Abstract: There is provided and fibrous layer for personal care products wherein the fibrous layer is made from micro-fine fibers deposited as an aqueous slurry onto a nonwoven web, and subsequently dried. The micro-fine fibers have a diameter from a positive amount to 0.5 microns. The nonwoven web may be produced from a number of methods, such as meltblowing, spunbonding, coforming, bonding and carding, and airlaying. The micro-fine fiber layer can be used to adjust the permeability of the nonwoven web, thus providing a method of controlling the rate of fluid movement through a personal care product, like diapers, training pants, incontinence garments and feminine hygiene products.

Abstract: There is provided a resilient, three dimensional material having fibrous texture and appearance and capable of fluid handling. It consists of a top surface and a bottom surface wherein fiber-like elements typically extend from one surface to the other forming flat to undulating surfaces characterized by a multiplicity of interconnected fluid passageways. Deformed, discontinuous film-like or encapsulated regions connect fiber-like elements and stabilize the material. The material of this invention is unique based on the three principle characteristics which are communicated in this application: 1) ff(?)<0.87, 2) SA/VV<186 cm2/cm3, and 3) caliper<0.150 inches. This material is useful for a number of purposes, such as for use as a liner for personal care products like diapers, absorbent underpants, swim wear, feminine hygiene products, adult incontinence products and the like.

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: The invention provides a water blocking tape for use in a variety of cable designs, such as power cable, data communications cable and telecommunications cable. A water blocking tape according to the invention includes layers of lightweight nonwoven fabric with one or more swellable water blocking compounds, such as water absorbent polymers, disposed between the layers. The nonwoven fabric layers are bonded in a pattern using an ultrasonic bonding technique. The bonding pattern helps to contain and to restrain movement of the water blocking compounds between the layers. The bonding pattern compartmentalizes the water blocking compounds to prevent pooling of the compounds and to facilitate a substantially consistent distribution of the compounds between the layers such that when a tape contacts water, the tape achieves a substantially consistent swell height.

Abstract: A nonwoven fabric printing medium comprises a first nonwoven fabric layer formed of thermoplastic polymer continuous filaments and at least one additional nonwoven fabric layer bonded to the first nonwoven fabric layer to form an integral unitary composite sheet material. The first nonwoven fabric layer has an outer surface adapted to receive printing ink, and the nonwoven fabric printing medium has a porosity of no more than 75 CFM pursuant to ASTM D-737-80, and in a preferred embodiment no more than 25 CFM. The first nonwoven fabric layer includes a thermoplastic polymer binder bonding together the thermoplastic polymer continuous filaments and also bonding the first nonwoven fabric layer to the one or more additional nonwoven fabric layers.

Abstract: A pattern bonded nonwoven fabric comprising a nonwoven fiber web having a geometrically repeating and visually discernable base pattern of bond points having at least one shape with at least one area defined by the shape and a second visually distinguishable bond pattern incorporated within said base pattern.

Abstract: Methods of making a barrier fabric include providing a web of nonwoven material that includes at least one meltblown nonwoven layer, applying a barrier finish to the web such that the web serves as a barrier to liquids, stretching the web in a widthwise or cross machine direction without hindering barrier properties of the web, and subjecting the web to conditions sufficient to cure the barrier material.

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 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: Disclosed herein is a process for producing a fibrous material for a member with which an ink-jet ink comes into contact, including the step of melt spinning a thermoplastic resin, the process comprising the step of treating a spun yarn by bringing it into contact with a glycol added with ethylene oxide.

Abstract: Materials and methods are provided for producing preform materials for impact-resistant composite materials suitable for liquid molding. An interlayer comprising a spunbonded, spunlaced, or mesh fabric is introduced between non-crimped layers of unidirectional reinforcing fibers to produce a preform for use in liquid-molding processes to produce composite materials. Interlayer material remains as a separate phase from matrix resin after infusion, and curing of the preform provides increased impact resistance by increasing the amount of energy required to propagate localized fractures due to impact. Constructions having the interlayer materials melt-bonded to the reinforcing fibers demonstrate improved mechanical preformance through improved fiber alignment compared to other fabrication and preforming methods.

Abstract: A composite fabric and a method for manufacturing the composite fabric that includes at least one planar structure and at least one nonwoven fabric thermally bonded to the planar structure via a plurality of welds arranged in a predetermined pattern. A sheet of parallel elastic threads is disposed between the nonwoven fabric and the planar structure, wherein portions of the elastic threads are embedded in the plurality of welds in a stretched state. The composite fabric can be used for manufacturing hygienic products, in particular diapers, including diaper pants.

Abstract: The present invention relates to a composite sheet material that is water vapor permeable and substantially liquid water impermeable. The composite sheet material includes an outer layer, a film, and a reinforcing layer and, preferably, has an ASTM D3833 water vapor transmission rate of greater than 250 g/m2/day, and a tensile strength of at least about 100 N/5 cm when tested in accordance with ASTM D5035. The sheet material is useful as a membrane for roofing, housewrap, insulation facing and in the fabrication of protective apparel.

Abstract: The present invention provides a process for producing a three dimensionally texturized liquid resistant laminate having a fibrous nonwoven layer and a liquid resistant layer. The process has the steps of placing the fibrous layer and the liquid resistant layer in juxtaposition to form a laminate, attaching the fibrous layer and the liquid resistant layer at a plurality of spaced-apart bond locations, heating the bonded laminate to a temperature that activates the latent shrinkability of the liquid resistant layer, and allowing the heated laminate to retract such that the liquid resistant layer shrinks and said fibrous layer forms gathers between said bond locations, thereby forming a three dimensional texture and heat annealing the laminate. The invention additionally provides a three dimensionally texturized laminate having a fibrous layer and a nonelastic liquid resistant layer.

Abstract: A lightweight nonwoven material is described. The nonwoven material includes at least three layers wherein a first layer is spunlaid, a second layer is meltblown, and a third layer is spunlaid, the first and third layers being external layers. The basis weight of the nonwoven material is 15.0 gsm or less and the weight of the second meltblown layer is about 5% or less of the total basis weight. The preferred polymer for the nonwoven material is polypropylene, in particular for the meltblown fibers is a resin having a molecular weight distribution Mw/Mn in a range of about 1.8-3.2. Hydrophilicity can be imparted to the nonwoven material by inclusion of a surfactant additive in an extrusion melt during formation of fibers, or by topical treatment following formation of the layers of the nonwoven material. The method of making the nonwoven material involves formation of the layers thereof as continuous fibers and forming the layers in a continuous sequential manner, i.e.

Abstract: A process for making an absorbent material involves flash-drying a superabsorbent polymer precursor composition. The process may be used to make a superabsorbent-fiber material without the necessity of mixing conventional superabsorbent solid particles with pulp fluff is provided. The synthesis (i.e., polymerization) of the superabsorbent is completely integrated into the process for forming the absorbent material. One or more streams of superabsorbent polymer precursor composition are provided, to which a plurality of individual fibers may be added. The resulting in-situ polymerized superabsorbent-fiber material is then flash-dried and can subsequently be formed into a superabsorbent-fiber composite. The flash-drying is relatively inexpensive and requires little drying time compared to conventional drying methods.

Abstract: A non-woven web formed from substantially continuous and uninterrupted multi-component filaments in which the filaments are spun at a spinning speed adequate for molecularly orienting less than all of the various constituent polymers. After collection, the non-woven web is either heated or receives a tensile force that causes each filament region formed from the polymer lacking molecular orientation to shrink in length considerably more than other filament regions formed from molecularly-oriented polymers. The differential length reduction enhances the loft of the non-woven web.

Abstract: A method of forming a plurality of substantially-continuous and uninterrupted multi-component filaments for use as a high-loft non-woven web. The multi-component filaments include at least two polymers of different melt flow rates, which imparts latent crimp in each filament. After collection, the latent crimp of the filaments is activated either thermally or by applying tension to the non-woven web.

Abstract: The present invention relates to fibrous web materials comprising polymeric material wherein the structure of the polymeric material contains elastic amorphous areas nano-scale-size reinforced with self arranged crystalline domains of nano-crystals.

Abstract: The invention is directed to a composite sheet suitable for use as artificial leather or a precursor to artificial leather, where both surfaces have a napped or brushed appearance. The composite sheet comprises a low-density, lightly bonded non-woven web that is stitch-bonded and bulked such that the stitch-bonding yarns are not visible to the naked eyes without the need of post-processing steps to hide the yarns. The composite sheet may have binder resin(s) dispersed therein and activated.

Abstract: Multi-layer nonwoven sheet structures are disclosed in which at least one synthetic polymeric fibrous nonwoven layer is adhesively bonded to a second layer using a water-based adhesive. The nonwoven layer is chosen to provide fast drying times. The multi-layer nonwoven sheet structures are useful in medical garments.

Abstract: There is provided a new nonwoven material for personal care products made of fibers, binder in an amount between 1 and 6 weight percent and superabsorbent in an amount between 1 and 80 weight percent, where the superabsorbent is contained in micro-pockets in the nonwoven. These micro-pockets may be made by creping a nonwoven fabric, orienting fibers in the Z-direction, and by passing a relatively lofty nonwoven fabric between unheated thermal pattern bond and anvil rolls. These materials exhibit good permeability to liquid in the pre- and post-wetted conditions, thus avoiding gel blocking and other negative effects of superabsorbent swelling within a fabric. Such a fibrous material is useful in personal care products, like diapers, training pants, incontinence garments and feminine hygiene products.

Abstract: Extruded fibers and nonwoven webs made from the fibers are disclosed having improved cloth-like properties and an improved aesthetic appearance. The fibers used to form the webs are made from a thermoplastic polymer containing titanium dioxide and at least one mineral filler such as kaolin or calcium carbonate. In particular, the fillers are added in the amount so that the fillers become encapsulated within the polymeric material.

Abstract: A composite restraint system composed of a composite restraint strap, a patch and a tensioning tool for restraining freight during transportation. The composite restraint strap includes a first layer and a second layer. The first layer includes a plurality of strands of yarn having a specified percentage of elongation before breaking and a specified creep. The second layer includes a nonwoven fabric. The composite restraint strap is capable of being attached to a floor or a wall of a transportation device in order to restrain the freight from movement. The composite restraint strap is typically tightened across the freight using the tensioning tool and held in place during transportation with the patch having a permanent-type adhesive for preventing the taut composite restraint strap from losing tension. The patch may be pre-attached to a strap prior to installation around freight.

Abstract: A composite restraint system composed of a composite restraint strap, a patch and a tensioning tool for restraining freight during transportation. The composite restraint strap includes a first layer and a second layer. The first layer includes a plurality of strands of yarn having a specified percentage of elongation before breaking and a specified creep. The second layer includes a nonwoven fabric. The composite restraint strap is capable of being attached to a floor or a wall of a transportation device in order to restrain the freight from movement. The composite restraint strap is typically tightened across the freight using the tensioning tool and held in place during transportation with the patch having a permanent-type adhesive for preventing the taut composite restraint strap from losing tension. The patch may be pre-attached to a strap prior to installation around freight.

Abstract: A textured fabric having at least one surface that contains peaks and valleys is provided. Greater than about 90% of the peaks and less than about 10% of the valleys are disposed with a treatment composition, the treatment composition comprising a latex polymer. In one embodiment, for example, the textured fabric is a hydraulically entangled composite fabric formed from a spunbond nonwoven web and pulp fibers. When coated onto the fabric, the treatment composition may form a thin film layer on the fiber surface that prevents fibers or zones of fibers from breaking away from the surface as lint. Further, because the coating is applied only to the peaks, the valleys may remain free of the latex polymer and substantially maintain the absorbency of the uncoated fabric.

Abstract: The present invention relates to a mattress cover formed of a composite material consisting of a nonwoven material and a woven layer, in which the nonwoven material comprises a single nonwoven layer, and in which said nonwoven layer and said woven layer are permanently bonded together whilst retaining the flexible character of the woven layer.

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: The present invention provides a nonwoven web prepared from an aliphatic polyester polymer which has sufficient tear strength and is biodegradable. Biodegradable nonwoven webs of the present are prepared from a polymer blend having from about 65% by weight to about 99% by weight of a biodegradable aliphatic polyester polymer and from about 1% by weight to about 35% by weight of a second polymer selected from the group consisting of a polymer having a lower melting point than the biodegradable aliphatic polyester polymer, a polymer having a lower molecular weight than the biodegradable aliphatic polyester polymer and mixtures thereof. Surprisingly, the nonwoven webs of the present invention have a tear strength greater than the tear strength of a nonwoven web prepared from the biodegradable aliphatic polyester polymer alone.

Abstract: The present invention provides multicomponent fine fiber webs and multilayer laminates thereof having an average fiber diameter less than about 7 micrometers and comprising a first olefin polymer component and a second distinct polymer component such as an amorphous polyolefin or polyamide. Multilayer laminates incorporating the fine multicomponent fiber webs are also provided such as, for example, spunbond/meltblown/spunbond laminates or spunbond/meltblown/meltblown/spunbond laminates. The fine multicomponent fiber webs and laminates thereof provide laminates having excellent softness, peel strength and/or controlled permeability.

Abstract: A disposable wipe-out sheet That comprises a plurality of synthetic resin filaments bonded to a synthetic resin base sheet. The synthetic resin filaments comprise core-sheath type conjugated fiber in which the sheath has a melting point that is at least 30° C. lower than the melting point of the core.

Abstract: In one embodiment, a flame resistant fabric includes a plurality of flame resistant body yarns that form a body of the fabric, and a plurality of relatively tough yarns provided in discrete positions within the fabric body, the relatively tough yarns comprising a filament yarn that includes a filament composed of one of polyolefin, flame resistant polyester, polytetrafluoroethylene, polyetheretherketone, polyetherimide, polysulfar, polyimide, polyamide, polyimideamide, polybenzoxazole, polybenzimidazole, carbon, and glass.

Abstract: Nonwoven webs with good barrier properties are disclosed. The nonwoven webs can be, for instance, meltspun webs such as meltblown webs and spunbonded webs. In accordance with the present invention, a hydrophobic agent is incorporated into the polymer that is used to produce the web for improving the barrier properties of the web. Hydrophobic agents that may be used in accordance with the present invention include polydimethyl siloxanes and guerbet esters.

Abstract: Disclosed is a fibrous web comprising a first region and at least one discrete integral second region, the second region having at least one portion being a discontinuity exhibiting a linear orientation and defining a longitudinal axis, and at least another portion being a deformation comprising a plurality of tufted fibers integral with but extending from the first region.

Abstract: A spunbonded non-woven fabric and a laminate composed of one or more such spunbonded non-woven fabrics and of one or more melt-blown non-woven fabrics under lamination, wherein the spunbonded non-woven fabric does scarcely suffer from occurence of rough surface and reveal scarce adherent touch with better hand feel due to permission of attaining more finer filament and can be produced efficiently without suffering from filament fracture on the spinning, wherein the said spunbonded non-woven fabric is made of fibers of a polypropylene resin composition having fiber finenesses of 0.8 to 2.8 denier and has an average friction factor (MIU) of 0.1 to 0.3, a thickness uniformity of 0.8 or less, a waterproof performance of at least 60 mmH2O and a gas permeability of not higher than 480 ml/cm2/sec.

Abstract: A thermoplastic polymer electret material comprising a porous substrate of a blend of a first thermoplastic polymer, such as a polyolefin or polyamide, and from 0.1% to about 25% by weight, of a compatible telomer. The porous substrate is electrostatically charge and is well suited for use in filter media, sterilization wraps, face masks, dust wipes and the like.

Abstract: A high strength polymeric composite laminate that has enhanced design features to perform as a roofing underlayment material for use in conjunction with modified bituminous materials such as APP or SBS membranes, as well as shingles, tiles, metal and other roof coverings.

Abstract: Nonwoven barrier laminates are provided having a desirable balance of properties, including barrier properties, strength, static dissipation, fluid repellency, aesthetics and tactile properties. The nonwoven barrier laminates of the invention generally include outer spunbonded layers, at least one hydrophobic microporous layer between the outer spunbonded layers, and at least one discrete layer of electrically conductive strands. A multiplicity of discrete bond sites bond the various layers of the nonwoven barrier laminate into a coherent fabric.

Abstract: The present invention is directed to improved elastic materials. More specifically, the present invention is directed to low basis weight elastic webs, such as elastic films and elastomeric fibrous meltblown or spunbond webs which may include elastomeric fibers and/or elastomeric continuous filaments. The present invention is also directed to laminate structures which include the elastic webs. The elastic webs include an elastomeric block copolymer and a polyolefin wax, and do not include a tackifier. The low basis weight elastic webs of the present invention may display tension values upon elongation equal to or greater than the tension values of previously known elastic webs of greater basis weight. The elastic laminate structures of the present invention comprise at least one layer an elastic web adhesively bonded to one or more other webs, such as, for instance a woven or nonwoven web.

Abstract: An oil-resistant elastic laminate including an elastomeric sheet laminated to one or more nonwoven facing sheets with an oil-insensitive adhesive applied to a surface of the elastomeric sheet and/or the facing sheet(s), an oil-insensitive adhesive incorporated within the elastomeric sheet, and/or an oil-insensitive adhesive incorporated within the nonwoven facing sheet(s). The invention further includes methods of making oil-resistant elastic laminates.

Abstract: This invention involves the addition of antistatic agents to the melt of spunbonded processes to improve fabric uniformity and reduce fabric defects.

Abstract: A composite fabric comprising a necked and creped spunbond nonwoven web of monocomponent fibers hydraulically entangled with a fibrous component that comprises cellulosic fibers. The nonwoven web contains thermoplastic fibers and the fibrous component comprises greater than about 50% by weight of the fabric.

Abstract: A sheet-like product is disclosed having a patterned indicia for signifying the existence of an additive or ingredient that is contained within the product. The present inventors have discovered that a particular burst-like pattern provides various advantages and benefits in comparison to other patterns. In order to differentiate patterns of the present invention from other patterns, patterns made according to present invention were image analyzed during a dilation process.

Abstract: A process for preparing a molded, textured, spunlaced, nonwoven web is provided and wipes made therefrom. Also provided is an apparatus for making molded, textured, spunlaced, nonwoven web. Molded, textured, spunlaced, nonwoven webs prepared by the inventive process and apparatus are also provided. Also provided is a molded, textured, spunlaced, nonwoven web.

Abstract: Melt processable, flushable polymer fibers and methods of making melt processable, flushable polymer fibers are disclosed. The fibers comprise poly(ethylene oxide). Preferably, the poly(ethylene oxide) is modified by grafting polar vinyl monomers, such as poly(ethylene glycol) methacrylate and 2-hydroxyethyl methacrylate, onto poly(ethylene oxide). The modified poly(ethylene oxide) has improved melt processability and can be used to melt process poly(ethylene oxide) fibers of thinner diameters.

Abstract: A composite sheet has a layer of reinforcing fiber impregnated with a thermoplastic resin. Non-woven fiber is partially impregnated with the thermoplastic resin to provide a bondable surface that can be subsequently bonded to other materials, such as plastics, foam and metal. Such an apparatus may be formed by heating and compressing the thermal plastic resin against the reinforcing fibers of the base layer and against the non-woven fibers, such that the base layer may be fully impregnated while the non-woven fibers may be partially impregnated. A thermal plastic resin must have a melting point less than either the reinforcing fibers of the base layer, or the non-woven fibers.

Abstract: The present invention provides nonwoven laminate materials with high overall uniformity of material properties, particularly tensile strength properties. The present invention also includes methods for forming the nonwoven laminate materials wherein the fiber extrusion and drawing apparati are oriented at a non-right angle with respect to the direction of web production or MD.

Abstract: A highly permeable and water resistant barrier sheet, comprising a porous buffer sheet and a water resistant nonwoven cloth of 100 mmH2O or higher in water resistance connected integrally with each other and combined with a permeable sheet-like absorber to form an absorbing core so as to make an absorber product highly permeable, wherein the porous buffer sheet is a perforated film formed desirably in an irregular structure having funnel-shaped perforated structures with top and bottom parts different in diameter from each other and, when the diameter thereof on the shorter diameter side is 1 mm or shorter when a hole is approximated in a complete round shape and the number of holes is 20/cm2 or more.

Abstract: The present invention provides continuous fiber nonwoven webs with high material formation uniformity and MD-to-CD balance of fiber directionality and material properties, as measured by a MD:CD tensile ratio of 1.2 or less, and desirably of about 1.0 or less, and laminates of the nonwoven webs. The invention also includes a method for forming the nonwoven webs wherein the fiber production apparatus is oriented at an angle less than 90 degrees to the MD direction and the fibers are subjected to deflection by a deflector oriented at an angle B with respect to the centerline of the fiber production apparatus where B is about 10 to about 80 degrees.

Abstract: A blend of fatty acid amides is incorporated into the polypropylene fibers of a thermally bonded, melt extruded nonwoven fabric to import softness to the fabric. The blend includes a greater amount of stearamide and a lesser amount of erucamide.