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

Abstract: Nonwoven webs of continuous filaments are provided having a mixture or blend of first and second continuous filaments wherein the first and second continuous filaments are different from the first continuous filaments in one or more respects such as size, cross-sectional shape, polymer composition, crimp level, wettability, liquid repellency, and charge retention. The second continuous filaments can be substantially surrounded by the first continuous filaments wherein the ratio of first continuous filaments to second continuous filaments exceeds about 2:1.

Abstract: PROBLEM TO BE SOLVED: To provide an elastic long-fiber non-woven fabric that exhibits excellent elasticity, appropriate stress upon elongation, an excellent anti-blocking property, and an excellent soft feel, and which is suitable for applications to fabric products; and to provide fabric products manufactured from such an elastic long-fiber non-woven fabric.

Abstract: In a preferred embodiment, the present process involves subjecting the nonwoven fabric both to an acidic treatment and to a caustic 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 caustic 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 caustic solution may be employed.

Abstract: An improved nonwoven web composite is formed by combining bicomponent thermoplastic filaments having adhesive properties with a component selected from other fibers and particles. The bicomponent filaments include distinct regions of first and second incompatible polymers across a cross-section of individual filaments. After the bicomponent filaments are combined with the other fibers and/or particles, the adhesive properties of the bicomponent filaments result in a web or matrix of filaments having improved ability to entrap, ensnare and contain the other fibers and/or particles within the web or matrix. The nonwoven web composite is particularly useful for making absorbent articles, which require stability and optimum levels of absorbent fibers and/or particles.

Abstract: This invention is a spunbonded nonwoven material which is formed of polytrimethylene terephthalate (PTT). This material may be a microfiber material which is 1 dpf or less in fiber diameter. This nonwoven material is unique in that it has a hydrostatic head of no more than 10 cm, preferably no more than 5 cm.

Abstract: High loft, low density nonwoven webs are produced by forming substantially continuous, spunbond, crimped, bicomponent fibers of A/B side by side morphology in an unheated fiber draw unit. The fibers are then heated and cooled in the absence of impeding forces to achieve maximum crimp in the z-direction and produce a web of lofted material. The resultant material is particularly suitable for use as an insulator. Particulates may be added to the webs if desired.

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 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: 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: The present invention is directed to multicomponent fibers having poly(ethylene oxide) in at least a portion of the exposed surface of the fiber. In one embodiment, the PEO is a grafted poly(ethylene oxide). The multicomponent fibers of the present may be used to manufacture nonwoven webs that can be used as components in medical and health care related items, wipes and personal care absorbent articles such as diapers, training pants, incontinence garments, sanitary napkins, pantiliners, bandages and the like.

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: 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: 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 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: A process for preparing nonwoven webs comprising multiple component continuous filaments having high levels of three-dimensional helical crimp utilizing draw rolls to provide a high degree of orientation to each of the polymeric components by mechanically drawing the filaments under conditions wherein the polymeric components remain substantially amorphous and a stretchable nonwoven web comprising multiple component, continuous filaments having high levels of three-dimensional helical crimp.

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: 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: This invention is a bicomponent meltblown microfiber nonwoven material wherein at least two different polymers have been extruded and spun together in either a side by side or core/sheath configuration and wherein at least one of the polymers is polytrimethylene terephthalate (PTT) and at least one of the polymers is one of but not limited to the following thermoplastics: polypropylene (PP), polyethylene (PE), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyamide (PA), and polylactide (PLA). The ratio of PTT to the other component ranges from 1:99 to 99:1, based on the weight of the polymers. The preferred weight ratio range of PTT:PP is 25:75 to 75:25 and the most preferred range is 25:75 to 50:50. The present invention also provides a process for making such a bicomponent fiber. The present invention also provides a process for making such a meltblown microfiber nonwoven material.

Abstract: A method for making improved sealability polyolefin fibers comprising extruding a polyolefin (2) and at least one polyolefin copolymer (4) having a melting temperature less than that of the melting temperature of the polyolefin to form fibers (9) having outer surfaces wherein at least part of the outer surfaces is comprised of the low-melting polymer and which have high sealability properties.

Abstract: A spun nonwoven fabric contains monofilaments and bicomponent filaments, the spun nonwoven fabric having, over its cross section, different quantities of the bicomponent filaments. The bicomponent filaments contain at least two outward-facing segments made of a binding component. The proportions of bicomponent filaments over the cross sectional planes of the spun nonwoven fabric can be in a range of approximately 1% to 100% by weight. The cross sectional planes of the nonwoven fabric containing the different proportions of bicomponent filaments transition into one another without detectable phase boundaries. The apparatus for manufacturing the nonwoven fabric contains at least one, and may contain up to forty or more, spinneret devices, such as rectangular spinneret plates or round spinneret disks. The spinneret devices may be arranged in rows or in staggered arrangement above a linearly moving collector belt.

Abstract: A color exhibition structure comprising a number of minute granular substances dispersed in a transparent substance. The materials of the transparent and granular substances are selected in such a manner as to exhibit a visible color produced by reflection and scattering of a light incident on the color exhibition structure. Alternatively, the color exhibition structure may comprise a number of minute granular substances dispersed in at least one of first and second layers laminated alternatively. The materials of the first and second layers and the granular substances are selected in such a manner as to exhibit a visible color produced by reflection, interference and scattering of a light incident on the color exhibit structure.

Abstract: A bonded web of multi-component strands that include a first polymeric component and a second polymeric component is capable of overcoming a number of problems associated with nonwoven webs including both stickiness and blocking. The first polymeric component and second polymeric components are arranged in substantially distinct zones extending longitudinally along at least a portion of a length of the strands which make up the web with the second component containing a zone constituting at least a portion of the peripheral surface of the strand. Moreover, the first polymeric component has an elasticity which is greater than that of the second polymer component. A process producing elastomeric spunbonded nonwoven fabrics which utilizes air in attenuating and/or drawing of strands is also provided.

Abstract: Nonwoven webs are fabricated by forming unitary multicomponent fibers comprising a plurality of individual segments partially exposed at the surface of the fiber; bonding the multicomponent fibers, such as by thermal point bonding, and then hydroentangling the bonded multicomponent fibers with a water pressure from about 400 to 3000 psi wherein the entangling process separates the individual segments of the unitary multicomponent fibers into microfibers and also entangles the fibers to form an integrated nonwoven web. The nonwoven webs include entangled webs of thermoplastic multicomponent fibers and microfibers having partially degraded bond areas comprising from about 5% to about 50% at the surface area of the web.

Abstract: A water-retentive sheath manufactured from a cellulose based fiber of high water-retentivity. The cellulose based fiber of high water rententivity includes a component of a non-cellulose based material of high absorbency uniformly contained in a cellulose fiber and a single component of cellulose; and these two components are attached together side by side. The cellulose fiber can be viscose rayon and the non-cellulose based material of high absorbency can be polyacrylate salt.

Abstract: To avoid breakage and weak points at the points of deflection in case of a large deflection angle and deep deformations a non-woven is formed of several fiber components, which forms a flexible, dimensionally stable molded article under pressure and temperature. An additional CoPES-fiber component facilitates lamination with other fibers without having to use additional auxiliaries.

Abstract: There is provided pressure-sensitive adhesive coated breathable nonwoven tape backing substrate where the nonwoven tape backing comprises a fibrous nonwoven web formed in part by multicomponent fibers having an adhesive component region. The multicomponent fibers are distributed throughout the width dimension of the nonwoven tape backing such that adhesive component region is exposed on both outer faces of the nonwoven tape backing. The adhesive component region is preferably a pressure-sensitive adhesive region formed by hot melt coextrusion of at least two components to form the multicomponent fibers.

Abstract: An outdoor protective fabric is disclosed having (i) a UV stable outer nonwoven web of multicomponent sheath/core fibers having a polyethylene polymer sheath component and a polypropylene polymer core component; (ii) a breathable barrier layer such as a meltblown web or microporous film; and (iii) an interior nonwoven web of multicomponent fibers comprising a polyethyfene polymer component and a nylon component.

Abstract: A filament non-woven fabric comprising thermoplastic conjugated filaments comprising at least one low melting point resin or low softening point resin selected from the group consisting of olefin binary copolymer or olefin terpolymer as the first component and crystalline thermoplastic resin as the second component. The thermoplastic conjugated filament contains inorganic powder in at least the first component, wherein the content of the inorganic powder is 500 to 50000 weight ppm with respect to the fibers. The present invention can provide a filament non-woven fabric that is excellent in the high adhesive property, low temperature adhesive property, hand feeling such as softness or touch etc., and uniformity. Furthermore, operating efficiency such as the spinning property is good. Absorbent articles can be produced using the above mentioned filament non-woven fabrics.

Abstract: Fibrous webs of bicomponent fibers are made by extruding a layered molten mass through a row of side-by-side orifices into a high-velocity gaseous stream. Bicomponent fibers of small size can be obtained, and the webs offer unique properties.

Abstract: A filament non-woven fabric comprises thermally adhesive conjugated filaments comprising a first component that contains not less than 20 weight % of ethylene-acrylic ester-maleic anhydride copolymer and that is formed in at least a part of the filament surface in the longitudinal direction of the filament, and a second component that is a crystalline thermoplastic resin having a melting point higher than that of the first component. At least the first component contains an inorganic powder and the content of the inorganic powder is 500 to 50000 weight ppm with respect to filament. The present invention can provide the non-woven fabric comprising filaments which is excellent in the high adhesive property, low temperature adhesive property, adhesion property to other kinds of materials, hand feeling such as softness or touch etc., and uniformity. Furthermore, the operating efficiency such as the spinning property is desirable.

Abstract: A thermoformable sheet material as made by use of homogeneously dispersed bicomponent fibers of polyester (12, 12A) and lower melting co-polyester (14, 14A) that are formed as a felt, heated to melt the lower melting component and resolidification of the melted fibers as blobs locking in cross over points of the polyester fibers and deifying and strengthening the felt as a whole into an enhanced thermoformable materials, with adhesives optionally applied to one or both surfaces thereof.

Abstract: Undrawn, tough, durably melt-bondable, macrodenier, thermoplastic, multicomponent filaments, such as sheath-core and side-by-side filaments, comprising a first plastic component and a second lower-melting component defining all or at least part of the material-air boundary of the filaments. The filaments can be made by melt-extruding thermoplastics to form hot filaments, cooling and solidifying the hot filaments, and recovering the solidified filaments without any substantial tension being placed thereon. Aggregations of the filaments can be made in the form of floor matting and abrasive articles.

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

Abstract: Disclosed herein are multicomponent fibers wherein at least one component will permit bonding of the fibers to themselves and other types of fibers and wherein the same first component is also degradable in an aqueous medium. Such fibers can be used to form fibrous nonwoven webs which can be used as components in such end-use products as medical and health care related items, wipes and personal care absorbent articles.

Abstract: The disclosed invention relates to split fibers and improved means and methods for obtaining them as well as their use in nonwovens and incorporation into personal care and other products. Multicomponent filaments are formed including at least two incompatible components. These filaments are drawn under hot aqueous, for example, steam, conditions causing them to split into fibers containing the incompatible components. These fibers are collected as a fine fiber nonwoven which finds utility as a component of sanitary napkins, diapers and other products.

Abstract: The present invention relates to a cleaning implement formed from spunbond fiber webs having a basis weight less than about 85 grams per square meter and wherein the fibers comprise macrofibers having an average fiber diameter greater than 50 microns and less than about 500 microns. A section of macrofiber web having a mass between about 10 and 30 grams is bundled into a deformable three-dimensional shape which is about 8 to 25 cm in at least one dimension. The cleaning implement is particularly well suited for use in conjunction with shower gels or soaps for washing the body.

Abstract: The invention disclosed herein is a synthetic reinforcing strand of filaments in which the strand density is reduced by spacing the filaments apart along their length with heat expandable hollow particles such as plastic microspheres expanded into microballoons and the method of making such strands. Also embodied in the invention are methods utilizing such strands in processes for making composite structures.

Abstract: A non-woven fabric comprising thermally fusible composite fibers with shortened heat-sealing time and improved heat-sealing strength is provided. The non-woven fabric is produced using side-by-side type or sheath-and-core type thermally fusible composite fibers comprising a first component consisting of polyethylene and a second component consisting of polyester, said polyethylene occupying continuously at least a portion of the surface of the fiber in the length direction, wherein said polyethylene is a copolymer having 1.6/1,000 C or more methyl branches in its molecular chains, a density from 0.940 to 0.965 g/cm.sup.3, and a Q value (weight average molecular weight Mw/number average molecular weight Mn) of 4.8 or less.

Abstract: The invention provides a sheet filter medium having autogenously bonded uncrimped conjugate fibers which contain a polyolefin and another thermoplastic polymer that have different melting points. The filter medium has a density between about 0.07 g/cm.sup.3 and about 0.2 g/cm.sup.3. The invention additionally provides a three-dimensionally thermoformed filter medium that has a density between about 0.07 g/cm.sup.3 and about 0.5 g/cm.sup.3.

Abstract: An improvement in the sealing of bonded batts of fiberfill is obtained by providing a barrier layer of bonded bicomponent binder fibers on one or both faces of the remainder of the batt to prevent or reduce the tendency of the fiberfill to leak through such faces.

Abstract: The invention provides a nonwoven fabric of stretched filaments of different kind polymers, having a strength equal to that of a woven fabric and features including an elongation, a uniformity, good feeling, a bulkiness and a thinness, characterized in that the nonwoven fabric is provided with stretched filament webs comprising long filaments formed out of a plural kinds of thermoplastic polymers of different properties, the long filaments as a whole being aligned in one direction, and a method for manufacturing the same. The invention provides also a nonwoven fabric of stretched filaments having a high strength as well as a high bulkiness and comprising different kind polymers which is provided with a first web layer of crimped filaments and a second web layer of substantially non-crimped, stretched long filaments, and a method for manufacturing the same.

Abstract: A breathing mask fabric is provided which has between 50 and 95 weight percent of a through-air bonded, electret treated, nonwoven microfiber first web of fibers where the fibers have an average diameter of between about 10 and 25 microns and where the first web has a Frazier Permeability above about 100 CFM/SF, a density of between about 0.015 and 0.15 gms/cc, and a basis weight between about 67 gsm and about 340 gsm, and between about 5 and 50 weight percent of an electret treated microfiber second web of fibers where the fibers have an average diameter of less than about 10 microns.

Abstract: A non-woven fabric having a high strength, a good bulkiness and a soft feeling, and hot-melt-adhesive conjugate fibers affording the non-woven fabric are provided, the above hot-melt-adhesive conjugate fibers being composed of conjugate fibers, of side-by-side type or sheath-and-core type, composed of a high melting component of a polypropylene or a polyester and a low melting component of a polyethylene, the polyethylene continuously forming at least one portion of the fiber surface in the direction of the fibers; hot-melt-adhesive conjugate fibers characterized in that the polyethylene has 0 to 1.5 methyl branch/1000 C in the molecular chain, a density of 0.950 to 0.965 g/cm 3 and a Q value (weight average molecular weight (Mw)/number average molecular weight (Mn)) of 4.5 or less, and the above hot-melt-adhered non-woven fabric being characterized by containing 20% by weight or more of the above hot-melt-adhesive conjugate fibers.

Abstract: A loose-fill insulation product having irregularly shaped glass fibers is provided. The loose-fill insulation product shows improved recovery, lower thermal conductivity and requires lower product densities than prior art loose-fill insulation at equivalent fiber diameters.

Abstract: Disclosed is a laminated non-woven fabric of a multi-layer structure comprising a layer of a composite, spun bond non-woven fabric composed of long fibers containing a low melting point resin component and a high melting point resin component, and a layer of a non-woven fabric of melt-blow ultrafine mixed fibers comprising low melting point ultrafine fibers and high melting point ultrafine fibers both of the fibers have an average fiber diameter of 10 .mu.m or less, both of the layers are laminated, and fibers in each of the non-woven fabrics and both of the layers are heat-melt adhered with each other. The laminated non-woven fabric has a good hand feeling and a high peeling strength of adjacent layers, but has no rough feeling.

Abstract: Disclosed are multicomponent fibers wherein at least one component forms an exposed surface on at least a portion of the multicomponent fiber which will permit thermal bonding of the multicomponent fiber to other fibers. The multicomponent fibers comprise two poly(lactic acid) polymers with different L:D ratios which provide biodegradable properties to the multicomponent fiber yet which allow the multicomponent fiber to be easily processed. The multicomponent fiber is useful in making nonwoven structures that may be used in a disposable absorbent product intended for the absorption of fluids such as body fluids.

Abstract: A biodegradable filament nonwoven fabric comprising a nonwoven web made up of filaments, each filament comprising a high melting point component composed of a first aliphatic polyester having biodegradability and a low melting point component composed of a second aliphatic polyester having biodegradability with a melting point lower than that of the high melting point component, the nonwoven web processed to a predetermined nonwoven fabric configuration. At least one of the high melting point component and the low melting point component is arranged in a plurality of divisions within the cross section of the filament. Both the high melting point component and the low melting point component extend continuously in the axial direction of the filament and are exposed on the surface of the filament. A method for manufacturing the biodegradable filament nonwoven fabric is also disclosed herein.

Abstract: Methods and apparatus for forming a nonwoven fiber web containing a pore size gradient resulting in enhanced wicking properties. A first method utilizes a conventionally formed web having an average pore size and comprises selectively contacting the web with a heat source to shrink the fibers in selected areas. The smaller pore sizes have greater wicking ability. A second method utilizes a novel apparatus and comprises forming a nonwoven fiber web having zones of fibers, each zone having generally an average set of fiber structure and/or composition, the zones preferably overlapping. The zones of fibers are exposed to a heat source, which shrinks the fibers according to their denier and composition.The apparatus uses a conventional meltblown or spunbond system and provides a plurality of resin sources which feed resin to a plurality of meltblowing dies. Each die produces fibers of a particular denier and/or composition which forms zones in a web collected on a collecting belt.