Abstract: Provided are antimicrobial nonwovens comprising antimicrobial chemical treated fibers and untreated binder fibers. 0.0003-0.1 wt. % of one or more silver containing antimicrobial chemicals are used in nonwovens to provide an excellent antimicrobial/antiviral property. Exemplary applications and methods of manufacturing antimicrobial products such as a facial covering, a mattress cover, a surface cover and an air filter are provided.

Abstract: Footwear with vertically lapped nonwoven layers in upper and sole structures for enhanced breathability and moisture wicking is disclosed. Exemplary vertically lapped nonwoven dual layers comprise one or more hydrophobic layers and one or more hydrophilic layers that are adhered to each other by a plurality of methods and are further integrated into the inside of the upper and sole of the footwear so that the hydrophilic layer is in direct contact with the feet. The hydrophilic part of the dual layer wicks sweat or bodily fluid from the wearer into the nonwoven and transports the moisture to the hydrophobic layer for fast evaporation, thus keeping the feet dry. The nonwoven footwear is environmentally friendly as the nonwoven layers can be made of recycled materials and may be fully recyclable.

Abstract: A mobile product manufacturing demonstration, apparatus and method is intended to cut through the clutter and rise above the noise of typical marketing language and tactics, replacing the same with demonstrable, real-world demonstrations of how a producer is making a difference in terms of environmentally conscious manufacturing and good environmental stewardship. The mobile product manufacturing demonstration, apparatus and method includes a vehicle for transportation between rural townships and urban centers which itself is preferably battery powered, hydrogen powered, or powered by some other environmentally friendly mechanism. On board is a plurality of display stations which allow the public to interact with and/or manipulate materials used in the recycling and/or manufacturing process. Thus, the consumers will be able to see, hear, and feel (through touch and/or manipulation) how the products are made from recycled or recyclable materials.

Abstract: A thermoelectric device suitable for power generation by the Seebeck effect or heating and cooling by the Peltier effect includes a flexible thermoelectric layer with a flexible heatsink layer. A thermally conductive layer can optionally be included on the side of the thermoelectric layer opposite the flexible heatsink layer. Because of its flexibility and durability, the thermoelectric device can be utilized for products such as a thermoelectric generator or cooling/heating system for consumer products, such as a bedding, clothing, hats, seat cushions, and personal portable devices.

Abstract: A low weight portable air sampling device comprising a housing at least partially enclosing an inlet for receiving an air or breath sample; a removable liner coupled to the inlet containing sorbing materials; a micro-pump for regulating air flow within the device; and an outlet for emitting the air or breath sample from the device is described. The device may be used to collect Volatile Organic Compounds (VOCs) of both biotic and abiotic origin.

Abstract: Vertically lapped nonwoven material is used without cross lapped nonwoven to provide enhanced breathability and comfort in mattresses by replacing foam material in one or more of, including all of top panel quilts, layers underneath the top panel quilts, and in side blocks which surround spring supports. The vertically lapped nonwoven may provide advantages in terms of cost, manufacturing ease, robustness in mattress design, while at the same time providing the user with a much more comfortable sleeping experience.

Abstract: Nonwovens having low-density and resilience have a chemical formulation applied on one surface (e.g., a top surface) by any of various application methods. Then, the chemical formulation is forced to move toward the opposite surface of the nonwoven (e.g., move downward through the nonwoven from top to bottom). The chemical-treated nonwoven is dried to fix the chemical on the nonwovens. Movement through the nonwoven is performed in a controlled fashion so that after drying the distribution of a chemical formulation throughout the nonwoven (e.g., from the top surface to the bottom surface of a nonwoven) is controlled.

Abstract: A mobile molding system, comprising a vehicle and one or more molds arranged on the vehicle configured for receiving one or more expandable nonwoven substrates, heating said one or more expandable nonwoven substrates so as to cause said one or more expandable nonwoven substrates to expand and fill the one or more molds with one or more expanded nonwoven containing articles of three dimensional shape, and releasing said one or more expanded nonwoven containing articles of three dimensional shape from the one or more molds is provided. Methods for manufacturing three dimensional objects using the mobile molding system are also provided.

Abstract: Expandable substrates, which are referred to as blanks, are created by compressing thermobonded nonwovens after heating the binder material above its melting temperature, and then cooling the compressed nonwovens so that the binder material hardens and holds the fibers of the nonwoven together in a compressed configuration with stored kinetic energy. A mold for the component to be manufactured can be partially filled with a number of boards (or blanks) in a stacked, vertically, adjacent or even random orientation. Upon application of heat to the boards or blanks or parts in the mold, the binder material is melted so as to allow the nonwoven material to expand in one or more directions, and thereby fill all or part of the mold. Upon cooling, the binder material again hardens, and the molded component is retrieved from the mold.

Abstract: A low weight portable air sampling device comprising a housing at least partially enclosing an inlet for receiving an air or breath sample; a removable liner coupled to the inlet containing sorbing materials; a micro-pump for regulating air flow within the device; and an outlet for emitting the air or breath sample from the device is described. The device may be used to collect Volatile Organic Compounds (VOCs) of both biotic and abiotic origin.

Abstract: Provided herein is a new fire barrier material composed of flame retardant (FR) cellulosic fiber(s) and one or more of an antimicrobial (AM) cellulosic fiber and an untreated cellulosic fiber(s). The fire barrier material may be a fabric woven or knitted from the yarn containing the FR cellulosic fiber(s) and the one or more of AM cellulosic fibers and untreated cellulosic fibers. When AM cellulosic fibers are combined with FR treated cellulosic fibers, the fire barrier material has the dual features of flame retardancy and antimicrobial properties. The fire barrier material may also be a nonwoven, and in preferred embodiments optionally includes a binder fiber. The FR cellulosic fiber contains FR chemical(s) or FR compound(s) that have a melting point or decomposition temperature at 400° C. (752° F.) or below.

Abstract: Vertically lapped nonwoven material is used to provide enhanced breathability and comfort in mattresses by replacing foam material in one or more of, including all of top panel quilts, layers underneath the top panel quilts, and in side blocks which surround spring supports. The vertically lapped nonwoven may provide advantages in terms of cost, manufacturing ease, robustness in mattress design, while at the same time providing the user with a much more comfortable sleeping experience.

Abstract: A fibrous nonwoven material which is vertically lapped in its entirety or which includes one or more lapped regions which include vertically lapped fibers provides for padding to be applied to a substrate (e.g., an article of interest such as a handle for sporting equipment or tool, or on the inside of a motorcycle or bicycle helmet, etc.). The skin contacting surface of the nonwoven has regions which are relatively thicker than other regions, and air, sweat, and the like are allowed to easily pass through these regions for cooling, wicking of fluid and enhanced breathability. The lapped nonwoven includes a backing material which helps define the pad shape and which permits securing to a substrate. A hook and loop fastener may be affixed to the lapped nonwoven at the backing material so as to allow retrieval and replacement of the nonwoven on the substrate. An acquisition layer on the surface can be used on the surface of the nonwoven, and a carded consolidated web may be positioned within the nonwoven.

Abstract: A continuous process for the wet chemical treatment of fibers employs one or more squeezing/opening operations post chemical treatment to provide even chemical distribution on the fibers being processed. For squeezing the fiber batt impregnated with chemicals, one or more sets of squeeze rollers which include at least one roller with grooves are used to remove the liquid chemicals from the fiber batt efficiently. The squeezing operation can be coupled with the ability to collect and recycle chemicals for reuse in the chemical treatment process. The continuous process for the chemical treatment of fibers may employ the use of a blending box for the dried chemical-treated fibers in order to compensate for any uneven chemical distribution on fibers occurred during the chemical treatment process.

Abstract: Repeatable and reliable chemical treatment for loose fibers is achieved by spraying or immersing loose fibers in a chemical treatment bath, and continuously moving the soaked fibers through a continuous centrifuge. The continuous centrifuge controls the wet pickup of the chemical formulation on the fibers and assures a substantially even chemical distribution on the centrifuged fibers. The centrifuged fibers may be dried to fix the chemicals in the chemical formulation to the fibers and/or to remove water from the chemical formulation. Recycling of the chemical formulation from the continuous centrifuge allows for the process to be performed more economically and in a more environmentally friendly fashion.

Abstract: Provided herein is a new fire barrier nonwoven composed of flame retardant (FR) cellulosic fiber(s) and untreated cellulosic fiber(s) and optionally a binder fiber and methods of making the same, wherein the FR cellulosic fiber contains FR chemical(s) or FR compound(s) that have melting point or decomposition temperature at 400° C. (752° F.) or below. The FR performance of the new nonwoven provided herein is comparable to the conventional FR nonwoven (FR cellulosic fiber/binder fiber), but has advantages in cost effectiveness.

Abstract: Repeatable and reliable chemical treatment for loose fibers is achieved by spraying or immersing loose fibers in a chemical treatment bath, and continuously moving the soaked fibers through a continuous centrifuge. The continuous centrifuge controls the wet pickup of the chemical formulation on the fibers and assures a substantially even chemical distribution on the centrifuged fibers. The centrifuged fibers may be dried to fix the chemicals in the chemical formulation to the fibers and/or to remove water from the chemical formulation. Recycling of the chemical formulation from the continuous centrifuge allows for the process to be performed more economically and in a more environmentally friendly fashion.

Abstract: Provided herein is a new fire barrier material composed of flame retardant (FR) cellulosic fiber(s) and one or more of an antimicrobial (AM) cellulosic fiber and an untreated cellulosic fiber(s). The fire barrier material may be a fabric woven or knitted from the yarn containing the FR cellulosic fiber(s) and the one or more of AM cellulosic fibers and untreated cellulosic fibers. When AM cellulosic fibers are combined with FR treated cellulosic fibers, the fire barrier material has the dual features of flame retardancy and antimicrobial properties. The fire barrier material may also be a nonwoven, and in preferred embodiments optionally includes a binder fiber. The FR cellulosic fiber contains FR chemical(s) or FR compound(s) that have a melting point or decomposition temperature at 400° C. (752° F.) or below.

Abstract: Provided herein is a new fire barrier nonwoven composed of flame retardant (FR) cellulosic fiber(s) and untreated cellulosic fiber(s) and optionally a binder fiber and methods of making the same, wherein the FR cellulosic fiber contains FR chemical(s) or FR compound(s) that have melting point or decomposition temperature at 400° C. (752° F.) or below. The FR performance of the new nonwoven provided herein is comparable to the conventional FR nonwoven (FR cellulosic fiber/binder fiber), but has advantages in cost effectiveness.

Abstract: Repeatable and reliable chemical treatment for loose fibers is achieved by spraying or immersing loose fibers in a chemical treatment bath, and continuously moving the soaked fibers through a continuous centrifuge. The continuous centrifuge controls the wet pickup of the chemical formulation on the fibers and assures a substantially even chemical distribution on the centrifuged fibers. The centrifuged fibers may be dried to fix the chemicals in the chemical formulation to the fibers and/or to remove water from the chemical formulation. Recycling of the chemical formulation from the continuous centrifuge allows for the process to be performed more economically and in a more environmentally friendly fashion.