A nonwoven recyclable fabric and associated methods are provided. The fabric is formed from 100% polyester, and may also include surface coatings such as hydrophilic coatings to promote heat transfer as well moisture vapor transmission rates and/or a silicone coating to promote fabric smoothness and reduce abrasiveness of the fabric.

Methods and systems are provided for a process to generate a nonwoven textile. In one example, the nonwoven textile may have layered, zonal properties resulting from entangling of two or more types of staple fibers through a merging region between the layers of staple fibers while maintaining distinct zones, each zone comprising a type of staple fiber. Furthermore, the process may include embedding a filament layer into the nonwoven textile via a continuous assembly line.

Methods and systems are provided for a process to generate a nonwoven textile. In one example, the nonwoven textile may have layered, zonal properties resulting from entangling of two or more types of staple fibers through a merging region between the layers of staple fibers while maintaining distinct zones, each zone comprising a type of staple fiber. Furthermore, the process may include embedding a filament layer into the nonwoven textile via a continuous assembly line.

The present invention provides a mounting mat (30) for mounting a pollution control element (20) or monolith in a pollution control device (10), said mounting mat comprising a layer having a mixture of long and short fibers wherein said short fibers have a length of not more than about 13 mm and wherein said long fibers have a length of at least about 20 mm and wherein the amount of said short fibers is at least about 3% by weight based on the total weight of said mixture of long and short fibers.

The present invention provides a mounting mat (30) for mounting a pollution control element (20) or monolith in a pollution control device (10), said mounting mat comprising a layer having a mixture of long and short fibers wherein said short fibers have a length of not more than about 13 mm and wherein said long fibers have a length of at least about 20 mm and wherein the amount of said short fibers is at least about 3% by weight based on the total weight of said mixture of long and short fibers.

Methods and systems are provided for a process to generate a nonwoven textile. In one example, the nonwoven textile may have layered, zonal properties resulting from entangling of two or more types of staple fibers through a merging region between the layers of staple fibers while maintaining distinct zones, each zone comprising a type of staple fiber. Furthermore, the process may include embedding a filament layer into the nonwoven textile via a continuous assembly line.

Methods and systems are provided for a process to generate a nonwoven textile. In one example, the nonwoven textile may have layered, zonal properties resulting from entangling of two or more types of staple fibers through a merging region between the layers of staple fibers while maintaining distinct zones, each zone comprising a type of staple fiber. Furthermore, the process may include embedding a filament layer into the nonwoven textile via a continuous assembly line.

Nonwoven fabrics including (i) continuous fibers and (ii) a blend of staple fibers comprising polyester staple fibers, bicomponent staple fibers, microfiber staple fibers, and wettable staple fibers, in which the continuous fibers are mechanically entangled with the blend of staple fibers. The continuous fibers and the blend of staple fibers may be mechanically entangled via a hydroentangling process.

Nonwoven fabrics including (i) continuous fibers and (ii) a blend of staple fibers comprising polyester staple fibers, bicomponent staple fibers, microfiber staple fibers, and wettable staple fibers, in which the continuous fibers are mechanically entangled with the blend of staple fibers. The continuous fibers and the blend of staple fibers may be mechanically entangled via a hydroentangling process.

Fibrous structures containing a mixture of three or more different fibrous elements (filaments and/or fibers) are provided.