Abstract: A method of manufacturing artificial turf creating a liquid polymer mixture, wherein the polymer mixture is at least a two-phase system. A first one of the phases includes a first polymer and a first dye, and a second one of the phases of the polymer mixture includes a second polymer and a second dye. The second dye has a different color than the first dye, the second polymer being of the same or of a different type as the first polymer. The first and the second phase are immiscible, the first phase forming polymer beads within the second phase. The method further includes extruding the polymer mixture into a monofilament including a marbled pattern of the first and second color; quenching the monofilament; reheating the monofilament; stretching the reheated monofilament to deform the polymer beads into threadlike regions and to form the monofilament into an artificial turf fiber; and incorporating the artificial turf fiber into an artificial turf backing.

Abstract: One or more nanofiber yarns can be placed in contact with one or more nanofiber sheets. The nanofiber yarns, which include single-ply and multi-ply nanofiber yarns, provide added mechanical stability to a nanofiber sheet that decreases the likelihood of a nanofiber sheet wrinkling, folding, or otherwise becoming stuck to itself. Furthermore, the nanofiber yarns integrated with the nanofiber sheet can also act as a mechanism to prevent the propagation of tears through the nanofiber sheet. In some cases, an infiltrating material can be infiltrated into interstitial spaces defined by the nanofibers within both the nanofiber yarns and the nanofiber sheets. The infiltrating material can then form a continuous network throughout the nanofiber yarns and the nanofiber sheet.

Abstract: Provided is a polymer nanofiber sheet having high delamination resistance, a high mechanical strength, and a high specific surface area. Specifically, provided is a polymer nanofiber sheet, including polymer nanofibers, the polymer nanofibers being laminated and three-dimensionally entangled with each other, in which: at least part of the polymer nanofibers are crosslinked at a crosslinked part having crosslinking portions and a non-crosslinking portion; and the crosslinked part contains a low-molecular weight epoxy compound having a molecular weight of from 100 to 3,000.

Abstract: Disclosed or provided are non-shutdown high melt temperature or ultra high melt temperature microporous battery separators, high melt temperature separators, battery separators, membranes, composites, and the like that preferably prevent contact between the anode and cathode when the battery is maintained at elevated temperatures for a period of time and preferably continue to provide a substantial level of battery function (ionic transfer, discharge) when the battery is maintained at elevated temperatures for a period of time, methods of making, testing and/or using such separators, membranes, composites, and the like, and/or batteries, high temperature batteries, and/or Lithium-ion rechargeable batteries including one or more such separators, membranes, composites, and the like.

Abstract: A membrane for skin comprising a plurality of randomly oriented core-shell nanofibers is provided in the present invention, where each of said core-shell nanofibers comprises at least an active-ingredient-loaded polymeric core and a non-polymeric shell consisting of active ingredients only surrounding the core. Related fabrication method of said membrane is also provided in the present invention.

Abstract: Disclosed herein is a process for forming a multilayer construction, and the multilayer constructions including at least one layer of an elastic meltblown fabric, the process comprising extruding one or more polyolefin polymer (e.g., a propylene-?-olefin copolymer) having a MFR from less than 90 dg/min through at least one die having a plurality of nozzles to form a plurality of continuous fibers, at least one die operating at a melt pressure from greater than 500 psi (3.45 MPa) to form at least one elastic meltblown fabric, and adhering the at least one elastic meltblown fabric to at least one extensible fabric.

Abstract: Provided is an adhesive tape including: a substrate; and an adhesive layer laminated on one surface or both surfaces of the substrate, wherein one or both of the substrate and the adhesive layer are produced in a nano-web form in which fiber strands are captured by a spinning method. Thus, the adhesive tape can be made thin, and an adhesive strength can be improved. In addition, the adhesive tape can be precisely attached on a corrugated surface. When the adhesive tape attached between components is separated from the components, the adhesive layers can be prevented from remaining on the surfaces of the components.

Abstract: A (semi)grain-finished leather-like sheet composed of an entangled nonwoven fabric of three-dimensionally entangled fiber bundles containing microfine long fibers and an elastic polymer contained in the entangled nonwoven fabric. When dividing the (semi)grain-finished leather-like sheet to five layers with equal thickness, i.e., surface layer, substrate layer 1, substrate layer 2, substrate layer 3 and back layer in this order along the thickness direction, part of the microfine long fibers forming the surface layer and/or the back layer are fuse-bonded to each other and the microfine long fibers forming the intermediate layer are not fuse-bonded. With such a fuse-bonding state of the microfine long fibers, the (semi)grain-finished leather-like sheet combines a low compression resistance and a dense feel each comparable to natural leathers, has a sufficient practical strength, and are excellent in properties which are required according to its use.

Abstract: Materials and methods are provided for producing preform materials for impact-resistant composite materials suitable for liquid molding. Interlayers formed of nonwoven, continuous fibers, such as spunbonded, spunlaced, or mesh fabric, are introduced between non-crimped layers of unidirectional reinforcing fibers to produce a preform for use in liquid-molding processes to produce a composite member. Curing of the preform provides increased impact resistance by increasing the amount of energy required to propagate localized fractures due to impact.

Abstract: One embodiment of the present invention is a nonwoven fabric comprising a support web and a fibrous barrier web, having a hydrohead of at least about 145 cm and a Frazier permeability of at least about 0.3 m3/m2-min.

Abstract: Porous fibrous sheets are provided that are useful in end uses requiring microbial barrier properties such as medical packaging and medical gowns and drapes. The porous fibrous sheets may contain nanofibers and wood pulp.

Abstract: An absorbent fiber web has a base layer of cellulose fibers and an external layer that is connected at least across areas thereof with the base layer. The external layer is a nonwoven of nano fibers. The base layer and the nonwoven are connected to one another across areas thereof without a binder.

Abstract: A core/shell nanofiber non-woven containing a plurality of core/shell nanofibers where at least 70% of the nanofibers are bonded to other nanofibers. The core of the nanofiber contains a core polymer and the shell of the nanofiber contains a shell polymer. At least a portion of the core polymer interpenetrates the shell of the nanofiber and at least a portion of the shell polymer interpenetrates the core of the nanofiber. The process for forming a core/shell nanofiber non-woven is also disclosed.

Abstract: A towel specifically designed for cleaning vehicles and other surfaces without the use of soap or other cleaning agents is formed of a combination of microfiber material and chamois material and comprises a first relatively thicker portion formed primarily of an underlying layer of material and an outer layer of microfiber material that is folded over and attached to both faces of the underlying layer of material; and a second relatively thinner portion formed primarily of chamois material.

Abstract: An elastic laminate capable of being rolled for storage and unwound from a roll when needed for use, includes an elastic layer of an array of continuous filament strands with meltblown deposited on the continuous filament strands, and a facing layer bonded to only one side of the elastic layer. The meltblown layer may include an elastic polyolefin-based meltblown polymer having a degree of crystallinity between about 3% and about 40%. The laminate suitably has an inter-layer peel strength of less than about 70 grams per 3 inches cross-directional width at a strain rate of 300 mm/min. Alternatively or additionally, the continuous filament strands and/or the facing layer may include an elastic polyolefin-based meltblown polymer having a degree of crystallinity between about 3% and about 40%.

Abstract: One embodiment of the present invention is a nonwoven fabric comprising a support web and a fibrous barrier web, having a hydrohead of at least about 145 cm and a Frazier permeability of at least about 0.3 m3/m2-min.

Abstract: A non-woven flame retardant barrier can be prepared from low denier, charring fibers and substantially free of polymers made from halogenated monomers. The charring fibers can be modified viscose fibers, for example Visil®. The blend of low denier fibers can be, for example, a blend of 1.5 denier fibers and 3.0 denier fibers.

Abstract: A thermally adhesive laminated nonwoven fabric that is a laminated nonwoven fabric in which nonwoven fabrics of the following (a) layer, (b) layer and (c) layer are integrated by heat contact bonding: (a) layer having at least one filament yarn nonwoven fabric layer composed of a thermoplastic resin; (b) layer having at least one extremely fine yarn nonwoven fabric layer composed of the same type of thermoplastic resin as that of the (a) layer; and (c) layer having at least one composite filament yarn nonwoven fabric layer composed of a thermoplastic resin, and that satisfies the following (1) and (2): (1) a difference between the melting point of the yarn forming the nonwoven fabric of the (a) layer and that of a yarn forming the nonwoven fabric of the (b) layer is 30° C.

Abstract: Multicomponent fiber and fabrics made therefrom are provided, wherein the multicomponent fibers may incorporate one or more elastomers or additive-containing polymers in a bicomponent core. The fiber includes a multilobal sheath fiber component surrounding the bicomponent core, wherein the components are sized such that the fiber can be fibrillated to expose the core fiber components and split the fiber into multiple microdenier fibers.

Abstract: An absorbent fiber web has a base layer of cellulose fibers and an external layer that is connected at least across areas thereof with the base layer. The external layer is a nonwoven of nano fibers. The base layer and the nonwoven are connected to one another across areas thereof without a binder.

Abstract: One embodiment of the present invention is a nonwoven fabric comprising a support web and a fibrous barrier web, having a hydrohead of at least about 145 cm and a Frazier permeability of at least about 0.3 m3/m2-min.

Abstract: A non-woven flame retardant barrier can be prepared from low denier, charring fibers and substantially free of polymers made from halogenated monomers. The charring fibers can be modified viscose fibers, for example Visil®. The blend of low denier fibers can be, for example, a blend of 1.5 denier fibers and 3.0 denier fibers.

Abstract: A multi-layer nonwoven composite material includes base layers which impart desired properties. The number of base layers can vary as desired for desired properties in order to tune the resulting multi-layer composite material. In a preferred composite material, three base layers are provided to impart sound deadening, sound dispersion, sound absorption, and sound durability. The base layers are first produced from constituent fibers to form constituent webs. These webs are then combined into a multi-layer substrate. A barrier layer may be applied to the multi-layer substrate to impart additional properties. A face layer may be adhered to form a multi-layer nonwoven composite material. The barrier material imparts fire retardancy water resistance while the face carpet imparts cosmetic and/or tactile qualities. Other materials, such as chemical additives, can be applied to the composite material to achieve desired characteristics.

Abstract: Disclosed herein is a single step sterilization wrapping material suitable for use, as an example, in wrapping surgical instruments and supplies for sterilization, transportation and storage. The material includes separate inner and outer wraps which, unlike previous wraps, are joined to one another. Common wrapping techniques involve wrapping items to be sterilized with two separate sheets of wrap. The present invention provides separate wraps which can be specially engineered to deliver specific properties for each sheet and then joined to one another so as to permit wrapping and opening in a neat single step process which increases efficiency and saves time and money. In special situations the outer wrap can be engineered with increased strength, the inner wrap with increased barrier properties and the inner and outer wraps can be made visually distinct from one another so that improper wrapping or opening is not a problem.

Abstract: A multilayer, pleatable, filter material is made of at least one melt-blown, fleece layer and at least one carded, fleece layer that are attached to one another without use of adhesives for filtering solid particles out of fluids, in particular, filtering solid particles out of gases, where the carded fleece has compacted and uncompacted sections, the melt-blown fleece is preferably attached to the carded fleece at the latter's uncompacted sections by means of multimicrofilament strands, and the filter material contains micropockets for storing dust.

Abstract: A composite textile fabric for rapidly moving moisture away from the skin, and for retaining body heat, is provided. The composite fabric includes an inner fabric layer made of a yarn comprising a plurality of fibers primarily of polyester or other synthetic yarns which have been rendered hydrophilic, and an outer fabric layer made of a yarn comprising a plurality of fibers primarily of polyester or other synthetic yarns which have also been rendered hydrophilic. The inner fabric layer and the outer fabric layer are formed concurrently by knitting a plaited construction so that the layers are distinct and separate, yet integrated one with the other. The yarn fibers of the inner fabric layer are embedded with particles of a refractory carbide, or may be treated by metal vapor deposition to enhance the retention of body heat.

Abstract: Multiple component meltblown webs are disclosed in which the meltblown fibers include an ionomer on at least a portion of the peripheral surface thereof. The meltblown webs are especially useful in dust wipe applications.

Abstract: A semipermeable membrane support includes, a non-woven fabric including main fiber and binder fiber, both of which are formed of synthetic resin fine fiber, the non-woven fabric being manufactured by heating and pressing after paper making, wherein the semipermeable membrane support has a ratio of a tensile strength in a paper feeding direction to that in a width direction of 2:1 to 1:1.

Abstract: A method of making a quilt includes a batting including a heat activated adhesive coating each side or faces of the batting. The quilt covers are attached to the batting by sequentially placing the covers onto the respective batting faces and heating each cover and adjacent adhesive by moving a hot iron over each cover. The covers are connected to each by a plurality of spaced yarn or other suitable decorative connecting means which extend through the covers and batting to secure the batting in place and may form a desired decorative pattern. The inactive adhesive remains in the quilt or is removed by washing of the quilt. The batting with the inactive adhesive is provided as a commercially available product.

Abstract: Nonwoven fabric fabrics suitable for undergoing pleating to form filtration media are provided. The fabrics generally include at least three layers. The fibers forming the inner layer has a cross section providing greater stiffness, while the fibers forming the outer layers have a cross section providing greater durability. The resulting fabrics provide improved particulate holding and pressure drop characteristics at no sacrifice to durability.

Abstract: The present invention is directed to nonwoven barrier fabrics, and more specifically, to medical, hygiene and industrial articles comprised of nonwoven compound fabrics with improved barrier to basis weight performance, wherein the improved nonwoven compound fabrics are prepared by forming an intermediate nonwoven construct by supplying a strong and durable substrate layer followed by deposition of a frangible fibrous layer onto the substrate layer thereby providing nonwoven barrier materials. The so formed intermediate construct is subsequently subjected to mechanical energy which induces the frangible fibrous layer to fragment into sub-fibers exhibiting an equivalent denier as the frangible fibrous component, said sub-fibers becoming inter-engaged in the strong and durable substrate layer, thereby providing nonwoven barrier materials exhibit useful barrier performance.

Abstract: The present invention is directed to an industrial 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.

Abstract: The gas adsorption sheet of the present invention has a granular activated carbon-containing sheet comprising a granular activated carbon having an average particle diameter of 60 to 600 &mgr;m, a supporting fiber for fixing the granular activated carbon in contact with it, and an adhesive fiber which mainly contributes to shape retention. An air-purifying filter of the present invention is obtained by forming the gas adsorption sheet into a shape of pleats or wave. A method for producing a gas adsorption sheet of the present invention comprises a step of forming a granular activated carbon-containing sheet by using an aqueous slurry containing a granular activated carbon, a supporting fiber and a water-swelling adhesive fiber.

Abstract: The present invention is a laminate of a low loft layer, the first layer, and a high loft layer, the second layer. More specifically, the present invention provides a nonwoven laminate containing a first layer from thermoplastic spunbond filaments having an average denier less than about 1.8 dpf (2.0 dtex); and a second layer containing thermoplastic multicomponent spunbond filaments having an average denier greater than about 2.3 dpf (2.55 dtex). The laminate has a structure such that the density of the first layer is greater than the density of the second layer and the thickness of the second layer is greater than the thickness of the first layer. Also disclosed is a laminate containing the laminate of a low loft layer containing spunbond filaments having an average denier less than 1.8 dpf (2.0 dtex), a high loft layer containing thermoplastic multicomponent spunbond filaments having an average denier greater than about 2.3 dpf (2.55 dtex) and layer containing a meltblown nonwoven web.

Abstract: A method of producing a chemical protective composite substrate by embedding chemical adsorbent layer between two nonwoven needlepunched substrates. The substrate in woven form is sandwiched between two needlepunched nonwoven mats. The nonwoven mats, in the preferred embodiment, are made from apparel grade polyester fibers of 1.5″ length and 1.5 denier, using H1 technology needlepunching machinery. A woven activated carbon cloth is sandwiched between two nonwoven substrates. The nonwoven substrates are double punched at a speed of 800 strokes/min. The three layers are fed to the conveyor belt that feeds the needleloom. The three-layer sandwich passes through the needling zone and gets compacted into a composite substrate. The three layers are needlepunched at 800 strokes/min resulting in a needle composite structure that has: a top or prefilter nonwoven layer; a middle or adsorbent layer and a bottom or base nonwoven layer.

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: A cleaning cloth having a nonwoven structure for wet, damp and/or dry cleaning, the cleaning cloth being made from micro staple fibers of at least two different polymers and from absorbent secondary staple fibers bound into the micro staple fibers and securely retained therein.

Abstract: A nonwoven laminate material for mechanical closure systems, method for its production, and its use. The multi-layer nonwoven fabric laminate material has at least one layer of a polyolefin endless filament nonwoven fabric having a maximum tensile strength in the machine running direction that is at least as great as crosswise to that direction, and made up essentially of fibers having a titer of less than 4.5 dtex, as well as a second layer of a nonwoven fabric that is bonded to the first layer, which includes a sheet of crimped staple fibers made of polyolefins, and whose crimped fibers are coarser than the fibers of the nonwoven fabric of the first layer. The at least two nonwoven fabric layers are bonded to one another at the common interface by bonding in the form of a pre-determined pattern. With this laminate, it is possible to produce diapers that are also suitable for adult incontinence patients, which have a mechanical closure system, e.g., a Velcro™ closure.

Abstract: A preferred filter media is provided. The media includes a fine fiber web secured to the surface of a coarse fiber support. A preferred filter media, comprising multiple layers of fine fiber media separated by coarse fiber support, is provided. Advantageous filter constructions result and are provided. Also according to the disclosure, methods for using such arrangements to filter are provided.

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 filter material for separating solid, particulate and gaseous components from fluids, which is enclosed on both the upstream and downstream sides with a particle filtering medium.

Abstract: A polishing and cleaning sheet for hard surfaces which comprises a sheet substrate impregnated with a polishing cleaner, wherein the substrate is a laminate comprising (A) a fiber aggregate comprising 50 to 100% by weight of ultrafine fibers having a fineness of 0.01 to 1.2 dtex and (B) a flexible material comprising 50 to 100% by weight of hydrophobic fibers and has a maximum absorption capacity of 4 to 15 times its own weight, the substrate is impregnated with 1 to 5 parts by weight, per part by weight of the substrate, of the polishing cleaner, provided that the amount of the polishing cleaner infiltrated in the substrate is not exceed 80% of the maximum absorption capacity, and the polishing cleaner comprises 0.01 to 10% by weight of a water-repellent compound and 50 to 99% by weight of water.

Abstract: The nozzle piece of the present invention is provided with circular cross sectional nozzles having different sizes disposed in a row in front of the die, with n-numbered smaller nozzles B (hole diameter: Db) between adjacent larger nozzles A (hole diameter: Da). It gives melt-blown non-woven fabric of monolithic structure in one step, composed of fine fibers having a diameter in a range from 1 to 10 &mgr;m diameter Variance ratio F of 2.0 or more and wide fiber diameter distribution.

Abstract: An absorbent composition is produced by drying a mixture obtained by mixing a micro-filler (B) with a hydrogel having a water absorptive resin (A) and water. The hydrogel is produced by performing polymerization to produce the resin (A) and not drying the resin (A) after the polymerization. The absorbent composition has a specific surface area at least 10% lager than that of a reference composition produced by drying the hydrogel without the micro-filler (B).

Abstract: A fiber reinforced composite material comprising a resin matrix and primary reinforcement fibers and further comprising secondary, smaller diameter, reinforcement fibers at one or more ply interfaces, or portion thereof, provides improved interlaminar toughness, strength, and delamination resistance without substantial reduction of in-plane properties and without substantial increase in weight. In one embodiment, the small fibers are attached to one side of a conventional prepreg prior to lamination. The small fibers are flexible and are expected to conform to the shape and distribution of the primary reinforcing fibers at the interface.

Abstract: A preferred filter media is provided. The media includes a fine fiber web secured to the surface of a coarse fiber support. A preferred filter media, comprising multiple layers of fine fiber media separated by coarse fiber support, is provided. Advantageous filter constructions result and are provided. Also according to the disclosure, methods for using such arrangements to filter are provided.

Abstract: A low trauma pressure-sensitive adhesive coated substrate comprising a sheet material, tape or laminate structure designed to adhere to skin or like surfaces. The pressure-sensitive adhesive layer of this adhesive coated substrate is a fibrous adhesive layer generally having a basis weight of from 5 to 200 g/m2 applied to a conformable backing or substrate. The fibrous adhesive layer has a textured outer face and persistent porosity between discrete adhesive fibers. Generally, the fibrous adhesive layer has a MVTR (measured by ASTM E 96-80 at 40° C.) of at least 1000 g/m2/day, preferably at least 6000 g/m2/day.

Abstract: There is provided a laminate having at least one layer of meltblown elastic fibers bonded on either side with a layer of soft non-elastic fibers of greater than 7 microns in average diameter. The laminate has a drape stiffness less than half of a similar fabric having a layer of meltblown non-elastic fibers in place of the layer of meltblown elastic fibers.

Abstract: The present invention relates to a textile laminate comprising a fiberfill web substrate and a face layer. The fiberfill web substrate has a plurality of first fibers at the surface of the substrate. The face layer comprises a plurality of extruded second fibers which are mechanically intertangled with the plurality of first fibers at the surface of the substrate to thereby form the textile laminate. Typically, the first fibers of the fiberfill web are polyester fiberfill fibers and the second fibers of the extruded face layer are polypropylene fibers.

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;.