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 relates to a die body consisting of a multiplicity of modular die plates, which are easily and rapidly interchangeable. The modular die plates can be configured to extrude different shapes and types of fibers. The apparatus may also be configured to extrude multiple types of materials each from a plurality of separate ports or from a plurality of common ports. The apparatus may also be designed to include single or multiple ports to direct air or other fluids to draw or attenuate the extrudate into fibers of a desired diameter. The extrudate may be treated with the air or various other gases or fluids within the die or exterior to the die tips.