Abstract: A nonwoven web of thermoplastic filaments is thermally bonded by conveying the web on a rotating hollow cylindrical roll having a pervious surface and passing hot air through the web into the roll to heat the filaments to the bonding temperature. The web is restrained against the roll surface with a stationary porous fabric under pressure developed by flow of the hot air through the fabric. Means for adjusting the length of fabric in contact with the web, and for measuring tension on the fabric, are provided in the apparatus.

Abstract: An endless tire-mounted anti-skid belt is produced by spreading an endless fibrous mesh to the diameter of the vehicle tire on which the belt is to be mounted, impregnating the spread endless mesh with a hot-vulcanizable elastomer dissolved in a solvent, drying the impregnated spread endless mesh until at least 80% of the solvent has been removed, repeating the impregnation and drying steps several times until a desired thickness of elastomer has been deposited on the spread endless mesh, and curing the elastomer by vulcanization in an autoclave under hot steam.

Abstract: A conjugate polycarbonate fiber comprising 95% to 50% by weight of a polycarbonate component and 5 to 50% by weight of a polypropylene component wherein ultrafine fibers composed of the polypropylene component are dispersed and arranged in a bundle-like form in the polycarbonate component as the fiber matrix, whereby the crazing resistance and oil resistance are improved. The conjugate polycarbonate fiber can be made into fibrous sheets and non-woven fabrics. The non-woven fabrics are adapted to be used as insulating layers in electric power cables.

Abstract: Disclosed is a method of producing a carbon fiber felt which includes the steps of preparing a substantially unidirectional array of continuous carbonizable filaments in oxydized state, cross-laying other such filaments on one side of said array in a state of restraint from displacement from their cross-laid relationship, and needle-punching the resulting assembly from the same side.Also disclosed is a method of pre-sizing a high bulk, low density carbon fiber felt comprising the steps of impregnating said felt with a thermoplastic or thermosetting resin highly diluted in a solvent, and removing said solvent either before or while the assembly is being reduced to its final dimensions to leave the resin per se as a coating on the fibrous material serving to adhere individual elements together at cross-over points to prevent displacement thereof, all prior to the addition of the matrix material in which the carbon fiber is embedded to form the final composite.

Abstract: Netting formed of longitudinal and transverse threads of thermoplastic material bonded at the thread crossings by individual moulded buttons of thermoplastic material is improved by the use of threads that have been subjected to irradiation to cross-link their thermoplastic material. Higher moulding temperatures can be used in the formation of the bonding buttons, for example in the case of polyethylene filaments up to 260.degree. C or more, and increased bond strength between the crossing threads is achieved. The moulded buttons can also be formed of irradiated material.

Abstract: This invention contemplates a method and apparatus for taking fine metal fibers having a diameter range from .5 microns to approximately 150 microns and cutting the fibers into precise short lengths. The method and apparatus utilized first moistening tows of metal fibers, unwinding the tows from spools and positioning them into tow bands, stiffening the ribbon made from the tow bands, and cutting the fibers to desired precise lengths in order to prevent cold welding or deformation of the ends of the fibers during the cutting operation. Materials that may be used for stiffening the fibers include starch, PVA, ice, etc.

Abstract: A method of producing a disposable diaper and the diaper produced thereby are disclosed. The disposable multi-layer diaper includes at one side a porous fibrous facing layer to be brought into contact with an infant's skin, and includes at the other side a water impervious backing sheet, with a double contoured cross-sectional batt being interposed between the facing layer and backing sheet. The batt is smoothly contoured by increased fiber content along the transverse and longitudinal medians from the edges to the center of the batt. The batt is positioned in face-to-face engagement with the backing sheet. The batt and lateral extremities of the facing layer which extend beyond the batt are each adhered to the backing sheet. In a preferred embodiment of the invention, a paper-like, densified, highly compacted cellulosic layer is formed integrally with the batt and is positioned in face-to-face engagement with the backing sheet.

Abstract: Dimensionally stable, high-tenacity non-woven webs and process for their manufacture. The non-woven webs of the invention are distinguished by a relative grab-tensile strength of at least 200 p/g/m.sup.2, a breaking extension of not more than 50% and a shrinkage of not more than 1%, as measured at 160.degree.C, and are primarily useful as reinforceing and backing materials in the manufacture of needle-punched and tufted carpets.

Abstract: A battery separator and the process for preparing it, having excellent abrasion resistance, stiffness, porosity, pore size, and electrical resistance is produced by a process that includes degrading a fiber forming polymer, melt-blowing fibers from the degraded polymers and forming a non-woven mat of the fibers randomly laid and self-bonded. The non-woven mat is then compacted, in a critical manner, preferably at temperatures for polypropylene of from 290.degree. to 310.degree.F., using relatively low pressures, i.e. 10 psi/in.sup.2 or lss, to obtain a battery separator meeting precise and essential specifications.

Abstract: Heat-fusible hair-like fibers, disposed as a tow in a flat manner, are provided a narrow common bond by being thermally fused together transversely to the direction of the tow, such fused bonds being provided at increments along the length of the tow to sever such increments from the tow, the bonds being split lengthwise of the bonds and the increments being mechanically severed intermediate the bonds to provide flat bundles of hair-like fibers whose strands lie in a generally common direction and which strands have a narrow common bond at only one end. The bond is brittle and the user is readily enabled to separate a portion of the fibers as a unit from the article for use, for instance as a fishing lure component.

Abstract: Disclosed is a method of producing a carbon fiber felt which includes the steps of preparing a substantially unidirectional array of continuous carbonizable filaments in oxidized state, cross-laying other such filaments on one side of said array in a state of restraint from displacement from their cross-laid relationship, and needle-punching the resulting assembly from the same side.Also disclosed is a method of pre-sizing a high bulk, low density carbon fiber felt comprising the steps of impregnating said felt with a thermoplastic or thermosetting resin highly diluted in a solvent, and removing said solvent either before or while the assembly is being reduced to its final dimensions to leave the resin per se as a coating on the fibrous material serving to adhere individual elements together at cross-over points to prevent displacement thereof, all prior to the addition of the matrix material in which the carbon fiber is embedded to form the final composite.

Abstract: A fibrous body which includes at least two layers of strands of continuous filaments and binder particles in each layer. One of the layers has filaments of the strands therein at least partially dispersed to form a mesh size which entraps binder particles therein which have a mesh size larger than the mesh size of the dispersed filament layer, as well as smaller size particles lodged at intersections and crossovers. Another layer has strands which form a mesh size which do not necessarily entrap binder particles but may retain particles therein at interstices of strands. The fibrous body has a binder content in the dispersed filament layer which is larger per unit volume than the binder content of the other layer. Preferably a plurality of successive layers of continuous multi-filament strands are deposited on a collecting surface in a mat-like mass.

Abstract: A high temperature tape for use in protecting a structural item to be subjected to high temperature, and the method whereby this novel tape is made are set forth. The tape is principally constituted by a number of elongated carrier fibers disposed in an essentially aligned array, and a large number of comparatively short fibers disposed in a nonwoven manner essentially transversely to the elongated fibers. The short fibers typically extend beyond the confines of the carrier fibers, at least on one side, thus to create a pliable, fringed tape capable of being wrapped for a number of turns about an item to be protected. This wrapping may be done in such a manner that the fringe formed by the short orthogonally placed fibers is available to extend over and cover previous turns of the tape. The fibers are of temperature resistant material, and various means are provided for securing the short fibers to the elongated fibers, including the use of certain resins.

Abstract: This invention provides a light ply of parallel continuous high-performance filaments, and a method of obtaining same.The ply is characterized by a weight per unit surface of at most 450 g/m2, a thickness of at most 1 mm, a content of at least 85% by weight of high-performance fibers, a close structure, and furthermore comprising on at least one of its two faces fused synthetic yarns arranged transversely with respect to the direction of the high-performance filaments which hold the latter in place without passing through the ply from one face to the other.The plies thus obtained are used for the manufacture of high-performance composite materials.

Abstract: The present invention relates to a method of and apparatus for manufacturing a net of non-woven threads, in which first and second laps of parallel threads, are drawn off, respectively, from a fixed creel and a rotary creel with the first lap longitudinal and the second lap transverse and wound about the first lap. The threads of the second laps are severed at each of two opposed longitudinal edges of the first lap and the net formed by part at least of the longitudinal threads of the first lap and those pieces of the transverse threads of the second lap which are situated on one and the same side of the first lap is collected and stabilized, while there is effected relative running ahead of the longitudinal threads which increases progressively from one thread to the next in relation to one of said edges, from the latter up to the other edge.

Abstract: Netting of small net size is economically made by forming a network of crossing longitudinal and transverse threads, bonding the threads together at the crossings by individually moulded buttons of thermoplastic material and moulding small masses of thermoplastic material (which may or may not be the buttons at the crossings) bearing integrally moulded elements radiating towards the centres of the mesh openings. The radiating elements may terminate close to one another or be joined together by an integrally moulded boss in the central region of each mesh opening. The radiating elements effectively block the mesh openings or divide them up into smaller openings without requiring correspondingly large and possibly excessive lengths of threads. The netting is suitable for security purposes, for example at expositions.

Abstract: A method for making a cellular article in which at least some of a plurality of extruded, generally parallel streams of strand-forming organic, thermoplastic, polymeric material are periodically expanded to provide bulbous portions along the lengths thereof, with such bulbous portions contacting and bonding with adjacent streams during their expansion, after which the streams are set to provide an integral article.

Abstract: A fabric, a method for its fabrication and an apparatus for its manufacture where a group of parallel yarns are fused with another group of parallel yarns perpendicular to the first group of yarns at predominantly lateral or peripheral portions of the resulting junctions by a high frequency current.

Abstract: Extra-wide, heat-sealed nonwoven sheets of thermoplastic synthetic polymer monofilaments are prepared by folding said sheets in layers with heat-insulating fabric between said layers before contact with heating and pressing means to effect heat sealing, followed by removal of the insulating fabric and heat sealing of the fold areas.

Abstract: A non-woven web contains bicomponent filaments having a core of polypropylene and a sheath of specified copolyamides, together with polypropylene homofilaments, in which is embedded parallel yarns extending in its lengthwise direction. The yarns are composed of bicomponent filaments having a copolyamide sheath. The combination of properties of the product makes it suitable for use as a primary backing for tufted carpets.

Abstract: An apparatus and process for smoothing and densifying both the upper and lower surfaces of a filamentary mat or sheet as rows of freshly melt spun filaments are permitted to fall freely onto the surface of a liquid cooling bath whereby the individual filaments spread laterally at the bath surface to form helical to sinuous loops which then become self-bonded at overlapping points of intersection within a short distance below the bath surface. A flattening or densifying of upper and lower surfaces of the mat into a more rigid structural member is accomplished by inserting at least one pair of downwardly diverging plates within the bath such that the upper apex thereof extends parallel to the rows of filaments and falls within at least one outermost row of filaments, thereby deflecting such a row inwardly and upwardly over the apex as it is incorporated into an outer bonded surface of the mat.

Abstract: A process is provided for the continuous production of nonwoven webs in cylindrical or sheet form from thermoplastic fibers, spinning the fibers continuously from a melt onto a rotating mandrel and winding them up on the mandrel to form a generally spirally wound cylinder. Density of the wound cylinder is controlled by controlling the distance between the rotating mandrel and the orifices of the spinning die through which the molten polymeric material is spun. If the spinning of the fibers is continuous, the cylinder can be formed in a continuous length. Control of the spinning rate in relation to the diameter and rate of rotation of the mandrel and the rate of advance of the cylinder on the mandrel controls the thickness of the cylinder. The cylinder can be drawn off the mandrel and used as a cylinder, or either slit lengthwise and opened out, or collapsed onto itself, for use as a sheet. The process is particularly adapted for forming filter elements.

Abstract: Thermoplastic resin mattings containing plastic rods fastened one above another with plastic strings to form an ornamental screen, which screen is covered with a plastic transparent sheet whereby they are both partially glued and cut by heat pressure to define the contour thereof and at the same time provide any desired three-dimensional designs on the ornamental screen portions, thus providing the manufactured goods with high impact-resistance, convenience in use, the sense of being thick and heavy and superiority in ornamental effect.