Abstract: Embodiments of the invention provide method for producing an internally-tufted laminate adapted to provide improved softness and cloth-like feel. In one embodiment, a process for producing a polymeric layer comprises forcing polymeric fibers through a forming surface to produce the polymeric layer, the polymeric layer having a plurality of projections, each projection surrounded by a valley.

Abstract: A method and a device are provided for bonding a dry fiber strip to a dry fiber strand in continuous, uninterrupted operation. A bonding agent, activatable by supplying heat, is provided on the fiber strip and the fiber strand, which has at least one flat mantle surface. The fiber strip and the fiber strand are unwound from respective supply rolls, and the flat mantle surface of the fiber strand is positioned on the fiber strip during the unwinding procedure. Heat is supplied during the unwinding procedure to cause activation of the binder and gluing of the fiber strip and the fiber strand.

Abstract: The invention relates to a new base interlining for producing roofing membranes which have to meet a wide variety of requirements. The new base interlining provides a sufficient mechanical stability, good perforation strength, good tensile strength and a high resistance to thermal stress, inter alia required for base interlining during bituminization. In addition, the new base interlining requires a considerable reduced volume of impregnating bitumen when producing bituminized roofing materials and therefore high costs of special bitumens for filling the base interlining can be avoided. Beside the new base interlining, a method for producing it as well as roofing membranes comprising the base interlining are subject matter of this invention.

Abstract: The invention concerns a plant for manufacturing parts made of composite material, in particular sections for an aircraft fuselage, having at least a compaction station in which, in operation, there are provided a mandrel coated of composite material to be compacted and a transport mechanism arranged to transport at least one compaction device on said composite material. The transport mechanism is associated with at least one sling having at least one strip of porous material that, in operation, is in direct contact with the compaction device, and the sling is configured to transport the compaction device onto the composite material through application of a vacuum source at least to the strip of porous material. The invention also concerns a method of and an apparatus for manufacturing parts made of composite material.

Abstract: A technique for incorporating odor control agent particles into an absorbent article is provided. More specifically, the odor control particles are “homogenously” distributed (e.g., in a substantially uniform manner) within an airformed fiber matrix of an absorbent core of an absorbent article. An absorbent core containing such a homogeneously distributed odor control particles may possess a greater surface area for contacting malodorous compounds, thereby increasing the likelihood of odor reduction.

Abstract: A vane having a profile capable of formation by pultrusion is disclosed. The vane can be used for removing liquids entrained in a gas stream. The vane includes a main curved section oriented generally parallel to the gas stream and curved to reorient the gas stream, the main curved section causing a first and a second change of direction of the gas stream; a first air pocket formed on a first side of the main curved section, the first air pocket sized and oriented into the gas stream where the gas stream first changes direction; and a second air pocket formed on a second side of the main curved section, the second air pocket smaller than the first air pocket and sized and oriented into the gas stream where the gas stream makes the second direction change.

Abstract: An elastic nonwoven laminate is made by applying spaced zones of adhesive to a face of an elastic film such that adhesive-free zones are left between the adhesive zones. This elastic film carrying the adhesive zones is advanced in a travel direction, and an unconsolidated fleece nonwoven layer of filaments is applied to the face of the advancing film such that the fleece layer adheres to the film at the adhesive zones. The fleece layer can be formed by extruding a multiplicity of fibers or filaments and depositing them directly on the face of the film. Alternately they can be deposited on a conveyor that transports the fleece to the film and presses it against the film. Either way, the fleece layer is not consolidated and the fleece layer is not compacted prior to application to the glued side of the film.

Abstract: An apparatus for fabricating a unique nonwoven fabric which has the appearance of a woven fabric includes a supply station for parallel warp yarns, a support structure for orienting the parallel warp yarns into a cylindrical orientation, a weft yarn applicator for wrapping weft yarns around the cylindrically oriented warp yarns after an adhesive scrim has been overlaid onto the warp yarns, a heating station for activating the adhesive and a cooling station for setting the adhesive, and a cutter for severing the cylindrically formed fabric laminate so that it can be flattened and wrapped onto a take-up roller. The weft yarn applicator including a rotating drum wherein a plurality of spools of weft yarn material are mounted in circumferentially spaced relationship and a tensioner is provided for applying the weft yarn material around the warp yarns in a predetermined tension which may be the same as, greater than, or less than the tension in the warp yarns.

Abstract: Included is a tip end portion being a feeding position from which a filiform elastic member is fed. By an arm member guiding the elastic member, the tip end portion is alternately moved in a first direction and a second direction, and thereby the elastic member is brought into contact with the web and is arranged in a gather waveform. Here, the first direction is from the center portion of a web being conveyed in a predetermined direction and having sequentially-arranged component parts forming one part of an absorbent article, to a first end portion in a cross direction crossing with a conveyance direction, and the second direction is from the center to a second end portion which is an end portion opposite to the first end portion. At this time, in a planar view of a composite web, when a nip point exceeds a position where an angle between the conveyance direction and a tangent to the gather waveform is largest, a distance between the tip end portion and the nip point is largest.

Abstract: An efficient flexible hose construction is provided which incorporates resistance, when subjected to high negative pressure loads, to the collapse failure known “rollover” or “shingling”. The construction relates to a means of increasing the torsion capability of a flexible hose where the hose is formed from a helical wire that is coated and thereafter is connected to and supports a shroud or cover. Improved resistance to rollover lies in mechanical enhancements to the interface between the helical wire and the coating material, where the enhancement assists in maintaining the wire and coating as an integral unit and prevents separation leading to shingling under high vacuum pressures. The mechanical enhancement requires use of a specialized cross-section for the helical reinforcing wire.

Abstract: A manufacturing method for an absorptive article according to the present invention includes: placing a continuum of the elastic members 4A and 5A in a desired layout, on at least one surface of a web 7A being transported continuously, while swinging the continuum of the elastic members 4A and 5A in a direction crossing a moving direction of the web 7A; feeding the web 7A on which the continuum of the elastic members 4A and 5A are placed, between a first roll 8, which is rotating in the moving direction, and a second roll 9; and pressing the continuum of the elastic members 4A and 5A, and the web 7A between the first roll 8 and the second roll 9.

Abstract: An elastic and resilient film for application to an endless moving handrail includes a first film layer having a top surface and a bottom surface and further including one or more materials selected from Thermoplastic Olefin (TPO), Thermoplastic Elastormer (TPE), Thermoplastic Ionomer Resins, metallized Thermoplastic Polyurethane, Thermoplastic Vulcanizate (TPV), Polyvinylidene Fluoride (PVDF), and Thermoplastic Polyurethane/Polyolefin blends, wherein a first adhesive is on a bottom surface of the first film layer, an optional second film layer has a top surface and a bottom surface, with print applied to the top surface of the first film layer and an adhesive is on the bottom surface of the second film layer, and a substantially transparent film layer overlying the top surface of the second layer.

Abstract: A method and a device are provided for bonding a dry fiber strip to a dry fiber strand in continuous, uninterrupted operation. A bonding agent, activatable by supplying heat, is provided on the fiber strip and the fiber strand, which has at least one flat mantle surface. The fiber strip and the fiber strand are unwound from respective supply rolls, and the flat mantle surface of the fiber strand is positioned on the fiber strip during the unwinding procedure. Heat is supplied during the unwinding procedure to cause activation of the binder and gluing of the fiber strip and the fiber strand.

Abstract: A laminating roller assembly comprises a frame, a movable support supported by the frame, a laminating roller and a lift mechanism. The laminating roller is attached to the movable support. The lift mechanism is attached to the frame and is configured to move the movable support and the attached laminating roller relative to the frame. Additional embodiments of the invention are directed to a credential substrate laminator and a method of laminating a credential substrate using a credential substrate laminator.

Abstract: This invention is directed to a process for the fabrication of features on a silicon wafer utilizing ribbons comprising organic polymer and inorganic material.

Abstract: A transport belt and method of making a transport belt for a web-processing machine, in particular a paper machine, paperboard machine or tissue machine, is provided. The transport belt has a load-bearing carrier structure which is covered at least in sections by a polymer areal structure, as the result of which the polymer areal structure and the load-bearing carrier structure make contact with each other in sections either indirectly or directly. The contact region between the load-bearing carrier structure and the polymer areal structure comprises sections in which the carrier structure can move relative to the polymer areal structure.

Abstract: The subject invention provides non-woven fabrics having yarns of varying characteristics. In a preferred embodiment the subject invention provides nonwoven fabrics that comprise yarns of different deniers or cross sections. The use of these yarns gives the nonwoven fabric a unique appearance and advantageous properties. The subject invention further pertains to the processes used to produce these fabrics.

Abstract: Disclosed is an apparatus for producing nonwoven fibrous webs. The apparatus comprises an extrusion die, first and second fluid supplies in cooperation with the die, first and second extrusion capillaries, first counterbores allowing fluid communication between first capillaries and first supply and second counterbores allowing fluid communication between second capillaries and second supply, each first counterbore having at least two first capillaries extending therefrom.

Abstract: Disclosed herein are elastic laminate materials. The elastic laminate materials are laminates of extensible nonwoven fibrous webs and thermoplastic elastic materials. The laminate may be a two-layer composite material having a single nonwoven fibrous web bonded to one side of the thermoplastic elastic material, or it may be a three-layer composite having a nonwoven fibrous web bonded to each side of the thermoplastic elastic material. The extensible nonwoven fibrous webs may be staple fiber webs. The thermoplastic elastic material may be single-layer or multi-layer elastic films, or elastic fibrous layers. Where single- or multi-layer elastic films are used, the films may be breathable films. The elastic material, or some of the staple fibers, or both, may be selected such that the staple fiber webs are thermally compatible with the thermoplastic elastic material to facilitate laminate bonding. Processes for forming the elastic laminate material are also disclosed.

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: A method of applying leg elastics to absorbent garments involves optimizing the spacing between multiple elastic members. The elastic members are bonded to a substrate with variable spacing along the length of the leg opening. More particularly, narrower spacing is provided in the crotch area, thereby providing higher gasketing pressure, while wider spacing is provided in areas outside the crotch area for lower gasketing pressure and greater comfort. Alternatively, narrower spacing can be applied to the back portion of the leg, with medium spacing in the crotch area and wider spacing in the front portion or the leg, or conversely, wider spacing in the back portion with medium spacing in the crotch area and narrower spacing in the front portion, depending on the wearer's needs. The resulting garments have optimized comfort, fit and containment about the leg openings.

Abstract: A method of producing an endless belt includes the steps of: securing axial fibers relative to a mandrel, the axial fibers being spaced apart from one another at desired intervals and extending substantially parallel to a longitudinal axis of the mandrel; applying a polymeric base layer to the mandrel in a thickness sufficient to embed the axial fibers; wrapping circumferential fibers onto the polymeric base layer with sufficient tension to partially embed the circumferential fibers in the polymeric base layer; applying a polymeric top stock layer over the polymeric base layer and circumferential fibers; and curing the base layer and the top stock layer. This method can improve productivity and performance of endless belts, particularly if the wrapping and latter applying steps closely follow the first applying step.

Abstract: A method of forming a disposable, refastenable absorbent article is disclosed. The method includes directing a first material parallel to and spaced apart from a second material. A pair of lines of perforations is formed across the width of the first material. A pair of attachment members is then secured to the first material such that each bridges across one of the pair of lines of perforations. An absorbent assembly is secured across the first and second materials to form a subassembly. The subassembly is then folded and the first and second materials are bonded together by first and second seam lines. The first and second materials are then separated at locations outward from each of the first and second seam lines to form a disposable, refastenable absorbent article.

Abstract: An apparatus for casting sails comprising a roll stand configured to supply a carrier film. The apparatus contains a support mechanism for the carrier film, and further comprises of a drawing mechanism, a first resin dispenser, a first wiper portion, two yarn applicators, a second resin dispenser, a second wiper portion, an element applicator, a calendar, and curing mechanism.

Abstract: One embodiment of the present invention is an endless non-woven tissue making fabric having a three-dimensional texture suitable for use as a fabric for producing three-dimensional fibrous webs. The endless non-woven tissue making fabric comprises a plurality of substantially parallel adjoining sections of non-woven material. Each section of non-woven material has a width substantially less than the width of the non-woven tissue making fabric. Each section of non-woven material may be joined to at least one other adjoining section of non-woven material. The non-woven tissue making fabric has a machine direction, a cross-machine direction, a tissue contacting surface and a tissue machine contacting surface. The tissue contacting surface comprises solid matter at a plurality of heights such that the tissue contacting surface of the non-woven tissue making fabric has an Overall Surface Depth of at least 0.2 mm in regions of solid matter on the tissue contacting surface.

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: 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: A method of forming a garment trim is provided. The method includes folding a peripheral edge of a fabric to a selected position to form a cavity, inserting a binding in the cavity, securing the binding in the cavity and the peripheral edge in the selected position with a seam, and exposing the fabric to at least one condition sufficient to cause the binding to bond to the cavity and to dissipate the seam.

Abstract: The invention relates to a folded honeycomb structure and to a method and device for producing said folded honeycomb structure from a corrugated core web. The folded honeycomb structure has a number of adjacent corrugated core strips which lie in one plane and are interconnected by cover layer strips. Said cover layer strips are folded about 180° and are perpendicular to said plane. According to the inventive method for producing the folded honeycomb structure, interconnected corrugated core strips are produced first by making a number of longitudinal scores in a corrugated core web. These corrugated core strips are then alternately rotated through 90° respectively so that the cover layer strips fold and the folded honeycomb structure is formed. The device corresponding to this method consists of a number of rotating blades for making the longitudinal scores and a number of guiding elements for rotating the interconnecting corrugated core strips.

Abstract: A process for producing a non-woven composite fabric by water-jet entangling. First, at least two webs are formed. These at least two webs include at least one spunbonded web or meltblown web. Then, the at least two webs are consolidated by water-jet entangling into a non-woven composite fabric. Compared to a conventional process using thermal bonding to consolidate webs, since the present invention uses water-jet entangling to consolidate webs, the non-woven composite fabric produced from the present invention has superior softness. In addition, the non-woven composite fabric produced from the present invention can be further processed to produce various non-woven composite fabric products such as disposable diapers, sanitary napkins, panty liners, and artificial leather, all with superior softness.

Abstract: A vehicle interior lining having very good sound absorbing properties and is air-permeable to air comprises an outside decorative layer, a barrier layer arranged on the rear side of the decorative layer, and a foamed layer which directly adjoins the barrier layer and is produced by back foaming. The barrier layer is formed from cellulose fleece and prevents the material used to form the foamed layer from seeping through to the decorative layer. The vehicle interior lining is air-permeable after the foamed layer is cured and can be used as, for example, a roof lining.

Abstract: Extruded net with at least some strands which melt away upon the application of heat while other strands maintain elastic, or other desirable, properties. This netting is advantageously combined with a fabric in which the low melting strands function as an adhesive, while the high melting strands maintain their designed properties in the final laminate product.

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 method of producing a textile preform to be used for making a fiber reinforced plastic composite product involves the following steps. A two- or three-dimensional semi-finished textile material or article is produced by essentially any textile production process, such as weaving, knitting or braiding. A binder is applied to the textile material, which is then subjected to a reforming and/or draping process by being applied onto a carrier and reforming tool having a contour or geometry adapted to that of the desired preform that is to be produced. Thereby, the previously unfixed fibers of the textile material are brought into the desired finished orientation and are then fixed, and the cross-sectional shape of the material is changed. This produces the preform having the desired contour, geometry and fiber orientation. The preform may then be subjected to further processing steps to form the finished composite product.

Abstract: A method of applying leg elastics to absorbent garments involves optimizing the spacing between multiple elastic members. The elastic members are bonded to a substrate with variable spacing along the length of the leg opening. More particularly, narrower spacing is provided in the crotch area, thereby providing higher gasketing pressure, while wider spacing is provided in areas outside the crotch area for lower gasketing pressure and greater comfort. Alternatively, narrower spacing can be applied to the back portion of the leg, with medium spacing in the crotch area and wider spacing in the front portion or the leg, or conversely, wider spacing in the back portion with medium spacing in the crotch area and narrower spacing in the front portion, depending on the wearer's needs. The resulting garments have optimized comfort, fit and containment about the leg openings.

Abstract: The present invention includes a method for producing individual folded labels incorporating a radio frequency device, the method comprising the steps of providing a ribbon of labels containing a woven logo or text. A carrier strip with a plurality of radio frequency devices spaced thereon is provided and the plurality of radio frequency devices are joined to the ribbon of labels. The ribbon of labels is then folded so as to form at least one folded portion. The folded ribbon is subjected to sufficient heat and pressure to set the at least one folded portion. The ribbon of labels is subdivided into individual folded labels. The present invention also relates to a label-making apparatus including a dispenser for a carrier strip having a plurality of radio frequency devices disposed thereon at spaced intervals. A mechanism linearly advances a ribbon of labels, the ribbon of labels containing a woven logo or text. Means join the plurality of radio frequency devices with the ribbon of labels.

Abstract: A hot melt adhesive polyolefin composition having a viscosity from 7,000 to less than 500,000 mPa·sec, at 190° C. including (by weight): I) 5-85% of a crystalline propylene polymer selected from a propylene homopolymer and a copolymer of propylene and ethylene or a C4-C10 &agr;-olefin or blends thereof, having an isotactic index from 80 to 98%; II) 5-85% of an heterophasic polyolefin composition including: (i) a crystalline propylene polymer and (ii) and an amorphous copolymer of ethylene and propylene or a C4-C10 &agr;-olefin or blends thereof, containing less than 40% of ethylene; III) 10-75% of a material selected from aliphatic hydrocarbon resins, terpene/phenolic resin, polyterpenes, rosin, rosin esters and blends thereof; and optionally IV) a mineral paraffinic or naphthalenic oil, an amorphous poly(&agr;-olefin) having low molecular weight or a mixture thereof.

Abstract: A process for the production of an acoustical attenuating panel comprises emplacing on a mold a layer (1′a) with structural properties constituted by filaments (7, 8) pre-impregnated with a thermoplastic or thermosetting resin, by draping, winding or wrapping, such that the layer has an open surface quantity of about 30% of the total surface of the exposed layer, emplacing from above the layer with structural properties a layer (1′b) with acoustical properties constituted by a microporous cloth of a thickness of about one tenth of that of the layer with structural properties, then emplacing a cellular structure (2) and a reflector (3) with if desired the addition of an adhesive (5, 6) between the components, at least one step of baking in an autoclave being practiced at the end of at least one of the above-mentioned emplacing steps.

Abstract: A method for producing an extruded sheet material wherein a polymeric material is formed into a sheet and a variety of materials are incorporated into the extruded material prior to hardening. The sheet materials produced incorporate, either sheet, filament or particulate matter onto either side of the finished product, allowing for great variability in the finished product.

Abstract: A multilayered polymeric structure having at least two polymeric layers is provided, each layer being a mixture of a polymeric composition with carbon fibrils. The multilayer polymeric structure may include an electrically conductive material between the first and second polymeric layers. A process for making a multilayered polymeric structure for packaging electronic components is also provided. The multilayered polymeric material is used to form trays and packages for containing electrical components.

Abstract: The present invention relates to electrically conductive impregnated fibers and their method of manufacture. More particularly, the invention relates to a method for forming electrically conductive fibers by impregnating conductive fibers with an organic wetting agent to form an impregnated fiber tow and subsequently sheathed. Such sheathed impregnated tows can be formed into a wide variety of products such as radio-frequency and electromagnetic shielded plastic articles.

Abstract: A method for applying elastic, preferably thread elastic, to a travelling web (1) of material in a direction that is generally perpendicular to the feed direction (20) of the web (1). An applicator (9) is moveable generally perpendicular to the web (1) and includes a thread guide (6) which is moveable between two outer positions, the thread guide (6) being adapted to apply elastic (5a-b) to the web (1). The thread guide (6) delivers the elastic (5a-b) to a stopper (16) as it passes the stopper (16) while moving to its outer position and the thread guide (6) again picks up the elastic (5a-b) as it passes the stopper on the way to the other position.

Abstract: A method for producing a film with attached fibrils having a cloth-like look and feel. A flocking or metering device is provided for dispensing a layer of the fibrils. The fibrils are next delivered onto a moving vacuum belt, which has a porous surface for drawing the layer of fibrils thereto. After dispersion, the fibril layer is transported and held by the vacuum conveyor belt to a position under a slot cast extrusion die, where a lower temperature melt polymer is released. Upon release, the lower temperature melt polymer and fibril layer fuse and combine to interlock to create a composite temporary web. In one embodiment, the fibril layer and lower temperature melt polymer are delivered at a first nip point between a pair of nip rollers to create the composite temporary web. The composite temporary web may next be collected on collection rolls, or combined with a higher temperature melt polymer under a second slot cast extrusion die to form a permanent film with fibrils.

Abstract: In the invention, a method is provided for producing a composite nonwoven fabric. A polymer is extruded into heated continuous filaments, possibly elastic, from the die head to a first chilled roller, wherein the extruder is configured to provide the continuous filaments to the chilled roller in a canted direction that is at a tangent or angle to the surface of the first chilled roller. The filaments are conveyed in a downward direction by way of chilled rollers to a nip. In a next step, the nonwoven web is sprayed with an adhesive and is laminated on the continuous filaments in the nip to form a composite nonwoven fabric. The continuous filaments move vertically downward approximately in line with the lamination process, facilitating automatic re-threading of filaments when they are broken or interrupted in their travel downward onto the chilled rolls.

Abstract: Process for manufacturing anti-theft and/or traceability devices associated with stoppering and covering means The invention relates to the high-rate industrial manufacture of remote-detectable devices used in particular as anti-theft devices but also to carry information, associated with means for stoppering and covering containers. To this end, a material in web form is unwound and caused to travel along, and at least one detectable means such as a filament or an oriented-particles film or an electronic tag is deposited in continuous or discontinuous form on this material, this or these detectable means running or following on from one another in the direction of travel of the web-form material. This material is cut according to the singular or plural detectable means deposited on it, so as to separate individual elements each equipped with a detectable means such as a filament, and themselves constituting stoppering or covering means, or parts of such means, for example gaskets for caps.

Abstract: A flooring material having a textile pad substructure with a density of greater than 13 pounds per cubic foot is provided. The textile pad has reinforcement and binding fibers. The binding fibers are thermoplastic and are used to bind the reinforcement fibers together. The pad is created by heating and compressing a fibrous textile batt so that it has a density of greater than 13 pounds per cubic foot.

Abstract: A spunbond web formation apparatus includes a spinneret (1) of a spin pack (2) that extrudes an array of fibers (5) that are drawn into an aspirator (6). The attenuated fibers (8) discharged from aspirator (6) are deflected sideways by a Coanda device (7) that entrains the exiting air stream along with the fibers. The fibers are deposited on a vertically moving belt (9) and subsequently bonded by calender rolls (20, 21) to form a non-woven spunbond web. The spinning distance L is adjusted by vertically moving the aspirator (6), while the laydown distance M is adjusted by horizontally moving the belt (9) or aspirator (6) or by adjusting the size of the Coanda device (7). Deflection of the fibers exiting the aspirator permits the spinning distance L to be adjusted independently of the laydown distance M, without having to move the spin beam or adjust the height of the web-forming belt.

Abstract: A method for producing a material having z-direction ridges or folds in which a layer of continuous fibers is conveyed on a first moving surface into a nip formed by the first moving surface and a second moving surface which is traveling at a slower speed than the first moving surface, resulting in formation of a plurality of z-direction loops in the fibers giving loft to the material and a wave pattern producing ridges on both major surfaces of the resultant nonwoven web. The method permits easy real time adjustment of manufacturing parameters to produce a variety of materials. The method further produces lofty nonwovens at a commercially viable rate.

Abstract: Fibrous sorbent media or pads are formed from non-woven mats of thermoplastic fibers, preferably polypropylene fibers, having a mean diameter between about 0.5 microns and about 25 microns. The mats have a weight between about 2 ounces/yd2 and about 25 ounces/yd2; a thickness of at least {fraction (1/20)} of an inch; an oil absorbency ratio of at least 5 to 1 or a water absorbency ratio of at least 5 to 1. The sorbent media have first and second major surfaces with abrasion resistant, liquid permeable, integral skins and fibrous cores. The liquid permeable skins of the media are formed by melting fibers at and immediately adjacent the major surfaces of the mats to form thermoplastic melt layers which are subsequently solidified into the skins on the major surfaces of the mats. For many applications, the thermoplastic fibers of the mats are point bonded together at spaced apart locations to increase the integrity of the mats.

Abstract: Nonwoven webs are fabricated by forming unitary multicomponent fibers comprising a plurality of individual segments partially exposed at the surface of the fiber; bonding the multicomponent fibers, such as by thermal point bonding, and then hydroentangling the bonded multicomponent fibers with a water pressure from about 400 to 3000 psi wherein the entangling process separates the individual segments of the unitary multicomponent fibers into microfibers and also entangles the fibers to form an integrated nonwoven web. The nonwoven webs include entangled webs of thermoplastic multicomponent fibers and microfibers having partially degraded bond areas comprising from about 5% to about 50% at the surface area of the web.