Abstract: The invention describes making core structures for tooling panels air permeable and resistant to higher temperatures. Core structures may be a non-woven made from fibers that may be treated with an adhesion promoter. The fiber is then treated with an outer-coating. Proper choice of outer coating allows the tooling panel to function at higher temperatures. The non-woven core may be constructed in various dimensions. Air permeability allows tooling panels to show superior response to changing temperatures. The non-woven may be bonded with another to form a larger tooling panel. The outer surface of the tooling panel may be coated with a material such as rigid foam that can be machined to a pattern placed in contact with material in manufacture a part. The permeable core structure can be made from permeated plastic, wood, metal, ceramic and the like.

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: 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: 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: The present invention provides continuously crimped propylene polymer nonwoven fabrics as well as processes for forming crimped multicomponent propylene polymer fibers by melt-attenuating extruded multicomponent fibers with heated or unheated air wherein the fibers spontaneously crimp without the need for additional heating and/or stretching steps.

Abstract: A method for stretching nonwoven sheet material in the cross-machine direction includes coursing a nonwoven sheet material through a deformable nip, the nip being formed between two rotating stretch surfaces having intermeshing peaks and troughs, the surfaces of the peaks and troughs being covered with a deformable material, and contemporaneously pressing the stretch surfaces together while rotating them, such that as the nonwoven material travels through the nip, the nip deforms from an initial flat formation into a convoluted formation.

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: Process for treating a textile product comprising propylene polymer fibers comprises heating the textile product with the fibers in a substantially relaxed state at at least one temperature that is below the melting point of the propylene polymer but no more than about 20.degree. C. below such melting point. In one embodiment, the propylene polymer fibers subjected to such heating are characterized by a particular crystalline microstructure as determined by small angle X-ray diffraction. In another embodiment, the propylene polymer fibers subjected to such heating are melt spun, oriented fibers heated at at least one lower temperature.

Abstract: There is provided a wiper comprising a first web of fibers of at most 50 microns in diameter wherein said web has been bonded using a point unbonded pattern having a bond area between about 25 and 50 percent. The wiper can be made from thermoplastic polymer nonwoven fibers made by the meltblowing, spunbonding, carding and bonding, or airlaying processes. The wiper may be a laminate of various thermoplastic layers joined with the point unbonded pattern and may be a coform web of thermoplastic polymer and pulp or other material.

Abstract: Propylene polymer fibers are characterized by a unique crystalline microstructure as determined by small angle X-ray diffraction. The fibers and yarns comprising same exhibit improved recovery from compression and bending and are suited for a wide range of applications including geotextile, apparel and upholstery fabrics, carpet yarns and other textile products.

Abstract: There is provided a absorbent material for personal care products which is made from wettable fibers of at most 40 microns in diameter which are made into a web and where the web has controlled spaces in the side away from a wearer point unbonded bonding pattern. The web will accept a liquid insult of 50 ml with a runover/run-through percentage ratio of less than 1.5.

Abstract: The present invention is directed to a pattern-unbonded nonwoven fabric having continuous bonded areas defining a plurality of discrete unbonded areas, which is suitable for use as an improved loop fastening material for hook and loop fastening systems. The fibers or filaments within the discrete unbonded areas of the present invention are dimensionally stabilized by the continuous bonded areas that encircle or surround each unbonded area. The spaces between fibers or filaments within the unbonded areas remain sufficiently open or large to receive and engage hook elements of a complementary hook material. The hook material can be any of a wide variety of commercially available hook components which, as is known in the art, typically include a base material from which a plurality of hook elements project.

Abstract: Nonwoven fabrics having a desirable level of bulk, elasticity and low permanent set are produced by creasing a precursor web and heat setting the creases. Such webs may have varying basis weights and compositions depending on the intended end use. Applications disclosed include components for personal care products such as disposable diapers and feminine hygiene products, for example, as well as garment applications such as training pants, surgical gowns and the like. Also, absorbent products such as wipers are disclosed. Methods for forming the creased nonwoven fabric are disclosed using interdigitated rolls for creasing in the machine direction or in the cross-machine direction.

Abstract: The present invention provides a splittable conjugate fiber containing at least two incompatible polymers that are arranged in distinct segments across the cross-section of the fiber, wherein the segments are continuous along the length of the fiber. The fiber can be characterized in that the segments of the fiber dissociate in less than about 30 seconds when contacted with a hot aqueous fibrillation-inducing medium. The invention also provides a fabric containing the split fibers produced from the precursor splittable conjugate fiber and laminates containing the split fiber fabric. Additionally provided is a process for producing the split fibers.