Abstract: A method of forming a thermally bonded, nonwoven polypropylene fabric is provided and includes passing a web of thermally bondable skin-core polypropylene fibers through a calender nip under heat and pressure to produce a nonwoven fabric having elongation. The patterned calender roll is embossed with a plurality of spaced and staggered lands particularly dimensioned, configured and oriented to provide the desired bonding spot size and spacing between the bonding spots such that when utilized in the calender roll, an improved soft polypropylene fabric or cover sheet having a high elongation results.

Abstract: Process and apparatus for spinning polymer filaments permits the obtaining of skin-core filament structure by feeding a polymer composition to a spinnerette at a flow rate sufficient to obtain a spinning speed of about 10 to 200 meters per minute through the spinnerette; heating the polymer composition at a location at or adjacent to the spinnerette so as to heat the polymer composition to a sufficient temperature to obtain a skin-core filament structure upon quenching in an oxidative atmosphere; extruding the heated polymer composition through the spinnerette at a spinning speed of about 10 to 200 meters per minute to form molten filaments; and quenching the molten filaments in an oxidative atmosphere so as to effect oxidative chain scission degradation of at least a surface of the molten filaments to obtain filaments having a skin-core structure.

Abstract: Process and apparatus for the manufacture of polyolefin-containing fibers, preferably high-smectic content polyolefin-containing fibers, wherein a spin height of less than about 4 meters is utilized at spinning speeds of at least about 500 m/min. Further, guidance wings and/or an exhaust extensions are disclosed for various spinning systems to assist in the quenching of fibers. Fibers produced by the invention, preferably skin-core fiber, enable the production of nonwoven materials having excellent properties.

Abstract: Process and apparatus for spinning polymer filaments permits the obtaining of skin-core filament structure by feeding a polymer composition to a spinnerette at a flow rate sufficient to obtain a spinning speed of about 10 to 200 meters per minute through the spinnerette; heating the polymer composition at a location at or adjacent to the spinnerette so as to heat the polymer composition to a sufficient temperature to obtain a skin-core filament structure upon quenching in an oxidative atmosphere; extruding the heated polymer composition through the spinnerette at a spinning speed of about 10 to 200 meters per minute to form molten filaments; and quenching the molten filaments in an oxidative atmosphere so as to effect oxidative chain scission degradation of at least a surface of the molten filaments to obtain filaments having a skin-core structure.

Abstract: The invention is directed to a device for spinning fibers, especially bicomponent fibers having a sheath/core configuration. The device has, in a preferred embodiment, disposed in the spinneret orifices a grooved pin with an axial bore (a hollow pin). A polymer distribution assembly is provided for directing separate sheath and core compositions to the grooves and the bore, respectively, such that the sheath and core compositions are co-spun from the spinneret orifice. The device can be easily disassembled and a different pin configuration inserted to alter the geometry and/or ratio of the sheath and/or core sections of the fiber.

Abstract: Apparatus and method for crimping fiber, especially polypropylene fiber, includes feeding a tow through driven rolls into a stuffer box. Heat, in the form of steam, is applied to the tow prior to the rolls. The stuffer box includes doctor blades for cooling the tow. The doctor blades include a leading tip portion, through which compressed air is fed over the tow, and a trailing section including at least one internal compartment for a cooling fluid.