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

Abstract: A nonwoven structure or web is provided where a binder fiber contains an energy receptive additive. The fiber provides rapid heating when subjected to dielectric energy such as radio frequency or microwave radiation. The energy receptive additive has a dielectric loss of at between 0.5, preferably 0.1 and most preferably 5, and 15.

Abstract: An absorbent article having a liner and an outer cover in generally opposed relationship with the liner. An absorbent body disposed therebetween includes a non-woven absorbent structure having a length, a width and a thickness. The absorbent structure is constructed of absorbent fibers and binder fibers activatable to form inter-fiber bonds within the absorbent structure, with the binder fibers being multi-component fibers in which at least one binder fiber component has a melt temperature that is lower than a melt temperature of at least one other binder fiber component. The width of the absorbent structure is non-uniform along its length prior to activation of the binder fibers. In another embodiment, the absorbent structure is of unitary construction and the concentration of binder fibers therein is non-uniform along at least one of the length, the width and the thickness of the absorbent structure.

Abstract: A fabric that comprises an entangled, creped and optionally stretched nonwoven web is provided. The nonwoven web is formed from splittable multicomponent thermoplastic fibers having individual segments exposed on an outer perimeter thereof. In one embodiment, the splittable multicomponent fibers are continuous spunbonded thermoplastic fibers. For example, in some embodiments, the creped nonwoven web can be hydraulically entangled with a fibrous material that contains cellulosic fibers and optionally synthetic staple fibers.

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.

Abstract: A spunbond nonwoven fabric is provided, formed from a multiplicity of substantially continuous bicomponent filaments randomly arranged and bonded to one another. The bicomponent filaments have a multilobal cross-sectional configuration including a first polymer component formed of a higher-melting composition occupying at least the central portion of the filament cross-section and a second polymer component formed of a lower-melting composition being present in at least one lobe of the multilobal cross-section.

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

Abstract: A web of thermoplastic multicomponent substantially continuous fibers is thoroughly and evenly mixed with absorbent materials prior to deposition on the forming wire to result in superior adherence of the absorbents to the thermoplastic components and hence result in superior performance of the web. The multicomponent fibers have a low melting point sheath which can be fully activated to melt and wet the absorbent particles. The web can then be densified and cooled, securing the absorbents to the web with hardened flow joints and enabling the web to carry high loadings of absorbent while maintaining good web integrity.

Abstract: A coform nonwoven web from multicomponent meltblown filaments and an absorbent, wherein the absorbent material is substantially uniformly dispersed in the z-direction is disclosed. A process of preparing the coform nonwoven web by perturbing the meltblown filaments as they are being produced is also disclosed. The coform material can be used in a variety of absorbent articles such as diapers as the primary liquid retention layer. In addition, the coform nonwoven web can be used in a variety of other articles such as wipes.

Abstract: A high pulp content nonwoven composite fabric is disclosed. The composite fabric contains 1) from more than about 0 to less than about 30 percent, by weight, of a nonwoven layer of conjugate spun filaments, the filaments containing at least one low-softening point component and at least one high-softening point component and having at least some exterior surfaces of the filaments composed of at least one low-softening point component; 2) more than about 70 percent, by weight, of pulp fibers; and 3) regions in which the low-softening point component at the exterior surfaces of the filaments is fused to at least a portion of the fibrous component. This high pulp content composite nonwoven fabric may be used as a heavy duty wiper or as a fluid distribution material, cover material, and/or absorbent material in an absorbent personal care product. Also disclosed is a method of making the high pulp content nonwoven composite fabric.

Abstract: This invention relates to antimicrobial fabrics which are treated with a specific durable and regenerable halamine/chlorine system and methods of removing residual active chlorine from the target textile surface without reducing the antimicrobial activity of the textile. Such methods comprise contacting an amine-treated fabric first with a halogen-based bleach (or other halogenated liquid) to produce halamines at the fabric surface, and subsequently washing the resultant halogenated fabric with a reducing agent which removes the residual, unbonded halogen (such as chlorine) from the fabric surface but does not, surprisingly, remove the halamine halogen. The remaining halamine halogen thus provides the desired antimicrobial activity.

Abstract: The present invention provides a process for producing yarn having reduced heatset shrinkage. Preferably, the fibers used in making the yarn are bicomponent fibers. The present invention also provides a process for producing yarn having reduced heatset shrinkage at reduced heat temperatures.

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

Abstract: The invention relates to a sound absorbing material, made from a microfilament nonwoven fabric having a mass per unit area of 40 to 300 g/m2, in which a nonwoven fabric is made from melt-spun, drawn, multi-component endless filament having a titer of 1.5 to 5 dtex and directly laid down to form a fibrous web; and the multi-component endless filaments, optionally after prebonding, are split at least to 80% to form micro-endless filaments having a titer of 0.1 to 1.2 dtex and bonded.

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

Abstract: A neckable nonwoven web is provided with a central region and two edge regions, the central region being selectively easier to neck than the two edge regions. The nonwoven fibers in the central region have a polymer composition and/or physical properties which differ from the nonwoven fibers in the two edge regions. The selectively easier necking in the central region causes the central region to neck to about the same extent as the two edge regions, which otherwise would experience greater necking than the central region if the starting nonwoven web were completely uniform. Necked nonwoven webs and neck-bonded laminates made using the improved neckable nonwoven web, are also provided.

Abstract: A polyolefin composition which contains 45 to 5 weight percent of a low viscosity propylene homopolymer having an as polymerized melt flow rate of 250 to 550 g/10 minutes and 55 to 95 weight percent of an olefin polymer composition, preferably a random copolymer of propylene and ethylene and/or a C4-10 alpha-olefin or mixtures thereof, containing from 90 to 99 weight percent propylene. The composition may be formed into fibers having a diameter of from 15 to 23 microns. The fibers may be used to produce nonwoven fabrics.

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.

Abstract: A fusible non-woven fibrous web for a quilt batt. The fusible non-woven fibrous web includes a non-woven fibrous web and a heat sealable and releasable adhesive. The adhesive is coated on the outer surface of the web and insinuates between the fibers of the web internally. The adhesive thus binds the fibers of the web and provides a tackiness sufficient to allow the web to be applied to, removed from, and reapplied to a backing material on other fabric.

Abstract: The present invention relates to a dry-laid composition comprising: hollow synthetic fiber, absorbent and a binder system. The hollow fiber comprises from about 10 to about 50 percent by weight of said composition. The hollow synthetic fiber has a denier of between about 2 to about 18. The hollow synthetic fiber is selected from the class of polyolefins, polyesters, polyamides, acrylics, as well as mixtures and copolymers thereof. The absorbent comprises from about 40% to about 80% of the weight of said composition. The absorbent is a natural absorbent, or a synthetic absorbent, or a mixture of these. The natural absorbent is selected from the class of wood pulp fluff, cotton, cotton linters, and regenerated cellulose fibers, or a mixture of these. The synthetic absorbent is selected from the class of agar, pectin, guar gum, and synthetic hydrogel polymers. The binder fiber comprises from about 3 to about 15 percent by weight of said composition.

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

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

Abstract: A battery separator material comprising 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.

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

Abstract: The present invention relates to a composite which is capable of use as a filter medium and a method for producing the same. The composite may include pulp fibers and conjugate glass fibers. The conjugate fibers are desirably composed of at least two glasses which have different thermal expansion properties. The difference in thermal expansion coefficients of the multicomponent fiber produces a fiber with a random helical crimp. The random helical crimp of the conjugate fibers reduces the packing efficiency of the glass itself and the other fibers. The reduced packing efficiency affords the opportunity to prepare pulp/conjugate glass fiber composite materials with higher porosity and higher permeability for a given basis weight. The addition of the polyester staple fibers to the composite lends sufficient stiffness to the web so as to allow pleating without further treatment such as with a binder material.

Abstract: The invention features a lining material for footwear. The material includes a non-woven felt including up to 80% by weight of grooved or multi-lobed cross section transport fibers and the remainder of thermally bondable fibers arranged to secure the transport fibers against abrasion and excessive mechanical stretch presented during incorporation of the lining material into a product during that product's manufacture.

Abstract: A polyethylene nonwoven fabric is produced by the meltblowing process using a resin composition comprising a polyethylene (A) and a polyethylene wax (B). The fabric is made up with fine fibers having a small fiber diameter and good formation. A nonwoven fabric laminate containing at least one layer comprising the polyethylene nonwoven fabric is excellent in softness, water impermeability and interlaminar bond properties. In particular, the laminate of a meltblown nonwoven fabric comprising the polyethylene nonwoven fabric and a spunbonded nonwoven fabric made up with a conjugate fiber comprising a propylene-based polymer (a) and an ethylene-based polymer (b) provides good uniformity and excellent softness, gas permeability, water impermeability and interlaminar bond strength. The laminate is advantageously used as substrate materials for sanitary goods such as disposable diapers and for packaging materials.

Abstract: This invention provides a process for making a nonwoven sheet of substantially continuous melt spun fibers by extruding melt spinnable polymer containing at least 30% by weight low IV poly(ethylene terephthalate), drawing the extruded fiber filaments at a rate of at least 6000 m/min, laying the fiber filaments down on a collection surface, and bonding the fiber filaments together to form a nonwoven sheet. The invention further provides a nonwoven sheet comprised of at least 30% by weight poly(ethylene terephthalate) having an intrinsic viscosity of less than 0.62 dl/g, where the sheet has a basis weight of less than 125 g/m2, and a grab tensile strength of at least 0.7 N/(g/m2).

Abstract: A polymeric fiber liner insulation includes of a resilient, insulation blanket core of randomly oriented entangled fibers with between 60% and 90% by weight of the fibers being standard polymeric fibers and/or flame retardant polymeric fibers and between 10% and 40% by weight of the fibers being polymeric lofting and bonding fibers. The first major surface the liner insulation has a low porosity or air and/or liquid impervious surface layer. The surface layer is formed by melting and consolidating fibers at and adjacent the first major surface of the blanket core or by coating the first major surface of the blanket core with a polymeric coating. The liner insulation exhibits a flame spread/smoke developed index of ≦25/50.

Abstract: To provide thermoadhesive conjugate fibers, nonwoven fabrics and cellulosic fiber blended nonwoven fabrics employing them, and wipers and absorbers employing the fabrics, thermoadhesive conjugate fibers comprise a thermoplastic resin (I) containing a modified polyolefin with at least one type of reactive functional group as a first component and having a second component composed of a thermoplastic resin (II) with a higher melting point than the thermoplastic resin (I) of the first component combined in a conjugate therewith, the first component being formed continuously along the length of at least a portion of the fiber surface, wherein the fiber surfaces are coated with a fiber treating agent containing a multifunctional compound capable of reacting with the reactive functional group of the modified polyolefin.

Abstract: A bicomponent elastic fiber that includes a core formed of an elastic fiber and having a sheath formed of a non-elastic material surrounding the core. The sheath has at least one cut therein extending at an angle to the length of the fiber to expose and release the elasticity of the core elastic fiber. This provides elasticity to the bicomponent elastic fiber.

Abstract: Disclosed is both a method and composition for forming a thermo-formable acoustical panel. The panel may be formed from multi-component polymer fibers or mono-filament polymer fibers dispersed in a mineral fiber batt. The polymer fibers are bound to the mineral fibers by the application of heat to form the acoustical panel.

Abstract: The present invention is directed to the combined use of first and second fatty acid amides to improve the softness of a thermoplastic polymer construct. A combination of fatty acid amides is provided in the blend ratio of about 10 to 90 percent by weight of a first fatty acid amide and 90 to 10 percent by weight of a second fatty acid amide. The first and second fatty acid amides are compounded into a thermoplastic polymer carrier resin and, preferentially, produced as concentrate pellets containing 0.5 to 75 percent by weight total fatty acid amide loading. The concentrate pellets are introduced into a thermoplastic polymer base, to form a thermoplastic resin, at a letdown level in the range of about 1 to 15 percent, with the range of 2 to 10 percent being preferred, and the range of 3 to 6 percent being most preferred.

Abstract: A composite nonwoven fabric includes a stretched unidirectionally aligned nonwoven fabric in which filaments composed of a thermoplastic resin are unidirectionally aligned and stretched and a dry nonwoven fabric that is provided on one side of the stretched unidirectionally aligned nonwoven fabric and that includes thermal-bonding fibers as a chief component. The filaments of the stretched unidirectionally aligned nonwoven fabric and the dry nonwoven fabric are intertwined by a needlepunch process, following which the two fabrics are unified by a thermal calendering process to produce the composite nonwoven fabric.

Abstract: 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.

Abstract: The present invention provides a composite nonwoven fabric with a superior combination of extensibility, tensile properties and abrasion resistance. The composite nonwoven fabric (10) comprises at least one layer containing multipolymer fibers, with a plurality of bonds bonding the fibers together to form a coherent extensible nonwoven web (11). This coherent extensible nonwoven web (11) has a Taber surface abrasion value (rubber wheel) of greater than 10 cycles and an elongation at peak load in at least one of the machine direction or the cross-machine direction of at least 70%. A second extensible layer (12) is laminated to this coherent extensible nonwoven web (11).

Abstract: A hood, dash, firewall or engine cover liner is provided for a vehicle. The liner includes a nonlaminate acoustical and thermal insulating layer of polymer fiber that shows no signs of any thickness increase, delamination, deterioration or any undesirable effect which may affect performance for at least 330 hours when maintained at a temperature of at least approximately 150° C. The liner may include a relatively high density, nonlaminate skin of polymer fiber and/or one or more facing layers constructed from polymer material.

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.

Abstract: A wiping cloth made of nonwoven fabric of which water-absorbing property is superior and deteriorates less with age is provided. This wiping cloth made of nonwoven fabric is obtained using specific splittable conjugate fibers. The splittable conjugate fibers are formed by sticking a polyester polymer component A containing polyoxyalkyleneglycol of 2000 to 20000 in mass average molecular weight and a polyolefin polymer component B not compatible with said polymer component A together. Fibers A composed of the polymer component A and fibers B composed of the polymer component B are formed by exfoliating the sticking of the splittable conjugate fibers. Plasma treatment is applied to exfoliated faces of the fibers A and the fibers B. The water-absorbing property is largely improved due to synergism of polyoxyalkyleneglycol and plasma treatment applied to the exfoliated faces of the fibers A and B.

Abstract: Bonded fluff structures and a method for producing such bonded fluff structures in which a pulp sheet having a material suitable for producing fluff and a heat activatable fiber material is fiberized to produce a mixture of fluff and heat activatable fibers. The mixture is contacted with a hot air stream, heating the heat activatable fibers to an activation temperature. The resulting heated mixture is then deposited onto a forming structure, forming a bonded fluff/fiber composite matrix structure.

Abstract: A nonwoven fabric comprised of a self-sustaining pre-bonded web formed by carding together first relatively thin monocomponent fibers, second relatively thicker monocomponent fibers, and 1-5% bicomponent fibers with the low softening point component thereof bonding together the first, second and bicomponent fibers to form the self-sustaining web. Six to ten percent by weight of cured latex particles are disposed within the fabric and smeared on the outer surfaces of the fabric, the particles being cured in situ to provide enhanced tensile strength to the fabric.

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

Abstract: A nonwoven material which is formed of a blend of fibers diagonally needled together into an integral web for subsequent molded component parts.

Abstract: This invention relates to antimicrobial fabrics which are treated with a specific durable and regenerable halamine/chlorine system and methods of removing residual active chlorine from the target textile surface without reducing the antimicrobial activity of the textile. Such methods comprise contacting an amine-treated fabric first with a halogen-based bleach (or other halogenated liquid) to produce halamines at the fabric surface, and subsequently washing the resultant halogenated fabric with a reducing agent which removes the residual, unbonded halogen (such as chlorine) from the fabric surface but does not, surprisingly, remove the halamine halogen. The remaining halamine halogen thus provides the desired antimicrobial activity.

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

Abstract: A laminate web and several uses of the laminate web are disclosed. The laminate web comprises a first web, a second web joined to the first web at a plurality of discrete bond sites; and a third material disposed between at least a portion of the first and second webs. The laminate webs of the present invention are suitable for a variety of uses. Such uses include flexible carrying implement, medical applications, kitchen or bathroom implements, decorative coverings, home accent items, pet industry articles, fabric, fabric backings, edible materials, bedding applications, absorbent food pads, clean room wipes, tack cloths, and many other uses.

Abstract: The invention concerns a method for producing a nonwoven web formed at least partly with hydrophilic elementary fibers which consist in: producing by carding a textile layer (10) which is then compressed and moistened; subjecting it to a bonding treatment using water jets acting at least against one of its surfaces; and transferring said bonded layer to a unit (32, 33) to be dewatered and dried. Said method is characterised in that, after the bonding treatment (20) with water jets and before drying and delivery, the pre-bonded and moistened layer is transferred to a supplementary unit (28) to be treated by the action of one or several series of water jets, said unit comprising a mobile suction surface in the form of a drum covered with an open-work structure (30) consisting of a wire-mesh fabric, comprising successive raised and recessed zones.

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.

Abstract: Process of producing skin-core fibers and the resulting fibers and nonwoven materials and articles wherein the fibers are composed of a polymer blend of a polyolefin and polymeric bond curve enhancing agents, such as ethylene vinyl acetate polymers.

Abstract: The present invention relates to a blend of at least one (meth)acrylate polymer and at least one amorphous propylene-derived polymer, and an optional tackifier that provide pressure sensitive adhesive compositions in which improved peel adhesion to at least one of low and relatively high surface energy substrates can be achieved.