Abstract: A film for use in absorbent articles is first microscopically textured and then macroscopically apertured while maintaining the microscopic texture. The micro-texturing may be done by a variety of means including vacuum forming, and may include micro-apertures. The macroscopic texture may be done by a variety of means including thermo-mechanical means with a heat shielding means. Where heated pins are used, the heat shielding means protects the micro-texture from the heat so that the heat does not deform the micro-texture.

Abstract: A method of making electret fibers, which method comprises: extruding a polymeric material to create fibers; and imparting an electric charge to the fibers; wherein the resulting fibers have a level of extractable hydrocarbon material that is less than 3.0 weight percent, based on the weight of the fibers.

Abstract: Air embossing systems, air lances and methods of air embossing fabrics produce fine detail, crisp transition between unembossed and embossed regions, and a high degree of uniformity across the width of an embossed fabric. The air embossing systems utilize air lances (210) for directing a stream of air onto the embossable surface (113) of a fabric (111) that have at least one nozzle (216) having an orifice dimension substantially less than that of conventional nozzles.

Abstract: The invention relates to a method and a device for producing substantially endless fine threads from polymer solutions, especially spinning material for lyocell, wherein the spinning material is spun from at least one spinning hole or a spinning slot. The spun thread or film is drawn by high-speed accelerated gas flows using a Laval nozzle whose narrowest cross-section is located beneath the point where the spinning material exists. The threads are arranged on a strip in the form of a non-woven or are taken up in the form of a yarn and are subsequently separated in spinning baths by means of solvents.

Abstract: A method of manufacturing a shaped polymeric article is provided. A sheet of extruded hot polymeric material is provided and disposed onto a rotating belt. The rotating belt includes a mold impression therein and a plurality of apertures therethrough. The mold impression resembles a plurality of adjacent shingle impressions of substantially the same length. Each of the shingle impressions includes a bottom edge where at least one of the bottom edges is beveled to give the appearance of shingles having different lengths. Vacuum pressure is applied to the hot polymeric material through the belt, so as to draw the sheet into intimate forming contact with the mold impression to form a patterned central portion. The patterned central portion is cooled below the heat deflection temperature of the polymeric material. A length of the sheet is severed to produce a shaped polymeric article.

Abstract: A system and process for producing spunbond nonwoven fabric in which two or more polymeric components are separately melted and are separately directed through a distribution plate configured so that the separate molten polymer components combine at a multiplicity of spinnerette orifices to form filaments containing the two or more polymer components. Multicomponent filaments are extruded from the spinnerette orifices into a quench chamber where quench air is directed from a first independently controllable blower and into contact with the filaments to cool and solidify the filaments. The filaments and the quench air are directed into and through a filament attenuator and the filaments are pneumatically attenuated and stretched. The filaments are directed from the attenuator into and through a filament depositing unit and are deposited randomly upon a moving continuous air-permeable belt to form a nonwoven web of substantially continuous filaments.

Abstract: A filter production method produces a filter having a shape substantially identical to the shape of a forming surface by extruding semi-molten fibers to the forming surface. When the semi-molten fibers are extruded to the forming surface, the semi-molten fibers are gathered to upstanding surface portions of the forming surface. Therefore, a sufficient amount of fibers can be layered onto the upstanding surface portions, so that the layering amount of fibers on the upstanding surface portions of the forming surface will not be considerably reduced in comparison with the layering amounts on other portions of the forming surface.

Abstract: 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.

Abstract: Improvements to processes and equipment for the manufacture of nonwoven webs useful in numerous applications including personal care, protective apparel, and industrial products. The fiber and/or filaments used to form the nonwoven fabric are deposited on a forming surface in a controlled orientation using application of an electrostatic charge to the fibers and/or filaments in combination with directing them to an electrode deflector plate while under the influence of the charge. The plate may be made up of teeth with a separation and angle orientation that are selected in accordance with the desired arrangement of the fibers and/or filaments in the nonwoven web. As a result, properties of the web such as relative strengths in the machine direction and cross-machine direction can be controlled.

Abstract: The present invention is directed to methods of making lyocell fibers. In particular, the process includes reducing the average degree of polymerization of a pulp to about 200 to 1100 without substantially reducing the hemicellulose content of the pulp, and reducing the copper number to less than 2.0.

Abstract: A method of forming bicomponent fibers into a web is disclosed. The 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 as a forming wire, to form an accumulation of 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.

Abstract: A method of forming 3-dimensional fibers into a web is disclosed. The 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 routed through a quenching chamber to form a plurality of continuous cooled fibers. The cooled 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.

Abstract: An apparatus for forming a non-woven mat of nanofibers by using a pressurized gas stream includes paralell, spaced apart, first, second, and third members, each having a supply end and an opposing exit end. The second member is located apart from and adjacent to the first member. The exit end of the second member extends beyond the exit end of the first member. The first and second members define a first supply slit. The third member is located apart from and adjacent to the first member on the opposite side of the first member from the second member. The first and third members define a first gas slit, and the exit ends of the first, second and third members define a gas jet space. A method for forming a non-woven mat of nanofibers utilizes this nozzle.

Abstract: Highly crimped, fully drawn bicomponent fibers, prepared by melt-spinning, followed by gas-flow quenching, heat treatment and high speed windup, are provided, as are fine-decitex and highly uniform polyester bicomponent fibers.

Abstract: A meltblowing method and system for dispensing first and second fluids from corresponding first and second orifices of a die assembly to form a meltblown first fluid filament. The die assembly directs the first and second fluid flows parallelly, or divergently, or directs two second fluid flows convergently toward a common first fluid flow, whereby the first and second fluids are dispensed from orifices at equal first fluid flow rates and equal second fluid flow rates. The die assembly is compressably retained between opposing end plates coupled to an adapter for further coupling to a main manifold having a fluid metering device for supplying first fluid to the die assembly. The meltblown filaments are depositing onto a moving substrate by vacillating the filament non-parallel to a direction of substrate movement, whereby vacillation a first fluid flow is controllable by an angle between the first fluid flow and one or more flanking second fluid flows, among other variables.

Abstract: 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.

Abstract: 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.

Abstract: A process for making a nonwoven fabric in which continuous fibers are evenly distributed and neither bundles nor lumps of the fibers, includes a guide box for continuous fibers being provided between extruding nozzles adapted to discharge the continuous fibers under hot air blast and a conveyor belt. The box has an upper end opening and a lower end opening being larger than the upper end opening. The continuous fibers are subjected to a suction effect provided from below the guide box so that the continuous fibers may be secondarily stretched and thereby thinned within the guide box.

Abstract: The present invention is directed to a draw jet for drawing thermoplastic polymer filaments including a drawing slot defined by an entrance member including a converging passageway communicating with a continuing passageway, terminating at an outlet portion, a drawing member including an inlet portion having a drawing gap width of about 2.0 to about 10 mm communicating with the outlet portion of the entrance member, and at least one air nozzle for directing high speed air onto the filaments in a downstream direction positioned between the outlet portion of the entrance member and the inlet portion of the drawing member, and with a nozzle gap width wherein the gap ratio of the drawing gap width to the combined width of all of the nozzle gaps is from about 1.0 to about 10.

Abstract: A method for producing fibers from a molten thermoplastic material includes the steps of extruding the molten thermoplastic material from a material outlet having a longitudinal axis and producing a stream of pressurized fluid that exists a fluid tube removably securable to a die head assembly and including an outlet coaxial with the material outlet longitudinal axis and extending at least into the material outlet. The method may be carried out using various material outlet and fluid tube configurations.

Abstract: The present invention relates to an apparatus for continuous vacuum forming of a thermoplastic material between a pair of rotating flexible belts in which one belt includes a plurality of teeth, which are received in a plurality of indentations of the other belt. Each of the belts includes a mold, which forms a channel when the belts are adjacent to one another. A vacuum is applied to at least one of the flexible belts for drawing material received in the channel and alignment of the belts. Preferably, a vacuum can be applied to both of the belts for improved alignment. Each belt can include a plurality of apertures, which are in fluid flow communication with a plurality of perforations of a flat support belt positioned over a vacuum manifold.

Abstract: A flexible structure comprises a plurality of starch filaments. The structure comprises 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.

Abstract: A sheet of plastics material is continuously extruded onto the upper run of an endless conveyor which carries aluminum vacuum mold plates each defining a cavity with a shingle pattern. The sheet is progressively vacuum-formed into the mold plate cavities, and opposite longitudinal upper and lower portions of the sheet are progressively vacuum-formed, with traveling plug assist in one embodiment, to define shingle panels with hook-shaped lower portions and upper portions defining grooves for receiving the lower portions. The upper portion of the sheet is punched with longitudinally spaced slots to form a nailing flange, and the sheet is then cut laterally at longitudinally spaced intervals to produce elongated siding panels each having integrally connected shingle panels. The shingle panels may have different bottom configurations or profiles and are interchangeable.

Abstract: A method for producing super fine meltblown fibers increases the length of the meltblown jet thermal core to increase the dwell time of the extruded thermoplastic polymer within the jet thermal core. Through use of the method it is practical to use low viscosity resins and further to provide meltblown nonwovens with superior barrier properties to the passage of fluids and particularly gases. The method further provides a useful means for blooming internal additives to the surface of the fibers.

Abstract: A cellular cushioning article comprises first and second multilayer films each having first and second outer layers, each of which contains an olefin-based polymer, and an inner O2-barrier layer. At least one of the O2-barrier layers contains recycled polyester. The first multilayer film is laminated to the second multilayer film so that a plurality of cells are formed between the first multilayer film and the second multilayer film. The cells can be discrete, fluid-filled cells produced by forming one or both of the films. Alternatively, the cushioning article can be an inflatable article in which the films are adhered to one another in a pattern to form a series of inflatable chambers connected by inflatable passageways terminating in a dead-end chamber. Processes for making the articles are also disclosed.

Abstract: The present invention is directed to a process for forming a plurality of multi-layered filaments from multiple thermoplastic synthetic polymers and an apparatus containing a melt spinning beam which comprises multiple polymer inlet passages each communicating with separate multiple coat hanger distribution manifolds, separate filters connected downstream of each coat hanger distribution manifold, a combining manifold connected downstream of said filters and spinneret orifices connected downstream of said combining manifold for spinning of said multi-layered filaments.

Abstract: A fiber spinning device and process for manufacturing a web of fibers including a homogeneous mixture of fibers of different characteristics. Monocomponent fibers of different polymers can be extruded side-by-side from the same die system. Sheath/core bicomponent fibers can be alternated with monocomponent fibers formed of the same core polymer as used in the bicomponent fibers. Bicomponent fibers having a common core polymer and different sheath polymers can be extruded from alternate spinneret orifices in the same die plate. Multiple distribution plates are provided with surface grooves or depressions to direct polymer materials from independent sources to only selected spinneret openings in an array of spinneret openings while maintaining the polymers segregated from each other.

Abstract: The invention relates to the field of processing starch. In particular, the invention relates to a process for extruding starch to obtain a starch product having a certain intrinsic viscosity when dissolved or dispersed in water, which process requires less specific mechanical energy input than conventional extrusions of starch.

Abstract: An apparatus for forming a non-woven mat of nanofibers by using a pressurized gas stream comprises a first member having a supply end defined by one side across the width of said first member and an opposing exit end defined by one side across the width of said first member; a second member having a supply end defined by one side across the width of said second member and an opposing exit end defined by one side across the width of said second member, the second member being located apart from and adjacent to said first member, the length of said second member extending along the length of said first member, said exit end of said second member extending beyond said exit end of said first member, wherein said first and second members define a first supply slit; and a third member having a supply end defined by one side across the width of said third member and an opposing exit end defined by one side across the width of said third member, said third member being located apart from and adjacent to said first me

Abstract: A fiber spinning device and process for manufacturing a web of fibers in the nature of a homogeneous mixture of fibers of different characteristics. Monocomponent fibers of different polymers can be extruded side-by-side from the same die system. Sheath/core bicomponent fibers can be alternated with monocomponent fibers formed of the same core polymer as used in the bicomponent fibers. Bicomponent fibers having a common core polymer and different sheath polymers can be extruded from alternate spinneret orifices in the same die plate. Multiple distribution plates are provided with surface grooves or depressions to direct polymer materials from independent sources to only selected spinneret openings in an array of spinneret openings while maintaining the polymers segregated from each other.

Abstract: A method and apparatus for monitoring the momentum of a meltspun jet thermal core used for making thermoplastic filaments is presented to aid in the uniformity of formation and elimination of waste in thermoplastic filament nonwoven web formation. The apparatus is easily and economically constructed and is relatively insensitive to positioning variations in the air stream of the filament formation apparatus.

Abstract: An arrangement for forming a web of fibrous media wherein at least one formed layered portion is attenuated from a first die source selectively unto a first collector and successively combining such portion with at least another formed layered portion which is attenuated from a second die source selectively unto a second collector, at least one of the outer surfaces of the web of fibrous media being of comparatively smooth skin-like nature to minimize projecting fiber ends.

Abstract: A woody formed article, characterized as being produced by admixing a woody material W and, as a binding agent, a fibrous and/or ribbon shaped thermoplastic resin R which is easy to be intertwined with the woody material W, and molding the resultant mixture. The thermoplastic resin R is preferably admixed in a state of being heated and melted. A method for producing a woody formed material, characterized in that it comprises providing a mat M of a raw material mixture Mx of a woody material W and a fibrous and/or ribbon-shaped thermoplastic resin R and subjecting the mat M to heat pressing, or comprises, in admixing the woody material W with the above fibrous thermoplastic resin R, stretching and thinning the resin R by means of a hot wind and/or a cold wind pressure, and admixing homogeneously it with the woody material W by utilizing a negative pressure zone due to the hot wind and/or the cold wind, to prepare a mat M of a raw material mixture Mx, and then subjecting the mat M to pressing.

Abstract: A melt blowing die for extruding filaments of a polymer by a suitable configured air supply system to provide critical influencing and control over the molecular orientation, crystallinity and crystal orientation in high speed fiber spin line applications. Control of the both the magnitude and location of the applied shearing force is provided, through the design characteristics of the air supply system and, in particular, the attenuation of the filament through an attenuation slot; in one form in conjunction with the introduction of the air flow to the filament in a parallel flow caused by a Coanda bend in a second form in conjunction with a properly designed internal channel.

Abstract: 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.

Abstract: The present invention provides a process and apparatus for blow spinning continuous fibers. The novel process utilizes a tensioning device to preclude slack in the fiber. The present invention also provides novel fiber products which utilize continuous fibers prepared by a blow spinning process.

Abstract: A method and an apparatus for melt spinning a multifilament yarn from a thermoplastic material, wherein a spinneret extrudes the thermoplastic material to strandlike filaments, which are initially in liquid form and then cooled to cause their solidification. For purposes of cooling, the filaments are precooled in a cooling zone downstream of the spinneret in such a manner that the filaments do not solidify. Subsequently, the filament bundle advances by the action of a coolant stream directed in the direction of the advancing yarn into a tension zone and undergoes further cooling until the filaments solidify in a solidification zone within the tension zone. To maintain the location of the solidification zone within the tension zone in a predetermined desired range thereof, an adjustable cooling of the filaments within the cooling zone is provided.

Abstract: Mechanically divisible multicomponent fibers are disclosed having at least a first component comprised of poly(lactic acid) polymer and at least a second component comprised of an aromatic polyester. The multicomponent fibers are particularly useful in the manufacture of nonwoven structures, and in particular nonwoven structures used as synthetic suede.

Abstract: A process for preparing nonwoven webs comprising 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 comprising multiple component, continuous filaments having high levels of three-dimensional helical crimp.

Abstract: 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.

Abstract: A process for forming multiple component meltblown webs in which a poor-spinning polymer is co-spun with a good-spinning polymer in a meltblowing process using high throughput and short die-to-collector distances.

Abstract: A fiber insulation product for use as, e.g., a ductliner, includes at least one textile fiber layer laminated with at least one rotary and/or flame attenuated fiber layer. The fiber laminate provides improved thermal and acoustic insulation and excellent strength, at a low production cost.

Abstract: A unique isotropic sub-denier spunbond nonwoven product created by an apparatus and method comprising a unique multi-head resin metering system, a spinneret head with spinning sections, separated by a quench fluid extraction zone, a two sided, multilevel quench system, a fluid volume control infuser system which automatically guides the filaments into the filament drawing system while conserving energy by using a portion of the quench fluid as part of the drawing fluid and also minimizing turbulence at the entrance to the draw slot. The filament drawing system comprises a draw jet assembly with adjustable primary and secondary jet-nozzles and a variable width draw jet-slot. The entire draw jet assembly is moveable vertically for filament optimization. The offset, constant flow secondary jet-nozzle system provides an unexpectedly high velocity increment to the filaments by oscillating the filaments and increasing their drag resulting in remarkably low fiber denier on the order of 0.5 to 1.2.

Abstract: A multi-density fibrous structure comprising a plurality of discrete pseudo-apertures disposed therein. The pseudo-apertures have individual areas of at least about 3 square millimeters and a basis weight from about 0.1 to about 5 gram per square meter. The fibrous structure can have from about 9,000 to about 90,000 pseudo-apertures per square meter.

Abstract: 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.

Abstract: The invention relates to a method for producing fibrous materials from thermoplastic material, wherein thermoplastic material is molten and fed into a rotating reactor to form a molten film and the fibers are formed on and stretched out along an open edge of the reactor. The fibers are formed on the reactor edge without using nozzles or ducts that are susceptible to clogging so that the rotating reactor is heated in such a way that the molten film has a temperature close to decomposition temperature of the thermic plastic material and the reactor is rotated on the edge at an orbital speed of no less than 10 m/s.

Abstract: An apparatus for manufacturing a nonwoven fabric has a spinning mechanism having a plurality of nozzles for extruding filaments, and a conveyor for collecting and delivering the extruded filaments. Between the spinning mechanism and the conveyor, there are disposed a high-speed air stream generating mechanism for generating a high-speed air stream to carry the filaments extruded from the nozzles to attenuate the filaments, and an air stream vibrating mechanism for periodically changing the direction of the high-speed air stream in the machine direction of the conveyor.

Abstract: The present invention is directed to a draw jet for drawing thermoplastic polymer filaments comprising a drawing slot defined by an entrance member comprising a converging passageway communicating with a continuing passageway, terminating at an outlet portion, a drawing member comprising an inlet portion having a drawing gap width of about 2.0 to about 10 mm communicating with said outlet portion of said entrance member, and at least one air nozzle for directing high speed air onto said filaments in a downstream direction positioned between said outlet portion of said entrance member and said inlet portion of said drawing member, and with a nozzle gap width wherein the gap ratio of said drawing gap width to the combined width of all of said nozzle gaps is from about 1.0 to about 10.

Abstract: A process for the relaxation of interlayer sheet is disclosed containing a heating section, an air-cushion table which serves to induce interlayer sheet relaxation and cooling, a sheet tension regulating step embodying a catenary loop and continuous depth measurement, followed by a cooling step to thus condition the relaxed sheet in accordance with needs. The disclosure herein equally refers to an apparatus suitable for carrying out the interlayer sheet relaxation in accordance with the process of the invention.

Abstract: A novel composition is disclosed comprising about 80 to about 99 weight percent based on the composition, of a linear ultra low density polyethylene (LULDPE) and about 1 to about 20 weight percent of a propylene polymer comprising 0 to about 40 weight percent olefin comonomer units having 2 to 10 carbon atoms and from about 60 to about 100 weight percent propylene, based on the propylene polymer, the propylene polymer having a Brookfield Thermosel viscosity of about 1 to about 30,000 mpa·s at 190° C. and a needle penetration of about 5 to about 300 dmm at 23° C. Also disclosed are films produced from the composition, both blown and cast, and both monolayer and multilayer. Also disclosed are processes for stretch wrapping and forming blown and cast film.