Patents by Inventor David D. Newkirk
David D. Newkirk has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Publication number: 20110039063Abstract: Disclosed is a process for continuous perforation of fabrics that comprise thermoplastic fibers. The process utilizes a combination of heat and pressure to perforate fabrics where the shape. size, and distribution of the individual fabric perforations is define solely by the design of the pattern embossing roll, In particular, the top side of the individual embossing points are not flat but rather have a raised peripheral edge so that the actual fabric contact area of the bond points is much less than total area circumscribed by each bond point. The small ratio of fabric contact area to total bond area concentrates the thermal and compressive forces in the embossing nip and allows a large perforation to be cut out of a fabric moving at high speed through the perforation nip.Type: ApplicationFiled: October 10, 2007Publication date: February 17, 2011Inventors: Samuel Charles Baer, Jay Darrell Gillespie, David D. Newkirk
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Patent number: 6632504Abstract: A nonwoven web is provided which can be readily converted to an apertured web by stretching. In its initial non-apertured state, the web comprises a plurality of multicomponent fibers comprising at least two thermoplastic polymer components arranged in at least first and second separate continuous structured domains. The polymer component of the first domain comprises polyethylene. Prior to stretch aperturing, the web has a peak elongation of at least 100 percent and is characterized by having a plurality of discrete, spaced-apart, frangible bond sites of polymer bonding the fibers to form a coherent extensible nonwoven web. The frangible bond sites are structured and arranged to readily rupture when subjected to tensile stress to form discrete, spaced-apart apertures in the nonwoven fabric. The web has a total energy absorption in at least one of the machine direction or the cross-machine direction of at least 50 gcm/cm2.Type: GrantFiled: March 17, 2000Date of Patent: October 14, 2003Assignee: BBA Nonwovens Simpsonville, Inc.Inventors: Jay Darrell Gillespie, David D. Newkirk, Michael M. Thomason, Gregory W. Farell, Harold E. Thomas
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Patent number: 6516472Abstract: Nonwoven fabrics and fabric laminates are formed from continuous filaments or staple fibers of a select blend of specific grades of polyethylene and polypropylene which give improved fabric performance not heretofore recognized or described, such as high abrasion resistance, good tensile properties, excellent softness and the like. Furthermore, these blends have excellent melt spinning and processing properties which permit efficiently producing nonwoven fabrics at high productivity levels. The polymers are present as a lower-melting dominant continuous phase and at least one higher-melting noncontinuous phase dispersed therein. The lower-melting continuous phase forms at least 70 percent by weight of the fiber and comprises a linear low density polyethylene polymer of a melt index of greater than 10 and a density of less than 0.945 g/cc. At least one higher-melting noncontinuous phase comprises a polypropylene polymer with melt flow rate of greater than 20 g/10 min.Type: GrantFiled: January 31, 2001Date of Patent: February 11, 2003Assignee: BBA Nonwovens Simpsonville, Inc.Inventors: Scott L. Gessner, J. Darrell Gillespie, Jared A. Austin, David D. Newkirk, William Fowells
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Patent number: 6506698Abstract: The present invention provides a composite nonwoven fabric with a superior combination of extensibility, tensile properties and abrasion resistance. The composite nonwoven fabric (10) comprises at least one layer containing multipolymer fibers, with a plurality of bonds bonding the fibers together to form a coherent extensible nonwoven web (11). This coherent extensible nonwoven web (11) has a Taber surface abrasion value (rubber wheel) of greater than 10 cycles and an elongation at peak load in at least one of the machine direction or the cross-machine direction of at least 70%. A second extensible layer (12) is laminated to this coherent extensible nonwoven web (11).Type: GrantFiled: March 1, 2000Date of Patent: January 14, 2003Assignee: BBA Nonwovens Simpsonville, Inc.Inventors: Thomas E. Quantrille, Harold E. Thomas, Barry D. Meece, Scott L. Gessner, J. Darrell Gillespie, Jared A. Austin, David D. Newkirk, William Fowells
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Publication number: 20020193032Abstract: A spunbond nonwoven fabric is provided from a multiplicity of substantially continuous filaments which form a web having a length dimension and a width dimension. The filaments are arranged to define a substantially uniform web basis weight along one of dimension of the fabric, while in the other dimension, the filaments are arranged to define adjacent zones of a relatively lower web basis weight and a relatively higher web basis weight which is at least 25 weight percent greater than the basis weight of the lower basis weight zone. The spunbond nonwoven fabric can be combined with one or more additional layer to form a composite nonwoven fabric. The fabric is useful in various articles that utilize nonwovens, such as diapers, protective clothing, and hygiene articles.Type: ApplicationFiled: May 8, 2002Publication date: December 19, 2002Applicant: BBA Nonwovens Simpsonville, Inc.Inventors: David D. Newkirk, Michael M. Thomason, Jay D. Gillespie
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Patent number: 6468931Abstract: A multilayer thermally bonded nonwoven fabric which is particularly useful as a liner in an absorbent product is described. The fabric includes at least two prebonded nonwoven webs having a multiplicity of intralaminar bonds bonding the fibers of the prebonded nonwoven webs together. The prebonded webs are secured together to form the fabric of the invention by a plurality of interlaminar thermal bonds formed of discrete areas of compressed and fused fibers of the prebonded webs.Type: GrantFiled: August 22, 1996Date of Patent: October 22, 2002Assignee: Fiberweb North America, Inc.Inventors: James O. Reeder, David D. Newkirk
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Patent number: 6465378Abstract: Nonwoven fabrics and fabric laminates are formed from continuous filaments or staple fibers of a select blend of specific grades of polyethylene and polypropylene which give improved fabric performance not heretofore recognized or described, such as high abrasion resistance, good tensile properties, excellent softness and the like. Furthermore, these blends have excellent melt spinning and processing properties which permit efficiently producing nonwoven fabrics at high productivity levels. The polymers are present as a lower-melting dominant continuous phase and at least one higher-melting noncontinuous phase dispersed therein. The lower-melting continuous phase forms at least 70 percent by weight of the fiber and comprises a linear low density polyethylene polymer of a melt index of greater than 10 and a density of less than 0.945 g/cc. At least one higher-melting noncontinuous phase comprises a polypropylene polymer with melt flow rate of greater than 20 g/10 min.Type: GrantFiled: January 31, 2001Date of Patent: October 15, 2002Assignee: BBA Nonwovens Simpsonville, Inc.Inventors: Scott L. Gessner, J. Darrell Gillespie, Jared A. Austin, David D. Newkirk, William Fowells
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Patent number: 6448194Abstract: Nonwoven fabrics and fabric laminates are formed from continuous filaments or staple fibers of a select blend of specific grades of polyethylene and polypropylene which give improved fabric performance not heretofore recognized or described, such as high abrasion resistance, good tensile properties, excellent softness and the like. Furthermore, these blends have excellent melt spinning and processing properties which permit efficiently producing nonwoven fabrics at high productivity levels. The polymers are present as a lower-melting dominant continuous phase and at least one higher-melting noncontinuous phase dispersed therein The lower-melting continuous phase forms at least 70 percent by weight of the fiber and comprises a linear low density polyethylene polymer of a melt index of greater than 10 and a density of less than 0.945 g/cc. At least one higher-melting noncontinuous phase comprises a polypropylene polymer with melt flow rate of greater than 20 g/10 min.Type: GrantFiled: January 31, 2001Date of Patent: September 10, 2002Assignee: BBA Nonwovens Simpsonville, Inc.Inventors: Scott L. Gessner, J. Darrell Gillespie, Jared A. Austin, David D. Newkirk, William Fowells
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Patent number: 6420285Abstract: The present invention provides multicomponent fibers arranged in structured domains. At least one of the polymer components is formed of a multipolymer blend. The present invention also provides nonwoven fabrics formed of the multicomponent fibers, the fabrics having a superior combination of extensibility, tensile properties and abrasion resistance. A second layer can be laminated to this coherent extensible nonwoven web.Type: GrantFiled: December 30, 1999Date of Patent: July 16, 2002Assignee: BBA Nonwovens Simpsonville, Inc.Inventors: David D. Newkirk, Harold Edward Thomas, David Bruce Christopher, Barry DeWayne Meece
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Patent number: 6417122Abstract: The present invention provides multicomponent fibers arranged in structured domains. At least one of the polymer components is formed of a multipolymer blend. The present invention also provides nonwoven fabrics formed of the multicomponent fibers, the fabrics having a superior combination of extensibility, tensile properties and abrasion resistance. A second layer can be laminated to this coherent extensible nonwoven web.Type: GrantFiled: December 30, 1999Date of Patent: July 9, 2002Assignee: BBA Nonwovens Simpsonville, Inc.Inventors: David D. Newkirk, Harold Edward Thomas, David Bruce Christopher, Barry DeWayne Meece
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Patent number: 6417121Abstract: The present invention provides multicomponent fibers arranged in structured domains. At least one of the polymer components is formed of a multipolymer blend. The present invention also provides nonwoven fabrics formed of the multicomponent fibers, the fabrics having a superior combination of extensibility, tensile properties and abrasion resistance. A second layer can be laminated to this coherent extensible nonwoven web.Type: GrantFiled: December 30, 1999Date of Patent: July 9, 2002Assignee: BBA Nonwovens Simpsonville, Inc.Inventors: David D. Newkirk, Harold Edward Thomas, David Bruce Christopher, Barry DeWayne Meece
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Publication number: 20010005662Abstract: Nonwoven fabrics and fabric laminates are formed from continuous filaments or staple fibers of a select blend of specific grades of polyethylene and polypropylene which give improved fabric performance not heretofore recognized or described, such as high abrasion resistance, good tensile properties, excellent softness and the like. Furthermore, these blends have excellent melt spinning and processing properties which permit efficiently producing nonwoven fabrics at high productivity levels. The polymers are present as a lower-melting dominant continuous phase and at least one higher-melting noncontinuous phase dispersed therein. The lower-melting continuous phase forms at least 70 percent by weight of the fiber and comprises a linear low density polyethylene polymer of a melt index of greater than 10 and a density of less than 0.945 g/cc. At least one higher-melting noncontinuous phase comprises a polypropylene polymer with melt flow rate of greater than 20 g/10 min.Type: ApplicationFiled: January 31, 2001Publication date: June 28, 2001Applicant: BBA Nonwovens Simpsonville. Inc.Inventors: Scott L. Gessner, Darrell Gillespie, Jared A. Austin, David D. Newkirk, William Fowells
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Publication number: 20010004574Abstract: Nonwoven fabrics and fabric laminates are formed from continuous filaments or staple fibers of a select blend of specific grades of polyethylene and polypropylene which give improved fabric performance not heretofore recognized or described, such as high abrasion resistance, good tensile properties, excellent softness and the like. Furthermore, these blends have excellent melt spinning and processing properties which permit efficiently producing nonwoven fabrics at high productivity levels. The polymers are present as a lower-melting dominant continuous phase and at least one higher-melting noncontinuous phase dispersed therein. The lower-melting continuous phase forms at least 70 percent by weight of the fiber and comprises a linear low density polyethylene polymer of a melt index of greater than 10 and a density of less than 0.945 g/cc. At least one higher-melting noncontinuous phase comprises a polypropylene polymer with melt flow rate of greater than 20 g/10 min.Type: ApplicationFiled: January 31, 2001Publication date: June 21, 2001Applicant: BBA Nonwovens Simpsonville, Inc.Inventors: Scott L. Gessner, J. Darrell Gillespie, Jared A. Austin, David D. Newkirk, William Fowells
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Publication number: 20010003693Abstract: Nonwoven fabrics and fabric laminates are formed from continuous filaments or staple fibers of a select blend of specific grades of polyethylene and polypropylene which give improved fabric performance not heretofore recognized or described, such as high abrasion resistance, good tensile properties, excellent softness and the like. Furthermore, these blends have excellent melt spinning and processing properties which permit efficiently producing nonwoven fabrics at high productivity levels. The polymers are present as a lower-melting dominant continuous phase and at least one higher-melting noncontinuous phase dispersed therein. The lower-melting continuous phase forms at least 70 percent by weight of the fiber and comprises a linear low density polyethylene polymer of a melt index of greater than 10 and a density of less than 0.945 g/cc. At least one higher-melting noncontinuous phase comprises a polypropylene polymer with melt flow rate of greater than 20 g/10 min.Type: ApplicationFiled: January 31, 2001Publication date: June 14, 2001Inventors: Scott L. Gessner, J. Darrell Gillespie, Jared A. Austin, David D. Newkirk, William Fowells
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Patent number: 6207602Abstract: Nonwoven fabrics and fabric laminates are formed from continuous filaments or staple fibers of a select blend of specific grades of polyethylene and polypropylene which give improved fabric performance not heretofore recognized or described, such as high abrasion resistance, good tensile properties, excellent softness and the like. Furthermore, these blends have excellent melt spinning and processing properties which permit efficiently producing nonwoven fabrics at high productivity levels. The polymers are present as a lower-melting dominant continuous phase and at least one higher-melting noncontinuous phase dispersed therein. The lower-melting continuous phase forms at least 70 percent by weight of the fiber and comprises a linear low density polyethylene polymer of a melt index of greater than 10 and a density of less than 0.945 g/cc. At least one higher-melting noncontinuous phase comprises a polypropylene polymer with melt flow rate of greater than 20 g/10 min.Type: GrantFiled: March 12, 1997Date of Patent: March 27, 2001Assignee: BBA Nonwovens Simpsonville, Inc.Inventors: Scott L. Gessner, J. Darrell Gillespie, Jared A. Austin, David D. Newkirk, William Fowells
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Patent number: 5997989Abstract: A spunbonded elastic nonwoven fabric comprises a web of bonded thermoplastic filaments of a thermoplastic elastomer. The spunbonded fabrics of the invention are prepared in a slot draw spunbonding process operated at a rate of less than about 2000 meters per minute. The elastic fabric is used in absorbent products, such as disposable diapers, adult incontinence pads, sanitary napkins and the like, and as coverstock for absorbent personal care products.Type: GrantFiled: February 5, 1998Date of Patent: December 7, 1999Assignee: BBA Nonwovens Simpsonville, Inc.Inventors: Scott L. Gessner, David D. Newkirk, Michael M. Thomason, James O. Reeder
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Patent number: 5921973Abstract: The invention is directed to composite elastic nonwoven fabrics and processes for producing the same. The fabric includes a layer of inelastic continuous or staple fibers formed from a blend of polyethylene and polypropylene laminated to an elastic layer. Preferably, the composition of the fibers ranges between 5 to 50 percent by weight of polypropylene with the balance made up of polyethylene. The nonelastic fibers are capable of being highly elongated upon mechanical stretching without adversely impacting fiber tie down. Accordingly, a smooth, strong, coherent fabric is obtained, which is especially well suited for incorporation into disposable absorbent articles such as diapers, training pants, incontinence briefs and feminine hygiene products.Type: GrantFiled: February 17, 1997Date of Patent: July 13, 1999Assignee: BBA Nonwoven Simpsonville, Inc.Inventors: David D. Newkirk, Jared A. Austin
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Patent number: 5804286Abstract: A fabric comprising at least two layers wherein at least one layer is an extensible, bonded non-woven composed of a fiber comprising multiple different polymers such as a fiber comprising isotactic polypropylene, polyethylene and a block or grafted polyolefin copolymer or terpolymer which is at least partially miscible with said polypropylene and polyethylene.Type: GrantFiled: August 27, 1996Date of Patent: September 8, 1998Assignee: Fiberweb North America, Inc.Inventors: Thomas E. Quantrille, Harold E. Thomas, Barry D. Meece, Scott L. Gessner, J. Darrell Gillespie, Jared A. Austin, David D. Newkirk, William Fowells
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Patent number: 5543206Abstract: The invention is directed to composite nonwoven fabrics and processes for producing the same. The fabric includes a layer of inelastic continuous or staple fibers formed from a blend of polyethylene and polypropylene laminated to an extensible web, such as a polyolefin film. Preferably, the composition of the fibers ranges between 5 to 50 percent by weight of polypropylene with the balance made up of polyethylene. The nonelastic fibers are capable of being highly elongated upon mechanical stretching without adversely impacting fiber tie down. Accordingly, a smooth, strong, coherent fabric is obtained, which is especially well suited for incorporation into disposable absorbent articles such as diapers, training pants, incontinence briefs and feminine hygiene products.Type: GrantFiled: November 23, 1994Date of Patent: August 6, 1996Assignee: Fiberweb North America, Inc.Inventors: Jared A. Austin, David D. Newkirk
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Patent number: 5470639Abstract: A spunbonded elastic nonwoven fabric comprises a web of bonded thermoplastic filaments of a thermoplastic elastomer. The spunbonded fabrics of the invention are prepared in a slot draw spunbonding process operated at a rate of less than about 2000 meters per minute. The elastic fabric is used in absorbent products, such as disposable diapers, adult incontinence pads, sanitary napkins and the like, and as coverstock for absorbent personal care products.Type: GrantFiled: February 3, 1992Date of Patent: November 28, 1995Assignee: Fiberweb North America, Inc.Inventors: Scott L. Gessner, David D. Newkirk, Michael M. Thomason, James O. Reeder