Abstract: A composite polymeric material is provided that may be used to construct an abrasion resistant layer or sheet such as an abrasion resistant meltblown layer. Desirably, the composite polymeric material comprises blends of syndiotactic and isotactic polypropylene with ferroelectric materials. The composite polymeric material is particularly useful for constructing a filter media comprising an abrasion resistant fine fiber layer such as a nonwoven layer. The composite polymeric material of the present invention also allows for electret treatment to improve its filtration characteristics.

Abstract: A composite polymeric material is provided that may be used to construct an abrasion resistant layer or sheet such as an abrasion resistant meltblown layer. Desirably, the composite polymeric material comprises blends of syndiotactic and isotactic polypropylene with ferroelectric materials. The composite polymeric material is particularly useful for constructing a filter media comprising an abrasion resistant fine fiber layer such as a nonwoven layer. The composite polymeric material of the present invention also allows for electret treatment to improve its filtration characteristics.

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: The present invention provides multicomponent fine fiber webs and multilayer laminates thereof having an average fiber diameter less than about 7 micrometers and comprising a first olefin polymer component and a second distinct polymer component such as an amorphous polyolefin or polyamide. Multilayer laminates incorporating the fine multicomponent fiber webs are also provided such as, for example, spunbond/meltblown/spunbond laminates or spunbond/meltblown/meltblown/spunbond laminates. The fine multicomponent fiber webs and laminates thereof provide laminates having excellent softness, peel strength and/or controlled permeability.

Abstract: The present invention provides nonwoven laminate materials with high overall uniformity of material properties, particularly tensile strength properties. The present invention also includes methods for forming the nonwoven laminate materials wherein the fiber extrusion and drawing apparati are oriented at a non-right angle with respect to the direction of web production or MD.

Abstract: The present invention provides multicomponent fine fiber webs and multilayer laminates thereof having an average fiber diameter less than about 7 micrometers and comprising a first olefin polymer component and a second distinct polymer component such as an amorphous polyolefin or polyamide. Multilayer laminates incorporating the fine multicomponent fiber webs are also provided such as, for example, spunbond/meltblown/spunbond laminates or spunbond/meltblown/meltblown/spunbond laminates. The fine multicomponent fiber webs and laminates thereof provide laminates having excellent softness, peel strength and/or controlled permeability.

Abstract: A printable material which includes a flexible first layer having first and second surfaces and a second layer. The first layer may be a film or a cellulosic nonwoven web. The second layer overlays and is bonded to the first surface of the first layer and includes a nonwoven web. The first layer has a basis weight of from about 20 to about 140 grams per square meter. The thermoplastic polymer has a melting point of from about 90° C. to about 250° C. and the second layer has a basis weight of at least about 10 grams per square meter. The first layer may be a cellulosic nonwoven web, such as a latex-impregnated paper. The second layer may be thermally bonded to the first layer or bonded by an adhesive. A release layer may be present between the first layer and the heat-activated adhesive. The second layer may contain from about 0.1 to about 20 percent by weight, based on the weight of the second layer, of a material which increases the viscosity of an ink jet ink when printed on the second layer.

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: The present invention provides filtration materials and face masks that include a spunbonded/meltblown/spunbonded (SMS) laminate.

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 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: 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: 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: A printable material which includes a flexible first layer having first and second surfaces and a second layer. The first layer may be a film or a cellulosic nonwoven web. The second layer overlays and is bonded to the first surface of the first layer and includes a nonwoven web. The first layer has a basis weight of from about 20 to about 140 grams per square meter. The thermoplastic polymer has a melting point of from about 90° C. to about 250° C. and the second layer has a basis weight of at least about 10 grams per square meter. The first layer may be a cellulosic nonwoven web, such as a latex-impregnated paper. The second layer may be thermally bonded to the first layer or bonded by an adhesive. A release layer may be present between the first layer and the heat-activated adhesive. The second layer may contain from about 0.1 to about 20 percent by weight, based on the weight of the second layer, of a material which increases the viscosity of an ink jet ink when printed on the second layer.

Abstract: A printable material which includes a flexible first layer having first and second surfaces and a second layer. The first layer may be a film or a cellulosic nonwoven web. The second layer overlays and is bonded to the first surface of the first layer and includes a nonwoven web. The first layer has a basis weight of from about 20 to about 140 grams per square meter. The thermoplastic polymer has a melting point of from about 90° C. to about 250° C. and the second layer has a basis weight of at least about 10 grams per square meter. The first layer may be a cellulosic nonwoven web, such as a latex-impregnated paper. The second layer may be thermally bonded to the first layer or bonded by an adhesive. A release layer may be present between the first layer and the heat-activated adhesive. The second layer may contain from about 0.1 to about 20 percent by weight, based on the weight of the second layer, of a material which increases the viscosity of an ink jet ink when printed on the second layer.

Abstract: Nonwoven webs prepared from a blend of polymer and a migrating internal additive are heat treated only in selected regions to cause surface migration of the additive in those regions. The nonwoven webs have a desired property attributed to the additive in the selective regions. Regions surrounding the selected regions are not heat treated, and are either devoid of the desired property, or manifest the property to a lesser extent than in the heat treated regions.

Abstract: An absorbent article, such as the shown diaper (10), has a front waistband portion (14), a back waistband portion (12) and an intermediate portion (16) interconnecting said front and back waistband portions. The article includes a backsheet member (30), a liquid permeable topsheet layer (28), and an absorbent body (32) sandwiched between the topsheet layer (28) and backsheet member (30). The backsheet member includes an air permeable, polymer sheet layer (96), and a first, outward nonwoven fibrous web (94) attached to or otherwise operatively joined with a major facing surface (78) of the polymer sheet layer (96) at a plurality of individual, spaced apart thermal bonds (98).

Abstract: There is provided a fabric which has been produced in a pneumatic chamber which has tiny grooves over an effective amount of its fluid contacting surface. Also provided is a method of producing a web having greater uniformity by producing it with pneumatic chambers having surface grooves. Fabrics produced in such a manner have greater uniformity when measured by permeability, basis weight or CD and MD strength properties.

Abstract: There is provided a high speed rotary valve which is relatively simple in design and which can effectively regulate the flow of fluid under high temperature conditions in such a manner as to produce perturbations in the fluid stream. Such a valve may be used to regulate the flow of fluid, e.g. air, toward a work piece to produce a perturbation in the piece for example. The clearance between the rotor and stator is such that the flow of fluid is never completely cut off, i.e., the valve continues to "leak through" the closed outlet port even when the rotor and stator openings are not aligned. Fluids having temperatures in the range of 40 to at least 900.degree. F. may be processed through this valve. The valve is also useful in creating aerosols of liquids and gases and in producing blown fibers.