Abstract: A nonwoven fabric having characteristics resembling woven and knitted fabrics is produced by extruding a plurality of plural component fibers, where each fiber includes first and second polymer components with the first polymer component having a degree of shrinkage when subjected to heat. A nonwoven web of the extruded fibers is formed on a web forming surface and bonded. The bonded web of fibers are post-bond treated to shrink at least the first polymer component and separate at least a portion of the second polymer component from the first polymer component utilizing any combination of heat, mechanical agitation and dissolving of fiber components. The resultant nonwoven fabric has a texture, drape and feel of woven and knitted fabrics.

Abstract: A closed fiber spinning system includes a spin beam assembly including a plurality of polymer distribution manifolds to independently deliver different polymer component fluid streams to a spin pack and independently maintain those fluid streams at different temperatures. The spin beam assembly in combination with the closed spinning system facilitates the production of a wide variety of multiple polymer component fiber and fabric products having a desired denier and degree of uniformity.

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 for extruding multiple types of liquid materials into multi-component filaments. A pair of outer manifold elements sandwich an intermediate manifold element. Respective channels are formed between opposing sides of the outer manifold elements and the respective opposite sides of the intermediate manifold element. These recesses form channels which diverge or widen away from associated inlets at the top of the manifold assembly. A die tip is coupled to the manifold assembly at a lower side and communicates with the outlets of the channels. The die tip includes a combining member for producing a desired multi-component filament configuration.

Abstract: A melt spinning apparatus including a spinpack with a die tip block having a recess with a converging portion, such as an angled trough, which terminates in a row of filament discharge outlets. The recess selectively receives a configuration insert, such as a side-by-side insert or a sheath-core insert, that separates the converging portion of the recess into two sheets of liquid that combine at the filament discharge outlets. The spinpack may be configured by inserting either of the inserts to produce filaments having different cross sectional configurations of two different materials. Separation of the two liquids prevents premature interaction between the two liquid flows which minimizes instabilities between the liquid flow interface. The minimization of these instabilities can result in less formation of shot and improve other significant finished product properties. In addition, each type of liquid material may be maintained at an optimum temperature for proper extrusion.

Abstract: An apparatus for meltblowing multiple types of liquid materials into multi-component filaments. A pair of outer manifold elements sandwich an intermediate manifold element. Respective channels are formed between opposing sides of the outer manifold elements and the respective opposite sides of the intermediate manifold element. These recesses form channels which diverge or widen away from associated inlets at the top of the manifold assembly. A die tip is coupled to the manifold assembly at a lower side and communicates with the outlets of the channels. The die tip includes a combining member for producing a desired multi-component filament configuration and further includes air discharge passages for impinging the discharged multi-component filaments with pressurized air.

Abstract: An apparatus for manufacturing an elongate composite element in undefined lengths, the composite element containing reinforcement fibers embedded in a matrix based on a composition containing a curable resin, including a vacuum chamber, rigid-walled inlet tubing, an impregnation chamber, rigid-walled transfer tubing between the vacuum chamber and the impregnation chamber, a sizing die and, downstream of the sizing die, irradiation tubes providing radiation in the ultraviolet-visible spectrum to prepolymerize the resin.

Abstract: Disclosed are water-dispersible fibers derived from sulfopolyesters having a Tg of at least 25° C. The fibers may contain a single sulfopolyester or a blend of a sulfopolyester with a water-dispersible or water-nondispersible polymer. Also disclosed are multicomponent fibers comprising a water dispersible sulfopolyester having a Tg of at least 57° C. and a water non-dispersible polymer. The multicomponent fibers may be used to produce microdenier fibers. Fibrous articles may be produced from the water-dispersible fibers, multicomponent fibers, and microdenier fibers. The fibrous articles include water-dispersible and microdenier nonwoven webs, fabrics, and multilayered articles such as wipes, gauze, tissue, diapers, panty liners, sanitary napkins, bandages, and surgical dressings. Also disclosed is a process for water-dispersible fibers, nonwoven fabrics, and microdenier webs.

Abstract: Fastener products having a multiplicity of fastener elements extending from a strip-form base, the base including first and second attachment members for attachment of a substrate therebetween, are formed by continuously introducing molten resin to a gap defined adjacent a peripheral surface of a rotating mold roll. The resin forms part of the strip-form base of the product at the peripheral mold roll surface and fills an array of fixed cavities defined in the rotating mold roll to form portions of the fastener elements as projections extending from a first side of the sheet-form base. While the resin is on the mold roll, a sheet material is introduced.

Abstract: A method of forming a plurality of substantially-continuous and uninterrupted multi-component filaments for use as a high-loft non-woven web. The multi-component filaments include at least two polymers of different melt flow rates, which imparts latent crimp in each filament. After collection, the latent crimp of the filaments is activated either thermally or by applying tension to the non-woven web.

Abstract: Disclosed is an air permeable film united with a nonwoven fabric, consisting of a polymer film having an inorganic material extruded to have a basic weight of 35 g/m2 or less and united to a partial or whole surface of a nonwoven fabric. The nonwoven fabric having a basic weight of 50 g/m2 or less is united to one surface of the extruded polymer film in a melted state, with an air permeable region centering around a drawn mark distributed to the whole surface of a nonwoven fabric-united film rolled and drawn by a press roll. A method of preparing such an air permeable film united with a nonwoven fabric and a device for preparing the same are also described.

Abstract: A new die insert for an extrusion machine and a method of using the invention that includes a continuous strand of fiber reinforcing material to be statically drawn directly to the center of the molten flow of polymer base matrix. The insert is placed in line with the discharge end of an injection molding apparatus. A molten flow of polymer base matrix proceeds in a straight linear fashion through the die. A fiber feed tube is centered on the interior of the die. As the polymer flows past the feed tube the molten polymer draws a continuous strand of fiber reinforcing into the center of the flow. The polymer is then extruded and cooled and the extrusion is further pelletized to produce injection molding feed stock material having continuous fiber reinforcing. The result provides a continuous extrusion process that allows the formation of a continuous fiber-reinforced product employing brittle fibers in one-step process.

Abstract: A process for forming a multiple component meltblown fiber comprising extruding a first distinct melt-processable polymer through a first extrusion orifice, simultaneously extruding a second distinct melt-processable polymer through a second extrusion orifice, fusing said first and second melt-processable polymers into an extruded composite filament after extrusion, and pneumatically attenuating said extruded composite filament with jets of high velocity gas so as to form said multiple component meltblown fiber.

Abstract: A two component interpenetrating polymer network wound dressing material is formed of a biocompatible, hydrophilic first component such as gelatin or polyvinyl alcohol and a biocompatible elastomer such as HydroThane (trademark) by dissolving the components in a common solvent, initiating cross-linking of at least one of the components in the solution, and forming a film, fiber, bead or mesh from the solution.

Abstract: The invention features methods and apparatuses for spinning silk protein fibers (biofilaments) from recombinant biofilament proteins. The methods are particularly useful for spinning fibers of spider silk or silkworm silk proteins from recombinant mammalian cells and may be used to spin such fibers for use in the manufacture of industrial and commercial products.

Abstract: The invention relates to a process for loading a polymer with one or more bioactive agents, using a wet spinning technique. The invention further relates to a polymer loaded with one or more bioactive agents, obtainable by said process and to the use thereof as a carrier for controlled drug release or as scaffold for tissue engineering.

Abstract: An oral brush is provided that includes an elongated body, a head portion extending from the body, and a plurality of bristles, formed of particular thermoplastic elastomers, extending from the body. In various embodiments, the thermoplastic elastomer has a Shore A hardness of at least 30; the thermoplastic elastomer is selected from the group consisting of polyetheramides, polyesters, styrene-ethylene-butylene-styrene block copolymers, polyurethanes, polyolefin elastomers, and mixtures thereof; and the thermoplastic elastomer has a flexural modulus of at least 5 MPa.

Abstract: A continuous process for the preparation of absorbable polymers and their processing into multifilament fibers is disclosed. The process comprises a reactive extrusion step where cyclic monomers and other additives are polymerized into absorbable homopolymer or copolymer compositions, which are then extruded continuously and spun into multifilament fibers using regular fiber spinning and drawing techniques.

Abstract: A dispersant slurry for making spandex, based on phosphated block poly(alkylsiloxane)-poly(alkyleneether) alcohol or aromatic- or alkylaromatic-terminated phosphated poly(alkyleneether) alcohol dispersants, is provided.

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 versatile covering process enabled through the identification and manipulation of a plurality of variables present in the electrospinning method of the present invention. By manipulating and controlling various identified variables, it is possible to use electrospinning to predictably produce thin materials having desirable characteristics. The fibers created by the electrospinning process have diameters averaging less than 100 micrometers. Proper manipulation of the identified variables ensures that these fibers are still wet upon contacting a target surface, thereby adhering with each other to form a cloth-like material and, if desired, adhering to the target surface to form a covering thereon. The extremely small size of these fibers, and the resulting interstices therebetween, provides an effective vehicle for drug and radiation delivery, and forms an effective membrane for use in fuel cells.

Abstract: Coagulation spinning produces structures such as fibers, ribbons, and yarns of carbon nanotubes. Stabilization, orientation, and shaping of spun materials are achieved by post-spinning processes. Advantages include the elimination of core-sheath effects due to carbonaceous contaminants, increasing mechanical properties, and eliminating dimensional instabilities in liquid electrolytes that previously prohibited the application of these spun materials in electrochemical devices. These advances enable the application of coagulation-spun carbon nanotube fibers, ribbons, and yarns in actuators, supercapacitors, and in devices for electrical energy harvesting.

Abstract: A self-crimping multicomponent fiber is manufactured utilizing the same-polymer components including at least one polymer component having a higher viscosity than at least one other polymer component. Crimping of the fiber is induced during fiber formation by achieving an effective crystallinity differential between the differing viscosity polymer components. The effective crystallinity differential may be obtained by varying a number of parameters during fiber formation, including the viscosity differential between polymer components and the transverse cross-sectional geometries of the differing viscosity components. Other factors, such as selecting a suitable drawing tension for the fiber can influence the crystallinity differential between differing viscosity components and thus resultant fiber crimp.

Abstract: Spinnerette including a plate comprising 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: Isopycnic or asymmetric mixed matrix hollow fiber membranes for gas separation can be made by a continuous spinning process. Mixed matrix membranes are characterized by a continuous phase of selectively gas permeable polymer in which are uniformly dispersed discrete absorbent particles such as molecular sieves that also have selectivity enhancing properties. The fibers can be monolithic in which the fiber wall is entirely mixed matrix, or composite in which an active mixed matrix layer is positioned adjacent to a supporting substrate layer. The novel mixed matrix hollow fiber membranes provide higher selectivity than dense film membranes of the continuous phase polymer.

Abstract: A spunbond nonwoven fabric useful as a topsheet is produced from polypropylene filaments including a high level of reclaimed polypropylene, while maintaining a product quality, including superior formation, comparable to that obtained when using 100 percent virgin polymer. The spunbond nonwoven fabric is made with multicomponent filaments having at least two different polymer components occupying different areas within the filament cross section, and wherein one of the polymer components comprises reclaimed polypropylene recovered from previously spun polypropylene fiber or webs comprised of previously spun polypropylene fiber. In a specific embodiment, the filaments are sheath-core bicomponent filaments and the reclaimed polypropylene is present in the core component. The core of the bicomponent filament can be comprised of up to 100% reclaimed polypropylene.

Abstract: A method is provided for making ligneous material boards into an endless board strand with a continuously operating press. The press includes two flexible endless steel belts which take the press material between them and carry it through the press. The steel belts thrust with friction-reducing elements against heated press plates of the press table and press ram and a cooling system that follows. The cooling system is configured as a double-belt holding apparatus with an applicable holding pressure up to a maximum of 0 to 0.05 N/mm2. A diagonal sawing apparatus, which is disposed directly behind the continuously operating press and ahead of the cooling system, divides the board strand into single boards. Several rows of coolant spray nozzles disposed on the backs of the holding belts making contact with the single boards.

Abstract: A method for making a biodegradable thermoplastic composition. The thermoplastic composition may be used in methods to produce multi-component fibers and non-woven materials that demonstrate a higher contact angle hysteresis, quicker intake times, and improved skin dryness as compared to prior art materials. In addition, biodisintegratable nonwoven materials made according to the present invention also exhibit high wetting rates, which is unexpected based upon the higher hysteresis values. The nonwoven material may be produced using thermoplastic compositions which comprise an unreacted mixture of an aliphatic polyester polymer as a continuous phase, polyolefin microfibers as a discontinuous phase encased within the aliphatic polyester polymer continuous phase, and a compatibilizer for the aliphatic polyester polymer and the polyolefin microfibers. The multicomponent fiber exhibits substantial biodisintegratable properties and good wettability yet is easily processed.

Abstract: An apparatus for extruding multiple types of liquid materials into multi-component filaments. A pair of outer manifold elements sandwich an intermediate manifold element. Respective channels are formed between opposing sides of the outer manifold elements and the respective opposite sides of the intermediate manifold element. These recesses form channels which diverge or widen away from associated inlets at the top of the manifold assembly. A die tip is coupled to the manifold assembly at a lower side and communicates with the outlets of the channels. The die tip includes a combining member for producing a desired multi-component filament configuration.

Abstract: A spunbond nonwoven fabric useful as a topsheet is produced from polypropylene filaments including a high level of reclaimed polypropylene, while maintaining a product quality, including superior formation, comparable to that obtained when using 100 percent virgin polymer. The spunbond nonwoven fabric is made with multicomponent filaments having at least two different polymer components occupying different areas within the filament cross section, and wherein one of the polymer components comprises reclaimed polypropylene recovered from previously spun polypropylene fiber or webs comprised of previously spun polypropylene fiber. In a specific embodiment, the filaments are sheath-core bicomponent filaments and the reclaimed polypropylene is present in the core component. The core of the bicomponent filament can be comprised of up to 100% reclaimed polypropylene.

Abstract: The present invention relates to a fibrous material which includes a plurality of polylactide containing fibers. The plurality of polylactide containing fibers can be considered low shrinkage or high shrinkage. The plurality of polylactide containing fibers are considered low shrinkage fibers if they provide a boiling water shrinkage propensity of less than about 20%. The plurality of polylactide containing fibers are considered high shrink fibers if they provide an average fiber boiling water shrinkage propensity of greater than about 10% and a heat of fusion of less than about 25 J/g. The invention additionally relates to the use of an extrusion process to provide low shrinkage fibers and high shrinkage fibers. The invention further relates to the use of these fibers in desirable products.

Abstract: A tape manufacturing system includes an extruder having a die that defines an elongated opening. The extruder provides molten NHFR polyolefin material through the die. The system further includes a cooling assembly, coupled to the extruder, that receives the extruded NHFR polyolefin material from the extruder and cools the extruded NHFR polyolefin material so that the extruded NHFR polyolefin material hardens into a contiguous sheet, and a cutting assembly that receives the contiguous sheet and cuts the contiguous sheet lengthwise to form multiple parallel feeds of NHFR polyolefin tape. The extruder, the cooling assembly and the cutting assembly operate simultaneously in a continuous manner so that the sheet of NHFR polyolefin material is unbroken between the cooling assembly and the cutting assembly. In general, the system is cost effective since multiple, unlimited length feeds of NHFR polyolefin tape can be made at the same time.

Abstract: Specified is an extrusion profile of a thermoplastic material for transport or drive belts. The extrusion profile is reinforced in that a content of approximately 0.5 to 40 percent by weight of glass fibers, aramide fibers, or carbon fibers are mixed with the plastic. The extrusion profile can be welded into infinite belts with or without plastic casing.

Abstract: The invention relates to a process of preparing pellets of a synthetic organic fiber reinforced polyolefin and discloses the process in which the reinforcing fiber is impregnated with the molten polyolefin. The invention is characterized in that the sufficient impregnation can be carried out by selecting the polyolefin and the synthetic organic fiber having the appropriate melting points and controlling the temperature of the molten polyolefin to minimize the heat deterioration of the synthetic organic fiber. The pellets obtained by the process of the invention provides a molded product having superior impact resistance and recyclability when used as raw materials for injection molding, injection-compression molding, extrusion, blow molding and a like molding process.

Abstract: At least two different liquid streams are sub-divided into a dense plurality of individually separated parallel pixels oriented in respective misregistered arrays. Therefore, an individual pixel of one of the liquid stream arrays will be surrounded by pixels of the other liquid stream array. These individual pixel arrays are then bought into contact with one another to form a multi-pixel liquid stream comprised of the misregistered pixel arrays of the two different liquid streams. The “pixelated” liquid stream—that is, the liquid stream containing in cross-section the misregistered pixel arrays of the two different liquid streams—may then be further processed. For example, the pixelated liquid stream may be subjected to further mixing by being directed along a tortuous flow path.

Abstract: A process for forming a multiple component meltblown fiber comprising extruding a first distinct melt-processable polymer through a first extrusion orifice, simultaneously extruding a second distinct melt-processable polymer through a second extrusion orifice, fusing said first and second melt-processable polymers into an extruded composite filament after extrusion, and pneumatically attenuating said extruded composite filament with jets of high velocity gas so as to form said multiple component meltblown fiber.

Abstract: A nonwoven fabric comprised of a lactide polymer. The lactide polymer comprises a plurality of poly(lactide) polymer chains, residual lactide in concentration of less than about 2 percent and water in concentration of less than about 2000 parts-per-million. A process for manufacturing a nonwoven fabric with the lactide polymer composition is also disclosed.

Abstract: A process for manufacturing composite sheets. The sheets are made of at least one ply of yarn with this ply having at least two materials with different melting points. The ply is introduced continuously into a zone where it is heated to a temperature between the two melting points and below the degradation temperature of the material having the lower melting point. This ply is then passed over at least one rotating bar heated to a temperature lying between the melting points and below the degradation temperature of the material with the lower melting point. The ply is then compressed on leaving the rotating bar and is cooled to form a composite web. The web is collected in the form of one or more composite plies.

Abstract: A leukocyte-removing filter medium which comprises a matrix and ultra-fine fibers having a fiber diameter of less than 1.0 &mgr;m and not less than 0.01 &mgr;m which contains ultra-fine fibers in an amount of less than 50 wt % and not less than 0.1 wt %, the degree of curvature of the ultra-fine fibers being 1.2 or more, and/or the ultra-fine fibers form pores having a roundness of 1.7 or less.

Abstract: The present invention provides an apparatus and process for improving the properties of braided ligature by hot stretching the braid.

Abstract: Disclosed is a thermoplastic composition comprising an unreacted mixture of an aliphatic polyester polymer as a continuous phase, polyolefin microfibers as a discontinuous phase encased within the aliphatic polyester polymer continuous phase, and a compatibilizer for the aliphatic polyester polymer and the polyolefin microfibers. The multicomponent fiber exhibits substantial biodegradable properties and good wettability yet is easily processed. The thermoplastic composition is useful in making nonwoven structures that may be used in a disposable absorbent product intended for the absorption of fluids such as body fluids.