Milliken + Co

Sujith Nair

Yunzhang Wang

Venkatkrishna Raghavendran

Sasha Stankovich

Johann Peschek

Charles William Prestridge

Howell Brewster Eleazer

Joseph R Royer

Padmakumar Puthillath

Ines El-Majid

Franck Catteau

Yves Duytschaever

Purushothama K Ullal

A reinforced rubber article containing a rubber article and a fibrous layer embedded into the rubber article. The fibrous layer contains monoaxially drawn tape elements having a rectangular cross-section and at least a first layer having a draw ratio of at least about 5, a modulus of at least about 2 GPa, a density of at least 0.85 g/cm. The first layer contains a polymer selected from the group consisting of polyamide, polyester, and co-polymers thereof. Methods of forming the reinforced rubber article are also disclosed.

Rubber reinforced article with high modulus, rectangular cross-section fibers

A reinforced rubber article containing a rubber article and a fibrous layer embedded into the rubber article. The fibrous layer contains monoaxially drawn tape elements having at least a first layer, an upper surface and a lower surface. The first layer comprises a blend of polyester and nylon 6. Methods of forming the reinforced rubber article are also disclosed.

Polyester/nylon 6 fibers for rubber reinforcement

A consolidated fibrous structure including a multiplicity of fibrous layers. Each fibrous layer comprises tape fibers, wherein the tape fibers contain a polypropylene core and a skin layer. At least a portion of the skin layers of the fibers in each fibrous layer are fused to at least a portion of other skin layers of fibers within the same fibrous layer and at least a portion of the skin layers of the fibers of each fibrous layer are fused with at least a portion of the skin layers of the fibers in an adjacent fibrous layer.

Consolidated fibrous structure

A consolidated fibrous structure including a multiplicity of fibrous layers. The fibers of each fibrous layer contain a core, a first layer and a second layer. The core has an exterior surface portion containing polypropylene. The first layer is disposed on at least a portion of the core and contains a first polymer. The first polymer contains a polymer having at least 70% &#x3b1;-olefin units and is characterized by a melting temperature lower than the melting temperature of the exterior surface portion of the core. The second layer is disposed on at least a portion of the first layer and contains a second polymer.

A method for forming multi-layered fiber including a core, a first layer, and a second layer. The core has an exterior surface portion containing polypropylene. The first layer is applied to at least a portion of the core and contains a first polymer. The first polymer contains a polymer having at least 70% &#x3b1;-olefin units and is characterized by a melting temperature lower than the melting temperature of the exterior surface portion of the core. The second layer is applied to at least a portion of the first layer and contains a second polymer. The second polymer contains a co-polymer having at least 50% &#x3b1;-olefin units and is characterized by a number-average molecular weight of about 7,000 g/mol to 50,000 g/mol, a viscosity of between about 2,500 and 150,000 cP measured at 170&#xb0; C., and a melting temperature lower than the melting temperature of the exterior surface portion of the core. The viscosity of the second polymer is not greater than about 10 percent of the viscosity of the first polymer measured at 170&#xb0; C.

Method of forming a multi-layered fiber

A consolidated fibrous structure including a multiplicity of fibrous layers. The fibers of each fibrous layer contain a core and a skin layer. The core has an exterior surface portion containing polypropylene. The skin layer is disposed on at least a portion of the core and contains a first polymer and a second polymer. The first polymer contains a polymer having at least 70% &#x3b1;-olefin units and is characterized by a melting temperature lower than the melting temperature of the exterior surface portion of the core. The second polymer contains a co-polymer having at least 50% &#x3b1;-olefin units and is characterized by a number-average molecular weight of about 7,000 g/mol to 50,000 g/mol, a viscosity of between about 2,500 and 150,000 cP measured at 170&#xb0; C., and a melting temperature lower than the melting temperature of the exterior surface portion of the core. The viscosity of the second polymer is not greater than about 10 percent of the viscosity of the first polymer measured at 170&#xb0; C. At least a portion of the skin layers of the fibers in each fibrous layer are fused to at least a portion of other skin layers of fibers within the same fibrous layer, at least a portion of the skin layers of the fibers of each fibrous layer are fused with at least a portion of the skin layers of the fibers in an adjacent fibrous layer, and the stiffness of the consolidated fibrous structure is at least 1 N-m. A fibrous layer is also described.

A multi-layered fiber containing a core and a skin layer. The core has an exterior surface portion containing polypropylene. The skin layer is disposed on at least a portion of the core and contains a first polymer and a second polymer. The first polymer contains a polymer having at least 70% &#x3b1;-olefin units and is characterized by a melting temperature lower than the melting temperature of the exterior surface portion of the core. The second polymer contains a co-polymer having at least 50% &#x3b1;-olefin units and is characterized by a number-average molecular weight of about 7,000 g/mol to 50,000 g/mol, a viscosity of between about 2,500 and 150,000 cP measured at 170&#xb0; C., and a melting temperature lower than the melting temperature of the exterior surface portion of the core. The viscosity of the second polymer is not greater than about 10 percent of the viscosity of the first polymer measured at 170&#xb0; C. Methods of forming the multi-layered fiber are also disclosed.

Multi-layered fiber

A method of consolidating thermoplastic fibrous layers by providing a plurality of fibers having a core with an exterior surface portion comprising polypropylene and a first layer disposed on at least a portion of the core containing at least 70% alpha-olefin units which is formed into a first fibrous layer. A second fibrous layer is applied to the first fibrous layer which second layer contains a second polymer being a co-polymer having at least 50% alpha-olefin units which is characterized by a number-average molecular weight of about 7,000 to 50,000 g/mol, a viscosity of between about 2,500 and 150,000 cP measured at 170&#xb0; C. and a melting temperature lower than the melting temperature of the exterior surface of the core. Heat and optionally pressure are applied to the assembly to consolidate the layers.

Method of forming a consolidated fibrous structure

A multi-layered fiber including a core, a first layer, and a second layer. The core has an exterior surface portion containing polypropylene. The first layer is disposed on at least a portion of the core and contains a first polymer. The first polymer contains a polymer having at least 70% &#x3b1;-olefin units and is characterized by a melting temperature lower than the melting temperature of the exterior surface portion of the core. The second layer is disposed on at least a portion of the first layer and contains a second polymer. The second polymer contains a co-polymer having at least 50% &#x3b1;-olefin units and is characterized by a number-average molecular weight of about 7,000 g/mol to 50,000 g/mol, a viscosity of between about 2,500 and 150,000 cP measured at 170&#xb0; C., and a melting temperature lower than the melting temperature of the exterior surface portion of the core. The viscosity of the second polymer is not greater than about 10 percent of the viscosity of the first polymer measured at 170&#xb0; C. Methods of forming the multi-layered fiber are also disclosed.

Growing community of inventors

Spartanburg, SC, United States of America

Sujith Nair