Abstract: A process for continuous, tailored lamination of aligned composite materials in such a way that either pre-formed or pre-consolidated sheets are made available for subsequent infusion molding or stamping processes, the process comprising the steps of: material placement, consolidation/stabilization, cut and kit, fabrication, and final trim. A tailored blank machine is also described. The blank machine includes a series of material placement heads arranged in a linear or serial fashion along a single moving placement table, wherein each head lays down a single angle of the prescribed stacking sequence as the conveyer passes under the head at a constant speed wherein the angle is proportional to head traverse rate divided by conveyer speed.

Abstract: A process for making an absorbent fibrous web composite including a stable, controllable dispersion of superabsorbent polymer is provided. A pre-formed web, desirably including cellulose fibers and, optionally, thermoplastic fibers is provided. First and second superabsorbent polymer precursor compositions are added to the fibrous web using separate streams. The first and second superabsorbent polymer precursor compositions combine with each other and chemically react on or in the fibrous web, to form a superabsorbent polymer which sticks to the surface of the fibrous web.

Abstract: A press belt for the formation of a nip between the belt and an opposing surface during processing of a fibrous pulp web, that includes a matrix of an elastomer material, a first layer of reinforcing fibers having a thickness and spacings therebetween, and extending in a direction transverse to a belt run direction, and a second layer of reinforcing fibers having a thickness and spacings therebetween, and extending in the belt run direction, where the thicknesses of the reinforcing fibers of the first layer and the second layer is about 0.5 mm, where the spacings between the reinforcing fibers of the first layer are less than or equal to about 3.0 mm, where the spacings between the reinforcing fibers of the second layer being less than or equal to 2.5 mm, and where the reinforcing fibers of the first layer are separated in a belt thickness direction from the reinforcing fibers of the second layer one layer by a distance of up to about 4 mm.

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: The method generally comprises the steps of providing a hydroentangled non-woven layer having a first binder component, and depositing a second non-woven layer having a high bulk and loft on to the hydroentangled layer to form an unbonded composite fabric. The second layer also has a binder component with a melting temperature substantially equal to the first binder melting temperature.

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 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: A nonwoven has low tensile and high elongation in the first direction (typically the CD) and high tensile and low elongation in the second direction (typically the MD). The nonwoven has a plurality of bonding points defining a total bonding area along the second direction greater than along the first direction. Accordingly, the nonwoven has unbonded fiber portions and bonded fiber portions, with a bonded portion/unbonded portion ratio greater along the second direction than along the first direction. The bonding points are preferably either circular or oval in plan.

Abstract: This invention relates to porous paper machine clothing (1, 11) for dewatering a paper web in a paper machine, comprising a filament lay-up made of at least one layer (2, 12) of longitudinal filaments (3, 13) and at least one layer (4, 14) of transverse filaments (5, 6, 7; 15) which cross the longitudinal filaments (3, 13), wherein the longitudinal and transverse filaments (3, 13; 5, 6, 7; 15) are adhesively bonded to each other via an adhesive at crossing points (8, 16). The invention further relates to a method of producing porous paper machine clothing such as this.

Abstract: A process for forming an absorbent fibrous web composite includes the initial step of forming a fibrous web from hydrophilic fibers and, optionally, thermoplastic fibers. Then, a superabsorbent polymer is completely formed in situ on or in the fibrous web by adding one or more superabsorbent polymer precursor compositions to the fibrous web using a non-contact process, and performing the polymerization reaction(s) completely on or in the web.

Abstract: A method for manufacturing a fiber aggregate formed by fiber having reforming surface comprises the steps of providing a fiber surface having thermoplastic resin at least on the surface layer thereof with a hydrophilic processing liquid containing polymer having a first portion with more hydrophilic group than the surface, and a second portion having interfacial energy different from that of the hydrophilic group, and interfacial energy substantially equal to the surface energy of the fiber; orientating the second portion toward the fiber surface, while orientating polymer to the side different from the surface of the first group; and forming a fiber absorber by heating the fiber having the reformed surface in the step of orientating polymer to thermally bond the contact points of fibers themselves.

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: 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: The polypropylene-based thermoplastic fibers are uniform in cross-section, not having any degraded surface skin, and they are heat-weldable at a pressure at a temperature which is lower than the melting temperature, by virtue of internal heating due to the effect of said pressure. They are made of a first constituent with high crystallinity and at least one second constituent, compatible with the first constituent, and of crystallinity that is lower than that of the first constituent. They have a quantity of primary oxidation inhibitor lying in the range 350 ppm to 1000 ppm. Such fibers are made by spinning under conditions that avoid molecular degradation by thermal oxidation at the periphery of the fibers, in particular with cooling that is rapid immediately on leaving the extrusion head. The non-woven fabric obtained by heat-bonding such fibers is characterized by weld points that are in the form of a polymer laminate that is uniform and transparent.

Abstract: A process and a device are suggested for the placement and fixing of a sheet, which is at least partially implemented as a closed flat structure, of filaments, lying essentially in a plane, for the production of scrims having the filament sheet, wherein the filament sheet is placed, as part of the filament sheet sections forming the closed surface and as separate filament sheet sections, between two conveyor units (13) supplying a connecting station (6), with the filament sheet sections (1) being fixed onto the conveyor unit at each of both end regions with a fixing element (2, 3) and the interval of the fixing elements (2, 3) of a filament sheet section (1) relative to the conveyor units (13) being selected in such a way that the filament sheet sections (1) are, in their fixed state, positioned essentially flat between the conveyor units (13), at least immediately before entering the connecting station (6).

Abstract: Fiber tow carrying a resin powder is dispensed from an unwind creel with the tow spread out using a comb. From here the tow is directed between a pair of bands and pressed onto the outer surface of a heated impregnation wheel. It is compressed against the wheel to melt the resin powder. The resin moves in a liquid state to be uniformly distributed across the tow strands. Pressure is applied by wheels pressing on the bands. The result is a composite tape that is cooled upon leaving the impregnation wheel and then wound onto a rewind drum or spool.

Abstract: Fiber tow carrying a resin powder is dispensed from an unwind creel with the tow spread out using a comb. From here the tow is directed between a pair of bands and pressed onto the outer surface of a heated impregnation wheel. It is compressed against the wheel to melt the resin powder. The resin moves in a liquid state to be uniformly distributed across the tow strands. Pressure is applied by wheels pressing on the bands. The result is a composite tape that is cooled upon leaving the impregnation wheel and then wound onto a rewind drum or spool.

Abstract: Disclosed are composite structures prepared using a hemicellulose-based adhesive. In a preferred embodiment, a laminate composed of plural laminae which have been bonded to one another using a hemicellulose-based adhesive is provided. The laminate is useful as a separator or partition in a shipping vessel. Most preferably, the hemicellulose-based adhesive contains one or more bonding agents and water., the hemicellulose being present in an amount of at least 10% by dry basis weight of the bonding agents.

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: 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: A method includes wetting fibers with a resin capable of being cured by at least two different cure treatments. At least partially curing the resin by subjecting the resin to a first cure treatment and at least partially curing the resin by subjecting the resin to a second cure treatment. A plurality of fibers are located adjacent each other so that a plurality of valleys are formed between the plurality of fibers along an outer side of the reinforcement. The resin is cured to retain the valleys in the outer side of the reinforcement. The outer side of the reinforcement is adhered to the structural member. An apparatus including a fiber locating mechanism adapted to retain the peaks and valleys during curing of the resin without rigidly confining the outer side of the reinforcement.

Abstract: A binder slurry (24) for a continuous filament mat (50) used in a phenolic pultrusion system comprising a phenolic compatible silane, a non-ionic surfactant, a defoamer, water, an organic acid and a polyvinyl acetate copolymer binder. The binder slurry resin is unique in that the polyvinyl acetate copolymer binder is compatible with presently available phenolic resins, and as such pultruded parts made have improved surface and mechanical properties as compared with traditional polyester type binder slurries which are not compatible with phenolic resins.

Abstract: The present invention provides a method of manufacturing a laminate flexible strip for attachment to a vehicle in the form of a weather sealing strip. The strip includes a core member and a filler layer of elastomeric seal material disposed about and into the voids of the core member. The core member is formed by bending a wire into an undulating pattern that forms a number of continuously connected longitudinally spaced and laterally extending unshaped metal clamping clips for reinforcing the seal material. A number of continuous laterally spaced and longitudinally extending linear fibers are attached to the clips to maintain the spatial relationship between the bent wire members. While the fibers or laminate maintain the longitudinal spacing of the wires, they also allow the core to flex laterally and compress longitudinally in the finished extrusion. The fibers may be made of the same material as or a material dissimilar to the clips.

Abstract: A process for manufacturing a composite sheet by joining a second web made of thermoplastic synthetic fiber and capable of inelastic extension to at least one surface of a first web capable of elastic stretch and contraction in an intermittent manner. The process involves a step of extending the first web and a step of allowing the first web to retract, and a step of joining a second web to the second web while in a retracted state are included.

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: 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 method for making a bulky web. A web is fed in a first direction. The web is subjected to incremental stretching in a direction perpendicular to the first direction to provide a bulky web. The bulky web is then stabilized to provide a stabilized bulked web, Optionally, the bulky web may be gathered after it has been subjected to incremental stretching.

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: 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: Improved filtration media or filter bodies can be made from fine fiber and can be formed into a filtration structure having no internal defects. The filter media or filter body comprises a collection of spot in fiber with defined fiber diameter, layer thickness and media solidity. The fine fiber is formed into a media body and obtains substantial flux and filtration efficiency. The filtration media or body can comprise single or multiple layers of fine fiber combined into the improved filter body.

Abstract: Improved filtration media or filter bodies can be made from fine fiber and can be formed into a filtration structure having no internal defects. The filter media or filter body comprises a collection of spot in fiber with defined fiber diameter, layer thickness and media solidity. The fine fiber is formed into a media body and obtains substantial flux and filtration efficiency. The filtration media or body can comprise single or multiple layers of fine fiber combined into the improved filter body.

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 nonwoven fabric comprised of a self-sustaining pre-bonded web formed by carding together first relatively thin monocomponent fibers, second relatively thicker monocomponent fibers, and 1-5% bicomponent fibers with the low softening point component thereof bonding together the first, second and bicomponent fibers to form the self-sustaining web. Six to ten percent by weight of cured latex particles are disposed within the fabric and smeared on the outer surfaces of the fabric, the particles being cured in situ to provide enhanced tensile strength to the fabric.

Abstract: The present invention provides wall and floor coverings based on a carrier coated with one or more layers. The carrier includes a fiberglass containing mat consolidated with a binder, a non-woven made of organic synthetic fibers bonded with the fiberglass containing mat by needling. Part of the organic fibers penetrate through the fiberglass mat, and one or more layers coated on a glass fiber side of said carrier, opposite the non-woven synthetic mat.

Abstract: A method and apparatus for forming an improved pultruded and clinched Z-axis fiber reinforced composite laminate structure. The upper and lower skins and the core are pulled automatically through tooling where the skin material is wetted-out with resin and the entire composite laminate is preformed in nearly its final thickness. The preformed composite laminate continues to be pulled into an automatic 3-dimensional Z-axis fiber deposition machine that deposits “groupings of fiber filaments” at multiple locations normal to the plane of the composite laminate structure and cuts each individual grouping such that a extension of each “grouping of fiber filaments” remains above the upper skin and below the lower skin. The preformed composite laminate then continues to be pulled into a secondary wet-out station.

Abstract: This invention relates to porous paper machine clothing (1, 11) for dewatering a paper web in a paper machine, comprising a filament lay-up made of at least one layer (2, 12) of longitudinal filaments (3, 13) and at least one layer (4, 14) of transverse filaments (5, 6, 7; 15) which cross the longitudinal filaments (3, 13), wherein the longitudinal and transverse filaments (3, 13; 5, 6, 7; 15) are adhesively bonded to each other via an adhesive at crossing points (8, 16). The invention further relates to a method of producing porous paper machine clothing such as this.

Abstract: A nonwoven fabric, and method of production, are disclosed, wherein the nonwoven fabric comprises textile length fibers with a portion being thermally fusible. The fabric exhibits sufficient durability to withstand commercial dyeing processes, with the resultant fabric finding widespread applicability by virtue of its durability and aesthetic appeal.

Abstract: The present invention relates to a nonwoven fabric, and more specifically, to a durable extensible nonwoven fabric comprising a hydroentangled fibrous blend of non-activated fusible fibers and non-fusible fibers, wherein said nonwoven fabric is subjected to compaction at an elevated temperature thereby activating said fusible fibers to bond with the surrounding fibrous composition and rendering said nonwoven fabric suitable for use in medical applications, such as stockings and wraps.

Abstract: The present invention relates to methods of preparing improved fiber glass compositions using an improved resin binder. The resin binder comprises an aqueous solution of a resole resin, a catalyst comprising an ammonia salt of an aryl sulfonic acid, and optional binder modifiers. It has been found that the use of ammonium aryl sulfonate salts in resin binder compositions, as in the present invention, provides an enhanced cure rate and also enables manufacture of a fiber glass composition exhibiting enhanced uncured storage properties, increased thermal stability, and reduced corrosiveness to metals.

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: The present invention provides wall and floor coverings based on a carrier coated with one or more layers. The carrier includes a fiberglass containing mat consolidated with a binder, a non-woven made of organic synthetic fibers bonded with the fiberglass containing mat by needling. Part of the organic fibers penetrate through the fiberglass mat, and one or more layers coated on a glass fiber side of said carrier, opposite the non-woven synthetic mat.

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: Method for the production of binder-bound mineral wool products, in which mineral fibers are deposited on a production surface (13) to form a mineral wool web (12) and are compacted, and their relative positions are reoriented by mechanical action, for which purpose the web is guided on its large faces and at the same time forces, in particular upsetting forces, are introduced into the web in parallel with the large faces, the forces being introduced in introduction regions which are located next to one another transversely to the running direction in zones and in each case at a distance from one another and one behind the other in the running direction in longitudinal zones, and the introduction regions of adjacent longitudinal zones being arranged so as to be offset relative to one another, after which the binder is cured.

Abstract: A process for continuous, tailored lamination of aligned composite materials in such a way that either pre-formed or pre-consolidated sheets are made available for subsequent infusion molding or stamping processes, the process comprising the steps of: material placement, consolidation/stabilization, cut and kit, fabrication, and final trim. A tailored blank machine is also described. The blank machine includes a series of material placement heads arranged in a linear or serial fashion along a single moving placement table, wherein each head lays down a single angle of the prescribed stacking sequence as the conveyer passes under the head at a constant speed wherein the angle is proportional to head traverse rate divided by conveyer speed.

Abstract: The present invention relates to a process for producing a laminated sheet comprising an alumina fiber precursor, which process comprises spinning out an alumina fiber precursor from a solution mainly comprising an aluminum compound, falling and stacking said alumina fiber precursor on the surface of an accumulator to form a thin lamina sheet of alumina fiber precursor, continuously pulling out said lamina sheet from the accumulator, transferring the resultant lamina sheet to a folding device, and folding the sheet by a predetermined width while stacking the folded sheet and continuously moving the stacking sheet in the direction orthogonal to the folding direction.

Abstract: A lofty, nonwoven material having a nonwoven web having a plurality of substantially continuous fibers oriented in a z-direction of the nonwoven web and a method for producing the lofty, nonwoven material from as-formed z-direction fibers. The method is fast, having no mechanical manipulation of the fibers to slow it down, easily adjustable and allows for in-line processing. The material can be varied from preponderantly open to preponderantly closed in its web structure.

Abstract: A process for making an absorbent fibrous web composite including a stable, controllable dispersion of superabsorbent polymer is provided. A pre-formed web, desirably including cellulose fibers and, optionally, thermoplastic fibers is provided. First and second superabsorbent polymer precursor compositions are added to the fibrous web using separate streams. The first and second superabsorbent polymer precursor compositions combine with each other and chemically react on or in the fibrous web, to form a superabsorbent polymer which sticks to the surface of the fibrous web.

Abstract: A method for hydroentangling a nonwoven web to increase the strength and abrasion resistance while maintaining highly desirable hand and drape characteristics. The method provides for carding and cross-lapping synthetic and/or natural fibers so as to form a desired substrate. The substrate is then hydroentangled under relatively low pressure to form a desired spunlace web, and a relatively low amount of a foam adhesive latex binding material is applied to the spunlace web. Thereafter, a force is applied to the foamed spunlace web so as to cause the foamed binding material to fully penetrate the spunlace web from face to back. The resulting hydroentangled (spunlace) nonwoven web provides an enhanced balance of tensile properties, abrasion resistance, and fabric aesthetics.