Abstract: A filter material includes a filter pad made from a thin, nonwoven fiber mat which has been accordion-pleated, compressed into a unit having a large number of substantially parallel interconnected filter strips, and treated to retain the filter strips in substantially parallel relation to each other. In a preferred embodiment, activated carbon particles are operatively associated with the filter pad. Selected fibers of the nonwoven fiber material are hollow fibers, each having an outer surface, a hollow internal cavity, and an extended slot formed therein, between the hollow internal cavity and the outer fiber surface. Carbon particles may be located between selected filter strips, and additional carbon particles may be disposed within the cavities of the hollow fibers. Methods of forming the filter material, and a filter element made with the filter material are also disclosed.

Abstract: Compositions and methods are directed to a sheath core fiber with a core and a sheath that comprises a fluoropolymer. Contemplated sheath materials include PVDF, ECTFE, and ETFE, and may have an apparent shear viscosity equal to or less than the apparent shear viscosity of the core material. Especially contemplated sheaths have a weight of 30% or less of the weight of the fiber. Preferred fibers are spun in a spin pack having a sheath material conduit with a ratio of open volume to sheath material mass flow of less than 0.75 for a fiber with a 30 wt % sheath, of less than 1.15 for a fiber with a 20 wt % sheath, and of less than 2.

Abstract: A composite having a plurality of filaments arranged in a fibrous web that is held together in a unitary structure by a domain matrix. The domain matrix comprises a plurality of matrix islands that individually connect, or bond, at least two filaments, to thereby hold the filaments in a unitary structure. Portions of the filament lengths within the unitary structure are free of matrix islands, causing the domain matrix to be discontinuous. The composite possesses a greater flexibility than coated structures. The composite may be formed into cross-plied structures. A method of making the composite also is disclosed.

Abstract: The present invention is related to a multi-filament article comprising filaments having a substantially hexagonal cross-section and a method for making the same. The filaments are formed by spinning a melt or solution of a polymer through a capillary spinneret having an orifice with a centrally disposed, generally circular, center cavity portion with six side cavity portions projecting radially away from the center cavity portion.