Production Of Continuous Or Running Length Patents (Class 264/555)
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Publication number: 20090020923Abstract: A method and an apparatus for continuously producing elongated siding panels is disclosed. The apparatus includes a conveyor, a plurality of mold plates, and a die for extruding a sheet of material onto the mold plates. The mold plates are formed of a rigid material and positioned adjacent one another and supported by the conveyor for forming the elongated siding panels. Each of the mold plates has an upper edge portion and a lower edge portion with an intermediate portion therebetween. The intermediate portion has an aesthetic pattern for imparting the pattern to the sheet of material with the adjacent mold plates having different aesthetic patterns. The lower edge portion has a lower leg extending substantially perpendicular from the intermediate portion defining a horizontal plane and a projection portion between the lower edge portion and the intermediate portion extends beyond the horizontal plane for imparting a jagged pattern to the intermediate portion.Type: ApplicationFiled: November 19, 2007Publication date: January 22, 2009Inventor: Daniel W. King
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Patent number: 7476350Abstract: Methods for making a nonwoven web on a collector traveling in a machine direction parallel to a length of the nonwoven web. The methods generally include forming a curtain of polymer filaments, mixing the curtain of polymer filaments with a flow of process air, depositing the curtain of polymer filaments on the collector to form the nonwoven web, and exhausting the process air through an air intake opening positioned below the collector. The method further comprises providing a substantially uniform air flow velocity across the air intake opening in a cross-machine direction perpendicular to the machine direction and adjusting an air flow velocity across the air intake opening in the machine direction to thereby define a ratio of the air flow velocity in the machine direction to the air flow velocity in the cross-machine direction.Type: GrantFiled: August 31, 2004Date of Patent: January 13, 2009Assignee: Aktiengesellschaft Adolph SaurerInventor: Martin A. Allen
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Patent number: 7470389Abstract: A new fiber-forming method, and related apparatus, and webs prepared by the new method and apparatus are taught. In the new method a) a stream of filaments is extruded from a die of known width and thickness; b) the stream of extruded filaments is directed through a processing chamber that is defined by two narrowly separated walls that are parallel to one another, parallel to said width of the die, and parallel to the longitudinal axis of the stream of extruded filaments; c) the stream of filaments passed through the processing chamber is intercepted on a collector where the filaments are collected as a nonwoven fibrous web; and d) a spacing between the walls of the processing chamber is selected that causes the stream of extruded filaments to spread before it reaches the collector and be collected as a web significantly wider in width than the die. Generally the increase in width is sufficient to be economically significant, e.g., to reduce costs of web manufacture.Type: GrantFiled: September 3, 2004Date of Patent: December 30, 2008Assignee: 3M Innovative Properties CompanyInventors: Michael R. Berrigan, William T. Fay
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Patent number: 7465481Abstract: The object the present invention is to provide an exterior molding body for automobile which is reinforced by a long fiber, is excellent in mechanical properties such as bending elastic modulus and bending strength, chemical resistance and heat resistance, is lightened, has high designability and is reduced in the anisotropy of linear expansion coefficient of molding body caused by the fiber orientation at filling thereof to a mold.Type: GrantFiled: September 7, 2005Date of Patent: December 16, 2008Assignee: Mitsubishi Engineering-Plastics CorporationInventors: Hiroyuki Imaizumi, Motonori Ueda, Kouji Nishida, Kei Morimoto
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Patent number: 7459121Abstract: Methods and devices are provided for the continuous production of a network of nanotubes or other nanoscale fibers. The method includes making a suspension of nanoscale fibers dispersed in a liquid medium, optionally with surfactant and/or sonication, and filtering the suspension by moving a filter membrane through the suspension, such that the nanoscale fibers are deposited directly on the filter membrane as the fluid medium flows through the filter membrane, thereby forming a continuous membrane of the nanoscale fibers. The deposition of the nanoscale fibers can occur when and where the filter membrane moves into contact with a static, porous filter element or a dynamic, porous filter element. The filtering can be conducted within a magnetic field effective to align the nanoscale fibers, and/or with the aid of vacuum to pull water through the filter membrane, applied pressure to press water though the filter membrane, or a combination thereof.Type: GrantFiled: July 20, 2005Date of Patent: December 2, 2008Assignee: Florida State University Research FoundationInventors: Zhiyong Liang, Ben Wang, Chun Zhang, Jonnattan T. Ugarte, Chih-Yen Lin, James Thagard
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Patent number: 7384588Abstract: A process for making a flexible structure that includes at least a first region and a second region, each of the first and second regions having at least one common intensive property that differs in value.Type: GrantFiled: October 24, 2005Date of Patent: June 10, 2008Assignee: The Procter + Gamble CompanyInventors: Gregory Charles Gordon, David William Cabell, Larry Neil Mackey, John Gerhard Michael, Paul Dennis Trokhan
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Publication number: 20080122143Abstract: An apparatus, system and method to maximize ultrafine meltblown fiber attenuation. The nozzle apparatus includes a polymer streaming channel, at least one gas delivery channel, a restricted throat area, and a bounded expansion area. In some embodiments, the nozzle comprises a two-dimensional converging-diverging Laval nozzle geometry. The gas delivery channels may provide the gas under a pressure exceeding critical pressure, such that the gas achieves supersonic speeds at the restricted throat area. The bounded expansion area may stabilize such supersonic speeds, thus maximizing ultrafine meltblown fiber attenuation while minimizing the formation of fly and other defects.Type: ApplicationFiled: November 28, 2006Publication date: May 29, 2008Inventors: Peter K. Herman, James O. Stuart, Yogeshwar K. Velu
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Publication number: 20080093778Abstract: A process and apparatus for producing sub-micron fibers, and more specifically a process and apparatus for effecting formation of sub-micron fibers by fibrillation of polymer films, and nonwoven materials and articles incorporating them.Type: ApplicationFiled: October 18, 2006Publication date: April 24, 2008Applicant: Polymer Group, Inc.Inventors: Michael H. Johnson, Timothy Krause, Michael W. Hayes, Rajeev Chhabra, Savas Aydore, Olaf Erik Alexander Isele, Han Xu
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Publication number: 20080038533Abstract: Provided are blends of linear low density polyethylene copolymers with very low density, low density, medium density, high density, and differentiated polyethylenes and other polymers. The invention also includes articles produced from the linear low density polyethylene and polyethylene blends described herein.Type: ApplicationFiled: April 24, 2007Publication date: February 14, 2008Inventors: Steven A. Best, Bernard L. Bossaert, Ronald N. Cooke, Paul M. German, Blair A. Graham, Carlos A. Mota, Calvin K. Schram, Barry C. Trudell
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Publication number: 20080029937Abstract: A device to produce strand-shaped products from thermoplastic or elastomer materials comprising a paste extruder having a specially implemented internal volume defined by a cylindrical internal mandrel (2) and an external cylinder mantle (1). The polymer material is charged in the internal volume. The polymer raw material may be provided as a powder or granulate or as material cores produced in a separate precursor process using the same device. The polymer mass is melted by heating and discharged using an expulsion piston (3). A static mixing line (5) is provided in the outlet area, in which penetration of the melt flow occurs due to special shaping and uniform mixing of the molten material. A homogeneous material flow is achieved, which is supplied via a melt duct to a conventional longitudinal or transverse extrusion head (4).Type: ApplicationFiled: July 12, 2007Publication date: February 7, 2008Applicant: BIOTRONIK VI PATENT AGInventor: Gerhard Gielenz
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Patent number: 7314557Abstract: A device for internal centrifugation of mineral fibers including a centrifuge equipped with a peripheral band perforated with orifices distributed in a plurality of annular zones arranged on top of each other, assuming that the centrifuge is in centrifugation position. The device also includes at least two annular zones whose number of orifices per unit of surface area differs by a value greater than or equal to 5%, in particular greater than or equal to 10%, and even 20%.Type: GrantFiled: February 13, 2002Date of Patent: January 1, 2008Assignee: Saint-Gobain IsoverInventors: Sébastien Beaufils, Christophe Wagner
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Patent number: 7276201Abstract: A process for making non-thermoplastic starch fibers comprises the steps of: (a) providing a non-thermoplastic starch composition comprising from about 50% to about 75% by weight of modified starch and from about 25% to about 50% of water and having a shear viscosity within the at least one nozzle from about 1 to about 80 Pascals·second at the processing temperature and at a shear rate of 3,000 sec?1; (b) extruding the non-thermoplastic starch composition through at least one extrusion nozzle terminating with a nozzle tip, thereby forming at least one embryonic starch fiber; (c) attenuating the at least one embryonic starch fiber with an attenuating air having an average velocity at the nozzle tip greater than about 30 meters per second, to cause the fiber to form an average equivalent diameter of less than about 20 microns; (d) dewatering the at least one embryonic starch fiber to a consistency of from about 70% to about 99% by weight, thereby producing at least one non-thermoplastic starch fiber, wherein thType: GrantFiled: March 18, 2004Date of Patent: October 2, 2007Assignee: The Procter & Gamble CompanyInventors: Michael David James, Larry Neil Mackey, Donald Eugene Ensign, Savas Aydore
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Publication number: 20070205541Abstract: A process and the resulting uniquely configured product called “Buck Shot Blues”. The base product is a fabric such as denim that has been processed and altered to accomplish an appearance that the fabric has been “blasted” by buck shot or small metal pellets. The resultant fabric has a plurality of holes or apertures in a “blast pattern” that is either specific or random. The holes or apertures after processing are “frayed” from the penetration of the blast elements. The manner of production includes a number of methods, from a simple blast scheme to more complex production processes. An alternative computer controlled manufacturing process is also provided where the individual interacts with the process that produces his garment.Type: ApplicationFiled: March 2, 2007Publication date: September 6, 2007Inventors: Dann Allen, Yolanda Brown
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Publication number: 20070145627Abstract: This invention provides a method of producing chitosan non-woven fabrics and an apparatus thereof. At first, a chitosan acidic solution is extruded to form a chitosan fibrous stream. Then, a solidifying agent is ejected to form a solidifying agent stream. The solidifying agent stream and the chitosan fibrous stream are combined to form a pre-solidified chitosan fiber. Then, high-pressure air is ejected on the pre-solidified chitosan fiber to stretch the pre-solidified chitosan fiber. Finally, the chitosan fibers are collected to form chitosan non-woven fabrics.Type: ApplicationFiled: September 29, 2006Publication date: June 28, 2007Applicant: Taiwan Textile Research InstituteInventors: Chao-Chun Peng, Tzu-Hsiang Huang, Jian-Min Lin, Jen-Hsiung Lee
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Patent number: 7192550Abstract: A device and method for spinning polymer fibers utilizes one or more independent sources of polymer materials, pumps for feeding polymer material from each of the sources, and a series of distribution plates with surface grooves, through holes and/or slots together defining separated distribution paths, each of which receives polymer material from one of said independent sources. The surface grooves are defined to a depth less than the thickness of the distribution plate. At least one distribution plate contains spinneret orifices defined by outlet surface grooves extending from the distribution path to the edge of that plate, whereby fibers are extruded from the spinneret orifices edgewise from the plate. The spinneret orifices may be defined by overlayed outlet surface grooves or slots defined in abutting plates.Type: GrantFiled: November 22, 2004Date of Patent: March 20, 2007Assignee: Hills, Inc.Inventors: Richard M. Berger, Jeff S. Haggard
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Patent number: 7157039Abstract: A process and apparatus for the production of a spiral or coil shaped puffed extrudate. A tube or other peripheral containment vessel is placed at the exit end of an extruder die. A force or resistance is then applied on the extrudate downstream of the glass transition point, thereby causing the extrudate to back up and coil in the containment vessel.Type: GrantFiled: December 5, 2003Date of Patent: January 2, 2007Assignee: Frito-Lay North America, Inc.Inventor: Eugenio Bortone
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Patent number: 7081224Abstract: A solution casting system has a tentering device, and produces polymer film of cellulose triacetate. Two web edge portions of the polymer film are sucked within a section from a downstream end of the tentering device to a first roller that the polymer film contacts first. Furthermore, the two web edge portions are subjected to blowing of gas, or suction, between the first roller and a second roller positioned next downstream from the first roller. Each range of two web edge portions has an effective size in a web width direction less than 25% of that of the polymer film.Type: GrantFiled: September 21, 2004Date of Patent: July 25, 2006Assignee: Fuji Photo Film Co., Ltd.Inventor: Hiroshi Nakashima
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Patent number: 7029620Abstract: A flexible structure includes a plurality of starch filaments. The structure includes at least a first region and a second region, each of the first and second regions having at least one common intensive property selected from the group consisting of density, basis weight, elevation, opacity, crepe frequency, and any combination thereof. The common intensive property of the first region differs in value from the common intensive property of the second region.Type: GrantFiled: March 13, 2003Date of Patent: April 18, 2006Assignee: The Procter & Gamble CompanyInventors: Gregory Charles Gordon, David William Cabell, Larry Neil Mackey, John Gerhard Michael, Paul Dennis Trokhan
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Patent number: 7029622Abstract: The present invention relates to a method for producing a continuously molded body from an extrusion solution preferably containing water, cellulose and a tertiary amine. The extrusion solution is extruded through an extrusion duct orifice to obtain a continuously molded body. The continuously molded body is passed through an air gap in which it is stretched. To increase the loop strength and to reduce the tendency to fibrillate, the mean acceleration and/or the mean heat flow density are controlled according to the invention in accordance with predetermined formulae.Type: GrantFiled: April 18, 2001Date of Patent: April 18, 2006Assignee: Zimmer A.G.Inventors: Stefan Zikeli, Friedrich Ecker
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Patent number: 7025926Abstract: The present invention relates to a method of producing a continuous molding making use of an extrusion solution containing preferably water, cellulose and a tertiary amine oxide. The extrusion solution is extruded through an extrusion-channel opening so as to form a continuous molding. The continuous molding is conducted through an air gap in which it is drawn. In order to increase the non-looping property and in order to reduce the fibrillation tendency, the present invention is so conceived that the mean acceleration and/or the mean heat flow density are controlled in accordance with predetermined formulae.Type: GrantFiled: April 12, 2002Date of Patent: April 11, 2006Assignee: Zimmer A.G.Inventors: Stefan Zikeli, Friedrich Ecker
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Patent number: 7001567Abstract: An air handler for collecting air discharged from a melt spinning apparatus. The air handler includes an outer housing having walls defining a first interior space. One of the walls has an intake opening for receiving the discharge air. Another wall has an exhaust opening for discharging the air. The intake opening is in fluid communication with the first interior space. An inner housing is positioned within the first interior space and has walls defining a second interior space. At least one of the walls of the inner housing has an opening. The first interior space communicates with the second interior space through the opening. The second interior space is in fluid communication with the exhaust opening.Type: GrantFiled: December 17, 2002Date of Patent: February 21, 2006Assignee: Nordson CorporationInventors: Martin A. Allen, Steve Clark
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Patent number: 6984350Abstract: An apparatus for manufacturing a transversely aligned web has a spinning device provided with a plurality of nozzles for extruding molten polymer as filaments, and a conveyor on which the filaments spun by the spinning device are piled and traveling in a direction cross to the direction of array of the nozzles. The spinning device is provided with a high-speed fluid blowing unit for blowing a high-speed fluid in a direction parallel with a direction in which the filaments are extruded from the nozzles so as to attenuate the filaments. Further, the apparatus for manufacturing the transversely aligned web has at least one air stream vibrating mechanism for cyclically changing the flowing direction of the high-speed fluid blown from the high-speed fluid blowing unit in a direction cross to the machine direction of the conveyor. The filaments are vibrated in a direction cross to the machine direction of the conveyor, owing to the high-speed fluid by the air stream vibrating unit.Type: GrantFiled: February 26, 2002Date of Patent: January 10, 2006Assignees: Nippon Petrochemicals Co., Ltd., Polymer Processing Research Institute Ltd.Inventors: Yuki Kuroiwa, Kazuhiko Kurihara, Kazuhiro Yabe, Shin-ichi Umejima, Yoshiro Morino
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Patent number: 6946093Abstract: An apparatus for meltblowing multiple types of liquid materials into multi-component filaments. A pair of outer manifold elements sandwich an intermediate manifold element. Respective channels are formed between opposing sides of the outer manifold elements and the respective opposite sides of the intermediate manifold element. These recesses form channels which diverge or widen away from associated inlets at the top of the manifold assembly. A die tip is coupled to the manifold assembly at a lower side and communicates with the outlets of the channels. The die tip includes a combining member for producing a desired multi-component filament configuration and further includes air discharge passages for impinging the discharged multi-component filaments with pressurized air.Type: GrantFiled: October 17, 2002Date of Patent: September 20, 2005Assignee: Nordson CorporationInventor: Martin A. Allen
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Patent number: 6911174Abstract: The present invention provides a multicomponent fiber containing at least two polymer components arranged in distinct zones or segments across the cross-section of the fiber wherein at least one component of the fiber contains a thermoplastic polymer and at least one component of the fiber contains a thermoset polymer. The invention also provides fabrics and fabric laminates containing the multicomponent fibers, and articles containing the fabric. Additionally provided is a process for producing the multicomponent fibers.Type: GrantFiled: December 30, 2002Date of Patent: June 28, 2005Assignee: Kimberly-Clark Worldwide, Inc.Inventor: Christopher Cosgrove Creagan
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Patent number: 6911522Abstract: Compositions based on ?-caprolactone polymer, comprising at least one ?-caprolactone polymer and calcium carbonate. Process for preparing these compositions, which are used for manufacturing articles, in particular films, preferably obtained by extrusion blow-moulding or by flat-die extrusion.Type: GrantFiled: January 19, 2001Date of Patent: June 28, 2005Assignee: SOLVAY (Societe Anonyme)Inventors: Dino Manfredi, Ivan Claeys
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Patent number: 6896843Abstract: A method includes the steps of co-extruding a first component and a second component. The first component has a recovery percentage R1 and the second component has a recovery percentage R2, wherein R1 is higher than R2. The first and second components are directed through a spin pack to form a plurality of continuous, molten fibers. The plurality of molten fibers is then routed through a quenching chamber to form a plurality of continuous cooled fibers. The plurality of continuous cooled fibers is then routed through a drawing unit to form a plurality of continuous, solid linear fibers. The linear fibers are then deposited onto a moving support, such ass a forming wire, to form an accumulation or fibers. The accumulation of fibers are stabilized and bonded to form a web. The web is then stretched by at least 50 percent in at least one direction before being allowed to relax.Type: GrantFiled: August 30, 2002Date of Patent: May 24, 2005Assignee: Kimberly-Clark Worldwide, Inc.Inventors: Vasily Aramovich Topolkaraev, Susan Elaine Shawver, Gregory James Wideman, Matthew Joseph Graham
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Patent number: 6890466Abstract: An elastically stretchable nonwoven fabric including thermoplastic elastomer filaments; the filaments being heat-sealed and/or mechanically intertwined together to form the nonwoven fabric that has crimped regions and non-crimped regions wherein each of the crimped regions has fine crimps in the rate of 50/cm or higher.Type: GrantFiled: March 11, 2002Date of Patent: May 10, 2005Assignee: Uni-Charm CorporationInventors: Toshio Kobayashi, Satoru Tange, Masaki Yoshida, Emiko Inoue
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Patent number: 6887423Abstract: A process for preparing nonwoven webs including multiple component continuous filaments having high levels of three-dimensional helical crimp utilizing draw rolls to provide a high degree of orientation to each of the polymeric components by mechanically drawing the filaments under conditions wherein the polymeric components remain substantially amorphous and a stretchable nonwoven web including multiple component, continuous filaments having high levels of three-dimensional helical crimp.Type: GrantFiled: September 24, 2002Date of Patent: May 3, 2005Assignee: E. I. du Pont de Nemours and CompanyInventors: James Edmond Van Trump, Vishal Bansal, Michael C. Davis
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Patent number: 6881362Abstract: A process for relaxation of interlayer sheet is provided which comprises heating the interlayer sheet, followed by leading the heated interlayer sheet over an air-cushion table with regulation of the tension on the interlayer sheet to induce interlayer sheet relaxation and thereafter cooling the relaxed interlayer sheet to the desired temperature for subsequent use. Apparatus suitable for carrying out the process of interlayer sheet relaxation comprising a heating section, an air-cushion table, a tension control and a cooling section is also provided in accordance with the present invention.Type: GrantFiled: February 12, 2001Date of Patent: April 19, 2005Assignee: N.V. Solutia Europe S.A.Inventor: Herbert Sybrant Van De Velde Keyser
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Patent number: 6881375Abstract: A method includes the steps of co-extruding a first component and a second component. The first component has a recovery percentage R1 and the second component has a recovery percentage R2, wherein R1 is higher than R2. The first and second components are directed through a spin pack to form a plurality of continuous, molten fibers. The molten fibers are then muted through a quenching chamber to form a plurality of continuous cooled fibers. The coiled fibers are then routed through a drawing unit to form a plurality of continuous, solid linear fibers. Each of the solid fibers is then stretched by at least 50 percent before it is allowed to relax. The relaxation step forms the linear fibers into a plurality of continuous 3-dimensional fibers each having a coiled configuration over at least a portion of its length. The continuous 3-dimensional, coiled fibers are then deposited onto a moving support to form a web.Type: GrantFiled: August 30, 2002Date of Patent: April 19, 2005Assignee: Kimberly-Clark Worldwide, Inc.Inventors: Vasily Aramovich Topolkaraev, Bernhardt Edward Kressner, Gregory James Wideman
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Patent number: 6861025Abstract: Melt blown nonwoven webs are formed by supplying attenuating fluid to a meltblowing die through an attenuating fluid distribution passage whose distribution characteristics can be changed while the die and manifold are assembled. By adjusting the distribution characteristics of the passage, the mass flow rate of attenuating fluid to channels in the meltblowing die and the temperature of the attenuating fluid at the die outlets can be made more uniform.Type: GrantFiled: June 20, 2002Date of Patent: March 1, 2005Assignee: 3M Innovative Properties CompanyInventors: Stanley C. Erickson, James C. Breister
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Patent number: 6858168Abstract: An apparatus and method for forming liquid spinning solution into a solid formed product whereby the solution is passed through at least one tubular passage (17) having walls formed at least partly of semipermeable and/or porous material. The semipermeable and/or porous material allows parameters, such as the concentration of hydrogen ions, water, salts and low molecular weight, of the liquid spinning solution to be altered as the spinning solution passes through the tubular passage(s).Type: GrantFiled: November 24, 2000Date of Patent: February 22, 2005Assignee: Spin'Tech Engineering GmbHInventors: Friedrich Wilhelm Ludwig Paul Vollrath, David Philip Knight
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Patent number: 6846450Abstract: 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.Type: GrantFiled: June 20, 2002Date of Patent: January 25, 2005Assignee: 3M Innovative Properties CompanyInventors: Stanley C. Erickson, James C. Breister, Michael G. Schwartz, Patrick J Sager
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Patent number: 6838043Abstract: A synthetic leather made of a nonwoven fabric impregnated and/or coated with a polymer, with a surface weight of 100 to 500 g/m2, and a tensile strength greater than 300 N/5 cm in the lengthwise and the crosswise direction, where the nonwoven fabric is made up of melt-spun multi-component endless filaments, aerodynamically stretched and directly laid up to form a nonwoven material, having a titer less than 2 dTex, and wherein the multi-component endless filaments, after preliminary bonding, are split and bonded by at least 90% to produce supermicro endless filaments having a titer less than 0.2 dTex.Type: GrantFiled: September 1, 2000Date of Patent: January 4, 2005Assignee: Carl Freudenberg KGInventors: Rudolf Wagner, Robert Groten
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Patent number: 6838040Abstract: A method for weakening a portion of a web includes moving a web in a machine direction between at least a first location and a second location, wherein the second location is positioned downstream of the first location, forming a line of weakness in the web at the first location, wherein the web has a first tensile strength across the line of weakness, and weakening the line of weakness at a second location, wherein the web has a second tensile strength across the line of weakness after the line of weakness is weakened at the second location and wherein the first tensile strength is greater than the second tensile strength.Type: GrantFiled: December 28, 2001Date of Patent: January 4, 2005Assignee: Kimberly-Clark Worldwide, Inc.Inventors: Joseph A. Mlinar, Todd W. Hajos, Kenneth J. Wagner
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Patent number: 6833104Abstract: A device and method for spinning polymer fibers utilizes one or more independent sources of polymer materials, pumps for feeding polymer material from each of the sources, and a series of distribution plates with surface grooves, through holes and/or slots together defining separated distribution paths, each of which receives polymer material from one of said independent sources. The surface grooves are defined to a depth less than the thickness of the distribution plate. At least one distribution plate contains spinneret orifices defined by outlet surface grooves extending from the distribution path to the edge of that plate, whereby fibers are extruded from the spinneret orifices edgewise from the plate. The spinneret orifices may be defined by overlayed outlet surface grooves or slots defined in abutting plates.Type: GrantFiled: April 29, 2003Date of Patent: December 21, 2004Assignee: Hills, Inc.Inventor: Richard M. Berger
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Patent number: 6824729Abstract: A method of preparing a nonwoven web that has substantially continuous synthetic fine fiber includes preparing an aqueous amide crosslinked polymer solution. The solution is extruded through a die having a plurality of orifices to form a plurality of threadlines. The threadlines are then attenuated with a primary gaseous source under conditions sufficient to permit the viscosity of each threadline to increase incrementally with increasing distance from the die, at a rate sufficient to provide fibers having a desired attenuation and mean fiber diameter without significant fiber breakage.Type: GrantFiled: March 4, 2002Date of Patent: November 30, 2004Assignee: Kimberly-Clark Worldwide, Inc.Inventors: Jian Oin, Yong Li, Wendy Lynn Van Dyke, Anthony John Wisneski, Palani Raj Ramaswami Wallajapet, Hannong Rhim
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Patent number: 6824733Abstract: Melt blown nonwoven webs are formed by supplying fiber-forming material to a planetary gear metering pump having a plurality of outlets, flowing fiber-forming material from the pump outlets through a plurality of inlets in one or more die cavities, and meltblowing the fiber-forming material. Each die cavity inlet 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.Type: GrantFiled: June 20, 2002Date of Patent: November 30, 2004Assignee: 3M Innovative Properties CompanyInventors: Stanley C. Erickson, James C. Breister, Michael G. Schwartz, Patrick J. Sager
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Publication number: 20040232602Abstract: A method of producing a non-lofted fiber veil of an orientable polymer for the production of insulation, e.g. thermal, for blown-in applications, having X, Y and Z vector directions of the fibers comprising, melt blowing the polymer to form molten fibers, having molecules oriented along the length of the fibers, the X vector direction, placing the fibers on a roller spinning at a rate to provide additional orientation of the molecules of the fibers, displacing some said fibers into the Y vector direction, and cooling the fibers while on the roller to form the non-lofted fiber veil. Also included is the product of the method, a blown in insulation, intermediate products, an apparatus and a method of producing a product for blown-in installation.Type: ApplicationFiled: May 5, 2004Publication date: November 25, 2004Inventors: Michael J. Noga, David Warren Arseneau, John D. Ireland, William Malcolm Worden, Zhiyong Fu, Reginald A. Cooke, Martin H. Beck
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Publication number: 20040222570Abstract: Nonwoven laminates are made by a multi-station line comprising at least one spunbond die assembly and at least one meltblowing die assembly. Each station includes (a) a melt spinning die which can be selectively equipped with a spunbond die insert or a meltblowing die insert and (b) a moveable support structure for adjusting the proper die-to-collector distance, depending on the spunbond or meltblowing mode of operation. The multi-station line permits the selective manufacture of a variety of spunbond (S) and meltblown (M) laminates, including the S-M-S laminate.Type: ApplicationFiled: June 15, 2004Publication date: November 11, 2004Applicant: Nordson CorporationInventor: Martin A. Allen
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Patent number: 6811740Abstract: A process for making non-thermoplastic starch fibers comprises the steps of: (a) providing a non-thermoplastic starch composition comprising from about 50% to about 75% by weight of modified starch and from about 25% to about 50% of water and having a shear viscosity within the at least one nozzle from about 1 to about 80 Pascals-second at the processing temperature and at a shear rate of 3,000 sec−1; (b) extruding the non-thermoplastic starch composition through at least one extrusion nozzle terminating with a nozzle tip, thereby forming at least one embryonic starch fiber; (c) attenuating the at least one embryonic starch fiber with an attenuating air having an average velocity at the nozzle tip greater than about 30 meters per second, to cause the fiber to form an average equivalent diameter of less than about 20 microns; (d) dewatering the at least one embryonic starch fiber to a consistency of from about 70% to about 99% by weight, thereby producing at least one non-thermoplastic starch fiber, wherType: GrantFiled: February 1, 2002Date of Patent: November 2, 2004Assignee: The Procter & Gamble CompanyInventors: Michael David James, Larry Neil Mackey, Donald Eugene Ensign, Savas Aydore
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Patent number: 6805965Abstract: A method is disclosed for topical application of compositions containing a chemical additive onto a paper web. The present invention is also directed to paper products formed from the method. In general, the method includes the steps of extruding a composition containing a chemical additive through a melt blown die and then applying the composition to a moving paper web. In one embodiment, the chemical composition is extruded into fibers and applied to the paper web. The chemical composition can contain, for instance, various additives, such as a polysiloxane softener.Type: GrantFiled: December 21, 2001Date of Patent: October 19, 2004Assignee: Kimberly-Clark Worldwide, Inc.Inventor: Kou-Chang Liu
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Patent number: 6803013Abstract: The present invention relates to an apparatus and method for forming meltblown material with a die assembly. The die may further include a die tip and a heating element positioned relative to the die tip apex to maintain the polymer material extruded from the die tip in a molten state.Type: GrantFiled: November 29, 2001Date of Patent: October 12, 2004Assignee: Kimberly-Clark Worldwide, Inc.Inventors: Jeffrey E. Fish, Lamar H. Gipson, Jark C. Lau
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Patent number: 6800226Abstract: The invention relates to a method and a device for the production of essentially continuous fine threads made of meltable polymers. The polymer melt is spun from at least one spin hole (5) and the spun thread is attenuated using gas flows which are accelerated to achieve high speeds by means of a Laval nozzle (6). As a result of the specific geometry of the melt hole (4) and the position thereof in respect to the Laval nozzle (6), the temperature of the polymer melt, the throughout per spin hole and the pressures determining the velocity of the gas flow upstream and downstream from the Laval nozzle (6) are controlled in such a way that the thread reaches an internal hydrostatic pressure before solidifying, whereby said thread bursts into a plurality of fine threads.Type: GrantFiled: December 26, 2001Date of Patent: October 5, 2004Inventor: Lüder Gerking
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Patent number: 6797226Abstract: A method for forming a wiping product. In particular, the wiping product contains a fabric formed from a nonwoven web that is bonded by microcreping at least one side of the web. The nonwoven web can contain melt-spinnable fibers, such as polyolefins, as well as various other fibers, such as pulp fibers, staple fibers, etc. For example, the nonwoven web can contain at least about 20% by weight of polyolefin fibers. By bonding the web using microcreping, the resulting bulk, absorption capacity, and softness of the fabric can be improved.Type: GrantFiled: October 9, 2001Date of Patent: September 28, 2004Assignee: Kimberly-Clark Worldwide, Inc.Inventor: Patricia A. Annable
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Publication number: 20040183238Abstract: A process for making non-thermoplastic starch fibers comprises the steps of: (a) providing a non-thermoplastic starch composition comprising from about 50% to about 75% by weight of modified starch and from about 25% to about 50% of water and having a shear viscosity within the at least one nozzle from about 1 to about 80 Pascals·second at the processing temperature and at a shear rate of 3,000 sec−1; (b) extruding the non-thermoplastic starch composition through at least one extrusion nozzle terminating with a nozzle tip, thereby forming at least one embryonic starch fiber; (c) attenuating the at least one embryonic starch fiber with an attenuating air having an average velocity at the nozzle tip greater than about 30 meters per second, to cause the fiber to form an average equivalent diameter of less than about 20 microns; (d) dewatering the at least one embryonic starch fiber to a consistency of from about 70% to about 99% by weight, thereby producing at least one non-thermoplastic starch fibeType: ApplicationFiled: March 18, 2004Publication date: September 23, 2004Inventors: Michael David James, Larry Neil Mackey, Donald Eugene Ensign, Savas Aydore
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Patent number: 6793854Abstract: A method and an apparatus for making a plastic film, and to a plastic film wherein the method includes extruding a film from plastic material by an extruder and orientating the film after extrusion. Material is mixed into the plastic so that when the plastic film is stretched, cavitation bubbles are formed in the material particles mixed into the plastic. After orientation, gas is arranged to act on the plastic film under high pressure so that the gas diffuses in the cavitation bubbles and causes overpressure in them. Thus it is possible to make a thin foamed film with a foaming degree of over 70%.Type: GrantFiled: March 11, 2002Date of Patent: September 21, 2004Assignee: Conenor OyInventor: Kari Kirjavainen
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Patent number: 6793858Abstract: A method and apparatus for continuously forming flexible mat structure in the form of spaced, interconnected concrete panels. The mat structure can serve as an erosion control mat along the banks of waterways and within drainage ditches and channels, and can also be utilized to provide temporary or permanent walkways and roadways. A rotatable drum includes peripherally-positioned mold cavities that receive concrete mix from a trough supplied from a source of concrete mix. A grid is fed against the drum periphery and over the mold cavities before the concrete mix is introduced, and after the mix is introduced a web of fibrous material is brought into contact with the concrete-mix-containing mold cavities to overlie the concrete-containing surface of the drum. As the drum rotates the fibrous material with overlying, interconnected concrete panels is deposited on the ground to provide the a finished mat structure.Type: GrantFiled: May 31, 2001Date of Patent: September 21, 2004Inventor: James G. Motz
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Patent number: 6783722Abstract: Spunbond nonwoven fabrics are produced with an apparatus which comprises a spinnerette having a plurality of orifices for extruding filaments; an attenuator for receiving and attenuating the filaments; and a collection surface upon which the filaments are deposited to form a nonwoven web. A filament diffuser is positioned between the attenuator and the collection surface in the path of filament travel. The diffuser comprises a pair of opposing divergingly arranged side walls and a pair of opposing end walls, these walls collectively defining filament passageway. In accordance with one embodiment of the invention, a flow of fluid is injected along the walls of the diffuser in the direction of filament travel. More particularly, fluid is injected along both the opposing divergingly arranged walls and the opposing ends walls which form the diffuser. In another aspect of the present invention, the filaments are electrostatically charged and a like electrical charge is imparted to the walls of the diffuser.Type: GrantFiled: August 15, 2002Date of Patent: August 31, 2004Assignee: BBA Nonwovens Simpsonville, Inc.Inventor: Thomas B. Taylor
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Patent number: 6780373Abstract: A film includes a core layer including a polyamide; two intermediate layers, disposed on opposite surfaces of the core layer, including an adhesive; and two outer layers, each disposed on a surface of the respective intermediate layer, comprising an ethylene/alpha olefin copolymer; wherein the two outer layers each constitute at least 27% of the total thickness of the film. The core layer can include either a single polyamide layer, or three layers wherein two layers of polyamide have therebetween a layer comprising a polymeric adhesive. The film is made preferably by a hot blown process at a blow up ratio of between 2.0:1 and 3.0:1. A process and package are also described.Type: GrantFiled: August 15, 1997Date of Patent: August 24, 2004Assignee: Cryovac, Inc.Inventor: Carlo E. Musco