William W Fowells

US Patent:

6448194, Sep 10, 2002

Filed:

Jan 31, 2001

Appl. No.:

09/773845

Inventors:

Scott L. Gessner - Encinitas CA
J. Darrell Gillespie - Simpsonville SC
Jared A. Austin - Greer SC
David D. Newkirk - Greer SC
William Fowells - Washougal WA

Assignee:

BBA Nonwovens Simpsonville, Inc. - Simpsonville SC

International Classification:

D04H 154

US Classification:

442363, 442365, 525240

Abstract:

Nonwoven fabrics and fabric laminates are formed from continuous filaments or staple fibers of a select blend of specific grades of polyethylene and polypropylene which give improved fabric performance not heretofore recognized or described, such as high abrasion resistance, good tensile properties, excellent softness and the like. Furthermore, these blends have excellent melt spinning and processing properties which permit efficiently producing nonwoven fabrics at high productivity levels. The polymers are present as a lower-melting dominant continuous phase and at least one higher-melting noncontinuous phase dispersed therein The lower-melting continuous phase forms at least 70 percent by weight of the fiber and comprises a linear low density polyethylene polymer of a melt index of greater than 10 and a density of less than 0. 945 g/cc. At least one higher-melting noncontinuous phase comprises a polypropylene polymer with melt flow rate of greater than 20 g/10 min.

US Patent:

6465378, Oct 15, 2002

Filed:

Jan 31, 2001

Appl. No.:

09/773901

Inventors:

Scott L. Gessner - Encinitas CA
J. Darrell Gillespie - Simpsonville SC
Jared A. Austin - Greer SC
David D. Newkirk - Greer SC
William Fowells - Washougal WA

Assignee:

BBA Nonwovens Simpsonville, Inc. - Simpsonville SC

International Classification:

B32B 506

US Classification:

442345, 442363, 442365, 442398, 442399, 442400, 442240

Abstract:

Nonwoven fabrics and fabric laminates are formed from continuous filaments or staple fibers of a select blend of specific grades of polyethylene and polypropylene which give improved fabric performance not heretofore recognized or described, such as high abrasion resistance, good tensile properties, excellent softness and the like. Furthermore, these blends have excellent melt spinning and processing properties which permit efficiently producing nonwoven fabrics at high productivity levels. The polymers are present as a lower-melting dominant continuous phase and at least one higher-melting noncontinuous phase dispersed therein. The lower-melting continuous phase forms at least 70 percent by weight of the fiber and comprises a linear low density polyethylene polymer of a melt index of greater than 10 and a density of less than 0. 945 g/cc. At least one higher-melting noncontinuous phase comprises a polypropylene polymer with melt flow rate of greater than 20 g/10 min.

US Patent:

6506698, Jan 14, 2003

Filed:

Mar 1, 2000

Appl. No.:

09/516309

Inventors:

Thomas E. Quantrille - Simpsonville SC
Harold E. Thomas - Greer SC
Barry D. Meece - Pelzer SC
Scott L. Gessner - Encinitas CA
J. Darrell Gillespie - Simpsonville SC
Jared A. Austin - Greer SC
David D. Newkirk - Greer SC
William Fowells - Washougal WA

Assignee:

BBA Nonwovens Simpsonville, Inc. - Simpsonville SC

International Classification:

B32B 526

US Classification:

442361, 442364, 442381, 442382, 442392, 442394, 442328, 442401, 428373

Abstract:

The present invention provides a composite nonwoven fabric with a superior combination of extensibility, tensile properties and abrasion resistance. The composite nonwoven fabric ( ) comprises at least one layer containing multipolymer fibers, with a plurality of bonds bonding the fibers together to form a coherent extensible nonwoven web ( ). This coherent extensible nonwoven web ( ) has a Taber surface abrasion value (rubber wheel) of greater than 10 cycles and an elongation at peak load in at least one of the machine direction or the cross-machine direction of at least 70%. A second extensible layer ( ) is laminated to this coherent extensible nonwoven web ( ).

US Patent:

6516472, Feb 11, 2003

Filed:

Jan 31, 2001

Appl. No.:

09/773880

Inventors:

Scott L. Gessner - Encinitas CA
J. Darrell Gillespie - Simpsonville SC
Jared A. Austin - Greer SC
David D. Newkirk - Greer SC
William Fowells - Washougal WA

Assignee:

BBA Nonwovens Simpsonville, Inc. - Simpsonville SC

International Classification:

A61F 1315

US Classification:

2111, 2 783, 604366, 604370, 604401, 442363, 442365, 442398, 442399, 442400

Abstract:

Nonwoven fabrics and fabric laminates are formed from continuous filaments or staple fibers of a select blend of specific grades of polyethylene and polypropylene which give improved fabric performance not heretofore recognized or described, such as high abrasion resistance, good tensile properties, excellent softness and the like. Furthermore, these blends have excellent melt spinning and processing properties which permit efficiently producing nonwoven fabrics at high productivity levels. The polymers are present as a lower-melting dominant continuous phase and at least one higher-melting noncontinuous phase dispersed therein. The lower-melting continuous phase forms at least 70 percent by weight of the fiber and comprises a linear low density polyethylene polymer of a melt index of greater than 10 and a density of less than 0. 945 g/cc. At least one higher-melting noncontinuous phase comprises a polypropylene polymer with melt flow rate of greater than 20 g/10 min.

US Patent:

62076027, Mar 27, 2001

Filed:

Mar 12, 1997

Appl. No.:

8/815551

Inventors:

Scott L. Gessner - Encinitas CA
J. Darrell Gillespie - Simpsonville SC
Jared A. Austin - Greer SC
David D. Newkirk - Greer SC
William Fowells - Washougal WA

Assignee:

BBA Nonwovens Simpsonville, Inc. - Simpsonville SC

International Classification:

D01F6/46
7
D04H1/54
7
C08L23/04
23/10

US Classification:

442363

Abstract:

Nonwoven fabrics and fabric laminates are formed from continuous filaments or staple fibers of a select blend of specific grades of polyethylene and polypropylene which give improved fabric performance not heretofore recognized or described, such as high abrasion resistance, good tensile properties, excellent softness and the like. Furthermore, these blends have excellent melt spinning and processing properties which permit efficiently producing nonwoven fabrics at high productivity levels. The polymers are present as a lower-melting dominant continuous phase and at least one higher-melting noncontinuous phase dispersed therein. The lower-melting continuous phase forms at least 70 percent by weight of the fiber and comprises a linear low density polyethylene polymer of a melt index of greater than 10 and a density of less than 0. 945 g/cc. At least one higher-melting noncontinuous phase comprises a polypropylene polymer with melt flow rate of greater than 20 g/10 min.

US Patent:

58042865, Sep 8, 1998

Filed:

Aug 27, 1996

Appl. No.:

8/676360

Inventors:

Thomas E. Quantrille - Simpsonville SC
Harold E. Thomas - Greer SC
Barry D. Meece - Pelzer SC
Scott L. Gessner - Encinitas CA
J. Darrell Gillespie - Simpsonville SC
Jared A. Austin - Greer SC
David D. Newkirk - Greer SC
William Fowells - Washougal WA

Assignee:

Fiberweb North America, Inc. - Simpsonville SC

International Classification:

B32B 526
B32B 710
B32B 714

US Classification:

428198

Abstract:

A fabric comprising at least two layers wherein at least one layer is an extensible, bonded non-woven composed of a fiber comprising multiple different polymers such as a fiber comprising isotactic polypropylene, polyethylene and a block or grafted polyolefin copolymer or terpolymer which is at least partially miscible with said polypropylene and polyethylene.

US Patent:

56121237, Mar 18, 1997

Filed:

Apr 19, 1996

Appl. No.:

8/635332

Inventors:

Scott L. Gessner - Encinitas CA
William Fowells - Washougal WA

Assignee:

Fiberweb North America, Inc. - Simpsonville SC

International Classification:

D03D 300

US Classification:

442401

Abstract:

Improved meltspinning productivity is achieved by employing polyolefin resins having key molecular weight distribution and rheological property parameters within predetermined ranges. These parameters include the molecular weight distribution breadth parameter, M. sub. z /M. sub. n ; and rheological property parameters of flow rate ratio, I. sub. 10 /I. sub. 2, and the power law index, n, of the regression analysis viscosity equation. These parameters additionally include one or both of the z-average molecular weight, M. sub. z, of the resin, or the second order constant, b. sub. 2, of the regression analysis viscosity equation, and unless both of the latter two parameters are met, the parameters further include the die swell and the spinnability factor (determined from the relationship between die swell and MFR) of the resin.

US Patent:

55498671, Aug 27, 1996

Filed:

Nov 3, 1994

Appl. No.:

8/333651

Inventors:

Scott L. Gessner - Encinitas CA
William Fowells - Washougal WA

Assignee:

Fiberweb North America, Inc. - Simpsonville SC

International Classification:

D01D 5088
D01F 604

US Classification:

264555

Abstract:

Improved meltspinning productivity is achieved by employing polyolefin resins having key molecular weight distribution and rheological property parameters within predetermined ranges. These parameters include the molecular weight distribution breadth parameter, M. sub. z /M. sub. n ; and rheological property parameters of flow rate ratio, I. sub. 10 /I. sub. 2, and the power law index, n, of the regression analysis viscosity equation. These parameters additionally include one or both of the z-average molecular weight, M. sub. z, of the resin, or the second order constant, b. sub. 2, of the regression analysis viscosity equation, and unless both of the latter two parameters are met, the parameters further include the die swell and the spinnability factor (determined from the relationship between die swell and MFR) of the resin.