American Filtrona Corporation

Filtrona Richmond, Inc.

Filtrona International Limited

Other

Hills, Inc.

Essentra Porous Technologies Corp.

Richard M Berger

Jeff S Haggard

Robert G Hemsworth

A device and method for spinning polymer fibers utilizes one or more independent sources of polymer materials, pumps for feeding polymer material from each of the sources, and a series of distribution plates with surface grooves, through holes and/or slots together defining separated distribution paths, each of which receives polymer material from one of said independent sources. The surface grooves are defined to a depth less than the thickness of the distribution plate. At least one distribution plate contains spinneret orifices defined by outlet surface grooves extending from the distribution path to the edge of that plate, whereby fibers are extruded from the spinneret orifices edgewise from the plate. The spinneret orifices may be defined by overlayed outlet surface grooves or slots defined in abutting plates.

Method and apparatus for spinning a web of mixed fibers, and products produced therefrom

A fiber spinning device and process for manufacturing a web of fibers including a homogeneous mixture of fibers of different characteristics. Monocomponent fibers of different polymers can be extruded side-by-side from the same die system. Sheath/core bicomponent fibers can be alternated with monocomponent fibers formed of the same core polymer as used in the bicomponent fibers. Bicomponent fibers having a common core polymer and different sheath polymers can be extruded from alternate spinneret orifices in the same die plate. Multiple distribution plates are provided with surface grooves or depressions to direct polymer materials from independent sources to only selected spinneret openings in an array of spinneret openings while maintaining the polymers segregated from each other. Unique products formed from the improved mixed fiber technology are useful as high efficiency filters in various environments, coalescent filters, reservoirs for marking and writing instruments, wicks and other elements designed to hold and transfer liquids for medical and other applications, heat and moisture exchangers and other diverse fibrous matrices.

A fiber spinning device and process for manufacturing a web of fibers in the nature of a homogeneous mixture of fibers of different characteristics. Monocomponent fibers of different polymers can be extruded side-by-side from the same die system. Sheath/core bicomponent fibers can be alternated with monocomponent fibers formed of the same core polymer as used in the bicomponent fibers. Bicomponent fibers having a common core polymer and different sheath polymers can be extruded from alternate spinneret orifices in the same die plate. Multiple distribution plates are provided with surface grooves or depressions to direct polymer materials from independent sources to only selected spinneret openings in an array of spinneret openings while maintaining the polymers segregated from each other. Unique products formed from the improved mixed fiber technology are useful as high efficiency filters in various environments, coalescent filters, reservoirs for marking and writing instruments, wicks and other elements designed to hold and transfer liquids for medical and other applications, heat and moisture exchangers and other diverse fibrous matrices.

A heat and moisture exchanger including a gas-permeable element, preferably a fibrous media, adapted to be warmed and to trap moisture from a patient's breath during exhalation and to be cooled and to release the trapped moisture for return to the patient during inspiration to effectively conserve the humidity and body heat of the patient's respiratory tract, wherein the media comprises a hydrophilic nylon polymer. The gas-permeable element can be formed entirely of monocomponent fibers of the hydrophilic nylon polymer or, preferably, fibers comprising at least a sheath of the hydrophilic nylon polymer can be bonded at their points of contact by a bonding agent, such as a polyester. Bicomponent fibers comprising a sheath of the hydrophilic nylon polymer can be bonded by other bicomponent fibers comprising a sheath of the bonding agent, with all of the bicomponent fibers comprising a core of a thermoplastic polymer, such as polypropylene, to minimize the cost and increase the strength of the heat and moisture exchanger element.

Heat and moisture exchanger comprising hydrophilic nylon and methods of using same

Bicomponent fibers comprising a core of a thermoplastic material, preferably polypropylene, and a sheath of a blend of the core-forming polymer and an ethylene-vinyl acetate copolymer are used to produce tobacco smoke filter elements which may be incorporated into tobacco smoke filter products such as filtered cigarettes. The addition of significant quantities of the core-forming material to the ethylene-vinyl acetate used to form the sheath avoids problems experienced heretofore in build-up of polymer in the forming dies using conventional filter-forming equipment Additionally, the blended sheath-forming polymer improves adhesion between the sheath and the core of the bicomponent fiber and, with the use of polypropylene, improves the hardness of the resultant tobacco smoke filter elements.

Sheath-core bicomponent fibers with blended ethylene-vinyl acetate polymer sheath, tobacco smoke filter products incorporating such fibers and tobacco smoke products made therefrom

A fiber spinning device and process for manufacturing a web of fibers comprising a homogeneous mixture of fibers of different characteristics. Monocomponent fibers of different polymers can be extruded side-by-side from the same die system. Sheath/core bicomponent fibers can be alternated with monocomponent fibers formed of the same core polymer as used in the bicomponent fibers. Bicomponent fibers having a common core polymer and different sheath polymers can be extruded from alternate spinneret orifices in the same die plate. Multiple distribution plates are provided with surface grooves or depressions to direct polymer materials from independent sources to only selected spinneret openings in an array of spinneret openings while maintaining the polymers segregated from each other. Unique products formed from the improved mixed fiber technology are useful as high efficiency filters in various environments, coalescent filters, reservoirs for marking and writing instruments, wicks and other elements designed to hold and transfer liquids for medical and other applications, heat and moisture exchangers and other diverse fibrous matrices.

Method and apparatus for spinning a web of mixed fibers, and products

Bicomponent fibers comprising a core of a thermoplastic material, preferably polypropylene, and a sheath of a blend of the core-forming polymer and an ethylene-vinyl acetate copolymer are used to produce tobacco smoke filter elements which may be incorporated into tobacco smoke filter products such as filtered cigarettes. The addition of significant quantities of the core-forming material to the ethylene-vinyl acetate used to form the sheath avoids problems experienced heretofore in build-up of polymer in the forming dies using conventional filter-forming equipment. Additionally, the blended sheath-forming polymer improves adhesion between the sheath and the core of the bicomponent fiber and, with the use of polypropylene, improves the hardness of the resultant tobacco smoke filter elements.

Tobacco smoke filter incorporating sheath-core bicomponent fibers and

A porous element particularly for use as a tobacco smoke filter plug in association with a cigarette or the like wherein the matrix comprises a multiplicity of biodegradable polyvinyl alcohol fibers bonded together at their points of contact to define a tortuous interstitial path for the passage of smoke. Because of the hygroscopic nature of polyvinyl alcohol, commercial production of such products require careful control of the moisture content of the polyvinyl alcohol fiber starting material, usually pre-drying the same to a residual moisture content of 7% by weight or less, and treatment of the low moisture fibrous mass by superheated steam to add about 2.5 to 5% moisture to a final moisture content of about 2.5 to 10%. The steam renders the fiber surface adhesive and, thus, bondable, and also lubricates the gathered fibers to improve processability.

Biodegradable polyvinyl alcohol tobacco smoke filters, tobacco smoke

A method for forming successive spaced crimps in a tow of fibrous material by passing the tow along a path defined by an apparatus comprising a plurality of crimping wheels disposed around the path, each wheel including teeth having crimping surfaces and adjacent sealing surfaces which slide over one another during crimping to prevent material from being squeezed between the teeth thereby forming crimped sections with elongate edges which are substantially free of flashing connecting non-crimped sections. A second crimping step may be incorporated to form longitudinal grooves in alternate non-crimped sections. The rod-like member produced by these techniques may be overwrapped to provide pockets surrounding the crimped sections which may be filled with a smoke-modifying material, for example, activated charcoal particles. Discrete elements cut from the rod-like member may be used in cigarettes and the like such as in the production of filtered cigarettes.

Crimped elements for cigarettes and the like and methods and apparatus

Sheath-core bicomponent fibers comprising a core of a low-cost, high strength, thermoplastic material, preferably polypropylene or polybutylene terephthalate, completely covered with a sheath formed of polyethylene terephthalate or a copolymer thereof are produced, preferably melt blown to an average diameter of 12 microns or less, and formed into a self-sustaining, three-dimensional, porous element having various applications, principally as an ink reservoir element for a marking or writing instrument, although the porous element may also find utility as a tobacco smoke filter. Other forms of the product have utility in diverse applications where its excellent capillary, absorption and filtering properties are advantageous. The resultant products retain or improve upon the desirable features and processing capabilities of conventional elements, but are substantially less expensive, requiring less high cost polyester for equivalent or better properties.

Growing community of inventors

Midlothian, VA, United States of America

Richard M Berger