Abstract: A spinning die for nonwoven fabric is provided which can spin fibers having fine diameters and can reduce the energy cost. A pair of hot air discharge slits are provided near the tips of nozzles for extruding a molten polymer, and a pair of cool air discharge slits are provided downstream to supply cool air in a large amount, thereby orientating molten polymer extruded from the nozzles by the negative pressure produced by current of cool air.

Abstract: A segmented die assembly comprising a plurality of side-by-side and separate units. Each die unit includes (a) a manifold segment having an internal gear pump, (b) a die module mounted on the manifold segment, and (c) a recirculating module mounted on the manifold segment. The manifold segments are interconnected and function to deliver process air and polymer melt to the modules. Each die module includes (a) a fiberization nozzle, and (b) a valve for controlling the flow of polymer therethrough. The gear pump of each manifold segment receives a polymer melt and delivers it either to the die module (with its valve open) or to the recirculation module (with the die module valve closed). Polymer melt flowing through the die module and is discharged as a filament or filaments onto a moving substrate or collector. On the other hand, polymer flow through the recirculation module is returned to the polymer melt hopper or reservoir for recirculation through the die assembly.

Abstract: There is claimed a method for depositing fluid material from a linear nozzle in a substantially uniform manner across and along a surface. The method includes directing gaseous medium through said nozzle to provide a gaseous stream at the nozzle exit that entrains fluid material supplied to the nozzle, said gaseous stream being provided with a velocity profile across the nozzle width that compensates for the gaseous medium's tendency to assume an axisymmetric configuration after leaving the nozzle and before reaching the surface. There is also claimed a nozzle divided into respective side-by-side zones, or preferably chambers, through which a gaseous stream can be delivered in various velocity profiles across the width of said nozzle to compensate for the tendency of this gaseous medium to assume an axisymmetric configuration.

Abstract: The present invention relates to an improved die for use in textile processes involving nonwoven melt blown fabrics. In a melt blown process, molten polymer resins are injected into a melt blowing die and ejected or extruded from the die in the form of filaments. The present invention is directed to an improved die faceplate in combination with an extension plate that provides an extended flow path for an air jet to extrude a molten polymer filament of a reduced diameter in the melt blowing process.

Abstract: The present invention relates to a die nosepiece for use in textile processes involving nonwoven melt blow fabrics. In a melt blown process, molten polymer resins are 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 slit with serrated edges through which resin filaments are ejected.

Abstract: A segmented die assembly comprises a plurality of side-by-side and separate units. Each die unit, includes a manifold segment and a die module mounted thereon. The manifold segments are interconnected and function to deliver process air and polymer melt to the modules. Each module including a nozzle through which the polymer melt is extruded forming a row of filament(s). The filaments from the array of modules are deposited on a substrate or collector. The die assembly is preferably used to apply a hot melt adhesive to a substrate, but also may be used to produce meltblown webs.

Abstract: An adhesive dispensing die module for mounting on a manifold incudes (a) a die body having formed therein polymer and air flow passages, and a valve for selectively closing the polymer flow passage and (b) a die tip or die nozzle detachably mounted on the die body. The die tip or die nozzle is secured to the die body by a pair of clamping members depending from the die body and adapted to engage die tip or die nozzle therebetween. The clamping members can selectively be moved toward one another to clampingly secure the die tip or die nozzle therebetween or moved away from one another to release the die tip or die nozzle, permitting it to be replaced without the need to remove the die module from the manifold.

Abstract: There is disclosed an improved, energy-saving granulation method, wherein use is made of a granulator (1) having a bottom floor (9) of a granulation section whose bottom is a perforated plate, an upper air feed pipe (23) for feeding air for fluidization to the bottom floor of the granulation section, a lower air feed pipe (2), air feed pipes (3, 4, 5) branched from the lower air feed pipe for jetting air into the granulation section, and jetting nozzles (6, 7, 8) provided at the centers of the air outlets for jetting a molten raw material; which involves the steps of jetting a molten raw material from the jetting nozzles to approximately spherical nuclei in the granulation section, which have been fed after the particle diameter has been caused to be an average particle diameter of 0.4 to 3.0 mm, to form granules. There is also disclosed an improved granulator.

Abstract: A composite filtration medium web of fibers containing a controlled dispersion of a mixture of sub-micron and greater than sub-micron diameter polymeric fibers is described. The filtration medium is made by a two dimensional array of cells, each of which produces a single high velocity two-phase solids-gas jet of discontinuous fibers entrained in air. The cells are arranged so that the individual jets are induced to collide in flight with neighboring jets in their region of fiber formation, to cause the individual nascent fibers of adjacent jets to deform and become entangled with and partially wrap around each other at high velocity and in a localized fine scale manner before they have had an opportunity to cool to a relatively rigid state. The cells are individually adjusted to control the mean diameters, lengths and trajectories of the fibers they produce.

Abstract: The present invention relates to an atomization apparatus and method for the formation of substantially uniform, at least nearly spherical particles, particularly for the formation of metal particles. The present invention provides an atomization apparatus having a nozzle positioned at the bottom of a cooling chamber. Rayleigh wave instability may be induced by imparting vibrations to a stream of molten material which is released in an upward direction. This produces uniform droplets having an initial velocity sufficient to increase the residence time of the droplets in an inert atmosphere. The parabolic trajectory of the droplets over a 2 m vertical displacement is approximately five times longer than a freefall, thus significantly increasing the cooling time without increasing the cooling chamber height. Further the kinetic energy of each droplet is much lower throughout its trajectory which serves to improve the formation of spherical shaped particles and to lower the impact velocity.

Abstract: Apparatus for impregnating surfaces, including edge surfaces, of fiberglass insulation batts with synthetic fibers, comprising a conveyor for advancing the batts in a common direction and, initially, in a side-by-side orientation. Separators thereafter interrupt the side-by-side orientation, exposing the edges of the batts. Extrusion heads located in the area of side edge exposure impregnate the exposed edges with synthetic fibers while other extruder heads apply synthetic fibers to one or optionally both of the top and bottom surfaces.

Abstract: A method of integrating organic fibers with mineral fibers includes centrifuging organic fibers from molten organic material, using a rotating organic fiber spinner, directing the organic fibers into a downwardly moving veil of organic fibers and gases, with the veil having an inwardly converging shape as it moves downward, centrifuging mineral fibers from molten mineral material using a rotary mineral fiber spinner positioned concentrically within the downwardly moving veil of organic fibers, directing the mineral fibers into a downwardly moving veil of mineral fibers and gases within the veil of organic fibers, wherein the veil of mineral fibers intersects with the veil of organic fibers to integrate the mineral fibers with the organic fibers, and collecting the integrated mineral fibers and organic fibers as a fibrous pack. An apparatus for performing the method is also disclosed.

Abstract: A method and a device for gentle continuous mixing of a droplet dispersion with a liquid are described, wherein the liquid is injected into the droplet dispersion in the form of a plurality of fine liquid jets, such that the kinetic energy of the liquid jets is dissipated at a short distance from the injection point and further mixing is effected by circulating flow generated in the vessel and exhibiting shear rates of less than 20/s.

Abstract: 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.

Abstract: Molten matte or slag is water granulated by feeding molten matte or slag through a launder to a granulator tank. The tank includes sloping walls and is equipped with adjustable overflow weirs and one or more of spray nozzles. These nozzles are positioned such that the water that they emit impacts on substantially all of the molten matte or slag that is fed to the granulator tank. The granulation tank is optionally coated with a polymeric material to reduce the potential for phreatic explosions. The granulator is also optionally equipped with a gas offtake which can be connected directly to a quench tower which in turn can be connected to an induced ventilation system.

Abstract: Fine fibers are formed and carried in a high energy, high temperature gaseous stream to a primary fine fiber collection surface where fine fibers are collected from the gaseous stream. Gases of the gaseous stream along with fine fibers not removed from the gaseous stream by the primary collection surface are drawn through the primary collection surface and formed into an exhaust gas stream which is passed through a secondary fine fiber collection surface to remove additional fibers from the exhaust gas stream before it is discharged to the atmosphere. To reduce the operating temperatures at and surrounding the primary and secondary collection surfaces, the gas streams are cooled by evaporative cooling. Water is sprayed into the gas streams by nozzles, shielded from the gas streams by scoops, so that fibers do not collect on the nozzles and form fiber wads.

Abstract: There is provided a fabric which has been produced in a pneumatic chamber which has tiny grooves over an effective amount of its fluid contacting surface. Also provided is a method of producing a web having greater uniformity by producing it with pneumatic chambers having surface grooves. Fabrics produced in such a manner have greater uniformity when measured by permeability, basis weight or CD and MD strength properties.

Abstract: The disclosure is a more economical process for producing fibrets of superior quality by directing a dope comprising a cellulose derivative and a suitable solvent therefor into a coagulant and exposing it there to a shearing field to coagulate of the dope and form the fibrets. The fibrets, the solvent and the coagulant are then separated off. The suspension formed from the dope and the coagulant is alternately accelerated and decelerated in the shearing field at least once, preferably at least twice. This makes it possible to maintain a high average degree of turbulence over a long distance, so that a dope of high viscosity can be processed. In the apparatus for producing fibrets, the at least one nozzle (46-49) is disposed within a dispersing facility (40) comprising rotor (44) and stator (43, 45) and further comprising at least two sprockets (50-53), of which at least one sprocket (50) is part of the rotor (44) of the dispersing facility (40).

Abstract: A method for the dewatering of a material layer of paper fibers in a double-screen former, where the sheet weight (oven-dried sheet weight (otro)) is more than 100 g/m.sup.2 and/or the screen circulates with a speed of at least 100 m/min. Two screens are guided at two guide surfaces that, for example, belong to open forming cylinders. In this arrangement forming cylinders of this kind are so dimensioned and positioned that no dewatering elements that contact one of the screens are present between the run-out line of the screens from the first guide surface and the run-in line at the second guide surface.

Abstract: An apparatus for producing spun-bond fleece has the process shaft connected to a source of process air and opening into a depositions shaft centrally thereof and flanked by streams of air bypassing the process shaft. The result is a random jumbling of the fibers as they deposit on the moving belt such that a uniform filament density and homogeneous mesh width are obtained without singularities and without conglomeration of the filaments in the shafts.

Abstract: An improved method and apparatus for producing flexible fibers (30) of superconducting material includes a crucible (12) for containing a charge of the superconducting material. The material is melted in the crucible (12) and falls in a stream (18) through a bottom hole (16) in the crucible (12). The stream (18) falls through a protecting collar (22) which maintains the stream (18) at high temperatures. The stream (18) is then supplied through a downwardly directed nozzle (26) where it is subjected to a high velocity of a heated gas (36') which breaks the melted superconducting material into ligaments which solidify into the flexible fibers (30). The fibers (30) are collected by directing them against a collection filter (32).

Abstract: The apparatus for manufacturing inorganic spherical particles according to the present invention consists of a vertical sphering furnace, a sphering burner disposed at the top of the furnace, a particle outflow pipe through which spherical particles formed in the furnace are drawn out therefrom and an air inflow pipe for introducing air for carrying the spherical particles toward the opening of the particle outflow pipe; wherein the particle outflow pipe and the air inflow pipe are arranged to oppose each other horizontally at a lower position of the furnace. The opening diameter of the particle outflow pipe is designed to be larger than that of the air inflow pipe.

Abstract: A die for melt-blowing apparatus, which has a die body, a nozzle piece, and a lip plate. The nozzle piece is divided into plural temperature-controlling regions in a direction crosswise to a spinning direction. A temperature sensor is used to measure the temperature at a portion surrounding a nozzle orifice in the nozzle piece in each of the divided temperature-controlling regions. A heated gas is applied directly to the nozzle piece for controlling the temperature of the portion surrounding the nozzle orifice to a predetermined temperature. Using this die body, a melt-blown non-woven fabric with a uniform distribution of the weight per unit area can be easily obtained.

Abstract: A modular die for applying hot melt adhesive onto a substrate comprises (a) a manifold having adhesive and air passages formed therein, (b) a plurality of self-contained and interchangeable die bodies mounted on the manifold, and (c) a die head detachably mounted on each die body. The die heads are selected from melt spraying, meltblowing, and linear bead applicators permitting the application of a variety of adhesive patterns on the substrate.

Abstract: An apparatus and method for distributing pressurized fiber attenuating fluid through a melt blowing multi-headed die body uniformly and contaminant filtered with a minimum of energy loss before reaching the fluid attenuating outlets of the die body.

Abstract: There is provided a fabric produced by a spunbond or a meltblown apparatus, wherein the apparatus has a pneumatic chamber having at least one wall containing a plurality of spaced protrusions. Preferably, both opposing walls contain protrusions aligned in staggered angled rows and the rows on one wall are angled opposite the rows on the opposing wall, thereby causing controlled lateral flow near the chamber walls. This lateral flow exhibits drag on the fibers, imparting rotational energy to the fibers. The fibers are imparted with rotational energy derived from the lateral component of the two turbulent airflow fields that oppose one another, and have a tendency to twist and crimp. Fabrics so produced have improved loft, drape, and feel and may be useable as a loop material for hook-and-loop type fasteners.

Abstract: The present invention relates to a die body consisting of a multiplicity of modular die plates, which are easily and rapidly interchangeable. The modular die plates can be configured to extrude different shapes and types of fibers. The apparatus may also be configured to extrude multiple types of materials each from a plurality of separate ports or from a plurality of common ports. The apparatus may also be designed to include single or multiple ports to direct air or other fluids to draw or attenuate the extrudate into fibers of a desired diameter. The extrudate may be treated with the air or various other gases or fluids within the die or exterior to the die tips.

Abstract: Meltblown thermoplastic fibers are cooled by microsized water droplets produced by airless ruby nozzles. The droplets have an average diameter of less than 20 microns.

Abstract: A metblowing die designed to efficiently receive a preassembled die tip assembly is described. The die assembly includes a die body (19) mounted on a meltblowing machine and a replaceable die tip assembly (20). The die tip assembly (20) includes a mounting block (25), to which are mounted a die tip (26) and air knives (27, 28) on opposite sides or the die tip (26). The positions of the air knives (27, 28) are adjustable to set air gap and set back parameters important in proper operation. The die tip assembly (20) is moved into and out of the die body (19) after air knife adjustment permitting adjustment to be made with the die tip assembly (20) off the machine, allowing rapid replacement. The replacement die tip assembly (20) is preheated, permitting replacement while the die body (19) is still hot.

Abstract: The present invention relates to an apparatus for the production of absorbent materials comprising fibers cross-linked by a suitable cross-linker therefor, and wherein said cross-linker is associated with substantially the entire surface of each fiber, said materials being preparable by mixing of an aerated suspension of the charged fibers with the cross-linker before heating and compressing, such fibers having a capacity for fluid absorption considerably greater than has been heretofore known for such materials.

Abstract: Modular die constructions includes a plurality of side-by-side self-contained, interchangeable meltblowing modules on a manifold so that the length of the die can be varied by adding modules or removing modules from the manifold.

Abstract: A meltblowing die for producing nonwoven polymer webs includes an inner tube having a plurality of orifices arranged in a row thereon, and an outer tube encasing the inner tube and having a slot formed therein in registry with the row orifices. The inner tube and outer tubes are constructed to define converging air passages on either side of the row of orifices, whereby hot air delivered to the outer tube converges on polymer fibers extruded through the orifices and imparts drag forces thereon to attenuate and draw down the fibers to microsize.

Abstract: A meltblowing die assembly featuring a preassembled die tip assembly permitting the rapid exchange thereof. The preassembled die tip assembly includes a die tip having a triangular nosepiece, a member mounted on the die tip assembly for conforming the die tip to the die body, and a pair of air plates mounted on the die tip and in combination with the nosepiece define converging air slots.

Abstract: Close-coupled atomization systems and methods employing axisymmetric fluid flow and non-axisymmetric melt guide tube exit orifice configuration have demonstrated superior efficiency in the production of fine superalloy powder, such as, for example, nickel base superalloys compared to conventional close-coupled atomization utilizing an axisymmetric annular gas orifice and an axisymmetric guide melt guide tube exit orifice configuration.

Abstract: Close-coupled atomization systems and methods employing non-axisymmetric gas flow have demonstrated superior efficiency in the production of fine superalloy powder, compared to conventional close-coupled atomization utilizing an axisymmetric annular gas orifice and an axisymmetric melt nozzle. A means has been devised for convening otherwise axisymmetric plenums into non-axisymmetric plenums that produce non-axisymmetric gas flow.

Abstract: Apparatus and method for making powder from a metallic melt by atomizing the melt to form droplets and reacting the droplets downstream of the atomizing location with a reactive gas. The droplets are reacted with the gas at a temperature where a solidified exterior surface is formed thereon and where a protective refractory barrier layer (reaction layer) is formed whose penetration into the droplets is limited by the presence of the solidified surface so as to avoid selective reduction of key reactive alloyants needed to achieve desired powder end use properties. The barrier layer protects the reactive powder particles from environmental constituents such as air and water in the liquid or vapor form during subsequent fabrication of the powder to end-use shapes and during use in the intended service environment.

Abstract: The invention relates to a process for the solvent-free and dry production of particles from plastics. According to the invention, the plastic is heated to form a viscous material, in this form, is conveyed as material stream through an outlet into a comminution device and there, with spraying of a pressurized liquid atomization medium against it, is comminuted into fibrids and/or fine particles.

Abstract: A granulation water control apparatus for a granulating machine used in a granular fertilizer production process and its granulation water control method. A particle size weight distribution of a semi-fabricated fertilizer discharged from the granulating machine is calculated, and a central particle size of the particle size weight distribution is calculated. The calculated central particle size and a previously set target central particle size are compared, and if they do not agree, a quantity of the granulation water to be charged into the granulating machine is calculated in accordance with a difference between the calculated central particle size and the target central particle size and the past statistical data.

Abstract: A meltblowing die designed to efficiently receive a preassembled die tip assembly is described. The die assembly includes a die body mounted on a meltblowing machine and a replaceable die tip assembly. The die tip assembly includes a mounting block, to which are mounted a die tip and air knives on opposite sides of the die tip. The positions of the air knives are adjustable to set air gap and set back parameters important in proper operation. The die tip assembly is moved into and out of the die body after air knife adjustment, permitting the adjustment to be made with the die tip assembly off the machine, and allowing rapid replacement. The replacement die tip assembly is preheated, permitting replacement while the die body is still hot.

Abstract: An apparatus and method for atomizing liquid metal are disclosed. A liquid metal supply is coupled to a nozzle for atomizing a stream of liquid metal in an atomizing zone extending from the nozzle. A viewing instrument provides a field of view extending to the atomization zone. A sensor coupled with the viewing instrument generates an image of the atomizing zone, and a control adjusts a flow rate of the stream responsive to the image.

Abstract: Apparatus for producing metal powders by atomization, the apparatus including melting means for melting the material to be atomized, an atomizing enclosure in which a dispersion head rotating at high speed is disposed to scatter the molten material in atomized form, means for cooling the atomized material and the head, and means for collecting the cooled powder material obtained in this way, said melting means including at least one vertical inductive plasma furnace producing an envelope of plasma-generating gases containing the top face of the dispersion head, and said cooling means comprising both a first series of members for dispensing a cooling fluid disposed in the top portion of the atomizing enclosure to create a cold zone at the periphery of the envelope, and a second series of members for circulating a cooling fluid disposed in the bottom portion of the enclosure to create a cold zone at the bottom face of the head.

Abstract: A spinneret device for side-by-side, conjugate melt-blow spinning can correspond to combinations of various heterogeneous polymers for conjugate spinning and is uniform in the conjugate state such as conjugate ratio between single fibers, the proportion of the peripheral percentage of both the components in the fiber cross-section, etc. and has fineness, a large nozzle plate width and a superior productivity. The device is composed mainly of a spinning resin-feeding plate; a distributing plate; a separating plate provided with confluent grooves of conjugate components engraved at the bottom part of the plate, corresponding in number to the spinning nozzles; a nozzle plate; and a plate for controlling the clearance for a gas. Even when the viscosity unevenness, spinning temperature unevenness, etc.

Abstract: The invention provides a method of producing metal powders which is less likely permit variations in cooling rate, ensures rapid solidification at a great cooling rate and readily gives fine particles, and a production apparatus for the method. The method comprises injecting a cooling liquid into a cooling tubular body (1) along an inner peripheral surface thereof to form a cooling liquid layer (9) moving toward a cooling liquid discharge end of the tubular body (1) while swirling along the inner peripheral surface of the tubular body (1); supplying a molten metal (25) to a space (23) inside the cooling liquid layer (9); applying a gas jet (26) as directed toward the cooling liquid layer (9) to the molten metal (25) to divide the molten metal and supply the divided molten metal to the cooling liquid layer (9); and discharging the cooling liquid containing a metal powder solidified in the liquid layer (9) from the cooling liquid discharge end of the tubular body (1) to outside.

Abstract: Apparatus for dispensing a material, such as by meltblowing, wherein the apparatus provides a flow of air in a first direction and a flow of material in a second direction at an angle with respect to the first direction, and wherein the air flow contacts the material flow and propels the material in a direction substantially parallel to the first direction of the air flow for deposition on a desired substrate.

Abstract: There is disclosed a novel apparatus and process for melt-blowing fiberforming thermoplastic polymers to form fine fibers by extruding through spinning nozzles arranged in four or more rows. The molten fibers are accelerated to near sonic velocity by gas being blown in parallel flow through small circular gas orifices surrounding each nozzle. The air orifices are formed by a family of plates which effect the perfect centering of each nozzle in each of the circular air orifices.

Abstract: Apparatus for close coupled atomization of melts of metals having high melting points with low superheats is taught. The atomization apparatus includes means for supplying melt to be atomized at the relatively low superheat, melt guide means for guiding the melt as a stream to an atomization zone and a gas supply and means for delivering the gas as a stream to the atomization zone where both the melt supply and gas supply to the atomization zone are in very close proximity. The melt supply has an inwardly tapered lower end disposed immediately above the atomization zone. The gas supply surrounds the melt guide tube and the gas is delivered as a jet against the melt emerging from the melt guide tube. The temperature of the gas impacting the end of the melt guide tube is very low because of the gas expansion.

Abstract: A meltblowing die assembly featuring a preassembled die tip assembly permitting the rapid exchange thereof. The preassembled die tip assembly includes a die tip having a triangular nosepiece, a member mounted on the die tip assembly for conforming the die tip to the die body, and a pair of air plates mounted on the die tip and in combination with the nosepiece define converging air slots.

Abstract: A method and apparatus are provided for generating seed particles. In one technique, a spray of water droplets is discharged to intersect a spray of liquid sulphur droplets to effect contact between some of the sulphur droplets and water droplets. The cooling sulphur droplets form seed particles. In another technique, water is sprayed into dispersed sulphur granules moving through a processing region. Subsequently, as the water is evaporating from the granules, liquid sulphur is sprayed onto the granules. Some of the liquid sulphur droplets impinge upon the water film-coated granules and solidify to form new seed particles which become detached from the granules. In another technique, a stream of liquid sulphur is discharged under pressure into a receiving region. A plurality of jets of atomizing fluid are injected into the stream to form a spreading spray of liquid sulphur droplets which solidify into seed particles.

Abstract: A slot die for producing a fibrous web of adhesive material includes a segmented shim having a plurality of fingers in said slat dividing adhesive material into a plurality of adhesive streams. The fingers have tapered ends which are flush with or extend slightly beyond the slot nozzle outlet. Separate material streams emanate from the slot nozzle outlet where they merge and are engaged by air flow producing a fibrous web of adhesive material. The adhesive and air flow are started and stopped at intervals to produce discrete fibrous webs having square, sharp leading and trailing edges.

Abstract: An apparatus and method for producing a meltblown continuous and seamless nonwoven tube is described. The apparatus comprises a meltblowing die for extruding two groups of polymer thermoplastic filaments onto a rotating mandrel to form a multilayer layer tube thereon. The tube is withdrawn from the mandrel by a rotating screw. The present apparatus is capable of producing nonwoven tubes having variable fiber diameters and/or composition in the radial direction, making them ideally suited for filtration purposes.