System and process for preparing a fibrous nonwoven composite fabric

A system for preparing a nonwoven fabric comprising:

• a first polymer source;
• a spin beam in fluid communication with the first polymer source, the spin beam including a spinneret assembly having a plurality of rows of filament nozzles that are arranged in an array, the filament nozzles being configured and arranged to extrude a plurality of filaments comprising a first polymer provided by the first polymer source;
• a gas distribution plate disposed downstream of the spinneret assembly, the gas distribution plate including a plurality of gas distribution slots that are each associated with one or more of the rows of the filaments nozzles;
• a gas source in fluid communication with the plurality of gas distribution slots such that a stream of gas is introduced into the plurality of gas distribution slots to draw and attenuate the filaments extruded by the plurality of filament nozzles;
• and
• a collection surface disposed downstream of the gas distribution plate for collecting the drawn and attenuated filaments thereon to form a nonwoven fabric,
• wherein the plurality of gas distribution slots are disposed adjacent to a corresponding row of filament nozzles, and wherein the spin beam comprises an alternating pattern of rows of filament nozzles and gas distribution slots.

A system for preparing a nonwoven fabric comprising:

• a first polymer source;
• a spin beam in fluid communication with the first polymer source, the spin beam including a spinneret assembly having a plurality of rows of filament nozzles that are arranged in an array, the filament nozzles being configured and arranged to extrude a plurality of filaments comprising a first polymer provided by the first polymer source;
• a gas distribution plate disposed downstream of the spinneret assembly, the gas distribution plate including a plurality of gas distribution slots that are each associated with one or more of the rows of the filaments nozzles;
• a gas source in fluid communication with the plurality of gas distribution slots such that a stream of gas is introduced into the plurality of gas distribution slots to draw and attenuate the filaments extruded by the plurality of filament nozzles;
• and
• a collection surface disposed downstream of the gas distribution plate for collecting the drawn and attenuated filaments thereon to form a nonwoven fabric,
• wherein the gas distribution slots comprise a plurality of successive chambers arranged in a row and wherein a fluid connecting channel provides fluid communication between adjacent chambers.

A system for preparing a nonwoven fabric comprising:

• a first polymer source;
• a spin beam in fluid communication with the first polymer source, the spin beam including a spinneret assembly having a plurality of rows of filament nozzles that are arranged in an array, the filament nozzles being configured and arranged to extrude a plurality of filaments comprising a first polymer provided by the first polymer source;
• a gas distribution plate disposed downstream of the spinneret assembly, the gas distribution plate including a plurality of gas distribution slots that are each associated with one or more of the rows of the filaments nozzles;
• a gas source in fluid communication with the plurality of gas distribution slots such that a stream of gas is introduced into the plurality of gas distribution slots to draw and attenuate the filaments extruded by the plurality of filament nozzles;
• and
• a collection surface disposed downstream of the gas distribution plate for collecting the drawn and attenuated filaments thereon to form a nonwoven fabric,
• wherein the gas distribution slot comprises a pair of converging first and second chambers wherein each chamber comprising a central chamber and a pair of opposing sides that extend from peripheral edges of the central chamber and that converge towards a central point disposed between the first and second chambers.

A method for preparing a nonwoven fabric comprising:

• providing a first polymer source;
• introducing a first polymer from said first polymer source into a spin beam in fluid communication with the first polymer source, the spin beam including a spinneret assembly having a plurality of rows of filament nozzles that are arranged in an array and
• a gas distribution plate disposed downstream of the spinneret assembly, the gas distribution plate including a plurality of gas distribution slots that are each associated with one or more of the rows of the filaments nozzles;
• extruding a plurality of filaments comprising the first polymer provided by the first polymer source;
• surrounding the filament nozzles and the extruded plurality of filaments with a stream of gas that is introduced into the plurality of gas distribution slots;
• drawing and attenuating the plurality of filaments extruded by the plurality of filament nozzles;
• and
• depositing the plurality filament nozzles onto a collection surface disposed downstream of the gas distribution plate to form a nonwoven fabric web, and wherein the gas distribution slots comprise a first chamber and a second chamber that are interconnected via a fluid channel, and wherein each chamber includes at least one filament nozzle disposed therein.