Abstract: Melt blown or spun bond nonwoven webs are formed by flowing fiber-forming material through a die cavity having a substantially uniform residence time and then through a plurality of orifices to form filaments, using air or other fluid to attenuate the filaments into fibers and collecting the attenuated fibers as a nonwoven web. Each die orifice receives a fiber-forming material stream having a similar thermal history. The physical or chemical properties of the nonwoven web fibers such as their average molecular weight and polydispersity can be made more uniform. Wide nonwoven webs can be formed by arranging a plurality of such die cavities in a side-by-side relationship. Thicker or multilayered nonwoven webs can be formed by arranging a plurality of such die cavities atop one another.

Abstract: Polymeric fibers along with methods and systems for extruding polymeric fibers are disclosed. The extrusion process preferably involves the delivery of a lubricant separately from a polymer melt stream to each orifice of an extrusion die such that the lubricant preferably encases the polymer melt stream as it passes through the die orifice.

Abstract: Multi-component liquid spray systems having a first array of first component spray nozzles and a second array of second component spray nozzles are provided. Each of the first component spray nozzles is adjacent at least one of the second component spray nozzles. Spray systems having co-aligned and parallel-aligned linear arrays of nozzles are described. Methods of making such spray systems and methods of using them to produce both multi-component sprays and coated articles are also described.

Abstract: Multi-component liquid spray system including a shim having a first array of first passages and a second array of second passages are described. When the shim is positioned between the first and second die portions of a housing, a first array of first liquid conduits and a second array of second liquid conduits are formed. The first array of first liquid conduits and second array of second liquid conduits are aligned such that at least one of the second liquid conduits is interspersed between successive first liquid conduits. Methods of making such spray systems and methods of using them to produce both multi-component sprays and coated articles are also described.

Abstract: Methods of applying multi-component liquid sprays are described. The methods include using the first array of first component spray orifices to produce a first spray of the first liquid; using the second array of second component spray orifices to produce a second spray of the second liquid; and mixing at least a portion of the first spray and at least a portion of second spray.

Abstract: Manifolds are designed to deliver fluid through multiple orifices of the manifold such that for a given inlet fluid pressure the fluid being output from the multiple orifices has a desired mass flow profile. The desired mass flow profile includes a desired mass flow rate and a desired direction and distribution of flow in three-dimensional space. The manifold is first modeled as a two-dimensional representation to determine manifold parameters necessary to achieve the desired mass flow profile within the two dimensions. Then, the manifold is modeled as a three-dimensional representation based on the parameters previously determined for the two-dimensional representation to determine manifold parameters of the third dimension that are necessary to achieve the desired mass flow profile within the three dimensions.

Abstract: Methods and apparatus for meltblowing utilize an auxiliary manifold to dispense a fluid between an orifice of a die that is expelling polymeric fibers and an exit of a duct that is dispensing a secondary flow of gas onto the fibers. The fluid dispensed from the auxiliary manifold reduces a recirculation zone of the secondary flow between the exit and the orifice that, absent the fluid from the manifold, results in errant fibers that are blown back into the face of the die by the recirculating secondary flow.

Abstract: A polarizer is formed with an arrangement of polymer fibers substantially parallel within a polymer matrix. The polymer fibers are formed of at least first and second polymer materials. At least one of the polymer matrix and the first and second polymer materials is birefringent, and provides a birefringent interface with the adjacent material. Light is reflected and/or scattered at the birefringent interfaces with sensitivity to the polarization of the light. In some embodiments, the polymer fibers are formed as composite fibers, having a plurality of scattering polymer fibers disposed within a filler to form the composite fiber. In other embodiments, the polymer fiber is a multilayered polymer fiber. The polymer fibers may be arranged within the polymer matrix as part of a fiber weave.

Abstract: A composite polymer fiber comprises a polymer filler material and a plurality of polymer scattering fibers disposed within the filler material. At least one of the filler material and the scattering fibers is formed of a birefringent material. The refractive indices of the filler material and the scattering fibers can be substantially matched for light incident in a first polarization state on the composite polymer fiber and unmatched for light incident in an orthogonal polarization state. The scattering fibers may be arranged to form a photonic crystal within the composite fiber. The composite fibers may be extruded and may be formed into a yarn, a weave or the like. If the filler material is soluble, it may be washed out of the yarn or weave, and the scattering fibers may then be infiltrated with a resin that is subsequently cured.

Abstract: The invention relates to a method of making retroreflective sheeting and other articles prepared from casting a fluid synthetic resin onto a tool having a microstructured surface with a slot die apparatus. The invention further relates to a slot die apparatus.

Abstract: Methods and systems for extruding polymeric fibers are disclosed. The extrusion process preferably involves the delivery of a lubricant separately from a polymer melt stream to each orifice of an extrusion die such that the lubricant preferably encases the polymer melt stream as it passes through the die orifice.

Abstract: Melt blown or spun bond nonwoven webs are formed by flowing fiber-forming material through a die cavity having a substantially uniform residence time and then through a plurality of orifices to form filaments, using air or other fluid to attenuate the filaments into fibers and collecting the attenuated fibers as a nonwoven web. Each die orifice receives a fiber-forming material stream having a similar thermal history. The physical or chemical properties of the nonwoven web fibers such as their average molecular weight and polydispersity can be made more uniform. Wide nonwoven webs can be formed by arranging a plurality of such die cavities in a side-by-side relationship. Thicker or multilayered nonwoven webs can be formed by arranging a plurality of such die cavities atop one another.