Abstract: A method correlates average fiber diameter with performance for a complex filtration media comprising a matrix of fibers having a fibrillated component with a diameter so small (e.g., less than 0.01 microns), that cannot be physically measured with accuracy. The method manufactures a selected matrix, derives the number average diameter of the fibers according to prescribed steps, some of which do not require actual physical measurements, and observes a performance characteristic. The method repeats the foregoing steps for different matrixes, yielding different number average diameters. The method expresses change in the selected performance characteristic as a function of change in number average diameter of the matrices.

Abstract: A method of molding a component such as a headliner or sun visor for the interior of automotive vehicles is molded from different thermoplastic materials from the same family that can be subsequently recycled as a whole without the need of separation into its constituents. The interior component is a multi layer composite of polyester (PET) finishing fabric, a resilient layer of bicomponent polyester fiber padding composed of blend of a low melting point fibers and high melting point fibers, and a relatively stiff core layer of polyester/glass fiber composite of polyester and glass fibers. The different fibers of the core layer are blended into a thin and porous sheet which is cut to size. The cut sheets are consolidated and molded under heat and pressure into a light weight, dense and structurally strong composite. A mold charge comprises the polyester/glass fiber composite layered with the bicomponent.

Abstract: The invention's first embodiment uses shape memory alloy (SMA) fibers that are blended into a concrete composite material as straight fibers and are made to deform themselves and anchor and interlock themselves after dispersement in the composite material resulting in a more evenly distributed and interlocked fiber reinforcement of the cementitious material. A self-shaping fiber can be imparted to the concrete material by making the fibers out of SMA such as nickel-titanium alloy known as nitinol where the cementitious composite material mixture is briefly heated above the "transition" temperature prior to hardening that causes the fibers to change shape. Nitinol fibers are used alone in place of conventional steel fibers.

Abstract: A method and apparatus of producing and using composite fibers in a liquid molding process. The composite fibers are formed from a base material and filler particles which are lighter or less expensive than the base material. A preform screen is placed at the bottom of a tank. The tank is filled with liquid, the composite fibers and a mass of reinforcing fibers creating a slurry above the screen. The screen is raised up through the slurry causing the composite fibers and the reinforcing fibers to be deposited on the screen creating a fiber preform. The preform is then removed from the screen and is placed in a mold for use in a liquid molding process.

Abstract: A ceramic fiber is made by spinning a plurality of polymeric materials each including at least one ceramic precursor into a composite fiber, and then pyrolysing the composite fiber to form a composite ceramic fiber of non-homogeneous composition. A preferred ceramic material for use in this method is made by pyrolysing an organo-metallic compound dispersed in an organic polymer carrier. The principal products are tailored matrix-compatible ceramic fibers for reinforcements, and have a core-sheath structure made by coaxial spinning methods. A core of desired mechanical properties, such as silicon carbide, is given a chemically appropriate surface layer. Transition metals compounds are preferred, in a range of organo-metallic ceramic precursors that include carborane derivatives. Allowed additives include metal-silicon compounds, other ceramics, corresponding metal oxides and elementary metals.

Abstract: A spinner is adapted to be fixed at one end of a rotatable shaft in a fiberizer, the spinner including a radial wall extending radially out from the shaft and having an upper surface, a dam separating the upper surface into an inner portion and an outer portion, a lower surface, at least one first flow hole connecting the upper surface to the lower surface, and at least one second flow hole connecting the inner portion and the outer portion of said upper surface, and an outer peripheral wall connected to the radial wall and having a plurality of orifices therethrough.

Abstract: A method of making an insulation product of hollow fibers whereby molten insulation material is centrifuged through a plurality of orifices and gas is directed into the molten insulation material through a plurality of gas conduits, wherein each gas conduit directs gas into one of the portions of the molten insulation material being centrifuged through one of the orifices to form a hollow fiber having a hollow bore formed therethrough. The hollow fibers are combined to form the insulation product.

Abstract: A method of producing a fibrous product is disclosed. Molten material is introduced into a rotating spinner which includes a peripheral wall having a plurality of orifices. The molten material is centrifuged through the orifices to create fibers. The fibers are directed generally downwardly and away from the spinner. The fibers are intercepted on a folded conveyor so that the fibers are draped over the folded conveyor. The fibers form first and second suspended portions which are oriented generally vertically. The folded conveyor and intercepted fibers are moved away from the spinner. The first and second portions of the suspended fibers are raised to a generally horizontal orientation by unfolding the conveyor, thereby producing a generally planar fibrous product.

Abstract: In a method of and an apparatus for forming composite and other fibers, individual filaments from two or more sets of continuous primary filaments of two or more heat-softenable fiberizable materials are brought together lengthwise to form pairs of continuous primary filaments. The groupings of continuous primary filaments are fed into a high energy attenuation blast where the filaments are heated, attenuated and formed into composite or other staple fibers of the heat-softenable fiberizable materials. Preferably, the individual continuous primary filaments of the groupings of continuous primary filaments are fused, adhesively bonded or otherwise joined together, prior to being introduced into the high energy attenuation blast, to prevent the individual primary filaments of the groupings of continuous primary filaments from separating in the high energy attenuation blast.

Abstract: A glass fiber insulation product comprises irregularly-shaped glass fibers of two different glasses having differing coefficients of thermal expansion, with the irregularly-shaped dual-glass fibers exhibiting a substantially uniform volume filling nature, and providing improved recovery and thermal conductivity abilities even in the absence of a binder material.

Abstract: Apparatus for making dual component fibers is provided and includes a spinner having a peripheral wall. The spinner includes orifices located on the peripheral wall thereof for centrifuging the dual component fibers, with the spinner being divided into a series of generally vertically-aligned compartments by baffles positioned circumferentially around the interior of the peripheral wall. First and second molten thermoplastic materials are supplied to the spinner and directed into alternate ones of the compartments so that adjacent compartments contain different thermoplastic materials. Passages are located in each of the compartments through which the respective molten thermoplastic materials flow to the orifices on the peripheral wall of the spinner. The passages in adjacent ones of the compartments communicate with one another and with the orifices to join the first and second molten thermoplastic materials together into dual component fibers.

Abstract: An apparatus for making dual component fibers is provided and includes a spinner having peripheral and bottom walls. The spinner includes orifices located on the peripheral wall thereof for centrifuging the dual component fibers, with the spinner being divided into a series of generally vertically-aligned compartments by baffles positioned circumferentially around the interior of the peripheral wall. A first divider is provided in the spinner for directing the first molten thermoplastic material into alternate ones of the compartments, and a second divider is provided for directing the second molten thermoplastic material into the remaining ones of the compartments so that adjacent compartments contain different thermoplastic materials. Passages are located in each of the compartments through which the respective molten thermoplastic materials flow to the orifices on the peripheral wall of the spinner.

Abstract: A method of melt spinning sheath/core bicomponent fibers including the steps of passing multiple streams of pressurized molten core polymer from distributor flow passages into multiple parallel spinneret flow passages in respective axial or coaxial alignment with said multiple distributor flow passages. In pressured molten sheath polymer is passed through channels positioned in the top surface of the spinneret and surrounding the inlets of the spinneret flow passages. The sheath polymer is directed to flow from the channels into each of the spinneret flow passages and each of the polymer streams at a controlled pressure drop.

Abstract: An apparatus is provided for making dual component fibers. The apparatus comprises a distributor, equipment for providing first and second thermoplastic materials to the distributor, a rotatable spinner and a rotation mechanism. The distributor has an outer casing and a divider cup fixedly positioned within the outer casing. The outer casing has first and second orifices extending through its peripheral wall. The divider cup defines with the outer casing first and second chambers for receiving first and second molten thermoplastic materials. The first orifices communicate with the first chamber and the second orifices communicate with the second chamber. The rotatable spinner includes first and second passages in its peripheral wall.

Abstract: Apparatus for making dual component fibers is provided and includes a spinner having a peripheral wall. The spinner includes orifices located on the peripheral wall thereof for centrifuging the dual component fibers, with the spinner being divided into a series of compartments by baffles positioned circumferentially around the interior of the peripheral wall. The baffles are positioned at an angle of from about 5.degree. to about 75.degree. from vertical, and most preferably about 45.degree. from vertical. The number of orifices on the spinner peripheral wall can thus be increased to increase the throughput of fibers from the spinner while still maintaining a minimum required spacing between orifices for the structural integrity of the spinner.

Abstract: Apparatus for making dual-component thermoplastic fibers, such as glass fibers, comprises a spinner having an orificed peripheral wall for centrifuging fibers from thermoplastic material, the spinner having vertically aligned compartments with first and second thermoplastic materials in alternate compartments, and a series of elongated orifices in the peripheral wall in communication with each of two adjacent compartments to enable centrifuging of both the first and second thermoplastic materials from a single orifice.

Abstract: A method is disclosed for making thermoplastic bicomponent fibers by contacting under thermally bonding conditions (a) a first component being at least one high performance thermoplastic polymer, such as PET, PBT, nylon or the like, and (b) a second component which is olefinic and which forms at least a portion of the fiber's surface characterized by (b) including at least one grafted olefinic polymer, preferably at least one grafted linear ethylene polymer, having pendant succinic acid or succinic anhydride groups; whereby the fiber is dyeable. The bicomponent fibers made by this process can be in a variety of shapes (e.g., round, oval, trilobal, flat, or hollow) and configurations (e.g., symmetrical sheath/core or side-by-side or asymmetrical crescent/moon).

Abstract: Provided is a polyethylene terephthalate-based meltblown nonwoven fabric comprising a mixed polymer comprising 75 to 98% by weight of polyethylene terephthalate and 2 to 25% by weight of a polyolefin. The meltblown fabric has excellent thermal resistance, dimensional stability, strength and hand. Also provided is a process for producing a polyethylene terephthalate-based meltblown nonwoven fabric, which comprises melt blowing a mixed polymer comprising 75 to 98% by weight of polyethylene terephthalate and 2 to 25% by weight of a polyolefin. It is preferable that the melt blowing is conducted at a single orifice throughput of 0.2 to 1.0 g/min and under an air-jet pressure of 0.1 to 1.0 kg/cm.sup.2.

Abstract: Compositions and methods are described that relate to the use of reaction products of metal compounds and protonic acids for plasticizing and neutralizing acidic, protonated compositions comprising substituted and unsubstituted polyanilines and co-polymers and or mixtures thereof; and for reducing the percolation threshold for conductivity in blends with insulating bulk polymers.

Abstract: A nonwoven fabric made with multicomponent polymeric strands includes a blend of a polyolefin and ethylene alkyl acrylate in one side or the sheath of the multicomponent polymeric strands. The fabric has improved abrasion resistance, strength, toughness and softness properties. Composite materials including such multicomponent material bonded to both sides of an inner meltblown layer are also disclosed.

Abstract: A shaped reinforced thermoplastic composite, such as composite laminate (10 or 10A), comprises a thermoplastic matrix polymer (22) and a plurality of fibers (20) of a liquid crystal polymer (LCP) which are formed in situ in the matrix polymer. This composite is formed by forming a prepreg as a plurality of individual sheets or layers (50), each of which comprises essentially unidirectionally oriented fibers (20) of said LCP in a thermoplastic polymer matrix (22). A lay-up is formed by cutting each individual sheet or layer into pieces so that the direction of fiber orientation in each such piece is either parallel to one pair of edges or at angles of 45.degree. to all of the edges. The lay-up is shaped under heat and pressure to form the composite.

Abstract: An apparatus for spinning bicomponent sheath/core filaments having a distributor plate and spinnerette and a shim positioned between the distributor plate and spinnerette to effect a controlled pressure drop of the sheath polymer material. In particular, the distributor plate and spinnerette each have a plurality of spaced core polymer flow passages and sheath polymer passages wherein the respective core polymer flow passages are axially aligned and the respective sheath polymer flow passages are aligned. The shim is positioned between the spinnerette and distributor plate to control the sheath polymer flow from the outlet of the distributor sheath polymer flow passages to the inlet of each spinnerette core polymer flow passage separately. Producing sheath/core bicomponent fibers using this apparatus results in fibers having concentric sheath/core configurations and increased throughput.

Abstract: Process for the production of an elongate body of longitudinally aligned acicular crystals (3) of the superconducting substance REBa.sub.2 Cu.sub.3 O.sub.6.5+y, with RE=rare earth metal, 0<y<1, in which fine-grained powder (1) with a particle diameter of 0.1-5 .mu.m is sintered for 1-100 h at a temperature of 600.degree.-850.degree. C. with application of a pressure of 100-5,000 bar. For the production of a filament conductor, the powder is filled into a small Ag tube (4), drawn, and pressure sintered at 800.degree. C./10 h under 2,000 bar.

Abstract: Deep-dyeing conjugate filaments are melt-spun by merging molten sub-streams of incompatible polymers to form combined streams, then quenching the combined streams to form the conjugate filaments. The filaments are preferably cold drawn prior to winding, increasing the bulk level in a fabric containing the filaments and increasing the dye stability of the filaments. When the sub-streams are merged outside of the spinneret, the filaments split into the sub-filaments upon exposure to boiling water while under no tension. When the sub-streams merge within the spinneret, the filament is not readily split into sub-filaments, but forms a helically crimped filament.

Abstract: Self-reinforced polymer composites of about 97.5-5% by weight of poly(phenylene oxide) and about 2.5-95% by weight of a melt processable wholly aromatic polyester which exhibt anisotropic properties in the melt phase. This wholly aromatic polyester is a liquid crystal polymer, or LCP. The wholly aromatic polyester is in the form of predominantly unidirectionally oriented continuous fibers primarily in the range of about 1 to 10 micrometers in diameter, distributed in a matrix of poly(phenylene oxide). The polymer composites of this invention have high tensile strength, high modulus, satisfactory elongation, good impact strength, and good high temperature properties.

Abstract: Self-reinforced polymer composities of 60-5 percent by weight of an at least partially crystalline high performance thermoplastic polymer and 40-95 percent by weight of a melt processable wholly aromatic polyester which exhibit anisotropic properties in the melt phase. This wholly aromatic polyester is a liquid crystal polymer, or LCP. The high performance themoplastic polymer has a melting point of at least 200.degree.. Polyether etherketone is a preferred at least partially crystalline polymer. The wholly aromatic polyester is in the form of predominantly unidirectionally oriented continuous fibers primarily in the range of about 1 to 10 micrometers in diameter, distributed in a matrix of polyether etherketone. The polymer composites of this invnetion have high tensile strength, high modulus, satisfactory elongation, good impact strength, and good high temperature properties.

Abstract: Manufacture of a multifilament polyester yarn which is suitable for use as an industrial yarn, particularly tire yarn, and displays a specific breaking strength at high spinning speeds, the yarn is made in accordance with a process comprising the successive steps of spinning a molten polymer through a plurality of holes, cooling and drawing the resulting filaments, and finally collecting them, the polymer flow in each of the spinneret holes exhibits a core portion having a higher relative viscosity and a sheath portion having a lower relative viscosity, the difference between said relative viscosities amounting to less than 0.100, preferably 0.040-0.003.

Abstract: Blends of high molecular weight linear polyethylene and low molecular weight linear polyethylene provide improved fiber-forming capabilities over that found with either polymer taken alone. Preferably at least one of the polymers used in the blend is a linear low density polyethylene, LLDPE, which is a linear polyethylene comprising ethylene copolymerized with an amount of a higher alpha-olefin which causes the density of the copolymer to be less than that of a homopolymer made using the same process and catalyst. The higher alpha-olefin can be at least one in the C.sub.3 -C.sub.12 range, preferably in the C.sub.4 -C.sub.8 range.

Abstract: A continuous, bicomponent, non-vitreous ceramic fiber comprises components existing in a longitudinal side by side relationship wherein each of the components is derived from the different fiber-forming precursor liquid. The precursor liquids are formed into a fiber and gelled or hydrolyzed to provide a bicomponent non-refractory green fiber. Firing the bicomponent green fibers in a reducing atmosphere can provide ceramic/cermet or cermet/cermet fibers wherein each cermet component has a graded composition.

Abstract: Disclosed is a novel polyethylene synthetic pulp giving synthetic paper which may be heat-treated with a heating apparatus attached to a conventional papermaking machine. The polyethylene synthetic pulp comprises fibers of polyethylene which has an MFR (Melt Flow Ratio) of 0.1 to 3,000 g/10 min., and the portion with a low melting point thereof, which melts at a temperature of 95.degree. C. or lower when measured with a DSC (Differential Scanning Calorimeter), is at least 20% by weight, preferably, 40% to 70%.

Abstract: Two-component fibers, having surface area of at least 1 m.sup.2 /g, suited for replacing cellulose fibers in the manufacture of paper and paper-like products comprise a core of olefinic polymer and from 2 to 50% by weight of a sheath of a hydrophilic polymer, and exhibit values of the tenacity higher than 3,000 meters and cohesion higher than 300 meters. They are prepared by extruding a stable emulsion formed by a mixture of a solution of the olefinic polymer with a solution of the hydrophilic polymer in reciprocally immiscible solvents, at a temperature exceeding the boiling temperature of the solvent of the olefinic polymer and at least equal to the dissolution temperature of such polymer in such solvent, in a medium at a lower pressure, by using a volume ratio of solvent for the olefinic polymer to solvent for the hydrophilic polymer of at least 2.5 and concentrations of hydrophilic polymer in its solution of at least 2 g/l of solvent.

Abstract: The invention provides improved composite and conjugate filaments to be used exclusively in in-water submerged purposes. Each of these filaments consists of a core of vinylidene fluoride resin consisting in turn of one or more filamentary element(s), while a sheath consists of polyamide resin. The composing ratio as measured between the cross-sections of these both resins is defined by a value extending from 1/99-to 40/60, preferably from 3/97 to 30/70, still more preferably between 3/97 and 20/80.

Abstract: A synthetic filament and a yarn composed thereof wherein the filament comprises at least two different incompatible synthetic linear high polymers, one being distributed as islands in the sea of the other polymer element when seen in cross-section, each island being continuous along the axis of the filament and being characterized by their uniformity in cross-sectional dimension in any cross-section of the filament.

Abstract: An integrated string primarily for use in connection with athletic rackets, such as tennis, badminton, squash and the like, but also usable for fishing line, musical strings, etc., said string in one embodiment comprising a thermoplastic core having a thermoplastic sheath covering same and integrated thereto, said core material and said sheath comprising strands therein having substantially different melting points, and in a second embodiment said string consisting of a braided sheath, with no inner core, said sheath comprising thermoplastic strands having substantially different melting points.

Abstract: Heat-adhesive side-by-side type composite fibers consisting of a component composed mainly of a crystalline polypropylene and a component composed mainly of an olefin polymer, having few naturally developed crimps and few latent crimpability and superiority in undetachability of the composite components, are produced by using two composite components having a specified relationship of melt flow ratio and by stretching unstretched composite fibers at a specified temperature range.

Abstract: A spinning assembly for use in a process for the production of sheath/core bicomponent fibres comprising a spinneret plate having at least one counter-bore terminating in an extrusion orifice, a distributor plate spaced apart from but facing the spinneret plate to provide a liquid channel therebetween for communication with a source of sheath-forming material, the distributor plate being provided with an aperture opposite each orifice in the spinneret plate for communication with a source of core-forming material and a plateau-like protrusion on the distributor plate extending about the axis common to the aperture and the extrusion orifice characterised in that there is provided an orifice plate for restricting the entrance to the counter-bore.

Abstract: A porous non-woven fabric having a good dimensional stability and uniformity is prepared from a web obtained by arranging side-by-side composite fibers alone or a blend thereof with another fibrous material into a web and heat-treating the resulting web at a specified temperature, said composite fibers having few naturally developed crimps and being obtained by stretching unstretched side-by-side composite fibers consisting of a polypropylene component and an olefin polymer component having a specified melting point and a specified melt flow rate.

Abstract: The cold drawing of fibers spun from a melt blended mixture of nylon and certain linear thermoplastic polymers provides a soil resistant, soil hiding fiber that is particularly suitable for use in carpets.

Abstract: Multi-component mixed filament, wherein at least two spinning materials having poor affinity are mixed and dispersed in unitary filament in a nebular configuration containing at least 50 stars at least in one portion of the cross-section of the filament and the nebular configuration continues substantially in the longitudinal direction of the filament is manufactured by subjecting said spinning materials to at least eight times of "joining and dividing step in different phase" repeatedly to layer-multiply said spinning materials so as to form a nebular configuration in the cross-section of the resulting filament and then extruding the resulting mixture from orifice in a spinneret. In this manufacture, the preferable combinations of said two spinning materials having poor affinity are polyamide-polyester, polyamide-polyalkylne oxide, polyester-polyalkylene oxide and polyamide-polyolefin.

Abstract: A novel unitary spun polyester composite filament is provided. The composite filament consists essentially of (a) a block copolymer, as the first component, having a melting point of not lower than 170.degree.C and consisting essentially of 35-80 wt. % of a polyester, as the hard segment, predominantly containing a tetramethylene terephthalate unit and 20-65 wt. % of a long-chain glycol having a molecular weight of 500 to 5,000 as the soft segment, and (b) a polyester, as the second component, predominantly containing a tetramethylene terephthalate unit. The composite filament produces crimps superior particularly in percent of crimp and percent of crimp retentivity when drawn and relaxed.