Abstract: Improvements to processes and equipment for the manufacture of nonwoven webs useful in numerous applications including personal care, protective apparel, and industrial products. The fiber and/or filaments used to form the nonwoven fabric are deposited on a forming surface in a controlled orientation using application of an electrostatic charge to the fibers and/or filaments in combination with directing them to an electrode deflector plate while under the influence of the charge. The plate may be made up of teeth with a separation and angle orientation that are selected in accordance with the desired arrangement of the fibers and/or filaments in the nonwoven web. As a result, properties of the web such as relative strengths in the machine direction and cross-machine direction can be controlled.

Abstract: An improved nonwoven web composite is formed by combining splittable bicomponent thermoplastic filaments with a component selected from other fibers and particles. The bicomponent filaments include distinct regions of first and second incompatible polymers extending the length of the filaments. After the bicomponent filaments are combined with the other fibers and/or particles, the bicomponent filaments are caused to split lengthwise along boundaries between the regions of different polymers, resulting in a web or matrix of finer filaments which entrap, ensnare and contain the other fibers and/or particles within the web or matrix. The nonwoven web composite is particularly useful for making absorbent articles, which require durability and optimum levels of absorbent fibers and/or particles.

Abstract: Described herein are improvements to processes and equipment for the manufacture of nonwoven webs useful in numerous applications including personal care, protective apparel, and industrial products. The fiber and/or filaments used to form the nonwoven fabric are deposited on a forming surface in a controlled orientation using application of an electrostatic charge to the fibers and/or filaments in combination with directing them to an electrode deflector plate while under the influence of the charge. The plate may be made up of teeth with a separation and angle orientation that are selected in accordance with the desired arrangement of the fibers and/or filaments in the nonwoven web. As a result, properties of the web such as relative strengths in the machine direction and cross-machine direction can be controlled. The charging of the pins is controlled so that not all pins remain at maximum charge during a cycle with the result that extended run times may be obtained.

Abstract: A personal care absorbent article made of a nonwoven material having a plurality of polymeric fibers having a fiber interior comprising at least one of a liquid fluid and a gaseous fluid. The nonwoven materials are produced by heating at least one polymer to a melting point, forming a molten polymer; extruding the molten polymer through a plurality of capillaries, injecting a liquid fluid and/or a gaseous fluid into the molten polymer prior to, during and/or after the extruding step, forming a plurality of fluid-filled polymeric fibers, wherein the liquid fluid and/or gaseous fluid is dispersed within the interior of the polymeric fibers, and depositing the fluid-filled polymeric fibers onto a web forming surface, forming a nonwoven material.

Abstract: A three-dimensional nonwoven web having a regional, bulk density of less than 0.04 grams per cubic centimeter, a top-side base surface that defines an x,y-plane and at least one macroscopic surface feature extending out of the x,y-plane wherein a macroscopic surface feature is characterized as a feature having an apex that extends at least about 1 millimeter above the x,y-plane of the top-side base surface is provided. The macroscopic feature maintains a height of at least 1 millimeter above the x,y-plane of the top-side base surface under a 1.2 kPa load (Pf) and results in contact of an object resting on the macroscopic feature such that the percent contact area of the nonwoven web with an article resting on the macroscopic surface feature at a 1.2 kPa load (Pf) is less than 50 percent of the bulk area of the nonwoven web supporting the article.

Abstract: A process of making a nonwoven fabric comprising providing a three-dimensional surface that comprises surface features that are air permeable, depositing fibers or a web comprising fibers onto the surface, and stabilizing the fibers to form a nonwoven fabric is provided.

Abstract: A method for producing super fine meltblown fibers increases the length of the meltblown jet thermal core to increase the dwell time of the extruded thermoplastic polymer within the jet thermal core. Through use of the method it is practical to use low viscosity resins and further to provide meltblown nonwovens with superior barrier properties to the passage of fluids and particularly gases. The method further provides a useful means for blooming internal additives to the surface of the fibers.

Abstract: An improved nonwoven web composite is formed by combining bicomponent thermoplastic filaments having adhesive properties with a component selected from other fibers and particles. The bicomponent filaments include distinct regions of first and second incompatible polymers across a cross-section of individual filaments. After the bicomponent filaments are combined with the other fibers and/or particles, the adhesive properties of the bicomponent filaments result in a web or matrix of filaments having improved ability to entrap, ensnare and contain the other fibers and/or particles within the web or matrix. The nonwoven web composite is particularly useful for making absorbent articles, which require stability and optimum levels of absorbent fibers and/or particles.

Abstract: High loft, low density nonwoven webs are produced by forming substantially continuous, spunbond, crimped, bicomponent fibers of A/B side by side morphology in an unheated fiber draw unit. The fibers are then heated and cooled in the absence of impeding forces to achieve maximum crimp in the z-direction and produce a web of lofted material. The resultant material is particularly suitable for use as an insulator. Particulates may be added to the webs if desired.

Abstract: A method and apparatus for monitoring the momentum of a meltspun jet thermal core used for making thermoplastic filaments is presented to aid in the uniformity of formation and elimination of waste in thermoplastic filament nonwoven web formation. The apparatus is easily and economically constructed and is relatively insensitive to positioning variations in the air stream of the filament formation apparatus.

Abstract: A coform nonwoven web from multicomponent meltblown filaments and an absorbent, wherein the absorbent material is substantially uniformly dispersed in the z-direction is disclosed. A process of preparing the coform nonwoven web by perturbing the meltblown filaments as they are being produced is also disclosed. The coform material can be used in a variety of absorbent articles such as diapers as the primary liquid retention layer. In addition, the coform nonwoven web can be used in a variety of other articles such as wipes.

Abstract: A web of thermoplastic multicomponent substantially continuous fibers is mixed with absorbent materials. The multicomponent fibers have a low melting point sheath which is fully activated to melt and wet the absorbent particles. The web is then densified and cooled, securing the aborbents to the web with hardened flow joints and enabling the web to carry high loadings of absorbent while maintaining good web integrity.

Abstract: A liquid reception device as a component, for example, of a personal care product such as a disposable diaper, an incontinent garment, or for other applications such as, for example, an industrial soaker pad or the like. The device includes liquid activated means to move a liquid insult from a target zone to a peripheral zone. The liquid activated transport means operated mechanically by suction created by compression or vacuum or by physical movement of a liquid container from the target zone to the peripheral zone. The disclosed device provides increased use of available liquid handling capacity.

Abstract: A method for producing super fine meltblown fibers increases the length of the meltblown jet thermal core to increase the dwell time of the extruded thermoplastic polymer within the jet thermal core. Through use of the method it is practical to use low viscosity resins and further to provide meltblown nonwovens with superior barrier properties to the passage of fluids and particularly gases. The method further provides a useful means for blooming internal additives to the surface of the fibers.

Abstract: Described herein are improvements to processes and equipment for the manufacture of nonwoven webs useful in numerous applications including personal care, protective apparel, and industrial products. The fiber and/or filaments used to form the nonwoven fabric are deposited on a forming surface in a controlled orientation using application of an electrostatic charge to the fibers and/or filaments in combination with directing them to an electrode deflector plate while under the influence of the charge. The plate may be made up of teeth with a separation and angle orientation that are selected in accordance with the desired arrangement of the fibers and/or filaments in the nonwoven web. As a result, properties of the web such as relative strengths in the machine direction and cross-machine direction can be controlled.

Abstract: A liquid reception device as a component, for example, of a personal care product such as a disposable diaper, an incontinent garment, or for other applications such as, for example, an industrial soaker pad or the like. The device includes liquid activated means to move a liquid insult from a target zone to a peripheral zone. The liquid activated transport means operated mechanically by suction created by compression or vacuum or by physical movement of a liquid container from the target zone to the peripheral zone. The disclosed device provides increased use of available liquid handling capacity.

Abstract: A method is provided for producing fine denier multicomponent thermoplastic polymer filaments incorporating high melt-flow rate polymers. Multicomponent filaments are extruded such that the high melt-flow rate polymer component is substantially surrounded by one or more low melt-flow rate polymer components. The extruded multicomponent filament is then melt-attenuated with a significant drawing force to reduce the filament diameter and form continuous, fine denier filaments.

Abstract: An apparatus and method for increasing the heating efficiency of a nonwoven web using heated air are provided. A flow modifier including a turbulence inducing bar arrangement is positioned between the heated air supply and the nonwoven web. The flow modifier increases the turbulence of the heated air before it contacts the nonwoven web, resulting in more thorough penetration of the web by the air, and better convective heat transfer between the heated air and the nonwoven web.

Abstract: A method and apparatus for improved quenching of nonwoven filaments utilizing a turbulence inducing bar arrangement disposed in a stream of quenching gas between the quenching gas supply apparatus and the group of filaments being extruded. The bar arrangement increases the turbulence of the quenching gas so that the gas applied to the filament group has a turbulence intensity of at least about 5%. The turbulent quenching gas penetrates the interior of the filament bundle to provide more efficient removal of heat.

Abstract: An apparatus and method for increasing the heating efficiency of a nonwoven web using heated air are provided. A flow modifier including a turbulence inducing bar arrangement is positioned between the heated air supply and the nonwoven web. The flow modifier increases the turbulence of the heated air before it contacts the nonwoven web, resulting in more thorough penetration of the web by the air, and better convective heat transfer between the heated air and the nonwoven web.