Autogenously Bonded Nonwoven Fabric Patents (Class 442/409)
  • Patent number: 9018112
    Abstract: Disclosed herein is a nonwoven fabric comprising within the range of from 50 to 99 wt %, by weight of the composition, of a reactor grade propylene-?-olefin copolymer possessing within the range of from 5 to 35 wt %, by weight of the copolymer, of units derived from one or more of ethylene and/or C4 to C12 ?-olefins; a melt flow rate (230° C./2.16 kg) within the range of from 500 to 7500 g/10 min; and a weight average molecular weight of less than 200,000; and a second polypropylene having a melting point, Tm, of greater than 110° C. and a melt flow rate (230° C./2.16 kg) within the range of from 20 to 7500 g/10 min; wherein the fabric has a CD Elongation value of greater than 50% (measuring the fabric of 35 g/m2 basis weight). The fabric described herein can be used in structures comprising one or more layers of the fabric described herein, and can include any number of other fabric layers made from other materials.
    Type: Grant
    Filed: August 4, 2008
    Date of Patent: April 28, 2015
    Assignee: ExxonMobil Chemicals Patents Inc.
    Inventors: Sudhin Datta, Derek Thurman, Chia Yung Cheng, Kuangyao B. Peng
  • Patent number: 8987151
    Abstract: A fiber pad having a core non-woven layer is disclosed. The core layer can have an upper surface and a lower surface. The core layer can comprise at least one fiber layer. The at least one fiber layer can comprise a plurality of parallel fibers. Selected groups of the parallel fibers can be folded into desired pleated configurations. Optionally, the core layer can comprise post-consumer carpet materials.
    Type: Grant
    Filed: May 24, 2011
    Date of Patent: March 24, 2015
    Assignee: Columbia Insurance Company
    Inventors: Jim Burns, John J. M. Rees, Tom Odum
  • Patent number: 8921244
    Abstract: Hydroxyl polymer fiber fibrous structures and processes for making same are provided. More particularly, hydroxyl polymer fiber fibrous structures comprising a non-naturally occurring hydroxyl polymer fiber wherein the fibrous structure exhibits a total pore volume of pores in the range of greater than 20 ?m to 500 ?m of greater than 3.75 mm3/mg of dry fibrous structure mass, and/or fibrous structures comprising a hydroxyl polymer fiber and a solid additive are provided.
    Type: Grant
    Filed: August 16, 2006
    Date of Patent: December 30, 2014
    Assignee: The Procter & Gamble Company
    Inventors: David William Cabell, David Warren Loebker, Paul Dennis Trokhan
  • Patent number: 8889572
    Abstract: A gradient nanofiber non-woven contains a plurality of nanofibers where at least 70% of the nanofibers are bonded to other nanofibers. The nanofibers each have a surface and a center and contain a bulk polymer and a third component. The majority by weight at the surface of the nanofiber is the third component and the majority by weight at the center of the nanofiber is the bulk polymer and there is a concentration gradient from most concentrated to least from the surface of the nanofiber to the center of the nanofiber. The process for forming a gradient nanofiber non-woven is also disclosed.
    Type: Grant
    Filed: September 29, 2010
    Date of Patent: November 18, 2014
    Assignee: Milliken & Company
    Inventors: Walter A. Scrivens, Hao Zhou
  • Publication number: 20140201960
    Abstract: Disclosed is an arc flash protection, multiple-use nonwoven fabric structure comprising one or more layers having fire resistant properties. The fabric structure has an arc flash facing nonwoven surface, and a nonwoven part of the fabric structure comprises non-inherent, and/or inherently fire resistant fibers, said fibers being mechanically, chemically, or thermally bonded, whereby the fabric structure has a minimum Arc Thermal Protection Value (ATPV) to fabric basis weight ratio of 250 cal/g, preferably greater than 350 cal/g, more preferably greater than 500 cal/g, when measured in accordance with ASTM F1959—Standard Test Method for Determining the Arc Rating of Materials for Clothing, and the fabric structure maintains said ATPV to fabric basis weight ratio through at least 25 washing cycles when washed according to AATCC Method 135 (3, IV, A iii).
    Type: Application
    Filed: March 26, 2014
    Publication date: July 24, 2014
    Applicant: NORAFIN INDUSTRIES GMBH
    Inventors: Stuart Smith, Marc Jolly, Jos van Hattum, Andre Lang, Bettina B. Sorensen
  • Publication number: 20140187115
    Abstract: Provided are a polyphenylene sulfide fiber including a PPS resin as a main component and having both excellent heat resistance and excellent thermal bonding properties, and a nonwoven fabric including the fiber. The polyphenylene sulfide fiber includes polyphenylene sulfide as a main component and having the sum of the crystallinity and the rigid amorphous fraction of 30% to 90%. The crystallinity is preferably not less than 5% and less than 25%. The polyphenylene sulfide fiber is used to form a nonwoven fabric. The nonwoven fabric is preferably produced by consolidation by thermal bonding or mechanical entanglement.
    Type: Application
    Filed: June 1, 2012
    Publication date: July 3, 2014
    Applicant: Toray Industries, Inc.
    Inventors: Yohei Nakano, Yoshikazu Yakake, Masashi Ito
  • Patent number: 8652977
    Abstract: The present invention provides a heat-resistant nonwoven fabric wherein the nonwoven fabric is formed from a poly(phenylene sulfide) fiber, and 30% by weight or more of the poly(phenylene sulfide) fiber has a crystallinity of 25 to 50%. Moreover, the properties of the heat-resistant nonwoven fabric can be further improved by making the nonwoven fabric have a multilayer structure in which layers composed of a poly(phenylene sulfide) filamentary fiber and layers composed of a poly(phenylene sulfide) fine fiber are stacked and integrated.
    Type: Grant
    Filed: September 21, 2007
    Date of Patent: February 18, 2014
    Assignee: Asahi Kasei Fibers Corporation
    Inventors: Toshiyuki Shimizu, Masahiko Maeda
  • Patent number: 8652976
    Abstract: The invention relates to a fixable nonwoven interlining material for use in the textile industry, comprising at least one melt-spun fiber layer and at least one additional fibrous material layer, the fixable interlining material being provided with an adhesive substance at least in partial regions. A particularly high elasticity of the fixable interlining material is achieved by the fact that the melt-spun fibers are composed of an elastic fibrous material, and the at least one layer of fibrous material is composed of staple fibers, and the at least one elastic melt-spun fiber layer and the at least one staple fiber layer are laid one on top of the other in the form of a flat unbonded fiber fabric, and are subsequently bonded by use of a bonding step known as such.
    Type: Grant
    Filed: April 20, 2006
    Date of Patent: February 18, 2014
    Assignee: Carl Freudenberg KG
    Inventors: Michael Kalbe, Oliver Staudenmayer, Manfred Jöst, Peter Rudek
  • Patent number: 8637414
    Abstract: A gradient density padding material includes a single layer of nonwoven material having at least one surface processed to form a portion of a thickness thereof having a density increased with respect to a remaining portion of the thickness thereof. The single layer of nonwoven material after processing has an airflow resistance within the range of 200-4000 MKS Rayls, wherein said single layer of nonwoven material has an enhanced acoustic performance. A method of making a gradient density padding material having an enhanced acoustic performance includes the steps of providing a single layer of nonwoven material and processing at least one surface of the single layer of nonwoven material to form a portion of a thickness thereof having a density increased with respect to a remaining portion of the thickness thereof. The single layer of nonwoven material after processing has an airflow resistance within the range of 200-4000 MKS Rayls.
    Type: Grant
    Filed: April 22, 2003
    Date of Patent: January 28, 2014
    Assignee: Lydall, Inc.
    Inventors: Durward Gomez, Steven Borchardt
  • Patent number: 8568853
    Abstract: A fiber reinforced thermoplastic composite having an improved combination of flexural, impact, and heat distortion characteristics. The composite comprises a fiber reinforced thermoplastic core containing fibers bonded together with a first thermoplastic resin in which the core has a first surface and a second surface and at least one first skin applied to the first surface. The first skin comprises one or more bi-directional continuous fiber tapes having a plurality of continuous fibers bonded together with one or more thermoplastic resins. The fibers in each first skin are arranged in a first and a second direction, with the fibers in each direction being unidirectionally oriented within the skin. Bi-directional orientation of the continuous fiber tapes is present in at least one of the tapes, or is achieved through the use of two or more tapes having unidirectional continuous fibers.
    Type: Grant
    Filed: December 14, 2007
    Date of Patent: October 29, 2013
    Assignee: Hanwha Azdel, Inc.
    Inventors: Venkat Raghavendran, Gary Francis Smith
  • Patent number: 8557722
    Abstract: A nonwoven material suitable for use as a wet wipe substrate is disclosed. The nonwoven material comprises thermoplastic fibers and is provided with a pattern of embossments that join at least a portion of the thermoplastic fibers. When the material is treated with a cleaning lotion to provide a wet wipe, the wet wipe has a wet CD modulus that is greater than about 25 N/m and less than about 80 N/m.
    Type: Grant
    Filed: June 23, 2005
    Date of Patent: October 15, 2013
    Assignee: The Procter & Gamble Company
    Inventors: Astrid Annette Sheehan, Jonathan Paul Brennan, Philip Andrew Sawin, Terrill Alan Young
  • Publication number: 20130260088
    Abstract: A consolidated fibrous mat comprises 20 to 50 weight percent of reinforcing fibers; and a continuous phase connecting the reinforcing fibers, comprising 50 to 70 weight percent of a polymer having a melt temperature at least 20° C. lower than the reinforcing fibers, and 5 to 10 weight percent of a binder having a melt temperature lower than the polymer; wherein the weight percent of each of the reinforcing fibers, the polymer, and the binder is based on the combined total weight of the reinforcing fibers, the polymer, and the binder.
    Type: Application
    Filed: March 14, 2013
    Publication date: October 3, 2013
    Applicant: SABIC Innovative Plastics IP B.V.
    Inventors: Benny Ezekiel David, Kim R. Choate, Dennis Lockyer, Thomas Adjei, Vincent L. Lanning, Craig Lawrence Milne, Erich Otto Teutsch
  • Publication number: 20130260629
    Abstract: A yarn or thread may include a plurality of substantially aligned filaments, with at least ninety-five percent of a material of the filaments being a thermoplastic polymer material. Various woven textiles and knitted textiles may be formed from the yarn or thread. The woven textiles or knitted textiles may be thermal bonded to other elements to form seams. A strand that is at least partially formed from a thermoplastic polymer material may extend through the seam, and the strand may be thermal bonded at the seam. The woven textiles or knitted textiles may be shaped or molded, incorporated into products, and recycled to form other products.
    Type: Application
    Filed: April 3, 2012
    Publication date: October 3, 2013
    Applicant: NIKE, INC.
    Inventors: Bhupesh Dua, Carrie L. Davis
  • Publication number: 20130228510
    Abstract: A catheter anchoring system, apparatus and method for securing a catheter to a patient's skin, having two flexible side members and a cross-member therebetween to which a retaining assembly is mounted. The retaining assembly may hold a catheter hub at an angle for patient comfort. Gripping tabs secure to each retaining assembly side are gripped while advancing a cannula guide needle into the patient's vein and while attaching the catheter hub to a medical accessory, such as intravenous (I.V.) tubing, for increased patient comfort, reduction of the risk in contamination and patient infection, and to more easily and quickly start an I.V.
    Type: Application
    Filed: October 6, 2011
    Publication date: September 5, 2013
    Applicant: FIBERWEB, INC.
    Inventor: John F. Baker, JR.
  • Patent number: 8486849
    Abstract: Absorbent articles such as disposable diapers, incontinent briefs, diaper holders, training pants and the like, having elastomeric ear panels and a fastening system that provides the user with different options as to how the absorbent article may be fitted to and removed from the wearer. The absorbent articles allow the wearer to choose between conventional and pull-on diaper configurations, or combinations thereof, and properly and comfortably fit a large range of wearer sizes. Further, the absorbent articles can be pulled on and/or off as a pant. This feature is provided by the ear panels which maintain sufficient tension to hold the diaper on the wearer throughout the period of use without harming the wearer's skin, while providing enough stretch to allow the diaper to be pulled up or down over the wearer's hips. The fastening system is refastenable for convenience yet strong enough to maintain the diaper in a fastened configuration without becoming detached if the diaper is pulled on or off the wearer.
    Type: Grant
    Filed: April 1, 2010
    Date of Patent: July 16, 2013
    Assignee: The Procter & Gamble Company
    Inventors: Mark James Kline, Miguel Alvaro Robles
  • Patent number: 8476173
    Abstract: Laminate material having a first liquid-permeable material layer and discretely-arranged material pieces of a second liquid-permeable material, wherein the material layer and the discrete material pieces are joined internally. The laminate material also has a second liquid-permeable material layer joined to the first liquid-permeable material layer and the discretely-arranged material pieces.
    Type: Grant
    Filed: December 7, 2005
    Date of Patent: July 2, 2013
    Assignee: SCA Hygiene Products AB
    Inventors: Ralph Dovertie, Roy Hansson
  • Patent number: 8420557
    Abstract: The present invention concerns a nonwoven fabric the fibers of which have polyethylene on at least part of their surface, where the fibers are thermally bonded and the non-woven fabric exhibits an abrasion of less than 0.5 mg/cm2, in particular of less than 0.4 mg/cm2, and an embossed area fraction of less than 35%, in particular of less than 28%. Furthermore a device is made available for the manufacture of a non-woven fabric, using a polyethylene-containing polymer, with a take-down system underneath a spinning plate that causes the take-down of the polyethylene, where the spinning plate has an L/D ratio of between 4 and 9.
    Type: Grant
    Filed: June 20, 2006
    Date of Patent: April 16, 2013
    Assignee: Fiberweb Corovin GmbH
    Inventors: Markus Haberer, Henning Röttger
  • Patent number: 8415263
    Abstract: A composite material as a sheet material is described, being relatively cheap, most useful as a raw material of a sanitary product or the like, such as underwear, dust-proof mask or dispensable paper diaper, etc., and good in processability, stretchability, gas-permeability, softness, and touch. The composite material is formed by laminating a stretchable layer and a conjugate spunbonded nonwoven fabric including conjugate fibers including a low-melting-point component and a high-melting-point component. The conjugate fibers are partially bonded to each other by thermocompression, wherein each bonded portion has fine folded structures including alternate hill and valley regions in the CD, and the distance between neighboring hills is 100-400 ?m in average. The conjugate spunbonded nonwoven fabric exhibits stretchability through the spread of the fine folded structures, and has, at 5% elongation, a CD-strength of 0.1 N/5 cm or less and an MD/CD strength ratio of 200 or more.
    Type: Grant
    Filed: March 30, 2011
    Date of Patent: April 9, 2013
    Assignees: JNC Corporation, JNC Fibers Corporation
    Inventors: Toshikatsu Fujiwara, Taiju Terakawa
  • Publication number: 20130071639
    Abstract: The present invention discloses a covering for placement on a surface, such as a wall on the inside of a house, for reduction or prevention of a singularity or a plurality of emissions, such as harmful emissions, released from the surface. The covering comprises a trapping agent and a carrier for retaining and supporting the trapping agent, such that the trapping agent can trap the singularity or plurality of emissions without being released from the carrier. The trapping agent is a substantially irreversible trapping agent independently selected from one or several of the group consisting of absorbing agents and adsorbing agents, such that the trapping agent is capable of fully or partly trapping the singularity or plurality of emissions substantially irreversibly by absorption or adsorption, or a combination of absorption and adsorption. The covering may further comprise a semi-permeable barrier. Methods for use and manufacturing of the covering are also disclosed.
    Type: Application
    Filed: May 26, 2011
    Publication date: March 21, 2013
    Inventor: Lennart Larsson
  • Patent number: 8389427
    Abstract: A hydroentangled nonwoven material (8), includes a mixture of randomized continuous filaments (3) and natural fibers (5), wherein at least part of the staple fibers and/or the continuous filaments includes thermoplastic material. The nonwoven material is bonded in a non-random bonding pattern including a plurality of bonding sites (14) in which thermoplastic material included in the nonwoven material has been caused to at least partly soften or melt to create thermal bonds between the continuous filaments. The nonwoven material includes no other thermal bonds between the filaments than provided by the non-random bonding pattern. The nonwoven material may also contain synthetic staple fibers (6).
    Type: Grant
    Filed: November 29, 2006
    Date of Patent: March 5, 2013
    Assignee: SCA Hygiene Products AB
    Inventors: Anders Gustafsson, Lars Fingal, Mikael Strandqvist, Kaveh Tondkar
  • Publication number: 20130040524
    Abstract: The invention according to the present invention relates to an intermediate layer (1) of friction decreasing material placed between two layers (2, 3). The intermediate layer (1) is adapted to create a sliding movement between the layers (2, 3) when a force (K) is applied and a tangential force component (KT) shears the layers. The friction decreasing material comprises fibers (F).
    Type: Application
    Filed: January 11, 2011
    Publication date: February 14, 2013
    Applicant: MIPS AB
    Inventors: Peter Halldin, Anders Bergner, Kay Grinneback
  • Patent number: 8322487
    Abstract: An acoustically coupled non-woven composite containing a non-woven layer and a thermoplastic film. The non-woven layer contains a plurality of binder fibers and a plurality of bulking fibers and has a binder zone and a bulking zone.
    Type: Grant
    Filed: August 19, 2011
    Date of Patent: December 4, 2012
    Assignee: Milliken & Company
    Inventors: Dale S. Kitchen, Pradipkumar Bahukudumbi, Gregory Thompson
  • Patent number: 8298969
    Abstract: A composite having a first layer and a second layer. The first layer is a nonwoven layer containing high modulus fibers having a modulus of at least 8 GPa and thermoplastic binder fibers, where at least a portion of the high modulus fibers are connected to the binder fibers, and where the first layer has a solidity of between about 10 and 90%. The second layer is a textile layer selected from the group consisting of a knit layer, a woven layer, bidirectional laminates, and a unidirectional layer. The second layer contains high modulus fibers having a modulus of at least 8 GPa in a thermoplastic matrix.
    Type: Grant
    Filed: August 19, 2009
    Date of Patent: October 30, 2012
    Assignee: Milliken & Company
    Inventor: Pradip Bahukudumbi
  • Patent number: 8088696
    Abstract: This invention relates to nonwoven fabrics with advantageous characteristics and the method to produce these fabrics. Advantageously, the fabrics of the subject invention have increased thickness (loft) compared to conventional nonwoven fabrics and have high air permeability and open space while maintaining softness and strength at the same basis weight.
    Type: Grant
    Filed: October 21, 2002
    Date of Patent: January 3, 2012
    Assignee: The Procter & Gamble Company
    Inventors: Albert E. Ortega, R. Wayne Thomley, Jan Mackey
  • Publication number: 20110293911
    Abstract: A method of forming a nonwoven material, the method comprising: receiving fibrous material comprising thermo-plastic fibers; processing the fibrous material to produce short fibers; adding the short fibers to a preformed web; and heating and optionally compressing the preformed web to form a nonwoven material.
    Type: Application
    Filed: December 4, 2009
    Publication date: December 1, 2011
    Applicant: Eman8 Pty Ltd.
    Inventors: Michael William Coates, Marek Henryk Kierzkowski, Philip John Gibbons, Alfred Johannas Eiden
  • Patent number: 8058192
    Abstract: A floral sleeve is made from two layers of non-woven thermoplastic fabric such as polypropylene. The layers are joined at the side seams of the sleeve by first pre-sealing the edges and thereafter trimming them. Pre-sealing compresses the fabric to make it denser along a band and applying heat causes the band to retain the compressed and at least partially fused set. Trimming may be done using a hot knife that completes the fusing process of the layers to each other. Alternately, the pre-sealing step may form a satisfactory fusion between the layers and the trimming step need not effect further fusion.
    Type: Grant
    Filed: May 21, 2002
    Date of Patent: November 15, 2011
    Assignee: Professional Package Company, Inc.
    Inventor: Tom Helms
  • Patent number: 8053074
    Abstract: A stretch nonwoven fabric 10 contains inelastic fibers having a varied thickness along the length and elastic fibers. The nonwoven fabric 10 preferably includes an elastic fiber layer 1 and a substantially inelastic, inelastic fiber layer 2 on at least one side of the elastic fiber layer 1. The fibers with a varied thickness along the length are contained in the inelastic fiber layer 2. The nonwoven fabric 10 is conveniently produced by (a) superposing a web containing low-drawn, inelastic fibers having an elongation of 80% to 800% on at least one side of a web containing elastic fibers, (b) subjecting the webs, while in a non-united state, to through-air technique to obtain a fibrous sheet having the webs united together by thermal bonding the fibers at their intersections, and (c) stretching the fibrous sheet in at least one direction to draw the low-drawn inelastic fibers, followed by releasing the sheet from the stretch.
    Type: Grant
    Filed: May 18, 2007
    Date of Patent: November 8, 2011
    Assignee: Kao Corporation
    Inventors: Takeshi Miyamura, Manabu Matsui, Tetsuya Masuki, Hideyuki Kobayashi, Koji Kanazawa, Hiroshi Kohira
  • Publication number: 20110236614
    Abstract: A net-shaped protective material for wire harness sheathing which has flame retardancy and is free from mesh deformation. Vertical strands (2) and horizontal strands (3) which are constituted of a flame-retardant resin wire having an elliptic sectional shape have been pressed and hot melt bonded at the intersections (4) thereof to form a net shape. The vertical strands and horizontal strands are superposed at the intersections without interlacing, and one or both of the vertical strands and horizontal strands are melted in a state where 40% to 50% of the sectional area has been melted and embedded in the other strands. The protective metal has a cut end which has undergone fraying prevention processing.
    Type: Application
    Filed: November 18, 2009
    Publication date: September 29, 2011
    Applicant: SUMITOMO WIRING SYSTEMS, LTD.
    Inventors: Tadao Ushikai, Tetsuya Iwasaki
  • Patent number: 8012565
    Abstract: Absorbent structures with nonwoven meltblown lyocell fiber webs are described which have excellent liquid distribution properties. The absorbent structures comprise at least two nonwoven meltblown lyocell fiber webs with superabsorbent polymer intermediate the two webs. Methods for making the structures are also described. The structures are particularly useful for use in disposable hygienic products.
    Type: Grant
    Filed: March 31, 2008
    Date of Patent: September 6, 2011
    Assignee: Weyerhaeuser NR Company
    Inventor: Mengkui Luo
  • Patent number: 7999031
    Abstract: A method of making an ion triggerable cationic polymer by solution copolymerizing one or more vinyl-functional cationic monomers, one or more water insoluble or hydrophobic vinyl monomers with alkyl side chains up to 4 carbons long, and, optionally, a minor amount of one or more vinyl monomers with linear or branched alkyl groups longer than 4 carbons, alkyl hydroxy, polyoxyalkylene, or other functional groups. The solution polymerization is accomplished by free radical polymerization in a mixture of an organic solvent such as acetone and water. After polymerization is complete, the organic solvent is preferably removed by a continuous process. The continuous process is preferably performed using a plate evaporator system.
    Type: Grant
    Filed: November 3, 2009
    Date of Patent: August 16, 2011
    Assignee: Bostik, Inc.
    Inventors: Glenn C. Calhoun, Rodney M. Weston
  • Patent number: 7998890
    Abstract: Provided herein is a non-stratified, or homogeneous, non-woven composite having (a) strength-imparting fibers of a relatively high denier and (b) binder fibers of a lower denier that adhere the composite together and that form a smooth, stiff skin on the outer surfaces of the composite. In one instance, the strength-imparting fibers are staple fibers and the binder fibers are bicomponent fibers having a low melt component. In a variation, the composite also contains a small percentage by weight (that is, less than 20%) of flame retardant fibers that impart flame resistant properties to the composite. Preferably, all of the fibers are comprised of the same polymeric material (e.g., polyester), so that the composite is recyclable. The resulting composite exhibits excellent flame retardance, strength, and stiffness, as well as having a smooth surface for attachment of a decorative fabric or other material. A process for manufacturing such composites is also provided.
    Type: Grant
    Filed: January 14, 2011
    Date of Patent: August 16, 2011
    Assignee: Milliken & Company
    Inventor: LeAnne O. Flack
  • Patent number: 7994081
    Abstract: A nonwoven fabric is provided having a plurality of semi-crystalline filaments that are thermally bonded to each other and are formed of the same polymer and exhibit substantially the same melting temperature. The fabric is produced by melt spinning an amorphous crystallizable polymer to form two components having different levels of crystallinity. During spinning, a first component of the polymer is exposed to conditions that result in stress-induced crystallization such that the first polymer component is in a semi-crystalline state and serves as the matrix or strength component of the fabric. The second polymer component is not subjected to stress induced crystallization and thus remains in a substantially amorphous state which bonds well at relatively low temperatures. In a bonding step, the fabric is heated to soften and fuse the binder component. Under these conditions, the binder component undergoes thermal crystallization so that in the final product, both polymer components are semi-crystalline.
    Type: Grant
    Filed: August 14, 2008
    Date of Patent: August 9, 2011
    Assignee: Fiberweb, Inc.
    Inventors: Gregory W. Farell, Edward Keith Willis
  • Patent number: 7981822
    Abstract: The instant invention is a hook and loop fastener device. According to the instant invention, the hook and loop fastener device includes a loop component. The loop component includes a binder-free non-woven material having a bottom layer and a top layer. The bottom layer includes a first bicomponent fiber and a first monocomponent fiber. The first bicomponent fiber comprises the majority of the bottom layer based on total weight of the bottom layer, and the first monocomponent fiber comprises the balance thereof. The top layer includes a second bicomponent fiber, and a second monocomponent fiber. The second monocomponent fiber comprises the majority of the top layer based on total weight of the top layer, and the second bicomponent layer comprises the balance thereof. The bottom layer and the top layer may further include interfiber bonding to form the binder-free non-woven material.
    Type: Grant
    Filed: July 11, 2005
    Date of Patent: July 19, 2011
    Assignee: Aplix S.A.
    Inventors: Donald H. Lester, Jr., David L. Lunceford
  • Patent number: 7977261
    Abstract: A thermal barrier fabric includes an inner impermeable material layer, an outer impermeable material layer, a spacer material disposed between the inner and outer impermeable material layers, and a reflective layer of material disposed between the spacer and a selected one of the inner impermeable material layer and the outer impermeable material layer. The inner and outer impermeable material layers are bound to each other along portions thereof outboard of the spacer material and the reflective layer of material to define a closed compartment. The compartment is under a vacuum, such that the reflective layer of the fabric reflects thermal energy back toward the source thereof and the vacuum substantially prevents thermal energy transfer through the compartment.
    Type: Grant
    Filed: August 11, 2006
    Date of Patent: July 12, 2011
    Assignee: The United States of America as represented by the Secretary of the Army
    Inventor: Stephen P. Szczesuil
  • Publication number: 20110165809
    Abstract: A novel terminally modified imide oligomer having excellent solubility in organic solvents, excellent solution storage stability, and excellent molding properties such as low melt viscosity. Also, a varnish obtained by dissolving the terminally modified imide oligomer in an organic solvent; a cure product obtained by using the terminally modified imide oligomer and having excellent thermal and mechanical characteristics such as heat resistance, elastic modulus, tensile strength at break and tensile elongation at break; a prepreg; and a fiber-reinforced laminate. The soluble terminally modified imide oligomer is represented by general formula (1). In the formula, R1 and R2 each represents a divalent aromatic diamine residue; R3 and R4 each represents a tetravalent aromatic tetracarboxylic acid residue; R5 and R6 each represents a hydrogen atom or a phenyl group, with R5 or R6 being a phenyl group; m and n satisfy the following relations: m?1, n?0, 1?m+n?20 and 0.
    Type: Application
    Filed: September 3, 2009
    Publication date: July 7, 2011
    Applicants: KANEKA CORPORATION, JAPAN AEROSPACE EXPLORATION AGENCY
    Inventors: Masahiko Miyauchi, Yuichi Ishida, Toshio Ogasawara, Rikio Yokota
  • Patent number: 7951731
    Abstract: An inorganic fiber mat includes an inorganic fiber aggregated body which includes inorganic fibers. At least a part of the inorganic fibers located on a surface of the inorganic fiber aggregated body is fused to each other by heat.
    Type: Grant
    Filed: March 27, 2008
    Date of Patent: May 31, 2011
    Assignee: Ibiden Co., Ltd.
    Inventor: Kenichi Mitani
  • Publication number: 20110092931
    Abstract: Disclosed are multicomponent fibers derived from a blend of a sulfopolyester with a water non-dispersible polymer wherein the as-spun denier is less than about 6 and wherein the water dispersible sulfopolyester exhibits a melt viscosity of less than 12,000 poise measured at 240° C. at a strain rate of 1 rad/sec, and wherein the sulfopolyester comprising less than about 25 mole % of residues of at least one sulfomonomer, based on the total moles of diacid or diol residues. The multicomponent fiber is capable of being drawn at a relatively high fiber speed, particularly at least about 2000 m/min, and may be used to produce microdenier fibers. Fibrous articles may be produced from the multicomponent fibers and microdenier fibers. Also disclosed is a process for multicomponent fibers, nonwoven fabrics, and microdenier webs.
    Type: Application
    Filed: December 22, 2010
    Publication date: April 21, 2011
    Applicant: EASTMAN CHEMICAL COMPANY
    Inventors: Rakesh Kumar Gupta, Scott Ellery George, Daniel William Klosiewicz, Kab Sik Seo, Coralie McKenna Fleenor, Allen Lynn Crain
  • Patent number: 7927690
    Abstract: It is an object of the present invention to provide a nonwoven fabric which is excellent in the heat resistance and the chemical resistance, of which the fiber diameter is small, which is excellent in the strength and of which the maximum pore diameter is small. A nonwoven fabric made of an ethylene/tetrafluoroethylene copolymer, characterized in that the nonwoven fabric is mutually fused continuous fibers of an ethylene/tetrafluoroethylene copolymer which has a melt viscosity of from higher than 100 to 1,500 Pa·s at 240° C.
    Type: Grant
    Filed: March 5, 2009
    Date of Patent: April 19, 2011
    Assignee: Asahi Glass Company, Limited
    Inventors: Daisuke Taguchi, Ken Iruya, Seigo Kotera
  • Publication number: 20110045724
    Abstract: A composite having a first layer and a second layer. The first layer is a nonwoven layer containing high modulus fibers having a modulus of at least 8 GPa and thermoplastic binder fibers, where at least a portion of the high modulus fibers are connected to the binder fibers, and where the first layer has a solidity of between about 10 and 90%. The second layer is a textile layer selected from the group consisting of a knit layer, a woven layer, bidirectional laminates, and a unidirectional layer. The second layer contains high modulus fibers having a modulus of at least 8 GPa in a thermoplastic matrix.
    Type: Application
    Filed: August 19, 2009
    Publication date: February 24, 2011
    Inventor: Pradip Bahukudumbi
  • Patent number: 7892991
    Abstract: Provided is an elastic network structure having durability and cushioning properties suitable for furniture, bedding such as a bed, seats for vehicles, seats for shipping, etc., the network structure being lightweight and having excellent chemical resistance, excellent light resistance, soft repellency, and excellent cushioning characteristics in a low temperature environment. The elastic network structure comprises a three-dimensional random loop bonded structure obtained by forming random loops with curling treatment of a continuous linear structure having not less than 300 decitex, and by making each loop mutually contact in a molten state to weld the majority of contacted part, the continuous linear structure mainly including a low density polyethylene resin with a specific gravity of not more than 0.94 g/cm3.
    Type: Grant
    Filed: December 20, 2005
    Date of Patent: February 22, 2011
    Assignee: Toyo Boseki Kabushiki Kaisha
    Inventors: Masaki Yamanaka, Yoshihiro Matsui
  • Patent number: 7871947
    Abstract: Provided herein is a non-stratified, or homogeneous, non-woven composite having (a) strength-imparting fibers of a relatively high denier and (b) binder fibers of a lower denier that adhere the composite together and that form a smooth, stiff skin on the outer surfaces of the composite. In one instance, the strength-imparting fibers are staple fibers and the binder fibers are bicomponent fibers having a low melt component. In a variation, the composite also contains a small percentage by weight (that is, less than 20%) of flame retardant fibers that impart flame resistant properties to the composite. Preferably, all of the fibers are comprised of the same polymeric material (e.g., polyester), so that the composite is recyclable. The resulting composite exhibits excellent flame retardance, strength, and stiffness, as well as having a smooth surface for attachment of a decorative fabric or other material. A process for manufacturing such composites is also provided.
    Type: Grant
    Filed: October 22, 2008
    Date of Patent: January 18, 2011
    Assignee: Milliken & Company
    Inventor: LeAnne O. Flack
  • Publication number: 20100310837
    Abstract: The present invention is directed to a structured fibrous web comprising thermally stable, hydrophilic fibers that are thermally bonded together using heat producing a base substrate that is thermally stable. The base substrate is textured via mechanical treatment to increase its thickness and optionally modified via over bonding to improve its mechanical and fluid handling properties. The structured fibrous web provides optimal fluid wicking and fluid acquisition capabilities and is directed toward fluid management applications.
    Type: Application
    Filed: June 3, 2009
    Publication date: December 9, 2010
    Inventors: Eric Bryan Bond, Carola Elke Beatrice Krippner, John Brian Strube
  • Publication number: 20100310845
    Abstract: The present invention is directed to a fluid permeable structured fibrous web comprising thermally stable, fibers that are thermally bonded together using heat producing a base substrate that is thermally stable. The base substrate is textured via mechanical treatment producing a structured fibrous web having an aged caliper of less than 1.5 mm, a vertical wicking height of at least 5 mm, a permeability of at least 10,000 cm2/(Pa·s) and a specific volume of at least 5 cm3/g. The structured fibrous web provides optimal fluid wicking and the fluid acquisition capabilities and is directed toward fluid management applications.
    Type: Application
    Filed: June 3, 2009
    Publication date: December 9, 2010
    Inventors: Eric Bryan Bond, Carola Elke Beatrice Krippner, Ute Froehlich
  • Patent number: 7820573
    Abstract: A fibrous blanket material is provided having a first fibrous layer selected from a group of fibers consisting of polyester, polypropylene, polyethylene, fiberglass, natural fibers, nylon, rayon and blends thereof and a layer of meltblown polypropylene fibers. In an alternative embodiment the blanket may also include a second fibrous layer made of the same material as the first layer where the layer of meltblown polypropylene fibers is sandwiched between the two fibrous layers.
    Type: Grant
    Filed: July 24, 2008
    Date of Patent: October 26, 2010
    Assignee: OCV Intellectual Capital, LLC,
    Inventor: Jeffrey A. Tilton
  • Publication number: 20100268331
    Abstract: The invention relates to a gel-spinning process for producing a high tensile strength ultra high molecular weight polyethylene (UHMWPE) multifilament yarn comprising ultra-low dtex filaments, the process being characterized in that the draw ratio DRfluid applied to fluid filaments obtained by spinning a solution of UHMWPE through a spinneret and into an air gap, is at least 450, wherein DRfluid=DRsp*DRag, the DRsp and DRag being the draw ratios in the spinholes and in the air gap, respectively; and provided that DRag is at least 30. The UHMWPE multifilament yarns produced thereof were characterized by a tensile strength of at least 3.5 GPa and contained filaments having a dtex of at most 0.5. The invention further relates to products comprising said yarns, e.g. fabrics, medical devices and composite and ballistic articles.
    Type: Application
    Filed: December 17, 2008
    Publication date: October 21, 2010
    Inventors: Joseph Arnold Paul Maria J.A.P.M Simmelink, Roelof Marissen
  • Patent number: 7816290
    Abstract: The invention relates to a nonwoven mat as half-stuff which contains a high performance thermoplast as melt fiber and a reinforcing fiber, and also a method for producing a nonwoven mat of this type and fiber composites produced from the nonwoven mat.
    Type: Grant
    Filed: April 1, 2004
    Date of Patent: October 19, 2010
    Assignee: Frenzelit-Werke GmbH & Co., K.G.
    Inventors: Wilfried Erb, Peter Übelmesser
  • Patent number: 7807591
    Abstract: A nonwoven fibrous web comprising a matrix of continuous meltspun fibers bonded to a coherent self-sustaining form, and separately prepared microfibers dispersed among the meltspun fibers. The microfibers may have median diameters less than one or two micrometers. A method for preparing such a nonwoven fibrous web comprises establishing a stream of continuous oriented meltspun fibers having a longitudinal axis, establishing a stream of meltblown microfibers that exit a meltblowing die at a point near the stream of meltspun fibers, the meltblown stream being aimed to merge with the meltspun stream and having a longitudinal axis that forms an angle of between 0 and 90 degrees to the longitudinal axis of the meltspun stream, capturing the meltblown fibers in the stream of meltspun fibers, and collecting the merged stream as a web on a collector spaced near the intersection point of the meltspun and meltblown streams.
    Type: Grant
    Filed: July 31, 2006
    Date of Patent: October 5, 2010
    Assignee: 3M Innovative Properties Company
    Inventors: Andrew R. Fox, John D. Stelter, Timothy J. Lindquist
  • Patent number: 7790641
    Abstract: The invention provides a sheet material comprising bicomponent filaments having first and second polymer components that are arranged in substantially distinct zones within the filaments, with the first polymer component formed of a relatively lower melting polymer and the second component formed of a relatively higher melting polymer. The filaments of the nonwoven fabric layer are densely arranged and compacted against one another to form smooth, substantially nonporous opposite outer surfaces, and the nonwoven fabric layer are calendered such that the lower melting sheath polymer is fused to the contacting surface portions of adjacent filaments to impart strength and coherency to the nonwoven fabric layer. The sheet material has excellent breathability and liquid barrier properties and may be useful in house wrap, medical garments, and envelope applications.
    Type: Grant
    Filed: July 27, 2006
    Date of Patent: September 7, 2010
    Assignee: Fiberweb, Inc.
    Inventors: John Frank Baker, Jr., Gregory W. Farell, Shannon Schoppman
  • Publication number: 20100199406
    Abstract: A non-woven textile may be formed from a plurality of thermoplastic polymer filaments. The non-woven textile may have a first region and a second region, with the filaments of the first region being fused to a greater degree than the filaments of the second region. A variety of products, including apparel (e.g., shirts, pants, footwear), may incorporate the non-woven textile. In some of these products, the non-woven textile may be joined with another textile element to form a seam. More particularly, an edge area of the non-woven textile may be heatbonded with an edge area of the other textile element at the seam. In other products, the non-woven textile may be joined with another component, whether a textile or a non-textile.
    Type: Application
    Filed: February 6, 2009
    Publication date: August 12, 2010
    Applicant: NIKE, INC.
    Inventors: Bhupesh Dua, Karen A. Hawkinson
  • Patent number: RE42765
    Abstract: A plant serves as a mean for production of a fibre web of synthetic fibres, such as plastic fibres and absorbent fibres, such as viscose and cellulose fibres. The plant includes a forming head preliminary to lay a homogeneously and smoothly distributed fibre layer on a net shaped wire. Furthermore the plant includes a hydro-entangling section with liquid nozzles with powerful liquid jets to treat the in the forming head formed fibre layer, which consists of both synthetic—and absorbent fibres. The plant also includes an oven subsequently to thermal bond the synthetic fibres with cross bonds in the affected areas. Finally the dried web is winded up in a roller. By the help of the plant according to the invention, by higher production speed than known previously a fibre web can be produced, which is far cheaper, and which has a better and more homogeneous structure than similar conventional fibre webs.
    Type: Grant
    Filed: October 12, 1998
    Date of Patent: October 4, 2011
    Assignee: Oerlikon Textile GmbH & Co. KG
    Inventor: Jens Ole Bröchner Andersen