A non-flip mattress with top side and bottom side and depending edges; wherein the bottom side is covered with a flame-resistant, highly needled, double-sided-calendered, needlepunch nonwoven fabric that passes 16 CFR 1633. The nonwoven fabric is a double-calendered, 80/20 flame-resistant rayon/polyester blend needled with a minimum of 190 punches per cm.sup.2 and with increased tensile strength.

A fiber blend comprising a staple fiber formed from cellulose acetate and a binder fiber. The staple fiber has a crimp frequency of 10 to 30 crimps per inch (CPI), a cut length of 55 mm or less, and a non-round cross-sectional shape. The blend can be made into nonwoven webs for heat-bonding and subsequent use as thermal insulation in, e.g., outerwear, bedding, etc. The cellulose acetate fibers provide superior thermal insulation clo value relative to at equivalent loft.

A recycled cellulose pulp composition is provided which comprises recycled cellulosic fibers and cellulose ester staple fibers. A wet-laid fibrous product is also provided which comprises recycled cellulosic fibers and cellulose ester staple fibers. A bailed article is also provided that comprises recycled cellulosic fibers and cellulose ester staple fibers. In embodiments, the recycled cellulosic fibers are present in an amount of 50 wt % or more, based on the total dry weight of fibers, and the cellulose ester staple fibers are present in an amount sufficient to increase the Canadian standard freeness (CSF) of the composition by 5% or more compared to a 100 wt % cellulosic fiber pulp composition processed under similar conditions.

A composition obtained by combining virgin cellulose fibers, cellulose ester (CE) staple fibers having a denier per filament (DPF) of less than 3, and water, and water. The CE staple fibers can also have a short cut length of less than 6 mm and can be crimped. The compositions, when co-refined, are useful to make wet laid products such as paper, cardboard, and filters that have improved water drainage, air permeability, tensile strength, bulk, burst strength, or stiffness, or a combination of these properties.

A composition is contained a blend zone prior to refining containing non-fibrillated virgin cellulose fibers, waste/recycle cellulose fibers or both; cellulose ester fibers, water, and one or more additives comprising fillers, internal sizing agents, biocides, process anti-foaming agents, colorants, optical modifiers, or a combination thereof. An in-line mixer can be used for adding the additives, and the consistency of the composition is lowered relative to a feed of material from a hydropulper.

After cellulose fibers and cellulose ester fibers are co-refined, they are fed to a blend tank continuously feeds a wet laid process. The composition in the blend tank includes co-refined cellulose fibers and cellulose ester fibers and one or more additives, and the cellulose ester fibers have a denier per filament (DPF) of less than 3, a cut length of less than 6 mm, crimped, or non-round with a DPF of less than 3.

Broke pulp in a paper making process is obtained by pulping broke, and the broke pulp is made of fibrillated cellulose fibers and cellulose ester (CE) staple fibers having a denier per filament (DPF) of less than 3, or a cut length of less than 6 mm, or crimped, or non-round with a DPF of less than 3. The broke pulp can be added to the stock preparation zone of a wet laid manufacturing facility and fed through a refiner.

The present invention provides compositions comprising cellulose fibers and cellulose ester fibers and wet laid articles made from the compositions, as well as wet laid processes to produce these compositions. More specifically, the present invention provided compositions comprising cellulose fibers and cellulose acetate fibers and wet laid articles made from these compositions as well as wet laid processes to produce these compositions. The present invention also relates to composition, process, wet laid product, or articles exhibiting any one of many desired benefits. The invention also relates to a composition comprising cellulose fiber and a staple fiber exhibiting improved texturing.

A recycled cellulose pulp composition is provided which comprises recycled cellulosic fibers and cellulose ester staple fibers. The recycled cellulose pulp containing co-refined re-cycled cellulose fibers and cellulose ester staple fibers can be added to a hydropulper and fed back through a refiner to make wet laid products.

The present invention relates to fibrillated lyocell fibers which have a fibrillation quotient Q of 20 or more and whose content of microfibers with a fineness of less than 14 mesh and a diameter of less than 2 m is at least 50%, as well as the use thereof for producing a wipe, which contains pulp and 5 to 20 wt. % of fibrillated lyocell fibers.