Abstract: The present invention provides bond patterns for nonwoven fabrics and laminates thereof, and a process of producing the bond patterns. The bond patterns provides highly distinct and recognizable patterns without significantly reducing the physical properties of the nonwoven fabrics. The bond pattern comprises a series of unbonded regions in a geometric pattern of regularly bonded regions, and each unbonded region forms an unbonded area enclosed by the bonded regions surrounding the unbonded region, whereby the series of unbonded regions forms a visually recognizable pattern, wherein the bonded regions cover from about 3% to about 50% of the surface of the nonwoven web, and wherein each of the unbonded areas has a size equal to or less than about 0.3 cm.sup.2.

Abstract: Disclosed is an improved structure that includes a nonwoven web including a viscoelastant treatment. The treated web, when contacted by a viscoelastic fluid such as menses alters the viscoelastic properties of the fluid and enhances its wicking and distribution throughout the absorbent structure. A desirable viscoelastant is a alkyl polyglycoside, particularly those having 8 to 10 carbon atoms in the alkyl chain. When applied so as to provide an amount of about 0.1% to about 5.0% solids add-on based on the weight of the dry nonwoven web, rapid fluid wicking and distribution may be obtained. Other viscoelastants are disclosed. Advantageously the treatment may be applied as a high solids composition using conventional application means such as spray coaters and the like or as an internal additive. The absorbent structure finds particular utility as a distribution layer component of a sanitary napkin for absorbing menses as well as other blood handling products such as surgical drapes, for example.

Abstract: A stabilizing additive package for nonwoven fabrics is provided. The package has a bismuth vanadate based pigment and a hindered amine light stabilizer. The bismuth vanadate is added to a nonwoven fiber polymer prior to extrusion in an amount between about 0.1 and 3 weight percent based on the weight of the fabric and the hindered amine in an amount between about 0.25 and 2.5 weight percent based on the weight of the fabric. The nonwoven fabric also provided by this invention may be used as protective covers for, for example, boats and cars, and as an outdoor fabric for, for example, canopies and tents.

Abstract: The present invention is directed to cloth-like, liquid-impervious, breathable composite barrier fabrics. More particularly, the present invention is directed to cloth-like, liquid-impervious, breathable film-nonwoven composite fabrics having biological liquid barrier capabilities for use as, for example, sterilization wrap, surgical draping, surgical gowns, cover garments, such as over-suits, and the like.

Abstract: Disclosed is an improved composition and method for treating substrates such as nonwoven fabrics to impart durable properties such as wettability. The composition includes a viscosity modifier that provides reduced viscosity to normally viscous treating agents allowing them to be applied at room temperature without adversely affecting the desired properties of the treated substrate. Advantageously the treating composition includes an alkyl polyglycoside having 8 to 10 carbon atoms in the alkyl chain and a surfactant such as a blend of ethoxylated hydrogenated castor oil and sorbitan monooleate. Nonwovens treated in accordance with the invention with high solids treating compositions at room temperature have a durability of at least 2 cycles in accordance with the runoff test. The treating compositions of the invention are stable and adapted to many conventional treating systems. As little as 1 part in 20 of the addition of the alkyl polyglycoside is effective.

Abstract: A composite material adapted for mechanical fastener use as a loop fastener component with a complementary hook component is made by laminating a film with an amorphous polymer layer to a prebonded nonwoven web under conditions producing laminate bonds corresponding to the prebond locations, and loose filaments or fibers between the bonds. The composite also desirably has a MVTR of at least about 100 g/m.sup.2 /24 hours and a hydrohead of at least about 50 mbar. In use as a component of a disposable personal care product such as a disposable diaper, the loop fastener component may be substantially the entire backing, providing comfort, protection and highly variable fit.

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: There is provided a fully elastic, breathable, barrier fabric comprising a nonwoven web layer of fibers of less than 40 microns in average diameter, where the web has a hydrohead of at least 10 mbar, a Frazier Permeability of at least 100 CFM, a basis weight of less than 68 gsm and which is made from an elastic polymer. If the fabric is a laminate it may be an SMS, SBL or NBL laminate. This fabric is particularly well suited to use as a containment flap for personal care products such as diapers, incontinence products and feminine hygiene products and in infection control products.

Abstract: Improved equipment and method for spinning filaments for nonwovens using an integral spinbank including one or more spinplates producing filament bundles separated by one or more central conduits for quench air. Embodiments include high velocity quench air driven into the central conduit or quench air blown or drawn in from outside the filaments into the central conduit. Means may also be provided for removal of undesired waxes and/or other condensates through a central exhaust removal using the central conduit. As quench air velocity is increased through the central conduit, the streams tend to improve total quench flow by deflecting opposing flows into a uniform stream. Other variations include division of quench air into flow zones that may be independently controlled and varying the angle of quench air flow and/or the spinplates to maintain separation distance between quench air and filament bundles.

Abstract: Odor reduction for products such as disposable diapers and training pants, sanitary napkins and tampons, incontinent products, and medical dressings is obtained by the use of an internal additive for synthetic polymers or an external additive for natural polymers. Results are further enhanced by the use of a surfactant especially in the case of synthetic polymers. Webs, fibers and films find uses as components of the described products and are effective in absorbing odors such as ammonia, triethylamine, indole and skatole, for example, which are commonly found in body fluids like sweat, menses, urine and fecal matter.

Abstract: Reactor for containing high pressure, high temperature, corrosive reactions, especially supercritical water reactions. The reactor comprises an inner reactor vessel which houses the corrosive reaction, an outer containment vessel which contains a substantial level of the pressure, and insulating means to contain the high temperature of the inner reactor, which prevents the outer containment vessel from rising above a specified maximum temperature. Using this reactor, the lifetime and reliability of the materials of construction are increased because the outer pressure-containing vessel does not experience the high temperatures which tend to cause metals and alloys to lose ductility, and the inner reactor vessel does not experience a high pressure drop across its walls and, therefore, can be made of temperature and corrosive-resistant materials which are not required to sustain high stress without failure.

Abstract: The disclosed invention relates to split fibers and improved means and methods for obtaining them as well as their use in nonwovens and incorporation into personal care and other products. Multicomponent filaments are formed including at least two incompatible components. These filaments are drawn under hot aqueous, for example, steam, conditions causing them to split into fibers containing the incompatible components. These fibers are collected as a fine fiber nonwoven which finds utility as a component of sanitary napkins, diapers and other products.

Abstract: A method for forming a web structure having a pore size gradient which utilizes a spunbond process for producing fibers. The fibers are deposited on a contoured collection surface. Preferably, the surface is shaped as an elongated dome, having the central zone at the apex and the peripheral zones along the curved sides. The fibers are deposited onto the central zone and accumulate until they flow down the sides onto the peripheral zones. Fibers deposited onto the central zone have greater average pore size and fibers deposited onto the peripheral zone have smaller average pore size and greater fiber alignment. In an alternative embodiment, a plurality of dies in a row is used, each providing extruded fibers of distinct composition. Pore size gradient formation permits improved control of wicking and absorption over a web structure, such as a diaper or similar absorptive article. An alternative embodiment comprises providing a meltblown source of attenuated fibers, preferably co-formed with fluff.

Abstract: A breathing mask fabric is provided which has between 50 and 95 weight percent of a through-air bonded, electret treated, nonwoven microfiber first web of fibers where the fibers have an average diameter of between about 10 and 25 microns and where the first web has a Frazier Permeability above about 100 CFM/SF, a density of between about 0.015 and 0.15 gms/cc, and a basis weight between about 67 gsm and about 340 gsm, and between about 5 and 50 weight percent of an electret treated microfiber second web of fibers where the fibers have an average diameter of less than about 10 microns.

Abstract: Nonwoven fabrics having a desirable level of bulk, elasticity and low permanent set are produced by creasing a precursor web and heat setting the creases. Such webs may have varying basis weights and compositions depending on the intended end use. Applications disclosed include components for personal care products such as disposable diapers and feminine hygiene products, for example, as well as garment applications such as training pants, surgical gowns and the like. Also, absorbent products such as wipers are disclosed. Methods for forming the creased nonwoven fabric are disclosed using interdigitated rolls for creasing in the machine direction or in the cross-machine direction.

Abstract: The present invention provides a process for producing a three dimensionally texturized liquid resistant laminate having a fibrous nonwoven layer and a liquid resistant layer. The process has the steps of placing the fibrous layer and the liquid resistant layer in juxtaposition to form a laminate, attaching the fibrous layer and the liquid resistant layer at a plurality of spaced-apart bond locations, heating the bonded laminate to a temperature that activates the latent shrinkability of the liquid resistant layer, and allowing the heated laminate to retract such that the liquid resistant layer shrinks and said fibrous layer forms gathers between said bond locations, thereby forming a three dimensional texture and heat annealing the laminate. The invention additionally provides a three dimensionally texturized laminate having a fibrous layer and a nonelastic liquid resistant layer.

Abstract: A method of producing a fabric comprising producing fine denier fibers, using either meltblown or spunbond processes, or a combination of the two, followed by crimping, spotbonding using differential bond roll temperatures, and neck-stretching. Fiber having less than or equal to about 1.5 denier is preferred. The bond temperature differential is about 10.degree.-50.degree. F. The mat produced has the unexpected result of improved strength, conformability and reduced stiffness.

Abstract: Disclosed is an improved high sorbency nonwoven fabric and its use particularly as an oilsorb material. The high sorbency nonwoven is preferably made by multi-bank meltblowing and different perturbing thermoplastic fibers of, for example, propylene polymers in separate banks to provide a fiber density gradient through the thickness of the fabric. The sorbent nonwovens have high bulk and strength, oil capacity and oil absorption rates making them particularly suited to such applications. Treatments and additives for such materials are also disclosed.

Abstract: A method and apparatus for forming artificial fibers and a non-woven web therefrom includes means for generating a substantially continuous fluid stream along a primary axis, at least one extrusion die located adjacent to the continuous fluid stream for extruding a liquified resin into fibers, means for injecting the fibers into the primary fluid stream, and perturbation means for selectively perturbing the flow of fluid in the fluid stream by varying the fluid pressure on either side of the primary axis to produce crimped fibers for forming the non-woven web. The inventive manufacturing method finely tunes non-woven web material characteristics such as tensile strength, porosity, barrier properties, absorbance, and softness by varying the fluid stream perturbation frequency and amplitude. Finally, the inventive method and apparatus may be implemented in combination with melt-blown, spunbond and coform techniques for producing non-woven webs.

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.