System and process for preparing a fibrous nonwoven composite fabric
Inventors
Newman, Marc • Ruschel, Rene • Xin, Yu
Assignees
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Publication Number
US-11891723-B2
Publication Date
2024-02-06
Expiration Date
Abstract
A system having a first polymer source and a spin beam in fluid communication with the first polymer source is provided. The spin beam includes a spinneret assembly having filament nozzles configured and arranged to extrude a plurality of filaments of a first polymer. A gas distribution plate is disposed downstream of the spinneret assembly, and includes a plurality of gas distribution slots that are configured and arranged to receive two or more corresponding filament nozzles of the spinneret assembly therein. A stream of gas is introduced into the plurality of slots to draw and attenuate the filaments extruded by the plurality of filament nozzles. The drawn and attenuated filaments are collected on a collection surface disposed downstream of the gas distribution plate to form a nonwoven fabric. A solid additive, such as pulp fibers may be blended with the filaments prior to collecting the filaments on the collection surface.
Core Innovation
The invention is a system for preparing a nonwoven fabric. It includes a first polymer source feeding a spin beam with a spinneret assembly that has a plurality of rows of filament nozzles arranged in an array. The filament nozzles extrude a plurality of filaments comprising a first polymer into a downstream region.
A gas distribution plate is disposed downstream of the spinneret assembly. The gas distribution plate includes a plurality of gas distribution slots associated with one or more of the rows of filament nozzles, and a gas source introduces a stream of gas into the gas distribution slots to draw and attenuate the filaments extruded by the filament nozzles. A collection surface disposed downstream of the gas distribution plate collects the drawn and attenuated filaments to form a nonwoven fabric web.
The gas distribution slot structures influence how gas is delivered relative to filament nozzles. In one implementation, the gas distribution slots comprise a first chamber and a second chamber interconnected via a fluid channel, where each chamber includes at least one filament nozzle disposed therein. In other implementations, the gas distribution slots are arranged in an alternating pattern with rows of filament nozzles, or the gas distribution slot comprises a pair of converging first and second chambers with a central chamber and opposing sides that converge towards a central point disposed between the first and second chambers.
Claims Coverage
The provided claims include four independent claims, directed to a nonwoven-fabric preparation system and one method claim. Each independent claim centers on polymer extrusion from a spinneret array, downstream gas distribution slots that draw and attenuate filaments, and deposition onto a collection surface, with variations focused on gas-slot and chamber geometry and positional arrangement of nozzle rows and slots.
Gas slots with interconnected first and second chambers and nozzle placement
The gas distribution slots comprise a first chamber and a second chamber that are interconnected via a fluid channel, and each chamber includes at least one filament nozzle disposed therein.
Alternating pattern of nozzle rows and gas distribution slot rows
The plurality of gas distribution slots are disposed adjacent to a corresponding row of filament nozzles, and the spin beam comprises an alternating pattern of rows of filament nozzles and gas distribution slots.
Successive chambers with a fluid connecting channel
The gas distribution slots comprise a plurality of successive chambers arranged in a row and a fluid connecting channel provides fluid communication between adjacent chambers.
Pair of converging chambers with a central chamber and opposing sides
The gas distribution slot comprises a pair of converging first and second chambers, each chamber comprising a central chamber and a pair of opposing sides that extend from peripheral edges of the central chamber and converge towards a central point disposed between the first and second chambers.
Surrounding filaments with gas and depositing to form a web
A stream of gas is introduced into the plurality of gas distribution slots to surround the filament nozzles and the extruded plurality of filaments, draw and attenuate the plurality of filaments, and deposit the plurality of filaments onto a collection surface disposed downstream of the gas distribution plate to form a nonwoven fabric web.
Across the independent claims, the inventive coverage is directed to introducing gas through gas distribution slots associated with rows of filament nozzles to draw and attenuate extruded filaments prior to collection, with variations specifying interconnected chambers with fluid communication and nozzle placement per chamber, an alternating spatial pattern of nozzle rows and slot rows, successive chambers with an interconnecting channel, and a converging-chamber slot geometry having a central chamber and opposing sides that converge toward a central point.
Stated Advantages
Not explicitly described in patent.
Documented Applications
Not explicitly described in patent.
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