Patent ID: 7709405
Filing Date: 2010-05-04
Classification: B32B,B60R,D04H,E04B,Y10T

Abstract:
1. A non-woven composite, comprising: a non-woven material comprising: wherein the non-woven material being a unitary material having: a first planar zone defined by a first boundary plane and a first zone inner boundary plane, the first planar zone including a portion of the first binder fibers, the first effect fibers, and the second binder fibers; a second planar zone defined by a second boundary plane and a second zone inner boundary plane, the second planar zone including a portion of the first binder fibers, the first effect fibers, and the second binder fibers; a first skin at the first boundary plane, the first skin comprising the first binder fibers; a second skin at the second boundary plane, the second skin comprising the second binder fibers; wherein concentrations of said first binder fibers in said first planar zone being greater than concentrations of the first binder fibers in said second planar zone, and the concentration of the first binder fibers decreases in a gradient from the first boundary plane to the first zone inner boundary plane; wherein concentrations of said second binder fibers being greater in said second planar zone than the concentration of the second binder fibers in second planar zone, and the concentration of the second binder fibers decreases in a gradient from the second boundary plane to the second zone inner boundary plane; and, wherein the non-woven composite has a density of between about 0.03 and 0.5 g/cm