Autogenously Bonded Nonwoven Fabric Patents (Class 442/409)
  • Patent number: 7132377
    Abstract: A disposable dish care and hard surface cleaning wipe is disclosed. In one embodiment, the wipe is comprised of a water insoluble substrate that includes a partially hydrophobic nonwoven first layer, and a low density nonwoven second layer that is adjacent to the said first layer and has melded onto the side facing away from the said first layer an abrasive coating of thermoplastic material nubs or hooks, and a cleaning paste containing a surfactant.
    Type: Grant
    Filed: November 14, 2002
    Date of Patent: November 7, 2006
    Assignee: The Procter & Gamble Company
    Inventors: Patrice Mar Luc Borgonjon, Jeffrey Lee Butterbaugh, Edward Paul Fitch, Peter Robert Foley, Francis Cornelio Ford, Brian Jeffreys
  • Patent number: 7087296
    Abstract: This invention provides multi-layered composites, laminates and composite joints in which at least one resin-impregnated, fiber-containing layer is joined or laminated to a core layer having a lower flexural modulus or higher elongation at break, higher toughness, or a combination of all or some of these properties. The multi-layer composite produced by laminating or joining these materials together has improved shearout, impact and cutting resistance, since stresses caused by outside forces can be more widely distributed throughout the composite.
    Type: Grant
    Filed: November 29, 2001
    Date of Patent: August 8, 2006
    Assignee: Saint-Gobain Technical Fabrics Canada, Ltd.
    Inventor: John Frederick Porter
  • Patent number: 7071130
    Abstract: Segregating membrane supporting material is a three-dimensional assembly of fibers thermo-compressed into non-woven fabric, and the non-woven fabric fibers are joined together in sheet form. This segregating membrane supporting material is non-woven fabric, including at least 10 weight % polyacrylonitrile-based synthetic fibers, which is thermo-compressed to give an overall bulk density 40% to 75% of the density of the fibers which make up the non-woven fabric.
    Type: Grant
    Filed: July 21, 2003
    Date of Patent: July 4, 2006
    Assignees: Awa Paper Mfg. Co., Ltd., Japan Exlan Company Limited
    Inventors: Yoshitsugu Hama, Hideo Naka, Yoshifumi Kusaka, Akihiro Okubo
  • Patent number: 7037569
    Abstract: A laminate web comprising a first web, a second web joined to the first web at a plurality of discrete bond sites; and a third material disposed between at least a portion of the first and second nonwovens. The third material is apertured in regions adjacent the bond sites, such that the first and second nonwoven webs are joined through the apertures. In one embodiment an apertured laminate web is disclosed, having a first extensible web having a first elongation to break, and a second extensible web joined to the first extensible web at a plurality of bond sites, the second extensible web having elongation to break. A third web material is disposed between the first and second nonwovens, the third web material having a third elongation to break which is less than both of the first or second elongations to break.
    Type: Grant
    Filed: December 20, 2000
    Date of Patent: May 2, 2006
    Assignee: The Procter & Gamble Company
    Inventors: John J. Curro, Douglas H. Benson, John B. Strube
  • Patent number: 6995099
    Abstract: The present invention is aimed at providing FRP formed by integrating a fiber reinforcing material and a non-woven fabric, and having excellent shaping ability, impact resistance after molding, and excellent reliability and low cost. The aim of the present invention is achieved by a complex fiber reinforcing material including a sheet-shaped fiber reinforcing material composed of reinforcing fibers, and a non-woven fabric laminated on at least one side of the fiber reinforcing material, wherein the fibers constituting the non-woven fabric pass through the fiber reinforcing material to integrate the non-woven fabric with the fiber reinforcing material.
    Type: Grant
    Filed: February 22, 2000
    Date of Patent: February 7, 2006
    Assignee: Toray Industries, Inc.
    Inventors: Akira Nishimura, Kiyoshi Homma, Ikuo Horibe, Takehiko Hirabara
  • Patent number: 6995100
    Abstract: A composite sheet that comprises an elastically stretchable layer and an inelastically stretchable layer formed with inelastically stretchable continuous fibers bonded to at least one surface of the elastically stretchable layer intermittently in one direction. The continuous fibers are oriented substantially in one direction thereof so that the composite sheet may present a ratio S1/S2 of 3.0 or higher where S1 represents a tensile strength in this one direction and S2 represents a tensile strength in the direction orthogonal to this one direction.
    Type: Grant
    Filed: March 29, 2001
    Date of Patent: February 7, 2006
    Assignee: Uni-Charm Corporation
    Inventors: Satoru Tange, Hiroyuki Ohata
  • Patent number: 6992028
    Abstract: A nonwoven fabric includes a first composite layer that includes from about 50% to about 90% by weight non-thermoplastic absorbent staple fibers and from about 10% to about 50% by weight thermoplastic fibers. A preponderance of the fibers at a first outer surface of the first composite layer comprise non-thermoplastic absorbent staple fibers and a preponderance of the fibers at a second outer surface of the first composite layer comprise thermoplastic fibers. The nonwoven fabric further includes a second composite layer that includes from about 50% to about 90% by weight non-thermoplastic absorbent staple fibers and from about 10% to about 50% by weight thermoplastic fibers. The second composite layer is adjacent the second outer surface of the first composite layer.
    Type: Grant
    Filed: September 9, 2002
    Date of Patent: January 31, 2006
    Assignee: Kimberly-Clark Worldwide, Inc.
    Inventors: Craig F. Thomaschefsky, Lawrence M. Brown
  • Patent number: 6964931
    Abstract: The present invention is directed to a method of making a substantially continuous filament web which includes providing a plurality of polymer extruders for supplying polymer streams of at least two different polymer compositions, and providing a spinneret assembly for receiving the polymer streams. The spinneret assembly includes a plurality of orifices from which the polymer streams are extruded for formation of substantially continuous filaments formed from the polymer compositions. The distribution of at least one of the polymer compositions within the spinneret assembly is selected to optimize selected physical characteristics of the resultant continuous filament web.
    Type: Grant
    Filed: February 26, 2001
    Date of Patent: November 15, 2005
    Assignee: Polymer Group, Inc.
    Inventors: Thomas Scott Carlyle, Marlene Storzer
  • Patent number: 6916752
    Abstract: Nonwoven fibrous webs comprise fibers of uniform diameter that vary in morphology along their length. The variation provides longitudinal segments that exhibit distinctive softening characteristics during a bonding operation. Some segments soften under the conditions of the bonding operation and bond to other fibers of the web, and other segments are passive during the bonding operation. Webs as described can be formed by a method that comprises a) extruding filaments of fiber-forming material; b) directing the filaments through a processing chamber in which the filaments are subjected to longitudinal stress; c) subjecting the filaments to turbulent flow conditions after they exit the processing chamber; and d) collecting the processed filaments; the temperature of the filaments being controlled so that at least some of the filaments solidify while in the turbulent field.
    Type: Grant
    Filed: May 20, 2002
    Date of Patent: July 12, 2005
    Assignee: 3M Innovative Properties Company
    Inventors: Michael R. Berrigan, Anne N. De Rovere, William T. Fay, Jill R. Munro, Pamela A. Percha
  • Patent number: 6884494
    Abstract: A laminate web is disclose, the laminate web comprising a first web, a second web joined to the first web at a plurality of discrete bond sites; and a third material disposed between at least a portion of the first and second nonwovens. The third material is apertured in regions adjacent the bond sites, such that the first and second nonwoven webs are joined through the apertures. In one embodiment an apertured laminate web is disclosed, having a first extensible web having a first elongation to break, and a second extensible web joined to the first extensible web at a plurality of bond sites, the second extensible web having a second elongation to break A third web material is disposed between the first and second nonwovens, the third web material having a third elongation to break which is less than both of the first or second elongations to break.
    Type: Grant
    Filed: December 21, 1999
    Date of Patent: April 26, 2005
    Assignee: The Procter & Gamble Company
    Inventors: John J. Curro, Douglas H. Benson, John B. Strube
  • Patent number: 6878433
    Abstract: A laminate web and several uses of the laminate web are disclosed. The laminate web comprises a first web, a second web joined to the first web at a plurality of discrete bond sites; and a third material disposed between at least a portion of the first and second webs. The laminate webs of the present invention are suitable for a variety of uses. Such uses include flexible carrying implement, medical applications, kitchen or bathroom implements, decorative coverings, home accent items, pet industry articles, fabric, fabric backings, edible materials, bedding applications, absorbent food pads, clean room wipes, tack cloths, and many other uses.
    Type: Grant
    Filed: June 21, 2001
    Date of Patent: April 12, 2005
    Assignee: The Procter & Gamble Company
    Inventors: John Joseph Curro, Douglas Herrin Benson, John Brian Strube
  • Patent number: 6872674
    Abstract: The present invention is a non-woven web or composite structure comprising (a) from about 50 to about 90 weight percent of a natural cellulose fiber; (b) from about 10 to about 50 weight percent of a binder fiber component; (c) from 0 to about 20 weight percent of a filler; and (d) from 0 to about 8 weight percent of a dye or pigment.
    Type: Grant
    Filed: September 17, 2002
    Date of Patent: March 29, 2005
    Assignee: Eastman Chemical Company
    Inventors: Freddie Wayne Williams, Eric Eugene Ellery
  • Patent number: 6867156
    Abstract: A method for producing a material having z-direction waves in which a layer of continuous fibers is conveyed on a first moving surface into a nip formed by the first moving surface and a second moving surface which is traveling at a slower speed than the first moving surface, resulting in formation of a plurality of z-direction loops in the fibers giving loft to the material and a wave pattern producing ridges on both major surfaces of the resultant nonwoven web. The method permits easy real time alignment of manufacturing parameters to produce a variety of materials. The method further produces lofty nonwovens at a commercially viable rate.
    Type: Grant
    Filed: March 30, 2000
    Date of Patent: March 15, 2005
    Assignee: Kimberly-Clark Worldwide, Inc.
    Inventors: Edward Jason White, Kurtis Lee Brown, John Herbert Conrad, Robert James Gerndt, Jose Enrique Maldonado
  • Patent number: 6855392
    Abstract: A patterned pile fabric of stitch-bonded construction. The fabric includes a substrate layer with an arrangement of ground yarns extending in stitched relation through the substrate layer so as to define a ground covering across the substrate layer. An arrangement of pile forming yarns extend in stitched relation through the substrate layer such that the pile forming yarns define a patterned arrangement of looped elements projecting away from the ground covering in predefined three dimensional patterned arrays disposed across the fabric.
    Type: Grant
    Filed: December 12, 2002
    Date of Patent: February 15, 2005
    Assignee: Tietex International, Ltd.
    Inventors: Martin Wildeman, Robert Fontaine
  • Patent number: 6849324
    Abstract: A nonwoven web of multipolymer fibers is described that is unidirectionally stretched and permanently elongated at ambient conditions and exhibits a substantial increase in tensile strength in the stretch direction. The ratio of tensile strength of the web in the direction of fiber orientation to the tensile strength in the other direction is at least about 10:1. The ratio of elongation at peak load in a direction transverse to the direction of fiber orientation is at least about 6:1. The multipolymer fibers normally are a blend of polyethylene and a polypropylene homopolymer or copolymer, one of which is a dominant phase and one of which is a dispersed phase. A third component having elastomeric properties that is at least partially miscible with one or both of the other components is included in some blends.
    Type: Grant
    Filed: September 6, 2001
    Date of Patent: February 1, 2005
    Assignee: BBA Nonwovens Simpsonville, Inc.
    Inventors: Barry DeWayne Meece, Thomas Edward Quantrille
  • Patent number: 6838401
    Abstract: A heat-resistant fiber paper sheet which is formed from staple fibers made from a heat-resistant organic polymer, undrawn or low ratio drawn para-aromatic polyamide staple fibers, and an organic resin binder and/or fibrids comprising a heat-resistant organic polymer as main components, wherein the amount of said staple fibers is 45 to 97 percent by weight based on the total amount of said heat-resistant fiber paper sheet; the total amount of said organic resin binder and/or said fibrids is 3 to 55 percent by weight based on the total amount of said heat-resistant fiber paper sheet; and said organic resin binder is cured, and/or said undrawn or low ratio drawn para-aromatic polyamide staple fibers and said fibrids are partially softened, deformed and/or melted to exhibit the actions of binders.
    Type: Grant
    Filed: August 4, 2000
    Date of Patent: January 4, 2005
    Assignee: Teijin Limited
    Inventors: Sadamitsu Murayama, Michikage Matsui, Masanori Wada, Shigeru Ishihara
  • Publication number: 20040259451
    Abstract: A fiber material is described herein that includes: a) a first base fiber component comprising a first denier and a first luster component; b) a second base fiber component comprising a second denier and a second luster component, wherein the first denier and the second denier are different and wherein the first luster component and the second luster component are different; and c) a plurality of binder fibers.
    Type: Application
    Filed: June 23, 2003
    Publication date: December 23, 2004
    Inventors: David P. Paradis, Charlie E. Bowers
  • Publication number: 20040253895
    Abstract: A wipe includes a porous and bulky thermoplastic non-woven carrier web. An absorbent non-woven web including a plurality of philic fibers has a first side and an opposite second side. The first side is disposed adjacent the carrier web. The absorbent web is co-extruded to the carrier web and is secured to the carrier web at a plurality of thermic embossments. An abrasive finish is applied to the second side of the absorbent non-woven web. The abrasive finish includes a plurality of abrasive fibers that are less than 40 microns in diameter.
    Type: Application
    Filed: September 9, 2003
    Publication date: December 16, 2004
    Inventor: Massimiliano Castellani
  • Patent number: 6830801
    Abstract: A disposable wipe-out sheet that includes a plurality of long fibers bonded to a heat-sealable base sheet by sealing lines. The long fibers include groups continuously extending between each pair of the adjacent sealing lines to form bridge-like portions and groups severed in two sections between each pair of the adjacent sealing lines so as to fluff upward on the base sheet.
    Type: Grant
    Filed: October 11, 2001
    Date of Patent: December 14, 2004
    Assignee: Uni-Charm Co., Ltd.
    Inventors: Yasuhiko Kenmochi, Yoshinori Tanaka
  • Patent number: 6830800
    Abstract: An elastic laminate web is disclosed. The elastic laminate web can be non-apertured or apertured, and comprises a first web, and a second web joined to the first web in a face to face relationship at a plurality of discrete bond sites having an aspect ratio of at least 2. The first and second webs form an interior region therebetween. An elastic material is disposed between the first and second webs. The elastic material is apertured in regions coincident the bond sites, such that the first and second webs are joined through the apertures. The laminate so produced can be stretched in a predetermined direction, such as by incremental stretching, to produce an apertured elastic laminate.
    Type: Grant
    Filed: June 21, 2001
    Date of Patent: December 14, 2004
    Assignee: The Procter & Gamble Company
    Inventors: John Joseph Curro, Douglas Herrin Benson, Anthony Stephen Spencer, John Brian Strube
  • Publication number: 20040248491
    Abstract: The polypropylene-based thermoplastic fibers are uniform in cross-section, not having any degraded surface skin, and they are heat-weldable at a pressure at a temperature which is lower than the melting temperature, by virtue of internal heating due to the effect of said pressure. They are made of a first constituent with high crystallinity and at least one second constituent, compatible with the first constituent, and of crystallinity that is lower than that of the first constituent. They have a quantity of primary oxidation inhibitor lying in the range 350 ppm to 1000 ppm. Such fibers are made by spinning under conditions that avoid molecular degradation by thermal oxidation at the periphery of the fibers, in particular with cooling that is rapid immediately on leaving the extrusion head. The non-woven fabric obtained by heat-bonding such fibers is characterized by weld points that are in the form of a polymer laminate that is uniform and transparent.
    Type: Application
    Filed: May 3, 2004
    Publication date: December 9, 2004
    Inventor: Galliano Boscolo
  • Publication number: 20040241399
    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.
    Type: Application
    Filed: March 21, 2003
    Publication date: December 2, 2004
    Inventors: Samuel E. Marmon, Edgar N. Rudisill
  • Publication number: 20040235380
    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.
    Type: Application
    Filed: October 3, 2003
    Publication date: November 25, 2004
    Inventor: Rene Kapik
  • Patent number: 6815382
    Abstract: A nonwoven fabric for manufacturing repeatedly re-usable clean-room protective clothing, made of super microfilaments having a titer of less the 0.2 dtex that are produced by water jet splitting multicomponent multisegment filaments having a titer of less than 2 dtex, the primary filaments being spun from the melt, aerodynamically stretched, laid to form a nonwoven fabric, and subjected to water-jet prebonding prior to splitting.
    Type: Grant
    Filed: May 9, 2002
    Date of Patent: November 9, 2004
    Assignee: Carl Freudenberg KG
    Inventors: Robert Groten, Holger Schilling, Arnold Bremann, Hartwig Von Der Mühlen
  • Publication number: 20040219854
    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.
    Type: Application
    Filed: April 23, 2004
    Publication date: November 4, 2004
    Applicant: Carl Freudenberg KG
    Inventors: Dieter Groitzsch, Hansjoerg Grimm, Nikolaus Hirn, Eric Knehr
  • Patent number: 6808791
    Abstract: A laminate web and several uses of the laminate web are disclosed. The laminate web comprises a first web, a second web joined to the first web at a plurality of discrete bond sites; and a third material disposed between at least a portion of the first and second webs. The laminate webs of the present invention are suitable for a variety of uses. Such uses include flexible carrying implement, medical applications, kitchen or bathroom implements, decorative coverings, home accent items, pet industry articles, fabric, fabric backings, edible materials, bedding applications, absorbent food pads, clean room wipes, tack cloths, and many other uses.
    Type: Grant
    Filed: June 21, 2001
    Date of Patent: October 26, 2004
    Assignee: The Procter & Gamble Company
    Inventors: John Joseph Curro, Daniel Charles Peck, Saeed Fereshtehkhou, Anneke Margaret Kaminiski, Alfred Franc Baldwin, Jr., Jessica Zingelmann Brown, Edward Kenneth Stahl, Charles Detwiler Roberson
  • Patent number: 6808598
    Abstract: Herein provided is a water-decomposable fibrous sheet includes water-dispersible fibers having a fiber length of at most 20 mm, and a gel compound.
    Type: Grant
    Filed: September 29, 2000
    Date of Patent: October 26, 2004
    Assignee: Uni-Charm Corporation
    Inventors: Naohito Takeuchi, Takayoshi Konishi
  • Publication number: 20040209541
    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.
    Type: Application
    Filed: May 10, 2004
    Publication date: October 21, 2004
    Applicant: Avgol Ltd.
    Inventor: Achai Bonneh
  • Publication number: 20040198128
    Abstract: A method of using nonwoven fabrics for wiping in cleanroom applications wherein the fabrics were heretofore believed less than optimum for such applications and a nonwoven fabric applicable for use in cleanroom applications
    Type: Application
    Filed: April 28, 2004
    Publication date: October 7, 2004
    Inventor: James Marshall Oathout
  • Patent number: 6797653
    Abstract: A polymeric fiber liner insulation includes of a resilient, insulation blanket core of randomly oriented entangled fibers with between 60% and 90% by weight of the fibers being standard polymeric fibers and/or flame retardant polymeric fibers and between 10% and 40% by weight of the fibers being polymeric lofting and bonding fibers. The first major surface the liner insulation has a low porosity or air and/or liquid impervious surface layer. The surface layer is formed by melting and consolidating fibers at and adjacent the first major surface of the blanket core or by coating the first major surface of the blanket core with a polymeric coating. The liner insulation exhibits a flame spread/smoke developed index of ≦25/50.
    Type: Grant
    Filed: September 28, 2001
    Date of Patent: September 28, 2004
    Assignee: Johns Manville International, Inc.
    Inventor: Ralph Michael Fay
  • Patent number: 6784127
    Abstract: A polyurethane elastomer fiber non-woven fabric contains polyurethane elastomer fiber filaments melt-bonded with one another, and has a tensile elongation of 100% or more, a 50% elongation recovery of 75% or more and a tear strength per METSUKE of 5.5 gf or more. The non-woven fabric can be prepared by a method of providing a thermoplastic polyurethane elastomer having Shore hardness A of 92 or more, drying the elastomer to a water content of 150 ppm or less, and melt-spinning and, at the same time, spraying it together with a high speed gas stream so as to deposit and laminate the elastomer into a sheet form. A synthetic leather using the non-woven fabric is also provided. The non-woven fabric has not only an excellent elasticity but also high tear strength.
    Type: Grant
    Filed: September 24, 2001
    Date of Patent: August 31, 2004
    Assignees: Kanebo, Limited, Kanebo Gohsen, Limited
    Inventors: Yukio Yamakawa, Tadashi Furuya, Eiji Kawabata, Yutaka Tanaka
  • Publication number: 20040161992
    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.
    Type: Application
    Filed: February 12, 2004
    Publication date: August 19, 2004
    Inventors: Darryl Franklin Clark, Justin Max Duellman, Bryan David Haynes, Matthew Boyd Lake, Jeffrey Lawrence McManus, Kevin Edward Smith
  • Patent number: 6770576
    Abstract: Disclosed are absorbent structures including fibers bound with a polyvalent cation-containing compound and superabsorbent polymer particles. The fibers exhibit an ion extraction factor of at least 5%. Also disclosed are multi-strata absorbent structures, such as disposable absorbent articles, including the treated fibers and SAP particles. Further disclosed are methods for preparing absorbent structures including the treated fibers; structures including fibers combined with a polyvalent cation-containing compound; and methods for treating or coating SAP particles with polyvalent cation-containing compounds.
    Type: Grant
    Filed: February 7, 2003
    Date of Patent: August 3, 2004
    Assignee: BKI Holding Corporation
    Inventors: Jeffery T. Cook, Robert Irvin Bell, Sonja McNeil Fields, Byron Jerry Lee Huff, Gerald Hunt Morton, Howard Leon Schoggen, David Jay Smith
  • Publication number: 20040121689
    Abstract: An entangled fabric that contains a nonwoven web hydraulically entangled with a fibrous component is provided. The nonwoven web is formed from staple fibers and is creped. For example, in one embodiment, the nonwoven web is a creped, point bonded, carded web. Excellent liquid handling properties can be achieved in accordance with the present invention without resulting in the poor liquid handling capabilities often associated with point bonded nonwoven webs. In fact, the entangled fabric of the present invention can have improved bulk, softness, and capillary tension.
    Type: Application
    Filed: December 23, 2002
    Publication date: June 24, 2004
    Applicant: Kimberly-Clark Worldwide, Inc.
    Inventors: Ralph L. Anderson, Eugenio G. Varona
  • Patent number: 6753276
    Abstract: A nonwoven fabric includes a cohesively integrated web of hydrodynamically entangled short-staple or “waste cotton” fibers. A batt of waste cotton fibers is hydrodynamically needled by high-pressure streams of water. The hydrodynamic energy of the streams causes the fibers to cohere and to become mutually entangled, which in turn results in a fabric of sufficient strength to be used for, among other things, a bag for a bulk material and particularly a bag or cover for a cotton bale.
    Type: Grant
    Filed: January 8, 2002
    Date of Patent: June 22, 2004
    Assignee: Magnolia Manufacturing Company, Inc.
    Inventors: Anderson Warlick, Quintin Shuler
  • Patent number: 6750163
    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.
    Type: Grant
    Filed: April 10, 2001
    Date of Patent: June 15, 2004
    Assignee: Kimberly-Clark Worldwide, Inc.
    Inventors: James Hongxue Wang, David Michael Schertz
  • Publication number: 20040110442
    Abstract: A method of forming fibers into a web includes the steps of co-extruding a first elastomeric component and a second thermoplastic component; directing the first and second components through a fiber spin pack to form a plurality of continuous molten fiber spinlines, where the first elastomeric component is present in an amount greater than about 70 percent by weight of the molten fibers and the second thermoplastic component is present in an amount of between about 10 and 30 percent by weight of the molten fibers; attenuating the spinlines and routing the plurality of molten fibers through a quench chamber to form a plurality of cooled fibers; routing the plurality of cooled fibers through a fiber draw unit, whereby the fibers are pulled downward; allowing the pulled fibers to be deposited onto a forming surface thereby forming a web wherein the fibers are relaxed; stabilizing the web; and bonding the web to produce a web demonstrating greater than about 25 percent machine direction stretch recovery.
    Type: Application
    Filed: August 22, 2003
    Publication date: June 10, 2004
    Inventors: Hannong Rhim, Sjon-Paul Conyer, Paul Windsor Estey, Ramonica Frances Green, Bernhardt Edward Kressner, Michael Tod Morman, Prasad Shrikrishna Potnis, Susan Elaine Shawver, Vasily Aramovich Topolkaraev, Duane Girard Uitenbroek
  • Patent number: 6746978
    Abstract: Heat bonded thermoplastic and partially thermoplastic nonwoven webs which have been thermomechanically treated while under low strain rate tension show significant improvement to their coformability and softness. More importantly the low strain rate thermomechanical treatment imparts a high degree of commercially valuable elasticity. The resultant webs find use in all nonwoven applications where softness, conformability and elasticity are useful. The resultant webs develop elasticity in only one direction but the two embodiments provide the ability to create elasticity in the machine or cross machine direction of a roll of precursor material. In addition virtually any precursor web containing at least 70% thermally bonded thermoplastic fibers can be used.
    Type: Grant
    Filed: March 22, 2000
    Date of Patent: June 8, 2004
    Inventor: Gregory F. Ward
  • Patent number: 6746976
    Abstract: Disclosed are thin until wet materials that are suitable for use as acquisition members for absorbent articles (e.g., diapers, catamenial products, and adult incontinence devices). Preferred materials according to the present invention are either: 1) fibrous assemblies that utilize wet strength means to stabilize the material or 2) compressed regenerated cellulosic sponges so that, when the material is saturated with an aqueous fluid, it has an expanded wet density of between about 0.04 grams/cm3 and about 0.4 grams/cm3 and an expanded capillary desorption height of less than about 25 cm and a temporary binding means that helps maintain the material at a compressed dry density between about 0.06 grams/cm3 and about 1.2 grams/cm3 until the material is exposed to an aqueous fluid. The ratio of the compressed dry density to the expanded wet density is also greater than about 1.5:1. A suitable process for making the materials and absorbent structures using the materials are also disclosed.
    Type: Grant
    Filed: September 20, 2000
    Date of Patent: June 8, 2004
    Assignee: The Procter & Gamble Company
    Inventors: Edward Joseph Urankar, Gerald Alfred Young, Mattias Schmidt, James Albert Cleary, Matthias Konrad Hippe, Giovanni Carlucci
  • Publication number: 20040103970
    Abstract: The present invention relates to a single layer air-laid composition comprising: hollow synthetic fiber, absorbent and a binder system. The hollow fiber comprises from about 10 to about 50 percent by weight of said composition. The hollow synthetic fiber has a denier of between about 2 to about 18. The hollow synthetic fiber is selected from the class of polyolefins, polyesters, polyamides, acrylics, as well as mixtures and copolymers thereof. The absorbent comprises from about 40% to about 80% of the weight of said composition. The absorbent is a natural absorbent, or a synthetic absorbent, or a mixture of these. The natural absorbent is selected from the class of wood pulp fluff, cotton, cotton linters, and regenerated cellulose fibers, or a mixture of these. The synthetic absorbent is selected from the class of agar, pectin, guar gum, and synthetic hydrogel polymers. The binder fiber comprises from about 3 to about 15 percent by weight of said composition.
    Type: Application
    Filed: November 25, 2003
    Publication date: June 3, 2004
    Inventors: Mabrouk Quederni, Paul L. Latten
  • Publication number: 20040097155
    Abstract: New nonwoven fibrous webs are taught which comprise a collected mass of a) directly formed fibers disposed within the web in a C-shaped cross-sectional configuration and b) staple fibers having a crimp of at least 15% dispersed among the directly formed fibers in an amount of at least 5% the weight of the directly formed fibers. The web is lofty but free of macrovoids. Preferably, the web has a filling ratio of at least 50 and a light transmittance variation of about 2% or less. Typically, fibers within the web are bonded together at points of fiber intersection, preferably with autogenous bonds, to provide a compression-resistant matrix. The webs are especially useful as acoustic and thermal insulation.
    Type: Application
    Filed: November 15, 2002
    Publication date: May 20, 2004
    Applicant: 3M Innovative Properties Company
    Inventors: David A. Olson, Jonathan H. Alexander, Michael R. Berrigan
  • Publication number: 20040089432
    Abstract: The present invention relates to a wet-laid non-woven sheet made from a essentially binder-free aramid floc, wherein the aramid floc includes at least 25 percent by weight of para-aramid floc based on the total weight of aramid floc only, and a process for making the sheet.
    Type: Application
    Filed: August 25, 2003
    Publication date: May 13, 2004
    Inventor: Mikhail R. Levit
  • Publication number: 20040084129
    Abstract: A composite textile includes a batting layer, a cushion layer, and a face fabric. The batting layer has high melt temperature and low melt temperature fibers. The cushion layer is needled to the batting layer. The face fabric is bonded to the cushion layer by an adhesive. The face material/cushion layer/batting layer is heat set and rolled onto a roll for use in forming composite parts. The composite textile is more readily recyclable when the batting layer, the cushion layer, the adhesive, and the face material are all formed completely from material of the same chemical nature, such as polyolefin, polyester, or the like.
    Type: Application
    Filed: October 24, 2003
    Publication date: May 6, 2004
    Applicant: Milliken & Company
    Inventor: David E. Wenstrup
  • Patent number: 6730387
    Abstract: An absorbent material having substantially improved structural stability in the dry and wet states. The absorbent materials are significantly less susceptible to handling losses of absorbent gelling particles during manufacturing operations. The absorbent material also is not subject to shifting of the absorbent gelling particles during or after swelling by fluids. The absorbent material comprises absorbent gelling particles comprising (a) a water-insoluble absorbent hydrogel-forming polymer; (b) a polycationic polymer bonded to the absorbent gelling particles at the surface thereof; (c) glue microfibers dispersed in the absorbent gelling particles; and (d) a carrier layer bonded to the absorbent gelling particles through the glue microfibers. The invention further relates to a method of making the absorbent materials, and the absorbent articles comprising the absorbent materials.
    Type: Grant
    Filed: October 12, 1998
    Date of Patent: May 4, 2004
    Assignee: The Procter & Gamble Company
    Inventors: Ebrahim Rezai, Kesyin Hsueh
  • Patent number: 6726983
    Abstract: An elastic laminate fabric useful for applications including apparel, sanitary products, and the like has an elastic vinylidene isoprene polymer film sandwiched between two outer non-woven layers. The laminate elastic fabric has CD elongation of at least 120%, and has recovery of at least 85% after several cycles of 100% elongation. A method of making the non-woven elastic laminate fabric includes extrusion coating a non-woven web having CD elongation of at least 120% with a vinylidene isoprene polymer film, and then thermocalendaring a second non-woven layer having a CD elongation of at least 120% to the exposed film surface. The mode of thermocalendering includes the use of an engraved calender roll having a discontinuous roll pattern and a land area no greater than 15%.
    Type: Grant
    Filed: September 6, 2001
    Date of Patent: April 27, 2004
    Assignee: Polymer Group
    Inventors: Valeria Griep Erdos, Ellen Mosley
  • Patent number: 6723671
    Abstract: Fragrance emitting articles are provided along with methods of making and using the same. The fragrance emitting articles provided contain microcapsules of a fragrance, which microcapsules are associated with the fragrance emitting article without the addition of a binder. The invention also relates to methods of making the subject fragrance emitting articles and methods of using those articles.
    Type: Grant
    Filed: April 13, 2001
    Date of Patent: April 20, 2004
    Assignee: Lavipharm Laboratories Inc.
    Inventors: Yelena Zolotarsky, David O'Halloran, Florence Bernard, Pradeep Thaker
  • Patent number: 6723669
    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.
    Type: Grant
    Filed: December 17, 1999
    Date of Patent: April 20, 2004
    Assignee: Kimberly-Clark Worldwide, Inc.
    Inventors: Darryl Franklin Clark, Justin Max Duellman, Bryan David Haynes, Matthew Boyd Lake, Jeffrey Lawrence McManus, Kevin Edward Smith
  • Publication number: 20040072491
    Abstract: A loop component for use in a hook and loop fastening system, and methods of making same are provided, wherein a spunlaced fabric having a plurality of loop structures is formed by entangling a plurality of non-interbonded fibers in a fibrous web of material. The loop structures are configured to engage hooks from a hook component having a hook density between about 30 and 400 hooks per square centimeter, and have a peel strength of between about 50 grams and 2000 grams. The spunlaced fabric may include a backing layer. Between about two percent and about twenty-five percent (2%-25%) of the spunlaced fabric may be bonded to reduce fiber fuzzing and pull out that may occur when hooks are engaged and disengaged from the loop material. The spunlaced fabric may be stretched in a cross web (widthwise) direction between about 5% and about 125% of the original width to produce a fabric with greater void area for better hook engagement.
    Type: Application
    Filed: August 19, 2003
    Publication date: April 15, 2004
    Inventors: Samuel Mark Gillette, James William Flippin, Walter Gomer Jones, Zareh Mikaelian, Alfred Frank Baldwin
  • Patent number: 6716775
    Abstract: Range-dyed fabrics that possess excellent hand characteristics and simultaneously exhibit substantially nondirectional appearances are provided. Such a combination permits the production and utilization of an extremely comfortable apparel fabric that can be attached to any other similar type of fabric to form a target apparel article without the time-consuming need to align such component fabrics to ensure an overall aesthetic appearance is met for the target apparel article. In general, such a fabric is produced through the initial immobilization of individual fibers within target fabrics and subsequent treatment through abrasion, sanding, or sueding of at least a portion of the target fabric. Such a procedure produces a fabric of short pile height and desirable hand. Upon range-dyeing the target fabric exhibits the extra benefit of nondirectional surface characteristics.
    Type: Grant
    Filed: May 12, 2000
    Date of Patent: April 6, 2004
    Assignee: Milliken & Company
    Inventors: Louis Dischler, Wesley M. Drexler, Scott W. Efird, Dale Robert Williams
  • Publication number: 20040058611
    Abstract: The object of the invention is a heat-bonding lining of the type comprising a non-woven textile support which is obtained by thermobinding of a web of at least one type of fibre, and a discontinuous layer comprising a hot-melt polymer which is disposed on at least one of the faces of the textile support, in which, in combination, the textile support comprises at least 70% fibres formed from a polymer material based on polyamide and the hot-melt polymer is formed from polyamide.
    Type: Application
    Filed: November 1, 2002
    Publication date: March 25, 2004
    Inventors: Marc Deleu, Jean-Paul Coutant