Abstract: The subject matter disclosed herein relates generally to the production of a predetermined ratio of multicomponent fibers in combination with monocomponent fibers or other multicomponent fibers, preferably through a spunbonding process. After extrusion, these fibers can produce a fiber network that is subsequently bonded to produce a nonwoven fabric comprising multiple types of fibers. The multicomponent fibers within the network may be processed to remove one component by dissolution or to split the individual components into separate fibers. As a result, the fabric will be comprised of fibers with a range of diameters (micro- or nano-denier fibers as well as higher denier fibers) such that the fibers will not pack as tightly as in a homogeneous nonwoven fabric produced from one type of monocomponent or multicomponent fiber. The present invention additionally relates to methods for producing nonwoven fabrics with increased loft, breathability, strength, compressive properties, and filtration efficiency.

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 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 subject matter disclosed herein relates generally to the production of a predetermined ratio of multicomponent fibers in combination with monocomponent fibers or other multicomponent fibers, preferably through a spunbonding process. After extrusion, these fibers can produce a fiber network that is subsequently bonded to produce a nonwoven fabric comprising multiple types of fibers. The multicomponent fibers within the network may be processed to remove one component by dissolution or to split the individual components into separate fibers. As a result, the fabric will be comprised of fibers with a range of diameters (micro- or nano-denier fibers as well as higher denier fibers) such that the fibers will not pack as tightly as in a homogeneous nonwoven fabric produced from one type of monocomponent or multicomponent fiber. The present invention additionally relates to methods for producing nonwoven fabrics with increased loft, breathability, strength, compressive properties, and filtration efficiency.

Abstract: A method of producing a nonwoven fabric comprising spinning a set of bicomponent fibers which include an external fiber component and an internal fiber component. The external fiber enwraps said internal fiber and has a higher elongation to break value than the internal fiber and a lower melting temperature than the internal fiber component. The set of bicomponent fibers are positioned onto a web and thermally bonded to produce a nonwoven fabric.

Abstract: A fabric including microdenier fibers is provided, the microdenier fibers prepared by fibrillating a multicomponent, multilobal fiber including a contiguous core fiber component enwrapped by a multilobal sheath fiber component such that the sheath fiber component forms the entire outer surface of the multicomponent fiber, wherein the core fiber component and the multilobal sheath fiber component are sized such that the multicomponent, multilobal fiber can be fibrillated to expose the core fiber component and split the fiber into multiple microdenier fibers.

Abstract: A capacitive sensor device, including electrode materials carried by fabric substrates, is provided for monitoring relative movement of an expanding and/or contracting structure, such as the mammalian chest and/or torso, corresponding to a performance parameter related, for example, to respiratory function. Some embodiments include non-woven fabric substrates comprising compliant portions configured to stretch only in a selected direction and non-compliant portions upon which electrode materials are disposed. In some embodiments, layers of fabric substrates, carrying corresponding first and second electrode materials, are configured to cooperate to form a parallel plate capacitive sensor having a variable capacitance corresponding to a relative motion of the fabric substrates.

Abstract: Methods and devices for providing flexible electronics are described. In an exemplary embodiment of the present invention, a conductive ink is applied to a nonwoven substrate. More particularly, the exemplary embodiment provides a nonwoven substrate with a general depth in the z-direction and a conductive ink carried by the nonwoven substrate on the surface of the substrate and at least partially but no more than 50% within the nonwoven substrate in the z-direction.

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: A drug delivery system in the form of homo-component, bi-component or multi-component fibers wherein one of more of the components comprise a drug compounded with a polymer carrier. These fibers are packed to form a tablet directly, or are chopped and placed in a capsule.

Abstract: The subject matter disclosed herein relates generally to the production of a predetermined ratio of multicomponent fibers in combination with monocomponent fibers or other multicomponent fibers, preferably through a spunbonding process. After extrusion, these fibers can produce a fiber network that is subsequently bonded to produce a nonwoven fabric comprising multiple types of fibers. The multicomponent fibers within the network may be processed to remove one component by dissolution or to split the individual components into separate fibers. As a result, the fabric will be comprised of fibers with a range of diameters (micro- or nano-denier fibers as well as higher denier fibers) such that the fibers will not pack as tightly as in a homogeneous nonwoven fabric produced from one type of monocomponent or multicomponent fiber. The present invention additionally relates to methods for producing nonwoven fabrics with increased loft, breathability, strength, compressive properties, and filtration efficiency.

Abstract: A method of producing a nonwoven fabric comprising spinning a set of bicomponent fibers which include an external fiber component and an internal fiber component. The external fiber enwraps said internal fiber and has a higher elongation to break value than the internal fiber and a lower melting temperature than the internal fiber component. The set of bicomponent fibers are positioned onto a web and thermally bonded to produce a nonwoven fabric.

Abstract: A system for hydroentangling a fabric material, while reducing the incidence of jet streaks therein, is provided. Various embodiments of the present invention provide an elongate hydroentangling jet strip spaced apart from the fabric material and extending substantially across a width of the fabric perpendicular to the processing direction. The strip defines a first row of orifices, each having a first diameter. The first plurality of orifices is spaced apart along a width of the elongate strip. The strip further defines a second plurality of orifices disposed downstream from the first plurality of orifices in the processing direction and offset therefrom along the width of the elongate strip. The second plurality of orifices each define a second diameter smaller than the first diameter such that fluid streams generated thereby impart a correspondingly smaller impact force on the fabric material than fluid streams generated by the first plurality of orifices.

Abstract: A method of constructing an antenna, filter, or similar structure comprising one or more planar electrically conductive radiating and/or receiving elements having conductive feedlines attached thereto and a planar around reference conductor spaced therefrom by a spacer layer, comprising the steps of: providing a planar dielectric fabric spacer layer; applying conductive material to a first side of said spacer layer, by an embroidery process employing conductive thread or yarn, to define said electrically conductive radiating and/or receiving elements having conductive feedlines attached thereto; providing a planar around reference conductor on the opposite side of said planar spacer layer in a position corresponding to the pattern of said electrically conductive radiating and/or receiving elements having conductive feedlines attached thereto; and providing a connection whereby said conductive feedlines attached to said electrically conductive radiating and/or receiving elements, and said planar around referen

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: A method of producing a nonwoven fabric comprising spinning a set of bicomponent fibers which include an external fiber component and an internal fiber component. The external fiber enwraps said internal fiber and has a higher elongation to break value than the internal fiber and a lower melting temperature than the internal fiber component. The set of bicomponent fibers are positioned onto a web and thermally bonded to produce a nonwoven fabric.

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 capacitive sensor device, including electrode materials carried by fabric substrates, is provided for monitoring relative movement of an expanding and/or contracting structure, such as the mammalian chest and/or torso, corresponding to a performance parameter related, for example, to respiratory function. Some embodiments include non-woven fabric substrates comprising compliant portions configured to stretch only in a selected direction and non-compliant portions upon which electrode materials are disposed. In some embodiments, layers of fabric substrates, carrying corresponding first and second electrode materials, are configured to cooperate to form a parallel plate capacitive sensor having a variable capacitance corresponding to a relative motion of the fabric substrates.

Abstract: A fabric including microdenier fibers is provided, the microdenier fibers prepared by fibrillating a multicomponent, multilobal fiber including a contiguous core fiber component enwrapped by a multilobal sheath fiber component such that the sheath fiber component forms the entire outer surface of the multicomponent fiber, wherein the core fiber component and the multilobal sheath fiber component are sized such that the multicomponent, multilobal fiber can be fibrillated to expose the core fiber component and split the fiber into multiple microdenier fibers.

Abstract: A hydroentangling jet strip device is provided, wherein such a device comprises a plate member having opposing sides and defining at least one nozzle orifice extending between the opposing sides. Each of the at least one nozzle orifice includes an axially-extending capillary portion having an aspect ratio between a length of the capillary portion and a diameter of the capillary portion, wherein the aspect ratio is less than about 0.70 so as to be capable of providing a cavitation-free constricted waterjet.