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)
  • Publication number: 20080045102
    Abstract: The present invention is directed to polymer blends having controlled flow properties. The polymer blends can be useful in various applications including bonding systems and additive delivery systems, which can provide durable binding and/or delivery and/or affixing of additives. The polymer blends can include at least two different components, at least one being a polymer component having a higher molecular than the other of the components. When heated to an activating temperature, the resultant blend exhibits desirable flow or wet out properties without applied pressure. Despite the controlled flow properties, the blends do not exhibit blocking or fusing properties typically associated with high flow polymer materials.
    Type: Application
    Filed: August 15, 2006
    Publication date: February 21, 2008
    Inventor: Gerald Timothy Keep
  • Publication number: 20080038980
    Abstract: The present invention proposes a spunbonded nonwoven fabric which has an excellent low modulus, retains a high elongating property, and has particularly excellent moldability and followability, and also has excellent dimensional stability after molding, and suitable for a backing ground fabric of automobile interior materials. The present invention pertains to (A) a spunbonded nonwoven fabric consisting of continuous fibers containing aromatic polyester (melting point: Tm1) and aromatic copolyester (a melting point: Tm2=150 degrees centigrade to (Tm1-20 degrees centigrade)) in an amount of 1 to 15% by weight with respect to the aromatic polyester, wherein the elongation rate of the nonwoven fabric is 20% or more and 100% or less, and the load of elongation of 5% is 1.
    Type: Application
    Filed: June 28, 2005
    Publication date: February 14, 2008
    Inventors: Shigeki Tanaka, Masataka Adachi, Toshiya Yamamoto
  • Patent number: 7329623
    Abstract: A nonwoven web of a wettable fiber matrix, wherein the wettable fiber matrix are thermoplastic polymeric fibers blended with at least one hydrophilic melt additive. In alternate embodiments, the nonwoven web further includes binder fibers which may be wettable or non-wettable or combinations of both.
    Type: Grant
    Filed: August 30, 2002
    Date of Patent: February 12, 2008
    Assignee: Ahlstrom Mount Holly Springs LLC
    Inventors: Larry L. Kinn, Ashish Mathur, Gregory Neil Henning
  • Patent number: 7326663
    Abstract: This invention relates to a spunbonded nonwoven made of thermoplastic material, which exhibits a filament diameter of less than 1.0 ?m. The filaments are made from bursted fibers, whereby the filaments exhibit a length of at least five centimeters and are connected to one another at discrete points.
    Type: Grant
    Filed: February 28, 2005
    Date of Patent: February 5, 2008
    Assignee: Fiberweb Corovin GmbH
    Inventors: Ralf Sodemann, Michael Voges
  • Patent number: 7319077
    Abstract: This invention relates to a nonwoven article comprising a heterogeneous blend comprising: 1) from 60 to 99 weight percent of one or more semi-crystalline polymers (based upon the weight of the semi-crystalline and semi-amorphous polymers), each semi-crystalline polymer comprising propylene and from 0 to 5 weight % alpha-olefin comonomer (based upon the weight of the polymer), said semi-crystalline polymers each having a melting point between 100 and 170° C. and a melt flow rate of 2000 dg/min or less; and 2) from 1 to 40 weight % of one or more semi-amorphous polymers (based upon the weight of the semi-crystalline and semi-amorphous polymers), each semi-amorphous polymer comprising propylene and from 10 to 25 weight % of one or more C2 and or C4 to C10 alpha-olefin comonomers, said semi-amorphous polymers each having: a) heat of fusion of 4 to 70 J/g; b) a Melt Flow Rate of 0.
    Type: Grant
    Filed: December 9, 2005
    Date of Patent: January 15, 2008
    Assignee: ExxonMobil Chemical Patents Inc.
    Inventors: Aspy K. Mehta, Chia Yung Cheng, Sudhin Datta, Wen Li, Chon Y. Lin, Srivatsan S. Iyer
  • Patent number: 7319078
    Abstract: A novel porous fibrous structure containing from 10 to 100% by weight of wet heat bonding fibers, having cellular cavities in the fibrous structure of the fibers, in which a plurality of indefinite cellular cavities are present independently or in a state of partially connected in the inside of the fibrous structure, at least a portion of the fibers constituting the fibrous structure is heat bonding by the wet heat bonding fibers, and a process for producing such porous fibrous structure.
    Type: Grant
    Filed: October 11, 2002
    Date of Patent: January 15, 2008
    Assignee: Kuraray Co., Ltd.
    Inventors: Tosirou Yamaguchi, Hisaharu Kuwahara, Hirokuni Tanii
  • Publication number: 20080003914
    Abstract: The present invention relates to a non-woven web comprising fibers and feathers for use as a substrate for cleaning articles. The non-woven web may be created using a variety of non-woven processing techniques and bonding treatments to bond the fibers. The non-woven web is made by combination of variety of fiber types and feathers in varying proportions which create non-woven webs with varying levels of loft, weight, tensile strength, absorbency and abrasiveness.
    Type: Application
    Filed: June 29, 2006
    Publication date: January 3, 2008
    Inventors: Marc Privitera, David Jackson Lestage, Gregory van Buskirk, Bernard Hill, Nikhil Dani
  • Patent number: 7314839
    Abstract: 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: Grant
    Filed: July 20, 2005
    Date of Patent: January 1, 2008
    Assignee: Ciba Specialty Chemicals Corporation
    Inventors: Colin J. H. Morton, Thomas Thompson, Ashutosh H. Sharma
  • Patent number: 7311209
    Abstract: A filter material has one or more plies of fiber layers, in particular for the production of filter bags and filter cones for infused beverages, the at least one fiber layer containing fibers or microcapsules having phase change material. Paraffinic hydrocarbons can be used as the phase change material.
    Type: Grant
    Filed: September 9, 2004
    Date of Patent: December 25, 2007
    Assignees: Outlast Technologies, Inc, Schoeller + Hoesch GmbH & Co. KG
    Inventors: Martin Bentz, Danny H. Meger
  • Publication number: 20070287348
    Abstract: An outer cover for use with an absorbent article having a layer of nonwoven fibrous material and optionally including a polymeric layer laminated or printed onto the layer of nonwoven fibrous material. The outer cover includes at least one plastic component and at least one elastic component in the nonwoven fibrous material and/or optional polymeric layer. The outer cover can have different structural combinations of spunbond fibers, meltblown fibers, and/or nanofibers. The combination of plastic and elastic components results in an outer cover that has favorable mechanical, physical, and aesthetic properties. The outer cover can be rendered either uniaxially or biaxially stretchable via a mechanical activation process.
    Type: Application
    Filed: November 15, 2006
    Publication date: December 13, 2007
    Inventors: Jean-Philippe Marie Autran, Donald Carroll Roe, Terrill Alan Young, Joan Helen Mooney, Fred Naval Desai
  • Patent number: 7303808
    Abstract: A bulky sheet material having three-dimensional protrusions 10 is disclosed. The sheet material comprises a first layer 1 and a second layer 2 adjacent to the first layer 1. The first layer 1 and the second layer 2 is partly joined together at joints 3 in a prescribed pattern. The first layer 1 has a number of raised portions which are located among the joints 3. The second layer 2 comprises a material which exhibits elastomeric behavior. The bulky sheet material 10 exhibits elastomeric behavior as a whole and breathability.
    Type: Grant
    Filed: October 11, 2001
    Date of Patent: December 4, 2007
    Assignee: KAO Corporation
    Inventors: Shoichi Taneichi, Manabu Kaneta, Yasuhiro Komori, Takanobu Miyamoto, Wataru Saka, Yoshihiro Sakai
  • Publication number: 20070270071
    Abstract: The invention relates to a nonwoven fabric towel comprising about 25 to 75% by weight a first fiber comprising a polyester or polyester co-polymer staple fiber having a staple length of between 3 and 6 inches and a surface area per unit length of between approximately 0.2 micrometer2/cm to 1.2 micrometer2/cm, about 25 to 50% by weight a second fiber comprising a multi-segment splitable staple fiber comprising a first component being a polyester or polyester co-polymer component and a second component being a polyamide component or a polyester or polyester co-polymer incompatible with the first component, wherein weight ratio of the first component and the second component is between 40:60 and 80:20, and wherein the first component and the second component have a denier per staple filament of between 0.05 and 0.5, wherein the nonwoven fabric towel is bonded with a stitches of a bulkable yarn, and wherein at least the first or second fiber comprises a hydrophilic surface treatment.
    Type: Application
    Filed: May 18, 2006
    Publication date: November 22, 2007
    Inventors: J. Travis Greer, Paul E. Dodd, Karen H. Stavrakas, Nathan B. Emery
  • Patent number: 7271113
    Abstract: The present invention relates to a multilayer product 1 having at least one first layer 2, an absorbent intermediate layer 3 and a second layer 4, whereby at least the first layer 2 contains at least one first material 5 and one second material 6. The first layer 2 and/or the second layer 4 is at least partially liquid permeable. The first material 5 has a higher melting point than the second material 6, with the second material 6 creating a bond to the second layer 4.
    Type: Grant
    Filed: January 23, 2003
    Date of Patent: September 18, 2007
    Assignee: Fiberweb Corovin GmbH
    Inventors: Joachim Bauer, Indra Roy
  • Patent number: 7241497
    Abstract: The invention relates to a multi-component fiber having enhanced reversible thermal properties and methods of manufacturing thereof. The multi-component fiber comprises a fiber body formed from a plurality of elongated members, at least one of the elongated members comprising a temperature regulating material dispersed therein. The temperature regulating material comprises a phase change material. The multi-component fiber may be formed via a melt spinning process or a solution spinning process and may be used or incorporated in various products where a thermal regulating property is desired. For example, the multi-component fiber may be used in textiles, apparel, footwear, medical products, containers and packagings, buildings, appliances, and other products.
    Type: Grant
    Filed: December 21, 2004
    Date of Patent: July 10, 2007
    Assignee: Outlast Technologies, Inc.
    Inventors: Monte C. Magill, Mark H. Hartmann, Jeffrey S. Haggard
  • Patent number: 7226879
    Abstract: In accordance with the purposes of the present invention as described herein, an improved acoustical, compressible, polymer fiber blanket of enhanced performance characteristics is provided. The polymer fiber blanket of the present invention is constructed of a plurality of individual pieces of polymer fiber blanket that have been bonded together via heat and pressure.
    Type: Grant
    Filed: December 30, 2003
    Date of Patent: June 5, 2007
    Assignee: Owens-Corning Fiberglas Technology Inc.
    Inventors: Jeffrey A. Tilton, Anthony L. Rockwell
  • Patent number: 7201777
    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.
    Type: Grant
    Filed: March 28, 2002
    Date of Patent: April 10, 2007
    Inventor: Archer E. D. Booker, Jr.
  • Patent number: 7196026
    Abstract: An agend fiber composed of an active agent/positive dispensing carrier combination and a fiber forming component. As a fiber or nonwoven or textile fabric containing the fiber, the agend delivers the active agent at a desired rate under conditions of use. Product applications include personal care products such as diapers, training pants, swimwear, refastenable pants, absorbent underwear, feminine hygiene products, incontinent wear, wound dressings and cleansing wipes. The fibers may be formed as monocomponent fibers or multicomponent fibers of varying configurations. Active agents that can be dispensed include skin wellness agents, therapeutic agents, and cleaning agents, for example. In accordance with the invention, agend fibers provide desirable uniformity of dispensing and control of dispensing rates.
    Type: Grant
    Filed: June 20, 2003
    Date of Patent: March 27, 2007
    Assignee: Kimberly-Clark Worldwide, Inc.
    Inventors: Robert Cosmo Di Luccio, Frank Jerrel Akin
  • Patent number: 7186451
    Abstract: The invention is directed to a composite sheet suitable for use as artificial leather or a precursor to artificial leather, where both surfaces have a napped or brushed appearance. The composite sheet comprises a low-density, lightly bonded non-woven web that is stitch-bonded and bulked such that the stitch-bonding yarns are not visible to the naked eyes without the need of post-processing steps to hide the yarns. The composite sheet may have binder resin(s) dispersed therein and activated.
    Type: Grant
    Filed: March 31, 2003
    Date of Patent: March 6, 2007
    Assignee: XYMID, LLC
    Inventors: Dimitri Peter Zafiroglu, Stephen H. Tsiarkezos
  • Patent number: 7175902
    Abstract: The subject invention provides non-woven fabrics having yarns of varying characteristics. In a preferred embodiment the subject invention provides nonwoven fabrics that comprise yarns of different deniers or cross sections. The use of these yarns gives the nonwoven fabric a unique appearance and advantageous properties. The subject invention further pertains to the processes used to produce these fabrics.
    Type: Grant
    Filed: October 18, 2002
    Date of Patent: February 13, 2007
    Assignee: Cerex Advanced Fabrics, Inc.
    Inventors: Albert E. Ortega, R. Wayne Thomley, Jan Mackey, Charles F. Shafer
  • Patent number: 7135096
    Abstract: A press felt for use in the press section of a papermaking machine is provided. The press felt includes a base fabric layer and at least one layer of a staple fiber batt material connected thereto. The staple fiber batt material is includes between 20% to 100% by weight of a regenerated cellulosic staple fiber material, such as rayon, and from 80% to 0% by weight of a polymeric staple fiber, such as nylon. A scrim including regenerated cellulosic material can also be incorporated into the press felt construction, either between two layers of batt material, or between a batt layer and the base fabric. The regenerated cellulosic staple fibers of the batt and/or scrim having a dtex from at least about 1.1 to about 44, and are preferably non-fibrillatable. As a further option, at least a portion of the base fabric includes a regenerated celluliosic material.
    Type: Grant
    Filed: August 12, 2004
    Date of Patent: November 14, 2006
    Assignee: AstenJohnson, Inc.
    Inventors: Marc P. Despault, Brady S. Patterson
  • Patent number: 7128848
    Abstract: A photoluminescent thermoplastic multi-component fiber comprising a pigmented component and processing enhanced luminescence and mechanical properties. Most suitably, the pigmented component comprises between 5% and 30% by weight of photoluminescent pigment and the pigmented component is between 20% and 50% by weight of the multi-component fiber. The multi-component fiber can be formed from either POY or FDY, and the multi-component fiber can have many different cross section shapes including sheath/core. These single component or multi-component fibers can be made into a variety of fabrics. Additionally, single component or multi-component fibers can also be formed into single or multi-component meltblown and spunbonded fabrics.
    Type: Grant
    Filed: June 26, 2002
    Date of Patent: October 31, 2006
    Assignee: North Carolina State University
    Inventors: Behnam Pourdeyhimi, Trevor J. Little
  • Patent number: 7111342
    Abstract: Interior design structures and lightweight furniture formed from a felted fibrous material such as needle punched felt as the material of construction in replacement for wood. The felted fibrous material is adapted to provide adequate strength to permit construction of three dimensional structures by use of standard joining techniques such as screws, nails, glue and the like. At the same time, the nature of the felted fibrous material affords the opportunity to bend and shape the material thereby allowing additional freedom in construction and use.
    Type: Grant
    Filed: February 14, 2003
    Date of Patent: September 26, 2006
    Assignee: The Felters Group
    Inventors: Jerry W. Owens, Jr., Joseph C. Moon, Susan K. Crow
  • Patent number: 7081423
    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.
    Type: Grant
    Filed: June 26, 2002
    Date of Patent: July 25, 2006
    Assignee: Celanese Acetate LLC
    Inventors: Jean-Claude Abed, Denis G. Fallon
  • Patent number: 7070884
    Abstract: The present invention is directed to a nonwoven composite fabric for use on batteries or fuel cells comprising one or more layers of fine denier spunbond filaments and at least one layer of barrier material, wherein said nonwoven composite fabric has an improved barrier performance as measured by an increase in the hydrostatic head to barrier layer basis weight ratio. In the present invention, a first fine denier layer is formed, comprising continuous spunbond thermoplastic filaments, with the size of the continuous filaments between about 0.7 and 1.2 denier, preferably less than or equal to 1 denier. A barrier layer is deposited onto the first fine denier layer. 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.
    Type: Grant
    Filed: October 8, 2002
    Date of Patent: July 4, 2006
    Assignee: Polymer Group, Inc.
    Inventors: Julia A. Thompson, Richard Ferencz, Nick Mark Carter
  • Patent number: 7063917
    Abstract: A nonwoven material having a laminated construction and including a first layer of nonwoven fibers defining a first surface of the material; a second layer of nonwoven fibers defining the opposite surface of the material; and a third layer of nonwoven fibers located between the first and second layers. The layers are bonded together to form a laminate. At least one of the nonwoven layers comprises a nonwoven web of meltblown fibers. Additionally, one or more of the layers has been rendered permanently hydrophilic by forming the nonwoven web from meltspun fibers of a normally hydrophobic polymer having a hydrophilic melt additive incorporated therein.
    Type: Grant
    Filed: February 19, 2002
    Date of Patent: June 20, 2006
    Assignee: Ahlstrom Mount Holly Springs, LLC
    Inventors: Larry L. Kinn, Clement J. Haley, Gregory N. Henning
  • Patent number: 7049025
    Abstract: A novel flexible non-woven carbon fibre gas diffusion substrate comprising a plurality of first carbon fibres orientated in the x-, y- and optionally z-directions, said first fibres being bonded with a thermoplastic polymeric substance, and a carbon based filler material, characterised, in that the flexible non-woven carbon fibre gas diffusion substrate has a total density of greater than 0.35 g/cm3, and a gas diffusion electrode obtained therefrom is disclosed. Also disclosed is a process for the manufacture of the substrate and electrode.
    Type: Grant
    Filed: November 2, 2001
    Date of Patent: May 23, 2006
    Assignee: Johnson Matthey Public Limited Company
    Inventors: Susan Joy Cooper, John Malcolm Gascoyne, Thomas Robertson Ralph, Karen Leanne Hogarth
  • Patent number: 7036197
    Abstract: A method for preparing stretchable bonded nonwoven fabrics which involves forming a substantially nonbonded nonwoven web of multiple-component continuous filaments or staple fibers which are capable of developing three-dimensional spiral crimp, activating the spiral crimp by heating substantially nonbonded web under free shrinkage conditions during which the nonwoven remains substantially nonbonded, followed by bonding the crimped nonwoven web using an array of discrete mechanical, chemical, or thermal bonds. Nonwoven fabrics prepared according to the method of the current invention have an improved combination of stretch-recovery properties, textile hand and drape compared to multiple-component nonwoven fabrics known in the art.
    Type: Grant
    Filed: December 13, 2002
    Date of Patent: May 2, 2006
    Assignee: Invista North America S.A.R.L.
    Inventors: Dimitri P. Zafiroglu, Geoffrey David Hietpas, Debora Flanagan Massouda, Thomas Michael Ford
  • Patent number: 6995099
    Abstract: The present invention is aimed at providing FRP formed by integrating a fiber reinforcing material and a non-woven fabric, and having excellent shaping ability, impact resistance after molding, and excellent reliability and low cost. The aim of the present invention is achieved by a complex fiber reinforcing material including a sheet-shaped fiber reinforcing material composed of reinforcing fibers, and a non-woven fabric laminated on at least one side of the fiber reinforcing material, wherein the fibers constituting the non-woven fabric pass through the fiber reinforcing material to integrate the non-woven fabric with the fiber reinforcing material.
    Type: Grant
    Filed: February 22, 2000
    Date of Patent: February 7, 2006
    Assignee: Toray Industries, Inc.
    Inventors: Akira Nishimura, Kiyoshi Homma, Ikuo Horibe, Takehiko Hirabara
  • Patent number: 6989194
    Abstract: A flame retardant fabric comprising bicomponent fibers having a sheath and a core wherein the sheath comprises a fully aromatic thermoplastic polymer with a Limited Oxygen Index of at least 26 and the core comprises a thermoplastic polymer.
    Type: Grant
    Filed: December 16, 2003
    Date of Patent: January 24, 2006
    Assignee: E. I. du Pont de Nemours and Company
    Inventors: Vishal Bansal, Hyun Sung Lim, Harry Vaughn Samuelson, Michael Robert Samuels
  • Patent number: 6964931
    Abstract: The present invention is directed to a method of making a substantially continuous filament web which includes providing a plurality of polymer extruders for supplying polymer streams of at least two different polymer compositions, and providing a spinneret assembly for receiving the polymer streams. The spinneret assembly includes a plurality of orifices from which the polymer streams are extruded for formation of substantially continuous filaments formed from the polymer compositions. The distribution of at least one of the polymer compositions within the spinneret assembly is selected to optimize selected physical characteristics of the resultant continuous filament web.
    Type: Grant
    Filed: February 26, 2001
    Date of Patent: November 15, 2005
    Assignee: Polymer Group, Inc.
    Inventors: Thomas Scott Carlyle, Marlene Storzer
  • Patent number: 6921570
    Abstract: The present invention provides a pattern-unbonded material that has at least two distinct regions. One region has different bond pattern than another region. The different bond pattern provides different, specific functionality or characteristics to the material. In an embodiment, the one region provides an optimal mechanical fastener, hook engagement. The different characteristics include, but are not limited to, opacity, tensile strength or stiffness. The different characteristics are provided by a bond pattern specific to the particular region. The outer regions, in an embodiment, are stronger and appear more substantial by being more opaque than or color-shifted relative to an inner region. The outer regions, in an embodiment, are not directly backed or supported by the garment to which the material is attached. Accordingly, it is important for the outer regions to provide adequate strength, stiffness, color, and opacity absent the garment backing the outer regions.
    Type: Grant
    Filed: December 21, 2001
    Date of Patent: July 26, 2005
    Assignee: Kimberly-Clark Worldwide, Inc.
    Inventors: Tom R. Belau, Timothy J. Blenke, Richard T. Wehrle, Rebecca J. Kuepper, Thomas D. Ehlert, Alan F. Schleinz
  • Patent number: 6919026
    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.
    Type: Grant
    Filed: September 20, 2001
    Date of Patent: July 19, 2005
    Assignees: Awa Paper Mfg. Co., Ltd., Nitto Denko Corporation
    Inventors: Yoshitsugu Hama, Yoshifumi Kusaka, Akihiro Okubo
  • Patent number: 6916752
    Abstract: Nonwoven fibrous webs comprise fibers of uniform diameter that vary in morphology along their length. The variation provides longitudinal segments that exhibit distinctive softening characteristics during a bonding operation. Some segments soften under the conditions of the bonding operation and bond to other fibers of the web, and other segments are passive during the bonding operation. Webs as described can be formed by a method that comprises a) extruding filaments of fiber-forming material; b) directing the filaments through a processing chamber in which the filaments are subjected to longitudinal stress; c) subjecting the filaments to turbulent flow conditions after they exit the processing chamber; and d) collecting the processed filaments; the temperature of the filaments being controlled so that at least some of the filaments solidify while in the turbulent field.
    Type: Grant
    Filed: May 20, 2002
    Date of Patent: July 12, 2005
    Assignee: 3M Innovative Properties Company
    Inventors: Michael R. Berrigan, Anne N. De Rovere, William T. Fay, Jill R. Munro, Pamela A. Percha
  • Patent number: 6887805
    Abstract: A screen formed from a stretched flexible surface, particularly for an external installation, comprises a non-woven fabric provided with a print. One face of the non-woven fabric is provided with a thin permeable layer formed by flakes which receive the print.
    Type: Grant
    Filed: April 9, 2002
    Date of Patent: May 3, 2005
    Inventor: Guy Gilbert Chenel
  • Patent number: 6878650
    Abstract: A method is provided for producing fine denier multicomponent thermoplastic polymer filaments incorporating high melt-flow rate polymers. Multicomponent filaments are extruded such that the high melt-flow rate polymer component is substantially surrounded by one or more low melt-flow rate polymer components. The extruded multicomponent filament is then melt-attenuated with a significant drawing force to reduce the filament diameter and form continuous, fine denier filaments.
    Type: Grant
    Filed: December 20, 2000
    Date of Patent: April 12, 2005
    Assignee: Kimberly-Clark Worldwide, Inc.
    Inventors: Darryl Franklin Clark, Justin Max Duellman, Bryan David Haynes, Jeffrey Lawrence McManus, Kevin Edward Smith
  • Patent number: 6863697
    Abstract: In a preferred embodiment, the present process involves subjecting a fabric having splittable conjugate yarns both to an acidic treatment and to a basic treatment, each of which erodes a portion of the components of the conjugate yarns. The acid treatment, given certain reaction kinetics, removes a portion of the polyamide element of the conjugate filament. The basic treatment has a similar effect on the polyester element of the conjugate filament, making it more hydrophilic. The at least partial removal of the polyamide component, coupled with the increased hydrophilicity of the polyester component, results in a fabric having enhanced absorptive properties. In an alternate embodiment, treatments with only acid or only basic solution may be employed.
    Type: Grant
    Filed: February 8, 2002
    Date of Patent: March 8, 2005
    Assignee: Milliken & Company
    Inventors: John Scott McDaniel, Kirkland W. Vogt, Woodrow P. Gilbert
  • Patent number: 6861380
    Abstract: A tissue product containing a multi-layered paper web that has at least one layer formed from a blend of pulp fibers and synthetic fibers is provided. By containing at least one layer of synthetic and pulp fibers, it has been discovered that lint and slough of a tissue product formed according to the present invention can be substantially reduced. In addition, by limiting the amount and layers to which the synthetic fibers are applied, the increase in hydrophobicity and cost of the tissue product may be minimized, while still achieving the desired reduction in lint and slough. In some embodiments, the tendency of the synthetic fibers to sink or float in the fibrous furnish may be minimized to enhance processability by selecting certain types of synthetic fibers, e.g., those with a certain density imbalance.
    Type: Grant
    Filed: November 6, 2002
    Date of Patent: March 1, 2005
    Assignee: Kimberly-Clark Worldwide, Inc.
    Inventors: Gil Bernard Didier Garnier, Sheng-Hsin Hu
  • Patent number: 6855422
    Abstract: The invention relates to a multi-component fiber having enhanced reversible thermal properties and methods of manufacturing thereof. The multi-component fiber comprises a fiber body formed from a plurality of elongated members, at least one of the elongated members comprising a temperature regulating material dispersed therein. The temperature regulating material comprises a phase change material. The multi-component fiber may be formed via a melt spinning process or a solution spinning process and may be used or incorporated in various products where a thermal regulating property is desired. For example, the multi-component fiber may be used in textiles, apparel, footwear, medical products, containers and packagings, buildings, appliances, and other products.
    Type: Grant
    Filed: January 15, 2002
    Date of Patent: February 15, 2005
    Inventors: Monte C. Magill, Mark H. Hartmann, Jeffrey S. Haggard
  • Patent number: 6852654
    Abstract: The invention is directed to a hydroentangled nonwoven fabric, the outer surface of which exhibits highly entangled fibers whereas the inner layer exhibits lightly entangled fibers. In particular, the present invention contemplates that a fabric is formed from a fibrous batt that is subjected to fluidic energy, preferably hydraulic energy, applied to one or both faces of a fibrous batt. The hydraulic energy is moderated against the basis weight of the fibrous batt to achieve the degree of surface entanglement desired. Fabrics formed in accordance with the present invention exhibit a sufficient degree of softness and non-linting performance, while providing the necessary resistance to tearing and abrasion, to facilitate use in a wide variety of applications such as cast padding or orthopedic wraps.
    Type: Grant
    Filed: October 12, 2001
    Date of Patent: February 8, 2005
    Assignee: Polymer Group, Inc.
    Inventors: Charles R. Fuller, Sheridan D. Ledbetter
  • Patent number: 6849324
    Abstract: A nonwoven web of multipolymer fibers is described that is unidirectionally stretched and permanently elongated at ambient conditions and exhibits a substantial increase in tensile strength in the stretch direction. The ratio of tensile strength of the web in the direction of fiber orientation to the tensile strength in the other direction is at least about 10:1. The ratio of elongation at peak load in a direction transverse to the direction of fiber orientation is at least about 6:1. The multipolymer fibers normally are a blend of polyethylene and a polypropylene homopolymer or copolymer, one of which is a dominant phase and one of which is a dispersed phase. A third component having elastomeric properties that is at least partially miscible with one or both of the other components is included in some blends.
    Type: Grant
    Filed: September 6, 2001
    Date of Patent: February 1, 2005
    Assignee: BBA Nonwovens Simpsonville, Inc.
    Inventors: Barry DeWayne Meece, Thomas Edward Quantrille
  • Patent number: 6838402
    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.
    Type: Grant
    Filed: September 21, 1999
    Date of Patent: January 4, 2005
    Assignee: Fiber Innovation Technology, Inc.
    Inventors: Frank O. Harris, Jeffrey S. Dugan, Jing-Peir Yu, Arthur Talley, Jr., Arnold Wilkie
  • Publication number: 20040265533
    Abstract: An absorbent article comprising a topsheet, a backsheet, and an absorbent core disposed between the topsheet and the backsheet is disclosed. The topsheet has a first side and a second side, the first side being a body-facing side and the second side being in fluid communication with the absorbent core. The topsheet also has a first relatively hydrophobic component and a second relatively hydrophilic component, the relatively hydrophilic component extending through the relatively hydrophobic component and being disposed on both of the sides of the topsheet. The absorbent article exhibits a rewet value of less than about 94 mg, and a fluid acquisition rate of at least about 0.10 ml/sec when tested by the Gush Acquisition and Rewet Test Method.
    Type: Application
    Filed: December 16, 2003
    Publication date: December 30, 2004
    Applicant: The Procter & Gamble Company
    Inventors: Jody Lynn Hoying, John Lee Hammons, Susan Nicole Lloyd, Robert Haines Turner, John Joseph Curro
  • Publication number: 20040265534
    Abstract: A laminate web comprising a first and second precursor webs, at least the first precursor web being a nonwoven web, the laminate web having a first side, the first side comprising the second precursor web and at least one discrete tuft, each of the discrete tufts having a linear orientation defining a longitudinal axis and comprising a plurality of tufted fibers being integral extensions of the first precursor web and extending through the second precursor web; and a second side, the second side comprising the first precursor web.
    Type: Application
    Filed: December 16, 2003
    Publication date: December 30, 2004
    Applicant: The Procter & Gamble Company
    Inventors: John Joseph Curro, Robert Haines Turner, Jody Lynn Hoying, Susan Nicole Lloyd, John Lee Hammons
  • Publication number: 20040253895
    Abstract: A wipe includes a porous and bulky thermoplastic non-woven carrier web. An absorbent non-woven web including a plurality of philic fibers has a first side and an opposite second side. The first side is disposed adjacent the carrier web. The absorbent web is co-extruded to the carrier web and is secured to the carrier web at a plurality of thermic embossments. An abrasive finish is applied to the second side of the absorbent non-woven web. The abrasive finish includes a plurality of abrasive fibers that are less than 40 microns in diameter.
    Type: Application
    Filed: September 9, 2003
    Publication date: December 16, 2004
    Inventor: Massimiliano Castellani
  • Publication number: 20040253893
    Abstract: A wipe includes a porous and bulky thermoplastic non-woven carrier web. An absorbent non-woven web including a plurality of philic fibers has a first side and an opposite second side. The first side is disposed adjacent the carrier web. The absorbent web is co-extruded to the carrier web and is secured to the carrier web at a plurality of thermic embossments. An abrasive finish is applied to the second side of the absorbent non-woven web.
    Type: Application
    Filed: June 10, 2003
    Publication date: December 16, 2004
    Inventor: Massimiliano Castellani
  • Patent number: 6831025
    Abstract: A spunbond nonwoven fabric is provided which is formed from continuous multiple component filaments which include a polyester component and a polyethylene component. The polyethylene component is a blend of high density polyethylene and a first linear low density polyethylene. The spunbond filaments are preferably formed in a sheath-core configuration with the polyester component in the core and the polyethylene component in the sheath. Composite sheets are provided which include the multiple component spunbond layer and a meltblown layer, wherein the meltblown fibers include a second linear low density polyethylene. The linear low density polyethylenes are preferably formed by polymerization of ethylene with an alpha-olefin co-monomer, where the same co-monomer is used in each of the first and second linear low density polyethylenes.
    Type: Grant
    Filed: June 18, 2001
    Date of Patent: December 14, 2004
    Assignee: E. I. du Pont de Nemours and Company
    Inventors: Edgar N. Rudisill, Vishal Bansal, Michael C. Davis
  • Publication number: 20040248491
    Abstract: The polypropylene-based thermoplastic fibers are uniform in cross-section, not having any degraded surface skin, and they are heat-weldable at a pressure at a temperature which is lower than the melting temperature, by virtue of internal heating due to the effect of said pressure. They are made of a first constituent with high crystallinity and at least one second constituent, compatible with the first constituent, and of crystallinity that is lower than that of the first constituent. They have a quantity of primary oxidation inhibitor lying in the range 350 ppm to 1000 ppm. Such fibers are made by spinning under conditions that avoid molecular degradation by thermal oxidation at the periphery of the fibers, in particular with cooling that is rapid immediately on leaving the extrusion head. The non-woven fabric obtained by heat-bonding such fibers is characterized by weld points that are in the form of a polymer laminate that is uniform and transparent.
    Type: Application
    Filed: May 3, 2004
    Publication date: December 9, 2004
    Inventor: Galliano Boscolo
  • Patent number: 6827764
    Abstract: A filter element that comprises a porous molded web 10′ that contains thermally bonded staple fibers 12 and non-thermally bonded electrically charged microfibers 14. The molded web is retained in its molded configuration, at least in part, by bonds between the staple fibers 12 at points of fiber intersection 13. The web may be molded, for example, into the shape of filtering face mask 16.
    Type: Grant
    Filed: July 25, 2002
    Date of Patent: December 7, 2004
    Assignee: 3M Innovative Properties Company
    Inventors: James E. Springett, Seyed Abolhassan Angadjivand
  • Publication number: 20040242100
    Abstract: 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: Application
    Filed: January 29, 2004
    Publication date: December 2, 2004
    Applicant: Kuraray Co., Ltd.
    Inventors: Yoshiki Nobuto, Yoshihiro Tanba
  • Publication number: 20040242097
    Abstract: The article contains a fibrous, non-woven web and having a personal care composition associated with this web. The present invention relates to disposable, personal care articles useful for cleansing and/or treating the skin, hair or other similar keratin-containing surfaces. These articles are used by the consumer by either wetting the dry article with water and then rubbing the article against the skin, hair or other similar keratin-containing surfaces, or taking a wet, disposable, personal care article and rubbing against the skin, hair or other similar keratin-containing surfaces or taking a moist, disposable, personal care article and rubbing against the skin, hair or other similar keratin-containing surfaces.
    Type: Application
    Filed: December 16, 2003
    Publication date: December 2, 2004
    Applicant: The Procter & Gamble Company
    Inventors: Erik John Hasenoehrl, Edward Dewey Smith, Daniel Burton Sears, Steven Kirk Hedges, Robert Haines Turner, John Joseph Curro, Daniel Charles Peck