Needling loops into carrier sheets

Abstract

Methods of making a sheet-form loop product are provided. One method includes placing a layer of staple fibers against a first side of a substrate comprising a nonwoven web; needling fibers of the layer through the substrate by penetrating the substrate with needles that drag portions of the fibers through the substrate, leaving exposed loops of the fibers extending from a second side of the substrate; and anchoring fibers forming the loops by fusing the fibers to each other and to filaments of the nonwoven web on the first side of the substrate, while substantially preventing fusion of the fibers on the second side of the substrate. Sheet-form loop products are also provided, including for example a flexible nonwoven substrate and a layer of staple fibers disposed on a first side of the substrate, exposed loops of the fibers extending from a second side of the substrate, with bases of the loops being anchored on the first side of the substrate, wherein the fibers on the first side of the substrate are fused together to a relatively greater extent than the fibers on the second side of the substrate.

Dependencies are inferred from the claim text.