Patents Assigned to BBA Nonwoven Simpsonville, Inc.
  • Patent number: 6448194
    Abstract: Nonwoven fabrics and fabric laminates are formed from continuous filaments or staple fibers of a select blend of specific grades of polyethylene and polypropylene which give improved fabric performance not heretofore recognized or described, such as high abrasion resistance, good tensile properties, excellent softness and the like. Furthermore, these blends have excellent melt spinning and processing properties which permit efficiently producing nonwoven fabrics at high productivity levels. The polymers are present as a lower-melting dominant continuous phase and at least one higher-melting noncontinuous phase dispersed therein The lower-melting continuous phase forms at least 70 percent by weight of the fiber and comprises a linear low density polyethylene polymer of a melt index of greater than 10 and a density of less than 0.945 g/cc. At least one higher-melting noncontinuous phase comprises a polypropylene polymer with melt flow rate of greater than 20 g/10 min.
    Type: Grant
    Filed: January 31, 2001
    Date of Patent: September 10, 2002
    Assignee: BBA Nonwovens Simpsonville, Inc.
    Inventors: Scott L. Gessner, J. Darrell Gillespie, Jared A. Austin, David D. Newkirk, William Fowells
  • Patent number: 6420285
    Abstract: The present invention provides multicomponent fibers arranged in structured domains. At least one of the polymer components is formed of a multipolymer blend. The present invention also provides nonwoven fabrics formed of the multicomponent fibers, the fabrics having a superior combination of extensibility, tensile properties and abrasion resistance. A second layer can be laminated to this coherent extensible nonwoven web.
    Type: Grant
    Filed: December 30, 1999
    Date of Patent: July 16, 2002
    Assignee: BBA Nonwovens Simpsonville, Inc.
    Inventors: David D. Newkirk, Harold Edward Thomas, David Bruce Christopher, Barry DeWayne Meece
  • Patent number: 6417122
    Abstract: The present invention provides multicomponent fibers arranged in structured domains. At least one of the polymer components is formed of a multipolymer blend. The present invention also provides nonwoven fabrics formed of the multicomponent fibers, the fabrics having a superior combination of extensibility, tensile properties and abrasion resistance. A second layer can be laminated to this coherent extensible nonwoven web.
    Type: Grant
    Filed: December 30, 1999
    Date of Patent: July 9, 2002
    Assignee: BBA Nonwovens Simpsonville, Inc.
    Inventors: David D. Newkirk, Harold Edward Thomas, David Bruce Christopher, Barry DeWayne Meece
  • Patent number: 6417121
    Abstract: The present invention provides multicomponent fibers arranged in structured domains. At least one of the polymer components is formed of a multipolymer blend. The present invention also provides nonwoven fabrics formed of the multicomponent fibers, the fabrics having a superior combination of extensibility, tensile properties and abrasion resistance. A second layer can be laminated to this coherent extensible nonwoven web.
    Type: Grant
    Filed: December 30, 1999
    Date of Patent: July 9, 2002
    Assignee: BBA Nonwovens Simpsonville, Inc.
    Inventors: David D. Newkirk, Harold Edward Thomas, David Bruce Christopher, Barry DeWayne Meece
  • Publication number: 20020063364
    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.
    Type: Application
    Filed: August 2, 2001
    Publication date: May 30, 2002
    Applicant: BBA Nonwovens Simpsonville, Inc.
    Inventors: Thomas B. Taylor, Robert C. Alexander
  • Patent number: 6350332
    Abstract: A composite nonwoven fabric is provided for use as a one-piece topsheet and barrier fabric for disposable absorbent articles including diapers, catamenial products, and adult incontinence products. The fabric is engineered to have a strikethrough region that is normally surfactant treated for receiving insults and transporting them to an absorbent core material for storage. The strikethrough region is bounded by liquid barrier regions that are suitable for defining containment structures, including diaper leg cuff. The barrier and strikethrough regions can be designed to have excellent low rewet characteristics and to have balanced properties comparable to or better than conventional spunbonded topsheet at comparable or lower basis weights.
    Type: Grant
    Filed: January 13, 2000
    Date of Patent: February 26, 2002
    Assignee: BBA Nonwovens Simpsonville, Inc.
    Inventors: Harold Edward Thomas, James O. Reeder
  • Publication number: 20020022424
    Abstract: A nonwoven web of multipolymer fibers is described that is unidirectionally stretched and permanently elongated at ambient conditions and exhibits a substantial increase in tensile strength in the stretch direction. The ratio of tensile strength of the web in the direction of fiber orientation to the tensile strength in the other direction is at least about 10:1. The ratio of elongation at peak load in a direction transverse to the direction of fiber orientation is at least about 6:1. The multipolymer fibers normally are a blend of polyethylene and a polypropylene homopolymer or copolymer, one of which is a dominant phase and one of which is a dispersed phase. A third component having elastomeric properties that is at least partially miscible with one or both of the other components is included in some blends.
    Type: Application
    Filed: September 6, 2001
    Publication date: February 21, 2002
    Applicant: BBA Nonwovens Simpsonville, Inc.
    Inventors: Barry DeWayne Meece, Thomas Edward Quantrille
  • Patent number: 6309987
    Abstract: A nonwoven fabric with UV stability and flame retardancy having at least one fabric layer. The fabric layer is made of a base resin, preferably polyolefinic, and a non-halogenated melt processable compound that is selected from the group consisting of N-alkyoxy amines and are combined into a homogeneous blend which is then either spunbonded or meltblown to form the fabric layer. A melt processable fluorochemical additive may also be combined into the homogeneous blend to provide liquid barrier properties to the fabric layer.
    Type: Grant
    Filed: April 19, 1999
    Date of Patent: October 30, 2001
    Assignee: BBA Nonwovens Simpsonville, Inc.
    Inventor: Ramesh Srinivasan
  • Publication number: 20010008965
    Abstract: Nonwoven webs in accordance with the present invention include multicomponent fibers bonded by a multiplicity of bond sites to form a coherent web. The multicomponent fibers include a first component formed of a hydrophobic polypropylene and a second component formed of a blend of a hydrophobic polyolefin and a hydrophilic melt additive. This second component is disposed at the surface of the fibers. The hydrophilic melt additive-modified polyolefin component can be arranged in various configurations in the cross-section of the fiber and the fibers can have various cross sections. For example, the hydrophilic component can occupy a portion of the surface of the fiber, as would occur for example with a side-by-side or segmented pie multicomponent fiber configuration. Alternatively, the modified hydrophilic polyolefin can occupy substantially the entire surface of fiber, as for example by producing the fibers in a sheath core configuration with the hydrophilic modified component forming the sheath.
    Type: Application
    Filed: November 29, 2000
    Publication date: July 19, 2001
    Applicant: BBA Nonwovens Simpsonville, Inc.
    Inventors: Larry L. Kinn, Gregory Neil Henning, Clement J. Haley
  • Publication number: 20010005662
    Abstract: Nonwoven fabrics and fabric laminates are formed from continuous filaments or staple fibers of a select blend of specific grades of polyethylene and polypropylene which give improved fabric performance not heretofore recognized or described, such as high abrasion resistance, good tensile properties, excellent softness and the like. Furthermore, these blends have excellent melt spinning and processing properties which permit efficiently producing nonwoven fabrics at high productivity levels. The polymers are present as a lower-melting dominant continuous phase and at least one higher-melting noncontinuous phase dispersed therein. The lower-melting continuous phase forms at least 70 percent by weight of the fiber and comprises a linear low density polyethylene polymer of a melt index of greater than 10 and a density of less than 0.945 g/cc. At least one higher-melting noncontinuous phase comprises a polypropylene polymer with melt flow rate of greater than 20 g/10 min.
    Type: Application
    Filed: January 31, 2001
    Publication date: June 28, 2001
    Applicant: BBA Nonwovens Simpsonville. Inc.
    Inventors: Scott L. Gessner, Darrell Gillespie, Jared A. Austin, David D. Newkirk, William Fowells
  • Publication number: 20010004574
    Abstract: Nonwoven fabrics and fabric laminates are formed from continuous filaments or staple fibers of a select blend of specific grades of polyethylene and polypropylene which give improved fabric performance not heretofore recognized or described, such as high abrasion resistance, good tensile properties, excellent softness and the like. Furthermore, these blends have excellent melt spinning and processing properties which permit efficiently producing nonwoven fabrics at high productivity levels. The polymers are present as a lower-melting dominant continuous phase and at least one higher-melting noncontinuous phase dispersed therein. The lower-melting continuous phase forms at least 70 percent by weight of the fiber and comprises a linear low density polyethylene polymer of a melt index of greater than 10 and a density of less than 0.945 g/cc. At least one higher-melting noncontinuous phase comprises a polypropylene polymer with melt flow rate of greater than 20 g/10 min.
    Type: Application
    Filed: January 31, 2001
    Publication date: June 21, 2001
    Applicant: BBA Nonwovens Simpsonville, Inc.
    Inventors: Scott L. Gessner, J. Darrell Gillespie, Jared A. Austin, David D. Newkirk, William Fowells
  • Patent number: 6225243
    Abstract: A bonded web of multi-component strands that include a first polymeric component and a second polymeric component is capable of overcoming a number of problems associated with nonwoven webs including both stickiness and blocking. The first polymeric component and second polymeric components are arranged in substantially distinct zones extending longitudinally along at least a portion of a length of the strands which make up the web with the second component containing a zone constituting at least a portion of the peripheral surface of the strand. Moreover, the first polymeric component has an elasticity which is greater than that of the second polymer component. A process producing elastomeric spunbonded nonwoven fabrics which utilizes air in attenuating and/or drawing of strands is also provided.
    Type: Grant
    Filed: August 3, 1998
    Date of Patent: May 1, 2001
    Assignee: BBA Nonwovens Simpsonville, Inc.
    Inventor: Jared A. Austin
  • Patent number: 6207602
    Abstract: Nonwoven fabrics and fabric laminates are formed from continuous filaments or staple fibers of a select blend of specific grades of polyethylene and polypropylene which give improved fabric performance not heretofore recognized or described, such as high abrasion resistance, good tensile properties, excellent softness and the like. Furthermore, these blends have excellent melt spinning and processing properties which permit efficiently producing nonwoven fabrics at high productivity levels. The polymers are present as a lower-melting dominant continuous phase and at least one higher-melting noncontinuous phase dispersed therein. The lower-melting continuous phase forms at least 70 percent by weight of the fiber and comprises a linear low density polyethylene polymer of a melt index of greater than 10 and a density of less than 0.945 g/cc. At least one higher-melting noncontinuous phase comprises a polypropylene polymer with melt flow rate of greater than 20 g/10 min.
    Type: Grant
    Filed: March 12, 1997
    Date of Patent: March 27, 2001
    Assignee: BBA Nonwovens Simpsonville, Inc.
    Inventors: Scott L. Gessner, J. Darrell Gillespie, Jared A. Austin, David D. Newkirk, William Fowells
  • Patent number: 6174826
    Abstract: A nonwoven composite web suitable for use, after post-treatment with a wetting agent, as a battery separator is formed by a wet process on a papermaking machine. One nonwoven composite material is made from a furnish of polyolefin binder fibers and polyolefin staple fibers. The web coming off the papermaking machine is dried using infra-red dryers followed by heated dryer cans. After drying, the web is thermally bonded using heated calendar rolls. The polyolefin binder fibers melt as the web passes through the calendar rolls and thermally bond the polyolefin staple fibers of the web when the melted binder fiber material fuses upon cooling.
    Type: Grant
    Filed: April 11, 1997
    Date of Patent: January 16, 2001
    Assignee: BBA Nonwovens Simpsonville, Inc.
    Inventors: Richard C. Williams, James A. Goettmann, Gerald L. Funk, Linda M. Gee
  • Patent number: 6156680
    Abstract: A nonwoven composite web is formed by a wet process on a papermaking machine. The web coming off the papermaking machine is dried and thermally bonded using heated calendar rolls. The nonwoven composite material is made from a furnish of polymeric staple fibers, a first binder fiber consisting, at least in part, of a first thermoplastic binder material which melts at a first melting temperature less than and a second binder fiber consisting, at least in part, of a second polymeric material which has second melting temperature which is higher than the first melting temperature. The first polymeric material is selected to have a first melting temperature less than the temperature to which the first material will be subjected in the papermaking machine. The melted first polymeric material gives the web strength on the papermaking machine. The second polymeric material is selected to have a second melting temperature less than the temperature to which the second material will be subjected in the calendar rolls.
    Type: Grant
    Filed: December 23, 1998
    Date of Patent: December 5, 2000
    Assignee: BBA Nonwovens Simpsonville, Inc.
    Inventor: James A. Goettmann
  • Patent number: 6150020
    Abstract: The specification discloses polymeric articles such as fibers and fibrous webs which exhibit improved hydrophobicity and methods for making the articles. The articles comprise a polymer selected from the group consisting of polyolefins and polyesters and an additive of the structure R.sup.1 --A--Si(R.sup.2 R.sup.3)--O--(Si(R.sup.4 R.sup.5)--O)n--Si--(R.sup.6 R.sup.7)--A--R.sup.8, wherein R.sup.1 and R.sup.8 are selected from the group consisting of alkyl, aryl, alkylaryl groups and acyl and arylacyl derivatives of an aliphatic or aliphatic/aromatic mono-acid with a molecular weight of from about 250 to about 600 daltons, A is selected from the group consisting of --O--, --NH--C(O)--NH--(CH.sub.2).sub.3 --, and --C(O)--NH--(CH.sub.2).sub.3 --, R.sup.2, R.sup.3, R.sup.6 and R.sup.7 are selected from the group consisting of CH.sub.3, C.sub.2 H.sub.5, C.sub.3 H.sub.7, and C.sub.4 H.sub.9, R.sup.4 and R.sup.5 are selected from the group consisting of CH.sub.3, C.sub.2 H.sub.5, C.sub.3 H.sub.7, and (CH.sub.2).sub.
    Type: Grant
    Filed: September 29, 1998
    Date of Patent: November 21, 2000
    Assignee: BBA Nonwovens Simpsonville, Inc.
    Inventors: Rahul K. Dharmadhikary, W. Andrew Coslett, Eric S. Gardiner
  • Patent number: 6139941
    Abstract: A zone-treated spunbonded/meltblown/spunbonded (SMS) fabric laminate that combines the separate functions of the topsheet and cuff in one component of an absorbent article. The SMS fabric laminate is treated with surfactant to form a hydrophilic zone. The untreated areas of the SMS fabric laminate remain hydrophobic and perform the function of the cuff. Alternatively, a spunbonded/spunbonded fabric laminate is formed and then zone-treated with surfactant. The fabric laminate is treated with surfactant on both sides using a foam applicator. The application of foam produces sharp transitions between the hydrophilic and hydrophobic zones. After foam application, the fabric laminate is dried and slitted. The treated and slitted material is then wound and sold in roll form for converting into the finished disposable diaper.
    Type: Grant
    Filed: December 23, 1998
    Date of Patent: October 31, 2000
    Assignee: BBA Nonwovens Simpsonville, Inc.
    Inventors: Juris Jankevics, Glenn Roberts
  • Patent number: 6120864
    Abstract: A transfer roll cover has an inner surface made of conductive and elastic material to fit snugly around and make conductive contact with a transfer roll, and an outer surface made of looped yarns which are attached to the inner surface and have outer looped ends which make light rolling contact with a sheet transported over the transfer roll. The looped yarns are a composite of a cleaning yarn for cleaning particulate contaminants and an antistatic yarn for removing static charges from the transported sheet. In a preferred embodiment, the transfer roll cover has an inner surface made of nylon knitted yarn as a base yarn that holds the cover together and a LYCRA.TM. inlayed yarn which has an elasticity that allows the cover to stretch over and fit snugly onto the transfer roll. As an alternative, a heat-shrinkable polyvinyl acetate (PVA) yarn may be used as the elastic material. The preferred outer surface includes rayon knitted yarn with looped outer ends as the cleaning yarn, and BEKINTEX.TM.
    Type: Grant
    Filed: February 17, 1998
    Date of Patent: September 19, 2000
    Assignee: BBA Nonwovens Simpsonville, Inc.
    Inventors: Robert A. Chiricosta, Thomas W. Harris, Stephen P. Major, Jeremy M. Oakhill, Douglas J. Pate, Artis Clifford Bufford
  • Patent number: 6075682
    Abstract: A nonwoven media wiping material is provided by a thermal point bonding process which comprises the steps of combining a carded web of predominantly textile-length thermoplastic fibers having a higher melting temperature and a polymeric sheet having a lower melting temperature, and applying heat and pressure to the combination of film and fiber layers through thermal calendering. The polymeric sheet melts and becomes bonded to the carded fibers in discrete points to provide a soft and lofty outer media contacting finish.
    Type: Grant
    Filed: July 8, 1998
    Date of Patent: June 13, 2000
    Assignee: BBA Nonwovens Simpsonville, Inc.
    Inventor: Jon A. Howey
  • Patent number: 6065591
    Abstract: A non-resealable package for wet wipes has a base layer and a flexible top layer which overlays a stack of wet wipes and is sealed to the base layer, and a slit is formed in the flexible top layer along one side of the stacked lateral edges of the stack near a topmost-lying one of the wipes. The top layer is made of a selected flexible material and the slit is positioned and cut with a selected length such that opposing slit ends of the flexible top layer can be pushed apart by a user with fingers of one hand while keeping evaporation of solvent or fluid to a low level. In one version, the slit is simply cut through the top layer and closed with a membrane and adhesive-coated covering for shipping and storage. In another version, a reinforcing layer of greater thickness or stiffness is adhered to the top layer around the slit so that the slit edges tend to resume their initial positions and realign to minimize the open area of the slit when the user's fingers are withdrawn.
    Type: Grant
    Filed: December 19, 1997
    Date of Patent: May 23, 2000
    Assignee: BBA Nonwovens Simpsonville, Inc.
    Inventors: Kevin Dill, Deborah L. Elsea