Abstract: A method of continuously manufacturing tubular filter products includes rotating a mandrel in a first rotational direction, depositing nonwoven fibers on the mandrel to form a tube and continuously withdrawing the tube from the mandrel by engaging a peripheral surface of the tube with one or more detents extending radially from a surface of a roller. The roller rotates in a direction opposite the first rotational direction as the one or more detents engage the tube to a predetermined depth relative. For carrying out such a method, an apparatus includes a melt blowing die assembly for expelling melt blown fibers, a rotating mandrel arranged to receive the melt blown fibers from the melt blowing die assembly for allowing the melt blown fibers to accumulate in a body thereon and a rotating roll having a pattern of protruding detents.

Abstract: A laminated sheet made by bonding a nonwoven fabric to a non-porous waterproof, windproof and moisture permeable film. The bonding may be carried out by hot pressing in combination with a hot-melt adhesive and the laminated sheet may have a water vapor transmission rate of 1,000 to 10,000 g/m2·h. The laminated sheet may be further bonded to a face fabric, making the resulting structure particularly suitable for use in the construction of garments.

Abstract: The present invention relates to a shoe sole that includes a polyamide in the form of powder or microfibers admixed with a thermoplastic base material to improve the strength, durability, abrasion resistance, and other desirable physical properties of the shoe sole. Suitable thermoplastic base materials include rubber, polyurethane or ethylene vinyl acetate. The polyamide microfibers are randomly and nonuniformly oriented to reinforce the shoe sole in all directions.

Abstract: An acoustical liner with integral water barrier is provided. The liner includes a pad of fibrous material having a lofty, acoustically insulating portion and at least one heat-seared face of relatively higher density to provide water barrier protection. The acoustical liner is a non-laminate made from polyester, fiberglass, polypropylene and any mixtures thereof. A method of insulating a door including an exterior body panel and an interior fascia panel as well as a door for a vehicle are also disclosed and claimed.

Abstract: An absorbent article having a body-facing cover layer, a garment facing barrier layer and an absorbent element between the cover layer and the barrier layer. The cover layer is a non-woven fabric formed from an interconnected network thermoplastic polymer fiber elements. At least a portion of the non-woven fabric is three-dimensional having a plurality of raised regions, semi-raised regions and compressed regions, the raised regions having a lower fiber density relative to the semi-raised regions, the semi-raised regions having a lower fiber density relative to the compressed regions.

Abstract: A single or multi-ply disposable wiping article is disclosed. The disposable wiping article comprises at least one web layer and has a surface topography exhibiting regions of minimum and maximum calipers. A continuous polymer network defining bonded regions and a plurality of unbonded regions is bonded to the web layer. The continuous polymer network is preferably a thermoplastic adhesive. After curing, the thermoplastic adhesive can contract upon heating, thereby creating puckered regions of maximum caliper coincident unbonded regions. The minimum caliper of the web layer is coincident the bonded regions. Methods of making the web of the present invention are disclosed. One method includes providing a first web layer; providing a thermoplastic adhesive; applying the thermoplastic adhesive to the first web layer in a continuous network; curing the thermoplastic adhesive; and heating the thermoplastic adhesive to effect contraction of the thermoplastic adhesive.

Abstract: A net fabric to be processed into a net product capable of simplifying processing during manufacturing of a net product, leading to a reduction in manufacturing cost of the net product is disclosed. The net fabric is so constructed that the side edge portions of the net fabric, which are subjected to processing such as cutting, vibrational welding or the like, have a higher compressibility in the thickness direction than the middle portions of the net fabric. This ensures that the net fabric exhibits a better workability during the manufacturing of the net product using the net fabric in order to simplify the manufacturing process, and to lead to a reduction in manufacturing cost, even though the net fabric has a three-dimensional structure.

Abstract: The self-cleaning surfaces of objects have an artificial surface structure of elevations and depressions wherein the distances between said elevations are in the range of from 5 to 200 &mgr;m, and the heights of said elevations are in the range of from 5 to 100 &mgr;m, and at least said elevations consist of hydrophobic polymers or permanently hydrophobized materials, and said elevations cannot be detached by water or by water containing detergents.

Abstract: A fibrous blanket, formed with a profiled weight and thickness across the width and/or along the length of the blanket, may be used for various thermal and/or acoustical applications or formed through molding into a molded part having: a uniform thickness and variable density; a variable thickness and a uniform density; or a variable thickness and a variable density. When forming the fibrous blanket on a collection surface, the deposition of fibers on the collection surface is controlled, by manipulating the fiber containing gas stream and the fibers in the gas stream with secondary gas streams, to obtain a desired weight and thickness profile for the fibrous blanket.

Abstract: Disclosed are cleaning sheets having at least two regions, where the regions are distinguished by basis weight. In particular, the cleaning sheet comprises one or more high basis weight regions having a basis weight of from about 30 to about 120 g/m2 and one or more low basis weight regions, wherein the low basis weight region(s) have a basis weight that is not more than about 80% of the basis weight of the high basis weight region(s). Also disclosed are cleaning sheets having substantial macroscopic three-dimensionality, in addition to having multiple basis weights. Optionally, the macroscopically three-dimensional cleaning sheets can comprise a scrim material, which when heated and then cooled, contracts so as to provide a macroscopic three-dimensional structure. Macroscopic three-dimensionality is described in terms of “average height differential”, as well as the “average peak-to-peak” distance.

Abstract: An oil tone artificial leather sheet having a blend of an oily substance of viscosity 50-10,000 mPa·s at 30° C. and a supporting polymer on part or all of a nap surface of a napped sheet comprising a non-woven fabric of microfine fibers and polyurethane existing in the non-woven fabric, wherein raised fibers comprising the microfine fibers are present in part or all of at least one surface and are forming the nap surface, and which has a high-quality appearance, and the soft hand touch and touch of natural leather. The sheet is useful in, for example, the manufacture of shoes or the like.

Abstract: The invention relates to a multi-layer composite material which consists of at least two thermoplastic layers. At least one first layer is a of thermoplastic fiber fleece. The layers are bonded to one another at bonding zones by thermal bonding and the materials of the layer are at least partially fused together in the area of the bonding zones. Said bonding zones impart a three-dimensional structure to the composite material. The inventive composite material is characterized in that the three-dimensional structure of at least one bonding zone has the shape of a curvate edgeless trough in the cross-section and the longitudinal section. Said trough is configured by a bottom area forming a bonding center and by lateral areas which are attached thereto without transition. The layers are thermobonded to one other only in the bottom area of the trough.

Abstract: A molded wood composite article man-made from wood fibers or wood particles on at least an upper, molded surface of the article, and a method of manufacturing the article to include a relatively uniform density, detailed design contours and textured aesthetics on one or more molded depression-interior inclined surfaces, while preventing embrittlement, softness and blistering of the article along the depression-interior inclined surfaces. These attributes are achieved by molding one or more depressions into an initially planar layer of cellulosic material, wherein the molded depressions have a length to depth ratio in the range of about 5.0 to about 8.5, and have one or more inclined walls that have upper surfaces, along essentially an entire inclined span, that include detailed design contours, including adjacent curved and planar portions, e.g., bead and cove.

Abstract: A type of relief engraved doorplate, comprising an inside plate that is composed of a first Bakelite layer and a second Bakelite layer, said first Bakelite layer and second Bakelite layer being composed of coarse wood dust and fine wood powder respectively, the second Bakelite layer enveloping the exterior of the first Bakelite layer before they are subjected to heated compression molding to obtain the relief engraved pattern on the top and bottom panels of the inside plate; and, at least one pair of outside decorative plates, including at least a layer of thin wood plate and a layer of water-resistant paper, the water-resistant paper being glued onto the thin wood plate and put in a compression mold with a pattern that is opposite to that of the inside plate, to obtain a depressed pattern on one side of the outside decorative plate, which is opposite to the relief engraved pattern on the inside plate, and then it is fitted to the top and bottom panels of the inside plate and subjected to compression molding

Abstract: A reverse molded fiberboard panel; a wainscot kit comprising a plurality of differently sized reverse molded panels, and a planar finishing or spacer panel, adapted to completely cover any size wall between a wall base board and a wall chair rail; and a method of reverse molding a loose cellulosic mat, in a single pressing step, to provide one or more relatively high density, raised panels without requiring preliminary pressing, or other pre-shaping step, such as scalping. The reverse-molded panels are molded in a conventional, multi-opening fiberboard press, in a single pressing step process, while achieving excellent transfer of mold detail (embossing fidelity) without visually noticeable fiber fracture.

Abstract: There is disclosed an absorbent article including an absorbent layer and a liquid-permeable surface sheet placed on a liquid-receiving side of the absorbent layer for introducing excreted liquid from the human body to the absorbent layer. The surface sheet is of a corrugated configuration to have valleys and peaks extending in a longitudinal direction of the article and alternately arranged in a transverse direction perpendicular to the longitudinal direction. Each valley has a connecting part raised to connect between two adjacent peaks.

Abstract: An in-line formed, non-laminated web is suitable for use as a composite fluid distribution and fluid retention layer in a disposable absorbent article. The web can be formed by selective deposition of airlaid materials including absorbents, such as pulp and superabsorbents, together with binder fibers. The web so constructed will have a plurality of intermingled lower basis weight areas and higher basis weight areas coexisting and distributed in at least a central region of the web, the alternations crossing the X axis or Y axis, or both, of the web, with the higher basis weight areas being a greater thickness in the Z-direction than the lower basis weight areas. The web so constructed will further have no discrete material boundaries between the lower basis weight stripes and the higher basis weight stripes. Further the necessity of later processing on the web to achieve a ridged structure is removed and the fibers will remain whole and undisturbed.

Abstract: Paper sheets useful for tissues, paper towels, napkins, disposable absorbent products and the like can be made to exhibit a high degree of wet resiliency. This property is achieved by using a combination of high yield pulp fibers (such as bleached chemithermomechanical pulp fibers) and a wet strength agent in an uncreped throughdrying process. The resulting product, when wetted, can spring back after being crumpled in one's hand.

Abstract: 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.

Abstract: Multilayer meltblown fibrous webs, as well as apparatus and methods of forming the webs. The webs are produced on a rotating collector that also moves parallel to its longitudinal axis. The webs are thus formed in a helical process, and the resulting tubular web is separated in a direction parallel to a helix angle. By separating the tubular web in a direction parallel to the helix angle, a flat multilayer meltblown fibrous web is provided that allows for incorporation of feathered edges formed during the article's manufacture.

Abstract: A liquid absorbent composite is disclosed. The composite comprising a first substrate and a laminate or bonded mixture, the laminate or bonded mixture comprising a mixture of binder particles and super-absorbent polymer particles, wherein the binder particles are on average smaller than the super-absorbent polymer particles, wherein at least some of the binder particles coalesce at least some of the bonded mixture to the substrate, wherein at least some of the bonded mixture forms a three-dimensional array of elongated channels upon contact with a liquid.

Abstract: The present invention relates to a process for manufacturing a gypsum-based substrate. The process includes the steps mixing gypsum and water to produce a gypsum slurry, providing a synthetic polymeric fibrous sheet on one side of a layer of the gypsum slurry, and adhering to the wet gypsum to the sheet with an adhesive strength of at least 7.5 lb. The present invention is also directed to a gypsum board comprised of first and second polymeric fibrous sheets adhered to opposite sides of a wet gypsum core, wherein the first surface of the first sheet and the first surface of the second sheet have pores containing set gypsum and the first and second sheets adhere to said wet gypsum core with an adhesive strength of at least 7.5 lb.

Abstract: A multilayer thermally bonded nonwoven fabric which is particularly useful as a liner in an absorbent product is described. The fabric includes at least two prebonded nonwoven webs having a multiplicity of intralaminar bonds bonding the fibers of the prebonded nonwoven webs together. The prebonded webs are secured together to form the fabric of the invention by a plurality of interlaminar thermal bonds formed of discrete areas of compressed and fused fibers of the prebonded webs.

Abstract: A process for manufacturing a part includes the steps of molding a thermoplastic material into a generally planar sheet form having a textured surface on at least one side. The textured surface is defined by a plurality of protuberances with at least one side wall extending outwardly from the sheet. The thermoplastic material is molded with a predetermined pressure between a die and within a perforated insert. The molded thermoplastic material sheet and perforated insert are removed from the die after molding. The molded thermoplastic material sheet is sintered at a predetermined temperature for a predetermined period of time. The molded, sintered, thermoplastic material sheet is stripped from the perforated insert. The sheet can be masked for etching if desired. The sheet can be inserted into a molding die, where a dissimilar material is introduced into the die under pressure.

Abstract: A base textile with a camouflage pattern is subjected to hot fluid streams to create flat regions and puckered or wrinkled regions, enhancing the three dimensional characteristics of the resulting material.

Abstract: The perceived softness of embossed tissue can be increased greatly while avoiding nesting when a particular pattern is embossed into the tissue. This pattern combines relatively shallow stitchlike bosses with deeper more sharply defined signature bosses. The stitchlike bosses can be rounded and arranged in wavy flowing intersecting lines. The signature bosses can be arranged in regions framed by the intersecting wavy flowing lines.

Abstract: A nonwoven fabric from spun fibers wherein the density of the spun fibers in the fabric varies between strips of relatively high density and strips of relatively low density. The strips extend along the length of the fabric in the machine direction in an alternating pattern, with the high density strips separated from each other by low density strips. The alternating high density and low density strips provide the fabric with a higher percent elongation in the cross direction than in the machine direction. The alternating pattern is achieved through use of a pattern screen defining a plurality of elongated air permeable regions separated by elongated substantially or relatively air impermeable regions, the elongated regions extending in the machine direction in an alternating pattern, with the air permeable regions separated from each other by the substantially or relatively air impermeable regions.

Abstract: Disclosed are cleaning sheets having substantial macroscopic three-dimensionality. Optionally, the macroscopically three-dimensional cleaning sheets can comprise a contractable material (e.g., a scrim material), which when heated and then cooled contracts so as to provide a macroscopic, three-dimensional structure. Macroscopic three-dimensionality is described in terms of “average peak-to-peak distance” and “surface topography index”, as well in terms of “average height differential”. Also disclosed are cleaning implements comprising a handle and the described cleaning sheets. Processes for the sheets, benefits of the processes, and articles of manufacture are also disclosed.

Abstract: In a fibrous web, press-welded line portions are formed, and press-welded dot portions are formed in portions other than the press-welded line portions. The formation of the press-welded line portions makes it possible to raise the surface of the fibrous web, to increase the bulkiness of the nonwoven fabric and to make the nonwoven fabric soft. Further, figures are drawn by the press-welded line portions, whereby the nonwoven fabric comes to have an excellent appearance in comparison to a conventional nonwoven fabric.

Abstract: The invention relates to an antiballistic shaped part composed of a stack of composite layers which layers are not linked to one another. Each composite layer having two or more monolayers of unidirectionally oriented fibers in a matrix. The fibers in each monolayer being at an angle to the fibers in an adjoining monolayer, and composed of poly(p-phenylenebenzobisoxazole. The composite layer containing at most 10% by weight of an elastomeric matrix material (calculated on the basis of the total weight of the composite layer), and having an areal density of at most 500 g/m2. The fiber content in each monolayer being between 10 and 200 g/m2. The invention also relates to method for fabricating said shaped part and body armour in which the shaped part is used.

Abstract: An article for absorbing fluid includes a fluid-storage region and a fluid receiving region. The fluid receiving region releases fluid to the fluid storage and has a dry laid web of staple fibers with a high bulkiness. The article may be used for treating female incontinence.

Abstract: An improved method for forming a vehicle trim panel, such as a headliner, utilizes a zig zag path to deposit fibrous pieces onto a fibrous layer to form part of the trim panel. In one method, the fibrous pieces are laid down in a zig zag pattern that does not extend across the entire lateral width of the layer. In this way, the designer can easily achieve selected areas having a greater amount of fibrous pieces. This allows the designer to achieve selected high density or thicker portions in the layer without requiring the entire layer to have the same amount of fibrous pieces. This results in greater control over the design of the layer, and also reduces the amount of fiber which must be utilized to form the layer.

Abstract: A molded wood composite article man-made from wood fibers or wood particles on at least an upper, molded surface of the article, and a method of manufacturing the article to include a relatively uniform density, detailed design contours and textured aesthetics on one or more molded depression-interior inclined surfaces, while preventing embrittlement, softness and blistering of the article along the depression-interior inclined surfaces. These attributes are achieved by molding one or more depressions into an initially planar layer of cellulosic material, wherein the molded depressions have one or more inclined walls that have upper surfaces, along essentially an entire inclined span, that include detailed design contours, including adjacent curved and planar portions, e.g., bead and cove.

Abstract: A non-through air dried paper web and method of making such a paper web are disclosed. The paper web includes at least two regions of different density and at least two regions of different basis weight. In one embodiment, the paper web includes a relatively high basis weight continuous network region, a plurality of discrete, relatively low basis weight regions dispersed throughout the relatively high basis weight continuous network region, and a plurality of discrete, intermediate basis weight regions circumscribed by the relatively low basis weight regions.

Abstract: An improved method for forming a vehicle trim panel, such as a headliner, utilizes a zig zag path to deposit fibrous pieces onto a fibrous layer to form part of the trim panel. In one method, the fibrous pieces are laid down in a zig zag pattern that does not extend across the entire lateral width of the layer. In this way, the designer can easily achieve selected areas having a greater amount of fibrous pieces. This allows the designer to achieve selected high density or thicker portions in the layer without requiring the entire layer to have the same amount of fibrous pieces. This results in greater control over the design of the layer, and also reduces the amount of fiber which must be utilized to form the layer.

Abstract: An absorbent structure comprising freestanding osmotic absorbent sites disposed on or within a capillary substrate. The sites extend outwardly normal to the plane of the absorbent structure or fill apertures within the plane of the absorbent structure. Upon imbibing liquids, the sites of osmotic absorbent can expand without constraint from the substrate.

Abstract: A 3-dimension thermoformed bicomponent fiber nonwoven material comprising a lofty bicomponent material layer forming a plurality of peaks separated from one another by channels and having a basis weight in the range of about 0.5 to 7.0 ounces per square yard. The bicomponent material layer comprises a structural component and a heat activatable adhesive component suitable for thermoforming. Also disclosed are various configurations of this material suitable for use in absorbent personal care articles such as sanitary napkins, disposable diapers, incontinent-care pads and the like.

Abstract: A process for preparing GMT/foam composites in an integral process without the prior preparation of a separate consolidated GMT part produces lightweight load-bearing structures suitable for use as vehicle components such as load floors, seatbacks, and the like. The structures have fully GMT-encapsulated foam cores abutting at least partially consolidated GMT layers and at least one fully densified GMT portion. The structures may be economically and rapidly molded without resort to necessary adhesives for assembly.

Abstract: A package including a web material that exhibits an elastic-like behavior along at least one axis when subjected to an applied and subsequently released elongation. The web material includes a strainable network having at least two visually distinct regions of the same material composition. The first region undergoes a molecular-level deformation and the second region initially undergoes a substantially geometric deformation when the web material is subjected to an applied elongation in a direction substantially parallel to the axis of elongation.

Abstract: The perceived softness of embossed tissue can be increased greatly while avoiding nesting when a particular pattern is embossed into the tissue. This pattern combines relatively shallow stitchlike bosses with deeper more sharply defined signature bosses. The stitchlike bosses can be rounded and arranged in wavy flowing intersecting lines. The signature bosses can be arranged in regions framed by the intersecting wavy flowing lines.

Abstract: The general application of the invention is a finishing process for an air-laid nonwoven web composed of short cellulosic fibers, bound by a thermoplastic binder and having a less than perfect homogeneous fiber distribution. In the invention, the process includes deforming under hot stress the web between an undeforming hard engraved cylinder and a slave cylinder having a hardness between about 60 and 90 degrees shore hardness D. The slave cylinder is resilient and deformable at the pressure applied to it by the engraved cylinder. In particular, the invention applies to the manufacture of webs and of disposable, decorative napkins.

Abstract: An essentially homogeneous, water-resistant, water-absorbent rod, containing a cohesive spiral winding of water-resistant, water-absorbent sheet material, in which the rod can absorb at least 50% by weight of water when placed in water at 23.degree. C. for one minute. Methods for fabricating and using this rod are also described.

Abstract: This invention relates to improved elongation properties for flash-spun plexifilamentary film-fibrils. The technique for obtaining the improved properties is to increase the length to diameter ratio of the spin orifice and to reduce the ratio of polymer in the spin solution.

Abstract: A multiple ply tissue paper structure is disclosed. The paper structure includes a ply comprising discrete relatively low density regions dispersed throughout a relatively high density continuous network. The paper structure also include a ply which does not include discrete relatively low density regions dispersed throughout a relatively high density continuous network. The different structures of the two plies provide improved absorbency over a homogeneous multiple ply structure.

Abstract: There is disclosed a thermally bonded spunbond web of thermoplastic filaments and a nonwoven fabric laminate comprising an internal layer of meltblown thermoplastic microfibers sandwiched between two layers of spunbond thermoplastic filaments. The spunbond web and the spunbond layers of the fabric laminate consist of thermoplastic filaments which are formed from a mixture of a thermoplastic polymer and an effective amount of a nucleating agent. The layers are bonded by thermal spot bonding. In the preferred embodiment, the thermoplastic polymer is polypropylene with a melt-flow rate of at 230.degree. C. of or greater than 12 grams per ten minutes. Also in the preferred embodiment, the nucleating agent constitutes from about 0.1 to 0.3 percent by weight of the mixture of polypropylene and nucleating agent.

Abstract: A structural component is disclosed which includes first and second extrusions each consisting of a plurality of strengthening fibers. A third extrusion comprises a thermoplastic matrix that encapsulates the first and second extrusions. The three extrusions together define a non-planar cross sectional configuration of substantially transverse dimensions sufficient to provide component strength and stiffness. Also disclosed is an elongated structural component formed by extrusion consisting of a first extruded portion of a plurality of segments of strengthening fibers joined in a thermoplastic matrix and a second extruded portion comprising a thermoplastic matrix compatible with the first extruded portion. The first and second extruded portions together define a predetermined non-planar cross sectional configuration of substantially transverse dimensions sufficient to provide component strength and stiffness.

Abstract: A molded core component includes a center plane piece and at least one wall extending from the center plane piece. The wall preferably includes contours which form a multiplicity of pods, cells, or protrusions integral with the center plane piece. The core component is preferably inserted into the space or void formed by two prefabricated molded fiberboard doorskins, wherein the center plane piece lies substantially in the central plane of the door product. Processes for the production of a molded core component and a composite door product are also disclosed.

Abstract: An elevated carpet system and method of applying the carpet system to a surface to protect the underlying surface from damaging exposure to water, salt and moisture. The carpet system includes a waterproofing membrane layer applied to the underlying surface and a weather-resistant carpet having a nibbed vinyl backing defined by an array of spaced nipple projections. The projections support the carpet in spaced relation above the waterproofing membrane layer so that an air gap is maintained therebetween to promote ventilation and drying of moisture which seeps through the carpet.

Abstract: A panel which comprises a substrate of transparent or translucent material having applied to one or both sides a design superimposed on, or forming part of, an opaque pattern so that the design on one side of the panel cannot be seen from the other side. This is a Reissue of a Patent which was the subject of a Reexamination Certificate No. B1 4,673,609, dated Jul. 25, 1995, Request No. 90/003,201, Sep. 21, 1993.

Abstract: Nonwoven fabrics having a fibrous background portion in one plane thereof and raised fibrous portions in another plane thereof. There may be two types of raised portions. In one type, the basis weight of the raised portion is substantially the same as the basis weight off the background portion. In another type of raised portion, the basis weight is greater than the basis weight of the background portion. The raised portions are joined to the background portion try a fibrous transition region.