Abstract: A nonwoven fabric comprises continuous polymer filaments of 0.5 to 3 denier that have been hydroentangled in a complex matrix for interconnecting filament loops, and that is otherwise substantially free of knotting, or of otherwise wrapping about one another. A process for making a nonwoven fabric comprises continuously extruding polymer filaments of 0.5 to 3 denier onto a moving support, pre-entangling the filaments with water jets, and entangling the filaments with a second set of water jets on a three-dimensional image transfer device. An apparatus for making a nonwoven fabric comprises means for continuously extruding substantially endless polymer filaments of 0.5 to 3 denier onto a moving support to form an unbonded web, a pre-entangling station for entangling the web with a plurality of water jets, and a plurality of water jets for final entanglement of the filament web on a three-dimensional image transfer device.

Abstract: The present invention is directed to a filter media comprised of an electro-conductive scrim so as to improve on the dissipation time of an electrostatic charge. Further, the present invention is directed to a method of making such a filter media, which is formed through hydroentanglement, thus avoiding the deleterious effects of mechanical needling, while providing a filter media having the requisite strength characteristics, without possessing a limiting factor in performance. The filtration media of the present invention also demonstrates a highly desirable uniformity for cost-effective use.

Abstract: The present invention is directed to a process for producing continuous filament nonwoven fabric which comprises the steps of providing a single polymeric resin having an MFR of between about 6 to 16, spinning said single polymeric resin using commercially available continuous filament spinning equipment, to yield a continuous filament nonwoven fabric exhibiting a tensile strength improvement of at least 30% when compared to similar resin of greater than 35 MFR.

Abstract: A method of forming flame-retardant nonwoven fabrics by hydroentanglement includes providing a precursor web. The precursor web is subjected to hydroentanglement on a three-dimensional image transfer device to create a patterned and imaged fabric. Treatment with a flame-retardant binder enhances the integrity of the fabric, permitting the nonwoven to exhibit desired physical characteristics, including strength, durability, softness, and drapeability. The treated nonwoven may then be dyed by means applicable to conventional wovens.

Abstract: The present invention relates to a dual performance cleaning article, wherein said cleaning article is comprised of a first abrasive meltblown surface that facilitates the process of loosening particulates, such as dust and dirt, and an opposing second soft, air permeable surface, which is capable of absorbing and/or picking up particulates and liquids. The meltblown layer comprises coarse discontinuous filamentary elements, formed from adjusting the variable commonly utilized in the traditional meltblown method.

Abstract: It is the objective of the present invention to disclose a method of continuously dyeing durable nonwoven fabrics, and more specifically, nonwoven fabrics comprising a cellulosic fibrous material dyed with indigo dyestuffs. It is in accordance with the present invention, to utilize synthetic fibers in combination with natural or cellulosic fibers in the formation of a nonwoven web. The natural fibers, preferably cotton, make up at least 10% of the fibrous nonwoven fabric.

Abstract: The present invention provides an irradiated crosslinked polyethylene containing reduced free radicals, preferably containing substantially no residual free radical. Disclosed is a process of making irradiated crosslinked polyethylene by irradiating the polyethylene in contact with a sensitizing environment at an elevated temperature that is below the melting point, in order to reduce the concentration of residual free radicals to an undetectable level. A process of making irradiated crosslinked polyethylene composition having reduced free radical content, preferably containing substantially no residual free radicals, by mechanically deforming the polyethylene at a temperature that is below the melting point of the polyethylene, optionally in a sensitizing environment, is also disclosed herein.

Abstract: A nonwoven fabric comprises continuous polymer filaments of 0.5 to 3 denier that have been hydroentangled in a complex matrix for interconnecting filament loops, and that is otherwise substantially free of knotting, or of otherwise wrapping about one another. A process for making a nonwoven fabric comprises continuously extruding polymer filaments of 0.5 to 3 denier onto a moving support, pre-entangling the filaments with water jets, and entangling the filaments with a second set of water jets on a three-dimensional image transfer device. An apparatus for making a nonwoven fabric comprises means for continuously extruding substantially endless polymer filaments of 0.5 to 3 denier onto a moving support to form an unbonded web, a pre-entangling station for entangling the web with a plurality of water jets, and a plurality of water jets for final entanglement of the filament web on a three-dimensional image transfer device.

Abstract: The present invention contemplates a method of forming a textile laminate or composite fabric from a plurality of woven fabric layers, with the method contemplating use of a three-dimensional image transfer device to facilitate efficient and commercially viable use of the method. Herein is disclosed a method of forming an imaged textile laminate or composite compound fabric, the fabric having a first textile fabric layer comprising a plurality of interwoven warp and weft yarns and at least one other textile fabric layer, the lamination of the fabric layers and imaging of the construct occurring on a three-dimensional image transfer device. The image transfer device has a foraminous, image-forming surface comprising a regular pattern of three-dimensional surface elements.

Abstract: The method generally comprises the steps of providing a hydroentangled non-woven layer having a first binder component, and depositing a second non-woven layer having a high bulk and loft on to the hydroentangled layer to form an unbonded composite fabric. The second layer also has a binder component with a melting temperature substantially equal to the first binder melting temperature.

Abstract: The present invention relates to a conveyor apparatus, and more specifically to a conveyor apparatus that is capable of accepting a web of material having little to no inherent structural integrity from a first direction, inverting the material, and dispatching said material in a second direction. A conveyor apparatus for handling and inverting a web of material in accordance with the present invention comprises a receiving conveyor having an upper run for receiving the web of material after inversion. The present apparatus further includes an inversion conveyor having first and second legs arranged at an angle to each other, with the second leg of the conversion conveyor being positioned above the upper run of the receiving conveyor.

Abstract: The present invention provides a system and a method for reducing pores, or air pockets, that form at the interface between the material used to attach or adhere the surface of a component, such as a prosthesis, to a site. A preferred embodiment of the invention includes an actuator that controls a coupler which transmits energy to a prosthesis being inserted into a material to reduce porosity at an interface between the prosthesis and the material. The system of the present invention can include an oscillating hand-held device that vibrates the stem component of an orthopedic prosthesis at a particular frequency and amplitude. The device is typically held by the hand of the surgeon, who guides the vibrating prosthesis into the cement-filled medullary cavity.

Abstract: The present invention is directed to a nonwoven fabric, and more specifically to a nonwoven fabric comprised of at least one foreground region and at least one background region, wherein the foreground region of the fabric is an extension of the background region of the fabric in the z-direction and imparted with an enhanced physical and/or aesthetic performance which is dissimilar to a performance that may be imparted within the background region. The foreground region is further characterized in that such region may extend away from the background region so that a continuous or discontinuous path is described. Further still, the foreground and background regions may be of similar or dissimilar basis weights.

Abstract: A protective layer embodying the principles of the present invention is configured for protection of automotive surfaces, including specifically, the protection of a truck-bed against wear induced by a truck-bed liner. The protective layer has a substantially planar configuration sized to permit the layer to be positioned generally between an associated truck-bed liner and a truck-bed, whereby the abrasion is significantly reduced. The layer comprises a fibrous nonwoven fabric formed from fibrous and/or filamentary elements, with the fibrous nonwoven fabric exhibiting a sufficiently reduced coefficient of friction and sufficient durability to absorb or distribute abrasive actions, while allowing passage of moisture, thus protecting the automotive surfaces against potentially detrimental environmental conditions.