Abstract: A method includes the steps of co-extruding a first component and a second component. The first component has a recovery percentage R1 and the second component has a recovery percentage R2, wherein R1 is higher than R2. The first and second components are directed through a spin pack to form a plurality of continuous, molten fibers. The plurality of molten fibers is then routed through a quenching chamber to form a plurality of continuous cooled fibers. The plurality of continuous cooled fibers is then routed through a drawing unit to form a plurality of continuous, solid linear fibers. The linear fibers are then deposited onto a moving support, such ass a forming wire, to form an accumulation or fibers. The accumulation of fibers are stabilized and bonded to form a web. The web is then stretched by at least 50 percent in at least one direction before being allowed to relax.

Abstract: A method for producing a spunbonded nonwoven fabric by extruding a linear sheet of filaments arranged parallelly side by side in the form of a curtain from a plurality of spinning capillaries, involving aerodynamical pulling off and drawing of the filament sheet, the filament sheet (8) which emerges from the drawing duct (12) or which is pulled off a spool being moved laterally crosswise by an air flow having periodically changing directions, the air flow being oriented alternately at an angle toward the filament sheet (8) as viewed in the horizontal plane.

Abstract: A fibrous material and a method of producing it, the material is mainly intended to be incorporated in an absorbent article and comprises a layer of continuous fibers, so-called tow, which have been bonded together in points, lines or spots in a bonding pattern, but otherwise are substantially unbonded to each other. The tow layer is bonded with at least two bonding patterns: a first relatively strong and diffuse bonding pattern, and a second more distinct second bonding pattern. Bonding of at least the first bonding pattern takes place by thermobonding, wherein a pattern roll is used which provide the desired bonding patterns. In the first welding step the pattern roll is driven at a higher speed than the feeding speed of the tow layer, so as to create a relatively diffuse and strong bonding pattern.

Abstract: A method includes the steps of co-extruding a first component and a second component. The first component has a recovery percentage R1 and the second component has a recovery percentage R2, wherein R1 is higher than R2. The first and second components are directed through a spin pack to form a plurality of continuous, molten fibers. The molten fibers are then muted through a quenching chamber to form a plurality of continuous cooled fibers. The coiled fibers are then routed through a drawing unit to form a plurality of continuous, solid linear fibers. Each of the solid fibers is then stretched by at least 50 percent before it is allowed to relax. The relaxation step forms the linear fibers into a plurality of continuous 3-dimensional fibers each having a coiled configuration over at least a portion of its length. The continuous 3-dimensional, coiled fibers are then deposited onto a moving support to form a web.

Abstract: Methods for the use of laser beams in the case of plastic monofilaments are proposed. For structural modifying monofilaments or individual monofilaments of a monofilament union, the monofilament to be structurally modified is extruded with LS-absorbing additives and subsequently treated with laser beams.

Abstract: Nonwoven webs having substantially aligned fibers can be formed in an apparatus having a direction of motion corresponding to the direction of web formation. The web is formed in the presence of at least one secondary fluid stream that oscillates the filaments or resulting attenuated fibers to and fro generally in and against the direction of motion so that a majority of the collected fibers are aligned within ±20° of the direction of motion and fibers having lengths of about 1-10 cm can be teased from the web. The resulting nonwoven webs are especially useful for forming pleated filtration media having pleats generally transverse to the direction of motion.

Abstract: A rubber composition including a natural or synthetic rubber, and an adhesive resin capable of unexpected adhesion to metal, polymer and glass substrates, particularly cords in radical tires, hoses, conveyor belts, transmission belts, and the like by the addition of a liquid composition containing long chain esters, including mono, di- and trimesters.

Abstract: The female component for engaging a complementary hook component in a refastenable fastening device is capable of engaging a hook component that has flexible, resilient individual hook elements. The female component comprises at least two, and preferably three zones or layers. These include a first zone for admitting and engaging at least some of the hooks of the complementary hook component (the “entanglement” zone), a second zone for providing space for the hooks to occupy after they have been admitted by the entanglement zone (referred to as the spacing zone), and a backing adjacent to the spacing zone. The present invention also provides a fastening device having a hook fastening component and a female component that comprises the multi-layer female component of the present invention. The present invention also relates to disposable articles and more particularly to a disposable diaper having such an improved fastening device.

Abstract: Disclosed is a process for preparing a fibrous web. The fibrous web includes a microencapsulated material, such as a microencapsulated phase change material, adhered to the web. Preferably, the web is prepared in a melt-blowing or spun-bonding process. In the melt-blowing process, cooling water containing the microcapsules is used to cool melt blown fibers prior to collection on a collector. In the spun-bonding process, microcapsules are applied in liquid suspension or in dry form to a heated web, for instance, after the web has been calendared. The fibrous webs thus prepared have numerous uses, and are particularly suited to the manufacture of clothing.

Abstract: A synthetic leather made of a nonwoven fabric impregnated and/or coated with a polymer, with a surface weight of 100 to 500 g/m2, and a tensile strength greater than 300 N/5 cm in the lengthwise and the crosswise direction, where the nonwoven fabric is made up of melt-spun multi-component endless filaments, aerodynamically stretched and directly laid up to form a nonwoven material, having a titer less than 2 dTex, and wherein the multi-component endless filaments, after preliminary bonding, are split and bonded by at least 90% to produce supermicro endless filaments having a titer less than 0.2 dTex.

Abstract: A laminated composite suitable for use in medical products such as tapes and wraps. The composite includes, for example, a first nonwoven fiber layer, an elastic layer, a melt blown adhesive fiber layer, and a second nonwoven fiber layer. A scrim layer serves as a deadstop, or stretch limit, to prevent over stretching. The non-woven fiber layer(s) and/or the scrim layer form suitable loops for a hook and loop fastening system. The scrim layer in some embodiments is employed to make the composite finger tearable. The melt blown adhesive layer, nonwoven web layer and elastic layer form a breathable, porous elastic composite. Methods of manufacturing the composite are also disclosed.

Abstract: Robust homofilament fibers are meltspun from a differently shaped dual capillary spinneret design to induce differential fiber morphology to produce crimping. Crimping may further be aided by quenching and drawing of the fibers.

Abstract: A fluidized mixture is issued from a nozzle comprising a fan jet at the outlet, causing the mixture to spread as it is issued. The issued material is collected on a moving collection surface located a distance of between 0.25 and 13 cm from the outlet of the nozzle, prior to the onset of large scale turbulence in the fluid jet. The resulting product has good basis weight uniformity.

Abstract: A method and device for producing melt-spun continuous threads includes two preparers spaced apart from one another, at each of which a partial quantity of a preparation is applied to the threads. A first preparation is performed upstream of a first draw-off device and a second downstream of the first draw-off device. As a result, high cohesion of the filaments in the thread is achieved.

Abstract: The subject invention concerns nonwoven fabrics containing filaments of at least two different cross sections. The subject invention further pertains to methods used to produce these fabrics. In an embodiment specifically exemplified herein, the nonwoven fabric of the subject invention is made of nylon.

Abstract: A method for producing hydrophobic polyolefin-containing fibers or filaments, in particular cardable staple fibers, using spin finishes applied after spinning and stretching, that comprise at least one water-insoluble ester of a mono-, di-, tri- or tetrahydric alcohol with a molecular weight not exceeding 500 and a branched or straight chain fatty acid with between 12 and 30 carbon atoms, e.g. a water-insoluble ester of ethylene or propylene glycol, glycerol, neopentyl glycol, trimethylolethane or trimethylolpropane and at least one saturated or unsaturated fatty acid residue having 12-24 carbons atoms, an anionic or nonionic antistatic agent preferably being applied after crimping; fibers produced by the method; and nonwovens produced from such fibers.

Abstract: A conductive (electrical, ionic, and photoelectric) polymer membrane article, comprising a non-woven membrane of polymer fibers, wherein at least some of the fibers have diameters of less than one micron; and wherein the membrane has an electrical conductivity of at least about 10−6 S/cm. Also disclosed is the method of making such an article, comprising electrostatically spinning a spin dope comprising a polymer carrier and/or a conductive polymer or conductive nanoparticles, to provide inherent conductivity in the article.

Abstract: An apparatus for providing a uniform web of filaments comprises tube filament transport means exiting through a confined zone of reduced turbulence, which preferably comprises a delivery slot. The delivery slot is configured with sidewalls substantially parallel to one another and to the transport tubes, so that filaments undergo minimal machine direction deflection in the slot. Charging means within the slot charge the filaments for further cross direction separation. A method of providing a uniform web of filaments comprises transporting filaments through transport tubes, through a tapered transition member, and into a delivery slot. The delivery slot is defined by sidewalls that are substantially parallel to one another and to the transport tubes, so that minimal machine direction deflection of the filaments occurs. The filaments are also charged by electrostatic charging means while they are in the slot for further separation.

Abstract: Mechanically divisible multicomponent fibers have at least a component including poly(lactic acid) polymer and at least a second component including at aromatic polyester. The multicomponent fibers are particularly useful in the manufacture of nonwoven structures, and in particular nonwoven structures used as synthetic suede.

Abstract: An apparatus is provided for manufacturing a flexible sheet product having liquid absorbent qualities. The apparatus generally includes first and second competing vacuum systems pulling air in substantially opposite directions into first and second oppositely rotating screens, respectively. A molten polymer-based material, which is blown into the first and second competing vacuum systems, is pulled in substantially opposite directions onto the first and second oppositely rotating screens. The liquid polymer-based material fiberizes as it is being pulled apart by the competing vacuum systems creating a web of fibrous material which cures to develop the flexible sheet product having liquid absorbent qualities.

Abstract: A process for forming multiple component meltblown fibers by extruding a first distinct melt-processable polymer through a row of first extrusion orifices, simultaneously extruding a second distinct melt-processable polymer through a row of second extrusion orifices, fusing the first and second melt-processable polymers into extruded composite filaments after extrusion, and pneumatically attenuating and breaking the extruded composite filaments with jets of high velocity gas so as to form the multiple component meltblown fibers.

Abstract: Spun bond is made by collecting thermoplastic filaments on a perforated surface and the spun bond is then subjected to hydrodynamic consolidation with high-pressure water jets. The filaments before the formation of the spun bond or after the formation of the spun bond are treated with a wetting agent prior to the hydrodynamic consolidation.

Abstract: The present invention is directed to a process for forming a plurality of multi-layered filaments from multiple thermoplastic synthetic polymers and an apparatus containing a melt spinning beam comprising an orthogonal beam having disposed within said beam multiple polymer inlet passages each communicating with separate multiple coat hanger distribution manifolds, separate filters connected downstream of each coat hanger distribution manifold, a spinneret connected downstream of said filters with separate polymer flow passages communicating with separate exit orifices for spinning of said multi-layered filaments.

Abstract: The present invention relates to an intermediate web comprising of high glass transition polymer fibers. The fibers are spun at low to moderate speeds and have a relative crystallinity of from 10% to 75% of the maximum achievable crystallinity. The intermediate web is a low crystallinity web that exhibits shrinkage of more than 30% and elongation to break of more than 80% at high strain rates. This web can be heat treated to reduce shrinkage to less than 15% while the web is capable of at least about 60% elongation at a strain rate of at least about 50 second−1.

Abstract: Nonwoven laminates are made by a multi-station line comprising at least one spunbond die assembly and at least one meltblowing die assembly. Each station includes (a) a melt spinning die which can be selectively equipped with a spunbond die insert or a meltblowing die insert and (b) a moveable support structure for adjusting the proper die-to-collector distance, depending on the spunbond or meltblowing mode of operation. The multi-station line permits the selective manufacture of a variety of spunbond (S) and meltblown (M) laminates, including the S-M-S laminate.

Abstract: The invention relates to an insulation product comprising an elongated fibrous batt with at least a partial polymeric encapsulating layer formed by melt-blowing or melt spraying a polymeric composition onto one or more surfaces of the fibrous batt and, optionally, a separate vapor retarding layer applied to one or more surfaces of the fibrous batt and an apparatus for manufacturing such an insulation product.

Abstract: A method of forming a blown micro-fiber filtration unit having multiple overlapping layers of fibrous material and an active material applied over said layers, The fibrous material layers being fused together.

Abstract: A composite is first formed by depositing on a breathable but water-impermeable synthetic resin film, a multiplicity of molten binding polymer threads from a multiplicity of orifices so that there is substantial space between the threads. A second web, e.g. an open-pore structure is then bonded to the first web by the molten thread so that the composite retains the flexibility and softness of the open-pore structure and the breathability of the film.

Abstract: A seal member is attached to a peripheral edge portion of a filter body by being fused to semi-melted fibers that form the filter body when the semi-melted fibers are layered over a forming surface. Therefore, the formation of the filter body and the attachment of the seal member can be simultaneously accomplished.

Abstract: A filter portion of a filter includes a plurality of bag-like members. The bag-like members are formed in a container shape having an opening and disposed with intervals therebetween. The periphery of the opening of each bag-like member is supported by a supporting member, and the bag-like members are mutually connected by the supporting member. Consequently, the strength of the filter portion comprising the bag-like members is improved.

Abstract: An arrangement for forming a web of fibrous media wherein at least one formed layered portion is attenuated from a first die source selectively unto a first collector and successively combining such portion with at least another formed layered portion which is attenuated from a second die source selectively unto a second collector, at least one of the outer surfaces of the web of fibrous media being of comparatively smooth skin-like nature to minimize projecting fiber ends.

Abstract: A process of forming a nonwoven fabric is disclosed which comprises the steps of forming a precursor web of multicomponent substantially continuous filaments, exposing the precursor web to a hydraulic arrangement treatment to form apertures without causing substantial filament entanglement, and thereafter forming inter-filament bonds and an integrated web. The resulting apertured nonwoven fabrics have good hand and tactile aesthetics and have a great variety of uses including use in absorbent personal care products, garments, medical applications, and cleaning applications.

Abstract: A system and process for producing spunbond nonwoven fabric in which two or more polymeric components are separately melted and are separately directed through a distribution plate configured so that the separate molten polymer components combine at a multiplicity of spinnerette orifices to form filaments containing the two or more polymer components. Multicomponent filaments are extruded from the spinnerette orifices into a quench chamber where quench air is directed from a first independently controllable blower and into contact with the filaments to cool and solidify the filaments. The filaments and the quench air are directed into and through a filament attenuator and the filaments are pneumatically attenuated and stretched. The filaments are directed from the attenuator into and through a filament depositing unit and are deposited randomly upon a moving continuous air-permeable belt to form a nonwoven web of substantially continuous filaments.

Abstract: A liquid dispensing module dispenses multiple filaments of adhesive material from a single die to coat multiple strands of a substrate material. The liquid filaments are dispensed primarily in an oscillatory or back and forth manner such that each filament coats multiple strands of the substrate material. This results in a coated substrate that exhibits more uniform characteristics across the strands after they are secured to a substrate or substrates.

Abstract: Spunbond multicomponent filaments and nonwoven webs made from the filaments are disclosed. In accordance with the present invention, the multicomponent filaments contain a crimp enhancement additive. Specifically, the crimp enhancement additive is added to the polymeric component that has the slower solidification rate. The additive enhances crimp, allows for highly crimped filaments to be made at low fiber linear densities, improves the integrity of unbonded webs made from the filaments, and produces webs with improved stretch and cloth-like properties. The additive incorporated into the filaments is a random copolymer of butylene and propylene.

Abstract: The presently disclosed invention relates to a phenolic binder comprising a premix of a urea modified phenol-formaldehyde resole resin, a curing agent, and an additive selected from the group consisting of ammonium lignosulfonate, melamine and a melamine derivative. A method for reducing gaseous emissions in the manufacture of fibrous insulation materials is also disclosed.

Abstract: This invention relates to a nonwoven fabric made from a nylon and polyethylene blend. The addition of polyethylene enhances specific properties such as softness, lower production cost, improved process capabilities, and ease of further downstream processing such as bonding to other fabrics or itself.

Abstract: A unique isotropic sub-denier spunbond nonwoven product created by an apparatus and method comprising a unique multi-head resin metering system, a spinneret head with spinning sections, separated by a quench fluid extraction zone, a two sided, multilevel quench system, a fluid volume control infuser system which automatically guides the filaments into the filament drawing system while conserving energy by using a portion of the quench fluid as part of the drawing fluid and also minimizing turbulence at the entrance to the draw slot. The filament drawing system comprises a draw jet assembly with adjustable primary and secondary jet-nozzles and a variable width draw jet-slot. The entire draw jet assembly is moveable vertically for filament optimization. The offset, constant flow secondary jet-nozzle system provides an unexpectedly high velocity increment to the filaments by oscillating the filaments and increasing their drag resulting in remarkably low fiber denier on the order of 0.5 to 1.2.

Abstract: A new, novel and useful Oriented Thermoplastic Elastomer Thread Wound Golf Ball providing improved combinations of good spin for ball control on iron or wedge shots while providing for higher hardness and long travel with driver shots. The Oriented Thermoplastic Elastomer Thread Wound Golf Ball's performance is acheived by the incorporation of oriented thermoplastic elastomer threads in the golf ball design.

Abstract: Melt blown or spun bond nonwoven webs are formed by flowing fiber-forming material through a die cavity having a substantially uniform residence time and then through a plurality of orifices to form filaments, using air or other fluid to attenuate the filaments into fibers and collecting the attenuated fibers as a nonwoven web. Each die orifice receives a fiber-forming material stream having a similar thermal history. The physical or chemical properties of the nonwoven web fibers such as their average molecular weight and polydispersity can be made more uniform. Wide nonwoven webs can be formed by arranging a plurality of such die cavities in a side-by-side relationship. Thicker or multilayered nonwoven webs can be formed by arranging a plurality of such die cavities atop one another.

Abstract: A method of making spunmelt/film composite materials, as well as the product of the method, is described. The method is a continuous in-line process including in-line production of a continuous filament spunmelt web, placement of a film on the spunmelt web, optional placement of at least one nonwoven fabric on the film, joining or bonding of the formed layered structure by subjecting the layered structure to calendering using heated rolls. The basis weight of the continuous filament spunmelt web is from about 13.5 gsm to about 100 gsm and of the polyolefin film from about 10 gsm to about 40 gsm. The total composite basis weight tolerance ranges from about 25 gsm to about 150 gsm. No adhesive or secondary thermal bonding is utilized in the process.

Abstract: A spectrum inverter receives optical values from a scanning device and applies a spectrum inversion method to the optical values. The spectrum inversion method is selected based on a medium identifier that identifies the medium upon which the scanned image is formed. The resulting spectral space values are then output and may be used by an image output device to reproduce the scanned image.

Abstract: A versatile covering process enabled through the identification and manipulation of a plurality of variables present in the electrospinning method of the present invention. By manipulating and controlling various identified variables, it is possible to use electrospinning to predictably produce thin materials having desirable characteristics. The fibers created by the electrospinning process have diameters averaging less than 100 micrometers. Proper manipulation of the identified variables ensures that these fibers are still wet upon contacting a target surface, thereby adhering with each other to form a cloth-like material and, if desired, adhering to the target surface to form a covering thereon. The extremely small size of these fibers, and the resulting interstices therebetween, provides an effective vehicle for drug and radiation delivery, and forms an effective membrane for use in fuel cells.

Abstract: A spinneret 20 for producing easily splittable plural-component fibers includes two passages 22 and 26 for respectively delivering two incompatible polymers (A and B) to two sets of inclined capillaries 34-39, 46-51. The two sets of capillaries converge toward each other in a downstream direction and direct molten polymer streams to two respective rows of orifices 40-45, 52-57. The centerlines of the polymer A capillaries lie along axes that, when extended beyond the spinneret, are offset and non-intersecting with axes along which the centerlines of the polymer B capillaries lie, such that the centerlines of the extruded polymer streams are directed along non-intersecting axes. The capillary angles and orifice arrangement cause the extruded polymer streams to extend toward each other in an interleaved fashion, with the polymer streams contacting each other in a generally tangential manner.

Abstract: The present invention provides a process whereby high quality, well-coalesced spandex can be made by dry-spinning a high-melting thermoplastic polyurethane, bundling the as-spun filaments into a side-by-side relationship, and passing the bundled filaments over or through a guide. The spandex made by this method has high-heat settability, high denier uniformity, good knittability and weavability, and provides fabrics having good surface uniformity.

Abstract: A method of securing an elastic strand to a flat substrate or sheet of material moving the elastic strand and the sheet in a converging manner from a first position in which the elastic strand is spaced from the sheet to a second position in which the elastic strand contacts one surface of the sheet. A filament of adhesive is dispensed onto the strand in a pattern configured with adhesive masses coupled by thinner filament sections. The adhesive masses are contacted with the strand when the strand is in the first position. The strand is bonded to the substrate with at least the adhesive masses.

Abstract: An apparatus is provided for manufacturing a flexible sheet product having liquid absorbent qualities. The apparatus generally includes first and second competing vacuum systems pulling air in substantially opposite directions into first and second moving screens, respectively. A molten polymer-based material, which is blown into the first and second competing vacuum systems, is pulled in substantially opposite directions onto the first and second moving screens. The liquid polymer-based material fiberizes as it is being pulled apart by the competing vacuum systems creating a web of fibrous material which cures to develop the flexible sheet product having liquid absorbent qualities.

Abstract: A composite web including an elastically stretchable web and an inelastically stretchable web bonded together is stretched on a course defined between at least two nip roll pairs to obtain an elastically stretchable composite sheet. The composite web is brought into contact with a peripheral surface of at least one roll of each nip roll pair over an area of the peripheral surface defined by a quadrant of this roll's circular cross section.

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: Curled decorative grasses and methods for producing same are disclosed wherein the curled decorative grasses have improved bulk and simulate Spanish moss in color and appearance.