By Fluid Jet Needling Or Perforating Patents (Class 28/104)
  • Publication number: 20070269644
    Abstract: A method of fabricating a porous, fiber-reinforced thermoplastic sheet having increased lofting properties is provided. The method includes adding reinforcing fibers having an average length of about 5 mm to about 50 mm, and thermoplastic resin powder particles to an agitated aqueous foam to form a dispersed mixture, laying the dispersed mixture of reinforcing fibers and thermoplastic resin particles down onto a support structure, evacuating the water to form a web, generating a z-axis orientation of a portion of the reinforcing fibers, heating the web above the glass transition temperature of the thermoplastic resin, and pressing the web to a predetermined thickness to form a porous thermoplastic composite sheet having a void content of about 1 percent to about 95 percent.
    Type: Application
    Filed: May 19, 2006
    Publication date: November 22, 2007
    Inventors: Coray Avery Harper, Charles William Peterson, Venkatkrishna Raghavendran
  • Patent number: 7293336
    Abstract: Production of a non-woven tissue from wood pulp on a wet strip is known. The above has a cardboardy, paper-like feel to it. In order to achieve a web with sufficient resilience, the desired wood pulp fibres used to advantage in the hygiene industry for absorbing liquids are thus always mixed with chemical fibres as support fibres. According to the invention, a consolidated tissue with a soft feel and high fluid absorption is obtained by means of needling a non-woven pure wood pulp tissue with water.
    Type: Grant
    Filed: May 24, 2002
    Date of Patent: November 13, 2007
    Assignee: Fleissner GmbH
    Inventor: Gerold Fleissner
  • Patent number: 7290314
    Abstract: The invention concerns a method for producing a complex nonwoven fabric which consists in continuously producing a complex wherein a first web of a cellulosic fibres is continuously sandwiched between two webs of spunbonded filaments, and which consists in: producing a first web of spunbonded filaments, the bundle of extruded and drawn filaments being received on a mobile conveyor belt in the form of a non-bonded lap; depositing on said web by airlaid process a second web of cellulosic fibres; depositing on the textile web a second web of non-bonded continuous filaments; transferring the resulting complex onto an installation for water-jet bonding and hydro-entanglement consolidation; and in drying the nonwoven mixed product and then recuperating it, for example in the form of a cloth wind-up.
    Type: Grant
    Filed: February 8, 2005
    Date of Patent: November 6, 2007
    Assignee: Rieter Perfojet
    Inventors: Andre Vuillaume, Frederic Noelle
  • Patent number: 7285240
    Abstract: A method of imaging a woven textile fabric comprises the steps of providing a woven textile fabric having a plurality of interwoven warp and weft yarns comprising aesthetically contrasting fibrous components. A three-dimensional image transfer device is provided with the woven textile fabric positioned thereon, and subjected to hydraulic imaging by application of pressurized liquid streams. The liquid streams are applied to a surface of the fabric facing away from the image transfer device, to thereby impart the pattern of the image-forming surface of the three-dimensional transfer device to the fabric. The resultant fabric can find application as an apparel article, a home fashion article, or an upholstery backing.
    Type: Grant
    Filed: September 30, 2002
    Date of Patent: October 23, 2007
    Assignee: Polymer Group, Inc.
    Inventors: Dennis Clark Scheer, Cynthia Dawson McNaull
  • Patent number: 7276132
    Abstract: A method of preparing a reinforcing structure for use in manufacture a pultruded part where the reinforcing structure is pulled through a pultrusion die in a continuous longitudinal pull direction. The method includes arranging a plurality of first reinforcing fibers in a transverse direction and attaching a permeable transport web of staple fibers to the first reinforcing fibers such that the portion of the first reinforcing fibers oriented in the direction transverse comprises at least 30% of a volume of materials comprising the reinforcing structure.
    Type: Grant
    Filed: February 22, 2005
    Date of Patent: October 2, 2007
    Assignee: Pella Corporation
    Inventors: Laurence W. Davies, Peter J. Fritz, Kenneth D. Beer
  • Patent number: 7237308
    Abstract: A composite nozzle strip for hydroentangling of a fibrous mass is provided to lower nozzle erosion potential and increase operational efficiency. The composite nozzle strip comprises a substrate comprising a material of a first hardness having at least one aperture and at least one orifice element comprising a material of a second hardness greater than the first hardness and further defining an aperture of a second diameter less than the first diameter. The at least one orifice element is affixed to the substrate so that the aperture in the orifice element is aligned with the at least one aperture in the substrate for creation of a constricted water jet when subjected to pressurized water.
    Type: Grant
    Filed: June 10, 2004
    Date of Patent: July 3, 2007
    Assignees: North Carolina State University, Advanced Fluid Technologies, Inc.
    Inventors: Michael D. Dixon, James T. Lowder, Behnam Pourdeyhimi, Hooman Vahedi Tafreshi
  • Patent number: 7232468
    Abstract: A method of forming abrasion resistant nonwoven fabrics by hydroentanglement includes providing a precursor web. The precursor web is subjected to hydroentanglement on a three-dimensional image transfer device to create a patterned and imaged fabric. Treatment with an initial pre-dye finish enhances the integrity of the fabric, permitting the nonwoven to exhibit desired physical characteristics, including strength, durability, softness, and drapeability. The pre-dye finish treated nonwoven may then be dyed by means applicable to conventional wovens. A post-dye finish may then be applied to further enhance the performance of the nonwoven fabric.
    Type: Grant
    Filed: September 7, 2004
    Date of Patent: June 19, 2007
    Assignee: Polymer Group, Inc.
    Inventor: Herbert Parks Hartgrove
  • Patent number: 7210205
    Abstract: Provided is a water-decomposable fibrous sheet including fibers containing at least 3% by mass of fibrillated rayon. The fibrillated rayon has a degree of beating of at most 700 cc and has primary fibers of a predetermined fiber length and microfibers extending from the primary fibers. In the fibrous sheet, the microfibers are entangled with at least either of other microfibers and other fibers therein, and the surface friction resistance of the fibrous sheet in dry, measured according to the abrasion resistance test method of JIS P-8136, is at least three rubbing cycles.
    Type: Grant
    Filed: November 26, 2003
    Date of Patent: May 1, 2007
    Assignee: Uni-Charm Corporation
    Inventors: Naohito Takeuchi, Kazuya Okada, Jyoji Shimizu, Toshiyuki Tanio, Takayoshi Konishi
  • Patent number: 7201777
    Abstract: The present invention relates to a nonwoven fabric having a relatively low level of ionic contaminates which is achieved by exposing the fabric to a deionized water wash, preferably, in-line with the nonwoven production process, thereby eliminating, or at least reducing, the need for an expensive and time consuming cleanroom laundering. The fabric is primarily comprised of continuous filament fibers and may be manufactured into such end-use products as cleaning wipes and protective clothing for cleanrooms and surface coating operations, such as automotive paintrooms. Also encompassed within this invention is a method for producing a nonwoven fabric having a relatively low level of ionic contaminates.
    Type: Grant
    Filed: March 28, 2002
    Date of Patent: April 10, 2007
    Inventor: Archer E. D. Booker, Jr.
  • Patent number: 7197795
    Abstract: The nozzle beam on a device for producing liquid jets in order to impinge said jets upon the fibres of a web of continuous material guided along the beam consists of a beam housing extending along the working width of the continuous web of fibre material, whereby two longitudinal bores placed on top of each other are accommodated in said housing and are separated from each other by means of an intermediate wall provided with continuous boreholes. The nozzle strip required to produce the liquid jets is mounted in a liquid-tight manner in the lower part of the housing and is cross-flown by pressurized water. In order to enable more needle water to reach the fabric than is usual with such a construction, two strips of nozzles are mounted in a housing and must be provided accordingly with pressurized water.
    Type: Grant
    Filed: December 5, 2001
    Date of Patent: April 3, 2007
    Assignee: Fleissner GmbH & Co. Maschinenfabrik
    Inventor: Gerold Fleissner
  • Patent number: 7194788
    Abstract: A composite fabric is provided that contains staple fibers hydraulically entangled with a nonwoven web formed from continuous filaments. A portion of the staple fibers is entangled with the web, while another portion protrudes through the web. The resulting surface topography has one surface with a preponderance of the smooth, staple fibers, and another surface with a preponderance of the continuous filaments from the nonwoven web, but also including some of the protruded smooth, staple fibers. Thus, each surface contains smooth staple fibers and is soft.
    Type: Grant
    Filed: December 23, 2003
    Date of Patent: March 27, 2007
    Assignee: Kimberly-Clark Worldwide, Inc.
    Inventors: James William Clark, Henry Skoog, James J. Detamore, Shawn Eric Jenkins
  • Patent number: 7194789
    Abstract: A nonwoven composite fabric is provided that contains one or more abraded (e.g., sanded) surfaces. In addition to improving the softness and handfeel of the nonwoven composite fabric, it has been unexpectedly discovered that abrading such a fabric may also impart excellent liquid handling properties (e.g., absorbent capacity, absorbent rate, wicking rate, etc.), as well as improved bulk and capillary tension.
    Type: Grant
    Filed: December 23, 2003
    Date of Patent: March 27, 2007
    Assignee: Kimberly-Clark Worldwide, Inc.
    Inventors: Craig Farrell Thomaschefsky, Larry M. Brown
  • Patent number: 7191500
    Abstract: The present invention relates to a soft feeling, aesthetically pleasing, and form-fitting disposable nonwoven undergarment for men, women, and youths, and optionally comprises a protective panel for those individuals with mild incontinence conditions. It is the object of the present invention to provide a comfortable, durable disposable undergarment by forming the undergarment of a three-dimensionally imaged nonwoven fabric. The present invention discloses an assortment of durable, disposable undergarments capable of meeting the needs of the general public, and specifically, to subsets of the population such as travelers, athletes, medical personnel and patients, for which routine care of conventional undergarments is inconvenient or unavailable.
    Type: Grant
    Filed: November 7, 2002
    Date of Patent: March 20, 2007
    Assignee: Polymer Group, Inc.
    Inventor: Cliff Bridges
  • Patent number: 7191501
    Abstract: The invention is directed to a hydroentangled nonwoven fabric, the outer surface of which exhibits highly entangled fibers whereas the inner layer exhibits lightly entangled fibers. In particular, the present invention contemplates that a fabric is formed from a fibrous batt that is subjected to fluidic energy, preferably hydraulic energy, applied to one or both faces of a fibrous batt. The hydraulic energy is moderated against the basis weight of the fibrous batt to achieve the degree of surface entanglement desired. Fabrics formed in accordance with the present invention exhibit a sufficient degree of softness and non-linting performance, while providing the necessary resistance to tearing and abrasion, to facilitate use in a wide variety of applications such as cast padding or orthopedic wraps.
    Type: Grant
    Filed: November 12, 2004
    Date of Patent: March 20, 2007
    Assignee: Polymer Group, Inc.
    Inventors: Charles R. Fuller, Sheridan D. Ledbetter
  • Patent number: 7188397
    Abstract: A method of forming flame-retardant nonwoven fabrics by hydroentanglement includes providing a precursor web. The precursor web is subjected to hydroentanglement on a three-dimensional image transfer device to create a patterned and imaged fabric. Treatment with a flame-retardant binder enhances the integrity of the fabric, permitting the nonwoven to exhibit desired physical characteristics, including strength, durability, softness, and drapeability. The treated nonwoven may then be dyed by means applicable to conventional wovens.
    Type: Grant
    Filed: May 18, 2005
    Date of Patent: March 13, 2007
    Assignee: Polymer Group, Inc.
    Inventors: Herbert Parks Hartgrove, Sergio Diaz de Leon, Samuel Keith Black, Friso Joost Hijenga
  • Patent number: 7178210
    Abstract: The invention concerns an installation for producing non-woven textile webs comprising a conveyor on one side of which the non-woven textile web passes between an injector and a vacuum chamber driven in an oscillating motion. The resulting web bears no mark.
    Type: Grant
    Filed: October 19, 2001
    Date of Patent: February 20, 2007
    Assignee: Rieter Perfojet
    Inventors: Frédéric Noelle, Jean-Michel Dubus
  • Patent number: 7168140
    Abstract: Fabrics having improved aesthetic characteristics in addition to good FR characteristics and strength are described, as well as a method for making the fabrics. The fabrics are made by subjecting a fabric containing inherently flame resistant fibers to a fluid treatment process such that a fabric with good comfort and aesthetic characteristics is formed. In one form of the invention, the fabric comprises plied yarns, and the fluid treatment process serves to separate the plies from each other. The fabrics have a soft hand, good protective characteristics, good strength and durability, as well as good wicking and soil release characteristics.
    Type: Grant
    Filed: August 8, 2002
    Date of Patent: January 30, 2007
    Assignee: Milliken & Company
    Inventors: Paul A. McKee, Joseph B. Glenn, Mathias Richardson, Nathan B. Emery, Roy P. DeMott
  • Patent number: 7160183
    Abstract: A buff is made from a non-woven fabric where the fibers are first carded and formed into a fairly thick fleece. The fleece is passed over a topographical surface on, for example, a moving belt or a drum. The fleece is subject to a bow-tie hydroentanglement process where many fine jets of water entangle the fibers on the topographical surface. Excess water is vacuumed from the system. The fabric is dried and chemically treated. With the fabric a variety of buffing tools are made, in wheel, belt or roll form. Tests against standard and mill treatment buffs show a remarkably lower fabric weight loss percentage and lower or normal operating temperatures. The fabric has exceptional mechanical strength having a tensile strength in excess of 650 N/50 mm according to DIN 29073/3. Preferably the fabric has a tensile strength of at least 1,000 N/50 mm in the machine direction and in excess of 900 N/50 mm in the cross direction according to such DIN.
    Type: Grant
    Filed: May 8, 2003
    Date of Patent: January 9, 2007
    Assignee: Jason Incorporated
    Inventor: Robert J. Weber
  • Patent number: 7082654
    Abstract: The present invention is directed to a method of forming a nonwoven fabric, which exhibits a plurality of three-dimensional images whereby the fabric is comprised of at least a first and second three-dimensional image that are dissimilar from one another. The three-dimensional images may be imparted into the fabric in a co-planar arrangement, multi-planar arrangement, or by utilizing both arrangements within the same fabric. Further, the present invention contemplates a fabric comprised of a plurality of three-dimensional images which can provide the fabric with various physical and/or aesthetic performances.
    Type: Grant
    Filed: May 7, 2003
    Date of Patent: August 1, 2006
    Assignee: Polymer Group, Inc.
    Inventors: Jerry Snider, Andrew Delaney, Nick Carter, Cheryl Carlson, Julie Thompson, Jennifer Mayhorn
  • Patent number: 7069629
    Abstract: The present invention is directed to a nonwoven fabric, and specifically to a durable lightweight nonwoven fabric wipe, comprising improved strength, as well as an improved MD to CD elongation ratio, which results in a material imminently suitable for application in the cleaning and cleansing of surfaces. A method of making the nonwoven fabric embodying the present invention includes the steps of providing a precursor web comprising a fibrous matrix. The method further comprises the steps of providing a precursor web, which is subjected to hydroentangling.
    Type: Grant
    Filed: December 15, 2004
    Date of Patent: July 4, 2006
    Assignee: Polymer Group, Inc.
    Inventors: Brian Burgess, Benjamin Nolan
  • Patent number: 7062824
    Abstract: Method of producing a composite nonwoven for receiving and storing liquids or the like, comprising a carded nonwoven, which is treated in order to consolidate it, and a pulp layer, such as a wood pulp fiber layer, applied to the consolidated carded nonwoven and brought into secure contact with same, characterised in that the carded nonwoven is consolidated dry before being coated with the super-absorbent material, then the layer formed from the pulp fibers is applied to this pre-consolidated carded nonwoven and everything is interconnected.
    Type: Grant
    Filed: November 12, 2004
    Date of Patent: June 20, 2006
    Assignees: Fleissner GmbH & Co., Maschinenfabrik, Orlandi SpA
    Inventor: Vittorio Orlandi
  • Patent number: 7055227
    Abstract: A process for face finishing fabrics, and in particular fabrics containing filaments, to provide them with good aesthetic characteristics is described. In addition, fabrics made from filaments having aesthetic characteristics and surface effects similar to those of fabrics made from spun yarns are described. Also, items of napery made from filaments and having good surface effects and low pick and snag performance are described. The process involves pre-abrading a fabric, such as one made from filaments, and then subjecting it to a high energy fluid treatment process.
    Type: Grant
    Filed: November 26, 2002
    Date of Patent: June 6, 2006
    Assignee: Milliken & Company
    Inventors: Franklin S. Love, James T. Greer
  • Patent number: 7047606
    Abstract: The present invention is directed to a method of forming a two-sided nonwoven fabric, which exhibits a pronounced three-dimensional image that is durable to both converting and end-use application. In particular, the present invention contemplates that a fabric is formed from a first precursor web comprising a first fibrous matrix and a second precursor web comprising a second fibrous matrix. Between the first and second precursor web, a fluid-pervious support layer or scrim, is interposed and subjected to hydroentanglement on a moveable imaging surface having a three-dimensional image transfer device. By formation of a nonwoven fabric in this fashion, a three-dimensional image that is durable to abrasion and distortion due to elongation is imparted and a product formed which exhibits on its opposite surfaces the unique properties of the respective fibrous matrix used.
    Type: Grant
    Filed: March 27, 2003
    Date of Patent: May 23, 2006
    Assignee: Polymer Group, Inc.
    Inventors: Miguel Rivera, Ralph A. Moody, III, Michael J. Putnam
  • Patent number: 7037866
    Abstract: A nonwoven fabric comprises a first layer formed of staple fibers having a smooth outer surface, a second layer formed of staple fibers having an outer surface with a roughened texture and a third, spunbond layer sandwiched between the first and second layers. A binder material is applied to the second layer which substantially covers its textured surface and is effective to resist deformation under the application of pressure even in the presence of liquid.
    Type: Grant
    Filed: August 5, 2002
    Date of Patent: May 2, 2006
    Assignee: Green Bay Nonwovens, Inc.
    Inventor: R. John Michaud
  • Patent number: 7025915
    Abstract: A method for producing an artificial leather includes mixed spinning an island polymer and a sea polymer having a different dissolving property from that of the island polymer at a predetermined temperature, producing a non-woven substrate from the fiber obtained, immersing the non-woven substrate into a polymer, dissolving and removing the sea polymer in the non-woven substrate to obtain an artificial leather as a semi-finished product, and polishing the surface of the artificial leather to obtain an artificial leather having excellent dyeability and advanced fluff-like property. The ratio of melt flow index of the sea polymer to relative viscosity of the island polymer is about 20 to about 55, in which the relative viscosity of the island polymer is about 2.7 to about 3.5 and the weight percentage of the sea polymer relative to the sum of the sea polymer and the island polymer is about 30% to about 70%.
    Type: Grant
    Filed: March 21, 2003
    Date of Patent: April 11, 2006
    Assignee: San Fang Chemical Industry Co., Ltd.
    Inventors: Ching-Tang Wang, Mong-Ching Lin, Chung-Chin Feng, Kuo-Kuang Cheng, Chin-Yi Lin
  • Patent number: 7013541
    Abstract: The present invention is directed to a method of forming a nonwoven fabric, which exhibits a first three-dimensional image and a second three-dimensional image whereby the first and second three-dimensional images are dissimilar from one another. In particular, the present invention contemplates a fabric comprised of sequentially formed three-dimensional images that are formed from a pre-entangled precursor web entangled on a first three-dimensional transfer device so as to impart a first image therein, then subjected to hydroentanglement on a second three-dimensional image transfer device wherein a second three-dimensional image is imparted to the web that is different from the first three-dimensional image, the resulting nonwoven fabric presenting aesthetic and tactile qualities representative of both imparted images.
    Type: Grant
    Filed: April 7, 2003
    Date of Patent: March 21, 2006
    Assignee: Polymer Group, Inc.
    Inventors: Miguel Rivera, Ralph A. Moody, III, Benjamin Nolan, Michael Putnam
  • Patent number: 7008889
    Abstract: A method of forming durable nonwoven fabrics by hydroentanglement includes providing a precursor web comprising a blend of matrix fibers, lyocell fibers, and fusible binder fibers. The precursor web is subjected to hydroentanglement on a three-dimensional image transfer device to create a patterned and imaged fabric. Fabrics formed in accordance with the present invention exhibit significant improvements in strength while remaining drapeable and are capable of withstanding multiple laundry washing with nominal shrinkage.
    Type: Grant
    Filed: September 6, 2002
    Date of Patent: March 7, 2006
    Assignee: Polymer Group, Inc.
    Inventors: Samuel K. Black, Sergio De Leon
  • Patent number: 6987075
    Abstract: The present invention describes a new mattress cover sheet with barrier effect against bacteria and parasites, consisting of a spunlace fiber based fabric. The spunlace fabric mattress cover can be produced in a structure with one or more layers, and can contain antibacterial substances. The sheet subject of the invention provides an effective barrier between the person and the mattress, in particular avoiding the transfer of pollutants from the mattress to the person and at the same time protecting the hygiene of the mattress itself.
    Type: Grant
    Filed: November 29, 2002
    Date of Patent: January 17, 2006
    Assignee: Orlandi S.p.A.
    Inventor: Vittorio Orlandi
  • Patent number: 6964749
    Abstract: The present invention relates to a nonwoven substrate, and specifically to a nonwoven substrate imparted with a three-dimensional image, wherein the three-dimensional nonwoven substrate is particularly suited as a support substrate for a PCB (Printed Circuit Board) and similar application. By the utilization of a hydroentangled, three-dimensionally imaged support substrate impregnated with a durable resinous matrix, PCB's, and similar applications, can be imparted with unique and useful performance properties, to improve structural performance.
    Type: Grant
    Filed: June 4, 2002
    Date of Patent: November 15, 2005
    Assignee: Polymer Group, Inc.
    Inventors: Jerry Zucker, Nick Mark Carter
  • Patent number: 6957474
    Abstract: A suction device for use in a textile machine, especially a water jet weaving installation has a slot between two glide strips for a transport device transporting the textile material that terminates radially inwards in a stationary suction tube into the thicker wall of which a suction slot is milled across the entire working length, thereby removing the need for bores having intermediate webs that are soiled by the lint suctioned off. The longitudinal slot in the suction tube is held at the desired distance by U-shaped straps that are distributed across the length of the slot. The straps are held on the suction tube by screws and are arrow-shaped in the zone of their base limbs so that the lint is unimpeded as it flows past this surface.
    Type: Grant
    Filed: April 14, 2001
    Date of Patent: October 25, 2005
    Assignee: Fleissner GmbH & Co. Maschinenfabrik
    Inventor: Gerold Fleissner
  • Patent number: 6921569
    Abstract: A soft, durable, nonwoven fabric formed of hydroentangled synthetic polymer fibers in sheet form. The polymer fiber is surface embossed on at least one major surface with a predetermined pattern to provide a fiber sheet having enhanced dimensional stability. The fiber sheet is surface napped to soften the surface and disturb and make indistinct the surface embossed pattern. The pattern may preferably be a twill pattern, and the napping process is preferably a wire-napping process. The fabric can be constructed into blankets and numerous apparel items.
    Type: Grant
    Filed: January 2, 2003
    Date of Patent: July 26, 2005
    Assignee: Outside the Box, Inc.
    Inventor: David A. Dillinger
  • Patent number: 6893522
    Abstract: The method generally comprises the steps of providing a hydroentangled non-woven layer having a first binder component, and depositing a second non-woven layer having a high bulk and loft on to the hydroentangled layer to form an unbonded composite fabric. The second layer also has a binder component with a melting temperature substantially equal to the first binder melting temperature.
    Type: Grant
    Filed: September 28, 2000
    Date of Patent: May 17, 2005
    Assignee: Polymer Group, Inc.
    Inventor: Sorin Crainic
  • Patent number: 6887486
    Abstract: The invention relates to a hydrophilic cotton pad for skin-care exhibiting a specific surface weight of at least 150 g/m2, and having two different outer sides of which the fibers are entangled. In the invention, the first outer side has hollow striae apart by a spacing s1 between 1 and 8 mm and having a depth d of at least 0.25 mm and wherein at least 50% of the fibers are entangled. The pad of the invention is used to apply skin-care products, such as cosmetics, to the skin.
    Type: Grant
    Filed: December 5, 2000
    Date of Patent: May 3, 2005
    Assignee: Georgia-Pacific France
    Inventor: Philippe Gregoire
  • Patent number: 6881288
    Abstract: A method of preparing a reinforcing structure for use in manufacture a pultruded part where the reinforcing structure is pulled through a pultrusion die in a continuous longitudinal pull direction. The method includes arranging a plurality of first reinforcing fibers in a transverse direction and attaching a permeable transport web of staple fibers to the first reinforcing fibers such that the portion of the first reinforcing fibers oriented in the direction transverse comprises at least 40% of a volume of materials comprising the reinforcing structure.
    Type: Grant
    Filed: December 11, 2001
    Date of Patent: April 19, 2005
    Assignee: Pella Corporation
    Inventors: Laurence W. Davies, Peter J. Fritz, Kenneth D. Beer
  • Patent number: 6877196
    Abstract: A method for changing the position of fibers in a nonwoven web to improve the isotropy of the web by using angled stream of fluid wherein the streams form a substantially coplanar curtain and impinge on the fibers at their leading ends, trailing ends or sides.
    Type: Grant
    Filed: August 3, 2001
    Date of Patent: April 12, 2005
    Assignee: E. I. du Pont de Nemours and Company
    Inventors: James Marshall Oathout, Phillip O. Staples, Donald Floyd Miller
  • Patent number: 6872273
    Abstract: A method of making a pultruded part having a uniform cross-section using a novel reinforcing mat. The method comprises orienting a plurality of longitudinal rovings along a longitudinal axis of a pultrusion die; providing a reinforcing structure comprising a permeable transport web of staple fibers attached to a plurality of first reinforcing fibers oriented so that the portion of the first reinforcing fibers oriented in a direction transverse to the longitudinal axis comprises at least 40% of a volume of materials comprising the reinforcing structure; shaping the reinforcing structure to generally conform with a profile of the pultrusion die; combining a resin matrix with the longitudinal rovings and the reinforcing structure in the pultrusion die so that the longitudinal rovings and the reinforcing structure are substantially surrounded by the resin matrix; at least partially curing the resin matrix in the pultrusion die; and pulling the pultruded part from the pultrusion die.
    Type: Grant
    Filed: December 11, 2001
    Date of Patent: March 29, 2005
    Assignee: Pella Corporation
    Inventors: Laurence W. Davies, Peter J. Fritz, Kenneth D. Beer
  • Patent number: 6865784
    Abstract: Machine for producing a patterned textile product, comprising a drum with a perforated lateral surface rotated about its axis, a sleeve with holes which is slipped over the drum, and having a ration of the sum of the surface area of the holes to the surface area of its total lateral surface of between 5 and 75% and, preferably, between 7 and 50% and a hole diameter not greater than 1 mm, a device for spraying water jets in the direction of the drum in a direction substantially radial thereto and means for creating a vacuum inside the drum wherein an apertured sheath is slipped over the sleeve and has apertures at least one dimension of which is greater than 2 mm.
    Type: Grant
    Filed: December 30, 2002
    Date of Patent: March 15, 2005
    Assignee: Rieter Perfojet
    Inventor: Frédéric Noelle
  • Patent number: 6859983
    Abstract: In the present invention, a hydroentangled and three-dimensionally patterned fibrous material is printed or dyed with suitable coloring agents that are beneficial in enhancing the ability of the material to disrupt or obscure objects placed beneath such material. A three-dimensional pattern in the fibrous material results in a camouflage fabric with enhanced realism due to ability of the fabric to transmit varying amounts of direct and incidental light, thus producing shape-obscuring shadows.
    Type: Grant
    Filed: September 18, 2002
    Date of Patent: March 1, 2005
    Assignee: Polymer Group, Inc.
    Inventors: Charles Curtis, Samuel K. Black
  • Patent number: 6851164
    Abstract: A method and plant for producing an air-laid non-woven web of cellulose fibers or of cellulose fibers mixed with synthetic fibers that includes at least one air-laying section for depositing fiber fluff into a layer upon a forming wire, an overlying second wire for transferring the layer of fluff to a third wire having a mesh count small enough for preventing the fibers from penetrating into the wire, and at least one nozzle for directing a water jet towards the fluff on the third wire, thereby hydroentangling the fluff into a coherent web. By the method and plant according to the invention, it is possible to produce hydroentangled fiber webs which are less expensive and have better absorption properties than hitherto known. The webs can be produced with weights between about 20 and 2000 g/m2.
    Type: Grant
    Filed: June 16, 2003
    Date of Patent: February 8, 2005
    Assignee: M & J Fibretech A/S
    Inventor: Jens Ole Bröchner Andersen
  • Patent number: 6842953
    Abstract: Method of producing a composite nonwoven for receiving and storing liquids or the like, comprising a carded nonwoven, which is treated in order to consolidate it, and a pulp layer, such as a wood pulp fiber layer, applied to the consolidated carded nonwoven and brought into secure contact with same, characterized in that the carded nonwoven is consolidated dry before being coated with the super-absorbent material, then the layer formed from the pulp fibers is applied to this pre-consolidated carded nonwoven and everything is interconnected.
    Type: Grant
    Filed: August 13, 2002
    Date of Patent: January 18, 2005
    Assignees: Fleissner GmbH & Co. Maschinenfabrik, Orlandi SpA
    Inventor: Vittorio Orlandi
  • Patent number: 6838043
    Abstract: A synthetic leather made of a nonwoven fabric impregnated and/or coated with a polymer, with a surface weight of 100 to 500 g/m2, and a tensile strength greater than 300 N/5 cm in the lengthwise and the crosswise direction, where the nonwoven fabric is made up of melt-spun multi-component endless filaments, aerodynamically stretched and directly laid up to form a nonwoven material, having a titer less than 2 dTex, and wherein the multi-component endless filaments, after preliminary bonding, are split and bonded by at least 90% to produce supermicro endless filaments having a titer less than 0.2 dTex.
    Type: Grant
    Filed: September 1, 2000
    Date of Patent: January 4, 2005
    Assignee: Carl Freudenberg KG
    Inventors: Rudolf Wagner, Robert Groten
  • Patent number: 6836938
    Abstract: Method for producing a composite non-woven fabric for the production of a hygiene product includes the steps of forming a spun-bonded non-woven fabric; compressing the spun-bonded non-woven fabric in the dry state in a continuous process after forming the spun-bonded non-woven fabric for pre-strengthening; coating the pre-strengthened spun-bonded non-woven fabric with a layer of pulp fibers; conducting a hydrodynamic water needling process to interconnect and strengthen the layer of pulp fibers and the pre-strengthened spun-bonded non-woven fabric to form a composite non-woven fabric; and then drying the composite non-woven fabric. The step of compressing the spun-bonded non-woven fabric provides only a light bonding of fibers of the spun-bonded non-woven fabric such that the pulp fibers enter into an internal bonding with fibers of the spun-bonded non-woven fabric in the hydrodynamic water needling process.
    Type: Grant
    Filed: January 13, 2001
    Date of Patent: January 4, 2005
    Assignee: Fleissner GmbH & Co., Maschinenfabrik
    Inventor: Gerold Fleissner
  • Patent number: 6836937
    Abstract: Known methods involve applying a layer of particularly highly absorbent fibers such as woodpulp on a carrier nonwoven and then compacting the composite nonwoven with the aid of water entanglement. One disadvantage of the compacting method is the high woodpulp fiber loss and the associated purification of the circulating water for the entanglement device. According to the invention, a fine layer of microfibers is initially applied before applying the woodpulp fibers. The microfibers are evenly distributed on the carrier nonwoven using, for instance, a meltblown process and the woodpulp fibers are only then applied in the separating layer. The water during entanglement can no longer merge the woodpulp fibers into the carrier nonwoven due to the fact that the microfibers act as a barrier.
    Type: Grant
    Filed: August 5, 2000
    Date of Patent: January 4, 2005
    Assignees: Fleissner GmbH & Co. Maschinenfabrik, Albis S.p.A.
    Inventor: Gianni Boscolo
  • Publication number: 20040255440
    Abstract: The present invention is directed to a hydroentangled nonwoven personal wipe, and more specifically to a hydroentangled three-dimensionally imaged personal wipe comprised of at least one raised portion and a background portion, wherein said personal wipe comprises a minimal amount of transverse apertures.
    Type: Application
    Filed: April 7, 2004
    Publication date: December 23, 2004
    Applicant: Polymer Group, Inc.
    Inventors: Nick Carter, Jennifer Mayhorn
  • Publication number: 20040258844
    Abstract: The present invention is directed to a method of forming a nonwoven cleaning article, which exhibits a first three-dimensional image and a second three-dimensional image whereby the first and second three-dimensional images are dissimilar from one another. In particular, the present invention contemplates a fabric comprised of sequential three-dimensional images that are formed from a pre-entangled precursor web entangled on a first three-dimensional transfer device so as to impart a first image therein, then subjected to hydroentanglement on a second three-dimensional image transfer device wherein a second three-dimensional image is imparted to the web that is different from the first three-dimensional image, the resulting nonwoven cleaning article presenting aesthetic and tactile qualities representative of both imparted images.
    Type: Application
    Filed: April 7, 2004
    Publication date: December 23, 2004
    Applicant: Polymer Group, Inc.
    Inventors: Miguel Rivera, Ralph A. Moody, Benjamin Nolan, Michael J. Putnam, Nick Carter
  • Patent number: 6832418
    Abstract: The present invention is directed to a method of forming a nonwoven fabric, which exhibits a pronounced durable three-dimensional image, permitting use of the fabric in secondary carpet backing of carpet backing systems so as to reduce deformation under normal use (walking) and provide better coverage in carpet system applications. In particular, the present invention contemplates that a fabric is formed from a precursor web comprising a spunbond and/or cast scrim, which when subjected to hydroentanglement on an imaging surface, an enhanced product is achieved. By formation in this fashion, hydroentanglement of the precursor web results in a more pronounced three-dimensional image; an image that is durable to abrasion and distortion.
    Type: Grant
    Filed: October 22, 2003
    Date of Patent: December 21, 2004
    Assignee: Polymer Group, Inc.
    Inventors: Herbert Hartgrove, Cynthia Dawson McNaull, Russell Tindall
  • Patent number: 6823568
    Abstract: A nonwoven fabric suitable to be used as a kitchen paper including thermoplastic synthetic fibers being 7˜30 mm long and as fine as of 0.1˜0.8 d, in 90˜10% by weight and pulp fibers being 2˜7 mm long, in 10˜90% by weight, these component fibers being mixed together as homogeneously as possible and mechanically entangled so as to have a basis weight of 10˜80 g/m2 as a whole.
    Type: Grant
    Filed: August 31, 2000
    Date of Patent: November 30, 2004
    Assignee: Uni-Charm Corporation
    Inventors: Toshio Kobayashi, Miou Suzuki, Naohito Takeuchi
  • Publication number: 20040221437
    Abstract: Production of a non-woven tissue from wood pulp on a wet strip is known. The above has a cardboardy, paper-like feel to it. In order to achieve a web with sufficient resilience, the desired wood pulp fibres used to advantage in the hygiene industry for absorbing liquids are thus always mixed with chemical fibres as support fibres. According to the invention, a consolidated tissue with a soft feel and high fluid absorption is obtained by means of needling a non-woven pure wood pulp tissue with water.
    Type: Application
    Filed: June 17, 2004
    Publication date: November 11, 2004
    Inventor: Gerold Fleissner
  • Patent number: 6810565
    Abstract: During the construction of the nozzle beam according to DE-A-195 01 738, the insertion slit for the nozzle strip (14) is sealed on the front side of the nozzle beam by means of a screwed cover (16,17). It is easier to exchange a nozzle strip (14) if a special closing unit (26) having an opening (3) for the nozzle strip is provided on the front side, and said opening (30) is closed in a liquid-tight manner by a simply fixed insertion mandrel (31).
    Type: Grant
    Filed: January 12, 2004
    Date of Patent: November 2, 2004
    Assignee: Fleissner GmbH & Co. Maschinenfabrik
    Inventor: Gerold Fleissner
  • Patent number: 6796010
    Abstract: A method for producing a nonwoven web formed at least partly with hydrophilic fibers is provided. In one aspect, the method comprises producing by carding a textile layer (10) which is then compressed and moistened; subjecting the textile layer to a bonding treatment using water jets acting at least against one of its surfaces; and transferring said bonded layer to a unit (32, 33) to be dewatered and dried. One aspect of the method is characterized in that, after the bonding treatment (20) with water jets and before drying and delivery, the pre-bonded and moistened layer is transferred to a supplementary unit (28) to be treated by the action of one or several series of water jets, the unit comprising a mobile suction surface in the form of a drum covered with an open-work structure (30) comprising a wire-mesh fabric, the wire-mesh fabric comprising successive raised and recessed zones.
    Type: Grant
    Filed: February 20, 2004
    Date of Patent: September 28, 2004
    Assignee: Rieter Perfojet
    Inventor: Frédéric Noelle