Abstract: Differential basis weight nonwoven webs and a process for producing the webs is disclosed. In particular, the webs contain areas of higher basis weight and areas of lower basis weight. For instance, in one embodiment, the higher basis weight areas and the lower basis weight areas form alternating columns. The webs can be made according to a spunbond process or a meltblown process using a thermoplastic polymer or an air laid process using pulp fibers. The nonwoven webs are particularly well suited for use in diapers and other liquid absorbent products.

Abstract: High loft, low density nonwoven webs are produced by forming substantially continuous, spunbond, crimped, bicomponent fibers of A/B bilateral morphology in an unheated fiber draw unit. The fibers are then heated and cooled in the absence of impeding forces to achieve maximum crimp in the z-direction and produce a web of lofted material. The resultant material is particularly suitable for use as an insulator. Particulates may be added to the webs if desired.

Abstract: A die head assembly for producing meltblown bicomponent fibers in a meltblown apparatus includes a die tip detachably mounted to an underside of a support member. The die tip has a row of channels defined therethrough terminating at exit orifices along a bottom edge of the tip. The channels receive and combine first and second polymers conveyed from the support member. A recess is defined along the top surface of the die tip and defines an upper chamber for each of the die tip channels. A plurality of breaker plates is removably supported in the recess in a stacked configuration. An upper one of the breaker plates has receiving holes defined therein to separately receive polymers from supply passages in the support member. The remaining breaker plates have holes defined therethrough configured to divide the polymers into separately polymer streams and to direct the polymer streams into the die tip channels, the number of polymer streams corresponding to the number of holes in the lowermost breaker plate.

Abstract: A die head assembly for producing bicomponent meltblown fibers includes a die tip detachably mountable to a support member. The support member conveys first and second polymers separately to the die tip. The die tip has a row of channels defined therethrough that terminate at exit orifices or nozzles along the bottom edge of the die tip. These channels receive and combine the separate first and second polymers conveyed from the support member. An elongated recess is defined in the top surface of the die tip. The recess defines an upper chamber for each of the die tip channels. Stacked breaker plates are removably supported in the recess. The breaker plates have vertically aligned pairs of adjacent holes defined therethrough such that a pair of the aligned holes is disposed in each upper chamber of each channel. A filter screen is in the recess to separately filter the polymers.