Abstract: Fluid filtration articles, including composite nonwoven fibrous webs, and methods of making and using such articles as gas or liquid filtration elements. The articles include a population of coarse microfibers having a population median diameter of at least 1 micrometer (?m) formed as a first layer, and a population of fine fibers having a population median diameter less than 10 ?m formed as a second layer adjoining the first layer. At least one of the fiber populations may be oriented. In one implementation, the coarse microfibers and fine fibers are polymeric, the coarse microfibers have a population median diameter of at least 10 ?m, and the fine fibers have a population median diameter less than 10 ?m. In another implementation, the population of fine fibers has a population median diameter less than 1 ?m. Optionally, one or both of the first and second layers may include particulates.

Abstract: A filter media is disclosed comprising a carrier and a web collected on the carrier. The web comprises hydrophilic polymeric meltblown fibers and a plurality of sorbent particles enmeshed in the hydrophilic polymeric meltblown fibers. The carrier comprises a porous sheet and has a carrier basis weight. The web has a web basis weight. The hydrophilic polymeric melt-blown fibers comprise at least 3% of the web basis weight and the plurality of sorbent particles comprise at most 97% of the web basis weight.

Abstract: Patterned spunbond fibrous webs include a population of spunbond filaments captured in an identifiable pattern corresponding to a patterned collector surface and bonded together without the use of an adhesive prior to removal from the collector surface. The webs may exhibit a high degree of filament orientation and/or a gradient of filament density in one or more directions determined by the patterned collector surface. Methods of making patterned spunbond fibrous webs, and articles including patterned spunbond fibrous webs made according to the methods, are also disclosed. In exemplary applications, the webs may be used in gas filtration articles, liquid filtration articles, sound absorption articles, surface cleaning articles, cellular growth support articles, drug delivery articles, personal hygiene articles, or wound dressing articles.

Abstract: Fluid filtration articles, including composite nonwoven fibrous webs, and methods of making and using such articles as gas or liquid filtration elements. The articles include a population of coarse microfibers having a population median diameter of at least 1 micrometer (?m) formed as a first layer, and a population of fine fibers having a population median diameter less than 10 ?m formed as a second layer adjoining the first layer. At least one of the fiber populations may be oriented. In one implementation, the coarse microfibers and fine fibers are polymeric, the coarse microfibers have a population median diameter of at least 10 ?m, and the fine fibers have a population median diameter less than 10 ?m. In another implementation, the population of fine fibers has a population median diameter less than 1 ?m. Optionally, one or both of the first and second layers may include particulates.

Abstract: Provided are filter elements and methods of making and using the same where the filter elements are suitable for liquid filtration and contain particle-loaded meltblown fiber webs. A filter element comprises: a porous article comprising a web of self-supporting nonwoven polymeric fibers and a plurality of sorbent particles enmeshed in the web, the article comprising a first surface and a second surface; a liquid-impermeable housing surrounding the porous article; an inlet in fluid communication with the first surface; and an outlet in fluid communication with the second surface. Spiral-wound webs, web-covered blocks, and stacked disks of webs are also provided.

Abstract: Multilayer articles having acoustical absorbance properties are disclosed. Methods of making and using the multilayer articles are also disclosed.

Abstract: A coherent nonwoven fibrous web comprises directly formed elastic fibers that have a molecular orientation sufficient to provide a birefringence number of at least 1×10?5 and preferably at least 1×10?2. The web can be made by a method that comprises a) extruding filaments of elastic-fiber-forming material; b) directing the filaments through a processing chamber in which gaseous currents apply a longitudinal stress to the filaments that attenuates and draws the filaments; c) maintaining the filaments at their orienting temperature while the filaments are under attenuating and drawing stress for a sufficient time for molecules within the filaments to become oriented along the length of the filaments; d) cooling the filaments to their orientation-locking temperature while the filaments are under attenuating and drawing stress and further cooling the filaments to a solidified fiber form; and e) collecting the solidified fibers as a fibrous nonwoven web.

Abstract: Provided are filter elements and methods of making and using the same where the filter elements are suitable for liquid filtration and contain particle-loaded meltblown fiber webs. A filter element comprises: a porous article comprising a web of self-supporting nonwoven polymeric fibers and a plurality of sorbent particles enmeshed in the web, the article comprising a first surface and a second surface; a liquid-impermeable housing surrounding the porous article; an inlet in fluid communication with the first surface; and an outlet in fluid communication with the second surface. Spiral-wound webs, web-covered blocks, and stacked disks of webs are also provided.

Abstract: Multilayer articles having acoustical absorbance properties are disclosed. Methods of making and using the multilayer articles are also disclosed.

Abstract: Methods of manufacturing composite webs including a substrate with one or more reinforcing discrete polymeric regions located on or within the composite web are disclosed. Molten nonelastomeric thermoplastic material of the discrete polymeric region is forced against the substrate by a transfer roll. If the substrate is porous, fibrous, etc., a portion of the nonelastomeric thermoplastic composition may infiltrate the substrate and/or encapsulate fibers of the substrate.

Abstract: Methods of manufacturing composite webs including a substrate with one or more reinforcing discrete polymeric regions located on or within the composite web are disclosed. Molten nonelastomeric thermoplastic material of the discrete polymeric region is forced against the substrate by a transfer roll. If the substrate is porous, fibrous, etc., a portion of the nonelastomeric thermoplastic composition may infiltrate the substrate and/or encapsulate fibers of the substrate. The composite webs also include elastomeric thermoplastic material in discrete polymeric regions on or within the composite web.

Abstract: There is provided an attachable ear element for use on a disposable absorbent article having a rectangular zone provided at least in part with an elastic and tapered zone for attachment to the article. The ear element has two opposing ends and a top edge and a bottom edge. A first free end is provided with a fastening element. A second opposing attached end is attachable to the article. The attachable ear element has a first rectangular zone adjacent the first free end and a second tapered zone adjacent the second attached zone.

Abstract: Methods of manufacturing composite webs including a substrate with one or more reinforcing discrete polymeric regions located on or within the composite web are disclosed. Molten nonelastomeric thermoplastic material of the discrete polymeric region is forced against the substrate by a transfer roll. If the substrate is porous, fibrous, etc., a portion of the nonelastomeric thermoplastic composition may infiltrate the substrate and/or encapsulate fibers of the substrate.

Abstract: Methods of manufacturing composite webs including a substrate with one or more reinforcing discrete polymeric regions located on or within the composite web are disclosed. Molten nonelastomeric thermoplastic material of the discrete polymeric region is forced against the substrate by a transfer roll. If the substrate is porous, fibrous, etc., a portion of the nonelastomeric thermoplastic composition may infiltrate the substrate and/or encapsulate fibers of the substrate. The composite webs also include elastomeric thermoplastic material in discrete polymeric regions on or within the composite web.

Abstract: Composite webs and methods and systems for manufacturing composite webs including a substrate with one or more discrete polymeric regions located thereon are disclosed. At least some of the discrete polymeric regions are formed of an elastomeric thermoplastic composition that is transferred to the substrate in depressions formed on a transfer roll. The discrete elastomeric polymeric regions can be used to provide elasticity to a substrate that is not elastic or they may be used to adjust the elasticity of a substrate that is itself elastic.

Abstract: There is provided an extensible elastic tab designed to be adhered to the edge of an article, formed using a coextruded elastic film comprising at least one elastic layer and at least one second layer on at least a first face of the elastic layer with at least one face of the coextruded elastic film attached to at least a partially extensible nonwoven layer. The partially expandable, or extensible nonwoven layer has at least one first portion with limited extensibility in a first direction and at least one second inextensible portion in the first direction. The extensible elastic tab when stretched to the extension limit of the first portion or portions in the first direction will elastically recover at least 1.0 cm, preferably at least 2 cm providing an elastic tab having a Useful Stretch Ratio (as defined in the Examples) of at least 30 percent.

Abstract: There is provided an extensible elastic tab designed to be adhered to the edge of an article, formed using a coextruded elastic film comprising at least one elastic layer and at least one second layer on at least a first face of the elastic layer with at least one face of the coextruded elastic film attached to at least a partially extensible nonwoven layer. The partially expandable, or extensible nonwoven layer has at least one first portion with limited extensibility in a first direction and at least one second inextensible portion in the first direction. The extensible elastic tab when stretched to the extension limit of the first portion or portions in the first direction will elastically recover at least 1.0 cm, preferably at least 2 cm providing an elastic tab having a Useful Stretch Ratio (as defined in the Examples) of at least 30 percent.

Abstract: An elastic strand construction comprising a plurality of spaced ribs separated by thin zones is provided. The elastic strand construction is preferred for applications in disposable garments or the like. A method of manufacturing the preferred elastic strand comprises extrusion of polymeric material through a profiled die or the like. In the alternative, a method of formation comprising extrusion between a profiled roller arrangement is described. A preferred disposable garment construction utilizing elastic strands according to the present invention is described.

Abstract: An elastic strand construction comprising a plurality of spaced ribs separated by thin zones is provided. The elastic strand construction is preferred for applications in disposable garments or the like. A method of manufacturing the preferred elastic strand comprises extrusion of polymeric material through a profiled die or the like. In the alternative, a method of formation comprising extrusion between a profiled roller arrangement is described. A preferred disposable garment construction utilizing elastic strands according to the present invention is described.

Abstract: Disposable diapers can be manufactured at high production speeds by using for the waistband a heat-shrinkable plastic film that is dimensionally stable at ordinary room temperatures and shrinks in one direction at least 25% within 5 seconds at 54.degree. C. Such a heat-shrinkable plastic film can be made by uniaxially cold-stretching a thin extrudate of a blend of an EVA copolymer and an (A-B) block copolymer of polystyrene and polyisoprene.