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: The present invention relates to an electrospinning device. The electrospinning device may apply the force of a supersonic flow acting at a predetermined angle with respect to an electrostatic force on a fiber discharged from an electrospinning nozzle to cause shearing stress on the fiber, thereby providing fibers having a very small diameter and collecting fibers having a finer diameter. Also, the electrospinning device may collect finer and more uniform fibers by adjusting the relative positions of the electrospinning nozzle for discharging the fiber and a gas spray nozzle for spraying a gas.

Abstract: This disclosure relates to articles that comprise polymeric winged fibers. The winged fibers have a high surface area because of their structure, which includes a core surrounded by a plurality of lobes. Channels of one micron or less in width are formed between adjacent lobes to form paths for the capture and/or transport of gases, liquids or particles. The winged fibers are assembled in woven or non-woven fabrics for use in wipes, absorbent pads, composite structures, apparel, outdoor wear, bedding, filtration systems, purification/separation systems, thermal and acoustic insulation, cell scaffolding, and battery membranes.

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.

Abstract: The present invention provides electrospun fibrous materials with various potential applications in the healthcare industry. Unique fiber morphologies are provided, which can allow the fibrous materials to exhibit a range of desirable properties. The electrospun fibrous materials are advantageously biocompatible and may be tailored for certain specific applications, e.g., by the incorporation of one or more therapeutic agents. Exemplary materials described herein can be employed in controlled, localized drug delivery, tissue engineering, and wound healing applications.

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 invention relates to an electrospinning device. The electrospinning device may apply the force of a supersonic flow acting at a predetermined angle with respect to an electrostatic force on a fiber discharged from an electrospinning nozzle to cause shearing stress on the fiber, thereby providing fibers having a very small diameter and collecting fibers having a finer diameter. Also, the electrospinning device may collect finer and more uniform fibers by adjusting the relative positions of the electrospinning nozzle for discharging the fiber and a gas spray nozzle for spraying a gas.

Abstract: A porous membrane structure includes a fibrous host material, which defines a plurality of inter-fiber voids, and a porous guest polymer that fills at least a subset of the plurality of inter-fiber voids of the fibrous host material. The porous guest polymer facilitates selective transport of materials across the porous membrane structure and provides selective barrier properties to the porous membrane structure. The porous membrane structure may be configured as a protective barrier material for use across a range of applications.

Abstract: A biodegradable delivery system for actives such as pharmaceutical drugs. The delivery system includes actives infused into the capsid of a purified plant virus. The loaded capsids are embedding in electrospun biodegradable polymer fibers, forming a nonwoven fabric.

Abstract: The invention provides methods for the preparation of nonwoven spunbonded fabrics and various materials prepared using such spunbonded fabrics. The method generally comprises extruding multicomponent fibers having an islands in the sea configuration such that upon removal of the sea component, the island components remain as micro- and nanofibers. The method further comprises mechanically entangling the multicomponent fibers to provide a nonwoven spunbonded fabric exhibiting superior strength and durability without the need for thermal bonding.

Abstract: The subject matter disclosed herein relates generally to fabrics composed of micro-denier fibers wherein said fibers are formed as bicomponent fibrillated fiber. The energy is sufficient for fibrillating as well as entangling (bonding) the fibers. These fabrics can be woven or knitted and made from made from bicomponent islands in the sea fibers and filaments or can be nonwovens and 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: The present invention is directed to a high surface area fibers and an improved filter composite media made from the same. More specifically, the composite media preferably comprises a winged-fiber layer having high surface area fibers for increased absorption and strength and a meltblown layer for additional filtration. In one preferred embodiment the high surface area fibers have a middle region with a plurality of projections that define a plurality of channels, which increases the surface area of the fiber. In one preferred embodiment, the high surface area fiber has a specific surface area of about 140,000 cm2/g or higher and a denier of about 1.0 to about 2.0. The high surface area fiber of the present invention is made using a bicomponent extrusion process using a thermoplastic polymer and a dissolvable sheath.

Abstract: The invention provides methods for the preparation of nonwoven spunbonded fabrics and various materials prepared using such spunbonded fabrics. The method generally comprises extruding multicomponent fibers having an islands in the sea configuration such that upon removal of the sea component, the island components remain as micro- and nanofibers. The method further comprises mechanically entangling the multicomponent fibers to provide a nonwoven spunbonded fabric exhibiting superior strength and durability without the need for thermal bonding.

Abstract: Multicomponent fibers and fabrics made therefrom are provided. The fibers include a multilobal sheath fiber component surrounding a core fiber component, wherein the fibers can be fibrillated to provide a plurality of intertwined microdenier fiber components. Methods of providing such fabrics are also disclosed.

Abstract: The present invention is directed to a high surface area fiber and method for making the same. The fiber includes a co-extruded internal fiber and an external sheath that is washed with a solvent to remove the dissolvable external sheath, the resulting fiber having a longitudinal axis and a cross-section, the cross-section having a middle region and projections extending from the middle region.

Abstract: A microwave patch antenna comprising: a plurality of conductive antenna patterns; a plurality of groundplanes; a plurality of feed elements; a plurality of feed slots to allow feed elements to pass through the non-woven dielectric spacers; and a plurality of dielectric separator layers comprised of corrugated non-woven fabric as necessary to form a patch antenna construction.

Abstract: The invention provides durable nonwoven fabrics comprising staple fibers. Methods of preparing durable nonwoven fabrics based on staple fibers are also provided. The methods can include the steps of at least one of needle punching and hydroentangling. The durable nonwoven fabric can be subjected to additional bonding techniques, such as resin bonding and/or thermal bonding. The durable nonwoven fabrics of the invention provide improved durability over conventional nonwoven fabrics. Further advantages of the inventive nonwoven fabrics include maintaining the smooth surface qualities of the fabric and desirable feel of the fabric even with the enhanced durability. The inventive nonwoven fabrics can also be subjected to additional post-processing techniques that conventional nonwoven fabrics would otherwise be unable to withstand. Further, inks and/or dyes can more readily become adhered to the smooth nature of the surfaces of the inventive durable nonwoven fabrics.

Abstract: The present invention is directed to a high surface area fiber and textiles made from the same. In one preferred embodiment the fiber has a middle region with a plurality of projections that define a plurality of channels, which increases the surface area of the fiber. In one preferred embodiment, the fiber has a specific surface area of about 140,000 cm2/g or higher and a denier of about 1.0 to about 2.0. The fiber of the present invention is made using a bicomponent extrusion process using a thermoplastic polymer and a dissolvable sheath.

Abstract: A nonwoven fabric has been developed as a delivery system for drugs or other actives which includes biodegradable and biocompatible fibers with plant virus nanoparticles. The plant virus nanoparticles are pre-loaded with one or more actives.

Abstract: The invention provides methods for the preparation of nonwoven spunbonded fabrics and various materials prepared using such spunbonded fabrics. The method generally comprises extruding multicomponent fibers having an islands in the sea configuration such that upon removal of the sea component, the island components remain as micro- and nanofibers. The method further comprises mechanically entangling the multicomponent fibers to provide a nonwoven spunbonded fabric exhibiting superior strength and durability without the need for thermal bonding.