JP2001279542A - Apparatus, method and system for air opening of textile tow and opened textile tow web produced thereby - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an air opening jet for use in a method for preparing a rectangular structure from a tow of fibers. SOLUTION: This air opening jet comprises a housing, an air jet for moving the tow through the housing and opening the tow, an accumulating chamber including at least one, preferably two perforated plates located in a path of the moving tow and an air controller for controlling the flow of air so that the moving tow is urged into engagement with the perforated plates to retard the movement of the tow and cause the moving tow to properly accumulate in the accumulating chamber. The method for using the air opening jet apparatus to produce a multi-tow band product is obtained and the product is produced by the method.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001] onset that Ming of fields this invention that "tows opening" of the resulting fiber is used to opening a tow of fibers to have a useful shape to the manufacture of the absorbent structure In particular, the invention relates to an air opening jet device and a method for use in such a system and to the products formed by such a system.

[0002] The onset Ming background many types of filaments, fibers and yarns (collectively "fiber") is sold as a "toe", in which a plurality of such fibers and packaging systems, for example bales ( Such tows are sold in bales and delivered to tow users)
Together, optionally by crimping, in a manner known to those skilled in the art to maximize the content of Prior to use, such users typically "spread" such tows and separate the compressed fibers by a greater distance than in the compressed state. Many methods and devices for opening tow are known and described in the literature. For example, US Pat. No. 3,282,768, 3523059, 309
9594, 4522616, 2794480, 3032
829, 5591297 and 5203775;
Those teachings are incorporated herein by reference. While such devices have found use in a variety of applications, such devices typically include "open" tows having a substantially circular cross-section, such as tobacco filters or writing instrument reservoirs. Make tows, which are used to make. However, a rectangular shape is preferred for other applications; for example, in absorbent structures intended for use in personal care products such as diapers, bandages, hygiene pads and similar absorbent products. . A shape having a substantially rectangular cross section is preferred for such use. Representative examples of these various types of products are found in U.S. Patents 4,289,130, 5,117,235 and 5,928,452, U.S. Statutory Invention Registration H1565, and P.
It is disclosed in CT International Publication WO 99/30661.

In a system of the above type, as disclosed in US Pat. Nos. 4,468,845 and 4,435,239, an air jet is used to open the tow and form it into a rectangular shape for use in tobacco filter rods and the like. It is also known. One of the notable advantages that has emerged with these systems is the fact that the air opening jets employed in this system are designed to operate at very low air pressures (eg, less than 3 psi), which is usually the case. This eliminates the need for expensive air compression and significant capital investment in plumbing equipment associated with air opening or "blooming" systems. This low pressure air moves the tow through the air opening jet, during which the tow is opened, and then the opened tow is decelerated through the bustle unit and stagnated in the bustle unit to achieve the desired opening and tow density. obtain. This slowing and stagnation of the tow is achieved by an adjustable tensioning device for engaging the tow, in particular a flat, non-perforated "tension" plate pivotally mounted at one of its ends in a bustle arrangement. And a relatively complex mechanical device for regulating the movement of the pivoting tension plate towards and away from the tow, whereby the tension applied to the tow by the tension plate can be varied. can get.

According to one embodiment of the [0004] onset Ming Overview invention, thin fiber filaments held together by condensation processing Ken air opening jet apparatus, by spreading the relatively wide tow, is opened The tow is provided for use in a system for forming a predetermined shape suitable for use as, for example, an absorbent structure for personal care products. The air opening jet apparatus includes a housing having an inlet opening for receiving a partially opened tow and having a shape substantially corresponding to the shape of the partially opened tow. This housing also has an outlet opening (through which the tow exits the housing),
The outlet opening has a shape substantially corresponding to a predetermined shape.

[0005] An air jet is formed in the housing adjacent to its inlet opening to create a venturi that moves the tow through an air opening jet device, which also opens the tow, and a source of compressed air communicates with the air jet. To supply carrier air for moving the tow through the air opening jet device.

A forming chamber is provided in the housing and downstream of the air jet, which gradually increases in the direction of tow flow and includes a cross-sectional area corresponding to a predetermined shape, wherein the air jet is located in the housing. The deployed tow completely opens the tow and substantially fills the forming chamber as it moves through it.

A storage chamber is located in the housing downstream of the forming chamber, wherein the opened tow accumulates in the storage chamber and is drawn out of the housing in a predetermined shape at various flow rates through the housing outlet opening. Configured and arranged to allow for The storage chamber includes at least one perforated plate disposed in the path of the tow, through which carrier air moves to engage the tow with the perforated plate and at least some carrier air is passed through the perforated plate.

[0008] At least some of the carrier air is passed through the perforated plate and the tow is forced into frictional engagement with the perforated plate with sufficient force to inhibit movement of the tow through the storage chamber, thereby causing the tow to enter the storage chamber. Control valves are provided to maintain the flow of carrier air at a level that will accumulate.

In a preferred embodiment of the present invention, the storage chamber may include a second perforated plate spaced from the first perforated plate described above, with the tow moving between the perforated plates. Are forced to engage them by the carrier air passing through the perforated plates. Finally, in a preferred embodiment of the invention, the predetermined shape of the outlet opening of the housing is rectangular.

[0010] Another aspect of the present invention provides an apparatus and method, wherein one or more air opening jets of the type described above open a multi-tow, such as an absorbent structure for personal care products. Can be used to form a composite multi-toe band of predetermined shape suitable for use as a. In this type of system, instead of a single tow delivered to the inlet end of the air opening jet device, two separate separate tows are provided at the inlet end of the single air opening jet or the separated air opening. Delivered to the jet, where it is combined with or downstream of the composite multi-tow band.

In this system, a first assembler receives a first tow from a tow bale having a predetermined denier unit per filament, spreads the filaments in the first tow into a first tow band, and pre-sets the first tow band. It has a defined width and has an outlet end for discharging therefrom. A second collecting device receives the second tow from the second tow bales having a predetermined denier unit per filament different from the predetermined denier of the first tow and spreads the filaments in the second tow into a second tow band. A second tow band having a predetermined width and having an outlet end for discharging therefrom.
The first and second tow bands are then simultaneously introduced to the inlet end of the air opening jet device and moved therethrough for opening and forming as described above for the single tow. The first and second tow bands can also be introduced into two separate air opening jet devices.

Each of the first and second collecting devices preferably includes a tow banding jet for receiving the first or second tow, respectively, and expanding the tow into a band, and a first and second banding jet, respectively. It includes at least one pair, preferably multiple pairs of delivery rolls disposed between the air-spreading jet device (s).

[0013] In one contemplated embodiment of the system, the width of one outlet end of the first or second banding device is smaller than the other, thereby reducing the outlet end of the air jet opening device (s). The multi-tow band discharged from has a toe band that is wider than the other.
It is preferred that the tow band having the larger width have a smaller denier per filament than the denier per filament of the other tow band. In addition, the system can include a surfactant applicator provided upstream of the inlet of the air opening jet to apply the surfactant to the tow band with a small width, and the system can be combined with a tow band with a large width. It may include a binder applicator provided upstream of the inlet of the air opening jet to apply the agent. It is also possible to individually change the speed at which the two tow bands are delivered to the inlet of the air opening jet device, and it is also possible to individually control the blooms of the two tow bands.

According to a further aspect of the present invention, there is provided a novel fibrous web made by the system apparatus and methodologies described above, which is preferred, but not necessary, in which the webs are essentially each filament-to-filament. A first and a second tow having multi-continuous fiber filaments that have been opened such that they are not aligned with respect to each other. In one embodiment, the filaments of the first and second tows are intermingled with each other within at least a portion of the web, e.g., predominantly with each other through the web or along the interface between the first and second tows. Can be mixed. In an alternative embodiment,
The first and second tows are generally layered with respect to each other within at least a portion of the web. The first and second tow filaments can be of different denier per filament, which can provide enhanced web performance as compared to a comparative web made from a single tow of the same average denier per filament. Was found. Additional components, such as superabsorbent polymers to enhance the liquid acquisition and absorption capabilities of the web, can be incorporated into the web. It is further contemplated that at least one filament of the first and second tows may include a fusible bicomponent fiber for bonding the first and second tow filaments together.

The onset Ming detailed description herein use lexical "fibers" in all materials, means for example, cellulose acetate and triacetate, polyesters, polyamides, polyolefins and similar polymeric material filaments, fibers or yarns .

As used herein, the phrase "tow" may be used to maximize the content of a packaging system in which such tow is sold and delivered, or from one point to another, for example, the transport of multiple fibers within a manufacturing facility. Means a plurality of fibers, optionally compressed together by "crimping" by methods known to those skilled in the art, such terms being used and understood in the literature.

As used herein, the terms "rectangular" and "substantially rectangular" refer to a structure having a substantially rectangular cross-section with perhaps minor defects, such as rounded corners and slight bends or depressions along the sides. Should be understood as

The fibers that make up the tow are polyester, polyamide, cellulose acetate and triacetate (collectively "acetate" tow), polypropylene oxide, polyethylene sulfide, liquid crystalline polymer materials that can be formed into fibers, polyamide, silk, wool. It can be made from any natural or synthetic material, including cotton, rayon, polyolefin, polyacrylate, polymethacrylate, and similar materials that can be formed into fibers, or mixtures and / or blends thereof.
Such fibers may or may not have a "finish" applied to them, depending on their use. Generally, an external finish is applied to such fibers to facilitate transport, but "internal" finishes contained in the material used to form the fibers can also be used, Such fibers are included within the scope of the present invention. In addition, the fibers of the tow can be of any denier, tex, diameter or other cross-section or cross-section related dimensional designation suitable for making the tow.

The terms "banded jet" and "air banded jet" are used to indicate a first tow opening device that utilizes air to spread the tow in a direction perpendicular to the direction of travel. "Banded jets" are also different and distinct from the "spreading jets" or "air spreading jets" described herein.

Although the present invention can have a wide range of tow opening applications, it is particularly useful for opening tow made from acetate, polyester, polyolefin and polyamide fibers, and mixtures thereof. Was found. For example, acetate tow is about 1 to about 1
It can consist of from about 2500 to about 25,000 fibers with 0, preferably about 3 to about 6, individual denier. The total denier of the entire tow, which is a collection of about 2500 to about 25,000 fibers, is therefore about 2500 to about 25
0000. Acetate tow is generally of from about 10,000 to about 20,000 fibers of about 3 to about 6 individual deniers, giving a tow having a total denier of about 30,000 to about 120,000.

The fibers of the tow should be distributed evenly or substantially uniformly across the width / cross-section of the crimped tow fiber bundle or band. This uniform fiber distribution is important in the process of opening the tow to a rectangular or substantially rectangular shape, and a more uniform distribution of fibers makes it easier to create a rectangular or substantially rectangular opened tow. It will be. Crimped bales of varying widths / sections in tow, for example, about 25 mm (mm) wide
From about 75 mm, preferably from about 40 mm to about 60 mm
With a height or thickness of about 1 mm to about 7 mm, preferably about 2 mm to about 5 mm, symbolically about 50 m in size
Tows that are m wide and about 3 mm thick can be used according to the present invention.

As mentioned above, an external finish can be applied to each fiber in the tow, such finish comprising about 0.3% to about 5%, preferably about 0.5%, of the weight of the fiber bundle. %
To about 2.0%.

The tow used to practice the present invention is a "crimped tow" which is a phrase commonly used and known to those skilled in the art. The crimping is performed at about 5 to about 30 crimps per inch of non-crimped tow, preferably about 20 to about 25 crimps per inch of non-crimped tow.

It should be understood that the present invention can have application in a variety of tow opening systems, but one exemplary system in which the present invention finds particular use is shown in FIG. Shown schematically. The tow 14 can be supplied through a conventional set of guides (not shown) to initially planarize and orient the tow 14. The tow is then fed to a conventionally designed banded jet 130.
The banded jet spreads the tow band evenly in a direction perpendicular to the towing direction. In general, the air banded jets 130 used in these preferred embodiments are known in the literature, for example, US Pat. No. 3,226,773, or co-pending US patent application Ser.
It can be any air banded jet as described in 9/219818. These teachings are incorporated herein by reference. The tow 14 is then fed to a pre-tension roller device 40 where the metal roller 42 and rubber roller 44 of the tension roller device 40
Between them, thus stretching the tow and dealigning and separating the tow fibers. The roller pressure, i.e., the force applied to the tow by the rollers 42 and 44, in the tension roller device 40 is from about 1 to about 25 psi, preferably from about 5 to about 15 psi. In the device 40 as shown in FIG.
The metal roller is element 42 (top roller) and the rubber roller is 44 (bottom roller).

After exiting the device 40, the tow is fed to a roller device 60 including a driving metal roller 62 and a rubber roller 64. The metal roller 62 has a circular groove or is a threaded or flat metal roller. During its passage from the device 40 to the device 60, the tow is stretched and this stretching is accomplished by traction combined with nip pressure between the rolls 42 and 44. The nip pressure between the rollers of the device 60 is about 1 to about 40 psi, preferably about 20 to about 30 psi.

After exiting the device 60, the tow 14 is
Through an optional first static elimination bar 100 to remove any electrostatic charge that may be present and may interfere with subsequent work required to form the absorbent structure.

After exiting the device 60, the tow is fed to a roller device 70 which includes a driving metal roller 72 and a rubber roller 74. The metal roller 72 has a circular groove or is threaded, or is a flat metal roller. During its passage from the device 60 to the device 70, the tow is stretched, which stretches the metal roller 72 by the drive roll 62.
This is achieved by driving at a higher rotational speed. The rotational speed of roll 72 is 20-60 percent faster than roll 62, preferably 30-50 percent faster. Each of the roller devices 40, 60 and 70 is conventional and well-known; they include a device for applying pressure to one of the rolls of the device and include two rolls of the device at a predetermined pressure level. To force them into engagement with each other. While these conventional devices can apply pressure pneumatically, hydraulically or electrically, pneumatic control is preferred. The nip pressure between the rollers of the device 70 is about 1 to about 40 psi, preferably about 20 to about 30 psi.

The tow exiting the device 70 is hereinafter referred to as tow 14. The grooves or threads in rollers 64 and 74 are of a design or orientation known to those skilled in the art of tow processing or opening. The fibers exiting the device 70 are substantially dealigned or opened to be suitable for opening or forming into a further bulky rectangular structure.

Substantial misalignment or blooming is due to the fact that 90% or more, preferably 95% or more, of the fibers constituting the rectangular structure or rectangular tow are tow 14
Are separated by a distance greater than the distance between the fibers when removed from the bale 12.

After exiting the device 70, the tow 14 is
Through an optional static elimination bar 101 to remove any electrostatic charge that may be present and may interfere with subsequent work required to form the absorbent structure.

After the antistatic treatment, the tow 14 is sent to an optional liquid addition device 80. The liquid addition device includes a liquid holding tank, a metering pump 84 and a liquid delivery applicator 86 in a device 80 for dispensing liquid onto the tow 14.
The liquid spray applicator 86 can be a spray nozzle, a disc applicator, a rotating brush applicator, a wicking contact roll, and similar devices of conventional design known to those skilled in the art. Liquids that can be sprayed on tow 14 include water; hydrophilic liquids such as alcohols, glycols, dimethyl sulfides, ketones, ethers, and the like; Fiberset 100 or Fiberset 200 (Henkel, Cincinnati, Ohio). Plasticizers; surfactants; and solutions containing plasticizers, surfactants and similar materials known to those skilled in the art. The liquid or solution can be applied to either side or both sides of the tow 14 as it passes through the device 86 to additionally transfer liquid within the absorbent composite structure containing the rectangular tow 14 or It can be applied in specific patterns of several liquids to produce a unique effect for storing.

After exiting the air opening jet 240, the tow 14 is delivered to an optional device 120 where a solid material such as superabsorbent polymer (SAP), glue, adhesive,
Fragrances, wood pulp, deodorants, germicides and similar materials can be applied to tow 14 by instruments such as spill feeders manufactured by Solid Flow Company of Fort Mill, South Carolina. For example, in the preparation of a diaper containing SAP, the SAP can be delivered on the tow 14 vertically downward as a powder or slurry. The low-density, open, rectangular towband structure exiting air jet 240 allows the solid particles to be evenly distributed within the tow fiber structure. A fibrous structure with uniformly distributed solid particles can be quickly delivered to the next step so that solid particle containment is achieved. Liquid addition from device 80 also enhances solid containment.

After the addition of the solid material by the device 120, the tow 14 is delivered to an optional high speed delivery device 90 including, inter alia, drive rollers 92 and rollers 94. Either or both of these rollers can have a rubber or metal surface for contacting tow 14. A drive roller 92 controls the overall operation of the process and the speed of the tow 14 as it is delivered to another process, such as a diaper or absorbent composite former. Generally, the drive roller 92 and the drive roller 72 have a surface speed ratio (72/92) of about 1.0:
1.0 to about 3.0: 1.0, preferably 1.8: 1.
It is operated at such a speed that it is between 0 and 2.2: 1.0.

The linear speed of the roll 92 is controlled by the line speed of the diaper or absorbent composite forming process, which is typically provided with a bulky rectangular tow structure.

In the preferred embodiment, the tow 14 is delivered directly to the diaper or absorbent complex formation process without the use of the delivery speed device 90. In this embodiment, the diaper or absorbent composite process acts as a delivery or takeoff rate control.
The towband structure with solids and applied liquid is sandwiched between rollers or wrapped around a drive-only roller and drawn from air jet 240. A tissue or other web can be introduced to encapsulate the fibrous solid structure.

[0036] Additional optional static elimination bar, element 102
And 103, the air opening jet 240 and the liquid adding device 8
0 and after the air opening jet 240. Static elimination bars 100, 101, 102 and 10
By limiting the static electricity, the control of the workability of the tow 14 and the control of the shape of the rectangular structure of the tow 14 can be facilitated. Additional static elimination bars can be employed as needed and are recommended when the moisture content of the environment is low. Such additional antistatic bars can not only be provided after the devices 60, 70 and 80, but also
0, 40 and 130 and between 120 and 90 can also be provided. The preferred embodiment includes at least an antistatic bar 1
00, 101 and 102.

The air opening jet 240 of the present invention includes a housing 242 formed with an inlet opening 244 at one of its ends. As best seen in FIG.
The inlet opening 244 has a generally rectangular shape that substantially corresponds to the shape of the partially opened tow 14 received in the inlet opening 244 as described above. The housing 242 also includes an outlet opening 246, which has a rectangular shape, as best seen in FIG. 5, and which corresponds to the desired shape of the tow leaving the air opening jet device 240.

An air jet (generally indicated by reference numeral 248) is formed adjacent the inlet end of the housing 242 and includes a source of compressed air 250 and a compressed air source 250 to the air manifold 254. Includes a conventional control valve 252 for regulating airflow. Compressed air is delivered through the manifold to jet orifice 256, which passes through tow 1 through central passage 258 in housing 242 as will be described in more detail herein.
Form a regular jet of air to move 4. As best seen in FIG. 3, passage 258 has a gradually increasing cross-sectional area in the direction of movement of tow 14, thus providing a forming chamber 260 downstream of air jet 248, which is also preferably Has a substantially rectangular shape corresponding to the rectangular shape of the toe 14.

A storage chamber 262 is provided downstream of the forming chamber 260 adjacent the outlet end of the housing 242, the storing chamber 262 having a larger vertical dimension than the outlet opening 264 of the forming chamber 260, which is also preferably rectangular. It is formed with a shape, and it is formed from the formation chamber 260 to the accumulation chamber 262.
Allowing the opened tow 14 to pass therethrough to accumulate in the accumulation chamber 262 and ultimately being drawn out of the housing 242 through the outlet opening 246 at various flow rates and in the preferred rectangular shape of the tow 14. Will make it possible.

As best seen in FIGS. 3 and 4, a pair of plates 268, each having a number of holes 270, form a storage chamber 2.
62 and tow 14 exits formation chamber 260 and accumulates chamber 26.
2 is located in the path of the toe 14 when entering. The plate 268 is fixed in place in the storage chamber 262 by a plurality of bolts 272 that maintain the plate 268 in a fixed position in the storage chamber 262.

The housing 242 also includes a pair of side plates 274 extending along both sides thereof (see FIG. 7).
62 and the side of the formation chamber 260, each of the side plates 274 is formed with a plurality of holes 276, and these holes 276 are substantially located at positions where the carrier air leaves the formation chamber and enters the accumulation chamber 262. Provided, so that some of the carrier air can be exhausted through holes 276.

In operation of the air opening jet apparatus 240, the compressed air from the compressed air source 250 flows to the air jet 248 at a flow rate controlled by the control valve 252, and the air jet formed by the orifice 256
4 would move through the forming chamber 260. When the tow 14 is moved through the forming chamber 260 by the carrier air,
The carrier air will partially open and expand the tow 14. Thus, it will gradually increase the cross-sectional area consistent with the gradually increasing cross-sectional area of the forming chamber 260. As the tow exits the forming chamber 260 and enters the storage chamber 262, it first opens further to correspond to the vertical distance between the upstream ends of the perforated plate 268 (see FIG. 3), and the tow 14 And engages with the inner surface of the perforated plate 2 which is disposed at

Some of the carrier air is provided in holes 276 in side plate 274.
However, a substantial portion of the carrier air moves the tow 14 through the space between the perforated plates 268 and passes outwardly through holes 270 in the plate 268. In doing so, the air passing outward through the holes 270 frictionally engages the tow 14 with the facing inner surface of the perforated plate 268, which creates a braking action on the tow 14, which is the accumulation chamber of the tow 14. The movement through 262 is slowed down and the tow is densified and accumulated in accumulation chamber 262 at a greater density than the tow had in formation chamber 260, and subsequently opened to increase the density of the now towed tow. 14
Exits the accumulation chamber 262 through the outlet opening 246 at various flow rates.

It is important that the tow 14 exiting through the outlet opening 246 have a desired and uniform density through the generally rectangular shape of the tow 14, and the present invention properly controls the density of the outgoing tow 14. Provides a unique and highly desirable method. In particular, it will be apparent that the flow rate of the carrier air will determine the deceleration or braking action applied to tow 14 passing between perforated plates 268. If the velocity of the carrier air is increased, the carrier air passing outward through holes 270 in the plate 268 will cause the tow 14 to engage the plate 268 with greater force, thereby reducing the deceleration applied to the tow 14 Or the braking action will increase. Conversely, if the flow rate of the carrier air is reduced, the braking action applied to tow 14 will be less.

Thus, a virtually endless adjustment of the braking action is obtained in the present invention by simple means of operating the control valve 252, and the flow of carrier air which will provide the desired braking action on the tow 14. , Thereby controlling the density of the tow 14 leaving the housing 242.

It will be appreciated that the actual flow rate of the carrier air will vary from application to application depending on a number of factors, however, in the operation of the prototype of the present invention, an air pressure of about 40 psi would require a 20 cm width and 2 cm. It has been found to provide the desired density of tow 14 consisting of 0.004 g / cm ³ exiting through an outlet opening having a height of 0.5 cm.

FIGS. 8, 12 and 16 schematically illustrate three alternative tow opening systems using the air opening jet 240 of the present invention in a unique manner. More specifically, FIG. 8 shows a system in which a plurality of tow bands are provided at the inlet of the air jet opening device 240. In FIG. 8, individual elements identical to those described above in connection with FIG. 1 are identified by the same reference numerals, and two tow bands 14A and 14B are shown, depending on the desired end product. It will be appreciated that more than one tow band can be used.

As best seen in FIG. 8, two tow bands 14A and 14B are each fed from tow bales into conventional banded jets 130A and 130B, respectively. Banded jets will now be described in more detail. After the tow bands 14A and 14B have been treated with the air banding jets 130A and 130B, both tow bands 14A and 14B are made up of a metal roller 42 and a rubber roller 44, all of which are described above in connection with FIG. It is delivered to the nip of the tension roller device 40. After the combined tow band leaves the pretensioning roller device 40, it is fed through the same series of elements described in connection with FIG.

FIG. 9 schematically shows in cross section the resulting end product exiting the air opening jet 240 in the system of FIG. 8, where the air banded jets 130A and 130A are shown.
B is set so that the individual tow bands 14A and 14B are delivered in the same width and in a precise lateral alignment with respect to each other. Prior to the air opening jet 240, the pretension roller device 40 and the roller device 6
0,70 effectively creates a significant degree of initial intermixing of the filaments of the tow bands 14A and 14B, followed by the air opening jet 240 effectively causing the individual filaments within the two tow bands 14A and 14B to substantially abut each other. A composite in which the individual filaments of the towbands 14A and 14B are intermixed essentially through the entire transverse extent and essentially through the entire thickness of the web, as shown schematically in FIG. The body web.

However, in the system shown in FIG. 8, the bandwidth of each individual tow band 14A and 14B is individually manipulated by manipulating conventional air banded jets 130A and 130B to change the width of the tow bands 14A and 14B. The tow band can be controlled and simultaneously delivered to the air opening jet 240 to provide a unique product, an example of which is shown in FIG. Thus, if desired, the tow bands 14A and 14B can be supplied from the tow bale first through conventional guide elements (not shown) that flatten and orient the tow bands 14A and 14B in a manner well known in the art. When 14A and 14B reach air banded jets 130A and 130B, the tow band is spread in a direction perpendicular to the direction of tow band movement, thereby opening the two tow bands 14A and 14B within banded jets 130A and 130B. be able to.
Further, the width of the tow bands 14A and 14B can be varied by the air banding jets 130A and 130B so that the final product delivered from the air opening jet 240 can have a particular desired composite tow structure.
As an example of such a composite tow structure, FIG. 10 is configured such that the air banded jet 130A delivers a narrow tow band 14A centered in a stacked relationship with respect to the large and wide tow band 14B delivered by the air banded jet 130B. 9 shows, in cross section, the final product exiting the air opening jet 240 of the system of FIG. In a manner similar to that described above, the roller devices 40, 60, 70 followed by the air opening jet 240 can effectively mix the individual filaments of the tow bands 14A and 14B into a composite web. While the central longitudinal region of the web has two tow bands 14A and 14B filaments substantially intermingled, the outer edge region of the composite web, as shown schematically in FIG.
Substantially entirely of the filaments of the wide towband 14B.

FIG. 11 schematically shows the intimate intermingling of the filaments of the tows 14A and 14B, characterized in that the respective filaments of the tow are essentially indistinguishable from each other, and the crimping of the tow filaments FIG. 11 is a schematic illustration of a longitudinal section taken through either of the composite tow webs of FIGS. 9 or 10 along a cross-section line 11-11 indicating the nature. Of course, as those skilled in the art will recognize, many other variations of the composite multi-tow web product are available, such as the processing system of FIG. 8 as well as those of FIGS. 12 and 16 which will be described in more detail below. It can be made as a result of other possible alternative processing systems of the present invention.

Another alternative processing system using a unique air opening jet 240 is shown in FIG.
To the extent that the elements shown in FIG. 2 are the same as those in FIG. 1, the same reference numerals have been used, and details need not be repeated here. In this system, tow bands 14A and 14B are fed from tow bales (as shown in FIG. 8) to individual air banded jets 130 in the same manner as described above in connection with FIG. However, in the system shown in FIG. 12, the tow bands 14A and 14B each have all the elements acting on the single tow band 14 of FIG. And each through a separate liquid addition device 80. The system effectively controls the width of the two tow bands 14A and 14B, since the two tow bands 14A and 14B are individually processed by various processing elements as shown in FIG. Toe band 14A,
It can be used to control the 14B bloom individually. In addition, the liquid addition is effected by the elements 80, 84 and 86 described in connection with FIG.
A and 14B are applied individually, so different additives can be applied to either or both towbands 14A and 14B or no additives can be applied,
Each tow element can be given a separate effect, such as altering the superabsorbent polymer encapsulation, solid adhesion, or fluid distribution enhancing properties of each tow band 14A and 14B.
Alternatively or additionally, the additives can also be applied to the composite tow web obtained downstream of the air opening jet 240.

In contrast to the system of FIG. 8, a separate pretensioning roller device 4 is provided for each of the two tow bands 14A and 14B of the system of FIG.
0, the use of roller devices 60, 70 and liquid addition device 80 prevents any intermixing of tow bands 14A and 14B prior to delivery to air opening jet 240. Thus, in the composite tow web exiting the air opening jet 240, the individual filaments of the two tow bands 14A and 14B are intermixed only through the action of the air opening jet 240, and thus the composite tow made by the system of FIG. Intermixed to a lesser extent than the web. More specifically, the composite tow web made by the system of FIG. 12 has essentially three distinct tow regions across the thickness of the composite web: adjacent to one outwardly facing surface of the composite web. The first region predominantly composed of the air-opened and de-aligned filaments of the tow band 14A is both cross-opened and de-aligned substantially intermingled with respect to each other across the center of the thickness of the tow web. Toe band 14
Gradually coalesced into an intermediate region composed of filaments A and 14B, the intermediate region being composed predominantly of the opened and disaligned filaments of the tow band 14B on the opposite outwardly facing surface of the composite tow web. Gradually coalesces into the third region. These three areas are schematically illustrated in cross-section by the composite tow web of FIGS. 13 and 14, and FIG. 13 shows one embodiment of a composite tow web made by the system of FIG. 14A and 14B
14 are of the same width and are stacked in lateral alignment with one another, and FIG. 14 shows an alternative embodiment of a composite tow similar to that of FIG. 10, where tow 14A is stacked with respect to wide tow 14B. It is of narrow lateral size, centered in relation.

FIG. 15 schematically shows three regions of the composite tow web of FIGS. 13 and 14 in a longitudinal section similar to that of FIG. In contrast to the composite tow web produced by the system of FIG. 8, the composite tow web space produced by the system of FIG. 12 is only in the area of the interface between the tow bands 14A and 14B when delivered into the air opening jet 240. Individual tow bands 14 substantially mixed with each other predominantly
A and 14B have respective filaments.

The ability to use a plurality of individually controlled and / or processed tow bands in combination with the air opening jet 240 provides a wide range of products with structures and compositions that can be tailored to specific functions. It will be appreciated that it provides an opportunity. For example, a composite tow web structure that is particularly suitable to act as an element of an absorbent disposable device such as a disposable diaper can be made. The exemplary composite tow structure as shown in FIG. 10 or 14 is suitable for this particular application and has a high denier per filament (DPF), for example, 6-8 DPF and a total denier between 12,000 and 20,000. Will consist of toe band 14A. The tow band 14A is oriented in the center of the composite structure as shown in FIG. 10 or 14, so it will be in contact with or close to the first fluid attack zone of the absorbent disposable device. The high DPF of towband 14A will provide improved fluid acquisition when hydrated due to its high strength and resistance to collapse. In a typical example, FIG.
A banding jet 130A, or banding jet 130 applied to towband 14A of FIG. 12, will limit the width of towband 14A to approximately 80 mm. If the system of FIG. 12 is used, the liquid application device 8
The liquid applied to the towband 14A via the zero will be a surfactant that will enhance fluid handling within the fluid acquisition structure. On the other hand, tow band 14B is 30,000-40
Low DPF with a total denier between 000, for example 2-
With 3, the tow band 14B will be oriented at the bottom of the composite structure so that it is the main core of the absorbent disposable device. A low DPF towband structure will provide high density, large fiber surface contact area and improved superabsorbent polymer containment for large numbers of individual fibers. Thus, for example, a 2.0 DPF / 40000 total denier tow band 14B has approximately 20,000 distinct fibers,
On the other hand, 6.0 DPF / 15000 total denier towband 14A will have only about 2500 distinct fibers. Preferably, banded jet 130B will limit the width of tow band 14B to 150mm, which would be the full inlet width of air opening jet 240. Thus, the composite tow structure exiting the air opening jet 240 will have a shape as shown schematically in FIG. Finally, if the system shown in FIG.
The liquid applied to the towband 14A via the is preferably a superabsorbent polymer within the structure of the towband 14B and / or a binder such as a plasticizer, water, or a water-based adhesive to enhance solid attachment or containment. Will be.

Of course, it will be appreciated that the specific composite tow structure described above is only representative of the various composite tow structures that can be made using the systems shown in FIGS. . For example, toe bands 14A and 1
In addition to controlling the width of 4B, if the system shown in FIG. 12 is used, the speed of roller devices 60 and 70 may be controlled to separate the delivery speed and / or bloom of each individual tow band 14A and 14B. It is also possible to control the characteristics of the tow bands 14A and 14B delivered to the air jet 240. Similarly, other types of filaments can be used to form tow bands 14A and 14B. For example, one of the tow bands may be subjected to a subsequent heat treatment of the composite tow web to form a tow band 1.
It is also contemplated that the filaments of 4A and 14B can be formed from filaments that include a fusible bicomponent fiber material that can be utilized to bond them together. Of course, many other alternative embodiments will readily occur to those skilled in the art.

Furthermore, the ability provided by the present invention for selectively combining and intermixing different tow bands into a composite tow web has the advantage that the resulting tow web has an advantage over an opened tow web made from a single tow band. It is also conceivable to be able to have excellent or enhanced features, properties and / or performance. To evaluate this possibility, experiments were performed comparing the composite tow web made by the system of FIG. 8 described above with the opened tow web made from a single tow band using the system of FIG. The results of such experiments are summarized in the tables of FIGS. Each web is treated identically to apply a layer of superabsorbent polymer (SAP), a suitable porous or non-porous adhesive layer, and a tissue outer cover to each web, and from each web in a disposable diaper as described above. An absorbent device was made as used. Two sample devices were made from different composite tow webs made by the system of FIG. 8 and three sample devices were made from a single tow web made by the system of FIG. These devices were then tested to determine their liquid acquisition and absorption capabilities. Various physical characteristics of the sample device are summarized in the table of FIG. 19 for comparison purposes. On the other hand, the test results of such a device are summarized in the table of FIG. Sample devices made from the composite tow using the system of FIG. 8 are identified as samples 6-0601 and 7-0601, while sample devices made from a single tow using the system of FIG. 1 are sample 2-0601. , 3-0
601 and 4-0601.

As can be seen, the sample device made with the composite tow web has superior acquisition and absorption compared to a device made with a single tow web, even for a single tow web having the same average denier per filament as the composite tow web. The result was achieved. From these experiments it is concluded that composite tow webs provide better superabsorbent polymer containment than webs made from single tow (which in turn indicates that this tow structure has a higher degree of stability). Is valid.

Another unique system using the air opening jet 240 of the present invention is shown in FIG. 16, where again like reference numerals are used to refer to elements of the same system as those described above in connection with FIG. Is used to identify In this system, each of the tow bands 14A, 14B is separately passed through a series of processing steps and then fed to the intake of a separate air opening jet 240. As shown in more detail in FIG. 16, each tow band 14A and 14B is individually passed through a banding jet 130, and then the roller units 40, 60 as described above.
And 70 are then passed through a liquid addition device 80,
Thereafter, each tow band is separated by a separate air opening jet 240
Supplied to the intake.

The tow bands exiting the air opening jet 240 are then coalesced and delivered together to the same element downstream of the air opening jet 240 as shown in FIG. When the combined tow band is moved through the high speed delivery roller device 90, a composite multi-tow web is created as shown schematically in FIGS.

As the tow bands 14A, 14B are individually opened and processed by separate air opening jets 240 and then combined together, the tow bands 14A, 14B are shown in FIG.
As schematically shown in FIGS. 7 and 18, FIGS.
Compared to the multi-tow web shown in FIGS. 14 and 14, the two tow bands 14A, 14B have a substantially laminated laminar relationship with a very small fiber entanglement.

Another advantage of the multi-tow web formed by the system of FIG. 16 is that the laminated structure of the web is useful for various types of specific processing. For example, each layer in the product may include a liquid addition station 80 and, if desired, one or both liquid addition stations 8.
0, or an additional processing station downstream of the air opening jet 240 can be provided with a separate and individualized finish, and the desired material (eg, superabsorbent) between the layers formed by the tow bands 14A, 14B. Molecule) can be inserted.

Thus, it will be readily appreciated by those skilled in the art that the present invention allows for widespread use and application. Many embodiments and adaptations of the invention other than those described herein,
And many modifications, changes and equivalents will be apparent from, or reasonably suggested by, the invention and its foregoing description without departing from the spirit or scope of the invention. Thus, while the present invention has been described in detail herein with reference to preferred embodiments thereof, this disclosure is only an illustration and exemplification of the invention and is only for the purpose of providing a complete and possible disclosure of the invention. It should be understood what was done. The above disclosure is not intended or should not be construed as limiting the invention, or otherwise excludes any such other embodiments, adaptations, modifications, changes, and equivalents. Instead, the present invention is limited only by the claims appended hereto and their equivalents.

[Brief description of the drawings]

FIG. 1 is a schematic diagram of a typical tow opening system of the type in which the air opening jet of the present invention can be used.

FIG. 2 is a perspective view of a preferred embodiment of the air opening jet of the present invention.

FIG. 3 is a side elevational view, partially in section, showing the air opening jet shown in FIG. 2;

FIG. 4 is a plan view of a housing of the air opening jet shown in FIG. 2;

FIG. 5 is an end elevation view showing the outlet opening of the housing.

FIG. 6 is an elevational view of one of the side plates of the housing.

FIG. 7 is an end elevation view of the inlet opening of the housing.

FIG. 8 is a schematic view of an alternative tow opening system using the air opening jet apparatus according to the present invention.

FIG. 9 is a cross-sectional, cross-sectional, schematic view of a first embodiment of a composite multi-tow web product formed by the system shown in FIG.

FIG. 10 is another schematic cross-section similar to FIG. 9 of a second embodiment of a composite multi-tow web product formed by the system shown in FIG.

FIG. 11 is an exaggerated schematic illustration of a longitudinal section taken along line 11-11 of FIGS. 9 and 10 showing the relationship of the filaments of the composite multi-tow web product of FIGS. 9 and 10;

FIG. 12 is a schematic view of yet another alternative tow opening system using the air opening jet apparatus according to the present invention.

13 is a schematic cross-sectional view of a first embodiment of a composite multi-tow web product formed by the system shown in FIG.

FIG. 14 is another schematic diagram of a cross section of a second embodiment of a composite multi-tow web product formed by the system of FIG.

FIG. 15 is an exaggerated schematic view of a longitudinal section taken along line 15-15 of FIGS. 13 and 14 showing the relationship of the filaments of the composite multi-tow product of FIGS. 13 and 14;

FIG. 16 is a schematic view of yet another alternative tow opening system using an air opening jet according to the present invention.

FIG. 17 is a schematic cross-sectional view of an exemplary composite multi-tow web product formed by the system shown in FIG.

FIG. 18 is an exaggerated schematic view of a longitudinal section taken along line 18-18 of FIG. 17 showing the general relationship of the fibers of the multi-tow product of FIG.

FIG. 19 is a table summarizing comparative physical data of a sample single tow web product formed by the system shown in FIG. 1 and a sample composite multi-tow web product formed by the system of FIG.

FIG. 20 is a table summarizing the results of a comparative performance test of the sample web product of FIG. 19;

 ──────────────────────────────────────────────────続 き Continued on the front page (72) Inventor Ricky Lee Kenly 28273, North Carolina, United States of America, Charlotte, Cane, Field, Drive 14733 (72) Inventor Bobby Ray Lomax 29715, South Carolina, Fort, Mill, United States of America 8427 (72) Inventor William West 28210, North Carolina, U.S.A., Charlotte, Watercrest, Rd. 7215 (72) Inventor William Thomas Wigand, 2811 North Carolina, U.S.A., Charlotte, Longbau, Rd 801 (72) Inventor Jean-Claude Abed 29680, South Carolina, USA Puson'viru, Kueiru, ridge, de live 208

Claims (49)

[Claims] 1. A method for opening a thin, relatively wide tow of fiber filaments held together by crimping,
And an air opening jet device for use in a system for forming the opened tow into a predetermined shape suitable for use as an absorbent structure for personal care products, comprising: (A) a housing having an inlet opening for receiving a partially opened tow and having a shape substantially corresponding to the shape of the partially opened tow; A housing for exiting the housing and having an outlet opening having a shape substantially corresponding to the predetermined shape; (b) moving the tow through an air opening jet device;
And an air jet formed in the housing adjacent to the inlet opening to create a venturi for opening the tow further; and (c) for supplying carrier air for moving the tow through the jet device. A source of compressed air in communication with the air jet; (d) a forming chamber in the housing and downstream of the air jet, the cross-sectional area increasing gradually in the direction of tow flow, wherein the predetermined shape is A forming chamber, wherein the air jet is fully opened as the tow moves through the forming chamber and is disposed within the housing to substantially fill the forming chamber; A storage chamber provided in the housing downstream of the forming chamber, wherein the opened tow is stored in the storage chamber, and the housing is provided at various flow rates from the housing. Wherein the storage chamber includes at least one perforated plate disposed in the path of the tow; and An accumulation chamber through which the carrier air moves to engage the tow with the perforated plate and allow at least some of the carrier air to pass through the perforated plate; and (f) removing at least the portion of the carrier air. Passing through the perforated plate, the tow will slow down the movement of the tow through the storage chamber and force frictionally engage the perforated plate with sufficient force to cause the tow to accumulate in the storage chamber. A control valve for maintaining the flow of the carrier air at a level. 2. The storage chamber includes a second perforated plate spaced from the at least one perforated plate, and further wherein the tow moves between the perforated plates, thereby causing both of the perforated plates to move. 2. The air-spreading jet apparatus according to claim 1, wherein the air-spreading jet apparatus is forcibly engaged by the carrier air passing through the jetting apparatus. 3. The air-opening jet apparatus according to claim 1, wherein the shape of the outlet opening in the housing is rectangular. 4. An air opening jet apparatus for opening a thin, relatively wide tow of fiber filaments and forming the opened tow into a predetermined shape, comprising: (a) A) housing having an inlet opening for receiving the partially opened tow and an outlet opening for the tow to exit the housing; (b) moving the tow through an air opening jet device;
And an air jet formed in the housing adjacent to the inlet opening to create a venturi for opening the tow further; and (c) for supplying carrier air for moving the tow through the jet device. A source of compressed air in communication with the air jet; and (d) a forming chamber in the housing and downstream of the air jet, the cross-sectional area increasing in the direction of tow flow, wherein the air jet is A forming chamber disposed within the housing so as to be substantially completely opened when moving through the forming chamber; (e) a storage chamber provided in the housing downstream of the forming chamber. Configured to accumulate the opened tow in a storage chamber and to be withdrawn from the housing at various flow rates through the housing outlet opening. Wherein the storage chamber includes at least one perforated plate disposed in the path of the tow, and wherein the carrier air moves therethrough to engage the tow with the perforated plate; and A storage chamber for passing at least some of the carrier air through the perforated plate; and (f) passing at least the portion of the carrier air through the perforated plate to slow the movement of the tow through the storage chamber. Maintaining the flow of carrier air at a level that will cause a forced frictional engagement with the perforated plate with sufficient force to cause the tows to accumulate in the accumulation chamber at a greater density than the tows have in the formation chamber. An air opening jet device comprising a control valve. 5. A method of opening a relatively wide tow having a thin fiber filament and forming the opened tow into a predetermined shape, the method comprising the following steps: (B) moving the tow through a forming chamber having a gradually increasing cross-sectional area in the direction of tow flow in the housing to move the tow from the inlet opening to the outlet opening through the housing; (C) moving the tow into an accumulation chamber downstream of the formation chamber;
Flowing at least a portion of the carrier air outwardly through the perforated plate while engaging the tow with at least one perforated plate disposed in the path of the tow; and (d) conveying air through the storage chamber. The flow of the carrier air is adjusted to forcefully engage the perforated plate with sufficient force to slow down the movement of the tow through and store the tow in the storage chamber at a greater density than the tow has in the formation chamber. A method comprising: 6. A system for opening a multi-tow band and forming it into a predetermined shape suitable for use as an absorbent structure for personal care products, the system comprising: (A) receiving from a tow bale a first tow having a predetermined denier unit per filament from a tow bale, and for spreading the filaments in the first tow to the first tow band, and wherein the first tow band has a predetermined width; (B) towing a second tow having a predetermined denier unit per filament different from the predetermined denier of the first tow. Receiving from the bale, spreading the filaments in the second tow to the second tow band, and discharging the second tow band therefrom with a predetermined width. (C) an air jet opening device including the following (i) to (iv): (i) a housing (ii) the first and second tow bands are connected to one another of the bands. (Iii) an air jet for opening the multi-tow band; and (iv) discharging the opened multi-tow band. An outlet end for the system. 7. The width of the outlet end of one of the first or second collecting device is smaller than the other, so that the multi-tow band discharged from the outlet end of the air jet opening device is larger than the other. 7. The system for forming a multi-toe band according to claim 6, wherein the system has one toe band of width. 8. The system for forming a multi-tow band according to claim 7, wherein said tow band having a greater width has a different denier per filament than filament of the other tow band. 9. The system for forming a multi-tow band according to claim 7, wherein said tow band having a larger width has a denier per filament smaller than the denier per filament of the other tow band. 10. The system according to claim 1, wherein the system includes a surfactant applicator provided upstream of an inlet of the air opening jet for individually applying a surfactant to one or both of the tow bands. A system for forming a multi-toe band according to claim 7. 11. The method of claim 1, wherein the surfactant is applied only to the tow band having a small width.
A system for forming a multi-toe band according to claim 0. 12. The method of claim 7, wherein the system includes a binder applicator provided upstream of an inlet of the air opening jet for applying a binder to one or both of the tow bands. A system for forming a multi-toe band. 13. The system for forming a multi-tow band according to claim 12, wherein the binder is applied to the tow band having a large width. 14. A tow-banded jet for each of said first and second collecting devices to receive and spread a tow, respectively, and said first and second banded jets and said air opening, respectively. Claims: It comprises at least one pair of delivery rolls arranged between jetting devices, further characterized in that the speed at which said first and second tow bands are delivered to said air jet opening device can be individually controlled. Item 7. A system for forming a multi-toe band according to Item 6. 15. The multi-tow band of claim 6, wherein the first and second collective devices can be individually controlled to change the bloom of the first and second tow bands. System to do. 16. A system for opening a multi-tow band and forming it into a predetermined shape suitable for use as an absorbent structure for personal care products, the system comprising: (A) receiving from a tow bale a first tow having a predetermined denier unit per filament from a tow bale, and for spreading the filaments in the first tow to the first tow band, and wherein the first tow band has a predetermined width; A first collecting device having an outlet end for discharging with a second tow having a predetermined denier unit per filament different from the predetermined denier of the first tow from the tow bale. An outlet end for receiving and discharging the filaments in the second tow band to the second tow band and discharging the second tow band with a predetermined width. A second collecting device; and (c) an air jet device including the following (i) to (iv): (i) for receiving the first and second tows simultaneously and substantially in the shape of the first and second tows. A housing having an inlet opening having a corresponding shape, wherein the first and second tows have an outlet opening exiting the housing as a multi-layered tow having a shape substantially corresponding to the predetermined shape. (Ii) formed in the housing adjacent the inlet opening thereof to move the first and second tows through the air opening jet device and also to create a venturi for opening the first and second tows. (Iii) a source of compressed air in communication with the air jet for providing carrier air for moving the first and second tows through the jet device; (iv) in the housing A forming chamber downstream of the air jet and including a gradually increasing cross-sectional area in the direction of the flow of the first and second tows, which corresponds to the predetermined shape, wherein the air jet is A forming chamber which is completely opened when the first and second tows move through the forming chamber and which is arranged in the housing so as to substantially fill the forming chamber; (v) the forming in the housing A storage chamber provided downstream of the chamber, wherein the opened first and second tows are stored in the storage chamber, and the predetermined shape through the housing outlet opening at various flow rates from the housing. Wherein the storage chamber includes at least one perforated plate disposed in the path of the first and second tows, and wherein the carrier air comprises A storage chamber moving through said first and second tows to engage said perforated plate and passing at least some of said carrier air through said perforated plate; and (vi) disposing at least said portion of said carrier air to said perforated plate. Sufficient to reduce the movement of the first and second tows through the storage chamber by passing the first and second tows through the perforated plate and accumulating the first and second tows in the storage chamber. A control valve for maintaining the flow of the carrier air at a level that will forcefully engage the perforated plate with the perforated plate. 17. A method of opening a multi-tow band and forming it into a predetermined shape suitable for use as an absorbent structure for personal care products, the method comprising the following steps: (A) moving a first tow from a tow bale having a predetermined denier unit per filament through a first assembler to spread filaments in the first tow into a first tow band, wherein the first tow band is predetermined; (B) discharging a second tow from a tow bale having a predetermined denier unit per filament different from the predetermined denier of the first tow from the first tow filaments in the second tow Moving through a second collecting device to spread the second tow band to a second tow band, and discharging the second tow band therefrom with a predetermined width; and (c) Combining the first and second tow bands into a two-layer tow band at the entrance of the air jet opening device, passing the air jet opening device to open the two-layer tow band, and opening the opened two-layer tow band. Discharging. 18. The method of claim 17, wherein the multi-tow band is spread and formed into a predetermined shape, further comprising the step of removing the tow band discharged from one of the first or second collecting devices. A method wherein the width is smaller than the other, whereby the multi-layered tow band discharged from the outlet end of the air jet opening device has one tow band layer larger than the other. 19. The method of claim 18, wherein the multi-tow band is spread and formed into a predetermined shape, wherein the tow band having a greater width has a denier per filament of the other tow band. A method comprising having a small denier per filament. 20. The method of claim 18, wherein the multi-tow band is spread and formed into a predetermined shape, wherein the surfactant further comprises the air jet spreading on the tow band having a small width. A method characterized in that it is applied downstream of a device. 21. The method according to claim 18, wherein the multi-tow band is spread and formed into a predetermined shape, further comprising a binder having a large width. Applied downstream of the method. 22. A method of opening a multi-tow band and forming it into a predetermined shape suitable for use as an absorbent structure for personal care products, the method comprising the following steps: (A) moving a first tow from a tow bale having a predetermined denier unit per filament through a first assembler to spread filaments in the first tow into a first tow band, wherein the first tow band is predetermined; (B) moving a second tow from a tow bale having a predetermined denier unit per filament different from the predetermined denier of the first tow; Spreading the filaments in a second tow band and discharging the second tow band therefrom with a predetermined width; (c) removing the first and second tow bands from the housing Creating a jet of carrier air to move from the inlet opening to the outlet opening through the housing; and (d) increasing the cross-sectional area of the first and second tow bands in the direction of flow of the first and second tow bands within the housing. (E) moving the first and second tow bands into a storage chamber downstream of the forming chamber and moving the first and second tow bands partially through the forming chamber having Flowing outwardly through the perforated plate at least a portion of the carrier air while engaging the at least one perforated plate disposed in the path of the first and second tow bands; and Sufficient force to slow down the movement of the first and second tow bands through the storage chamber and cause the first and second tow bands to accumulate in the storage chamber at a greater density than it has in the formation chamber. Wherein the including, regulate the flow of the transport air so as to engage forcibly frictional engagement between the apertured plate. 23. A system for opening a multi-tow band and forming it into a predetermined shape suitable for use as an absorbent structure for personal care products, the system comprising: (A) receiving a first tow from a tow bale having a predetermined denier unit per filament, expanding the filaments in the first tow to the first tow band, and providing the first tow band with a predetermined width; (B) removing a second tow from a tow bale having a predetermined denier unit per filament different from the predetermined denier of the first tow; An outlet end for receiving and discharging the filaments in the second tow band to the second tow band and discharging the second tow band with a predetermined width. (C) a first air jet opening device including the following (i) to (iv): (i) a housing; (ii) the first air jet sent from an outlet end of the first banded jet. (Iii) an air jet for opening the first tow band; and (iv) an outlet end for discharging the opened first tow band; (d) the following (i): (I) a housing; (ii) an inlet for receiving the second tow band delivered from an outlet end of the second banded jet; (iii) the second air jet opening device; An air jet for opening the two tow band; and (iv) an outlet end for discharging the opened second tow band; and (e) discharging downstream of the first and second air jet opening devices. Receiving the said toe band System characterized in that it comprises a; serial tow band arranged collection device to combine the multi-tow band. 24. The multi-tow formed at the outlet end of the first and second air jet opening devices, wherein the width of the outlet end of one of the first or second collecting devices is smaller than the other. 24. The system for forming a multi-toe band according to claim 23, wherein the band has one toe band that is wider than the other. 25. The system for forming a multi-tow band according to claim 24, wherein said tow band having a greater width has a different denier per filament than filament of the other tow band. 26. The system for forming a multi-tow band according to claim 24, wherein the tow band having a larger width has a denier per filament smaller than the denier per filament of the other tow band. 27. A surfactant applicator provided upstream of one or both inlets of said first and second air opening jets for a system for individually applying a surfactant to one or both of said tow bands. 25. The system for forming a multi-toe band according to claim 24, comprising: 28. The method of claim 2, wherein the surfactant is applied only to the tow band having a small width.
A system for forming a multi-toe band according to claim 7. 29. The system further comprising a binder applicator provided upstream of one or both inlets of the first and second air opening jets for applying a binder to one or both of the tow bands. The system for forming a multi-toe band according to claim 24. 30. The system for forming a multi-toe band according to claim 29, wherein the binder is applied to the tow band having a large width. 31. The multi-toe band of claim 23, wherein the first and second collective devices can be individually controlled to change the bloom of the first and second tow bands. System to do. 32. A method of opening a multi-tow band and forming it into a predetermined shape suitable for use as an absorbent structure for personal care products, the method comprising the following steps: (A) moving a first tow from a tow bale having a predetermined denier unit per filament through a first assembler to spread filaments in the first tow into a first tow band, wherein the first tow band is predetermined; (B) moving a second tow from a tow bale having a predetermined denier unit per filament different from the predetermined denier of the first tow through a second collecting device; Spreading the filaments in the second tow into a second tow band and discharging the second tow with a predetermined width; (c) the first collecting device Moving the first tow band discharged from the device to a first air opening jet to spread and bloom the first tow band and discharge the first tow band therefrom; (d) the second set Moving the second tow band discharged from the apparatus to a second air opening jet to spread and bloom the second tow band and discharge the second tow band therefrom; Combining the first and second tow bands discharged from the second air opening jet into a composite multi-tow band. 33. The tow band discharged from one of the first or second collecting device has a width smaller than the other, whereby the multi-tow band has one tow band layer larger than the other. 32. A method of opening the multi-tow band according to 32 and forming it into a predetermined shape. 34. The multi-tow band of claim 33, wherein the wider tow band has a denier per filament less than the denier per filament of the other tow band. A method of forming into a given shape. 35. The method according to claim 33, wherein a surfactant is applied to the tow band having a small width, and the multi-tow band is spread and formed into a predetermined shape. 36. A method for opening a thin, relatively wide band of continuous filament fibers and using the opened fiber band as an absorbent structure for personal care products. An air opening jet device for use in a system for forming into a defined shape, comprising: (a) receiving a partially opened fiber band and partially opening. A housing having an inlet opening having a shape substantially corresponding to the shape of the fiber band,
A housing having an outlet opening for the fiber band to exit the housing and having a shape substantially corresponding to the predetermined shape; (b) moving the fiber band through an air-spreading jet device, and or even fibers. An air jet formed in the housing adjacent to the inlet opening to create a venturi for opening the band; (c) the air for supplying carrier air for moving the fiber band through the jet device. A source of compressed air in communication with the jet; (d) a forming chamber in the housing and downstream of the air jet, the cross-sectional area increasing gradually in the direction of flow of the fiber band, wherein the cross-sectional area is reduced to the predetermined shape. Correspondingly, the air jet is fully opened as the fiber band moves through the forming chamber and substantially fills the forming chamber. (E) a storage chamber provided downstream of the formation chamber in the housing, wherein the opened fiber band is stored in the storage chamber; And a storage chamber configured and arranged to allow it to be withdrawn from the housing. 37. An article formed by the method of claim 5. 38. An article formed by the method of claim 17. 39. An article formed by the method of claim 22. 40. An article formed by the method of claim 32. 41. A fibrous web comprising respective first and second tows of a multi-continuous fiber filament that has been opened such that the filaments are dealigned with respect to each other. 42. The fibrous web of claim 41, wherein the filaments of the first and second tows are intermingled within at least a portion of the web. 43. The fibrous web of claim 41, wherein the first and second tows are substantially layered with respect to each other within at least a portion of the web. 44. The fibrous web of claim 41, wherein the filaments of the first and second tows are of different denier per filament. 45. The fibrous web according to claim 42, wherein the first and second tow filaments are intermingled with each other essentially through the web. 46. The fibrous web according to claim 42, wherein the filaments of the first and second tows are intermingled with one another essentially along the interface between them. 47. The filament according to claim 41, wherein one of the filaments of the first and second tows comprises a fusible composite fiber that binds the filaments of the first and second tows together.
A fiber web according to claim 1. 48. The fibrous web according to claim 41, further comprising a superabsorbent polymer. 49. The fibrous web according to claim 41, wherein the first and second tows are of different widths.