Abstract: Heat bonded thermoplastic and partially thermoplastic nonwoven webs which have been thermomechanically treated while under low strain rate tension show significant improvement to their coformability and softness. More importantly the low strain rate thermomechanical treatment imparts a high degree of commercially valuable elasticity. The resultant webs find use in all nonwoven applications where softness, conformability and elasticity are useful. The resultant webs develop elasticity in only one direction but the two embodiments provide the ability to create elasticity in the machine or cross machine direction of a roll of precursor material. In addition virtually any precursor web containing at least 70% thermally bonded thermoplastic fibers can be used.

Abstract: A unique isotropic sub-denier spunbond nonwoven product created by an apparatus and method comprising a unique multi-head resin metering system, a spinneret head with spinning sections, separated by a quench fluid extraction zone, a two sided, multilevel quench system, a fluid volume control infuser system which automatically guides the filaments into the filament drawing system while conserving energy by using a portion of the quench fluid as part of the drawing fluid and also minimizing turbulence at the entrance to the draw slot. The filament drawing system comprises a draw jet assembly with adjustable primary and secondary jet-nozzles and a variable width draw jet-slot. The entire draw jet assembly is moveable vertically for filament optimization. The offset, constant flow secondary jet-nozzle system provides an unexpectedly high velocity increment to the filaments by oscillating the filaments and increasing their drag resulting in remarkably low fiber denier on the order of 0.5 to 1.2.

Abstract: A unique isotropic sub-denier spunbond nonwoven product created by an apparatus and method comprising a unique multi-head resin metering system, a spinneret head with spinning sections, separated by a quench fluid extraction zone, a two sided, multilevel quench system, a fluid volume control infuser system which automatically guides the filaments into the filament drawing system while conserving energy by using a portion of the quench fluid as part of the drawing fluid and also minimizing turbulence at the entrance to the draw slot. The filament drawing system comprises a draw jet assembly with adjustable primary and secondary jet-nozzles and a variable width draw jet-slot. The entire draw jet assembly is moveable vertically for filament optimization. The offset, constant flow secondary jet-nozzle system provides an unexpectedly high velocity increment to the filaments by oscillating the filaments and increasing their drag resulting in remarkably low fiber denier on the order of 0.5 to 1.2.

Abstract: A unique isotropic sub-denier spunbond nonwoven product created by an apparatus comprising a unique multi-head resin metering system, a spinneret head with spinning sections, separated by a quench fluid extraction zone, a two sided, multilevel quench system, a fluid volume control infuser system which automatically guides the filaments into the filament drawing system while conserving energy by using a portion of the quench fluid as part of the drawing fluid and also minimizing turbulence at the entrance to the draw slot. The filament drawing system comprises a draw jet assembly with adjustable primary and secondary jet-nozzles and a variable width draw jet-slot. The entire draw jet assembly is moveable vertically for filament optimization. The offset, constant flow secondary jet-nozzle system provides an unexpectedly high velocity increment to the filaments by oscillating the filaments and increasing their drag resulting in remarkably low fiber denier on the order of 0.5 to 1.2.

Abstract: A novel concentricity stabilizer acts as both a structural coupling and an alignment device and a means for providing a concentric structure from a series of segmental modules. The concentricity stabilizer creates a self support system that permits construction of the individual modular pocket assemblies into a perfectly circular drum ready for attachment to suitable drum flanges or discs and shaft assemblies.

Abstract: An apparatus and method for filtration of particulate matter in fluid streams. A unique high efficiency, two element filter embodying an enclosure containing a tandem rotary disk and drum filter mounted on a common shaft is described. A method of operation including manual and computer control modes are described.

Abstract: A series of nonwoven webs and the processes for their production are disclosed. The resultant webs have equal or superior strength characteristics to conventional nonwoven fabrics made using spunbond processes but their constituent fibers are of a finer diameter. This is accomplished through a process of melt blowing a nonwoven fabric made from at least one polymer at low polymer flows per die hole and low air and polymer pressures using modular die technology to provide a die with one or more rows of die holes. The nonwoven fabric of this invention may be used in products such as diapers, feminine hygiene products, filters, progressive layer filters, adult incontinence products, wound dressings, bandages, sterilization wraps, surgical drapes, geotextiles, wipers, insulation and other related products.

Abstract: The present invention provides an improved apparatus for forming a fibrous pad for absorbent products with improved density control. Fibers entrained in a high speed air flow are deposited onto the foraminous surface of a spaced, three-dimensional pad-forming pocket. The fine foraminous pad forming screen is supported on its periphery by two top plates, a coarse forming screen, two subplates and end rails which incorporate a device to hold the pad forming screen.A gas flow regulating system consisting of precisely placed cross directional fixed and adjustable airflow control louvers controls the air flow direction and reduces spill over and turbulence during the pad formation and especially during the transition of the forming pocket into and out of the air stream as the rotary former shell rotates through the filling position.

Abstract: A process for thermomechanically treating heat bonded thermoplastic and partially thermoplastic nonwoven webs while under low strain rate tension results in significant improvements to the nonwoven web's conformability, softness and impart a high degree of commercially valuable elasticity. The resultant webs find use in all nonwoven applications where softness, conformability and elasticity are useful. The process develops elasticity in only one direction but the two embodiments provide the ability to create elasticity in the machine or cross machine direction of a roll of precursor material. In addition virtually any precursor web containing at least 60% thermally bonded thermoplastic fibers can be used.

Abstract: The present invention relates to a rapid and low cost procedure for joining webs and films containing dissimilar polymers. It is especially applicable but not limited to the construction and assembly of disposable products such as infant and adult incontinent products, feminine hygiene products, and other low-cost, high volume disposable products. The process involves producing a high rate of heat flux through the dissimilar materials where the material with the higher plastic point is at the influx point and the lower plastic point material is adjacent and further from the heat source. In addition to this constraint and as a necessary component the application of the high rate of heat flux must be accompanied by a pressure of appropriate to the difference in plastic points and to the relative thickness of the dissimilar materials to be joined.

Abstract: The present invention provides an inlet and outlet plenum apparatus for improving the forming of fibrous pads for absorbent products and providing improved density control. Fibers entrained in a high speed air flow coming from a fiberizer or other fiber source enter an inlet plenum which reduces velocity by increasing the area of the inlet plenum in a linear manner thereby decreasing turbulence and improving the density distribution of the fiber deposited onto the foraminous surface of a pad-former screen. The outlet plenum allows for a controlled velocity increase which reduces under-screen turbulence and further improves fiber distribution and density control.