A polymer filament molded product and a method of making a filament network that includes coating filaments with a latex polymer and shaping the filaments into a molded product; one in which a polymer is shaped and molded into a larger filament network. The molded products can be objects for apparel, home and garden, furnishings, health care, engineering, industrial and consumer goods. The molded filament mesh is “fractal” in nature because it is a filament interconnected network at the molecular scale and at the scale of the molded product. The natural tendency of the long molecule filaments to be an entangled structure is maintained.

A synthetic leather has high flame retardance in addition to excellent mechanical strength and durability, which may yield a covered article having an excellent texture, and a covered article which has been covered with the synthetic leather. The covered article includes a synthetic leather and a covered article covered with the synthetic leather, the synthetic leather having a fiber base material layer including a non-woven fabric containing: a non-melting fiber A having a high-temperature shrinkage rate of 3% or less, and a thermal conductivity, conforming to ISO22007-3 (2008), of 0.060 W/m.Math.K or less; and a thermoplastic fiber B having an LOI value, conforming to JIS K 7201-2 (2007), of 25 or more.

A sheet material includes a polymeric elastomer and a fiber-entangled body including, as a constituent element, a nonwoven fabric including ultrafine fibers having an average single fiber diameter of 1.0 μm or more and 10.0 μm or less. The ultrafine fibers include a polyester-based resin including a black pigment (a.sub.1). The black pigment (a.sub.1) has an average particle diameter of 0.05 μm or more and 0.20 μm or less and has a coefficient of variation (CV) of the average particle diameter of 75% or less. The polymeric elastomer includes a polyurethane including a black pigment (b). The sheet material has a nap coverage of 70% or more and 100% or less on a surface having a nap.

Disclosed is a napped artificial leather including: an artificial leather base material that includes a non-woven fabric of polyester fibers having a Young's modulus of 1 to 6 GPa, an average fiber-toughness of 8 to 40 cN.Math.%, and a crystallinity of 35% or less, and an elastic polymer, the artificial leather base material having, on at least one surface thereof, a napped surface on which the polyester fibers are napped. Also disclosed are polyester fibers having a Young's modulus of 1 to 6 GPa, an average fiber-toughness of 8 to 40 cN.Math.%, and a crystallinity of 35% or less, and a non-woven fabric including the polyester fibers.

The invention relates to moisture-permeable, microporous luxury food packaging material made of nonwoven fabric, consisting of a carded web of staple fibres and at least one thermoplastic binder. According to the invention the nonwoven fabric has a uniformly distributed perforation in the form of a plurality of holes, the fluctuation around the median value of the diameter of the holes being in the region of +/- 30%. In the method according to the invention the perforation is formed by creating holes by means of piercing the pre-bonded nonwoven fabric.

The present invention relates to a process for producing a nonwoven fabric, comprising the steps of: (a) extruding a plurality of filaments from a spinneret; (b) depositing said filaments in a substantially not-crimped condition to make a nonwoven fabric on an element collecting the filaments; (c) heating said nonwoven fabric to crimp at least part of the filaments, so that the volume of said nonwoven fabric is increased; (d) bonding said nonwoven fabric;
wherein said filaments are at least bicomponent filaments.

The present invention relates to a process for producing a nonwoven fabric, comprising the steps of: (a) extruding a plurality of filaments from a spinneret; (b) depositing said filaments in a substantially not-crimped condition to make a nonwoven fabric on an element collecting the filaments; (c) heating said nonwoven fabric to crimp at least part of the filaments, so that the volume of said nonwoven fabric is increased; (d) bonding said nonwoven fabric;
wherein said filaments are at least bicomponent filaments.

A coated nonwoven product used to make engine hood insulation material is produced by a method which involves needle punching a carded, cross-lapped web, then calendering the resulting web and then applying a foam coating. Rotary screen printing is used to apply a dot pattern of an acrylic emulsion to the dried, foam-coated web. Thermoplastic and/or thermoset material is deposited onto the acrylic coating and excess material is removed by vacuum, leaving a corresponding dot coating pattern of said material. The coated web is heated using infrared energy before cooling, cold calendering and winding-up.

A dual layer nonwoven acoustic insulating material having a more densified layer and a less densified layer that is comprised of shoddy fibers and other fibers.

A sheet is produced by (i) producing a sheet by entangling woven or knitted material including a thread composed of a composite fiber such that two kinds or more of polyethylene terephthalate polymers different in intrinsic viscosity are stuck together in a side-by-side type along the fiber length direction and/or of a core-in-sheath type composite fiber such that two kinds or more of polyethylene terephthalate polymers different in intrinsic viscosity form an eccentric core-in-sheath structure, with a fiber capable of converting into ultra fine fibers composed of two kinds or more of polymeric substances different in solubility in solvent, (ii) developing an ultra fine fiber with an average single fiber fineness of 0.001 dtex or more and 0.5 dtex or less by treating the sheet with a solvent to thereafter provide elastomer having polyurethane as a main component by impregnating and solidifying solvent solution of elastomer having polyurethane as a main component into the sheet, or of providing elastomer having polyurethane as a main component by impregnating and solidifying solvent solution of elastomer having polyurethane as a main component into the sheet to thereafter develop an ultra fine fiber with an average single fiber fineness of 0.001 dtex or more and 0.5 dtex or less by treating the sheet with a solvent, and (iii) rubbing and shrinking the woven or knitted material under the condition of 110° C. or more.