Abstract: A filter media for liquid particulate filtration applications is provided. The filter media includes a substrate and fine fibers, which are compressed together.

Abstract: A method of preparing a composite configured to release refrigerant therefrom comprises providing a substrate material comprising polarized fibers of glass, polyamide, phenylene sulfide, carbon or graphite bonding thereon a metal compound comprising a complex compound of a polar gaseous refrigerant and a metal salt and/or a hydrated metal hydroxide and/or a metal hydroxide of a metal comprising alkali metal, alkaline earth metal, transition metal, zinc, cadmium, tin, aluminum, or two or more thereof, at a concentration of at least about 0.

Abstract: Composite materials that have at least one substrate layer, and at least one fibrous mat are described. The fibrous mat may include fibers in a cured binder made from a binder composition that includes a carbohydrate and an amino-amide. The amino-amide may be formed from a reaction of an amine and an acid anhydride. In addition, methods of making a composite material are described. The methods may include the steps of providing a first substrate layer and contacting the first substrate layer with a fibrous mat comprising fibers in a partially cured, “B”-stage binder made from a binder composition that includes a carbohydrate and an amino-amide. The amino-amide may be formed from a reaction of an amine and an acid anhydride. The fibrous mat in contact with the first substrate layer may be cured to make a fully-cured binder composite.

Abstract: The method of forming a lightweight, high performance, glass fiber blanket for acoustical and thermal insulation, that includes treating glass fibers with a fluid binding agent at elevated temperature to form a first cohesive glass fiber layer of thickness t1 traveling endwise, and winding that layer into a roll above a travel zone of that layer, repeating said treating to form a second cohesive glass fiber layer of thickness t2 traveling endwise over said zone below said roll and into an oven, and unrolling said first layer from said roll to travel into the oven in overlying surface to surface contacting relation to the traveling second layer, subjecting said layers to heat treatment and pressurization in the oven to compress the first and second layers to a controlled density thickness t3 which is substantially less than t1 and t2, and to progressively bond said first and second layers together in laminated relation to form the blanket, and removing said laminated product from the oven.

Abstract: A method and apparatus for forming a batt of particulate material which may be used in an absorbent article. The apparatus may include a vacuum zone, an air impermeable fence zone adjacent to the vacuum zone, and an air permeable fence zone adjacent to the vacuum zone. The air permeable fence zone may comprise an ambient air entry conduit in communication with an ambient air exit port. The method may include providing a laydown drum and a first web of material, positioning the first web of material substantially adjacent to the laydown drum, generating a vacuum through the laydown drum, depositing particulate matter onto the first web of material, and rotating the laydown drum.

Abstract: A reinforced mat (10) for a pollution control device has a first major surface (12), a second major surface (14) and a thickness, and the mat comprises ceramic fibers and a reinforcing mesh (22) disposed between the first major surface and the second major surface such that the mat is generally separated into two layers (16,18) by the mesh. The mesh comprises non-metallic fibers that are spaced-apart so as to define a space therebetween that is large enough that the layers of the mat are integrally joined together through the mesh. The mat has a total organic component weight that is up to about 5% of the total weight of the mat, and the mat is dimensioned for use, either as a mounting mat for mounting a pollution control element or as an insulator for insulating a region within a pollution control device in an exhaust system of an internal combustion engine.

Abstract: A ballistic-resistant laminate assembly having a pair of films with an array of stacked pairs of first and second of unidirectionally-oriented bundles of high strength filaments therebetween, with the stacked filament bundles being arranged substantially interlinear with adjacent unidirectionally-oriented adhesions between the pair of films. The adhesions form continuous tubular sleeves between the pair of films with the stacked bundles of high strength filaments being substantially free floating yet contained therein. Optionally, the high strength filaments are coated or soaked in a liquid-to-solid phase change material or PCM.

Abstract: An insulation product and method of making the same are provided. The insulation product includes a mat containing randomly oriented fibers bonded by a binder, the mat having first and second major surfaces and a pair of side portions, and at least one flexible reinforcing layer bonded to the mat between the first and second major surfaces and extending along a length of said mat.

Abstract: A mat having a highly uniform porosity distribution is produced by consolidating 15 or more layers of melt blown webs (or the like) having different orientations. Control over the porosity is provided by using webs that exhibit a narrow, unimodal distribution of fiber diameters over the bulk of its distribution, such as in the top 80%. A compliance of the mats can be chosen by selecting a number and orientation of the webs. It is thus possible to produce mats that are good candidates for vascular grafts, for example. The uniformity of the porosity within the range of 6 ?m to 30 ?m permits seeding of the vascular graft with endothelial and smooth muscle cells. The mats have the demonstrated ability to retain, and support growth of, smooth muscle cells and endothelial cells.

Abstract: Fluid filtration articles, including composite nonwoven fibrous webs, and methods of making and using such articles as gas or liquid filtration elements. The articles include a population of coarse microfibers having a population median diameter of at least 1 micrometer (?m) formed as a first layer, and a population of fine fibers having a population median diameter less than 10 ?m formed as a second layer adjoining the first layer. At least one of the fiber populations may be oriented. In one implementation, the coarse microfibers and fine fibers are polymeric, the coarse microfibers have a population median diameter of at least 10 ?m, and the fine fibers have a population median diameter less than 10 ?m. In another implementation, the population of fine fibers has a population median diameter less than 1 ?m. Optionally, one or both of the first and second layers may include particulates.

Abstract: A method of preparing a composite configured to release refrigerant therefrom comprises providing a substrate material comprising polarized fibers of glass, polyamide, phenylene sulfide, carbon or graphite bonding thereon a metal compound comprising a complex compound of a polar gaseous refrigerant and a metal salt and/or a hydrated metal hydroxide and/or a metal hydroxide of a metal comprising alkali metal, alkaline earth metal, transition metal, zinc, cadmium, tin, aluminum, or two or more thereof, at a concentration of at least about 0.

Abstract: A process for manufacturing a sheet material comprising at least two fibrous plies juxtaposed one on top of the other, including the following steps: a first paper ply is produced by filtration of an aqueous suspension of fibers on the wire of a cylinder mould or of a former, a partly transparent element being inserted into the ply during the formation of the ply, and such that the transparent element is placed in the elongate region of zero thickness; a second paper ply is produced on the wire of a second cylinder mould so as to form at least one recess in the second ply; the two plies are joined together so that at least one recess in the second ply is located facing the elongate region of zero thickness of the first ply; and the structure thus obtained is dried.

Abstract: A composite sheet material in one embodiment includes a porous core layer. The porous core layer includes a thermoplastic polymer, about 20 weight percent to about 80 weight percent of reinforcing fibers based on a total weight of the porous core layer, and an effective amount of a flame retardant agent.

Abstract: A method for making a disposable absorbent core comprises depositing absorbent particulate polymer material from a plurality of reservoirs in a printing roll onto a substrate disposed on a grid of a support which includes a plurality of cross bars extending substantially parallel to and spaced from one another so as to form channels extending between the plurality of cross bars. The plurality of reservoirs in the first peripheral surface are arranged in an array comprising rows extending substantially parallel to and spaced from one another. The support and printing roll are arranged such that the plurality of cross bars are substantially parallel to the rows of the plurality of reservoirs and the absorbent particulate polymer material is deposited on the substrate in a pattern such that the absorbent particulate polymer material collects in rows on the first substrate formed between the first plurality of cross bars.

Abstract: A disclosed laminated sheet to be wound around an outer surface of an exhaust gas processing unit includes a first mat containing first inorganic fibers and a second mat containing second inorganic fibers, the second mat being laminated on the first mat. The average fiber length of the first inorganic fibers is larger than the average fiber length of the second inorganic fibers and the laminated sheet is to be wound around the exhaust gas processing unit such that the first mat forms an outermost layer. Development of cracks in the outer surface of the laminated sheet can be prevented by winding the laminated sheet around an exhaust gas processing unit such that the first mat faces outward.

Abstract: A stitching geometry and method for selective interlaminar reinforcement of a CMC wall (20A). The CMC wall is formed of ceramic fiber layers (22) individually infused with a ceramic matrix, stacked, and at least partially cured. A row of holes is formed in the wall, and a ceramic fiber thread (25) is infused with a wet ceramic matrix and passed through the holes to form stitches (28, 30, 31). The stitches are then cured, causing them to shrink more than any remaining wall shrinkage, thus tensioning the stitches and compressing the wall laminae together. The stitches may have through-wall portions (30, 31) that are angled differently in different wall areas as a function of interlaminar shear over interlaminar tension, optimizing wall reinforcement locally depending on magnitude and direction of shear. Alternate rows of stitches (54, 56) may have offsets in a stitch direction (34) and/or different through-wall angles (A1, A2).

Abstract: A method and apparatus for forming an absorbent core assembly containing a batt of particulate material which may be used in an absorbent article. The apparatus may include a laydown drum having a plurality of vacuum zones, a plurality of fence zones, and a plurality of blow-off zones. The vacuum zones may be substantially permeable to permit air to pass through and into the laydown drum. The fence zones may be substantially impermeable to inhibit air from passing through. The blow-off zones may be substantially permeable to permit air to pass out of and through said laydown drum. The apparatus may also include a deposition chute for depositing particulate material on a web of material in close proximity to the laydown drum. A shield may also be attached to the deposition chute in order to prevent the particles from bouncing off of the laydown drum.

Abstract: A method for the production of a weblike material including a flocked substrate (F) is described, in which: on at least a first side of the substrate (F) is applied an adhesive (R); on said first face are distributed flock fibers (13); the fibers are anchored to the substrate by way of the adhesive.

Abstract: A sheet comprising thermoplastic polymer (TP) and short high tensile modulus fibers, in which the concentration of TP in the middle of the sheet is higher than at the surface of the sheet, useful for making prepregs with a thermoset resin.

Abstract: A manufacturing method for producing a unitized composite material has been discovered. An assembly of loose fibers or fiber and fabric combinations is formed where at least one of the layered elements contains a bondable material such as a thermally sensitive bonding fiber. The un-bonded layered assembly is shaped into a wavy form having a repeating wave-like pattern of the desired amplitude and wavelength. The amplitude and wavelength of the repeating waves can be altered such as by changing the relative speeds of a transfer device and an oven wire and the height of the transfer device relative to the height of the oven wire using simple machinery control settings. The shaped assembly is subsequently bonded in an oven or other activation step preserving the wave-like shaping when cooled or removed from the activation effect.

Abstract: The present invention relates to a method for forming a fire combustion modified batt. The method comprises the step of forming a blend of nonwoven and oxidized polyacrylonitrile fibers into a web. The oxidized polyacrylonitrile fibers are fire resistant and when blended with nonwoven fibers are relatively easily processed into a batt. A second blend of nonwoven fibers can be formed into a web and layered with the oxidized polyacrylonitrile fiber web to form the batt. The fibers are bonded together with heat, resin or other bonding material and are compressed and cooled. The fire combustion modified batt is useful as fire barriers and fillers in bedding, upholstery and vehicle and aircraft seats, as insulators for apparel, appliances, walls and ducting, as barriers to separate control systems from a heat source, and as components in fire safety gear such as race driver suits and oven and welding mitts.

Abstract: The present invention relates to a method for forming a fire combustion modified batt. The method comprises the step of forming a blend of nonwoven and oxidized polyacrylonitrile fibers into a web. The oxidized polyacrylonitrile fibers are fire resistant and when blended with nonwoven fibers are relatively easily processed into a batt. A second blend of nonwoven fibers can be formed into a web and layered with the oxidized polyacrylonitrile fiber web to form the batt. The fibers are bonded together with heat, resin or other bonding material and are compressed and cooled. The fire combustion modified batt is useful as fire barriers and fillers in bedding, upholstery and vehicle and aircraft seats, as insulators for apparel, appliances, walls and ducting, as barriers to separate control systems from a heat source, and as components in fire safety gear such as race driver suits and oven and welding mitts.

Abstract: A bi-layered fire resistant (FR) nonwoven fiber batt and an associated method for manufacturing the same. The bi-layered FR nonwoven fiber batt includes a first, gray, FR layer, formed from a blend of black oxidized polyacrylonitrile (oxidized PAN), white dry polyester carrier fibers and white low-melt polyester binder fibers, and a second, white, layer, formed from a blend of white FR rayon, white dry polyester carrier fibers and white low-melt polyester binder fibers, disposed in a conforming relationship with the first, gray, FR layer.

Abstract: Disclosed are uni-layer and bi-layer FR nonwoven fiber batts formed of various blends of charring fibers such as FR treated rayon, oxygen-depleting fibers such as modacrylic fibers and nonwoven fibers such as carrier fibers and binder fibers and associated methods for forming the same. Variously, the uni-layer and bi-layer FR nonwoven fiber batts may include layers formed entirely of blends of charring fibers and nonwoven fibers, layers formed entirely of blends of oxygen-depleting fibers and nonwoven fibers and/or layers formed of blends of charring fibers, oxygen-depleting fibers and nonwoven fibers.

Abstract: A non-woven fabric which consists of a blend 75% to 95% by weight of polypropylene based fibers and 5 to 25% by weight of polyester based fibers. The polypropylene fibers are extruded from a melt mixture of about 80 to 99% by weight polypropylene and about 1 to 20% by weight of a suitable heat stabilizer. The polyester based fibers are extruded from a melt mixture of 80% to 100% by weight polyester and 0 to 20% by weight of other stabilizers and/or fire retardants. The flame retardant compounds are added to and blended with the polyester melt prior to the extrusion of the polyester based fibers. Most preferably, the extruded polypropylene and polyester based fibers are staple fibers of between about 2 and 12 denier.

Abstract: A method for making high temperature filter media is provided by melt-spinning a plurality of fibers of preceramic thermoplastic polymer to form a nonwoven textile web of the fibers, curing and cross-linking the thermoplastic polymer to a thermoset polymer, and thermally decomposing the thermoset polymer to ceramic. Between the melt-spinning step and the curing step, the web is formed to a filter pre-form in a green state while still pliable and malleable. The filter pre-form is cured without re-melting the thermoplastic polymer and without destroying morphology.

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 multi-layer elastic flat-shaped article having a predefined shape, consisting of at least two outer layers made of a porous fibrous or filamentous batting, and at least one inner layer, disposed between and adherent to a pair of said at least two outer layers. The inner layer is applied as at least one adhesive skein forming a latticework configuration. The adhesive skein is formed of a thermoplast having elastic properties at room temperature, and being adapted to recover its latticework configuration after tensile loading. The resulting article flat shaped article may be elastically stretched, and return to its original configuration. A preferred method for depositing the thermoplast is a printing process, for example intaglio printing, flexoprinting or screen printing. Nozzles may also be used to extrude hot thermoplast in a pattern defined by a relative movement of the outer layer or layers and the nozzle. The pattern may be continuous or interrupted.

Abstract: A method of producing a lightweight heat resistant and insulative composite sheet, and containing glass fibers, consisting essentially of homogenized glass fiber and binder materials forming a first layer, binder material extending in a second layer on a surface of the first layer and bonded thereto, woven glass fiber facing cloth extending in a third layer on a surface of the second layer and bonded thereto so that the second layer is sandwiched between the first and third layers, binder material in all layers being cured, to integrate the layers.

Abstract: A method of forming a lap mat for use in a subsequent molding operation to form a headliner includes forming a first continuous particulate layer having a non-uniform composition; folding the first continuous particulate layer to form a plurality of first layers; and binding the first layers together wherein the first layers cooperate to define a first region having a first material composition, and a second region having a second material composition different than the first material composition.

Abstract: A composite textile includes a batting layer, a cushion layer, and a face fabric. The batting layer has high melt temperature and low melt temperature fibers. The cushion layer is needled to the batting layer. The face fabric is bonded to the cushion layer by an adhesive. The face material/cushion layer/batting layer is heat set and rolled onto a roll for use in forming composite parts. The composite textile is more readily recyclable when the batting layer, the cushion layer, the adhesive, and the face material are all formed completely from material of the same chemical nature, such as polyolefin, polyester, or the like.

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: A shrink wrap material for protecting articles includes at least one non-woven fabric and a woven scrim defining apertures. A sufficient portion of the fibers from the non-woven fabric being forced into the apertures of the scrim such that the scrim reinforces and supports the non-woven fabric, thus increasing their strength. A shrinkable, stretchable film is intermittently bonded to at least one non-woven fabric. The material is used by placing the material around the article to be protected and then shrinking the film.

Abstract: In a method of producing an interior trim material, a laminated structure is formed by laminating a skin material, a mat-like fiber structure, and a high-melting-point fiber sheet in this order. The mat-like fiber structure is prepared by blending thermoplastic fibers and inorganic fibers, and the high-melting-point fiber sheet is formed from fibers having a melting point higher than that of the thermoplastic fibers. At least the mat-like fiber structure is heated so that the thermoplastic fibers are melted. The laminated structure is then compressed under pressure by a hot press machine, and then expanded to restore at least part of the thickness thereof. The laminated structure thus expanded is then formed into a certain shape by a cold press machine, while the thermoplastic fibers of the mat-like fiber structure maintains plasticity.

Abstract: A filter media having a synthetic microfiber polymer fine fiber web wherein the diameter of the fibers is between about 0.8 to about 1.5 microns. The filter media is acceptable for use in ASHRAE applications. Constructions with a low DP backing, support or prefilter layers of coarse fiber provide large area filter webs of high efficiency and a stale and high threshold value of alpha above eleven.

Abstract: The present invention provides a stable material having enhanced extensibility and a method for making the same. A neckable material is fed in a first direction. The neckable material is subjected to incremental stretching in a direction perpendicular to the first direction. A tensioning force is applied to the neckable material to neck the material in a direction perpendicular to the first direction. The necked material is then subjected to mechanical stabilization to provide a stabilized extensible necked material. The stabilized extensible necked material is then passed between the peripheral surface of a cylinder which is driven in rotating motion and a device for pressing the stabilized extensible necked material against the peripheral surface of the cylinder. A retarding member retards the passage of the stabilized extensible necked material and directs the material away from the peripheral surface of the cylinder.

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 object of the present invention is to provide a particle board which is improved at its entirety in the resistance to water without impairing its performance as a bearing board member and provide a method of making the particle board.

Abstract: A method for making a unitary composite headliner adapted to be installed in a motor vehicle includes providing an inner layer and two reinforcing layers, each of which comprises polymeric material, the inner layer being configured to absorb sound and vibrations, and the reinforcing layers being configured to provide sufficient flexibility to the headliner to facilitate installation in the vehicle, while also providing sufficient rigidity to the headliner to enable the headliner to be self-supporting once installed in the vehicle; differentially heating the layers such that each reinforcing layer is heated to a respective predetermined reinforcing layer temperature, and the inner layer is heated to a predetermined inner layer temperature less than either respective reinforcing layer temperature; inserting the layers into a mold such that the inner layer is disposed between the reinforcing layers; and compressing the layers together to bond the layers and form the headliner.

Abstract: The present invention provides a process for producing a carded and air-laid non-woven composite fabric. First, a fiber is subjected to carding treatment through a carding machine to form a carded web. Then, a fiber, powder, or particulate material is subjected to air-laying through an air-laying device to form an air-laid web. The sequence of carding and air-laying steps can be exchanged, and the carding machine and the air-laying device are disposed on the same production line. Finally, the above webs are consolidated into a non-woven composite fabric. In the present invention, since carding and air-laying are conducted on the same production line, the procedure for producing air-laid webs off-line can be omitted. Therefore, the thermoplastic polymer amount added to increase the web strength can be decreased, thus decreasing the production cost.