Abstract: A process for preparing nonwoven webs including multiple component continuous filaments having high levels of three-dimensional helical crimp utilizing draw rolls to provide a high degree of orientation to each of the polymeric components by mechanically drawing the filaments under conditions wherein the polymeric components remain substantially amorphous and a stretchable nonwoven web including multiple component, continuous filaments having high levels of three-dimensional helical crimp.

Abstract: A synthetic leather made of a nonwoven fabric impregnated and/or coated with a polymer, with a surface weight of 100 to 500 g/m2, and a tensile strength greater than 300 N/5 cm in the lengthwise and the crosswise direction, where the nonwoven fabric is made up of melt-spun multi-component endless filaments, aerodynamically stretched and directly laid up to form a nonwoven material, having a titer less than 2 dTex, and wherein the multi-component endless filaments, after preliminary bonding, are split and bonded by at least 90% to produce supermicro endless filaments having a titer less than 0.2 dTex.

Abstract: A device and method for spinning polymer fibers utilizes one or more independent sources of polymer materials, pumps for feeding polymer material from each of the sources, and a series of distribution plates with surface grooves, through holes and/or slots together defining separated distribution paths, each of which receives polymer material from one of said independent sources. The surface grooves are defined to a depth less than the thickness of the distribution plate. At least one distribution plate contains spinneret orifices defined by outlet surface grooves extending from the distribution path to the edge of that plate, whereby fibers are extruded from the spinneret orifices edgewise from the plate. The spinneret orifices may be defined by overlayed outlet surface grooves or slots defined in abutting plates.

Abstract: Robust homofilament fibers are meltspun from a differently shaped dual capillary spinneret design to induce differential fiber morphology to produce crimping. Crimping may further be aided by quenching and drawing of the fibers.

Abstract: Fastener products having a multiplicity of fastener elements extending from a strip-form base, the base including first and second attachment members for attachment of a substrate therebetween, are formed by continuously introducing molten resin to a gap defined adjacent a peripheral surface of a rotating mold roll. The resin forms part of the strip-form base of the product at the peripheral mold roll surface and fills an array of fixed cavities defined in the rotating mold roll to form portions of the fastener elements as projections extending from a first side of the sheet-form base. While the resin is on the mold roll, a sheet material is introduced.

Abstract: A process for the preparation of a side-by-side or eccentric sheath-core bicomponent fiber wherein each component comprises a different poly(trimethylene terephthalate) composition.

Abstract: A melt spinning apparatus includes fiber producing features to produce multi-component filaments by extruding two or more single-component strands that combine after extrusion and are then attenuated by process air. The two or more liquid materials do not contact one another in the spinpack. Separation of the two types of liquid material throughout the spinpack prevents premature leakage between two liquid materials and allows for an optimized temperature for each type of liquid material for proper extrusion.

Abstract: A soft stretch yarn produced by spinning yarn of conjugate fibers including two types of polyester in which one component is PTT at a take-up velocity of at least 1200 m/min, drawing at a drawing temperature of 50 to 80° C. at a draw ratio such that the drawn yarn tensile elongation is 20 to 45%, and then heat setting.

Abstract: Mechanically divisible multicomponent fibers have at least a component including poly(lactic acid) polymer and at least a second component including at aromatic polyester. The multicomponent fibers are particularly useful in the manufacture of nonwoven structures, and in particular nonwoven structures used as synthetic suede.

Abstract: A process for forming multiple component meltblown fibers by extruding a first distinct melt-processable polymer through a row of first extrusion orifices, simultaneously extruding a second distinct melt-processable polymer through a row of second extrusion orifices, fusing the first and second melt-processable polymers into extruded composite filaments after extrusion, and pneumatically attenuating and breaking the extruded composite filaments with jets of high velocity gas so as to form the multiple component meltblown fibers.

Abstract: The present invention provides a multicomponent fiber containing at least two polymer components arranged in distinct zones or segments across the cross-section of the fiber wherein at least one component of the fiber contains a thermoplastic polymer and at least one component of the fiber contains a thermoset polymer. The invention also provides fabrics and fabric laminates containing the multicomponent fibers, and articles containing the fabric. Additionally provided is a process for producing the multicomponent fibers.

Abstract: The invention provides an improved method for making a poly(ester) bicomponent fiber wherein at least one poly(ester) contains a styrene polymer.

Abstract: A process for forming flexible noise attenuating cutting line for use in rotary vegetation trimmers formed of at least two monofilament polymer strands bonded together in a twisted disposition or a single strand twisted about its central axis in which the strand or strands are extruded in a molten disposition through a single die that is rotated during the extruding step either to twist the two strands together about a central longitudinal axis or a single strand about its own longitudinal axis such that upon cooling, stretching and heating, a flexible noise attenuating line is created in a continuous online process.

Abstract: A system and process for producing spunbond nonwoven fabric in which two or more polymeric components are separately melted and are separately directed through a distribution plate configured so that the separate molten polymer components combine at a multiplicity of spinnerette orifices to form filaments containing the two or more polymer components. Multicomponent filaments are extruded from the spinnerette orifices into a quench chamber where quench air is directed from a first independently controllable blower and into contact with the filaments to cool and solidify the filaments. The filaments and the quench air are directed into and through a filament attenuator and the filaments are pneumatically attenuated and stretched. The filaments are directed from the attenuator into and through a filament depositing unit and are deposited randomly upon a moving continuous air-permeable belt to form a nonwoven web of substantially continuous filaments.

Abstract: A side-by-side or eccentric sheath-core bicomponent fiber wherein each component comprises a different poly(trimethylene terephthalate) composition and wherein at least one of the compositions comprises styrene polymer dispersed throughout the poly(trimethylene terephthalate), and preparation and use thereof.

Abstract: Spunbond multicomponent filaments and nonwoven webs made from the filaments are disclosed. In accordance with the present invention, the multicomponent filaments contain a crimp enhancement additive. Specifically, the crimp enhancement additive is added to the polymeric component that has the slower solidification rate. The additive enhances crimp, allows for highly crimped filaments to be made at low fiber linear densities, improves the integrity of unbonded webs made from the filaments, and produces webs with improved stretch and cloth-like properties. The additive incorporated into the filaments is a random copolymer of butylene and propylene.

Abstract: Highly crimped, fully drawn bicomponent fibers, prepared by melt-spinning, followed by gas-flow quenching, heat treatment and high speed windup, are provided, as are fine-decitex and highly uniform polyester bicomponent fibers.

Abstract: A method for producing a pleated filter material from a nonwoven fabric having spacers for the pleated folds formed from the filter material itself, a formed fabric made of stretched synthetic fibers and thermoplastic and/or thermally cross-linked binding agent being heated in an oven to a temperature lying at least in the softening temperature range and/or the cross-linking temperature range of the binding agent, and subsequently, the formed fabric being formed between profiled calender rolls and cooled simultaneously.

Abstract: The present invention relates to a textile filament with a contact angle greater than or equal to 90 degrees. Such filaments are either water-repellent or resistant to chemicals, and yarns made therefrom readily processible into fabrics. In a detailed embodiment, the filaments are water-repellent and comprise a first longitudinally-extending component comprising at least one polymer selected from nylon, polyester, polypropylene, or other filament-forming polymer, and a second longitudinally-extending component, comprising a halogenated polymer. In a second detailed embodiment, the filaments are chemical-resistant and comprise a first longitudinally-extending component comprising at least one fiber-forming polymer and a second longitudinally-extending component comprising an olefin copolymer. In both embodiments, the second longitudinally-extending component is present on the exterior of the first longitudinally-extending component.

Abstract: A spinneret 20 for producing easily splittable plural-component fibers includes two passages 22 and 26 for respectively delivering two incompatible polymers (A and B) to two sets of inclined capillaries 34-39, 46-51. The two sets of capillaries converge toward each other in a downstream direction and direct molten polymer streams to two respective rows of orifices 40-45, 52-57. The centerlines of the polymer A capillaries lie along axes that, when extended beyond the spinneret, are offset and non-intersecting with axes along which the centerlines of the polymer B capillaries lie, such that the centerlines of the extruded polymer streams are directed along non-intersecting axes. The capillary angles and orifice arrangement cause the extruded polymer streams to extend toward each other in an interleaved fashion, with the polymer streams contacting each other in a generally tangential manner.

Abstract: A spinneret holder assembly for producing a continuous plastic multiple-component yarn with a preset component ratio, comprising in a mutually superimposed arrangement: a plate for conveying a first component and at least one second component; a distribution plate with first channels for the passage of the first component and a first compensation element for the second component; a pre-spinneret with second channels for the passage of the first component which are aligned with the first channels and a second compensation element for the second component; and a spinneret with extrusion holes which are connected to the channels for the passage of the first component and extend from a region for the distribution of the second component.

Abstract: A fiber spinning device and process for manufacturing a web of fibers including a homogeneous mixture of fibers of different characteristics. Monocomponent fibers of different polymers can be extruded side-by-side from the same die system. Sheath/core bicomponent fibers can be alternated with monocomponent fibers formed of the same core polymer as used in the bicomponent fibers. Bicomponent fibers having a common core polymer and different sheath polymers can be extruded from alternate spinneret orifices in the same die plate. Multiple distribution plates are provided with surface grooves or depressions to direct polymer materials from independent sources to only selected spinneret openings in an array of spinneret openings while maintaining the polymers segregated from each other.

Abstract: The present invention is directed to a process for forming a plurality of multi-layered filaments from multiple thermoplastic synthetic polymers and an apparatus containing a melt spinning beam which comprises multiple polymer inlet passages each communicating with separate multiple coat hanger distribution manifolds, separate filters connected downstream of each coat hanger distribution manifold, a combining manifold connected downstream of said filters and spinneret orifices connected downstream of said combining manifold for spinning of said multi-layered filaments.

Abstract: A fiber spinning device and process for manufacturing a web of fibers in the nature of a homogeneous mixture of fibers of different characteristics. Monocomponent fibers of different polymers can be extruded side-by-side from the same die system. Sheath/core bicomponent fibers can be alternated with monocomponent fibers formed of the same core polymer as used in the bicomponent fibers. Bicomponent fibers having a common core polymer and different sheath polymers can be extruded from alternate spinneret orifices in the same die plate. Multiple distribution plates are provided with surface grooves or depressions to direct polymer materials from independent sources to only selected spinneret openings in an array of spinneret openings while maintaining the polymers segregated from each other.

Abstract: A fiber having a surface with a relatively low coefficient of friction portion and a relatively high coefficient of friction portion. The fiber maybe produced by slitting a film/sheet which has been coextruded, laminated and/or coated, or by partially coating a base fiber. Fabrics made from such fibers exhibit increased structural integrity.

Abstract: This invention provides a process for making a nonwoven sheet of substantially continuous melt spun fibers by extruding melt spinnable polymer containing at least 30% by weight low IV poly(ethylene terephthalate), drawing the extruded fiber filaments at a rate of at least 6000 m/min, laying the fiber filaments down on a collection surface, and bonding the fiber filaments together to form a nonwoven sheet. The invention further provides a nonwoven sheet comprised of at least 30% by weight poly(ethylene terephthalate) having an intrinsic viscosity of less than 0.62 dl/g, where the sheet has a basis weight of less than 125 g/m2, and a grab tensile strength of at least 0.7 N/(g/m2).

Abstract: A method for making a biodegradable thermoplastic composition. The thermoplastic composition may be used in methods to produce multi-component fibers and non-woven materials that demonstrate a higher contact angle hysteresis, quicker intake times, and improved skin dryness as compared to prior art materials. In addition, biodisintegratable nonwoven materials made according to the present invention also exhibit high wetting rates, which is unexpected based upon the higher hysteresis values. The nonwoven material may be produced using thermoplastic compositions which comprise an unreacted mixture of an aliphatic polyester polymer as a continuous phase, polyolefin microfibers as a discontinuous phase encased within the aliphatic polyester polymer continuous phase, and a compatibilizer for the aliphatic polyester polymer and the polyolefin microfibers. The multicomponent fiber exhibits substantial biodisintegratable properties and good wettability yet is easily processed.

Abstract: Hybrid matrix fiber composites having enhanced compressive performance as well as enhanced stiffness, toughness and durability suitable for compression-critical applications. The methods for producing the fiber composites using matrix hybridization. The hybrid matrix fiber composites comprised of two chemically or physically bonded matrix materials, whereas the first matrix materials are used to impregnate multi-filament fibers formed into ribbons and the second matrix material is placed around and between the fiber ribbons that are impregnated with the first matrix material and both matrix materials are cured and solidified.

Abstract: Mechanically divisible multicomponent fibers are disclosed having at least a first component comprised of poly(lactic acid) polymer and at least a second component comprised of an aromatic polyester. The multicomponent fibers are particularly useful in the manufacture of nonwoven structures, and in particular nonwoven structures used as synthetic suede.

Abstract: A process for forming multiple component meltblown webs in which a poor-spinning polymer is co-spun with a good-spinning polymer in a meltblowing process using high throughput and short die-to-collector distances.

Abstract: A composite nonwoven fabric includes a stretched unidirectionally aligned nonwoven fabric in which filaments composed of a thermoplastic resin are unidirectionally aligned and stretched and a dry nonwoven fabric that is provided on one side of the stretched unidirectionally aligned nonwoven fabric and that includes thermal-bonding fibers as a chief component. The filaments of the stretched unidirectionally aligned nonwoven fabric and the dry nonwoven fabric are intertwined by a needlepunch process, following which the two fabrics are unified by a thermal calendering process to produce the composite nonwoven fabric.

Abstract: An apparatus for extruding multiple types of liquid materials into multi-component filaments. A pair of outer manifold elements sandwich an intermediate manifold element. Respective channels are formed between opposing sides of the outer manifold elements and the respective opposite sides of the intermediate manifold element. These recesses form channels which diverge or widen away from associated inlets at the top of the manifold assembly. A die tip is coupled to the manifold assembly at a lower side and communicates with the outlets of the channels. The die tip includes a combining member for producing a desired multi-component filament configuration.

Abstract: An apparatus for meltblowing multiple types of liquid materials into multi-component filaments. A pair of outer manifold elements sandwich an intermediate manifold element. Respective channels are formed between opposing sides of the outer manifold elements and the respective opposite sides of the intermediate manifold element. These recesses form channels which diverge or widen away from associated inlets at the top of the manifold assembly. A die tip is coupled to the manifold assembly at a lower side and communicates with the outlets of the channels. The die tip includes a combining member for producing a desired multi-component filament configuration and further includes air discharge passages for impinging the discharged multi-component filaments with pressurized air.

Abstract: Disclosed is to provide generally to a microfiber substrate of improved carding ability and its manufacturing method, and more particularly to a micro-fiber spun by conjugated melting of crystallization difference of high crystallization polymer and low crystallization polyester, drawn to form an unsplit microfiber staple having a layer of thin film in its surrounding, the said microfiber staple which is still kept in unsplitting state during opening , carding and lapping treatment, will be split just at the layer of thin layer of its surrounding of the said microfiber staple by spunlace to completely split from the said microfiber, knitted to form water-jet punch web, then subject to hot water to shrink to densification. The microfiber nonwoven web excellent in the wiping effect, cleaning effect and microfiber artificial leather excellent in the hand feeling and fluff compaction without environment pollution is enabled to offer the artificial leather more cheaply and easily finished.

Abstract: A continuous fiber nonwoven comprising composite continuous fibers having the spiral crimps obtained by compositely spinning two thermoplastic resins having the difference in the melting points of 15° C. or more is provided, and it is characterized in that the contact points of the fibers are adhered one another by fusing of the thermoplastic resin having a low melting point and located on the outside of the spiral crimps.

Abstract: Robust homofilament fibers are meltspun from a differently shaped dual capillary spinneret design to induce differential fiber morphology to produce crimping. Crimping may further be aided by quenching and drawing of the fibers.

Abstract: In a method for producing a monofilament with reduced secondary binding forces of at least two commonly extruded polymers for the production of bristles or interdental cleaners which are slittable substantially axially through the action of mechanical forces, the at least two polymers of the monofilament are disposed in a regular geometrical arrangement with substantially axially extending boundary layers in which the reduced secondary binding forces prevail for generation of defined slits of flags.

Abstract: The invention provides deodorant rayon fibers having a superior deodorization performance. The deodorant rayon fibers are produced by implanting a large quantity of fine grains produced by milling white charcoal in a matrix of the rayon fiber. After adding and mixing a water dispersion which disperses the large quantity of fine grains into viscose solutin, and then spinning, thereby the deodorant rayon fibers are produced. The fine grains obtained by milling the white charcoal do not form spheres with smooth surfaces, but their configurations are irregular with projections. As a result, even when they are implanted in the matrix of the rayon fiber, the projections tend to be exposed on the surfaces of the rayon fibers. The exposed fine grains adsorb odor gases into themselves, thereby their superior deodoization performance is performed.

Abstract: The present invention provides continuously crimped propylene polymer nonwoven fabrics as well as processes for forming crimped multicomponent propylene polymer fibers by melt-attenuating extruded multicomponent fibers with heated or unheated air wherein the fibers spontaneously crimp without the need for additional heating and/or stretching steps.

Abstract: The present invention relates to fibers having both relatively low and relatively high coefficient of friction characteristics. The fibers of the present invention are useful for toothbrush bristles and dental floss.

Abstract: The present invention is directed to a method of making a substantially continuous filament web which includes providing a plurality of polymer extruders for supplying polymer streams of at least two different polymer compositions, and providing a spinneret assembly for receiving the polymer streams. The spinneret assembly includes a plurality of orifices from which the polymer streams are extruded for formation of substantially continuous filaments formed from the polymer compositions. The distribution of at least one of the polymer compositions within the spinneret assembly is selected to optimize selected physical characteristics of the resultant continuous filament web.

Abstract: A process of forming a nonwoven fabric is disclosed which comprises the steps of forming a precursor web of multicomponent substantially continuous filaments, exposing the precursor web to a hydraulic arrangement treatment to form apertures without causing substantial filament entanglement, and thereafter forming inter-filament bonds and an integrated web. The resulting apertured nonwoven fabrics have good hand and tactile aesthetics and have a great variety of uses including use in absorbent personal care products, garments, medical applications, and cleaning applications.

Abstract: Dry-spun polyurethane-based spandex ® containing 1-10 weight percent poly(vinylpyrrolidone) and a process of their preparation, are provided.

Abstract: A system and process is provided for producing spunbond nonwoven fabric. Two or more polymeric components are separately melted and are separately directed through a distribution plate configured so that the separate molten polymer components combine at a multiplicity of spinnerette orifices to form filaments containing the two or more polymer components. Multicomponent filaments are extruded from the spinnerette orifices into a quench chamber where quench air is directed from a first independently controllable blower and into contact with the filaments to cool and solidify the filaments. The filaments and the quench air are directed into and through a filament attenuator and the filaments are pneumatically attenuated and stretched. The filaments are directed from the attenuator into and through a filament depositing unit and are deposited randomly upon a moving continuous air-permeable belt to form a nonwoven web of substantially continuous filaments.

Abstract: The present invention relates to melt spun fibers prepared from blends of poly(tetrafluoroethylene) and poly(tetrafluoroethylene-co-perfluoro-alkylvinyl ether).

Abstract: An apparatus and process for applying finish to an expanded filament array in a quench system with air directed inward to the filament bundle. The applicator may be used inside or proximate quench zones in a radial, pneumatic, or cross-flow quench system. The apparatus includes a spinneret, a quench zone located below said spinneret, wherein cooling gas is directed inward to an expanded filament array inside said quench zone, and an applicator inside or below said quench zone, wherein the applicator contacts the filament and delivers the finish to the expanded filament array.

Abstract: The carbon fiber precursor fiber bundle of the present invention is an acrylonitrile-based fiber bundle wherein the ratio of the length and width of the fiber cross section of a monofilament (length/width) is 1.05 to 1.6, and the amount of Si measured by ICP (Inductively Coupled Plasma) atomic emission spectrometry is in the range of 500 to 4,000 ppm. This type of carbon fiber precursor fiber bundle has a high compactness, and the carbonizing processing ability is good. Furthermore, for the carbon fiber bundle which is to obtained hereafter, the resin impregnating ability and tow spreading ability are good, the strength increases, and it has bulkiness. Furthermore, the carbon fiber precursor fiber bundle of the present invention is an acrylonitrile-based fiber bundle wherein the liquid content ratio HW is 40 wt. % or more and less than 60 wt. %.

Abstract: Highly crimped, fully drawn bicomponent fibers, prepared by melt-spinning, followed by gas-flow quenching, heat treatment and high speed windup, are provided, as are fine-decitex and highly uniform polyester bicomponent fibers.

Abstract: A method for making heat-retaining fiber and fabrics. According to the present invention, the white conductive particles and the white particles with good radiating efficiency of far-infrared radiation are added in fiber-forming polymers to obtain the mixed composition. The fiber and fabrics made of the mixed composition is characteristic of excellent effect of heat-retaining usable for the use of requiring good heat-retaining effectiveness.

Abstract: Multilayer plastic composites containing at least two incompatible plastics, A and B, in which the layering sequence alternates between A and B, the layers of plastic B are discontinued at regular intervals, and the resulting gaps in the layers are filled in with plastic A, exhibit good adhesion between the layers. In preferred embodiments of the invention, the amorphous, crystalline, or semi-crystalline plastic B has a higher coefficient of thermal expansion than the amorphous plastic A. The plastic composite is preferably produced via coextrusion.