Abstract: The present invention provides a method of making a nonwoven web with desired fiber orientation, the method including the steps of providing a source of fibers, subjecting the fibers to an electrostatic charge, deflecting the fibers with a non-contacting deflecting device, collecting the fibers on a moving forming surface to form the nonwoven web. The invention also provides an apparatus for forming fibrous nonwoven webs, the apparatus comprising a source of fibers, a device for applying an electrostatic charge to the fibers, a non-contacting fiber deflecting device adapted to affect the fibers while the fibers are under the influence of the applied electrostatic charge, and a forming surface for collecting the fibers as a fibrous nonwoven web.

Abstract: A nonwoven fabric composite that comprises at least one extensible layer of elastomeric fine fibers treated with a wetting agent is provided. The nonwoven fabric composite can be used a barrier layer or a wrap for an absorbent materials to prevent particles form migrating out of the absorbent material.

Abstract: Disclosed herein is an apparatus for forming sheath-and-core fibers, the apparatus comprising a series of stacked distribution plates comprising channels arranged to convey first and second fluidized polymers separately and comprising a restriction zone for distributing the second fluidized polymer around the first polymer as a sheath. Also disclosed is a method for forming such sheath-and-core fibers. The apparatus and method are well suited to forming sheath-and-core fibers having very low percentage of sheath component.

Abstract: The present invention provides a method of making a nonwoven web with desired fiber orientation, the method including the steps of providing a source of fibers, subjecting the fibers to an electrostatic charge, deflecting the fibers with a non-contacting deflecting device, collecting the fibers on a moving forming surface to form the nonwoven web. The invention also provides an apparatus for forming fibrous nonwoven webs, the apparatus comprising a source of fibers, a device for applying an electrostatic charge to the fibers, a non-contacting fiber deflecting device adapted to affect the fibers while the fibers are under the influence of the applied electrostatic charge, and a forming surface for collecting the fibers as a fibrous nonwoven web.

Abstract: A targeted elastic laminate material is provided having at least one low tension zone with first filaments having a first basis weight and at least one high tension zone having second filaments with a second basis weight greater than the first basis weight. The second basis weight is greater due to increased average thickness of the second filaments and/or increased frequency of second filaments relative to the first filaments. Methods and modifications of those methods are provided to produce a targeted elastic laminate material according to the preferred embodiments of this invention.

Abstract: A blown film process for producing low gauge, latent elastic films with high cross-direction orientation includes preferentially regulating the temperature gradient of the film along the expansion length. The regulation of temperature along the bubble profile allows more effective “down gauging” of the film and improved melt strength of the hot film. The choice of raw materials is an important element in producing cross-direction-oriented, low gauge, latent elastic films. The method of this invention can be carried out as either a multiple-bubble process or a single-bubble process.

Abstract: A method of preparing a nonwoven web that has substantially continuous synthetic fine fiber includes preparing an aqueous amide crosslinked polymer solution. The solution is extruded through a die having a plurality of orifices to form a plurality of threadlines. The threadlines are then attenuated with a primary gaseous source under conditions sufficient to permit the viscosity of each threadline to increase incrementally with increasing distance from the die, at a rate sufficient to provide fibers having a desired attenuation and mean fiber diameter without significant fiber breakage.

Abstract: A method of forming fibers into a web includes the steps of co-extruding a first elastomeric component and a second thermoplastic component; directing the first and second components through a fiber spin pack to form a plurality of continuous molten fiber spinlines, where the first elastomeric component is present in an amount greater than about 70 percent by weight of the molten fibers and the second thermoplastic component is present in an amount of between about 10 and 30 percent by weight of the molten fibers; attenuating the spinlines and routing the plurality of molten fibers through a quench chamber to form a plurality of cooled fibers; routing the plurality of cooled fibers through a fiber draw unit, whereby the fibers are pulled downward; allowing the pulled fibers to be deposited onto a forming surface thereby forming a web wherein the fibers are relaxed; stabilizing the web; and bonding the web to produce a web demonstrating greater than about 25 percent machine direction stretch recovery.

Abstract: Improvements to processes and equipment for the manufacture of nonwoven webs useful in numerous applications including personal care, protective apparel, and industrial products. The fiber and/or filaments used to form the nonwoven fabric are deposited on a forming surface in a controlled orientation using application of an electrostatic charge to the fibers and/or filaments in combination with directing them to an electrode deflector plate while under the influence of the charge. The plate may be made up of teeth with a separation and angle orientation that are selected in accordance with the desired arrangement of the fibers and/or filaments in the nonwoven web. As a result, properties of the web such as relative strengths in the machine direction and cross-machine direction can be controlled.

Abstract: A nonwoven web and method of preparing a novel nonwoven web of synthetic fiber are disclosed. An aqueous solution amide crosslinked synthetic precursor polymer is extruded under defined conditions through a plurality of die orifices to form a plurality of threadlines. The threadlines are attenuated with a defined primary gaseous source to form fiber under conditions of controlled macro scale turbulence and under conditions sufficient to permit the viscosity of each threadline, as it leaves a die orifice and for a distance of no more than about 8 cm, to increase incrementally with increasing distance from the die, while substantially maintaining uniformity of viscosity in the radial direction, at a rate sufficient to provide fiber having the desired attenuation and mean fiber diameter without significant fiber breakage. The attenuated threadlines are dried with a defined secondary gaseous source. The resulting fibers are deposited randomly on a moving foraminous surface to form a substantially uniform web.

Abstract: A nonwoven web and method of preparing a novel nonwoven web of synthetic fiber are disclosed. An aqueous solution amide crosslinked synthetic precursor polymer is extruded under defined conditions through a plurality of die orifices to form a plurality of threadlines. The threadlines are attenuated with a defined primary gaseous source to form fiber under conditions of controlled macro scale turbulence and under conditions sufficient to permit the viscosity of each threadline, as it leaves a die orifice and for a distance of no more than about 8 cm, to increase incrementally with increasing distance from the die, while substantially maintaining uniformity of viscosity in the radial direction, at a rate sufficient to provide fiber having the desired attenuation and mean fiber diameter without significant fiber breakage. The attenuated threadlines are dried with a defined secondary gaseous source. The resulting fibers are deposited randomly on a moving foraminous surface to form a substantially uniform web.

Abstract: A blown film process for producing low gauge, latent elastic films with high cross-direction orientation includes preferentially regulating the temperature gradient of the film along the expansion length. The regulation of temperature along the bubble profile allows more effective “down gauging” of the film and improved melt strength of the hot film. The choice of raw materials is an important element in producing cross-direction-oriented, low gauge, latent elastic films. The method of this invention can be carried out as either a multiple-bubble process or a single-bubble process.

Abstract: A nonwoven web and method of preparing a novel nonwoven web of synthetic fiber are disclosed. An aqueous solution amide crosslinked synthetic precursor polymer is extruded under defined conditions through a plurality of die orifices to form a plurality of threadlines. The threadlines are attenuated with a defined primary gaseous source to form fiber under conditions of controlled macro scale turbulence and under conditions sufficient to permit the viscosity of each threadline, as it leaves a die orifice and for a distance of no more than about 8 cm, to increase incrementally with increasing distance from the die, while substantially maintaining uniformity of viscosity in the radial direction, at a rate sufficient to provide fiber having the desired attenuation and mean fiber diameter without significant fiber breakage. The attenuated threadlines are dried with a defined secondary gaseous source. The resulting fibers are deposited randomly on a moving foraminous surface to form a substantially uniform web.

Abstract: A nonwoven web and method of preparing a novel nonwoven web of synthetic fiber are disclosed. An aqueous solution amide crosslinked synthetic precursor polymer is extruded under defined conditions through a plurality of die orifices to form a plurality of threadlines. The threadlines are attenuated with a defined primary gaseous source to form fiber under conditions of controlled macro scale turbulence and under conditions sufficient to permit the viscosity of each threadline, as it leaves a die orifice and for a distance of no more than about 8 cm, to increase incrementally with increasing distance from the die, while substantially maintaining uniformity of viscosity in the radial direction, at a rate sufficient to provide fiber having the desired attenuation and mean fiber diameter without significant fiber breakage. The attenuated threadlines are dried with a defined secondary gaseous source. The resulting fibers are deposited randomly on a moving foraminous surface to form a substantially uniform web.

Abstract: A nonwoven web and method of preparing a novel nonwoven web of synthetic fiber are disclosed. An aqueous solution amide crosslinked synthetic precursor polymer is extruded under defined conditions through a plurality of die orifices to form a plurality of threadlines. The threadlines are attenuated with a defined primary gaseous source to form fiber under conditions of controlled macro scale turbulence and under conditions sufficient to permit the viscosity of each threadline, as it leaves a die orifice and for a distance of no more than about 8 cm, to increase incrementally with increasing distance from the die, while substantially maintaining uniformity of viscosity in the radial direction, at a rate sufficient to provide fiber having,the desired attenuation and mean fiber diameter without significant fiber breakage. The attenuated threadlines are dried with a defined secondary gaseous source. The resulting fibers are deposited randomly on a moving foraminous surface to form a substantially uniform web.

Abstract: A nonwoven web and method of preparing a novel nonwoven web of synthetic fiber are disclosed. An aqueous solution amide crosslinked synthetic precursor polymer is extruded under defined conditions through a plurality of die orifices to form a plurality of threadlines. The threadlines are attenuated with a defined primary gaseous source to form fiber under conditions of controlled macro scale turbulence and under conditions sufficient to permit the viscosity of each threadline, as it leaves a die orifice and for a distance of no more than about 8 cm, to increase incrementally with increasing distance from the die, while substantially maintaining uniformity of viscosity in the radial direction, at a rate sufficient to provide fiber having the desired attenuation and mean fiber diameter without significant fiber breakage. The attenuated threadlines are dried with a defined secondary gaseous source. The resulting fibers are deposited randomly on a moving foraminous surface to form a substantially uniform web.

Abstract: Described herein are improvements to processes and equipment for the manufacture of nonwoven webs useful in numerous applications including personal care, protective apparel, and industrial products. The fiber and/or filaments used to form the nonwoven fabric are deposited on a forming surface in a controlled orientation using application of an electrostatic charge to the fibers and/or filaments in combination with directing them to an electrode deflector plate while under the influence of the charge. The plate may be made up of teeth with a separation and angle orientation that are selected in accordance with the desired arrangement of the fibers and/or filaments in the nonwoven web. As a result, properties of the web such as relative strengths in the machine direction and cross-machine direction can be controlled.

Abstract: There is provided a fibrous web which includes a binder and which is compressed to a density of up to about 0.3 g/cc. The web may preferably be formed by the bonded carded web process or air lay process. The binder may depend on hydrogen bonding using moisture or may be a non-aqueous solution, a powder, a fibrous binder or a conjugate fiber binder including a moisture triggerable component. Conjugate fibers may be crimped. When wetted the web of this invention should expand rapidly to greater than 80% of its uncompressed thickness and greater than 90% of its thickness when saturated if starting from the uncompressed state.

Abstract: A targeted elastic laminate material having different zones of tension across a width of a material roll and methods for making the same. At least two polymers or polymer blends having different set properties are used to produce varying tension zones across the material. The targeted elastic laminate material has elastic properties that provide improved fit characteristics to disposable personal care products, while maintaining a flat roll profile that allows the material to be easily processed at a high speed.

Abstract: A disposable garment includes a gasket around one or more openings for the legs, arms, waist or the like on a wearer. At least a portion of the garment includes a targeted elastic material including zones of high and low elastic tension and/or high and low stretch in the same material, integrated during formation of the material. The targeted elastic material is positioned so that at least one high tension and/or low stretch zone is aligned with at least one garment opening, and at least one low tension and/or high stretch zone is aligned inward of the high tension and/or low stretch zone, thereby functioning as a gasket without requiring a separately manufactured, attached elastic band.