Abstract: A nonwoven structure is provided having a fiber with a lower melting point than conventional fibers, preferably less than 110° C., more particularly less than 90° C., more particularly less than 80° C. The fiber may also include an energy receptive additive that provides rapid heating when subjected to dielectric energy such as radio frequency or microwave radiation. When included in a structure and subjected to electromagnetic radiation, the fiber is heated by contact with materials like pulp and superabsorbent, which absorb electromagnetic radiation.

Abstract: A wet-laid nonwoven reinforcing mat includes a base web having about 10 to about 80 percent by weight glass fibers, about 20 to about 90 percent by weight polyethylene terephthalate fibers and polyvinyl alcohol in an amount of about 5 to about 35 percent of the combined weight of the glass fibers and the polyethylene terephthalate fibers. The reinforcing mat also includes a secondary binder in an amount of about 10 to about 30 percent of the total weight of the base web.

Abstract: This invention relates to nonwoven fabrics with advantageous characteristics and the method to produce these fabrics. Advantageously, the fabrics of the subject invention have increased thickness (loft) compared to conventional nonwoven fabrics and have high air permeability and open space while maintaining softness and strength at the same basis weight.

Abstract: Fibers or filaments made by using a spinneret orifice having a regular polygonal cross-section. Melt-spinnable thermoplastic polymer is melted and extruded through a spinneret orifice having a regular polygonal cross-section to form molten filaments. The molten filaments are then solidified, and optionally are subsequently subjected to stretching and false twisting processes.

Abstract: Dual glass fibers can be processed into coherent webs and felts by first blending the dual glass fibers with an equal or greater amount of uncrimped fibers. Optionally, other crimped fibers can be added without significant impact on processibility.

Abstract: A bulky fibrous fabric is provided, made by a process comprising obtaining an unbonded, consolidated batt of fibers wherein each fiber has a ribbon-shaped cross-section, and needling said batt to obtain the bulky fibrous fabric. The fabric has a surface area of at least 2 m2/g and a thickness/basis weight ratio of at least 0.005 mm/g/m2 (7 mil/oz/yd2) The fabric has utility particularly as a dry wipe for cleaning and dusting.

Abstract: A sound absorption material excellent in moldability, wherein a filament nonwoven fabric (A) having a weight of 20 to 200 g/m2 and including fiber having a fiber diameter of not more than 15 &mgr;m and a staple fiber nonwoven fabric (B) having a weight of 50 to 2000 g/m2 and a fiber diameter of 7 to 40 &mgr;m are laminated and integrated, and 5 to 50% by mass of the staple fiber nonwoven fabric (B) is a thermally adhesive fiber having a melting point of 100 to 190° C.

Abstract: A biodegradable porous device for tissue engineering is disclosed, which comprises (A) a porous polymeric scaffold comprising a co-continuous phase of a first biodegradable polymer and a second biodegradable polymer which are incompatible with each other, wherein the first biodegradable polymer contains a continuous network of large, interconnected pores, and the second biodegradable polymer contains small, partially interconnected pores; (B) a biodegradable polymer fiber dispersed in, and compatible with the matrix of the first biodegradable polymer; and optionally (C) an active ingredient provided in the polymeric scaffold.

Abstract: A process for treating high-loft porous fabrics with topically applied active agents is provided and includes the steps of applying an active agent to a surface of the fabric and forcing the active agent through the entirety of the web by directing a focused stream of air or steam, at a rate above 25 meters/second, into and through the web and also applying a vacuum to the opposite side of the web to collect the air, condensate and/or active agent drawn out of the fabric. Fabrics having a thickness in excess of 50 mils with densities between 0.2 g/cc and 0.008 g/cc have a topically applied active agent substantially uniformly distributed throughout the entire fabric thickness.

Abstract: The subject invention concerns nonwoven fabrics containing filaments of at least two different cross sections. The subject invention further pertains to methods used to produce these fabrics. In an embodiment specifically exemplified herein, the nonwoven fabric of the subject invention is made of nylon.

Abstract: This invention relates to a process for making polymer blends and copolymers by ultrasonic treatment during or after mixing the polymers. In the process of the present invention, an unexpected phenomenon occurs. The process brings about enhancement of the mechanical properties when compared with identical blends not subjected to ultrasonic treatment. The ultrasonic treatment of the blends is believed to enhance intermolecular interaction and improve adhesion between dissimilar polymers and make chemical bonds between polymers that otherwise are incompatible or immiscible with each other.

Abstract: A plurality of substantially parallel continuous filaments, e.g. of cellulose acetate or rayon, and preferably newly formed, are consolidated or partially stabilised, e.g. by application of solvent and pressure, by hydroentanglement, by embossing, or by crimping and stretching. The filament assembly or subassemblies thus produced are further stablised by folding, bundling, twisting or intertwining, e.g. to form braids (10), and are then bonded to a carrier layer or sandwiched between outer layers (12, 14), e.g. by hydroentanglement, melt blowing, spinbonding etc. The stablised filament assemblies may be arranged spaced transversely and may be cut just prior to bonding so as also to provide longitudinally spaced three dimensionally thicker regions, ready for conversion to finished products such as absorbant feminine hygiene products or medical swabs or the like.

Abstract: A method of making a non-woven fibrous media, combining high vapor permeability and low liquid permeability, includes the steps of providing a non-woven fabric formed from fibers that are prematurely crystallized during fabric formation and have a wide heat of fusion range distribution, and calendering the fabric to soften the small polymer crystals therein of low heats of fusion, but not the relatively larger polymer crystals therein of relatively higher heats of fusion, thereby to retain high vapor permeability while providing low liquid permeability. The polymer is preferably isotactic polypropylene.

Abstract: An artificial leather sheet substrate comprising: a fiber entangled nonwoven fabric composed of bundles of a polyamide-based microfine fibers comprising a polyamide or a polyamide composition having a hot toluene swelling degree of 2 to 10%, and having a fineness of 0.1 decitex or less; and an elastic polymer and a releasing agent between the bundles, the releasing agent being also added to the inside of the bundles. This leather-like sheet substrate is soft and is excellent in denseness, dyeability and color fastness. The sheet is suitable, as a suede-like artificial leather or a grain surface like artificial leather, for fields for which high quality is required, for example, for clothing. The sheet is high in denseness of surface napped fiber and is excellent in hand touch, writing effect and draping ability, especially as a suede-like artificial leather.

Abstract: A fabric for moisture management which contains first fibers and second fibers. The first fibers have either circular cross-sections or multiply indentations along the longitudinal side of the fibers. The second fibers have multiply indentations along the longitudinal side of the fibers. The capillary action of the first fibers is induced by either the inter-fiber spaces alone (i.e., where the fibers have circular cross-sections) or a combination of both the inter-fiber spaces and the indentation spaces, which are formed due to indentations. The capillary action of the second fibers is induced by the combination of both the inter-fiber spaces and the indentations spaces, which are formed due to indentations. The capillary action of the second fibers is greater than that of the first fibers so that the moisture absorbed by the first fibers can be easily transferred to the second fiber.

Abstract: A filter media having a high dust holding capacity and increased stiffness is provided. The filter media includes a middle filtering layer formed from at least one meltblown layer and having a dust entering side and a dust exiting side. A first outer layer is disposed on the dust entering side of the filter media and is formed from a meltblown polymer fiber web, and a second outer supporting layer, or backing, is disposed on the dust exiting side of the filter media, and is formed from a spunbond polymer fiber web and, optionally, a meltblown polymer fiber web. The filter media is particularly useful to form ASHRAE filters for applications including heating, refrigeration, and air conditioning filtration.

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: Disclosed is an apparatus and a method for the manufacture of continuous micro label strips containing a unique identifier, and the placement of the micro label strips into various articles such as cloth and clothing. Microfilm bearing a plurality of transverse or longitudinal rows, each row including one or more unique like identifiers, is longitudinally severed into continuous micro label strips. The strips, or portions thereof, are then woven, sewn or knitted into or onto cloth or clothing.

Abstract: A nonwoven textile substrate formed from microfibers with a polyuerthane matrix fully and/or partially impregnated therein, a nonazo disperse dye within microfibers, including the surface, and the matrix. The dyed fibers having an L value of about 35 or less, an &Dgr;E light fastness of about 6 or less when subjected to about 225 kilo-joules, and a long term crock of at least about 1.5.

Abstract: A composite fabric for use in dewatering high solids content fluid materials comprising a multiplicity of corrugated strands of compression resistant material, and one or more sheets of porous material bonded along its length at sheet bonding locations to the strands, some of which strands have arcuate portions projecting from the strands between those sheet bonding locations. The sheet-like composite may be incorporated where there is a need to dewater high solids content fluids such as in disposable garments such as diapers or training pants.

Abstract: Composite nonwoven material through which liquid can pass at a high speed and having an excellent resistance to rewetting and fluffing. The material comprises at least one first layer (2) of combed-type fibres and a second layer (3) of combed-type fibres, the fibres of the first layer having a denier greater than that of the fibres of the second layer, the layers being joined to one another by needling. Application to absorbent sanitary articles.

Abstract: Dual glass fibers can be processed into coherent webs and felts by first blending the dual glass fibers with an equal or greater amount of uncrimped fibers. Optionally, other crimped fibers can be added without significant impact on processibility.

Abstract: Spunbond multicomponent filaments and nonwoven webs made from the filaments are disclosed. In accordance with the present invention, the multicomponent filaments contain a crimp enhancement additive. Specifically, the crimp enhancement additive is added to the polymeric component that has the slower solidification rate. The additive enhances crimp, allows for highly crimped filaments to be made at low fiber linear densities, improves the integrity of unbonded webs made from the filaments, and produces webs with improved stretch and cloth-like properties. The additive incorporated into the filaments is a random copolymer of butylene and propylene.

Abstract: Disclosed is a battery separator consisting essentially of a nonwoven fabric having a substantially unilayered structure, wherein an apparent total surface area of fibers per a surface density of the nonwoven fabric is 20 m2/m2 or more, a thickness of the nonwoven fabric is 0.1 mm or less, a uniformity index of the nonwoven fabric is 0.15 or less, and the nonwoven fabric contains fine fibers having a fiber diameter of 4 &mgr;m or less.

Abstract: A moisture vapor permeable, substantially liquid impermeable composite sheet material includes a powder-bonded nonwoven web adhered to a moisture vapor permeable thermoplastic film. The nonwoven web includes a first layer comprised primarily of fibers that are compatible with an adhesive used to bond the web, and a second layer comprised of a blend of fibers, some of which are compatible with, and some of which are incompatible with the bonding adhesive and the thermoplastic film. A method for making the composite sheet material and an item of apparel made from the sheet material are also provided.

Abstract: The laminated sheet of the present invention comprises (A) a nonwoven fabric having a basis weight of 30 g/m2 or less made of polyolefin-based ultra-fine fibers of 5 &mgr;m or less in average fiber diameter; (B) a heat-bonding nonwoven fabric having a basis weight of 15 g/m2 or less made of thermoplastic elastomer ultra-fine fibers of 15 &mgr;m or less in average fiber diameter; and (C) a spun-bonded nonwoven fabric having a basis weight of 30 g/m2 or more made of thermoplastic polymer fibers. The nonwoven fabric A and the spun-bonded nonwoven fabric C are face-bonded via the heat-bonding nonwoven fabric B. The laminated sheet is excellent and well-balanced in a wind breaking performance, a water vapor permeability and a waterproof performance. The laminated sheet is also excellent mechanical properties and durability. With these excellent properties, the laminated sheet is suitably used as house wrap materials and roof underlay sheets.

Abstract: Nonwoven sheet materials, and adhesive articles formed therefrom are provided that are made with fibers, preferably tensilized nonfracturable staple fibers, and binder fibers, and formed from a combination of interbonding, smooth roll calendering, and pattern embossing techniques. These sheet materials are especially useful as tape backings that are finger tearable in the cross web and the down web directions and also possess a number of other desirable properties, including acceptable tensile strength and enhanced overtaping, for example. A nonwoven sheet material, and adhesive article including the same, can include an embossed pattern having a variety of discontinuous configurations to enhance tearing properties in both the down web and cross web directions.

Abstract: A targeted elastic laminate material is provided having at least one low tension zone with first filaments having a first basis weight and at least one high tension zone having second filaments with a second basis weight greater than the first basis weight. The second basis weight is greater due to increased average thickness of the second filaments and/or increased frequency of second filaments relative to the first filaments. Methods and modifications of those methods are provided to produce a targeted elastic laminate material according to the preferred embodiments of this invention.

Abstract: A composite absorbent structure and method are disclosed including providing a first wicking layer having preferred liquid transport properties in a preferred contact with a second absorbent retention layer. The composite absorbent structure of the present invention provides preferred liquid transport and liquid retention properties. The composite absorbent structure has a first wicking layer in a preferred contact with the second retention layer by a novel intimate contact means effective to achieve a Contact Intimacy Ratio providing the preferred liquid transport and liquid retention functions when the first wicking layer and the second absorbent retention layer are combined together in accordance with the present invention.

Abstract: Aromatic polyamide fibers which have a crystalline structure having (1) crystal size (A) in a (110) plane of 7.5 nm, (2) crystal size (B) in a (200) plane of 8.2 nm and (3) a product A×B of 61.50 to 630.00, and exhibit a thermal linear expansion coefficient of −1.0×10−6/° C. to −7.5×10−6/° C. and thus a high dimensional stability even upon moisture-absorbing and desorbing, are useful for forming a resin-reinforcing fiber sheet, a pre-preg containing the fiber sheet, and a laminate for, for example, an electric insulating material or electric circuit board, having an excellent cutting, shaving, perforating or laser processability and capable of forming a smooth cut, shaved or perforated face.

Abstract: A spun nonwoven fabric contains monofilaments and bicomponent filaments, the spun nonwoven fabric having, over its cross section, different quantities of the bicomponent filaments. The bicomponent filaments contain at least two outward-facing segments made of a binding component. The proportions of bicomponent filaments over the cross sectional planes of the spun nonwoven fabric can be in a range of approximately 1% to 100% by weight. The cross sectional planes of the nonwoven fabric containing the different proportions of bicomponent filaments transition into one another without detectable phase boundaries. The apparatus for manufacturing the nonwoven fabric contains at least one, and may contain up to forty or more, spinneret devices, such as rectangular spinneret plates or round spinneret disks. The spinneret devices may be arranged in rows or in staggered arrangement above a linearly moving collector belt.

Abstract: A printed circuit board is made from at least one non-woven sheet or web layer comprising at least 50% by weight acrylic fibers, with any balance substantially electrically non-conductive fibers, filler, and binder. The sheet or web is preferably made by the foam process, and may contain 60-80% straight polyacrylonitrile fibers and 40-20% fibrillated (pulp) ones. The web or sheet is preferably compressed by thermal calendering so that it has a density of about 0.1-1 grams per cubic centimeter; and the web or sheet may have a basis weight of between about 20-120 grams per square meter. The web or sheet may also have a 1-40% of substantially electrically non-conductive organic or inorganic binder, or may be substantially binder free.

Abstract: A liquid and stain-resistant antimicrobial fabric is provided that can withstand the high temperatures required for transfer printing. A coating composition comprising a copolymer composition, an antimicrobial agent and a fluorochemical composition is applied to fabric such as polyester, to produce the coated fabric. The liquid and stain-resistant, antimicrobial, printed fabric retains its natural texture, is durable and easy to handle.

Abstract: Nonwoven fibrous webs having substantial strength in the direction normal to their planes and the preparation of such webs.

Abstract: A building material includes shives, previously considered to be a waste material. Shives of bast fibers are added to bast fibers and a binder. The shives may contain fibers which are still partially attached to the shives with their natural bond. These partially attached fibers project laterally from the shives in an irregular fashion and are between 2 mm and 100 mm long. The shives and the loose fibers and/or the shives with the partially attached fibers are fed into a coating device for liquid additives and/or into a spreading system for solid additives, and subsequently form a fleece or cake. An air flow may be used for performing a mechanical felting of the fleece. A method and an apparatus for producing the building material are also provided.

Abstract: A felt for use in a papermaking machine includes a woven base fabric and a batt layer for supporting the paper web. A flow control layer is interposed between the base fabric and the fibrous batt layer, to impede rewetting of the paper web as the paper web exits a press nip of the papermaking machine. The flow control layer is formed of a porous hydrophobic material. Pressure exerted by the press nip forces water from the paper web through the batt layer and the flow control layer into the base fabric. When the pressure is relieved, the hydrophobic properties of the flow control layer impede back-flow of water to the batt layer and thence to the paper web, thereby impeding rewetting of the web. The flow control layer is preferably formed of a spunbonded filamentary nylon material which is non-circular in cross-section, such as tri-lobed/triangular, and which may be treated with an hydrophobic chemical composition to enhance hydrophobic properties.

Abstract: A low density body such as a sheet, board or molding usable as a cushioning material, heat-insulating material, sound-absorbing material, filter, low density base paper or the like is provided. The low density body having a density of 0.05 to 0.45 g/cm.sup.3 is prepared by dewatering a slurry containing fine fibers having a bond-reinforcing factor of at least 0.15 and curled fibers having a wet curl factor of 0.4 to 1.0, and drying the resultant product.

Abstract: In a wet friction material formed from carbon fibers as a main ingredient and synthetic organic highly-fine fibers as reinforcing material, the carbon fibers as a main ingredient are formed into a shape. Further, the compounding ratio of each of the carbon fibers and the reinforcing material is made to be within a range from 10 to 50% with respect to paper ingredients.

Abstract: This invention concerns a composition comprising a blend of polyolefin with the reaction of a functionalized polyolefin and polyetheramine in which the polyetheramine is grafted into the functionalized polyolefin in a customary mixing apparatus. A process for producing the reaction product of functionalized polypropylene and polyetheramine by melting with polypropylene in a customary mixing apparatus is also disclosed. Blends of the present invention are advantageously useful to prepare paintable automotive body parts. This invention further includes dyeable polyolefin compositions containing the reaction product of functionalized polyolefin and polyetheramine. Dyeable polyolefin fibers, including polypropylene fibers, are disclosed, which may be made by melt spinning, and which may be employed to make woven and non-woven fabric.

Abstract: The present invention provides a laminated body comprising a uniaxially stretched laminate composed of (I) a first thermoplastic resin layer and (II) an adhesion layer which has a lower melting point than said first thermoplastic resin layer (I) and is provided on at least one surface of said thermoplastic resin layer (I), said adhesion layer (II) being composed of a composition containing (A) 100 to 30% by weight of an .alpha.-olefin (co)polymer having a melt flow rate of 0.01 g to 100 g/10 minutes obtained by (co)polymerizing an .alpha.-olefin in the presence of a catalyst which includes at least one compound of a transition metal of Group IV in the Periodic Table containing a ligand having a cyclopentadienyl skeleton, and (B) up to 70% by weight of an olefin-based polymer; in one embodiment, the present invention relates to a nonwoven or woven fabric and a reinforced laminated body, each derived from the laminated body.

Abstract: Disclosed is a base inliner comprising a textile sheet material and a reinforcement, wherein said reinforcement comprises monofilaments whose diameter is at least 0.1 mm, preferably between 0.1 and 1 mm. The base inliner is useful for producing optionally bituminized roofing and sealing membranes.

Abstract: Disclosed are head bands comprising a sliver of spontaneously wettable staple fibers. The fibers are of an irregular, grooved shape in cross section and are lightly bound together to permit easy separation into suitable lengths for head bands.

Abstract: The present invention overcomes drawbacks of prior composite sheets consisting of a spun-bonded nonwoven fabric and pulp fibers and provides an inexpensive composite sheet with excellent draping qualities, a nearly fabric-like touch and good usability. According to the present invention, a composite sheet made by entangling a web of thermoplastic filaments with pulp fibers under water stream is creped to increase the elongation in machine direction as high as in cross direction enough to obtain a usability equal to those of fabric wipers.

Abstract: Disclosed is a process for fractionating cellulosic fibers that is effective to result in cellulosic fibers that exhibit desired properties such as fiber length and fiber coarseness values. The fractionating process is quite efficient and has been found to produce cellulosic fibers that are more homogeneous in their properties as compared to the starting mixture of cellulosic fibers. Also disclosed is a handsheet prepared from the fractionated cellulosic fibers for use in disposable absorbent products.

Abstract: This invention relates to improved sheets of flash-spun plexifilamentary film-fibrils useful in fluid microfiltration and sterile packaging. The sheet material suitable for use in microfiltration of liquids has a permeability that causes a pressure drop of less than 21 kPa at a water flow rate per unit area of 12.55 ml/min/cm.sup.2, and that has a filtration efficiency of 99% of dust particulates in the size range of 1 to 2 microns suspended in a stream of distilled water pumped through the sheet material at a pressure differential of 207 kPa. The sheet material suitable for use in sterile packaging that has a Gurley Hill Porosity of less than 15 seconds and a bacteria spore log reduction value of at least 2.5.

Abstract: A process for fractionating cellulosic fibers that is effective to result in cellulosic fibers that exhibit desired properties such as fiber length and fiber coarseness values. The fractionating process is quite efficient and has been found to produce cellulosic fibers that are more homogeneous in their properties as compared to the starting mixture of cellulosic fibers. Also disclosed is a handsheet prepared from the fractionated cellulosic fibers for use in disposable absorbent products.

Abstract: Improved sheets of bonded plexifilamentary film-fibril strands spun from a polyolefin and a pigment are provided. The polyolefin comprises at least 90% by weight of the fibril strands, and the pigment comprises between 0.05% and 10% by weight of the fibril strands. The sheet has a high opacity and high smoothness, even when the sheet is bonded to a delamination strength greater than 120 N/m or when subjected to calendering. The sheet material is highly printable.

Abstract: The present invention is directed to a nonwoven fabric which is formed from a network of interconnected multi-length, multi-denier thermoplastic fibers. The nonwoven fabrics of the present invention provide enhanced comfort and performance not found in conventional nonwoven fabrics and have been found to be particularly useful as cover materials in disposable sanitary absorbent articles.

Abstract: This invention concerns a composition comprising a blend of polyolefin with the reaction of a functionalized polyolefin and polyetheramine in which the polyetheramine is grafted into the functionalized polyolefin in a customary mixing apparatus. A process for producing the reaction product of functionalized polypropylene and polyetheramine by melting with polypropylene in a customary mixing apparatus is also disclosed. Blends of the present invention are advantageously useful to prepare paintable automotive body parts. This invention further includes dyeable polyolefin compositions containing the reaction product of functionalized polyolefin and polyetheramine. Dyeable polyolefin fibers, including polypropylene fibers, are disclosed, which may be made by melt spinning, and which may be employed to make woven and non-woven fabric.

Abstract: Disclosed are fibers that are capable of spontaneously transporting certain fluids, for example aqueous fluids, such as water, on their surfaces. The fibers, especially in the form of tow, can be incorporated into absorbent articles, such as diapers, in order to transport fluids to more effectively utilize the absorbent portion of the article. The fibers can be synthetically coated with absorbent materials.