Biax-fiberfilm Corporation

Reifenhauser Gmbh & Co Kg Maschinenfabrik

Reifenhauser Gmbh & Co. Kg

Jeffrey D Stark

Douglas B Brown

Mohammad A Hassan

Duane Kenneth Zacharias

Carmen A Granato, Sr

A spun-blown non-woven web is disclosed which is formed from a plurality of fibers formed from a single polymer having an average fiber diameter ranging from between about 0.5 microns to about 50 microns; a basis weight of at least about 0.5 gsm; a tensile strength, measured in a machine direction, ranging from between about 20 g to about 4,200 g; a ratio of tensile strength, measured in the machine direction, to basis weight of at least about 20:1; and a ratio of percent elongation, measured in the machine direction, to fiber diameter of at least about 15.

Spun-blown non-woven web

A high loft, nonwoven web is disclosed having a three dimensional structure with fibers oriented in the x, y and z directions. The web has a fiber size distribution of from 0 &#x3bc;m to about 15 &#x3bc;m with at least about 25% of the fibers being above 4 &#x3bc;m. The web has a thickness of less than about 250 millimeters and a basis weight ranging from about 20 g/m2 to about 3,000 g/m2. The web also has a vertical cross-section, when taken parallel to a machine direction, exhibiting a plurality of snugly stacked, approximately V, U or C-shaped structures, with each V, U or C-shaped structure having an apex facing in the machine direction. The web further has a recovery value ranging from about 20% to about 99% after being compressed under a pressure of 0.25 psi for a time period of 30 minutes.

High loft, nonwoven web exhibiting excellent recovery

A process for forming a high loft, nonwoven web is disclosed. The process includes introducing a single molten polymer to a die having a plurality of nozzles. Emitting the molten polymer through the nozzles to form a plurality of filaments. Using air streams to facilitate movement and drawing of the filaments. Directing the filaments, which are transformed into fibers, towards a pair of heated moving surfaces. The pair of heated moving surfaces forming a convergent passage having an entry and an exit. Depositing the fibers into the entry of the convergent passage and routing the fibers between the pair of heated moving surfaces in a machine direction to form a high loft, non-woven web. The web having a fiber size distribution of from 0 &#x3bc;m to about 15 &#x3bc;m with at least about 25% of the fibers being above 4 &#x3bc;m.

Process for forming a high loft, nonwoven web exhibiting excellent recovery

A hybrid non-woven web is disclosed which is a matrix of a stream of fibers of a first material joined to streams of first and second spun-blown fibers. Each of the first and second spun-blown fibers are formed from a thermoplastic composition that contains at least one polymer having a melt flow rate of from between about 5 grams/10 minutes to about 6,000 grams/10 minutes at 230&#xb0; C. Each of the first and second spun-blown fibers also have an average diameter of between about 1 microns to 10 microns and a standard deviation of from between about 0.9 microns to about 5 microns. In addition, the hybrid non-woven web has a tensile strength of at least about 5 gf/gsm/cm width, measured in a machine direction. An apparatus and a method of forming the hybrid non-woven web are also disclosed.

Hybrid non-woven web and an apparatus and method for forming said web

A process is disclosed for forming a non-woven web.

Process for forming a non-woven web

An apparatus is disclosed for forming a non-woven web.

Apparatus for forming a non-woven web

A process is disclosed of forming cellulose fibers. The process includes extruding an aqueous solution of cellulose and a solvent through a first member to form filaments. The first member has multiple rows of first and second openings with a nozzle positioned in each of the first openings. At least one of the nozzles in one row is staggered from at least one of the nozzles in an adjacent row. At least a portion of each of the filaments is shrouded in a pressurized gas emitted through each of the first openings. Each of the filaments is contacted with a liquid to remove some of the solvent and transform each of the filaments into a continuous solid fiber. The continuous solid fibers are then collected on a moving surface to form a non-woven cellulose web.

Process of forming a non-woven cellulose web and a web produced by said process

An apparatus is disclosed for extruding cellulose fibers. The apparatus includes a first member, a second member and a third member all secured together. Multiple nozzles extend outward from the first member and each is designed to direct an aqueous cellulose solution therethrough. As the aqueous solution is extruded, it is accentuated and accelerated by pressurized gas flowing through the first member and the second member and out through first openings formed in the third member. The pressurized gas at least partially surrounds each nozzle and shelters the molten filaments extruded therefrom. The third member also has multiple second openings formed therethrough which are also connected to a source of pressurized gas. The pressurized gas streams exiting each of the second openings function to keep each of the molten filaments from contacting an adjacent molten filament.

Apparatus for extruding cellulose fibers

An array of nozzles is disclosed for forming multiple cellulose fibers. Each nozzle has a longitudinal central axis and includes a tube with a cross-section having a diameter through which an aqueous solution of cellulose and a solvent can be extruded into a molten filament. A first opening is present which surrounds each of the tubes. The first opening has a cross-section with a diameter, and each of the first openings is capable of emitting a pressurized gas which surrounds one of the extruded molten filaments. At least three second openings are spaced away from each of the first openings. Each of the second openings is capable of emitting a pressurized gas stream essentially parallel to the longitudinal central axis of each of the nozzles, and each of the pressurized gas streams functions to shroud one of the extruded molten filaments.

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Neenah, WI, United States of America

Jeffrey D Stark