Abstract: The invention provides a method for controlling the width of a plurality of extruded filaments comprising providing a polymer supply and an extrusion die comprising a plurality of extrusion capillaries and a plurality of counterbores allowing fluid communication between the extrusion capillaries and polymer supply, providing an adjustable insert for interrupting fluid communication between the polymer supply and at least one extrusion capillary, providing at least one fluidized polymer, conveying the polymer through the polymer supply, counterbores and extrusion capillaries to extrude a plurality of filaments, and interrupting the fluid communication between the polymer supply and at least one extrusion capillary by adjusting the insert.

Abstract: An apparatus for forming meltblown material from a molten polymer includes a die configured with channels in the tip of the die through which molten polymer is extruded for forming meltblown fibers. Air plates are disposed relative to the die tip to define air channels proximate to the die tip for directing attenuating air against the molten polymer fibers extruded from the tip. The air channels include a zone of convergence adjacent the apex of the die tip at an included angle that is within a range of about 10 degrees to about 20 degrees such that each of the air channels defines a convergence angle with respect to a longitudinal axis of the polymer channels of between about 5 degrees to about 10 degrees.

Abstract: Disclosed is an apparatus for producing nonwoven fibrous webs. The apparatus comprises an extrusion die, first and second fluid supplies in cooperation with the die, first and second extrusion capillaries, first counterbores allowing fluid communication between first capillaries and first supply and second counterbores allowing fluid communication between second capillaries and second supply, each first counterbore having at least two first capillaries extending therefrom.

Abstract: In the invention, a method is provided for producing a composite nonwoven fabric. A polymer is extruded into heated continuous filaments, possibly elastic, from the die head to a first chilled roller, wherein the extruder is configured to provide the continuous filaments to the chilled roller in a canted direction that is at a tangent or angle to the surface of the first chilled roller. The filaments are conveyed in a downward direction by way of chilled rollers to a nip. In a next step, the nonwoven web is sprayed with an adhesive and is laminated on the continuous filaments in the nip to form a composite nonwoven fabric. The continuous filaments move vertically downward approximately in line with the lamination process, facilitating automatic re-threading of filaments when they are broken or interrupted in their travel downward onto the chilled rolls.

Abstract: A support for a web forming machine which allows for vertical adjustment of a web forming belt with respect to at least one die head positioned above the web forming belt, and allows for tilting of the web forming belt. The support allows linear motion along a y-axis defined by a length of a guide shaft while preventing linear motion along a x-axis and a z-axis, e.g. the two axes perpendicular to the y-axis. Further, the support allows rotational or axial motion about the x-axis perpendicular to the y-axis but prevents rotational or axial motion about the y-axis and the z-axis.

Abstract: Robust round homofilament fibers are meltspun from a spinneret having two conjoined capillaries of different length to diameter ratio to induce differential shear to produce fiber crimping. Crimping may further be aided by quenching of the fibers.

Abstract: A extruded filament die tip, such as meltblown filaments, has a plurality of bores communicating with the main polymer distribution channel. The bores have a plurality of capillary openings, or spinnerettes, drilled into the bore to act as extrusion orifices for the die tip. The present die tip differs from conventional die tips in which capillaries are drilled into a deep slot formed in the die tip for polymer distribution. The invention allows more material to remain in the body of the die tip while facilitating more spinnerette openings per linear inch in the die tip and permitting higher operating pressures and smaller diameter fibers such as between 1 and 4 microns. A resultant nonwoven fabric made with the die tip will have a higher hydrohead resistance due to the increased number of fine filaments per inch for the same osy of fabric.

Abstract: In the invention, a method is provided for producing a composite nonwoven fabric. A polymer is extruded into heated continuous filaments, possibly elastic, from the die head to a first chilled roller, wherein the extruder is configured to provide the continuous filaments to the chilled roller in a canted direction that is at a tangent or angle to the surface of the first chilled roller. The filaments are conveyed in a downward direction by way of chilled rollers to a nip. In a next step, the nonwoven web is sprayed with an adhesive and is laminated on the continuous filaments in the nip to form a composite nonwoven fabric. The continuous filaments move vertically downward approximately in line with the lamination process, facilitating automatic re-threading of filaments when they are broken or interrupted in their travel downward onto the chilled rolls.

Abstract: Robust round homofilament fibers are meltspun from a spinneret having two conjoined capillaries of different length to diameter ratio to induce differential shear to produce fiber crimping. Crimping may further be aided by quenching of the fibers.

Abstract: A support for a web forming machine which allows for vertical adjustment of a web forming belt with respect to at least one die head positioned above the web forming belt, and allows for tilting of the web forming belt. The support allows linear motion along a y-axis defined by a length of a guide shaft while preventing linear motion along a x-axis and a z-axis, e.g. the two axes perpendicular to the y-axis. Further, the support allows rotational or axial motion about the x-axis perpendicular to the y-axis but prevents rotational or axial motion about the y-axis and the z-axis.