Abstract: Spinnerette including a plate including a plurality of capillaries which have capillary ends with dividers which divide each capillary end into a plurality of openings, and a process of making polymeric fiber. The process includes passing a molten polymer through a spinnerette comprising a plurality of capillaries which have capillary ends with dividers which divide each capillary end into a plurality of openings so that the molten polymer is formed into separate polymeric fibers for each opening or the molten polymer is formed into partially split fiber for each capillary, and quenching the molten polymer to form polymeric fiber.

Abstract: A method of producing a stain-resistant and soil-resistant polyamide yarn comprises the steps of (a) melt compounding a sulfonated aromatic acid with a thermoplastic polyester or polyamide carrier resin to form a concentrate; (b) adding said concentrate to a fiber-forming polyamide to form a fiber-forming polyamide composition; (c) melt extrusion spinning said fiber-forming polyamide composition to form a yarn; and (d) drawing said yarn.

Abstract: A luminescent coating compound of organic binder and luminescent fibers containing at least one organic binder and fibers which of a fiber-forming material with at least one luminescent dye or pigment distributed therein. Also a process of producing coatings of such compounds and articles with such coatings.

Abstract: Disclosed is a filter medium having at least a first layer containing a stabilized matrix of thermoplastic filaments and at least one secondary material; and a second layer having a stabilized matrix of thermoplastic filaments and optionally of at least one secondary material. Each of the layer of the filter medium has a different compositional ratio of the components to result in a gradient structure. The compositional gradient for the layers of the coform results in a filter having improved capacity, which extends the life of the filter medium, as compared to a filter without the compositional gradient. The present invention also provides a method of removing particles from a fluid containing particles. The method of the present invention includes contacting the fluid containing particles with the filter medium of having the two layers described above in a manner such that the fluid containing particles is passed through the first layer of the filter medium before the second layer.

Abstract: A separable tow of elongated polymeric filaments comprises a plurality of distinct sub-tows lightly and individually and separably joined, as by light crimping together along their edges or, if uncrimped, joined by presence of moisture, and capable of being packed into a container and later removed and separated. The filaments are preferably acrylic and have a total fineness of about 300,00-1,500,000 denier and the sub-tows each of which has a total fineness of about 50,000-250,000 denier, with a filament fineness of about 1-2 denier, and each sub-tow has a degree of entanglement of about 10-40 m−1 as measured by the hook drop test. The separable tow is made of a plurality of sub-tows, after separately drawing the sub-tows and subsequently removably joining the sub-tows into a single tow.

Abstract: Stable, heat-set, helically crimped fibers are economically produced with in-line fabric deposition and heat setting and are uncompacted to retain their loft.

Abstract: A process is disclosed for the manufacture of a spunbonded fabric consisting of thermobonded curled bicomponent fibers where the bicomponent fibers consist of two plastic materials with different properties. The process according to the invention consist of three steps: the fibers spun from the two plastic materials are drawn off uncurled and stretched in a first step. In a second step the fibers are placed on a sieve belt and thermobonded. In a third step the bicomponent fibers of the obtained nonwoven fabric are finally curled by lengthwise and/or transverse stretching and heat treatment.

Abstract: The present invention relates to industrial high relative viscosity (RV) filaments, such as, for use in papermaking machine felts and other staple fiber applications. The invention is further directed to apparatus and processes for solid phase polymerization (SPP) of polyamide flake suitable for use, such as, in remelting and then spinning the industrial high RV filaments. The invention is also directed to processes for melt phase polymerization (MPP) of molten polymer for making the filaments.

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

Abstract: In a method for producing hollow fiber membranes which comprises melt kneading a mixture comprising polyvinylidene fluoride and an organic liquid or a mixture comprising polyvinylidene fluoride, an organic liquid and an inorganic fine powder, extruding the kneaded mixture to form hollow fibers, and extracting the organic liquid or the organic liquid and the inorganic fine powder from the hollow fibers, which includes the steps of drawing the hollow fibers before or after termination of the extraction and then shrinking the fibers. According to this method, it is possible to stably produce hollow fiber membranes having dense pores and having a high water permeation performance, excellent endurance and stain resistance, and which are suitable for filtration uses such as removal of turbidity of water.

Abstract: Described is wet-spun plural-end elastane yarn having a yarn linear density of up to 2500 dtex, high surface lustre and a ribbony cross section and formed from bonded-together individual filaments having an oval to circularly round cross section, the width of the elastane yarn in cross section being at least four times the thickness of the elastane yarn.

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

Abstract: A process for preparing nonwoven webs comprising 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 comprising multiple component, continuous filaments having high levels of three-dimensional helical crimp.

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: Polyolefin fibers and polyolefin yarns of high strength and elongation and textile fabrics produced therefrom, which consist of modified propylene polymers, unmodified propylene polymers and adjuvants, are produced by melting the polyolefin mixtures in the extruder, transferring the melt by extrusion pumps to the spinnerets and drawing off the extruded filaments by high-speed galettes and/or winders.

Abstract: A stabilized creped nonwoven web and a method for producing the same, wherein a creped nonwoven web is thermally stabilized, for example by through-air-bonding or embossing, to produce the stabilized creped nonwoven web. The stabilized creped nonwoven web having increased tensile strength in the machine direction and an enhanced appearance. The stabilized creped nonwoven web of this invention id capable of withstanding a tensile force or load in a machine direction of at least about 2.0 lbs. at 20% strain and a tensile force or load in the machine direction of at least about 5.0 lbs. at 50% strain.

Abstract: A continuous fiber nonwoven comprising composite continuous fibers having the spiral crimps obtained by compositely spinning two thermoplastic resins having the difference in the melting points of 15° C. or more is provided, and it is characterized in that the contact points of the fibers are adhered one another by fusing of the thermoplastic resin having a low melting point and located on the outside of the spiral crimps.

Abstract: The invention relates to webs or batts comprising 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 comprising polytrimethylene terephthalate staple fibers, comprising 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: The present invention provides continuously crimped propylene polymer nonwoven fabrics as well as processes for forming crimped multicomponent propylene polymer fibers by melt-attenuating extruded multicomponent fibers with heated or unheated air wherein the fibers spontaneously crimp without the need for additional heating and/or stretching steps.

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: A hollow shrinkable fiber is manufactured by wet spinning a copolymer of acrylonitrile and a halogen-containing vinyl monomer, and then carrying out steam treatment, followed by drying treatment, and then heat treatment, thus forming a marrow-like or network-like hollow portion comprising a large number of voids in a core part of the fiber cross section. The void ratio of the fiber cross section is 10 to 50%, and the dry heat shrinkage percentage of the fiber is at least 15%. The fiber has a hollow form similar to that of natural fur, is excellent in terms of bulkiness, a lightweight feeling and warmth retention, and can be used as down hairs in pile products.

Abstract: The present invention provides a partially or whole flat synthetic fiber which is suitably used for preparing a high strength non-woven fabric even if the basis weight is very small, as well as a non-woven fabric prepared using such flat synthetic fibers. According to the present invention, a flat polybenzazole fiber such as PBO fiber is provided which has a flattened portion having a degree of flatness defined by the ratio of the long diameter/the short diameter of the cross section of the fiber being 2 or higher and having a short diameter being 7 &mgr;m or less. Also, a partially flat synthetic fiber is provided which has a flattened portion along the longitudinal direction of the fiber, wherein the ratio of Wmax (the maximum fiber width)/Wmin (narrowest fiber width) is 2 or higher or wherein the ratio of Wmax (the maximum fiber width)/Wav (average fiber width) is 1.5 or higher.

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: Stable, heat-set, helically crimped fibers are economically produced with in-line fabric deposition and heat setting and are uncompacted to retain their loft.

Abstract: A process of forming a nonwoven fabric is disclosed which comprises the steps of forming a precursor web of multicomponent substantially continuous filaments, exposing the precursor web to a hydraulic arrangement treatment to form apertures without causing substantial filament entanglement, and thereafter forming inter-filament bonds and an integrated web. The resulting apertured nonwoven fabrics have good hand and tactile aesthetics and have a great variety of uses including use in absorbent personal care products, garments, medical applications, and cleaning applications.

Abstract: A process of making polytrimethylene terephthalate staple fibers, comprising (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 comprising determining the relationship between denier and crimp take-up and manufacturing staple fibers having a denier selected based upon that determination.

Abstract: A cut-resistant yarn formed of a multifilament yarn, each filament of a polyester material having ceramic platelets embedded to provide a yarn having cut resistance, and the yarn having a friction-textured false twist inserted therein to provide a surface exhibiting comfort characteristics rendering the yarn suitable for use in apparel. An embodiment of the method of forming a cut-resistant yarn according to the invention includes the steps of providing a multifilament. The filament is a polyester material having ceramic platelets embedded to provide a yarn having cut-resistance. False twist by the friction-texturing method is inserted to provide a surface exhibiting comfort characteristics rendering the yarn suitable for use in apparel.

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.

Abstract: The present invention relates to a method for the manufacture of synthetic fibers from a melt mixture of fiber forming matrix polymers, wherein at least one second amorphous additive polymer, which is immiscible with the fiber forming matrix polymer, is added to the fiber forming matrix polymers in a quantity of 0.05-5 wt % (with reference to the total weight of fiber forming matrix polymer and the additive copolymer). The additive polymer is obtained by multiple initiation. Furthermore, the present invention also relates to the synthetic fibers produced by the method.

Abstract: Polyolefin fibers and polyolefin yarns of high strength and elongation and textile fabrics produced therefrom, which consist of modified propylene polymers, unmodified propylene polymers and adjuvants, are produced by melting the polyolefin mixtures in the extruder, transferring the melt by extrusion pumps to the spinnerets and drawing off the extruded filaments by high-speed galettes and/or winders.

Abstract: A method for making heat-retaining fiber and fabrics. According to the present invention, the white conductive particles and the white particles with good radiating efficiency of far-infrared radiation are added in fiber-forming polymers to obtain the mixed composition. The fiber and fabrics made of the mixed composition is characteristic of excellent effect of heat-retaining usable for the use of requiring good heat-retaining effectiveness.

Abstract: A separable tow of elongated polymeric filaments comprises a plurality of distinct sub-tows lightly and individually and separably joined, as by light crimping together along their edges or, if uncrimped, joined by presence of moisture, and capable of being packed into a container and later removed and separated. The filaments are preferably acrylic and have a total fineness of about 300,00-1,500,000 denier and the sub-tows each of which has a total fineness of about 50,000-250,000 denier, with a filament fineness of about 1-2 denier, and each sub-tow has a degree of entanglement of about 10-40 m−1 as measured by the hook drop test.

Abstract: The invention relates to a method and an apparatus for spinning and crimping a multifilament yarn, and wherein a thermoplastic melt is extruded through a spinneret to form a filament bundle. The filament bundle is divided into a plurality of bundle components before being crimped. Each bundle component is separately crimped and combined to a multifilament yarn after being crimped. The yarn is subsequently wound to a package.

Abstract: A process is disclosed for the manufacture of a spunbonded fabric consisting of thermobonded curled bicomponent fibers where the bicomponent fibers consist of two plastic materials with different properties. The process according to the invention consists of three steps: the fibers spun from the two plastic materials are drawn off uncurled and stretched in a first step. In a second step the fibers are placed on a sieve belt and thermobonded. In a third step the bicomponent fibers of the obtained nonwoven fabric are finally curled by lengthwise and/or transverse stretching and heat treatment.

Abstract: Polyester carpets of poly(trimethylene terephthalate) are disclosed which have excellent stain-resistance, texture retention and resistance to crushing. The bulked continuous filament yarn used to make the carpets and the process for making the yarns are also disclosed.

Abstract: A for the production of polymeric fibers in the form of a tow includes drawing and heat setting, with and without crimping, in which the tow has a constant denier per inch during the processing. The process permits very large drawn tows to be produced having a thickness of at least 150,000 denier per inch of width during processing through the production equipment/apparatus. The production apparatus includes a conventional stacker, followed by drawing apparatus, followed by heat setting apparatus, and optionally followed by crimping apparatus. Positioning the stacker before the drawing apparatus allows very large tows to be produced using drawing and heat setting apparatus having rolls significantly shorter than is conventionally known.

Abstract: Hydrophobic polyolefin fibers are provided with an internal hydrophobic polysiloxane of the formula in which X, Y, R1, and R2, which may be the same or different, or substituted or unsubstituted independently of each other, are aliphatic groups having not more than about sixteen carbon atoms, R1 and R2 also being selected from among aryl groups, and z being a positive number sufficiently high that the polysiloxane is hydrophobic (z is generally a least 10). The invention also provides a novel polymer melt for spinning these hydrophobic fibers. The fibers can be cut into staple lengths and carded and bonded to form hydrophobic woven and nonwoven products suitable for use in hygiene devices such as diapers. Such devices are improved by these fibers, which, as spun, present a greater hydrophobicity than melt-spun polyolefin fibers lacking the internal siloxane lubricant, the improved hydrophobicity is evidenced by an advancing contact angle for the as-spun fibers of at least about 95°.

Abstract: A method for producing a yarn for constructing non-carpet textile articles which comprises producing a large denier synthetic carpet face yarn by a bulked continuous filament or bulked crimped filament sheath-core extrusion process. The yarn has a denier of at least 300, and preferably around 1400, and is comprised of a plurality of filaments in the denier range of 10-20 denier per filament. Each filament has an outer sheath of nylon or polyester and an inner core of polyolefin, with the sheath comprising 20 to 60% of the total weight of each filament and the core constituting the remainder. The yarn, although very large by the standards applied to non-carpet textile articles, has a silky, soft feel similar to yarns composed of much smaller filaments of homopolymer nylon or polyester, and is thus well suited for the manufacture of non-carpet textile articles, such as upholstery fabrics, sweaters and the like.

Abstract: A method for producing a substantial helical crimp in a continuous filament of thermoplastic material by generating a turbulence in the thermoplastic material while the material is in its glass transition phase and maintaining stresses induced in the formed filament by said turbulence while the material passes into its crystallized phase.

Abstract: In a method of producing poly(trimethylene terephthalate) yarn from PTT chip which has been extruded through a spinneret into filaments and coated, the coated filaments are passed between an unheated feed roll and a tension roll to tension them without causing permanent stretching, and then are passed from the tension roll to a heated draw roll to draw the filaments in a single draw step to a draw ratio of 1.25 to 4.0 and to heat them to a temperature between their glass transition temperature and their crystallization temperature.

Abstract: A protective cover for application to multi-surface or multi-faceted structures or objects, such as posts, piers, stairs, which have two or more parallel edges or corners. The protective cover includes a foldable elongated flexible sheet of shock absorbing material adapted to be folded about the structure. The foldable elongated flexible sheet of shock absorbing material includes spaced apart fold lines that extend in the same direction as the edges or corners the fold lines are to fold about. The foldable elongated flexible sheet preferably comprises a flexible porous filamentary cover.

Abstract: An apparatus for thermal extrusion of a polymeric material to manufacture prototype mechanical elements from said polymeric material, said apparatus used for deposition of a liquefied ribbon of said polymeric material in patterned layers which solidify to form a three-dimensional prototype element, said apparatus comprising in combination, a mounting frame, said mounting frame including a mounting plate with a movable platen movable in the x and y directions, said frame further including an extrusion cylinder, said extrusion cylinder comprising a cylindrical housing having a uniform diameter cylindrical through passage, a head member having a uniform diameter bore connected with a reduced diameter, integral tip opening, said head member attached by a clamp to one end of the cylindrical housing to align the bore with the through passage, said-bore and through passage having an equal diameter, said head member including a circumferential heater to liquefy contents of the head member, a reciprocal piston slidabl

Abstract: Side-by-side conjugate filaments made from thermoplastic elastomers and spunbond-type polyolefins exhibit an extremely high propensity to self-crimp. At appropriate polymer ratios and processing conditions (with mechanical or aerodynamical drawing) the crimp develops spontaneously after relaxation of the attenuation force. The amount of crimp and the degree of elastic properties depend on the elastomer content and the processing conditions. The resulting crimp is typically in the range of 25-200 crimps per inch. This combination of exceptionally high crimp and an elastomer component imparts stretch and recovery properties. The filaments can be wrapped around a cylindrical supporting structure to create a continuous, seamless elastic band, useful for body-fit articles.

Abstract: The present invention provides a lofty nonwoven web containing pneumatically drawn filaments, wherein the web has a density from about 0.01 g/cc to about 0.075 g/cc and the microfilaments have a weight-per-unit length between about 0.1 dtex and about 1.5 dtex. The invention also provides a process for producing the lofty nonwoven web.

Abstract: A process for producing a non-woven fabric of ultrafine polyolefin fibers by subjecting a web of splittable conjugate polyolefin fibers to a water needle processing, and non-woven fabric thus obtained are described. The polyolefin composite fibers, contain 1.0 to 7.0% by weight of a hydrophilic component blended therein. The non-woven fabrics include ultrafine fibers having a size of 0.5 denier or less and a non-circular cross-section. Splitting and peeling off of the conjugate fibers and generation of static electricity with the composite fibers at a carding step is suppressed. The non-woven fabrics have an excellent wiping property, softness, and hydrophilic property.

Abstract: The present invention is directed to a method of forming a heteroconstituent nonwoven web including a mixture of different filament types simultaneously formed into the same web. The filament types may differ as to polymer composition, additive loadings, fiber size, fiber shape, and/or degree of crimping. The invention is also directed to a method of forming a multilayered nonwoven structure in which different filament types constituting different layers are simultaneously formed.

Abstract: Crimped polybenzazole staple fibers which satisfy the following specifications at the same time:(1) 2.ltoreq.number of crimps (number/inch).ltoreq.40(2) 2.ltoreq.crimp index (%).ltoreq.30(3) 0.3.ltoreq.crimp index/number of crimps.ltoreq.3.0; methods for manufacturing crimped polybenzazole staple fibers; and the rotary cutter therefor. The crimped polybenzazole staple fibers of the present invention are superior in crimp property and are useful for manufacturing spun yarn and unwoven fabric. According to the method of the present invention, crimped polybenzazole staple fibers superior in spinnability can be manufactured with ease. In addition, the cutting blade of the present invention stands a long time use for manufacturing staple fibers from a continuous filaments tow of high tenacity fibers.

Abstract: A method of making a toothed belt. A toothed belt is made by guiding a strip of fabric to pass through a thermosetting resin to soak it with thermosetting resin, then the soaked fabric is guided to pass through a pair of toothed rollers to form a series of toothed grooves thereon, thereafter the fabric is guided to pass around a plane roller and simultaneously rubber material is fed into the space between the outer peripheral surface of the plane roller and said fabric. Then, the fabric is wound onto a cylindrical mold having corresponding toothed grooves thereon and its two ends are glued together to loop around the cylindrical mold, then reinforcing cords and rubber sheets are covered over the fabric. Finally, the rubber material is vulcanized to form a toothed belt. Fabrics treated by the method demonstrate considerately greater flexibility or extendibility to comply with bending when under operation. Furthermore, the tooth contour of the belt will be more accurate than conventional ones.

Abstract: A direct melt spinning process for providing high filament count fine filament polyester yarns having excellent mechanical quality and along-end uniformity and unitary interlace by spinning all the filaments of such high filament count yarn from a single spinneret. Such yarns may be used as direct-use yarns and as draw-feed yarns for preparing drawn flat yarns and draw-textured yarns.

Abstract: There is provided in accordance with the present invention a process for making a helically crimped conjugate fiber containing at least a first polymeric composition and a second polymeric composition. The first and second polymeric compositions respectively contain different thermoplastic polymers having different solidification periods. The degree of latent helical crimp is controlled by selective addition of a nucleating agent to at least one of the first and second polymeric compositions. Addition of the nucleating agent to the polymeric composition with a faster solidification period increases the latest crimp and addition of the nucleating agent to the polymeric composition with a slower solidification period decreases the latent crimp.