally bonding nonwoven fibers of assemblages of nonwoven fibers loosely held together may include a processing duct including an inlet end, an outlet end, and an intermediate portion extending between the inlet end and the outlet end. The system also may include one or more heat inlets located in the intermediate portion and configured to facilitate introduction of heat and air flow into the intermediate portion. The system further may include an inlet air feed at the inlet end and configured to separate the assemblages upon entry into the inlet end and propel the assemblages into the intermediate portion. The system also may include one or more heating devices configured to heat the assemblages as the assemblages are conveyed toward the outlet end to form processed assemblages, each of the processed assemblages including at least some nonwoven fibers adhered to one another.

A composite material developed for manufacturing thermoformed products has applications in furniture making, automotive industry, etc. The composite material for thermoforming is made of a thermoplastic fibrous component consisting of 4-60 mm long and 7-16 DEN 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 and 5 to 100 mm in length and represents 60% to 50% of the total material weight. Manufacturing the composite material comprises proportioning the components, followed by mixing and coarse defibering, then fine mixing in a four-chamber module which also opens the natural fibers to 70-80 DEN, followed by the consolidation of the fibers and rolling of the resulting fabric in a roll. The machinery for manufacturing the 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 fine mixing and fiber opening, an interlacing module (8), and a module (9) for pulling and rolling the final fabric.

A nonwoven fabric 10, wherein, on a side of the one surface, a plurality of longitudinal ridge portions 11 protruding on the side of the one surface in thickness direction of the nonwoven fabric is extended in one direction Y on the side of the one surface in a plane view, and is aligned at intervals on the side of the one surface in the plane view, in other direction X, different from the one direction Y on the side of the one surface, transverse ridge portions 21 extending in the other direction X on the side of the one surface are arranged by linking the longitudinal ridge portions 11, and a fiber orientation direction in the longitudinal ridge portions 11 is different from a fiber orientation direction in the transverse ridge portions 21.

The present disclosure provides: a biodegradable nonwoven fabric for thermoforming, the biodegradable nonwoven fabric being composed of a fiber of a polylactic acid-based polymer, and having a basis weight of 20-300 g/m.sup.2, preferably, a biodegradable nonwoven fabric characterized by being composed of a long fiber of a polylactic acid polymer, having an MD-direction elongation of 50% or more at 120° C., and having an MD-direction dimensional change rate of ±4% or less at 80-140° C. as determined by thermomechanical analysis; a method for producing a molded body by using said biodegradable nonwoven fabric; and a method for molding a biodegradable beverage extraction container, the method being characterized in that the molded body has an MD-direction elongation change rate of 4% or less, as determined by thermomechanical analysis (TMA) under a load of 0.05 N/2 mm at 30-100° C.