Abstract: A composite sheet comprising two or more layers is described where the degree of abrasiveness of can be controlled. The sheet can comprise partially or wholly biodegradable or compostable materials or blends thereof. Methods of preparing the composite sheets are also described.

Abstract: The disclosure relates to a pleatable nonwoven fabric including greater than 50% by weight of a majority polymer component, based on total weight of the fabric, and a minority polymer component, wherein there is a difference of at least 10° C. in melting point between the majority polymer component and the minority polymer component, and wherein the fabric is arranged in layers with a first layer, a second layer, and a mid-layer positioned between the first layer and the second layer, and wherein the top layer and the bottom layer comprise a plurality of bicomponent fibers comprising both the majority polymer component and the minority polymer component; and wherein the mid-layer comprises monocomponent fibers constructed from either the majority polymer component or the minority polymer component. A method of making the pleatable nonwoven fabric is also provided.

Abstract: The disclosure relates to a mask including a perforated exterior shell sized to cover the nose and mouth of a user and constructed of one or more fabric layers, and a removable multi-layer nonwoven fabric insert sized to cover the nose and mouth of a user and adapted for abutting contact with the exterior shell, the nonwoven fabric including a layer of a spunbond material and a layer of meltblown material adjacent to the layer of spunbond material.

Abstract: The present invention is directed toward a method of making a composite structure including receiving a substantially planar nonwoven spunbond layer including a plurality of multicomponent fibers, thermally bonding the nonwoven spunbond layer at a first bond temperature, laying down a meltblown layer on top of the thermally bonded nonwoven spunbond layer to form an intermediate structure, and thermally bonding the intermediate structure at a second bond temperature to form a final composite structure. Composite structures including a spunbond layer and a meltblown layer, wherein the composite structure has a tensile strength of at least about 130 N/2.54 cm in both machine and cross directions, a tear strength of at least 3.0 N/2.54 cm, and an LRV of about 2.0 or higher are also provided herein.

Abstract: The subject matter disclosed herein relates generally to microdenier fabrics comprising fibrillated bicomponent fibers. The bicomponent fibers can be fibrillated mechanically by hydroentangling, where the hydroentangling energy is sufficient for fibrillating as well as entangling or bonding the fibers. The bicomponent fibers can have an island-in-the-sea configuration. The micro-denier fabrics can be woven, knitted, or nonwoven. A nonwoven fabric made from the bicomponent fibers can be formed by either spunbonding or through the use of bicomponent staple fibers formed into a web by any one of several means and bonded similarly to those used for the spunbonded filament webs.

Abstract: A bimorph meta fiber is formed through spinning of two antagonistic polymer melts, one of which contains pre-compounded optical nanostructures, into an eccentric sheath-core configuration or a side-by-side key-lock configuration. The bimorph meta fiber is capable of an adaptive regulation of the infrared radiation responsive to humidity level deviation from a comfort zone or perspiration level of the wearer of the garment fabricated from the meta fibers. The bimorph meta fibers are humidity/heat trained to attain dynamical environmentally responsive behavior to maintain the humidity/thermal comfort zone at various the humidity level fluctuations.

Abstract: A non-shedding hybrid nonwoven web comprised of 99% by mass of functional material(s) co-mingled with the filaments. High level of particle retention within the fabric is provided without the aid of adhesives, binders, adhesive polymers, or post processes. This composite web has a multi-layered structure with a uniform distribution of sorptive particles and desired opposed color contrast on each side. The process includes providing two converging streams of blown polymeric filaments, passive feed of functional material(s) in between the filament streams, and collecting the hybrid webs.

Abstract: Method of producing fibers comprises forming a blend of a liquid additive and a poly-alpha-olefin (PAO) fluid. The method also includes adding the blend to a polymer to form a composition. The method further includes melting the composition within an extruder. The method furthermore includes spinning fiber, through the extruder, from the composition.

Abstract: Composites where nonwoven fabrics having multicomponent synthetic fibers with adhered particles thereon are disclosed. The multicomponent fibers have at least one polymer component with a melting point below that of the other components, and the average apparent particle diameter is less than the average apparent fiber diameter. Methods of making the disclosed composites are also disclosed.

Abstract: The invention provides polymer-grafted and functionalized nonwoven membranes adapted for use in bioseparation processes, the membranes including a nonwoven web of polyester fibers having an average fiber diameter of less than about 1.5 microns, each of the plurality of polyester fibers having grafted thereon a plurality of polymer segments constructed of a methacrylate polymer, each polymer segment carrying a functional group adapted for binding to a target molecule. The invention also provides a method of bioseparation comprising passing a solution comprising the target molecule, such as a protein, through the nonwoven membrane of the invention such that at least a portion of the target molecule in the solution binds to the nonwoven membrane. A method for preparing a polymer-grafted and functionalized nonwoven membrane adapted for use in bioseparation processes is also provided.

Abstract: Disclosed are methods of partially or fully fibrillating bicomponent filaments of the island-in-the-sea configuration by hydroentangling. The hydroentangling energy can both fibrillate the sea component as well as entangling the sea and island components for bonding. Fabrics that are made from these at least partially fibrillated and bonded fibers are also disclosed. These fabrics have low pressure drop and high efficiency and can be used for filters and masks.

Abstract: A melt blowing system for the manufacturing of pleatable/moldable nonwoven fabrics includes a collector positioned to receive a plurality of fibers, a first die in fluid communication with a first liquid polymer supply having a melt flow index of about 500 or lower, and a second die in fluid communication with a second liquid polymer supply having a melt flow index of about 500 or higher. The first die has a concentric air design, includes a plurality of spinneret nozzles facing the collector surface, and is configured to draw a first plurality of fibers. The second die includes a plurality of spinneret nozzles having smaller capillary diameter than those of the first die and is positioned to draw a second plurality of fibers such that the first and second pluralities of fibers form a co-mingled nonwoven web with varying fiber diameters on the collector surface.

Abstract: A composite sheet comprising two or more layers is described where the degree of abrasiveness of can be controlled. The sheet can comprise partially or wholly biodegradable or compostable materials or blends thereof. Methods of preparing the composite sheets are also described.

Abstract: The present invention is directed toward a method of making a composite structure including receiving a substantially planar nonwoven spunbond layer including a plurality of multicomponent fibers, thermally bonding the nonwoven spunbond layer at a first bond temperature, laying down a meltblown layer on top of the thermally bonded nonwoven spunbond layer to form an intermediate structure, and thermally bonding the intermediate structure at a second bond temperature to form a final composite structure. Composite structures including a spunbond layer and a meltblown layer, wherein the composite structure has a tensile strength of at least about 130 N/2.54 cm in both machine and cross directions, a tear strength of at least 3.0 N/2.54 cm, and an LRV of about 2.0 or higher are also provided herein.

Abstract: The present disclosure provides a depth filter medium comprising at least one elastomeric nonwoven web strengthened by combination with one or more structural support layers. The resulting material is particularly useful in the field of filtration, wherein particulates captured within the elastomeric nonwoven web can be readily released, such as by applying pressure to the web through backwashing. The elastomeric nonwoven web advantageously can stretch under such pressure and return substantially to its original structure and shape upon the removal of the pressure, rendering the filter available for reuse.

Abstract: The present disclosure provides a depth filter medium comprising at least one elastomeric nonwoven web strengthened by combination with one or more structural support layers. The resulting material is particularly useful in the field of filtration, wherein particulates captured within the elastomeric nonwoven web can be readily released, such as by applying pressure to the web through backwashing. The elastomeric nonwoven web advantageously can stretch under such pressure and return substantially to its original structure and shape upon the removal of the pressure, rendering the filter available for reuse.

Abstract: Methods and apparatuses for printing a three-dimensional fibrous structure are disclosed. A fibrous layer is printed onto a printing surface by forcing fibers through at least one extrusion die and onto the printing surface. The extrusion die and/or printing surface are moved in the X, Y, and/or Z direction while printing the fibers.

Abstract: The invention provides polymer-grafted and functionalized nonwoven membranes adapted for use in bioseparation processes, the membranes including a nonwoven web of polyester fibers having an average fiber diameter of less than about 1.5 microns, each of the plurality of polyester fibers having grafted thereon a plurality of polymer segments constructed of a methacrylate polymer, each polymer segment carrying a functional group adapted for binding to a target molecule. The invention also provides a method of bioseparation comprising passing a solution comprising the target molecule, such as a protein, through the nonwoven membrane of the invention such that at least a portion of the target molecule in the solution binds to the nonwoven membrane. A method for preparing a polymer-grafted and functionalized nonwoven membrane adapted for use in bioseparation processes is also provided.

Abstract: Substantially compostable nonwoven fabrics comprising staple fibers made from natural cellulosic fibers optionally mixed with other natural, man-made or synthetic fibers are described. Also described are methods of preparing such nonwoven fabrics that can include the steps of at least one of needle punching and/or hydroentangling and optionally resin bonding and/or thermal bonding. The compostable, or substantially compostable nonwoven fabrics disclosed herein provide improved durability over conventional nonwoven fabrics.

Abstract: Methods of making an artificial leather substrate from leather waste (e.g., shavings, such as wet blue, and/or pulverized trim scrap) and products formed using the artificial leather substrate are disclosed. In one example, the artificial leather substrate comprises a composite web comprising leather waste mixed with a lightweight web, a lightweight web atop the composite web, and another lightweight web atop the first lightweight web. A method of making the artificial leather substrate includes the steps of mixing one or more fiber components, leather shavings, and/or pulverized leather trim scrap to form the composite web; needle punching the composite web; and bonding the composite web.