Kimberly-clark Worldwide, Inc.

Chad Michael Freese

Bryan David Haynes

Kurtis Lee Brown

Darryl Franklin Clark

Christopher Dale Fenwick

Susan Elaine Shawver

Jark Chong Lau

James Russell Fitts, Jr

Ty Jackson Stokes

Michael Charles Cook

Alexander J Neeb

Terry K Timmons

Robert James Gerndt

Eric Scott Kepner

Monica Graciela Varriale

Braulio Arturo Polanco

James Richard Neely

Rebecca Willey Griffin

Brian Stephen Forbes

Warren L Collier, Iv

High loft, low density nonwoven webs are produced by forming substantially continuous, spunbond, crimped, bicomponent fibers of A/B bilateral morphology in an unheated fiber draw unit. The fibers are then heated and cooled in the absence of impeding forces to achieve maximum crimp in the z-direction and produce a web of lofted material. The resultant material is particularly suitable for use as an insulator. Particulates may be added to the webs if desired.

High loft low density nonwoven webs of crimped filaments and methods of making same

High loft, low density nonwoven webs suitable for use in a variety of applications requiring strong fabric layers are produced by forming substantially continuous, spunbond, crimped, bicomponent fibers of crimpable, e.g., side by side or eccentric sheath/core (A/B) configuration which are unheated prior to collection. The fibers are then heated and cooled in the absence of impeding forces to achieve maximum crimp in the Z-direction and produce a web of lofted material of greater uniformity than attained with comparable material whose fibers are drawn by a heated process. The resultant nonwoven material can then be pattern bonded or laminated for additional strength without interfering with the desired loft of the low density nonwoven. The additionally strengthened nonwoven may then be further processed such as by lamination or the like to further increase its utility.

Strong high loft low density nonwoven webs and laminates thereof

The present invention provides a series of plates for distributing a molten polymer composition, the series of plates includes at least two plates: a first plate that includes an upper surface, a lower surface, and a plurality of polymer distribution channels connecting the upper surface and the lower surface. In certain illustrated embodiments, the plurality of polymer distribution channels consist essentially of substantially horizontal channels at one or both the upper surface and lower surface and substantially linear downwardly sloping channels connecting the substantially horizontal channels at the upper surface to the substantially horizontal channels at the lower surface, the upper surface to the substantially horizontal channels at the lower surface or the substantially horizontal channels at the upper surface to lower surface; and a second plate that includes an upper surface, a lower surface, and a plurality of polymer distribution channels connecting the upper surface and the lower surface wherein the plurality of polymer distribution channels consist essentially of substantially horizontal channels at one or both the upper surface and lower surface and substantially linear downwardly sloping channels connecting the substantially horizontal channels at the upper surface to the substantially horizontal channels at the lower surface, the upper surface to the substantially horizontal channels at the lower surface or the substantially horizontal channels at the upper surface to lower surface.

Melt spinning extrusion head system

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.

Process of making a crimped multicomponent fiber web

A method and apparatus for improved quenching of nonwoven filaments utilizing a turbulence inducing bar arrangement disposed in a stream of quenching gas between the quenching gas supply apparatus and the group of filaments being extruded. The bar arrangement increases the turbulence of the quenching gas so that the gas applied to the filament group has a turbulence intensity of at least about 5%. The turbulent quenching gas penetrates the interior of the filament bundle to provide more efficient removal of heat.

Method and apparatus for improved quenching of nonwoven filaments

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Martinez, CA, United States of America

Chad Michael Freese