Production Of Continuous Or Running Length Patents (Class 264/555)
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Patent number: 6495078Abstract: The present invention relates to a method of producing a transversely aligned web comprising the steps of extruding melted resin from a spinning nozzle to direct the metal resin downward, blowing off a primary airflow at a high temperature and at high velocity from an annular primary airflow nozzle, blowing off a pair of secondary airflows at a high temperature from a pair of secondary airflow nozzles, colliding with the pair of airflow blown off from the pair of secondary airflow nozzles each other below the spinning nozzle, spreading the colliding secondary airflow at least partly in the width direction of the conveyor, and piling on the conveyor the spun filaments so that transversely aligned web is formed of the filaments which are aligned in the width direction of the conveyor.Type: GrantFiled: September 29, 2000Date of Patent: December 17, 2002Assignees: Nippon Petrochemicals Co., Ltd., Polymer Processing Research Institute, Ltd.Inventors: Kazuhiko Kurihara, Yoichi Mazawa, Yoshiro Morino
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Publication number: 20020163107Abstract: A spinning die for spinning mesophase pitch into carbon fibers. The die includes a central cavity having a bottom and at least one side wall which intersects the bottom. At least one capillary for forming a fiber is in fluid communication with the cavity, the capillary having a first open end, a second open end, an axis and a diameter (d). A flow disruption shoulder is positioned at the juncture of the bottom of the central cavity and the first open end of the capillary to create turbulence at the capillary entrance.Type: ApplicationFiled: May 1, 2001Publication date: November 7, 2002Inventors: John A. Rodgers, Roger A. Ross, Daniel F. Rossillon
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Publication number: 20020158362Abstract: 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: ApplicationFiled: February 26, 2002Publication date: October 31, 2002Applicant: NIPPON PETROCHEMICALS , CO., LTD.Inventors: Yuki Kuroiwa, Kazuhiko Kurihara, Kazuhiro Yabe, Shin-ichi Umejima, Yoshiro Morino
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Patent number: 6471910Abstract: Nonwoven fabric is formed from a spunbond process by extruding generally ribbon-shaped fibers 126 through slot-shaped orifices 124 of a spinneret 122. The ribbon-shaped fibers are rapidly quenched after extrusion to achieve a substantially uniform molecular orientation throughout a transverse cross section of the fibers, yielding stronger fibers. The rapid quenching results largely from the relatively high aspect ratio (thinness) of the fibers and the relatively large surface area of the fibers, which permits the fibers to quickly cool throughout the transverse cross section. The ribbon-shaped fibers are drawn longitudinally by an aspirator 128 that exerts a generally downward force produced by an air stream that longitudinally stretches and transversely attenuates the ribbon-shaped fibers in such a manner that the transverse cross-sectional shape of the ribbon-shaped fibers enhances the interaction between the air stream and the ribbon-shaped fibers to maximize the downward force.Type: GrantFiled: March 22, 2000Date of Patent: October 29, 2002Assignee: Hills, Inc.Inventors: Jeffrey S. Haggard, W. Scott Harris, William H. Hills, Fumin Lu, Arnold E. Wilkie
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Publication number: 20020135106Abstract: 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.Type: ApplicationFiled: March 18, 2002Publication date: September 26, 2002Applicant: TOYODA BOSHOKU CORPORATIONInventors: Takanari Takagaki, Koushin Wakayama
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Patent number: 6454989Abstract: The present invention provides continuously crimped propylene polymer nonwoven fabrics as well as processes for forming crimped multicomponent propylene polymer fibers by melt-attenuating extruded multicomponent fibers with heated or unheated air wherein the fibers spontaneously crimp without the need for additional heating and/or stretching steps.Type: GrantFiled: November 10, 1999Date of Patent: September 24, 2002Assignee: Kimberly-Clark Worldwide, Inc.Inventors: James Richard Neely, Darryl Franklin Clark, Ty Jackson Stokes, Chad Michael Freese, Rebecca Willey Griffin
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Patent number: 6454975Abstract: Bulk yarns having improved elasticity and recovery and methods for their manufacture are described. A first embodiment of the invention involves providing a solution-dyed multifilament yarn of polybutylene terephthalate (PBT) and a multifilament yarn of a second thermoplastic polymer to an air jet texturizer such that the PBT component forms a core and the other yarn forms a plurality of loops and coils extending outwardly from the core. In addition to a high degree of elasticity and recovery, the composite yarn also has a low amount of shrinkage, which enables the yarns to be used in the production of woven fabrics without significant losses in fabric yield. Another embodiment of the invention involves false twisting a multifilament PBT yarn and a second multifilament yarn as individual threadlines to impart crimp thereto, then entangling the two components together using an air interlacing jet, to produce a bulk yarn having high elasticity and recovery.Type: GrantFiled: May 31, 2000Date of Patent: September 24, 2002Assignee: O'Mara IncorporatedInventors: J. Joseph O'Mara, Jr., Anthony Nesbitt Dotson
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Publication number: 20020125601Abstract: A melt spinning apparatus includes fiber producing features to produce multi-component filaments by extruding two or more single-component strands that combine after extrusion and are then attenuated by process air. The two or more liquid materials do not contact one another in the spinpack. Separation of the two types of liquid material throughout the spinpack prevents premature leakage between two liquid materials and allows for an optimized temperature for each type of liquid material for proper extrusion.Type: ApplicationFiled: March 9, 2001Publication date: September 12, 2002Inventor: Martin A. Allen
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Publication number: 20020117782Abstract: 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.Type: ApplicationFiled: December 21, 2000Publication date: August 29, 2002Inventors: Bryan David Haynes, Jeffrey Lawrence McManus, Justin Max Duellman, Darryl Franklin Clark, Roger Bradshaw Quincy
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Publication number: 20020117770Abstract: Described herein are 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.Type: ApplicationFiled: November 1, 2001Publication date: August 29, 2002Applicant: Kimberly-Clark Worldwide, Inc.Inventors: Bryan David Haynes, Matthew Boyd Lake, Hannong Rhim
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Publication number: 20020101011Abstract: In method for the production of industrial filament yarns by swirling a polyester multifilament at increased temperature, under a thread traction force of less than 140 cN, in an air-loaded swirl nozzle consisting of a nozzle body with a perforated plate and a baffle plate, the heat is directly transmitted to the polyester multifilament and the air is directly transmitted, via the nozzle body, to a highly heat-conductive metal block which is connected directly to the baffle plate and in which a bore is provided for receiving a heating body.Type: ApplicationFiled: November 20, 2001Publication date: August 1, 2002Inventor: Istvan Csonka
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Publication number: 20020089098Abstract: A granular, ground filler of plant origin, such as kenaf fiber, is mixed into a synthetic resin to form a melted synthetic resin Ca, which is extruded from an output port 36 of a low-pressure extruder 30 as an intermediate resin layer C. A first coating material A and a second coating material B are superimposed on the two surfaces of the intermediate resin layer C. Thereafter, both coating materials A and B are pressed and adhered to the melted intermediate resin layer C by a roller press 50.Type: ApplicationFiled: July 10, 2001Publication date: July 11, 2002Applicant: Araco Kabushiki KaishaInventors: Tamotsu Nagaya, Mitsuharu Aoyama, Kouichi Oshitani, Shinji Tomita, Shigenori Hirota
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Publication number: 20020089093Abstract: 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: ApplicationFiled: November 29, 2001Publication date: July 11, 2002Inventors: Jeffrey E. Fish, Lamar H. Gipson, Jark C. Lau
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Patent number: 6416859Abstract: Polymeric compositions include a nonaqueous additive system having dispersant-coated pigments physically dispersed in a liquid nonaqueous polymeric carrier which may be added directly to a melt flow of a polymeric host material. The additive system employed in the polymeric systems is most preferably in the form of a particulate paste which can be added in metered amounts (dosed) to a melt flow of the polymeric host material prior to being spun into filaments. By providing a number of additive systems having a number of different additive attributes, and controllably dosing one or more into the melt flow of host polymeric material, shaped objects of the polymeric material (e.g., melt-spun filaments) having different additive attributes may be produced on a continuous basis without shutting down the shaping operation.Type: GrantFiled: October 17, 2000Date of Patent: July 9, 2002Assignee: BASF CorporationInventors: Donald Caswell, Frank R. Jones, David B. Ledford, Stanley A. McIntosh, Gary W. Shore, Karl H. Buchanan, Wayne S. Stanko, G. Daniel Gasperson, Charles F. Helms, Jr.
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Publication number: 20020073662Abstract: A filter portion of a filter includes a plurality of bag-like members. The bag-like members are formed in a container shape having an opening and disposed with intervals therebetween. The periphery of the opening of each bag-like member is supported by a supporting member, and the bag-like members are mutually connected by the supporting member. Consequently, the strength of the filter portion comprising the bag-like members is improved.Type: ApplicationFiled: December 14, 2001Publication date: June 20, 2002Applicant: TOYODA BOSHOKU CORPORATIONInventors: Kouichi Oda, Minoru Honda, Takanari Takagaki
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Publication number: 20020070471Abstract: A method of manufacturing a non-woven material uses a contoured honeycomb drum with an outer microporous surface, more particularly with a contoured outer surface, for the manufacture of contoured non-woven fibrous materials. The method can use spunbonded, melt blown, or electro-static spun techniques for depositing solidifying filaments on the microporous surface such that the non-woven material conforms to the contour of the drum. The drum facilitates continuous production of non-woven articles with three-dimensional shapes such as surgical masks or pleated air filters. Airflow through the drum can be controlled with an internal adjustable manifold with independent valves to obtain non-woven material articles of various configurations and properties. In addition, efficiency can be improved by including turning vanes. Vacuum or pressure can be applied.Type: ApplicationFiled: December 8, 2000Publication date: June 13, 2002Inventors: George Lee, George J. Bontaites
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Publication number: 20020063364Abstract: A system and process is provided for producing spunbond nonwoven fabric. 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.Type: ApplicationFiled: August 2, 2001Publication date: May 30, 2002Applicant: BBA Nonwovens Simpsonville, Inc.Inventors: Thomas B. Taylor, Robert C. Alexander
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Publication number: 20020060382Abstract: 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.Type: ApplicationFiled: October 30, 2001Publication date: May 23, 2002Applicant: Weyerhaeuser CompanyInventors: Mengkui Luo, Vincent A. Roscelli, Amar N. Neogi, James E. Sealey, Richard A. Jewell
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Publication number: 20020041045Abstract: Electret fibers that contain a polymeric material and a fluorochemical additive. The electret fibers have a low level of extractable hydrocarbon material. Electret filters that have low extractable hydrocarbon levels exhibit improved filtration performance.Type: ApplicationFiled: September 25, 2001Publication date: April 11, 2002Applicant: 3M Innovative Properties CompanyInventors: Alan D. Rousseau, Joel W. Miller
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Patent number: 6365091Abstract: The invention concerns a method for making industrial continuous filament yarn by entangling a polyester multifilament yarn at high temperature, under yarn traction force less than 140 cN. By means of a tangling cop tube consisting of a body (1) provided with a perforated plate (2) and a deflection plate (3), heat is directly transmitted to the polyester filament and the air passing through the cop tube body (1) is directly transmitted to a metal block (8) with high thermal conductivity directly connected to the deflection plate (3). In the device for implementing said method, the deflection plate (3) is directly connected to a metal block (8) with high thermal conductivity, wherein a bore (7) is provided for housing a heating element. The polyester continuous filament designed for spinning applications, with a yarn count of 500-2000 dtex, has a resistance of at least 70 cN/tex for a breaking elongation less than 24%, and a knot strength higher than 80% and a spacing between 2 knots more than 4.0 cm.Type: GrantFiled: February 2, 2000Date of Patent: April 2, 2002Assignee: Rhodia Filtec AGInventor: Istvan Csonka
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Publication number: 20020033562Abstract: A nonwoven fabric from spun fibers wherein the density of the spun fibers in the fabric varies between strips of relatively high density and strips of relatively low density. The strips extend along the length of the fabric in the machine direction in an alternating pattern, with the high density strips separated from each other by low density strips. The alternating high density and low density strips provide the fabric with a higher percent elongation in the cross direction than in the machine direction. The alternating pattern is achieved through use of a pattern screen defining a plurality of elongated air permeable regions separated by elongated substantially or relatively air impermeable regions, the elongated regions extending in the machine direction in an alternating pattern, with the air permeable regions separated from each other by the substantially or relatively air impermeable regions.Type: ApplicationFiled: September 14, 2001Publication date: March 21, 2002Inventors: Michael Kauschke, Mordechai Turi
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Publication number: 20020025433Abstract: 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.Type: ApplicationFiled: January 11, 2001Publication date: February 28, 2002Inventors: Jing-Chung Chang, Joseph V. Kurian, Young D. Nguyen, James E. Van Trump, George Vassilatos
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Publication number: 20020013112Abstract: A method of manufacturing a multi-layered web uses contoured honeycomb drums for the manufacture of non-woven webs used to make the multi-layered web. The method can use spunbonded, melt blown, or electro-static spun techniques for depositing solidifying filaments on outer collection surfaces of a multi-drum system. The multi-drum system may be employed to improve multi-layered web uniformity and the overall quality of the multi-layered web by presenting a single optimal collection surface for each independent web layer being produced.Type: ApplicationFiled: June 19, 2001Publication date: January 31, 2002Inventors: George J. Bontaites, George Lee
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Patent number: 6338814Abstract: A spunbond web formation apparatus includes a spinneret (1) of a spin pack (2) that extrudes an array of fibers (5) that are drawn into an aspirator (6). The attenuated fibers (8) discharged from aspirator (6) are deflected sideways by a Coanda device (7) that entrains the exiting air stream along with the fibers. The fibers are deposited on a vertically moving belt (9) and subsequently bonded by calender rolls (20, 21) to form a non-woven spunbond web. The spinning distance L is adjusted by vertically moving the aspirator (6), while the laydown distance M is adjusted by horizontally moving the belt (9) or aspirator (6) or by adjusting the size of the Coanda device (7). Deflection of the fibers exiting the aspirator permits the spinning distance L to be adjusted independently of the laydown distance M, without having to move the spin beam or adjust the height of the web-forming belt.Type: GrantFiled: February 2, 2000Date of Patent: January 15, 2002Assignee: Hills, Inc.Inventor: William H. Hills
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Publication number: 20010054783Abstract: 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.Type: ApplicationFiled: March 15, 2001Publication date: December 27, 2001Inventors: Toshio Kobayashi, Satoru Tange
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Patent number: 6331268Abstract: A nonwoven fabric from spun fibers wherein the density of the spun fibers in the fabric varies between strips of relatively high density and strips of relatively low density. The strips extend along the length of the fabric in the machine direction in an alternating pattern, with the high density strips separated from each other by low density strips. The alternating high density and low density strips provide the fabric with a higher percent elongation in the cross direction than in the machine direction. The alternating pattern is achieved through use of a pattern screen defining a plurality of elongated air permeable regions separated by elongated substantially or relatively air impermeable regions, the elongated regions extending in the machine direction in an alternating pattern, with the air permeable regions separated from each other by the substantially or relatively air impermeable regions.Type: GrantFiled: August 13, 1999Date of Patent: December 18, 2001Assignee: First Quality Nonwovens, Inc.Inventors: Michael Kauschke, Mordechai Turi
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Patent number: 6319455Abstract: A nonwoven fabric from spun fibers wherein the density of the spun fibers in the fabric varies between strips of relatively high density and strips of relatively low density. The strips extend along the length of the fabric in the machine direction in an alternating pattern, with the high density strips separated from each other by low density strips. The alternating high density and low density strips provide the fabric with a higher percent elongation in the cross direction than in the machine direction. The alternating pattern is achieved through use of a pattern screen defining a plurality of elongated air permeable regions separated by elongated substantially or relatively air impermeable regions, the elongated regions extending in the machine direction in an alternating pattern, with the air permeable regions separated from each other by the substantially or relatively air impermeable regions.Type: GrantFiled: July 10, 2000Date of Patent: November 20, 2001Assignee: First Quality Nonwovens, Inc.Inventors: Michael Kauschke, Mordechai Turi
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Patent number: 6319452Abstract: A method of making electret fibers, which method comprises the steps of: blending a polymeric material with a fluorochemical additive compound; extruding the blend at a temperature maintained below 290° C. to form extruded fibers; and annealing and charging the extruded fibers; wherein the polymeric material and extrusion conditions are selected such that the resulting fibers have a level of extractable hydrocarbon material that is less than about 3.0 weight percent based on the weight of the fibers.Type: GrantFiled: January 18, 2000Date of Patent: November 20, 2001Assignee: 3M Innovative Properties CompanyInventors: Alan D. Rousseau, Joel W. Miller
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Publication number: 20010039778Abstract: 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.Type: ApplicationFiled: July 31, 2001Publication date: November 15, 2001Inventor: Daniel W. King
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Patent number: 6312823Abstract: A compostable multilayer film includes a core layer having a first surface and a second surface, a first blocking reducing layer covering the first surface of the core layer, and a second blocking reducing layer covering the second surface of the core layer. The core layer comprises a lactic acid residue-containing polymer having a glass transition temperature (Tg) below 20° C. At least one of the first and second blocking reducing layers comprise a semicrystalline aliphatic polyester. The core layer may be peroxide modified polylactide polymer which exhibits bridging between polylactide polymer chains.Type: GrantFiled: September 29, 1998Date of Patent: November 6, 2001Assignee: Cargrill, IncorporatedInventors: Ali Zakareya El-Afandi, Patrick Richard Gruber, Jeffrey John Kolstad, James Lunt, Christopher M. Ryan, James Zakareya Nangeroni, Nancy Uzelac Buehler, Mark Hartmann, Jed Richard Randall, Andrea Lee Brosch
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Patent number: 6270705Abstract: This invention is directed to a method and system for using laminar barrier inerting techniques to shroud a selected area in an open space covering the polymeric film outlet and/or raw material inlet with inert gas.Type: GrantFiled: February 16, 1999Date of Patent: August 7, 2001Assignee: Praxair Technology, Inc.Inventors: Robert Marcel De Wilde, Pascal Yves Duro
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Patent number: 6245282Abstract: Fibers are produced a from molten thermoplastic fiberizable material in a rotary fiberizing process by passing the fiberizable material through rows of fiberizing holes in an annular sidewall of a fiberizing disk. A first manifold supplies a combustible gas or gaseous mixture into the fiberizing disk where the combustible gas or gaseous mixture combusts to help maintain the fiberizing disk and the molten fiberizable material supplied to the fiberizing disk within a desired temperature range for fiberization. A second manifold supplies a combustible gas or gaseous mixture externally of the fiberizing disk where the combustible gas or gaseous mixture combusts. The products of combustion from the burning of the combustible gases or gaseous mixtures discharged from the first and second manifolds heat an annular fiber attenuation zone surrounding the disk sidewall and help attenuate fibers in the heated attenuation zone.Type: GrantFiled: August 5, 1999Date of Patent: June 12, 2001Assignee: Johns Manville International, Inc.Inventors: John Wayne Baker, Rodney Roger Smalley
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Patent number: 6200120Abstract: A die head assembly for meltblowing thermoplastic material comprising a first chamber for receiving a pressurized fluid, a second chamber for receiving a pressurized molten thermoplastic material, the second chamber defining an outlet through which the molten thermoplastic material exits the die head, and a fluid tube removably securable to the first chamber and defining a passageway having an inlet in communication with the first chamber and an outlet extending at least into the outlet of the second chamber. The die head assembly of claim 1, wherein the outlet of the second chamber defines a longitudinal axis, and the outlet of the second chamber and the outlet of the fluid tube define at least one elongated opening therebetween elongated in a direction extending substantially perpendicular to the longitudinal axis, the molten thermoplastic material passing through the elongated opening as it exits the die head.Type: GrantFiled: December 31, 1997Date of Patent: March 13, 2001Assignee: Kimberly-Clark Worldwide, Inc.Inventors: Jeffrey E. Fish, Jark C. Lau, Bryan D. Haynes
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Patent number: 6183684Abstract: An apparatus for producing a non-woven polymeric fabric web, such as a spunbond web, having filaments of 0.1 to 5 or higher denier with equivalent production rates is provided. A plurality of continuous polymeric filaments are extruded from an extruder and attenuated by a drawing unit that includes a longitudinal elongated slot strategically positioned at an optimum distance very close to the spinneret to increase the filament velocity by reducing air viscous drag on filaments and a drawing unit slot having a lower slot length of approximately 210 mm or less to increase form drag. A web forming table is positioned below the drawing unit for collecting the filaments and forming the filaments into a non-woven fabric web. Filaments of increased tensile strength are created by stress-induced crystallization resulting from higher filament velocity due to increased force on the filaments with less air viscous drag between the filaments and air streams.Type: GrantFiled: March 26, 1999Date of Patent: February 6, 2001Assignee: Ason Engineering, Ltd.Inventor: Fumin Lu
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Patent number: 6146580Abstract: A method of manufacturing a non-woven material using a contoured honeycomb drum with an outer microporous surface, more particularly with a contoured outer surface, for the manufacture of contoured non-woven fibrous materials. The method can use spunbond or melt blown techniques for depositing solidifying filaments on the microporous surface such that the non-woven material conforms to the contour of the drum, and then removing the non-woven material from the drum. The drum of the current invention facilitates continuous production of non-woven articles with three dimensional shapes such as surgical masks or pleated air filters.Type: GrantFiled: November 17, 1998Date of Patent: November 14, 2000Assignee: Eldim, Inc.Inventor: George J. Bontaites, Jr.
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Patent number: 6136261Abstract: A photo film cassette includes a spool core (13) on which photo film is wound in a form of a roll. A cassette shell (3, 4) contains the spool core in rotatable fashion. In each of a pair of disks (16, 17), a bearing hole (16a, 17a) is formed. The disks are secured to first and second ends of the spool core, and regulate edges of the photo film. To produce at least one kind of disk, a continuous sheet (27, 78, 88, 162, 171, 215) of thermoplastic synthetic resin is partially masked with a mask plate (48, 87, 160, 161, 170). A portion of the sheet emerging out of the mask plate is heated at temperature higher than a softening point of the sheet. The emerging portion is subjected to vacuum/air-pressure forming, so as to form a disk-like portion (20) in the sheet. The bearing hole and a contour of the disks is cut in the disk-like portion, to produce the disks.Type: GrantFiled: June 29, 1999Date of Patent: October 24, 2000Assignee: Fuji Photo Film Co., Ltd.Inventors: Akira Wakabayashi, Yukiya Shimizu, Eiji Suzuki, Masayuki Kubota
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Patent number: 6132670Abstract: A process for spinning polymeric filaments into yarn at high spinning speeds for producing yarn of high quality that includes the steps of extruding molten polymer through a spinneret, providing an aspirator at a preselected position relative to the slinneret and, after start up, adjusting the aspirator distance from the spinneret thereby moving the aspirator drawing force closer to the spinneret, forming a yarn path made from the filaments, supplying a finish to the yarn, and drawing the yam up with a take up wheel The spinning speed of the yarn on the take up reel is increased while moving the aspirator containing the drawing force within five to fifty centimeters to the spinneret. Using this method much higher filament velocities can be reached (above 10,000 meters per minute) without breaking the filaments or the yarn.Type: GrantFiled: November 24, 1998Date of Patent: October 17, 2000Assignee: Ason Engineering, Ltd.Inventor: Fumin Lu
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Patent number: 6103181Abstract: A fiber spinning device and process for manufacturing a web of fibers comprising 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.Type: GrantFiled: February 17, 1999Date of Patent: August 15, 2000Assignee: Filtrona International LimitedInventor: Richard M. Berger
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Patent number: 6099282Abstract: The present invention relates to a die for use in textile processes involving nonwoven melt blown fabrics. In a melt blown process, molten polymer resin is injected into a melt blown die and ejected from the die in the form of filaments. The present invention is directed to an improved die nosepiece comprising a multiplicity of adjacent holes offset with respect to each other at an angle greater than or equal to 5.degree. and less than 90.degree., through which resin filaments are ejected.Type: GrantFiled: April 20, 1999Date of Patent: August 8, 2000Assignee: The University of Tennessee Research CorporationInventor: Mancil W. Milligan
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Patent number: 6086800Abstract: This invention is an improved thermoforming process and apparatus for the production of rigid plastic containers. The apparatus employs a molten sheet of thermoplastic material that is processed through two extrusion rolls, thermoformed on the periphery of a rotating form tool, mechanically ejected from the form tool, conveyed to a conventional punch press where the formed articles are trimmed from the sheet then packaged for shipment. The operation of the extruder, extrusion rolls, forming wheel, mechanical ejection and trim stations are operated as a continuous, integrated system.Type: GrantFiled: February 23, 1998Date of Patent: July 11, 2000Assignee: ICON Engineering, Inc.Inventor: Steven F. Manlove
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Patent number: 6074597Abstract: A meltblowing method and apparatus for dispensing an adhesive through a plurality of first orifices of a die assembly fabricated from a plurality of laminated members to form a plurality of adhesive flows at a first velocity, and dispensing air through a plurality of second orifices in the die assembly to form a plurality of air flows at a second velocity. The plurality of first and second orifices arranged in an alternating series so that each of the plurality of first orifices is flanked on substantially opposing sides by one of the plurality of second orifices, wherein the plurality of first and second orifices are oriented to direct non-convergently the plurality of adhesive flows and the plurality of air flows.Type: GrantFiled: February 20, 1999Date of Patent: June 13, 2000Assignee: Illinois Tool Works Inc.Inventors: Kui-Chiu Kwok, Donald L. Van Erden, Hugh J. Zentmyer
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Patent number: 6074592Abstract: A method and associated apparatus in which decorative ribbons of varying thickness, width, and material can be automatically curled. The apparatus serves to impart a tendency to curl the strand in a helical formation by drawing the ribbon in a helical path around a curling tube. The tube is divided into two parts, so that the first part heats the ribbon while in a helical configuration and the second part cools the ribbon while still in the helical configuration, thereby setting into the ribbon material a tendency to curl. The helical path on the tube is defined between convolutions of a helically-wound fin on the exterior of the tube. The tube is hollow and has apertures opening into the helical path, so that temperature-controlled air may be blown into the two parts of the path through the hollow interior of the tube.Type: GrantFiled: July 20, 1998Date of Patent: June 13, 2000Assignee: Berwick Delaware, Inc.Inventor: Scott Shea
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Patent number: 6051180Abstract: A parallel plate nozzle for extruding visco-elastic fluidic materials, useable in the manufacture of non-woven materials, and method therefor dispenses a plurality of first and second fluids from a corresponding plurality of first and second orifices to form first and second adjacent fluid flows. The first fluid flows are drawn and attenuated by not more than one corresponding second fluid flow at a second velocity greater than a first velocity of the first fluid flow to form corresponding first fluid filaments, which are preferably relatively continuous and vacillated chaotically. The first and corresponding second fluid flows are spaced as closely as possible to maximize filament drawing efficiency, and adjacent first fluid orifices are spaced sufficiently apart to prevent merging of the first fluid flows prior filament formation.Type: GrantFiled: August 13, 1998Date of Patent: April 18, 2000Assignee: Illinois Tool Works Inc.Inventor: Kui-Chiu Kwok
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Patent number: 6039911Abstract: A method and apparatus for capping a headed stem fasteners. The precursor web having a backing with a rear surface, a front surface, and a multiplicity of polymeric stems projecting distally from the front surface of the backing is fed into a variable nip between a heated member opposite a support surface. The support surface has a shape generally conforming to the contour of the heated member. The variable nip compressively engages the polymeric stems between the heated member and the support surface so that distal ends of the polymeric stems are deformed. The heated member can be a heated roll or a heated belt. The support surface may be a curved capping shoe or a belt shaped to create a particular nip profile.Type: GrantFiled: January 9, 1997Date of Patent: March 21, 2000Assignee: 3M Innovative Properties CompanyInventors: Philip Miller, Thomas R. LaLiberte
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Patent number: 6015626Abstract: Described is a weather-resistant, plasticizer-free, deep-drawable film based on a semicrystalline ethylene/propylene/diene terpolymer and a homo- and/or copolymer of an alkene plus stabilizers and optional fillers, lubricants, pigments, and other ordinary additives. This film is characterized by the fact that the mixture of the semicrystalline ethylene/propylene/diene terpolymer and the homo- and/or copolymer of the alkene contains:70-30 wt % semicrystalline ethylene/propylene/diene terpolymer (A) with approximately 56-76 wt % ethylene, approximately 15-30 wt % propylene, and approximately 9-14 wt % third component,while the terpolymer (A) has a melt-flow index MFI (230/2, 16) of approximately 5-15.0 g/10 min,and 70-30 wt % homo- and/or copolymer (B) of ethylene and/or propylene,while the homo- and/or copolymer has a melt-flow index MFI (230/2, 16) greater than 2.5 g/10 min. This film is especially suited for the interior covering and fittings of motor vehicles.Type: GrantFiled: February 19, 1998Date of Patent: January 18, 2000Assignee: Benecke-Kaliko AGInventor: Walter Kopytko
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Patent number: 6013223Abstract: An apparatus and process for extruding fiberforming thermoplastic polymers through spinning nozzles arranged in multiple rows are forming a non-woven web of high strength fibers. The molten fibers are accelerated by expanding hot gas flowing parallel to the extrusion nozzles and the fibers to a first velocity and cooled below their melting point, and subsequently accelerated to a higher velocity by an air jet fed with compressed cold air. The resulting fibers have a high degree of molecular orientation and tenacity and are collected on a moving collecting surface as a non-woven web.Type: GrantFiled: May 28, 1998Date of Patent: January 11, 2000Assignee: Biax-Fiberfilm CorporationInventor: Eckhard C.A. Schwarz
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Patent number: 6001303Abstract: An apparatus and process for producing meltblown fibers employs a coflowing primary cold air flow and secondary hot air flow in a meltblowing nozzle. The primary cold air flow provides the majority of the force used to attenuate the polymer stream into fibers, while a secondary hot air flow shrouds the die tip and prevents premature quenching.Type: GrantFiled: December 19, 1997Date of Patent: December 14, 1999Assignee: Kimberly-Clark Worldwide, Inc.Inventors: Bryan D. Haynes, Jeffrey L. McManus, Rick Busby
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Patent number: 5976453Abstract: An expanding device for expanding strand material into a wool-type product includes outer and internal nozzle sections. The outer nozzle section has an entrance portion, an intermediate portion and an exit portion. At least a portion of the internal nozzle section is adapted to be received in the outer nozzle section. It includes a main body portion and a needle portion extending from the main body portion. The main body and needle portions include a first inner passage through which strand material passes to be expanded into a wool-type product. The needle and main body portions define with inner surfaces of the entrance and intermediate portions of the outer nozzle section an inner chamber. The main body portion has at least two bores extending through the main body portion which receive gas supplied by a gas stream source. The at least two bores communicate with the inner chamber and define a path for gas to travel to the inner chamber.Type: GrantFiled: June 29, 1998Date of Patent: November 2, 1999Assignee: Owens-Corning Sweden ABInventors: Bengt G. Nilsson, Lennart O. Svensson
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Patent number: 5972280Abstract: A method of embossing thermoplastic sheet by continuously advancing thermoplastic sheet through an embossing nip defined by a rotating embossing roll with an engraved surface at elevated embossing temperature and an opposite fixed rigid concave member and pneumatically forcing the sheet against the engraved surface while within and continuously passing through the nip.Type: GrantFiled: March 23, 1998Date of Patent: October 26, 1999Assignee: Solutia Inc.Inventor: John C. Hoagland
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Patent number: 5961906Abstract: The use of dispersions of polyurethanes containing urea groups and based on selected starting materials, optionally via the intermediate stage of granules obtained by spray drying the dispersions, for the production of fully biodegradable shaped bodies.Type: GrantFiled: November 4, 1997Date of Patent: October 5, 1999Assignee: Bayer AktiengesellschaftInventors: Hanns-Peter Muller, Jochen Kalbe, Rainhard Koch