Abstract: The apparatus of the present invention employs a collector drum with an electrically charged surface for use in preparing electrically charged meltblown fibrous webs. The apparatus may be used as a primary charging system or, alternatively, with other charging system to enhance the charging of the web. The invention produces webs with exceptional filtration properties.

Abstract: An apparatus (10) is disclosed for simultaneously forming two dough sheets from a single cooker extruder (12), with the dough sheets each being formed by a plurality of dough ropes which are guided by guide posts (44) at equally spaced intervals on a conveyor (16) for passing between the pressing rollers (42) of a sheeting device (18). Specifically, the die (24) attached to the die head (20) of the cooker extruder (12) includes a roof-shaped extension formed by first and second die plates (26) interconnected by their front edges at an obtuse angle. Top and bottom pates (28) are interconnected to the top and bottom edges of the die plates (26). The back edges of the die plates (26) and of the top and bottom plates (28) are interconnected to an annular connection plate (30) which is attached to the die head (20) by bolts (34) passing through counterbored bores (32) in the connection plate (30) and threaded into the die head (20).

Abstract: Fine denier polyester fibers are obtainable from polymer of low molecular weight to have improved uniformity and excellent mechanical properties by a high throughput process.

Abstract: An apparatus for radially quenching melt spun filaments features a quenching chamber having a foraminous distribution cylinder between the filaments and the gas supply chamber with areas of porosity that increases, from a first low value at a location immediately below the spinneret, through a larger value at lower location, and then decreases toward the exit of the quench chamber.

Abstract: There is disclosed a meltblown die head having a heated gas reservoir extending the length of the die head. The heated gas used in the meltblowing process is introduced into the reservoir and serves as a heat source for maintaining the temperature of the polymer and maintaining a uniform temperature of the die assembly during the meltblowing process.

Abstract: An apparatus for forming extruded pasta shapes. The apparatus is a die plate having a plurality of orifices wherein the die plate is heated, e.g., to a temperature of at least about 130.degree. F. (about 54.degree. C.), and preferably about 160.degree. F. (about 71.degree. C.) A coating is provided on only a portion of the interior surface of each orifice such that heat transfer to the paste is substantially inhibited in a given orifice until the cross section of the orifice has reached its smallest value.

Abstract: The present invention relates to spinnerets for forming synthetic filaments having a trilobal or tetralobal cross-sectional shape with substantial convex curves, connected by cusps, along the contour of each lobe. The filaments are especially suitable for making carpets which exhibit low glitter, high bulk, and resistance to fibrillation. The spinnerets have a central circular orifice with three or four radial slots radiating from the orifice. Peripheral orifices are located on the longitudinal axis of each radial slot.

Abstract: A melt-blowing method having notches formed in the tip portions of capillaries of a melt-blowing die. This allows, during spinning, a high-speed gas blowing from orifices of the die to flow through the notches whereby the flow of a molten resin being extruded through each capillary is divided into two parts or more. This prevents fibers from becoming entangled or ball-shaped.

Abstract: Small diameter high strength carbon fibers are produced in a process in which the spinneret has a small diameter, the spinneret capillary temperature is at least 10.degree. C. higher than the predicted spin temperature of the pitch and the pitch flows through a high aspect ratio opening upstream of the spinneret.

Abstract: This invention relates to an extruder having a granulating head for the granulation of a plastic molding compound which does not flow under gravity, more particularly an enzyme concentrate suitable for detergents, to granules having a particle size of at most 1 mm and, more particularly, at most 0.8 mm. To obtain uniform distribution of the molding compound to be processed over the entire cross-section of the molding plate, the granulating head has an externally arranged die plate support carrying perforated disks, a displacement cone arranged behind the die plate support and a preliminary distributor in the form of a perforated plate arranged between the die plate support and the displacement cone.

Abstract: A device for changing the filament count from a spinnerette assembly includes a sealing plate positioned upstream from the spinnerette assembly to prevent the passage of the material being spun into one or more particular spinnerette bores.

Abstract: A meltblowing die assembly features (a) intermittent operation, (b) modular valve actuator to selectively shut off polymer flow, (c) an in-line electric heater, and (d) meltblowing units arranged in side-by-side relationship.

Abstract: A spinneret plate defines at least one counterbore, and within the counterbore, at least one non-round curved capillary. The capillary has a plurality of extending tips, wherein for any one capillary, at least two of the extending tips have a different radius of curvature.

Abstract: Electrically charged meltblown webs are formed by convergingly discharging electrically charged hot air onto a row of extruded polymer fibers to contact the fibers thereby (i) attenuating and stretching the fibers and (ii) imparting an electric charge to the fibers. The fibers may be continuous or discontinuous.

Abstract: A novel spinneret for producing superfine fibers having a total denier of not less than 20 denier and a monofilament denier of not more than 1.1 denier when winding up upon spinning is disclosed. The spinneret has nozzle orifices arranged in a lattice pattern extending toward a quench direction and the right angled direction to the quench direction. The arrangement is provided so as to satisfy the following formulas (1) to (4):(1/5)D.ltoreq.P.sub.i (P-1).ltoreq.(1/2)D (1)(1/2)D.ltoreq.Q.sub.i (Q-1).ltoreq.D (2)Q.sub.i /P.sub.i .ltoreq.2 (3)Q(P-1).ltoreq.H.ltoreq.P.times.Q (4)wherein D is an effective diameter of the spinneret (mm), P.sub.i is a nozzle orifice pitch in the quench direction (mm), P is the maximum number of nozzle orifices arranged in the quench direction, Q.sub.i is a nozzle orifice pitch in the right angled direction to the quench direction (mm), Q is the maximum number of nozzle orifices arranged in the right angled direction to the quench direction and H is a total number of the orifices.

Abstract: A free-standing die assembly, for use in the production of extruded products, which is mounted as a separate unit apart from the extruder in which product ingredients are processed. The die assembly includes a center plate having a die unit secured to one or more planar faces of the plate, with each of the die units having at least one die orifice in the outer surface thereof. Hot flowable dough processed in an extruder is carried via suitable tubing to the center plate from where it is distributed to the planar faces of the plate and into the die units, from which it is extruded through the die orifices in the die units. The die assembly may be modified to permit the production of coextruded product from the die orifices in the die units of the assembly. One or more of the die assemblies may be associated with a single extruder. In accordance with a preferred embodiment, die units are secured to opposing side faces of the center plate to provide a free standing, dual-faced die assembly.

Abstract: Novel method and apparatus for forming a substrate or honeycomb article with multi-cellular densities and/or multi-cellular geometries by positioning a pair of extrusion dies adjacent one another, such that one surrounds the other, and such that discharge slots of one die produce different cellular densities and/or geometries from that of the other. Further, an annular batch reservoir is formed between the mating surfaces of such dies so as to facilitate the flow of batch material from one die to the other, and an integral inner skin is formed between the differing cellular structures.

Abstract: In pelletizing apparatus, an orifice plate forms plastic strands, the orifice plate having a distributor channel at its inlet side in the form of a grooved annular inlet. A cutting plate is provided with outlet openings which are connected to the distributor channel by inlet channels arranged around the distributor channel in successive adjoining relation. In order to improve the melt flow in the inlet region, the distributor channel has a cross-sectional width in the radial direction that is less than the radial extent of the inlet channels where they are joined to the outlet openings. The longitudinal axes of adjacent inlet channels are arranged at an angle of inclination relative to each other.

Abstract: Novel method and apparatus is disclosed for forming an integral skin on an extruded honeycomb structure, wherein the skin material is collected in a peripheral area of a die body, is passed through an adjustable flow control gap, and then through a predetermined gap thickness of a skin forming slot so as to then knit with the honeycomb structure extruded by the die prior to being extruded from the die. A plurality of flow control plates having different internal peripheral diameters are provided so as to provide different flow control gaps, as desired. In addition, a plurality of shims having different thicknesses are provided so as to position the mask a given distance away from the die, and thereby control the skin thickness gap. The die may be formed by merely relieving a peripheral portion of a typically automotive catalytic converter extrusion die and providing a trim ring about the relieved portion so as to inhibit the flow of batch material from partially open feed holes.

Abstract: A meltblowing apparatus includes a die having a triangular nosepiece with a plurality of orifices at the apex of the nosepiece; a pair of air chambers positioned on both sides of the die; converging air passages formed on each side of the nosepiece; a plurality of holes interconnecting each air chamber with its associated air passage; and an air flow deflector in each flow passage.

Abstract: Melt blown die apparatus are provided for producing a fibrous web from a polymer material. The apparatus includes a die and a primary gas assembly for providing a pressurized gas at the exit end of the die. The primary gas assembly includes a tubular chamber for receiving and distributing the pressurized gas along the first dimension of the die. The tubular chamber includes a pressure control diverter for providing a substantially even gas pressure distribution across the first dimension of the die. This apparatus can be operated at exit air flow rates of up to about 200 pounds of air per pound of polymer at a polymer flow rate of about 4.0 pounds per linear die inch per minute. Constructions are provided for minimizing bending moments and for providing thermal and structural stability to the apparatus.

Abstract: A die assembly for configuring extrudate flow is provided. The die assembly includes a die head having a feed member passage, first and second die head passages, and first and second die surfaces respectively associated with the first and second die head passages. The die head passages are located intermediate the corresponding die surfaces and the feed member passage. A feed member is supported in the feed member passage of the die head and has a feed passage and a feed opening for supplying extrudate to the die head. The feed member is supported for relative movement within the die head whereby the feed opening may be moved to communicate with either the first die head passage or the second die head passage. The central axis feed of the feed opening is moveable with respect to the central axis of the first or second die head passage to correspondingly configure extrudate exiting the respective die head passage when the feed opening is in communication with this die head passage.

Abstract: An extrusion die for forming honeycomb type structures, such as filters. In a typical prior art extrusion die, the feed holes are circular in cross section throughout their length and feed into respective intersecting discharge slot portions. There is an abrupt change in cross section area and shape, from circular to cross shaped, at the entrance to the discharge slots. This construction results in flow inhibiting land portions at the entrance to the discharge slot portions. Such a construction causes bending forces or moments on these flow obstructing entrance portions of the discharge slots and also subjects them to increased abrasive wear whenever the material being extruded contains ceramic or other hard particles. By this invention, the feed holes are uniformly tapered from an annular or polygonal transverse cross section at their input ends to a (conventional) cross shape at their outlet ends where by feed the discharge slots.

Abstract: A method and an apparatus for extruding a ceramic batch supplied from a vacuum auger machine into a formed body by a plunger molding machine, wherein the temperature distribution of the ceramic batch at the outlet portion is measured and is controlled so as to supply the ceramic batch having substantially a uniform temperature to the plunger molding machine from the vacuum auger machine.

Abstract: A melt-spinning apparatus includes a feed device for feeding a molten polymer composition from at least one extruder to a multiplicity of spinning orifices provided by a plurality of spinnerets for producing a multiplicity of discrete continuous extrudates emerging from the orifices in a generally downward direction; quenching devices for cooling the extrudates and for solidifying them to form a multiplicity of discrete continuous filaments; take-up and stretching devices provided downstream from the orifices for contacting and stretching the filaments; the quenching devices include guides for directing at least one stream of a cooling gas having a quenching temperature onto a portion, at least, of the extrudates; the orifices or spinnerets are arranged to form an annular array and a portion, at least, of the quenching devices is provided to direct the cooling gas stream in a substantially radial manner onto the extrudates that emerge from the orifices in the annular array.

Abstract: A trilobal or quadrilobal fiber formed from thermoplastic polymers, said fiber having a cross-section comprised of a central core having three or four T-shaped lobes, the legs of each intersecting at the center of said core such that the angle between the legs of adjacent lobes is from about 80.degree. to about 130.degree..

Abstract: An improved spin head for a melt spinning machine is capable of being readily disassembled. The spin head is provided with a tubular sleeve member which defines an elongate open ended interior cavity oriented along the melt spinning axis and a core insert member removably received within this interior cavity. A spinneret is removably coupled to an end of the core insert member and a pump is fluid connected via polymer passageways defined in the insert member between a molten polymer supply apparatus (e.g., a screw extruder) and the spinneret. Heating elements (which, in the preferred embodiment, are integral with the sleeve member) maintain the various structural components at elevated temperatures so that, during operation, the polymer is likewise maintained at elevated temperatures sufficient to maintain it in a molten state.

Abstract: The invention relates to an extrusion plate for the production of membranes of an organic material including at least one longitudinal passageway. This extrusion plate includes an annular body (1) provided with a cylindrical cavity into which opens at least one radial fluid conduit (5), an upper ferule (3) adapted to be inserted into the cavity of the body and comprising at least one hollow needle (8) extending in the extension of said insert and a longitudinal centering fluid feed conduit (9), and a lower insert (4) adapted to be inserted into the cavity of the body and having a bore (6) defining an extrusion chamber around the needles (8). The upper (3) and lower (4) inserts are in abutment at assembly faces at the level of which open the fluid conduits (5), and a fluid passage (7) is provided on these opposing faces in continuity with the passages (5), for communicating with the extrusion chamber.

Abstract: A melt-blowing die including a plurality of capillaries and orifices is used to obtain more than one flow of a molten resin from the tip portion of the capillary die by providing a plurality of notches on the tip portion of the die. A high-speed gas flows through the notches between the tip portions of the die to divide the resin into more than one flow. The invention prevents fibers from becoming entangled or ball-shaped.

Abstract: In accordance with a preferred embodiment, a monolith extrusion die is formed by a plurality of individual tube elements bonded together as a tube stack defining a plurality of extrudable material feed holes and reference guides for a plurality of individual shaping teeth each having a root segment located in a reference guide and each having a shaping head spaced apart from adjacent shaping heads to form intersecting rows of extrusion slots having a shape corresponding to the monolith formed by extrudable material directed from the feed holes through the shaping teeth.

Abstract: A method of making a honeycomb die by using an electrode with parallel grooves in an electrical discharge machining process. The parallel grooves in the electrode are formed by a grinding wheel having a reverse tapered shape. The grinding wheel is progressively dressed during cutting of the parallel grooves.

Abstract: Disclosed is a novel polyester fiber, such as a poly(ethylene terephthalate) fiber, having at least one continuous groove wherein the surface of the groove is rougher than the surface outside the groove. Also disclosed is a drafting process involving surface hydrolysis for the preparation of such fibers. The fibers have improved cover, softness, and wetting characteristics.

Abstract: An improved spinneret for use in dry spinning spandex filaments has coaxial inner and outer rings of grouped orifices. The number of grouped orifices in each ring is equal. Each group of orifices is radially equally spaced from the next preceding or next succeeding orifice group. The spinneret provides spandex yarns with improved decitex uniformity.

Abstract: An extrusion die is described for extruding a polymer from a reactive precursor mixture without plugging of the die. The extrusion die includes a die inlet leading to at least one channel having dimensions which produce a wall shear stress value that exceeds the critical wall shear stress value for the particular reactive precursor mixture to prevent occlusion of the die. The preferred configuration of the die channels is a tree-like structure to obtain a coating width which is greater than the dimensions of the individual channels. Other features of the invention include a method for determining the critical wall shear stress value and a method for extruding reactive precursor mixtures.

Abstract: A die tip of a meltblowing die is mounted on the die body to provide a residual compressive force in the die tip nosepiece thereby resisting internal extrusion pressures.

Abstract: A rigid mini-monolith structure formed by extrusion from a die. Such structures are useful as catalyst supports for treating exhaust gases from automobile. The structure is in the shape of a right circular cylinder with a plurality of internal cells extending along the substrate and an opening on both ends. In order to provide maximum crushing strength of the structure, as well as permitting uniform intercell wall thickness at the downstream face of the extrusion die which forms the structure, the majority of the cells are formed in the transverse cross section of a truncated (circular) sector and have the property that they each possess the same hydraulic diameter, although not all are of the same transverse cross sectional shape. The invention also is defined by a novel extrusion die formed by a plurality of concentric, collared tubes provided with longitudinally running slots in the tubes and notches on the collars, the tubes being radially spaced from each other.

Abstract: A perforated granulating plate construction in which conically tapering inlet channels are connected to several outlet channels, the collective cross-sectional area of the outlet channels being substantially equal to the cross-sectional area at the outlet of the associated inlet channel. The outlet channels form an angle of inclination with respect to the longitudinal axis of the associated inlet channel and the discharge outlets of the outlet channels are arranged in a plane about an axis of symmetry which is coincident with the longitudinal axis of the inlet channel.

Abstract: Shaping device and method for shaping extrudable material including at least one extrusion nozzle for feeding extrudable material and being supported in a carrier common to all nozzles, motors for moving either the carrier or a movable support surface for receiving extruded material directly from the nozzles and a programmable computer for controlling the motors.

Abstract: An extrusion die assembly for making honeycomb structures of ceramics, glass, and other extrudable materials. The assembly is provided with an apertured, flow controlling forming plate placed against the input (upstream) surface of the extrusion die. The forming plate has a central opening through which the batch material to the input face of the die passes. A series of angularly spaced, flow controlling openings lies radially outwardly of the rim of this central opening. These forming plate openings are axially aligned with a shim reservoir downstream of the discharge slots of the die. This arrangement permits both the flow volume and rate of the batch material being extruded to the skin forming portions of the die assembly to be at least partially independently controlled relative to the flow volume to the main, radially central portion of the extrudate. By this construction, the formation of air checks in the shim reservoir and the formation of rippled skin on the extrudate is inhibited.

Abstract: Meltblowing apparatus includes electrodes spaced from the meltblowing die discharge and protruding grounded emitters positioned proximate the die discharge. The preferred emitters are in the form of pointed pins spaced along and flanking the die discharge.

Abstract: A metal block melt blowing die has paired longitudinal grooves within its bottom surface adjacent a triangular cross section die tip nose. A series of vertical circular bores within the body opening to the grooves support cartridge heaters sized to the bores permitting rod penetration into the bores from either end for removing wedged cartridge heaters. The grooves carry upper and lower air deflector blocks which are spaced from each other to form a tortuous air passage therebetween for insuring turbulence to the attenuating air streams passing therethrough and between laterally and vertically adjustable air plates for varying the air gap between the ends of the air plates at the bottoms of the grooves and the die tip nose and the velocity of the air streams converging at the die tip extrusion holes. A rectangular frame carries unitary diametrically opposed mounting blocks within the rectangular frame with cylindrical air manifolds on respective sides thereof. The die mounts at its ends to the blocks.

Abstract: A honeycombed structure is extruded and wash coat applied to the interior channels of the structure before the honeycomb structure is separated from the die in which it is formed. This method produces the honeycombed structure using a die that includes a die body having an inlet and an outlet side, a plurality of parallel pins defined by the body that correspond to the shape of the channels in the honeycombed structure, and a discharge zone that communicates directly with the outlet side of the die and is defined by the open area between the pins. The extrudable material enters the discharge zone from a series of feed passages defined by the pins and a plurality of webs that interconnect the pins. Each pin has an interior duct with an opening at the end of each pin. A series of internal passages in the die body receive fluid from one or more ports on the periphery of the die and distribute the fluid to the ducts.

Abstract: An extrusion die for extruding ceramic honeycomb structural bodies includes body discharge channels having a desired honeycomb arrangement and independent body supply holes communicating with the body discharge channels. The body supply holes are so designed that each of them has inner peripheral surface zones of different inner dimensions and the inner peripheral surface zones may be coaxially arranged.

Abstract: Spinning apparatus for the production of monofilament yarn includes a spinning tool having a flow channel in the form of a flattened U for providing polymer melt to a group of nozzles, the flow channel having a cross-sectional area which becomes larger, at least in an upper part thereof, in a direction of polymer melt flow therethrough.

Abstract: A hollow fiber with a plurality of members projecting from its outer surface in an arc turned back on itself is formed from a spinneret having a segmented orifice wherein each segment comprises a first portion in the form of an arc curved about the center of the orifice, a second portion extending from the first and connected to a third portion which is in the form of a reverse curve with respect to the first.

Abstract: A die for forming honeycomb structures has an arrangement that facilitates fabrication and the support of channel forming pins across the surface of the die by the use of multiple die sections. The die is used for forming multi-channeled honeycomb structures from extrudable materials. The die has a first die body that has an inlet face and outlet face and integrally formed channel forming pins that extend past the outlet face of the die. A set of integrally formed links interconnect the channeled pins and support the channeled pins from the die body. Together the channel forming pins and links define a set of cavity for passing extrudable material through the die body. The die includes at least one additional die body, which is at least partially superimposed above the inlet face of the first die body.

Abstract: An extrusion-forming jig for extruding a ceramic batch to regulate a sectional shape and external dimensions of a honeycomb structure is formed by the extrusion. The jig includes electric discharge coating layers on surfaces of the jig contacting the ceramic batch. The electric discharge coating layers are made of a cemented carbide such as tungsten carbide. The jig is able to be used for many hours without necessitating replacement.

Abstract: Dies for extruding honeycomb structures are disclosed, which comprise wear resistant alloy plates, a die base body having a coefficient of thermal expansion different from that of the wear resistant alloy plates, forming channels having a sectional shape conforming to that of honeycomb structural bodies to be extruded and a given depth from a front face of the die toward a rear face thereof, and a plurality of opening holes indepndently formed from the die rear face toward the die front face and communicating with the forming channels. The die base body and the wear resistant alloy plates are bonded together such that the forming channels may communicate with the opening holes. A method for producing such dies is also disclosed, which is characterized in that slits are preliminarily formed in one of machined faces of the die base before the wear resistive alloy plates are bonded to the die base portion, and are located at a predetermined width in an arrangement conforming to the forming channels.

Abstract: A honeycomb structure forming die has a forming section provided with at least forming channels and a plurality of opening holes. The forming channels have a sectional shape conforming to that of honeycomb structural bodies to be extruded by the die, and have a given depth from a front face of the die toward a rear face thereof. The opening holes are independently formed from the die rear face toward the die front face and communicate with the forming channels. The honeycomb structure forming die is further provided with communicating holes which communicate with the opening holes of the forming section.

Abstract: A honeycomb structural body-extruding die apparatus is disclosed herein, which includes an extruding die and a die mask provided around an outer peripheral portion of the extruding die on an extruding material outlet side. The extruding die also includes a plurality of extruding material-feeding holes formed on the extruding material inlet side and a plurality of shaping channels formed communicating with each other in a lattice fashion on the extruding material outlet side. The honeycomb structural body-extruding die apparatus is further provided with an annular perforated plate arranged concentrically with the extruding die on the extruding material inlet side. The perforated plate has through holes of which respective central axes are in conformity with those of the extruding material feeding holes.