Disclosed are an undercover for vehicles with high elasticity and rigidity and a method of manufacturing the same. The undercover for vehicles with high elasticity and rigidity may include a needle-punched nonwoven fabric having a multi-layer structure of felt layers including a first PET fiber and a low-melting-point PET fiber, and each of the felt layers may have improved tensile strength and have optimized fiber alignment, to thereby improve the binding between fibers, mechanical rigidity and elasticity, as well as to reduce the weight of components, improve durability and secure harmlessness and inline workability.

A nonwoven fabric. The nonwoven fabric can include a first surface and a second surface and a visually discernible pattern of three-dimensional features on one of the first or second surface. Each of the three-dimensional features can define a microzone comprising a first region and a second region. The first and second regions can have a difference in values for an intensive property.

A nonwoven fabric. The nonwoven fabric can include a first surface and a second surface and a visually discernible pattern of three-dimensional features on one of the first or second surface. Each of the three-dimensional features can define a microzone comprising a first region and a second region. The first and second regions can have a difference in values for an intensive property. The nonwoven further has a plurality of apertures, wherein at least a portion of the aperture abuts at least one of the first region and the second region of the microzone.

Disclosed are an undercover for vehicles with high elasticity and rigidity and a method of manufacturing the same. The undercover for vehicles with high elasticity and rigidity may include a needle-punched nonwoven fabric having a multi-layer structure of felt layers including a first PET fiber and a low-melting-point PET fiber, and each of the felt layers may have improved tensile strength and have optimized fiber alignment, to thereby improve the binding between fibers, mechanical rigidity and elasticity, as well as to reduce the weight of components, improve durability and secure harmlessness and inline workability.

A non-woven fabric board for an exterior of a vehicle and a method for manufacturing same are provided. The non-woven fabric board includes a matrix fiber having a non-circular cross-section and an adhesive fiber having a non-circular cross-section, and the matrix fiber is included in an amount of 50 wt % or greater based on the total weight of the non-woven fiber board. Each of the matrix fiber and the adhesive fiber have a linear density of about 6 to 15 denier and a degree of non-circular shape of about 1.3 to 3.0.

The non-woven fabric board for an exterior of a vehicle has a substantially increased specific surface area by using the non-circular cross-section fibers, improved adhesion efficiency between fibers, and substantially improved mechanical properties. In addition, heat moldability thereof is improved, weight thereof is reduced, and the sound-absorbing performance thereof is substantially improved.

A method for making nonwoven fabric. The nonwoven fabric can include three-dimensional features that define a microzone comprising a first region and a second region. The first and second regions can have a difference in values for an intensive property. The nonwoven further has a plurality of apertures, wherein at least a portion of the aperture abuts at least one of the first region and the second region of the microzone.

A nonwoven fabric. The nonwoven fabric can include a first surface and a second surface and a visually discernible pattern of three-dimensional features on one of the first or second surface. Each of the three-dimensional features can define a microzone comprising a first region and a second region. The first and second regions can have a difference in values for an intensive property. The nonwoven further has a plurality of apertures, wherein at least a portion of the aperture abuts at least one of the first region and the second region of the microzone.

A method for making nonwoven fabric. The nonwoven fabric can include three-dimensional features that define a microzone comprising a first region and a second region. The first and second regions can have a difference in values for an intensive property. The nonwoven further has a plurality of apertures, wherein at least a portion of the aperture abuts at least one of the first region and the second region of the microzone.

A nonwoven fabric comprises a first surface, a second surface, and a visually discernible pattern on at least one of the first and second surfaces. The visually discernible pattern has a regular, repeating pattern of three-dimensional features. Each of the three-dimensional features define a microzone comprising a first region and a second region. The first and second regions having a difference in values for an intensive property. The first surface has a TS7 value in the range of about 1 dB V.sup.2 rms to about 15 dB V.sup.2 rms. The second surface has a TS7 value in the range of about 1 dB V.sup.2 rms to about 15 dB V.sup.2 rms. A ratio of the TS7 value of the first surface to the TS7 value of the second surface is in the range of about 1 to about 3.

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.