Abstract: An apparatus for stabilizing a low-strength sheet having a width and a top surface and moving in a first direction at a rate sufficient to entrain air. The apparatus includes an airfoil adapted to extend along the top surface of the sheet. The airfoil, in turn, includes:a bottom surface adapted to extend along a portion of the top surface of the sheet;a first surface extending a first distance from the bottom surface at a first juncture;a second surface extending a second distance from the bottom surface at a second juncture; anda top surface extending from the first surface at a third juncture to the second surface at a fourth juncture. The first distance in general is less than the second distance.

Abstract: An apparatus and method for increasing the heating efficiency of a nonwoven web using heated air are provided. A flow modifier including a turbulence inducing bar arrangement is positioned between the heated air supply and the nonwoven web. The flow modifier increases the turbulence of the heated air before it contacts the nonwoven web, resulting in more thorough penetration of the web by the air, and better convective heat transfer between the heated air and the nonwoven web.

Abstract: A method of stabilizing a low strength sheet which involves passing the sheet under an apparatus having a width and a top surface and moving in a first direction at a rate sufficient to entrain air. The apparatus includes an airfoil adapted to extend along the top surface of the sheet. The airfoil, in turn, includes:a bottom surface adapted to extend along a portion of the top surface of the sheet;a first surface extending a first distance from the bottom surface at a first juncture;a second surface extending a second distance from the bottom surface at a second juncture; anda top surface extending from the first surface at a third juncture to the second surface at a fourth juncture. The first distance in general is less than the second distance.

Abstract: An apparatus for stabilizing a low-strength sheet having a width and a top surface and moving in a first direction at a rate sufficient to entrain air. The apparatus includes an airfoil adapted to extend along the top surface of the sheet. The airfoil, in turn, includes:a bottom surface adapted to extend along a portion of the top surface of the sheet;a first surface extending a first distance from the bottom surface at a first juncture;a second surface extending a second distance from the bottom surface at a second juncture; anda top surface extending from the first surface at a third juncture to the second surface at a fourth juncture. The first distance in general is less than the second distance.

Abstract: A method of forming substantially continuous filaments which involves the steps of (1) extending a molten thermoplastic polymer through a die having a plurality of orifices to give a plurality of substantially continuous filaments; (2) quenching the filaments by contacting them with a quenching fluid having a temperature less than that of the filaments and a zero to high imposed velocity which, if other than zero, has a component which is in a direction other than parallel with the movement of filaments; (3) entraining and drawing the filaments in a nozzle with an attenuating liquid having a linear speed of at least about 400 feet/minute; and (4) collecting the drawn filaments. The filaments have an average diameter in the range of from about 5 to about 75 micrometers and a high variability of filament diameter from filament to filament and along the length of any given filament. In addition, at least some of such filaments are present as filament bundles.

Abstract: A fluid-operated stabilizing apparatus receives an article having loose, wrinkled overlapping surfaces and by use of fluid flow control devices directs flows of fluid to the overlapping surfaces to fluidly shake the surfaces to smooth out wrinkles and any folded portions thereof, and then to align and hold the surfaces for subsequent treatment, such as bonding together. A method is also provided for smoothing and aligning the overlapping surfaces for subsequent treatment.

Abstract: A thermoplastic material extrusion mechanism is provided which includes a die head having a centrally disposed high velocity gas delivery means adapted to continuously emit a jet of a gas having shear layers, at least one chamber for the thermoplastic material, thermoplastic material delivery means arranged at least partially surrounding the centrally disposed high velocity gas delivery means for directing extruded thermoplastic material emitted from the thermoplastic material delivery means toward the gas jet, causing the extruded thermoplastic material to be introduced into the shear layers of the gas jet, and a thermoplastic material conduit which communicates the at least one chamber with each of the thermoplastic material extrusion openings.

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: The present invention provides an improved apparatus and method for forming a fibrous web. In accordance with the invention, a distributor housing delimits a fiberizing zone, and a delivery mechanism supplies a fiberizable material into the fiberizing zone. A moveable striking mechanism located in the fiberizing zone contacts the fiberizable material to initially separate the material into individual fibers. A discharging mechanism exits the fibers from the fiberizing zone into a web forming zone and toward a foraminous web forming layer. A gas delivering mechanism forces a stream of gas into the fiberizing zone to entrain the fibers therein and to eject a moving stream of the gas and fibers through the discharging mechanism into the web forming zone. The gas-fiber stream moves at a velocity sufficient to draw an induced supplementary gas flow past the discharging mechanism and toward the foraminous forming layer.

Abstract: Improvement to the die and method of forming meltblown fibers and webs using a relatively cool fluid for meltblowing. Thermoplastic polymers such as polyolefins, polyamides, polyesters and the like are spun in accordance with the meltblowing process and contacted by a fluid which forms fibers and attenuates them. In accordance with the invention, the fluid is substantially cooler than the molten polymer and permits formation of webs at shorter forming distances greatly improving web formation. In addition, the costs of manufacture are improved since heating of the attenuating fluid may be reduced or avoided. In a particularly preferred embodiment, the die is provided with insulation between the attenuating fluid and the polymer chamber to avoid or reduce the tendency of the molten polymer to cool and cause plugging of the die. Alternatively, the die may, itself, be formed from an insulating material.