A synthetic nonwoven fabric having bonded fibers forming channels surrounding unbonded fibers forming raised slip resistant spots. The fabric is made by extruding hot polymer through a spinneret die onto a moving belt to form a sheet of random fibers, which sheet undergoes a calendering process between a pair of heated rollers, one of which rollers having a plurality of cavities defined in its surface. The resulting fabric can be laminated and otherwise combined with other layers as desired to provide an end product having good slip resistant properties.

The present invention is directed to an acoustical baffle that has use in vehicle interiors, such as an interior headliner. In particular, the baffle can provide improved acoustics while maintaining a desired airflow resistance and can be configured to provide for different sound attenuation characteristics at selected locations of the baffle construction.

Tear and heat resistant foams used in packaging, protective packaging bags and related methods are provided. The tear and heat resistant foam can include a nonwoven substrate, a polyethylene film, and a base layer of polyethylene foam joined together by applying at least one of heat or heat and pressure to the top nonwoven substrate, the polyethylene film and the polyethylene foam to heat the first surface of the top nonwoven substrate to a temperature that is above the melting point of polyethylene film but below the melting point of top nonwoven substrate. The temperature of the polyethylene film rises causing the polyethylene film to melt and bind the top nonwoven substrate to the polyethylene foam to form the heat and tear resistant packaging foam.

Provided is a functional laminate including a porous intermediate layer having air permeability laminated between a porous surface layer and a resin foamed layer, the porous intermediate layer having an affinity to a foaming resin forming the resin foamed layer.

A method for producing a water-tight, water-vapour-permeable segment, having a three-dimensional contour, for a shoe shaft, an item of clothing or a rucksack or for producing a shoe shaft, an item of clothing or a rucksack, the segment being free of connection points in its surface, and the method for producing the segment being a thermoforming process in which the two-dimensional flat structure obtained is completely laminated in its entirety, the segment being free of connection points in its surface. Also, a water-tight, water-vapour-permeable segment of a three-dimensional functional laminate for introduction into a shoe or shoe shaft, an item of clothing or a rucksack, the segment being dimensionally stable under its own weight, of a single piece and free of connection points in its surface.

A method for producing an elastic laminate with at least a first top layer and an elastic film, wherein the first top layer is fed along a production direction to a first stretching device, is subsequently stretched transverse to the production direction by means of the first stretching device and is puckered, and is either connected to an extrusion web provided for forming the elastic film such that the top layer is connected to the extrusion web only by portions facing the melt web or is connected to a pre-produced elastic film in that the elastic film is at least incipiently melted on its side facing the first top layer, the first top layer is pressed against the at least incipiently melted side of the elastic film only by portions, and is therefore at least partially embedded in a polymer matrix of the elastic film.

A carpet tile and process for making the same, wherein the carpet tile comprises a facecloth having a plurality of face yarns tufted through a primary backing, an extruded polymer secondary backing layer, and a cushion, comprising a reinforcing scrim layer within a polymer layer. The top surface and bottom surface of the carpet tile are defined by the facecloth and the cushion, respectively. A polymer-based resin is extruded onto the facecloth to form an at least substantially uniform secondary backing layer, and the cushion is laid onto the extruded polymer secondary backing layer while the extruded polymer secondary backing layer remains above a softening temperature for the resin. The entire multi-layer web is then passed through a nip to embed the reinforcing scrim layer into the extruded polymer secondary layer, and the entire web is chilled.

A roofing underlayment includes a hydrophobic nonwoven core layer that provides enhanced resistance to water infiltration. In addition to the hydrophobic nonwoven core layer, the roofing underlayment includes a coating layer adhered to a surface of the hydrophobic nonwoven core layer, and an exterior surface layer adhered to the coating layer. A roofing system that includes the roofing underlayment is also provided.

The present invention relates to methods for forming a composite product having a patterned surface. A substrate including a porous structure (136), a sheet-form material (134) and a patterned sheet (131) are pressed together to form the composite product. In preferred examples, the patterned sheet is permeable to curable material in the sheet-form material.

A method and a mineral wool product include a multiple of lamellae, such as a sandwich panel core. The product includes a plurality of lamellae cut from a mineral wool web, and bonded together by applying an adhesive on the surfaces of two adjacent lamellae to form a web-like product, wherein the adhesive comprises at least one hydrocolloid.