BREAKER PLATE ASSEMBLY FOR PRODUCING BICOMPONENT FIBERS IN A MELTBLOWN APPARATUS

A die head assembly (30) for producing meltblown bicomponent fibers in a meltblown apparatus includes a die tip (32) detachably mounted to an underside of (36) a support member (34). The die tip (32) has a row of channels (44) defined therethrough terminating at exit orifices (46) along a bottom edge of the tip. The channels (44) receive a combine first and second polymers conveyed from the support member (34). A recess (48) is defined along the top surface of the die tip (32) and defines an upper chamber for each of the die tip channels (44). A plurality of breaker plates (52, 56) is removably supported in the recess (48) in a stacked configuration. An upper one of the breaker plates (52) has receiving holes (68a, 68b) defined therein to separately receive polymers from supply passages (40, 42) in the support member (34). The remaining breaker plates have holes defined therethrough configured to divide the polymers into separately polymer streams and to direct the polymer streams into ...

Printable elastic composite

A composite that contains an elastic film laminated to a meltblown facing is provided. During lamination, apertures and discrete bond sites may be concurrently formed in the elastic film. The discrete bond sites may be located proximate (adjacent or near to) a perimeter defined by corresponding apertures formed by displacement of the film. The location of the bond sites adjacent to or near the apertures may enhance the durability of the meltblown facing by strengthening the area surrounding the apertures. Furthermore, the content of the elastic film and the temperature/pressure of lamination may be selected to that the film possesses a sufficient tack for adhering to the facing at regions other than those fused together by the bonding elements of the patterned roll. Such secondary bonding further stabilizes the meltblown facing and renders it suitable for printing. Further, the film is under tension in the machine direction during lamination. Subsequent to lamination, however, the film is retracted so that the facing retracts toward its original machine direction length, thereby gathering and forming pleats. It has been discovered that these pleats have a relatively small amplitude (height), as well as a substantially uniform frequency across the surface of the facing. Such a small height and increased regularity improves the ability to transfer an ink to “peaks” of the pleats, thereby improving print quality and uniformity.

Cross directional zoned bicomponent films, film laminates, and systems and methods for manufacture of the same

Coextruded films provide cross directional zoned multiple components side-by-side to one another. Systems and methods relate to coextruding such films. During coextrusion, a first polymer conjoins with a second polymer while a temperature differential is maintained between the first and second polymers. This temperature differential is selected to reduce a difference between the viscosities of the first and second polymers making the viscosity of the first polymer close enough to the viscosity of the second polymer to avoid separation upon coextrusion. Further, the films may form a layer in subsequent lamination to other material layers.

Nonwoven Composite Including an Apertured Elastic Film and Method of Making

An elastic nonwoven composite that contains an elastic film laminated to one or more nonwoven web materials is provided. The composite is formed by passing an extrusion-coated film/nonwoven laminate through a nip to create apertures through both the film and the nonwoven. The apertures are of a size sufficient to provide a desired level of texture, softness, hand feel, and/or aesthetic appeal to the composite without having a significant adverse effect on its elastic properties. Apertures are accomplished in the present invention by selectively controlling certain parameters of the lamination process, such as film content, element pattern, degree of film tension, temperature and pressure conditions, and so forth.

Cross directional zoned bicomponent films, film laminates, and systems and methods for manufacture of the same

Coextruded films provide cross directional zoned multiple components side-by-side to one another. Systems and methods relate to coextruding such films. During coextrusion, a first polymer conjoins with a second polymer while a temperature differential is maintained between the first and second polymers. This temperature differential is selected to reduce a difference between the viscosities of the first and second polymers making the viscosity of the first polymer close enough to the viscosity of the second polymer to avoid separation upon coextrusion. Further, the films may form a layer in subsequent lamination to other material layers.

BREAKER PLATE ASSEMBLY FOR PRODUCING BICOMPONENT FIBERS IN A MELTBLOWN APPARATUS

A die head assembly (30) for producing bicomponent meltblown fibers includes a die tip (32) detachably mountable to a support member (34). The support member (34) conveys first and second polymers separately to the die tip (32). The die tip (32) has a row of channels (44) defined therethrough that terminate at exit orifices or nozzles (46) along the bottom edge of the die tip (32). These channels (44) receive and combine the separate first and second polymers conveyed from the support member (34). An elongated recess (48) is defined in the top surface of the die tip (32). The recess (48) defines an upper chamber for each of the die tip channels (44). Stacked breaker plates (52, 56) are removably suppoted in the recess (48). The breaker plates (52, 56) have vertically aligned pairs of adjacent holes (58a, 58b, 60a, 60b) defined therethrough such that a pair of the aligned holes is disposed in each upper chamber of each channel (44). A filter screen is in the recess to separately filter the ...

Printable Elastic Composite

A composite that contains an elastic film laminated to a meltblown facing is provided. During lamination, apertures and discrete bond sites may be concurrently formed in the elastic film. The discrete bond sites may be located proximate (adjacent or near to) a perimeter defined by corresponding apertures formed by displacement of the film. The location of the bond sites adjacent to or near the apertures may enhance the durability of the meltblown facing by strengthening the area surrounding the apertures. Furthermore, the content of the elastic film and the temperature/pressure of lamination may be selected to that the film possesses a sufficient tack for adhering to the facing at regions other than those fused together by the bonding elements of the patterned roll. Such secondary bonding further stabilizes the meltblown facing and renders it suitable for printing. Further, the film is under tension in the machine direction during lamination. Subsequent to lamination, however, the film ...

Method and apparatus for the production of nonwoven web materials

The present invention provides a method of making a nonwoven web with desired fiber orientation, the method including the steps of providing a source of fibers, subjecting the fibers to an electrostatic charge, deflecting the fibers with a non-contacting deflecting device, collecting the fibers on a moving forming surface to form the nonwoven web. The invention also provides an apparatus for forming fibrous nonwoven webs, the apparatus comprising a source of fibers, a device for applying an electrostatic charge to the fibers, a non-contacting fiber deflecting device adapted to affect the fibers while the fibers are under the influence of the applied electrostatic charge, and a forming surface for collecting the fibers as a fibrous nonwoven web.

NONWOVEN COMPOSITE INCLUDING AN APERTURED ELASTIC FILM AND METHOD OF MAKING

An elastic nonwoven composite that contains an elastic film laminated to one or more nonwoven web materials is provided. The composite is formed by passing an extrusion-coated film/nonwoven laminate through a nip to create apertures through both the film and the nonwoven. The apertures are of a size sufficient to provide a desired level of texture, softness, hand feel, and/or aesthetic appeal to the composite without having a significant adverse effect on its elastic properties. Apertures are accomplished in the present invention by selectively controlling certain parameters of the lamination process, such as film content, element pattern, degree of film tension, temperature and pressure conditions, and so forth.

CROSS DIRECTIONAL ZONED BICOMPONENT FILMS, FILM LAMINATES, AND SYSTEMS AND METHODS FOR MANUFACTURE OF THE SAME

Coextruded films provide cross directional zoned multiple components side-by-side to one another. Systems and methods relate to coextruding such films. During coextrusion, a first polymer conjoins with a second polymer while a temperature differential is maintained between the first and second polymers. This temperature differential is selected to reduce a difference between the viscosities of the first and second polymers making the viscosity of the first polymer close enough to the viscosity of the second polymer to avoid separation upon coextrusion. Further, the films may form a layer in subsequent lamination to other material layers. 1. An edge laminated film , comprising:a first polymer shaped in a planar form that is continuously extended by a second polymer laminated along an edge of the first polymer as defined by a thickness of the planar form,wherein the first polymer has a viscosity versus temperature curve, as measured at shear rates of 500 1/s, 1000 1/s or 1500 1/s, at least 10 percent different in viscosity than the second polymer at every common temperature throughout a melt temperature range of each as calculated relative to the higher viscosity value of each of the polymers, the viscosity determined by a capillary rheometer equipped with a 1 mm die utilizing a 10:1 length to diameter ratio and a 60° entrance angle, andwherein the melt temperature range for a respective one of the polymers is defined as a temperature at a softening peak of a differential scanning calorimetry (DSC) curve to a maximum of 25° C. less than a degradation peak of the DSC curve, as determined by the DSC curve obtained for a 5.5 mg sample of the respective one of the polymers heated at 20° C./minute.2. The edge laminated film of claim 1 , wherein the polymers have at least one matched viscosity value at disparate temperatures throughout the melt temperature range of each of the polymers.3. The edge laminated film of claim 1 , wherein the first polymer includes poly(styrene/ ...

Method of making uniform spunbond filament nonwoven webs

A method of making nonwoven webs comprising providing a spinneret wherein the spinneret includes a pattern of conduits, the pattern of conduits forming an extrusion region; directing only a first stream of molten propylene polymer having a first temperature into a region adjacent of the first side of the spinneret, directing only a second stream of molten propylene polymer having a second temperature into a region distal to the first side of the spinneret, extruding only the first stream of molten propylene polymer through the exit openings in a first zone; extruding only the second stream of molten propylene polymer through the exit openings of a second zone; the second zone is distal to the first side with the first zone being between the second zone and the first side.

Cross directional zoned bicomponent films, film laminates, and systems and method for manufacture of the same

Coextruded films provide cross directional zoned multiple components side- by-side to one another. Systems and methods relate to coextruding such films. During coextrusion, a first polymer conjoins with a second polymer while a temperature differential is maintained between the first and second polymers. This temperature differential is selected to reduce a difference between the viscosities of the first and second polymers making the viscosity of the first polymer close enough to the viscosity of the second polymer to avoid separation upon coextrusion. Further, the films may form a layer in subsequent lamination to other material layers.

Printable elastic composite

A composite that contains an elastic film laminated to a meltblown facing is provided. During lamination, apertures and discrete bond sites may be concurrently formed in the elastic film. The discrete bond sites may be located proximate (adjacent or near to) a perimeter defined by corresponding apertures formed by displacement of the film. The location of the bond sites adjacent to or near the apertures may enhance the durability of the meltblown facing by strengthening the area surrounding the apertures. Furthermore, the content of the elastic film and the temperature/pressure of lamination may be selected to that the film possesses a sufficient tack for adhering to the facing at regions other than those fused together by the bonding elements of the patterned roll. Such secondary bonding further stabilizes the meltblown facing and renders it suitable for printing. Further, the film is under tension in the machine direction during lamination. Subsequent to lamination, however, the film is retracted so that the facing retracts toward its original machine direction length, thereby gathering and forming pleats. It has been discovered that these pleats have a relatively small amplitude (height), as well as a substantially uniform frequency across the surface of the facing. Such a small height and increased regularity improves the ability to transfer an ink to 'peaks' of the pleats, thereby improving print quality and uniformity.

Printable Elastic Composite

A composite that contains an elastic film laminated to a meltblown facing is provided. During lamination, apertures and discrete bond sites may be concurrently formed in the elastic film. The discrete bond sites may be located proximate (adjacent or near to) a perimeter defined by corresponding apertures formed by displacement of the film. The location of the bond sites adjacent to or near the apertures may enhance the durability of the meltblown facing by strengthening the area surrounding the apertures. Furthermore, the content of the elastic film and the temperature/pressure of lamination may be selected to that the film possesses a sufficient tack for adhering to the facing at regions other than those fused together by the bonding elements of the patterned roll. Such secondary bonding further stabilizes the meltblown facing and renders it suitable for printing. Further, the film is under tension in the machine direction during lamination. Subsequent to lamination, however, the film is retracted so that the facing retracts toward its original machine direction length, thereby gathering and forming pleats. It has been discovered that these pleats have a relatively small amplitude (height), as well as a substantially uniform frequency across the surface of the facing. Such a small height and increased regularity improves the ability to transfer an ink to “peaks” of the pleats, thereby improving print quality and uniformity.

Method of making uniform spunbond filament nonwoven webs

A method of making nonwoven webs comprising providing a spinneret wherein the spinneret includes a pattern of conduits, the pattern of conduits forming an extrusion region; directing only a first stream of molten propylene polymer having a first temperature into a region adjacent of the first side of the spinneret, directing only a second stream of molten propylene polymer having a second temperature into a region distal to the first side of the spinneret, extruding only the first stream of molten propylene polymer through the exit openings in a first zone; extruding only the second stream of molten propylene polymer through the exit openings of a second zone; the second zone is distal to the first side with the first zone being between the second zone and the first side.

Method and apparatus for the production of nonwoven web materials

The present invention provides a method of making a nonwoven web with desired fiber orientation, the method including the steps of providing a source of fibers, subjecting the fibers to an electrostatic charge, deflecting the fibers with a non-contacting deflecting device, collecting the fibers on a moving forming surface to form the nonwoven web. The invention also provides an apparatus for forming fibrous nonwoven webs, the apparatus comprising a source of fibers, a device for applying an electrostatic charge to the fibers, a non-contacting fiber deflecting device adapted to affect the fibers while the fibers are under the influence of the applied electrostatic charge, and a forming surface for collecting the fibers as a fibrous nonwoven web.

Method of making uniform spunbond filament nonwoven webs

A method of making nonwoven webs comprising providing a spinneret including a pattern of conduits forming an extrusion region; directing only a first stream of molten propylene polymer into a region adjacent the first side of the spinneret, directing only a second stream of molten propylene polymer into a region distal to the first side of the spinneret, extruding only the first stream propylene polymer through the exit openings in a first zone where the exit opening comprises exit ports in the first zone having a first density; extruding only the second stream propylene polymer through the exit openings of a second zone where the exit opening comprises exit ports in the second zone having a second density less than the first density; and the second zone is distal to the first side with the first zone being between the second zone and the first side.

Manufacturing Method of Uniform Spunbond Filament Nonwoven Webs

Un método para la fabricación de tramas no tejidas que comprende proporcionar una hilera, en donde la hilera incluye un patrón de conductos, el patrón de conductos que forman una región de extrusión; dirigir solo una primera corriente de polímero de propileno fundido que tiene una primera temperatura hacia una región adyacente al primer lado de la hilera, dirigir solo una segunda corriente de polímero de propileno fundido que tiene una segunda temperatura hacia una región distal al primer lado de la hilera, extruir solo la primera corriente de polímero de propileno fundido a través de las aberturas de salida en una primera zona; extruir solo la segunda corriente de polímero de propileno fundido a través de las aberturas de salida de una segunda zona; la segunda zona es distal al primer lado con la primera zona que se encuentra entre la segunda zona y el primer lado. A method of manufacturing nonwoven webs comprising providing a spinneret, wherein the spinneret includes a pattern of ducts, the pattern of ducts forming an extrusion region; directing only a first stream of molten propylene polymer having a first temperature toward a region adjacent to the first side of the die, directing only a second stream of molten propylene polymer having a second temperature toward a region distal to the first side of the die spinneret, extruding only the first stream of molten propylene polymer through the outlet openings in a first zone; extruding only the second stream of molten propylene polymer through the outlet openings of a second zone; the second zone is distal to the first side with the first zone lying between the second zone and the first side.

Cross directional zoned bicomponent films, film laminates, and systems and method for manufacture of the same

Method of making uniform spunbond filament nonwoven webs

A method of making nonwoven webs comprising providing a spinneret wherein the spinneret includes a pattern of conduits, the pattern of conduits forming an extrusion region; directing only a first stream of molten propylene polymer having a first temperature into a region adjacent of the first side of the spinneret, directing only a second stream of molten propylene polymer having a second temperature into a region distal to the first side of the spinneret, extruding only the first stream of molten propylene polymer through the exit openings in a first zone; extruding only the second stream of molten propylene polymer through the exit openings of a second zone; the second zone is distal to the first side with the first zone being between the second zone and the first side.

Method and apparatus for the production of nonwoven web materials

The present invention provides a method of making a nonwoven web with desired fiber orientation, the method including the steps of providing a source of fibers, subjecting the fibers to an electrostatic charge, deflecting the fibers with a non-contacting deflecting device, collecting the fibers on a moving forming surface to form the nonwoven web. The invention also provides an apparatus for forming fibrous nonwoven webs, the apparatus comprising a source of fibers, a device for applying an electrostatic charge to the fibers, a non-contacting fiber deflecting device adapted to affect the fibers while the fibers are under the influence of the applied electrostatic charge, and a forming surface for collecting the fibers as a fibrous nonwoven web.

Nonwoven composite including an apertured elastic film and method of making.

Se proporciona un compuesto no tejido elástico que contiene una película elástica laminada a uno o más materiales de tela no tejida. El compuesto es formado mediante el pasar un laminado de no tejido/película recubierto por extrusión a través de un punto de presión para crear perforaciones a través de ambas la película y el no tejido. Las perforaciones son de un tamaño suficiente para proporcionar un nivel de textura deseado, una suavidad deseada, una sensación de tacto y/o una atracción estética para el compuesto sin tener un efecto adverso significante sobre las propiedades elásticas. Las aberturas son logradas en la presente invención mediante el controlar selectivamente ciertos parámetros del proceso de laminación, tal como el contenido de película, el patrón de elementos, el grado de tensión de película, la temperatura y las condiciones de presión y otros.

LAMINATED EDGE MOVIE, EXTRUSION SYSTEM AND POLYMER COEXTRUSION METHOD IN EDGE LAMINATED MOVIES "

Metodo de fabricacion de tramas no tejidas de filamento de union por hilado uniforme.

Un método para la fabricación de tramas no tejidas que comprende proporcionar una hilera, en donde la hilera incluye un patrón de conductos, el patrón de conductos que forman una región de extrusión; dirigir solo una primera corriente de polímero de propileno fundido que tiene una primera temperatura hacia una región adyacente al primer lado de la hilera, dirigir solo una segunda corriente de polímero de propileno fundido que tiene una segunda temperatura hacia una región distal al primer lado de la hilera, extruir solo la primera corriente de polímero de propileno fundido a través de las aberturas de salida en una primera zona; extruir solo la segunda corriente de polímero de propileno fundido a través de las aberturas de salida de una segunda zona; la segunda zona es distal al primer lado con la primera zona que se encuentra entre la segunda zona y el primer lado.

Method of making uniform spunbond filament nonwoven webs

A method of making nonwoven webs comprising providing a spinneret wherein the spinneret includes a pattern of conduits, the pattern of conduits forming an extrusion region; directing only a first stream of molten propylene polymer having a first temperature into a region adjacent of the first side of the spinneret, directing only a second stream of molten propylene polymer having a second temperature into a region distal to the first side of the spinneret, extruding only the first stream of molten propylene polymer through the exit openings in a first zone; extruding only the second stream of molten propylene polymer through the exit openings of a second zone; the second zone is distal to the first side with the first zone being between the second zone and the first side.

Method of making uniform spunbond filament nonwoven webs

Method of making uniform spunbond filament nonwoven webs

A method of making nonwoven webs comprising providing a spinneret wherein the spinneret includes a pattern of conduits, the pattern of conduits forming an extrusion region; directing only a first stream of molten propylene polymer having a first temperature into a region adjacent of the first side of the spinneret, directing only a second stream of molten propylene polymer having a second temperature into a region distal to the first side of the spinneret, extruding only the first stream of molten propylene polymer through the exit openings in a first zone; extruding only the second stream of molten propylene polymer through the exit openings of a second zone; the second zone is distal to the first side with the first zone being between the second zone and the first side.

Method of making uniform spunbond filament nonwoven webs

Method of making uniform spunbond filament nonwoven webs

A method of making nonwoven webs comprising providing a spinneret wherein the spinneret includes a pattern of conduits, the pattern of conduits forming an extrusion region; directing only a first stream of molten propylene polymer having a first temperature into a region adjacent of the first side of the spinneret, directing only a second stream of molten propylene polymer having a second temperature into a region distal to the first side of the spinneret, extruding only the first stream of molten propylene polymer through the exit openings in a first zone; extruding only the second stream of molten propylene polymer through the exit openings of a second zone; the second zone is distal to the first side with the first zone being between the second zone and the first side.