Abstract: A spunbonding apparatus capable of producing multicomponent spunbond filaments. The spunbonding apparatus includes a spunbonding apparatus comprises a spinneret discharging multicomponent filaments and a filament-drawing device applying a first force that is effective to attenuate the filaments. A force applicator stationed between the spinneret and the filament-drawing device is operative for applying a second force to the filaments that promotes filament splitting. Splitting may occur before the filaments enter the filament-drawing device, within the filament-drawing device, and/or after discharge from the filament-drawing device.

Abstract: A stabilized filament drawing device for a meltspinning apparatus and a meltspinning apparatus including the stabilized filament drawing device. 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 filaments and high-velocity flow of air to deviate from the discharge direction. Each of the guides has a major surface that is angled relative to a common plane containing the discharge direction and a cross-machine direction of the device outlet of the filament drawing device. The guides are oriented such that the major surface is also inclined relative to the discharge direction.

Abstract: A method of making an absorbent core structure includes meltspinning at least one layer of fibrous material. At least one valley is formed separating at least two peaks in substantially parallel rows in the layer of fibrous material. A first portion of the first layer of fibrous material is folded over a second portion of the first layer of fibrous material. A least part of the first layer of fibrous material is densified.

Abstract: An absorbent core structure having at least one acquisition region, at least one distribution region, at least one storage region. The acquisition region being constructed from a fibrous material. The acquisition region having a relatively low density from about 0.018 g/cc to about 0.20 g/cc. The at least one distribution region being constructed from the fibrous material. The distribution region being consolidated to have a relatively medium density from about 0.024 g/cc to about 0.45 g/cc. The distribution region being in fluid communication with said acquisition region. The storage region being constructed from the fibrous material. The storage region being consolidated to have a relatively high density from about 0.030 g/cc to about 0.50 g/cc. The storage region being in fluid communication with the distribution region. The fibrous material may be folded to form said absorbent core structure. The fibrous material may be rolled to form the absorbent core structure.

Abstract: A method of making an absorbent core structure includes meltspinning at least one layer of fibrous material. A first amount of superabsorbent material is deposited on the layer of fibrous material. A first portion of the layer of fibrous material is folded over the first amount of superabsorbent material. A second amount of superabsorbent material is deposited on the layer of fibrous material. A second portion of the layer of fibrous material is folded over the second amount of superabsorbent material. Additional embodiments involve rolling the fibrous material and/or densifying one of the layers relative to the other.

Abstract: An absorbent core structure having at least one acquisition region, at least one distribution region, and at least one storage region. The acquisition region being constructed from a fibrous material. The acquisition region having a relatively low density from about 0.018 g/cc to about 0.20 g/cc. The distribution region being constructed from said fibrous material. The distribution region being consolidated to have a relatively medium density from about 0.024 g/cc to about 0.45 g/cc. The distribution region being in fluid communication with said acquisition region. The storage region being constructed from said fibrous material. The storage region being consolidated to have a relatively high density from about 0.030 g/cc to about 0.50 g/cc. The storage region being in fluid communication with said distribution region. A portion of the fibrous material being formed into at least one peak and at least one valley and then subsequently folded in order to form said absorbent core structure.

Abstract: A method of making an absorbent core structure includes meltspinning at least a first layer of fibrous material having a plurality of first portions and a plurality of second portions. A superabsorbent material is deposited between the respective first and second portions of the first layer. The first portions of the first layer are moved with respect to the second portions of the first layer so as to at least substantially encapsulate the deposited superabsorbent material between the respective first and second portions.

Abstract: A stabilized filament drawing device for a meltspinning apparatus and a meltspinning apparatus including the stabilized filament drawing device. 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 filaments and high-velocity flow of air to deviate from the discharge direction. Each of the guides has a major surface that is angled relative to a common plane containing the discharge direction and a cross-machine direction of the device outlet of the filament drawing device. The guides are oriented such that the major surface is also inclined relative to the discharge direction.

Abstract: A melt spinning apparatus including a spinpack with a die tip block having a recess with a converging portion, such as an angled trough, which terminates in a row of filament discharge outlets. The recess selectively receives a configuration insert, such as a side-by-side insert or a sheath-core insert, that separates the converging portion of the recess into two sheets of liquid that combine at the filament discharge outlets. The spinpack may be configured by inserting either of the inserts to produce filaments having different cross sectional configurations of two different materials. Separation of the two liquids prevents premature interaction between the two liquid flows which minimizes instabilities between the liquid flow interface. The minimization of these instabilities can result in less formation of shot and improve other significant finished product properties. In addition, each type of liquid material may be maintained at an optimum temperature for proper extrusion.

Abstract: Methods, apparatus and disposable hygienic absorbent products involving melt processing a synthetic resin or resins, such as a thermoplastic, in an in-line process. The melt processing operations can be melt spinning processes such as spunbonding and/or meltblowing the resin(s). One or more through air bonders are used in the process to provide bonding between fibers or filaments while retaining the liquid management properties of the fibers or filaments in the disposable hygienic absorbent product. Other melt processing operations, such as film extrusion, may also be used to form one or more layers in the disposable hygienic absorbent product.

Abstract: Methods, apparatus and disposable hygienic absorbent products involving mesh processing a synthetic resin or resins, such as a thermoplastic, in an in-line process. The mesh processing operations can be melt spinning processes such as spunbonding and/or meltblowing the resin(s). One or more through air bonders are used in the process to provide bonding between fibers or filaments while retaining the liquid management properties of the fibers or filaments in the disposable hygienic absorbent product. Other melt processing operations, such as film extrusion, may also be used to form one or more layers in the disposable hygienic absorbent product.

Abstract: A meltspinning apparatus that provides for uniform distribution of a flow of a melt-processable thermoplastic polymer in a machine direction of the meltspinning apparatus. The meltspinning apparatus includes a spin pack having a plurality of side-by-side coathanger-shaped distribution chambers. Each of the distribution chambers uniformly distributes the polymer flow in the machine direction so that the molten polymer has a substantially uniform residence time in the chamber during distribution.

Abstract: A melt spinning apparatus including a spinpack with a die tip block having a recess with a converging portion, such as an angled trough, which terminates in a row of filament discharge outlets. The recess selectively receives a configuration insert, such as a side-by-side insert or a sheath-core insert, that separates the converging portion of the recess into two sheets of liquid that combine at the filament discharge outlets. The spinpack may be configured by inserting either of the inserts to produce filaments having different cross sectional configurations of two different materials. Separation of the two liquids prevents premature interaction between the two liquid flows which minimizes instabilities between the liquid flow interface. The minimization of these instabilities can result in less formation of shot and improve other significant finished product properties. In addition, each type of liquid material may be maintained at an optimum temperature for proper extrusion.

Abstract: A melt spinning apparatus including a spinpack with a die tip block having a recess with a converging portion, such as an angled trough, which terminates in a row of filament discharge outlets. The recess selectively receives a configuration insert, such as a side-by-side insert or a sheath-core insert, that separates the converging portion of the recess into two sheets of liquid that combine at the filament discharge outlets. The spinpack may be configured by inserting either of the inserts to produce filaments having different cross sectional configurations of two different materials. Separation of the two liquids prevents premature interaction between the two liquid flows which minimizes instabilities between the liquid flow interface. The minimization of these instabilities can result in less formation of shot and improve other significant finished product properties. In addition, each type of liquid material may be maintained at an optimum temperature for proper extrusion.

Abstract: A melt spinning apparatus including a spinpack with a die tip block having a recess with a converging portion, such as an angled trough, which terminates in a row of filament discharge outlets. The recess selectively receives a configuration insert, such as a side-by-side insert or a sheath-core insert, that separates the converging portion of the recess into two sheets of liquid that combine at the filament discharge outlets. The spinpack may be configured by inserting either of the inserts to produce filaments having different cross sectional configurations of two different materials. Separation of the two liquids prevents premature interaction between the two liquid flows which minimizes instabilities between the liquid flow interface. The minimization of these instabilities can result in less formation of shot and improve other significant finished product properties. In addition, each type of liquid material may be maintained at an optimum temperature for proper extrusion.