Abstract: In a first aspect the invention is a solid core fibrillation-resistant, synthetic polymeric filament having three substantially equal length convex sides. The sides through substantially rounded tips centered by a distance “a” from the axis of the filament. Each rounded tip has a radius substantially equal to a length “b”. Each tip lies on a circumscribed circle having a radius substantially equal to a length (a+b) and the midpoint of each side lies on an inscribed circle having a radius substantially equal to a length “c”. The filament has a denier-per-filament in the range 10<“dpf”<35; the distance “a” lies in the range 0.00025 inches (6 micrometers)<“a”<0.004 inches (102 micrometers); the distance “b” lies in the range from 0.00008 inches (2 micrometers)<“b”<0.001 inches (24 micrometers); the distance “c” lies in the range from 0.0003 inches (8 micrometers)<“c”<0.0025 inches (64 micrometers); and the modification ratio (“MR”) lies in the range from about 1.1<“MR”<about 2.0.

Abstract: A thermal bonding conjugate fiber constituted from a first component comprising a polyester resin and a second component comprising a polyolefin resin with a melting point lower than that of the polyester resin by not less than 20° C., characterized in that a post-heat treatment bulk retention rate thereof is 20% or more when calculated by the following measurement method: Bulk retention rate=(H1 (mm)2/H0 (mm))×100 (%) (wherein H0 is the web height when a 0.1 g/cm2 load is applied to a web with a mass per unit area of 200 g/m2; and H1 is the web height after a heat treatment for 5 min at 145° C. when a 0.1 g/cm2 load is applied to that web).

Abstract: To provide a fiber bundle for artificial hair which has a well balanced combination of properties such as bulkiness, yarn separability, weaving efficiency and hot water-curling efficiency. The fiber bundle for artificial hair is a fiber bundle obtained by crimping fibers (A) having a flexural rigidity of from 0.7 to 2.5 gf·cm2 as measured by the KES method and has a crimp wave shape satisfying the following formula: 1 mm?R?20 mm wherein R is the distance between the top and the bottom of the crimp wave shape. Further, in the fiber bundle for artificial hair, the fibers (A) are vinyl chloride fibers obtained by melt-spinning a vinyl chloride resin composition.

Abstract: Disclosed herein are monofilament fibers and staple fibers comprising at least one polymeric resin and at least one coated filler, wherein the at least one coated filler has an average particle size of less than or equal to about 3 microns, and wherein the at least one coated filler is present in an amount of less than or equal to about 50% by weight, relative to the total weight of the monofilament fibers. Also disclosed herein are methods for producing monofilament fibers, staple fibers, webs, and fabrics comprising adding ground calcium carbonate to at least one polymeric resin and processing the resulting mixture.

Abstract: The present invention is directed to a process for preparing bicomponent fibers by melt spinning two semi-crystalline polymers differing in crystallization rate.

Abstract: An object of the invention is to provide a polyester based fiber for airlaid nonwoven fabrics enabling one to manufacture an airlaid nonwoven fabric which is extremely excellent in airlaid web formability, especially in spinning properties from a screen, is satisfactory in texture and is bulky. This object can be achieved by a manufacturing method of a polyester fiber for airlaid nonwoven fabrics made of, as a fiber forming resin component, a polyester having a fineness of not more than 10.0 dtex or a fiber length of 8.0 mm or more, having a number of crimp of 8.5 peaks/25 mm or more, a percentage of crimp/number of crimp ratio of not more than 0.65 and a crimp modulus of elasticity of 70% or more and containing 80% by mole or more of an alkylene terephthalate repeating unit in the whole of repeating units, which includes drawing an undrawn yarn taken up at a spinning rate of not more than 1,500 m/min in a low draw ratio of from 0.60 to 1.20 times at a temperature of at least 10° C.

Abstract: A process for making a cigarette tow comprising: spinning a dope; taking-up the as-spun cellulose acetate filaments; lubricating the filaments; forming a tow from the filaments; crimping the tow with a stuffer box crimper; drying the crimped tow; and baling the dried crimped tow. The process further comprises at least two of the following: A. crimping further comprising one roller of the pair of nip rollers being adapted to induce crimp into the tow; B. crimping further comprising one roller of the pair of nip rollers being made of a solid ceramic material; C. crimping further comprising a pair of tow edge lubricators; D. crimping further comprising a steam injector; E. further comprising plasticizing the tow; F. lubricating the filaments further comprises a finish consisting of a water emulsion.

Abstract: In the manufacture of a fiber tow, particularly cellulose acetate tow, the tow is plasticized prior to entry into the crimper. The preferred plasticizer is water.

Abstract: Improved staple fibers and processes for producing them are provided. The processes are particularly useful for forming staple fibers from poly(trimethylene terephthalate), especially carpet staple fibers. The processes include prewetting undrawn yarns and drawing the fibers under wet and warm conditions, thermo-fixing the texture, and drying at relatively low temperatures. Fibers produced according to the processes disclosed herein have improved properties and reduced brittleness as compared to fibers prepared using conventional processes.

Abstract: Disclosed is a method and device for creating three dimensional (3D) self-crimping fluoropolymer(s) and perfluoropolymer(s) filaments via extrusion through a spinneret plate orifice with a hole and elliptical gap and using die swell to close the elliptical gap in the filament forming a seam causing uneven stresses in the longitudinal length of the filament while cooling thereby causing the filament to self-crimp toward the seam.

Abstract: A method of making a spunbond fleece from continuous filaments wherein at least some of the filaments produced have natural crimp. The filaments are deposited in the deposition station of a conveyor creating a filament mass and the conveyor transports the filament mass toward a consolidating device. A gas stream is produced that flows along the upper surface of the filament mass in the travel direction of the filament mass.

Abstract: A heat extensible fiber comprises a conjugate fiber including a first resin component having an orientation index of 30% to 70% and a second resin component having a lower melting point or softening point than the melting point of the first resin component and an orientation index of 40% or more, the second resin component being present on at least part of the surface of the conjugate fiber in a lengthwise continuous configuration. The conjugate fiber is a heat-treated or crimped fiber and being configured to thermally extend when heated at a temperature lower than the melting point of the first resin component. The heat extensible fiber has higher heat self-extensibility than conventional extensible fibers.

Abstract: In the manufacture of a fiber tow, particularly cellulose acetate tow, a stuffer box crimper has a pair of tow edge lubricators adapted to lubricate the lateral edges of the tow immediately prior to contact with the nip rollers of the crimper.

Abstract: In the manufacture of a fiber tow, particularly cellulose acetate tow, a stuffer box crimper has a steam injector in communication with the stuffer channel of the crimper. The steam injector consists of a single pair of injectors vertically aligned with one another above and below the stuffer channel of the crimper.

Abstract: A polyolefin fiber includes 0.2 to 5.0 wt % of hydrophilic additive, and 0.05 to 3.00 wt % of titanium dioxide (TiO2). The polyolefin fiber may further include 0.2 to 1.0 wt % of spin finish provided on a surface thereof. The polyolefin fiber is spun to have a circular section, a modified cross-section including an X-shaped section, a Y-shaped section, a deltaic section, an oval section, a diamond section, a bladebone-shaped section, and a combined section thereof, or a combined section of the circular section and the modified cross-section. A method of producing a polyolefin fiber includes (a) melt extruding a composition which contains 93 to 99 wt % of polyolefin resin, 0.2 to 5.0 wt % of hydrophilic additive, and 0.05 to 3.00 wt % of any one titanium dioxide (TiO2) of rutile titanium dioxide, anatase titanium dioxide, and brookite titanium dioxide at 240 to 300° C. and performing winding at a spin speed of 500 to 2,000 mpm to produce a undrawn yarn, and (b) drawing the undrawn yarn at a draw ratio of 1.

Abstract: A crimped yarn includes a synthetic fiber which contains an aliphatic polyester resin (A) and a thermoplastic polyamide resin (B) and exposed area ratio of the aliphatic polyester resin (A) with respect to fiber surface area is 5% or less and a crimp is imparted to a multifilament comprising said synthetic fiber, and a fiber structure containing said crimped yarn as at least a part thereof. Furthermore, a crimped yarn in which the aliphatic polyester resin (A) and the thermoplastic polyamide resin (B) are constituted of a polymer alloy type synthetic fiber, or a crimped yarn constituted by a sheath/core type composite fiber in which the core component comprises the aliphatic polyester resin (A) or a polymer alloy of the aliphatic polyester resin (A) and the thermoplastic polyamide resin (B) and the sheath component comprises the thermoplastic polyamide resin (B), and a fiber structure containing said crimped yarn as at least a part thereof.

Abstract: The present invention relates to a method for manufacturing nonwoven and nonwoven obtainable by said method. Particularly, the invention relates to a nonwoven provided with improved tactile and absorbent characteristics, which make it suitable for use in the field of surface cleaning, personal hygiene, or formation of garments.

Abstract: In the manufacture of a fiber tow, particularly cellulose acetate tow, a stuffer box crimper has one roller adapted to induce crimp into the tow. This roller induces crimp by preferentially weakening a portion of the tow. This roller has an axially grooved surface. This roller may be located in the stuffer box crimper or before the stuffer box crimper.

Abstract: In the manufacture of a fiber tow, particularly cellulose acetate tow, a stuffer box crimper has a pair of nip rollers, at least one, made of a solid ceramic material.

Abstract: A bicomponent fiber wherein (a) the first component comprises from about 90 to 100 wt. % poly(trimethylene terephthalate) and (b) the second component is a polymer composition comprising (i) poly(trimethylene terephthalate) and (ii) polymer containing polyalkylene ether repeating units. Yarn, fiber, fabrics and carpets comprising the bicomponent fiber, as well as the process of making the bicomponent fiber, yarn, fabric, and carpet.

Abstract: High loft, low density nonwoven webs are produced by forming substantially continuous, spunbond, crimped, bicomponent fibers of A/B bilateral morphology in an unheated fiber draw unit. The fibers are then heated and cooled in the absence of impeding forces to achieve maximum crimp in the z-direction and produce a web of lofted material. The resultant material is particularly suitable for use as an insulator. Particulates may be added to the webs if desired.

Abstract: A method for preparing stretchable bonded nonwoven fabrics which involves forming a substantially nonbonded nonwoven web of multiple-component continuous filaments or staple fibers which are capable of developing three-dimensional spiral crimp, activating the spiral crimp by heating substantially nonbonded web under free shrinkage conditions during which the nonwoven remains substantially nonbonded, followed by bonding the crimped nonwoven web using an array of discrete mechanical, chemical, or thermal bonds. Nonwoven fabrics prepared according to the method of the current invention have an improved combination of stretch-recovery properties, textile hand and drape compared to multiple-component nonwoven fabrics known in the art.

Abstract: This invention relates to a poly(trimethylene terephthalate) BCF carpet yarn having a Y-shaped cross-section that has an modification ratio and a arm angle within a specific range, and a method for preparing it. The BCF carpet yarn has excellent bulk property and spinning efficiency, and a carpet made from it has good appearance, sense of touch, and tufting efficiency.

Abstract: A multilayer laminate is produced with in-line fabric deposition. One layer of the multilayer laminate has stable, heat-set, helically crimped fibers which are uncompacted and therefore retain their loft.

Abstract: This invention relates to a method for preparing nonwoven fabrics having an improved balance of properties in the machine and cross-directions. More specifically, the invention utilizes nonwoven webs that include relatively low levels of multiple-component fibers having latent three-dimensional spiral crimp combined with fibers that do not develop spiral crimp. The latent spiral crimp of the multiple-component fibers is activated, such as by heating, under free shrinkage conditions, after formation of the nonwoven web to achieve re-orientation of the non-spirally-crimpable fibers and an improved balance of properties such as tensile strength and modulus.

Abstract: A process for preparing poly(trimethylene terephthalate) fibers including (a) providing a poly(trimethylene terephthalate) composition comprising about 0.05 to about 10 weight % ionomer and (b) spinning the polymer composition to form fibers. In addition, a poly(trimethylene terephthalate) fiber including poly(trimethylene terephthalate) with about 0.1 to about 10 weight % ionomer dispersed throughout the poly(trimethylene terephthalate), and use thereof in yarns, fabrics, and carpets, as well as the yarns, fibers and fabrics.

Abstract: A process for preparing poly(trimethylene dicarboxylate) multifilament yarns and monofilaments. One process for preparing poly(trimethylene dicarboxylate) multifilament yarns includes (a) providing a polymer blend including poly(trimethylene dicarboxylate) and about 0.1 to about 10 weight % styrene polymer, by weight of the polymer in the polymer blend, (b) spinning the polymer blend to form poly(trimethylene dicarboxylate) multiconstituent filaments containing dispersed styrene polymer, and (c) processing the multiconstituent filaments into poly(trimethylene dicarboxylate) multifilament yarn including poly(trimethylene dicarboxylate) multiconstituent filaments containing styrene polymer dispersed throughout the filaments. Another process includes spinning at a speed of at least 3,000 m/m and processing a blend including poly(trimethylene dicarboxylate) to form partially oriented poly(trimethylene dicarboxylate) multifilament yarn.

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: An elastically stretchable nonwoven fabric including thermoplastic elastomer filaments; the filaments being heat-sealed and/or mechanically intertwined together to form the nonwoven fabric that has crimped regions and non-crimped regions wherein each of the crimped regions has fine crimps in the rate of 50/cm or higher.

Abstract: A process for preparing nonwoven webs including multiple component continuous filaments having high levels of three-dimensional helical crimp utilizing draw rolls to provide a high degree of orientation to each of the polymeric components by mechanically drawing the filaments under conditions wherein the polymeric components remain substantially amorphous and a stretchable nonwoven web including multiple component, continuous filaments having high levels of three-dimensional helical crimp.

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: The invention provides a process for treating a polyester fiber comprising the steps of providing a bicomponent fiber comprising poly(ethylene terephthalate) and poly(trimethylene terephthalate) which has been heat-treated at a first temperature and cooled to lower than about 70° C. and has an initial crimp contraction value and a developed crimp contraction value, applying tension to the fiber of about 0.001 to 0.088 dN/tex, heat-treating the fiber at a second heat-treating temperature no lower than about 75° C. and no higher than the first heat-treating temperature, cooling the fiber to lower than the second heat-treating temperature, and releasing the tension from the fiber to give a fiber having a reduced crimp contraction value. The invention also provides a bicomponent fiber comprising poly(ethylene terephthalate) and poly(trimethylene terephthalate) having a reduced crimp contraction value of about 6% to 15%.

Abstract: The invention relates to webs or batts including polytrimethylene terephthalate crimped staple fibers and fiberfill products comprising such webs and batts, as well as the processes of making the staple fibers, webs, batts and fiberfill products. According to the preferred process of making a web or batt, polytrimethylene terephthalate staple fibers, containing polytrimethylene terephthalate is melt spun at a temperature of 245-285° C. into filaments. The filaments are quenched, drawn and mechanically crimped to a crimp level of 8-30 crimps per inch (3-12 crimps/cm). The crimped filaments are relaxed at a temperature of 50-130° C. and then cut into staple fibers having a length of about 0.2-6 inches (about 0.5-about 15 cm). A web is formed by garnetting or carding the staple fibers and is optionally cross-lapped to form a batt. A fiberfill product is prepared with the web or batt.

Abstract: An acid dye stain-resistant fiber-forming polyamide composition comprising a fiber-forming polyamide and a reagent, at least a portion of which associates with free acid dye sites in the polyamide, thereby disabling the acid dye sites in fibers formed from the composition from taking up acid dye stains; a masterbatch concentrate for addition to a fiber-forming polyamide to form an acid dye stain-resistant fiber-forming polyamide composition comprising a carrier compatible with the fiber-forming polyamide combined with an amount of the above reagent in excess of that desired in the acid dye stain-resistant fiber-forming polyamide; as well as fibers and articles of manufacture prepared therefrom.

Abstract: Poly(trimethylene terephthalate) tetrachannel cross-section staple fibers, as well as yarns, fiberfill webs, batts and products, and fabrics made therewith. Also, the process of making such staple fibers, yarns, fiberfill webs, batts and products, and fabrics.

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 present invention is directed to a process for preparing bicomponent fibers by melt spinning two semi-crystalline polymers differing in crystallization rate.

Abstract: A process for the preparation of a side-by-side or eccentric sheath-core bicomponent fiber wherein each component comprises a different poly(trimethylene terephthalate) composition.

Abstract: An apparatus and method for producing self-texturing hollow fiber that exhibits a desirable tendency to coil rather than to bend sharply or zig-zag. In one embodiment the invention is a spinneret for the production of hollow filament having first and second curved slots where each slot is defined by a first end having a first width and a second end having a second width and where the first and second ends are separated by an intermediate portion possessing a non-uniform width. In another embodiment the invention is a method for of producing generally cylindrical hollow filaments comprising extruding a polymer melt through a spinneret having first and second curved slots where each slot has a first end having a first width and a second end having a second width and where the first and second ends are separated by a intermediate portion possessing a non-uniform width along the continuum defined by the distance between the first end and the second end.

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

Abstract: An acid dye stain-resistant fiber-forming polyamide composition comprising a fiber-forming polyamide and a reagent, at least a portion of which associates with free acid dye sites in the polyamide, thereby disabling the acid dye sites in fibers formed from the composition from taking up acid dye stains; a masterbatch concentrate for addition to a fiber-forming polyamide to form an acid dye stain-resistant fiber-forming polyamide composition comprising a carrier compatible with the fiber-forming polyamide combined with an amount of the above reagent in excess of that desired in the acid dye stain-resistant fiber-forming polyamide; as well as fibers and articles of manufacture prepared therefrom.

Abstract: A process of making polytrimethylene terephthalate staple fibers, including (a) providing polytrimethylene terephthalate, (b) melt spinning the melted polytrimethylene terephthalate at a temperature of 245-285° C. into filaments, (c) quenching the filaments, (d) drawing the quenched filaments, (e) crimping the drawn filaments using a mechanical crimper at a crimp level of 8-30 crimps per inch (3-12 crimps/cm), (f) relaxing the crimped filaments at a temperature of 50-120° C., and (g) cutting the relaxed filaments into staple fibers having a length of about 0.2-6 inches (about 0.5-about 15 cm), and polytrimethylene terephthalate staple fibers, yarns and fabrics. Further, a process of optimizing the crimp take-up of a polytrimethylene terephthalate staple fiber including determining the relationship between denier and crimp take-up and manufacturing staple fibers having a denier selected based upon that determination.

Abstract: Improvements in creating resilient high denier polypropylene yarns are provided. Generally, high denier polypropylene yarns exhibit poor resiliency (such as crush resistance, for example, when utilized as carpet face yarns) that effectively prevents widespread use in articles that require high degrees of resiliency. As a result, higher cost, but more resilient, yarns, such as polyesters or polyamides, have found greater acceptance in such end-use articles. Furthermore, previous attempts at texturing high denier polypropylene fibers have failed to attain suitable resilience levels therein is insufficient to permit proper return to initial shape and/or length after impact.

Abstract: A side-by-side or eccentric sheath-core bicomponent fiber wherein each component comprises a different poly(trimethylene terephthalate) composition and wherein at least one of the compositions comprises styrene polymer dispersed throughout the poly(trimethylene terephthalate), and preparation and use thereof.

Abstract: A method and apparatus for producing a high-strength and low-shrinkage synthetic flat yarn. After melt spinning, the filaments are combined to a yarn and drawn. Subsequently, the yarn is compressed to form a plug under the influence of heat. This plug is transported over a certain distance, so that the yarn relaxes in a low-tension state and under the influence of the increased temperature. Finally the plug is disentangled under tension to form the flat yarn, which is wound into a package.

Abstract: A pipe blanket is provided for wrapping around and insulating a pipe. The pipe blanket comprises an insulation mat having an outer surface and an inner surface adapted to lie adjacent the pipe when the pipe blanket is wrapped around the pipe. An outer cover of the pipe blanket is coupled to the outer surface of the insulation mat. The insulation mat is configured to enclose a variety of pipes having different sized diameters. The pipe blanket further includes a closure means configured for securing the insulation mat and outer cover about the pipe. The insulation mat further includes a plurality of pleats.

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: A method of forming bicomponent fibers into a web is disclosed. The 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 as a forming wire, to form an accumulation of fibers. The accumulation of fibers are stabilized and bonded to form a web. The web is then stretched by at least 50 percent in at least one direction before being allowed to relax.

Abstract: A method of forming 3-dimensional fibers into a web is disclosed. The 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 routed through a quenching chamber to form a plurality of continuous cooled fibers. The cooled 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: Highly crimped, fully drawn bicomponent fibers, prepared by melt-spinning, followed by gas-flow quenching, heat treatment and high speed windup, are provided, as are fine-decitex and highly uniform polyester bicomponent fibers.