A hydro-enlarged apertured non-woven web includes a plurality of fibers with a plurality of bond points, a first surface defining a planar top, and a second surface defining a planar bottom. The second surface is separated from the first surface by a first distance defining a loft. A plurality of apertures extending through the non-woven web. The plurality of apertures is formed by spraying a fluid against an unapertured precursor web, causing a plurality of pins disposed on a pinned roller to punch through the unapertured precursor web. The unapertured precursor web has a third surface defining a planar top and a fourth surface defining a planar bottom, where the third surface is separated from the fourth surface by a second distance defining a precursor loft. The loft is greater than the precursor loft by a loft increase within a range of 50-110%.

The invention relates to a water-repellent and lipophilic composite needle-punched nonwoven fabric and a preparation method thereof. The method comprises the following steps: blending a PET fiber and a polyolefin-based fiber in a mass ratio of 3:1-1:3, and performing needle punching to obtain a composite needle-punched nonwoven fabric; carrying out hot-drying treatment on the composite needle-punched nonwoven fabric at 110-160° C. for 40-90 min; and carrying out water-repellent finishing on the hot-dried fabric using 50-70 mL/L of an aqueous solution of a modified resin-based fluorine-free waterproofing agent, and drying to obtain the water-repellent and lipophilic composite needle-punched nonwoven fabric, wherein the water-repellent finishing is dip rolling, the air pressure is 1.8 kPa and the liquid carrying rate is 160-230%. The preparation method of the invention is simple, and the prepared composite needle-punched nonwoven fabric has significantly improved water repellency, lipophilicity and tensile strength compared with the fabric before treatment.

A liner, comprising a layered material in which a carded nonwoven wadding is thermally bonded to a thin carded nonwoven top layer, for upholstered furniture. In the liner, a high proportion of the staple fibers in the top layer are thin bi-component binder fibers. Further, at least 20 wt % of the staple fibers in the wadding is thick staple fibers. Furthermore, also the wadding comprises bi-component binder fibers.

A liner, comprising a layered material in which a carded nonwoven wadding is thermally bonded to a thin carded nonwoven top layer, for upholstered furniture. In the liner, a high proportion of the staple fibers in the top layer are thin bi-component binder fibers. Further, at least 20 wt % of the staple fibers in the wadding is thick staple fibers. Furthermore, also the wadding comprises bi-component binder fibers.

Covers comprising a nonwoven fabric including a plurality of recycled polyester fibers, such as a plurality of staple fibers, is provided. The plurality of recycled polyester fibers may be formed from a post-consumer polyester, a post-industrial waste polyester, or a combination thereof. The covers provide desirable vapor transmission while also providing an improved hydrostatic head. The covers may be provided in a variety of configurations. Methods of forming such covers are also provided.

Covers comprising a nonwoven fabric including a plurality of recycled polyester fibers, such as a plurality of staple fibers, is provided. The plurality of recycled polyester fibers may be formed from a post-consumer polyester, a post-industrial waste polyester, or a combination thereof. The covers provide desirable vapor transmission while also providing an improved hydrostatic head. The covers may be provided in a variety of configurations. Methods of forming such covers are also provided.

The provided articles and methods use a non-woven fibrous web containing 60-100 wt % of oxidized polyacrylonitrile fibers; and 0-40 wt % of reinforcing fibers having outer surfaces comprised of a polymer with a melting temperature of from 100° C. to 300° C. The non-woven fibrous web has an average bulk density of from 15 kg/m.sup.3 to 50 kg/m.sup.3, with the plurality of fibers substantially entangled along directions perpendicular to a major surface of the non-woven fibrous web. Optionally, the oxidized polyacrylonitrile fibers can have a crimped configuration. Advantageously, these articles can display a combination of low thermal conductivity, high tensile strength, and flame resistance.

The provided articles and methods use a non-woven fibrous web containing 60-100 wt % of oxidized polyacrylonitrile fibers; and 0-40 wt % of reinforcing fibers having outer surfaces comprised of a polymer with a melting temperature of from 100° C. to 300° C. The non-woven fibrous web has an average bulk density of from 15 kg/m.sup.3 to 50 kg/m.sup.3, with the plurality of fibers substantially entangled along directions perpendicular to a major surface of the non-woven fibrous web. Optionally, the oxidized polyacrylonitrile fibers can have a crimped configuration. Advantageously, these articles can display a combination of low thermal conductivity, high tensile strength, and flame resistance.

Described is a composite made from a woven fabric, a non-woven fabric, or a knitted face fabric and a non-woven fabric. The woven fabric, the non-woven fabric, or the knitted face fabric is needle punched such that fibers protrude into the non-woven fabric. The woven fabric, the non-woven fabric, or the knitted face fabric has a first polymer having a first melting point and a second polymer having a second melting point being higher than the first melting point. The nonwoven backing material comprises a third polymer having a third melting point and a fourth polymer having a fourth melting point being higher than the third melting point. The woven fabric, the non-woven fabric, or the knitted face fabric is further bonded to the nonwoven backing material applying heat to at least partially melt or soften the first polymer and the third polymer such that they bond together.

Described is a composite made from a woven fabric, a non-woven fabric, or a knitted face fabric and a non-woven fabric. The woven fabric, the non-woven fabric, or the knitted face fabric is needle punched such that fibers protrude into the non-woven fabric. The woven fabric, the non-woven fabric, or the knitted face fabric has a first polymer having a first melting point and a second polymer having a second melting point being higher than the first melting point. The nonwoven backing material comprises a third polymer having a third melting point and a fourth polymer having a fourth melting point being higher than the third melting point. The woven fabric, the non-woven fabric, or the knitted face fabric is further bonded to the nonwoven backing material applying heat to at least partially melt or soften the first polymer and the third polymer such that they bond together.