Including Strand Or Fiber Material Which Is A Monofilament Composed Of Two Or More Polymeric Materials In Physically Distinct Relationship (e.g., Sheath-core, Side-by-side, Islands-in-sea, Fibrils-in-matrix, Etc.) Or Composed Of Physical Blend Of Chemically Different Polymeric Materials Or A Physical Blend Of A Polymeric Material And A Filler Material Patents (Class 442/361)
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Publication number: 20110263172Abstract: A multi-component article with controllable degradation and/or disintegration, comprising: a first part (A) which comprises at least one polyolefin combined with at least one prodegradation/prodisintegration agent; and; a second part (B) which comprises at least one polyolefin combined with at least one prodegradation/prodisintegration agent, provided that said first and said second parts differ at least by either one of type of polyolefin, type of prodegradation/prodisintegration agent and level of prodegradation/prodisintegration agent, the types of polyolefin and of prodegradation/prodisintegration agent and the levels of prodegradation/prodisintegration agent being selected so as said part (B) degrades more slowly than said part (A), and said part (B) at least partially covers said part (A).Type: ApplicationFiled: November 13, 2009Publication date: October 27, 2011Applicant: Total Petrochemicals Research FeluyInventors: Gloria Vendrell, Hugues Haubruge, Thierry Saudemont
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Publication number: 20110230110Abstract: A nonwoven fabric is provided having a plurality of semi-crystalline filaments that are thermally bonded to each other and are formed of the same polymer and exhibit substantially the same melting temperature. The fabric is produced by melt spinning an amorphous crystallizable polymer to form two components having different levels of crystallinity. During spinning, a first component of the polymer is exposed to conditions that result in stress-induced crystallization such that the first polymer component is in a semi-crystalline state and serves as the matrix or strength component of the fabric. The second polymer component is not subjected to stress induced crystallization and thus remains in a substantially amorphous state which bonds well at relatively low temperatures. In a bonding step, the fabric is heated to soften and fuse the binder component. Under these conditions, the binder component undergoes thermal crystallization so that in the final product, both polymer components are semi-crystalline.Type: ApplicationFiled: June 1, 2011Publication date: September 22, 2011Inventors: Gregory W. Farell, Edward Keith Willis
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Patent number: 8021996Abstract: The present invention provides a nonwoven web prepared from multicomponent fibers which are partially split. The partially split multicomponent fibers have at least one component of the multicomponent fiber separated from the remaining components of the multicomponent fiber along a first section of the longitudinal length of the multicomponent fibers. Along a second section of the longitudinal length of the multicomponent fibers the components of the multicomponent fibers remain together as a unitary fiber structure. In addition, part of the second section of the multicomponent fibers is bonded to part of a second section of an adjacent multicomponent fiber.Type: GrantFiled: December 23, 2008Date of Patent: September 20, 2011Assignee: Kimberly-Clark Worldwide, Inc.Inventors: Susan Kathleen Walser, Leon Eugene Chambers, Jr., Reginald Smith, Nancy J. Zimmerman, Kiran K. Reddy, Nina Frazier, David Myers
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Patent number: 8021997Abstract: A multicomponent spunbonded nonwoven is provided which is composed of at least two polymers which form interfaces toward one another, which are produced by at least one spinning machine having uniform spinning nozzle apertures, and which are hydrodynamically drawn, lapped in a sheet-like manner, and bonded, the multicomponent spunbonded nonwoven being composed of different filaments which contain at least two polymers, or it being composed of a mixture of multicomponent filaments and monocomponent filaments which each contain only one of the polymers, the multicomponent filament being composed of at least two elementary filaments and the titer of the individual filaments varying by the number of elementary filaments contained in the filaments.Type: GrantFiled: July 20, 2005Date of Patent: September 20, 2011Assignee: Carl Freudenberg KGInventors: Robert Groten, Ulrich Jahn, Georges Riboulet
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Patent number: 8017535Abstract: Densified non-woven materials having acoustic and thermal properties are provided. The non-woven material is formed of a thermoplastic material or fibers and a thermoplastic material. The fibers may be an organic, inorganic, or thermoplastic fiber and are desirably devoid of conventional sizing compositions. The densified portion of the non-woven material is formed by applying a moisture additive and subsequently applying heat. Heating the non-woven material causes the water in the moisture additive to turn to steam, which causes a molecular change in the polymer based thermoplastic material(s) of the non-woven material that was treated with the moisture additive. The moisture additive is preferably water, but may include a dilute alkali, a dilute acid, or additives to enhance surface, fire, or mold release characteristics. The water additive may be utilized to surface treat, partially treat, or completely treat the air-laid mat to achieve desired acoustic or thermal properties and/or stiffness.Type: GrantFiled: December 14, 2006Date of Patent: September 13, 2011Assignee: Owens Corning Intellectual Capital, LLCInventor: Anthony L. Rockwell
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Patent number: 8007904Abstract: A multicomponent fiber having a metal phobic component and a metal philic component that allows for the selective distribution of metal across the surface of the fiber is disclosed. The inventive multicomponent fibers may be used in fabrics and other products manufactured therefrom for economically imparting at least one of an antistatic quality, antimicrobial and antifungal efficacy, and ultraviolet and/or electromagnetic radiation shielding.Type: GrantFiled: January 12, 2009Date of Patent: August 30, 2011Assignee: Fiber Innovation Technology, Inc.Inventor: Jeffrey S. Dugan
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Patent number: 8003555Abstract: A flame retardant synthetic fiber and a flame retardant fiber composite that satisfy high flame retardance and high fire resistance, a method for producing the flame retardant synthetic fiber and the flame retardant fiber composite, and a textile product are provided. The flame retardant synthetic fiber of the present invention includes a polymer (1) containing 30 to 70 parts by mass of acrylonitrile, 70 to 30 parts by mass of a halogen-containing vinylidene monomer and/or a halogen-containing vinyl monomer, and 0 to 10 parts by mass of a vinyl-based monomer copolymerizable therewith, based on 100 parts by mass of the polymer, and at least one kind of a metal compound (2) that accelerates a dehalogenation reaction of the polymer (1) during burning and a carbonization reaction of the polymer (1) during burning, wherein the flame retardant synthetic fiber has a shrinkage variation of 45% or less when a temperature is raised from 50° C. to 300° C. under a load of 0.0054 mN/dtex.Type: GrantFiled: July 21, 2009Date of Patent: August 23, 2011Assignee: Kaneka CorporationInventors: Takeshi Tanaka, Hiroyasu Hagi, Toshiaki Ebisu
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Patent number: 7998579Abstract: The present invention relates to fibers and nonwovens made from plasticized polyolefin compositions comprising a polyolefin, a non-functionalized hydrocarbon plasticizer and a slip agent.Type: GrantFiled: April 29, 2005Date of Patent: August 16, 2011Assignee: ExxonMobil Chemical Patents Inc.Inventors: Chon Yie Lin, Bryan Robert Chapman, Chia Yung Cheng, William Michael Ferry, Michael Brian Kelly, Bruce Robert Lundmark, Wen Li
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Patent number: 7998890Abstract: Provided herein is a non-stratified, or homogeneous, non-woven composite having (a) strength-imparting fibers of a relatively high denier and (b) binder fibers of a lower denier that adhere the composite together and that form a smooth, stiff skin on the outer surfaces of the composite. In one instance, the strength-imparting fibers are staple fibers and the binder fibers are bicomponent fibers having a low melt component. In a variation, the composite also contains a small percentage by weight (that is, less than 20%) of flame retardant fibers that impart flame resistant properties to the composite. Preferably, all of the fibers are comprised of the same polymeric material (e.g., polyester), so that the composite is recyclable. The resulting composite exhibits excellent flame retardance, strength, and stiffness, as well as having a smooth surface for attachment of a decorative fabric or other material. A process for manufacturing such composites is also provided.Type: GrantFiled: January 14, 2011Date of Patent: August 16, 2011Assignee: Milliken & CompanyInventor: LeAnne O. Flack
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Patent number: 7998384Abstract: A spunbond nonwoven fabric useful as a topsheet is produced from polypropylene filaments including a high level of reclaimed polypropylene, while maintaining a product quality, including superior formation, comparable to that obtained when using 100 percent virgin polymer. The spunbond nonwoven fabric is made with multicomponent filaments having at least two different polymer components occupying different areas within the filament cross section, and wherein one of the polymer components comprises reclaimed polypropylene recovered from previously spun polypropylene fiber or webs comprised of previously spun polypropylene fiber. In a specific embodiment, the filaments are sheath-core bicomponent filaments and the reclaimed polypropylene is present in the core component. The core of the bicomponent filament can be comprised of up to 100% reclaimed polypropylene.Type: GrantFiled: August 2, 2001Date of Patent: August 16, 2011Assignee: Fiberweb Simpsonville, Inc.Inventors: Jay Darrell Gillespie, Daniel Deying Kong, Robert C. Alexander
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Patent number: 7993727Abstract: An advanced grid structure has high strength and low thermal expansion, and includes first, second, and third tape prepreg groups each including a plurality of tape prepregs. Each tape prepreg includes carbon fibers that are aligned in a first, second, or third direction and that form respective first, second, and third grid sides. A plurality of each the first, second, and third grid sides are spaced apart at equal intervals in the respective first, second, or third direction to form respective first, second, and third grid side groups. A structure ratio of the advanced grid structure is larger than 0 and 0.107 or less, 0.053 or less, or 0.040 or less. A thermal expansion coefficient of the advanced grid structure is ?0.9 ppm/K or more and 0.9 ppm/K or less. The carbon fibers have a tensile modulus of elasticity of 280 GPa or more and 330 GPa or less.Type: GrantFiled: June 2, 2008Date of Patent: August 9, 2011Assignee: Mitsubishi Electric CorporationInventors: Kazushi Sekine, Hajime Takeya, Tsuyoshi Ozaki, Masami Kume
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Patent number: 7989062Abstract: A biodegradable nonwoven web comprising substantially continuous multicomponent filaments is provided. The filaments comprise a first component and a second component. The first component contains at least one high-melting point aliphatic polyester having a melting point of from about 160° C. to about 250° C. and the second component contains at least one low-melting point aliphatic polyester. The melting point of the low-melting point aliphatic polyester is at least about 30° C. less than the melting point of the high-melting point aliphatic polyester. The low-melting point aliphatic polyester has a number average molecular weight of from about 30,000 to about 120,000 Daltons, a glass transition temperature of less than about 25° C., and an apparent viscosity of from about 50 to about 215 Pascal-seconds, as determined at a temperature of 160° C. and a shear rate of 1000 sec?1.Type: GrantFiled: April 7, 2006Date of Patent: August 2, 2011Assignee: Kimberly-Clark Worldwide, Inc.Inventors: Jayant Chakravarty, Vasily Topolkaraev, John Herbert Conrad, Stephen Avedis Baratian, Jared L. Martin
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Patent number: 7981822Abstract: The instant invention is a hook and loop fastener device. According to the instant invention, the hook and loop fastener device includes a loop component. The loop component includes a binder-free non-woven material having a bottom layer and a top layer. The bottom layer includes a first bicomponent fiber and a first monocomponent fiber. The first bicomponent fiber comprises the majority of the bottom layer based on total weight of the bottom layer, and the first monocomponent fiber comprises the balance thereof. The top layer includes a second bicomponent fiber, and a second monocomponent fiber. The second monocomponent fiber comprises the majority of the top layer based on total weight of the top layer, and the second bicomponent layer comprises the balance thereof. The bottom layer and the top layer may further include interfiber bonding to form the binder-free non-woven material.Type: GrantFiled: July 11, 2005Date of Patent: July 19, 2011Assignee: Aplix S.A.Inventors: Donald H. Lester, Jr., David L. Lunceford
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Publication number: 20110165470Abstract: The present invention relates to a new bicomponent fiber, a nonwoven fabric comprising said new bicomponent fiber and sanitary articles made therefrom. The bicomponent fiber contains a polyethylene-based resin forming at least part of the surface of the fiber longitudinally continuously and is characterized by a Co-monomer Distribution Constant greater than about 45, a recrystallization temperature between 85° C. and 110° C., a tan delta value at 0.1 rad/sec from about 15 to 50, and a complex viscosity at 0.1 rad/second of 1400 Pa.sec or less. The nonwoven fabric comprising the new bicomponent fiber according to the instant invention are not only excellent in softness, but also high in strength, and can be produced in commercial volumes at lower costs due to higher thoughputs and requiring less energy.Type: ApplicationFiled: January 4, 2010Publication date: July 7, 2011Inventors: Jörg Dahringer, Bernd Blech, Werner Stefani, Werner Grasser, Mehmet Demirors, Gert Claasen
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Patent number: 7972692Abstract: A multicomponent fiber that contains a high-melting aliphatic polyester and a low-melting aliphatic polyester is provided. The multicomponent fibers are substantially biodegradable, yet readily processed into nonwoven structures that exhibit effective fibrous mechanical properties.Type: GrantFiled: December 15, 2005Date of Patent: July 5, 2011Assignee: Kimberly-Clark Worldwide, Inc.Inventors: Jayant Chakravarty, Vasily Topolkaraev, Gregory J. Wideman
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Patent number: 7968481Abstract: A heat fusible conjugate fiber produced by high-speed melt spinning is disclosed. The conjugate fiber is composed of a first resin component having an orientation index of 40% or higher and a second resin component having a lower melting or softening point than the melting point of the first resin component and an orientation index of 25% or lower. The second resin component is present on at least part of the surface of the fiber in a lengthwise continuous configuration. The conjugate fiber preferably has a heat shrinkage of 0.5% or less at a temperature higher than the melting or softening point of the second resin component by 10° C.Type: GrantFiled: December 19, 2003Date of Patent: June 28, 2011Assignee: KAO CorporationInventors: Manabu Matsui, Takeshi Kikutani
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Publication number: 20110142896Abstract: Disclosed are water-dispersible fibers derived from sulfopolyesters having a Tg of at least 25° C. The fibers may contain a single sulfopolyester or a blend of a sulfopolyester with a water-dispersible or water-nondispersible polymer. Also disclosed are multicomponent fibers comprising a water dispersible sulfopolyester having a Tg of at least 57° C. and a water non-dispersible polymer. The multicomponent fibers may be used to produce microdenier fibers. Fibrous articles may be produced from the water-dispersible fibers, multicomponent fibers, and microdenier fibers. The fibrous articles include water-dispersible and microdenier nonwoven webs, fabrics, and multilayered articles such as wipes, gauze, tissue, diapers, panty liners, sanitary napkins, bandages, and surgical dressings. Also disclosed is a process for water-dispersible fibers, nonwoven fabrics, and microdenier webs.Type: ApplicationFiled: December 13, 2010Publication date: June 16, 2011Applicant: EASTMAN CHEMICAL COMPANYInventors: William Alston Haile, Scott Ellery George, Wesley Raymond Hale, Waylon Lewellyn Jenkins
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Patent number: 7960299Abstract: A reinforced fabric that includes a first fiber group and a thread. The first fiber group includes a plurality of fiber sets positioned substantially parallel to one another. Each of the fiber sets includes a plurality of fibers. The thread is formed of at least one strand of material. The thread has an outer surface that is formed of a material having a melting point that is less than the melting point of the fibers in the fiber sets. The thread is stitched about the fiber sets to at least partially maintain a position of the fiber sets relative to one another. The thread forms a plurality of heat created permanent closed loop structures in the reinforced fabric. At least one of the loop structures encircles at least one fiber set. At least one of the fibers in the fibers sets is not strongly bonded to the thread that encircles the fiber set.Type: GrantFiled: November 16, 2006Date of Patent: June 14, 2011Assignee: Garland Industries, Inc.Inventor: Louis Kevin Horne
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Patent number: 7938908Abstract: The present invention relates to a fiber including unmodified and/or modified starch and a crosslinking agent, and a web employing such a fiber.Type: GrantFiled: January 5, 2010Date of Patent: May 10, 2011Assignee: The Procter & Gamble CompanyInventors: Valerie Ann Bailey, Larry Neil Mackey, Paul Dennis Trokhan
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Publication number: 20110105975Abstract: Disclosed are multicomponent fibers derived from a blend of a sulfopolyester with a water non-dispersible polymer wherein the as-spun denier is less than about 6 and wherein the water dispersible sulfopolyester exhibits a melt viscosity of less than 12,000 poise measured at 240° C. at a strain rate of 1 rad/sec, and wherein the sulfopolyester comprising less than about 25 mole % of residues of at least one sulfomonomer, based on the total moles of diacid or diol residues. The multicomponent fiber is capable of being drawn at a relatively high fiber speed, particularly at least about 2000 m/min, and may be used to produce microdenier fibers. Fibrous articles may be produced from the multicomponent fibers and microdenier fibers. Also disclosed is a process for multicomponent fibers, nonwoven fabrics, and microdenier webs.Type: ApplicationFiled: December 22, 2010Publication date: May 5, 2011Applicant: EASTMAN CHEMICAL COMPANYInventors: Rakesh Kumar Gupta, Scott Ellery George, Daniel William Klosiewicz, Kab Sik Seo, Coralie McKenna Fleenor, Allen Lynn Crain
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Patent number: 7935644Abstract: A machine for producing a nonwoven feeds continuous filaments onto two surfaces that form a convergent passage. At least one of the surfaces is moving to drive the continuous filaments through the passage to form the nonwoven web. The continuous filaments have filament portions that are respectively received on the two surfaces to form spaced lateral web parts joined by a central web part formed by the continuous filament portions bridging the convergent passage. A vacuum is applied through the surfaces to assist placement of the filament portions and to direct the web as it emerges from the passage onto a horizontal take-up conveyor.Type: GrantFiled: April 8, 2009Date of Patent: May 3, 2011Assignee: Maschinenfabrik Rieter AGInventors: Frederic Noelle, Rolf Helmut Joest, Peter Anderegg
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Patent number: 7935645Abstract: A method of producing a nonwoven fabric comprising spinning a set of bicomponent fibers which include an external fiber component and an internal fiber component. The external fiber enwraps said internal fiber and has a higher elongation to break value than the internal fiber and a lower melting temperature than the internal fiber component. The set of bicomponent fibers are positioned onto a web and thermally bonded to produce a nonwoven fabric.Type: GrantFiled: September 26, 2008Date of Patent: May 3, 2011Assignee: North Carolina State UniversityInventors: Behnam Pourdeyhimi, Nataliya V. Fedorova, Stephen R. Sharp
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Patent number: 7928024Abstract: A composite pad is made of two layers joined together at their interface. The top layer of the composite pad, which has a smooth surface has a dense and firm fine denier fibrous structure. The bottom layer of the composite pad has a lighter and softer coarser denier fibrous structure in order to be able to have a large fluid holding capacity. A method of manufacturing the composite stamp pad is described.Type: GrantFiled: March 21, 2006Date of Patent: April 19, 2011Assignee: American Felt and Filter CompanyInventors: Francis F. Kochesky, Kalyn S. Kimler, Mark A. Pryne
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Patent number: 7919419Abstract: The present invention provides high strength nonwoven wipe materials and the process of making the materials. The high strength nonwoven wipe materials contain cellulosic fibers, synthetic fibers, or mixtures thereof, with bicomponent fibers and optionally, a binder. The present invention provides a high strength, high elongation, reduced stiffness nonwoven wipe material with superior tensile strength.Type: GrantFiled: November 5, 2008Date of Patent: April 5, 2011Assignee: Buckeye Technologies Inc.Inventors: Jeffrey Scott Hurley, Brian E. Boehmer, Alan Jeffrey Campbell, Jerry Michael Moore, Douglas William Vercauteren, Barry George Burgess, Heather Fielder Horton
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Patent number: 7902094Abstract: Disclosed are water-dispersible fibers derived from sulfopolyesters having a Tg of at least 25° C. The fibers may contain a single sulfopolyester or a blend of a sulfopolyester with a water-dispersible or water-nondispersible polymer. Also disclosed are multicomponent fibers comprising a water dispersible sulfopolyester having a Tg of at least 57° C. and a water non-dispersible polymer. The multicomponent fibers may be used to produce microdenier fibers. Fibrous articles may be produced from the water-dispersible fibers, multicomponent fibers, and microdenier fibers. The fibrous articles include water-dispersible and microdenier nonwoven webs, fabrics, and multilayered articles such as wipes, gauze, tissue, diapers, panty liners, sanitary napkins, bandages, and surgical dressings. Also disclosed is a process for water-dispersible fibers, nonwoven fabrics, and microdenier webs.Type: GrantFiled: August 16, 2005Date of Patent: March 8, 2011Assignee: Eastman Chemical CompanyInventors: William Alston Haile, Scott Ellery George, Wesley Raymond Hale, Waylon Lewellyn Jenkins
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Patent number: 7892993Abstract: Disclosed are multicomponent fibers derived from a blend of a sulfopolyester with a water non-dispersible polymer wherein the as-spun denier is less than about 6 and wherein the water dispersible sulfopolyester exhibits a melt viscosity of less than 12,000 poise measured at 240° C. at a strain rate of 1 rad/sec, and wherein the sulfopolyester comprising less than about 25 mole % of residues of at least one sulfomonomer, based on the total moles of diacid or diol residues. The multicomponent fiber is capable of being drawn at a relatively high fiber speed, particularly at least about 2000 m/min, and may be used to produce microdenier fibers. Fibrous articles may be produced from the multicomponent fibers and microdenier fibers. Also disclosed is a process for multicomponent fibers, nonwoven fabrics, and microdenier webs.Type: GrantFiled: January 31, 2006Date of Patent: February 22, 2011Assignee: Eastman Chemical CompanyInventors: Rakesh Kumar Gupta, Scott Ellery George, Daniel William Klosiewicz, Kab Sik Seo, Coralie McKenna Fleenor, Allen Lynn Crain
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Patent number: 7892389Abstract: A reinforced fabric that includes a first fiber group and a thread. The first fiber group includes a plurality of fiber sets positioned substantially parallel to one another. Each of the fiber sets includes a plurality of fibers. The thread is formed of at least one strand of material. The thread has an outer surface that is formed of a material having a melting point that is less than the melting point of the fibers in the fiber sets. The thread is stitched about the fiber sets to at least partially maintain a position of the fiber sets relative to one another. The thread forms a plurality of heat created permanent closed loop structures in the reinforced fabric. At least one of the loop structures encircles at least one fiber set. At least one of the fibers in the fibers sets is not strongly bonded to the thread that encircles the fiber set.Type: GrantFiled: May 4, 2010Date of Patent: February 22, 2011Assignee: Garland Industries, Inc.Inventor: Louis Kevin Horne
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Publication number: 20110011792Abstract: There is provided a hybrid polymer fiber material containing a non-electrolytic polymer and an electrolytic polymer and having properties and advantages of both polymers, and provided a method of producing the hybrid polymer fiber material, and provided a filter made of the hybrid polymer fiber material. A voltage is applied between a nozzle 1 and a target 3 (opposite surface) such that the nozzle 1 is positive and such that the target 3 is negative. Then, the mixed solution of the non-electrolytic polymer and the electrolytic polymer is ejected from the nozzle 1 to the target 3, so that hybrid polymer fiber material 2 containing the non-electrolytic polymer and the electrolytic polymer is accumulated on the target 3. The hybrid polymer fiber material 2 is used as a filter for fluid filtration.Type: ApplicationFiled: March 25, 2009Publication date: January 20, 2011Applicant: KURITA WATER INDUSTRIES LTD.Inventors: Takahiro Kawakatsu, Hideki Kobayashi, Yuichi Ogawa
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Patent number: 7871946Abstract: A nonwoven fabric composed of ultra-fine continuous fibers having a mean fineness of not more than 0.5 dtex is prepared. The nonwoven fabric comprises a water-soluble thermoplastic resin in a proportion of not more than 5% by weight relative to the nonwoven fabric, has an absorbing height of not less than 30 mm as determined at 20° C. after 10 minutes based on Byreck method when the nonwoven fabric immersion-treated for 60 minutes in a water of 80° C. is used, and satisfies the following formula: (B)/(A)?0.25, wherein the symbol (B) represents a tensile strength [N/5 cm] in the longitudinal direction and the lateral direction of the nonwoven fabric and the symbol (A) represents a fabric weight [g/m] of the nonwoven fabric. In the nonwoven fabric, not less than 30% of the surface may be coated with the water-soluble thermoplastic resin. The water-soluble thermoplastic resin may be a water-soluble thermoplastic polyvinyl alcohol, e.g.Type: GrantFiled: September 27, 2004Date of Patent: January 18, 2011Assignee: Kuraray Co., Ltd.Inventors: Takuya Tsujimoto, Naoki Fujiwara, Midori Okazaki, Nozomu Sugo
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Patent number: 7871947Abstract: Provided herein is a non-stratified, or homogeneous, non-woven composite having (a) strength-imparting fibers of a relatively high denier and (b) binder fibers of a lower denier that adhere the composite together and that form a smooth, stiff skin on the outer surfaces of the composite. In one instance, the strength-imparting fibers are staple fibers and the binder fibers are bicomponent fibers having a low melt component. In a variation, the composite also contains a small percentage by weight (that is, less than 20%) of flame retardant fibers that impart flame resistant properties to the composite. Preferably, all of the fibers are comprised of the same polymeric material (e.g., polyester), so that the composite is recyclable. The resulting composite exhibits excellent flame retardance, strength, and stiffness, as well as having a smooth surface for attachment of a decorative fabric or other material. A process for manufacturing such composites is also provided.Type: GrantFiled: October 22, 2008Date of Patent: January 18, 2011Assignee: Milliken & CompanyInventor: LeAnne O. Flack
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Publication number: 20110003524Abstract: A bicomponent fiber is obtainable from or comprises an ethylene/?-olefin interpolymer characterized by an elastic recovery, Re, in percent at 300 percent strain and 1 cycle and a density, d, in grams/cubic centimeter, wherein the elastic recovery and the density satisfy the following relationship: Re>1481?1629(d). Such interpolymer can also be characterized by other properties. The fibers made therefrom have a relatively high elastic recovery and a relatively low coefficient of friction. The fibers can be cross-linked, if desired. Woven or non-woven fabrics, such as spunbond, melt blown and spun-laced fabrics or webs can be made from such fibers.Type: ApplicationFiled: February 20, 2009Publication date: January 6, 2011Applicant: DOW GLOBAL TECHNOLOGIES INC.Inventors: Gert J. Claasen, Ronald J. Weeks, Andy C. Chang, Debra H. Niemann
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Patent number: 7863206Abstract: Nonwoven fabrics and methods for making the same are described, wherein the fabrics comprise two or more propylene-based elastomers in combination with one or more propylene-based thermoplastic polymers. Specifically, the first propylene-based elastomer comprises at least 7% by weight ethylene or non-propylene alpha-olefin units, the second propylene-based elastomer comprises less than 7% by weight ethylene or non-propylene alpha-olefin units, the first and second propylene-based elastomers each have a heat of fusion less than 80 J/g, and the propylene-based thermoplastic polymer has a heat of fusion greater than 80 J/g.Type: GrantFiled: November 9, 2007Date of Patent: January 4, 2011Assignee: ExxonMobil Chemical Patents Inc.Inventors: Bruce A. Harrington, Smita Kacker, Vetkav Rajagopalan Eswaran
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Patent number: 7851391Abstract: The present invention is directed to multicomponent fibers. The fibers may be in a side-by-side, sheath-core, segmented pie, islands-in-the-sea configuration, or any combination of configurations. Each component of the fiber will comprise destructurized starch and/or a thermoplastic polymer. The present invention is also directed to nonwoven webs and disposable articles comprising the multicomponent fibers. The nonwoven webs may also contain other synthetic or natural fibers blended with the multicomponent fibers of the present invention.Type: GrantFiled: April 26, 2004Date of Patent: December 14, 2010Assignee: The Procter & Gamble CompanyInventors: Eric Bryan Bond, Jean-Philippe Marie Autran, Larry Neil Mackey, Isao Noda, Hugh Joseph O'Donnell, Dean Van Phan
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Patent number: 7846855Abstract: A nonwoven fabric containing a polyvinyl butyral fiber is provided. In particular, continuous fiber nonwoven fabrics, such as a melt-blown nonwoven fabric and a spunbonded nonwoven fabric, are preferred. By laminating a plurality of layers via an adhering layer made of such a nonwoven fabric and then heating, a laminate is obtained by a simple process. In particular, an interior material in which an inorganic fiber layer, a foam layer and a surface material layer are adhered together via the aforementioned type of adhering layers is a desirable embodiment. Such an interior material is excellent in rigidity, sound absorbency and thermal deformation resistance, and therefore is useful as an interior material to be used for cars, railway vehicles, vessels, and the like.Type: GrantFiled: March 23, 2006Date of Patent: December 7, 2010Assignees: Kuraray Co., Ltd., Kuraray Europe GmbHInventors: Toshimitsu Harada, Soichi Obata, Hideo Hayashi, Yasurou Araida, Tomoaki Kimura, Martin Steuer
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Patent number: 7846856Abstract: Fibers that durably contain antimicrobial materials such that the antimicrobial materials are resistant to being abraided away or washed off during use. The antimicrobial materials contained in the fibers are not prone to the development of resistant strains of bacteria. Also disclosed are methods of making and using the fibers.Type: GrantFiled: April 14, 2010Date of Patent: December 7, 2010Assignee: Rohm and Haas CompanyInventors: Tirthankar Ghosh, Barry Weinstein
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Patent number: 7842630Abstract: The present invention is aimed at a method of providing wettability to polyester fibers or filaments, to woven or nonwoven fabrics made therefrom and to resultant articles of manufacture. The method comprises melt extruding a mixture comprising a polyester and one or more alkyl metal sulfonates where the metal is Na, Li or K and the alkyl is straight or branched chain alkyl of 12 to 15 carbon atoms, or is straight or branched chain alkenyl of 12 to 18 carbon atoms. The alkyl metal sulfonates are present from about 2% to about 5% by weight based on the weight of the polyester. A post treatment step such as an alkaline treatment step is not included. The melt extrusion mixtures do not include certain additives such as polyoxyalkylene compounds, alkylmonoethonolamide compounds, alkyldiethanolamine compounds and polyetheramide compounds.Type: GrantFiled: November 14, 2007Date of Patent: November 30, 2010Assignee: Ciba Specialty Chemicals CorporationInventors: Colin J. H. Morton, Thomas Thompson, Ashutosh H. Sharma
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Patent number: 7838449Abstract: A dryer sheet substrate is provided having improved loft and reduced fuzz wherein the substrate comprises relatively low denier bicomponent fibers. The bicomponent fibers may comprise two or more polymers having different melting temperatures, with the relatively lower melting temperature polymer making up at least a portion of the outer surface of the fiber. Upon heating to a sufficient temperature, the lower melting temperature fibers may soften and melt, providing bonding at crossover points of the fibers in the laid web. The web indicates advantageous characteristics with respect to thickness (loft), fuzz factor and ability to absorb a fabric treating composition.Type: GrantFiled: May 29, 2008Date of Patent: November 23, 2010Assignee: Freudenberg Spunweb CompanyInventors: Samuel Keith Black, Terezie Zapletalova, John McNabb, Jeffrey Stine
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Patent number: 7829484Abstract: The present invention is aimed at a method of providing wettability to polyester fibers or filaments, to woven or nonwoven fabrics made therefrom and to resultant articles of manufacture. The method comprises melt extruding a mixture comprising a polyester and one or more alkyl metal sulfonates where the metal is Na, Li or K and the alkyl is straight or branched chain alkyl of 1 to 24 carbon atoms, or is straight or branched chain alkenyl of 2 to 24 carbon atoms. The alkyl metal sulfonates are present from about 0.1% to about 1.9% by weight based on the weight of the polyester. A post treatment step such as an alkaline treatment step is not included. The melt extrusion mixtures do not include certain additives such as polyoxyalkylene compounds, alkylmonoethonolamide compounds, alkyldiethanolamine compounds and polyetheramide compounds.Type: GrantFiled: November 10, 2006Date of Patent: November 9, 2010Assignee: Ciba Specialty Chemicals Corp.Inventors: Ashutosh Sharma, Michael Tinkl, Andrew Leggio, Matthew Gande, Armin Schneider
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Patent number: 7829486Abstract: The leather-like sheet substrate of the present invention comprises a fiber-entangled nonwoven fabric that comprises a microfine fiber bundle (A) and a microfine fiber bundle (B) in a blending ratio (A)/(B) of 30/70 to 70/30 by mass and a polymeric elastomer contained in the fiber-entangled nonwoven fabric. The microfine fiber bundle (A) comprises 10 to 100 microfine fibers each of which has a single fiber fineness of 0.5 dtex or less and which are made of an elastic polymer having a JIS A hardness of 90 to 97. The microfine fiber bundle (B) comprises a microfine fiber which has a single fiber fineness of 0.5 dtex or less and which is made of a non-elastic polymer. Because of its excellent stretchability in both the machine and transverse directions and drapeability, the leather-like sheet substrate is particularly suitable as the material for clothing.Type: GrantFiled: January 29, 2004Date of Patent: November 9, 2010Assignee: Kuraray Co., Ltd.Inventors: Yoshiki Nobuto, Yoshihiro Tanba
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Patent number: 7829485Abstract: An integral composite fiber is formed by integrally joining a stretchable fiber and unstretchable fibers. The stretchable fiber has longitudinally extending first exposed surfaces that are circumferentially spaced from each other. The unstretchable fibers has longitudinally extending second exposed surfaces each disposed between a circumferentially adjacent pair of the first exposed surfaces. One of the first exposed surfaces has a larger surface area than the other or others of the first exposed surfaces. Said other or each of the others of the first exposed surfaces has a surface area ratio of less than 0.8 with respect to the surface area of said one of the first exposed surfaces.Type: GrantFiled: July 6, 2007Date of Patent: November 9, 2010Assignee: Suetomi Engineering Co.Inventor: Masamichi Mikura
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Patent number: 7829487Abstract: An extensible nonwoven fabric comprises a fiber comprising at least two olefin-based polymers. These olefin-based polymers are of the same kind and have different induction periods of strain-induced crystallization as measured at the same temperature and shear strain rate. A composite nonwoven fabric of the invention comprises at least one layer comprising the extensible nonwoven fabric.Type: GrantFiled: November 25, 2003Date of Patent: November 9, 2010Assignee: Mitsui Chemicals, Inc.Inventors: Kenichi Suzuki, Hisashi Morimoto, Katsuaki Harubayashi, Shigeyuki Motomura, Pingfan Chen
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Patent number: 7807593Abstract: In one embodiment the invention is an article comprising at least two layers, a first or low crystallinity layer comprising a low crystallinity polymer and a second or high crystallinity layer comprising a high crystallinity polymer. The high crystallinity polymer has a melting point as determined by differential scanning calorimetry (DSC) that is about the same or within less than 25 C of the melting point of the low crystallinity polymer. The article is elongated at a temperature below the melting point of the low crystallinity polymer in at least one direction to an elongation of at least about 50% of its original length or width, to form a pre-stretched article. Preferably, the high crystallinity layer is capable of undergoing plastic deformation upon the elongation.Type: GrantFiled: October 24, 2006Date of Patent: October 5, 2010Assignee: Dow Global Technologies Inc.Inventors: Rajen M. Patel, Andy Chang
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Patent number: 7790641Abstract: The invention provides a sheet material comprising bicomponent filaments having first and second polymer components that are arranged in substantially distinct zones within the filaments, with the first polymer component formed of a relatively lower melting polymer and the second component formed of a relatively higher melting polymer. The filaments of the nonwoven fabric layer are densely arranged and compacted against one another to form smooth, substantially nonporous opposite outer surfaces, and the nonwoven fabric layer are calendered such that the lower melting sheath polymer is fused to the contacting surface portions of adjacent filaments to impart strength and coherency to the nonwoven fabric layer. The sheet material has excellent breathability and liquid barrier properties and may be useful in house wrap, medical garments, and envelope applications.Type: GrantFiled: July 27, 2006Date of Patent: September 7, 2010Assignee: Fiberweb, Inc.Inventors: John Frank Baker, Jr., Gregory W. Farell, Shannon Schoppman
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Patent number: 7790283Abstract: Cellulosic fibers having enhanced reversible thermal properties and applications of such cellulosic fibers are described. In one embodiment, a cellulosic fiber includes a fiber body including a cellulosic material and a set of microcapsules dispersed in the cellulosic material. The set of microcapsules contain a phase change material having a latent heat of at least 40 J/g and a transition temperature in the range of 0° C. to 100° C., and the phase change material provides thermal regulation based on at least one of absorption and release of the latent heat at the transition temperature. The cellulosic fiber can be formed via a solution spinning process, and can be used in various products where thermal regulating properties are desired.Type: GrantFiled: June 29, 2007Date of Patent: September 7, 2010Assignee: Outlast Technologies, Inc.Inventors: Mark Hartmann, James Brice Worley, Matthew North
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Patent number: 7790640Abstract: The present disclosure generally relates to absorbent articles. More specifically, the present disclosure relates to an absorbent article comprising a surge management layer comprising a nonwoven web. The nonwoven web includes a filler fiber and a binder fiber. A portion of the cross-sectional area of the filler fiber is hollow, and the binder fiber includes a sheath component and a core component.Type: GrantFiled: March 23, 2006Date of Patent: September 7, 2010Assignee: Kimberly-Clark Worldwide, Inc.Inventors: Jayant Chakravarty, Vasily A. Topolkaraev, Cliff J. Ellis
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Patent number: 7786028Abstract: A flexible nonwoven mat of polymeric fibers is liquid water transmission resistant and is particularly well suited for use as a prefabricated building construction underlayment. The polymeric fibers may be standard polymeric fibers or sheathed polymeric fibers that have fiber sheaths with a lower softening point temperature than the softening point temperature of the fiber cores. Preferably, the polymeric fibers are spunbond fibers and are bonded together through the application of heat and pressure. Where the fibers are sheathed fibers, interstices of the nonwoven mat are at least partially filled by a portion of the polymeric material of the sheaths that is dispersed into the interstices to reduce the porosity of the mat.Type: GrantFiled: March 15, 2006Date of Patent: August 31, 2010Assignee: Johns ManvilleInventors: Roger Lee Souther, Ralph Michael Fay, Ruben Gregory Garcia
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Patent number: 7785710Abstract: Particles comprising a combination of a carboxyalkyl cellulose and a galactomannan polymer or a glucomannan polymer, wherein the particles comprise a plurality of non-permanent metal crosslinks.Type: GrantFiled: October 2, 2006Date of Patent: August 31, 2010Assignee: Weyerhaeuser NR CompanyInventors: S. Ananda Weerawarna, Mengkui Luo, Alena Michalek
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Publication number: 20100197183Abstract: A product and process of manufacturing a non-woven web from cotton regin for use as an industrial hydrophobic absorbent, a filter or insulator. The method of processing the cotton regin creates a low-density and, thus, a high-absorbency web. The finished web has a bulk-to-weight ratio of about 25 to 40 mils/osy. The method includes processing cotton regin to a suitable range of fiber and particle sizes, mixing the cotton regin with a thermoplastic bonding agent, and depositing the material onto a steadily advancing belt to produce a relatively low density, loosely formed web. Subsequent processing of the web in an oven softens or melts the bonding agent, thereby adheres it to other web material to give the web its required strength and integrity. One or more continuous, air-permeable layers of scrim or netting may be incorporated on or within the web to provide additional strength or particular surface characteristics.Type: ApplicationFiled: January 29, 2010Publication date: August 5, 2010Inventors: David C. Drapela, John Sellars
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Patent number: 7767598Abstract: A liquid acquisition layer having a multitude of fibers and a binder is useful in a variety of absorbent articles, such as diapers and sanitary napkins. The liquid acquisition layer has a caliper which decreases in response to external pressure and increases upon removal of said external pressure. The increase in caliper is measured by a recovery value, wherein the liquid acquisition layer recovery value at 45° C. is at least 65% of the recovery value at 20° C.Type: GrantFiled: August 6, 2004Date of Patent: August 3, 2010Assignee: The Procter & Gamble CompanyInventors: Manuela Schneider, Christofer Fuchs, Olaf Van Gansewinkel
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Publication number: 20100190406Abstract: A POM/POM thermoadhesive conjugate fiber is produced by providing two kinds of POM-based polymers A and B which satisfy 30<MIA wherein MIA is a before-spinning melt index (g/10 min) of the POM-based polymer A (conditions: 190° C., load: 21.18N (2.16 kg)), and TB>TA+10 wherein TA and TB are before-spinning fusion peak temperatures of the POM-based polymers A and B respectively, compositely spinning a first component containing the POM-based polymer A and a second component containing the POM-based polymer B such that the first component is exposed with an exposed length of not less than 20% relative to a peripheral length of the fiber, subjecting the spun fiber to a drawing treatment, and subjecting the drawn fiber to an annealing treatment at a temperature of from 60° C. to 110° C.Type: ApplicationFiled: July 15, 2008Publication date: July 29, 2010Inventors: Yoshiji Usui, Koji Nagai, Akihiko Kawanaka