KR0128432B1 - Process and apparatus for forming fibers - Google Patents

Abstract

An apparatus (10) for forming a nonwoven web (26) from a fiber forming thermoplastic polymer resin which includes a reservoir for supplying a quantity of melted fiber forming thermoplastic resin, a pump for pumping the molten resin to a fiber forming die (16) and a die for forming a discrete resin stream to flow therefrom. The die includes a first fluid passageway (20) for forming a stream of fluid, such as air, in contact with and substantially surrounding the formed flow of resin for a predetermined distance within the die (16) and an interrupt system (18) for selectively cycling the flow of resin on and off and clearing the resin from the fiber forming die (16). A receiving belt (26) collects the fibers (22) formed from the resin flow below the first fluid passageway spaced at a predetermined distance (A') from the die (16). <IMAGE>

Description

Apparatus and method for forming nonwoven webs

1 is a schematic representation of a device made in accordance with the present invention.

2 is a cross-sectional view of a die made in accordance with the present invention.

3 is a plain view of a die plate produced according to the present invention.

FIG. 4 is a cross sectional view of line 4-4 of FIG.

5 is an enlarged partial cross-sectional view of a nozzle in a die assembly.

6 is a side view of a nozzle made in accordance with the present invention.

FIG. 7 is a plan view substantially taking the 7-7 line of FIG.

8 is a side view of another nozzle made in accordance with the present invention.

9 is a side view of the nozzle shown in FIG.

FIG. 10 is another side view of the nozzle of FIG. 6 showing flute helix angle G '.

FIG. 11 is a perspective view of the nozzle of FIG. 6 showing flute cutting angle H '. FIG.

12 is a side view of another embodiment of a nozzle made in accordance with the present invention.

FIG. 13 is a plan view substantially taking the 13-13 line of FIG.

* Explanation of symbols for the main parts of the drawings

10 device 12 storage container

16: single die 18: pressurized air

20: fibrous fluid 22: fiber

26: web 28: winding roller

33: air forming chamber 35: air plate

The present invention relates to apparatus and methods for making nonwoven webs useful for a wide range of uses, such as personal care products, household cleaning products, wipers, and the like. In particular, the present invention relates to novel apparatus and methods for forming fibrous bodies from fibers forming thermoplastic polymer resins.

The manufacture of nonwoven webs is a fairly advanced technique. In general, nonwoven webs or mats are laminated on a carrier such that the fibers overlap or entangle so as to form fibers of different or specific diameters and to be webs of the required basis weight.

Various means have been developed to control the formation of processed fibers that affect the properties of the formed web. For example, U.S. Patent No. 2,571,457, issued to Radish on October 16, 1951, is about 1 micron by passing polymers through the center hole of the nozzle with an elastic fluid to spiral the air into a conical peak. Spray nozzles for forming fibers of or smaller diameters are described. In US Pat. No. 3,017,664, issued to Radish on January 23, 1962, fiber forming nozzles are described, wherein the flow of polymeric material exits the tubular nozzle holes, and the formation of the tubes is carried out in a circular position. It is a cause of extending | stretching a polymer on the outer wall of a body. An elastic fluid that spirals around the polymer film at ultrafast speeds creates a vacuum between the film and the elastic fluid.

The fibers are gripped from the film of the fibrous forming liquid and discharged to be refined in the elastic fluid. Although the helical air surrounds the resin flow from the aperture in the two Radish patents above, the released air is delivered through a nozzle aperture that does not enclose the polymerization retention.

U.S. Patent No. 3,543,332, issued to Wagner et al. On December 1, 1970, describes fabrication using spinning nozzles, the spinning nozzles having a central hole for forming a polymer, with additional holes forming the fiber forming air. Surround the center hole for the passage of the.

U.S. Patent No. 3,755,527, issued to Keller et al. On August 28, 1973, describes a method for making a meltblown nonwoven synthetic polymer mat. The melt blowing method utilizes a plurality of extrusion holes through which the molten polymer resin can be extruded. A hot air slot for supplying a flow of hot gas in the form of a sheet on each side of a plurality of fibers formed from resin on each side of the plurality of holes. In order to produce fibers having a diameter between 10 and 40 microns, a combination of die tip temperature, resin flow rate and resin molecular weight is chosen to give a viscosity within a die hole of about 10 to 800 poise. Viscosity is adjusted within the range that can be effected by changing the die tip temperature.

US Patent No. 3,9095,734, issued to Blair on September 16, 1975, describes an improved apparatus for forming continuous tubes by meltblowing technology. The assembly utilizes a sword flow of forming gas on each side of the polymer outlet aperture. United States Patent No. 3,978,185, issued to Buntin et al. On August 31, 1976, describes meltblown nonwoven mats prepared from thermoplastic polymer fibers that are believed to be virtually free of polymer shorts, which are high power polymers in certain meltblowing processes. Thermoplastic polymer resins produced in yields and having certain viscosities here are degraded by the presence of free fundamental source composites.

U.S. Patent No. 4,135,903, issued to Oshido et al. On January 23, 1979, and U.S. Patent No. 4,185,981, issued on January 29, 1980, provide an apparatus for making fibers from heat softening materials using a high velocity gas stream, and The method is described herein where the molten polymer is rotated about a central axis and transferred to a substantially angular shape with a cross-section gradually decreasing toward the flow direction in the first cone, radially outward and flow direction within the second cone. To advance in the form of fibers from the tip of the cone.

There is a need for further development of methods and apparatuses for forming fibers from molten fiber forming resins and for forming mats from the formed fibers, where the apparatus and methods are required to provide increased yields in every aperture and in a wide range of action.

The above referenced patents indicate that the device and method can form a flat mat or web of nonwoven material and are most suitable for additional methods for incorporation into other products such as diapers and other personal or disposable articles. With the development of nonwoven fiber forming technology, the usage and application of these materials has been greatly improved. As new applications and applications are discovered, the design limitations of current installations become clear. As the increased cost of the polymers used to form the fibers, the overall manufacturing cost has become an important factor early on. One way to reduce the manufacturing cost of nonwoven materials is to increase the manufacturing capability of the equipment. Unfortunately, current nonwoven equipment has several limitations on the polymer yield that can be tolerated by meltblown dies. As the polymer viscosity and pressure increase, the die itself is prone to cleavage or zipper rings as is known in the art.

It is therefore an object of the present invention to provide an apparatus and method which allows for a practically high polymer pressure and thereby a high yield of holes with respect to the normal meltblown die tip structure.

Another major problem in the formation of nonwoven fibers and thus webs is a phenomenon called stot. Short occurs when the exhaust air is improperly applied to the extruded polymers. When this condition occurs, small beads of polymer are formed along the fibers, whereby the roll paper formed gives a very rough feel. This can also be caused by equipment design, inadequate control of air to polymer content, treatment conditions or a combination of these three. For almost all applications, short is not desirable.

It is therefore an object of the present invention to provide an apparatus and method which reverses treatment when necessary or increases the fiber formation efficiency and reduces short, and when required, has an extruded polymer circumference and an increased air flow relative thereto.

As nonwoven materials become more complex, it is often required that fibers of different polymer blends and / or different fiber dimensions be closely intertwined to form nonwoven materials. It is required to be produced in a multilayer structure to actually produce the material using one or more polymers and / or fibers, one layer of die forming one size of fiber or polymer, and another set of dies of different sizes Prepare fibers or polymers.

Accordingly, it is an object of the present invention to provide an apparatus and method that allow the formation of multicomponent nonwoven materials in a more local and efficient manner.

Another drawback of current meltblowing apparatuses and methods is the inability to produce nonwoven materials having density three-dimensional structures and / or regions in one or both directions in the machine and cross directions. The primary reason for this is that the meltblown facility described above is planar in design and must be operated continuously in accordance with the heating requirements of the polymer and the die holes are blocked by the stagnant polymer. Thus, such equipment cannot be cycled on and off to produce nonwoven materials having properties different from these densities.

It is therefore an object of the present invention to provide a method and apparatus that can periodically release a polymer during a fiber forming process.

With current meltblowing installations, manufacturing capabilities are produced in a particular width corresponding to the width of the layer of the meltblown die tip or hole. To change the width, the holes must be closed or the system must be stopped to recombine the lines with a large or small die tip. Accordingly, it is an object of the present invention to provide an apparatus and method capable of varying the manufacturing width of a nonwoven material. Finally, current meltblowing installations often become clogged when small die holes are filled with solidified polymer. Typically, it is very difficult to drill holes while the machine is in operation. A slightly clogged hole will not normally affect the quality of the product, and once enough holes are clogged, the die tip will have to stop the line, clean up the cost and spend time. Accordingly, another object of the present invention is to provide an apparatus and method for self cleaning.

These and other objects of the present invention will become more apparent from the following specification, drawings and claims.

In accordance with the present invention there is provided an apparatus and method for forming a nonwoven web from a fiber forming thermoplastic polymer resin, the apparatus comprising a resin from a storage means to a fiber forming die and a storage means for supplying a large amount of molten fiber forming thermoplastic polymer resin. And pump means for pumping. The die means form a separate flow of the pumped resin from the storage means. The die means is a fiberizing means for forming fibers from the flow of the resin using a first fluid passage means for contacting the formed flow of the resin by a predetermined distance within the die means and forming a flow into the oil, such as the air enclosed substantially. It includes. The fiberizing means may further comprise a second fluid passage means for contacting and refining the formed fiber. A receiver means spaced apart from the die means by a predetermined distance collects the fibers formed from the fluid passing means and thereby forms a nonwoven web. The hydraulically actuated stem in the die means provides on / off control for selectively stopping the flow of the fiber forming resin. The stem may be used to clean resin debris from the die means.

An apparatus 10 for forming a nonwoven web from a fiber forming thermoplastic polymer resin is shown schematically in FIG. 1 with reference numeral 10. Generally, the apparatus includes a reservoir 12 for supplying an amount of molten fiber forming thermoplastic polymer resin. Such resins are well known in the art. Examples of such resins that may be used in the practice of the present invention include, but are not limited to, polypropylene, polyethylene, polyester, polyether copolymers, polyurethanes, polyether-amide copolymers, styrene-methylene and butylene copolymers It is not limited to. Moreover, the properties of such polymers and copolymers can be further enhanced by the addition of various flow modifiers and other additives known in the art.

Many of these polymers are difficult if they are unable to operate at high throughput on discharge plants, such as meltblowing plants, depending on the high viscosity of the polymer, which can cause the zipper ring of the die at increased pressure. Examples of these polymers include PEF polyester, styrene-ethylene, butylene copolymers and polyester copolymers. As described in the Examples below, these polymers can be extruded using the apparatus and methods of the present invention.

The storage container 12 includes means for melting the polymer resin and means for holding the resin in a molten state. Typical resins melt at temperatures ranging from 149 degrees to 260 degrees. Therefore, the storage container must be able to maintain the resin at least within this range. The pump 14 pumps the molten resin from the reservoir 12 into one or more fibrous dies 16, indicated generally by reference numeral 16. Apparatus 10 comprises a source of fibrous fluid 20 and a pressurized air 18 source for actuating on / off control means to fiber the melt as described below. As shown in FIGS. 3 and 4, a single die 16 or multi-die assembly may be used to form the fiber and nonwoven materials according to the present invention.

The fibers 22 exiting the die 16 are collected on a receiver, such as a continuous wire forming belt 24 in the form of a web 26. The receiver assembly may include means 27 to create a vacuum under the receiving portion of the belt 24 and to achieve a density of the composite nonwoven web 26 to effectively support the web 27 on the belt surface. The receiving surface of the belt 24 is spaced apart from the die 16 by a predetermined distance A '. The forming web 26 may be collected on the winding roller 28. Arge, web 26 may be treated further downstream from the forming process. In general, the predetermined molding distance A 'is between about 7 and 100 cm.

2, the fiber forming die 16 includes an air plate 35 with a cap and a main housing 29 for receiving a die assembly comprising a resin nozzle 31 coupled within the air forming chamber 33. As shown in FIG. Have The air plate 35 includes a plurality of holes located over the plurality of nozzles. 3-4 show four assemblies 36 aligned. The resin nozzle 31 is in combination with a shrinkable plunger assembly 37 (part of the on / off control means) which in turn blocks the resin flow and allows the nozzle hole to be cleaned. The die 16 is employed to accommodate the supply of air and molten resin. The air is operated separately to operate the shrinkable plunger assembly 37 and to be described in more detail below and to refine and draw the melt into fibers.

2, when the flow of molten resin is traced from the inlet to the outlet of the die 16, the molten resin is passed through the resin inlet port 38, which is guided to the inside of the nozzle 31 located in the die 16. It enters the main housing 29 of the die 16. The nozzle 31 includes a resin chamber or main flow body 39 that encloses and surrounds a hydraulically actuated plunger assembly 37. Therefore, the resin inflow port 38 and the main flow body 39 are in fluid communication with each other. When the molten resin enters the main flow body 39, it fills the chamber and pressurizes the chamber. The molten resin is then disassembled through the resin fluid capillary 40 from the chamber through the resin discharge hole 41 located in the air plate assembly 35 to form fibers. First, the plunger assembly 37 is positioned relative to the base of the resin discharge hole 41, whereby the release of the molten resin is prevented. When the plunger 37 is retracted and separated from the resin discharge hole 41, the resin is allowed to exit from the main flow body 39 and fiber formation is started.

In order to fiberize and to refine the resin discharged from the resin discharge hole 41, fiberizing / micronized air or other fluid is used to draw and surround the resin with the fibers 22. Thus, the die means 16 comprise primary means for drawing and miniaturizing the fibers 22 and, if necessary, secondary means.

Air or other fluid fibrosis source enters die 16 through fluid inlet port 42. As shown in FIG. 2, the fluid inlet port 42 is formed by the space between the outside of the nozzle 31 and the inside of the main die housing 29 / air plate 35 of the die 16. In fluid communication with the chamber 33. The air forming chamber 33 extends into the air plate assembly 35 where it surrounds at least the lower portion of the nozzle 31 and terminates in the annular fluid discharge port 43. The fluid discharge port 43 has a diameter in the range of 3.0 to 5.0 mm. This fluid discharge port 43 forms a primary means for refining and refining the fibers 22. As the diameter of the fluid outlet port 43 decreases, the fibrillated / micronized air is increased in speed so that the fiber 22 is reduced more seriously.

Secondary fiberizing means may also be used to further dampen and fiber the molten fibers 22. 2 and 3, the air plate assembly 35 is radially spaced outwardly from the first or primary flow outlet port 43 to further fiber the melt and create a plurality of secondary fluid flows. May be coupled to the secondary fluid outlet port 44. These secondary fluid discharge ports 44 are in fluid communication with the air supply 20 via a fluid channel 45 connecting the air forming chamber 33 and the secondary fluid discharge port 44. Alternatively, a secondary fluid discharge port 44, not shown, may be connected to an independent pneumatic fluid source and the fluid pressure therefrom may independently control the primary fibrosis fluid. In order to moderate the formation of fibers and webs, it is important to balance the formation of the fibers with their subsequent clamping. The interaction and design between the nozzle 31 with the resin outlet 41 and the secondary fibrous fluid flow will be described in more detail below.

As shown in detail in FIG. 5 with reference to FIG. 2, the resin discharge hole 41 and the annular fluid discharge port 43 are located on the annular wall 46 located in the air plate 35 of the die 16. Come directly. The height of the annular wall 46 is defined by the distance B 'between the lines 48 and 49. This distance B 'is limited by the processing capability, but the height B' of the upper wall 46 is preferably 0.5 mm or less. If this height is excessively high, the molten resin discharged from the resin outlet 41 will be collected at the annular wall 46, whereby many molten resin droplets will be transported onto the formed web 26. Many drops are called “shots” and are preferred or undesirable depending on the end use of the fiber / nonwoven web.

Since the resin discharge hole 41 and the fluid discharge port 43 come directly on the annular wall 46, the nozzle 31 and the resin discharge hole 41 change the amount of recesses in the die 16 to change the air plate ( 35).

The distance C 'is measured between the end of the resin discharge hole 41 (line 50) and the bottom of the annular wall 46 (line 48). The distance C 'can be adjusted to adjust the effect of air flow from the fluid discharge port 43 to finely adjust the fiberization of the molten resin. Preferably, the recess distance C 'is between 0 and 5 mm, and although this distance depends on the air flow conditions, the polymer viscosity and various other factors can effectively control the fiberization of the molten resin. The nozzle, that is, the end of the resin discharge hole 41 and the fluid discharge port 43 lie in the same plane formed by the outer surface of the air plate part 35 of the die housing 29 without 0.0 mm or groove. This coplanar will also include the line 48 shown in FIG. In general, when the distance C 'is reduced, the air coming out of the fluid discharge port 43 is high speed to more strongly damp the resin coming out of the resin discharge hole 41. On the contrary, when the distance C 'is increased, the air coming out of the fluid discharge port 34 is slow to weaken the resin coming out of the resin discharge hole 41 more weakly. In some cases it is desirable to extend to the nozzle 31 away from the plane formed by the outer surface of the die housing 29.

2 and 5, air is supplied to the fluid discharge port 43 via an inlet port 42 in the side of the main housing 29 in the die 16. The inlet port 42 communicates with the fluid outlet port 43 in the air plate 35 to direct air into the air forming chamber 33 surrounding the nozzle 31 in communication with the fluid outlet port 43. The air forming chamber 33 as a whole has a cavity surface 56 indicated by reference numeral 56. The cavity surface 56 has a second truncated cone portion located in the air plate 35 and a substantially cylindrical portion 58 having a substantially annular shape when viewed in cross section. Surface 60 is inclined at the primary fluid flow angle formed by angle D 'in FIGS. 4 and 5. The primary fibrous fluid is the angle opposite to the flow of the melt and the flow of the melt moves along the first axis 61. The primary fluid flow angle D 'is the angle between the first axis 61 or vertical axis of the nozzle 31 and the line tangent to the surface of the truncated cone portion 60. In general, the primary fluid flow angle D 'should be between about 15 and 60 degrees. This first angle 61 forms an initial flow path of the molten resin as it is discharged from the resin discharge hole 41.

2-5, the air plate assembly 35 radially and axially from the first or primary fluid discharge port 43 to further fiberize the molten resin into fibers and create a plurality of secondary fluid flows that are impacted. The secondary fluid discharge port 44 spaced outward may be fixed. These secondary fluid discharge ports 44 are in fluid communication with the air supply 20 via a fluid channel 45 connecting the air forming chamber 33 and the secondary fluid discharge port 44. In the arge, the secondary fluid discharge port 44 may be connected to an independent fluid source and the pressure of the fluid exiting therefrom may be controlled independently of the primary fiber and the source. The secondary fluid outlet port 44 may have round or other shaped cross sections of different dimensions to produce other fiber forming effects.

The secondary fluid discharge port 44 is angled radially inward toward the longitudinal axis 61 of the nozzle 31 so that the secondary fiberizing fluid strikes the preformed fiber 22 at a predetermined angle. This angle is called the secondary fluid flow angle E 'and is tangent to either the first axis of the resin flow (also the longitudinal axis 61 of the nozzle 31) and the fluid flow exiting the secondary fluid discharge port 44. 52) is measured as the internal angle between. See Figure 5. This angle E 'may vary between 1 and 45 degrees.

Concave lower surface 62 of air plate 35 in relation to the primary secondary fibrous fluid flow provides limited fibrosis and contacts the primary fibrous fluid through discharge port 43 and prevents resin flow from the resin discharge hole 41. Surround. Secondary fibrous fluids cost preformed fibers. By the discharge of the die, the fibrous air discharged to the primary and secondary fluid discharge ports 43 and 44 acts as a free expansion jet. Ultrafast disturbances create jet expansion that causes melt flow to be withdrawn and discharged in any direction, thereby fiberizing and dampening melt flow at ultrafast speeds. Secondary Fibrillated Flows are reoriented to produce acyclic expansion jets, shown by arrows 63, 64, 65, and 66 in FIG. 5, at which point the two flows collide with the stretching of the fibers formed by the primary fibrillated fluid flow. . This type of turbulent fiberization method is similar to the melt blown method conventional in the industry. In contrast, the apparatus and method of the present invention, however, allows a power per hole that is 50 times or more compared to current meltblowing equipment and techniques. As a continuous fiber sustaining method, such as spunbonding, the fibrous air is controlled in the host area. This allows the melt to be damped in a controlled environment. The advantages of the turbulent fiberization method, which is a high accuracy of attenuation, can be achieved through the redworm, continuous fiber method. This high degree of attenuation can form fibers of small dimensions.

In addition to changing the primary and secondary fiberizing fluid flow with respect to the fibers, it is also possible to make changes to the nozzles 31 to achieve fiber formation. As shown in FIGS. 6 and 7, the first embodiment of the nozzle 31 comprises an axial end portion 70 comprising a predetermined first radial extension and a land surface 72. It has one axial portion, and the land surface 72 includes a resin discharge hole 41. The axial end portion 70 has a predetermined second radial extension that is smaller than the first radial extension of the first axial portion 68. The nozzle portion 31 further comprises a tapered axial portion 74 extending between the first axial portion 68 and the axial end portion 70. The angle of the tapered axial portion 74 is defined as the internal angle F ′ between the longitudinal axis 61 of the nozzle 31 and the line 73 tangent to the surface of the frustoconical portion 74. Typically, this truncated cone angle F 'is between about 15 and 60 degrees. The nozzle 31 may also include an end portion 75 with screws for connecting the nozzle 31 into the main housing 29 of the die 16.

The nozzle 31 may further comprise means for directing the flow of fluid relative to the nozzle. Such fluid flow orientation means may comprise a plurality of flutes 76 on the outer surface of the nozzle 31. The flute 76 may extend over the tapered axial portion 74, the axial end portion 70, and to the land surface 72.

In the second embodiment of the nozzle portion of the present invention shown in FIGS. 8 and 9, a similar structure is shown with a backed reference numeral. The nozzle 31 ′ does not include an axial end portion 70. Moreover, the land surface 72 'is located adjacent to the distal end of the tapered axial portion 74'. As shown in the practice of FIGS. 7 and 7, the flutes 76, 76 ′ extend into the land surfaces 72, 72 ′.

The fibrous air source 20 has a primary airflow feeder that is introduced into the die through the fluid inlet 42 shown in FIG. The inner cavity 33 provides a balancing channel for disturbing the incoming air with respect to the nozzle 31. The air is balanced around the nozzle 31 and directed towards the rapeseed discharge port 43 of the airflow channel formed in the cavity 33 depending on the air pressure used in the system. This primary air flows through the flute 76, 76 ′ within the outer diameter of the nozzle at a compound angle and thereby attenuates the newly formed fibers 22 and causes the fibrillated air movement in this regard.

The flute helix angle G 'around the nozzle tip is a line 78 parallel to the longitudinal axis of one of the flutes 76 shown at an angle G' within the first axis 61 and 10 degrees of the nozzle 31. Cabinet measured between). The flute helix angle G 'should be between about 20 and 45 degrees. This helix angle determines the rotational and centrifugal forces of the fluid flow acting on the melt flow from the resin discharge hole 41.

The flute attack angle H 'is determined by how quickly air comes into contact with the resin flow. This angle is the angle measured between the longitudinal axis 61 of the nozzle 31 and the line 79 parallel to the inner surface 83 of one flute 76. Referring to FIG. 11, the flute attack angle H 'in relation to the angle of the truncated cone portion 60 of the air forming chamber 33 is a flow of molten resin in which primary air flow is discharged from the resin discharge hole 41. And the impact location of the primary airflow as it flows over the flute 76. The flute attack angle H 'should be in the range of about 7 degrees to 60 degrees.

In the third embodiment of the nozzle shown in Figs. 12 and 13, the nozzle 31 does not contain flutes on the tapered axial portion 74 and on the land surface 72. Figs. There is no flute in this third embodiment to minimize the rotational force in the airflow. This may be good for any molten polymer with a relatively low melt strength.

There are many surfaces in the housing 29 that can be altered to alter the flow characteristics and thereby the formation of the fibers 22 is produced by current apparatus and methods. A particular advantage and advantage of the present invention is the exchangeability of the nozzle 31. By removing the air plate 35, the nozzle 31 can be removed and a new nozzle can be inserted. As a result, the change of resin and fiber formation can be achieved by replacement of the nozzle.

Means are provided for selectively starting and stopping the flow of the resin, thereby adding additional functionality to the present invention that provides for the formation of fibers. In multi-die structures such as those shown in FIGS. 3 and 4, one, several or all nozzles can be turned on and off periodically. As a result it is possible to interrupt the fiber forming process whereby individual nonwoven webs are created by varying the basis weight in the machining direction and in the cross-sectional direction. In line processes such as the formation of personal care products (basis, sanitary napkins, etc.) it is possible to design specific areas, for example local area absorbers, which contribute to the product. To accomplish this, the apparatus 10 includes control means for selectively stopping and starting the resin flow from the resin discharge hole 41 and at the same time removing the resin debris.

2 and 5, the on / off control means comprises a pneumatic attachment 90, which is generally indicated by reference numeral 90, which forms part of the main die housing 29 and is connected thereto. Extending from the pneumatic attachment 90 into the main flow body 39 is a plunger assembly or reciprocating stem 92 with a spacing tip 94 positioned over the resin flow capillary 40. Stem 92 has an unsecured state as shown in FIGS. 2 and 5, tip 94 is retracted into main flow body 39, spaced from capillary 40, and seated (not shown). ) And the stem 92 is reciprocated to seat the tip 94 relative to the capillary 40. Hydrostatic pressure by seating the stem 92 is generated in the capillary 40 which removes any debris located therein and restricts the flow of melt from the resin flow outlet 41.

The pneumatic fixing unit 90 includes a pneumatic chamber 96 including an upper chamber 96a and a lower chamber 96b, as shown in FIG. The stem 92 includes an end portion 98 extending into the pneumatic chamber 96. The end portion 98 of the stem 92 is attached with the seal 102 in contact with the walls of the chamber to form a piston 100 mounted thereon and an upper chamber 96a and a lower chamber 96b. . The chamber 96 includes a pair of hydraulic fluid ports 104, 106 open into the pneumatic chamber to supply varying fluid pressure to each side of the piston 100 to reciprocate to the piston 100 within the pneumatic chamber 96. And thereby the stem 92 reciprocates between seated (off) and non-seated (on) positions.

The main body body 39 includes a stem 92 and a stem port 108 extending through the stem port 108. The die 16 has a high temperature resistant dynamic seal 110 to achieve sealing between the stem 92 and the stem port 108 and to allow sliding coupling to prevent passage of the molten resin through the port 108. Include. The seal 110 may have a U-shaped cross section to expand into the space between the stem 92 and the wall of the port 108 by the pressure applied by the incoming polymer resin. Thus, the seal 110 provides a separation between the molten material and the external environment under the pressure of the molten material. The sealing mechanism must provide a positive seal at temperatures above 350 ° C.

Operation of the on / off mechanism includes selectively pressurizing the upper chamber 96a and the lower chamber 96b. In order to turn on the mechanism and start the flow of the molten resin from the resin discharge hole 41, the pressure from the upper chamber 96a is relieved through the fluid port 104 and the atmospheric air is passed through the fluid port 10b to the lower chamber. 96b is fed into. As a result of the unbalance of pressure on each side of the piston 100, the piston 100 moves further into the upper chamber 96a which disengages the tip 94 of the stem 92 from the capillary 40 and thereby the resin. Allow release of the molten resin from the main flow body (39) through the discharge hole (41). The order is reversed to turn off the instrument and stop the flow of melt. That is, the pressure from the lower chamber 96b is decreased, the pressure from the upper chamber 96a is increased, and the pressure imbalance is caused by seating the tip 94 of the stem 92 against the capillary tube 40 and Pressurized to block flow. In addition, this action will create sufficient hydrostatic pressure in the capillary 40 to remove any debris located therein. Alternatively, the pneumatic fixture 90 may be machined in one of the chambers 96a or 96b to further act on the piston 100 to maintain the stem 92 in the seated or unseated state using air pressure in the opposing chamber. It can also be modified by adding an optional spring (not shown). Therefore, the present invention can be used under varying conditions by providing a very useful range of outputs and a sufficiently high melt blowing method.

The present invention comprises the steps of supplying a large amount of molten fiber forming thermoplastic resin, pumping the resin into the fiber forming die 16, forming a flow of resin from the die 16, and in contact with the formed flow or resin And substantially flowing a flow of fibrous fluid, such as surrounding air, and collecting the fibers formed at a distance A ′ from the die 16. Provide a method. In particular, the flow of the fiberizing fluid is completely contained in relation to the resin by a predetermined distance, which is called the die yaw distance C ', which is the distance between the lines 48 and 50 in FIG. This distance can be changed by recessing the discharge hole from the primary air hole 43.

The invention further includes balancing the fluid flow from the fluid inlet port 42 with respect to the nozzle in the die 16 in the air forming chamber 33. The flow of fluid is oriented with respect to the nozzle 31 by the flow of the fluid on the flute 76 formed outside the nozzle 31. At least two fluids collide with the fluid flow and impinge the fiber formed substantially surrounding the primary air flow to form an acyclic expanding zep as shown in FIG. 5 by arrows 63 to 66 by arrows 63-66. Further fibrosis is achieved by forming a secondary fiberizing fluid flow comprising the flow. Secondary fiberizing fluid flowing from two outlet holes 44 on opposite sides of the surrounding fluid flows at an angle toward the surrounding fluid flow formed at an angle E 'in FIG.

The present invention further includes a step for selectively stopping the flow of resin from the resin discharge hole 41. The stem 92 reciprocates to stop the resin flow so that the spacing tip 94 of the stem 92 seats against the surface of the resin discharge capillary 40 and stops the resin discharge capillary 40 to stop the resin flow. It is not seated on the spacing tip 94 in order not to stop the resin flow from. The seating of the spacing tip 94 creates hydrostatic pressure in the capillary 40 to remove debris from the capillary 40 and the resin outlet hole 41. The stem 92 reciprocates by pneumatic actuation of the piston 100 connected to the stem 92 arranged in the pneumatic chamber 96 to seat and disengage the spacing end 94. The stem 92 can only be reciprocated in a long stroke.

In operation, it is preferable that the resin discharge holes 41 have a diameter between 0.5 and 1.0 mm even if the diameter of the fiberized polymer holes shown is 3 mm or more. The nozzle recess C 'may be varied between 0 and 5 mm to allow for effective fiberization. The nozzle temperature is varied between 138 and 330 ° C. The test shows 56 to 1558 liters of airflow per minute for each nozzle with effective fibrosis. The nozzle air pressure is used for testing at high pressures up to 317 kpa but varies between 6.9 and 172 kpa. The fiberizing air temperature varies between 137 and 343 ° C. depending on the polymer used. The forming distance A 'between the nozzle tip and the landing belt's landing area varies between 15 and 64 cm, although successful in the test using a distance of 7,5 cm to 102 cm. Polymer yields vary between 0.16 per minute per nozzle and 151 g per minute per nozzle, even between 0.76 and 38 g per minute per nozzle, although experimentally achieved. Polymers that can be fiberized with the present invention are polypropylene, polyethylene, polybutylene, PET polyester, PETG copolymer, PBT polyester, ethylene vinyl acetate copolymer, polyurethane, polyether copolymer, styrene, ethylene-butyl Lene copolymers, including but not limited to.

In order to show the properties and functions of the device and the product manufactured according to the invention, a series of experiments were carried out as described below, using a device of the type schematically shown in FIG. 1 and as shown in FIG. Includes common die tips. In all embodiments, the shape of the nozzle tip and the shape and structure of the air plate can be changed to alter the properties of the fiber formation. Moreover, the forming distance and nozzle crevice between the die and the receiver can be modified to achieve fiber formation and can be changed to achieve a nonwoven web. Depending on the particular copolymer used, other factors achieve fiber formation, including the melting temperature of the copolymer and polymer output in grams per hole (nozzle) per minute, air flow in liters per minute per nozzle, and air temperature of the forming air. Can be changed to do so. In most cases, the resin is extruded through the four nozzle head assembly. However, a single nozzle assembly was used in Examples VIII, IX, XIII and XIV, an 8 nozzle assembly was used in Example IV and an 18 nozzle assembly was used in Example IXX. All data is given per hole (nozzle).

(Example 1)

PET polyether, designated 9028, manufactured by Eastman Chemical, was extruded at a melt temperature of 287 ° C. at a yield of 3.1 g per hole per minute at a melt pressure of 455 kpa. The fiberizing fluid had an air temperature of 293 ° C. and a flow volume of 177 liters of air per minute per nozzle. The nozzle located in the die housing has a diameter of the first axial portion of 12 mm, a diameter of the cylindrical end portion of 5 mm, and a diameter of the resin discharge hole of 1 mm with the angle of the truncated conical portion at 45 ° C. The nozzle includes six flutes with a flute helix angle of 20 degrees and a flute attack angle of 7 degrees. The airflow configuration includes two secondary air holes with a primary air hole diameter of 5 mm and a primary fluid flow angle of 45 degrees and a 1.5 mm diameter separated by 180 degrees. Secondary fluid flow angle was 45 °. The nozzle recess was 2 mm and the forming distance between the die and the receiver was 38.10 cm. Under these conditions, the average fiber diameter was 15.5 microns and the web formed from the extruded filtrate had a density of about 0.061 g / cm 3 and an average shot using an optical microscope of 0.015 mm 2.

(Example 2)

A melt pressure of 896 kpa of PETG copolyester manufactured by Eastman Chemicals and designated Coda 6763 is extruded at a melt temperature of 287 degrees with a yield of 7.4 g per nozzle per minute. The fiberizing fluid had an air temperature of 283 ° C. and a flow rate of 127 liters of air per minute per nozzle. The nozzle located in the die housing has a diameter of the first axial portion of 12 mm and a cylindrical end portion of 5 mm, and a resin discharge hole diameter of 1 mm with an angle of a truncated conical portion of 45 degrees. The nozzle includes six flutes with a flute spiral angle of 20 degrees and a flute attack angle of 7 degrees. The airflow shape includes two secondary air holes having a primary air hole diameter of 5 mm and a primary fluid flow angle of 45 degrees and a 2.0 mm diameter separated by 180 degrees. Secondary fluid flow angle was 58 °. The nozzle recess distance was 2 mm and the forming distance between the die and the receiver was 58 cm. Under these conditions, the average fiber diameter was 24.9 microns and the web formed from the extruded fibers had a density of about 0.050 g / cm 3 and an average shot using an optical microscope of 0.0076 mm 2.

(Example 3)

ratio. F. The polyurethane, designated 5740 × 732, manufactured by Goodrich, was compressed to a melting temperature of 216 ° C. with a yield of 6.6 g per hole per minute at a melt pressure of 827 kpa. The fiberizing fluid had an air temperature of 232 ° C. and a flow volume of 184 liters of air per minute per nozzle. The nozzle located within the die housing has a diameter of the first axial portion of 12 mm, a diameter of the cylindrical end portion of 5 mm, and a diameter of the resin discharge hole of 1 mm with an angle of a truncated conical portion of 45 °. . The nozzle includes six flutes with a flute helix angle of 20 degrees and a flute attack angle of 7 degrees. The airflow phenomenon includes two secondary air holes having a primary air hole diameter of 5 mm and a primary fluid flow angle of 45 degrees and a 1.5 mm diameter separated by 180 degrees. Secondary fluid flow angle was 25 degrees. The nozzle recess was 2 mm and the forming distance between the die and the receiver was 15 cm. Under these conditions, the average fiber diameter was 24 microns and the web formed from the extruded fibers had a density of about 0.150 g / cm 3 and an average shot using an optical microscope of 0.0098 mm 2.

(Example 4)

Styrene-ethylene-butylene-styrene, designated by KRATON G-2740X manufactured by Shell Chemicals, was extruded at a melt temperature of 238 ° C with a yield of 3.7 g at 586 kpa melt pressure. The fiberizing fluid had an air temperature of 263 ° C. and a flow volume of 120 liters of air per minute per nozzle. The nozzle located in the die housing has a diameter of the first axial portion of 12 mm, a diameter of the cylindrical end portion of 4 mm, and a diameter of the resin discharge hole of 1 mm with an angle of 45 ° truncated cone portion. . The nozzle includes six flutes with a flute helix angle of 20 degrees and a flute attack angle of 45 degrees. The airflow shape includes two secondary air holes having a primary air hole diameter of 4 mm and a primary fluid flow angle of 45 degrees and a 1.5 mm diameter separated by 45 degrees. Secondary fluid flow angle was 45 °. The nozzle recess was 2 mm and the forming distance between the die and the receiver was 23 cm. Under these conditions, the average fiber diameter was 86 microns and the web formed from the extruded fibers had a density of about 0.161 g / cm 3 and an average shot using an optical microscope of 0.025 mm 2.

(Example 5)

Asphalt Tau 6814 Polyethylene manufactured by Dow Chemical Co., Ltd. Polymer with a weight of 83%, 12% Allied Chemical A-9-9 polyethylene and 1% absorbent at 18.9 g per hole per minute with 4% blue polyethylene coloring and 2758 kpa melt pressure The output was extruded at a melting temperature of 232 ° C. The fiberizing fluid had an air temperature of 210 ° C. and a flow rate of 384 liters of air per minute per nozzle. The nozzle located within the die housing has a diameter of the first axial portion of 12 mm, a diameter of the cylindrical end portion of 5 mm, and a diameter of the resin discharge hole of 1 mm with an angle of a truncated cone portion of 45 °. . The nozzle includes six flutes with a flute helix angle of 20 degrees and a flute attack angle of 7 degrees. The airflow shape includes two secondary air holes having a primary air hole diameter of 5 mm and a primary fluid flow angle of 45 degrees and a 2 mm diameter separated by 180 degrees. Secondary fluid flow angle was 45 °. The nozzle recess was 4 mm and the forming distance between the die and the receiver was 54 cm. Under these conditions, the average fiber diameter was 21 microns and the web formed from the extruded fibers had a density of about 0.072 g / cm 3 and an average shot using an optical microscope of 0.24 mm 2.

(Example 6)

Highmond PF-015 polypropylene, 5834 blue polypropylene color concentrate, and 2.5% absorbent from 4.0% Standage Color Inc. were extruded at a melt temperature of 235 ° C. at a yield of 18.9 g per hole per minute at a melt pressure of 1172 kpa. The fiberizing fluid had an air temperature of 235 ° C. and a flow rate of 266 liters of air per minute per nozzle. The nozzle located in the die housing has a diameter of the first axial portion of 12 mm, a diameter of the cylindrical end portion of 5 mm, and a diameter of the 1 mm resin drain hole with an angle of 45 ° truncated cone portion. . The nozzle includes six flutes with a flute helix angle of 20 degrees and a flute attack angle of 7 degrees. The airflow shape includes two secondary air holes having a primary air hole diameter of 4 mm and a 1.5 mm diameter with a primary fluid flow angle of 45 degrees. Secondary fluid flow angle was 45 °. The nozzle recess was 2 mm and the forming distance between the die and the receiver was 48 cm. Under these conditions, the average fiber diameter was 21 microns and the web formed from the extruded fibers had a density of about 0.080 g / cm 3 and an average shot using an optical microscope of 0.11 mm 2.

(Example 7)

Profax PF-015 polypropylene was extruded at a melt temperature of 260 ° C. with a yield of 2.8 g per hole per minute at a melt pressure of 103 kpa. The fiberizing fluid had an air temperature of 260 ° C. and a flow volume of 545 liters of air per minute per nozzle. The nozzle located in the die housing has a diameter of the first axial portion of 12 mm, a diameter of the cylindrical end portion of 1.25 mm, and a diameter of the resin discharge hole of 1 mm with an angle of a truncated conical portion of 30 °. . The nozzle does not have a flute. The airflow configuration includes two secondary air holes having a primary air hole diameter of 1.5 mm and a 1.5 mm diameter with a primary fluid flow angle of 30 degrees. Secondary fluid flow angle was 45 °. The nozzle recess distance was 0.5 mm and the forming distance between the die and the receiver was 48 cm. Under these conditions, the average fiber diameter was 2.3 microns and the web formed from the extruded fibers had a density of about 0.069 g / cm 3 and an average shot using an optical microscope of 0.034 mm 2.

(Example 8)

Highmond Propax PF-015 polypropylene was extruded at a melt temperature of 260 ° C. with a yield of 148 g per hole per minute at a melt pressure of 1710 kpa. The fibrous fluid had an air temperature of 260 ° C. and a flow volume of 1558 liters of air per minute per nozzle. The nozzle located in the die housing has a diameter of the first axial portion of 12 mm, a diameter of the cylindrical end portion of 1 mm, and a diameter of the resin discharge hole of 1 mm with an angle of a truncated conical portion of 45 °. . The nozzle has an airflow phenomenon that includes six flutes with a flute spiral angle of 20 degrees and a flute attack angle of 7 degrees. The nozzle has a primary air hole diameter of 5 mm and a 1.5 mm diameter separated from a primary fluid flow angle of 45 degrees and 180 degrees. It includes two secondary air holes. Secondary fluid flow angle was 45 °. The nozzle recess distance was 2 mm and the forming distance between the die and the receiver was 38 cm. Under these conditions, the average fiber diameter was 30 microns and the web formed from the extruded fibers had a density of about 0.069 g / cm 3 and an average shot using an optical microscope of 0.30 mm 2.

(Example 9)

Highmond Propax PF-015 polypropylene was extruded at a melt temperature of 260 ° C. with a yield of 37 g per hole per minute at a melt pressure of 690 kpa. The fiberizing fluid had an air temperature of 260 ° C. and a flow rate of 651 liters of air per minute per nozzle. The nozzle located within the die housing has a diameter of the first axial portion of 12 mm, a diameter of the cylindrical end portion of 5 mm, and a diameter of the resin discharge hole of 1 mm with an angle of a truncated conical portion of 45 °. . The nozzle includes six flutes with a flute helix angle of 20 degrees and a flute attack angle of 7 degrees. The airflow phenomenon includes two secondary air holes having a primary air hole diameter of 5 mm and a primary fluid flow angle of 45 degrees and a 1.5 mm diameter separated by 180 degrees. Secondary fluid flow angle was 45 °. The nozzle recess was 2 mm and the forming distance between the die and the receiver was 38 cm. Under these conditions, the average fiber diameter was 3.1 microns and the web formed from the compressed fibers had a density of about 0.049 g / cm 3 and an average shot using an optical microscope of 0.078 mm 2.

(Example 10)

The Arnitel EM-450 polyether polymer prepared by arc irradiation was extruded at a melting temperature of 266 ° C. at a yield of 2.95 g per hole per minute at a melting pressure of 869 kpa. The fiberizing fluid had an air temperature of 264 ° C. and a flow rate of 404 liters of air per minute per nozzle. The nozzle located in the die housing has a diameter of the first axial portion of 12 mm, a diameter of the cylindrical end portion of 5 mm, and a diameter of the 1 mm resin drain hole with an angle of 45 ° truncated cone portion. . The nozzle includes six flutes with a flute helix angle of 20 degrees and a flute attack angle of 7 degrees. The airflow phenomenon includes two secondary air holes having a primary air hole diameter of 5 mm and a primary fluid flow angle of 45 degrees and a 1.5 mm diameter separated by 180 degrees. Secondary fluid flow angle was 25 degrees. The nozzle recess was 2 mm and the forming distance between the die and the receiver was 24 cm. Under these conditions, the average fiber diameter was 12 microns and the web formed from the extruded fibers had a density of about 0.104 g / cm 3 and an average shot using an optical microscope of 0.058 mm 2.

(Example 11)

Himond Profax PF-015 polypropylene was extruded at a melt temperature of 260 ° C. at a yield of 23 g per hole per minute at a melt pressure of 193 kpa. The fiberizing fluid had an air temperature of 274 ° C. and a flow rate of 375 liters of air per minute per nozzle. The nozzle located in the die housing has a diameter of the first axial portion of 12 mm, a diameter of the cylindrical end portion of 4 mm, and a diameter of 0.5 mm of resin drain hole with an angle of 45 ° truncated conical portion. . The nozzle has an airflow shape comprising six flutes with a flute spiral angle of 20 degrees and a flute attack angle of 7 degrees, a primary air hole diameter of 5 mm, a primary fluid flow angle of 45 degrees, and a 2 mm diameter separated from 180 degrees. It includes two secondary air holes. Secondary fluid flow angle was 45 °. The nozzle recess was 2 mm and the forming distance between the die and the receiver was 13 cm. Under these conditions, the average fiber diameter was 5.7 microns and the web formed from the compressed fiber had a density of about 0.035 g / cm 3 and an average shot using an optical microscope of 0.079 mm 2.

(Example 12)

Profax PF-015 polypropylene was extruded at a melt temperature of 260 ° C. with a yield of 0.34 g per hole per minute at a melt pressure of 69 kpa. The fiberizing fluid had an air temperature of 304 ° C. and a flow rate of 136 liters of air per minute per nozzle. The nozzle located in the die housing has a diameter of the first axial portion of 12 mm, a diameter of the cylindrical end portion of 1.25 mm, and a diameter of 0.5 mm of resin discharge hole with an angle of a truncated cone portion of 30 °. . The nozzle does not have a flute. The airflow shape includes two secondary air holes having a primary air hole diameter of 4 mm and a primary fluid flow angle of 45 degrees and a 1.5 mm diameter separated by 180 degrees. Secondary fluid flow angle was 45 °. The nozzle recess was 2 mm and the forming distance between the die and the receiver was 39 cm. Under these conditions, the average fiber diameter was 2.0 microns and the web formed from the extruded fibers had a density of about 0.039 g / cm 3 and an average shot using an optical microscope of 0.020 mm 2.

(Example 13)

Himond Profax PF-015 polypropylene was extruded at a melt temperature of 260 ° C with a yield of 38.4 g per hole per minute at a melt pressure of 462 kpa. The fiberizing fluid had an air temperature of 260 ° C. and a flow volume of 1104 liters of air per minute per nozzle. The nozzle located in the die housing has a diameter of the first axial portion of 12 mm, a diameter of the cylindrical end portion of 5 mm, and a diameter of the resin drain hole of 2 mm with an angle of 45 ° truncated conical portion. . The nozzle includes six flutes with a flute helix angle of 20 degrees and a flute attack angle of 7 degrees. The airflow shape includes two secondary air holes having a primary air hole diameter of 5 mm and a primary fluid flow angle of 45 degrees and a 1.5 mm diameter separated by 180 degrees. Secondary fluid flow angle was 45 °. The nozzle recess was 2 mm and the forming distance between the die and the receiver was 38 cm. Under these conditions, the average fiber diameter was 3.3 microns and the webs formed from the compressed fibers had a density of about 0.095 g / cm 3 and an average shot using an optical microscope of 0.14 mm 2.

(Example 14)

Highmond Propax PF-015 polypropylene was extruded at a melt temperature of 260 ° C. with a yield of 38.3 g per hole per minute at a melt pressure of 283 kpa. The fiberizing fluid had an air temperature of 260 ° C. and a flow rate of 651 liters of air per minute per nozzle. The nozzle located in the die housing has a diameter of the first axial portion of 12 mm, a diameter of the cylindrical end portion of 5 mm, and a diameter of the resin discharge hole of 3 mm with an angle of a truncated conical portion of 45 °. . The nozzle has an airflow shape comprising six flutes with a flute spiral angle of 20 degrees, a flute attack angle of 7 degrees, a primary air hole diameter of 5 mm, a 1.5 mm diameter separated from a primary fluid flow angle of 45 degrees, and 180 degrees. It includes two secondary air holes. Secondary fluid flow angle was 45 °. The nozzle recess was 2 mm and the forming distance between the die and the receiver was 38 cm. Under these conditions, the average fiber diameter was 3.1 microns and the web formed from the extruded fibers had a density of about 0.065 g / cm 3 and an average shot using an optical microscope of 0.075 mm 2.

From the above embodiments, the apparatus and method of the present invention allow the formation of fibers and the formation of nonwoven webs from a wide variety of polymers under various conditions. Under the best conditions, the meltblown facility can typically process the surface polymer at flow rates of up to 3 g per nozzle per minute. Some polymers do not allow these yields due to the risk of the zipper ring of the meltblown die. In contrast, the apparatus and method of the present invention are capable of treating polymers at flow rates as high as 150 g per nozzle per minute. At the port, this high output capability follows the high melt pressure potential of the nozzle. As described in the Examples, the melt pressure of 2758 kpa or more can be tolerated. Other experiments showing a high melt pressure of 6900 kpa can withstand failure of the plant. It is believed that the meltblown die tip pressure has a maximum pressure of 2100 kpa. Therefore, the apparatus of the present invention may be used in single or multiple die structures, which will far exceed current meltblowing capabilities per nozzle. As a result, the device of the present invention may be used in areas where the closed space is critical. In addition, the device can be used to produce localized fiber formation thereby allowing the production of nonwoven webs having a wide range of changes in their basis weight. Nonwoven webs with variables at their basis weights above 10% are produced by local increases and / or decreases in fiber formation in both or one side of the processing direction and the transverse direction. Thus, the apparatus and method of the present invention can apply a wide range of variables to improve current nonwoven forming techniques.

Although the present invention has been described in an illustrative manner, the present invention is not limited to the above embodiments, and the present invention may be modified and modified by the technical spirit. Therefore, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described above.

Claims (69)

A method for forming fibers from a fiber forming resin, the method comprising: (a) forming a flow in which the resin extends along a first axis from a die housing having a resin discharge hole, and (b) completely surrounding and contacting the flow of resin Fibrating the resin to form fibers by a flow of primary fibrinating fluid, wherein the primary fibrous fluid contacts the flow of resin at a primary fluid flow angle between about 15 degrees and 60 degrees, Is measured by the internal angle between the intersection of the first axis of the flow of resin and the line tangential to the flow of the primary fibrosis fluid. The method of claim 1, comprising collecting the fibers in the form of a nonwoven web. The resin of claim 1, wherein the resin is further contacted with the resin having a flow of secondary fibrous fluid comprising at least two fluid flows that respectively strike the resin at a secondary fluid flow angle between about 1 degree and about 45 degrees. Fiberizing, wherein the angle is measured as an internal angle between the intersection of the first axis to the flow of resin and the line tangential to the flow of the fluid flow. The method of claim 1 wherein the flow of resin is at a melt pressure of 6900 kpa or less. 4. The method of claim 3 wherein said flow of resin is at a melt pressure of 6900 kpa or less. 6. The method of claim 5 wherein said flow of resin is an output of about 0.1 to 151 g per nozzle per minute. 6. The method of claim 5 wherein said flow of resin is an output of about 0.75 to 38.0 g per nozzle per minute. 7. The method of claim 6, wherein the primary fibrillation fluid of the resin flows at a rate of about 57 to 1558 liters per minute. 7. The method of claim 6, wherein said primary fibrosis fluid flows at a rate of about 57 to 708 liters per minute. The method of claim 1. And wherein said angle of said primary fiberizing fluid flow is helical about said first axis of said flow of resin. 4. The method of claim 3, comprising the step of causing said angle of said primary fibrillation fluid flow to be helical about said first axis of said flow of resin. 3. The method of claim 2, wherein the collection of the fibers in the form of a nonwoven web occurs about 7.5 to 102 cm away from the resin outlet aperture. 3. The method of claim 2 wherein the collection of said fibers in the form of a nonwoven web occurs about 15 to 64 cm away from said resin outlet aperture. 10. The method of claim 8, wherein said primary fiberizing fluid is under input between about 6.9 and 317 kpa. 10. The method of claim 8, wherein said primary fiberizing fluid is under input between about 6.9 and 172 kpa. 15. The method of claim 14, wherein said primary fibrosis fluid is under input between about 137 ° C and 344 ° C. 17. The method of claim 16 wherein the resin outlet aperture has a diameter between about 0.25 and 3.0 mm. 17. The method of claim 16 wherein the resin outlet aperture has a diameter between about 0.5 and 1.0 mm. A method for forming a fiber from a fiber forming resin, the method comprising: (a) forming a flow in which the resin extends along a first axis from a die housing having a resin discharge hole, and (b) completely surrounding and contacting the flow of resin. Fibrating the resin to form fibers by flow of the primary fibrosis fluid, wherein the primary fibrosis fluid is in contact with the flow of resin at a primary fluid flow angle between about 15 and 60 degrees and the angle of the resin Measure an internal angle between the intersection of the first axis of the flow and the line tangential to the flow of the primary fibrous fluid, the primary fibrous fluid having a flow rate between about 57 and 1558 liters per minute having a pressure between about 6.9 and 317 kpa (c) at least two fluid flows each costing the resin with a secondary fluid flow between about 1 degree and about 45 degrees. Contacting the resin with a flow of a secondary fiberizing fluid, the fiber comprising further fiberizing the resin, wherein the angle is an angle between the intersection of the first axis of the flow of resin and the line tangential to the flow of the fluid flow. And (d) the collection of the fibers in the form of a nonwoven web occurs about 7.5 to 102 cm away from the resin outlet aperture. A method for forming fibers from a fiber forming resin, wherein (a) each assembly has a resin chamber for containing the molten fiber forming resin and a resin discharge hole in fluid communication with the chamber for discharging the resin; A plunger is retracted from the resin discharge hole to allow the flow of the resin from the hole and the plunger is in contact with the resin discharge hole to prevent the flow of the resin from the open position and the hole and in the resin chamber in the closed position. Further comprising a plunger capable of shrinkage and pumping the molten fiber forming resin into at least one die assembly, and (b) intermittent extending along a respective first axis of resin from the outlet hole with the plunger in an open position; One or more from closed position to gang position in the form of flow Contracting the plunger, (c) selectively circulating the plunger between the open and closed positions to stop one or more of the flows of resin, and (d) collecting the fibers in the form of a nonwoven web. Fiber forming method comprising the step. 21. The method of claim 20, further comprising fiberizing the fibrous flow to form fibers by a flow of primary fibrous fluid in full encirclement and contact with each respective flow of resin, wherein the primary fibrous fluid is from about 15 to 60 Contacting said respective resin flow with a primary fluid flow angle between degrees, said angle tangential to the intersection of the first axis of each said flow of resin and the flow of said primary fibrous fluid with respect to said individual flow of resin. The fiber forming method characterized by measuring the cabinet. 22. The method of claim 21, wherein the fibers are collected in contact with the respective resin flow with a flow of secondary fibrous fluid comprising at least two fluid flows each striking the resin flow at a secondary fluid flow angle between about 1 and 45 degrees. Further fiberizing the fiber flow, wherein the angle measures an internal angle between the intersection of the first axis of the flow of resin and the line tangential to the flow of the secondary fiberizing fluid with respect to the individual flow of resin. The fiber formation method characterized by the above-mentioned. 23. The method of claim 22, comprising the step of causing said angle of said primary fibrillation fluid flow to be helical about said first axis of said flow of resin. 21. The method of claim 20, wherein said interruption of said flow of resin results in the formation of a separate nonwoven web. 21. The method of claim 20, wherein said interruption of said flow of resin results in the formation of a variable nonwoven fabric within a basis weight of at least 10%. 22. The method of claim 21, wherein said interruption of said flow of resin results in the formation of a separate nonwoven web. 22. The method of claim 21 wherein the interruption of the flow of resin results in the formation of a variable nonwoven with a basis weight of at least 10%. An apparatus for forming fibers from a fiber forming resin, the apparatus comprising a chamber having a resin discharge hole in fluid communication for discharging the molten resin in the form of a flow defining a first axis for receiving a supply of molten fiber forming resin And a housing and primary fiberizing means completely surrounding the resin discharge hole for extracting the resin into the fiber. 29. A fiber forming apparatus according to claim 28, comprising collecting means for receiving said fibers in the form of a nonwoven web. 29. The fluid in the die housing of claim 28 wherein the fiberizing means completely encircles the flow of the resin from the resin outlet opening and the primary fibrous fluid exiting the fluid discharge port for fiberizing the resin to form fibers. And a discharge port, wherein the primary fiberizing fluid adheres to the flow of resin at a primary fluid flow angle of between about 15 and 60 degrees, the angle being at the intersection of the first axis of the flow of resin and the flow of the primary fibrous fluid. A fiber forming apparatus, characterized in that it is measured by a cabinet between tangent lines. 31. The fiber forming apparatus of claim 30, wherein the resin comprises secondary fiberizing means located externally from the primary fiberizing means for supplying a further fiberizing secondary fiberizing fluid. 32. The secondary fibrous fluid of claim 31, wherein the secondary fibrous fluid comprises a secondary fibrous fluid comprising at least two fluid flows each striking the flow of resin at a secondary fluid flow angle between about 1 and 45 degrees, the angle being a resin. And an internal angle between the intersection of the first axis of the flow and the line tangential to the flow of the primary fibrous fluid. 33. The apparatus of claim 32 wherein at least two of said fluid flows are symmetrically spaced radially and circumferentially about said first axis externally from said fluid discharge port. 31. The fiber of claim 30, wherein the die housing has an inner surface that forms one plane with the fluid discharge port that lies substantially in the same plane defined by the resin outlet hole and the outer surface of the housing. Forming device. 35. The fluid discharge port of claim 34 wherein the fluid discharge port is substantially lying in the plane defined by the inner surface of the die housing and into the die housing at a distance no greater than 5 mm when measuring the resin discharge hole from the plane. Fiber forming apparatus characterized in that it entered. 33. The fiber forming apparatus according to claim 32, wherein the resin discharge hole has a diameter of about 0.25 to 3.0 mm. 37. The apparatus of claim 36 wherein the fluid discharge port has a diameter between about 3 and 5 mm. 33. The fiber forming apparatus of claim 32, wherein the primary and secondary fiberizing fluids are supplied from a separate supply of fluids. 33. The device of claim 32, comprising a nozzle terminated in the fluid discharge port and at least partially surrounded by and located within the fibrous fluid chamber, wherein the nozzle comprises the resin chamber and the resin discharge hole. Fiber forming device. 40. The apparatus of claim 39 wherein the nozzle is removably retained in the die housing. 40. The surface of claim 39, wherein an outer surface of the nozzle comprises a first axial portion having a predetermined first radial extension and a LAN lamp surface comprising the resin discharge hole extending and a predetermined second smaller than the first radial extension. And an axial end portion having a radial extension, wherein the nozzle comprises a tapered axial portion extending between the first axial portion and the axial end portion. 40. The fiber forming apparatus of claim 39, wherein the nozzle has a nozzle outer surface and a plurality of flutes adjacent the resin discharge hole for directing the nozzle outer surface to the primary fibrous fluid. 43. The apparatus of claim 42 wherein the nozzle has a flute attack angle of about 7 to 60 degrees. 43. The apparatus of claim 42 wherein the nozzle has a flute helix angle of about 20 to 45 degrees. 43. The apparatus of claim 42 wherein the nozzle has a truncated conical angle of about 15 to 60 degrees. 43. The predetermined surface of claim 42, wherein the outer surface of the nozzle has a land surface including a first axial portion with a predetermined first radial extension and a land surface including the resin ejection aperture extending therefrom. An axial end portion with two radial extensions, the nozzle including a tapered axial portion extending between the first axial portion and the axial end portion, the tapered weight portion being a plurality of And a flute, said flute extending into said land surface. 47. The fiber forming apparatus of claim 46, wherein the axial end portion comprises a substantially cylindrical outer surface comprising the flute. An apparatus for forming fibers from a fiber forming resin, the apparatus comprising a resin chamber having a resin discharge hole in fluid communication for discharging the molten resin in the form of a flow defining a first axis to receive a supply of molten fiber forming resin Primary fiberizing means completely surrounding the resin discharge hole for drawing the die housing and the resin into fibers, and primary fiberizing means for discharging the primary fiberizing fluid and the resin discharged from the fluid discharge port for fiberizing the resin to form fibers A fluid drain port in the die housing completely surrounding the flow of resin from the aperture, wherein the fluid drain port has a weave between about 3 to 5 mm and the primary fibrous fluid is between about 15 to 60 degrees In contact with said flow of resin at a fluid flow angle, Is measured as the internal angle between the intersection of the first axis of the flow of resin and the line tangential to the flow of the primary fibrillar fluid, and between the intersection of the line tangential to the flow of the fluid flow and the first axis of the flow of the resin A secondary fiberizing means located externally from said primary fiberizing means having a secondary fibrous fluid comprising at least two fluid flows each striking a secondary fluid flow between about 1 and 45 degrees measured in an interior angle, said die The housing further comprises a nozzle at least partially enclosed in and positioned within the fibrous fluid chamber terminating in the fluid discharge port, the nozzle including the resin outlet hole and the resin chamber, the nozzle further comprising a nozzle outer surface. And the nozzle outer surface is inserted into the resin discharge hole so as to face the primary fiberizing fluid. Having a plurality of flutes, the nozzle having a flute attack angle of about 7 to 60 degrees, a flute helix angle of about 20 to 45 degrees, and a conical angle of about 15 to 60 degrees, the nozzle outer surface extending to a predetermined first radial extension And an axial end portion having a first axial portion having a portion and a land surface including the resin discharge hole extending and a predetermined second radial extension smaller than the first radial extension, wherein the nozzle comprises the first axis. And a tapered axial direction extending between the directional portion and the axial end portion, the tapered axial portion comprising a plurality of the flutes, the flutes extending into the land surface. . An apparatus for intermittently forming fibers from a fiber forming resin, comprising: (a) a die housing and (b) discharging the molten resin in the form of a flow forming a first axis to accommodate a supply of molten fiber forming resin A die assembly located in the housing including a resin chamber having a resin discharge hole in fluid communication; (c) fiberizing means for drawing the melt flow into fibers; and (d) flow of the melt from the resin discharge hole. And an on / off control means for selectively stopping the. 50. The apparatus according to claim 49, wherein the on / off control means includes a plunger in a closed position in the resin chamber and the plunger is in contact with the resin discharge hole for preventing the flow of the molten resin from the hole and the open position. And the plunger is retracted from the hole to allow flow of the molten resin from the hole. 51. The apparatus of claim 50, wherein the die housing comprises a hydraulic chamber, the plunger comprising an end portion extending into the hydraulic chamber and a piston mounted therein, the chamber extending the plunger between the open and closed positions. And a hydraulic fluid port opened into said hydraulic chamber for supplying fluid pressure by changing on each side of said piston to reciprocate said piston in said hydraulic chamber for movement. 52. The fiber forming apparatus of claim 51, wherein the fiberizing means comprises a primary fiberizing fluid that completely surrounds the flow of molten resin. 53. The apparatus of claim 52 wherein the die housing includes a fluid discharge port that completely encloses the resin discharge aperture for discharging the primary fiberizing fluid. An apparatus for forming a nonwoven web of basic weight varying from fiber forming resin, comprising: (a) a die housing and (b) a molten fiber forming resin having a resin discharge hole in fluid communication for discharging the molten resin in the form of a flow A plurality of die assemblies comprising a resin chamber for receiving a supply of carbon fiber, and (c) fiberizing means for drawing fibers collected in the form of a nonwoven web from the flow of the molten resin, and (d) And an on / off control means for selectively stopping the flow of the resin from at least one of the resin discharge holes to change the concentration of the nonwoven web. 55. The apparatus of claim 54, wherein said on / off control means includes a plunger in said resin chamber having a closed position and said plunger is in contact with said resin discharge aperture for preventing flow of said molten resin from said aperture and an open position. And the plunger is retracted from the hole to allow flow of the flow resin from the hole. 56. The apparatus of claim 55, wherein the die housing comprises a hydraulic chamber, the plunger comprising an end portion extending into the hydraulic chamber and a piston mounted therein, wherein the chamber is located between the open and closed positions. And a hydraulic fluid port opened into said hydraulic chamber for supplying a varying fluid pressure on each side of said piston to reciprocate said piston in said hydraulic chamber to move the piston. An apparatus for forming individual nonwoven webs from a fiber forming resin by a continuous molding method, comprising: (a) a die housing and (b) a resin discharge hole in fluid communication for discharging the molten resin in the form of a flow extending along a first axis At least one die assembly comprising a resin chamber for accommodating a supply of molten fiber forming resin, and positioned within the housing; and (c) fibrosis for drawing fibers collected in the form of a nonwoven web to flow the molten resin. Means and (d) on / off control means for selectively stopping the flow of the resin from the resin outlet aperture to form the individual nonwoven web. 58. The apparatus of claim 57, wherein the on / off control means includes a plunger in the resin chamber, the plunger has a closed position and the plunger discharges the resin to prevent flow of the molten resin from the aperture and the open position. And the plunger is in contact with the hole and retracts from the hole to allow flow of the molten resin from the hole. 59. The apparatus of claim 58, wherein the die housing comprises a hydraulic chamber, the plunger comprising an end portion extending into the hydraulic chamber and a piston mounted therein, the chamber extending the plunger between the open and closed positions. And a hydraulic fluid port open into said hydraulic chamber for supplying varying fluid pressure on each side of said piston for reciprocating said piston in said hydraulic chamber for movement. 60. The fluid discharge of claim 59 wherein the fiberizing means is fluid discharged within the die housing completely enclosing the primary fiberizing fluid exiting the fluid drain port and the resin flow from the resin drain hole to fiber the resin to form a fiber. And a port, wherein the primary fiberizing fluid is in contact with the flow of resin at a primary fluid flow angle between about 15 and 60 degrees, the angle being at the intersection of the first axis of flow of the resin and the flow of the primary fiberizing fluid. An individual nonwoven web forming apparatus, characterized in that it is measured at an angle between tangent lines. 61. The method of claim 60, wherein the fiberizing means comprises a secondary fibrous fluid comprising at least two fluid flows that strike the flow of the resin at a secondary fluid flow angle of between about 1 and 45 degrees, wherein the angle of the resin An individual nonwoven web forming apparatus, characterized by a cabinet angle between an intersection of a first axis of flow and a line tangential to the fluid flow. 62. The apparatus of claim 61, wherein the die housing comprises a nozzle at least partially surrounded by and located in the fibrous fluid chamber terminated in the fluid discharge port, wherein the nozzle comprises the resin chamber and the resin discharge hole. Individual nonwoven web forming apparatus, characterized in that. 63. The apparatus of claim 62 wherein the nozzle is removably retained in the die housing. 63. The apparatus of claim 62 wherein the nozzle has a nozzle outer surface, the nozzle outer surface having a plurality of flutes adjacent the resin outlet aperture for directing the primary fibrillation fluid. 66. The resin discharge of claim 64 wherein the outer surface of the nozzle has a first axial portion with a predetermined first radial extension and a predetermined second radial extension from the first radial extension and extends therein. And an axial end portion having a land surface including a hole, wherein the nozzle extends into the land surface including the first axial portion and a plurality of the flutes. 66. The apparatus of claim 65 wherein the end portion comprises a substantially cylindrical outer surface including the flute. 67. The apparatus of claim 66 wherein the nozzle has a flute attack angle of about 7 to 60 degrees. 68. The apparatus of claim 67 wherein the nozzle has a flute helix angle of about 20 to 45 degrees. 69. The apparatus of claim 68 wherein the nozzle has a truncated cone angle of about 15 to 60 degrees.

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