Abstract: A system having a first polymer source and a spin beam in fluid communication with the first polymer source is provided. The spin beam includes a spinneret assembly having filament nozzles configured and arranged to extrude a plurality of filaments of a first polymer. A gas distribution plate is disposed downstream of the spinneret assembly, and includes a plurality of gas distribution slots that are configured and arranged to receive two or more corresponding filament nozzles of the spinneret assembly therein. A stream of gas is introduced into the plurality of slots to draw and attenuate the filaments extruded by the plurality of filament nozzles. The drawn and attenuated filaments are collected on a collection surface disposed downstream of the gas distribution plate to form a nonwoven fabric. A solid additive, such as pulp fibers may be blended with the filaments prior to collecting the filaments on the collection surface.

Abstract: Hydroxyl polymer fiber fibrous structures and processes for making same are provided. More particularly, hydroxyl polymer fiber fibrous structures comprising a non-naturally occurring hydroxyl polymer fiber wherein the fibrous structure exhibits a total pore volume of pores in the range of greater than 20 ?m to 500 ?m of greater than 3.75 mm3/mg of dry fibrous structure mass, and/or fibrous structures comprising a hydroxyl polymer fiber and a solid additive are provided.

Abstract: Provided are a mixed-fiber nonwoven fabric suitable for air filters and a filter medium using the mixed-fiber nonwoven fabric. The nonwoven fabric includes at least two types of fibers having different melting points, which fibers are low melting point fibers made of a polyolefin resin component A, and high melting point fibers made of a high melting point resin component B having a higher melting point than that of the polyolefin resin component A. The number average fiber diameter of the high melting point fibers is larger than that of the low melting point fibers. At least one high melting point fiber having a fiber diameter of 20 ?m to 100 ?m is present per 1.00 mm of the length of the cross section of the nonwoven fabric. The number average fiber diameter of all fibers constituting the nonwoven fabric falls within the range of 0.3 ?m to 10 ?m.

Abstract: An absorbent fiber web has a base layer of cellulose fibers and an external layer that is connected at least across areas thereof with the base layer. The external layer is a nonwoven of nano fibers. The base layer and the nonwoven are connected to one another across areas thereof without a binder.

Abstract: A lightweight mat material having excellent sound absorption and thermal insulation properties comprises a mixture of glass fibers and sheath-core composite fibers, wherein the melting temperature of the sheath portion is lower than the melting temperature of the core portion. The glass fibers are fused with the sheath portions of the composite fibers by melting on at least one surface of the sheet-shaped mat material.

Abstract: An article is provided that comprises fibers, as is a method of forming the article. The fibers comprise an organopolysiloxane component selected from (i) an organopolysiloxane having the formula (R3SiOi/2)w(R2Si?2/2)x(RSi?3/2)y(Si?4/2)z (I), wherein each R is selected from the group of an inorganic group, an organic group, and combinations thereof, w is from 0 to 0.95, x is from 0 to 0.95, y is from 0 to 1, z is from 0 to 0.9, and w+x+y+z=1, and (ii) a cured product of said organopolysiloxane having the formula (I), and combinations of (i) and (ii), provided that the fibers are free from organic polymers, organic copolymers, and organosiloxane-organic copolymers. The method of forming the article includes the step of forming fibers from a composition. The composition used to form the fibers comprises the organopolysiloxane having the formula (I), provided that the composition is free from organic polymers, all-organic copolymers, and organosiloxane-organic copolymers.

Abstract: A nonwoven fibrous web comprising a matrix of continuous meltspun fibers bonded to a coherent self-sustaining form, and separately prepared microfibers dispersed among the meltspun fibers. The microfibers may have median diameters less than one or two micrometers. A method for preparing such a nonwoven fibrous web comprises establishing a stream of continuous oriented meltspun fibers having a longitudinal axis, establishing a stream of meltblown microfibers that exit a meltblowing die at a point near the stream of meltspun fibers, the meltblown stream being aimed to merge with the meltspun stream and having a longitudinal axis that forms an angle of between 0 and 90 degrees to the longitudinal axis of the meltspun stream, capturing the meltblown fibers in the stream of meltspun fibers, and collecting the merged stream as a web on a collector spaced near the intersection point of the meltspun and meltblown streams.

Abstract: An apparatus and method in which the apparatus includes a first electrospinning device configured to electrospin first fibers of a first substance, a second electrospinning device configured to electrospin second fibers of a second substance such that first and second fibers combine in a mat formation region, and a biasing device configured to bias the first electrospinning device with a first electric polarity and to bias the second electrospinning device with a second electric polarity of opposite polarity to the first electric polarity to promote attraction and coalescence between the first and second fibers. The method electrospins under the first electric polarity first fibers from the first substance, electrospins under the second electric polarity fibers from the second substance, and coalesces the first and second fibers to form the fiber mat.

Abstract: Disclosed is a battery separator consisting essentially of a nonwoven fabric having a substantially unilayered structure, wherein an apparent total surface area of fibers per a surface density of the nonwoven fabric is 20 m2 or more, a thickness of the nonwoven fabric is 0.1 mm or less, a uniformity index of the nonwoven fabric is 0.15 or less, and the nonwoven fabric contains fine fibers having a fiber diameter of 4 ?m or less.

Abstract: Nonwoven fibrous webs including amorphous polymeric fibers with improved and/or more convenient bondability are disclosed. The nonwoven fibrous webs may include only amorphous polymeric fibers or they may include additional components in addition to amorphous polymeric fibers. The amorphous polymeric fibers within the web may be autogeneously bonded or autogeneously bondable. The amorphous polymeric fibers may be characterized as varying in morphology over the length of continuous fibers so as to provide longitudinal segments that differ from one another in softening characteristics during a selected bonding operation.

Abstract: A cleaning device (2) for in-situ cleaning of metal strings (50) on a stringed musical instrument comprising a manually bendable, resilient laminate having a first planar portion and end portion extending out of the plane of the first portion, the laminate comprising a layer of plastics material (4) sandwiched between two layers (6,8) of a plastics micro-fibre fabric. The device (2) allows the metal strings (50) of, for example, a guitar (52) to be readily cleaned in-situ while on the instrument to maintain the brightness of tone of the string. A method of manufacturing the device is also disclosed.

Abstract: A shrink wrap material for protecting articles includes at least one non-woven fabric and a woven scrim defining apertures. A sufficient portion of the fibers from the non-woven fabric being forced into the apertures of the scrim such that the scrim reinforces and supports the non-woven fabric, thus increasing their strength. A shrinkable, stretchable film is intermittently bonded to at least one non-woven fabric. The material is used by placing the material around the article to be protected and then shrinking the film.

Abstract: The gas adsorption sheet of the present invention has a granular activated carbon-containing sheet comprising a granular activated carbon having an average particle diameter of 60 to 600 &mgr;m, a supporting fiber for fixing the granular activated carbon in contact with it, and an adhesive fiber which mainly contributes to shape retention. An air-purifying filter of the present invention is obtained by forming the gas adsorption sheet into a shape of pleats or wave. A method for producing a gas adsorption sheet of the present invention comprises a step of forming a granular activated carbon-containing sheet by using an aqueous slurry containing a granular activated carbon, a supporting fiber and a water-swelling adhesive fiber.

Abstract: The present invention provides multicomponent fine fiber webs and multilayer laminates thereof having an average fiber diameter less than about 7 micrometers and comprising a first olefin polymer component and a second distinct polymer component such as an amorphous polyolefin or polyamide. Multilayer laminates incorporating the fine multicomponent fiber webs are also provided such as, for example, spunbond/meltblown/spunbond laminates or spunbond/meltblown/meltblown/spunbond laminates. The fine multicomponent fiber webs and laminates thereof provide laminates having excellent softness, peel strength and/or controlled permeability.

Abstract: An integrated nonwoven laminate material suitable for use as a filter medium having a microfiber layer integrated with a low loft multicomponent spunbond layer and a high loft multicomponent spunbond layer and a method of producing the integrated nonwoven laminate material. In one embodiment of this invention, a laminate material is through-air bonded to form an integrated nonwoven laminate material which is then electret treated to enhance attraction between particles being filtered and the fibers of the integrated nonwoven laminate material. In one embodiment of this invention, the integrated nonwoven laminate material is used as a filter having an ASHRAE Standard 52.1-1992 Dust Spot Efficiency of about 40% to about 95% and an ASHRAE Standard 52.2-1999 MERV (Minimum Efficiency Reporting Value) of 12 to 16.

Abstract: The present invention provides nonwoven fabrics formed of hollow filaments and/or hollow staple fibers and processes for producing the same. The hollow spunbonded filaments and hollow staple fibers are formed of a polypropylene composition. The resultant fabrics of the invention can be useful in numerous applications, such as components of medical garments and disposable absorbent products.

Abstract: Adhesive materials and articles containing adhesive materials are disclosed. Adhesive articles include adhesive fibers, adhesive films, an adhesive layer of fibers, adhesive nonwoven webs, and articles containing one or more of the adhesive materials. Stretched adhesive materials are also disclosed. Methods of making and using the adhesive materials and articles are also disclosed.

Abstract: The invention relates to a sound absorbing material, made from a microfilament nonwoven fabric having a mass per unit area of 40 to 300 g/m2, in which a nonwoven fabric is made from melt-spun, drawn, multi-component endless filament having a titer of 1.5 to 5 dtex and directly laid down to form a fibrous web; and the multi-component endless filaments, optionally after prebonding, are split at least to 80% to form micro-endless filaments having a titer of 0.1 to 1.2 dtex and bonded.

Abstract: A cleaning cloth having a nonwoven structure for wet, damp and/or dry cleaning, the cleaning cloth being made from micro staple fibers of at least two different polymers and from absorbent secondary staple fibers bound into the micro staple fibers and securely retained therein.

Abstract: A nonwoven laminate material for mechanical closure systems, method for its production, and its use. The multi-layer nonwoven fabric laminate material has at least one layer of a polyolefin endless filament nonwoven fabric having a maximum tensile strength in the machine running direction that is at least as great as crosswise to that direction, and made up essentially of fibers having a titer of less than 4.5 dtex, as well as a second layer of a nonwoven fabric that is bonded to the first layer, which includes a sheet of crimped staple fibers made of polyolefins, and whose crimped fibers are coarser than the fibers of the nonwoven fabric of the first layer. The at least two nonwoven fabric layers are bonded to one another at the common interface by bonding in the form of a pre-determined pattern. With this laminate, it is possible to produce diapers that are also suitable for adult incontinence patients, which have a mechanical closure system, e.g., a Velcro™ closure.

Abstract: A unique isotropic sub-denier spunbond nonwoven product created by an apparatus and method comprising a unique multi-head resin metering system, a spinneret head with spinning sections, separated by a quench fluid extraction zone, a two sided, multilevel quench system, a fluid volume control infuser system which automatically guides the filaments into the filament drawing system while conserving energy by using a portion of the quench fluid as part of the drawing fluid and also minimizing turbulence at the entrance to the draw slot. The filament drawing system comprises a draw jet assembly with adjustable primary and secondary jet-nozzles and a variable width draw jet-slot. The entire draw jet assembly is moveable vertically for filament optimization. The offset, constant flow secondary jet-nozzle system provides an unexpectedly high velocity increment to the filaments by oscillating the filaments and increasing their drag resulting in remarkably low fiber denier on the order of 0.5 to 1.2.

Abstract: Bonded fluff structures and a method for producing such bonded fluff structures in which a pulp sheet having a material suitable for producing fluff and a heat activatable fiber material is fiberized to produce a mixture of fluff and heat activatable fibers. The mixture is contacted with a hot air stream, heating the heat activatable fibers to an activation temperature. The resulting heated mixture is then deposited onto a forming structure, forming a bonded fluff/fiber composite matrix structure.

Abstract: Fibrous sorbent media or pads are formed from non-woven mats of thermoplastic fibers, preferably polypropylene fibers, having a mean diameter between about 0.5 microns and about 25 microns. The mats have a weight between about 2 ounces/yd2 and about 25 ounces/yd2; a thickness of at least {fraction (1/20)} of an inch; an oil absorbency ratio of at least 5 to 1 or a water absorbency ratio of at least 5 to 1. The sorbent media have first and second major surfaces with abrasion resistant, liquid permeable, integral skins and fibrous cores. The liquid permeable skins of the media are formed by melting fibers at and immediately adjacent the major surfaces of the mats to form thermoplastic melt layers which are subsequently solidified into the skins on the major surfaces of the mats. For many applications, the thermoplastic fibers of the mats are point bonded together at spaced apart locations to increase the integrity of the mats.

Abstract: The present invention provides nonwoven fabrics formed of hollow filaments and/or hollow staple fibers and processes for producing the same. The hollow spunbonded filaments and hollow staple fibers are formed of a polypropylene composition. The resultant fabrics of the invention can be useful in numerous applications, such as components of medical garments and disposable absorbent products.

Abstract: A fibrous insulation media is formed from a non-woven mat of thermoplastic fibers having a mean diameter of less than about 15 microns. Preferably, when used as an acoustical insulation, the media is formed of fibers having a mean diameter of less than about 13 microns; the media has a density of less than about 60 Kg/m3; and the media has a Fraiser air permeability of less than 75 cubic feet per minute per square foot of surface area. The media has first and second major surfaces and a fibrous core with at least one of the major surfaces having an integral skin thereon. The skin is formed by melting fibers at and immediately adjacent the major surface of the mat formed into the media to form a thermoplastic melt layer which is subsequently solidified into a skin on the major surface of the mat. The thermoplastic fibers of the mat are point bonded together at spaced apart locations to increase the integrity of the mat.

Abstract: The present invention relates to a nonwoven fabric exhibiting dense, delicate, high quality appearance, and also relates to man made leathers exhibiting dense, delicate, high quality appearance, and bearing a resemblance to high quality natural leathers.

Abstract: Nonwoven webs are fabricated by forming unitary multicomponent fibers comprising a plurality of individual segments partially exposed at the surface of the fiber; bonding the multicomponent fibers, such as by thermal point bonding, and then hydroentangling the bonded multicomponent fibers with a water pressure from about 400 to 3000 psi wherein the entangling process separates the individual segments of the unitary multicomponent fibers into microfibers and also entangles the fibers to form an integrated nonwoven web. The nonwoven webs include entangled webs of thermoplastic multicomponent fibers and microfibers having partially degraded bond areas comprising from about 5% to about 50% at the surface area of the web.

Abstract: A low trauma pressure-sensitive adhesive coated substrate comprising a sheet material, tape or laminate structure designed to adhere to skin or like surfaces. The pressure-sensitive adhesive layer of this adhesive coated substrate is a fibrous adhesive layer generally having a basis weight of from 5 to 200 g/m2 applied to a conformable backing or substrate. The fibrous adhesive layer has a textured outer face and persistent porosity between discrete adhesive fibers. Generally, the fibrous adhesive layer has a MVTR (measured by ASTM E 96-80 at 40° C.) of at least 1000 g/m2/day, preferably at least 6000 g/m2/day.

Abstract: Disclosed are head bands comprising a sliver of spontaneously wettable staple fibers. The fibers are of an irregular, grooved shape in cross section and are lightly bound together to permit easy separation into suitable lengths for head bands.

Abstract: A lining for interior comprises a first layer composed of fibers of higher melting point, which are bound by a thermoplastic resin of lower melting point. A second layer is placed on the first layer, which is constructed of a thermoplastic resin of lower melting point. A third layer is placed on the second layer. The third layer is composed of fibers of higher melting point which are bound by a thermoplastic resin of lower melting point. A fourth layer is placed on the third layer, which is constructed of a thermoplastic resin of lower melting point. A fifth layer is placed on the fourth layer, which is constructed of an skin member having higher melting point. The first and third layers are bonded to each other through the second layer and the third and fifth layers are bonded to each other through the fourth layer.

Abstract: Oriented microfibers and processes for making them are disclosed, together with blends of such microfibers with other fibers such as crimped staple fibers and non-oriented microfibers.

Abstract: A nonwoven fabric which is particularly useful as a liquid transport layer in an absorbent product. The fabric is formed of a mixture of fibers of varying sizes and polymer compositions, selected to provide the desired liquid transport properties to the fabric, and thermally bonded by calendering to form a coherent fabric structure.

Abstract: A water-dispersible coformed fibrous nonwoven fabric structure comprising a primary reinforcing polymer material, preferably capable of being meltspun; a secondary reinforcing polymer material having an average fiber length less than or equal to about 15 mm and preferably having a softening point at least about 30.degree. C. lower than the softening point of the primary reinforcing polymer; and, an absorbent material, such as pulp or a superabsorbent. The fabric structure maintains desired tensile strength and softness while being water-dispersible and flushable. The fabric produced can be incorporated into an article and can be flushed down a commode. The fabric is flushable when placed in water, with agitation, if necessary, and will disperse into unrecognizable pieces without clogging conventional plumbing or piping.

Abstract: Disclosed herein is a fibrous nonwoven composite structure more commonly referred to as a coform structure. Unlike current coform structures, the material of the present invention is more water-dispersible due to the use of a water-degradable reinforcing fiber matrix.

Abstract: The present invention relates to a cleaning implement formed from spunbond fiber webs having a basis weight less than about 85 grams per square meter and wherein the fibers comprise macrofibers having an average fiber diameter greater than 50 microns and less than about 500 microns. A section of macrofiber web having a mass between about 10 and 30 grams is bundled into a deformable three-dimensional shape which is about 8 to 25 cm in at least one dimension. The cleaning implement is particularly well suited for use in conjunction with shower gels or soaps for washing the body.

Abstract: 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.

Abstract: There is disclosed a thermally bonded spunbond web of thermoplastic filaments and a nonwoven fabric laminate comprising an internal layer of meltblown thermoplastic microfibers sandwiched between two layers of spunbond thermoplastic filaments. The spunbond web and the spunbond layers of the fabric laminate consist of thermoplastic filaments which are formed from a mixture of a thermoplastic polymer and an effective amount of a nucleating agent. The layers are bonded by thermal spot bonding. In the preferred embodiment, the thermoplastic polymer is polypropylene with a melt-flow rate of at 230.degree. C. of or greater than 12 grams per ten minutes. Also in the preferred embodiment, the nucleating agent constitutes from about 0.1 to 0.3 percent by weight of the mixture of polypropylene and nucleating agent.

Abstract: The present invention provides a splittable conjugate fiber containing at least two incompatible polymers that are arranged in distinct segments across the cross-section of the fiber, wherein the segments are continuous along the length of the fiber. The fiber can be characterized in that the segments of the fiber dissociate in less than about 30 seconds when contacted with a hot aqueous fibrillation-inducing medium. The invention also provides a fabric containing the split fibers produced from the precursor splittable conjugate fiber and laminates containing the split fiber fabric. Additionally provided is a process for producing the split fibers.

Abstract: Disclosed are fibrous structures comprised of shaped fibers wherein the thickness of the compressed fibrous structure at 1.00 psi is .gtoreq.1.3 times that of a similar compressed structure having the same area density and made from round cross section fibers of the same dpf as the shaped fibers. The invention is useful in articles such as coats, gloves, boats, shoes, etc. made using the structures disclosed herein. The surprising feature of structures according to the present invention is the thickness retention at high pressures. This retained thickness under pressure translates directly into decreased heat transfer or improved insulation.

Abstract: The present invention provides a lofty nonwoven web containing pneumatically drawn filaments, wherein the web has a density from about 0.01 g/cc to about 0.075 g/cc and the microfilaments have a weight-per-unit length between about 0.1 dtex and about 1.5 dtex. The invention also provides a process for producing the lofty nonwoven web.

Abstract: A shaped nonwoven fabric comprises continuous spunbond filaments made by directly forming the spunbond filaments into a web in a single process. The fabric has an array of discrete surface features such as apertures or projections, or both. The spunbond filaments are bonded together with an adhesive polymeric component so that the shape of the fabric is retained. The fabric can be engineered to have particular fluid handling properties, strength properties, abrasive properties and aesthetic properties. Articles such as personal care products, garments, medical products and cleaning products are also disclosed.

Abstract: There is provided an abrasion resistant, oil absorbing fabric comprising at least one layer of fine microfibers having an average diameter of at least 10 samples of between about 1 and 7 microns bonded with at least one layer of coarse microfibers having an average diameter of at least 10 samples of between about 8 and 23 microns wherein said fabric has a basis weight between about 190 and 407 gsm and has not been secondarily bonded, except, if desired, the fabric may be pin bonded. Such a fabric has been found to be well suited to use as an oil absorbent floor mat. It has further been found that such a fabric has sufficient integrity to withstand wringing out in order to reclaim absorbed fluids.