Abstract: The present invention provides a non-woven felt material that includes a blend of cotton shoddy and synthetic fibers, and a method of making the same. The blend of cotton shoddy and synthetic fibers is carded and needled to form a batt. The batt is compacted and unified into its stable final shape by heating and soft-pressing, which causes at least a portion of the synthetic fibers to soften and/or melt and thereby bond the needled cotton shoddy and synthetic fibers together. The non-woven felt material according to the invention is strong, tear resistant, yet provides a non-slip, cushioned walking surface that readily absorbs and contains spilled oils, water and/or glycols.

Abstract: A dispersible fibrous structure having an in-use wet tensile strength of at least about 40 g/cm; a disposable wet tensile decay of at least about 35% and a method of making the structure. The structure has at least one property selected from a group consisting of: a wet CD maximum slope of less than about 12 kg/7.62 cm, a wet CD Elongation of greater than about 50%, a low elongation CD modulus of less than about 5.0 kg/7.62 cm, and a wet CD Bending of less than about 0.05 gf cm/cm.

Abstract: A polypropylene based nonwoven fabric is excellent in surface appearance and stretch properties and exhibits a small residual strain and excellent adhesiveness to polyolefins. The nonwoven fabric is obtained by forming a polypropylene resin composition comprising 1 to 40 weight parts of (i) an isotactic polypropylene, and 60 to 99 weight parts of (ii) a propylene/ethylene/?-olefin copolymer obtained by copolymerizing 45 to 89 mole % of propylene, 10 to 25 mole % of ethylene and the balance of ?-olefin having 4 to 20 carbon atoms (with the proviso that the copolymerized amount of the ?-olefin having 4 to 20 carbon atoms does not exceed 30 mole %), characterized by a small residual strain after stretching at a stretch ratio of 150%. The nonwoven fabric can be effectively used as sanitary materials or the like by virtue of its characteristics including stretch properties.

Abstract: A fibrous sheet containing cotton fibers and at least two kinds of synthetic fibers is disclosed. The synthetic fibers form a nonwoven fabric. The cotton fibers enter a fiber network of the nonwoven fabric and interlace with the fiber network thereby to form a cotton fiber layer on one side of the nonwoven fabric, with part of the cotton fiber layer entering the nonwoven fabric. The synthetic fibers contain a combination of heat fusible fiber (a) and heat fusible fiber (b) having a small thickness than the fiber (a) or a combination of the fiber (a) and a fiber (c) that is not thermally bonded with the fiber (a).

Abstract: A water dispersible nonwoven web is disclosed. The nonwoven web is produced in an airlaying process and contains pulp fibers mixed with water soluble fibers. The water soluble fibers may be, for instance, polyvinyl alcohol fibers. The nonwoven web may be pre-saturated with a cleaning solution. Once pre-saturated with a cleaning solution, the wiping product is particularly well suited to cleaning and/or disinfecting surfaces, such as toilet seats prior to use. Because the nonwoven web is water dispersible, the wiper may be disposed of by being flushed down a toilet.

Abstract: Mattress and home furnishing items are made open flame resistant by a fire barrier fabric that includes chlorine-free rayon fiber. The fire barrier fabric at least partially encloses the core of the open flame resistant mattress or home furnishing item. When tested in accordance with the flame resistance test protocols of NFPA 267 or ASTM E 1590, the mattress has a maximum heat release rate of less than 250 kW and a total energy release of less than 40 MJ in the first five minutes of the test. The home furnishing items may be tested under test protocols such as California Technical Bulletin #604 or #117. TEQ of the products of the combustion of chlorine-free fibers, yarns and fabrics is less than or equal to 2 nanograms.

Abstract: A down-feather and manmade fiber filled product has an outer layer, an inner layer, and a filler filled between the outer layer and the inner layer. The filler is formed by agitating dry down-feathers and manmade fibers with a predetermined ratio in an agitating chamber. The sizes of the fibers are between 0.71 deniers to 0.91 deniers and lengths are between 22 to 26 mm. A plurality of lattices with sizes of 8 inches×10 inches are formed on the outer layer and inner layer. A weight ratio of the fiber is below 50% of the filler. Furthermore, a down-feather and manmade fiber mixed filler is disclosed. The filler is formed by agitating dry down-feathers and manmade fibers with a predetermined ratio in an agitating chamber; sizes of the manmade fibers being between 0.71 deniers to 0.91 deniers and a length between 22 to 26 mm.

Abstract: A sound absorbing material having a homogenous mixture of an organic man-made fiber, an inorganic man-made fiber, a co-binder, and a cellulose material wherein the organic man-made fiber is polyester, the inorganic man-made fiber is fiberglass, and the co-binder is a thermo-setting resin. The cellulose material may include Kaolin clay and/or boric acid.

Abstract: The present invention is directed to ion-sensitive, water-dispersible polymers. The present invention is also directed to a method of making ion-sensitive, water-dispersible polymers and their applicability as binder compositions. The present invention is further directed to fiber-containing fabrics and webs comprising ion-sensitive, water-dispersible binder compositions and their applicability in water-dispersible personal care products.

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: An under carpet heat shield/floor pan insulator is provided for a vehicle. The shield/insulator includes an acoustical and thermal insulating layer of polymer fiber that shows no signs of any thickness increase, delamination, deterioration or any undesirable effect which may affect performance for at least 330 hours when maintained at a temperature of at least approximately 150° C. The shield/insulator may include a relatively high density, nonlaminate skin of polymer fiber and/or one or more facing layers constructed from polymer material.

Abstract: Provided is a paper structure comprised of two outside layers and at least one inside layer. The two outside layers are comprised of substantially cellulosic pulp fiber, and the inside layer is comprised of a high temperature fiber and a polymeric binder, and preferably cellulosic pulp fiber. In a preferred embodiment, the structure comprises at least three inside layers, all comprised of cellulosic pulp fiber, high temperature fiber and a polymeric binder. The resulting paper structure finds particular use as a high temperature transformer paper in the manufacture of transformers.

Abstract: A fusible quilt batt. The fusible batt 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 a backing material at an elevated temperature and removed from the backing at room temperature or an elevated temperature. After removal of the web from the backing material it may be reapplied to a backing material at an elevated temperature. The attachment, removal and reattachment process is repeatable.

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: 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.

Abstract: The invention is directed to a hydroentangled nonwoven fabric, 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. Fabrics formed in accordance with the present invention exhibit a sufficient degree of softness and non-linting performance, while providing the necessary resistance to tearing and abrasion, to facilitate use in a wide variety of applications such as cast padding or orthopedic wraps.

Abstract: A gypsum board comprises a set gypsum layer having a first face and a second face. A fibrous mat is affixed to at least one of the faces. The mat comprises a non-woven web bonded together with a resinous binder. The web comprises a blend of a major portion composed of chopped continuous glass fibers having an average fiber diameter ranging from about 8 to 17 &mgr;m and a minor portion composed of fine staple fibers having an average fiber diameter of less than about 5.5 &mgr;m, the minor portion comprising about 1-30 percent of the dry weight of the web. The board is exceedingly durable. It has a smooth surface that is readily finished in an aesthetically pleasing way, using paint or other wall covering systems.

Abstract: Wet-laid nonwoven webs having mechanical reinforcement properties are provided by employing unpulped vegetable fiber bundles as the predominant fiber component. The unpulped fiber bundles have a modulus of elasticity of about 2-5×106 psi and a chopped fiber length of about 25 mm. The fibers are cordage fibers including sisal, abaca, henequen, kenaf and jute. Composites of the unpulped fiber webs with cellulosic and spunbonded sheets find application as thermoformed vehicle interior trim products.

Abstract: An absorbing article has a hydrophobic, liquid impermeable back side layer and a liquid permeable top layer together with an interposed hydrophilic core layer. The article is made so that at least the back side layer comprises hydrophobic vegetable fibers, preferably kapok fibers, and that the top lay can comprise wool fibers. Such an article is advantageous since it may be used for keeping the user warm in situations where there is need for liquid absorption without the risk of unintended temperature elevation known from plastic products.

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.

Abstract: There is provided an elastic thermal insulating wrap having a insulating skin facing layer and an airflow impeding layer, with elastic strands interposed therebetween. The elastic strands are arranged in a substantially parallel manner and the strands and layers are bonded to produce the wrap laminate.

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: The present invention is directed to ion-sensitive, water-dispersible polymers. The present invention is also directed to a method of making ion-sensitive, water-dispersible polymers and their applicability as binder compositions. The present invention is further directed to fiber-containing fabrics and webs comprising ion-sensitive, water-dispersible binder compositions and their applicability in water-dispersible personal care products.

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: 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: 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: Disclosed is a filter medium having at least a first layer containing a stabilized matrix of thermoplastic filaments and at least one secondary material; and a second layer having a stabilized matrix of thermoplastic filaments and optionally of at least one secondary material. Each of the layer of the filter medium has a different compositional ratio of the components to result in a gradient structure. The compositional gradient for the layers of the coform results in a filter having improved capacity, which extends the life of the filter medium, as compared to a filter without the compositional gradient. The present invention also provides a method of removing particles from a fluid containing particles. The method of the present invention includes contacting the fluid containing particles with the filter medium of having the two layers described above in a manner such that the fluid containing particles is passed through the first layer of the filter medium before the second layer.

Abstract: A fibrous moldable substrate is provided having a fibrous material and a binder. The fibrous material and binder is subjected to heat such that only a portion of the binder is wetted to the fibrous material.

Abstract: A stretchable nonwoven, laminated fabric having one or more cotton containing surface layers thermally bonded to one or both sides of a thermoplastic filament fiber core layer and a method for fabricating the fabric. These fabrics after being subjected to a heat-stretching process can provide instantaneous elastic recoveries of 83% to 93% for 50% extension. Furthermore, the fabric exhibits a hand similar to cotton knits, good strength, good wetting, good wicking good water retention, and minimal linting characteristics and can be used for medical applications. Consolidated nonwoven laminated fabrics are also disclosed which can provide instantaneous elastic recovery.

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: An absorbing article has a hydrophobic, liquid impermeable back side layer and a liquid permeable top layer together with an interposed hydrophilic core layer. The article is made so that at least the back side layer comprises hydrophobic vegetable fibers, preferably kapok fibers, and that the top lay can comprise wool fibers.

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: 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: The present invention discloses environmentally degradable multicomponent fibers. The configuration of the multicomponent fibers may be side-by-side, sheath-core, segmented pie, islands-in-the-sea, or any combination of configurations. Each component of the fiber will comprise destructurized starch and/or a biodegradable thermoplastic polymer. The present invention is also directed to nonwoven webs and disposable articles comprising the environmentally degradable multicomponent fibers. The nonwoven webs may also contain other synthetic or natural fibers blended with the multicomponent fibers of the present invention.

Abstract: The present invention relates to a method of creating a textured nonwoven fabric for apparel and home fashions applications, wherein the nonwoven fabric becomes aesthetically altered upon laundering. Once laundered during manufacture, the nonwoven fabric exhibits a permanent distressed appearance that becomes an integral part of the fabric. Subsequent to laundering, the fabric can be formed into a roll for shipment and storage. The distressed appearance of the nonwoven fabric is best described by comparing the laundered fabric to an elephant's skin.

Abstract: This invention relates to fibrous absorbent articles containing particles useful in the manufacture of disposable diapers, adult incontinence pads, sanitary napkins and the like, scrubbing pads, scouring pads and cleaning pads that contain a detergent or soap and the like, and pads that contain coffee, tea, and the like More particularly, the invention is directed to an absorbent articles having sealed lateral edges to contain loose fibers and particles within the structure. Additionally, this invention is related to airlaid methods to manufacture unitary absorbent products.

Abstract: In a wet friction material and a method therefor of the present invention, an excessive binder coating on the outermost surface layer of the friction material is removed or prevented while at least one of impregnation, drying and setting of a binder, and further the surface of the friction material is smoothed by means of heating, pressurizing and molding.

Abstract: A composition of material for manufacturing women's elastic free size winter shirts having an omasum inner-wall-like textile structure to render desired elasticity to a shirt.

Abstract: A hood, dash, firewall or engine cover liner is provided for a vehicle. The liner includes a nonlaminate acoustical and thermal insulating layer of polymer fiber that shows no signs of any thickness increase, delamination, deterioration or any undesirable effect which may affect performance for at least 330 hours when maintained at a temperature of at least approximately 150° C. The liner may include a relatively high density, nonlaminate skin of polymer fiber and/or one or more facing layers constructed from polymer material.

Abstract: This invention relates to antimicrobial fabrics which are treated with a specific durable and regenerable halamine/chlorine system and methods of removing residual active chlorine from the target textile surface without reducing the antimicrobial activity of the textile. Such methods comprise contacting an amine-treated fabric first with a halogen-based bleach (or other halogenated liquid) to produce halamines at the fabric surface, and subsequently washing the resultant halogenated fabric with a reducing agent which removes the residual, unbonded halogen (such as chlorine) from the fabric surface but does not, surprisingly, remove the halamine halogen. The remaining halamine halogen thus provides the desired antimicrobial activity.

Abstract: The present invention discloses environmentally degradable multicomponent fibers. The configuration of the multicomponent fibers may be side-by-side, sheath-core, segmented pie, islands-in-the-sea, or any combination of configurations. Each component of the fiber will comprise destructurized starch and/or a biodegradable thermoplastic polymer. The present invention is also directed to nonwoven webs and disposable articles comprising the environmentally degradable multicomponent fibers. The nonwoven webs may also contain other synthetic or natural fibers blended with the multicomponent fibers of the present invention.

Abstract: Disclosed is an absorbent structure including a liquid acquisition layer and a fibrous liquid storage layer in liquid communication with the acquisition layer. The storage layer includes SAP particles. The acquisition layer includes synthetic fibers and the fibers are latex bonded. A fluid acquisition and/or distribution layer (ADL) containing at least two layers, a top layer of latex bonded synthetic fibers and a bottom layer of latex and/or thermal bonded cellulose fibers and method for preparation thereof are disclosed. The synthetic fiber layer is highly porous and provides rapid fluid acquisition under load. The cellulose layer provides z-direction capillary force to pull fluid into the absorbent product, to provide temporary fluid immobilization, and to act as a conduit for fluid to be pulled into unsaturated portion of the permanent fluid storage layer. The ADL of the invention provides increased protection against leakage relative to single-layer ADLS.

Abstract: The invention concerns a method for producing a nonwoven web formed at least partly with hydrophilic elementary fibers which consist in: producing by carding a textile layer (10) which is then compressed and moistened; subjecting it to a bonding treatment using water jets acting at least against one of its surfaces; and transferring said bonded layer to a unit (32, 33) to be dewatered and dried. Said method is characterised in that, after the bonding treatment (20) with water jets and before drying and delivery, the pre-bonded and moistened layer is transferred to a supplementary unit (28) to be treated by the action of one or several series of water jets, said unit comprising a mobile suction surface in the form of a drum covered with an open-work structure (30) consisting of a wire-mesh fabric, comprising successive raised and recessed zones.

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: A wound dressing comprises a blend of at least two types of discrete fibers wherein one discrete fiber is of a modified cellulose gel-forming material and a second discrete fiber is of another type of gel-forming material such as an alginate.

Abstract: Wet-laid nonwoven webs having mechanical reinforcement properties are provided by employing unpulped vegetable fiber bundles as the predominant fiber component. The unpulped fiber bundles have a modulus of elasticity of about 2-5×10 6 psi and a chopped fiber length of about 25 mm. The fibers are cordage fibers including sisal, abaca, henequen, kenaf and jute. Composites of the unpulped fiber webs with cellulosic and spunbonded sheets find application as thermoformed vehicle interior trim products.

Abstract: A water disintegratable non-woven fabric having excellent water disintegratability and high wet strength can be obtained by a step of forming a fiber web from fibers having a fiber length of 10 mm or less, a step of applying a water jet treatment to the fiber web to obtain a fiber sheet having wet strength of less than 100 g/25 mm in MD and CD, the wet strength being defined by tensile strength at break of the fiber sheet, as measured by using a tensilon tester with a chuck distance of 100 mm, at a tensile speed of 100 mm/min to the fiber sheet which is cut into 25 mm width and 150 mm length and impregnated with water in an amount 2.5 times the weight of the fiber sheet, and a step of adding at least one binder selected from the group consisting of carboxymethyl cellulose, alkylcellulose, polyvinyl alcohol and modified polyvinyl alcohol to the fiber sheet. The water disintegratable non-woven fabric is sufficiently bulky and has an excellent wiping effect.