Kimberly-clark Worldwide, Inc.

Extrusion Group, LLC

Michael Charles Cook

Bryan David Haynes

Kurtis Lee Brown

Mark Michael Mleziva

Richard Daniel Pike

James Russell Fitts, Jr

Charles John Morell

Howard Martin Welch

Debra Jean McDowall

Michael David Powers

Samuel Edward Marmon

John A Brewer

Lavada Campbell Boggs

John Joseph Lassig

Douglas Jay Hulslander

Ronald H Wideman

Robert James Gerndt

Donald V Willitts

Marion C Morris

Jeffrey David Shelley

Jose Enrique Maldonado

Raymond Jeffrey May

Chad Michael Freese

Leslie D Dobbins

Kenneth Michael Salter

Brian Stephen Forbes

Dana Elizabeth Stano

Vicky Susan Smith

Micheal Troy Houston

Stephen T Farmer, Jr

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

The invention provides a method for controlling the width of a plurality of extruded filaments comprising providing a polymer supply and an extrusion die comprising a plurality of extrusion capillaries and a plurality of counterbores allowing fluid communication between the extrusion capillaries and polymer supply, providing an adjustable insert for interrupting fluid communication between the polymer supply and at least one extrusion capillary, providing at least one fluidized polymer, conveying the polymer through the polymer supply, counterbores and extrusion capillaries to extrude a plurality of filaments, and interrupting the fluid communication between the polymer supply and at least one extrusion capillary by adjusting the insert. An apparatus for extruding filaments is also provided, comprising an extrusion die, polymer supply, extrusion capillaries, counterbores allowing fluid communication between the capillaries and polymer supply, and an adjustable insert for interrupting fluid communication between the polymer supply and at least one extrusion capillary.

Apparatus and method for controlled width extrusion of filamentary curtain

An apparatus for forming meltblown material from a molten polymer includes a die configured with channels in the tip of the die through which molten polymer is extruded for forming meltblown fibers. Air plates are disposed relative to the die tip to define air channels proximate to the die tip for directing attenuating air against the molten polymer fibers extruded from the tip. The air channels include a zone of convergence adjacent the apex of the die tip at an included angle that is within a range of about 10 degrees to about 20 degrees such that each of the air channels defines a convergence angle with respect to a longitudinal axis of the polymer channels of between about 5 degrees to about 10 degrees.

Low turbulence die assembly for meltblowing apparatus

Disclosed is an apparatus for producing nonwoven fibrous webs. The apparatus comprises an extrusion die, first and second fluid supplies in cooperation with the die, first and second extrusion capillaries, first counterbores allowing fluid communication between first capillaries and first supply and second counterbores allowing fluid communication between second capillaries and second supply, each first counterbore having at least two first capillaries extending therefrom.

Apparatus for nonwoven fibrous web

A die tip adapted for extruding a plurality of meltblown multicomponent filaments that includes at least two series of conduits that extend and converge in to the interior of the die tip to convey a multicomponent thermoplastic structure in to the interior of the die tip to a series of capillaries that extend to a series of die opening for extruding multicomponent filaments is provided.

Die for producing meltblown multicomponent fibers and meltblown nonwoven fabrics

A nozzle is described for downwardly directing air from an air intake of a fiber draw unit into a longitudinal channel of the fiber draw unit for forming spunbond polymeric fibers. The nozzle includes an upper eductor connected to the fiber draw unit and a lower eductor adjustably connected to the fiber draw unit and below the upper eductor. The nozzle includes a nozzle cavity that narrows from a nozzle inlet to a nozzle outlet and includes a downward turn of 90 degrees or less. Air directed through the nozzle outlet flows in a direction parallel to a wall of the longitudinal channel.

Fiber draw unit nozzles for use in polymer fiber production

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 a meltblown die which has a considerable smaller width in the machine direction of the meltblowing process compared to conventional and commercially used meltblown dies. The meltblown die of the present invention has a. a die body; b. a die tip mounted to the die body; c. a first air plate mounted to the die body; and d. a second air plate mounted to the die body. In addition, the small size of the meltblown die of the present invention provides advantages over conventional meltblown die, including improved air entrainment.

Meltblown die having a reduced size

In the invention, a method is provided for producing a composite nonwoven fabric. A polymer is extruded into heated continuous filaments, possibly elastic, from the die head to a first chilled roller, wherein the extruder is configured to provide the continuous filaments to the chilled roller in a canted direction that is at a tangent or angle to the surface of the first chilled roller. The filaments are conveyed in a downward direction by way of chilled rollers to a nip. In a next step, the nonwoven web is sprayed with an adhesive and is laminated on the continuous filaments in the nip to form a composite nonwoven fabric. The continuous filaments move vertically downward approximately in line with the lamination process, facilitating automatic re-threading of filaments when they are broken or interrupted in their travel downward onto the chilled rolls.

Method and apparatus for producing laminated articles

A support for a web forming machine which allows for vertical adjustment of a web forming belt with respect to at least one die head positioned above the web forming belt, and allows for tilting of the web forming belt. The support allows linear motion along a y-axis defined by a length of a guide shaft while preventing linear motion along a x-axis and a z-axis, e.g. the two axes perpendicular to the y-axis. Further, the support allows rotational or axial motion about the x-axis perpendicular to the y-axis but prevents rotational or axial motion about the y-axis and the z-axis.

Tiltable web former support

Robust round homofilament fibers are meltspun from a spinneret having two conjoined capillaries of different length to diameter ratio to induce differential shear to produce fiber crimping. Crimping may further be aided by quenching of the fibers.

Dual capillary spinneret with single outlet for production of homofilament crimp fibers

A extruded filament die tip, such as meltblown filaments, has a plurality of bores communicating with the main polymer distribution channel. The bores have a plurality of capillary openings, or spinnerettes, drilled into the bore to act as extrusion orifices for the die tip. The present die tip differs from conventional die tips in which capillaries are drilled into a deep slot formed in the die tip for polymer distribution. The invention allows more material to remain in the body of the die tip while facilitating more spinnerette openings per linear inch in the die tip and permitting higher operating pressures and smaller diameter fibers such as between 1 and 4 microns. A resultant nonwoven fabric made with the die tip will have a higher hydrohead resistance due to the increased number of fine filaments per inch for the same osy of fabric.

Meltblown die tip with capillaries for each counterbore

A method of maintaining a die system for the extrusion of polymer permits external cleaning and maintenance without shutting down the operation. Removable die inserts are located on one or both sides of the die opening section through which polymer is extruded. The inserts are spaced from the die opening section, by a very small distance, so as to avoid interfering with the opening section. When molten polymer accumulates and burns in areas surrounding the die opening section, the inserts can be removed and replaced without interrupting the extrusion of polymer.

Method of maintaining an exterior of an operating die system

The present disclosure is directed to a method of forming a treated fiber. A molten polymer is delivered to a fiber spinning assembly adapted to form and distribute polymer streams. At least one treatment is applied in a liquid state to at least one region on the surface of at least one molten polymer stream within the fiber spinning assembly. A substantial portion of the treatment remains on the surface of the resulting fiber within the treated region. One or more regions on the surface of the molten polymer may be treated with one or multiple treatments. The degree of coverage may vary from little coverage to complete coverage of the fiber surface. The treated regions may be in contact with one another or may be separate and distinct. A nonwoven web may be produced with selectively treated fiber regions by designing one or more fiber spinning assemblies to treat selected fibers or to apply multiple treatments. The regions of the nonwoven web may vary in treatment type, amount, or degree of coverage.

Method of forming a treated fiber and a treated fiber formed therefrom

A die system for the extrusion of polymer permits external cleaning and maintenance without shutting down the operation. Removable die inserts are located on one or both sides of the die opening section through which polymer is extruded. The inserts are spaced from the die opening section, by a very small distance, so as to avoid interfering with the opening section. When molten polymer accumulates and burns in areas surrounding the die opening section, the inserts can be removed and replaced without interrupting the extrusion of polymer.

Growing community of inventors

Marietta, GA, United States of America

Michael Charles Cook