GB2299350A - Non-woven valance material - Google Patents

Non-woven valance material Download PDF

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Publication number
GB2299350A
GB2299350A GB9606853A GB9606853A GB2299350A GB 2299350 A GB2299350 A GB 2299350A GB 9606853 A GB9606853 A GB 9606853A GB 9606853 A GB9606853 A GB 9606853A GB 2299350 A GB2299350 A GB 2299350A
Authority
GB
United Kingdom
Prior art keywords
valance
fibres
bat
felt
material according
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Withdrawn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
GB9606853A
Other versions
GB9606853D0 (en
Inventor
Simon John Irwin
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.)
VITAFIBRES Ltd
Original Assignee
VITAFIBRES 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
Priority claimed from GBGB9506749.2A external-priority patent/GB9506749D0/en
Application filed by VITAFIBRES Ltd filed Critical VITAFIBRES Ltd
Priority to GB9606853A priority Critical patent/GB2299350A/en
Publication of GB9606853D0 publication Critical patent/GB9606853D0/en
Publication of GB2299350A publication Critical patent/GB2299350A/en
Withdrawn legal-status Critical Current

Links

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
    • 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
    • D04H1/46Non-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 needling or like operations to cause entanglement of fibres
    • 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
    • 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
    • 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
    • D04H1/5414Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres side-by-side
    • 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
    • D04H1/5418Mixed fibres, e.g. at least two chemically different fibres or fibre blends

Landscapes

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

Abstract

A valance material comprises a thermally bonded felt having a loft lying in the range 3 - 5mm and a weight lying in the range 100 - 450 gms per sq.m. The felt is preferably made from a blend of base fibres and binder fibres. The latter may be of bicomponent or multi-component type both fibres may be of polyester. The felt may be needle-punched from both sides prior to heating to bond the fibres.

Description

Title: "Valance and material therefor" Description of Invention This invention relates to a valance and to material for a valance and to a method of making material for a valance.
According to one aspect of the present invention we provide a valance material comprising a thermally bonded felt having a loft lying in the range 3 5mm and a weight lying in the range 100 - 450 gms per sq.m.
The felt may comprise a blend of 50 - 90% of base fibres and 50 - 10% of binder fibres.
The binder fibres may have a lower softening or melting point than the base fibres and may be of homogeneous composition or may be of bi or multi component type comprising one component having a higher melting or softening point which may be the same as that of the base fibre, and a lower softening or melting point component.
The components may be arranged side by side or the lower melting or softening point component may comprise a sheath around the higher melting or softening point component.
The base fibre may be of 1.7 - 18 d.tex and 38 - 150mm long.
The binder fibre may be of 1-13 d.tex and 38-150mm long.
The base fibres may comprise polyester.
The binder fibres may comprise polyester.
The material may have a crease resistance such as to permit of bending in any direction through a radius of down to 5mm without the material incurring a crease or other permanent deformation.
According to a second aspect of the invention we provide a method of making a thermally bonded valance material comprising the steps of producing a bat comprising a blend of base fibres and binder fibres, needle punching the bat to form a felt and heating the felt to thermally bond the fibres.
The bat may comprise a plurality of webs.
The webs may be layered by a cross-lapper to obtain a predetermined bat weight.
The bat may comprise between eight and twelve layers.
Each web may have a weight of approximately 19gms per sq.m and the bat may have a weight lying in the range 180 - 250gms per sq.m.
The bat may be subjected to a double sided needle punching operation.
The double sided needle punching operation may be performed in a double sided needle punching loom which may utilise two upstroke and two downstroke boards.
The boards on the input side may have 38 gauge needles and the boards on the output side 40 gauge needles.
All the needles may have six barbs.
The barbs may be of the "formed zero protrusion" type.
Different needle types may be used if found appropriate, for example, different barb configuration, and gauges.
Alternatively, the double sided needle punching operation may be carried out by using a separate down punch loom or looms and a separate up punch loom or looms.
Alternatively, the double sided needle punching operation may be performed by passing of the material through a single punching machine a plurality of times punching from opposite sides of the material as desired.
Alternatively, if desired, the bat may be subjected to a single sided needle punching operation.
The needles may have a penetration depth of 6.2mm top and bottom of the bat.
The needles may have a needle density of 200 - 700 needles per sq.cm.
The thus formed felt may be heated to give a surface temperature of 110- 2000C.
According to a third aspect of the invention we provide a valance comprising material according to the first aspect of the invention or material made in accordance with the second aspect of the invention.
According to the fourth aspect of the invention we provide an article of furniture having a valance according to the third aspect of the invention.
An embodiment of the invention will now be described by way of example with reference to the accompanying drawings wherein FIGURE 1 is a diagrammatic plan view of apparatus for use in making a valance according to the invention, and FIGURE 2 is a diagrammatic cross-section on the line 2-2 of Figure 1.
Referring to the drawings, a web having a weight of approximately 9gms per sq.m is produced on a card 10. The web is made from a blend of base and binder fibres. The fibres comprise 70% base fibre of 7 d.tex and 58mm length comprising polyester fibres and 30% of binder fibres of 4.4 d.tex and 58mm long and comprising bi-component fibres having a core of polyester and a sheath of polyester.
If desired the base fibre may be of between 1.7 and 1.8 d.tex and 38 - 150mm long and preferably 50 - 80mm long whilst the binder fibre may be of between 1 - 13 d.tex and 38 - 150mm long and preferably between 50 - 80mm long. The blend may comprise 50 - 90% of base fibres and 50 - 10% of binder fibres.
If desired, the binder component fibres may comprise a lower melting point/softening point component side by side with a higher melting point or softening point component. Further alternatively, the binder component may comprise wholly a lower softening/melting point component. The lower softening/melting point component may have a softening/melting point lying in the range 1000C to 120 C and the higher softening/melting point component may have a softening/melting point lying in the range 200 C to 260"C.
A bat is layered by the cross-layer 11 to achieve a desired bat weight.
In the present example the cross-layer produces a bat comprising eight layers of web having a bat weight of 180gms per sq.m but in a second example the bat comprises twelve layers and has a weight of 250gms per sq.m. If desired the bat may have a weight lying in the range 100 - 450gms per sq.m.
In each example the bat is fed through a Dilo double sided needle punching loom 12 of type OUG11 utilising two upstroke boards 13, 14 and two downstroke boards 15, 16 which give a total needle density of 18,000 needles per metre.
The two boards 13, 15 on an input side I of the loom have 38 gauge needles whilst the boards 14, 16 on the output side 0 of the loom have 40 gauge needles.
All needles have six barbs which are of "formed zero protrusion" type and the loom is arranged to provide a penetration depth of 6.2mm top and bottom with a total needle density of 480 needles per sq.cm. That is a density of 240 needles per sq.cm from the top and a density of 240 needles per sq.cm from the bottom. If desired the total needle density may lie in the range 200 - 700 needles per sq.cm and preferably in the range 350 - 550 needles per sq.cm. This total needle density may be distributed as desired between top and bottom or may be provided wholly from one side.
Different needle types may be used if found appropriate, for example, different barb configuration, and gauges.
After thus being formed into a felt the felt is passed through a gas fired oven 18 which provides a surface temperature on the felt of 154"C. If desired, however, the temperature may lie in the range 110 - 200"C.
The felt shrinks approximately 10% in length, breadth and thickness during passage through the oven during which thermal bonding between the fibre components takes place.
The thus formed felt is then passed to a cutting stage 19 where the material can be slit longitudinally and cross cut as desired to form pads or rolls.
Although in the above described examples a particular arrangement has been described, if desired similar needle densities may be attained by using separate down punch loom or looms and up punch loom or looms or by passing the material several times through a single punching machine punching from opposite sides of the material as desired. Further alternatively the felt may be formed by passing the material several times through a single punching machine punching from one side of the material only. Although similar needle densities to those described hereinbefore may be attained, generally speaking, the needle densities would tend to be towards the lower ends of the above mentioned ranges.
In all cases, if desired, needles of similar configuration and penetration to those mentioned above may be used.
By adjusting the temperature to which the felt is subjected, the stiffness of the valance material can be adjusted, higher temperatures producing higher stiffness.
The resultant felt may have a loft lying in the range 3 - 5mm and a weight lying in the range 100 - 450 gms per sq.m.
The resultant valance material is relatively stiff and has a relatively high resistance to creasing. The material may have a crease resistance, for example, such as to permit of bending in any direction to a radius of down to Smm without the material incurring a crease or other permanent deformation.
The valance material embodying the present invention may be used to provide valance material by stitching or adhesive bonding the furnishing fabric to the valance or the valance is inserted into a fabric pocket.
Such valance material may be used in any desired application. For example it may be used as a valance around the bottom of an article of furniture such as a chair, settee or bed to hide the base structure and/or legs or castors.
Alternatively the valance may be used to provide a pelmet or the like to provide curtain rails.
The features disclosed in the foregoing description, or the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for attaining the disclosed result, or a class or group of substances or compositions, as appropriate, may, separately or in any combination of such features, be utilised for realising the invention in diverse forms thereof.

Claims (36)

1. A valance material comprising a thermally bonded felt having a loft lying in the range 3 - 5mm and a weight lying in the range 100 - 450 gms per sq.m.
2. A valance material according to Claim 1 wherein the felt comprises a blend of 50 - 90% of base fibres and 50 - 10% of binder fibres.
3. A valance material according to Claims 1 and 2 wherein the binder fibres have a lower softening or melting point than the base fibres.
4. A valance material according to Claim 3 wherein the base fibres are of homogeneous composition.
5. A valance material according to Claim 3 wherein the base fibres are of bi or multi component type comprising one component having a higher melting or softening point and a lower melting or softening point component.
6. A valance material according to Claim 5 wherein the higher melting point is the same as that of the base fibre.
7. A valance material according to Claim 5 or 6 wherein the components are arranged side by side.
8. A valance material according to Claim 5 or 6 wherein the lower melting or softening point component comprises a sheath around the higher melting or softening point component.
9. A valance material according to Claim 7 or 8 wherein the base fibre is of 1.7 - 18 d.tex and 38 - 150mm long.
10. A valance material according to any one of Claims 2 to 9 wherein the binder fibre is of 1-13 d.tex and 38-150mm long.
11. A valance material according to any one of Claims 2 to 10 wherein the base fibres comprise polyester.
12. A valance material according to Claims 2 to 11 wherein the binder fibres comprise polyester.
13. A valance material according to any one of the preceding Claims wherein the material has a crease resistance such as to permit of bending in any direction through a radius of down to 5mm without the material incurring a crease or other permanent deformation.
14. A valance material as hereinbefore described with reference to the accompanying drawings.
15. A method of making a thermally bonded valance material comprising the steps of producing a bat comprising a blend of base fibres and binder fibres, needle punching the bat to form a felt and heating the felt to thermally bond the fibres.
16. A method according to Claim 15 wherein the bat comprises a plurality of webs.
17. A method according to Claim 16 wherein the webs are layered by a cross-lapper to obtain a predetermined bat weight.
18. A method according to Claim 16 or 17 where the bat comprises between eight and twelve layers.
19. A method according to any one of Claims 16 to 18 wherein each web has a weight of approximately 19gms per sq.m.
20. A method according to Claim 19 wherein the bat has a weight lying in the range 180 - 250gms per sq.m.
21. A method according to any one of Claims 15 to 20 wherein the bat is subjected to a double sided needle punching operation.
22. A method according to Claim 21 wherein the double sided needle punching operation is performed in a double sided needle punching loom.
23. A method according to Claim 22 wherein the loom utilises two upstroke and two downstroke boards.
24. A method according to any one of Claims 22 to 23 wherein the loom comprises boards on an input side which have 38 gauge needles and boards on the output side which have 40 gauge needles.
25. A method according to any one of Claims 22 to 24 wherein all the needles have six barbs.
26. A method according to Claim 25 wherein the barbs are of the "formed zero protrusion" type.
27. A method according to Claim 21 or any one of Claims 24 to 26 when dependant on Claim 21 wherein the double sided needle punching operation is carried out by using a separate down punch loom or looms and a separate up punch loom or looms.
28. A method according to Claim 21 or any one of Claims 24 to 26 when dependant on Claim 21 wherein the double sided needle punching operation is performed by passing of the material through a single punching machine a plurality of times punching from opposite sides of the material as desired.
29. A method according to any one of Claims 15 to 20 wherein the bat is subjected to a single sided needle punching operation.
30. A method according to any one of Claims 21 to 29 wherein the needle has a penetration depth of 6.2mm top and bottom of the bat.
31. A method according to any one of Claims 21 to 30 wherein there is a total needle density of 200 - 700 needles per sq.cm.
32. A method according to any one of Claims 15 to 31 wherein the felt is heated to give a surface temperature of 110 - 2000C.
33. A method substantially as hereinbefore described with reference to the accompanying drawings.
34. A valance comprising material according to any one of Claims 1 to 14 or material made in accordance with any one of Claims 15 to 33.
35. An article of furniture having a valance according to Claim 34 of the invention.
36. Any novel feature or novel combination of features hereinbefore described and/or shown in the accompanying drawings.
GB9606853A 1995-03-31 1996-04-01 Non-woven valance material Withdrawn GB2299350A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB9606853A GB2299350A (en) 1995-03-31 1996-04-01 Non-woven valance material

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GBGB9506749.2A GB9506749D0 (en) 1995-03-31 1995-03-31 Valance and material therefor
GB9606853A GB2299350A (en) 1995-03-31 1996-04-01 Non-woven valance material

Publications (2)

Publication Number Publication Date
GB9606853D0 GB9606853D0 (en) 1996-06-05
GB2299350A true GB2299350A (en) 1996-10-02

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2313383A (en) * 1996-05-24 1997-11-26 British United Shoe Machinery Insole material
GB2314097A (en) * 1996-06-14 1997-12-17 British United Shoe Machinery Resilient fleece
EP0990730A2 (en) * 1998-10-02 2000-04-05 Rawson Carpets Limited Fabric composition
EP1008684A1 (en) * 1998-12-09 2000-06-14 Milliken Industrials Limited Method of manufacturing a non-woven felt for use in cue sports and gaming tables and a non-woven felt thus obtained

Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4296168A (en) * 1980-02-19 1981-10-20 Ambrose Jere B Padding sheet formed of a mixture of fibers bonded at their intersections
EP0106604A2 (en) * 1982-09-30 1984-04-25 Chicopee Patterned belt bonded material and method for making the same
US4488928A (en) * 1983-05-16 1984-12-18 Kimberly-Clark Corporation Method and apparatus for forming soft, bulky absorbent webs and resulting product
US4551378A (en) * 1984-07-11 1985-11-05 Minnesota Mining And Manufacturing Company Nonwoven thermal insulating stretch fabric and method for producing same
EP0264112A2 (en) * 1986-10-17 1988-04-20 Chisso Corporation Nonwoven fabrics and method for producing them
EP0388072A2 (en) * 1989-03-14 1990-09-19 Emhart Materials UK Limited Improved needling process
EP0505568A1 (en) * 1990-10-03 1992-09-30 Teijin Limited Heat-resistant nonwoven fabric and method of manufacturing said fabric
WO1993022486A1 (en) * 1992-05-01 1993-11-11 British United Shoe Machinery Limited Absorbent material and a method of making same

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4296168A (en) * 1980-02-19 1981-10-20 Ambrose Jere B Padding sheet formed of a mixture of fibers bonded at their intersections
EP0106604A2 (en) * 1982-09-30 1984-04-25 Chicopee Patterned belt bonded material and method for making the same
US4488928A (en) * 1983-05-16 1984-12-18 Kimberly-Clark Corporation Method and apparatus for forming soft, bulky absorbent webs and resulting product
US4551378A (en) * 1984-07-11 1985-11-05 Minnesota Mining And Manufacturing Company Nonwoven thermal insulating stretch fabric and method for producing same
EP0264112A2 (en) * 1986-10-17 1988-04-20 Chisso Corporation Nonwoven fabrics and method for producing them
EP0388072A2 (en) * 1989-03-14 1990-09-19 Emhart Materials UK Limited Improved needling process
EP0505568A1 (en) * 1990-10-03 1992-09-30 Teijin Limited Heat-resistant nonwoven fabric and method of manufacturing said fabric
WO1993022486A1 (en) * 1992-05-01 1993-11-11 British United Shoe Machinery Limited Absorbent material and a method of making same

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2313383A (en) * 1996-05-24 1997-11-26 British United Shoe Machinery Insole material
GB2313383B (en) * 1996-05-24 2000-01-12 British United Shoe Machinery Insole material
GB2314097A (en) * 1996-06-14 1997-12-17 British United Shoe Machinery Resilient fleece
EP0990730A2 (en) * 1998-10-02 2000-04-05 Rawson Carpets Limited Fabric composition
EP0990730A3 (en) * 1998-10-02 2000-06-07 Rawson Carpets Limited Fabric composition
GB2342362B (en) * 1998-10-02 2002-12-24 Rawson Carpets Ltd Floor covering
EP1008684A1 (en) * 1998-12-09 2000-06-14 Milliken Industrials Limited Method of manufacturing a non-woven felt for use in cue sports and gaming tables and a non-woven felt thus obtained

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Publication number Publication date
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