Abstract: Melt blown or spun bond nonwoven webs are formed by flowing fiber-forming material through a die cavity having a substantially uniform residence time and then through a plurality of orifices to form filaments, using air or other fluid to attenuate the filaments into fibers and collecting the attenuated fibers as a nonwoven web. Each die orifice receives a fiber-forming material stream having a similar thermal history. The physical or chemical properties of the nonwoven web fibers such as their average molecular weight and polydispersity can be made more uniform. Wide nonwoven webs can be formed by arranging a plurality of such die cavities in a side-by-side relationship. Thicker or multilayered nonwoven webs can be formed by arranging a plurality of such die cavities atop one another.

Abstract: Polymeric fibers along with methods and systems for extruding polymeric fibers are disclosed. The extrusion process preferably involves the delivery of a lubricant separately from a polymer melt stream to each orifice of an extrusion die such that the lubricant preferably encases the polymer melt stream as it passes through the die orifice.

Abstract: Multi-component liquid spray system including a shim having a first array of first passages and a second array of second passages are described. When the shim is positioned between the first and second die portions of a housing, a first array of first liquid conduits and a second array of second liquid conduits are formed. The first array of first liquid conduits and second array of second liquid conduits are aligned such that at least one of the second liquid conduits is interspersed between successive first liquid conduits. Methods of making such spray systems and methods of using them to produce both multi-component sprays and coated articles are also described.

Abstract: Methods of applying multi-component liquid sprays are described. The methods include using the first array of first component spray orifices to produce a first spray of the first liquid; using the second array of second component spray orifices to produce a second spray of the second liquid; and mixing at least a portion of the first spray and at least a portion of second spray.

Abstract: Multi-component liquid spray systems having a first array of first component spray nozzles and a second array of second component spray nozzles are provided. Each of the first component spray nozzles is adjacent at least one of the second component spray nozzles. Spray systems having co-aligned and parallel-aligned linear arrays of nozzles are described. Methods of making such spray systems and methods of using them to produce both multi-component sprays and coated articles are also described.

Abstract: The invention relates to a method of making retroreflective sheeting and other articles prepared from casting a fluid synthetic resin onto a tool having a microstructured surface with a slot die apparatus. The invention further relates to a slot die apparatus.

Abstract: Methods and systems for extruding polymeric fibers are disclosed. The extrusion process preferably involves the delivery of a lubricant separately from a polymer melt stream to each orifice of an extrusion die such that the lubricant preferably encases the polymer melt stream as it passes through the die orifice.

Abstract: Melt blown or spun bond nonwoven webs are formed by flowing fiber-forming material through a die cavity having a substantially uniform residence time and then through a plurality of orifices to form filaments, using air or other fluid to attenuate the filaments into fibers and collecting the attenuated fibers as a nonwoven web. Each die orifice receives a fiber-forming material stream having a similar thermal history. The physical or chemical properties of the nonwoven web fibers such as their average molecular weight and polydispersity can be made more uniform. Wide nonwoven webs can be formed by arranging a plurality of such die cavities in a side-by-side relationship. Thicker or multilayered nonwoven webs can be formed by arranging a plurality of such die cavities atop one another.