International Paper Company

Bba Nonwovens Simpsonville, Inc.

International Paper

Polyweave International, LLC

James A Goettmann

Stephen H Monroe

John R Boylan

Peter J Angelini

Richard C Williams

Guy D'Anna

Gerald A Funk

Linda M Gee

Gerald L Funk

Ashish Mathur

Timothy Connolly

Roland Smith

A nonwoven composite web suitable for use, after post-treatment with a wetting agent, as a battery separator is formed by a wet process on a papermaking machine. One nonwoven composite material is made from a furnish of polyolefin binder fibers and polyolefin staple fibers. The web coming off the papermaking machine is dried using infra-red dryers followed by heated dryer cans. After drying, the web is thermally bonded using heated calendar rolls. The polyolefin binder fibers melt as the web passes through the calendar rolls and thermally bond the polyolefin staple fibers of the web when the melted binder fiber material fuses upon cooling.

Wet-laid nonwoven polyolefin battery separator substrate

A high-opacity cellulose-free synthetic paper is formed from a wet-laid nonwoven web of thermoplastic fibers, all or most of which fibers are made of a predetermined polymeric material. The wet-laid web is dried to remove excess water, drying being carried cut at temperatures below the melting temperature of the predetermined polymeric material. The dried nonwoven web is saturated on at least one side with a pigmented binder forming a continuous coating thereon. The binder is cured at temperatures below the melting temperature of the predetermined polymeric material.

Recyclable polymeric synthetic paper and method for its manufacture

A nonwoven composite web is formed by a wet process on a papermaking machine. The web coming off the papermaking machine is dried and thermally bonded using heated calendar rolls. The nonwoven composite material is made from a furnish of polymeric staple fibers, a first binder fiber consisting, at least in part, of a first thermoplastic binder material which melts at a first melting temperature less than and a second binder fiber consisting, at least in part, of a second polymeric material which has second melting temperature which is higher than the first melting temperature. The first polymeric material is selected to have a first melting temperature less than the temperature to which the first material will be subjected in the papermaking machine. The melted first polymeric material gives the web strength on the papermaking machine. The second polymeric material is selected to have a second melting temperature less than the temperature to which the second material will be subjected in the calendar rolls. Thus, the second polymeric material is melted as the web passes through the calendar rolls and thermally bonds the other fibers of the web when the melted second polymeric material fuses upon cooling. The staple fibers are made of polyester and the bicomponent binder fibers are of the co-polyester/polyester sheath/core variety. The support substrate has a sheet porosity in the range of 5-10 cfm.

Reverse osmosis support substrate and method for its manufacture

A nonwoven composite web suitable for use as a battery separator is formed by a wet process on a papermaking machine. The nonwoven composite material is made from a furnish of nylon binder fibers and nylon staple fibers. The web coming off the papermaking machine is dried using infra-red dryers followed by heated dryer cans. After drying, the web is thermally bonded using heated calendar rolls. The nylon binder fibers melt as the web passes through the calendar rolls and thermally bond the nylon staple fibers of the web when the melted binder fiber material fuses upon cooling. The use of dryer cans to dry and partially bond the web eliminates the need for surfactant treatment to improve potassium hydroxide absorption.

Wet-laid nonwoven nylon battery separator material

A degradable agricultural mulch, mat or ground cover including cotton linters fibers, hardwood kraft pulp fibers, softwood kraft pulp fibers, and a water holdout material which is strong enough to be laid mechanically and is 100% photo- or biodegradable.

Degradable cotton base cellulosic agricultural mat

A gloss coating composition comprising radiation curable oligomers and monomers, and photosensitizers in a homogeneous mixture having a viscosity in the range of 4500 to 8000 cps; wherein the presence of the photosensitizers causes polymerization of the radiation curable oligomers and monomers when exposed to an ultraviolet light source. The coating composition is applied to at least one surface of a substrate and exposed to an ultraviolet light source resulting in curing of the composition onto the substrate surface without substantial penetration into the substrate surface forming a gloss coated substrate.

High gloss ultraviolet curable coating for porous substrates

An in-mold label material is a nonwoven mat of fibers having one side fused with the outer surface of a polymeric container and the other side coated with a pigment-containing latex suitable for printing thereon. The label paper is manufactured from commercially available fibers combined in water into a homogeneous mixture and then formed into a mat employing a wet-lay process. For use with polyethylene containers, the label may be a web consisting of 88-100% polyethylene fibers and 0-15% polyvinyl alcohol fibers or 70-100% polyethylene fibers, 0-15% polyvinyl alcohol fibers and 0-30% polypropylene fibers. For use with polyester containers, the label may be a web consisting of 50-90% polyester staple fibers, 10-40% bicomponent polyester/co-polyester, core/sheath binder fibers and 0-10% polyvinyl alcohol binder fibers thermally bonded together. The nonwoven web of fibers has a pigmented coating. After the material has been cut into labels, the labels may be applied to the blow-molded containers in-mold without the use of an adhesive material using a conventional in-mold labeling technique or post-mold using adhesive.

Recyclable polymeric label paper

A degradable agricultural ground cover which is composed of high density polyethylene polymer fiber and cellulose pulp which is 100% photo and biodegradable for use in weed control and moisture retention in soil. The unique agricultural mat or cover lasts 8-12 weeks before serious photo and biodegradability occurs, while allowing crop plants sufficient time to mature and produce. The sheet totally disappears with plowing and tilling, becoming a soil extender until complete degradation occurs.

Degradable agricultural mat

High gloss ultraviolet curable coating

A nonwoven composite web consists of 15 to 50 wt. % of first polyester fibers having a length of 5 mm to 3/4 inch and a denier of 0.3 to 3, 5 to 50 wt. % of second polyester fibers having a length of 5 mm to 1-1/2 inches and a denier of 3 to 15, and 10 to 40 wt. % of binder fibers comprising thermoplastic binder material having a melting temperature which is less than the first and second melting temperatures respectively. The first and second polyester fibers are bonded to each other at least in part by solidification of the thermoplastic binder material after subjecting the web to temperatures in excess of the melting temperature of the binder material but not in excess of the melting temperature of either the first or second polyester fibers. In particular, the web is thermally bonded by calendaring at a temperature of in the range of 360.degree. to 410.degree. F. and at a pressure in the range of 40 to 70 psi. Preferably the binder fibers comprise bicomponent fibers having a co-polyester sheath and a polyester core.

Printable, high-strength, tear-resistant nonwoven material and related

A nonwoven composite web consists of 15 to 50 wt. % of first polyester fibers having a first length, a first denier and a first melting temperature; 15 to 50 wt. % of second polyester fibers having a second length, a second denier and a second melting temperature; 15 to 50 wt. % of third polyester fibers having a third length, a third denier and a third melting temperature; 10 to 35 wt. % of polypropylene fibers; and 1 to 25 wt. % of cellulose fibers. The first, second and third lengths are no less than 1/2 inch, the first, second and third denier are no less than 1.5, and the third melting temperature is less than the first and second melting temperatures respectively. The first and second polyester fibers, the polypropylene fibers and the cellulose fibers are bonded to each other at least in part by solidification of the third polyester fibers after subjecting the web to temperatures in excess of the third melting temperature but not in excess of the first and second melting temperatures. In particular, the web is thermally bonded by calendaring at a temperature of approximately 385.degree. F. The web can be manufactured to have high opacity by adding titanium dioxide and silicone-acrylic latex to the composition. The titanium dioxide and latex are agglomerated and the resulting agglomerates are thermally bonded to the fiber matrix.

Growing community of inventors

North East, PA, United States of America

James A Goettmann