Abstract: This disclosure describes meltblown methods, assemblies, and systems for polymer production. In one such implementation, a meltblown system provides improved uniform output and reduction of fiber size given certain polymer material and production rate. In certain meltblown implementations, the equipment may be ready and quickly swapped while provided in hot standby mode such that the maintenance down time is minimized. The disclosed meltblown equipment may include a polymer beam and air chamber and a die tip assembly. The die tip assembly, in certain embodiments, may quickly be attached onto or removed from the polymer beam and air chamber. In preferred embodiments, the meltblown system includes a single input (e.g., a specific type of polymer material). The meltblown system includes some tapered structures that facilitate polymer flow. The assembly mechanisms used in the meltblown system enables cleaning of the polymer distribution components with each use.

Abstract: This disclosure describes meltblown methods, assemblies, and systems for polymer production. In one such implementation, a meltblown system provides improved uniform output and reduction of fiber size given certain polymer material and production rate. In certain meltblown implementations, the equipment may be ready and quickly swapped while provided in hot standby mode such that the maintenance down time is minimized. The disclosed meltblown equipment may include a polymer beam and air chamber and a die tip assembly. The die tip assembly, in certain embodiments, may quickly be attached onto or removed from the polymer beam and air chamber. In preferred embodiments, the meltblown system includes a single input (e.g., a specific type of polymer material). The meltblown system includes some tapered structures that facilitate polymer flow. The assembly mechanisms used in the meltblown system enables cleaning of the polymer distribution components with each use.

Abstract: This disclosure describes meltblown methods, assemblies, and systems for polymer production. In one such implementation, a meltblown system provides improved uniform output and reduction of fiber size given certain polymer material and production rate. In certain meltblown implementations, the equipment may be ready and quickly swapped while provided in hot standby mode such that the maintenance down time is minimized. The disclosed meltblown equipment may include a polymer beam and air chamber and a die tip assembly. The die tip assembly, in certain embodiments, may quickly be attached onto or removed from the polymer beam and air chamber. In preferred embodiments, the meltblown system includes a single input (e.g., a specific type of polymer material). The meltblown system includes some tapered structures that facilitate polymer flow. The assembly mechanisms used in the meltblown system enables cleaning of the polymer distribution components with each use.

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: High loft, low density nonwoven webs suitable for use in a variety of applications requiring strong fabric layers are produced by forming substantially continuous, spunbond, crimped, bicomponent fibers of crimpable, e.g., side by side or eccentric sheath/core (A/B) configuration which are unheated prior to collection. 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 of greater uniformity than attained with comparable material whose fibers are drawn by a heated process. The resultant nonwoven material can then be pattern bonded or laminated for additional strength without interfering with the desired loft of the low density nonwoven. The additionally strengthened nonwoven may then be further processed such as by lamination or the like to further increase its utility.

Abstract: The present invention provides a series of plates for distributing a molten polymer composition, the series of plates includes at least two plates: a first plate that includes an upper surface, a lower surface, and a plurality of polymer distribution channels connecting the upper surface and the lower surface.

Abstract: A lofty, nonwoven material having a nonwoven web having a plurality of substantially continuous fibers oriented in a z-direction of the nonwoven web and a method for producing the lofty, nonwoven material from as-formed z-direction fibers. The method is fast, having no mechanical manipulation of the fibers to slow it down, easily adjustable and allows for in-line processing. The material can be varied from preponderantly open to preponderantly closed in its web structure.

Abstract: A method for producing a material having z-direction waves in which a layer of continuous fibers is conveyed on a first moving surface into a nip formed by the first moving surface and a second moving surface which is traveling at a slower speed than the first moving surface, resulting in formation of a plurality of z-direction loops in the fibers giving loft to the material and a wave pattern producing ridges on both major surfaces of the resultant nonwoven web. The method permits easy real time alignment of manufacturing parameters to produce a variety of materials. The method further produces lofty nonwovens at a commercially viable rate.

Abstract: Robust homofilament fibers are meltspun from a differently shaped dual capillary spinneret design to induce differential fiber morphology to produce crimping. Crimping may further be aided by quenching and drawing of the fibers.

Abstract: High loft, low density nonwoven webs suitable for use in a variety of applications requiring strong fabric layers are produced by forming substantially continuous, spunbond, crimped, bicomponent fibers of crimpable, e.g., side by side or eccentric sheath/core (A/B) configuration which are unheated prior to collection. 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 of greater uniformity than attained with comparable material whose fibers are drawn by a heated process. The resultant nonwoven material can then be pattern bonded or laminated for additional strength without interfering with the desired loft of the low density nonwoven. The additionally strengthened nonwoven may then be further processed such as by lamination or the like to further increase its utility.

Abstract: High loft, low density nonwoven webs of increased uniformity are produced by forming substantially continuous, spunbond, crimped, bicomponent fibers of A/B side by side 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: The present invention provides a series of plates for distributing a molten polymer composition, the series of plates includes at least two plates: a first plate that includes an upper surface, a lower surface, and a plurality of polymer distribution channels connecting the upper surface and the lower surface.

Abstract: A lofty, nonwoven material having a nonwoven web having a plurality of substantially continuous fibers oriented in a z-direction of the nonwoven web and a method for producing the lofty, nonwoven material from as-formed z-direction fibers. The method is fast, having no mechanical manipulation of the fibers to slow it down, easily adjustable and allows for in-line processing. The material can be varied from preponderantly open to preponderantly closed in its web structure.

Abstract: A process of making a nonwoven fabric comprising providing a three-dimensional surface that comprises surface features that are air permeable, depositing fibers or a web comprising fibers onto the surface, and stabilizing the fibers to form a nonwoven fabric is provided.

Abstract: A three-dimensional nonwoven web having a regional, bulk density of less than 0.04 grams per cubic centimeter, a top-side base surface that defines an x,y-plane and at least one macroscopic surface feature extending out of the x,y-plane wherein a macroscopic surface feature is characterized as a feature having an apex that extends at least about 1 millimeter above the x,y-plane of the top-side base surface is provided. The macroscopic feature maintains a height of at least 1 millimeter above the x,y-plane of the top-side base surface under a 1.2 kPa load (Pf) and results in contact of an object resting on the macroscopic feature such that the percent contact area of the nonwoven web with an article resting on the macroscopic surface feature at a 1.2 kPa load (Pf) is less than 50 percent of the bulk area of the nonwoven web supporting the article.

Abstract: A method for producing a material having z-direction ridges or folds in which a layer of continuous fibers is conveyed on a first moving surface into a nip formed by the first moving surface and a second moving surface which is traveling at a slower speed than the first moving surface, resulting in formation of a plurality of z-direction loops in the fibers giving loft to the material and a wave pattern producing ridges on both major surfaces of the resultant nonwoven web. The method permits easy real time adjustment of manufacturing parameters to produce a variety of materials. The method further produces lofty nonwovens at a commercially viable rate.

Abstract: A lofty, nonwoven material having a nonwoven web having a plurality of substantially continuous fibers oriented in a z-direction of the nonwoven web and a method for producing the lofty, nonwoven material from as-formed z-direction fibers. The method is fast, having no mechanical manipulation of the fibers to slow it down, easily adjustable and allows for in-line processing. The material can be varied from preponderantly open to preponderantly closed in its web structure.

Abstract: High loft, low density nonwoven webs are produced by forming substantially continuous, spunbond, crimped, bicomponent fibers of A/B side by side 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: There is provided a nonwoven fabric for use in personal care absorbent articles where the fabric is made from single polymer, helically crimped fibers. Such a fabric provides economical production since it uses only one polymer. These fabrics have superior void volume and resilience and are useful in a number of applications, including as outercovers, liners, surge layers and even as an absorbent core.

Abstract: Robust homofilament fibers are meltspun from a differently shaped dual capillary spinneret design to induce differential fiber morphology to produce crimping. Crimping may further be aided by quenching and drawing of the fibers.