Abstract: There is disclosed a melt-blowing die head having a die tip which, instead of a number of individual orifices, has a single continuous slot opening running its length. In addition the die tip is reinforced by means of aerodynamically shaped bosses in the fluid delivery channels which bear between the air plate and the exterior surface of the die tip. The die tip may also have reservoirs at either end in which debris may be collected when the slot is cleaned while the die head is in place on a melt-blowing machine.

Abstract: An improved method and apparatus for forming nonwoven webs by spinning filaments into a quench chamber where they are contacted with a quenching fluid, then utilizing the quench fluid to draw the filaments through a two-dimensional nozzle spanning the full machine width, and collecting the filaments as a web on a porous surface. In contrast with the prior art, low motive fluid pressures can be used, and a non-eductive drawing means utilized to minimize air turbulence and the resulting filament entanglement in the drawing means while maintaining substantially constant cross machine filament distribution. The apparatus and process reduce problems relating to filament breakage and spreading and result in increased productivity and improved web formation. Other advantages include the ability to continuously spin highly pigmented polymer filaments and reduced hazards associates with high noise levels.

Abstract: A method therefor for forming an air-laid web of dry fibers suitable for use in a wide variety of products ranging from bath and facial tissues to towels having basis weights on the order of 13 lbs./2880 ft..sup.2 to 50 lbs./2880 ft..sup.2 on a high-speed production basis, wherein the web is characterized by random array of individualized fibers substantially undamaged by mechanical action and having a controlled cross-directional profile, and by its freedom from nits, pills, rice and the like, thereby improving both the appearance and the tensile strength of the web. The full-width feeding of dry fibers to a 2-dimensional flow control and fiber screening system is described wherein substantially no cross-flow forces are created in the system, ensuring a uniform cross-directional basis weight profile.

Abstract: An improved method and apparatus for forming nonwoven webs by spinning filaments into a quench chamber where they are contacted with a quenching fluid, then utilizing the quench fluid to draw the filaments through a two-dimensional nozzle spanning the full machine width, and collecting the filaments as a web on a porous surface. In contrast with the prior art, low motive fluid pressures can be used, and a non-eductive drawing means utilized to minimize air turbulence and the resulting filament entanglement in the drawing means while maintaining substantially constant cross machine filament distribution. The apparatus and process reduce problems relating to filament breakage and spreading and result in increased productivity and improved web formation. Other advantages include the ability to continuously spin highly pigmented polymer filaments and reduced hazards associated with high noise levels.

Abstract: A heated roll member especially adapted to provide a uniform temperature surface for embossing or calendering low basis weight cellulose or polymeric webs. The roll member comprises outer and inner shells with an annular chamber therebetween and apertures in the inner shell which introduce fluid into or remove fluid from the annular chamber. Specially constructed apertures, each provided with a flow diverting means, produce fully turbulent flow in a heated fluid moving axially within the annular chamber. A controlled level of turbulence in the fluid is initiated at the aperture and is maintained throughout the annular chamber, such that "hot" or "cold" areas do not develop on the surface of the outer shell.

Abstract: An extrusion die for thermoplastic polymer is disclosed having a distributor which provides substantially constant residence time and pressure loss of polymer flowing through the die from the inlet to the extrusion aperture. Dies are disclosed for extrusion of sheet, film and discontinuous microfibers. The distributor has cross flow channels for conveying the polymer laterally and axially connected pressure loss and residence time control sections for independently compensating for the varying pressure loss and residence time characteristics of the polymer flow through the distribution channels. With a distributor so constructed, the overall height of the die remains substantially the same as the die width increases so that the distributor is particularly suitable for dies for wide extrusion lines.