Abstract: Methods for making a nonwoven web on a collector traveling in a machine direction parallel to a length of the nonwoven web. The methods generally include forming a curtain of polymer filaments, mixing the curtain of polymer filaments with a flow of process air, depositing the curtain of polymer filaments on the collector to form the nonwoven web, and exhausting the process air through an air intake opening positioned below the collector. The method further comprises providing a substantially uniform air flow velocity across the air intake opening in a cross-machine direction perpendicular to the machine direction and adjusting an air flow velocity across the air intake opening in the machine direction to thereby define a ratio of the air flow velocity in the machine direction to the air flow velocity in the cross-machine direction.

Abstract: A stabilized filament drawing device for a meltspinning apparatus. The stabilized filament drawing device applies a high-velocity flow of air to attenuate the filaments, which are discharged from a device outlet in a discharge direction. The filament drawing device includes multiple inclined guides adjacent to the outlet that cause the high-velocity flow of air to deviate from the discharge direction by the Coanda effect. The filaments, which are entrained in the high-velocity process air, likewise deviate from the discharge direction. The guides are arranged such that spaces are absent between adjacent guides.

Abstract: A multi-layer absorbent product in a preferred embodiment includes a fibrous nonwoven top sheet, a fibrous nonwoven absorbent core layer, and a fibrous nonwoven substantially water-impervious back sheet. Each component layer or sheet is manufactured at a fiberizing station (i.e., melt spinning) and laminated together at a combining station. The preferred melt spinning apparatus is spunbond for the top sheet, meltblowing for the core layer, and a combination of spunbond and meltblowing for the bottom sheet.

Abstract: Apparatus and methods for folding a nonwoven web without mechanical contact against a folding surface. A first portion of the nonwoven web is secured to a collector by vacuum and a positive pressure differential is applied to a second portion of the moving nonwoven web. An unbalanced lifting force applied by the positive pressure differential causes the first portion to fold along a longitudinal fold line extending in a machine direction and to assume an overlapping relationship with the second portion. The vacuum assists in the folding process and maintains the overlapping relationship until the nonbonded nonwoven web is consolidated. One or more elastic strands or bands may be captured in the space defined between the overlapped first and second portions.

Abstract: A lamellar die apparatus for extruding a heated liquid into single or multiple component filaments. The apparatus includes a plurality of plates each having opposite side faces. At least two of the side faces confront each other and have a liquid passage positioned therebetween for transferring the heated liquid. At least two of the side faces confront each other and have a heating element passage therebetween. A heating element is positioned within the heating element passage for heating at least two of the plates. An extrusion die is coupled with the plurality of plates and communicates with the liquid passage for discharging the heated liquid as multiple filaments.

Abstract: A lamellar die apparatus for extruding a heated liquid into filaments and directing air at the filaments. The apparatus includes a plurality of plates each having opposite side faces. At least two of the side faces confront each other and have a liquid passage positioned therebetween for transferring the heated liquid. At least two of the side faces confront each other and have an air passage positioned therebetween for transferring the air. At least two of the side faces confront each other and have a heating element passage therebetween. A heating element is positioned within the heating element passage for heating at least two of the plates. An extrusion die is coupled with the plurality of plates and communicates with the liquid passage and the air passage for discharging the heated liquid as multiple filaments and for discharging the air at the filaments.

Abstract: Apparatus and methods for folding a nonwoven web without mechanical contact against a folding surface. A first portion of the nonwoven web is secured to a collector by vacuum and a positive pressure differential is applied to a second portion of the moving nonwoven web. An unbalanced lifting force applied by the positive pressure differential causes the first portion to fold along a longitudinal fold line extending in a machine direction and to assume an overlapping relationship with the second portion. The vacuum assists in the folding process and maintains the overlapping relationship until the nonbonded nonwoven web is consolidated. One or more elastic strands or bands may be captured in the space defined between the overlapped first and second portions.

Abstract: An apparatus for extruding multiple types of liquid materials into multi-component filaments. A pair of outer manifold elements sandwich an intermediate manifold element. Respective channels are formed between opposing sides of the outer manifold elements and the respective opposite sides of the intermediate manifold element. These recesses form channels which diverge or widen away from associated inlets at the top of the manifold assembly. A die tip is coupled to the manifold assembly at a lower side and communicates with the outlets of the channels. The die tip includes a combining member for producing a desired multi-component filament configuration.

Abstract: An air handler for collecting air discharged from a melt spinning apparatus. The air handler includes an outer housing having walls defining a first interior space. One of the walls has an intake opening for receiving the discharge air. Another wall has an exhaust opening for discharging the air. The intake opening is in fluid communication with the first interior space. An inner housing is positioned within the first interior space and has walls defining a second interior space. At least one of the walls of the inner housing has an opening. The first interior space communicates with the second interior space through the opening. The second interior space is in fluid communication with the exhaust opening.

Abstract: An apparatus for meltblowing multiple types of liquid materials into multi-component filaments. A pair of outer manifold elements sandwich an intermediate manifold element. Respective channels are formed between opposing sides of the outer manifold elements and the respective opposite sides of the intermediate manifold element. These recesses form channels which diverge or widen away from associated inlets at the top of the manifold assembly. A die tip is coupled to the manifold assembly at a lower side and communicates with the outlets of the channels. The die tip includes a combining member for producing a desired multi-component filament configuration and further includes air discharge passages for impinging the discharged multi-component filaments with pressurized air.

Abstract: Nonwoven laminates are made by a multi-station line comprising at least one spunbond die assembly and at least one meltblowing die assembly. Each station includes (a) a melt spinning die which can be selectively equipped with a spunbond die insert or a meltblowing die insert and (b) a moveable support structure for adjusting the proper die-to-collector distance, depending on the spunbond or meltblowing mode of operation. The multi-station line permits the selective manufacture of a variety of spunbond (S) and meltblown (M) laminates, including the S-M-S laminate.

Abstract: A melt spinning apparatus includes fiber producing features to produce multi-component filaments by extruding two or more single-component strands that combine after extrusion and are then attenuated by process air. The two or more liquid materials do not contact one another in the spinpack. Separation of the two types of liquid material throughout the spinpack prevents premature leakage between two liquid materials and allows for an optimized temperature for each type of liquid material for proper extrusion.

Abstract: A non-woven web formed from substantially continuous and uninterrupted multi-component filaments in which the filaments are spun at a spinning speed adequate for molecularly orienting less than all of the various constituent polymers. After collection, the non-woven web is either heated or receives a tensile force that causes each filament region formed from the polymer lacking molecular orientation to shrink in length considerably more than other filament regions formed from molecularly-oriented polymers. The differential length reduction enhances the loft of the non-woven web.

Abstract: A method of forming a plurality of substantially-continuous and uninterrupted multi-component filaments for use as a high-loft non-woven web. The multi-component filaments include at least two polymers of different melt flow rates, which imparts latent crimp in each filament. After collection, the latent crimp of the filaments is activated either thermally or by applying tension to the non-woven web.

Abstract: A system and methods for collecting and managing air discharged from a melt spinning apparatus. The air management system includes an outer housing defining a first interior space, an intake opening for receiving the discharged air into the first interior space, and an exhaust opening for discharging the air. Positioned within the first interior space is an inner housing defining a second interior space coupled in fluid communication with the exhaust opening and an opening fluidically coupling the first and second interior spaces. The air management system includes a flow control device inside the first interior space that controls the flow of air from the first interior space to the second interior space and an air-directing member outside of the first interior space near the intake opening that extends in a cross-machine direction for dividing the intake opening into two portions in a machine direction.

Abstract: Nonwoven laminates are made by a multi-station line comprising at least one spunbond die assembly and at least one meltblowing die assembly. Each station includes (a) a melt spinning die which can be selectively equipped with a spunbond die insert or a meltblowing die insert and (b) a moveable support structure for adjusting the proper die-to-collector distance, depending on the spunbond or meltblowing mode of operation. The multi-station line permits the selective manufacture of a variety of spunbond (S) and meltblown (M) laminates, including the S-M-S laminate.

Abstract: A system and methods for collecting and managing air discharged from a melt spinning apparatus. The air management system includes an outer housing defining a first interior space, an intake opening for receiving the discharged air into the first interior space, and an exhaust opening for discharging the air. Positioned within the first interior space is an inner housing defining a second interior space coupled in fluid communication with the exhaust opening and an opening fluidically coupling the first and second interior spaces. The air management system includes a flow control device inside the first interior space that controls the flow of air from the first interior space to the second interior space and an air-directing member outside of the first interior space near the intake opening that extends in a cross-machine direction for dividing the intake opening into two portions in a machine direction.

Abstract: An air handler for collecting air discharged from a melt spinning apparatus. The air handler includes an outer housing having walls defining a first interior space. One of the walls has an intake opening for receiving the discharge air. Another wall has an exhaust opening for discharging the air. The intake opening is in fluid communication with the first interior space. An inner housing is positioned within the first interior space and has walls defining a second interior space. At least one of the walls of the inner housing has an opening. The first interior space communicates with the second interior space through the opening. The second interior space is in fluid communication with the exhaust opening.

Abstract: An apparatus for meltblowing multiple types of liquid materials into multi-component filaments. A pair of outer manifold elements sandwich an intermediate manifold element. Respective channels are formed between opposing sides of the outer manifold elements and the respective opposite sides of the intermediate manifold element. These recesses form channels which diverge or widen away from associated inlets at the top of the manifold assembly. A die tip is coupled to the manifold assembly at a lower side and communicates with the outlets of the channels. The die tip includes a combining member for producing a desired multi-component filament configuration and further includes air discharge passages for impinging the discharged multi-component filaments with pressurized air.

Abstract: A segmented die assembly comprises a plurality of side-by-side and separate units. Each die unit, includes a manifold segment and a die module mounted thereon. The manifold segments are interconnected and function to deliver process air and polymer melt to the modules. Each module including a nozzle through which the polymer melt is extruded forming a row of filament(s). The filaments from the array of modules are deposited on a substrate or collector. The die assembly is preferably used to apply a hot melt adhesive to a substrate, but also may be used to produce meltblown webs.