Continuous Or Indefinite Length Patents (Class 264/518)
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Patent number: 5766388Abstract: The present invention utilizes the smooth continuous motion of a masking belt to concentrate air-entrained absorbent materials on the surface of a moving fibrous substrate. Air flowing through the open areas of the masking belt carries the entrained material into the fibrous web. The fibrous web acts as a filter to separate the entrained material from the air stream. Substantially all dispensed material is captured by the fibrous web, and expensive and complex absorbent material recycle systems can be eliminated.Type: GrantFiled: March 4, 1997Date of Patent: June 16, 1998Assignee: McNeil-PPC, Inc.Inventors: Kenneth Pelley, Lynn Foelsch, William M. Bickley
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Patent number: 5750066Abstract: The present invention provides a method and apparatus for applying discrete particles of absorbent material to a predetermined location on a fibrous web. The apparatus comprises a continuously rotating mask, and a means for directing a supply stream of absorbent particles to form an acute included angle with a diverting surface on the rotating mask. The mask diverting surface splits the supply stream of absorbent particles into a first intermittent stream passing through the mask and a second intermittent stream deflected by the diverting surface. The absorbent particles in one of the first and second intermittent streams is directed to the fibrous web.Type: GrantFiled: May 19, 1995Date of Patent: May 12, 1998Assignee: The Procter & Gamble CompanyInventors: Michael Francis Vonderhaar, James Michael Fleming
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Patent number: 5695377Abstract: There is provided a fabric produced by a spunbond or a meltblown apparatus, wherein the apparatus has a pneumatic chamber having at least one wall containing a plurality of spaced protrusions. Preferably, both opposing walls contain protrusions aligned in staggered angled rows and the rows on one wall are angled opposite the rows on the opposing wall, thereby causing controlled lateral flow near the chamber walls. This lateral flow exhibits drag on the fibers, imparting rotational energy to the fibers. The fibers are imparted with rotational energy derived from the lateral component of the two turbulent airflow fields that oppose one another, and have a tendency to twist and crimp. Fabrics so produced have improved loft, drape, and feel and may be useable as a loop material for hook-and-loop type fasteners.Type: GrantFiled: October 29, 1996Date of Patent: December 9, 1997Assignee: Kimberly-Clark Worldwide, Inc.Inventors: Thomas Gregory Triebes, Jark Chong Lau
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Patent number: 5672306Abstract: Disclosed is an adsorbent fibrous nonwoven structure composed of a matrix of pulp fibers having a first exterior surface and a second exterior surface; and an adsorbent material integrated into the pulp fiber matrix so that the concentration of adsorbent material adjacent the first exterior surface of the nonwoven structure is at least about 60 percent, as determined by optical image analysis, and the concentration of adsorbent material adjacent the second exterior surface is less than about 40 percent, as determined by optical image analysis. This adsorbent nonwoven structure provides useful strength and low-lint characteristics. The fibrous nonwoven structure of the present invention may be laminated together or to surfaces of other materials.Type: GrantFiled: May 30, 1995Date of Patent: September 30, 1997Assignee: Kimberly-Clark CorporationInventors: Troy Alan Sprang, Annmarie Veronica Douglas, Benji Dawn Morgan
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Patent number: 5656232Abstract: A topsheet of body fluid absorptive articles comprising a first sheet made of thermoplastic synthetic resin sheet and having liquid passages each downwardly extending therethrough and a second sheet containing 70 to 100% by weight of cellulose fibres bonded to said first sheet around lower openings of the respective liquid passages and comprises mechanically intertwined fibres only. The second sheet has a density higher than a density of fibres contained in the liquid-absorbent core.Type: GrantFiled: June 19, 1995Date of Patent: August 12, 1997Assignee: Uni-Charm CorporationInventors: Hisashi Takai, Tsutomu Kido
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Patent number: 5614147Abstract: A method for applying particulate powder material to a moving, pre-formed, fibrous substrate. In this method, particulate powder material is entrained in a continuous airstream. The air-entrained stream of particulate material exits a nozzle to be applied to the substrate or recirculated. The stream of air-entrained particulate matter has a velocity component in the direction of movement of the fibrous substrate.Type: GrantFiled: March 10, 1995Date of Patent: March 25, 1997Assignee: McNeil-PPC, Inc.Inventor: Kenneth A. Pelley
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Patent number: 5589117Abstract: There is provided by this invention a least three integrated regions, each region having wherein the density and fluid affinity of the composite continuously increases from top to bottom thereby facilitating effective fluid transport and efficient utilization of storage capacity. An additional layer of SA and tissue may be provided to the absorbent product to provide an absorbent structure with dry feel and low stain. Methods of forming integrated, multi-layered absorbent composites and structures comprising at least three regions wherein each region has distinct density and fluid affinity gradients and wherein the density and fluid affinity of the composite continuously increases from top to bottom, are also provided herein.Type: GrantFiled: June 8, 1995Date of Patent: December 31, 1996Assignee: McNeil-PPC, Inc.Inventor: Ching-Yun M. Yang
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Patent number: 5575874Abstract: A shaped nonwoven fabric comprises continuous spunbond filaments made by directly forming the spunbond filaments into a web in a single process. The fabric has an array of discrete surface features such as apertures or projections, or both. The spunbond filaments are bonded together with an adhesive polymeric component so that the shape of the fabric is retained. The fabric can be engineered to have particular fluid handling properties, strength properties, abrasive properties and aesthetic properties. Articles such as personal care products, garments, medical products and cleaning products are also disclosed.Type: GrantFiled: May 5, 1995Date of Patent: November 19, 1996Assignee: Kimberly-Clark CorporationInventors: Henry L. Griesbach, III, Richard D. Pike, Sharon W. Gwaltney, Ruth L. Levy, Lawrence H. Sawyer, Richard M. Shane, Philip A. Sasse
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Patent number: 5558832Abstract: A forming station used to make a substrate. The forming station has a forming chamber which deposits particles and fibers from an air carrier onto a forming screen movable relative to the forming chamber. Inside the forming chamber is at least one baffle, which creates a velocity gradient and low pressure zone for the air carrier. Different sized components of the substrate have different momentums, and thus are differently affected by the velocity gradient and low pressure zone. This difference causes the different sized components to be sorted according to size. The sorted components are then distributed according to size within the substrate.Type: GrantFiled: August 25, 1995Date of Patent: September 24, 1996Assignee: The Procter & Gamble CompanyInventors: John R. Noel, Mark R. Richards
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Patent number: 5540872Abstract: A method of manufacturing a three-dimensional fabric of the type which may be used in absorbent garments, dressings or the like involves the use of an apertured collector element which has a predetermined three-dimensional shape. The method involves positioning material adjacent to one side of the apertured collector element and developing a pressure differential between the one side of the apertured collector element and a second, opposite side to force the fabric material against the apertured collector element. The material, which has conformed to the shape of the collector element, is then solidified into its intended three-dimensional shape.Type: GrantFiled: December 31, 1992Date of Patent: July 30, 1996Assignee: McNeil-PPC, Inc.Inventor: John T. Ulman
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Patent number: 5523033Abstract: A method of attenuating a molten thermoplastic polymer stream into polymer fibers for forming a non-woven fiber mat, and the non-woven fiber mat formed thereby. The method applying a gas stream to a molten polymer stream, and inducing a cyclic pulsation in the gas stream. The cyclic pulsation further comprises a discontinuous flow of the gas stream. The application of the gas stream to the molten polymer stream causes the attenuation of the molten polymer stream into a plurality of fibers which are collected onto a receiving surface thereby forming a non-woven fiber mat. The method may be used to impart a particularly unique or otherwise desirable configuration to the fibers or to the fiber mat produced from them. The gas stream may be comprised of a primary gas flow having a first stream and a second stream. The gas stream may be further comprised of a secondary gas flow having a first stream and a second stream.Type: GrantFiled: June 5, 1995Date of Patent: June 4, 1996Assignee: The Board of Regents of the University of OklahomaInventor: Robert L. Shambaugh
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Patent number: 5514324Abstract: A sheet of an absorbent material which, comprises a blend of a fibrous substance and of a granulated substance in which the granulated substance is non-uniformly distributed in the sheet, there being alternating zones of higher and of lower density of said substance along the sheet, is prepared by vacuum depositing (16) a dispersion of the fibrous substance (20) on a moving screen (14) and continuously applying the granulated substance (24) while changing the zone of application in a pendulum-like fashion (34, 36) along the screen.Type: GrantFiled: April 7, 1993Date of Patent: May 7, 1996Assignee: Tafnukim Amir Paper ProductsInventor: Moshe Bachar
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Patent number: 5466409Abstract: A method and apparatus for forming a layer structure, such as an airlaid fibrous web, include a supplying mechanism for providing a stream of particulate material, such as fibers. Also included is a substantially endless, foraminous forming belt which has an appointed outward surface and a minimum thickness of at least about 3/16 inch. A selected contour is formed into the outward surface of the belt at selected locations, and the contour is distributed along a lengthwise machine-direction of the forming belt. The forming belt is configured to flex along a thickness direction thereof, and to recoverably bend and substantially straighten when traveling along a selected belt path circuit. A conveying mechanism moves the forming belt past the supplying mechanism along a forming path section of the belt circuit which is substantially straight, and moves the forming belt along a return path section of the belt circuit which includes curved portions therein.Type: GrantFiled: October 19, 1993Date of Patent: November 14, 1995Assignee: Kimberly-Clark CorporationInventors: Mary E. Partridge, Timothy J. Blenke, Stephen R. Everson, Carl G. Schroth, Michael B. Venturino
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Patent number: 5460500Abstract: A spun-filament nonwoven web is deposited on a sieve belt from a spinning head producing a curtain of thermoplastic filaments which traverse a cooling chamber by drawing the filaments in a drawing nozzle separate from the cooling chamber and passing the filaments through a delivery unit and in the form of a jet pump, air flow through which is controlled at least in part by a suction blower below that sieve belt.Type: GrantFiled: April 15, 1994Date of Patent: October 24, 1995Assignee: Reifenhauser GmbH & Co. MaschinenfabrikInventors: Hans G. Geus, Hermann Balk, Bernd Kunze
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Patent number: 5447677Abstract: An apparatus and method for making absorbent products in which a first material, such as absorbent fluff formed from wood pulp, is introduced into a vacuum forming chamber. A portion of the fluff is deposited into the cavity of a mold transported through the forming chamber by a forming wheel so as to form a layer of pure fluff within the bottom of the mold cavity. A second material, such as superabsorbent particles or heat stabilized fibers, is introduced into the forming chamber so that streams of the first and second materials collide within a mixing zone. As the mold continues it travel through the forming chamber, a mixture of first and second materials from the mixing zone is deposited within the mold cavity, thereby filling it. The portion of the mixture that extends above the surface of the mold is scraped off by a scarfing brush that directs the mixture back into the mixing zone, thereby creating turbulence that ensures thorough mixing of the two materials.Type: GrantFiled: June 2, 1993Date of Patent: September 5, 1995Assignee: McNeil-PPC, Inc.Inventors: Thomas Griffoul, Martin Wislinski
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Patent number: 5445777Abstract: An air laying forming station (ALFS) forms a nonwoven substrate from a first material and a second material having at least one physical characteristic substantially different from the first material. The ALFS includes a forming chamber and a forming screen, moving relative to the forming chamber, for receiving deposit of the first and second materials. A first distributor supplies the first material. A vacuum source provides an air flow which deposits the first material onto the forming screen. A second distributor delivers the second material, independently from the first material between the first distributor and the forming screen, by gravity along one or more baffle members.Type: GrantFiled: December 8, 1994Date of Patent: August 29, 1995Assignee: The Procter & Gamble CompanyInventors: John R. Noel, Mark R. Richards, Edward H. Krautter
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Patent number: 5435708Abstract: To simplify the cleaning and maintenance of a meltblowing head, the lips defining with the spinneret the flowing slits adjusting the row of orifices can be swung away from the spinneret on respective lip guides pivotally connected to respective setback bars. The setback bars can be adjusted and locked in place with respect to the blowing housing and the lips can be adjusted and locked in place relative to the lip guides independently of the swinging action.Type: GrantFiled: November 12, 1993Date of Patent: July 25, 1995Assignee: Reifenhauser GmbH & Co. MaschinenfabrikInventor: Achim Kaun
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Patent number: 5429788Abstract: An apparatus and method for forming a discrete layer of particulate material within a composite fibrous web includes a first forming chamber and a supplying mechanism for providing a flow of a selected fibrous material into the first forming chamber. A second forming chamber is selectively located within the first forming chamber to selectively divide the flow of fibrous material. A conveying mechanism transports a particulate material into the second forming chamber. A depositing mechanism is located within the second forming chamber to selectively dispense the particulate material. A foraminous forming layer is movably disposed within the first forming chamber and receives the fibrous material and the particulate material.Type: GrantFiled: March 28, 1994Date of Patent: July 4, 1995Assignee: Kimberly-Clark CorporationInventors: Brendon F. Ribble, David J. Arteman, Lyle T. Lamers, David J. Van Eperen, Thomas W. Van Eperen
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Patent number: 5395564Abstract: A rate control system to deliver a constant throughput for batt forming equipment that forms the batts by maintaining a pressure gradient across fibers deposited on a rotating condenser screen, the weight of a moving fiber batt is continuously measured as it passes over an inclined slide mounted on load cells. This measurement is converted electronically to a rate value which is then used with the pressure gradient signal to control the delivery of fiber to the condenser screen by adjusting the speed of the feed rolls used to feed the fiber to the condenser screen.Type: GrantFiled: November 15, 1993Date of Patent: March 7, 1995Assignee: E. I. Du Pont de Nemours and CompanyInventors: Elizabeth L. Frisbie, Stephen E. Moore, Lyles H. Sowell
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Patent number: 5389431Abstract: There are disclosed a nonwoven fabric comprising fibrillated three-dimensional network fibers prepared by the use of a styrenic polymer having a high degree of syndiotactic configuration as the pricipal component and also a process for producing the above nonwoven fabric comprising flash-spinning a homogeneous solution containing a styrenic polymer having a high degree of syndiotactic configuration.The resultant nonwoven fabric is excellent in heat resistance, dimensional stability and solvent resistance.Type: GrantFiled: January 7, 1993Date of Patent: February 14, 1995Assignee: Idemitsu Kosan Co., Ltd.Inventor: Komei Yamasaki
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Patent number: 5382403Abstract: In the production of growth blocks of sphagnum there are considerable operational problems with the required compacting of the loose sphagnum, as both compaction worms and pistons may easily get stuck. Instead, the invention provides for the use of a suction technique, whereby the loose sphagnum (2) is sucked into a perforated pipe (34) in a suction chamber (28), whereby a marked compaction of the material is achievable without any use of mechanical devices. The compacted block material may be surrounded by a decomposable paper casing, which is laid in successively as a lining hose of air permeable paper. The compacted material can be delivered as a compact string (46) by successive projection movements of the suction chamber (28) for being cut into blocks (56), and the suction chamber can temporarily opened for free return movements into its initial position.Type: GrantFiled: May 14, 1993Date of Patent: January 17, 1995Inventor: Oyvind Ellegaard
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Patent number: 5306453Abstract: Apparatus and method for the forming of fiber structures or webs utilizing a rotor having a plurality of blade sets helically arranged about its periphery for detangling and declumping air-entrained fibers which are deposited against a sizing screen, said blades act to push individualized fibers, with the assistance of positive air pressure, through the screen into a free-fall zone for deposit on an underlying forming wire.Type: GrantFiled: August 18, 1993Date of Patent: April 26, 1994Inventor: Edward Shulman
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Patent number: 5302332Abstract: In the method for manufacturing a product in the form of a mat containing mineral fibers and a binding agent, the binding agent is mixed with the fibers before the formation of the product. The material used as the binding agent includes thermoplastic particles, such as fibers, a powder, or particles in a dispersion, which are supplied to the fibers being formed of melted mineral into the stream of air. The fibers and the binding agent are carried by a turbulent air flow, in which the heat contained in the melting mineral and the fibers forming therefrom are used for melting or softening thermoplastic particles into a state, in which they effect the binding of the fibers to each other.Type: GrantFiled: March 8, 1993Date of Patent: April 12, 1994Assignee: Roctex Oy ABInventors: Jarmo Simola, Jean Le Bell, Ulf Westerlund
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Patent number: 5296286Abstract: A process for preparing subdenier fibers and structures thereof from isotropic polymer solutions is disclosed. The process comprises extruding a stream of the polymer solution into a chamber, introducing a pressurized gas into the chamber, directing the gas in the flow direction of and in surrounding contact with the stream within the chamber, passing both the gas and the stream into a zone of lower pressure at a velocity sufficient to attenuate the stream and fragment it into fibers, and contacting the fragmented stream in the zone with a coagulating fluid.Type: GrantFiled: January 11, 1993Date of Patent: March 22, 1994Assignee: E. I. Du Pont de Nemours and CompanyInventors: Steven R. Allen, David M. Gale, Aziz A. Mian, Sam L. Samuels, Hsiang Shih
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Patent number: 5269049Abstract: The invention relates to a process and an apparatus for the dry forming of a material web from a long-fiber material, wherein fibrous material is blown into a forming space to form a porous material web on a wire passing through the forming space. The dry forming of long fibers in lengths of at least 20 mm is problematic. In accordance with the invention, this problem has been solved in such a way thatthe fibrous material is blown into the forming space by at least one air current (A) that is substantially horizontal and transverse to the wire,the fibrous material is guided onto the surface of the wire (1) by an air current (D) that is substantially vertical and passes through the wire downwardly,and the desired material web (F) is formed by the combined effect of said horizontal and vertical air currents.Type: GrantFiled: September 9, 1992Date of Patent: December 14, 1993Assignee: Yhtyneet Paperitehtaat Oy, Walkisoft EngineeringInventors: Helmer Gustafsson, Pentti Pirinen
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Patent number: 5260003Abstract: A process and device for manufacturing ultrafine fibers and ultrafine-fibre mats from thermoplastic polymers with mean fibre diameters of 0,2-15 .mu.m, preferably 0,5-10 .mu.m, by a melt blowing technique. The polymer melt (12) flows through at least one bore (15) in a melt blowing nozzle (18). Immediately on emerging from the bore, gas is blown against the extrusion from both sides of the bore exit (15), thus breaking up the melt to form fibers. To this end, the gas is accelerated to supersonic speed in Laval nozzles (25, 26; 31, 32), disposed in mirror symmetry round the bore exits (15), and decelerated to just below the speed of sound in channels (27) with constant cross-section, or a cross-section which decreases in the direction of flow, fitted downstream of the Laval nozzles, and the melt (12) fed into the gas stream emerging from the channels (27).Type: GrantFiled: July 22, 1992Date of Patent: November 9, 1993Inventors: Peter R. Nyssen, Armin Kreimer, Wolfram Wagner, Dirk Berkenhaus
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Patent number: 5248247Abstract: In a apparatus of making a nonwoven mat wherein a multiplicity of filaments are extruded in a row and a pair of jets of compressed gas are played symmetrically from nozzles upon the filaments as same are extruded to stretch the filaments and deposit same on a substrate the compressed gas is made to flow from a source along respective paths to the nozzles and each of the flows and paths is branched upstream of respective flow-equalizing stations. The speed of the respective flows is decreased and their pressures are increased with at least one diffuser. The flows are then baffled and united between the flow-equalizing station and the respective nozzles in a flow guide.Type: GrantFiled: November 14, 1991Date of Patent: September 28, 1993Assignee: Reifenhauser GmbH & Co. MaschinenfabrikInventors: Anton Rubhausen, Daniel Roock
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Patent number: 5246653Abstract: An apparatus and a process for the continuous production of mineral wool nonwovens in the nonwoven formation process on the drums of the accumulating conveyors arranged at the lower end of a chute. Several fiberization units (1, 2, 3, 4) communicate with a chute (9) for the formation of a nonwoven (14). The fibres are deposited under the influence of suction pressure onto the curved surface of the accumulating conveyor (10, 11). At least one of the drum-shaped accumulating conveyors (10) is designed to swivel around a pivot (23) essentially arranged perpendicular to the flow direction (22) of the mineral wool such and to the extent that a discharge gap (21) can be adjusted to a width corresponding to the thickness of the nonwoven (14) to be formed.Type: GrantFiled: July 13, 1992Date of Patent: September 21, 1993Assignee: Grunzweig and Hartmann AGInventor: Johannes Horres
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Patent number: 5242632Abstract: This invention provides a bulky nonwoven fabric made of thermoplastic resin filaments, which is soft and highly permeable to water and gas and effectively absorbs moisture as well as shocks.A nonwoven fabric according to the invention is made of fiber-like filaments of a thermoplastic resin material and comprises a base cloth layer made having densely distributed holes and a large number of cylindrical projections, each standing from the peripheral edge of one of the holes and made of fiber-like filaments similar to those of the base cloth layer and soft, its height being at least twice as large as the thickness of the base cloth layer.Type: GrantFiled: September 8, 1992Date of Patent: September 7, 1993Assignees: Mitsui Petrochemical Industries, Ltd., Uni-Charm CorporationInventor: Takayuki Mende
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Patent number: 5236641Abstract: A meltblowing system with a modular die design and on-line monitoring of web properties is described. The modular die consists of individually fed side-by-side meltblowing units. Automated control of the polymer feed rates to the units have been shown to produce a web with excellent uniformity of basis weight. The die also features a valve assembly for minimizing polymer afterflow and die tip plugging.Type: GrantFiled: September 11, 1991Date of Patent: August 17, 1993Assignee: Exxon Chemical Patents Inc.Inventors: Martin A. Allen, John T. Fetcko
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Patent number: 5227107Abstract: The present invention relates to a multicomponent fibrous nonwoven structure and the process and apparatus for producing the same. More specifically, the present invention relates to a process for forming nonwoven materials using a forming chamber in conjunction with multiple fiber sources and a forming surface to create multicomponent nonwoven materials with varying features. The materials so produced are suitable for use in a wide variety of applications including personal care products such as diapers, feminine pads and adult incontinence products.Type: GrantFiled: September 14, 1992Date of Patent: July 13, 1993Assignee: Kimberly-Clark CorporationInventors: F. Lee Dickenson, Frank P. Abuto, Leon E. Chambers, Jr., Edward E. Werner, Tony J. Wisneski
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Patent number: 5225014Abstract: A precision cartridge filter having an average filter diameter of 10 .mu.m or less is produced by preparing a web composed of conjugate microfine fibers by a conjugate melt-blowing process, wherein the conjugate microfine fibers have a lower melting point component, a higher melting point component, and a melting point difference between the lower melting point component and higher melting point component of 20.degree. C. or more; followed by heating and molding the web at a temperature greater than or equal to the melting point of said lower melting point component, but less than the melting point of said higher melting point component.Type: GrantFiled: July 2, 1991Date of Patent: July 6, 1993Assignee: Chisso CorporationInventors: Satoshi Ogata, Kazuyuki Nagae, Yoshimi Tsujiyama
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Patent number: 5207970Abstract: A method for forming melt-blown fiber webs which webs have multiple layers of polymeric material. The method provides novel webs and control over web properties.Type: GrantFiled: September 30, 1991Date of Patent: May 4, 1993Assignee: Minnesota Mining and Manufacturing CompanyInventors: Eugene G. Joseph, Daniel E. Meyer
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Patent number: 5204030Abstract: A method for producing pitch-type carbon fiber, comprising the steps of discharging, from a spinning nozzle, a spinning pitch comprising an optically isotropic pitch and/or optically anisotropic pitch, maintained at such a temperature that the spinning pitch can have a viscosity of 20 poises or less, to form pitch fiber, while jetting a gas preheated to a temperature of 100.degree. C. lower than the temperature at which the spinning pitch can have a viscosity of 20 poises or less, or higher from the periphery of the spinning nozzle in the same direction as the discharging direction of the spinning pitch and parallel to the discharged pitch fiber to give extremely fine fiber having an average diameter of 5 .mu.m or less, and subjecting the thus spun fine fiber to infusibilization and carbonization.Type: GrantFiled: November 18, 1991Date of Patent: April 20, 1993Assignees: Koa Oil Company, Limited, Tanaka Kikinzoku Kogyo Kabushiki KaishaInventors: Eiji Kitajima, Takashi Oyama, Makoto Kitai, Haruki Yamasaki, Susumu Shimizu
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Patent number: 5188783Abstract: An ion-conductive article and method of making the same. A charge material is formed that includes an ion-conductive polymer and a generally non-ion-conductive polymer. The charge material is fabricated into an ion-conductive article.Type: GrantFiled: February 20, 1990Date of Patent: February 23, 1993Assignee: Hughes Aircraft CompanyInventor: Brian M. Pierce
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Patent number: 5156797Abstract: Nonwoven fabrics are disclosed, which are produced by molding a material containing as a main component a styrene-based polymer with mainly syndiotactic configuration, in such a manner that a difference between the absolute value of heat of fusion .vertline..DELTA.Hf.vertline. and the absolute value of crystallizing enthalpy on heating .vertline..DELTA.Htcc.vertline. of the molded polymer is at least 1 cal/g. These nonwoven fabrics are excellent in heat-resistant and chemical-resistant characteristics, and are suitable for use as medical fabrics, industrial filters, battery separators and so forth.Type: GrantFiled: October 10, 1991Date of Patent: October 20, 1992Assignee: Idemitsu Kosan Co., Ltd.Inventors: Komei Yamasaki, Keisuke Funaki
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Patent number: 5149468Abstract: A method for producing a melt-blown non-woven mat wherein a fiber-forming thermoplastic polymer resin is extruded in molten form through a row of nozzles into a stream of hot gas which attenuates the molten resin into fibers that form a fiber stream. The fibers are collected on a receiver in the path of the fiber stream to form the non-woven mat. At least two spaced rows of nozzles are provided to produce first and second fiber streams spaced from each other. The spaced fiber streams are collected on the receiver to form a first non-woven mat portion and a second non-woven mat portion and with the first non-woven mat portion overlaying the second non-woven mat portion. At a position intermediate the first and second fiber streams, material different than the fiber-forming resin is injected to have the different material captured between the first and second fiber streams and thereby form a collected structure of the first and second mat portions sandwiching the different material.Type: GrantFiled: November 17, 1989Date of Patent: September 22, 1992Assignee: Moldex/Metric Products, Inc.Inventor: James W. Hershelman
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Patent number: 5145631Abstract: A melt-blowing process for producing a fiber preferably a microfiber of a syndiotactic vinyl aromatic polymer, which comprises supplying a vinyl aromatic polymer having a high degree of syndiotacticity in a molten form from at least one orifice of a nozzle into a gas stream which attenuates the molten polymer into microfibers. Such microfibers are particularly useful in the field of high temperature filtration, coalescing and insulation.Type: GrantFiled: April 19, 1991Date of Patent: September 8, 1992Assignee: The Dow Chemical CompanyInventor: Zdravko P. Jezic
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Patent number: 5143680Abstract: A method and apparatus for forming a non-woven pad of fibrous material is provided in which highly moisture-absorbent particles and fibers of thermoplastic material are intermixed with the fibrous material throughout one or more predetermined portions of the thickness of the non-woven pad while maintaining other portions of the thickness of the pad substantially free of highly moisture-absorbent particles and/or thermoplastic fiber material. The non-woven pad is formed on one side of a conveyor moving through a forming chamber which has a duct connected to a source of vacuum operable to draw fibrous material injected into the chamber onto the conveyor.Type: GrantFiled: May 17, 1990Date of Patent: September 1, 1992Assignee: Nordson CorporationInventors: Julius J. Molnar, Ernest J. Fena, David W. Folden, Douglas A. Schneider, Richard A. Becker, Charles L. Fimmen, David M. Selestak, Robert Shlapak
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Patent number: 5141699Abstract: A method for preparing melt-blown microfibers comprising extruding fiber-forming material through the orifices of a die into a high-velocity gaseous stream where the extruded material is rapidly attenuated into fibers, directing the attenuated fibers into a first open end of a tubular chamber disposed near the die and extending in a direction parallel to the path of the attenuated fibers as they leave the die, introducing air into the tubular chamber at a velocity sufficient to maintain the fibers under tension during travel through the chamber, and collecting the fibers after they leave the tubular chamber.Type: GrantFiled: January 16, 1990Date of Patent: August 25, 1992Assignee: Minnesota Mining and Manufacturing CompanyInventors: Daniel E. Meyer, Dennis L. Krueger, Hassan Bodaghi
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Patent number: 5128082Abstract: A liquid absorbent structure is made by dry laying a fibrous web having incorporated therein a superabsorbent material, and applying a latex coating to at least one surface of said web, which on curing imparts integrity to the resulting structure without substantially impairing the effectiveness of said superabsorbent material to absorb liquid.Type: GrantFiled: April 20, 1990Date of Patent: July 7, 1992Assignee: James River CorporationInventor: Kambiz B. Makoui
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Patent number: 5123983Abstract: An improvement is disclosed for reducing or even preventing interferences or interactions between adjacent, closely-spaced laydown jets utilized in a fibrous sheet laydown process. The improvement comprises positioning an inverted "V-shaped" baffle between adjacent, closely-spaced laydown jets so that the turbulent gas streams produced by each laydown jet are diverted and vented away from the area of sheet laydown on a moving collection belt. The baffle vents the fountain of gas produced by the collision of adjacent laydown jets in a cross-direction to that of the direction of belt movement.Type: GrantFiled: August 24, 1990Date of Patent: June 23, 1992Assignee: E. I. du Pont de Nemours and CompanyInventor: Larry R. Marshall
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Patent number: 5122211Abstract: An applicator is utilized in applying a thermoplastic composite filament to a mandrel so as to form a structure. The filament and the surface of the mandrel are caused to move simultaneously and in a common direction relative to the applicator so that the filament is continuously fed from the applicator into engagement with the surface of the mandrel. At least one stream of heated fluid is applied to the filament so that it impinges thereon not only at a location preceding the location of the applicator, but also along the length of the filament to and beyond the applicator and up to and including the region where the filament first comes into contact with the mandrel. At the same time a stream of heated fluid is applied directly to the surface of the mandrel within that region so that the mandrel is heated prior to being contacted by the filament.Type: GrantFiled: October 11, 1989Date of Patent: June 16, 1992Assignee: Heat Transfer Technologies, Inc.Inventor: Henry P. Roach
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Patent number: 5120380Abstract: In the manufacture of an in-line cored pultruded profile, filler is bonded with polyester or methacrylate type resin and enclosed in fiberglass, carbon or aramid fiber cloth. The cloth is preformed to replicate the desired profile shape by means of a pre-die former and the external surface of a hollow duct. Filler is delivered into the interior of the duct by a variable output venturi blower. Precise distribution of packing is effected by the internal configuration of the duct and the creation of a raised moving wall when non-foaming resin is used. Precise configuration of ducts can be achieved by fashioning from reinforced cloth. Adjustable start drums provide time and labor saving benefits. Complete resin wet through using either foaming or non-foaming resin ensures exellent filler bonding and surface finish.Type: GrantFiled: October 17, 1989Date of Patent: June 9, 1992Assignee: Caledonia Composites LimitedInventor: Robert Strachan
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Patent number: 5102585Abstract: A method for forming a zoned distribution of particulate material within a fibrous web includes a conveying step for providing a gas entrained supply of the particulate material and a segregating step centrifugally directing at least a portion of the particulate material into an accumulation region. A transferring step selectively directs particulate material from the accumulation region into a delivery gas stream to provide an intermittent flow volume of a selected quantity of particulate material from the accumulation region through a delivery conduit and into a web forming chamber. A fiberizing step provides a flow of a selected fibrous material into the web forming chamber, and a directing step controls the intermittent flow of particulate material from the delivery conduit into the forming chamber.Type: GrantFiled: March 26, 1991Date of Patent: April 7, 1992Assignee: Kimberly-Clark CorporationInventors: Christopher M. Pieper, Jeffrey W. King, Bruce R. Shafer, Robert A. Stevens, Timothy L. Wehman, Edward E. Werner
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Patent number: 5102595Abstract: A method and apparatus for depositing straight elongate fiber-bundle strands, such as sugarcane or sweet sorghum rind strands, in a loose pile on a conveyor with the strands randomly oriented in substantially parallel planes during manufacture of structural panel from such strands. The method includes dropping bit by bit a randomly-oriented collection of strands over a drop edge located above the conveyor and flicking the strands onto the conveyor by quick downward motion of counter-rotating arrays of flicker tines in the drop zone.Type: GrantFiled: January 4, 1991Date of Patent: April 7, 1992Inventor: Sydney E. Tilby
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Patent number: 5100435Abstract: Epoxy-based nonwoven webs are provided. The webs are formed by meltblowing a blend of an epoxy resin and a polycaprolactone (PCL) polymer. Whereas epoxy resins by themselves produce nonwoven webs which are brittle and glassy, epoxy/PCL blends have been found to produce webs which have good flexibility and elongation and are not glassy. If desired, once formed, the epoxy/PCL webs can be cured with, for example, an epoxy crosslinking agent to produce webs having enhanced solvent resistance properties.Type: GrantFiled: December 4, 1990Date of Patent: March 31, 1992Assignee: Kimberly-Clark CorporationInventor: Fidelis C. Onwumere
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Patent number: 5093963Abstract: A cylinder, for example a lickerin, and feed mechanism create a supply of individual fibers, for example pulp, which follow the rotation of the lickerin. These fibers are deflected from the lickerin in the form of a stream by means of a plate arranged parallel to the lickerin. A conveying screens intercepts the stream of fibers and accumulates them into a web without the use of a high pressure stream of air to doff the fibers from the lickerin or to capture fibers on the conveyor. Further, the housing for the apparatus is opened so that there are no seals to compress the web after it is produced. A feed tray located next to the lickerin can be used to include other particulate materials (fiber or granules) in the main fiber stream and a tapering of the deflector plate can separate the component of the blended fiber-particulate material stream into layers in the resulting web distinguished by particle weight.Type: GrantFiled: August 16, 1990Date of Patent: March 10, 1992Assignee: ChicopeeInventors: Allan P. Farrington, Gerald M. Marshall, Theodore J. Krainski
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Patent number: 5094798Abstract: In the manufacture of lightweight structural profile including a resin-bonded core of closely compacted particulate filler, loose filler is packed into a shaping die by means of applied vacuum. The filler is packing within a sheath of glass rovings which is used to draw the packed filler through the die. As the sheath and packed filler are progressed through the die, a liquid bonding resin is introduced to permeate and bond together the packed filler and the sheath. The filler includes layer mineral foam in a coarse particulate form and a free-flowing relatively fine material (such as hollow silicate microspheres) as an additional filler, the additional filler being vacuumed in to occupy the interstices of previously packed foam filler.Type: GrantFiled: September 19, 1990Date of Patent: March 10, 1992Inventor: Michael J. Hewitt
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Patent number: 5094791Abstract: In a process for producing fibrous mats from starting material for compression moulded articles, fiberized waste materials are mixed with thermoplastic and/or duroplastic binders, the mixture is spread on to an air-permeable conveyor belt to form a first fleece layer, a fabric is placed loosely on said fleece layer, then a second fleece layer is spread on the fabric or lattice and subsequently the composite fleece is compressed at elevated temperature and under pressure to form a transportable mat from which individual moulded articles can be produced by compression moulding at temperatures between 180.degree. and 220.degree. C., the fabric being sprayed with a liquid phase duroplastic finish prior to its deposition. In this way the fabric finish composition can be matched to the binder for the fibres, so that completely satisfactory binding or tying in of the fabric into the fleece layers can be achieved.Type: GrantFiled: May 7, 1990Date of Patent: March 10, 1992Assignee: Casimir Kast GmbH & Co. KGInventor: Herbert Nopper