Abstract: Halogen-free, microporous polyolefin membranes are disclosed herein. The halogen-free, microporous polyolefin membranes can be manufactured using an environmentally friendly manufacturing process that includes extrusion of polymer-plasticizer mixtures followed by sheet formation and extraction of the plasticizer with a halogen-free solvent. The halogen-free solvent has a flashpoint greater than about 23° C. and an initial boiling point at least about 50° C. lower than the flashpoint of the plasticizer. The process can further be a closed loop process in which the halogen-free solvent can be reused.

Abstract: Halogen-free, microporous polyolefin membranes are disclosed herein. The halogen-free, microporous polyolefin membranes can be manufactured using an environmentally friendly manufacturing process that includes extrusion of polymer-plasticizer mixtures followed by sheet formation and extraction of the plasticizer with a halogen-free solvent. The halogen-free solvent has a flashpoint greater than about 23° C. and an initial boiling point at least about 50° C. lower than the flashpoint of the plasticizer. The process can further be a closed loop process in which the halogen-free solvent can be reused.

Abstract: This disclosure relates to battery separators for use in lead acid batteries. In particular, the disclosure relates to nonporous polymer sheets in which the porosity manifests itself after cavitation and/or biaxial stretching to form a microporous membrane. The disclosure also relates to nonporous polymer sheets in which the porosity manifests itself after dissolution of an acid soluble filler to form a microporous membrane. In addition to meeting all battery performance requirements, these microporous membranes eliminate environmental and health concerns because they do not require the use of an organic solvent during their production.

Abstract: A polymer fiber sheet exhibits high porosity and good tensile properties in both “wet” and “dry” states. A fiber modifying agent is incorporated into a polymer extrusion and fiber formation process to produce a highly porous polymer fiber sheet that is instantaneously wettable by an aqueous medium. The fiber modifying agent functions as either one or both (1) a plasticizer that reduces the polymer extrudate melt viscosity and allows the formation of fine fibers during processing and (2) a surface modifying agent that promotes the instantaneous and sustainable wettability of individual polymer fibers and a porous fiber sheet formed from them. The polymer fiber sheet maintains its wettability even after repeated washing and drying cycles. The resultant fiber sheet can be densified and embossed to provide a desired thickness and porosity, while at the same time longitudinal ribs with desired pattern can also be formed on the fiber sheet.

Abstract: A multi-row melt-blown fiber spinneret (8) enables stacking rows (121, 122, 123) of polymer outlet orifices (36) more closely together than is achievable with conventional melt-blown fiber spinnerets. The fiber spinneret configuration also enables dense side-by-side packing of the polymer outlet orifices. The fiber spinneret is configured so that air knife channels (141c, 142c, 143c, 144c) and individual intricate small air knife passage feeds, together with their associated melt flow channels (501, 502, 503), are formed in the same body member. The rows of polymer outlet orifices are supplied with a polymer melt by a single polymer inlet (20), which delivers the polymer melt to the individual polymer melt flow channels. The air knife channels are directed through the body member, in which the polymer melt flow channels are formed by islands and air flow passage feeds. The body member is constructed by operation of a 3D printer for direct metal printing.

Abstract: A polymer fiber sheet exhibits high porosity and good tensile properties in both “wet” and “dry” states. A fiber modifying agent is incorporated into a polymer extrusion and fiber formation process to produce a highly porous polymer fiber sheet that is instantaneously wettable by an aqueous medium. The fiber modifying agent functions as either one or both (1) a plasticizer that reduces the polymer extrudate melt viscosity and allows the formation of fine fibers during processing and (2) a surface modifying agent that promotes the instantaneous and sustainable wettability of individual polymer fibers and a porous fiber sheet formed from them. The polymer fiber sheet maintains its wettability even after repeated washing and drying cycles. The resultant fiber sheet can be densified and embossed to provide a desired thickness and porosity, while at the same time longitudinal ribs with desired pattern can also be formed on the fiber sheet.

Abstract: A conformable structured therapeutic dressing (120) has maximum available surface area (102) of a therapeutic agent (122) to stimulate therapeutic response in wounded tissue of a mammalian subject. In preferred embodiments, the therapeutic agent includes a procoagulant to quickly arrest bleeding and prevent life-threatening blood loss. The wound dressing exhibits a structured adsorbent (104) that maximizes available surface area of a functional filler (72). This is achieved with a minimal amount of binder (82) and small, porous particles of the functional filler. Minimizing the binder maximizes the amount of functional filler and reduces the chance that the binder will block access to the surface area of the functional filler. Porous particles have a large internal surface area. Structured adsorbents with higher surface areas, higher inter- and intra-fiber porosities, and low internal mass transfer resistances produce higher rates of mass transfer of an adsorbent onto the functional filler.

Abstract: A conformable structured therapeutic dressing (120) has maximum available surface area (102) of a therapeutic agent (122) to stimulate therapeutic response in wounded tissue of a mammalian subject. In preferred embodiments, the therapeutic agent includes a procoagulant to quickly arrest bleeding and prevent life-threatening blood loss. The wound dressing exhibits a structured adsorbent (104) that maximizes available surface area of a functional filler (72). This is achieved with a minimal amount of binder (82) and small, porous particles of the functional filler. Minimizing the binder maximizes the amount of functional filler and reduces the chance that the binder will block access to the surface area of the functional filler. Porous particles have a large internal surface area. Structured adsorbents with higher surface areas, higher inter- and intra-fiber porosities, and low internal mass transfer resistances produce higher rates of mass transfer of an adsorbent onto the functional filler.