Abstract: The present disclosure relates to a patterned nonwoven fabric, wherein the pattern comprises an arrangement of discrete regions that project outwardly from a median plane of the nonwoven fabric. The outwardly projecting pattern may be created on one or both sides of the fabric, although the pattern may project further on one side than the other. In one embodiment, the patterned nonwoven fabric further includes a second arrangement of discrete regions, these regions projecting inwardly toward the median plane of the nonwoven fabric. Again, the pattern of inwardly and outwardly projecting regions may occur on one or both sides of the nonwoven fabric. The patterned nonwoven may be used in a variety of applications, such as drapery, upholstery, apparel, and office panels, for example.

Abstract: A composite abrasive nonwoven web is prepared by passing fibers through a card to yield a pre-bond web following by the bonding of the pre-web in a calender to achieve a composite abrasive nonwoven web. The composite abrasive nonwoven web may be manufactured in, for example, one or two stages. The produced composite web may have at least two layers where, for example, one layer is an absorbent smooth layer and another layer is a rough abrasive layer.

Abstract: The present invention relates to a nonwoven fabric having a relatively low level of ionic contaminates which is achieved by exposing the fabric to a deionized water wash, preferably, in-line with the nonwoven production process, thereby eliminating, or at least reducing, the need for an expensive and time consuming cleanroom laundering. The fabric is primarily comprised of continuous filament fibers and may be manufactured into such end-use products as cleaning wipes and protective clothing for cleanrooms and surface coating operations, such as automotive paintrooms. Also encompassed within this invention is a method for producing a nonwoven fabric having a relatively low level of ionic contaminates.

Abstract: The present invention relates to a nonwoven fabric having a relatively low level of ionic contaminates which is achieved by exposing the fabric to a deionized water wash, preferably, in-line with the nonwoven production process, thereby eliminating, or at least reducing, the need for an expensive and time consuming cleanroom laundering. The fabric is primarily comprised of continuous filament fibers and may be manufactured into such end-use products as cleaning wipes and protective clothing for cleanrooms and surface coating operations, such as automotive paintrooms. Also encompassed within this invention is a method for producing a nonwoven fabric having a relatively low level of ionic contaminates.

Abstract: The present invention provides a web containing superfine microfibers. The web contains a blend of a first group of split microfibers which contains a first polymer component and a second group of split microfibers which contains a second polymer component, wherein at least one of the polymer components is hydrophilic. The invention additionally provides a meltblown fiber web having at least two groups of fibers, wherein each group of the fibers has a distinct cross-sectional configuration.

Abstract: The present invention relates to a method for improving the abrasion resistance of a spun-bonded nonwoven without substantially adversely affecting its hand or drape characteristics, by incorporating low melt binder fibers into the web during the laydown phase of the spun-bonded nonwoven production process. More specifically, improved abrasion resistance is achieved by intimately blending continuous binder fibers with the primary extruded fibers in a spun-bonded nonwoven web. Also encompassed within this invention is a spun-bonded nonwoven fabric having improved abrasion resistance and comprised of primary extruded fiber and low melt binder fiber such that the binder fiber comprises between about 1 and about 50 weight percent on weight of the spun-bonded nonwoven fabric.

Abstract: In one aspect the present invention provides medical devices 10 that each include a plurality of fibers 22, substantially all of the plurality of fibers 22 each including a portion having a maximum diameter of at least five micrometers, wherein substantially all of fibers 22 form a layer on at least one external surface of medical device 10. In another aspect, the present invention provides methods of manufacturing medical devices 10, the methods including the steps of: (a) applying a layer comprising a plurality of fibers 22 to at least one surface of medical device 10; and (b) matching the value of the Young's modulus of the layer to ±35% (in some embodiments to ±20%) of the value of the Young's modulus of an animal tissue.

Abstract: The present invention relates to film-fibril plexifilamentary sheet products which demonstrate improved balance of toughness and softness combined with improved balance of air permeability and liquid barrier resistance, which are prepared by point bonding a nonwoven sheet on both sides by passing said sheet between embossing rolls at a combination of bonding temperature, pressure and residence time such that the majority of bond points are not bonded to the point of translucency. The present invention relates to the use of these products in rooflining materials.

Abstract: Thermally divisible multicomponent fibers having at least a first component including an elastomeric polymer and at least a second component including a non-elastomeric polymer. The multicomponent fibers are useful in the manufacture of nonwoven structures, and in particular nonwoven structures used as synthetic suede and filtration media.

Abstract: Polyolefin resin-based non-woven fabric characterized by containing a fatty acid amide compound, and by having a static friction coefficient of 0.1 to 0.4. Production of such non-woven fabric is achieved by subjecting, for example, non-woven fabric containing 0.05 to 1 wt. % erucamide to an aging treatment at 30 to 60° C. for 5 to 50 hours.

Abstract: The present invention concerns absorbent articles. This invention concerns in particular an absorbent article comprising cellulose fibers (14) present at least partially in the form of granules. Furthermore, the present invention also concerns the use of cellulose fibers (14) present at least partially in the form of granules as a material in an absorbent article.

Abstract: A device for producing a porous fiber structure. One or more points of high surface curvature is produced in a liquefied polymer, such as a polymer solution or a polymer melt. The points of high surface curvature may be produced by forcing the liquefied polymer through narrow nozzles, or by wetting sharp protrusions with the liquefied polymer. The liquefied polymer is charged to a high negative electrical potential relative to a grounded moving belt. Thin jets of liquefied polymer emerge from the points of high surface curvature to impinge as fibers on the moving belt, thereby forming a nonwoven fiber structure of relatively uniform porosity. A powdered aerosol is charged to a high positive electrical potential relative to the moving belt. As the belt moves past the aerosol, the aerosol particles are attracted to fill interstices in the fiber structure, thereby creating a composite filtering material.

Abstract: Adhesive materials and articles containing adhesive materials are disclosed. Adhesive articles include adhesive fibers, adhesive films, an adhesive layer of fibers, adhesive nonwoven webs, and articles containing one or more of the adhesive materials. Stretched adhesive materials are also disclosed. Methods of making and using the adhesive materials and articles are also disclosed.

Abstract: The invention relates to a skin cleaning device that consists of textile structure and that is at least partially provided with lipophilic fibers. Due to the provision of lipophilic fibers the inventive skin cleaning device is especially useful for cleaning oily and mixed skin since the fibers impart to the device a higher fat absorption capacity as compared to conventional skin cleaning textiles. The inventive skin cleaning device is further very environmentally friendly as it allows to widely or completely avoid the use of fat-dissolving cleaning agents.

Abstract: The present invention is directed to a nonwoven compound fabric comprising one or more layers of nano-denier continuous filaments and at least one layer of a strong and durable substrate, wherein said nonwoven compound fabric has an improved barrier performance as measured by the hydrostatic head to barrier layer basis weight ratio. In the present invention, one or more strong and durable substrate layers are formed, each layer comprising continuous thermoplastic filament spunbond. A barrier layer preferentially comprising nano-fibers of infinite length, wherein the average fiber diameter of the nano-fiber is in the range of less than or equal to 1000 nanometers, and preferably less than or equal to 500 nanometers, is applied to at least one substrate layer.

Abstract: A blowable insulation material comprising batt shredded into blowable clusters. In preferred embodiments, the clusters comprise water-repellant or lubricant-finished fiber and/or dry fiber and/or binder fiber and may be mixed with opened fiber. A process to produce the blowable clusters is also disclosed.

Abstract: Low denier, high extensible fibers, soft extensible nonwoven webs comprising such fibers, and disposable articles comprising such nonwoven webs are obtained by spinning a polymer composition through small diameter holes.

Abstract: Disclosed are melt processable multicomponent fibers in which at least one component includes a polyacrylonitrile polymer and at least one component includes a fugitive polymer. The melt processable multicomponent fibers of the present invention may be separated into microfilaments formed entirely of polyacrylonitrile, suitable for the production of carbon and graphite fibers. The fibers of the present invention may be used in a variety of applications, including composites and filtration media.

Abstract: An adhesion preventive membrane including a nonwoven fabric layer of collagen fibers, having on a surface thereof a coating layer containing a mixture of collagen and hyaluronic acid, or a method of producing a continuous collagen single strand, wherein a strand-like collagen is dehydrated/coagulated in a hydrophilic organic solvent having a water content of about 10% or less and then dried under conditions of a relative humidity of about 50% or less and a temperature of about 42° C. or less. A collagen nonwoven fabric of first and second layers composed of a plurality of collagen strand-like materials spun out of a solubilized collagen solution, and arranged in parallel, the first and second layers being laminated and bonded to each other so that directions of arrangements of the strand-like materials of the first and the second layers are at an angle therebetween.

Abstract: An alkali dispersible article comprises a sheath-core microfiber. The sheath layer comprises a hydrolytically degradable polymer, and the core layer comprises another polymer that is different than the sheath polymer. The core polymer may be a hydrolytically degradable polymer or more preferably a water soluble polymer.

Abstract: Disclosed are improved polymer materials. Also disclosed are fine fiber materials that can be made from the improved polymeric materials in the form of microfiber and nanofiber structures. The microfiber and nanofiber structures can be used in a variety of useful applications including the formation of filter materials.

Abstract: 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.

Abstract: Disclosed is a water disintegratable sheet of which fibers are hydroentangled about each other. The water disintegratable sheet includes: at least one kind of primary fibers having a fiber length of at most 10 millimeter; and bast/leaf fibers having a Canadian Standard freeness value of at most 600 milliliter and a fiber length of at most 10 millimeter.

Abstract: A non-woven fabric having such a structure that fine fibers having a small fineness are entangled with one another and a sheet obtained by impregnating the non-woven fabric with an elastic polymer satisfy the following requirements: the fine fibers should be obtained by splitting a strippable and splittable composite short fiber comprising at least two components; the fine fibers should have a monofilament size of 0.01 to 0.5 denier; the fine fibers should form a fine non-woven fabric structure that they are entangled with one another at random; the apparent density should be 0.18 to 0.

Abstract: The present invention is directed to a protective outdoor fabric comprising one or more layers of fine denier spunbond filaments and at least one layer of barrier material, wherein said protective outdoor fabric has a significant barrier performance as measured by the hydrostatic head to barrier layer basis weight ratio being of about at least 4.9 cm/gsm. In the preferred practice of the present invention, first and second outer fabric layers are formed, each comprising continuous filament spunbond layers of thermoplastic fibers, with the size of the continuous filaments between about 0.7 and 1.2 denier, preferably less than or equal to 1 denier. The barrier layer preferentially comprises microfibers of finite length, wherein the average fiber diameter is in the range of about 1 micron to about 10 microns, and preferably between about 1 micron and 5 microns, said layers being consolidated into a composite fabric.

Abstract: This invention relates to rigid porous carbon structures and to methods of making same. The rigid porous structures have a high surface area which are substantially free of micropores. Methods for improving the rigidity of the carbon structures include causing the nanofibers to form bonds or become glued with other nanofibers at the fiber intersections. The bonding can be induced by chemical modification of the surface of the nanofibers to promote bonding, by adding “gluing” agents and/or by pyrolyzing the nanofibers to cause fusion or bonding at the interconnect points.

Abstract: The present invention discloses environmentally degradable multicomponent fibers. The configuration of the multicomponent fibers may be side-by-side, sheath-core, segmented pie, islands-in-the-sea, or any combination of configurations. Each component of the fiber will comprise destructurized starch and/or a biodegradable thermoplastic polymer. The present invention is also directed to nonwoven webs and disposable articles comprising the environmentally degradable multicomponent fibers. The nonwoven webs may also contain other synthetic or natural fibers blended with the multicomponent fibers of the present invention.

Abstract: A transversely stretched nonwoven fabric is manufactured by transversely stretching a nonwoven fabric. First, an original web comprising a plurality of un-oriented filaments is heated to a temperature higher than its stretch suitable temperature by 5° C. or more. Next, the heated original web is stretched at a rate of 1.2 to 3 in its transverse direction to stretch the filaments of the original web with almost no molecular orientation involved. Then, the original web stretched transversely at a rate of 1.2 to 3 is heated to the stretch suitable temperature and the original web is further stretched transversely at the stretch suitable temperature. With these steps, a transversely stretched nonwoven fabric in which the original web is stretched transversely at a rate of 7 times or more in total as compared with the state of the stretch thereof is manufactured with a high tensile strength of 132.5 mN/tex (1.5 g/d) in the transverse direction.

Abstract: A transversely stretched nonwoven fabric is manufactured by transversely stretching a nonwoven fabric. First, an original web comprising a plurality of unoriented filaments is heated to a temperature higher than its stretch suitable temperature by 5° C. or more. Next, the heated original web is stretched at a rate of 1.2 to 3 in its transverse direction to stretch the filaments of the original web with almost no molecular orientation involved. Then, the original web stretched transversely at a rate of 1.2 to 3 is heated to the stretch suitable temperature and the original web is further stretched transversely at the stretch suitable temperature. With these steps, a transversely stretched nonwoven fabric in which the original web is stretched transversely at a rate of 7 times or more in total as compared with the state of the stretch thereof is manufactured with a high tensile strength of 132.5 mN/tex (1.5 g/d) in the transverse direction.

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 dash insulator for an automotive vehicle is formed of an interior material which includes a sound absorbing material layer, and a moldable layer. The sound absorbing material layer includes first and second polyester fibers (A), (C). The first polyester fiber (A) is in an amount ranging from 20 to 95 parts by weight. The first polyester fiber has a size smaller than 1 denier. The second polyester fiber (C) is in an amount ranging from 5 to 50 parts by weight. The second polyester fiber includes a component having a softening point lower than that of the first polyester fiber by at least a temperature of 20° C. The second polyester fiber has a size ranging from 1 to 100 denier. The moldable layer is laminated to the sound absorbing material layer and includes fourth polyester fiber (E) in an amount ranging from 5 to 100 parts by weight. The fourth polyester fiber has a size ranging from 1 to 100 denier.

Abstract: An absorbent material having substantially improved structural stability in the dry and wet states. The absorbent materials are significantly less susceptible to handling losses of absorbent gelling particles during manufacturing operations. The absorbent material also is not subject to shifting of the absorbent gelling particles during or after swelling by fluids. The absorbent material comprises absorbent gelling particles comprising (a) a water-insoluble absorbent hydrogel-forming polymer; (b) a polycationic polymer bonded to the absorbent gelling particles at the surface thereof; (c) glue microfibers dispersed in the absorbent gelling particles; and (d) a carrier layer bonded to the absorbent gelling particles through the glue microfibers. The invention further relates to a method of making the absorbent materials, and the absorbent articles comprising the absorbent materials.

Abstract: The present invention relates to a composite structure which is capable of use as a filter medium and a method for producing the same. The composite structure contains at least a first nonwoven layer, said first layer having a first surface and a second surface, as well as a rigidifying or stiffening component. The rigidifying component is applied in semi-molten state to the one surface of the nonwoven layer and provides sufficient stiffness and/or resilience to the composite such that the composite is self-pleatable yet retains flexibility. The rigidifying or stiffening component may be filaments of a polymer or polymer blend or alternatively the rigidifying or stiffening component may also be a wax or wax blend.

Abstract: A unique isotropic sub-denier spunbond nonwoven product created by an apparatus and method comprising a unique multi-head resin metering system, a spinneret head with spinning sections, separated by a quench fluid extraction zone, a two sided, multilevel quench system, a fluid volume control infuser system which automatically guides the filaments into the filament drawing system while conserving energy by using a portion of the quench fluid as part of the drawing fluid and also minimizing turbulence at the entrance to the draw slot. The filament drawing system comprises a draw jet assembly with adjustable primary and secondary jet-nozzles and a variable width draw jet-slot. The entire draw jet assembly is moveable vertically for filament optimization. The offset, constant flow secondary jet-nozzle system provides an unexpectedly high velocity increment to the filaments by oscillating the filaments and increasing their drag resulting in remarkably low fiber denier on the order of 0.5 to 1.2.

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 leather-like sheet material comprising a substrate layer composed of an entangled nonwoven fabric consisting of ultrafine fibers and an elastic polymer or elastomer filled therein and having, on one side (side A) of the substrate layer, a grain layer comprising an elastomer mainly consisting of a polyurethane, wherein the ultrafine fibers (a) constituting the side A of the substrate layer have a mean fineness substantially within the range of 0.01 to 0.

Abstract: The invention is lyocell fiber characterized by a pebbled surface as seen at high magnification and having a variable cross section and diameter along and between fibers. The fiber is produced by centrifugal spinning, melt blowing or its spunbonding variation. The fibers can be made in the microdenier range with average weights as low as one denier or less. The fibers have inherently low gloss and can be formed into tight yarns for making fabrics of very soft hand. Alternatively, the fibers can be formed into self bonded nonwoven fabrics.

Abstract: A disposable garment includes a nonwoven backsheet formed by melt-blowing. The melt-blown nonwoven web has a basis weight of from about 3 g/m2 to about 60 g/m2 and an air permeability value of at least about 15 cm3/cm2/sec. The melt-blowing web is made by fine fibers having an average fiber diameter of from about 3 &mgr;m to about 10 &mgr;m.

Abstract: A method of making a spunbond nonwoven fabric embodying the principles of the present invention contemplates use of an aliphatic-aromatic polyester resin, such as Eastar BioGP, for formation of fabrics which exhibit desirable softness and drapeability characteristics, excellent gamma-radiation stability and, where required, desirable elasticity. In distinction from previous formation techniques, the present invention contemplates formation of such fabrics by spunbonding at relatively low filament spinning speeds, thus facilitating practice of the present invention with generally available and conventional spunbonding equipment.

Abstract: The invention relates to a skin cleaning device that consists of a textile structure and that has lipophobic fibers or lipophobically finished fibers. Due to the lipophobic fibers and/or lipophobically finished fibers contained in it the inventive skin cleaning device is especially adapted to the cleaning requirements of dry skin since the fat absorption capacity of the skin cleaning device is limited by to the fibers. As a result, less fat is removed from the skin during the cleaning process as compared to conventional textile cleaning devices.

Abstract: A cleaner and polish article comprises a substrate capable of absorbing and retaining a fluid and having two opposed surfaces wherein at least one surface is abrasive, and a nonabrasive aqueous cleaner and polish formulation absorbed, in the substrate. The cleaner and polish formulation comprises an aqueous cleaning emulsion containing water, a surfactant and an organic solvent, a polishing agent, and a carrier, whereby cleansing and polishing action is achieved by the formulation, and abrasive cleansing action and polishing action is achieved by the cleaner and polish formulation as well as by the abrasive surface of the substrate. The substrate is further capable of absorbing the dissolved or softened soil residue to assist in the cleansing action. The substrate can comprise a cloth-like towel. A plurality of such towels is provided in a continuous roll placed in a selectively sealable, essentially airtight container.

Abstract: A cleaning sheet for removing particulate matter from a surface comprises a substrate comprising a first fibrous web comprising carded staple fibers and a reinforcing fibrous web comprising fibers selected from the group consisting of thermal bonded fibers, meltblown fibers, hydroentangled fibers, and spunbonded fibers. The first fibrous web is hydroentangled with the reinforcing fibrous web to form the substrate. The resulting cleaning sheet has a CD elongation of less than about 100% at a load of 500 grams. The cleaning sheet is preferably free of a scrim material and can further comprise an optional additive material. A method of removing particulate matter from a surface comprises contacting the surface with a cleaning sheet of the present invention.

Abstract: A cleaning sheet for removing particulate matter from a surface comprises a substrate comprising first fibers and second fibers having different denier to improve caliper of the cleaning sheet. The first and second fibers will typically have a denier of from about 0.5 to about 15, wherein the difference in denier between the first fibers and the second fibers is at least about 0.5. The cleaning sheet is preferably free of a scrim material and can further comprise an optional additive material. A method of removing particulate matter from a surface comprises contacting the surface with a cleaning sheet of the present invention.

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 invention is directed to a nonwoven material made of a bicomponent fiber in which the first polymer is a cellulose ester polymer, preferably cellulose acetate, and the second polymer is selected from the group consisting of polyolefins, polyesters, polyamides and polyimides. The bicomponent fiber can be either a side-by-side or a core-and-sheath fibers. When core-and-sheath, the cellulose acetate is the sheath polymer. The nonwoven material of the invention can be used to prepare grips, materials for use in absorbent products such as diapers and personal hygiene products, disposable towels and other products. The nonwoven of the invention has particular utility for disposable diaper products due to the superior fluid acquisition, retention and distribution properties of the cellulose ester, yet avoids the high cost of all cellulose acetate fibers by use of a much less expensive second polymer to form part the bicomponent fiber.

Abstract: Biodegradable and/or bioabsorable fibrous articles and methods for using the articles in medical applications are disclosed. The biodegradable and/or bioabsorable fibrous articles, which are formed by elctrospinning fibers of biodegradable and/or bioabsorbable fiberizable material, comprise a composite (or asymmetric composite) of different biodegradable and/or bioabsorbable fibers. Articles having specific medical uses include an adhesion-reducing barrier and a controlled delivery system. The methods include methods for reducing surgical adhesions, controlled delivery of a medicinal agent and providing controlled tissue healing.

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 melt-blown, non-woven fabric constituted by extremely fine polyarylene sulfide fibers having an average fiber diameter of 10 &mgr;m or less is stably produced from branched and/or cross-linked polyarylene sulfide having a non-Newtonian coefficient of 1.05-1.20.

Abstract: The present invention provides a filter media comprising (a) a nonwoven composite material comprising a stabilized mixture of thermoplastic microfibers and at least about 50%, by weight, of a secondary fibrous material such as pulp or polymeric staple fibers; (b) a first outer nonwoven web comprising a substantially uniform nonwoven web of autogenously bonded multicomponent fibers; and (c) a second outer nonwoven web wherein the nonwoven composite material is positioned between the first outer nonwoven web and second outer nonwoven web. The filter material is well suited to filtering liquid borne particulate matter ranging in size from 5&mgr; to about 25&mgr;.