Patents by Inventor Darrell Gillespie

Darrell Gillespie has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Patent number: 7998384
    Abstract: A spunbond nonwoven fabric useful as a topsheet is produced from polypropylene filaments including a high level of reclaimed polypropylene, while maintaining a product quality, including superior formation, comparable to that obtained when using 100 percent virgin polymer. The spunbond nonwoven fabric is made with multicomponent filaments having at least two different polymer components occupying different areas within the filament cross section, and wherein one of the polymer components comprises reclaimed polypropylene recovered from previously spun polypropylene fiber or webs comprised of previously spun polypropylene fiber. In a specific embodiment, the filaments are sheath-core bicomponent filaments and the reclaimed polypropylene is present in the core component. The core of the bicomponent filament can be comprised of up to 100% reclaimed polypropylene.
    Type: Grant
    Filed: August 2, 2001
    Date of Patent: August 16, 2011
    Assignee: Fiberweb Simpsonville, Inc.
    Inventors: Jay Darrell Gillespie, Daniel Deying Kong, Robert C. Alexander
  • Publication number: 20110039063
    Abstract: Disclosed is a process for continuous perforation of fabrics that comprise thermoplastic fibers. The process utilizes a combination of heat and pressure to perforate fabrics where the shape. size, and distribution of the individual fabric perforations is define solely by the design of the pattern embossing roll, In particular, the top side of the individual embossing points are not flat but rather have a raised peripheral edge so that the actual fabric contact area of the bond points is much less than total area circumscribed by each bond point. The small ratio of fabric contact area to total bond area concentrates the thermal and compressive forces in the embossing nip and allows a large perforation to be cut out of a fabric moving at high speed through the perforation nip.
    Type: Application
    Filed: October 10, 2007
    Publication date: February 17, 2011
    Inventors: Samuel Charles Baer, Jay Darrell Gillespie, David D. Newkirk
  • Publication number: 20030203698
    Abstract: A spunbond nonwoven fabric useful as a topsheet is produced from polypropylene filaments including a high level of reclaimed polypropylene, while maintaining a product quality, including superior formation, comparable to that obtained when using 100 percent virgin polymer. The spunbond nonwoven fabric is made with multicomponent filaments having at least two different polymer components occupying different areas within the filament cross section, and wherein one of the polymer components comprises reclaimed polypropylene recovered from previously spun polypropylene fiber or webs comprised of previously spun polypropylene fiber. In a specific embodiment, the filaments are sheath-core bicomponent filaments and the reclaimed polypropylene is present in the core component. The core of the bicomponent filament can be comprised of up to 100% reclaimed polypropylene.
    Type: Application
    Filed: May 13, 2003
    Publication date: October 30, 2003
    Applicant: BBA Nonwoven Simpsonville, Inc.
    Inventors: Jay Darrell Gillespie, Daniel Deying Kong, Robert C. Alexander
  • Patent number: 6632504
    Abstract: A nonwoven web is provided which can be readily converted to an apertured web by stretching. In its initial non-apertured state, the web comprises a plurality of multicomponent fibers comprising at least two thermoplastic polymer components arranged in at least first and second separate continuous structured domains. The polymer component of the first domain comprises polyethylene. Prior to stretch aperturing, the web has a peak elongation of at least 100 percent and is characterized by having a plurality of discrete, spaced-apart, frangible bond sites of polymer bonding the fibers to form a coherent extensible nonwoven web. The frangible bond sites are structured and arranged to readily rupture when subjected to tensile stress to form discrete, spaced-apart apertures in the nonwoven fabric. The web has a total energy absorption in at least one of the machine direction or the cross-machine direction of at least 50 gcm/cm2.
    Type: Grant
    Filed: March 17, 2000
    Date of Patent: October 14, 2003
    Assignee: BBA Nonwovens Simpsonville, Inc.
    Inventors: Jay Darrell Gillespie, David D. Newkirk, Michael M. Thomason, Gregory W. Farell, Harold E. Thomas
  • Publication number: 20030041953
    Abstract: An apparatus for producing a thermally bonded nonwoven web and a process for producing such a web wherein there is provided a patterned embossing roll mounted for contacting the nonwoven web. The patterned embossing roll has an outer surface including a multiplicity of individual raised calender lands which are spaced apart from one another by intervening depressions, the raised calender lands being present at a concentration of 40 to 500 lands per square inch and forming from 4 to 40 percent of the surface area of the embossing roll, and the roll having a hard tie coating adhered to the surface of said roll core and overlying at least said depressions, and a fluoropolymer surface coating adhered to said tie coat.
    Type: Application
    Filed: August 31, 2001
    Publication date: March 6, 2003
    Applicant: BBA Nonwovens Simpsonville, Inc.
    Inventors: Gregory W. Farell, Jay Darrell Gillespie
  • Publication number: 20030032357
    Abstract: A spunbond nonwoven fabric useful as a topsheet is produced from polypropylene filaments including a high level of reclaimed polypropylene, while maintaining a product quality, including superior formation, comparable to that obtained when using 100 percent virgin polymer. The spunbond nonwoven fabric is made with multicomponent filaments having at least two different polymer components occupying different areas within the filament cross section, and wherein one of the polymer components comprises reclaimed polypropylene recovered from previously spun polypropylene fiber or webs comprised of previously spun polypropylene fiber. In a specific embodiment, the filaments are sheath-core bicomponent filaments and the reclaimed polypropylene is present in the core component. The core of the bicomponent filament can be comprised of up to 100% reclaimed polypropylene.
    Type: Application
    Filed: August 2, 2001
    Publication date: February 13, 2003
    Applicant: BBA Nonwovens Simpsonville, Inc.
    Inventors: Jay Darrell Gillespie, Daniel Deying Kong, Robert C. Alexander
  • Patent number: 6516472
    Abstract: Nonwoven fabrics and fabric laminates are formed from continuous filaments or staple fibers of a select blend of specific grades of polyethylene and polypropylene which give improved fabric performance not heretofore recognized or described, such as high abrasion resistance, good tensile properties, excellent softness and the like. Furthermore, these blends have excellent melt spinning and processing properties which permit efficiently producing nonwoven fabrics at high productivity levels. The polymers are present as a lower-melting dominant continuous phase and at least one higher-melting noncontinuous phase dispersed therein. The lower-melting continuous phase forms at least 70 percent by weight of the fiber and comprises a linear low density polyethylene polymer of a melt index of greater than 10 and a density of less than 0.945 g/cc. At least one higher-melting noncontinuous phase comprises a polypropylene polymer with melt flow rate of greater than 20 g/10 min.
    Type: Grant
    Filed: January 31, 2001
    Date of Patent: February 11, 2003
    Assignee: BBA Nonwovens Simpsonville, Inc.
    Inventors: Scott L. Gessner, J. Darrell Gillespie, Jared A. Austin, David D. Newkirk, William Fowells
  • Patent number: 6506698
    Abstract: The present invention provides a composite nonwoven fabric with a superior combination of extensibility, tensile properties and abrasion resistance. The composite nonwoven fabric (10) comprises at least one layer containing multipolymer fibers, with a plurality of bonds bonding the fibers together to form a coherent extensible nonwoven web (11). This coherent extensible nonwoven web (11) has a Taber surface abrasion value (rubber wheel) of greater than 10 cycles and an elongation at peak load in at least one of the machine direction or the cross-machine direction of at least 70%. A second extensible layer (12) is laminated to this coherent extensible nonwoven web (11).
    Type: Grant
    Filed: March 1, 2000
    Date of Patent: January 14, 2003
    Assignee: BBA Nonwovens Simpsonville, Inc.
    Inventors: Thomas E. Quantrille, Harold E. Thomas, Barry D. Meece, Scott L. Gessner, J. Darrell Gillespie, Jared A. Austin, David D. Newkirk, William Fowells
  • Patent number: 6465378
    Abstract: Nonwoven fabrics and fabric laminates are formed from continuous filaments or staple fibers of a select blend of specific grades of polyethylene and polypropylene which give improved fabric performance not heretofore recognized or described, such as high abrasion resistance, good tensile properties, excellent softness and the like. Furthermore, these blends have excellent melt spinning and processing properties which permit efficiently producing nonwoven fabrics at high productivity levels. The polymers are present as a lower-melting dominant continuous phase and at least one higher-melting noncontinuous phase dispersed therein. The lower-melting continuous phase forms at least 70 percent by weight of the fiber and comprises a linear low density polyethylene polymer of a melt index of greater than 10 and a density of less than 0.945 g/cc. At least one higher-melting noncontinuous phase comprises a polypropylene polymer with melt flow rate of greater than 20 g/10 min.
    Type: Grant
    Filed: January 31, 2001
    Date of Patent: October 15, 2002
    Assignee: BBA Nonwovens Simpsonville, Inc.
    Inventors: Scott L. Gessner, J. Darrell Gillespie, Jared A. Austin, David D. Newkirk, William Fowells
  • Patent number: 6448194
    Abstract: Nonwoven fabrics and fabric laminates are formed from continuous filaments or staple fibers of a select blend of specific grades of polyethylene and polypropylene which give improved fabric performance not heretofore recognized or described, such as high abrasion resistance, good tensile properties, excellent softness and the like. Furthermore, these blends have excellent melt spinning and processing properties which permit efficiently producing nonwoven fabrics at high productivity levels. The polymers are present as a lower-melting dominant continuous phase and at least one higher-melting noncontinuous phase dispersed therein The lower-melting continuous phase forms at least 70 percent by weight of the fiber and comprises a linear low density polyethylene polymer of a melt index of greater than 10 and a density of less than 0.945 g/cc. At least one higher-melting noncontinuous phase comprises a polypropylene polymer with melt flow rate of greater than 20 g/10 min.
    Type: Grant
    Filed: January 31, 2001
    Date of Patent: September 10, 2002
    Assignee: BBA Nonwovens Simpsonville, Inc.
    Inventors: Scott L. Gessner, J. Darrell Gillespie, Jared A. Austin, David D. Newkirk, William Fowells
  • Publication number: 20010005662
    Abstract: Nonwoven fabrics and fabric laminates are formed from continuous filaments or staple fibers of a select blend of specific grades of polyethylene and polypropylene which give improved fabric performance not heretofore recognized or described, such as high abrasion resistance, good tensile properties, excellent softness and the like. Furthermore, these blends have excellent melt spinning and processing properties which permit efficiently producing nonwoven fabrics at high productivity levels. The polymers are present as a lower-melting dominant continuous phase and at least one higher-melting noncontinuous phase dispersed therein. The lower-melting continuous phase forms at least 70 percent by weight of the fiber and comprises a linear low density polyethylene polymer of a melt index of greater than 10 and a density of less than 0.945 g/cc. At least one higher-melting noncontinuous phase comprises a polypropylene polymer with melt flow rate of greater than 20 g/10 min.
    Type: Application
    Filed: January 31, 2001
    Publication date: June 28, 2001
    Applicant: BBA Nonwovens Simpsonville. Inc.
    Inventors: Scott L. Gessner, Darrell Gillespie, Jared A. Austin, David D. Newkirk, William Fowells
  • Publication number: 20010004574
    Abstract: Nonwoven fabrics and fabric laminates are formed from continuous filaments or staple fibers of a select blend of specific grades of polyethylene and polypropylene which give improved fabric performance not heretofore recognized or described, such as high abrasion resistance, good tensile properties, excellent softness and the like. Furthermore, these blends have excellent melt spinning and processing properties which permit efficiently producing nonwoven fabrics at high productivity levels. The polymers are present as a lower-melting dominant continuous phase and at least one higher-melting noncontinuous phase dispersed therein. The lower-melting continuous phase forms at least 70 percent by weight of the fiber and comprises a linear low density polyethylene polymer of a melt index of greater than 10 and a density of less than 0.945 g/cc. At least one higher-melting noncontinuous phase comprises a polypropylene polymer with melt flow rate of greater than 20 g/10 min.
    Type: Application
    Filed: January 31, 2001
    Publication date: June 21, 2001
    Applicant: BBA Nonwovens Simpsonville, Inc.
    Inventors: Scott L. Gessner, J. Darrell Gillespie, Jared A. Austin, David D. Newkirk, William Fowells
  • Publication number: 20010003693
    Abstract: Nonwoven fabrics and fabric laminates are formed from continuous filaments or staple fibers of a select blend of specific grades of polyethylene and polypropylene which give improved fabric performance not heretofore recognized or described, such as high abrasion resistance, good tensile properties, excellent softness and the like. Furthermore, these blends have excellent melt spinning and processing properties which permit efficiently producing nonwoven fabrics at high productivity levels. The polymers are present as a lower-melting dominant continuous phase and at least one higher-melting noncontinuous phase dispersed therein. The lower-melting continuous phase forms at least 70 percent by weight of the fiber and comprises a linear low density polyethylene polymer of a melt index of greater than 10 and a density of less than 0.945 g/cc. At least one higher-melting noncontinuous phase comprises a polypropylene polymer with melt flow rate of greater than 20 g/10 min.
    Type: Application
    Filed: January 31, 2001
    Publication date: June 14, 2001
    Inventors: Scott L. Gessner, J. Darrell Gillespie, Jared A. Austin, David D. Newkirk, William Fowells
  • Patent number: 6207602
    Abstract: Nonwoven fabrics and fabric laminates are formed from continuous filaments or staple fibers of a select blend of specific grades of polyethylene and polypropylene which give improved fabric performance not heretofore recognized or described, such as high abrasion resistance, good tensile properties, excellent softness and the like. Furthermore, these blends have excellent melt spinning and processing properties which permit efficiently producing nonwoven fabrics at high productivity levels. The polymers are present as a lower-melting dominant continuous phase and at least one higher-melting noncontinuous phase dispersed therein. The lower-melting continuous phase forms at least 70 percent by weight of the fiber and comprises a linear low density polyethylene polymer of a melt index of greater than 10 and a density of less than 0.945 g/cc. At least one higher-melting noncontinuous phase comprises a polypropylene polymer with melt flow rate of greater than 20 g/10 min.
    Type: Grant
    Filed: March 12, 1997
    Date of Patent: March 27, 2001
    Assignee: BBA Nonwovens Simpsonville, Inc.
    Inventors: Scott L. Gessner, J. Darrell Gillespie, Jared A. Austin, David D. Newkirk, William Fowells
  • Patent number: 5804286
    Abstract: A fabric comprising at least two layers wherein at least one layer is an extensible, bonded non-woven composed of a fiber comprising multiple different polymers such as a fiber comprising isotactic polypropylene, polyethylene and a block or grafted polyolefin copolymer or terpolymer which is at least partially miscible with said polypropylene and polyethylene.
    Type: Grant
    Filed: August 27, 1996
    Date of Patent: September 8, 1998
    Assignee: Fiberweb North America, Inc.
    Inventors: Thomas E. Quantrille, Harold E. Thomas, Barry D. Meece, Scott L. Gessner, J. Darrell Gillespie, Jared A. Austin, David D. Newkirk, William Fowells
  • Patent number: 5783503
    Abstract: Multicomponent thermoplastic continuous filaments are provided, including hollow core multicomponent filaments. The filaments are at least partially splittable into smaller filaments in the absence of mechanical treatment or application of high pressure water jets. The surface energy of the components can be controlled to control separation of the multi-component filaments. Sub-denier and micro-denier filaments of low orientation can be produced from relatively high molecular weight polymers to produce nonwovens of surprising strength, barrier, and cover.
    Type: Grant
    Filed: July 22, 1996
    Date of Patent: July 21, 1998
    Assignee: Fiberweb North America, Inc.
    Inventors: Jay Darrell Gillespie, David Bruce Christopher, Harold Edward Thomas, John Henry Phillips, Scott Louis Gessner, Lloyd Edwin Trimble, Jared Asher Austin