Abstract: Improvements in permitting greater efficiency for high denier polypropylene fiber and yarn production are provided. Generally, spinning speeds are limited for polypropylene fibers and yarns as such materials tend to break easily upon exposure to excessively high tensions associated with low- to medium-spinning speeds. As spinning is required to properly draw such high denier fibers sufficiently for fiber and yarn production, such limitations effectively prevent widespread utilization of such fibers and yarns in various end-use applications. Thus, it has been surprisingly been determined that such high denier manufactured fibers and yarns can be produced with certain nucleating additives that permit tensile strength increases to the level required for high-speed spinning procedures to be followed. Additionally, low-shrink and/or better resiliency properties are also available with the addition of such nucleating compounds within the target high denier polypropylene resins.

Abstract: Improvements in preventing heat- and moisture-shrink problems in specific polypropylene tape fibers are demonstrated herein. Such fibers are manufactured through the initial production of polypropylene films or tubes which are then slit into very thin, though flat tape fibers thereafter. Such fibers include rigidifying nucleating compounds that nucleate polymer crystals within the target polypropylene after exposure to sufficient heat to melt the initial pelletized polymer and upon allowing such a melt to cool. Specific methods of manufacture of such inventive tape fibers, as well as fabric articles made therefrom, are also encompassed within this invention.

Abstract: Improvements in preventing heat- and moisture-shrink problems in specific polypropylene tape fibers are provided. Such tape fibers are basically manufactured through the initial production of polypropylene films or tubes which are then slit into very thin, though flat (and having very high cross sectional aspect ratios) tape fibers thereafter. These inventive tape fibers (and thus the initial films and/or tubes) require the presence of relatively high amounts of certain compounds that quickly and effectively provide rigidity to the target polypropylene tape fiber. Generally, these compounds include any structure that nucleates polymer crystals within the target polypropylene after exposure to sufficient heat to melt the initial pelletized polymer and allowing such an oriented polymer to cool. The compounds must nucleate polymer crystals at a higher temperature than the target polypropylene without the nucleating agent during cooling.

Abstract: Unique thermoplastic (polypropylene, specifically) monofilament and/or tape fibers and yarns that exhibit heretofore unattained physical properties are provided. Such fibers are basically manufactured through the extrusion of thermoplastic resins that include a certain class of nucleating agent therein, and are able to be drawn at high ratios with such nucleating agents present, that the tenacity and modulus strength are much higher than other previously produced thermoplastic fibers (particularly those produced under commercial conditions), particularly those that also simultaneously exhibit extremely low shrinkage rates. Thus, such fibers require the presence of certain compounds that quickly and effectively provide rigidity to the target thermoplastic (for example, polypropylene), particularly after heat-setting.

Abstract: A pile fabric suitable for use as a primary carpet fabric within a carpet construction or composite such as a cushioned carpet or tile. The primary carpet fabric includes a plurality of pile-forming yarns tufted through or adhered to a primary backing of integral dimensionally stable character. A cushioning layer of foam, felt, fabric, or other suitable cushioning material may be disposed at a position below the primary carpet fabric.

Abstract: Unique thermoplastic (polypropylene, specifically) monofilament and/or tape fibers and yarns that exhibit heretofore unattained physical properties are provided. Such fibers are basically manufactured through the extrusion of thermoplastic resins that include a certain class of nucleating agent therein, and are able to be drawn at high ratios with such nucleating agents present, that the tenacity and modulus strength are much higher than other previously produced thermoplastic fibers (particularly those produced under commercial conditions), particularly those that also simultaneously exhibit extremely low shrinkage rates. Thus, such fibers require the presence of certain compounds that quickly and effectively provide rigidity to the target thermoplastic (for example, polypropylene), particularly after heat-setting.

Abstract: Improvements in preventing heat- and moisture-shrink problems in specific polypropylene tape fibers are provided. Such tape fibers are basically manufactured through the initial production of polypropylene films or tubes which are then slit into very thin, though flat (and having very high cross sectional aspect ratios) tape fibers thereafter. These inventive tape fibers (and thus the initial films and/or tubes) require the presence of relatively high amounts of certain compounds that quickly and effectively provide rigidity to the target polypropylene tape fiber. Generally, these compounds include any structure that nucleates polymer crystals within the target polypropylene after exposure to sufficient heat to melt the initial pelletized polymer and allowing such an oriented polymer to cool. The compounds must nucleate polymer crystals at a higher temperature than the target polypropylene without the nucleating agent during cooling.

Abstract: Improvements in permitting greater efficiency for low denier polypropylene fiber and yarn production are provided. Generally, spinning speeds are limited for polypropylene fibers and yarns as such materials tend to break easily upon exposure to excessively high tensions associated with low- to medium-spinning speeds. Low production speeds negatively impact the economics of producing such low denier fibers which prevents the widespread utilization of such fibers and yarns in various end-use applications, particularly applications for which low denier provides desirable hand characteristics. Thus, it has surprisingly been determined that such low denier manufactured fibers and yarns can be produced with certain nucleating additives that permit high tension levels in the quench stack as required for high-speed spinning procedures to be followed.

Abstract: Improvements in preventing heat- and moisture-shrink problems in specific polypropylene tape fibers are provided. Such fibers are basically manufactured through the initial production of polypropylene films or tubes which are then slit into very thin, though flat (and having very high cross sectional aspect ratios) tape fibers thereafter. Such fibers (and thus the initial films and/or tubes) require the presence of certain compounds that quickly and effectively provide rigidity to the target polypropylene tape fiber after heat-setting. Generally, these compounds include any structure that nucleates polymer crystals within the target polypropylene after exposure to sufficient heat to melt the initial pelletized polymer and upon allowing such a melt to cool. The compounds must nucleate polymer crystals at a higher temperature than the target polypropylene without the nucleating agent during cooling.

Abstract: Unique thermoplastic monofilament fibers and yarns that exhibit heretofore unattained physical properties are provided. Such fibers are basically manufactured through the extrusion of thermoplastic resins that include a certain class of nucleating agent therein, and are able to be drawn at high ratios with such nucleating agents present that the tenacity and modulus strength are much higher than any other previously produced thermoplastic fibers, particularly those that also simultaneously exhibit extremely low shrinkage rates. Thus, such fibers require the presence of certain compounds that quickly and effectively provide rigidity to the target thermoplastic (for example, polypropylene), particularly after heat-setting. Generally, these compounds include any structure that nucleates polymer crystals within the target thermoplastic after exposure to sufficient heat to melt the initial pelletized polymer and allowing such an oriented polymer to cool.

Abstract: Improved polypropylene fibers exhibiting greatly reduced heat- and moisture-shrink problems are provided. Such fibers require the presence of certain compounds that quickly and effectively provide rigidity to the target polypropylene fiber after heat-setting. Generally, these compounds include any structure that nucleates polymer crystals within the target polypropyelene after exposure to sufficient heat to melt the initial pelletized polymer and upon allowing such a melt to cool. The compounds must nucleate polymer crystals at a higher temperature than the target polypropylene without the nucleating agent during cooling. In such a manner, the “rigidifying” nucleator compounds provide nucleation sites for polypropylene crystal growth. After drawing the nucleated composition into fiber form, the fiber is then exposed to sufficient heat to grow the crystalline network, thus holding the fiber in a desired position.

Abstract: A base substrate having a first side and a second side, first and second receiving loops extending from the first and second side of the base substrate, respectively, and first and second stiff loops extending from the first and second side of the base substrate, respectively. The base substrate is a flexible cloth or cloth-like material. The receiving loops are an absorbent material such as the material used in the base substrate. The stiff loops are formed of a yarn having at least one filament with a cross-section having an aspect ratio of greater than about 1.2, a corner edge, and/or at least a concave portion.

Abstract: A method of manufacturing a polyester textile fabric having a relatively low level of particulate contaminates and high absorbency is provided by heatsetting the fabric at a temperature of 300° F. or less.

Abstract: Improvements in permitting greater efficiency for high denier polypropylene fiber and yarn production are provided. Generally, spinning speeds are limited for polypropylene fibers and yarns as such materials tend to break easily upon exposure to excessively high tensions associated with low- to medium-spinning speeds. As spinning is required to properly draw such high denier fibers sufficiently for fiber and yarn production, such limitations effectively prevent widespread utilization of such fibers and yarns in various end-use applications. Thus, it has been surprisingly been determined that such high denier manufactured fibers and yarns can be produced with certain nucleating additives that permit tensile strength increases to the level required for high-speed spinning procedures to be followed. Additionally, low-shrink and/or better resiliency properties are also available with the addition of such nucleating compounds within the target high denier polypropylene resins.

Abstract: Unique thermoplastic (polypropylene, specifically) monofilament and/or tape fibers and yarns that exhibit heretofore unattained physical properties are provided. Such fibers are basically manufactured through the extrusion of thermoplastic resins that include a certain class of nucleating agent therein, and are able to be drawn at high ratios with such nucleating agents present, that the tenacity and modulus strength are much higher than other previously produced thermoplastic fibers (particularly those produced under commercial conditions), particularly those that also simultaneously exhibit extremely low shrinkage rates. Thus, such fibers require the presence of certain compounds that quickly and effectively provide rigidity to the target thermoplastic (for example, polypropylene), particularly after heat-setting.

Abstract: Improvements in color management for polypropylene fiber production in terms of permitting similar if not identical processing conditions for both colored and uncolored fiber production are provided. Generally, either separate polypropylene fiber manufacturing lines or different processing conditions on the same manufacturing line are required for the production of colored and non-colored polypropylene fibers. This coloring is, for example, done by using pigments that may have a nucleation effect on the PP polymer which affects fiber properties. Such an inefficient situation exists due to the physical properties of drawn polypropylene fibers during manufacture, particularly the different properties exhibited between fibers including color and fibers that are colorless.

Abstract: Unique thermoplastic monofilament fibers and yarns that exhibit heretofore unattained physical properties are provided. Such fibers are basically manufactured through the extrusion of thermoplastic resins that include a certain class of nucleating agent therein, and are able to be drawn at high ratios with such nucleating agents present, that the tenacity and modulus strength are much higher than any other previously produced thermoplastic fibers, particularly those that also simultaneously exhibit extremely low shrinkage rates. Thus, such fibers require the presence of certain compounds that quickly and effectively provide rigidity to the target thermoplastic (for example, polypropylene), particularly after heat-setting. Generally, these compounds include any structure that nucleates polymer crystals within the target thermoplastic after exposure to sufficient heat to melt the initial pelletized polymer and allowing such an oriented polymer to cool.

Abstract: Improvements in creating resilient high denier polypropylene yarns are provided. Generally, high denier polypropylene yarns exhibit poor resiliency (such as crush resistance, for example, when utilized as carpet face yarns) that effectively prevents widespread use in articles that require high degrees of resiliency. As a result, higher cost, but more resilient, yarns, such as polyesters or polyamides, have found greater acceptance in such end-use articles. Furthermore, previous attempts at texturing high denier polypropylene fibers have failed to attain suitable resilience levels therein is insufficient to permit proper return to initial shape and/or length after impact.

Abstract: Unique thermoplastic monofilament fibers and yarns that exhibit heretofore unattained physical properties are provided. Such fibers are basically manufactured through the extrusion of thermoplastic resins that include a certain class of nucleating agent therein, and are able to be drawn at high ratios with such nucleating agents present, that the tenacity and modulus strength are much higher than any other previously produced thermoplastic fibers, particularly those that also simultaneously exhibit extremely low shrinkage rates. Thus, such fibers require the presence of certain compounds that quickly and effectively provide rigidity to the target thermoplastic (for example, polypropylene), particularly after heat-setting. Generally, these compounds include any structure that nucleates polymer crystals within the target thermoplastic after exposure to sufficient heat to melt the initial pelletized polymer and allowing such an oriented polymer to cool.

Abstract: Improvements in preventing heat- and moisture-shrink problems in specific polypropylene tape fibers are provided. Such tape fibers are basically manufactured through the initial production of polypropylene films or tubes which are then slit into very thin, though flat (and having very high cross sectional aspect ratios) tape fibers thereafter. These inventive tape fibers (and thus the initial films and/or tubes) require the presence of relatively high amounts of certain compounds that quickly and effectively provide rigidity to the target polypropylene tape fiber. Generally, these compounds include any structure that nucleates polymer crystals within the target polypropylene after exposure to sufficient heat to melt the initial pelletized polymer and allowing such an oriented polymer to cool. The compounds must nucleate polymer crystals at a higher temperature than the target polypropylene without the nucleating agent during cooling.