ES2477318T3 - Method and apparatus for producing polymer fibers and fabrics that include multiple polymer components in a closed system - Google Patents

Abstract

A system for the manufacture of a nonwoven web of fibers comprising: a spinning folder assembly configured to process and supply a plurality of polymer streams for extrusion through spinneret holes for spinning yarn extrusion, the spinning folder assembly including a plurality of supply steps in fluid communication with the holes in the spinneret spinneret for spinning yarn, in which at least two of the supply steps are configured to supply separate streams of polymers of different polymer components to the holes in the row for spinning yarn for spinning yarn; wherein the spinning folder assembly includes a plurality of manifolds to independently segregate and maintain the polymer streams of different polymer components at different temperatures, in which each manifold provides uniform heating of a flowing polymer stream between Polymer distribution tube within each manifold surrounding each distribution tube with a heat transfer medium at a substantially uniform temperature, a fast-cooling chamber configured to quickly receive and cool extruded filaments from the holes in the spinneret spinneret for extrusion of yarns, including the fast-cooling chamber a gas supply source for directing a gas stream to the extruded filaments; a stretching chamber in communication with the rapid cooling chamber and configured to receive and attenuate the rapidly cooled filaments; and a forming surface configured to receive stretched filaments that emerge from the stretching chamber and form a non-woven fibrous fabric on the forming surface; in which the system maintains the extruded filaments in a closed environment between the holes in the row for spinning yarn extrusion and the stretching chamber to prevent uncontrolled gas streams from contacting the filaments.

Description

Method and apparatus for producing polymer fibers and fabrics that include multiple polymer components in a closed system

Background of the invention

Field of the Invention

The present invention relates to methods and apparatus for producing fibers and fabrics in a closed fiber spinning system, in which the fibers and fabrics include a plurality of different polymer components.

Description of the related technique

A plurality of closed fiber spinning systems for manufacturing adhesion spun fabrics having certain desirable characteristics are known in the art. For example, U.S. Patents Nos. 5,460,500, 5,503,784, 5,571,537, 5,766,646, 5,800,840, 5,814,349 and 5,820,888 all describe closed systems for producing spunbond fiber webs . Descriptions of these patents are incorporated herein by reference in their entirety. In a typical closed system, the filaments are spun, cooled and stretched in a common enclosed chamber or environment, such that the current of air or gas used to cool the fibers emerging from an extruded row No yarn is also used to stretch and attenuate the fibers down the rapid cooling phase.

In direct contrast to open fiber spinning systems (i.e. systems in which extruded filaments are not spun, cooled and stretched in a common chamber or environment and that are typically exposed to the environment during some or all stages of fiber formation) closed systems eliminate any interference from uncontrolled air currents and during fiber formation. In fact, a typical closed cold spinning system limits the exposure of extruded filaments to undesirable air or gas streams that have selected temperatures during fiber formation, thus facilitating the production of very strong fibers. delicate and uniform that have desirable deniers that are difficult to obtain from a typical open fiber spinning system.

An important component in any fiber spinning system is the polymer delivery system, typically referred to as a spinning folder, which provides streams of molten polymers with a flow rate

or selected dosing flow to the fiber spinning system for filament extrusion in a row for spinning yarn. A type of spinning machine typically used and very advantageous for spinning fibers in a closed system is commonly referred to as a "clothes hanger" spinning machine. This type of spinning machine is typically formed by two sections, constructed of metal or other suitable material joined together in a fluid-tight relationship on facing or matching surfaces, when each matching surface has notched strips on the surface corresponding to samples in mirror symmetry stripped on the matching surface of the other section. Pickled notches on each matching surface form a profile that resembles a triangular "clothes hanger" configuration.

An exploded view of a conventional "clothes hanger" spinner is illustrated in the figure

1. The spinner 2 includes two generally rectangular halves or sections 3 having a plurality of electric radiators 12 disposed within each section to heat polymer fluid flowing into the spinner into the spinneret for extrusion. of yarns In operation, the molten polymer stream is directed (for example, by means of a pump) to an inlet portion 4 of the "clothes hanger" channel profile of the spinner 2 and advances within a portion upper part of the triangular channel portion 6 of the "clothes hanger" profile that is disposed below and in fluid communication with the inlet portion 4. The "clothes hanger" channel defined by the inlet portion and the portion triangular is formed by corresponding notches on the coincident surfaces of the two sections of the spinner 3. After entering the channel 6, the molten polymer stream is divided into the two sections of the divergent channel 7 of the portion triangular channel, where the divided currents continue to advance and then converge within a horizontal channel section 8 arranged at a lower end of the "clothes hanger" channel between the lower ends of the divergent channel sections. The horizontal channel section also extends longitudinally along a lower end of the spinner 2. On the lower end of the spinner, a screen filter and a plate 9 and a row for extrusion are fixed. n of yarns 10 having a plurality of holes arranged along its longitudinal dimension. The screen filter, the plate and the spinneret spinneret also extend longitudinally along the lower end of the spinner 2 and are aligned and in fluid communication with the horizontal channel section 8. Therefore, the molten polymer stream that travels within the horizontal channel section 8 of the "clothes hanger" channel continues to flow through the screen filter and the support plate 9 to the extrusion row n of yarns 10, where the polymer stream is then extruded through the holes in the spinneret spinneret to form a plurality of polymer filaments. The configuration of the "clothes hanger" channel is particularly advantageous because it is of simple design and creates a substantially uniform pressure differential within the

channels, resulting in a uniform supply of the polymer stream within the horizontal channel portion of the "clothes hanger" channel and a uniform extrusion of the molten polymer through the holes in the row for yarn extrusion.

While a closed fiber spinning system combined with a "clothes hanger" spinner is useful for manufacturing certain polymer fibers that have desirable uniformities and deniers, the "clothes hanger" beam folding machine encounters problems. when two or more polymer components are used to produce more complex fibers and spunbond fabrics. In particular, it is very difficult in the closed "clothes hanger" system to process two or more different polymer components that have different melting temperatures when manufacturing multicomponent fibers or fabrics containing multiple polymer components. For example, a two-component fiber consisting of two polymer components with significantly different melting points would be extremely difficult to produce using a closed fiber spinning system with a "clothes hanger" spinner (for example, using a double "clothes hanger" spinner with "clothes hanger" channels that are arranged side-by-side), because the "clothes hanger" spinner would tend to stay substantially at the same temperature by the electric radiators arranged in the sections of the spinner. The difficulty is further aggravated when polymer components are used that must be maintained at temperatures very close to their melting point to avoid gelling and crosslinking of the polymers. In addition, while the "clothes hanger" systems supply a uniform molten polymer stream to the spinneret spinneret, it is difficult to modify the dosage of the molten polymer stream through the folding folder. "clothes hanger" spinning to the spinning package, which is an important feature in the manufacture of more complex types of fibers, such as multicomponent fibers having variable geometries and / or variable cross sections of the polymer components. Therefore, the flexibility of "clothes hanger" spinners is very limited to allow the manufacture of a wide variety of different fibers and fabrics within a closed fiber spinning system.

Accordingly, there is a need to provide a wide variety of fibers and fabrics that include two

or more polymeric components in a closed fiber spinning system and with a spinning folder capable of supplying streams of molten polymers of two or more different polymer components for the production of fibers within the closed system.

Summary of the invention

Therefore, in the light of the foregoing, and for other reasons that will be apparent when the invention is fully described, an object of the present invention is to provide a closed fiber spinning system capable of producing a wide variety of fibers and single and multi-component fabrics, which include different polymer components and have a desired denier and degree of uniformity.

Another object of the present invention is to provide a spinning folder assembly for the closed system that is capable of supplying streams of molten polymers to the spinneret for spinning of the closed system, in which the streams of pol� mere melts include at least two different polymer components that have different melting temperatures.

Another object of the present invention is to uniformly maintain the two different polymer components at their essentially different melting temperatures within the spinning folder assembly during the supply of molten polymer streams to the spinneret spinneret. .

Still another object of the present invention is to provide a plurality of dosing pumps to individually control the flow rate of different streams of molten polymer fluids for extrusion in the spinneret spinneret.

The aforementioned objects are achieved individually and in combination and it is not intended that the present invention be interpreted in the sense that two or more objects are required to be combined, unless expressly required by the appended claims.

In accordance with the present invention, the aforementioned difficulties associated with the formation of fibers and fabrics having multiple polymer components in a closed system are solved using a closed fiber spinning system, which includes a spinning folder assembly that It is capable of supplying a plurality of streams of molten polymers to a row for yarn extrusion, in which at least two of the polymer streams contain different polymer components, to form multicomponent fibers and fabrics that they include multiple polymer components that have adequate uniformity and denier. The spinning machine includes a plurality of dosing pumps to independently control the causes of flow of one or more polymer streams, as well as at least two thermal control units that independently and uniformly heat the different pol components Emers up to their appropriate melting temperatures, while maintaining thermal segregation between the different components

polymers

The foregoing objects and still other objects, features and advantages of the present invention will be apparent after consideration of the following definitions, descriptions and descriptive figures of specific embodiments thereof, in which the same numbers are used. reference to designate similar components. Although these descriptions go into specific details of the invention, it should be understood that they may exist and variations exist and would be apparent to those skilled in the art on the basis of the descriptions presented herein.

Brief description of the drawings

Figure 1 is an exploded perspective view of a conventional "clothes hanger" spinner for supplying molten polymer fluid to a spinning package in a closed system.

Figure 2 is a side elevational view in partial section of an embodiment of the closed fiber spinning system of the present invention.

Figure 3 is a perspective view in partial section of an embodiment of the spinning folder assembly for the closed system of Figure 1.

Figures 4 to 8 are cross-sectional views of the cross-section illustrating embodiments of different groups of fibers that can be produced by a closed system of the present invention.

Description of the preferred embodiments

The closed fiber spinning system of the present invention is described below with reference to Figures 2 and 3. The terms "closed system" and "closed fiber spinning system", as used herein, refer to a system of fiber spinning which includes an extrusion stage, a rapid cooling stage and a stretching stage, where a stream of air or other gas, which is used to cool the cold in the rapid cooling stage, is used also for stretching and attenuating the fibers in the stretching stage, and the extrusion, rapid cooling and stretching stages are performed in a common closed environment (for example, an individual chamber or a plurality of cameras that communicate between yes). The term "fiber" used herein refers to both finite length fibers, such as conventional staple fibers, as well as substantially continuous structures, such as filaments, unless otherwise indicated. The terms "bicomponent fibers" and "multicomponent fibers" refer to a fiber having at least two portions or segments, where at least one of the segments comprises a polymer component, and the remaining segments comprise another different polymer component. . The term "individual component fiber" refers to a fiber that is constituted of an individual polymer component. The term "mixed polymer fiber" refers to a fiber that is constituted by two or more different polymer components mixed together to form a substantially uniform composition of the polymer components within the fiber formed.

The extruded fibers in the closed system of the present invention can have virtually any cross-sectional shape of the cross-section, including, but not limited to: round, elliptical, tape-shaped, dog-bone-shaped, and forms of the multilobular cross section. The fibers may comprise any combination of molten spun resins, including, but not limited to: homopolymers, copolymers, terpolymers or mixtures thereof of: polyolefins, polyamides, polyesters, polylactic acid , nylon, poly (trimethylene terephthalate), and elastomeric polymers, such as thermoplastic grade polyethylene. Suitable polyolefins include, without limitation, polymers such as polyethylene (e.g., polyethylene terephthalate, low density polyethylene, high density polyethylene, linear low density polyethylene), polypropylene (isothetic polypropylene, syndiotic polypropylene and polypropylene mixtures isotopic and atactic polypropylene), poly-1-butene, poly-1pentene, poly-1-hexene, poly-1-octene, polybutadiene, poly-1,7-octadiene, and poly-1,4-hexadiene , and the like, as well as copolymers, terpolymers and mixtures thereof. In addition, the manufactured fibers can have any selected ratio of polymer components within the fibers.

Referring to FIG. 2, a closed system 100 is illustrated that includes a spinning folder assembly 102 for supplying streams of molten polymers to a spinning package 104 and a closed chamber 106 for forming and supplying extruded filaments 108 to a fabric-forming tape 116, thereby forming a non-woven fabric of fibers 118. It should be noted that the design of the closed chamber illustrated in Figure 2 is intended for exemplary purposes only and the present invention is not limited in any way to such design. For example, any number of closed chamber designs can be used in the practice of the present invention, including, without limitation, the closed chamber designs of US Pat. Nos. 5,460,500, 5,503,784, 5,571 .537, 5,766,646, 5,800,840, 5,814,349 and 5,820,888. The spinning folder assembly, the spinning package, the closed chamber and the tape are constructed of metal or any other suitable material to receive and process fluids of molten polymer fluid.

Spinning folder assembly 102 provides a number of dosed molten polymer streams

independent to the spinning package 104 for extrusion and fiber formation within the closed system 100. These separate and independent heating systems are provided in the spinning folder assembly as described below to independently heat two segregated streams of fluids. of polymers that flow into the spinning folder assembly and into the spinning life. Referring to FIG. 3, the spinner folder assembly 102 includes a generally rectangular and hollow frame 103 that includes a pair of distribution manifolds 122, 130 and a generally rectangular yarn folder 140. Each distribution manifold 122, 130 extends longitudinally along a rear wall 150 of the frame, with the manifold 130 suspended slightly above and aligned substantially parallel with the manifold 122. An inlet tube 123 extends transversely from a central location of manifold 122 and through the rear wall 150 of frame 103 for connection with a polymer supply source (not shown). Similarly, another inlet tube 131 extends transversely from a central location of the manifold 130 and through an upper rear wall 151 of the frame for connection with another polymer supply source (not shown). A portion of each inlet tube also extends into each manifold for connection with a polymer distribution tube disposed within the manifold, as described below. The manifold 122 is sealed at one end and is connected to a heat medium supply conduit 124 at the other end, with the conductor 124 extending through a side wall 152 of the frame 103 and in connection with a source of heat medium supply (not shown). The manifold 130 is also sealed at one end that corresponds to the sealed end of the manifold 122 and is connected at the other end to another heat medium supply conduit 132, which extends through the side wall 152 of the frame, where the supply conduit 132 is also connected to a source of heat medium supply (not shown). The manifolds are slightly staggered in alignment with each other, with the end of the manifold 122, which is connected to the conduit 124, arranged closer to the side wall 152 of the frame than the corresponding end of the manifold

130.

A polymer distribution tube is arranged and extends longitudinally with each distribution manifold 122, 130 and is connected to the corresponding inlet tube 123, 131 projecting within the interior of the manifold. Each manifold 122, 130 basically surrounds and wraps the distribution tube disposed therein, allowing to supply a fluid heat transfer medium (eg Dowtherm) through the respective supply conduit 124, 132 to the manifold to surround and transfer heat to the fluid of polymer disposed within the distribution tube. The collectors and the tubing associated with the collectors facilitate independent and segregated heating of two different polymer components at different temperatures within the spinning folder assembly 102. According to the invention, the design of the collector provides uniform heating of the flow fluid. polymer circulating within each distribution tube within each manifold surrounding each distribution tube with a medium at a substantially uniform temperature. This heating characteristic is a significant improvement over the design of electric heating provided in the "clothes hanger" style spinning folder, because the electric radiators in the "clothes hanger" spinning folder can provide thermal gradients not desired within the sections of spinners.

Each distribution manifold 122, 130 further includes a set of six polymer transfer tubes 126, 134 that extend transversely and at approximately equal longitudinally spaced locations from the manifold to a front wall 153 of the frame 103, where the transfer tubes 126 (which extend from the manifold 122) are substantially parallel with transfer tubes 134 (which extend from the manifold 130). Each transfer tube 126, 134 also extends into its respective manifold 122, 130 and is connected in an appropriate location with the corresponding distribution tube disposed therein. Due to the vertical deviation between the manifold 122 and the manifold 130 within the frame of the spinner folder assembly, the transfer tubes 134 are immediately driven vertically downward to the manifold 122 after emerging from the manifold 130 to be aligned substantially vertical with transfer tubes 126 as they extend toward the front wall 153 of the frame. One skilled in the art will recognize that each distribution tube and transfer tubes that are connected to each distribution tube within each manifold can be independently designed to ensure adequate residence time of polymer fluid flowing through the tube. of distribution and that is heated inside the collector. In addition, the lengths of each of the transfer tubes extending from a particular distribution tube are preferably equal to ensure that the residence times of fluid streams advancing within those transfer tubes are substantially equal.

The spinner 140 is disposed substantially near the front wall 153 within the frame 103. The spinner houses a set of six generally rectangular pump blocks 142 longitudinally spaced along the spinner to correspond with a tube individual transfer 126, 134 extending from each manifold 122, 130 to the pumping blocks. Each pump block 142 includes a first dosing pump 128 that is connected to a corresponding polymer transfer tube 126 that extends to that pump block and a second dosing pump 136 that is connected to a pol transfer tube Corresponding number 134 extending to that pump block. The transfer tubes 126, 134 extend through a rear wall of the spinner 140 for connection with their corresponding metering pumps 128, 136. A heat supply conduit 144 extends from a lower portion of the rear wall of the spinner and through the side wall of the

frame 152 for connection with a source of heat transfer fluid medium (not shown). The spinning folder is heated by the fluid heat transfer medium supplied by the conduit 144 which, in turn, heats and maintains the pump blocks 142 and the pumps 128, 136 at a suitable temperature during the operation of the spinning assembly . The pump blocks are further constructed of a material that has a low thermal conductivity to control or limit the amount of heat transferred between the pump blocks, the pumps and the polymer fluid that advances through the bombs For example, in fiber manufacturing processes, where two different polymeric components having different melting temperatures are used, the pump blocks are heated to the highest temperature melting point. However, the polymer component with the lowest melting temperature will never reach the highest temperature due to the limited heat transfer capacity of the pump block.

Each metering pump 128, 136 further includes an inlet for receiving polymer fluid from a corresponding polymer transfer tube 126, 134 and multiple outputs for feeding polymer fluid streams at a selected flow rate. up to an input channel in the spinning package 104. In a preferred embodiment, each metering pump includes four outlets, such that the spinning folder assembly is capable of providing two sets of twenty four streams of pollutant fluid. merely, the temperature and flow rate of each set being controlled independently of each other. Such an embodiment could provide, for example, currents of dosed polymers from each set of approximately six inches each along a spinner which has a length of approximately twelve feet. However, it should be noted that the metering pumps can include any number of polymer streams that must be transferred to the spinning package.

The spinning package 104 includes a plurality of input channels for receiving polymer fluid streams from a spinning folder assembly, a polymer filtration system, distribution systems and a spinneret spinneret. with a series of spinning holes to extrude filaments of polymers therethrough. For example, the holes in the spinneret spinneret can be arranged in a rectangular, substantially horizontal matrix, typically from 1000 to 5000 per meter of length of the spinneret spinneret. As used herein, the term "spinneret spinneret" refers to the lowest portion of the yarn package that supplies the molten polymer up to and through extrusion holes within the closed chamber 106. . The row for spinning yarn can be implemented with drilled or pickled holes through a plate or any other structure capable of emitting the required fiber streams. The spinning package basically coordinates flow of molten polymer fluid from the spinner to form a desired type of fiber (e.g., multi-component fibers, fibers having a particular geometric configuration of the cross-section, etc.) as well. as a desired number of fibers that are continuously extruded by the system. For example, the spinning package may include channels that combine two or more streams of different polymer fluids fed from the spinner before extrusion through the holes in the spinneret spinneret. Additionally, the holes in the spinneret spinneret can include a variety of different shapes (for example, round, square, oval, cotter-shaped, etc.) that result in variable types of geometries resulting from the section transverse of the fibers. An exemplary yarn package for use with system 100 is described in US Pat.

U. S. No. 5,162,074 in the name of Hills, whose description is incorporated herein by reference in its entirety. However, it should be noted that any conventional or other yarn package can be used to spin fibers with the system 100.

The closed chamber 106 includes a rapid cooling station 110 arranged directly below the spinning pack 104 and a stretching station 112 arranged directly below the rapid cooling station. A conductor pair 114 is also connected on opposite surfaces of the chamber 106 in the vicinity of the rapid cooling station 110. Each conduit 114 directs a stream of air (generally indicated by the arrows in Figure 2) in the opposite direction. from each other and towards extruded filaments 108 leaving from the spinning pack 104 and advancing through the rapid cooling station 110. The extruded filaments are cooled in this way by the convergent air currents that come from ducts 114 in the rapid cooling station. The air currents are preferably directed in a direction generally perpendicular to the filaments 108 or slightly angled in a direction towards the stretching station 112, which is arranged below the rapid cooling station. However, it should be noted that any number of air streams (for example an individual air stream) can be directed in any suitable orientation towards the extruded filaments arranged in the rapid cooling station. In addition, it should be noted that any other suitable gas other than air can be used to rapidly cool the filament in the rapid cooling station. In addition, depending on the types of polymer components used and the types of fibers to be formed, one or more controlled streams of steam or gas treatment can also be used to chemically treat the extruded filaments within the closed chamber. 106 at the rapid cooling station 110 or at any other suitable station.

The chamber 106 preferably has a venturi profile at the stretching station 112, where the walls of the chamber are constricted to form a conical or narrowed section of the chamber within the stretching station to facilitate a flow rate increased combined air currents that pass through

Of the same. The increased flow rate of the air currents within the stretching station provides adequate stretching force to stretch and attenuate the filaments. The stretching station 112 extends to an exit hole in the chamber 106 that is separated at a suitable established distance from the fabric forming tape 116.

The fabric forming tape 116 is preferably a continuous sieve tape through which air can pass, such as a Fourdrinier metallic fabric. The fibers exiting from the closed chamber 106 are spread over the tape to form a nonwoven fabric. The belt is driven, for example, by rollers or any other suitable drive mechanism, to supply the fiber belt to one or more additional processing stations. A recirculation chamber 120 is arranged under the belt 116 and in line with the outlet opening of the chamber 106. The recirculation chamber 120 includes a blower (not shown) that develops a negative pressure or suction inside of the chamber 106 for directing the combined air currents from the rapid cooling station 110 through the stretching station 112 and into the recirculation chamber (generally indicated by the arrows in Figure 2). The drained air streams inside the chamber 120 are suitable for being recycled and returned to the ducts 114 for supply again within the fast-flushing station 110. Preferably, the recycled air streams are also directed through an exchanger of heat and / or are combined with fresh air to maintain a temperature suitable for rapid cooling of the air before being recirculated to the rapid cooling station 110. In an alternative embodiment, the closed system may not employ recirculated air currents. Instead, a blower can continuously direct streams of fresh air directly into and through the closed chamber 106, the air leaving the closed system dissipating after emerging from the stretching station instead of being recirculated for later use.

Next, the operation of the closed system 100 is described using an exemplary bicomponent fiber spinning process, where the polymer components A and B are fed to the yarn folding assembly to form the bicomponent fibers. However, it should be noted that the system 100 can produce a wide variety of fibers that include single component fibers and multi-component fibers. A molten stream of the polymer A is supplied to the spinner folder assembly 102 through the inlet tube 123, where it enters the polymer distribution tube disposed within the distribution manifold 122. Simultaneously, a molten polymer stream B to the spinner folder assembly through the inlet tube 13, where it enters the polymer distribution tube disposed within the distribution manifold 130. A fluid heat transfer medium supplied through conduits 124, 132, it is provided within both manifolds to surround the distribution tubes arranged there and to heat and / or maintain in a uniform and independent manner each of the polymers A and B at a suitable temperature.

The polymer stream A advances through the distribution tube in the manifold 122 and enters the polymer transfer tubes 126, which carry polymer A to the set of six metering pumps 128 arranged on pump blocks 142 in the spinner 140. Similarly, the polymer stream B advances through the distribution tube in the manifold 130 and enters the polymer transfer tubes 134, which carry polymer B to the set of six metering pumps 136 arranged on the pump blocks in the spinning machine. The metering pumps 128 establish a suitable flow rate to transfer a plurality of streams (for example, twenty four) of polymer A to correspondingly aligned inlet channels arranged on the spinning package 104, while the metering pumps 136 establish a flow rate of suitable flow (which is independent of the flow rate established for polymer streams A) to transfer a plurality of polymer streams B to correspondingly aligned input channels disposed on the spinning package.

The independently dosed sets of streams of molten polymers A and B are directed through channels in the spinning pack 104 and through the spinneret spinneret to form bicomponent polymer fibers consisting of these two polymers The type of bicomponent fiber formed (for example, side-winged, sheath / core, "islands in the sea", etc.) is established by the design of the spinner, where separate streams of polymers A and B are they combine in an appropriate manner after emerging from the spinneret spinneret. Additionally, a suitable cross-sectional geometry can also be established for the extracted elements, for example, by providing row hole for yarn extrusion of one or more selected geometries.

The filaments 108 which are constituted of the polymers A and B are extruded through the spinneret spinneret and enter the rapid cooling station 110 of the closed chamber 106, where the filaments are exposed to fast cooling air streams directed to the filaments from conduit 114. The blower in the recirculation chamber 120 creates an aspiration within the closed chamber that directs the air currents through the rapid cooling station 110 and into of the stretching station 112, where the speed of the air currents is increased due to the profile constrained within a portion of the stretching station. The extruded filaments are also directed downwards with the air currents from the rapid cooling station to the stretching station, at which point the filaments are stretched and attenuated in the stretching station. The stretched fibers continue through the closed chamber 106 to exit and form a

fiber nonwoven fabric 118 on the belt 116. The fiber fabric is carried out by the tape 116 for further processing. The air currents that circulate through the closed chamber 120 and leave it are sucked into the circulation chamber 20, where the currents are ultimately directed back to the ducts 114 and to the rapid cooling station 110 .

The combined characteristics of temperature segregation and independent supply of multiple dosed streams of molten polymer fluids into the spinning machine in the closed system of the present invention facilitate the production of a broadly diverse range of fibers and fabrics with achieved previously or even not considered in conventional closed systems. For example, by providing independent and substantially uniform temperature control within the different streams of molten polymers in the spinner, the number of different combinations and ratios of polymers that can be achieved in individual fibers is greatly increased. during fiber formation. A uniform temperature profile of the spinneret spinneret can be maintained in the system without forcing temperature changes in the polymer streams, which is not applicable in the "clothes hanger" spinning machine. electrically heated. The uniform temperature control provided by the spinning machine of the present invention, which eliminates potential thermal gradients during the lift is much greater than the electrically heated "clothes hanger" yarn folding machines typically used in closed systems.

Independent control of different polymer component supply pressures through separate sets of metering pumps offers greater flexibility for the section and distribution of polymers for any given machine configuration providing improved control for uniform pol supply Number over the entire width of the machine. The residence time can be controlled more precisely with the spinning folder assembly and the spinning package of the present invention compared to the "clothes hanger" system, a particularly important feature for heat sensitive polymers, which They require a reduced residence time. In particular, short residence times can be established in the closed system of the present invention to minimize heat transfer between polymer streams and the spinner assembly and the yarn package equipment.

The improved uniformity of stretching and the prevention of external disturbances of the air flow or of the temperature of the air provided by a closed system further improves the extension and production of certain types of sensitive multi-component fibers. Additionally, the closed system facilitates the spinning of certain bicomponent fibers in a controlled atmosphere of steam or gas for chemical treatment of filaments formed during spinning, while vapors are easily contained in the closed system. The spinning folder assembly and the spinning package also increase the hole density of the yarn extrusion row and the possible hole configurations compared to the "clothes hanger" spinning folder (which only produces a linear or narrow matrix of extruded filaments from the yarn extrusion row) to increase productivity and the products of multiple polymer components manufactured in an individual closed system. In addition, the multi-stream dosing spinner combined with the closed system of the present invention facilitates the production of high-value fabrics, which include, but are not limited to unsightly fabrics, skin-friendly fabrics, resistant fabrics to moisture and abrasion, and fabrics formed by differential adhesion methods (instead of conventionally used thermal frizz). Multiple fabric products can also be produced continuously by an individual closed system of the invention, for example, by varying the types and groups of fibers that are extruded in the transverse direction of the system machine.

Some examples of polymer fibers that can be produced in accordance with the present invention are illustrated in Figures 4 to 8. Figure 4 illustrates an individual fiber of core / core 202 of low percentage formed between a group of component fibers. individual or homopolymer 204 to introduce an additive of high value, of low melt resistance, sensitive to temperature and residence time within a high quality fabric formed by the fibers.

Figure 5 illustrates a group of side-by-side fibers with three-component sheath 302. These fibers show both benefits of side-to-side fibers and sheath / core fibers in a fabric formed with the system of the present invention In certain combinations of polymers sensitive to rapid cooling, or in combinations where there is a poor match of viscosity between polymer components, the system spinning package can be configured to provide fibers formed for optimum orientation relative to the fast cooling air to minimize the negative effects associated with the sudden bending or bending of extruded filaments from the spinning yarn row and thereby increasing the density of processing holes and overall productivity . Figures 6a and 6b illustrate different arrangements of side-by-side two-component fiber configurations, where the fibers 402, 502 of each configuration are oriented differently with respect to a double system of rapid air cooling (the direction of the fast cooling air in figures 6a and 6b is illustrated by means of arrows). Figure 7 illustrates yet another grouping of fibers that can be produced by the system of the present invention, where exclusive dosing techniques are used to produce two-component sheath / core fibers 602 mixed with single component fibers 604. Still in another form of embodiment, the spinner and the spinning package of the present invention are

they can design to deliver exact sizes of mixed fibers through the exclusive dosing of multiple streams to produce fabrics with gradients of custom-made pores sizes. Figure 8 illustrates a fiber cluster that would produce such a fabric, where fibers 702 of larger diameters are combined with fibers 704 of smaller diameters during the fiber spinning process in the closed system.

Other examples of fibers that can be formed using the system of the present invention are sheath / core fibers, where the sheath is a thermoplastic material with a low melting point and the core material is a thermoplastic material with characteristics High strength A fabric spun by adhesion of these fibers can be thermally bonded (for example, used calender rollers, air circulation, etc.) at temperatures high enough to soften or melt the outer sheath material, but low enough not to compromise Strength characteristics of the core material. Such fibers may also have special properties available in the sheath, such as soft touch, anti-microbial capabilities, and gamma ray stability. Excisible fibers can also be formed, in which two or more polymer components in separate filaments are separated after the formation of a fabric, thereby creating a fabric of finer fibers. Additionally, side-by-side fibers can be formed that curl and sponge spontaneously when subjected to proper treatment. Mixed polymer fibers can also be formed in the closed system of the present invention to provide a number of useful properties for final products manufactured using those fibers.

From the above examples, it can be seen that the closed system of the present invention is extremely versatile and facilitates the production of a wide variety of combinations of fibers and fabrics of multiple polymer components in an individual system.

The present invention is not limited to the particular embodiments described above, and additional or modified processing techniques are considered to be within the scope of the invention. As indicated above, the present invention is not limited to the configuration of the closed chamber of Figure 2; instead, the closed system of the present invention can use any closed environment configuration that prevents exposure of extruded filaments to uncontrolled temperatures and air currents during fiber formation.

Similarly, the spinning folder assembly is not limited to the configuration of Figure 3; instead, the spinning folder assembly may be designed to receive and thermally process and dose any number of segregated streams of polymer fluid supply. In other words, the spinning folder assembly may include any suitable number of polymer supply inlets that connect to any suitable number of distribution tubes within distribution manifolds to independently heat and / or maintain any number of streams. different from polymers in a variety of different temperatures. The spinning folder assembly may further include any suitable number of dosing pumps, where each pump has any suitable number of output streams, to independently provide different polymer fluid streams at different flow rates to the package. spinning In addition, each of the dosing pumps may be configured to supply one or more polymer fluid streams to the spinning package at a flow rate independent of the flow rates for streams dosed by any of the other dosing pumps.

The spinning package may be designed in any suitable manner to facilitate the production of fibers and fabrics including any combination of single-component or multi-component fibers of any suitable cross-sectional geometry. In addition, any number or combination of fiber processing techniques, thread formation techniques, and woven and notey-woven fabric formation processes can be applied to the fibers formed in accordance with the present invention.

Having described preferred embodiments of a new and improved closed system for producing fibers and fabrics having multiple polymer components, it is believed that other modifications, variations and changes will be suggested to those skilled in the art in view of The teachings shown here. Therefore, it is understood that all these variations, modifications and changes are considered within the scope of the present invention, as defined by the appended claims. Although specific terms are used here, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims (6)

1.-A system for the manufacture of a nonwoven fiber fabric comprising: a spinning folder assembly configured to process and supply a plurality of polymer streams for extrusion through spinneret holes for yarn extrusion for extrusion of 5 yarns, including the spinning folder assembly a plurality of supply passages in fluid communication with the holes in the spinneret for spinning yarn, in which at least two of the supplying steps they are configured to supply separate streams of polymers of different polymer components to the holes in the row for spinning yarn for spinning yarn; 10 wherein the spinning folder assembly includes a plurality of manifolds to independently segregate and maintain polymer streams of different polymer components at different temperatures, in which each manifold provides uniform heating of a stream of pol Number flowing between a polymer distribution tube within each manifold surrounding each distribution tube with a heat transfer medium at a substantially uniform temperature, 15 a fast-cooling chamber configured to quickly receive and cool extruded filaments from the holes in the spinneret for spinning yarn, including the fast-cooling chamber a source of gas supply to direct a gas stream to extruded filaments; a stretching chamber in communication with the rapid cooling chamber and configured 20 to receive and attenuate the rapidly cooled filaments; Y a forming surface configured to receive stretched filaments that emerge from the stretching chamber and form a non-woven fibrous fabric on the forming surface; in which the system maintains the extruded filaments in a closed environment between the holes in the spinneret for yarn extrusion and the stretching chamber for 25 prevent uncontrolled gas streams from contacting the filaments. 2. The system of claim 1, wherein the spinning folder assembly includes a plurality of metering pumps configured to independently supply polymer streams of different components of variable flow flow polymers to the holes of the row for spinning yarn extrusion for spinning yarn. 3. The system of claim 1, wherein the system is configured to produce series of multicomponent fibers. 4. The system of claim 1, wherein the system is configured to produce series of bicomponent fibers. 5. The system of claim 1, wherein the system is configured to produce single-fiber series of fibers. Component, in which at least one individual component consists of a polymer component that is different from a polymer component of at least one other individual component fiber. 6.-In a system for the manufacture of fibers that includes a spinning folder assembly and a rapid cooling chamber in communication with a stretching chamber, in which the system maintains a closed environment between the spinning folder assembly, the fast cooling chamber and the stretching chamber for 40 preventing uncontrolled gas streams from entering the enclosed environment, a method of forming a nonwoven fiber web comprising: (a) supplying a plurality of polymer streams from the spinning folder assembly to spinneret holes for spinning yarn for yarn extrusion, in which at least two of the polymer streams they include different polymer components; in which the folder assembly Spinning 45 includes a plurality of manifolds to independently segregate and maintain polymer streams of different polymer components at different temperatures, and in which each manifold provides uniform heating of a stream of polymer flowing within a polymer distribution tube within each manifold surrounding each distribution tube with a heat transfer medium at a substantially uniform temperature; 50 (b) extrude the plurality of polymer streams through the holes in the spinneret spinneret for spinning yarn to form a plurality of filaments;

(C)

Quickly cool extruded filaments by contacting the filaments with a current of 10

gas in the rapid cooling chamber;

(d)

 stretch the rapidly cooled filaments in the stretching chamber; Y

(and)

 deposit the stretched filaments on a formation surface to form a non-woven fibrous fabric on the formation surface.

The method of claim 6, wherein step (a) includes: (a.1) supply segregated polymer streams in varying flow rates to the holes in the spinneret spinneret. 8. The method of claim 6, further comprising: (f) form a series of multicomponent fibers. The method of claim 6, further comprising: (f) form a series of bicomponent fibers. 10. The method of claim 6, further comprising: (f) forming a series of individual component fibers, in which at least one component fiber Individual consists of a polymer component that is different from a polymer component of at least one individual component fiber.