Fabric

This application claims benefit of priority of U.S. Provisional Application No. 63/644,019 filed May 8, 2024, which is hereby incorporated by reference in its entirely.

The present disclosure generally relates to the field of fabrics, and in particular a fabric incorporating graphene or durability enhancing agents.

Fabrics and textiles have different applications and uses. In addition to clothing, coverings, bags, shoes, and homewares, fabrics are also found in construction and architectural materials, vehicles, filtration systems, chemical processing, and electronics. As such, there is a continued need for need for improved fabrics for different applications and uses.

For example, there is a need for improved fabrics with high material durability and/or impact shielding. As another example, there is a need for improved fabrics for sound modification, dampening, or reduction. This may be desirable for musical instrument manufacturing, acoustic room manufacturing, sound equipment manufacturing, ear protection, surface (such as wall, floor, ceiling, etc.) applications, and sports equipment manufacturing. As an illustrative example, noise is generated from impact between a ball and a playing surface of a paddle. There is a need for a durable fabric with sound dampening qualities that can be applied to a paddle.

In an aspect, there is provided a fabric incorporating graphene. In some embodiments, a graphene-infused fabric is provided for a sound reducing layer of a pickleball paddle, wherein the graphene-infused fabric reduces sound generation from the pickleball paddle, the graphene-infused fabric comprising polymer fibers, wherein the polymer fibers comprise N66 fiber, polypropylene fiber, and graphene-infused polyethylene terephthalate fiber, wherein the graphene-infused fabric comprises by weight: i) between 5% to 15% graphene-infused polyethylene terephthalate fiber, ii) between 40% to 60% N66 fiber, and iii) between 30% to 40% polypropylene fiber, wherein the polymer fibers are blended and compressed to form the graphene-infused fabric.

In one embodiment, the graphene-infused polyethylene terephthalate fiber is a composite fiber made from polyethylene terephthalate and graphene. In one embodiment, the graphene-infused polyethylene terephthalate fiber is an extruded fiber made from a mixture of graphene powder and molten polyethylene terephthalate. In one embodiment, the fabric comprises about 10% graphene-infused polyethylene terephthalate fiber by weight of the graphene-infused fabric. In one embodiment, the fabric comprises about 55% N66 fiber by weight of the graphene-infused fabric. In one embodiment, the fabric comprises about 35% polypropylene fiber by weight of the graphene-infused fabric. In one embodiment, the fabric comprises about 1-10% by weight waterproofing or water resistant additive sprayed onto the polymer fibers.

In one embodiment, the fabric comprises by weight: i) between 5% to 10% graphene-infused polyethylene terephthalate fiber, ii) between 40% to 55% N66 fiber, iii) between 30% to 40% polypropylene fiber, and iv) about 5% waterproofing or water resistant additive.

In one embodiment, the graphene-infused fabric is a non-woven fabric. In one embodiment, the fabric comprises a felt. In one embodiment, the polymer fibers are repeatedly compressed into a fabric by needle punching.

In an aspect, there is provided a pickleball paddle for reducing the loudness and/or frequency of sound generated when a ball strikes the pickleball paddle, wherein the paddle comprises a sound reducing fabric layer applied to a playing surface of the paddle, wherein the sound reducing fabric layer reduces sound generation from the exterior playing surface, wherein the sound reducing fabric layer comprises graphene-infused fabric of polymer fibers, wherein the polymer fibers comprise N66 fiber, polypropylene fiber, and graphene-infused polyethylene terephthalate fiber.

In one embodiment, the polymer fibers are blended, and compressed to form the sound reducing fabric layer. In one embodiment, the paddle has an internal layer of the graphene-infused fabric. In one embodiment, the sound reducing fabric layer is applied on opposing outer surfaces of the paddle to cover the playing surface of the paddle. In one embodiment, the sound reducing fabric layer comprises a shell encasing the playing surface of the pickleball paddle. In one embodiment, the sound reducing fabric layer is applied along an edge of the paddle, and on the playing surface. In one embodiment, the sound reducing fabric layer is removable. In one embodiment, the graphene-infused fabric of the paddle comprise by weight: between 5% to 15% graphene-infused polyethylene terephthalate fiber, between 40% to 60% N66 fiber, and between 30% to 40% polypropylene fiber.

In another aspect, there is provided sound reducing acoustic fabric for application to a surface, the fabric comprising polymer fibers, wherein the polymer fibers comprise N66 fiber, polypropylene fiber, and graphene powder-polyethylene terephthalate composite fiber, wherein the polymer fibers are blended and compressed to form the sound reducing acoustic fabric. In one embodiment, the sound reducing acoustic fabric comprise a non-woven felt.

In some embodiments, there is provided a graphene-infused fabric for a surface, the graphene-infused fabric comprising one or more polymer fibers, wherein at least one of the polymer fibers comprise a graphene-infused polymer. In one embodiment, the graphene-infused polymer is a graphene-polymer composite fiber. In one embodiment, the graphene-infused polymer is an extruded fiber from a molten mixture of the polymer and graphene. In some embodiments, there is provided a graphene-infused fabric for a surface, the graphene-infused fabric comprising a plurality of polymer fibers, wherein one or more of the polymer fibers comprise a graphene-infused polymer fiber.

In some embodiments, there is provided a graphene-infused polymer fiber comprising graphene distributed throughout the polymer material of the fiber. In one embodiment, the graphene is graphene powder. In one embodiment, the graphene-infused polymer fiber is an extruded fiber, extruded from a material comprising a blend of graphene and polymer. In one embodiment, the graphene-infused polymer fiber is a graphene-polymer composite fiber.

In this respect, before explaining at least one embodiment in detail, it is to be understood that the embodiments are not limited in application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.

Many further features and combinations thereof concerning embodiments described herein will appear to those skilled in the art following a reading of the instant disclosure.

Numerous details are set forth to provide an understanding of the examples described herein. The examples may be practiced without these details. The description is not to be considered as limited to the scope of the examples described herein.

In some embodiments, the fabrics disclosed herein are developed for increased strength. Fabric may refer to textile, cloth, material, and so on. In some embodiments, the fabrics disclosed herein are developed for sound management or modification. In some embodiments, the fabrics disclosed herein are developed for sound dampening or buffering. In some embodiments, the fabrics disclosed herein are developed for sound reduction. In some embodiments, the fabrics disclosed herein are developed for impact shielding. In some embodiments, the fabrics disclosed herein are developed for durability while maintaining sound reduction. In some embodiments, the fabrics disclosed herein are developed for electrical conductivity and smart fabrics. In some embodiments, the fabrics disclosed herein provide for sound dampening, impact shielding, and durability enhancement.

In some embodiments, the fabric is non-woven. An exemplary non-woven fabric includes felt. Felt is created by compressing and matting fibers together. Non-woven fabrics may be spunbond, meltblown, or thermal bonded. In some embodiments, the fabric is woven. In some embodiments, the fabric is flexible. In one embodiment, the fabric is at least semi-rigid, and/or able to hold its shape or structure. In one embodiment, the fabric is at least partially pliable, and/or capable of bending or moulding around an object.

When an object makes contact a surface it generates a vibrational wave that travels through surface, which subsequently produces a sound. Modifications of the surface, such as by applying a material with viscoelastic properties, introduces damping to this process. The viscoelastic material converts vibrational energy into heat, diminishing the amplitude of sound waves and thereby reducing the perceived noise level. Such modified surfaces dissipates vibrational energy, preventing it from being fully converted into sound waves, which reduces the noise generated upon impact.

The present inventors have developed a fabric that minimizes noise upon impact. This has different useful applications. For example, the fabric may be applied to the playing surface of paddles to minimize noise. Sports equipment should be durable. It is also important that materials applied to paddles to not impact game play. There may be regulations governing sports with requirements for the sports equipment. In an aspect, embodiments described herein provide a fabric layer for application to a playing surface of sports equipment such as a paddle. The fabric layer has enhanced durability while maintaining sound reduction from the playing surface. The fabric layer does not impact game play.

In an aspect, embodiments described herein provide an improved fabric that is durable and has sound reduction properties. In some embodiments, the fabric reduces the decibel sound or loudness of a striking object. In some embodiments, the fabric eliminates the sound of a striking object. In some embodiments, the fabric dampens the sound of a striking object. In some embodiments, the fabric changes the sound of a striking object. In some embodiments, the fabric changes the frequency sound of a striking objected. In one embodiment, the frequency sound of a striking object is reduced from about 1200 hz to 1000-500 hz, 800-500 hz, 800 hz or lower, 700 hz or lower, 600 hz or lower, about 500 hz, about 400-500 hz. By absorbing some of the impact energy, the fabric also reduces the overall vibration transferred to adjacent material, which is particularly useful for managing shock and impact.

In some embodiments, the fabrics disclosed herein are configured for application to a surface, where the fabric forms a sound reducing fabric covering or layer. In some embodiments, the fabrics disclosed herein are configured for application to a surface, where the fabric forms a sound reducing fabric layer on said surface. In some embodiments, a surface comprise the fabrics disclosed herein, where the fabric comprises a sound reducing layer.

Embodiments described herein provide infused fabrics, and in particular, fabrics that are infused with particles. As used herein, “fiber” refers to a thin elongated length of material capable of forming into thread or a fabric. In some embodiments, infused fabrics are manufactured from fibers infused with one or more types of particles. In some embodiments, infused fabrics are manufactured from composite fibers. Composite fibers are fibers spun or extruded from a mixture of two or more materials. In some embodiments, infused fabrics are manufactured from fibers impregnated or incorporated with one or more types of particles. In some embodiments, the particles are solid particles. In some embodiments, the particles are powders. In one embodiment, the particles are microparticles or nanoparticles. In some embodiments, the particles are elongated or fibrous particles. In some embodiments, the particles are chemically incorporated into the fibers. In one embodiment, the particles are provided in a chemical solution or liquid form and deposited into the fibers by wet impregnation and subsequently dried. In some embodiments, the particles are mechanically incorporated into the fibers, such as by blending. In one embodiment, the particles are spun into the fibers. In one embodiment, the particles are beaten and/or compressed into the fibers. In one embodiment, the particles are mixed with the fibers. In one embodiment, the particles are mixed in with molten material, and subsequently extruded into fibers.

In some embodiments, the fibers are short fibers or fiber fragments. In other embodiments, the fibers are long spun or extruded fibers. In some embodiments, the fibers are threads. In some embodiments, the fibers are polymer fibers. In some embodiments, the fibers are natural fibers. Exemplary natural fibers include, but are not limited to: cotton, silk, wool, hemp, jute, linen, flax, hair, or sisal fibers. In some embodiments, the fibers are synthetic fibers. Exemplary synthetic fibers include, but are not limited to: nylon, polyester, acrylic, polyethylene (PE), polyethylene terephthalate (PET), polypropylene (PP), aramid, carbon fiber, fiberglass, polyvinyl chloride (PVC) fibers. In one embodiment, the fiber is nylon. In one embodiment, the fiber is polyethylene. In one embodiment, the fiber is polypropylene. In one embodiment, the fiber is polyethylene terephthalate. In one embodiment, the fiber comprises a combination of synthetic fibers. Once fibers are infused with the one or more types of particles, the fibers are then manufactured into woven or non-woven fabric. In some embodiments, infused fibers are made into thread for weaving into a woven fabric. In some embodiments, the infused fibers beaten and condensed into a non-woven fabric, such as a felt fabric.

By first infusing the fiber with the particles and subsequently manufacturing the fibers into fabric, the characteristics of a standard flexible fabric is maintained while simultaneously imparting the properties of the particles to the fabric. For example, the fabric made from the particle infused fibers may be further manufactured into clothing, furniture, parts, insulation, etc. A fabric manufactured from infused fibers is advantageous over fabric that is directly impregnated with a substance, in that the former remains pliable and/or flexible. Fabrics directly impregnated with substances (for example, wax, resin, silicone) often becomes rigid. Oftentimes, fabrics that are directly impregnated with substances are designed for the fabric to act as a support structure or scaffold to hold the substances in place. As a result, the impregnated fabric loses its original fabric characteristics and is reduced to specific applications only. On the other hand, fabric manufactured from infused fibers maintain its wide range of application.

In accordance with the present disclosure, a fabric is provided that is manufactured from fibers infused with graphene. Graphene is an allotrope of carbon consisting of a single layer of atoms arranged in a hexagonal lattice nanostructure. Graphene has been known as hardest or strongest material known to exist, being about 200 stronger than steel while lighter than paper. Graphene is a very useful nanomaterial due to its exceptionally high tensile strength, electrical conductivity, transparency, and being the thinnest two-dimensional material in the world. Prior to addition of graphene, the fabric was easily scratched and fragile. After addition of graphene, the present inventors have discovered that the fabric threads and bounds of the threads were significantly strengthened. In some embodiments, the fabric is a non-woven fabric. In some embodiments, the fabric is manufactured as non-woven fabric sheets with a degree of stiffness.

The present inventors have discovered that the graphene infused fabric of the present disclosure is particularly effective at minimizing noise or absorbing kinetic energy of moving objects. In particular, where a moving objection strikes a surface, the movement of the object and the subsequent contact with the surface triggers the sound reduction properties of the graphene infused fabric. In some embodiments, the fabric disclosed herein absorbs sound into kinetic energy. The graphene infused fabric is both is durable and sound reducing. A fabric covering a surface can reduce sound when an object contacts the surface. However, the fabric may not be durable if objects contact the surface numerous times. If a fabric (or surface covered in fabric) is coated in resin then the fabric or surface may be durable but the hardness of the coated fabric or surface can result in increased sound when an object makes contact with the surface.

In accordance with the present disclosure, a fabric is provided that is manufactured from fibers infused with a durability enhancing agent. For example, the durability enhancing agent can be graphene.

In some embodiments, the fabric absorbs noise or kinetic energy of a moving object striking a stationary surface applied with the fabric. In some embodiments, the fabric is applied to a mobile surface and absorbs noise or kinetic energy when the mobile surface impacts with a stationary object. In yet other embodiments, the fabric is applied to a mobile surface and absorbs noise or kinetic energy when the mobile surface impacts with a mobile object.

The present inventors have also discovered that a surface comprised of or applied with a fabric infused with graphene surprisingly also reduces vibration. The lower the vibration, the lesser the travel of the vibration, thereby reducing impact when an object strikes against the surface. The graphene infused fabric also adds durability, extending the material lifespan of the fabric thereby reducing waste.

In some embodiments, graphene is infused into a material by preparing a graphene-infused raw material. In some embodiments, the raw material is a polymer material for manufacture into polymer fibers. In some embodiments, the raw material is blended with graphene to form a composite raw material. The graphene comprise a reinforcing phase distributed within a continuous raw material (such as a polymer material) for manufacture into fibers. In one embodiment, graphene is blended with molten polymer material to form a mixture that is spun or extruded into fibers. In one embodiment, graphene powder is blended with molten polymer material to form a mixture that is spun or extruded into fibers. In some embodiments, the graphene powder is a white graphene powder. In one embodiment, the graphene powder is a graphene oxide powder. In one embodiment, the graphene powder is fine graphene powder.

Infusing the graphene first into a raw polymer material is advantageous as it allows for even distribution of graphene in the final product, and simultaneously allows for greater flexibility and variety of fiber compositions that can be used to made a fabric. Furthermore, infusing graphene into a raw polymer material also imparts mechanical durability and performance enhancements (e.g., conductivity, strength, thermal resistance) to the resulting extruded fibers themselves.

In some embodiments, a graphene-infused fabric is made of graphene-infused polymer fibers. In some embodiments, a graphene-infused fabric is made of two or more types of graphene-infused polymer fibers. In some embodiments, graphene-infused polymer fibers comprise composite fibers made from a synthetic fiber polymer and graphene. Exemplary synthetic fiber polymers include, but are not limited to: nylon, polyester, acrylic, polyethylene (PE), polyethylene terephthalate (PET), polypropylene (PP), aramid, carbon fiber, fiberglass, polyvinyl chloride (PVC) fibers. In some embodiments, a graphene-infused fabric is made of graphene-infused polymer fibers combined with other synthetic or non-synthetic fibers. In one embodiment, graphene-infused polymer fibers comprise composite fibers made from polyethylene terephthalate and graphene. In one embodiment, graphene-infused polymer fibers comprise composite fibers made from polypropylene and graphene. In one embodiment, graphene-infused polymer fibers comprise composite fibers made from nylon and graphene. In one embodiment, graphene-infused polymer fibers comprise composite fibers made from two or more types of polymer materials and graphene.

In some embodiments, a fabric is made of polyethylene terephthalate fiber, nylon fiber, polypropylene fiber, or combinations thereof. In some embodiments, one or more of the polymer fibers comprise graphene-infused polymer fiber. In some embodiments, a graphene-infused fabric is manufactured from polyethylene terephthalate fiber, nylon fiber, polypropylene fiber, or combinations thereof, where one or more of the polymer fibers comprise a graphene-infused polymer fiber. In some embodiments, a graphene-infused fabric is manufactured from polyethylene terephthalate fiber, nylon fiber, polypropylene fiber, or combinations thereof, where one or more of the polymer fibers comprise a graphene-infused polymer composite fiber. Introducing nylon fiber to a graphene-infused fabric has an added benefit of reducing stretch, thereby reducing warping or stretching of the graphene infused fabric over time. In some embodiments, the nylon fiber is N66 fiber In some embodiments, the fabric further comprises a waterproofing or water resistant additive. Exemplary waterproofing or water resistant additive includes durable water repellents, such as per-and polyfluoroalkyl substances (PFAs) and long-chain (C8) fluorocarbon-based treatments. In some embodiments, the fabric provided herein is made of non-woven material, hence lacking the traditional warp and weft found in woven fabrics. Instead, the density of the fabric is increased by applying pressure, and the waterproofing or water resistant additive is integrated into the raw materials. In some embodiments, the fabric provided herein has a waterproof or water resistant coating overing at least a majority of the surface, preferably the entirety of the surface. In some embodiments, the the waterproof or water resistant additive is spray coated onto the fibers of a fabric. The fabric provided herein is at least water-repellant, more preferably at least water-resistant. Water droplets applied to the fabric surface rolls off; however, if significant pressure is applied, forcing the water droplets into the non-woven fabric, the water can seep through due to pressure. In one embodiment, the fabric is waterproof, having a thicker protective coating that prevents water molecules from penetrating the fabric under pressure, at least for a short duration.

In some embodiments, a graphene-infused fabric is manufactured from polyethylene terephthalate fiber, nylon fiber, and polypropylene fiber, where the polyethylene terephthalate fiber comprise a graphene-infused polyethylene terephthalate fiber. In some embodiments, a graphene-infused fabric is manufactured from polyethylene terephthalate fiber, nylon fiber, and polypropylene fiber, where the polyethylene terephthalate fiber comprise a graphene-polyethylene terephthalate composite fiber. In some embodiments, a graphene-infused fabric is manufactured from polyethylene terephthalate fiber, nylon fiber, and polypropylene fiber, where the polyethylene terephthalate fiber comprise fibers extruded from a blend of molten polyethylene terephthalate and graphene, preferably graphene powder. In one embodiment, the nylon fiber comprise N66 fiber.

In one embodiment, a fabric is made of graphene, Nylon 66 (N66), and polypropylene, and graphene-infused polyethylene terephthalate fibers. In one embodiment, a graphene infused fabric comprises about 5%-15%, preferably about 5%-10%, more preferably approximately 10% graphene-infused polyethylene terephthalate fiber by total weight of the fabric. In one embodiment, a graphene infused fabric comprises about 5%-15%, preferably about 5%-10%, more preferably approximately 10% graphene-infused polyethylene terephthalate fiber by total weight of the fabric. In one embodiment, a graphene infused fabric comprises about 25-75%, about 40-60%, 50-60%, about 50%, or about 55% N66 fiber by total weight of the fabric. In one embodiment, a graphene infused fabric comprises about 25-50%, about 30-40%, about one third, or about 35% polypropylene fiber by total weight of the fabric. In some embodiments, the fabric comprises about 1-10%, about 2-8%, about 3-7%, or about 5% waterproofing or water resistant additive by total weight of the fabric. Ranges provided herein includes the endpoints. As used herein the term “about” with respect to a percentage value indicates variance of 3%. All polymer fibers remain in fiber form, and are mixed together. During the fiber mixing process, waterproof materials are incorporated (spray on the fibres). The fibres are then thoroughly opened and evenly blended, followed by multiple compression treatments and needle punching to produce a flat fabric.

Turning to, an exemplary protocol for the manufacture of a graphene-infused polyethylene terephthalate fiber is provided. In some embodiments, a graphene-infused fiber is provided made by the processes and protocols disclosed herein. First, polyethylene terephthalate polymer (PET) material is provided, for example, in pellet or granule form, or chemically created from terephthalic acid and ethylene glycol. The PET materials is heated until molten form. Graphene powder is introduced into this molten form, preferably ensuring that the graphene powder is well blended into the molten PET material. This blended material is then extruded into fibers, such as by forcing the blended material through spinnerets to form continuous filaments. The filaments solidify into fibers. Optionally, the filaments are drawn or stretched as desired into fine fibers. Optionally, these graphene-infused fibers are mixed with a second fiber, or one or more other fibers. In some cases, the fibers are woven into a fabric. In some cases, the fibers are beaten (such as by needle punching) and condensed into a felt. Infusing graphene into polyethylene terephthalate as advantages, such as excellent physical properties, wide availability, cost-effectiveness, and compatibility with existing manufacturing equipment, for example.

The relative proportion of the graphene-infused polymer fiber relative to the total fiber content of the fabric can be adjusted to adjust the graphene content of the graphene-infused fabric. If the graphene content of the fabric is too low, the fabric is at risk of deteriorating after repeated use. However, if the graphene content of the fabric is too high, the fabric may become too heavy for use. In some embodiments, the graphene infused fabric is 1.5 mm to 5 mm thick.

In some embodiments, the graphene is introduced into the N66 as a very fine powder.

The graphene infused fabric is manufactured such that the internal structure of the fabric is porous enough to capture, trap, and dissipate sound energy as heat. The surface of the fabric repels liquids. When the fabric is applied to a surface or structure, the combined surface or structure as a whole returns an adequate amount of kinetic energy when an object strikes against it. By introducing graphene to the fabric, this also allows for the manufacture of wearable technology using the fabric. For example, wearable technology may be utilized to gather wearer movement data which can be processed to analyze performance, health, and well-being.

Turning to, graphene-infused raw materialcomprising graphene, N66, and polypropylene are mixed with non-graphene-infused raw materialcomprising polypropylene. In some embodiments, the graphene-infused raw material is graphene-infused fibers or threads. In some embodiments, the graphene-infused raw material comprises graphene-infused polymer fibers or graphene-polymer composite fibers. In the shown implementation, graphene-infused raw materialcomprises black threads or fibers while non-graphene-infused raw materialcomprises white threads or fibers, such that when mixed together a gray coloured raw material is produced with target amount of graphene incorporated. The raw materialsandmay be mixed together in different proportion to produce a raw material mixturehaving a desired shade of gray, or a desired graphene content. In some embodiments, the raw material mixture comprises a ratio of graphene-infused raw material to non-graphene-infused raw material of about 1:9, 1:4, 3:7, 2:3, 1:1, 3:2, 7:3, 4:1, or 9:1. In some embodiments, the graphene-infused raw materialis directly used without mixing with other raw material to produce a black fabric. In some embodiments, the graphene-infused raw materialcomprises white threads or fibers infused with white graphene powder.

In some embodiments, one or more waterproofing or water resistant additive are sprayed onto the threads or fibers. In one embodiment, one or more waterproofing or water resistant additive are sprayed onto the graphene-infused raw materialand/or the non-graphene-infused raw materialprior to mixing. In one embodiment, one or more waterproofing or water resistant additive are sprayed onto the raw material mixtureafter or during mixing.

The raw material mixturehas a weight of around 450-500 grams per square meter. In some embodiments, the weight is around 400, 425, 450, 475, or 500 grams per square meter. In some embodiments, the weight is around 450, 460, 470, 480, 490, or 500 grams per square meter. In one embodiment the weight is 471 grams per square meter. In one embodiment the weight is 495 grams per square meter.

The threads of the raw material mixtureis chopped into smaller, finer threads. In some embodiments, the raw material mixtureis chopped while mixing to produce even threads or fibers. As shown in, after chopping the raw material mixturebecomes finer, lighter, and fluffy, resembling spider webs. The raw material mixtureis laid out into a layer.

Turning to, the layeris folded into stacks. In some embodiments, the stacks are staggered, producing a continuous line of stacked layers for assembly line efficiency. As shown in, the stacksare stitched or beaten together by a needle assemblyinto a felt or batting fabric. The needle assemblyhas multiple needles that reciprocate up and down as the stacked layeris fed through. Since the fabric is a non-woven fabric, warp and weft or weaving is not needed. In some embodiments, the batting fabric is passed through multiple needle assemblies to produce thinner and tighter fabric. Each needle assembly may comprise different densities or sizes of needles to produce fabric of different density. In some embodiments, the batting fabric is passed through progressively denser and/or smaller needles to produce thinner and tighter fabric.

Turning to, in addition to passing fabricthrough a needle assembly, the fabric is also pressed through rollers. The rollersapply pressure to compress the fabricinto a sheet of fabric with increased hardness. The rollersalso flatten the fabricto a desired thickness. In some embodiments, the needle assemblyand the rollersare provided in one machinery. For example, stacked fabric may be fed through the needle assembly of the machine first, followed by rollers. In other embodiments, he needle assemblyand the rollersare provided in separate machinery. Lastly, the fabric sheet is heated, for example, with an iron to produce an end product. Preferably, the end product is lighter and/or thinner than the starting material. In some embodiments, the end product has a weight of around 430-450 grams per square meter. In some embodiments, the weight is around 400, 425, 450, or 475 grams per square meter. In some embodiments, the weight is around 420, 430, 440, 450, or 460 grams per square meter. In some embodiments, the weight is around 430, 435, 440, 445, or 450 grams per square meter. The iterative approach of stitching or beating the material through multiple passes together with one more passes through rollers to compress the material allows for the production of an end product with a desired weight and thickness. For example, for some applications (i.e. sport equipment) an end product that is too heavy will weigh down on the user. However, an end product that is too thin will not provide the desired properties, such as sound dampening.

Lastly as shown in, the fabric sheetis cut into desired shapes and sizes.

In some embodiments, the fabrics disclosed herein are used in the manufacture of textiles, clothing, or equipment requiring high material durability and/or impact shielding. For example, safety or protection clothing or equipment, camping gear, sport and/or out-door equipment, and construction material or tools.

In some embodiments, the fabrics disclosed herein are used where sound modification, dampening, or reduction are needed. For example, musical instrument manufacturing, acoustic room manufacturing, sound equipment manufacturing, and ear protection.

In some embodiments, a sound reducing acoustic fabric is for application to a surface (such as wall, floor, ceiling, etc.). In some embodiments, the sound reducing acoustic fabric disclosed herein is used in acoustic sound panels for walls, ceilings, floors, etc. The sound reducing acoustic fabric is molded into various shapes or contours to adapt to a object's surface. In one embodiment, the sound reducing acoustic the fabric for surface application is made of polymer fibers. The polymer fibers comprise N66 fiber, polypropylene fiber, and graphene powder-polyethylene terephthalate composite fiber. These polymer fibers are blended and compressed to form the sound reducing acoustic fabric. For example, these polymer fibers are blended and compressed into a felt. The felt is then shaped and applied onto a surface. The sound reducing acoustic fabric can be removably applied to the surface. Alternatively, the sound reducing acoustic fabric can be affixed to the surface. For example, adhesives can be used to secure the sound reducing acoustic fabric to the surface.