A primary homo staple fiber including a melt-modified polyester component having a melt temperature in the range of 100 degrees Celsius to 260 degrees Celsius and configured in staple fiber form. Also, a non-woven composite article including a primary homo staple fiber including a melt-modified polyester component configured in staple fiber form and having melt temperature in the range of 100 degrees Celsius to 260 degrees Celsius. Also, a non-woven composite article including a non-woven composite material, the non-woven composite material including a fibrous first component of singular fibers of melt-modified polyester configured in a staple fiber form, and a fibrous second component including one or more fibers of various type, the fibrous first and second components are blended together, and the melt-modified polyester includes a low melting point polyethylene terephthalate (LPET) polyester as a primary binder in the non-woven composite material.

An exterior trim part for a vehicle comprises a fibrous porous structural layer. The fibrous porous structural layer consists of staple fibers, only. At least 50%, preferably between 70% and 100%, of the staple fibers comprise a first polymer made of modified polyester, such as CoPET, with a melting temperature between 150 C. and 240 C., preferably between 190 C. and 240 C.

An exterior trim part for a vehicle comprises a fibrous porous structural layer. The fibrous porous structural layer consists of staple fibers, only. At least 50%, preferably between 70% and 100%, of the staple fibers comprise a first polymer made of modified polyester, such as CoPET, with a melting temperature between 150 C. and 240 C., preferably between 190 C. and 240 C.

An electrospinning apparatus according to an embodiment is configured to deposit a fiber on a collector or a member. The electrospinning apparatus includes a first nozzle head provided on one side of the collector or the member, and a second nozzle head provided on the side opposite to the first nozzle head with the collector or the member interposed. The first nozzle head and the second nozzle head are at a section where the collector or the member moves in a direction tilted with respect to a horizontal direction.

The present invention provides a biodegradable nonwoven fabric which has biodegradability, while having extremely excellent texture, or having good formability and being suppressed in fluffing in an embossed part during forming. One embodiment of the present invention provides: a biodegradable nonwoven fabric which is configured from fibers that contain a biodegradable thermoplastic resin, and is characterized in that the shear viscosity thereof is more than 0 Pa.Math.s but not more than 41.4ln(x)+500.84 Pa.Math.s at a shear rate x (x is from 20/s to 10,000/s) at 230 C., or is characterized in that the biodegradable nonwoven fabric has an embossed part and a non-embossed part, and the embossed part thickness index that is obtained by dividing the thickness of the embossed part by the square root of weight is 2.75 to 4.36 mm/(g/m.sup.2).sup.0.5; or a food filter such as a coffee filter or a filter for tea bags, a mask, a diaper, an agricultural material or a lightweight packaging material, each of which comprises this biodegradable nonwoven fabric.

In some embodiments, the inventive subject matter is directed to an arrangement of discrete elements of fill material on a substrate consisting of a sheet material wherein the discrete elements are fixed relative to the sheet material by pilings, fusion, and/or entanglement to fix the insulating elements in a layered arrangement over the sheet material. A second sheet of material may be used to create a sandwiched assembly of the discrete elements. In some embodiments, the inventive subject matter is generally directed to discrete elements of fill material that are engaged together to form a cohesive sheet-like or layered arrangement of the elements.

In some embodiments, the inventive subject matter is directed to an arrangement of discrete elements of fill material on a substrate consisting of a sheet material wherein the discrete elements are fixed relative to the sheet material by pilings, fusion, and/or entanglement to fix the insulating elements in a layered arrangement over the sheet material. A second sheet of material may be used to create a sandwiched assembly of the discrete elements. In some embodiments, the inventive subject matter is generally directed to discrete elements of fill material that are engaged together to form a cohesive sheet-like or layered arrangement of the elements.

A nonwoven ceiling tile or wall panel with noise absorption properties utilizes unique acoustical absorbing fibers. During manufacturing, binder fibers melt between interstitial spaces to fill spaces and create impedance to air flow and sound flow through the fibers. Various shapes and/or sizes of fibers may also be utilized to further impedance of air and sound through the ceiling tile or panel. The ceiling tiles and panels are made from 100% organic fibers that are either virgin or recycled material. The material is structurally self-supporting eliminating need for structural additives or structural design features. Fire and smoke retardants are incorporated into the fibers. Antimicrobial and anti-stain additives may also be used in the fibers. The material is 100% polyester fibers (PET and PETG). The material is printable using sublistatic printing or transfer printing process. The ceiling tiles and panels are light weight and moldable in a wide range of designs.

A nonwoven ceiling tile or wall panel with noise absorption properties utilizes unique acoustical absorbing fibers. During manufacturing, binder fibers melt between interstitial spaces to fill spaces and create impedance to air flow and sound flow through the fibers. Various shapes and/or sizes of fibers may also be utilized to further impedance of air and sound through the ceiling tile or panel. The ceiling tiles and panels are made from 100% organic fibers that are either virgin or recycled material. The material is structurally self-supporting eliminating need for structural additives or structural design features. Fire and smoke retardants are incorporated into the fibers. Antimicrobial and anti-stain additives may also be used in the fibers. The material is 100% polyester fibers (PET and PETG). The material is printable using sublistatic printing or transfer printing process. The ceiling tiles and panels are light weight and moldable in a wide range of designs.

A thermal insulation batt is created from recycled carpet fibers and fire resistant cotton shoddy bonded by staples of bi-component fiber having a polyester core and low melting polymeric sheath. The low melting polymeric sheath melts at a temperature well below the melting or degradation temperature of any of the carpet fibers from the recycled carpets. Since the sheath has a small thickness, the amount of melt created is small and bonding occurs only between the bi-component staple fiber and adjacent carpet fiber or fire resistant cotton shoddy without melt overflow. The rigidized thermal insulation batt can be used in a building between studs and may be used in an automobile door for sound proofing. This product is particularly well suited for use as acoustic and thermal insulation in buildings as non-load bearing partitions in interior offices of commercial buildings. This bonded low density composite fibrous structure has fire retarding constituents incorporated within the batt to retard propagation of building fire. These stated uses are non-limiting; and other uses are contemplated, including automobile interior structures.