Multilayer nonwoven fabrics for foam molding that have excellent resistance to the separation of layers, have reinforcing effects and urethane leakage prevention performance, and are producible without the occurrence of fiber dust on the surface. In the multilayer nonwoven fabric for foam molding, a reinforcing layer is stacked on at least one side of a dense layer, the dense layer includes a meltblown nonwoven fabric layer (A) and spunbonded nonwoven fabric layers (B) that are stacked on both sides of the layer (A), and the meltblown nonwoven fabric layer (A) and the spunbonded nonwoven fabric layers (B) are partially thermocompression bonded with each other.

The present invention is directed to a nonwoven fabric made from a composite of nonwoven and pulp where the nonwoven has a high loft derived from a heat set three-dimensional relief structure and/or hydroengorged fiber structure. A nonwoven web is hydraulically treated to create a hydroengorged material having an increased loft. Alternatively a nonwoven web is treated to have a heat set three-dimensional relief structure. The treated web is then hydroentangled with pulp to form a cotendered nonwoven/pulp composite fabric.

The present invention is directed to a nonwoven fabric made from a composite of nonwoven and pulp where the nonwoven has a high loft derived from a heat set three-dimensional relief structure and/or hydroengorged fiber structure. A nonwoven web is hydraulically treated to create a hydroengorged material having an increased loft. Alternatively a nonwoven web is treated to have a heat set three-dimensional relief structure. The treated web is then hydroentangled with pulp to form a cotendered nonwoven/pulp composite fabric.

Disclosed is a nonwoven laminate having a texture for improved absorption and distribution of body liquids in sanitary products. The absorption and distribution effect is caused by perforations distributed in a pattern-like manner in combination with elevations present on one side of the nonwoven laminate.

A process for forming a nonwoven composite begins with forming a first nonwoven from a plurality of primary fibers and optionally binder fibers. A second nonwoven layer is formed from a plurality of bulking fibers and binder fibers. A thermoplastic elastomeric film is placed between the two nonwoven layers, the film containing a thermoplastic elastomeric polymer having an elongation at break greater than 300% and a max softening point (thermomechanical analysis end point) between 150 C. and 200 C. as tested according to ASTM E2347-04. The layers are needled together creating a plurality of holes in the thermoplastic elastomeric layer and moving a portion of the primary fibers from the first nonwoven layer into the second nonwoven layer. The needled stacked layers are heated to alter the median size of the holes in the thermoplastic elastomeric film forming the nonwoven composite.

A process for forming a nonwoven composite begins with forming a first nonwoven from a plurality of primary fibers and optionally binder fibers. A second nonwoven layer is formed from a plurality of bulking fibers and binder fibers. A thermoplastic elastomeric film is placed between the two nonwoven layers, the film containing a thermoplastic elastomeric polymer having an elongation at break greater than 300% and a max softening point (thermomechanical analysis end point) between 150 C. and 200 C. as tested according to ASTM E2347-04. The layers are needled together creating a plurality of holes in the thermoplastic elastomeric layer and moving a portion of the primary fibers from the first nonwoven layer into the second nonwoven layer. The needled stacked layers are heated to alter the median size of the holes in the thermoplastic elastomeric film forming the nonwoven composite.

A composite flame barrier includes at least one layer of nonwoven flame resistant fibers, and at least one layer of heat absorbing intumescing expandable graphite held together with polymeric binders and fire resistant fibers in a sheet structure. The composite material provides thermal protection that cannot be achieved using the expandable graphite is alone. By mechanically attaching a nonwoven felt or hydro-entangled nonwoven material to the layer containing expandable graphite, the graphite becomes stabilized and is more resistant to forces that may damage the material (wind, high velocity flames etc.) and decrease or eliminate the thermal performance of the expandable graphite. The composite flame barrier is useful in applications where prolonged fire and heat resistance is required, and has an advantage of being flexible and lightweight. The uses for the material include emergency portable fire shelters, structural protection of aircraft, structural steel fire proofing, fire-rated wall assemblies, and other fire-resistant applications.

A composite panel with a thermosetting cellular matrix, a method for manufacturing said panel, and a structure for covering a wall that is formed from an assembly of such panels. The structure provides the wall with heat insulation against cryogenic fluids and/or protection against fire or flames and/or sealing against the fluids. A panel having a thermosetting cellular matrix, includes at least one substrate that includes short, non-woven basalt fibers and is impregnated by the matrix. The panel is such that the at least one substrate includes a plurality of non-woven layers stacked to a stacking thickness. The non-woven layers each include the short basalt fibers and are needled through the thickness without using thermoplastic fibers.

A composite panel with a thermosetting cellular matrix, a method for manufacturing said panel, and a structure for covering a wall that is formed from an assembly of such panels. The structure provides the wall with heat insulation against cryogenic fluids and/or protection against fire or flames and/or sealing against the fluids. A panel having a thermosetting cellular matrix, includes at least one substrate that includes short, non-woven basalt fibers and is impregnated by the matrix. The panel is such that the at least one substrate includes a plurality of non-woven layers stacked to a stacking thickness. The non-woven layers each include the short basalt fibers and are needled through the thickness without using thermoplastic fibers.

An extensible nonwoven fabric, and method for its manufacture, on which the source, medicinal component, pattern and/or other pieces of information are recognizable at the beginning of and during fabric use. It is made mainly of highly crimped fibers, with a compressed region where no fibers are melted and bonded together, with a tensile strength of 25 N/5-cm-width or more in both the machine direction and the cross direction. It may be manufactured by causing a water jet having a pressure of 5 MPa or more to act onto a web made mainly of a latent crimpable fiber, forming an entangled fiber web, causing heat to act on it, crimping the fiber converting it to a highly crimped fiber while contracting the web's area by 30% or more forming a contracted fiber web, and embossing it such that the fibers are not melted and bonded together.