Milliken & Company

Pradipkumar Bahukudumbi

Kirkland W Vogt

Yunzhang Wang

Gregory Thompson

Dale S Kitchen

Gregg J Blaszak

Gregory A Norton

Mark T Mapes

James R Theobald

A process for forming a nonwoven composite begins with forming a first nonwoven from a plurality of primary fibers and optionally binder fibers. A second nonwoven layer is formed from a plurality of bulking fibers and binder fibers. A thermoplastic elastomeric film is placed between the two nonwoven layers, the film containing a thermoplastic elastomeric polymer having an elongation at break greater than 300% and a max softening point (thermomechanical analysis end point) between 150&#xb0; C. and 200&#xb0; C. as tested according to ASTM E2347-04. The layers are needled together creating a plurality of holes in the thermoplastic elastomeric layer and moving a portion of the primary fibers from the first nonwoven layer into the second nonwoven layer. The needled stacked layers are heated to alter the median size of the holes in the thermoplastic elastomeric film forming the nonwoven composite.

Process for forming a nonwoven composite

A process for forming a moldable, uncured nonwoven composite containing forming a outermost nonwoven layer, forming a structural nonwoven layer, needling the structural nonwoven layer and the outermost nonwoven layer together from both the outer surface of the outermost nonwoven layer and the second surface of the structural nonwoven layer, applying an uncured, water-based thermosetting resin having a cure temperature of at least about 160&#xb0; C. to the second surface of the structural nonwoven layer, and at least partially drying the uncured, wet nonwoven composite. Heat and pressure may be applied to form the moldable, uncured composite. A moldable, uncured nonwoven composite and a molded, cured nonwoven composite are also disclosed.

Moldable uncured nonwoven composite and molded cured composite

A process for forming a moldable, uncured nonwoven composite containing forming a structural nonwoven layer, at least partially impregnating the structural nonwoven layer with an uncured, water-based thermosetting resin having a cure temperature of at least about 160&#xb0; C., and at least partially drying the uncured, wet nonwoven composite such that the temperature at the inner plane is less than about 130&#xb0; C. forming an moldable, uncured composite. The structural nonwoven layer contains a plurality of bi-component binder fibers and a plurality of reinforcing fibers, the bi-component fibers containing a core and a sheath. The core contains a polymer having a melting temperature of at least about 180&#xb0; C. and the sheath contains a polymer having a melting temperature less than about 180 &#xb0; C. A process for forming a molded, cured composite containing forming a structural nonwoven layer and a molded cured nonwoven composite are also disclosed.

A nonwoven composite containing a first nonwoven layer having a plurality of primary fibers and optionally binder fibers, a thermoplastic film comprising a thermoplastic polymer having an elongation at break greater than 300% and a max softening point (thermomechanical analysis end point) between 150&#xb0; C. and 200&#xb0; C. as tested according to ASTM E2347-04 and containing a plurality of holes and an air flow resistance great than 1,500 Rayls. A second nonwoven layer having a plurality of bulking fibers and optionally binder fibers. The thermoplastic film is adjacent the bottom surface of the first nonwoven layer and the top surface of the second nonwoven layer and sandwiched between the first and second nonwoven layers. At least a portion of the primary fibers from the first nonwoven layer are located in the holes of the thermoplastic film and within the second nonwoven layer.

Nonwoven composite

Disclosed is a method of strengthening existing structures containing the following steps. An existing structure made of concrete, steel, timber, masonry to be reinforced and a reinforcing sheet are provided, where the reinforcing sheet contains an alternating arrangement of reinforcement zones and slitting zones. The reinforcement zones contain unidirectional strengthening fibers in the warp direction of the reinforcement sheet and the slitting zones have an absence of strengthening fibers. The reinforcement sheet is slit through the slitting zones and the reinforcement zones are adhered to the existing structure.

Method of strengthening existing structures using strengthening fabric having slitting zones

A process for forming a high efficiency filter containing the steps of forming a non-woven layer having pores from a plurality thermoplastic fibers having a median diameter of less than about 2 micrometers, saturating the non-woven layer in a wetting liquid, and drying the wetted non-woven layer.

Process for forming a high efficiency nanofiber filter

An acoustic composite containing at least a first acoustically coupled non-woven composite and a second acoustically coupled non-woven composite, each acoustically coupled non-woven composite containing a non-woven layer and a facing layer. The non-woven layer contains a plurality of binder fibers and a plurality of bulking fibers and has a binder zone and a bulking zone. The facing layer of the second acoustically coupled non-woven composite is adjacent the second surface of the non-woven layer of the first acoustically coupled non-woven composite.

Acoustic composite

An acoustically coupled non-woven composite containing a non-woven layer and a thermoplastic film. The non-woven layer contains a plurality of binder fibers and a plurality of bulking fibers and has a binder zone and a bulking zone.

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Greenville, SC, United States of America

Pradipkumar Bahukudumbi