Abstract: Bulked continuous filament yarns comprise a plurality of substantially continuous filaments comprising propylene polymer and having recovery from compression, as measured by Plug Crush Recovery, of at least about 85%. The yarns exhibit improved resilience and are well suited as face yarns for residential, commercial and automotive carpets.

Abstract: The present invention is directed to crimped and resilient polymeric fibers and to fabrics and laminates made from the fibers. In general, the fibers are produced by crimping a polymeric fiber and then cross-linking a polymer and/or monomer contained within the fiber. Cross-linking the polymer makes the crimp contained with the fiber more permanent and more resilient. When formed into a nonwoven web, the fibers produce high loft fabrics which are resilient to compressive forces. Nonwoven webs made in accordance with the present invention are particularly well suited for use in filter products and liquid absorbent products.

Abstract: There is provided herein a protective cover made from conjugate fiber nonwoven fabric having a basis weight between about 1 and 8 osy laminated with a film. The conjugate fibers may be in a configuration such as sheath/core, side-by-side and islands in the sea and may be formed from polyolefins and polyamides. The preferred fiber embodiments are a side-by-side polypropylene-polyethylene fiber and a sheath/core polyethylene/nylon 6 fiber. The fabric is preferably extrusion coated with a polyethylene film to form the protective cover. The cover is light weight, waterproof and provides sufficient burst and tensile strength so that the cover may be used during transportation of, for example, a boat.

Abstract: The present invention provides conjugate fibers having an ethylene polymer component and a propylene polymer component, which are highly crimpable even at fine deniers. Also provided are nonwoven fabrics made from the fibers. The propylene polymer component of the conjugate fiber contains a propylene polymer having a melt flow rate between about 50 g/10 min. and 200 g/10 min. as measured in accordance with ASTM D1238, Testing Condition 230/2.16.

Abstract: Laminates with improved peel strength are obtained by point bonding thermoplastic layers wherein one of the layers comprises sheath/core bicomponent fibers or filaments wherein the density of the core component exceeds the density of the sheath component and both layers contain compatible components. Peel strengths of at least about 125% of those obtained without such bicomponent fibers or filaments are obtained. Laminates with films and other nonwovens also have a broad bonding window. They are useful for many nonwoven applications including barrier applications such as health care including surgical gowns and drapes, institutional garments, agricultural fabrics, recreational fabrics, and personal care product components.

Abstract: The present invention provides a pattern bonded nonwoven fabric containing conjugate fibers. The conjugate fibers contain a higher melting component polymer and a lower melting component polymer, wherein the higher melting component polymer envelopes the lower melting component polymer and forms the peripheral surface along the length of the fibers. The present invention also provides articles produced from the conjugate fiber fabric.

Abstract: The present invention provides a conjugate fiber containing a polyolefin and a polyamide selected from polycaprolactam, copolymers of caprolactam and hexamethylene adipamide, hydrophilic copolymers of caprolactam and ethylene oxide diamine, and blends thereof, wherein the polyamide has a number average molecular weight up to about 16,500. Further provided are a nonwoven fabric produced from the conjugate fiber and the process of producing the nonwoven fabric.

Abstract: The present invention provides a point bonded polyolefin nonwoven fabric fabricated from conjugate fibers containing a polyolefin and a polyamide. Advantageously, the nonwoven fabric can be point bonded at a temperature significantly below conventional polyolefin nonwoven web bonding temperatures and in a wide range of different bonding temperatures without significantly sacrificing its tensile strength. Additionally provided is a process for producing the point bonded nonwoven fabric.