Abstract: An insulating (nonconductive) microporous polymeric battery separator comprised of a single layer of enmeshed microfibers and nanofibers is provided. Such a separator accords the ability to attune the porosity and pore size to any desired level through a single nonwoven fabric. Through a proper selection of materials as well as production processes, the resultant battery separator exhibits isotropic strengths, low shrinkage, high wettability levels, and pore sizes related directly to layer thickness. The overall production method is highly efficient and yields a combination of polymeric nanofibers within a polymeric microfiber matrix and/or onto such a substrate through high shear processing that is cost effective as well. The separator, a battery including such a separator, the method of manufacturing such a separator, and the method of utilizing such a separator within a battery device, are all encompassed within this invention.

Abstract: A new class of high modulus polypropylene multifilament fiber and/or yarn is provided. Such a multifilament fiber and/or yarn exhibits an exceptional combination of high strength and toughness with low weight and density. The inventive fibers thus permit replacement of expensive polymeric fibers within certain applications with lower cost alternatives, or replacement of high density components with such low density fibers, without sacrificing strength or durability. Such multifilament fibers are produced through melt-spinning processes and exhibit highly unique microstructures therein, including significant void volumes, interspersed and crossed voids, and nanofilament bridges within such voids. Such microstructural characteristics appear to impart the exceptional properties noted above.

Abstract: The present invention relates to a microporous polymeric battery separator comprised of a single layer of enmeshed microfibers and nanofibers. Such a separator accords the ability to attune the porosity and pore size to any desired level through a single nonwoven fabric. As a result, the inventive separator permits a high strength material with low porosity and low pore size to levels unattained. The combination of polymeric nanofibers within a polymeric microfiber matrix and/or onto such a substrate through high shear processing provides such benefits, as well. The separator, a battery including such a separator, the method of manufacturing such a separator, and the method of utilizing such a separator within a battery device, are all encompassed within this invention.

Abstract: The present invention relates to a microporous polymeric battery separator comprised of a single layer of enmeshed microfibers and nanofibers. Such a separator accords the ability to attune the porosity and pore size to any desired level through a single nonwoven fabric. As a result, the inventive separator permits a high strength material with low porosity and low pore size to levels unattained. The combination of polymeric nanofibers within a polymeric microfiber matrix and/or onto such a substrate through high shear processing provides such benefits, as well. The separator, a battery including such a separator, the method of manufacturing such a separator, and the method of utilizing such a separator within a battery device, are all encompassed within this invention.

Abstract: Disclosed are composites that can exhibit low transmission energy loss and can also be temperature resistant. The composites include reinforcement fibers held in a polymeric matrix. The reinforcement fibers can include an amorphous polymer component. The fibers can be woven or knit to form a fabric or can be included in a nonwoven fabric. The composites can include other fibers as well, such as fiberglass. The composites can be multi-layer structures and can include layers of other materials, for instance layers formed of polyaramids, fiberglass, or carbon fiber wovens or nonwovens. The composites can advantageously be utilized in low loss dielectric applications, such as in forming circuit board substrates.

Abstract: Disclosed are composite laminates that can exhibit high strength and/or low dielectric loss and can also be lightweight. The laminates include layers formed of high modulus polyolefin fiber. The fibers can be woven or knit to form a fabric or can be included in a nonwoven fabric that can be one or more layers of the composite structures. The layers including the high modulus polyolefin fibers can include other fibers, such as fiberglass. The composites can also include layers of other materials, for instance layers formed of polyaramids, fiberglass, or carbon fiber wovens or nonwovens. The composites can advantageously be utilized in low loss dielectric applications, such as in forming circuit board substrates, or in applications beneficially combining strength with low weight, such as automobile and boat materials.

Abstract: Disclosed are composite laminates that can exhibit high strength and/or low dielectric loss and can also be lightweight. The laminates include layers formed of high modulus polyolefin fiber. The fibers can be woven or knit to form a fabric or can be included in a nonwoven fabric that can be one or more layers of the composite structures. The layers including the high modulus polyolefin fibers can include other fibers, such as fiberglass. The composites can also include layers of other materials, for instance layers formed of polyaramids, fiberglass, or carbon fiber wovens or nonwovens. The composites can advantageously be utilized in low loss dielectric applications, such as in forming circuit board substrates, or in applications beneficially combining strength with low weight, such as automobile and boat materials.

Abstract: A new class of high modulus polypropylene multifilament fiber and/or yarn is provided. Such a multifilament fiber and/or yarn exhibits an exceptional combination of high strength and toughness with low weight and density. The inventive fibers thus permit replacement of expensive polymeric fibers within certain applications with lower cost alternatives, or replacement of high density components with such low density fibers, without sacrificing strength or durability. Such multifilament fibers are produced through melt-spinning processes and exhibit highly unique microstructures therein, including significant void volumes, interspersed and crossed voids, and nanofilament bridges within such voids. Such microstructural characteristics appear to impart the exceptional properties noted above.

Abstract: Disclosed are structural materials including polymeric reinforcement fibers that can provide added strength and fracture toughness to the matrix. The polymeric reinforcement fibers are polypropylene-based monofilament fibers or tape fibers exhibiting extremely favorable mechanical characteristics for structural reinforcement including modulus greater than 12 MPa and elongation less than about 10%. The disclosed reinforced composite materials can exhibit desired average residual strength values with less total fiber loading necessary to attain the ARS values as compared to previously known polymer reinforced materials. Very high strength and fracture toughness can be attained in the disclosed composite materials.

Abstract: Disclosed are composite materials that can exhibit low transmission energy loss and can also be temperature resistant. The composites include reinforcement fibers held in a polymeric matrix. The polymeric matrix can include an amorphous polymer component. Also disclosed are methods of forming the composites. Methods can include forming amorphous thermoplastic polymer fibers, forming a fabric from the fibers, combining the fabric with reinforcement fibers, and molding the structure thus formed under heat and pressure such that the amorphous thermoplastic polymer flows and forms a polymeric matrix incorporating the reinforcement fibers. The composites can be molded from multi-layer structures that can include layers of differing materials, for instance layers formed of polyaramids, fiberglass, or carbon fiber wovens or nonwovens. The composites can advantageously be utilized in low loss dielectric applications, such as in forming circuit board substrates, radomes, antennas, and the like.

Abstract: Disclosed are composite laminates that can exhibit high strength and/or low dielectric loss and can also be lightweight. The laminates include layers formed of high modulus polyolefin fiber. The fibers can be woven or knit to form a fabric or can be included in a nonwoven fabric that can be one or more layers of the composite structures. The layers including the high modulus polyolefin fibers can include other fibers, such as fiberglass. The composites can also include layers of other materials, for instance layers formed of polyaramids, fiberglass, or carbon fiber wovens or nonwovens. The composites can advantageously be utilized in low loss dielectric applications, such as in forming circuit board substrates, or in applications beneficially combining strength with low weight, such as automobile and boat materials.

Abstract: Disclosed are structural materials including polymeric reinforcement fibers that can provide added strength and fracture toughness to the matrix. The polymeric reinforcement fibers are polypropylene-based monofilament fibers or tape fibers exhibiting extremely favorable mechanical characteristics for structural reinforcement including modulus greater than 12 MPa and elongation less than about 10%. The disclosed reinforced composite materials can exhibit desired average residual strength values with less total fiber loading necessary to attain the ARS values as compared to previously known polymer reinforced materials. Very high strength and fracture toughness can be attained in the disclosed composite materials.

Abstract: Disclosed are structural materials including polymeric reinforcment fibers that can provide added strength and fracture toughness to the matrix. The polymeric reinforcement fibers are polypropylene-based monofilament fibers or tape fibers exhibiting extremely favorable mechanical characteristics for structural reinforcement including modulus greater than 12 MPa and elongation less than about 10%. The disclosed reinforced composite materials can exhibit desired average residual strength values with less total fiber loading necessary to attain the ARS values as compared to previously known polymer reinforced materials. Very high strength and fracture toughness can be attained in the disclosed composite materials.

Abstract: Disclosed is a method of forming multifilament polyolefin yarns and yarns formed according to the disclosed method. The yarns can be polypropylene yarns and can exhibit any of a high modulus, high tenacity, and a unique crystalline structure for multifilament polyolefin yarns. The process can generally include extruding a polymeric melt including the polyolefin at a relatively high throughput and low spinline tension and quenching the filaments in a liquid bath prior to drawing the fiber bundle at a relatively high draw ratio, for example greater than 10, in some embodiments.

Abstract: A material having a woven layer and a nonwoven layer needled together. The woven layer contains a plurality of interwoven polypropylene tape elements and the nonwoven layer contains a plurality of intermingled polyester fiber elements.

Abstract: Disclosed are composite materials that can exhibit low transmission energy loss and can also be temperature resistant. The composites include reinforcement fibers held in a polymeric matrix. The polymeric matrix can include an amorphous polymer component. Also disclosed are methods of forming the composites. Methods can include forming amorphous thermoplastic polymer fibers, forming a fabric from the fibers, combining the fabric with reinforcement fibers, and molding the structure thus formed under heat and pressure such that the amorphous thermoplastic polymer flows and forms a polymeric matrix incorporating the reinforcement fibers. The composites can be molded from multi-layer structures that can include layers of differing materials, for instance layers formed of polyaramids, fiberglass, or carbon fiber wovens or nonwovens. The composites can advantageously be utilized in low loss dielectric applications, such as in forming circuit board substrates, radomes, antennas, and the like.

Abstract: Disclosed are composite materials that can exhibit low transmission energy loss and can also be temperature resistant. The composites include reinforcement fibers held in a polymeric matrix. The polymeric matrix can include an amorphous polymer component. Also disclosed are methods of forming the composites. Methods can include forming amorphous thermoplastic polymer fibers, forming a fabric from the fibers, combining the fabric with reinforcement fibers, and molding the structure thus formed under heat and pressure such that the amorphous thermoplastic polymer flows and forms a polymeric matrix incorporating the reinforcement fibers. The composites can be molded from multi-layer structures that can include layers of differing materials, for instance layers formed of polyaramids, fiberglass, or carbon fiber wovens or nonwovens. The composites can advantageously be utilized in low loss dielectric applications, such as in forming circuit board substrates, radomes, antennas, and the like.

Abstract: Disclosed are composites that can exhibit low transmission energy loss and can also be temperature resistant. The composites include reinforcement fibers held in a polymeric matrix. The reinforcement fibers can include an amorphous polymer component. The fibers can be woven or knit to form a fabric or can be included in a nonwoven fabric. The composites can include other fibers as well, such as fiberglass. The composites can be multi-layer structures and can include layers of other materials, for instance layers formed of polyaramids, fiberglass, or carbon fiber wovens or nonwovens. The composites can advantageously be utilized in low loss dielectric applications, such as in forming circuit board substrates.

Abstract: A base substrate having a first side and a second side, first and second receiving loops extending from the first and second side of the base substrate, respectively, and first and second stiff loops extending from the first and second side of the base substrate, respectively. The base substrate is a flexible cloth or cloth-like material. The receiving loops are an absorbent material such as the material used in the base substrate. The stiff loops are formed of a yarn having at least one filament with a cross-section having an aspect ratio of greater than about 1.2, a corner edge, and/or at least a concave portion.

Abstract: Disclosed is a method of forming multifilament polyolefin yarns and yarns formed according to the disclosed method. The yarns can be polypropylene yarns and can exhibit any of a high modulus, high tenacity, and a unique crystalline structure for multifilament polyolefin yarns. The process can generally include extruding a polymeric melt including the polyolefin at a relatively high throughput and low spinline tension and quenching the filaments in a liquid bath prior to drawing the fiber bundle at a relatively high draw ratio, for example greater than 10, in some embodiments.