Union Carbide Corporation

Amoco Corporation

Propex Operating Company, LLC

Bp Corporation North America Inc.

Propex Fabrics, Inc.

Rheinische Kunststoffewerke Gmbh

Canco Hungary Investment Ltd.

Hugh C Gardner

Shahid P Qureshi

Richard H Newman-Evans

Robert J Cotter

George L Brode

Linda A Domeier

Michael J Michno, Jr

Kam Chung Lui

Markus Matzner

Jeffrey H Mumm

Thomas Lee Baker

Richard C Moon

Lloyd Mahlon Robeson

George T Kwiatkowski

Ismael Colon

Edward D Barkis

Mitchell H Berger

Larry M Bailey

Thomas L Oakley

Kenneth R Jones

Stephen G Ceisel

James E Haire

Mark B Williams

Andy Rakovac

Charles W Galpin

Philippe Combier

Jack F Godfrey

Eric J Bryant

Gregory P Shelnutt

Josef Uesbeck

Robert J White

Thomas L Baker

A woven geotextile fabric derived from beta-nucleated polyolefin yarn or monofilament, the method of manufacture of fabric, and the use of such fabric are disclosed. The yarn is made by compounding one or more polyolefins and a beta-nucleator reagent wherein the compounded mixture is extruded then drawn to at least 9 times its original length. The yarn or monofilament is woven into synthetic fabric useful for roadway construction, embankment stabilization, and mechanically stabilized earth.

Woven geotextile fabric derived from beta-nucleated, polypropylene yarn or monofilament

Making foamed polyolefin tapes can include combining a polyolefin resin and a chemical blowing agent to form a mixture. This mixture can then be heated in an extruder to create a supersaturated solution of gas within the polyolefin resin. A cooling device can be positioned adjacent to a die at a set distance for receiving extruded resin and for allowing exposure of the extruded resin to ambient air between a die outlet and the cooling device. This predetermined distance or space between the cooling device and die outlet allows bubbles to grow in the extruded resin and to be shaped such that voids or empty spaces can be generated within the extruded polyolefin resin. The voids or empty spaces allow the formation of tapes which use less material but have adequate strength for various applications, such as for carpet backings, geotextiles, packaging, housewrap, bags, wire insulation, and reinforcement elements in concrete.

Method and system for manufacturing foamed polyolefin tapes at cost effective line speeds

A two-layer secondary carpet backing including a woven scrim layer and a fibrous layer is described. The woven scrim layer is characterized as having a low open area and a flat weave. The two-layer secondary backing is capable of having a non-abrasive, textile back surface. The secondary carpet backing is also capable of having a construction that permits high carpet manufacturing speeds due to high air permeability and is capable of providing high dimensional stability, seam strength, and delamination strength to tufted carpets made therefrom.

Composite secondary carpet backing, method of manufacture thereof, and carpet made therefrom

Tufted carpets bonded with thermoplastic binders and having improved resistance to fuzz formation due to removal of pile yarn filaments from tuft bundles comprise one or more backings, face yarn that forms a pile on one side and stitches on an opposite side, a thermoplastic binder that binds stitches and the backing or backings, and an organic polymer that bonds filaments of the stitches. Processes for making carpets comprise applying to a stitched side of a tufted backing a liquid stitch bind composition comprising an organic polymer component, removing a liquid component of the composition to bond filaments of the stitches and bonding stitches and one or more backings with a thermoplastic binder that is melted or applied as a melt in contact with the stitched side and the backing or backings and solidified.

Carpets with improved fuzz-resistance

Carpet backings and use thereof in tufted carpets with good tuft bind and fuzz resistance and free of inorganic and latex materials are disclosed. Backings suitable as tuftable primary backings or as secondary backings have a nonwoven fabric with thermoplastic filaments and a thermoplastic supporting fabric operatively attached as by needling, thermal calendaring or point bonding.

Carpet construction and carpet backings for same

Tuftable primary backings comprise a closed-weave, woven tape fabric to which is affixed a coherent web layer comprising staple fibers with fibers oriented in at least two directions and a plurality of the fibers being fused. The web layer is affixed to the fabric by penetration of fibers from the web into the fabric. The backings have substantial weftline straightness and stability against deformations in the machine, cross and off-axis directions. Improved tufted goods and methods for making the composites and tufted goods are also provided.

Tuftable and tufted fabrics

This invention provides breathable composite materials with good liquid barrier properties comprising a laminate of a nonwoven web layer and a breathable film layer wherein breathability of the composite is provided by a plurality of point-like deformations of the film layer. In one embodiment, the composites also have a soft, cloth-like texture at at least one surface thereof. Also provided is a process for making such composites comprising applying a molten film-forming resin composition capable of developing breathability on deformation to a nonwoven web, cooling the molten composition to form a coated web having a web layer bonded to a film layer, and subjecting the coated web to heat and pressure at a plurality of points on a surface thereof wherein the heat, pressure and density of, and proportion of the composite surface occupied by, the deformations are effective to impart breathability to the film without loss of liquid barrier properties. In another embodiment of the process, web and cast film components are subjected to heat and pressure at a plurality of points to bond the film and the web and provide a plurality of point-like deformations of the film layer, thereby imparting breathability without loss of liquid barrier properties.

Breathable composite and method therefor

Described herein are compositions containing (a) a cycloaliphatic epoxy resin, (b) an aromatic amine hardener, and (c) a particular cure accelerator. These compositions afford unreinforced castings with a high level of mechanical properties and improved heat deflection temperatures.

Accelerated cycloaliphatic epoxide/aromatic amine resin systems

Described herein are compositions useful for the preparation of high modulus matrix resins for composites comprising a cycloaliphatic epoxide and a particular modifier.

Epoxy resin systems containing modifiers

Described herein is a composition comprising an epoxy resin containing at least one glycidyl amine group wherein the resin contains three or more epoxide groups per molecule and a particular aromatic amine hardener. These compositions possess the necessary balance of properties required for making prepreg and afford unreinforced castings with high moduli and strength.

High modulus prepregable epoxy resin systems

Described herein are resinous compositions comprising a particular cycloaliphatic epoxy resin and the adduct of these epoxy resins with an aromatic active hydrogen-containing compound. These compositions afford unreinforced castings with higher heat deflection temperatures, faster cure rates, and reduced water uptake than similar compositions containing epoxy adducts made from aliphatic polyols.

High modulus epoxy resin systems

Matrix resin formulations comprising cyanate esters of phenol adducts of dicyclopentadiene, epoxy resins and particular thermoplastics, provide fiber reinforced composites with excellent toughness and hot/wet properties.

Fiber-reinforced composite of cyanate ester, epoxy resin and thermoplast

Prepreg comprising structural fiber and matrix resin formulated from epoxys selected from the group consisting of polyglycidyl ethers of polycyclic bridged hydroxy-substituted polyaromatic compounds and N,N,N',N'-tetraglycidyl-bis(4-amino-3-ethylphenyl) methane with from about 6 to about 150 pbw, per hundred parts by weight of the epoxy resin components, of a solid aromatic diamine hardener insoluble in said composition in an amount effective to cure said epoxy resin exhibiting improved storage stability characteristics at room temperature.

Prepreg with improved room temperature storage stability

Epoxy resin formulations having improved storage stability comprising epoxys selected from the group consisting of polyglcidyl ethers of polycyclic bridged hydroxy-substituted polyaromatic compounds and N,N,N',N'-tetraglycidyl-bis(4-amino-3-ethylphenyl) methane with from about 6 to about 150 pbw, per hundred parts by weight of the epoxy resin components, of a solid aromatic diamine hardener insoluble in said composition at room temperature in an amount effective to cure said epoxy resin.

Epoxy matrix resin formulations with improved storage stability

Fiber reinforced composite structures based on epoxy resin formulations having a phase-separated or multiphase morphology when cured are effectively toughened by adding preformed carboxylated rubber particles to the matrix resin prior to curing the composite.

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Somerville, NJ, United States of America

Hugh C Gardner