Abstract: A lofted mat of filaments is produced from process and apparatus including: supplying a plurality of streams of molten polymeric material; attenuating said streams of material into continous filaments through the action of a stream of fluid moving from an attenuation means; said filaments being entrained in said fluid moving from said attenuation means, said filaments having non-uniform residual stresses established therein; moving said stream of fluid and filaments along a first surface positioned intermediate said attenuation means and a foraminous surface; establishing a vacuum at said foraminous surface; directing said stream of fluid and filaments into said foraminous surface obliquely oriented with respect to said first surface such that a first portion of said fluid separates from the filaments and passes through said foraminous surface and a second portion of said fluid moves said filaments along the foraminous surface; collecting said filaments in a randomly dispersed, substantially uniform layer hav

Abstract: Apparatus for fluidically attenuating streams of molten material into filaments is provided comprising; a base having a first chamber and a recess separated by a wall having a plurality of apertures therethrough, said first chamber being adapted to receive a fluid; a first member having a first arcuate surface and a distal end, the first member being adapted to be joined to said base such that first arcuate surface is adjacent said recess and said apertures of said base; a second member having a second arcuate surface, a head region, and a third arcuate surface, said head region being located intermediate and contiguous with said second and third arcuate surfaces, said second member being joined to said base such that said second arcuate surface is positioned adjacent said recess and said apertures of said base such that said first arcuate surface, said second arcuate surface and said head region form a smoothly converging passageway, the head region being positioned relative to the distal end to form an outl

Abstract: A lofted mat of filaments is produced from process and apparatus including: supplying a plurality of streams of molten polymeric material; attenuating said streams of material into continuous filaments through the action of a stream of fluid moving from an attenuation means; said filaments being entrained in said fluid moving from said attenuation means, said filaments having non-uniform residual stresses established therein; moving said stream of fluid and filaments along a first surface positioned intermediate said attenuation means and a foraminous surface; establishing a vacuum at said foraminous surface; directing said stream of fluid and filaments into said foraminous surface obliquely oriented with respect to said first surface such that a first portion of said fluid separates from the filaments and passes through said foraminous surface and a second portion of said fluid moves said filaments along the foraminous surface; collecting said filaments in a randomly dispersed, substantially uniform layer ha

Abstract: Process and apparatus are provided for producing filaments comprising: supplying a plurality of streams of molten material; attenuating said streams of material into continuous filaments through the action of a stream of fluid moving from an attenuation means; said filaments being entrained in said fluid moving from said attenuation means, moving said stream of fluid and filaments along a first surface positioned intermediate said attenuation means and a foraminous surface; establishing a vacuum at said foraminous surface; directing said stream of fluid and filaments into said foraminous surface obliquely oriented with respect to said first surface such that a first portion of said fluid separates from the filaments and passes through said foraminous surface and a second portion of said fluid moves said filaments along the foraminous surface; collecting said filaments.

Abstract: Production of a high-strength, convoluted polyester staple fiber which includes use of a spinneret having a slot aperture having a width of greater than about 0.07 mm, and a length to width ratio of at least 2, spinning at a spin stretch factor of equal to or greater than 100N, where N is the number of elongated slots that make up each outlet orifice, at a spinning speed of greater than about 1500 m/min., drawing the fiber under amorphous retaining conditions by an amount greater than the natural draw ratio, mechanically crimping the fiber, cutting it to staple lengths, and relaxing the fiber 10 to 40%. The fiber is cotton-like. The preferred polyester is polyethylene terephthalate.