초록

An apparatus is disclosed for forming a non-woven web.

대표청구항 ▼

1. An apparatus for producing a non-woven web comprising: a) a die block having a cavity and an inlet connected to said cavity which conveys a molten material therethrough, said die block also having a gas passage formed therethrough for conveying pressurized gas, said gas passage having an inside d

1. An apparatus for producing a non-woven web comprising: a) a die block having a cavity and an inlet connected to said cavity which conveys a molten material therethrough, said die block also having a gas passage formed therethrough for conveying pressurized gas, said gas passage having an inside diameter;b) an insert positioned in said gas passage having an inside diameter and an outside diameter, a major portion of said outside diameter being smaller than said inside diameter of said gas passage to form a gas chamber therebetween;b) a spinnerette body secured to said die block having a gas chamber, and a gas passageway connecting said gas chamber to said gas passage;c) a plurality of nozzles and a plurality of stationary pins secured to said spinnerette body, said plurality of nozzles and said plurality of stationary pins being grouped into an array forming a plurality of rows and a plurality of columns, said array having a periphery, and each of said plurality of nozzles being connected to said cavity;d) a gas distribution plate secured to said spinnerette body having a plurality of first, second and third openings formed therethrough, each of said first openings accommodating one of said nozzles, each of said second openings accommodating one of said stationary pins, and each of said third openings being located adjacent to said first and second openings;e) an exterior member secured to said gas distribution plate having a plurality of first and second enlarged openings formed therethrough, each of said first enlarged openings surrounding one of said nozzles and each of said second enlarged openings surrounding one of said stationary pins, said array having at least one row and at least one column of said second enlarged openings which are located adjacent to said periphery, whereby an extruded filament exiting each of said nozzles is shrouded by pressurized gas exiting each of said first enlarged openings, and all of said extruded filaments are shrouded by pressurized gas exiting said second enlarged openings from surrounding ambient air, and said exterior member having a lower surface with a pair of cover strips secured to said lower surface, said pair of cover strips facilitating the flow of ambient air around said pressurized gas exiting through at least some of said second enlarged openings; andf) a moving surface located downstream of said exterior member onto which said fibers are collected into a non-woven web. 2. The apparatus of claim 1 wherein said gas chamber provides thermal insulation between said insert and said die block. 3. The apparatus of claim 1 wherein said inserts are formed from ceramic. 4. The apparatus of claim 1 wherein said outside diameter of said insert is coated with a thermal insulating coating. 5. The apparatus of claim 4 wherein said thermal insulating coating is ceramic. 6. The apparatus of claim 1 wherein said inside diameter of said air passage is coated with a thermal insulating coating. 7. The apparatus of claim 1 wherein said gas chamber has an interior surface which is coated with a thermal insulating coating. 8. The apparatus of claim 1 wherein said gas passageway is coated with a thermal insulating coating. 9. The apparatus of claim 1 wherein each of said plurality of nozzles and each of said plurality of stationary pins have an exterior surface which is coated with a thermal insulating coating. 10. An apparatus for producing a non-woven web comprising: a) a die block having a cavity and an inlet connected to said cavity which conveys a molten material therethrough, said die block also having a gas passage formed therein for conveying pressurized gas, said gas passage having an inside diameter;b) a ceramic insert positioned in said gas passage having an inside diameter and an outside diameter, a major portion of said outside diameter being smaller than said inside diameter of said gas passage to form a gas chamber therebetween;b) a spinnerette body secured to said die block having a gas chamber, and a gas passageway connecting said gas chamber to said gas passage;c) a plurality of nozzles and a plurality of stationary pins secured to said spinnerette body, said plurality of nozzles and said plurality of stationary pins being grouped into an array forming a plurality of rows and a plurality of columns, said array having a periphery, and each of said plurality of nozzles being connected to said cavity;d) a gas distribution plate secured to said spinnerette body having a plurality of first, second and third openings formed therethrough, each of said first openings accommodating one of said nozzles, each of said second opening accommodating one of said stationary pins, and each of said third openings being located adjacent to said first and second openings;e) an exterior member secured to said gas distribution plate having a plurality of first and second enlarged openings formed therethrough, each of said first enlarged openings surrounding one of said nozzles and each of said second enlarged openings surrounding one of said stationary pins, said array having at least one row and at least one column of said second enlarged openings which are located adjacent to said periphery, whereby an extruded filament exiting each of said nozzles is shrouded by pressurized gas exiting each of said first enlarged openings, and all of said extruded filaments are shrouded by pressurized gas exiting said second enlarged openings from surrounding ambient air, and said exterior member having a lower surface with a pair of cover strips secured to said lower surface, said pair of cover strips facilitating the flow of ambient air around said pressurized gas exiting through at least some of said second enlarged openings;f) an aspirator located downstream of said exterior member through which said filaments pass, said filaments being attenuated into fibers by gas travelling through said aspirator at a velocity that is at least two times greater than the velocity of said pressurized gas exiting said first and second openings formed in said exterior member; andg) a moving surface located downstream of said aspirator onto which said fibers are collected into a non-woven web. 11. The apparatus of claim 10 wherein said inside diameter of said gas passage is coated with a thermal insulating coating. 12. The apparatus of claim 10 wherein said a vacuum chamber is positioned adjacent to said moving surface and applies a vacuum to said non-woven web to remove ambient air therefrom. 13. The apparatus of claim 12 wherein a bonder is positioned downstream of said vacuum chamber for bonding said non-woven web. 14. The apparatus of claim 10 wherein said pair of cover strips is formed from stainless steel. 15. The apparatus of claim 10 wherein said plurality of second enlarged openings formed in said exterior member surround all of said plurality of first enlarged openings formed in said exterior member. 16. An apparatus for producing a non-woven web comprising: a) a die block having a cavity and an inlet connected to said cavity which conveys a molten material therethrough, said die block also having a gas passage formed therein for conveying pressurized gas, said gas passage having an inside diameter;b) an insert positioned in said gas passage having an inside diameter and an outside diameter, a major portion of said outside diameter being smaller than said inside diameter of said gas passage to form a gas chamber therebetween;b) a spinnerette body secured to said die block having a gas chamber, and a gas passageway connecting said gas chamber to said gas passage;c) a plurality of nozzles and a plurality of stationary pins secured to said spinnerette body, said plurality of nozzles and said plurality of stationary pins being grouped into an array forming a plurality of rows and a plurality of columns, said array having a periphery, and each of said plurality of nozzles being connected to said cavity;d) a gas distribution plate secured to said spinnerette body having a plurality of first, second and third openings formed therethrough, each of said first openings accommodating one of said nozzles, each of said second opening accommodating one of said stationary pins, and each of said third openings being located adjacent to said first and second openings;e) an exterior member secured to said gas distribution plate having a plurality of first and second enlarged openings formed therethrough, each of said first enlarged openings surrounding one of said nozzles and each of said second enlarged openings surrounding one of said stationary pins, said array having at least one row and at least one column of said second enlarged openings which are located adjacent to said periphery, whereby an extruded filament exiting each of said nozzles is shrouded by pressurized gas exiting each of said first enlarged openings, and all of said extruded filaments are shrouded by pressurized gas exiting said second enlarged openings from surrounding ambient air, and said exterior member having a lower surface with a pair of cover strips secured to said lower surface, said pair of cover strips facilitating the flow of ambient air around said pressurized gas exiting through at least some of said second enlarged openings;f) an aspirator located downstream of said exterior member through which said filaments pass, said filaments being attenuated into fibers by gas travelling through said aspirator at a velocity that is at least two times greater than the velocity of said pressurized gas exiting said first and second openings formed in said exterior member;g) a moving surface located downstream of said aspirator onto which said fibers are collected into a non-woven web; andh) a vacuum chamber positioned adjacent to said moving surface which applies a vacuum to said non-woven web to remove ambient air therefrom. 17. The apparatus of claim 16 wherein said pair of cover strips is formed from stainless steel. 18. The apparatus of claim 16 wherein said insert is an elongated cylindrical member having a first end and a second end, each of said first and second ends contain an outward extending flange sized to snuggly fit into said gas passage. 19. The apparatus of claim 18 wherein said outside diameter of said insert, between said first and second flanges, is coated with a thermal insulating coating. 20. The apparatus of claim 16 wherein said gas chamber has an interior surface which is coated with a thermal insulating coating and said gas passageway is coated with a thermal insulating coating.