Milliken + Co

Martin E Cowan

Brian G Morin

Darin L Dotson

Nathan A Mehl

Kenneth M Wiencek

Kenneth B Higgins

Le Zhang

Jack A Smith

Keith Alan Keller

Xiaodong Edward Zhao

Joseph R Royer

Brian Michael Burkhart

Jeffrey R Jones

Raymond C Sturm

T Andrew Canada

Robert M MacMeccan

William S Parks

Jason L Kreider

Thomas A Canada

Mark K Wiencek

Andrew Thomas Canada

K Mark Wiencek

A composite article comprises a fluid transport layer having first and second surfaces and a hydrophobic layer applied to the first surface of the fluid transport layer. When the composite article is used as a wound dressing, the first surface of the fluid transport layer provides a skin-facing surface. The hydrophobic layer comprises a plurality of discontinuities, and at least a portion of the discontinuities have a dimension sufficient to permit the passage of fluid through the hydrophobic layer and into the fluid transport layer.

Composite article suitable for use as a wound dressing

A composite article comprises a fluid transport layer, a fluid retentive layer, and, optionally, a moisture vapor permeable film. The first surface of the fluid transport layer provides a fluid contacting surface. The fluid retentive layer is positioned so that the first surface layer of the fluid retentive layer is adjacent to the second surface of the fluid transport layer. The moisture vapor permeable film is positioned so that it is adjacent to the second surface of the fluid retentive layer. The composite article is suitable for use as a wound dressing.

This disclosure relates to wound care devices which are capable of one-way, directional flow of fluids and contaminants away from the wound site to the opposite side of the wound care device, which functions as a fluid reservoir. This fluid transport mechanism generally aids in reducing wound maceration by removing excess fluid, and potentially even bacteria, and is carried out without loss of physical integrity of the wound care device itself. In addition to providing a uni-directional fluid transport mechanism, the wound care device may contain a topically applied silver-based antimicrobial finish which provides certain levels of antimicrobial agent to the wound in order to clear infection from the wound site and control bacterial growth in the wound care dressing. Exemplary topical antimicrobial finishes include silver ion-releasing compounds.

Wound care device having fluid transfer properties

This disclosure relates to wound care devices which are capable of one-way, directional flow of fluids and contaminants away from the wound site to the opposite side of the wound care device, which functions as a fluid reservoir. This fluid transport mechanism generally aids in reducing wound maceration by removing excess fluid, and potentially even bacteria, and is carried out without loss of physical integrity of the wound care device itself. In addition to providing a unidirectional fluid transport mechanism, the wound care device may contain a topically applied silver-based antimicrobial finish which provides certain levels of antimicrobial agent to the wound in order to clear infection from the wound site and control bacterial growth in the wound care dressing. Exemplary topical antimicrobial finishes include silver ion-releasing compounds.

Improvements in permitting greater efficiency for high denier polypropylene fiber and yarn production are provided. Generally, spinning speeds are limited for polypropylene fibers and yarns as such materials tend to break easily upon exposure to excessively high tensions associated with low- to medium-spinning speeds. As spinning is required to properly draw such high denier fibers sufficiently for fiber and yarn production, such limitations effectively prevent widespread utilization of such fibers and yarns in various end-use applications. Thus, it has been surprisingly been determined that such high denier manufactured fibers and yarns can be produced with certain nucleating additives that permit tensile strength increases to the level required for high-speed spinning procedures to be followed. Additionally, low-shrink and/or better resiliency properties are also available with the addition of such nucleating compounds within the target high denier polypropylene resins.

High speed spinning procedures for the manufacture of high denier polypropylene fibers and yarns

Improvements in preventing heat- and moisture-shrink problems in specific polypropylene tape fibers are demonstrated herein. Such fibers are manufactured through the initial production of polypropylene films or tubes which are then slit into very thin, though flat tape fibers thereafter. Such fibers include rigidifying nucleating compounds that nucleate polymer crystals within the target polypropylene after exposure to sufficient heat to melt the initial pelletized polymer and upon allowing such a melt to cool. Specific methods of manufacture of such inventive tape fibers, as well as fabric articles made therefrom, are also encompassed within this invention.

Method of producing low-shrink polypropylene tape fibers

Improvements in preventing heat- and moisture-shrink problems in specific polypropylene tape fibers are provided. Such tape fibers are basically manufactured through the initial production of polypropylene films or tubes which are then slit into very thin, though flat (and having very high cross sectional aspect ratios) tape fibers thereafter. These inventive tape fibers (and thus the initial films and/or tubes) require the presence of relatively high amounts of certain compounds that quickly and effectively provide rigidity to the target polypropylene tape fiber. Generally, these compounds include any structure that nucleates polymer crystals within the target polypropylene after exposure to sufficient heat to melt the initial pelletized polymer and allowing such an oriented polymer to cool. The compounds must nucleate polymer crystals at a higher temperature than the target polypropylene without the nucleating agent during cooling. In such a manner, the 'rigidifying' nucleator compounds provide nucleation sites for polypropylene crystal growth. Subsequent to slitting the initial film and/or tube, the fiber is then exposed to sufficient heat to grow the crystalline network, thus holding the fiber in a desired position. The preferred 'rigidifying' compounds include dibenzylidene sorbitol based compounds, as well as less preferred compounds, such as [2.2.1]heptane-bicyclodicarboxylic acid, otherwise known as HPN-68, sodium benzoate, certain sodium and lithium phosphate salts [such as sodium 2,2'-methylene-bis-(4,6-di-tert-butylphenyl)phosphate, otherwise known as NA-11]. Specific methods of manufacture of such inventive tape fibers, as well as fabric articles made therefrom, are also encompassed within this invention.

Low-shrink polypropylene tape fibers comprising high amounts of nucleating agents

A pile fabric suitable for use as a primary carpet fabric within a carpet construction or composite such as a cushioned carpet or tile. The primary carpet fabric includes a plurality of pile-forming yarns tufted through or adhered to a primary backing of integral dimensionally stable character. A cushioning layer of foam, felt, fabric, or other suitable cushioning material may be disposed at a position below the primary carpet fabric.

Textile constructions with stabilized primary backings and related methods

Improvements in permitting brighter colorations within polypropylene fibers and/or yarns while simultaneously providing more efficient production methods of manufacturing of such colored fibers as well are provided. Generally, such fibers and/or yarns have been colored with pigments, which exhibit dulled results, or dyes, which exhibit high degrees of extraction and low levels of lightfastness. Such dull appearances, high extraction levels, and less than stellar lightfastness properties negatively impact the provision of such desirable colored polypropylene fibers and/or yarns which, in turn, prevents the widespread utilization of such fibers and yarns in various end-use applications. Thus, it has surprisingly been determined that brighter colorations, excellent extraction, and more-than-acceptable lightfastness characteristics can be provided, preferably, through manufacture with certain polymeric colorants that include poly(oxyalkylene) groups thereon. Fabric articles comprising such novel fibers and/or yarns are also encompassed within this invention.

Thermoplastic fibers exhibiting durable high color strength characteristics

Improvements in preventing heat- and moisture-shrink problems in specific polypropylene tape fibers are provided. Such tape fibers are basically manufactured through the initial production of polypropylene films or tubes which are then slit into very thin, though flat (and having very high cross sectional aspect ratios) tape fibers thereafter. These inventive tape fibers (and thus the initial films and/or tubes) require the presence of relatively high amounts of certain compounds that quickly and effectively provide rigidity to the target polypropylene tape fiber. Generally, these compounds include any structure that nucleates polymer crystals within the target polypropylene after exposure to sufficient heat to melt the initial pelletized polymer and allowing such an oriented polymer to cool. The compounds must nucleate polymer crystals at a higher temperature than the target polypropylene without the nucleating agent during cooling. In such a manner, the &ldquo;rigidifying&rdquo; nucleator compounds provide nucleation sites for polypropylene crystal growth. Subsequent to slitting the initial film and/or tube, the fiber is then exposed to sufficient heat to grow the crystalline network, thus holding the fiber in a desired position. The preferred &ldquo;rigidifying&rdquo; compounds include dibenzylidene sorbitol based compounds, as well as less preferred compounds, such as &lsqb;2.2.1&rsqb;heptane-bicyclodicarboxylic acid, otherwise known as HPN-68, sodium benzoate, certain sodium and lithium phosphate salts &lsqb;such as sodium 2,2&prime;-methylene-bis-(4,6-di-tert-butylphenyl)phosphate, otherwise known as NA-11&rsqb;. Specific methods of manufacture of such inventive tape fibers, as well as fabric articles made therefrom, are also encompassed within this invention.

Unique thermoplastic monofilament fibers and yarns that exhibit heretofore unattained physical properties are provided. Such fibers are basically manufactured through the extrusion of thermoplastic resins that include a certain class of nucleating agent therein, and are able to be drawn at high ratios with such nucleating agents present that the tenacity and modulus strength are much higher than any other previously produced thermoplastic fibers, particularly those that also simultaneously exhibit extremely low shrinkage rates. Thus, such fibers require the presence of certain compounds that quickly and effectively provide rigidity to the target thermoplastic (for example, polypropylene), particularly after heat-setting. Generally, these compounds include any structure that nucleates polymer crystals within the target thermoplastic after exposure to sufficient heat to melt the initial pelletized polymer and allowing such an oriented polymer to cool. The compounds must nucleate polymer crystals at a higher temperature than the target thermoplastic without the nucleating agent during cooling. In such a manner, the &ldquo;rigidifying&rdquo; nucleator compounds provide nucleation sites for thermoplastic crystal growth. The preferred &ldquo;rigidifying&rdquo; compounds include dibenzylidene sorbitol based compounds, as well as less preferred compounds, such as &lsqb;2.2.1&rsqb;heptane-bicyclodicarboxylic acid, otherwise known as HPN-68, sodium benzoate, certain sodium and lithium phosphate salts &lsqb;such as sodium 2,2&prime;-methylene-bis-(4,6-di-tert-butylphenyl)phosphate, otherwise known as NA-11&rsqb;. Specific methods of manufacture of such inventive thermoplastic fibers, as well as fabric articles made therefrom, are also encompassed within this invention.

Thermoplastic monofilament fibers exhibiting low-shrink, high tenacity, and extremely high modulus levels

Compounds and compositions comprising specific metal salts of bicyclo&lsqb;2.2.1 &rsqb;heptane dicarboxylate salts in order to provide highly desirable properties within polyolefin articles are provided. The inventive salts and derivatives thereof are useful as nucleating and/or clarifying agents for such polyolefin, provide excellent crystallization temperatures, stiffness, and calcium stearate compatibility within target polyolefin. Also, such compounds exhibit very low hygroscopicity and therefore excellent shelf stability as powdered or granular formulations. Polyolefin additive compositions and methods of producing polyolefin with such compounds are also contemplated within this invention.

Growing community of inventors

Moore, SC, United States of America

Martin E Cowan