Method of forming a molded nonwoven knitted material
OwnerDavid E. Wenstrupinventor
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Abstract
A nonwoven textile formed of first fibers and second fibers. The first fibers are standard polyester staple fibers and the second fibers are staple fibers of a blend of polyester material having a melt temperature below the material of the first fibers and above the mold temperature of a subsequent molding process. The nonwoven textile has a base area and a pile area extending from the base area. The pile area is the combination of first fibers and second fibers oriented generally perpendicular to the planar direction of the textile. The base area is a knitted portion of the first fibers and the second fibers. The nonwoven textile can also include a cover area being a knitted portion of the first fibers and second fibers disposed on the pile area opposite to the base area.
Claims56
A nonwoven textile for use in a molding process having a mold temperature, said nonwoven textile comprising:
- a plurality of first fibers having a first fiber melt temperature, the first melt temperature being greater than the mold temperature;
- a plurality of second fibers having a second fiber melt temperature being lower than the first fiber melt temperature of said first fibers and greater than the mold temperature;
- wherein a first plurality of said first fibers and said second fibers are secured together in a base area and a second plurality of said first fibers and said second fibers extend from said base area as a pile area;
- and
- wherein said first fibers and said second fibers are bonded together into a planar textile.
Dependencies are inferred from the claim text.