KR100486802B1 - Method and Apparatus for the Production of Artificial Fibers, Non-Woven Webs and Sorbency Non-Woven Fabrics - Google Patents

Abstract

The method and apparatus for producing synthetic fibers and nonwoven fabrics of the present invention comprise at least one means for generating a substantially continuous fluid stream along a primary axis, at least one for extruding molten resin into fibers while being located adjacent to the continuous fluid stream. An extrusion die, means for conveying fibers of the elementary fluid stream, and disturbing means for producing crimped fibers for producing nonwovens by selectively disturbing the fluid flow of the fluid stream by varying the fluid pressure on either side of the elementary axis. . The manufacturing method of the present invention finely adjusts the properties of nonwoven materials such as tensile strength, porosity, barrier properties, absorbency and softness by varying the disturbance frequency and amplitude of the fluid stream. Finally, the method and apparatus of the present invention may be practiced with meltblown, spunbond and coform techniques to produce nonwovens. The invention also encompasses superabsorbent nonwovens and oil absorption and other applications.

<Representative figure>

6a

Description

Method and Apparatus for Manufacturing Synthetic Fibers, Nonwoven Webs and Absorbent Nonwovens {Method and Apparatus for the Production of Artificial Fibers, Non-Woven Webs and Sorbency Non-Woven Fabrics}

The present invention relates to the production of synthetic fibers, and more particularly to the field of manufacturing synthetic fibers using meltblown, coform and spunbond techniques.

In the manufacture of synthetic fibers, meltblown, coform and spunbond techniques have long been used to produce fibers for the production of nonwoven webs of materials. 1A-3B show conventional apparatus for making nonwoven webs by meltblown and spunbond techniques. Meanwhile, the conventional coform technique is described in detail later.

1A-1C illustrate representative approaches for making meltblown fibers. Referring to FIG. 1A, the hopper 10 includes resin pellets. The extruder 12 melts the resin pellets by conventional heating to form a melt extrudable composition, which is melt blown by the action of a rotating extruder screw (not shown) in the extruder 12 ( 14). As shown in FIG. 1C, the extrusion composition is fed to the orifice 18 through the extrusion slot 28. Die 14 and the gas source supplied through it are heated by a conventional apparatus (not shown).

1B shows die 14 in more detail. The tip 16 of the die 14 has a plurality of meltblown die orifices 18 arranged linearly across it. Referring to FIG. 1C, the inlets 20 and 21 supply heated gas to the plenum chambers 22 and 23. The gas then exits through passages 24 and 25, respectively, to form a gas stream, which traps and thins the polymer or resin yarn that is extruded from orifice 18, FIG. 1A. As shown in FIG.

The meltblown die 14 comprises a die member 36 having a base 38 and a protruding center 39, in which the extrusion slot 28 extends so that a plurality of die members 36 are provided. In fluid communication with the orifice 18, the outer end of the orifice 18 terminates at the die tip. The gaseous fiber stream 26 is blown onto the collecting device, which comprises a porous circulation belt 30 that is driven by roller 31, as shown specifically in FIG. 1A, and the fiber It may be provided with one or more stationary vacuum chambers (not shown) positioned below the collection surface on which the nonwoven web 34 of is formed. The collected entangled fibers form a coherent web 34, a portion of which is shown in plan view in FIG. 2. This web 34 may be separated from the belt 30 by a pair of pinch rollers 33 (shown in FIG. 1A) that compress the tangled fibers. The conventional meltblown apparatus shown in FIGS. 1A-1C may optionally include pattern embossing means (not shown), such as a calender nip or ultrasonic embossing apparatus inscribed with a pattern, and thereafter. The web 34 may be wound on a plenum roll or transferred to the next manufacturing process. Other embossing means, such as pressurization pins between the calender and the anvil roll, may be used, or the embossing step may be omitted.

3A shows a conventional apparatus 44 for making spunbond fibers. This spunbond device is generally equipped with a fiber draw unit 46 located above the endless belt 78 supported by a roller 76. 3b shows the fiber draw apparatus in more detail. The fiber draw apparatus 46 is provided with the longitudinal air chamber which consists of the upper air parts 48 and 50, the upper part 52, the intermediate part 54, and the lower or end pipe 56. As shown in FIG. In addition, the fiber draw apparatus includes a first air plenum 58 and an air inlet 60 extending therefrom to the middle portion 54 of the fiber draw apparatus. The second air plenum 62 is also in communication with the intermediate portion 54 of the fiber draw device via an air inlet 64. The spunbond device 44 has a general device for melting the extruded resin through a die to form the fibers 68. Generally, the apparatus feeds the resin supplied from the feed into a hopper extruder through a filter, and finally a die, to produce fibers 68.

High velocity air enters the fiber draw apparatus through air plenums 58 and 62 via inlets 72 and 74, respectively. The supply of air to the fiber draw apparatus through the inlets 60 and 64 sucks air through the inlets 48 and 50. Air and fibers then exit through the end tube 56 to the discharge zone 70. In general, the air drawn into the fiber draw device through the inlets 48 and 50 draws the fiber 68 through the fiber draw device. The drawn fibers are seated on the endless belt 78 to form the nonwoven web 80, as shown in FIG. 3A. The roller 82 may assist in web formation by removing the nonwoven web from the circulation belt 78 and further compressing the tangled fibers. The web 80 is then combined by embossing with a calendar and anvil, ultrasonic embossing, or other known techniques to form a finished material.

In the process of manufacturing meltblown and spunbond fibers in order to produce fabrics with the required properties, it is well known in the art to produce fibers of the required physical properties by varying various process parameters. However, most of the prior art for changing the properties of the fibers required more time-consuming machinery or process changes, such as changing dies or changing resins. Thus, this technique required production lines to be interrupted while the necessary changes were made, resulting in inefficiency when new materials had to be run.

As the prior art has already pointed out, various effects can be obtained by manipulating the air flow in the vicinity of the fiber outlet in meltblown and spunbond fiber making apparatus. For example, according to Shambaugh U.S. Patent No. 5,405,559, the air flow provided to the meltblown process can be alternately opened and closed on both sides of the die, thereby reducing the energy required for the manufacture of meltblown fibers. Will be. However, Samboo's point has several shortcomings. Under some conditions, complete blockage of air on one side tends to blow the liquefied resin onto the air plate on the other side of the die, thus impeding the movement of the machinery at normal manufacturing air flow rates (especially for nonwoven web production). For high MFR polymers or other polymers commonly used in the process of Moreover, this technique fears accumulation of resin mass or “shots” in the fabricated web because the resin is only minimally affected while moving from the air flow on one side of the die to the air flow on the other side. There is. After all, Samboo's literature teaches the opening and closing of air to reduce the fiber size for a given flow. Its main emphasis is that such opening and closing operations save energy by reducing the overall air flow requirements in the meltblown process. Moreover, the low frequency taught by Sambo will lead to manufacturing failures in high speed machines. The fibers produced in that example are coarser, for example larger in diameter than those commonly found in commercial nonwoven fabrics. In the end, Samboo's literature teaches that selective alteration of airflow properties cannot be applied to changing the parameters of the fiber in the spunbond fiber manufacturing process.

Summary of the Invention

The foregoing and other objects are realized in the method and apparatus for making fibers according to the disclosure and preferred embodiments of the present invention, the present invention provides nonwoven webs and absorbent articles for oil absorption and other uses.

In general, the present invention relates to an apparatus for producing synthetic fibers and nonwoven webs from liquefied resins. The apparatus of the present invention comprises a means for generating a substantially continuous air stream carrying fibers along a base axis, at least one first extrusion die for extruding molten resin while being located adjacent to the air stream, and Disturbing means for selectively disturbing the air stream by varying the air pressure on either or both sides. The apparatus of the present invention may also include a substrate positioned below the first die, a substrate conveying means for moving the substrate relative to the die, wherein the transported fibers are deposited on the substrate to form a nonwoven web.

The apparatus of the present invention comprises a first air source connected to first and second air plenum chambers located opposite each other about an axis, the outlet of the plenum chamber being substantially continuous to taper the fibers. Provide an air stream. The disturbing means may comprise a valve that selectively varies the rate of airflow to the first and second plenums to provide airflow disturbances to the transported fibers. In addition, disturbance of the air stream may be achieved by superposing a second supply air that is disturbed on the first supply air in the plenum chamber. Alternatively, the disturbing means includes first and second pressure transducers adjacent or attached to the first and second plenum chambers, and the first and second to selectively change pressure in the first and second plenum chambers. It may also comprise means for the selective operation of the two pressure transducers. In general, the disturbing means changes the steady state pressure at a disturbing frequency of less than approximately 1000 Hz in the first and second plenum chambers, and the average plenum of the first and second plenum chambers in the absence of the disturbing means. The over pressure is changed to about 100% or less of the total average plenum pressure.

In addition, the apparatus of the present invention may include a fiber draw apparatus positioned below the first die and configured to allow basic airflow to flow. The fiber draw apparatus includes a fiber inlet for receiving fluid flow thereon and fibers transported thereon, and an outlet for distributing air-borne fibers on a substrate. The apparatus of the present invention may include a plurality of die apparatuses for simultaneously extruding various types of resins, and means (coforms) for adding other fibers or particulates.

The apparatus of the present invention may also include secondary first and second disturbing air sources positioned alternately of the axis and in the vicinity of the die or fiber draw apparatus, which alternately disturb substantially continuous airflow. have.

The present invention also provides a method of generating a substantially continuous stream of air along a basic axis, extruding a liquefied resin through a first die located adjacent to the air stream, transporting the liquefied resin into an air stream to convey the fibers. A method of making synthetic fibers and nonwoven webs from liquefied resins, the method comprising forming, selectively disrupting air flow in an air stream by varying the air pressure on either side of the base shaft.

1A-1C are schematic diagrams of conventional apparatus for making meltblown fibers.

2 is a surface view of a nonwoven web manufactured according to a conventional method.

3A and 3B are schematic diagrams of conventional apparatus for making spunbond fibers.

4 is a surface photograph of a nonwoven web made without disturbing the air stream.

5 is a photograph of the surface of a nonwoven web prepared according to the present invention.

6A-6D are schematic views of an apparatus for producing meltblown fibers according to the present invention.

7a-7e schematically illustrate an embodiment of a three-way valve that can be used in accordance with the present invention.

8A and 8D are graphs showing plenum pressure versus time in a conventional apparatus for making meltblown fibers.

8b and 8c are graphs showing the plenum pressure versus time in an apparatus according to the invention for producing meltblown fibers.

Figure 9 is a graph showing the distribution of fiber diameter in the meltblown fibers prepared according to the prior art.

Figure 10 is a graph showing the distribution of the fiber diameter in the meltblown fibers produced according to the present invention.

11 is a graph showing Fraser porosity versus disturbance frequency in the meltblown nonwoven web prepared according to the present invention.

12 is a graph showing hydrohead versus disturbance frequency in the meltblown nonwoven web prepared according to the present invention.

13 is a photograph of the surface of a nonwoven web made without disturbing the air stream.

14 is a photograph of the surface of a nonwoven web made in accordance with the present invention.

15 is a graph showing peak load versus disturbance frequency of a spunbond fiber nonwoven web.

16 is a schematic diagram of a coform device disposed in accordance with the present invention.

17A-17D and 19 illustrate various forms of apparatus for making nonwoven webs of spunbond fibers in accordance with the present invention.

18A-18F, 20A and 20B, and 21A-21D illustrate various forms of secondary jets for use in the present invention.

22 and 23 are graphs showing X-ray diffraction scans of conventional meltblown fibers and fibers made according to the present invention.

FIG. 24 is a differential scanning calorimetry (DSC) graph comparing calorimetric characteristics of conventional meltblown fibers and fibers prepared according to the present invention.

The following techniques can be applied to methods of making meltblown, spunbond and coform fibers. For clarity, the general principles of the invention will be described with reference to these techniques. After describing the technique of the present invention in general, specific applications in the field of meltblown, spunbond and coform will be described. In the following description subheadings are provided for convenience and these subheadings are for clarity only and should not be construed as limiting the scope of the invention as defined in the claims. As used herein, the term "disturbance" refers to a small or moderate change from the normal flow of a fluid or the like, such as less than 50% of the normal flow, with no discontinuous flow to one side. it means. In addition, the term "fluid" as used herein means any liquid or gaseous medium, generally the preferred fluid is a gas, more preferably air. The term "resin," as used herein, also refers to any type of liquid or material capable of forming fibers or nonwoven webs, including but not limited to polymers, copolymers, thermoplastics, waxes, and emulsions. .

<General description of air flow disturbance method>

As described above, the production of fibers with various properties is known in the art. However, preferred embodiments of the present invention provide a much wider range of changes in fiber properties and provide a much wider range of control for producing various nonwoven web materials from such fibers, which techniques can be used in the manufacturing process. With no or little obstacles, the properties of the nonwoven web produced are changed. This basic technique involves disturbing the air used to draw the fibers from the die. Preferably, the airflow carrying the fibers is alternately disturbed on opposite sides of the axis parallel to the conveying direction of the fibers. Thus, the air stream carrying the production fibers is disturbed, which causes disturbance of the fibers during production. Air stream disturbances in accordance with the methods and apparatus of the present invention may be performed in meltblown and spunbond production, but are not limited to these.

In general, air flow can be disturbed in a number of ways, and regardless of the method used to disturb the air flow, disturbance has two basic characteristics: frequency and amplitude. The disturbance frequency can be defined as the number of pulses provided on either side per unit time. As usual, frequencies will be described in hertz (Hz, number of cycles per second) throughout the specification. In addition, the amplitude can be described as a percentage (ΔP / P × 100) of the increase or difference in air pressure of the disturbed stream compared to the steady state. In addition, the disturbance amplitude can be described as a percentage of the increase or difference in air flow rate during the disturbance compared to the steady state. Thus, the primary variables that can be controlled by the novel fiber manufacturing technology are the disturbance frequency and the disturbance amplitude. The technique described below easily adjusts these parameters. The final variable that can be changed is the phase of disturbance. In most cases, the 180 ° phase difference of the disturbance is described below (ie, after some of the airflow on one side of the axis parallel to the flow direction is disturbed, then the other side is alternatingly disturbed), and the phase difference is It is adjustable between 0 ° and 180 ° to get the result. The tests were performed with the disturbing phases symmetrical (concordance of phases) and the phase relations changing. This change allows much more control over the fabric and the web or material produced.

Disturbance of the air stream and fibers during manufacture has several positive effects on the fibers produced. First, the properties of the fiber, such as strength and crimp, can be adjusted by changing the disturbances. Thus, an increase in bulkiness and tensile strength can be obtained by selecting the appropriate disturbance frequency and amplitude in the nonwoven web material. The increase in crimp in the fiber contributes to an increase in bulkiness in the nonwoven web because the crimped fiber tends to take up more space. In addition, according to a preliminary examination of the properties of the meltblown fibers made according to the invention, compared to those made by the prior art, the fibers made according to the invention exhibit different crystal and heat transfer properties. This difference is considered to be due to the heat transfer effect (including cooling) due to the movement of the fibers in the disturbing air stream. This difference also appears to contribute to the improvement of the properties of the fibers and nonwovens produced according to the techniques of the present invention. In addition, disturbances in the air flow lead to improved deposition of the fibers on the substrate, which improves the strength and other properties of the produced web.

Moreover, since the variables of disturbance frequency and amplitude are easily controlled, it is possible to produce fibers of various characteristics by changing this frequency and / or amplitude. Thus, it is possible to change the properties of the nonwoven web produced during the process (or "on the fly"). This type of adjustment allows one machine to produce nonwoven web fabrics having various properties required for various product specifications, while eliminating or reducing the need for major hardware or process changes as described above. In addition, the present invention does not preclude the use of conventional process control techniques to control fiber properties.

4 and 5, an enlarged photograph of the meltblown web (FIG. 4) manufactured by the prior art and the meltblown web (FIG. 5) manufactured by the present invention can be compared. As can be seen in FIG. 4, the individual fibers of the web are relatively linear, as shown in FIG. 5, the fibers in the web produced by the disturbing technique of the present invention are more crimped, in one direction Are not predominantly arranged. Thus, as can also be seen in the results below, the webs produced by the present invention exhibit greater bulkiness for a given weight and tend to have greater strength in the machine and transverse directions (where the machine Direction is the direction of motion with respect to the die of the substrate on which the web is manufactured, and the transverse direction is the direction perpendicular to the machine direction). Increasing the crimp will provide more contact points to the fibers of the web, which will increase the web strength. It should be noted that initially there appears to be more and larger voids in the web of FIG. 5 compared to FIG. 4, but in fact, the web of FIG. 5 does not contain more or larger voids than FIG. 4. Since the SEM photographs of these figures show the top surface of the material, the increased bulkiness of the web of FIG. 5 is not seen in the photograph, but bulky in such a way that a larger number of larger voids appear. Conversely, since the web of FIG. 4 has a smaller bulkiness, the fibers of the web are more located in the plane of the picture, showing the appearance of fewer and smaller voids. As can be seen below, the barrier properties of the web produced by the present invention can be chosen better than that produced by the prior art, which demonstrates that the appearance of the voids in the photograph of FIG. 5 is incorrect.

<Application to Melt Blown>

6A-6D illustrate various embodiments of the invention using alternating air pulses to disrupt air flow near the exit of the meltblown die 59. Each meltblown embodiment of the present invention is an air passage in communication with the tips of the plenum / manifolds 22, 23 and melt die 59 opposite in diameter to produce a jet stream of fiber stream 26. (24, 25). The function of the present invention is to maintain steady flow and alternately add pressure disturbances near the tip of the melt die 59 by alternately increasing or decreasing the pressure in the manifolds 22, 23 on this steady flow. will be. This technique ensures a controlled change of the gaseous fiber stream 26, allowing for regular pressure fluctuations of the gaseous fiber stream. In addition, the steady-state air flow, which is relatively high relative to the amplitude of the disturbing air flow, serves to prevent the fiber stream carried into the air from becoming entangled on the air plates 40, 42. Thus, the air delivery rate (and thus cooling rate) of the jet structure and fiber entanglement are preferably improved.

7A-7D show some examples of valves that alternately increase the pressure in the plenum chambers 22, 23 as shown in FIGS. 6A-6D. With reference to FIG. 7A, disturbing valve 86 essentially includes branching main air line 84 to air intake lines 20, 21. Immediately near the branch point, the flexible flapper 98 alternately traverses the width of all or part of the branch portion. This alternately limits the air flow to one air intake line 20, 21, providing a means of superimposing fluctuations in air pressure on the manifolds 22, 23. Alternatively, the actuator may mechanically cause the flapper to reciprocate across the branching portion to produce an appropriate variation in the air pressure of the plenums 22, 23. The flapper valve 98 may reciprocate the branched portions of the main line 84 in an alternating manner simply by air disturbance of the main line 84 using the natural frequency of the flapper. The vibration frequency of the valve 86 shown in FIG. 7A can be changed mechanically or simply by adjusting the length of the flapper 98 by changing its natural frequency by an actuator that reciprocates the flapper.

FIG. 7B illustrates a second embodiment of the disturbing valve 86, which may include a motor 100 that rotates the shaft 102. The shaft 102 may be fixed to the rotating plate 109 in which a plurality of apertures 108 are formed. Behind the rotating plate 109 is a stop plate 104 with a plurality of apertures 106. Both disks can be mounted so that flow can occur through the aperture of the fixed disk only when the aperture of the rotating plate 109 coincides with the aperture of the stop plate 104. The apertures of each plate may be arranged such that the steady flow is increased periodically when the apertures of each plate match. The frequency of increased flow can be controlled by the speed regulation of the motor 100.

FIG. 7C shows another embodiment of a disturbing valve 86, in which the motor 100 supports a shaft for supporting a butterfly valve having essentially a cross section slightly smaller than the main air line 84. 112 is rotatably connected. Thus, disturbances formed downstream from the rotating butterfly valve 110 alternately provide an increase in air pressure in the air intake lines 20, 21 and the air plenums 22, 23, thus providing a flow according to the invention. To achieve the conditions.

FIG. 7D illustrates another embodiment of a disturbing valve 86 in accordance with the present invention, wherein the motor 100 has a butterfly valve 110, 114 in the shaft 112 and air intake lines 20, 21. ) As can be seen from FIG. 7D, the butterfly valves 110, 114 are mounted to the shaft 112 at approximately 90 ° to each other. In addition, each butterfly valve 110, 114 is apertured to provide a constant air flow to each plenum while alternately providing a pressure increase of each plenum 22, 23 when the appropriate valve is in the open position. And may include 111.

FIG. 7E illustrates another embodiment of the disturbing valve 86, in which the driver 124 is connected to a shaft 122 mounted to the spool 123. The spool 123 includes channels 118, 120 in communication with each air intake line 20, 21 according to the longitudinal position. Each channel 118, 120 is fluidly connected to a main channel 116 fluidly connected to a main air line 84. In this embodiment, the disturbing valve 86 may alternately cause an increase in the air pressure of each plenum by the reciprocating motion of the shaft 122 from the driver 124. In addition, in order to achieve an alternating pressure increase in the plenum chambers 22, 23, the driver 124 reciprocates the spool 123 so that the amount of redundancy, thus lines 20, 21 and channels 118, While changing the air flow restriction between 120, channels 118, 120 can be connected to the main air line 84 at the same time. The driver 124 includes any known means for achieving reciprocating motion. This includes, but is not limited to, pneumatic means, hydraulic means or solenoid means.

8a-8d show the plenum air pressure in the conventional melt blown device and the melt blown device according to the invention, respectively. As shown in FIG. 8A, the air pressure of a conventional plenum chamber is essentially constant over time, while in FIGS. 8B and 8C the air pressure of the plenum chamber is essentially increased in a vibrating manner. For example, the point where the average pressure meets the ordinate is about 7 psig. 8D shows conventional air pressure in the vicinity of a conventional extrusion die in which air is opened and closed. In this case the average pressure meets the ordinate for example at about 0.5 psig. Conventional air flow opening and closing control as shown in FIG. 8D causes die failure due to intermittent flow, as described above. In addition, conventional air flow opening and closing control (implemented by Sambo) as shown in FIG. 8D utilizes lower average pressure, lower frequency and smaller pressure amplitude than the present invention. The air flow characteristics shown in FIG. 8A do not cause die failure, but because the flow is substantially constant over time, control over the crimp or web properties of the fibers cannot be exercised.

A number of disturbing valves 86 may be provided to achieve an alternating flow increase of the plenum chambers 22, 23 of the meltblown device according to the invention. For example, FIG. 6B shows another embodiment according to the present invention. In this embodiment the main air line 84 distributes a constant air flow to the air intake lines 20, 21 while flowing the proper air flow through the outlet valve 90 to the disturbing valve 86. Thus, in this embodiment, the plenum chambers 23 and 22 each comprise two inlets. The first inlet essentially introduces a constant flow from the air intake lines 20, 21. The second inlet of each plenum chamber introduces alternating flow into the chamber, adding vibratory flow to a constant flow from lines 20 and 21. The amount of air that flows out of the outlet valve 88 controls the amplitude of the pressure increase for accurate control of the fiber properties, as described in more detail below, while the disturbing valve 86 adjusts the frequency.

6C illustrates another embodiment of the present invention. In this embodiment, the main air line 84 is distributed to the air lines 21, 22 to supply air pressure to the plenum chambers 22, 23. In addition, the auxiliary air line 92 branches off the disturbing valve 86. The disturbing valve 86 then adds alternately increased air pressure on the plenum chambers 22 and 23 to achieve the vibratory flow conditions in accordance with the present invention. Here, the pressure in the auxiliary air line 92 controls the amplitude of the air pressure disturbance, while the disturbance valve 86 controls the disturbance frequency, as described above.

6d illustrates another embodiment of the present invention. In this embodiment, the main air line 84 branches to air intake lines 20 and 21, which are connected to plenum chambers 22 and 23, respectively. The alternately increased pressure of the plenum chambers 22, 23 may be provided by transducers 94, 96, respectively. The transducers 94 and 96 can be operated by electrical signal means. For example, the transducer may actually be a large speaker that accepts an electrical signal that pulses the phase 180 ° to provide an alternating pressure increase in the plenum chambers 22 and 23. However, any type of suitable transducer can produce increased air flow using any drive means. Such drive means include, but are not limited to, electromagnetic means, hydraulic means, pneumatic means or mechanical means.

As mentioned above, all of the above embodiments enable precise control of the disturbance frequency and amplitude, in particular without interrupting the operation of the fiber making apparatus. As described below, the ability to precisely control the disturbance parameters allows for relatively precise control of the properties of the fibers and the web produced thereby. In general, there are a number of fiber parameters, and certain combinations of parameters may be required to make one type of nonwoven material such as filter material, while combinations of other fiber variables to produce other types of material, such as disposable garments. This may be required.

For example, in filter applications, the material is preferably made of small diameter fibers. However, larger diameter fibers may be required for other materials. Moreover, many end products consist of layers of materials having various properties. For example, disposable diapers generally include a wick layer designed to remove moisture from the skin of the infant and keep it spaced apart from the skin. The middle absorbent layer is used to retain moisture. Finally, an external barrier layer is required to prevent the moisture absorbed from the diaper from seeping out. The properties of the fibers for each layer of the diaper are different to achieve the specific function of each type of material. With the techniques of the present invention, different parts of the web can be made by varying the disturbance parameters over time to form each layer of the diaper continuously into one nonwoven web. One nonwoven web may then be folded to provide a laminated final material.

Oil absorbing structures are described, for example, in US Pat. No. 5,364,680 (Cotton, incorporated herein by reference). For application to oil absorption, a fibrous web is required which is lipophilic and characterized by bulkyness of density of about 0.1 g / cc or less, preferably 0.06 g / cc or less. Low densities are generally preferred, but densities of 0.01 g / cc or less are difficult to handle. Such webs have the ability to absorb and retain oil at least about 10 times, preferably at least about 20 times, the weight of the web. In some applications, treatment with one or more compositions may be required to increase wettability with an aqueous liquid. Such treatments are well known and are described, for example, in commonly assigned US Pat. No. 5,057,361, incorporated herein by reference. Conventional attempts to produce such webs by meltblown techniques provide useful fibrous materials, but due to the manner in which the air stream still applies tacky fibers to its fabrication surface, they lack desirable bulkiness and absorbency. there was.

Therefore, the nonwoven web can be manufactured very flexibly by precise control of the fiber and material properties by controlling the disturbing properties. This control allows for greater efficiency and the ability to design a wide range of materials that can be manufactured with little interruption of the manufacturing process.

One of the drawbacks of conventional melt blown devices is the inability to control the diameter of the fibers produced relatively accurately. The manufacture of materials with certain properties often requires precise control over the diameter of the fibers used in the production of the nonwoven web. By the disturbing technique of the present invention, the nonuniformity of the fiber diameter can be made much smaller than that possible by the prior art.

9 and 10 show the distribution of fiber diameters in samples prepared by the conventional meltblown technique and in meltblown fiber samples prepared by the technique according to the meltblown apparatus of the embodiment shown in FIG. 6C. 9 shows a distribution of diameters according to the prior art. 10 shows a graph of the distribution of fiber diameters of meltblown fibers made according to the techniques of the present invention. The fiber distribution of FIG. 10 shows a sample of fiber diameter with a distribution concentrated at peaks between about 1 and 2 microns. The narrow fiber distribution band achieved here by the disturbing method and apparatus of the present invention shows that the degree to which the fiber diameter can be controlled is large only by changing the disturbing frequency or amplitude.

FIG. 11 shows the Fraser porosity of meltblown nonwoven webs made in accordance with the present invention as a function of the disturbance frequencies of the plenum chambers 22, 23. This Fracture Porosity is a standard measure of the nonwoven web of air flow rate through a material per ft ² , which is the permeability of the material in ft ³ / (ft ² * min)). The procedure used to determine the fragile air permeability for all samples was performed according to the specifications of Federal Test Method Standard No. 191A, Method 5450, except that the sample size was 8 × 8 instead of 7 × 7. . Larger sample sizes ensure that all sides of the sample extend well over the retaining ring, and that the sample is securely and flatly fixed across the orifice.

As shown in FIG. 11, the Fraser porosity is generally first minimized and then increases as the disturbance frequency increases from steady state to approximately 500 Hz. Thus, it will be appreciated that in order to produce a material having a desired Fraser porosity, the present invention only needs to change the vibration frequency (and / or amplitude). In the prior art, changing the porosity often required changing the die or starting material or redundancy of the machine. Therefore, according to the present invention, once the operation is completed, it is possible to easily change the porosity of the material. This is because it requires only the adjustment of the disturbing frequency (or amplitude), which can be easily achieved by simple control without interruption of manufacture. Accordingly, the meltblown apparatus according to the present invention enables to quickly and easily manufacture filter materials having various porosities by simply changing the disturbance frequency.

12 shows a graph of head pox as a function of disturbance frequency. This head test is a measure of the liquid barrier properties of the fabric. The hydrocephalus test determines the height (cm) of the water that the fabric supports before a certain amount of liquid passes. Fabrics showing higher head points mean greater barrier to liquid passage than fabrics with lower head points. The head pox test is performed according to Federal Test Standard No. 191A, Method 5514. In general, the head point is initially increased in the frequency range of approximately 75-525 Hz, and then decreases as the disturbing frequency increases. Since the disturbance frequency directly affects the head point, proper control of the disturbance valve 86 provides the liquid barrier required for a particular application. The disturbance frequency can be used to change the head point to suit the particular application to the material.

The following examples provide a basis for demonstrating the advantages of the present invention over prior art in the manufacture of meltblown, coform and spunbond webs and materials. These examples are provided solely for the purpose of illustrating how the method of the present invention may be practiced and should not be construed as limiting the scope of the invention as set forth in the claims.

<Example 1>

<Process conditions>

Die tip shape: recessed; Die width = 20 "; gap = 0.090"; 30 hpi

Basic air flow: heating (about 608 ° F. in the heater); 488 scfm; Pressure P _T = 6.6 psig

Auxiliary air flow: unheated (ambient air temperature); 60 scfm; Suction pressure = 20 psig

Polymer: Copolymer of Butylene and Propylene

            Polypropylene *-79%

            Polybutylene-20%

            Blue pigment-1%

      (* 800 MFR polypropylene coated with peroxide, final MFR = about 1500)

Polymer throughput: 0.5 GHM

Melt Temperature: 470 ℉

Disturbance Frequency: 0, 156, 462 Hz

Base weight: 0.54 oz / yd ²

Manufacture Height: 10 "

<Test Result> Blockability

Disturbance Frequency (Hz) 0 156 462 Fracture Porosity (cfm / ft ² ) 45.18 35.70 65.89 Head pressure (cm) 86.40 103 74.60

In this example, the meltblown process was carried out under the conditions as described above and corresponds to the embodiment shown in FIG. 6C, where the primary air flow is supplemented by the secondary air flow. In this embodiment, the hpi unit represents the number of holes per inch present in the die, and P _T is defined as the total pressure measured in the stagnant region of the base manifold. Since GHM is defined as the flow rate of each hole per minute (g / min), the GHM unit is defined as the weight of the polymer passing through each hole of the meltblown die per minute. As noted above, Fraser porosity is a measure of the material's permeability (unit is ft ³ / (ft ² · min)). The head point is measured by the height of the column of water supported by the web prior to penetration of the water into the web, a measure of the liquid barrier effect of the web.

The process conditions and results described above provide a basic comparison of typical meltblown manufacturing processes in the absence of air disturbances (0 Hz disturbance frequency) and when performed at disturbance frequencies of 156 and 462 Hz. As can be seen from Table 1-1, in general, the blocking properties of materials produced using disturbed airflow improved with increasing disturbance frequency. Thus, by simply changing the disturbance frequency, i.e. in a relatively easy process, a material or web having the desired blocking properties can be produced without changing the main process conditions. This ability to control the blocking properties was not possible in the prior art without substantial changes in process conditions that required much time and effort. As can be seen, there is an initial reduction in Fraser porosity at the disturbance frequency of 156 Hz (meaning a decrease in the permeability of the web or material to air). Similarly, there is an increase in the supported head point at a disturbing frequency of 156 Hz. Therefore, the web material produced at the disturbance frequency of 156 Hz has a more effective blocking effect. At the disturbance frequency of 462 Hz, the Fraser porosity was increased and the head pox was decreased than the 0 Hz (prior art) and 156 Hz manufacturing processes. Thus, at higher disturbance frequencies, the web material has a lower barrier effect, but is more suitable for use as an absorbent or deeper material.

In addition, the change of the blocking characteristic with respect to the change of the disturbance frequency (in a process condition different from that of Example 1) is shown in FIGS. As FIG. 11 shows, as the process changes from a disturbance to a disturbing frequency between 1 and 200 Hz, the Fraser porosity initially decreases. As the disturbance frequency increases above about 200 Hz, the Fraser porosity increases and the initial 0 Hz Fracture Porosity is overtaken between about 300 and 400 Hz. Above 400 Hz, the Fraser Porosity increases relatively rapidly as the disturbance frequency increases. Similarly, referring to FIG. 12, the supported head point initially increases between disturbance frequencies of about 1 to 200 Hz. The head point then decreases steadily with increasing disturbance frequency such that the head point between 400 and 500 Hz becomes smaller than that at a frequency of 0 Hz (normal flow). Thus, as these graphs show, a wide range of various ranges with desired barrier properties, without changing basic process conditions such as polymer type, flow conditions, and die geometry, except for a simple change in the disturbance frequency of air flow. Web materials can be prepared. For example, a material having more effective barrier properties can be produced by simply setting the disturbance frequency in the range of 100 to 200 Hz without changing all other process conditions. If less effective barrier materials are required, the only necessary process change will be an increase in the disturbance frequency, which can be performed with simple control without interruption of the production line. In the prior art, alteration of the barrier properties during manufacture required substantial changes in process conditions, requiring a break in the manufacturing line for this change. In practice, such alterations are generally not possible on one machine in question, and in general have produced one type of web material (or an extremely narrow range of materials) in which a plurality of machines have the required properties.

<Example 2>

<Process conditions>

Die tip shape: recessed; Die width = 20 "; gap = 0.090"; 30 hpi

Basic air flow: heating (about 608 ° F. in the heater); 317 scfm; Pressure P _T = 2.6 psig

Auxiliary air flow: unheated (ambient air temperature); 80 scfm; Suction pressure = 20 psig

Polymer: High MFR PP *

  (* E.g. 800 MFR polypropylene coated with peroxide, final MFR = about 1500)

Polymer throughput: 0.5 GHM

Melt Temperature: 470 ℉

Disturbance Frequency: 0 Hz (Control), 70 Hz

Base weight: 5 oz / yd ²

Manufacture Height: 10 "

<Test result>

In this example, the bulkiness of the web prepared using the disturbance frequency of 70 Hz was compared with that of the control web (the disturbance frequency of 0 Hz).

   Control-0.072 "(thickness)

   70 Hz-0.103 "

Therefore, it can be seen that the use of a medium disturbance frequency of 70 Hz resulted in a 43% increase in bulkiness compared to the prior art. Increased bulkiness is often required in the final web or material because it often provides better hand and absorbency.

Moreover, with regard to the required feel or appearance, the use of the disturbing techniques of the present invention enables control of the ordered feel or appearance. Referring to the photographs of FIGS. 13 and 14, FIG. 13 shows an appearance of a web manufactured at a disturbing frequency of 0 Hz, while FIG. 14 shows a web manufactured using a disturbing frequency of 70 Hz. As can be seen from these figures, the web of FIG. 14 has a leathery appearance and feel that does not exist in the web of FIG. Thus, as the appearance and texture are required, the techniques of the present invention allow for additional control and modification in the manufacture of various types of webs having such characteristics.

<Example 2A-2I>

<Process conditions>

Die tip shape: Die width 100 in, 30 hpi

Basic air flow: 1500-1800 scfm (typical range)

       2A = 1800 scfm, 2B = 1750 scfm, 2C; 1750 scfm (per bank),

       2D = 1750 scfm (per bank), 2E = 1800 scfm, 2F = 1800 scfm,

       2G = 1600 scfm, 2H = 1500 scfm, 2I = 1750 scfm

Base air temperature: 575-625 ℉ (typical range)

       2A = 625 ° F, 2B = 600 ° F, 2C = 600 ° F (per bank),

       2D = 600 ° F (per bank), 2E = 625 ° F, 2F = 575 ° F,

       2G = 575 ° F, 2H = 575 ° F, 2I = 600 ° F

Disturbance Frequency: 75-200 Hz

Polymer: PF-015-Polypropylene

Polymer throughput: 4.8 PIH

Melt Temperature: 600 ℉

This series of examples shows the results of the high bulkiness and oil absorption obtained with the meltblown web according to the invention. Using the apparatus as shown in FIG. 6B, the meltblown web was prepared under the above process conditions. The bulkiness and oil absorption were tested for this material, and the oil absorption rate was also tested for the roll sample.

<Oil Absorption Test>

Oil absorption test results were obtained using a test procedure based on ASTM D 1117-5.3. Weigh a 4 inch ² fabric sample and check the oil to be tested (white mineral oil for roll samples, +30 Saybolt color, NF grade, 80-90 SU viscosity; and for hand samples) 10W40 motor oil) in a pot containing 2 minutes. This sample was then suspended and dried (20 minutes for roll samples and 1 minute for hand samples). The sample was reweighed and the difference calculated for oil absorption.

The difference in the results of bulkiness and oil absorption between the roll sample and the hand sample is due to the compression in the roll shape. In both cases the improvement of the present invention is clear. Since the control is not disturbed, it is compressed at the time of manufacture and is relatively unaffected by being formed into a roll.

<Oil rate test>

Oil rate results were obtained according to TAPPI Standard Method T 432 su-72 with the following differences.

That is, to measure the rate of oil absorption, 0.1 ml of white mineral oil was used as the test solution, instead of one drop, timed for three separate drops for each sample and five from each sample instead of ten. The sample was tested (ie, time was measured for a total of 15 drops for each sample instead of 10 drops).

<Oil Absorption Data>

 Roll sample Example Disturbance condition Bulk (inch) Density (g / cm ³ ) Oil absorption (g / g) Oil speed (sec) 2A control 1 bank 0 Hz 0.1294 0.057 11.91 (18.21 *) 1.847 2B1 bank 200 Hz 0.1678 0.047 12.84 1.673 2C2 bank 200/150 Hz 0.1537 0.050 11.25 1.805 2D control 2 bank 0 Hz 0.0987 0.075 9.79 2.200 • test method of hand samples; Table 2-2

<Example 3>

<Process conditions>

Die tip shape: recessed; Gap: 0.090 "; 30 hpi

Basic air flow: heating (approximately 600 ° F. in the heater); 426 scfm; Pressure P _T = 5 psig

Auxiliary air flow: unheated (ambient air temperature); 80 scfm; Suction pressure = 20 psig

Polymer: High MFR PP *, 1% Blue Pigment

 (E.g. 800 MFR polypropylene coated with peroxide, final MFR approximately 1500)

Polymer throughput: 0.6 GHM

Melt Temperature: 480 ℉

Disturbance Frequency: 0 (Control), 192, 436Hz

Base weight: 0.54 oz / yd ²

Manufacture Height: 10 "

<Test result>

<Flexibility> cup crush

       0 Hz-1352

       192 Hz-721

The cup crush covers the web on an open cylinder of known diameter and measures the force required to push the material into the cup while pushing the web or material into the open cylinder using a rod of diameter slightly smaller than the inner diameter of the cup cylinder. It is a measure of flexibility obtained. The cupcrush test is used to evaluate the stiffness of the fabric, which requires a 4.5 cm diameter hemispherical foot to push a 22.9 cm x 22.9 cm piece of cloth into an inverted cup approximately 6.5 cm in diameter and 6.5 cm high. This is obtained by measuring the peak load to be obtained, where the cup-shaped fabric is surrounded by a cylinder of approximately 6.5 cm diameter to maintain a uniform deformation of the cup-shaped fabric. Arrange the feet and cups in a line to prevent contact between the cup wall and the foot, which may affect peak loads. Peak load is measured using a model 3108-128 10 load cell, available from MTS Systems, North Carolina Cary, USA, while the foot descends at a rate of about 0.64 cm / s. A total of 7-10 repetitions for each material were made and averaged to obtain the reported measurements.

The low grade of cup crush achieved by the material produced using the disturbance frequency of 192 Hz indicates that the material is more flexible. In addition, secondary flexibility tests, such as hand or hand, confirm that materials made using disturbance frequencies of 192 Hz are more flexible than those made using prior art.

<Strength>

Disturbance Frequency (Hz) 0 192 436 MD peak load (lbs) 1.989 2.624 2.581 MD Shinto (in) 0.145 0.119 0.087 CD peak load (lbs) 1.597 1.322 1.743 CD Shinto (in) 0.202 0.212 0.135

As can be seen from Table 3-1, the machine direction strength increases when the disturbance frequency is driven greater than 0 Hz. In the manufacturing process of Example 3, the direction of disturbance is generally parallel to the machine direction MD. The increase in strength in the machine direction seems to be due to well-controlled and regular overlap (duplication) in substrate deposition of the web when the fibers vibrate as a result of disturbances. Similar results are shown in FIG. 15, which is a graph showing the change in MD and CD peak loads as a function of disturbance frequency. As can be seen from FIG. 15, the MD intensity increases with increasing disturbance frequency. In general, the CD intensity is relatively constant (a slight change) regardless of the disturbance frequency. The increase in CD strength seems to be achievable by changing the angle of disturbance with respect to the machine direction. Thus, by causing disturbance at a predetermined angle between perpendicular and parallel to the MD, not only the MD strength but also the CD strength can be improved.

<Blockability>

Disturbance Frequency (Hz) 0 192 Fracture Porosity (cfm / ft ² ) 31.5 22.3 Chickenpox (cm of water) 90.8 121.6 Corresponding pore diameter (μm) 13.2 10.8

As Table 3-2 shows and as shown in Example 1, at a relatively low disturbance frequency (in the range of about 100 to 200 Hz), the blocking properties of the manufactured web increase. This result is explained by the measurement of the diameter of the corresponding circular pores in the case of 0 Hz and in the case of 192 Hz. As Table 3-2 shows, the pore size of the web material produced using the 192 Hz disturbance frequency is 2.4 μm smaller than that of the material produced without disturbance. Therefore, since the pores of the material are smaller, the permeability of the material is smaller and the blocking properties are larger.

<Example 4>

<Process conditions>

Die tip shape: recessed; Die width = 20 "; gap = 0.090"; 30 hpi

Basic air flow: heating (about 608 ° F. in the heater); 422 scfm; Pressure P _T = 5 psig

Auxiliary air flow: unheated (ambient air temperature); 40 scfm; Suction pressure = 15 psig

Polymer: Copolymer of Butylene and Propylene

           Polypropylene *-79%

           Polybutylene-20%

           Blue pigment-1%

    (* 800 MFR polypropylene coated with peroxide, final MFR = about 1500)

Polymer throughput: 0.6 GHM

Melt Temperature: 471 ℉

Disturbance Frequency: 0-463 Hz

Base weight: 0.8 oz / yd ²

Manufacture Height: 12 "

<Test result>

<Blockability>

Disturbance Frequency (Hz) 0 305 463 Fracture Porosity (cfm / ft ² ) 46.27 26.85 59.34

Once again, it can be seen that the porosity of the web material initially decreases when the air flow is disturbed, but also increases as the disturbance frequency increases. The results of Example 4 are consistent with the blocking characteristic results of the other examples, and also with the results reported in FIGS. 11 and 12.

While the above-mentioned embodiments use polypropylene or a mixture of high melt flow polypropylene and polybutylene resins for the production of nonwoven webs, a plurality of thermoplastic resins and elastomers produce a meltblown nonwoven web according to the present invention. It may be used for. Since most of the causes of the obtained improvement are the web structure of the present invention, the raw materials used can be variously selected. For example, not limited to the above outline, thermoplastic resins such as polystyrene as well as polyolefin including polyethylene, polypropylene can be used. Polyesters may also be used, including polyamides such as polyethylene, terephthalate and nylon. The web need not necessarily be elastic, but is not intended to exclude elastic compositions. Compatible blends of any of the foregoing may also be used. In addition, additives such as process aids, wetting agents, flocculants, compatibilizers, waxes, fillers and the like may be incorporated in amounts consistent with the fiber manufacturing process used to achieve the required results. Other fiber or filament forming materials will be suggested by those skilled in the art. It is only necessary that the composition be able to be made of any form of filament or fiber that can be spun and deposited on the production surface. Since many of these polymers are hydrophobic, if a wettable surface is desired, known compatible surfactants can be added to the polymer, which is well known to those skilled in the art. Such surfactants include anions such as sodium dialkylsulfosuccinate (Aerosol OT available from American Cyanamid or Triton X-100 available from Rohm & Hass) or There are nonionic surfactants, which are exemplary but not limiting. The amount of surfactant added depends on the desired end use, which is also apparent to those skilled in the art. Other additives such as pigments, fillers, stabilizers, compatibilizers may also be incorporated. Further discussion of the use of such additives is described, for example, in US Pat. No. 4,374,888 (born February 22, 1983) to Bonslaeger and US Pat. No. 4,070,218 to Weber (January 24, 1978). One patent).

In addition, a number of die shapes and die cross sections can be used to make the meltblown nonwoven webs according to the present invention. For example, an orifice diameter of 20-50 hpi (holes / inch) is preferred, although any suitable orifice diameter may be used. In addition, for the manufacture of meltblown nonwoven webs, orifice cross sections of a star shape, oval, circular, square, triangular, or any other geometric shape can be used.

<Application to coform>

Lau et al., US Pat. No. 4,818,464 (April 4, 1989), is incorporated herein by reference, which incorporates a plurality of separate polymer melt streams in extrusion through orifices in the manufacture of nonwoven webs. By combining in a polymer melt stream, a coform method of a polymer process is disclosed. In addition, US Pat. No. 4,818,464 (April 4, 1989) to Roh is cited as a reference for the present invention, which refers to superabsorbent materials as well as pulp, cellulose or short fibers for bonding with resin fibers in nonwoven webs. It is disclosed to introduce the extrusion die through a centralized chute. With reference to FIG. 16, the coform method is demonstrated. In essence, coform die 170 is basically a combination of two meltblown die heads 173 and 175. Air flows 176, 178 are provided around die 172, and air flows 180, 182 are provided around die 174. A chute 184 is provided to which pulp, short fibers, or other materials can be applied to change the properties of the fabrication web. Since any of the techniques described above that change the air flow around the meltblown die can be used in the coform technique, the specific description of all valve techniques will not be repeated. However, as will be apparent to those skilled in the art, it will be necessary to double the apparatus used to control the disturbance of the air flow to change the four air flows present in the coform die.

In Coform technology, there are several possible combinations of disturbances. The most basic is to disturb each part of a given die 172, 174, as described above in connection with the meltblown technique (basically, the air flows 176 and 178 alternate with each other and the air flow 176 And 178). However, it is also possible to disturb the air flow around die 172 with respect to the air flow around die 174. Thus, the air flows 176 and 182 may be disturbed in the same phase with each other, but may be out of phase with respect to the air flows 178 and 180 to achieve the desired properties of the fiber or web. To achieve different effects, it may be desirable to allow the air flows 176 and 180 to be in phase with each other and the air flows 178 and 182 to be disturbed in different phases. As is evident, several combinations of disturbances are possible for the four air flows, all of which are within the scope of the present invention. For example, the concentrated chute may be disposed between two concentrated air flows to introduce pulp or cellulose fibers and particulates. This centralized arrangement facilitates the integration of pulp into the nonwoven web and results in a consistent distribution of pulp in the web.

Example 5

As described above with reference to FIG. 16, the coform material is essentially made in the same manner as the meltblown material with the addition of a second die. Thus, there are two air flows around each die, a total of four air flows, which can be disturbed as described above. In addition, there is generally a gap between the two dies, through which pulp or other material can be applied to the fabric produced and bonded to the web being manufactured. The following examples use such coform heads, but follow the meltblown method described above for other air flow disturbances.

<Process conditions>

Die tip shape: recessed; Gap = 0.070 "; Die Width = 20"

Basic air flow: 350 scfm per bank (20 "bank)

Base air temperature: 510 ℉

Auxiliary air flow: 40 scfm per MB bank

Polymer: PF-015 (Polypropylene)

Polymer ratio: 65/35

Basic weight: 75 gsm (2.2 osy)

<Test result>

Disturbance Frequency (Hz) 0 67 208 320 MD peak load 1.578 1.501 1.67 2.355 MD Elongation (%) 23.86 22.48 24.21 20.23 CD peak load 0.729 0.723 0.759 0.727 CD Elongation (%) 49.75 52.46 58.08 71.23 Cup Crush (g / mm) 2518 2485 2434 2281

From Table 5-1, it can be seen that the results are generally consistent with those in the meltblown example. In general, as the disturbance frequencies arranged along the MD increase, the CD intensity remains almost the same, but the MD intensity increases. Similarly, the flexibility measured by cup crush generally increases as the disturbing frequency increases (the lower the cup crush indicates that the flexibility increases). Thus, according to this embodiment, the above-described technique can be applied to the coform manufacturing technique to achieve control of the process and the material by simple adjustment of the disturbance frequency in the same manner as that applied to the melt blown process.

<Application to Spunbond>

17A-17D illustrate various embodiments utilizing alternately increased air pressure in the plenum chambers 58, 62 of the standard fiber draw apparatus, as described in FIG. 3B. In a similar manner to the valve device for the melt blown device, the fiber draw device passes through the disturbance valve 86 and alternately increases the air pressure through the branches 72 and 74 through the plenum chamber. (62, 58). Alternatively, as shown in FIG. 17B, main air line 66 is branched to supply lines 130, 128 by valve 86, and supplies a third outlet to disturbing valve 86. While lines 128 and 130 receive a relatively constant pressure of air from the outlet valve 88, the disturbance valve 86 receives the outlet air from the outlet valve 88 and disturbs the air to form a vibrating pressure, This is added on the supply lines 128, 130 causing an alternating pressure increase in the lines 74, 72 which are fed to the plenum chambers 58, 62. In another embodiment shown in FIG. 17C, main supply line 66 branches to lines 128 and 130. This embodiment uses an auxiliary air supply 92, which is disturbed by the valve 86 and added on a constant air pressure of the lines 128, 130, alternatingly increasing air in the lines 72, 74. A flow source is created to supply air to the plenum chambers 62 and 58 of the fiber draw apparatus. Finally, FIG. 17D shows another embodiment of the present invention using a disturbing valve 86, which alternately disturbs the air flow before the main air supply line branches.

Figures 18A-18F are used in a conventional standard fiber draw apparatus such as that shown in Figure 3B, resulting in secondary disturbance jets that create suitable flow conditions for increasing the desirable properties of the fibers made in accordance with the present invention. It shows several different locations. For example, FIG. 18A shows the end tube 56 of a fiber draw apparatus using secondary disturbing jets 132, 134. As noted above, these secondary disturbing jets exert an alternately increased flow through the end tubes 56 of the present invention in a direction perpendicular to the main air flow. This orthogonal relationship between the primary and secondary air flows increases both the degree and condition of disturbances in the air flow in the vicinity of the end tube 56.

In addition, as shown in FIG. 18B, the end tube 56 intersects or otherwise is activated with a simultaneous flow jet 136, 138 which creates a disturbing flow in accordance with the invention near the end tube of the fiber draw apparatus. Can be included as states. 18C shows secondary disturbing jets 142, 140 installed near the top of the fiber draw apparatus upstream of the plenum chamber inlets 60, 64. FIG. 18D illustrates yet another embodiment of the present invention that uses alternatingly increased flow through Coanda nozzles 144, 146 at the outlet of the end tube 56 to create a disturbing air flow near the end tube 56. Example. 18E also shows Coanda-like nozzles 190, 192 disposed in the middle portion 54 of the fiber draw apparatus. Finally, FIG. 18F shows the jets disposed on the intakes 48, 50 of the fiber draw apparatus. Each jet, as shown in FIGS. 18A-18F, may alternately disturb the air flow through the fiber draw apparatus in addition to any disturbance that may be performed upstream of the jet. Also, each jet shown in FIGS. 18A-18F can be executed without further disturbing means upstream thereof.

19 shows another embodiment of the present invention. Alternately increased pressure of the plenum chambers 147, 150 may be provided by transducers 148, 152 via inlets 150, 154, respectively. The transducers 148 and 152 are preferably operated by electrical signal means. For example, the transducer actually receives an electrical signal and operates in a different phase of 0-180 °, providing alternately increased pressure in the plenum chambers 147 and 150. By the way, any type of suitable transducer can increase the air flow rate using any means of operation. This actuating means includes, but is not limited to, electromagnetic means, hydraulic means, pneumatic means or mechanical means.

20A and 20B show another embodiment of the present invention in which heating and cooling jets are alternately used to increase fiber crimp. Referring to FIG. 20A, the fiber draw apparatus 69 includes secondary disturbing jets 156, 158. The vibratory jet 156 supplies heated air, while the vibratory air jet 158 supplies cold air. Alternatively, FIG. 20B illustrates disturbing air jets 164 and 166 alternately supplying heated air to the fiber bundle and the basic air flow exiting the end tubes of the fiber draw apparatus. 20A and 20B both show the warpage of the fiber bundles by the application of secondary disturbances. This secondary disturbance creates a heating or cooling effect and warpage of the fiber bundle that adds a crimp to the fibers distributed in the web on the circulation belt. Disturbance at varying temperatures provides additional variables that can be changed and controlled during manufacturing. The jets can be arranged symmetrically or asymmetrically to achieve the required fiber properties, ie fiber crimps. Like disturbance frequencies and amplitudes, the temperature of the air is more complicated to control, but can be controlled without interrupting the manufacturing process. Thus, materials with various properties can be produced without the need for substantial line delays and additional equipment. This technique can be applied to processes using homopolymer fibers as well as multicomponent fibers and materials.

21A-21D also show another embodiment of the present invention, in which a standard fiber draw device includes a secondary disturbing jet at the outlet of the end pipe and at least one bank of the disturbing jet is in the machine direction. By rotating relative to the belt to form a crimp in the transverse direction to the movement of the belt or to move the fiber to increase the tensile strength in the transverse direction of the nonwoven. For example, as shown in FIG. 21A, the jet bank 160 is essentially half parallel to the machine direction, while the jet bank 162 is disposed at an angle to the machine direction. 21B shows the opposing jet banks 202, 200, all arranged at an angle to the machine direction. 21C also shows another form of jet direction, where the jet banks 202 and 204 are rotated and directed in the same direction, respectively, relative to the machine direction. Finally, FIG. 21D shows the opposing jet banks 208, 210.

Finally, FIG. 15 shows the peak load of the nonwoven web sample as a function of the disturbance frequency of the secondary disturbance jet in the embodiment used in Example 6. FIG. As shown graphically, the machine direction strength of the nonwoven web increases with increasing disturbance frequency. In the operation process used to calculate the data of FIG. 15, the direction of disturbance was parallel to the machine direction as in FIG. 21D. Furthermore, by changing the direction of the disturbing jet or air stream relative to the machine direction, the cross direction strength can be increased.

The following examples demonstrate the application of the techniques of the present invention to the production of fibers and nonwoven webs in spunbond processes. The process and apparatus are described using terms and units well known in the art. The first examples describe fibers or webs made using conventional techniques to provide a basis for comparison with fibers and webs made using the techniques of the present invention.

<Example 6>

This example shows the application of air flow disturbances to the spunbond process. In this particular embodiment, disturbance of air flow was applied to the air stream carrying the fibers at the outlet of the fiber draw apparatus (FDU), which corresponds to the embodiment shown in FIG. 21D. However, as mentioned above, this process is equally applicable to the disturbance of air flow by the application of auxiliary air or effluent air flow in the air flow in the FDU itself or in the manifold before the FDU.

<Process conditions>

FDU draw pressure: 4 psi; Drawer Width = 14 "

Polymer throughput: 0.5 GHM

Polymer: 3445 Polypropylene *

  (* EXXON trademark 3445 polymer, peroxide coated)

Melt Temperature: 430 ℉

Auxiliary Flow: 40 scfm

Basic weight: 0.5 osy (17 gsm)

<Test result>

Disturbance Frequency (Hz) 0 67 227 338 463 MD peak load (lb) 0.921 1.687 1.844 2.108 2.452 CD peak load (lb) 0.824 0.645 0.462 0.586 0.521 MD Elongation (%) 23.85 52.79 18.03 11.08 23.05 CD Elongation (%) 60.84 46.5 42.31 38.76 57.10 Total Tension [(MD ² + CD ² ) ^1/2 ] 1.24 1.81 1.90 2.19 2.51

As can be seen from the table, the use of air flow disturbances in the spunbond process provides substantially increased MD strength (in this embodiment the disturbing air flows are arranged in the machine direction). As with the meltblown process by disturbed airflow, the CD strength remained relatively constant after a slight decrease. However, as the calculation of the total tensile strength shows, the overall strength of the web is increased by the application of disturbing air flow. Once again, as evidenced by the use of air flow disturbances in the meltblown process, the use of air flow disturbances provides a selectable range of properties for the final web material only by adjustment of the disturbance frequency. Such ease of process control is impossible with spunbond technology up to now. In general, in order to produce spunbond web materials having various properties, it was necessary to completely shut down a running device and to change process conditions such as replacing a die or changing other substantial devices. Although the present invention does not exclude such a process, in the process of the present invention, the change of the web material may be performed by only changing the disturbing frequency during operation while maintaining other process conditions. This feature of the present invention allows greater flexibility and efficiency in the operation of the spunbond device.

<Example 7>

In this embodiment, the spunbond process was improved using the techniques of the present invention to provide for disturbance of the air flow disposed at the outlet of the FDU. For the purposes of this embodiment, the disturbance of the air flow is not arranged directly opposite, as in Example 6, and as schematically shown in Fig. 21A, one bank of auxiliary air nozzles is parallel to the machine direction, while The other bank is arranged at an angle to the transverse direction to provide some transverse trajectory.

<Process conditions>

Fiber Draw Pressure: 9 psi

Polymer throughput: 0.75 GHM

Basic Weight: 1.0 oz / yd ²

Polymer: 3445 Polypropylene *

   (EXXON trademark 3445 polymer, coated with peroxide)

Melt Temperature: 450 ° F

Auxiliary Air Flow: 75 scfm

<Test result>

Disturbance Frequency (Hz) 0 115 195 338 500 MD peak load (lb) 12.00 19.96 21.00 21.13 20.00 MD Elongation (%) 34.75 37.36 38.36 39.77 37.48 CD peak load (lb) 8.965 11.30 10.53 10.34 12.69 CD Elongation (%) 40.10 49.78 52.84 43.18 47.94

Again, it can be seen that various changes can be made in the final nonwoven web by simply changing the disturbing frequency of the air flow. Thus, as materials with varying properties are required, a change in the disturbance frequency of the disturbing air flow can cause a substantial change in the final nonwoven material. This change represents a substantial difference from the conventional spunbond technology, which has traditionally had to change other process conditions that are much more difficult to achieve in order to change the properties of the final material.

As can be seen from Examples 1-7 of the meltblown, coform and spunbond nonwoven fabrics prepared according to the present invention, the technique of the present invention provides a method for the production of nonwoven webs having various properties by controlling relatively simple Enable manufacturing. Some differences may be due to the deposition of fibers onto the production surface, but according to preliminary inspection, the technique of the present invention also results in a fundamental change in the fibers produced. 22 and 23 are X-ray diffraction tests (Fig. 22) of the meltblown fibers produced according to the prior art under the same process conditions and polymer types, respectively, and X-ray diffraction tests of the meltblown fibers made according to the present invention (Fig. 23). ). As can be seen from the contrast of FIGS. 22 and 23, the X-ray inspection of the meltblown fibers made in accordance with the present invention has two peaks, while the meltblown fibers of the prior art have several peaks. The difference observed in FIG. 23 appears to be due to the presence of smaller crystals in the fiber, possibly due to better cooling of the fiber during manufacture. In summary, this X-ray diffraction test indicates that the fibers produced according to the present invention are more amorphous than the fibers according to the prior art and may have greater bonding opportunities.

The characteristic difference between the fiber produced according to the invention and the prior art is again demonstrated in FIG. 24. 24 is a graph showing the results of DSC tests performed on conventional meltblown fibers (dashed lines) and the fibers of the present invention (solid lines), respectively. Basically this test observes the absorption or release of heat from the sample while the sample is heated. As can be seen from FIG. 24, the DSC test of the fibers of the prior art differs significantly from the fibers of the present invention. A comparison of DSC tests shows two main features of the present invention that do not appear in conventional fibers: (1) heat is released at 80-110 ° C. (obvious exothermic), and (2) there is a double melting peak. will be. This DSC result confirms that the manufacturing technique of the present invention produces a fiber having a significant difference from the fiber according to the prior art. Again, these differences appear to be related to the crystal structure and cooling of the fibers during manufacture.

While the preferred embodiments of the present invention have been described in detail above, the present invention can be variously modified, replaced, added to, and deleted from the various embodiments described above without departing from the scope of the invention as grasped from the claims. . For example, the present invention is applicable to atomization of liquids (or to transport liquids in a flow of fluid such as air). This liquid conveying device is very similar in cross section to the meltblown device shown in Figs. 6A-6D. In this embodiment, the device does not have a typical meltblown width of just a few inches to several feet. In addition, the components of the nebulizer may generally be of various arrangements of smaller size. In any case, the disturbing technique of the present invention in spraying provides a narrow droplet distribution and an even distribution of the liquid droplets in the transport air flow. Such embodiments require several applications, such as fuel / air mixtures for engines, improved paint sprays, improved insecticide spreaders, or where liquids are transported in airflow, even distribution of liquids in airflow and narrow particle size distributions are required. It can be used for any application.

Claims (76)

Generating a substantially continuous fluid stream along a basic axis, extruding liquefied resin through a first die positioned adjacent to the fluid stream, injecting the liquefied resin into the fluid stream to form fibers; Varying fluid pressure on either side of the primary axis to selectively disrupt fluid flow in the fluid stream. 2. The method of claim 1, further comprising: providing a substrate disposed below the first die, conveying the substrate relative to the first die (the direction of movement of the substrate is in the machine direction), Arranging in a transverse direction perpendicular to the machine direction, and depositing fibers on the substrate to form a nonwoven web. A fiber made according to the method of claim 1. Nonwoven web prepared according to the method of claim 2. The method of claim 1, further comprising: providing a first source of fluid having a flow rate, providing first and second fluid plenum chambers adjacent to the first die, wherein at least the fluid Directing a portion of a first source to an inlet of the first and second fluid plenum chambers, directing fluid from each of the first and second plenum chambers to a position adjacent to the first die; Forming a continuous fluid stream. 6. The method of claim 5, further comprising: providing a main fluid conduit connected between the first source of fluid and the disturbing means, connecting a first plenum conduit between the disturbing means and the first plenum chamber inlet; Connecting a second plenum conduit between the disturbing means and the second plenum chamber inlet, distributing a first source of fluid between the first and second plenum conduits, and the first and second Selectively changing the pressure of the fluid flow of each of the two plenum conduits. 6. The method of claim 5, further comprising the steps of: providing a second source of fluid having a flow rate, providing a second inlet located in the first and second plenum chambers; And directing to the second inlet of the second plenum chamber, and selectively varying the fluid flow rate provided from the second fluid source to provide a change in fluid flow rate that provides a pressure change on either side of the primary axis. Further comprising the step of achieving. 8. The method of claim 7, further comprising the step of adjustablely distilling fluid flow from the first source of fluid to provide a second source of fluid. 6. The method of claim 5, further comprising: providing first and second pressure transducers to the first and second plenum chambers, respectively, and selectively changing the pressure of the first and second plenum chambers. Selectively operating the first and second pressure transducers. 6. The method of claim 5, further comprising varying steady state pressures of the first and second plenum chambers to a disturbing frequency of less than approximately 1000 Hz. 6. The method of claim 5, further comprising changing the average plenum pressure of the first and second plenum chambers in the absence of disturbing means to less than about 100% of the total average plenum pressure. 8. The method of claim 7, further comprising providing first and second secondary disturbing jets opposite one another and near the axis of the axis to alternately disturb substantially continuous flow of the fluid. 13. The method of claim 12, further comprising directing fluid flow from at least one of the first and second secondary jets in a direction substantially perpendicular to the base axis. 13. The method of claim 12, further comprising directing fluid flow from at least one of the first and second secondary jets in a direction defined at an acute angle relative to the primary axis. 13. The method of claim 12, further comprising providing a heating fluid from the first secondary jet, and providing a fluid at approximately ambient temperature from the second secondary jet. 2. The method of claim 1, further comprising extruding a second liquefied resin through a second die located adjacent to the first die, and injecting the liquefied resin into a fluid stream to form fibers. Positioning adjacent to the stream. 17. The method of claim 16 further comprising introducing pulp fibers into the continuous fluid stream through a chute located between the first die and the second die. 17. The method of claim 16, further comprising: providing a substrate under the first die, conveying the substrate relative to the first die (the direction of movement of the substrate is in the machine direction), and moving the first die in the machine direction. Arranging in a transverse direction perpendicular to, and depositing fibers on the substrate to form a nonwoven web. A nonwoven web made according to the method of claim 18. The method of claim 1, further comprising: supplying a first fluid flow having a flow rate, providing first and second fluid plenum chambers opposite each other on the axis, wherein at least a portion of a source of the fluid is supplied to the first and second fluids. Directing each of the two longitudinal fluid plenum chambers, and said substantially continuous flow of fluid from each of said first and second plenum chambers into a fiber draw unit towards said fiber draw apparatus; Forming a fluid stream. 21. The method of claim 20, further comprising: distributing the first source of fluid between the first and second plenum chamber inlets, and selectively varying the pressure of fluid flowing to each of the first and second plenum chamber inlets. The method further comprises the step of. 21. The method of claim 20, further comprising: providing a second source of fluid having a flow rate, connecting the second source of fluid to the disturbing means, and transferring fluid flow from the disturbing means to the first and second plenum chambers. And directing the fluid flow rate from the second fluid source to provide a pressure change on either side of the primary axis. 23. The method of claim 22, further comprising the step of tunably draining fluid flow from the first source of fluid to provide a second source of fluid. 21. The method of claim 20, further comprising the steps of providing first and second pressure transducers adjacent to the first and second plenum chambers to form disturbing means, and selectively selecting pressure in the first and second plenum chambers. Selectively operating the first and second pressure transducers to change. 21. The method of claim 20, further comprising providing first and second secondary pulse jets opposite each other on the axis and near the fiber draw device to alternately disturb substantially continuous flow of the fluid. Way. 27. The method of claim 25, further comprising directing fluid flow from at least one of the first and second secondary jets in a substantially horizontal direction. 27. The method of claim 25, further comprising directing fluid flow from at least one of the secondary jets in a non-parallel direction with respect to a machine direction. 26. The method of claim 25, further comprising providing a heating fluid from the first secondary jet, and providing a fluid at approximately ambient temperature from the second secondary jet. 21. The method of claim 20, further comprising varying the steady state pressure of said first and second plenum chambers to a disturbing frequency of less than approximately 1000 Hz. Generating a substantially continuous fluid stream along the base axis, injecting liquid into the fluid stream through a nozzle, and selectively disrupting fluid flow in the fluid stream by varying the fluid pressure on either side of the base axis And injecting liquid into the fluid flow. Means for generating a substantially continuous fluid stream along the primary axis, a first extrusion die for extruding the liquefied resin, positioned adjacent to the fluid stream and injecting the liquefied resin into the fluid stream to form fibers, and the primary axis And disturbing means for selectively disturbing the fluid flow in the fluid stream by varying the fluid pressure of either. 32. The apparatus of claim 31, further comprising a substrate disposed below the first die, and substrate transport means for transporting the substrate relative to the first die (the direction of movement of the substrate is in the machine direction). And a die arranged in a transverse direction perpendicular to the machine direction, wherein fibers are deposited on the substrate to form a nonwoven web. 32. The apparatus of claim 31, wherein the means for generating the substantially continuous fluid stream comprises: a first source of fluid having a flow rate, first and second, respectively located at opposite sides of the axis, the at least a first inlet and an outlet; A longitudinal fluid plenum chamber, first and second plenum conduits that direct at least a portion of the first source of fluid to the inlets of the first and second respective longitudinal fluid plenum chambers, and opposite one another of the base axis Extending substantially from the outlet of the first and second plenum chambers to a position adjacent the die and directing fluid from the first and second plenum chambers to a position adjacent to the first die at And first and second outlet conduits to form a continuous fluid stream. 34. The apparatus of claim 33, wherein: a main fluid conduit connected between the first source of fluid and the disturbing means, a first plenum conduit connected between the disturbing means and the first plenum chamber inlet, and the disturbing means and the first And further comprising a second plenum conduit connected between the two plenum chamber inlets, the disturbing means distributing a first source of fluid between the first and second plenum conduits, wherein the first and second angles A device for selectively varying the pressure of fluid flow in a plenum conduit. A second source of fluid having a flow rate, an auxiliary conduit connected between the second fluid source and the disturbing means, a second inlet located in each of the first and second plenum chambers, At least one first two fluidly connected between the disturbing means and the second inlet of the first plenum chamber to direct fluid flow from the disturbing means to the second inlet of the first plenum chamber A secondary conduit and at least one fluidly connected between the disturbing means and the second inlet of the second plenum chamber to direct fluid flow from the disturbing means to the second inlet of the second plenum chamber And further comprising a second secondary conduit, wherein said disturbing means is adapted for selectively varying the fluid flow rates provided from said auxiliary conduit to said first and second secondary conduits. Further comprising a disturbing valve means, wherein the selective change in fluid flow rate provides a change in pressure on either side of the base axis. 36. The apparatus of claim 35, wherein the disturbing means comprises: an inlet for receiving fluid flow from the auxiliary conduit, and first and second for transferring the selectively changed fluid flow to the first and second secondary conduits. A device comprising a disturbing valve comprising an outlet. 34. The apparatus of claim 33, wherein the disturbing means comprises: an inlet for receiving fluid flow from a second fluid source, and optionally first and second fluids for transferring the changed fluid flow to the first and second plenum conduits The apparatus further comprises a disturbing valve comprising an outlet. 34. The apparatus of claim 33, wherein the disturbing means comprises: first and second pressure transducers adjacent to the first and second plenum chambers, and the first to selectively change the pressures of the first and second plenum chambers. The apparatus further comprises optional actuation means of the first and second pressure transducers. 34. The apparatus of claim 33, wherein said disturbing means changes the steady state pressure of said first and second plenum chambers to a disturbing frequency of less than approximately 1000 Hz. 34. The apparatus of claim 33, wherein the disturbing means changes the average plenum pressure of the first and second plenum chambers in the absence of operation of the disturbing means to less than about 50% of the total average plenum pressure. 36. The apparatus of claim 35, further comprising first and second secondary pulse jets disposed on opposite sides of the axis and near the die while alternately disturbing substantially continuous flow of the fluid. 42. The apparatus of claim 41, further comprising means for positioning the first and second secondary jets between the inlet and the outlet of the fiber draw apparatus. 42. The apparatus of claim 41, further comprising means for directing fluid flow from at least one of the first and second secondary jets in a substantially horizontal direction. 42. The apparatus of claim 41, further comprising means for directing fluid flow from at least one of the first and second secondary jets in a downward direction. 42. The apparatus of claim 41, further comprising means for directing fluid flow from at least one of the secondary jets in a non-parallel direction with respect to a machine direction. 42. The apparatus of claim 41, further comprising means for providing a heating fluid from the first secondary jet, and means for providing a fluid at approximately ambient temperature from the second secondary jet. 32. The apparatus of claim 31, further comprising means for extruding a second liquefied resin through a second die positioned adjacent to the first die, the second die injecting the liquefied resin into a fluid stream to form a fiber. Apparatus positioned adjacent to the fluid stream for 48. The apparatus of claim 47, further comprising means for directing fluid flow between the first and second die, and means for directing fluid flow near the periphery of the first and second die. 49. The apparatus of claim 48 further comprising a chute disposed between the first and second die to introduce pulp fibers into the continuous fluid stream. 32. The apparatus of claim 31, further comprising a fiber draw device disposed below the first die and configured to allow basic fluid flow to pass through, the fiber draw device dispensing the fiber inlet and fibers at the top that receive fluid flow and fibers. A substrate disposed below the first die, and substrate conveying means for conveying the substrate relative to the first die (the direction of movement of the substrate is in the machine direction); And a die arranged in a transverse direction perpendicular to the machine direction, wherein the fibers are deposited on the substrate to form a nonwoven web. 32. The apparatus of claim 31, further comprising a fiber draw device disposed below the first die and configured to allow basic fluid flow to pass through, the fiber draw device dispensing the fiber inlet and the upper fiber inlet through which fluid flow and fiber are received. Wherein said means for generating a substantially continuous fluid stream comprises: a first source of fluid having a flow rate, a first located at opposite sides of said axis, each comprising at least a first inlet and an outlet; And a second longitudinal fluid plenum chamber, first and second plenum conduits for directing at least a portion of the source of fluid to the inlets of the first and second respective longitudinal fluid plenum chambers, and the primary axis The first and second plenum chambers extending from the outlets of the first and second plenum chambers opposite to each other to the fiber draw device; And first and second outlet conduits for directing fluid to a fiber drawer device to form said substantially continuous fluid stream directed to said fiber draw device. 53. The apparatus of claim 51, wherein a main fluid conduit connected between the first fluid source and the disturbing means, the first plenum conduit connected between the disturbing means and the inlet of the first plenum chamber, the disturbing means and the second The second plenum conduit connected between the inlet of the plenum chamber, wherein the disturbing means distributes the first fluid source between the first and second plenum conduits and first and second plenum conduits A device for selectively varying the pressure of fluid flow in a conduit. 53. The method of claim 51, wherein a second source of fluid having a flow rate, an auxiliary conduit connected between the second source of fluid and the disturbing means, a second inlet located in each of the first and second plenum chambers, the disturbance At least one first secondary conduit fluidly connected between the means and the second inlet of the first plenum chamber to direct fluid flow from the disturbing means to the second inlet of the first plenum chamber, and At least one second secondary conduit fluidly connected between the disturbing means and the second inlet of the second plenum chamber to direct fluid flow from the disturbing means to the second inlet of the second plenum chamber And wherein the disturbing means selectively varies the flow rate of the fluid provided from the auxiliary conduit to the first and second secondary conduits, the selective variation of the fluid flow rate Further comprising a disturbing valve means adapted to provide a pressure change on either side of the base axis. 55. The apparatus of claim 53, wherein an inlet for connecting to said first fluid source to receive a first fluid source, first and second outlets for directing fluid flow to said first and second plenum conduits, and And a three-way valve comprising a third outlet for controllably exiting fluid flow from a first source to the auxiliary conduit to provide a second supply of fluid. 53. The apparatus of claim 51, wherein the disturbing means comprises: an inlet for receiving fluid flow from a second fluid source, and first and second outlets for selectively transferring the fluid flow to the first and second plenum conduits Apparatus further comprising a disturbing valve comprising a. 53. The apparatus of claim 51, wherein the disturbing means comprises: first and second pressure transducers adjacent to the first and second plenum chambers, and to selectively change the pressure of the first and second plenum chambers. The apparatus further comprises optional actuation means of the first and second pressure transducers. 53. The apparatus of claim 51 further comprising first and second secondary pulse jets disposed opposite each other on the axis and in the vicinity of a fiber draw apparatus to alternately disturb the substantially continuous fluid flow. 59. The apparatus of claim 57, further comprising means for directing fluid flow from at least one of the at least one secondary jet non-parallel to the machine direction. 59. The apparatus of claim 57, further comprising means for providing a heating fluid from the first secondary jet, and means for providing a fluid at approximately ambient temperature from the second secondary jet. 52. The apparatus of claim 51, wherein said disturbing means changes the steady state pressure of said first and second plenum chambers to a disturbing frequency of less than approximately 1000 Hz. 32. The apparatus of claim 31 wherein the fluid is a gas. Means for generating a substantially continuous fluid stream along the primary axis, a first nozzle positioned adjacent to the fluid stream and injecting liquid into the fluid stream, and varying the fluid pressure on either side of the primary axis in the fluid stream. A disturbing means for selectively disturbing the fluid flow, the apparatus for delivering liquid to the fluid flow. A high bulky nonwoven absorbent fabric comprising an array of interbonded fine fibers having a density of about 0.10 g / cc or less and a pore structure that provides an absorption capacity of about 10 g / g or more. 64. The absorbent fabric of claim 63, wherein said fabric comprises polyolefin fine fibers. 65. The absorbent fabric of claim 64 having an oil absorption rate of about 2 seconds or less. 66. The absorbent fabric of claim 65 comprising a treatment that increases aqueous wettability. 67. The absorbent fabric of claim 66 wherein said wettable treatment comprises a surfactant. 64. The absorbent fabric of claim 63, wherein the absorbent fabric comprises fibers or particles distributed within said fibrous array. A high bulky nonwoven absorbent fabric comprising an array of thermoplastic polyolefin fine fibers produced by meltblowing under conditions in which fine fibers are perturbed to achieve a fabric density of about 0.10 g / cc or less and an absorbance of about 10 g / g or more. 70. The absorbent fabric of claim 69, wherein said polyolefin comprises a propylene polymer. 71. The absorbent fabric of claim 70, further comprising coform fibers or particles in said array. 70. The absorbent fabric of claim 69 wherein the oil absorbency is at least 20 g / g and the oil absorption rate is at most about 2 seconds. The absorbent fabric of claim 70 wherein the oil absorbency is at least 20 g / g and the oil absorption rate is at most about 2 seconds. 72. The absorbent fabric of claim 70 comprising a treatment that increases aqueous wettability. The arrangement of meltblown propylene polymer fibres produced by meltblowing under conditions that disturb the fibrils to achieve a fabric density of about 0.06 g / cc or less, an oil absorption of 20 g / g or more and an oil absorption rate of 2 seconds or more. Containing oil absorbent products. 76. The oil absorbent article of claim 75 wherein said meltblowing conditions comprise water cooling.