A preform manufacturing apparatus comprising a supply of fiber strip, a moveable positive fiber strip delivery mechanism coupled between a desired lay down location and the supply of fiber strip to positively deliver and orient the supply of fiber strip to the desired lay down location, and an electronic unwinder coupled to the supply of fiber strip is described herein. The electronic unwinder is configured to interact with the moveable positive fiber strip delivery mechanism.

The subject matter of the invention is a method for draping on a form, which includes a step of deposition on the form of a first fold support in the form of one or more polymer nonwoven fabrics. The invention further relates to a thermoplastic nonwoven material manufactured with a nonwoven fabric of polymer fibers.

The subject matter of the invention is a method for draping on a form, which includes a step of deposition on the form of a first fold support in the form of one or more polymer nonwoven fabrics. The invention further relates to a thermoplastic nonwoven material manufactured with a nonwoven fabric of polymer fibers.

A cross-lapped multilayered batt, and a method of making the same is presented. The batt includes one or more layers of a carded web of staple fibers, and one or more continuous filament fiber layers. At least some of the staple fibers and, in some instances, some of the continuous filament fibers are mechanically entangled through a thickness of the batt. The method includes folding both the carded web and the continuous filament fiber layers together, and subjecting the folded layers to a needle-punching process to impart structural stability and enhance the Z-directional strength of the batt.

The present invention, in embodiments, is a fitted mattress core covering having a non-woven fabric comprising a plurality of flame-retardant fibers and elastic piping located along an edge of the non-woven fabric. The non-woven fabric, in embodiments, is substantially free of fiberglass, and the fitted mattress core covering is configured to fit over a mattress core such that the elastic piping extends underneath the mattress core when the fitted mattress core covering fits over the mattress core.

The present invention, in embodiments, is a fitted mattress core covering having a non-woven fabric comprising a plurality of flame-retardant fibers and elastic piping located along an edge of the non-woven fabric. The non-woven fabric, in embodiments, is substantially free of fiberglass, and the fitted mattress core covering is configured to fit over a mattress core such that the elastic piping extends underneath the mattress core when the fitted mattress core covering fits over the mattress core.

A hydroentangled nonwoven sheet material produced by a process including: 0) optionally providing a polymer web on a carrier; a) providing an aqueous suspension containing short fibres and a surfactant; h) depositing the aqueous suspension on the carrier; c) removing aqueous residue of the aqueous suspension deposited in step h) to form a fibrous web; b) depositing aqueous suspension on a surface of the fibrous web formed in step c); c) removing aqueous residue of the aqueous suspension deposited in step b) to form a combined fibrous web; d) hydroentangling the combined fibrous web; and optionally e) drying the hydroentangled web, and/or f) further processing and finalising the dried, hydroentangled web the web to produce the nonwoven end material. The hydroentangled non-woven sheet material obtainable by this process has a low degree of surface irregularity and contains low residues of surfactants.

A hydroentangled nonwoven sheet material produced by a process including: 0) optionally providing a polymer web on a carrier; a) providing an aqueous suspension containing short fibres and a surfactant; h) depositing the aqueous suspension on the carrier; c) removing aqueous residue of the aqueous suspension deposited in step h) to form a fibrous web; b) depositing aqueous suspension on a surface of the fibrous web formed in step c); c) removing aqueous residue of the aqueous suspension deposited in step b) to form a combined fibrous web; d) hydroentangling the combined fibrous web; and optionally e) drying the hydroentangled web, and/or f) further processing and finalising the dried, hydroentangled web the web to produce the nonwoven end material. The hydroentangled non-woven sheet material obtainable by this process has a low degree of surface irregularity and contains low residues of surfactants.

A process of forming a non-woven web including spinning continuous polymeric filaments including one selected from a poly(phenylene ether) component, a poly(phenylene ether)-polysiloxane block copolymer, and combinations thereof. The filaments can have a length to diameter ratio that is more than 1,000,000, and a diameter ranging from 50 nanometers to 5 microns. The spinning can include passing a polymer through a spinneret having a plurality of orifices in a non-electrospinning environment. The process can further include chopping the plurality of continuous filaments and obtaining a plurality of chopped nano-fibers and forming the nano-fibers into a nonwoven web. The spinning can be conducted at a rate of at least 300 grams/hour/spinneret.

A process of forming a non-woven web including spinning continuous polymeric filaments including one selected from a poly(phenylene ether) component, a poly(phenylene ether)-polysiloxane block copolymer, and combinations thereof. The filaments can have a length to diameter ratio that is more than 1,000,000, and a diameter ranging from 50 nanometers to 5 microns. The spinning can include passing a polymer through a spinneret having a plurality of orifices in a non-electrospinning environment. The process can further include chopping the plurality of continuous filaments and obtaining a plurality of chopped nano-fibers and forming the nano-fibers into a nonwoven web. The spinning can be conducted at a rate of at least 300 grams/hour/spinneret.