GB2209353A - Non-woven sheet material which includes synthetic fibres - Google Patents

Non-woven sheet material which includes synthetic fibres Download PDF

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Publication number
GB2209353A
GB2209353A GB8818251A GB8818251A GB2209353A GB 2209353 A GB2209353 A GB 2209353A GB 8818251 A GB8818251 A GB 8818251A GB 8818251 A GB8818251 A GB 8818251A GB 2209353 A GB2209353 A GB 2209353A
Authority
GB
United Kingdom
Prior art keywords
sheet material
woven sheet
synthetic fibres
fibres
synthetic
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
GB8818251A
Other versions
GB8818251D0 (en
Inventor
Robert Michael Rowan
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
J&D Wilkie Ltd
Original Assignee
J&D Wilkie Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by J&D Wilkie Ltd filed Critical J&D Wilkie Ltd
Publication of GB8818251D0 publication Critical patent/GB8818251D0/en
Publication of GB2209353A publication Critical patent/GB2209353A/en
Withdrawn legal-status Critical Current

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Classifications

    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H5/00Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length
    • D04H5/02Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length strengthened or consolidated by mechanical methods, e.g. needling
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4266Natural fibres not provided for in group D04H1/425
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/52Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by applying or inserting filamentary binding elements
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/541Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
    • D04H1/5412Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres sheath-core
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H5/00Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length
    • D04H5/06Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length strengthened or consolidated by welding-together thermoplastic fibres, filaments, or yarns

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Laminated Bodies (AREA)

Abstract

Non-woven sheet material (2) comprising synthetic fibres and auxiliary material (4) for imparting strength and rigidity to the sheet material, the auxiliary material having been subjected to heat and pressure so that the auxiliary material binds the synthetic fibres together and forms the sheet material, the synthetic fibres being such that they form the major component of the sheet material, and the synthetic fibres having been formed as a web which is over laid to form layers, the web having first threads which extend in a weft direction and second threads which extend in a warp direction and which are stitched to the web. <IMAGE>

Description

NON-WOVEN SHEET MATERIAL WHICH INCLUDES SYNTHETIC FIBRES This invention relates to non-woven sheet material which includes synthetic fibres.
Accordingly, this invention provides non-woven sheet material comprising synthetic fibres and auxiliary material for imparting strength and rigidity to the sheet material, the auxiliary material having been subjected to heat and pressure so that the auxiliary material binds the synthetic fibres together and forms the sheet material, the synthetic fibres being such that they form the major component of the sheet material, and the synthetic fibres having been formed as a web which is over laid to form layers, the web having first threads which extend in a weft direction and second threads which extend in a warp direction and which are stitched to the web.
The non-woven sheet material of the invention can be economically produced. In addition, with known woven sheet material, there often occurs the problem of threads being snagged and subsequently running. This problem is obviated with the non-woven sheet material of the present invention.
The auxiliary material may comprise bi-component synthetic fibres which are formed to have a core of a material suitable for imparting strength and rigidity to the sheet material and a sheath of meltable material which melts such that when it is subjected to heat and pressure, it binds the synthetic fibres together with the coreof material to form the non-woven sheet material. The bi-component synthetic fibres may include polyester plastics material. The meltable material may be randomly dispersed in the auxiliary material.
Alternatively, the auxiliary material may comprise plastics fibres. Preferably the plastics fibres are polypropylene fibres. Generally, any plastics fibres may be employed that melt at an appropriate temperature, for example under 2200C.
Still further, the auxiliary material may be an adhesive material which has been applied as a powder or as a liquid to the synthetic Thbres The adhesive material may be, for example, a polyvinyl acrylic material.
The synthetic fibres form at least 65% by weight of the non-woven sheet material. Preferably, the synthetic fibres .form from 70-95% by weight of the non-woven sheet material.
The non-woven sheet material is preferably one in which the synthetic fibres are arranged in an even form by using a plurality of carding systems including a fine carding system, and in which the jute fibres are over laid to achieve a desired thickness and width for the non-woven sheet material.
The fine carding system may employ carding apparatus suitable for giving a semi-worsted finish. The over laying is preferably effected by folding a web of the synthetic fibres back on itself a desired number of times to give a desired weight in grams per square meter.
After the synthetic fibres and the auxiliary material have been carded and over laid, they are subsequently consolidated under heat and pressure. The amount of pressure employed is variable. Generally, increasing pressures give more solid non-woven sheet material.
The temperatures employed may be from 1800C to 3500C.
The actual temperature employed and also the actual pressure employed depend upon the speed of feeding of the formed sheet material through the apparatus supplying the heat and pressure.
For example, a temperature of 1800C to 2200C is a preferred temperature for a feed rate of 5 to 20 metres per minute.
The second threads form reinforcing stitching in the warp direction. This reinforcing stitching will usually be applied prior to the application of the heat and pressure.
The first threads may also be provided in the form of stitching in the weft direction. Again, this reinforcing stitching will usually be applied prior to the application of heat and pressure.
Advantageously, the first threads are formed such that reinforcing weft threads are laid on the back of a web of the synthetic fibre, for example at the above mentioned cross laying stage. These weft threads are not in themselves in the form of stitches and they are held in position by warp stitched threads. Since the weft reinforcing is positioned between one or more layers of the cross laid synthetic material, then the weft reinforcement becomes hidden between the layers as they overlap.
Various types of synthetic fibres may be employed.
The fibres may be for example, polyester, blends of polyester and nylon, viscose ( a regenerated fibre which is regarded as being a synthetic fibre ), polypropylene or acrylic material fibres.
The non-woven sheet material of the present invention may be used for many of the purposes used by conventional woven jute sheet material. Thus, the non-woven sheet material of the invention may be used as a component in the formation of products such for example as roofing felt, linoleum, upholstery, torchfelt, shoe liner materials, polyvinyl chloride coated tarpaulins, reinforcing in conveyor belts, insulating materials, sound-proofing materials, as a basis and/or reinforcement for paper and plastics material laminates, fabrics for being printed on, slipper liner materials, ironing boards, cushion liners and capillary mats.
An embodiment of the invention will now be described solely by way of example and with reference to the accompanying drawings in which: Figure 1 is an isometric view of a piece of non-woven sheet material of the invention; Figure 2 shows in enlarged form a small piece of the material shown in Figure 1 and it illustrates how fibres are bonded at intersections; Figure 3 shows somewhat schematically a heat and pressure applying roller arrangement; and Figure 4 is a side view through a machine that may be employed to apply the heat and pressure to a mat of synthetic fibre material.
Referring to Figure 1, there is shown a piece of nonwoven sheet material 2 comprising synthetic fibres and auxiliary sheet material in the form of bi-component plastics fibres 4 sold by Wellman Inc., United States of America, under the Trade Mark FILLWELL. The synthetic fibres and the plastics fibres 4 are formed as a composite material due to the application of heat and pressure causing the plastics fibres 4 to melt and bond together the synthetic fibres, in addition to imparting strength and rigidity to the sheet material 2. The sheet material 2 is provided with lines of stitching 6 to impart further strength to the sheet material 2. The lines of stitching 6 extend in the warp direction and they can be effected with any desired and appropriate type of thread.
The non-woven sheet material 2 is produced by folding of synthetic material back upon itself and, between the various folds of the synthetic material, weft threads 8 are laid. These weft threads 8 are held in position by being sandwiched between the various layers of the synthetic material and also they are held in position by the warp line of stitching 6.
Figure 2 shows an enlarged part of Figure 1 and it shows particularly how the plastics fibres 4 become bonded together at intersection points under the application of heat and pressure. The darkened parts indicate where bonding has taken place and these darkened parts will also be effective to bond together synthetic fibres, shown somewhat schematically as synthetic fibres 10 in Figure 2.
Referring now to Figure 3, there is shown a heat and pressure arrangement 12 comprising a pair of heated rollers 14, 16. A web of non-woven synthetic fibres in a finely carded form passes as sheet material 18 through a nip 20 between the rollers 14, 16. The applied heat and pressure in the nip 20 cause the formation of the non-woven sheet material 2 shown in Figure 1.
In order to further illustrate the non-woven sheet material of the present invention, reference will now be made to the following Example which is given for illustrative purposes only.
EXAMPLE Synthetic fibres were introduced into a breaker card machine in which the fibres were torn apart with a high speed roller. The fibres were then introduced into a friction card machine which further refined the synthetic fibres. The refined synthetic fibres were then passed to a finisher card machine which formed the fibres into sheet material. The finisher card machine was of a type known as a semi-worsted synthetic card. The finisher card machine is effective to refine and align the synthetic fibres, drawing them out into a fine web. The fine web was then over laid in a cross folding machine to give sheet material of the required thickness and weight.
Reinforcing threads of material, for example cotton, were laid in the weft direction between various layers of the over laid web. Stitching in the warp direction was then effected to help to reinforce the web and also to hold the weft threads in position.
The web was then fed through apparatus of the type shown in Figure 4 in order to apply auxiliary material in the form of polypropylene plastics fibres.
In Figure 4, there is shown dry laminating apparatus comprising a bonding agent roller 21, a first fabric supply roller 22, blanket tensioning and guiding rollers 23, and a second fabric supply roller 24. The apparatus also includes an input pressure roller 25, a Teflon (registered trade mark) coated heated roller 26, an output pressure roller 27, a cooling pipe 28, and a rewind roller 29 for rewinding fabric under tension. The apparatus also includes a rewinding roller 30 for rewinding the fabric in a relaxed condition, and rewind support rollers 31. In addition, the apparatus has a cooling fan 32 and a main motor 33.
Parts of the apparatus which would not normally be used but which could be employed if desired are a print material supply roller 34, and a print paper out roller 37.
Using heat and pressure, the synthetic fibres and the polypropylene plastics fibres are consolidated together to form composite sheet material using heat and pressure.
The rollers were heated to 1800C and the fibres were passed through the rollers at a rate of 15 meters per minute.
It is to be appreciated that the embodiment of the invention described above with reference to the accompanying drawings and the Examples has been given for illustrated purposes only and that it is not to be read in any limiting sense. Thus, for example, the amount of stitching employed can be varied. Furthermore, instead of using polypropylene plastics fibres, other auxiliary material such for example as bi-component synthetic fibres or powdered or liquid adhesives can be employed. The non-woven sheet material of the present invention may be very economical to produce, for example because it can be stitch bonded with longer stitches than would normally be required for strengthening/ bonding purposes, because the auxiliary material effects a strengthening/bonding action. Preferably, the above mentioned over laying is effected with the web being caused to change direction, for example through 900, to cause the over laid fibres in the layers to be at an angle to each other.

Claims (13)

1. Non-woven sheet material comprising synthetic fibres and auxiliary material for imparting strength and rigidity to the sheet material, the auxiliary material having been subjected to heat and pressure so that the auxiliary material binds the synthetic fibres together and forms the sheet material, the synthetic fibres being such that they form the major component of the sheet material, and the synthetic fibres having been formed as a web which is over laid to form layers, the web having first threads which extend in a weft direction and second threads which extend in a warp direction and which are stitched to the web.
2. Non-woven sheet material according to claim 1 in which the auxiliary material comprises bi-component synthetic fibres which are formed to have a core of a material suitable for enhancing strength and rigidity to the sheet material and a sheet of meltable material which melts such that when it is subjected to heat and pressure, it binds the synthetic fibres together with the core of material to form the non-woven sheet material.
3. Non-woven sheet material according to claim 2 in which the bi-component synthetic fibres include polyester plastics material.
4. Non-woven sheet material according to claim 2 or claim 3 in which the meltable material is randomly dispersed in the auxiliary material.
5. Non-woven sheet material according to claim 1 in which the auxiliary material comprises plastics fibres.
6. Non-woven sheet material according to claim 5 in which the plastics fibres are polypropylene fibres.
7. Non-woven sheet material according to claim 1 in which the auxiliary material is an adhesive material which has been applied as a powder or as a liquid to the synthetic fibres.
8. Non-woven sheet material according to claim 7 in which the adhesive material is polyvinyl acrylic material.
9. Non-woven sheet material according to any one of the preceding claims in which the synthetic fibres form at least 6556 by weight of the non-woven sheet material.
10. Non-woven sheet material according to claim 9 in which the synthetic fibres form 70-95% by weight of the non-woven sheet material.
11. Non-woven sheet material according to any one of the preceding claims in which the synthetic fibres are arranged in an even form by using a plurality of carding systems including a fine carding system, and in which the jute fibres are over laid to achieve a desired thickness and width for the non-woven sheet material.
12. Non-woven sheet material according to any one of the preceding claims in which the first threads are formed such that reinforcing weft threads are laid on the back of a web of the synthetic fibre.
13. Non-woven sheet material substantially as herein described with reference to the accompanying drawings.
GB8818251A 1987-09-04 1988-08-01 Non-woven sheet material which includes synthetic fibres Withdrawn GB2209353A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB878720840A GB8720840D0 (en) 1987-09-04 1987-09-04 Non-woven sheet material

Publications (2)

Publication Number Publication Date
GB8818251D0 GB8818251D0 (en) 1988-09-07
GB2209353A true GB2209353A (en) 1989-05-10

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Application Number Title Priority Date Filing Date
GB878720840A Pending GB8720840D0 (en) 1987-09-04 1987-09-04 Non-woven sheet material
GB8818251A Withdrawn GB2209353A (en) 1987-09-04 1988-08-01 Non-woven sheet material which includes synthetic fibres

Family Applications Before (1)

Application Number Title Priority Date Filing Date
GB878720840A Pending GB8720840D0 (en) 1987-09-04 1987-09-04 Non-woven sheet material

Country Status (1)

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GB (2) GB8720840D0 (en)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2236771A (en) * 1989-09-13 1991-04-17 Du Pont Stitch-stabilized non woven fabric
EP0493082A1 (en) * 1990-12-27 1992-07-01 E.I. Du Pont De Nemours And Company Stitchbonded comfort fabric
US5203186A (en) * 1989-09-13 1993-04-20 E. I. Du Pont De Nemours And Company Stitch-stabilized nonwoven fabric

Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB640571A (en) * 1947-06-02 1950-07-26 Frank Edward Vaughan Methods of making sheet material for constructional purposes and sheet material madeaccording thereto
US3649427A (en) * 1970-03-12 1972-03-14 Beacon Mfg Co Stitched self-bonded nonwoven fabric
GB1380081A (en) * 1971-02-23 1975-01-08 Lantor Ltd Laminated fabric
GB1399153A (en) * 1972-03-03 1975-06-25 Wildeman A E Manufacture of fabrics
GB1456049A (en) * 1973-03-28 1976-11-17 Kufner Textilwerke Kg Fleece lining web for garments
GB2143868A (en) * 1983-07-20 1985-02-20 Malcolm Otty Electrically insulating board
GB2152875A (en) * 1984-01-21 1985-08-14 Uniroyal Ltd Carpet underlay and its manufacture
GB2175930A (en) * 1985-05-30 1986-12-10 Composite Dev Ltd Reinforced resinous material
EP0205276A2 (en) * 1985-05-30 1986-12-17 Composite Developments Limited Making reinforced resinous sheet material

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB640571A (en) * 1947-06-02 1950-07-26 Frank Edward Vaughan Methods of making sheet material for constructional purposes and sheet material madeaccording thereto
US3649427A (en) * 1970-03-12 1972-03-14 Beacon Mfg Co Stitched self-bonded nonwoven fabric
GB1380081A (en) * 1971-02-23 1975-01-08 Lantor Ltd Laminated fabric
GB1399153A (en) * 1972-03-03 1975-06-25 Wildeman A E Manufacture of fabrics
GB1456049A (en) * 1973-03-28 1976-11-17 Kufner Textilwerke Kg Fleece lining web for garments
GB2143868A (en) * 1983-07-20 1985-02-20 Malcolm Otty Electrically insulating board
GB2152875A (en) * 1984-01-21 1985-08-14 Uniroyal Ltd Carpet underlay and its manufacture
GB2175930A (en) * 1985-05-30 1986-12-10 Composite Dev Ltd Reinforced resinous material
EP0205276A2 (en) * 1985-05-30 1986-12-17 Composite Developments Limited Making reinforced resinous sheet material

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2236771A (en) * 1989-09-13 1991-04-17 Du Pont Stitch-stabilized non woven fabric
US5203186A (en) * 1989-09-13 1993-04-20 E. I. Du Pont De Nemours And Company Stitch-stabilized nonwoven fabric
GB2236771B (en) * 1989-09-13 1994-02-02 Du Pont Stitch-stabilized nonwoven fabric
EP0493082A1 (en) * 1990-12-27 1992-07-01 E.I. Du Pont De Nemours And Company Stitchbonded comfort fabric
US5192600A (en) * 1990-12-27 1993-03-09 E. I. Du Pont De Nemours And Company Stitchbonded comfort fabric

Also Published As

Publication number Publication date
GB8720840D0 (en) 1987-10-14
GB8818251D0 (en) 1988-09-07

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