A method of forming a multi-layer needled non-woven article, comprising forming a web of a fiber base layer, an intermediate film and a fiber top layer, wherein the intermediate film is disposed between the fiber base layer and the fiber top layer; needle punching the web with a plurality of needles; and wherein, during needle punching, fibers of the fiber base layer are carried by the needles, extended through perforations in the intermediate film formed by the needles and entangled with fibers of the fiber top layer.

Stabilizing a textile sheet structure was achieved by forming a plurality of discrete fiber tufts extending from a first face of a fibrous layer of the textile sheet structure, through the fibrous layer and beyond a second face opposite the first face. Each discrete fiber tuft included a plurality discrete fibers. Each discrete fiber tuft was anchored to the first face and the second face of the fibrous layer by joining together the plurality of each discrete fiber tuft at the first face and the second face and bonding the joined plurality of discrete fiber tuft to the first face and the second face.

A method of forming a multi-layer needled non-woven article, comprising forming a web of a fiber base layer, an intermediate film and a fiber top layer, wherein the intermediate film is disposed between the fiber base layer and the fiber top layer; needle punching the web with a plurality of needles; and wherein, during needle punching, fibers of the fiber base layer are carried by the needles, extended through perforations in the intermediate film formed by the needles and entangled with fibers of the fiber top layer.

A planar composite material comprises an UD fiber layer A made of discrete reinforcing fiber rovings and a fiber nonwoven layer B made of a thermoplastic nonwoven which may contain reinforcing fibers, wherein the layers A and B are needled to 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 disclosure provides a nonwoven material including a blend of a first plurality of monocomponent fibers and a second plurality of segmented fibers having segments of a first polymer and segments of a second polymer different from the first polymer, wherein the nonwoven material includes about 75 to about 95% by weight of the monocomponent fibers, and about 5 to about 25% by weight of the segmented fibers, based on the total weight of the nonwoven material, and wherein the segmented fibers are at least partially fibrillated or split. An air filter including the nonwoven material is also provided.

A molded and shaped acoustical insulating vehicle panel having a dry-laid needled fibrous composite composed of a first portion of about 50 to 80 percent meltable binder fibers and about 20 to 50 percent stable fibers and having a second portion of about 20 to 50 percent meltable binder fibers and 50 to 80 percent of staple fibers. The meltable binder fibers are in a molded and resolidified state such that the resolidified binder fibers of the first portion form a substantially continuous, semi-impervious, densified skin integrally associated with and bonded to a surface of the first portion. The molded composite is in such a heat and pressure molded state that the composite has over a predominance of its area a density of from about 12 to 22 lbs./cubic foot (192 to 352 kg/cubic meter) and the panel is sufficiently rigid as to be self-supporting.

An installation for consolidating a batt of fibers, for example a nonwoven web, includes a mechanical consolidation workstation using needlepunching from which the fiber batt emerges in a machine or MD direction. A device is provided downstream of the consolidation workstation for stretching in the cross or CD direction which is transverse, in particular perpendicular, to the machine direction, and parallel to the plane of the batt, particularly before it is wound onto a reel. A consolidated nonwoven that can be obtained by the installation is also provided.

A planar composite material comprises an UD fiber layer A made of discrete reinforcing fiber rovings and a fiber nonwoven layer B made of a thermoplastic nonwoven which may contain reinforcing fibers, wherein the layers A and B are needled to each other.

An improved fire resistant textile product that includes a substrate base layer. The substrate base layer may comprise a needle punched, nonwoven substrate formed from a synthetic material such as a polyetherimide fiber. A first coating is applied to the substrate. The first coating may comprise a mixture including: about 1-65 wt. % aluminum trihydroxide; about 1-33 wt. % polyurethane polymer; and about 1-11 wt. % H2O. An effective amount of pigment may be added to the above composition to produce a desired color. The first coating may be applied in two steps with a first rolling application followed by a spraying application to provide a coated substrate. Finally, a clear top coat may be added to the coated substrate. The finished textile product may have a maximum acceptable two minutes total heat release (HR) of 65 KW min/m2 and a peak heat release of 65 KW/m2.