Abstract: An apparatus for meltblowing multiple types of liquid materials into multi-component filaments. A pair of outer manifold elements sandwich an intermediate manifold element. Respective channels are formed between opposing sides of the outer manifold elements and the respective opposite sides of the intermediate manifold element. These recesses form channels which diverge or widen away from associated inlets at the top of the manifold assembly. A die tip is coupled to the manifold assembly at a lower side and communicates with the outlets of the channels. The die tip includes a combining member for producing a desired multi-component filament configuration and further includes air discharge passages for impinging the discharged multi-component filaments with pressurized air.

Abstract: An apparatus for extruding multiple types of liquid materials into multi-component filaments. A pair of outer manifold elements sandwich an intermediate manifold element. Respective channels are formed between opposing sides of the outer manifold elements and the respective opposite sides of the intermediate manifold element. These recesses form channels which diverge or widen away from associated inlets at the top of the manifold assembly. A die tip is coupled to the manifold assembly at a lower side and communicates with the outlets of the channels. The die tip includes a combining member for producing a desired multi-component filament configuration.

Abstract: A multi-layer absorbent product in a preferred embodiment includes a fibrous nonwoven top sheet, a fibrous nonwoven absorbent core layer, and a fibrous nonwoven substantially water-impervious back sheet. Each component layer or sheet is manufactured at a fiberizing station (i.e., melt spinning) and laminated together at a combining station. The preferred melt spinning apparatus is spunbond for the top sheet, meltblowing for the core layer, and a combination of spunbond and meltblowing for the bottom sheet.

Abstract: A multi-layer absorbent product in a preferred embodiment includes a fibrous nonwoven top sheet, a fibrous nonwoven absorbent core layer, and a fibrous nonwoven substantially water-impervious back sheet. Each component layer or sheet is manufactured at a fiberizing station (i.e., melt spinning) and laminated together at a combining station. The preferred melt spinning apparatus is spunbond for the top sheet, meltblowing for the core layer, and a combination of spunbond and meltblowing for the bottom sheet.

Abstract: An air handler for collecting air discharged from a melt spinning apparatus. The air handler includes an outer housing having walls defining a first interior space. One of the walls has an intake opening for receiving the discharge air. Another wall has an exhaust opening for discharging the air. The intake opening is in fluid communication with the first interior space. An inner housing is positioned within the first interior space and has walls defining a second interior space. At least one of the walls of the inner housing has an opening. The first interior space communicates with the second interior space through the opening. The second interior space is in fluid communication with the exhaust opening.

Abstract: Nonwoven laminates are made by a multi-station line comprising at least one spunbond die assembly and at least one meltblowing die assembly. Each station includes (a) a melt spinning die which can be selectively equipped with a spunbond die insert or a meltblowing die insert and (b) a moveable support structure for adjusting the proper die-to-collector distance, depending on the spunbond or meltblowing mode of operation. The multi-station line permits the selective manufacture of a variety of spunbond (S) and meltblown (M) laminates, including the S-M-S laminate.

Abstract: An apparatus for meltblowing multiple types of liquid materials into multi-component filaments. A pair of outer manifold elements sandwich an intermediate manifold element. Respective channels are formed between opposing sides of the outer manifold elements and the respective opposite sides of the intermediate manifold element. These recesses form channels which diverge or widen away from associated inlets at the top of the manifold assembly. A die tip is coupled to the manifold assembly at a lower side and communicates with the outlets of the channels. The die tip includes a combining member for producing a desired multi-component filament configuration and further includes air discharge passages for impinging the discharged multi-component filaments with pressurized air.

Abstract: An apparatus for extruding multiple types of liquid materials into multi-component filaments. A pair of outer manifold elements sandwich an intermediate manifold element. Respective channels are formed between opposing sides of the outer manifold elements and the respective opposite sides of the intermediate manifold element. These recesses form channels which diverge or widen away from associated inlets at the top of the manifold assembly. A die tip is coupled to the manifold assembly at a lower side and communicates with the outlets of the channels. The die tip includes a combining member for producing a desired multi-component filament configuration.

Abstract: A melt spinning apparatus includes fiber producing features to produce multi-component filaments by extruding two or more single-component strands that combine after extrusion and are then attenuated by process air. The two or more liquid materials do not contact one another in the spinpack. Separation of the two types of liquid material throughout the spinpack prevents premature leakage between two liquid materials and allows for an optimized temperature for each type of liquid material for proper extrusion.

Abstract: Nonwoven laminates are made by a multi-station line comprising at least one spunbond die assembly and at least one meltblowing die assembly. Each station includes (a) a melt spinning die which can be selectively equipped with a spunbond die insert or a meltblowing die insert and (b) a moveable support structure for adjusting the proper die-to-collector distance, depending on the spunbond or meltblowing mode of operation. The multi-station line permits the selective manufacture of a variety of spunbond (S) and meltblown (M) laminates, including the S-M-S laminate.

Abstract: A meltblowing die includes a die tip having an outwardly projecting triangular nosepiece defining an apex therealong, a row of hot melt holes spaced along the apex, and air holes positioned in relation to the hot melt holes to cause at least some of the filaments discharging therefrom to flare outwardly so that the hot melt filaments deposited on an underlying moving substrate has a lateral dimiension greater than the length of the row of hot melt holes. The die may be operated to cause the filaments to be deposited on the substrate in a side-by-side sinusoidal, stitch-like pattern.

Abstract: A modular applicator for dispensing liquid including a plurality of manifold segments, a plurality of removable pumps, and a drive motor coupled to each pump. The manifold segments are coupled in side-by-side relation and each includes a liquid supply passage and a liquid discharge passage. Each pump includes an inlet communicating with the liquid supply passage, an outlet communicating with the liquid discharge passage and a pumping mechanism for pumping the liquid from the inlet to the outlet. The drive motor is coupled to each pump to simultaneously operate each pumping mechanism and dispense the liquid from a plurality of dispensing modules coupled with each manifold segment. The dispensing modules are recirculating modules which direct the liquid back into the corresponding manifold segment when they are in closed positions.

Abstract: A yarn of meltblown thermoplastic fibers is manufactured by meltblowing fibers onto a collector to form a thin web thereon, and continuously withdrawing and twisting the web into a generally circular yarn. In a preferred embodiment the yarn has a reinforcing cord disposed therein to lend strength thereto. The yarn is suited for many applications, including knitted and woven fabrics, and cartridge filters.

Abstract: An air handler for collecting air discharged from a melt spinning apparatus. The air handler includes an outer housing having walls defining a first interior space. One of the walls has an intake opening for receiving the discharge air. Another wall has an exhaust opening for discharging the air. The intake opening is in fluid communication with the first interior space. An inner housing is positioned within the first interior space and has walls defining a second interior space. At least one of the walls of the inner housing has an opening. The first interior space communicates with the second interior space through the opening. The second interior space is in fluid communication with the exhaust opening.

Abstract: Nonwoven laminates are made by a multi-station line comprising at least one spunbond die assembly and at least one meltblowing die assembly. Each station includes (a) a melt spinning die which can be selectively equipped with a spunbond die insert or a meltblowing die insert and (b) a moveable support structure for adjusting the proper die-to-collector distance, depending on the spunbond or meltblowing mode of operation. The multi-station line permits the selective manufacture of a variety of spunbond (S) and meltblown (M) laminates, including the S-M-S laminate.

Abstract: A die tip for use in meltblowing liquid material onto a moving substrate having a layer of entrained air moving in a common direction therewith. The die tip includes a base member having a plurality of liquid dispensing outlets for dispensing liquid material toward the substrate and a plurality of air discharge outlets for discharging air toward the liquid material dispensed from the liquid dispensing outlets. The base member includes at least one air deflecting member extending outwardly from the base member and toward the substrate. The air deflecting member is operable to deflect the moving entrained air in a direction away from the air discharge outlets of the meltblowing die tip. The air deflecting member substantially reduces the build up of dust and other debris carried in the entrained air around the air discharge outlets to maintain consistent and reliable operation of the meltblowing die tip.

Abstract: A segmented die assembly comprising a plurality of side-by-side and separate units. Each die unit includes (a) a manifold segment having an internal gear pump, (b) a die module mounted on the manifold segment, and (c) a recirculating module mounted on the manifold segment. The manifold segments are interconnected and function to deliver process air and polymer melt to the modules. Each die module includes (a) a fiberization nozzle, and (b) a valve for controlling the flow of polymer therethrough. The gear pump of each manifold segment receives a polymer melt and delivers it either to the die module (with its valve open) or to the recirculation module (with the die module valve closed). Polymer melt flowing through the die module and is discharged as a filament or filaments onto a moving substrate or collector. On the other hand, polymer flow through the recirculation module is returned to the polymer melt hopper or reservoir for recirculation through the die assembly.

Abstract: A conductor connector includes a generally tubular connector body having a non-uniform wall thickness and defining a central bore extending from a first end of the body. The connector also includes at least one groove passing along an exterior surface of the body. The groove has a pair of side edges and a base edge.

Abstract: A segmented die assembly comprises a plurality of side-by-side and separate units. Each die unit, includes a manifold segment and a die module mounted thereon. The manifold segments are interconnected and function to deliver process air and polymer melt to the modules. Each module including a nozzle through which the polymer melt is extruded forming a row of filament(s). The filaments from the array of modules are deposited on a substrate or collector. The die assembly is preferably used to apply a hot melt adhesive to a substrate, but also may be used to produce meltblown webs.

Abstract: An adhesive dispensing die module for mounting on a manifold incudes (a) a die body having formed therein polymer and air flow passages, and a valve for selectively closing the polymer flow passage and (b) a die tip or die nozzle detachably mounted on the die body. The die tip or die nozzle is secured to the die body by a pair of clamping members depending from the die body and adapted to engage die tip or die nozzle therebetween. The clamping members can selectively be moved toward one another to clampingly secure the die tip or die nozzle therebetween or moved away from one another to release the die tip or die nozzle, permitting it to be replaced without the need to remove the die module from the manifold.