Abstract: Composite nonwoven webs are provided having two distinct regions extending adjacent one another in the machine direction of the web; the first region is formed from first continuous filaments and the second region is formed from second continuous filaments. The interface of the first and second region is formed from a mixture the first and second continuous filaments in a confluent relationship with one another and such that the two distinct regions form a unitary nonwoven web. The respective first and second regions can have distinct physical attributes as a result of utilizing first and second filaments which are different from one another. The first and second continuous filaments can vary with respect to average fiber denier, cross-sectional shape, cross-sectional configuration, polymer composition, crimp level, and additive composition.

Abstract: The present invention relates to a flexible sheet having a composite structure for stabilizing coatings, comprising a first layer of fiber material and a second layer of fiber material impregnated by a first and a second impregnating material, respectively, and a body layer set between said first layer and said second layer according to a general sandwich structure, where the body layer consists of a third material. The first and the second impregnating materials and the third material constituting the body layer are polymeric materials presenting a substantial affinity, so that the flexible sheet has a physically heterogeneous and chemically homogeneous structure.

Abstract: The present invention is directed to a durable and imaged flame-retardant nonwoven fabric that can be used for flame-retardant apparel and other related applications. The fabric is formed by providing a precursor web consisting of a blend of melamine fibers and aramid fibers. The precursor web is hydroentangled on a three-dimensional image transfer device for formation of the fabric. The resultant fabric provides desirable air permeability and Thermal Protective Properties.

Abstract: The gas adsorption sheet of the present invention has a granular activated carbon-containing sheet comprising a granular activated carbon having an average particle diameter of 60 to 600 &mgr;m, a supporting fiber for fixing the granular activated carbon in contact with it, and an adhesive fiber which mainly contributes to shape retention. An air-purifying filter of the present invention is obtained by forming the gas adsorption sheet into a shape of pleats or wave. A method for producing a gas adsorption sheet of the present invention comprises a step of forming a granular activated carbon-containing sheet by using an aqueous slurry containing a granular activated carbon, a supporting fiber and a water-swelling adhesive fiber.

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.

Abstract: The present invention is directed to enhancing the cleaning of surfaces by the contact application of a nonwoven fabric having a three-dimensional image imparted therein. The three-dimensional image of the nonwoven fabric induces the formation of lather due to pronounced surface projections that come in contact with the cleaning surface and provide air passageways that are parallel to the plane of the substrate. The imaged nonwoven fabric disclosed herein exhibits low linting qualities thereby reducing the potential of fiber contamination of the cleaned surface and is sufficiently durable that the sample can be used in a brisk manner.

Abstract: A vehicle headliner panel is provided which has a core layer having a binding resin, randomly-oriented sisal fibers, and randomly-oriented natural filler fibers.

Abstract: A vertically stacked aramid set contains carded p-aramid and m-aramid fibers useful as an inner lining in fire fighting clothing.

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.

Abstract: A tissue product containing a multi-layered paper web that has at least one layer formed from a blend of pulp fibers and synthetic fibers is provided. By containing at least one layer of synthetic and pulp fibers, it has been discovered that lint and slough of a tissue product formed according to the present invention can be substantially reduced. In addition, by limiting the amount and layers to which the synthetic fibers are applied, the increase in hydrophobicity and cost of the tissue product may be minimized, while still achieving the desired reduction in lint and slough. In some embodiments, the tendency of the synthetic fibers to sink or float in the fibrous furnish may be minimized to enhance processability by selecting certain types of synthetic fibers, e.g., those with a certain density imbalance.

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.

Abstract: A turf reinforcement mat (TRM) comprises a lofty polymer grid having integrally attached thereto a fibrous mat. The turf reinforcement mat is preferably produced by needle punching a fibrous mat containing low melt temperature thermoplastic fibers and a lofty polymer grid followed by heating to an elevated temperature to fuse fibers of the fibrous mat to strands of the lofty polymer grid. The integral TRM does not necessitate stitching to hold the various layers together in the integral product.

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.

Abstract: A buffing or polishing material has a nonwoven fleece layer and a backing layer that adds strength and dimensional stability to the material. The nonwoven fleece layer is a needled blend of natural fibers and synthetic fibers having a uniform density and working surface, resulting in a better polishing or finishing consistency. The material can withstand high heat levels and can be worked quickly, resulting in a more efficient polishing or finishing operation. The buff material can be converted into any preferred shape or tool, such as an endless belt, disc, flapwheel, or spiral band.

Abstract: A thermal insulating material which can be efficiently produced while the content of organic matters, such as organic fibers and/or an organic binder, is reduced to the same or lower degree as compared with the thermal insulating material used in a conventional pollution control device (e.g., catalytic converter), and which can be applied to a pollution control element (e.g., catalytic element) while avoiding, as much as possible, an unpleasant feeling to the operator. A thermal insulating material comprising a thermal insulating material body formed of a bulk material of inorganic fibers, and a coating provided on at least one surface of said thermal insulating material body.

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.

Abstract: A fibrous absorbent composite containing absorbent material, methods for its formation, and absorbent articles that include the composite are described. The composite is a fibrous structure that includes absorbent material dispersed throughout the composite and in increased concentration in bands that extend along the composite's length.

Abstract: This invention consists of “orienting” the activity (or activities) of textiles, in particular their antimicrobial activity, as well as antistatic, antifungal, and similar useful functions, the “orientation” of the activity (or effect or functions, these terms being used here as being equivalent) of a textile, and especially of the antibacterial activity, of one side of the textile being carried out in relation to the other side.

Abstract: Cleaning articles comprising a nonwoven web or foam, binder, and organic particles.

Abstract: Nonwoven webs in accordance with the present invention include multicomponent fibers bonded by a multiplicity of bond sites to form a coherent web. The multicomponent fibers include a first component formed of a hydrophobic polypropylene and a second component formed of a blend of a hydrophobic polyolefin and a hydrophilic melt additive. This second component is disposed at the surface of the fibers. The hydrophilic melt additive-modified polyolefin component can be arranged in various configurations in the cross-section of the fiber and the fibers can have various cross sections. For example, the hydrophilic component can occupy a portion of the surface of the fiber, as would occur for example with a side-by-side or segmented pie multicomponent fiber configuration. Alternatively, the modified hydrophilic polyolefin can occupy substantially the entire surface of fiber, as for example by producing the fibers in a sheath core configuration with the hydrophilic modified component forming the sheath.

Abstract: Absorbent articles including an absorbent core having multiple absorbent layers. The absorbent layers interact in a manner which desirably locates absorbed liquid in an appointed, high saturation wicking layer. The localization of the liquid within this wicking layer increases the potential of this layer to move liquid through capillary action due to the higher saturation level and increased amount of liquid available. The intake capability of the absorbent system is maintained or improved over current systems by keeping a second layer of the absorbent system at low saturation levels through as many insults of the absorbent article as possible, while providing enhanced intake performance through appropriate control of the composite properties.

Abstract: An electrically insulating non-woven fabric having a main component of poly-p-phenileneterephthalamide fibers bonded with each other by a binder of thermosetting resin and a second binder of one selected from fiber chops, fiber pulps and fibrids of thermoplastic resin having a softening point of 220° C. or higher, the poly-p-phenileneterephthalamide fibers being pulps or both of chops and pulps with a blend mass ratio of the chops to the pulps being 0/100 through 95/5 and preferably 50/50 through 90/10, a fiber length of the poly-p-phenileneterephathalamide fiber chops being preferably 3 to 6 mm, a content of the thermosetting resin binder in the non-woven fabric being 5 to 30 mass % and a content of the second binder being is 5 to 15 mass %.

Abstract: A moldable batt is disclosed that comprises a fire-retardant cellulose, a fiber component, and a binder component. In one version of the invention, the fiber and binder components are provided as a conjugate fiber material. The batt is compressed and heated to form panels or other products that are particularly useful in the office furniture industry.

Abstract: An adhesive tape having a tape-like textile support and an adhesive coating applied to the support, wherein the tape can be unwound easily ready for use without special covering or treatment of the adhesive coating. A tape-like support comprises at least partially a needle punched nonwoven from at least partially thermoplastic fibers, in which the thermoplastic fibers are bonded to each other at least partially by melting on the side opposite the adhesive coating. Melting of the fibers preferably occurs by one-sided heat calendering of the support material. The surface produced by treatment of the fiber material prevents unduly strong adhesion with the following layer during winding of the tape and tearing out of the fibers from their bond during unwinding of the tape. A cost-effective textile adhesive tape from needle punched nonwoven is therefore created without additional interliner.

Abstract: An orthopedic casting material comprising a substrate impregnated with a water-curable resin comprising an aromatic polyisocyanate and a polyol, wherein the free NCO level of said prepolymer is from about 6% to about 10%. Preferably the free NCO level is from about 7% to about 8%. Preferably the polyol has a molecular weight of at least 2,000, and a hydroxyl number of from about 28 to about 56, preferably from about 35 to about 40. The casting material may be packaged as a kit with a casting aid comprising a substrate impregnated with a lubricating material.

Abstract: This invention is related to a protective fabric resistant to molten metals, comprising 10 to 40 percent by weight meta-aramid fiber, 30 to 50 percent by weight wool fiber, and at least 20 percent by weight flame-retardant viscose fiber. Such fabrics typically have a total weight in the range of 200 to 450 grams per square meter and preferably have a total weight in the range of 200 to 260 grams per square meter.

Abstract: The present invention is related to a cleansing tissue, comprising a thermobonded non-woven fabric formed from a mixture of fibers containing greater than 75% of thermoplastic fibers, the non-woven fabric having a plurality of cells, each cell having a first density and a first volume, the cells being disposed adjacent to one another defining a region between adjacent cells, the region having a second density and a second volume, the second density being higher than the first density, and the second volume being less than the first volume. The fabric becomes thicker and its softness is increased because the cells have a low density large sized regions.

Abstract: Nonwoven fibrous webs including amorphous polymeric fibers with improved and/or more convenient bondability are disclosed. The nonwoven fibrous webs may include only amorphous polymeric fibers or they may include additional components in addition to amorphous polymeric fibers. The amorphous polymeric fibers within the web may be autogeneously bonded or autogeneously bondable. The amorphous polymeric fibers may be characterized as varying in morphology over the length of continuous fibers so as to provide longitudinal segments that differ from one another in softening characteristics during a selected bonding operation.

Abstract: A dual texture coform nonwoven web prepared from meltblown filaments and at least one secondary material is disclosed. The dual texture coform nonwoven web is useful as cleaning pads, wipes, mops, among other articles of manufacture. One surface of the dual texture coform nonwoven web contains coarse filaments, which impart an abrasive characteristic to this surface of the nonwoven web and the other surface contains fine filaments, which impart a non-abrasive or soft surface to the nonwoven web. Also disclosed is the process of producing the dual texture coform nonwoven web, method of using the dual texture coform nonwoven web as a wipe, mop, and the like, along with cleaning kits containing the coform nonwoven web.

Abstract: The present invention provides a web containing superfine microfibers. The web contains a blend of a first group of split microfibers which contains a first polymer component and a second group of split microfibers which contains a second polymer component, wherein at least one of the polymer components is hydrophilic. The invention additionally provides a meltblown fiber web having at least two groups of fibers, wherein each group of the fibers has a distinct cross-sectional configuration.

Abstract: In a preferred embodiment, the present process involves subjecting the nonwoven fabric both to an acidic treatment and to a caustic treatment, each of which erodes a portion of the components of the conjugate yarns. The acid treatment, given certain reaction kinetics, removes a portion of the polyamide element of the conjugate filament. The caustic treatment has a similar effect on the polyester element of the conjugate filament, making it more hydrophilic. The at least partial removal of the polyamide component, coupled with the increased hydrophilicity of the polyester component, results in a fabric having enhanced absorptive properties. In an alternate embodiment, treatments with only acid or only caustic solution may be employed.

Abstract: The present invention concerns absorbent articles. This invention concerns in particular an absorbent article comprising cellulose fibers (14) present at least partially in the form of granules. Furthermore, the present invention also concerns the use of cellulose fibers (14) present at least partially in the form of granules as a material in an absorbent article.

Abstract: A method of manufacturing a non-woven fabric which is bulky caused by fiber-raised construction on the surface of a non-woven fabric includes adhering a non-woven web with its surface layer portion containing an easy-to-heat-melt component showing a property to be adhesive as heated to a smooth surface heated at the temperature for the easy-to-heat-melt component to show a property to be adhesive with the surface layer portion in contact with the smooth surface, and then raising the fibers of the non-woven web by peeling the non-woven fabric like web off the smooth surface so that a fiber-raised bulky state is generated, whereby a fiber-raised bulky structure is formed on the surface of the non-woven fabric.

Abstract: Method and apparatus for fiber-reinforced mats and asphalt coated sheets for use in roofing and water resistant membranes. Mats and sheets according to the invention exhibit superior tensile strength and resistance to wrinkling. The mat aspect of the invention comprises product and method for producing mats comprised of organic matting materials such as cellulose, paper, other wood products, or felt, and reinforcing fibers such as fiberglass, plastics, and other relatively high-strength natural and synthetic fibers, the fibers being incorporated within the matting material during production of the mat. The sheet aspect of the invention comprises product and method for mats of the type described above with added asphalt coatings to improve the water-proofing qualities of the mats.

Abstract: A method for preparing stretchable bonded nonwoven fabrics which involves forming a substantially nonbonded nonwoven web of multiple-component continuous filaments or staple fibers which are capable of developing three-dimensional spiral crimp, activating the spiral crimp by heating substantially nonbonded web under free shrinkage conditions during which the nonwoven remains substantially nonbonded, followed by bonding the crimped nonwoven web using an array of discrete mechanical, chemical, or thermal bonds. Nonwoven fabrics prepared according to the method of the current invention have an improved combination of stretch-recovery properties, textile hand and drape compared to multiple-component nonwoven fabrics known in the art.

Abstract: The invention is directed to a hydroentangled nonwoven wipe, the outer surface of which exhibits highly entangled fibers whereas the inner layer exhibits lightly entangled fibers. In particular, the present invention contemplates that a fabric is formed from a fibrous batt that is subjected to fluidic energy, preferably hydraulic energy, applied to one or both faces of a fibrous batt. The hydraulic energy is moderated against the basis weight of the fibrous batt to achieve the degree of surface entanglement desired. Wipes formed in accordance with the present invention exhibit a sufficient degree of strength, softness and non-linting performance, while providing the necessary resistance to tearing and abrasion, to facilitate use in a wide variety of applications utilizing wipes, such as graphic arts and lithography.

Abstract: A liner is disclosed that is capable of being tuned or adjusted during manufacturing to absorb or reflect sound energy, as necessary or desired for a particular application. The liner is formed of a composite material comprising a combination or mixture of mineral fibers, such as glass fibers, and organic fibers, such as polypropylene fibers.

Abstract: This invention relates to a method for preparing nonwoven fabrics having an improved balance of properties in the machine and cross-directions. More specifically, the invention utilizes nonwoven webs that include relatively low levels of multiple-component fibers having latent three-dimensional spiral crimp combined with fibers that do not develop spiral crimp. The latent spiral crimp of the multiple-component fibers is activated, such as by heating, under free shrinkage conditions, after formation of the nonwoven web to achieve re-orientation of the non-spirally-crimpable fibers and an improved balance of properties such as tensile strength and modulus.

Abstract: The present invention provides a cardable fiber blend which forms a moldable fiber batt, the blend comprising fibers having a modulus of 550 g/denier or more with fibers of a thermoplastic polymer wherein the high modulus polymer fibers are all uncrimped fibers or a mixture of crimped and uncrimped fibers. The moldable batt is useful in making speaker cones.

Abstract: A nonwoven structure is provided having a fiber with a lower melting point than conventional fibers, preferably less than 110° C., more particularly less than 90° C., more particularly less than 80° C. The fiber may also include an energy receptive additive that provides rapid heating when subjected to dielectric energy such as radio frequency or microwave radiation. When included in a structure and subjected to electromagnetic radiation, the fiber is heated by contact with materials like pulp and superabsorbent, which absorb electromagnetic radiation.

Abstract: An in-line formed, non-laminated web is suitable for use as a composite fluid distribution and fluid retention layer in a disposable absorbent article. The web can be formed by selective deposition of airlaid materials including absorbents, such as pulp and superabsorbents, together with binder fibers. The web so constructed will have a plurality of intermingled lower basis weight areas and higher basis weight areas coexisting and distributed in at least a central region of the web, the alternations crossing the X axis or Y axis, or both, of the web, with the higher basis weight areas being a greater thickness in the Z-direction than the lower basis weight areas. The web so constructed will further have no discrete material boundaries between the lower basis weight stripes and the higher basis weight stripes. Further the necessity of later processing on the web to achieve a ridged structure is removed and the fibers will remain whole and undisturbed.

Abstract: An absorbent article having a liner, an outer cover, and an absorbent body disposed therebetween. The absorbent body includes a non-woven absorbent structure of unitary construction. The absorbent structure is constructed of absorbent fibers and binder fibers activated to form inter-fiber bonds within the absorbent structure, and has a length, a width, a thickness and a permeability throughout the absorbent structure of greater than about 20 square microns. In another embodiment, the absorbent structure has an outer surface and a core, the absorbent structure having less than about five times more oxidation at its outer surface than at its core. In another embodiment, the binder fibers have an energy receptive additive in the range of about 2 to about 40 weight percent and a dielectric loss factor of at least about 0.5.

Abstract: This invention relates to a disposable wash cloth. The disposable wash cloth includes an aqueous solution incorporated onto a basehseet. The aqueous solution includes a fragrance, at least one mild surfactant, at least one moisturizer, and at least one preservative. The disposable wash cloth is capable of being heated to a select temperature at least twice while maintaining chemical stability.

Abstract: A wrapped absorbent structure that includes two or more absorbent materials to maximize the absorbent functionality of the structure without sacrificing integrity. The structure includes an absorbent core surrounded by an absorbent wrap. The absorbent core is primarily intended to provide absorbent capacity while the absorbent wrap is used to maintain wetness integrity, although the absorbent wrap also provides a considerable amount of absorbent capacity. The absorbent structure is particularly suitable for use in absorbent swimwear.

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: A wet-laid nonwoven reinforcing mat includes a base web having about 10 to about 80 percent by weight glass fibers, about 20 to about 90 percent by weight polyethylene terephthalate fibers and polyvinyl alcohol in an amount of about 5 to about 35 percent of the combined weight of the glass fibers and the polyethylene terephthalate fibers. The reinforcing mat also includes a secondary binder in an amount of about 10 to about 30 percent of the total weight of the base web.

Abstract: An adherent article, such as a bandage or adhesive tape, having a nonwoven substrate that contains water soluble fibers is provided. The water soluble fibers of the nonwoven substrate can include polyvinyl alcohol fibers that only dissolve at temperatures greater than 37° C. and/or polyvinyl alcohol fibers that can dissolve at temperatures less than about 37° C. The adherent article also includes a pressure-sensitive adhesive applied to the nonwoven substrate that facilitates adherence of the substrate to human skin. The pressure-sensitive adhesive can be water soluble or generally insoluble, but dispersible in water.

Abstract: A neckable nonwoven web is provided with a central region and two edge regions, the central region being selectively easier to neck than the two edge regions. The nonwoven fibers in the central region have a polymer composition and/or physical properties which differ from the nonwoven fibers in the two edge regions. The selectively easier necking in the central region causes the central region to neck to about the same extent as the two edge regions, which otherwise would experience greater necking than the central region if the starting nonwoven web were completely uniform. Necked nonwoven webs and neck-bonded laminates made using the improved neckable nonwoven web, are also provided.

Abstract: A fusible non-woven fibrous web for a quilt batt. The fusible non-woven fibrous web includes a non-woven fibrous web and a heat sealable and releasable adhesive. The adhesive is coated on the outer surface of the web and insinuates between the fibers of the web internally. The adhesive thus binds the fibers of the web and provides a tackiness sufficient to allow the web to be applied to, removed from, and reapplied to a backing material on other fabric.

Abstract: The present invention provides a filter media comprising (a) a nonwoven composite material comprising a stabilized mixture of thermoplastic microfibers and at least about 50%, by weight, of a secondary fibrous material such as pulp or polymeric staple fibers; (b) a first outer nonwoven web comprising a substantially uniform nonwoven web of autogenously bonded multicomponent fibers; and (c) a second outer nonwoven web wherein the nonwoven composite material is positioned between the first outer nonwoven web and second outer nonwoven web. The filter material is well suited to filtering liquid borne particulate matter ranging in size from 5&mgr; to about 25&mgr;.