Abstract: A nonwoven fabric is provided having a plurality of semi-crystalline filaments that are thermally bonded to each other and are formed of the same polymer and exhibit substantially the same melting temperature. The fabric is produced by melt spinning an amorphous crystallizable polymer to form two components having different levels of crystallinity. During spinning, a first component of the polymer is exposed to conditions that result in stress-induced crystallization such that the first polymer component is in a semi-crystalline state and serves as the matrix or strength component of the fabric. The second polymer component is not subjected to stress induced crystallization and thus remains in a substantially amorphous state which bonds well at relatively low temperatures. In a bonding step, the fabric is heated to soften and fuse the binder component. Under these conditions, the binder component undergoes thermal crystallization so that in the final product, both polymer components are semi-crystalline.

Abstract: The present invention concerns a nonwoven fabric the fibers of which have polyethylene on at least part of their surface, where the fibers are thermally bonded and the non-woven fabric exhibits an abrasion of less than 0.5 mg/cm2, in particular of less than 0.4 mg/cm2, and an embossed area fraction of less than 35%, in particular of less than 28%. Furthermore a device is made available for the manufacture of a non-woven fabric, using a polyethylene-containing polymer, with a take-down system underneath a spinning plate that causes the take-down of the polyethylene, where the spinning plate has an L/D ratio of between 4 and 9.

Abstract: A moisture vapor permeable, water impermeable composite sheet material is provided which is suitable for use as a housewrap material, and is also useful for other applications such as tarpaulins, or as covers for automobile, boats, patio furniture or the like. The composite sheet material includes a nonwoven substrate and an extrusion-coated polyolefin film layer overlying one surface of the substrate. The nonwoven substrate is comprised of polymeric fibers randomly disposed and bonded to one another to form a high tenacity nonwoven web. The nonwoven substrate has a grab tensile strength of at least 178 Newtons (40 pounds) in at least one of the machine direction (MD) or the cross-machine direction (CD). The extrusion coated polyolefin film layer is intimately bonded to the nonwoven substrate. The film layer has micropores formed therein to impart to the composite sheet material a moisture vapor transmission rate (MVTR) of at least 35 g/m2/24 hr. at 50% relative humidity and 23° C.

Abstract: Disclosed herein are ground-reinforcing grids comprising a plurality of modular units, wherein each modular unit comprises: a plurality of cells, rib members connecting the cells together such that the cells are spaced apart from each other by the rib members, and connector means for connecting the modular units together, wherein the cells are configured to flex more than the rib members; wherein each modular unit has sufficient rigidity to enable the ground-reinforcing grid to provide ground reinforcement; and wherein each modular unit has sufficient flexibility provided by the flexing of the plurality of the cells to enable the ground-reinforcing grid to flex and accommodate loads without adversely affecting the rigidity of the ground-reinforcing grid.

Abstract: This disclosure relates to an article (e.g., a vapor-permeable, substantially water-impermeable multilayer article) that can include a nonwoven substrate and a film supported by the nonwoven substrate. The film can include a polyolefin grafted with an anhydride, an acid, or an acrylate.

Abstract: This disclosure relates to an article that includes a nonwoven substrate, a first film supported by the nonwoven substrate, and a second film such that the first film is between the nonwoven substrate and the second film. The first film includes a first polymer and a pore-forming filler. The difference between a surface energy of the first film and a surface energy of the nonwoven substrate is at most about 10 mN/m. The second film includes a second polymer capable of absorbing and desorbing moisture and providing a barrier to aqueous fluids.

Abstract: This disclosure relates to an article that includes a nonwoven substrate and a film supported by the nonwoven substrate. The film can include a first polymer and a polymer that is immiscible with the first polymer. The first polymer can include a polyolefin and the second polymer can include a polycycloolefin, a polymethylpentene, or a copolymer thereof.

Abstract: This disclosure relates to an article (e.g., a vapor-permeable, substantially water-impermeable multilayer article) that includes a nonwoven substrate and a film supported by the nonwoven substrate. The film includes a polyolefin, a nanoclay, and a pore-forming filler.

Abstract: Disclosed herein are methods of preparing a composite sheet material having strength and barrier properties suitable for use as a housewrap, the methods comprising extrusion coating a polyolefin film layer onto a surface of an area-bonded, spunbond nonwoven substrate to form a composite sheet material, the composite sheet material having a grab tensile strength of at least 178 Newtons in at least one of the machine direction (MD) or the cross-machine direction (CD), and stretching the composite sheet material to impart to the composite sheet material a hydrostatic head of at least 100 cm, and a moisture vapor transmission rate (MVTR) of at least 35 g/m2/24 hr at 50% relative humidity and 23° C.

Abstract: Disclosed herein are methods of preparing a composite sheet material having strength and barrier properties suitable for use as a housewrap, the methods comprising extrusion coating a polyolefin film layer onto a surface of an area-bonded, spunbond nonwoven substrate to form a composite sheet material, the composite sheet material having a grab tensile strength of at least 178 Newtons in at least one of the machine direction (MD) or the cross-machine direction (CD), and stretching the composite sheet material to impart to the composite sheet material a hydrostatic head of at least 100 cm, and a moisture vapor transmission rate (MVTR) of at least 35 g/m2/24 hr at 50% relative humidity and 23° C.

Abstract: The invention provides a roll assembly including a pair of cylindrical rolls that are positioned in an opposing cooperating relation for receiving a sheet material therebetween. A plurality of projections on at least one of the rolls extending radially outward from a surface thereof and a plurality of corresponding recesses is provided on the other roll. The projections and corresponding recesses are positioned and arranged on the rolls for contacting and engaging a sheet passing between the pair of rolls. The projections each include an outermost surface portion that is positioned for contacting a discrete portion of the sheet and for entering a corresponding recess on the opposite roll. When rolls rotate about their axes, the projections engage the discrete portion of the sheet material which results in the discrete portion entering the recesses with the projections so as to stretch the sheet in multiple directions.

Abstract: A moisture vapor permeable, water impermeable composite sheet material is provided which is suitable for use as a housewrap material, and is also useful for other applications such as tarpaulins, or as covers for automobile, boats, patio furniture or the like. The composite sheet material includes a nonwoven substrate and an extrusion-coated polyolefin film layer overlying one surface of the substrate. The nonwoven substrate is comprised of polymeric fibers randomly disposed and bonded to one another to form a high tenacity nonwoven web. The nonwoven substrate has a grab tensile strength of at least 178 Newtons (40 pounds) in at least one of the machine direction (MD) or the cross-machine direction (CD). The extrusion coated polyolefin film layer is intimately bonded to the nonwoven substrate. The film layer has micropores formed therein to impart to the composite sheet material a moisture vapor transmission rate (MVTR) of at least 35 g/m2/24 hr. at 50% relative humidity and 23° C.

Abstract: The present invention provides a composite sheet material (10) that is particularly useful as an underlayment material in roofing applications. In particular, the present invention provides a composite sheet material (10) that is flexible, relatively lightweight, resistant to water as well as being water vapor permeable and resistant to tearing. In addition, the composite sheet material (10) includes an outer non-skid surface (18) that can help prevent slippage of workers during installation of the roofing system. Embodiments of the composite sheet material can help provide a roofing\structure, such as a shingled roof, with fire resistance so that the roof can meet the Fire Resistance requirements of ASTM E 108-07a, Class A.

Abstract: Disclosed is a spunbonded non-woven made of polyolefin filaments having a titer <1.6 dtex, the spunbonded non-woven having a surface weight ?20 g/m2, a density ?0.06 g/cm3, a maximum tensile force of between 9.5 and 62 N in the direction of the machine and of between 4.5 and 35 N perpendicular to the direction of the machine.

Abstract: The present invention relates to the production of a non-woven material having high extensibility and comprising polymer fibers using mixtures with amphiphilic block copolymers as compatibilizers for preparing blends, as well as their production and use.

Abstract: The present invention relates to the perforation of nonwovens with a perforating roll and an opposing roll. The perforating roll and opposing roll form a gap, through which a nonwoven being perforated, is guided and perforated. The perforation apparatus comprises a feed device and a withdrawal device. The feed device is arranged such that the nonwoven being perforated advances first onto the opposing roll, before it enters the gap. The withdrawal device is arranged such that after leaving the gap, the perforated nonwoven remains on the perforating roll. Furthermore, a perforation method and a corresponding nonwoven structure are provided.

Abstract: The invention relates to polyolefin materials, in particular fibers, and/or filaments, and/or nonwovens, and/or nonwoven products made from at least one polyolefin and a melt additive containing a fatty acid ester, wherein a subsequent activation of the fatty acid ester contained in the melt additive occurs on the surface of the polyolefin materials by applying a formulation, which contains a silicone compound and a quaternary ammonium compound.

Abstract: A spunbond nonwoven fabric useful as a topsheet is produced from polypropylene filaments including a high level of reclaimed polypropylene, while maintaining a product quality, including superior formation, comparable to that obtained when using 100 percent virgin polymer. The spunbond nonwoven fabric is made with multicomponent filaments having at least two different polymer components occupying different areas within the filament cross section, and wherein one of the polymer components comprises reclaimed polypropylene recovered from previously spun polypropylene fiber or webs comprised of previously spun polypropylene fiber. In a specific embodiment, the filaments are sheath-core bicomponent filaments and the reclaimed polypropylene is present in the core component. The core of the bicomponent filament can be comprised of up to 100% reclaimed polypropylene.

Abstract: A nonwoven fabric is provided having a plurality of semi-crystalline filaments that are thermally bonded to each other and are formed of the same polymer and exhibit substantially the same melting temperature. The fabric is produced by melt spinning an amorphous crystallizable polymer to form two components having different levels of crystallinity. During spinning, a first component of the polymer is exposed to conditions that result in stress-induced crystallization such that the first polymer component is in a semi-crystalline state and serves as the matrix or strength component of the fabric. The second polymer component is not subjected to stress induced crystallization and thus remains in a substantially amorphous state which bonds well at relatively low temperatures. In a bonding step, the fabric is heated to soften and fuse the binder component. Under these conditions, the binder component undergoes thermal crystallization so that in the final product, both polymer components are semi-crystalline.

Abstract: The present invention provides an impact resistant sheet material that helps provide exterior walls of a building with resistance to impacts so that the building structure can meet building standards, such as the Miami-Dade County Large Missile Impact Test, for resisting impacts in high wind areas. In one embodiment, sheet material comprises an impact resistant layer that attached to fibrous substrate. The impact resistant layer provides impact resistance to the sheet material so that a wall structure employing the sheet material is able to successfully withstand an impact from a projectile comprising a 9 pound, 7 foot two-by-four (“2×4”) traveling at a speed of at least 34 miles per hour. The impact resistant sheet material may comprise a moisture vapor permeable, water-impermeable barrier layer having a hydrohead of at least 55 cm and a moisture vapor transmission rate of at least 35 g/m2/day. Such a sheet material is particularly useful in barrier applications, such as a house wrap.