Abstract: A method of forming flame-retardant nonwoven fabrics by hydroentanglement includes providing a precursor web. The precursor web is subjected to hydroentanglement on a three-dimensional image transfer device to create a patterned and imaged fabric. Treatment with a flame-retardant binder enhances the integrity of the fabric, permitting the nonwoven to exhibit desired physical characteristics, including strength, durability, softness, and drapeability. The treated nonwoven may then be dyed by means applicable to conventional wovens.

Abstract: It is the objective of the present invention to disclose a method of continuously dyeing durable nonwoven fabrics, and more specifically, nonwoven fabrics comprising a cellulosic fibrous material dyed with indigo dyestuffs. It is in accordance with the present invention, to utilize synthetic fibers in combination with natural or cellulosic fibers in the formation of a nonwoven web. The natural fibers, preferably cotton, make up at least 10% of the fibrous nonwoven fabric.

Abstract: The present invention is directed to a method of using a nonwoven medical wrap, and more specifically, to a method of supplying a medical wrap in a continuous form for a more convenient means of wrapping surgical instruments. In a first embodiment, the medical wrap may be in rolled form comprising one or more plies that may be detached from the roll in user determined lengths.

Abstract: A method of electroforming tissue comprises creating stress in the tissue; and causing a direct current to flow in the tissue to change the stress, strain, or intrinsic mechanical properties including shape of the tissue. Force is mechanically applied to the tissue to create external stresses or material parameters of the tissue are used to create internal stresses in the tissue by causing a current to flow in the tissue. The method further comprises the step of monitoring the stresses in the tissue and controlling the current flowing in the tissue according to the stresses therein by monitoring impedance, the optical properties, the pH, acoustic properties of the tissue, the gas formation in the tissue, the color of the tissue as caused by a chemical dye disposed therein or as caused by electroplating a material thereon.

Abstract: The present invention is directed to a durable and imaged flame-retardant nonwoven fabric that can be used for flame-retardant apparel and other related applications. The fabric is formed by providing a precursor web consisting of a blend of melamine fibers and aramid fibers. The precursor web is hydroentangled on a three-dimensional image transfer device for formation of the fabric. The resultant fabric provides desirable air permeability and Thermal Protective Properties.

Abstract: A stretchable laminate is formed by providing a hydroentangled nonwoven fabric exhibiting cross-direction extensibility and recovery, which fabric comprises a nonwoven web of staple length fibers of about 0.8 to 3.0 denier having a basis weight of about 1.0 to 4.0 ounces per square yard. A polymeric binder composition substantially uniformly applied to the nonwoven web imparts desired elasticity to the web, with the fabric exhibiting at least about 50% extensibility in a cross-direction thereof, and at least about 90% recovery in a cross-direction. The nonwoven web may comprise synthetic fibers, natural fibers, and blends thereof, as well as continuous filaments. An elastomeric composition comprising polyurethane or polyvinylchloride is applied to the extensible nonwoven fabric, which forms the stretchable laminate. The laminate provides a highly conformable and aesthetically pleasing leather-like product.

Abstract: The present invention relates generally to nonwoven materials, and specifically, to a nonwoven fabric comprised of at least two continuous filament precursor webs, each precursor web being of a polyolefin polymer dissimilar from that of the other precursor web, wherein the resulting lightweight nonwoven laminate fabric exhibits improved tactile and ductile qualities, the nonwoven fabric being imminently suitable for application in improving the comfort and use of hygiene, medical and industrial products. The lightweight nonwoven fabric is manufactured with a minimum level of processes complexity, and can be either used as a replacement for an existing facing layer, such as a topsheet of a hygiene product, or used in conjunction with an existing construct so as to improve long-term comfort.

Abstract: The present invention is directed to a garment comprised of nonwoven fabric, and particularly, to nonwoven fabric garments that exhibit prolonged durability while maintaining acceptable fit and finish. Garments fabricated in accordance with the present invention are particularly suited for use in daily-wear applications, such as in shirts and blouses.

Abstract: A protective cover for protection of agricultural products comprises a fibrous nonwoven fabric exhibiting sufficient vapor permeability to alter or control the ripening of the agricultural product so ensconced while retarding passage of dust and insects. The protective cover is positioned generally about associated agricultural products, with the cover being particularly suited for use on products prior to harvest, such as bananas. The cover may be formed from fibrous and/or filamentary elements, and may be formed from fibrous material selected from the group consisting of thermoplastic polymers, thermoset polymers, natural fibers, and combinations thereof. The nonwoven fabric may be formed with protection-enhancing agents such as insecticidal, fungicidal, algaecidal, decay-inhibiting, and UV-protective agents. The nonwoven fabric may be pigmented as desired.

Abstract: A method of forming durable nonwoven fabrics by hydroentanglement includes providing a precursor web comprising a blend of matrix fibers, lyocell fibers, and fusible binder fibers. The precursor web is subjected to hydroentanglement on a three-dimensional image transfer device to create a patterned and imaged fabric. Fabrics formed in accordance with the present invention exhibit significant improvements in strength while remaining drapeable and are capable of withstanding multiple laundry washing with nominal shrinkage.

Abstract: It is the objective of the present invention to disclose a method of continuously dyeing durable nonwoven fabrics, and more specifically, nonwoven fabrics comprising a cellulosic fibrous material dyed with indigo dyestuffs. It is in accordance with the present invention, to utilize synthetic fibers in combination with natural or cellulosic fibers in the formation of a nonwoven web. The natural fibers, preferably cotton, make up at least 10% of the fibrous nonwoven 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: A stretchable laminate is formed by providing a hydroentangled nonwoven fabric exhibiting cross-direction extensibility and recovery, which fabric comprises a nonwoven web of staple length fibers of about 0.8 to 3.0 denier having a basis weight of about 1.0 to 4.0 ounces per square yard. A polymeric binder composition substantially uniformly applied to the nonwoven web imparts desired elasticity to the web, with the fabric exhibiting at least about 50% extensibility in a cross-direction thereof, and at least about 90% recovery in a cross-direction. The nonwoven web may comprise synthetic fibers, natural fibers, and blends thereof, as well as continuous filaments. An elastomeric composition comprising polyurethane or polyvinylchloride is applied to the extensible nonwoven fabric, which forms the stretchable laminate. The laminate provides a highly conformable and aesthetically pleasing leather-like product.

Abstract: A method of forming flame-retardant nonwoven fabrics by hydroentanglement includes providing a precursor web. The precursor web is subjected to hydroentanglement on a three-dimensional image transfer device to create a patterned and imaged fabric. Treatment with a flame-retardant binder enhances the integrity of the fabric, permitting the nonwoven to exhibit desired physical characteristics, including strength, durability, softness, and drapeability. The treated nonwoven may then be dyed by means applicable to conventional wovens.

Abstract: A multi-component nonwoven fabric can be formed with integrated liquid-acceptance and liquid-distribution layers by hydroentanglement on a three-dimensional image transfer device. Appropriate fiber selection promotes efficient fluid management, with the fabric optionally being provided with a liquid-retention layer. The invention further contemplates the formation of liquid-retention layers by hydroentanglement, with such layers exhibiting desirably high structural integrity, while providing the desired absorbent characteristics required for use in disposable absorbent products.

Abstract: The present invention is directed to a durable and imaged flame-retardant nonwoven fabric that can be used for flame-retardant apparel and other related applications. The fabric is formed by providing a precursor web consisting of a blend of melamine fibers and aramid fibers. The precursor web is hydroentangled on a three-dimensional image transfer device for formation of the fabric. The resultant fabric provides desirable air permeability and Thermal Protective Properties.