Abstract: The invention relates to the field of composite brake disks formed from fibrous structures. A brake disk according to the invention comprises an annular fibrous structure having two opposing generally planar faces and a binding matrix permeating the annular fibrous structure. Two outer portions are adjacent the planar faces, and an inner portion is disposed between the two outer portions. The two outer portions have lesser tensile strength parallel to the planar faces and greater resistance to wear than the inner portion.

Abstract: This invention relates to a new nonwoven material which has very high Frazier permeability while having substantial hydrostatic head liquid barrier properties. The material is comprised of fibers which are approximately one denier and finer fibers which have sufficient strength properties so as not to need a support scrim. The fabric is quite comfortable because of its breathability, quite soft because of its construction, and protective from liquids from rain to hazardous chemicals.

Abstract: A breathable elastic laminate is formed by bonding a film including an elastic water vapor-soluble polymer to a neckable nonwoven web such that when the film is relaxed, the web is in a necked state. The breathable laminate is stretchable in a direction parallel to the narrowing or necking of the web. The laminate possesses excellent water vapor permeability but acts as a barrier to the passage of odor-causing chemicals including ammonia.

Abstract: The present invention is directed to novel face masks, which include a spunbonded/meltblown/spunbonded (SMS) laminate. The face masks of the present invention may include other layers, in addition to the SMS layer, such as an electret meltblown layer, a spunbonded layer, a wet-laid layer or a second SMS laminate. In one embodiment, the face mask includes an outermost SMS layer, an intermediate electret meltblown layer, and an innermost layer in the form of a spunbonded layer, a wet-laid layer or a second SMS laminate.

Abstract: A method for producing asphalt fibers includes supplying molten asphalt to a rotating asphalt spinner, centrifuging asphalt fibers from the asphalt spinner, and collecting the asphalt fibers. The molten asphalt is supplied to the asphalt spinner at a temperature within the range of from about 270.degree. to about 500.degree. F. Also disclosed is a method for integrating asphalt with reinforcement fibers including the steps of establishing a downwardly moving veil of reinforcement fibers, such as glass fibers, and centrifuging asphalt fibers from a rotating asphalt spinner positioned within the veil of reinforcement fibers to integrate the asphalt with the reinforcement fibers. A method for making an asphalt roofing shingle includes the steps of assembling together a mat of asphalt fibers with a mat of reinforcement fibers, coating the assembled mats to form an asphalt coated sheet, applying granules to the asphalt coated sheet, and cutting the asphalt coated sheet into roofing shingles.

Abstract: A waterproof multi-layered non-woven fabric having good vapor permeability and method for its production are provided. At least one layer of coarse melt-spun filaments of a thermoplastic polymer is thermally bonded at intermittent points to at least one layer of fine melt-blown microfibers. The bonded layers next are subjected while heated to a force in at least one direction in the absence of tearing so as to accomplish the permanent elongation of coarse melt-spun filaments and the straightening of fine melt-blown microfibers in the direction of the force in the substantial absence of drawing. Fine melt-blown microfibers when straightened in this manner form a less thick and denser array within the resulting fabric. The resulting product is capable of deterring the passage of liquid water, exhibits substantial vapor permeability, and exhibits a reduced basis weight.

Abstract: A composite elastic material is provided having improved hysteresis comprising a layer of an elastic material bonded to a layer of nonelastic material at least one side. The elastic material layer is made from a blend of a narrow polydispersity number polymer and a conventional elastomer, and the blend is essentially free of low molecular weight polyethylene processing aids. The composite elastic material laminate should have a hysteresis at least 15 percent better than a similar laminate made without the narrow polydispersity number elastomer but with the processing aid.

Abstract: The present invention is directed to film-nonwoven laminates incorporating stretch-thinned, breathable films onto which a pattern or network of adhesive areas is applied to improve durability and strength of the stretch-thinned film. The present invention has applicability in a wide variety of areas where strength, comfort, liquid impermeability and breathability are needed or desired, including without limitation, personal care absorbent articles, articles of clothing, roll goods and health care-related items.

Abstract: A sterilizable nonwoven material which is subjected to electreting, and more particularly electrostatic electreting is provided. The nonwoven materials may include laminate nonwovens wherein one or more layers are subjected to electreting. The nonwoven material(s) may also be treated with an antistatic material before or after subjecting the same to electreting.

Abstract: A nonwoven web having improved particulate barrier properties is provided. A surface treatment having a breakdown voltage no greater than 13 KV direct current is present on the nonwoven web. The particulate barrier properties are improved by subjecting said surface treatment treated nonwoven web to corona discharge.

Abstract: An absorbent article for use in cleaning oil spills comprises a first exposed outer layer of hydrophobic, liquid-permeable, fibrous polymeric nonwoven web and an absorbent body, adjacent the outer layer, comprising oil absorbent, cellulose-based material. Desirably, the article further comprises a second exposed outer layer of hydrophobic polymeric material with the absorbent body disposed between the first and second exposed outer layers. The absorbent article is placed on a layer of oil resting on the surface of a body of water for oil spill clean up. The absorbent article selectively absorbs oil over water because the outer hydrophobic layer repels water but attracts oil and transfers the oil to the oil absorbent body encased between the exposed outer layers. This invention results in considerable savings in cost and in non-renewable resources because the bulk of the product is a cellulose-based material, which is renewable, while only a small portion is polymeric nonwoven, which is non-renewable.

Abstract: A plasma sterilizable fabric which is subjected to charging, for example electrostatic charging, is provided. Plasma sterilizable fabrics may include nonwovens and laminate nonwovens. The plasma sterilizable fabrics may also be treated with an antistatic material before or after subjecting the same to charging.

Abstract: A cleaning card has a flat, semirigid base with a first and second material mechanically bonded to the side surfaces thereof. The first material is an abrasive substantially impenetrable material and the second material is a soft spunlaced fabric of high absorptive capacity. The differences in physical qualities of the first and second materials allow for one card to be used both as frequent cleaning card as well as a corrective cleaning card and provides a cleaning card that enables operation of the machine quickly after cleaning thereof.

Abstract: A nonwoven web laminate having improved particulate barrier properties, and particularly improved particulate barrier properties for particles in the size range of between 0.19 microns and 0.5 microns, is provided. The particulate barrier properties are improved by subjecting one or more of the layers forming the nonwoven web laminate to corona discharge. The improved particulate barrier properties are further achieved without substantially altering or increasing the amount of surface charge on the nonwoven web laminate.

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 ethylene oxide sterilizable nonwoven material which is subjected to charging, and more particularly electrostatic charging is provided. The nonwoven materials may include laminate nonwovens wherein one or more layers are subjected to charging. The nonwoven material(s) may also be treated with an antistatic material before or after subjecting the same to charging.

Abstract: A nonwoven laminate fabric includes first and second nonwoven webs formed of spunbonded substantially continuous filaments and a nonwoven web of meltblown microfibers having a basis weight between about one and twenty grams per square meter sandwiched between and bonded to the first and second nonwoven webs to form a composite nonwoven fabric. The meltblown web includes a plurality of thermoplastic microfine fibers having an average fiber diameter of less than 1.5 microns. The nonwoven laminate exhibits good barrier properties and can be used as a sterile wrap.

Abstract: There is provided a web which has been spun from a mixture of thermoplastic polymer and a softening additive in an amount up to about 3 weight percent, and which has been mechanically treated to increase softness. The web has a final cup crush value which is less than 50 percent of the starting cup crush value and the drop in cup crush value is greater than the sum of the treatments individually. The web may be a single layer or may be a laminate of spunbond and other materials such as meltblown and coform fabrics.

Abstract: A nonwoven bulky composite sheet material as first and second vapor permeable layers on opposite sides of a third layer of a bulky, flexible material. The third layer has a thickness in the range of 0.3 to 3.0 mm before being bonded between said first and second layers. The first layer, the second layer and the third layer are bonded together to form a flexible composite sheet with a thickness of at least 0.3 3 mm and a moisture vapor transmission of at least 100 g/m.sup.2 in 24 hours.

Abstract: Disclosed is a method of attaching a substantially uniform distribution of particulates to individual exposed surfaces of a matrix of fibrous material. The method includes the following steps: 1) electrically charging a matrix of fibrous material having individual exposed surfaces to create a substantially uniform distribution of charged sites at the exposed surfaces; 2) applying particulates to the charged matrix of fibrous material so that at least some particulates adhere at the charged sites; and 3) attaching particulates adhering to the fibrous material at charged sites by substantially non-transient bonding. Also disclosed is a fibrous composite structure composed of a matrix of fibrous material having individual exposed surfaces; and a relatively uniform distribution of particulate material attached to individual exposed surfaces of the fibrous material by substantially non-transient bonding.

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: The present invention provides composite nonwoven fabric laminates and processes for producing such. The fabric is comprised of a web of thermoplastic filaments laminated to at least one other web. Preferably, the filaments are spunbonded continuous polyolefin filaments which have an oxidatively degraded outer sheath portion to promote better interfilamentary bonding and improved fabric laminate strength. In a preferred embodiment, two outer nonwoven webs comprise oxidatively degraded spunbonded filaments and are positioned around and laminated to a web of meltblown microfibers thus forming an spunbond/meltblown/spunbond fabric. Additionally, a stretch compatible fabric may be formed in which a web of oxidatively degraded filaments is laminated to an elastic web. The fabrics of the invention may be advantageously used in numerous applications such as medical garments and disposable adsorbent products.

Abstract: Described is a rollable thermal insulation comprising synthetic fiber material and having a thermal conductivity of not more than 0.04 W/m*K (determined in accordance with DIN 4108 Part 1) and a DIN 4102 Part 1 fire behavior corresponding to building material class B1, wherein the synthetic fiber material is composed of carrier and bonding fibers made of polyester, preferably polyethylene terephthalate, the bonding fibers consisting in at least parts of the surface of a polyester having a melting point which is below the melting point of the carrier fibers.

Abstract: The present invention provides a self-supporting laminate filter medium having an electret lofty spunbond web and an electret microfiber web, wherein the spunbond web has a density between about 0.01 g/cm.sup.3 and about 0.1 g/cm.sup.3.

Abstract: The present invention relates to a thermally insulating material, specifically designed for garments or cloth articles, quilts, sleeping-bags and the like, the main feature of which is that said material comprises a synthetic fibre lap, bound by low-melting synthetic fibres and/or aqueous emulsion resins, which are spray applied. To the lap at least a textile supporting layer, processed by a resin, is coupled. The textile supporting layer has an air permeability less than that of the lap.

Abstract: A multi-layered structure having improved liquid barrier properties is provided. The multi-layered structure includes a porous hydrophobic layer and a spacing layer adjacent to and in juxtaposition with the porous hydrophobic layer. The function of the spacing layer is to provide sufficient channels for a liquid while supporting all or substantially all of a compressive pressure exerted against the spacing layer. As such, when the spacing layer is contacted with a liquid, such as water, saline or a bodily fluid such as blood, and subjected to a compressive pressure, of at least 2 psi, applied generally perpendicularly to the spacing layer, the channels are available within the bulk of the spacing layer for such liquid to flow therein or therebetween, while all or substantially all of the compressive pressure is supported by the spacing layer. In this way, the liquid in contact with the spacing layer flows into these channels without passing through the porous hydrophobic layer.

Abstract: There is provided a laminate of nonwoven fabrics for barrier applications which has improved ratios of barrier and strength to weight, of softness to strength and of vapor transmission to barrier. The laminate has a meltblown layer sandwiched between spunbond layers to produce an SMS laminate. The meltblown and spunbond layers may have between 0.1 to 2.0 weight percent of a fluorocarbon and the meltblown layer preferably between 5 and 20 weight percent polybutylene. The laminate also may have pigments if desired. Such laminates are useful for garments.

Abstract: A spun-bonded nonwoven composite web has randomly laid continuous matrix filaments (average linear density per filament less than 25 denier) and one or more continuous reinforcement filament (average linear density per filament which exceeds 20 denier and exceeds the average linear density per filament of said matrix filaments by at least 10 denier). The continuous matrix filaments are at least partially bonded together to form the web. The one or more continuous reinforcement filament is enmeshed in the web without substantially bonding to other filaments in the web, so as to exhibit pulled fiber behavior when the web is born.

Abstract: The invention features a nonwoven composite material which includes a layer of staple fiber aligned surface-to-surface with a spunbonded continuous filament web layer, the layers being continuously thermally bonded.

Abstract: There is disclosed fibers and fabrics formed from a polymer which is a "hand enhancing" polymer. The "hand enhancing" polymer is a copolymer of polypropylene which contains ethylene, 1-butene, or 1-hexene or a terpolymer of propylene, ethylene and butene. If the polymer is an ethylene copolymer, the copolymer may be random or random and block and the ethylene must be present in an amount between greater than 5 and 7.5 weight percent of the copolymer. If the copolymer contains 1-butene, it must be present in an amount between 1 and 15.4 weight percent of the copolymer. If the copolymer contains 1-hexene, it must be present in an amount between 2 and 5 weight percent of the copolymer. If the polymer is a terpolymer of propylene, ethylene and butylene, the polypropylene is present in an amount between 90 and 98 weight percent, the ethylene is present in an amount between 1 and 6 weight percent and the butylene is present in an amount between 1 and 6 weight percent.

Abstract: A nonwoven disposable face mask includes a filtration layer formed of a plurality of thermoplastic microfine meltblown microfibers having an average fiber diameter of less than 1.5 microns. The filtration layer also has a basis weight of less than ten grams per square meter. The resultant face mask provides improved wearer comfort and barrier and filtration properties.

Abstract: The present invention provides a natural fiber knit-like multi-layer composite containing at least one layer of a nonwoven fiber web and at least one layer of an elastomeric material, wherein the nonwoven web layer is joined to the elastic layer at spaced-apart locations and is gathered between said spaced-apart locations. The nonwoven fiber web is fabricated from multicomponent conjugate fibers or filaments that contain at least one polyolefin, and is a spunbond fiber web, staple fiber web or hydroentangled web. The composite exhibits soft, cloth-like texture of natural fiber knits as well as highly useful elastic properties.

Abstract: Conductive meltblown fabrics are disclosed which have improved strength and hand over conventional conductive meltblown fabrics. Also disclosed is a process for spraying a solution containing a conductive agent into a molten stream of meltblown fibers before they are deposited onto a forming wire. By applying the solution onto the fibers before they are deposited onto the forming wire, the heat of the molten stream vaporizes the solvent carrying the conductive agent and thereby eliminates the need to subsequently dry the formed material. By eliminating the drying step, degradation of the strength and hardening of the hand of the material normally resulting from the wetting and drying of meltblown fabrics are avoided. There is also disclosed a conductive SMS laminate having a conductive meltblown layer sandwiched between two untreated and nonconductive spunbond layers.

Abstract: A laminate comprising a fabric is provided wherein the fabric has comparable strength characteristics to conventional fabrics yet is softer. The fibers of the fabric are a blend of a high crystallinity polypropylene polymer and a random block copolymer of polypropylene and polyethylene. The laminate of this invention may include other spunbond layers, meltblown nonwoven fabrics or films.The laminate of this invention may be used in products such as, for example, garments, personal care products, medical products, protective covers and outdoor fabrics.

Abstract: There is provided a protective laminate having barrier properties which has a first outer layer having liquid repellency through the use of an internal, low surface tension liquid repellency additive and a bulky second outer layer having liquid absorbency through the use of an internal wetting agent, where the layers are bonded to form a laminate. When the laminate is used as part of a garment, the absorbent layer goes against the wearer.