Patents by Inventor Jeffrey D. Stark

Jeffrey D. Stark 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: 11598026
    Abstract: A spun-blown non-woven web is disclosed which is formed from a plurality of fibers formed from a single polymer having an average fiber diameter ranging from between about 0.5 microns to about 50 microns; a basis weight of at least about 0.5 gsm; a tensile strength, measured in a machine direction, ranging from between about 20 g to about 4,200 g; a ratio of tensile strength, measured in the machine direction, to basis weight of at least about 20:1; and a ratio of percent elongation, measured in the machine direction, to fiber diameter of at least about 15.
    Type: Grant
    Filed: July 17, 2017
    Date of Patent: March 7, 2023
    Assignee: BIAX-FIBERFILM CORPORATION
    Inventors: Douglas B. Brown, Jeffrey D. Stark, Mohammad A. Hassan
  • Patent number: 10961644
    Abstract: A high loft, nonwoven web is disclosed having a three dimensional structure with fibers oriented in the x, y and z directions. The web has a fiber size distribution of from 0 ?m to about 15 ?m with at least about 25% of the fibers being above 4 ?m. The web has a thickness of less than about 250 millimeters and a basis weight ranging from about 20 g/m2 to about 3,000 g/m2. The web also has a vertical cross-section, when taken parallel to a machine direction, exhibiting a plurality of snugly stacked, approximately V, U or C-shaped structures, with each V, U or C-shaped structure having an apex facing in the machine direction. The web further has a recovery value ranging from about 20% to about 99% after being compressed under a pressure of 0.25 psi for a time period of 30 minutes.
    Type: Grant
    Filed: January 23, 2017
    Date of Patent: March 30, 2021
    Assignee: Biax-Fiberfilm Corporation
    Inventors: Douglas B Brown, Jeffrey D Stark, Mohammad A. Hassan
  • Patent number: 10704173
    Abstract: A process for forming a high loft, nonwoven web is disclosed. The process includes introducing a single molten polymer to a die having a plurality of nozzles. Emitting the molten polymer through the nozzles to form a plurality of filaments. Using air streams to facilitate movement and drawing of the filaments. Directing the filaments, which are transformed into fibers, towards a pair of heated moving surfaces. The pair of heated moving surfaces forming a convergent passage having an entry and an exit. Depositing the fibers into the entry of the convergent passage and routing the fibers between the pair of heated moving surfaces in a machine direction to form a high loft, non-woven web. The web having a fiber size distribution of from 0 ?m to about 15 ?m with at least about 25% of the fibers being above 4 ?m.
    Type: Grant
    Filed: February 9, 2017
    Date of Patent: July 7, 2020
    Assignee: Biax-Fiberfilm Corporation
    Inventors: Douglas B Brown, Jeffrey D Stark, Mohammad A. Hassan
  • Patent number: 10633774
    Abstract: A hybrid non-woven web is disclosed which is a matrix of a stream of fibers of a first material joined to streams of first and second spun-blown fibers. Each of the first and second spun-blown fibers are formed from a thermoplastic composition that contains at least one polymer having a melt flow rate of from between about 5 grams/10 minutes to about 6,000 grams/10 minutes at 230° C. Each of the first and second spun-blown fibers also have an average diameter of between about 1 microns to 10 microns and a standard deviation of from between about 0.9 microns to about 5 microns. In addition, the hybrid non-woven web has a tensile strength of at least about 5 gf/gsm/cm width, measured in a machine direction. An apparatus and a method of forming the hybrid non-woven web are also disclosed.
    Type: Grant
    Filed: May 13, 2015
    Date of Patent: April 28, 2020
    Assignee: Biax-Fiberfilm Corporation
    Inventors: Douglas B. Brown, Jeffrey D. Stark, Mohammad A. Hassan
  • Publication number: 20180002832
    Abstract: A spun-blown non-woven web is disclosed which is formed from a plurality of fibers formed from a single polymer having an average fiber diameter ranging from between about 0.5 microns to about 50 microns; a basis weight of at least about 0.5 gsm; a tensile strength, measured in a machine direction, ranging from between about 20 g to about 4,200 g; a ratio of tensile strength, measured in the machine direction, to basis weight of at least about 20:1; and a ratio of percent elongation, measured in the machine direction, to fiber diameter of at least about 15.
    Type: Application
    Filed: July 17, 2017
    Publication date: January 4, 2018
    Applicant: Biax-Fiberfilm Corporation
    Inventors: Douglas B. Brown, Jeffrey D. Stark, Mohammad A. Hassan
  • Publication number: 20170211216
    Abstract: A process for forming a high loft, nonwoven web is disclosed. The process includes introducing a single molten polymer to a die having a plurality of nozzles. Emitting the molten polymer through the nozzles to form a plurality of filaments. Using air streams to facilitate movement and drawing of the filaments. Directing the filaments, which are transformed into fibers, towards a pair of heated moving surfaces. The pair of heated moving surfaces forming a convergent passage having an entry and an exit. Depositing the fibers into the entry of the convergent passage and routing the fibers between the pair of heated moving surfaces in a machine direction to form a high loft, non-woven web. The web having a fiber size distribution of from 0 ?m to about 15 ?m with at least about 25% of the fibers being above 4 ?m.
    Type: Application
    Filed: February 9, 2017
    Publication date: July 27, 2017
    Inventors: Douglas B Brown, Jeffrey D Stark, Mohammad A. Hassan
  • Publication number: 20170152616
    Abstract: A high loft, nonwoven web is disclosed having a three dimensional structure with fibers oriented in the x, y and z directions. The web has a fiber size distribution of from 0 ?m to about 15 ?m with at least about 25% of the fibers being above 4 ?m. The web has a thickness of less than about 250 millimeters and a basis weight ranging from about 20 g/m2 to about 3,000 g/m2. The web also has a vertical cross-section, when taken parallel to a machine direction, exhibiting a plurality of snugly stacked, approximately V, U or C-shaped structures, with each V, U or C-shaped structure having an apex facing in the machine direction. The web further has a recovery value ranging from about 20% to about 99% after being compressed under a pressure of 0.25 psi for a time period of 30 minutes.
    Type: Application
    Filed: January 23, 2017
    Publication date: June 1, 2017
    Inventors: Douglas B. Brown, Jeffrey D. Stark, Mohammad A. Hassan
  • Publication number: 20170121874
    Abstract: An apparatus for making a high loft, non-woven web exhibiting excellent recovery is disclosed. The web has a 3-dimensional structure with fibers oriented in the x, y and z directions. The apparatus includes a die having 2 to 20 rows of nozzles with each row containing a plurality of nozzles. A pair of moving surfaces is located from a distal end of each nozzle. The pair of moving surfaces form a convergent passage. A pair of heaters is used to heat each of the pair of moving surfaces. A plurality of filaments are deposited onto the pair of moving surfaces and are routed through the convergent passage to form a 3-dimensional structure having two thin outer skins.
    Type: Application
    Filed: January 18, 2017
    Publication date: May 4, 2017
    Inventors: Douglas B. Brown, Jeffrey D. Stark, Mohammad A. Hassan
  • Patent number: 9309612
    Abstract: A process is disclosed for forming a non-woven web.
    Type: Grant
    Filed: May 7, 2014
    Date of Patent: April 12, 2016
    Assignee: Biax-Fiberfilm
    Inventors: Douglas B. Brown, Jeffrey D. Stark, Mohammad A. Hassan
  • Patent number: 9303334
    Abstract: An apparatus is disclosed for forming a non-woven web.
    Type: Grant
    Filed: May 7, 2014
    Date of Patent: April 5, 2016
    Assignee: Biax-fiberfilm
    Inventors: Douglas B. Brown, Jeffrey D. Stark, Mohammad A. Hassan
  • Publication number: 20150322603
    Abstract: A process is disclosed for forming a non-woven web.
    Type: Application
    Filed: May 7, 2014
    Publication date: November 12, 2015
    Applicant: BIAX-FIBERFILM
    Inventors: Douglas B. Brown, Jeffrey D. Stark, Mohammad A. Hassan
  • Publication number: 20150322592
    Abstract: An apparatus is disclosed for forming a non-woven web.
    Type: Application
    Filed: May 7, 2014
    Publication date: November 12, 2015
    Applicant: BIAX-FIBERFILM
    Inventors: Douglas B. Brown, Jeffrey D. Stark, Mohammad A. Hassan
  • Publication number: 20150322602
    Abstract: A non-woven web is disclosed.
    Type: Application
    Filed: May 7, 2014
    Publication date: November 12, 2015
    Applicant: BIAX-FIBERFILM
    Inventors: Douglas B. Brown, Jeffrey D. Stark, Mohammad A. Hassan
  • Publication number: 20150322601
    Abstract: A hybrid non-woven web is disclosed which is a matrix of a stream of fibers of a first material joined to streams of first and second spun-blown fibers. Each of the first and second spun-blown fibers are formed from a thermoplastic composition that contains at least one polymer having a melt flow rate of from between about 5 grams/10 minutes to about 6,000 grams/10 minutes at 230° C. Each of the first and second spun-blown fibers also have an average diameter of between about 1 microns to 10 microns and a standard deviation of from between about 0.9 microns to about 5 microns. In addition, the hybrid non-woven web has a tensile strength of at least about 5 gf/gsm/cm width, measured in a machine direction. An apparatus and a method of forming the hybrid non-woven web are also disclosed.
    Type: Application
    Filed: May 13, 2015
    Publication date: November 12, 2015
    Inventors: Douglas B. Brown, Jeffrey D. Stark, Mohammad A. Hassan
  • Publication number: 20150211158
    Abstract: A process for forming a high loft, nonwoven web exhibiting excellent recovery.
    Type: Application
    Filed: January 29, 2014
    Publication date: July 30, 2015
    Applicant: BIAX-FIBERFILM
    Inventors: Mohammad A. Hassan, Douglas B. Brown, Jeffrey D. Stark
  • Publication number: 20150211160
    Abstract: A high loft, nonwoven web exhibiting excellent recovery.
    Type: Application
    Filed: January 29, 2014
    Publication date: July 30, 2015
    Applicant: BIAX-FIBERFILM
    Inventors: Mohammad A. Hassan, Douglas B. Brown, Jeffrey D. Stark
  • Publication number: 20150211159
    Abstract: An apparatus for making a high loft, nonwoven web exhibiting excellent recovery.
    Type: Application
    Filed: January 29, 2014
    Publication date: July 30, 2015
    Applicant: BIAX-FIBERFILM
    Inventors: Mohammad A. Hassan, Douglas B. Brown, Jeffrey D. Stark
  • Patent number: 8303888
    Abstract: A process is disclosed of forming cellulose fibers. The process includes extruding an aqueous solution of cellulose and a solvent through a first member to form filaments. The first member has multiple rows of first and second openings with a nozzle positioned in each of the first openings. At least one of the nozzles in one row is staggered from at least one of the nozzles in an adjacent row. At least a portion of each of the filaments is shrouded in a pressurized gas emitted through each of the first openings. Each of the filaments is contacted with a liquid to remove some of the solvent and transform each of the filaments into a continuous solid fiber. The continuous solid fibers are then collected on a moving surface to form a non-woven cellulose web.
    Type: Grant
    Filed: April 11, 2008
    Date of Patent: November 6, 2012
    Assignee: Reifenhauser GmbH & Co. KG
    Inventors: Douglas B. Brown, Jeffrey D. Stark, Carmen A. Granato, Sr., Duane K. Zacharias
  • Patent number: 8029259
    Abstract: An array of nozzles is disclosed for forming multiple cellulose fibers. Each nozzle has a longitudinal central axis and includes a tube with a cross-section having a diameter through which an aqueous solution of cellulose and a solvent can be extruded into a molten filament. A first opening is present which surrounds each of the tubes. The first opening has a cross-section with a diameter, and each of the first openings is capable of emitting a pressurized gas which surrounds one of the extruded molten filaments. At least three second openings are spaced away from each of the first openings. Each of the second openings is capable of emitting a pressurized gas stream essentially parallel to the longitudinal central axis of each of the nozzles, and each of the pressurized gas streams functions to shroud one of the extruded molten filaments.
    Type: Grant
    Filed: April 11, 2008
    Date of Patent: October 4, 2011
    Assignee: Reifenhauser GmbH & Co. KG Maschinenfabrik
    Inventors: Douglas B. Brown, Jeffrey D. Stark, Carmen A. Granato, Sr., Duane K. Zacharias
  • Patent number: D864997
    Type: Grant
    Filed: April 15, 2019
    Date of Patent: October 29, 2019
    Assignee: Google LLC
    Inventors: Elizabeth Belg, Christopher Bettig, Steve Rura, Peter Smith, Jeffrey D. Stark, Katrin Von Niederhäusern, Mario Sifuentes, Johanne Bruun Rasmussen