Abstract: The present invention is directed to a novel process of making N-isopropyl acrylamide (NiPAm) polymers based upon the reaction of poly(acrylic acid) and N-isopropylamine. The disclosed method of the present invention uses polyacrylic acid as a starting material to synthesize NiPAm polymers. In one embodiment, the present invention discloses a condensation reaction of an intermediate salt to form homopolymers, copolymers and terpolymers of N-isopropyl acrylamide (NiPAm) with acrylic acid and/or alkyl acrylates in a molten state, which is adaptable to a continuous reactive extrusion process. Binder compositions, water-dispersible products and thermoformable articles containing the NiPAm polymers are also disclosed.

Abstract: The laminated sheet of the present invention comprises (A) a nonwoven fabric having a basis weight of 30 g/m2 or less made of polyolefin-based ultra-fine fibers of 5 &mgr;m or less in average fiber diameter; (B) a heat-bonding nonwoven fabric having a basis weight of 15 g/m2 or less made of thermoplastic elastomer ultra-fine fibers of 15 &mgr;m or less in average fiber diameter; and (C) a spun-bonded nonwoven fabric having a basis weight of 30 g/m2 or more made of thermoplastic polymer fibers. The nonwoven fabric A and the spun-bonded nonwoven fabric C are face-bonded via the heat-bonding nonwoven fabric B. The laminated sheet is excellent and well-balanced in a wind breaking performance, a water vapor permeability and a waterproof performance. The laminated sheet is also excellent mechanical properties and durability. With these excellent properties, the laminated sheet is suitably used as house wrap materials and roof underlay sheets.

Abstract: Fibrous sorbent media or pads are formed from non-woven mats of thermoplastic fibers, preferably polypropylene fibers, having a mean diameter between about 0.5 microns and about 25 microns. The mats have a weight between about 2 ounces/yd2 and about 25 ounces/yd2; a thickness of at least {fraction (1/20)} of an inch; an oil absorbency ratio of at least 5 to 1 or a water absorbency ratio of at least 5 to 1. The sorbent media have first and second major surfaces with abrasion resistant, liquid permeable, integral skins and fibrous cores. The liquid permeable skins of the media are formed by melting fibers at and immediately adjacent the major surfaces of the mats to form thermoplastic melt layers which are subsequently solidified into the skins on the major surfaces of the mats. For many applications, the thermoplastic fibers of the mats are point bonded together at spaced apart locations to increase the integrity of the mats.

Abstract: A nonwoven material including at least a meltblown web is stretched by about 1-35% in at least one direction using a short-distance drawing process, to provide a fabric having improved softness and liquid barrier compared to otherwise similar fabrics prepared using longer drawing distances. The drawing process may include one or multiple stages. When multiple stages are employed, the fabric has adequate liquid barrier at a lower basis weight.

Abstract: An object of the present invention is to provide a filter cartridge having an high filtering accuracy, a long filter life and a good liquid-passing property, in which an initial trapped particle diameter little changes, a pressure loss is small and neither bubbling nor falling of the filter material is observed.

Abstract: An extrudable thermoplastic superabsorbent polymer blend composition is disclosed. The blend compositions are especially well suited for preparation of extruded or molded articles such as monolayer films, multilayer films, nonwoven webs, sheets, foams, profiles, multilayer laminates, fibers, tubes, rods or pipes which in turn are well suited for preparation of power and communication cables or disposable absorbent articles such as diapers, sanitary napkins, tampons, incontinence products, hospital gowns or bed pads.

Abstract: A multilayer laminate comprising a fine fiber nonwoven composite web which is a mixture of a first group of fibers and a second group of fibers such that the first and second fibers comprise polymers that are incompatible with each other. The fine fiber nonwoven composite web is bonded to a barrier layer such as a microporous film or a nonwoven web of meltblown fibers.

Abstract: A meltblown fiber comprising at least 20% by weight polyester selected from the group consisting of poly(ethylene terephthalate) having an intrinsic viscosity of less than 0.55 dl/g and poly(trimethylene terephthalate) having an intrinsic viscosity of less than 0.80 dl/g is provided. The meltblown fibers are collected as a web that can be incorporated into composite sheet structures.

Abstract: A targeted elastic laminate material having different zones of tension across a width of a material roll and methods for making the same. At least two polymers or polymer blends having different set properties are used to produce varying tension zones across the material. The targeted elastic laminate material has elastic properties that provide improved fit characteristics to disposable personal care products, while maintaining a flat roll profile that allows the material to be easily processed at a high speed.

Abstract: A nonwoven fabric suitable to be used as a kitchen paper including thermoplastic synthetic fibers being 7˜30 mm long and as fine as of 0.1˜0.8 d, in 90˜10% by weight and pulp fibers being 2˜7 mm long, in 10˜90% by weight, these component fibers being mixed together as homogeneously as possible and mechanically entangled so as to have a basis weight of 10˜80 g/m2 as a whole.

Abstract: A breathable, substantially liquid impermeable film and laminate are provided for use in a wide variety of personal care garments and protective garments. The film, and laminate containing the film, are extendible in a cross-direction to a stretched width which is at least 25% greater than an original, unstretched width. The film and laminate have a first water vapor transmission rate of at least about 500 grams/m2-24 hours coinciding with the unstretched width. The film and laminate have a much higher second water vapor transmission rate which is at least about 225% of the first water vapor transmission rate, and not less than about 4000 grams/m2-24 hours, coinciding with a stretched width that is only 25% greater than the stretched width.

Abstract: The nozzle piece of the present invention is provided with circular cross sectional nozzles having different sizes disposed in a row in front of the die, with n-numbered smaller nozzles B (hole diameter: Db) between adjacent larger nozzles A (hole diameter: Da). It gives melt-blown non-woven fabric of monolithic structure in one step, composed of fine fibers having a diameter in a range from 1 to 10 &mgr;m diameter Variance ratio F of 2.0 or more and wide fiber diameter distribution.

Abstract: A nonwoven fabric with UV stability and flame retardancy having at least one fabric layer. The fabric layer is made of a base resin, preferably polyolefinic, and a non-halogenated melt processable compound that is selected from the group consisting of N-alkyoxy amines and are combined into a homogeneous blend which is then either spunbonded or meltblown to form the fabric layer. A melt processable fluorochemical additive may also be combined into the homogeneous blend to provide liquid barrier properties to the fabric layer.

Abstract: A process for producing a multi-layered non-woven fabric includes: (a) forming a plurality of non-woven fabric layers from a plurality of filament materials which are produced respectively from a plurality of spinning devices disposed along an advancing forming screen; (b) forming at least one of the filament materials as a composite filament material which includes at least two filament components having high and low melting points by means of one of the spinning devices; and (c) depositing the filament materials on the advancing forming screen one over the other to form a plurality of non-woven fabric layers. An apparatus to carry out the process, and a multi-layered non-woven fabric produced thereby are also disclosed.

Abstract: A die head assembly for meltblowing thermoplastic material comprising a first chamber for receiving a pressurized fluid, a second chamber for receiving a pressurized molten thermoplastic material, the second chamber defining an outlet through which the molten thermoplastic material exits the die head, and a fluid tube removably securable to the first chamber and defining a passageway having an inlet in communication with the first chamber and an outlet extending at least into the outlet of the second chamber.

Abstract: A wettable fiber or filament comprises a melt additive to a thermoplastic polyolefin such as polypropylene.

Abstract: A spunbond nonwoven fabric is provided which has superior strength characteristics to conventional fabrics yet is comparably soft. The fabric is a laminate having a web made from a high melt flow rate polyolefin polymer and a low melt flow rate polymer. The spunbond laminate fabric of this invention may have therebetween a layer of meltblown nonwoven fabric or film. The laminate produced according to this invention has a strength which is at least 10% greater than a comparable fabric made without the high melt flow rate polymer web. The nonwoven fabric of this invention may be used in products such as, for example, garments, personal care products, medical products, protective covers and outdoor fabrics.

Abstract: The present invention relates to a polyester product excellent in resilient elasticity, shape retainability and shape stability, and a process for producing the same. The invention provides a polyester product with high resilient elasticity, shape retainability, and shape stability, which is produced by heat-treating a product comprising polyester fibers or a film prepared by taking up a molten polyester at a take-up speed of 2000 m/min to 4000 m/min, in wet heat and/or dry heat at not lower than 120° C. with the product maintained in a loose or constrained condition without being drawn. The product is very suitable, for example, as a collar interlining cloth of a shirt, a base fabric of a shirt, or a fabric of a lady's dress, etc.

Abstract: A cleaning sheet which is attached to a cleaning tool during use which comprises a wiping region having a wiping layer and attaching regions positioned on both sides of the wiping region, where a plurality of recesses are formed at intervals along boundaries between the wiping region and the attaching regions such that the recesses extend from the boundaries toward the center of the wiping region.

Abstract: The present invention relates to polypropylene copolymer alloys which are especially suited for soft fiber and fabric applications. These alloys comprise an ethylene-propylene random copolymer having an ethylene content of from about 1.0 to 5.0% by weight, in an amount of from about 40 to 90% by weight of the alloy; and an ethylene-propylene bipolymer having an ethylene content of from about 10 to 30% by weight, in an amount of from about 10 to 60% by weight of the alloy. The present invention further relates to fiber and fabric articles made from such alloys.

Abstract: A composite filter media (100) includes a meltblown/spunbond composite fiber material and a mixed fiber triboelectric material are preferably attached to each other by needling the mixed fiber material with the meltblown/spunbond composite fiber material. A netting (104) is then attached by preferably needling the mixed fiber triboelectric material and meltblown through the netting (104).

Abstract: The disclosure relates to a melt-blown non-woven fabric based on cellulose esters, with fibers of mean diameter less than about 10 microns. The fabric contains 0-10 wt. % extractable softener, has a reflection factor determined according to DIN 53 145 Part I (1992) of more than 60% and the cellulose ester has a degree of substitution DS of about 1.5-3.0. The softener is preferably water-extractable. A melt-blown non-woven fabric is produced with the cellulose ester as follows: a cellulose ester, cellulose acetate, with a DS of about 1.5-3.0, in particular 1.7-2.7, is mixed with softener in a weight ratio of about 2:1 to 1:4 and simultaneously heated and melted. The mixture of softener and cellulose ester has a melting index MFI (210/2.16) according to DIN 53 735 of about 400 to 5 g/10 min., in particular 300 to 50 g/10 min. The melt is worked in a melt-blown spinning device into a melt-blown non-woven fabric and the softener is then extracted with a softener solvent to leave a proportion of 0-10 wt. %.

Abstract: The present invention provides a fiber containing remarkably high heat resistance and softness and fiber-processed products using the same. A fiber formed from a polypropylene serving as at least one raw material, wherein the polypropylene is confirmed with NMR spectrometry that an isotactic pentad fraction (mmmm) of 0.950-0.995, a syndiotactic pentad fraction (rrrr) of 0-0.004, different bonds due to 2,1-insertion reaction and 1,3-insertion reaction in an amount of 0-0.3 mol %, and absence of terminal double bonds, and has a weight average molecular weight (Mw) of 50,000-1,000,000, and has a ratio (Mw/Mn) of weight average molecular weight (Mw) to number average molecular weight (Mn) of 1.5-3.8; and fiber-processed products using the fiber.

Abstract: A surfactant and skin wellness composition useful for imparting durability and wettability to a substrate as well as skin wellness, includes a first surfactant in combination with aloe vera. The first surfactant includes a compound selected from ethoxylated hydrogenated fatty oils, monosaccharides, monosaccharide derivatives, polysaccharides, polysaccharide derivatives, and combinations thereof. Other ingredients can also be added. The composition can be applied as an aqueous emulsion to a substrate such as a nonwoven web, to provide enhanced wettability combined with skin enhancement to the wearer.

Abstract: This invention is directed towards a porous composite having an inlet face and an exit face and further comprises intermingled meltblown fibers and staple fibers which define a density gradient from coarse pores at the inlet face to fine pores at the exit face.

Abstract: A water soluble polymer comprising from about 25 weight % to about 90 weight % of an unsaturated carboxylic acid/unsaturated carboxylic acid ester terpolymer; from about 10 weight % to about 75 weight % of a divalent ion inhibitor and from about 0 weight % to about 10 weight % of a plasticizer is soluble in an aqueous environment having a divalent ion concentration less than about 50 ppm and a monovalent ion concentration of less than about 0.5 weight %. Also disclosed is a water dispersible fibrous fabric having a fibrous substrate and an effective amount of the binder distributed on the substrate and a method of making a water dispersible fibrous fabric.

Abstract: The process and apparatus of the present invention involves treating a well-integrated woven or non-woven web of hydrophobic fibers to make selected areas hydrophilic. It also can be used to make a web of hydrophilic fibers selectively hydrophobic. It uses a plurality of selectively adjustable covers on an applicator roll rotating in a bath of liquid to place the liquid material on selected areas of the web as the web moves over the roll. In a preferred embodiment the web is non-woven and the fibers are hydrophobic in nature, e.g., dry-laid or melt-blown polypropylene or polyethylene fibers or spun-bonded hydrophobic filaments. A woven web made of cotton or other hydrophilic fibers may also be used if the end result is to create partially hydrophobic areas on a hydrophilic web. The areas of liquid are positioned on the web only where desired so as to eliminate the excessive cost of unwanted and unnecessary coating material. If the web is hydrophobic, the liquid makes that area hydrophilic.

Abstract: The present invention desirably provides a fabric including a synthetic fiber structure first zone, a synthetic fiber structure second zone, and a short fiber third zone. The first zone may include a spunbond web layer and a meltblown web layer. The synthetic fiber structure second zone may be positioned proximate to the synthetic fiber structure first zone and the short fiber third zone may be positioned substantially between the first and second zones. Desirably, the first and second zones are entwined.

Abstract: A flame retardant composition for treating a high pulp content nonwoven web is provided. The flame retardant composition includes soluble solids formed from inorganic salts, such as ammonium polyphosphate and sulfur. The TGA range of such soluble solids is from about 175.degree. C. to about 370.degree. C. The flame retardant composition may be continuously and uniformly applied to the high pulp content nonwoven web by a non-compressive process.

Abstract: A zone-treated spunbonded/meltblown/spunbonded (SMS) fabric laminate that combines the separate functions of the topsheet and cuff in one component of an absorbent article. The SMS fabric laminate is treated with surfactant to form a hydrophilic zone. The untreated areas of the SMS fabric laminate remain hydrophobic and perform the function of the cuff. Alternatively, a spunbonded/spunbonded fabric laminate is formed and then zone-treated with surfactant. The fabric laminate is treated with surfactant on both sides using a foam applicator. The application of foam produces sharp transitions between the hydrophilic and hydrophobic zones. After foam application, the fabric laminate is dried and slitted. The treated and slitted material is then wound and sold in roll form for converting into the finished disposable diaper.

Abstract: A nonwoven fabric comprising thermoplastic resin fiber bundles, wherein numerically at least about 50% of all the fibers present are bonded to each other in the form of fiber bundles. The fiber bundles are arranged along substantially one direction.

Abstract: A dispensable nonwoven cohesive wrap that is generally dispensed from a self-wound roll. The nonwoven cohesive wrap comprises mutually entangled fibers at least some of which are pressure-sensitive adhesive fibers. The cohesive wrap also generally has a basis weight of from 40 to 200 grams/m.sup.2, a tensile strength of at least 100 grams/2.5 cm and a T-peel from itself of from 1 to 30 grams/2.5 cm. The wrap is preferably a single layer material without a separate adhesive coating or release coating where the adhesive fibers extend through the entire depth dimension of the wrap, such that a portion of the adhesive fibers are on both faces of the wrap, and preferably are uniformly distributed across the length and width dimensions of the wrap.

Abstract: A diaper outer cover of a layered nonwoven material having an outer meltblown fiber layer of a meltblown material having an average basis weight in the range of about 1 g/m.sup.2 to about 7 g/m.sup.2 disposed on an inner nonwoven material layer, preferably a spunbond web.

Abstract: The present invention provides a stable nonwoven web having enhanced extensibility and a method for making the same. A neckable nonwoven web is fed in a first direction. The neckable nonwoven web is subjected to incremental stretching in a direction perpendicular to the first direction. A tensioning force is applied to the neckable nonwoven web to neck the nonwoven web. The necked nonwoven web is then subjected to mechanical stabilization to provide a stabilized extensible necked nonwoven web. The stabilized extensible necked nonwoven web is easily extended in a direction parallel to the direction necking.

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: A method of coating the surface of a substrate, such as a film or a fibrous web, which is composed of a hydrophobic polymer. The method involves providing a solution of a first polyelectrolyte having ionizable groups and a solution of a second polyelectrolyte having ionizable groups. The two solutions then are mixed under conditions adapted to result in the formation of a nonstoichiometric polyelectrolyte complex. Finally, the surface of the hydrophobic polymer substrate is contacted with a solution of the complex under conditions sufficient to result in the coating of the surface of the substrate with the complex. The ionizable groups of the second polyelectrolyte have a latent charge opposite the latent charge of the ionizable groups of the first polyelectrolyte.

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 stabilizing additive package for nonwoven fabrics is provided. The package has a bismuth vanadate based pigment and a hindered amine light stabilizer. The bismuth vanadate is added to a nonwoven fiber polymer prior to extrusion in an amount between about 0.1 and 3 weight percent based on the weight of the fabric and the hindered amine in an amount between about 0.25 and 2.5 weight percent based on the weight of the fabric. The nonwoven fabric also provided by this invention may be used as protective covers for, for example, boats and cars, and as an outdoor fabric for, for example, canopies and tents.

Abstract: Disclosed is a fabric which includes a microbial adsorbent and which is capable of providing a microbial barrier while still being able to allow passage of water vapor. The fabric is formed from a plurality of fibers which define at least one microporous passageway which allows communication, through the fabric, between its respective first and second surfaces. In particular, a portion of the microporous passageway is defined by the microbial adsorbent so that microbes attempting to pass through the fabric via such a passageway must pass in close proximity to the microbial adsorbent. This arrangement allows the microbial adsorbent to interdict the microbe by adsorbing it. Passage of the microbe through the fabric is thereby prohibited. Laminates of the fabric with other materials are also disclosed.

Abstract: The present invention relates to a planar consolidated multilayered nonwoven web comprising reduced pore sizes. The present invention also relates to a method for forming a planar consolidated multilayered nonwoven web which is elastic in the cross direction and which comprises a first and a second layer.

Abstract: An improved allergen-barrier cover for completely surrounding an allergen-carrier article, such as bedding, is provided. The cover is formed from a multilayer fabric such as an SMS fabric that allows passage of air, but blocks the passage of allergens and liquid water. This fabric is formed into an enclosure by thermally welding any seams necessary to provide a enclosure which completely encases the allergen-carrier article except for an opening sufficient to allow insertion of the allergen-carrier article into the enclosure. The cover also includes a closure in the form of a plastic seal made up of two portions: a first portion having at least two parallel ridges spaced apart from one another by a first distance and a second portion comprising at least two parallel grooves spaced apart from one another by the same distance as the parallel ridges and sized to receive the at least two parallel ridges in sealing engagement.

Abstract: A surfactant composition useful for imparting durability and wettability to a substrate includes first and second surfactants in combination. The first surfactant includes a compound selected from ethoxylated hydrogenated fatty oils, monosaccharides, monosaccharide derivatives, polysaccharides, polysaccharide derivatives, and combinations thereof. The second surfactant includes an organosilicon compound. The surfactant composition can be applied as an aqueous emulsion to a substrate such as a nonwoven web, to provide enhanced wettability after repeated washing cycles.

Abstract: A water soluble polymer comprising from about 25 weight % to about 90 weight % of an unsaturated carboxylic acid/unsaturated carboxylic acid ester terpolymer; from about 10 weight % to about 75 weight % of a divalent ion inhibitor and from about 0 weight % to about 10 weight % of a plasticizer is soluble in an aqueous environment having a divalent ion concentration less than about 50 ppm and a monovalent ion concentration of less than about 0.5 weight %. Also disclosed is a water dispersible fibrous fabric having a fibrous substrate and an effective amount of the binder distributed on the substrate and a method of making a water dispersible fibrous fabric.

Abstract: A nonwoven fabric formed from filaments made from a polymer derived from L- and D-lactic acid. The nonwoven fabric is biodegradable and especially suitable for use in disposable hygiene products.

Abstract: A wall lining material consists of an upper mat body, a lower mat body and a granular moisture absorbent. The upper mat body and the lower mat body are made of a nonwoven fabric containing a multiplicity of fibers. The moisture absorbent is located between these two mat bodies. The mat bodies are sewn together over the laminated portion at many points by means of needle punching. This needle punching causes the fibers in the upper mat body to be connected with those in the lower mat wed and vice versa.

Abstract: A water soluble polymer comprising from about 25 weight % to about 90 weight % of an unsaturated carboxylic acid/unsaturated carboxylic acid ester terpolymer; from about 10 weight % to about 75 weight % of a divalent ion inhibitor and from about 0 weight % to about 10 weight % of a plasticizer is soluble in an aqueous environment having a divalent ion concentration less than about 50 ppm and a monovalent ion concentration of less than about 0.5 weight %. Also disclosed is a water dispersible fibrous fabric having a fibrous substrate and an effective amount of the binder distributed on the substrate and a method of making a water dispersible fibrous fabric.

Abstract: A floor mat includes an upper layer having a top surface and a bottom surface with the upper layer capable of absorbing liquid and wicking the liquid from the top surface toward the bottom surface of the top layer. The upper layer allows water to evaporate from the floor mat so that it may dry. The mat also includes an upper intermediate layer disposed adjacent the upper layer. The upper intermediate layer is capable of wicking liquid from the upper layer and retaining the liquid within its body. A lower intermediate layer is disposed adjacent the upper intermediate layer. The lower intermediate layer is also capable of absorbing and retaining liquid from the upper intermediate layer when the upper intermediate layer is fully saturated. A liquid impervious layer is disposed below the lower intermediate layer such that water may not seep out of the bottom of the lower intermediate layer.

Abstract: There is provided a fully elastic, breathable, barrier fabric comprising a nonwoven web layer of fibers of less than 40 microns in average diameter, where the web has a hydrohead of at least 10 mbar, a Frazier Permeability of at least 100 CFM, a basis weight of less than 68 gsm and which is made from an elastic polymer. If the fabric is a laminate it may be an SMS, SBL or NBL laminate. This fabric is particularly well suited to use as a containment flap for personal care products such as diapers, incontinence products and feminine hygiene products and in infection control products.

Abstract: Composite fabrics particularly suited for upholstery backings and furniture decking comprise at least one layer of a needlepunched web of nonwoven staple fibers adhered to at least one layer of a substantially continuous filament nonwoven web comprising substantially randomly disposed filaments. The filaments comprise a multi-phase, thermoplastic, elastomeric olefin copolymer.

Abstract: There is provided a laminate of nonwoven fabrics for outdoor applications which has good resistance to ultraviolet light. The laminate has two meltblown layers sandwiched between spunbond layers to produce an SMMS laminate. The layers have a large amount of a UV stabilizer and metal oxide pigments. Such laminates are useful for car covers, awnings and canopies, etc. When the laminate is used as a car cover, it is preferred to skew the basis weights of the outer layers so that the layer against the car is significantly lighter than the other outer layer and to reduce the denier of the fibers in the layer against the car.