Abstract: A pleated filter is made from a monocomponent monolayer nonwoven web of continuous monocomponent meltspun partially crystalline and partially amorphous oriented fibers of the same polymeric composition that are bonded to form a coherent and handleable web having a Gurley Stiffness of at least 100 mg and which further may be softened while retaining orientation and fiber structure. Rows of pleats are formed in the nonwoven web, and the web is cut to a desired size and shape to provide a pleated filter element containing a self-supporting porous monocomponent monolayer matrix of fibers bonded to one another at least some points of fiber intersection and having an average initial submicron efficiency of at least 15% at a 1.52 meters/sec face velocity. The filter element is deformation resistant without requiring stiffening layers, bicomponent fibers, adhesive or other reinforcement in the filter media layer.

Abstract: A pleated filter is made from a monocomponent monolayer nonwoven web of continuous monocomponent meltspun partially crystalline and partially amorphous oriented fibers of the same polymeric composition that are bonded to form a coherent and handleable web having a Gurley Stiffness of at least 100 mg and which further may be softened while retaining orientation and fiber structure. Rows of pleats are formed in the nonwoven web, and the web is cut to a desired size and shape to provide a pleated filter element containing a self-supporting porous monocomponent monolayer matrix of fibers bonded to one another at least some points of fiber intersection and having an average initial submicron efficiency of at least 15% at a 1.52 meters/sec face velocity. The filter element is deformation resistant without requiring stiffening layers, bicomponent fibers, adhesive or other reinforcement in the filter media layer.

Abstract: Nonwoven fibrous webs comprise fibers of uniform diameter that vary in morphology along their length. The variation provides longitudinal segments that exhibit distinctive softening characteristics during a bonding operation. Some segments soften under the conditions of the bonding operation and bond to other fibers of the web, and other segments are passive during the bonding operation. Webs as described can be formed by a method that comprises a) extruding filaments of fiber-forming material; b) directing the filaments through a processing chamber in which the filaments are subjected to longitudinal stress; c) subjecting the filaments to turbulent flow conditions after they exit the processing chamber; and d) collecting the processed filaments; the temperature of the filaments being controlled so that at least some of the filaments solidify while in the turbulent field.

Abstract: Nonwoven fibrous webs including amorphous polymeric fibers with improved and/or more convenient bondability are disclosed. The nonwoven fibrous webs may include only amorphous polymeric fibers or they may include additional components in addition to amorphous polymeric fibers. The amorphous polymeric fibers within the web may be autogeneously bonded or autogeneously bondable. The amorphous polymeric fibers may be characterized as varying in morphology over the length of continuous fibers so as to provide longitudinal segments that differ from one another in softening characteristics during a selected bonding operation.

Abstract: A new fiber-forming method, and related apparatus, and webs prepared by the new method and apparatus are taught. In the new method a) a stream of filaments is extruded from a die of known width and thickness; b) the stream of extruded filaments is directed through a processing chamber that is defined by two narrowly separated walls that are parallel to one another, parallel to said width of the die, and parallel to the longitudinal axis of the stream of extruded filaments; c) the stream of filaments passed through the processing chamber is intercepted on a collector where the filaments are collected as a nonwoven fibrous web; and d) a spacing between the walls of the processing chamber is selected that causes the stream of extruded filaments to spread before it reaches the collector and be collected as a web significantly wider in width than the die. Generally the increase in width is sufficient to be economically significant, e.g., to reduce costs of web manufacture.

Abstract: A method for making a bonded nonwoven fibrous web comprising 1) providing a nonwoven fibrous web that comprises oriented semicrystalline polymeric fibers, and 2) subjecting the web to a controlled heating and quenching operation that includes a) forcefully passing through the web a fluid heated to at least the onset melting temperature of said polymeric material for a time too short to wholly melt the fibers, and b) immediately quenching the web by forcefully passing through the web a fluid at a temperature at least 50° C. less than the Nominal Melting Point of the material of the fibers. The fibers of the treated web generally have i) an amorphous-characterized phase that exhibits repeatable softening (making the fibers softenable) and ii) a crystallite-characterized phase that reinforces the fiber structure during softening of the amorphous-characterized phase, whereby the fibers may be autogenously bonded while retaining orientation and fiber structure.

Abstract: A pleated filter is made from a monocomponent monolayer nonwoven web of continuous monocomponent meltspun partially crystalline and partially amorphous oriented fibers of the same polymeric composition that are bonded to form a coherent and handleable web having a Gurley Stiffness of at least 100 mg and which further may be softened while retaining orientation and fiber structure. Rows of pleats are formed in the nonwoven web, and the web is cut to a desired size and shape to provide a pleated filter element containing a self-supporting porous monocomponent monolayer matrix of fibers bonded to one another at at least some points of fiber intersection and having an average initial submicron efficiency of at least 15% at a 1.52 meters/sec face velocity. The filter element is deformation resistant without requiring stiffening layers, bicomponent fibers, adhesive or other reinforcement in the filter media layer.

Abstract: Nonwoven fibrous webs including amorphous polymeric fibers with improved and/or more convenient bondability are disclosed. The nonwoven fibrous webs may include only amorphous polymeric fibers or they may include additional components in addition to amorphous polymeric fibers. The amorphous polymeric fibers within the web may be autogeneously bonded or autogeneously bondable. The amorphous polymeric fibers may be characterized as varying in morphology over the length of continuous fibers so as to provide longitudinal segments that differ from one another in softening characteristics during a selected bonding operation.

Abstract: Nonwoven fibrous webs comprise fibers of uniform diameter that vary in morphology along their length. The variation provides longitudinal segments that exhibit distinctive softening characteristics during a bonding operation. Some segments soften under the conditions of the bonding operation and bond to other fibers of the web, and other segments are passive during the bonding operation. Webs as described can be formed by a method that comprises a) extruding filaments of fiber-forming material; b) directing the filaments through a processing chamber in which the filaments are subjected to longitudinal stress; c) subjecting the filaments to turbulent flow conditions after they exit the processing chamber; and d) collecting the processed filaments; the temperature of the filaments being controlled so that at least some of the filaments solidify while in the turbulent field.

Abstract: A new fiber-forming method, and apparatus useful for performing the method, are taught in which extruded filaments of fiber-forming material are directed through a processing chamber that is defined by two parallel walls, at least one of which is instantaneously movable toward and away from the other wall; preferably both walls are instantaneously movable toward and away from one another. Movement means provide instantaneous movement to the at least one movable wall. In one embodiment, the movement means comprises biasing means for resiliently biasing the wall toward the other wall. Movement of the wall toward and away from the other wall is sufficiently easy and rapid that the wall will move away from the other wall in response to increases in pressure within the chamber but will be quickly returned to its original position by the biasing means upon resumption of the original pressure within the chamber.

Abstract: Nonwoven fibrous webs including amorphous polymeric fibers with improved and/or more convenient bondability are disclosed. The nonwoven fibrous webs may include only amorphous polymeric fibers or they may include additional components in addition to amorphous polymeric fibers. The amorphous polymeric fibers within the web may be autogeneously bonded or autogeneously bondable. The amorphous polymeric fibers may be characterized as varying in morphology over the length of continuous fibers so as to provide longitudinal segments that differ from one another in softening characteristics during a selected bonding operation.

Abstract: Nonwoven fibrous webs comprise fibers of uniform diameter that vary in morphology along their length. The variation provides longitudinal segments that exhibit distinctive softening characteristics during a bonding operation. Some segments soften under the conditions of the bonding operation and bond to other fibers of the web, and other segments are passive during the bonding operation. Webs as described can be formed by a method that comprises a) extruding filaments of fiber-forming material; b) directing the filaments through a processing chamber in which the filaments are subjected to longitudinal stress; c) subjecting the filaments to turbulent flow conditions after they exit the processing chamber; and d) collecting the processed filaments; the temperature of the filaments being controlled so that at least some of the filaments solidify while in the turbulent field.

Abstract: A new fiber-forming method, related apparatus, and new fibers prepared by the method are taught. In the method extruded filaments of fiber-forming material are directed through a processing chamber that is defined by two parallel walls, at least one of which is instantaneously movable toward and away from the other wall; preferably both walls are instantaneously movable toward and away from one another. Movement means provide instantaneous movement to the at least one movable wall. New fibers collected as a product of the process can include fiber randomly interrupted by isolated fiber segments, the isolated fiber segments constituting a minor amount of the fiber and forming the terminus of an unaffected main portion of the fiber, being of a fiber form, and having a larger diameter than the main portion of the fiber. The isolated fiber segments usually comprise oriented polymer chains but differ in morphology from the main portion of the fiber.

Abstract: A new fiber-forming method, and related apparatus, are taught in which extruded filaments of fiber-forming material are directed through a processing chamber that is defined by two parallel walls, at least one of which is instantaneously movable toward and away from the other wall; preferably both walls are instantaneously movable toward and away from one another. Movement means provide instantaneous movement to the at least one movable wall. In one embodiment, the movement means comprises biasing means for resiliently biasing the wall toward the other wall. Movement of the wall toward and away from the other wall is sufficiently easy and rapid that the wall will move away from the other wall in response to increases in pressure within the chamber but will be quickly returned to its original position by the biasing means upon resumption of the original pressure within the chamber. In another embodiment the movement means comprises oscillating means for oscillating the wall at a rapid rate.

Abstract: A new fiber-forming method, and apparatus useful for performing the method, are taught in which extruded filaments of fiber-forming material are directed through a processing chamber that is defined by two parallel walls, at least one of which is instantaneously movable toward and away from the other wall; preferably both walls are instantaneously movable toward and away from one another. Movement means provide instantaneous movement to the at least one movable wall. In one embodiment, the movement means comprises biasing means for resiliently biasing the wall toward the other wall. Movement of the wall toward and away from the other wall is sufficiently easy and rapid that the wall will move away from the other wall in response to increases in pressure within the chamber but will be quickly returned to its original position by the biasing means upon resumption of the original pressure within the chamber.

Abstract: A new fiber-forming method, and related apparatus, and webs prepared by the new method and apparatus are taught. In the new method a) a stream of filaments is extruded from a die of known width and thickness; b) the stream of extruded filaments is directed through a processing chamber that is defined by two narrowly separated walls that are parallel to one another, parallel to said width of the die, and parallel to the longitudinal axis of the stream of extruded filaments; c) the stream of filaments passed through the processing chamber is intercepted on a collector where the filaments are collected as a nonwoven fibrous web; and d) a spacing between the walls of the processing chamber is selected that causes the stream of extruded filaments to spread before it reaches the collector and be collected as a web significantly wider in width than the die. Generally the increase in width is sufficient to be economically significant, e.g., to reduce costs of web manufacture.

Abstract: A new fiber-forming method, and related apparatus, are taught in which extruded filaments of fiber-forming material are directed through a processing chamber that is defined by two parallel walls, at least one of which is instantaneously movable toward and away from the other wall; preferably both walls are instantaneously movable toward and away from one another. Movement means provide instantaneous movement to the at least one movable wall. In one embodiment, the movement means comprises biasing means for resiliently biasing the wall toward the other wall. Movement of the wall toward and away from the other wall is sufficiently easy and rapid that the wall will move away from the other wall in response to increases in pressure within the chamber but will be quickly returned to its original position by the biasing means upon resumption of the original pressure within the chamber. In another embodiment the movement means comprises oscillating means for oscillating the wall at a rapid rate.

Abstract: A method of inhibiting algae growth on an asphalt shingle surface exposed to varying humidity using a blend of copper-containing algae-resistant granules and non-algae-resistant granules. The copper-containing algae-resistant granules comprise a substrate granule having at least one inner ceramic coating layer comprising cuprous oxide and a seal coating having a thickness covering the inner layer and which is at time t.sub.o devoid of copper.

Abstract: An electrically regenerable diesel particulate trap or filter comprising an electrically resistive expanded metal sheet or sleeve which when energized heats the filter element to a temperature sufficient to allow the trapped soot particulates to burn.

Abstract: A diesel particulate trap has a filtering element which is a mass of fibrous filter material that radially fills a tubular casing. The filtering element employs lofty yarn extending in straight lines in a repeating pattern, which lines of lofty yarn have been compacted to form a plurality of fibrous walls that intersect to form tunnels extending in the axial or longitudinal direction of the casing. Some of the tunnels are filled with plugs that afford structural integrity while others of the tunnels remain open. The ends of the filtering element are covered by endplates. Substantially one-half of the open tunnels are axially aligned with openings in the inlet endplate and with imperforate areas in the outlet endplate, and the other open tunnels are axially aligned with openings in the outlet endplate and with imperforate areas in the inlet endplate. Exhaust gases entering tunnels open to the inlet pass through the compact fibrous walls and exit through tunnels open to the outlet.