Abstract: The present invention is directed to a nonwoven composite fabric for use on batteries or fuel cells comprising one or more layers of fine denier spunbond filaments and at least one layer of barrier material, wherein said nonwoven composite fabric has an improved barrier performance as measured by an increase in the hydrostatic head to barrier layer basis weight ratio. In the present invention, a first fine denier layer is formed, comprising continuous spunbond thermoplastic filaments, with the size of the continuous filaments between about 0.7 and 1.2 denier, preferably less than or equal to 1 denier. A barrier layer is deposited onto the first fine denier layer. The barrier layer preferentially comprises microfibers of finite length, wherein the average fiber diameter is in the range of about 1 micron to about 10 microns, and preferably between about 1 micron and 5 microns, said layers being consolidated into a composite fabric.

Abstract: The present invention relates to a nonwoven substrate, and specifically to a nonwoven substrate imparted with a three-dimensional image, wherein the three-dimensional nonwoven substrate is particularly suited as a support substrate for a PCB (Printed Circuit Board) and similar application. By the utilization of a hydroentangled, three-dimensionally imaged support substrate impregnated with a durable resinous matrix, PCB's, and similar applications, can be imparted with unique and useful performance properties, to improve structural performance.

Abstract: The present invention is directed to a nonwoven fabric, and more specifically to a nonwoven fabric comprised of at least one foreground region and at least one background region, wherein the foreground region of the fabric is an extension of the background region of the fabric in the z-direction and imparted with an enhanced physical and/or aesthetic performance which is dissimilar to a performance that may be imparted within the background region. The foreground region is further characterized in that such region may extend away from the background region so that a continuous or discontinuous path is described. Further still, the foreground and background regions may be of similar or dissimilar basis weights.

Abstract: A protective layer embodying the principles of the present invention is configured for protection of automotive surfaces, including specifically, the protection of a truck-bed against wear induced by a truck-bed liner. The protective layer has a substantially planar configuration sized to permit the layer to be positioned generally between an associated truck-bed liner and a truck-bed, whereby the abrasion is significantly reduced. The layer comprises a fibrous nonwoven fabric formed from fibrous and/or filamentary elements, with the fibrous nonwoven fabric exhibiting a sufficiently reduced coefficient of friction and sufficient durability to absorb or distribute abrasive actions, while allowing passage of moisture, thus protecting the automotive surfaces against potentially detrimental environmental conditions.

Abstract: The present invention is directed to a nonwoven fabric, and more specifically to a nonwoven fabric comprised of at least one foreground region and at least one background region, wherein the foreground region of the fabric is an extension of the background region of the fabric in the z-direction and imparted with an enhanced physical and/or aesthetic performance which is dissimilar to a performance that may be imparted within the background region. The foreground region is further characterized in that such region may extend away from the background region so that a continuous or discontinuous path is described. Further still, the foreground and background regions may be of similar or dissimilar basis weights.

Abstract: The present invention is directed to absorbent articles comprised of one or more components exhibiting an improved barrier to basis weight performance. The improved barrier performance of the aforementioned absorbent article components is a result of supplying a strong and durable nonwoven substrate layer followed by deposition of a nano-denier, essentially continuously filament barrier layer onto the nonwoven substrate layer thereby providing absorbent articles that exhibit enhanced barrier performance in comparison to conventional absorbent articles.

Abstract: The present invention is directed to medical fabrics, and more specifically, to medical gowns and drapes comprised of nonwoven compound fabrics with improved barrier performance relative to basis weight, wherein the improved nonwoven compound fabrics are prepared by supplying a strong and durable substrate layer followed by deposition of a nano-denier, essentially continuously filament barrier layer onto the substrate layer thereby providing nonwoven barrier materials, which exhibit enhanced barrier performance in comparison to conventional medical gowns and drapes.

Abstract: A method of forming a nonwoven fabric suitable for metal-finishing buffing operations includes providing a precursor web comprising polyester, staple length fibers, with hydroentanglement of the web effected to impart desired physical characteristics. Hydroentanglement is effected on a three-dimensional, image transfer device having an array of three-dimensional surface elements for patterning the fabric which is formed. Application of a binder composition lends desired durability to the fabric, with the binder composition preferably including a melamine polymeric composition to achieve the desired strength and abrasion resistance.

Abstract: The present invention is directed to enhancing the cleaning of surfaces by the contact application of a non-apertured nonwoven fabric having a three-dimensional image imparted therein. The three-dimensional image of the non-apertured nonwoven fabric induces the formation of lather due to pronounced surface projections that come in contact with the cleaning surface and provide air passageways that are parallel to the plane of the substrate. The imaged nonwoven fabric disclosed herein exhibits low linting qualities thereby reducing the potential of fiber contamination of the cleaned surface and is sufficiently durable that the sample can be used in a brisk manner.

Abstract: A method of providing a color enhanced, patterned nonwoven based composite fabric wherein a hydroentangled, imaged nonwoven facing fabric exhibits variable fiber density in selected regions and where a colored backing material is laminated to the facing layer such that the color of the backing layer is observed as variable hues which coincide with regions of lower fiber density in the facing layer.

Abstract: A method of forming a nonwoven fabric suitable for metal-finishing buffing operations includes providing a precursor web comprising polyester, staple length fibers, with hydroentanglement of the web effected to impart desired physical characteristics. Hydroentanglement is effected on a three-dimensional, image transfer device having an array of three-dimensional surface elements for patterning the fabric which is formed. Application of a binder composition lends desired durability to the fabric, with the binder composition preferably including a melamine polymeric composition to achieve the desired strength and abrasion resistance.

Abstract: The present invention is directed to enhancing the aesthetic appearance of surfaces by the contact application of a nonwoven fabric having a three-dimensional image imparted therein. The three-dimensional image of the nonwoven fabric induces a topical modification in either the actual or perceived texture of a surface when the imaged nonwoven fabric is applied to, then removed from, the surface. The imaged nonwoven fabric disclosed herein exhibits low linting qualities thereby reducing the potential of fiber contamination of the treated surface and is sufficiently durable that the sample can be used and rinsed clean a plurality of times, markedly increasing the working life-span.

Abstract: A method of providing a color enhanced, patterned nonwoven based composite fabric wherein a hydroentangled, imaged nonwoven facing fabric exhibits variable fiber density in selected regions and where a colored backing material is laminated to the facing layer such that the color of the backing layer is observed as variable hues which coincide with regions of lower fiber density in the facing layer.

Abstract: A protective layer embodying the principles of the present invention is configured for protection of automotive surfaces, including specifically, the protection of a truck-bed against wear induced by a truck-bed liner. The protective layer has a substantially planar configuration sized to permit the layer to be positioned generally between an associated truck-bed liner and a truck-bed, whereby the abrasion is significantly reduced. The layer comprises a fibrous nonwoven fabric formed from fibrous and/or filamentary elements, with the fibrous nonwoven fabric exhibiting a sufficiently reduced coefficient of friction and sufficient durability to absorb or distribute abrasive actions, while allowing passage of moisture, thus protecting the automotive surfaces against potentially detrimental environmental conditions.

Abstract: The present invention is directed to a nonwoven composite fabric for use on batteries or fuel cells comprising one or more layers of fine denier spunbond filaments and at least one layer of barrier material, wherein said nonwoven composite fabric has an improved barrier performance as measured by an increase in the hydrostatic head to barrier layer basis weight ratio. In the present invention, a first fine denier layer is formed, comprising continuous spunbond thermoplastic filaments, with the size of the continuous filaments between about 0.7 and 1.2 denier, preferably less than or equal to 1 denier. A barrier layer is deposited onto the first fine denier layer. The barrier layer preferentially comprises microfibers of finite length, wherein the average fiber diameter is in the range of about 1 micron to about 10 microns, and preferably between about 1 micron and 5 microns, said layers being consolidated into a composite fabric.

Abstract: The present invention is directed to a protective outdoor fabric comprising one or more layers of fine denier spunbond filaments and at least one layer of barrier material, wherein said protective outdoor fabric has a significant barrier performance as measured by the hydrostatic head to barrier layer basis weight ratio being of about at least 4.9 cm/gsm. In the preferred practice of the present invention, first and second outer fabric layers are formed, each comprising continuous filament spunbond layers of thermoplastic fibers, with the size of the continuous filaments between about 0.7 and 1.2 denier, preferably less than or equal to 1 denier. The barrier layer preferentially comprises microfibers of finite length, wherein the average fiber diameter is in the range of about 1 micron to about 10 microns, and preferably between about 1 micron and 5 microns, said layers being consolidated into a composite fabric.

Abstract: The present invention is directed to a soap-bar cover comprising a water-permeable fabric, and particularly a soap-bar cover exhibiting a stretch and recovery performance while maintaining a substantially planar surface. Soap-bar covers fabricated in accordance with the present invention are particularly useful as a means for enhancing the cleansing properties of commercially available soap-bar products. The soap-bar cover is composed of a woven or nonwoven fabric exhibiting stretch and recovery properties. Use of a stretch and recovery fabric in the soap-bar cover allows for the cover to conform to the contours of the soap-bar and is thus able to adjust to a wide variety of soap-bar profiles including cubic and ovoid.

Abstract: The present invention is directed to enhancing the cleaning of surfaces by the contact application of a non-apertured nonwoven fabric having a three-dimensional image imparted therein. The three-dimensional image of the non-apertured nonwoven fabric induces the formation of lather due to pronounced surface projections that come in contact with the cleaning surface and provide air passageways that are parallel to the plane of the substrate. The imaged nonwoven fabric disclosed herein exhibits low linting qualities thereby reducing the potential of fiber contamination of the cleaned surface and is sufficiently durable that the sample can be used in a brisk manner.

Abstract: The present invention relates to a nonwoven substrate, and specifically to a nonwoven substrate imparted with a three-dimensional image, wherein the three-dimensional nonwoven substrate is particularly suited as a support substrate for a PCB (Printed Circuit Board) and similar application.