By Fluid Jet Needling Or Perforating Patents (Class 28/104)
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Publication number: 20030131454Abstract: 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: ApplicationFiled: December 30, 2002Publication date: July 17, 2003Inventor: Frederic Noelle
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Publication number: 20030134560Abstract: Artificial leather sheet material is made by hydroentanglement of waste leather fibres. A web (28) of the fibres is advanced on a porous belt (8, 9) high pressure water jet heads (13) in a number of successive hydroentanglement steps. Screens (14) are pressed onto the surface of the web (28) between the water jet heads (13) and the web (28). The screens (14) have apertures which allow deep penetration of the water jets into the web (28) whilst thin screen portions between the apertures act to interrupt the jets * and limit formation of furrows (30). Deflector plates (19) are provided alongside water jet heads (13) to remove re-bounding water.Type: ApplicationFiled: November 27, 2002Publication date: July 17, 2003Inventor: Christopher Graham Bevan
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Patent number: 6592713Abstract: Method for producing a nonwoven material comprising at least one layer of continuous filaments, such as spunbond- or meltblown fibers. A first web of continuous filaments (19) are laid on a wire (14) or other permeable support member having a resilient extensibility in the transverse direction and which substantially resumes its original dimension when the extension is discontinued, that the wire is stretched in the transverse direction to at least 120% of its original width when the continuous filaments are laid on the wire. The stretching is discontinued after the continuous filaments have been laid on the wire.Type: GrantFiled: December 18, 2001Date of Patent: July 15, 2003Assignee: SCA Hygiene Products ABInventor: Hannu Ahoniemi
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Patent number: 6579391Abstract: A method for hydroentangling a nonwoven web to increase the strength and abrasion resistance while maintaining highly desirable hand and drape characteristics. The method provides for carding and cross-lapping synthetic and/or natural fibers so as to form a desired substrate. The substrate is then hydroentangled under relatively low pressure to form a desired spunlace web, and a relatively low amount of a foam adhesive latex binding material is applied to the spunlace web. Thereafter, a force is applied to the foamed spunlace web so as to cause the foamed binding material to fully penetrate the spunlace web from face to back. The resulting hydroentangled (spunlace) nonwoven web provides an enhanced balance of tensile properties, abrasion resistance, and fabric aesthetics.Type: GrantFiled: January 15, 1999Date of Patent: June 17, 2003Assignee: North Carolina State UniversityInventors: Donald A. Shiffler, Amit Shahani, Thomas F. Gilmore
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Publication number: 20030106195Abstract: A conventional method for the production of a composite non-woven fibre from at least one spun non-woven fibre and subsequent application of a wood pulp layer to the above for production of a hygiene product is known. Accordingly, the spunbonded non-woven fibre is hydrodynamically needled, before the application of the pulp layer, in order to increase the fluid dispersion properties. Consequently, the pulp layer can no longer be needled, as the pulp would be washed out through the non-woven fibre. Due to the required abrasion resistance a bonding of the non-woven fibre is, however, necessary. According to the invention, the above problem is resolved, whereby a non-woven fibre is compressed or calendered with compressed air, as a pre-bonding treatment, before coating with the super-absorbent material, then the woodpulp layer is applied and both are bonded with a hydrodynamic water needling, followed by drying. A further calandering can be added.Type: ApplicationFiled: October 9, 2002Publication date: June 12, 2003Inventor: Gerold Fleissner
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Publication number: 20030101556Abstract: The conventional method for production of a multiple-layer, non-woven fibre is by means of the air-lay method, with thermal bonding using bonding fibres. The same method can be applied to a composite non-woven fibre with an intermediate pulp layer. This method of bonding does not reduce the later pilling wear and hardly influences the inner composition of the layers of the composite. According to the invention, the outer non-woven fibre is preferably made from a bicomponent fibre and treated by hydrodynamic needling for bonding, such that not just the surface is bonded, but also the layers are bonded to each other.Type: ApplicationFiled: September 27, 2002Publication date: June 5, 2003Inventor: Gerold Fleissner
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Publication number: 20030104749Abstract: The invention relates to a sound absorbing material, made from a microfilament nonwoven fabric having a mass per unit area of 40 to 300 g/m2, in which a nonwoven fabric is made from melt-spun, drawn, multi-component endless filament having a titer of 1.5 to 5 dtex and directly laid down to form a fibrous web; and the multi-component endless filaments, optionally after prebonding, are split at least to 80% to form micro-endless filaments having a titer of 0.1 to 1.2 dtex and bonded.Type: ApplicationFiled: October 22, 2002Publication date: June 5, 2003Inventors: Ararad Emirze, Robert Groten, Matthias Schuster
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Publication number: 20030101557Abstract: Colored patterning of a web-shaped nonwoven or a composite made of a nonwoven and a fabric or knit is achieved by water jet needling. The nonwoven provided as the upper layer of two layers is provided with one or more colors or is colored or printed itself and is placed on a second nonwoven or a woven or one that has a different color. Then both layers are subjected to the water jets that displace the fibers, with the colored fibers in the first layer being displaced into the second layer to produce a pattern on the underside of the second layer. It is also possible, instead of colored fibers in the nonwoven of the upper layer, to move them when they are not colored into a second layer that can have any color.Type: ApplicationFiled: January 3, 2003Publication date: June 5, 2003Inventor: Gerold Fleissner
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Patent number: 6571441Abstract: A nonwoven fabric making apparatus adapted to continuously feed a fibrous web in one direction, to eject streams of high pressure fluid from a plurality of nozzles against at least one surface of the web, thereby to entangle component fibers of the web and to obtain a predetermined nonwoven fabric. On the assumption that a Y-axis extends in a direction along which the web travels and an X-axis extends to intersect the Y-axis at right angles, the nozzles are arranged at predetermined intervals to define a straightly extending a first nozzle array R1 which is declined at a predetermined angle with respect to the Y-axis. The nonwoven fabric obtained has no impact traces by ejection of the streams of high pressure.Type: GrantFiled: April 4, 2000Date of Patent: June 3, 2003Assignee: Uni-Charm CorporationInventors: Toshio Kobayashi, Hideyuki Ishikawa
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Patent number: 6568049Abstract: The method for hydraulic seaming together of two layers of consolidated nonwoven fabric in one or two directions simultaneously provides soft, supple seam lines, along which formed seam lines, cuts can be made for producing bag like articles from the seamed layers, such as, for example, pillow cases, or industrial filters.Type: GrantFiled: June 15, 2000Date of Patent: May 27, 2003Assignee: Polymer Group, Inc.Inventor: Michael Putnam
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Patent number: 6564436Abstract: The present invention contemplates a method of forming a textile laminate or composite fabric from a plurality of woven fabric layers, with the method contemplating use of a three-dimensional image transfer device to facilitate efficient and commercially viable use of the method. Herein is disclosed a method of forming an imaged textile laminate or composite compound fabric, the fabric having a first textile fabric layer comprising a plurality of interwoven warp and weft yarns and at least one other textile fabric layer, the lamination of the fabric layers and imaging of the construct occurring on a three-dimensional image transfer device. The image transfer device has a foraminous, image-forming surface comprising a regular pattern of three-dimensional surface elements.Type: GrantFiled: December 6, 2001Date of Patent: May 20, 2003Assignee: Polymer Group, Inc.Inventors: Samuel Keith Black, Charles Keith Curtis, Shane James Moran
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Publication number: 20030088956Abstract: Method and device for manufacturing a nonwoven material by hydroentangling a fibre web by means of water jets at a high pressure, wherein the fibre web is supported by a moulded, close-meshed screen (12) of a thermoplastic material during the hydroentanglement. Possibly, the screen can be reinforced with reinforcement wires (14).Type: ApplicationFiled: November 4, 2002Publication date: May 15, 2003Inventors: Mikael Strandqvist, Hannu Ahoniemi
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Patent number: 6557224Abstract: Colored patterning of a web-shaped nonwoven or a composite made of a nonwoven and a fabric or knit is achieved by water jet needling. The nonwoven provided as the upper layer of two layers is provided with one or more colors or is colored or printed itself and is placed on a second nonwoven or a woven or one that has a different color. Then both layers are subjected to the water jets that displace the fibers, with the colored fibers in the first layer being displaced into the second layer to produce a pattern on the underside of the second layer. It is also possible, instead of colored fibers in the nonwoven of the upper layer, to move them when they are not colored into a second layer that can have any color.Type: GrantFiled: June 13, 2002Date of Patent: May 6, 2003Assignee: Fleissner GmbH & Co., MashinenfabrikInventor: Gerold Fleissner
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Patent number: 6557223Abstract: Improvements in Hydroenhancement efficiency are obtained by operating a manifold in relative movement to fabric transported under the manifold so as to deliver a low energy to the fabric per pass in multiple passes on the fabric. This results in greater enhancement efficiency and reduction in wasted energy, and also improves fabric coverage and reduces fabric shrinkage. The low-energy per pass, multiple-pass approach can be implemented with improved hydroenhancing equipment of reduced equipment size and cost which simulate multiple passes on the fabric. Embodiments employ a manifold or manifold system that is reciprocated, oscillated, or rotated to simulate multiple passes on the fabric. Other variations for improving hydroenhancement include angling the manifold at a diagonal to the fabric travel direction, using a high density number of double rows of jets to eliminate interference patterns.Type: GrantFiled: February 15, 2002Date of Patent: May 6, 2003Assignee: Polymer Group, Inc.Inventors: J. Michael Greenway, Jackson Lawrence, Herschel Sternlieb, Frederick Ty, Frank E. Malaney
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Publication number: 20030079323Abstract: The present invention relates to a nonwoven fabric structure, formed by hydroentanglement of a precursor fibrous web, which has demonstrated particular suitability for cleansing/wiping applications. Testing has shown the present product to provide a desirable tactile impression with users, which is believed to result from the disposition of relatively large denier fibers on the surface of the fabric structure. Such relatively large denier fibers have been found to provide good cleansing/wiping performance.Type: ApplicationFiled: August 13, 2002Publication date: May 1, 2003Applicant: Polymer Group, Inc.Inventor: Mou Chung Ngai
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Publication number: 20030079324Abstract: In the present invention, a hydroentangled and three-dimensionally patterned fibrous material is formed from a fibrous matrix to produce a nonwoven fabric of pronounced open area and enhanced physical properties, including abrasive, and particularly wet abrasive, performance. A three-dimensional pattern utilized on the forming surface results in the nonwoven fabric having a diaphanous gauze-like or cheesecloth-like presentation.Type: ApplicationFiled: September 20, 2002Publication date: May 1, 2003Applicant: Polymer Group, Inc.Inventors: David Collins, Charles Keith Curtis, Jerry Parker
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Patent number: 6550115Abstract: The present invention desirably provides a fabric including a synthetic fiber structure first zone, a synthetic fiber structure second zone, and a short fiber third zone. The first zone may include a spunbond web layer and a meltblown web layer. The synthetic fiber structure second zone may be positioned proximate to the synthetic fiber structure first zone and the short fiber third zone may be positioned substantially between the first and second zones. Desirably, the first and second zones are entwined.Type: GrantFiled: October 16, 2000Date of Patent: April 22, 2003Assignee: Kimberly-Clark Worldwide, Inc.Inventors: Henry Skoog, Fred R. Radwanski, Terry R. Cleveland, Frances W. Mayfield, Lawrence M. Brown
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Patent number: 6546605Abstract: A fabric having at least one hydraulically napped surface comprised of tangled fibers is disclosed. Because the fiber tangles are created from intact, undamaged fibers, fabric strength is not adversely affected by treatment. In addition, laundering enhances entanglement and the aesthetic qualities attributed to this fabric property: surface texture (hand), resistance to pilling, drapeability, and the like. These subjective characteristics have been quantified using values from the Kawabata Evaluation System. A process for creating such fabrics has also been disclosed. The fabric passes through one or two treatment zones in which high pressure fluids (e.g., water) are directed at the fabric surface as the fabric moves away from a support member. In the case of dual treatment zones, a substantially lower pressure is used in the second treatment zone.Type: GrantFiled: July 10, 2001Date of Patent: April 15, 2003Assignee: Milliken & CompanyInventors: Nathan B. Emery, Franklin S. Love, III, Mathias B. Richardson, Joseph E. Rumler, Karen H. Stavrakas
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Patent number: 6539596Abstract: This invention relates to making high quality, soft and relatively elastic nonwoven fiber webs from polytrimethylene terephthalate (PTT). Staple PTT fibers are first manufactured. Usually, this involves spinning the polymer into fibers and then cutting them to a length of from 10 to 200 millimeters. Thereafter, the fibers are carded and hydroentangled. This combination of steps produces high quality PTT nonwoven fabrics, i.e., which are softer than fabrics from other materials, require less energy to hydroentangle, can be manufactured at higher carding rates, and have a higher dye yield. The staple polymers are first carded. This can be carried out in conventional carding machines such as roller top carding machines, layered carding machines, and flat top carding machines. The web is crosslapped to from 5 to 500 g/m2 basis weight web. Next, the webs are hydroentangled.Type: GrantFiled: September 21, 2001Date of Patent: April 1, 2003Assignee: Shell Oil CompanyInventors: Charles Chiu-Hsiung Hwo, Donald Albert Shiffler
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Patent number: 6516502Abstract: A composite nonwoven fabric is formed by providing a synthetic fiber web comprising staple length polymeric fibers, and a cellulosic fiber web, preferably comprising wood pulp fibers. Prior to integration of the webs, the synthetic fiber web is subjected to hydroentangling to form a partially entangled web, with the cellulosic fiber web thereafter juxtaposed with the partially entangled web for hydroentanglement and integration of the webs. Pre-entanglement of the synthetic fiber web desirably acts to minimize the energy input required for integration of the cellulosic fiber and synthetic fiber webs, and also desirably acts to abate loss of the cellulosic fibers during hydroentanglement and integration of the webs.Type: GrantFiled: March 12, 2002Date of Patent: February 11, 2003Assignee: Polymer Group, Inc.Inventor: Ralph A. Moody, III
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Publication number: 20030024092Abstract: 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: ApplicationFiled: August 13, 2002Publication date: February 6, 2003Inventor: Vittorio Orlandi
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Publication number: 20030019089Abstract: A method is disclosed for the production of a textile surface construction of at least one base layer and mesh-needled to the base layer a useful surface layer showing an optically non-uniform, substantially rapport-free upper side. Apart from staple fibers, the upper side contains a multitude of stochastically distributed fiber elements with a pre-selected, possible variable geometric form, which distinguish from the staple fibers in terms of color and/or fiber characteristics. In addition, the present invention relates to a textile surface construction which is produced by such a method.Type: ApplicationFiled: July 2, 2002Publication date: January 30, 2003Applicant: FILZFABRIK FULDA GMBH & CO.Inventor: Ralf Winter
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Publication number: 20030019088Abstract: The present invention is directed to enhancing the cleaning of surfaces by the contact application of a non-apertured nonwoven fabric having a three-dimensional image imparted therein. The three-dimensional image of the non-apertured nonwoven fabric induces the formation of lather due to pronounced surface projections that come in contact with the cleaning surface and provide air passageways that are parallel to the plane of the substrate. The imaged nonwoven fabric disclosed herein exhibits low linting qualities thereby reducing the potential of fiber contamination of the cleaned surface and is sufficiently durable that the sample can be used in a brisk manner.Type: ApplicationFiled: June 5, 2002Publication date: January 30, 2003Applicant: Polymer Group, Inc.Inventor: Nick Mark Carter
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Publication number: 20030021970Abstract: Nonwoven which comprises at least one hydroentangled web of thermoplastic discontinuous fibres, hydroentangled with an unstretched batt of independent, inelastic, continuous filaments oriented at random.Type: ApplicationFiled: July 1, 2002Publication date: January 30, 2003Inventor: Frederic Noelle
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Patent number: 6509079Abstract: A non-woven fabric having improved absorbent characteristics. The fabric has three different fiber arrays which are interconnected to produce a unique fiber distribution in the fabric.Type: GrantFiled: October 14, 1999Date of Patent: January 21, 2003Assignee: McNeil-PPC, Inc.Inventors: Susan Lynn Suehr, Linda J. McMeekin, James E. Knox, Frank J. Flesch
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Publication number: 20030009862Abstract: The present invention contemplates a method of forming a textile laminate or composite fabric from a plurality of woven fabric layers, with the method contemplating use of a three-dimensional image transfer device to facilitate efficient and commercially viable use of the method.Type: ApplicationFiled: May 20, 2002Publication date: January 16, 2003Inventors: Samuel Keith Black, Charles Keith Curtis, Shane James Moran
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Patent number: 6502288Abstract: A method of forming durable nonwoven fabrics by hydroentanglement includes providing a precursor web comprising a fibrous matrix of staple length fibers and/or substantially continuous filaments. The precursor web is subjected to hydroentanglement on a three-dimensional image transfer device to create a patterned and imaged fabric. Enhanced imaging is achieved by advancing the precursor web onto the movable imaging surface of the image transfer device at a rate substantially equal to the rate at which the image surface moves relative to one or more associated hydroentangling manifolds. Treatment with a polymeric binder composition enhances the integrity of the fabric, permitting it to exhibit desired physical characteristics, including strength, durability, softness, and drapeability. Mechanical compaction of the imaged and patterned fabric, such as by sanforizing, enhances the desired physical properties.Type: GrantFiled: February 9, 2001Date of Patent: January 7, 2003Assignee: Polymer Group, Inc.Inventors: Samuel K. Black, Charles Keith Curtis, Cheryl L. Carlson
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Patent number: 6487762Abstract: It is known to produce a colored pattern by a printing process or for example during weaving. The idea according to the invention is to produce a pattern by the water jets of a needling device in which, for colored patterning of a web-shaped nonwoven or a composite made of a nonwoven and a fabric or knit, the webs resting on a substrate moves past a nozzle beam located crosswise to the transport direction and are impacted by the water jets. The nonwoven provided as the upper layer of two layers is provided with one or more colors or is colored or printed itself and is placed on a second nonwoven or a woven or one that has a different color. Then both layers are subjected to the water jets that displace the fibers, with the colored fibers in the first layer being displaced into the second layer to produce a pattern on the underside of the second layer.Type: GrantFiled: November 21, 2000Date of Patent: December 3, 2002Assignee: Fleissner GmbH & Co., MaschinenfabrikInventor: Gerold Fleissner
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Patent number: 6478829Abstract: A method for producing a battery separator from a slurry of fibers which are resistant to the chemicals which are found in a battery, and a thermoplastic binder for the fibers. The method comprises the steps of casting the slurry onto a screen, draining the liquid of the slurry from fibers and binder which collect on the screen, and drying the fibers and binder without softening the binder. Subsequently, usually after the it has been rolled, packaged and shipped, the separator is cut to size and heated to soften the binder. In a preferred embodiment, the fibers are glass fibers having an average diameter less than 3 &mgr;m. In another preferred embodiment, the fibers are organic.Type: GrantFiled: February 8, 2000Date of Patent: November 12, 2002Assignee: KVG Technologies, Inc.Inventor: George C. Zguris
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Publication number: 20020160676Abstract: A stretchable laminate is formed by providing a hydroentangled nonwoven fabric exhibiting cross-direction extensibility and recovery, which fabric comprises a nonwoven web of staple length fibers of about 0.8 to 3.0 denier having a basis weight of about 1.0 to 4.0 ounces per square yard. A polymeric binder composition substantially uniformly applied to the nonwoven web imparts desired elasticity to the web, with the fabric exhibiting at least about 50% extensibility in a cross-direction thereof, and at least about 90% recovery in a cross-direction. The nonwoven web may comprise synthetic fibers, natural fibers, and blends thereof, as well as continuous filaments. An elastomeric composition comprising polyurethane or polyvinylchloride is applied to the extensible nonwoven fabric, which forms the stretchable laminate. The laminate provides a highly conformable and aesthetically pleasing leather-like product.Type: ApplicationFiled: February 19, 2002Publication date: October 31, 2002Applicant: Polymer Group, Inc.Inventors: Michael Putnam, Sergio Diaz de Leon, Herbert Hartgrove
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Publication number: 20020148085Abstract: Colored patterning of a web-shaped nonwoven or a composite made of a nonwoven and a fabric or knit is achieved by water jet needling. The nonwoven provided as the upper layer of two layers is provided with one or more colors or is colored or printed itself and is placed on a second nonwoven or a woven or one that has a different color. Then both layers are subjected to the water jets that displace the fibers, with the colored fibers in the first layer being displaced into the second layer to produce a pattern on the underside of the second layer. It is also possible, instead of colored fibers in the nonwoven of the upper layer, to move them when they are not colored into a second layer that can have any color.Type: ApplicationFiled: June 13, 2002Publication date: October 17, 2002Inventor: Gerold Fleissner
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Publication number: 20020146957Abstract: 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: ApplicationFiled: October 12, 2001Publication date: October 10, 2002Applicant: Polymer Group Inc.Inventors: Charles R. Fuller, Sheridan D. Ledbetter
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Patent number: 6460233Abstract: The invention concerns a method which consists in continuously: producing by carding (1) a web (10 from chemical fibers; subjecting the resulting web (1) to a hydro-entanglement using water jets, treatment which consists in: (a) consolidating the web (10) by the action of a first series of water jets (3), the web (10) being supported by a drum (4) comprising micro-perforations; (b) subjecting the consolidated web (10) to structuring, by the action of one or several series of water jets (12); depositing on the surface of the resulting structured lap (10a) natural fibers (14) by pneumatic layering (6); subjecting the resulting complex (20) to the action of another series of water jets (7) acting on the surface covered with natural fibers.Type: GrantFiled: January 9, 2001Date of Patent: October 8, 2002Assignee: Rieter PerfojetInventor: Frédéric Noelle
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Publication number: 20020142689Abstract: The present invention relates to a wet-laid non-woven sheet made from a essentially binder-free aramid floc, wherein the aramid floc includes at least 25 percent by weight of para-aramid floc based on the total weight of aramid floc only, and a process for making the sheet.Type: ApplicationFiled: January 23, 2001Publication date: October 3, 2002Inventor: Mikhail R. Levit
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Publication number: 20020121009Abstract: Improvements in hydroenhancement efficiency are obtained by operating a manifold in relative movement to fabric transported under the manifold so as to deliver a low energy to the fabric per pass in multiple passes on the fabric. For example, a low energy per pass of {fraction (1/10)} to {fraction (1/48)} the total energy delivered in 10 passes or more can obtain good enhancement results as compared to conventional hydroenhancing at higher total energy levels delivered in fewer passes. This results in greater enhancement efficiency and reduction in wasted energy, and also improves fabric coverage and reduces fabric shrinkage. The low-energy-per-pass, multiple-pass approach can be implemented with improved hydroenhancing equipment of reduced equipment size and cost which simulate multiple passes on the fabric. In one embodiment, a jigging hydroenhancing equipment transports the fabric back and forth under a stationary manifold between a pair of unwind/windup reels to simulate multiple passes on the fabric.Type: ApplicationFiled: February 15, 2002Publication date: September 5, 2002Inventors: J. Michael Greenway, Jackson Lawrence, Herschel Sternlieb, Frederick Ty, Frank E. Malaney
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Patent number: 6442809Abstract: Improvements in hydroenhancement efficiency are obtained by operating a manifold in relative movement to fabric transported under the manifold so as to deliver a low energy to the fabric per pass in multiple passes on the fabric. This results in greater enhancement efficiency and reduction in wasted energy, and also improves fabric coverage and reduces fabric shrinkage. The low-energy-per-pass, multiple-pass approach can be implemented with improved hydroenhancing equipment of reduced equipment size and cost which simulate multiple passes on the fabric. In one embodiment, a jigging hydroenhancing equipment transports the fabric back and forth under a stationary manifold between a pair of unwind/windup reels to simulate multiple passes on the fabric. Other embodiments employ a manifold or manifold system that is reciprocated, oscillated, or rotated to simulate multiple passes on the fabric.Type: GrantFiled: December 5, 1997Date of Patent: September 3, 2002Assignee: Polymer Group, Inc.Inventors: J. Michael Greenway, Jackson Lawrence, Herschel Sternlieb, Frederick Ty, Frank E. Malaney
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Patent number: 6442810Abstract: Improvements in hydroenhancement efficiency are obtained by operating a manifold in relative movement to fabric transported under the manifold so as to deliver a low energy to the fabric per pass in multiple passes on the fabric. This results in greater enhancement efficiency and reduction in wasted energy, and also improves fabric coverage and reduces fabric shrinkage. The low-energy-per-pass, multiple-pass approach can be implemented with improved hydroenhancing equipment of reduced equipment size and cost which simulate multiple passes on the fabric. In one embodiment, a jigging hydroenhancing equipment transports the fabric back and forth under a stationary manifold between a pair of unwind/windup reels to simulate multiple passes on the fabric. Other embodiments employ a manifold or manifold system that is reciprocated, oscillated, or rotated to simulate multiple passes on the fabric. Other variations for improving hydroenhancement are disclosed.Type: GrantFiled: April 25, 2001Date of Patent: September 3, 2002Assignee: Polymer Group, Inc.Inventors: J. Michael Greenway, Jackson Lawrence, Herschel Sternlieb, Frederick Ty, Frank E. Malaney
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Publication number: 20020116801Abstract: 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: ApplicationFiled: August 3, 2001Publication date: August 29, 2002Inventors: James Marshall Oathout, Phillip O. Staples, Donald Floyd Miller
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Patent number: 6440192Abstract: Disclosed is a process for manufacturing a filtration device. The process includes a fibre carding procedure which forms a web. The filtration device in accordance with the invention takes the form of a web having a single layer lap.Type: GrantFiled: December 9, 1998Date of Patent: August 27, 2002Assignee: ValeoInventors: Richard Guerin, Claude Legrand
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Patent number: 6430788Abstract: A process is disclosed for hydroentangling polymeric filament webs for production of low basis weight nonwoven fabrics. A three-dimensional image transfer device is employed for patterning a precursor web to form a fabric preferably having a rectilinear pattern. High-speed production of relatively low basis weight fabrics can be achieved, with the fabrics exhibiting desired softness, uniformity, and strength characteristics.Type: GrantFiled: December 30, 1999Date of Patent: August 13, 2002Assignee: Polymer Group, Inc.Inventors: Michael Putnam, Richard Ferencz, Marlene Storzer, Jian Weng
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Publication number: 20020104203Abstract: Improvements in hydroenhancement efficiency are obtained by operating a manifold in relative movement to fabric transported under the manifold so as to deliver a low energy to the fabric per pass in multiple passes on the fabric. For example, a low energy per pass of 1/10 to 1/48 the total energy delivered in 10 passes or more can obtain good enhancement results as compared to conventional hydroenhancing at higher total energy levels delivered in fewer passes. This results in greater enhancement efficiency and reduction in wasted energy, and also improves fabric coverage and reduces fabric shrinkage. The low-energy-per-pass, multiple-pass approach can be implemented with improved hydroenhancing equipment of reduced equipment size and cost which simulate multiple passes on the fabric. In one embodiment, a jigging hydroenhancing equipment transports the fabric back and forth under a stationary manifold between a pair of unwind/windup reels to simulate multiple passes on the fabric.Type: ApplicationFiled: February 11, 2002Publication date: August 8, 2002Inventors: J. Michael Greenway, Jackson Lawrence, Herschel Sternlieb, Frederick Ty, Frank E. Malaney
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Publication number: 20020100153Abstract: Disclosed are a method and an apparatus for manufacturing a non-woven fabric, in which a predetermined pattern of a forming body is transferred to a non-woven fabric immediately after or simultaneously with its formation by urging the non-woven fabric onto the forming body with water jets.Type: ApplicationFiled: November 16, 2001Publication date: August 1, 2002Applicant: Uni-Charm CorporationInventors: Hisashi Takai, Kazuya Okada, Takayoshi Konishi
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Patent number: 6412140Abstract: The suction slit between two sliding strips for a transport device transporting the textile material is filled by a cleaning strip which has holes on one side to carry away the fluid to be drawn off and preferably on the other side as well, on the top of a separating strip, to determine the width of the suction slit. In this fashion, the fibers loosened by needling come to rest on the ribs of the holes in the cleaning strip and not on the ribs on the openings in the suction tube and thus can be removed quickly from the suction device by replacing the cleaning strip. In addition, the width of the effective suction slit can be changed quickly by replacing it by another cleaning strip in which the width of one or two separating strips is dimensioned accordingly.Type: GrantFiled: June 6, 2000Date of Patent: July 2, 2002Assignee: Fleissner GmbH & Co., MaschinenfabrikInventor: Gerold Fleissner
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Patent number: 6412155Abstract: A device is known in which the bulky nonwoven arriving on a continuous belt for water needling is slowly compressed between a needling drum and another belt and at the same time is wetted by a first water curtain from the nozzle bank; its water jets first flow through the continuous belt and then the fiber web and ultimately the needling drum. There is a simpler and thus more economically producible device of this type when instead of the needling drum this compacting unit consists only of two continuous belts which however should be guided such that at the inlet the two working sides of the continuous belts slowly compact and press the incoming nonwoven, and then the belts lying on one another are moved past the nozzle bank as they are held pressed. Additional deflection rollers are used for this purpose.Type: GrantFiled: February 14, 2001Date of Patent: July 2, 2002Assignee: Fleissner GmbH & Co., MaschinenfabrikInventor: Gerold Fleissner
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Patent number: 6412154Abstract: The present invention provides a method for the production of bounded non-wovens carriers. The method includes providing a glass staple fiber containing non-woven which is pre-consolidated with a binder. The glass staple fiber non-woven is placed adjacent to one or more non-wovens of synthetic fibers and hydro-dynamically needling at a water beam pressure in the range of 100 to 400 bar.Type: GrantFiled: July 19, 2000Date of Patent: July 2, 2002Assignee: Johns Manville International, Inc.Inventor: Kurt Plötz
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Publication number: 20020078538Abstract: A method for creating a nonwoven laminate fabric has steps of depositing a first nonwovne layer on a moving support, depositing a second nonwoven layer over the first layer, and conveying the layers under a manifold. The manifold has a plurality of jet clusters separated from one another by a distance. Water is directed form the jet clusters onto the underlying layers to thereby create a laminated fabric. Because the jet clusters are separated from one another, the laminate fabric is “pattern entangled”. Bundling occurs along substantially linear lines, with much lighter bundling in regions between the linear bundling regions. The result is a fabric with regions of relative strong entanglement and other regions of much lighter entanglement. When three layers are laminated, with top and bottom layers of thin veneer and a center layer of pulp the method of the invention has been discovered to result in a laminate fabric with particular utility as a flushable wipe product.Type: ApplicationFiled: November 29, 2001Publication date: June 27, 2002Inventor: Mou-Chung Ngai
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Patent number: 6405416Abstract: Method and device for producing perforated nonwovens by hydrodynamic needling. A nonwoven with a basically clean hole structure on a drum with plastic elevations can be produced by energy-rich water jets. Depending on the thickness of the fibers used in the nonwoven, however, certain fibers can nevertheless be stretched transversely across a hole. In order to avoid or eliminate this, the perforated nonwoven is subjected to singeing flames after drying.Type: GrantFiled: December 20, 2001Date of Patent: June 18, 2002Inventor: Gerold Fleissner
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Patent number: 6381817Abstract: A composite nonwoven fabric is formed by providing a synthetic fiber web comprising staple length polymeric fibers, and a cellulosic fiber web, preferably comprising wood pulp fibers. Prior to integration of the webs, the synthetic fiber web is subjected to hydroentangling to form a partially entangled web, with the cellulosic fiber web thereafter juxtaposed with the partially entangled web for hydroentanglement and integration of the webs. Pre-entanglement of the synthetic fiber web desirably acts to minimize the energy input required for integration of the cellulosic fiber and synthetic fiber webs, and also desirably acts to abate loss of the cellulosic fibers during hydroentanglement and integration of the webs.Type: GrantFiled: March 23, 2001Date of Patent: May 7, 2002Assignee: Polymer Group, Inc.Inventor: Ralph A. Moody, III
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Patent number: 6378179Abstract: A system is provided for structurally reconstituting fibers from recycled waste fabric material, including cotton denim waste, wherein the reconstituted fibers are incorporated into a hydroentangled or needle punched product without binders or additives. A tearing line includes the application of steam and enzymes at a rate sufficient to remove surface additives from the fibers. The process completely opens the fibers and eliminates fraying, twisting and nonconformities. A fiber finishing process provides fibers which are substantially uniform with respect to a desired characteristic such as length, weight, type, or a desired blend thereof. The finishing process also provides a fiber web characterized by a uniform directional orientation of fibers, making the fibers more amenable to hydroentanglement. The resulting nonwoven product is characterized by high strength, fiber integrity and high uniformity and can be cross lapped to thereby provide greatly increased strength and absorbency.Type: GrantFiled: January 5, 2001Date of Patent: April 30, 2002Inventor: Gary F. Hirsch
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Publication number: 20020046449Abstract: Method and device for producing perforated nonwovens by hydrodynamic needling. A nonwoven with a basically clean hole structure on a drum with plastic elevations can be produced by energy-rich water jets. Depending on the thickness of the fibers used in the nonwoven, however, certain fibers can nevertheless be stretched transversely across a hole. In order to avoid or eliminate this, the perforated nonwoven is subjected to singeing flames after drying.Type: ApplicationFiled: December 20, 2001Publication date: April 25, 2002Inventor: Gerold Fleissner