Kimberly-clark Worldwide, Inc.

Extrusion Group, LLC

Kurtis Lee Brown

John Herbert Conrad

Jeffrey David Shelley

Jose Enrique Maldonado

Edward Jason White

Darryl Franklin Clark

Robert James Gerndt

Braulio Arturo Polanco

Chad Michael Freese

Mark Michael Mleziva

Bryan David Haynes

Richard Daniel Pike

Peter W Shipp, Jr

Christopher Cosgrove Creagan

Samuel Edward Marmon

Michael Charles Cook

Christopher Dale Fenwick

James Richard Neely

Richard Wallace Hoefer

Susan Elaine Shawver

James Russell Fitts, Jr

Terry K Timmons

Alexander J Neeb

Eric Scott Kepner

Monica Graciela Varriale

Brian Stephen Forbes

Micheal Troy Houston

Warren L Collier, Iv

This disclosure describes meltblown methods, assemblies, and systems for polymer production. In one such implementation, a meltblown system provides improved uniform output and reduction of fiber size given certain polymer material and production rate. In certain meltblown implementations, the equipment may be ready and quickly swapped while provided in hot standby mode such that the maintenance down time is minimized. The disclosed meltblown equipment may include a polymer beam and air chamber and a die tip assembly. The die tip assembly, in certain embodiments, may quickly be attached onto or removed from the polymer beam and air chamber. In preferred embodiments, the meltblown system includes a single input (e.g., a specific type of polymer material). The meltblown system includes some tapered structures that facilitate polymer flow. The assembly mechanisms used in the meltblown system enables cleaning of the polymer distribution components with each use.

Meltblown die tip assembly and method

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

A multilayer laminate is produced with in-line fabric deposition. One layer of the multilayer laminate has stable, heat-set, helically crimped fibers which are uncompacted and therefore retain their loft.

Multilayer approach to producing homofilament crimp spunbond

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

A lofty, nonwoven material having a nonwoven web having a plurality of substantially continuous fibers oriented in a z-direction of the nonwoven web and a method for producing the lofty, nonwoven material from as-formed z-direction fibers. The method is fast, having no mechanical manipulation of the fibers to slow it down, easily adjustable and allows for in-line processing. The material can be varied from preponderantly open to preponderantly closed in its web structure.

Controlled loft and density nonwoven webs and method for producing same

A method for producing a material having z-direction waves in which a layer of continuous fibers is conveyed on a first moving surface into a nip formed by the first moving surface and a second moving surface which is traveling at a slower speed than the first moving surface, resulting in formation of a plurality of z-direction loops in the fibers giving loft to the material and a wave pattern producing ridges on both major surfaces of the resultant nonwoven web. The method permits easy real time alignment of manufacturing parameters to produce a variety of materials. The method further produces lofty nonwovens at a commercially viable rate.

Materials having z-direction fibers and folds and method for producing same

Robust homofilament fibers are meltspun from a differently shaped dual capillary spinneret design to induce differential fiber morphology to produce crimping. Crimping may further be aided by quenching and drawing of the fibers.

Dual capillary spinneret for production of homofilament crimp fibers

Spunbond multicomponent filaments and nonwoven webs made from the filaments are disclosed. In accordance with the present invention, the multicomponent filaments contain a crimp enhancement additive. Specifically, the crimp enhancement additive is added to the polymeric component that has the slower solidification rate. The additive enhances crimp, allows for highly crimped filaments to be made at low fiber linear densities, improves the integrity of unbonded webs made from the filaments, and produces webs with improved stretch and cloth-like properties. The additive incorporated into the filaments is a random copolymer of butylene and propylene.

Crimped multicomponent filaments and spunbond webs made therefrom

A method for producing a material having z-direction ridges or folds in which a layer of continuous fibers is conveyed on a first moving surface into a nip formed by the first moving surface and a second moving surface which is traveling at a slower speed than the first moving surface, resulting in formation of a plurality of z-direction loops in the fibers giving loft to the material and a wave pattern producing ridges on both major surfaces of the resultant nonwoven web. The method permits easy real time adjustment of manufacturing parameters to produce a variety of materials. The method further produces lofty nonwovens at a commercially viable rate.

Method for producing materials having z-direction fibers and folds

Stable, heat-set, helically crimped fibers are economically produced with in-line fabric deposition and heat setting and are uncompacted to retain their loft.

In-line heat treatment of homofilament crimp fibers

Controlled loft and density nonwoven webs and method for producing

Spunbond multicomponent filaments and nonwoven webs made from the filaments are disclosed. In accordance with the present invention, the multicomponent filaments contain a crimp enhancement additive. Specifically, the crimp enhancement additive-is added to the polymeric component that has the slower solidification rate. The additive enhances crimp, allows for highly crimped filaments to be made at low fiber linear densities, improves the integrity of unbonded webs made from the filaments, and produces webs with improved stretch and cloth-like properties. The additive incorporated into the filaments is a random copolymer of butylene and propylene.

The invention provides a sheet filter medium having autogenously bonded uncrimped conjugate fibers which contain a polyolefin and another thermoplastic polymer that have different melting points. The filter medium has a density between about 0.07 g/cm.sup.3 and about 0.2 g/cm.sup.3. The invention additionally provides a three-dimensionally thermoformed filter medium that has a density between about 0.07 g/cm.sup.3 and about 0.5 g/cm.sup.3.

Growing community of inventors

Alpharetta, GA, United States of America

Kurtis Lee Brown