Nonwoven fabric having a single layer with a plurality of different fiber types, and an apparatus, system, and method for producing same

A system for preparing a nonwoven fabric having a single fabric layer in which the single fabric layer comprises a plurality of different fiber types, the system comprising:

• a first polymer source configured to provide a stream of a molten or semi-molten first polymer;
• a second polymer source configured to provide a stream of a molten or semi-molten second polymer, wherein the first polymer and the second polymer are of a different type;
• a first spin beam in fluid communication with the first and second polymer sources, the spin beam including a zoned distribution plate disposed upstream of a spinneret, the zoned distribution plate comprising a plurality of distribution apertures arranged in zones, wherein each zone is configured and arranged to extrude a plurality of polymer streams that are of a different polymer type than polymer streams extruded by an adjacent zone to the spinneret, wherein the zoned distribution plate has one of the following zoned distribution configurations:
• a. a first zoned distribution configuration comprising first and second distribution zones in fluid communication with the first polymer source, the first and second distribution zones of the first zoned distribution configuration being configured to produce multicomponent or monocomponent filaments, and a third distribution zone disposed between the first and second distribution zones of the first zoned distribution configuration, the third distribution zone being in fluid communication with both the first and second polymer sources, and being configured to produce multicomponent filaments, and
• b. a second zoned distribution configuration comprising first and second distribution zones in fluid communication with both the first and second polymer sources, the first and second distribution zones of the second zoned distribution configuration being configured to produce multicomponent filaments, and a third distribution zone disposed between the first and second distribution zones and in fluid communication with the first polymer source, the third distribution zone of the second zoned distribution configuration being configured to produce monocomponent filaments or multicomponent filaments;
• a collection surface disposed below the spinneret onto which continuous filaments are deposited to form a single layer comprising two or more types of fibers that are of a different type from each other;
• and
• one or more fiber producing beams disposed upstream or downstream of the first spin beam, the one or more fiber producing beams being configured to produce one or more additional nonwoven layers that are disposed under said single fabric layer comprises a plurality of different fiber types or overlying said single fabric layer comprises a plurality of different fiber types.

A system for preparing a nonwoven fabric having a single fabric layer in which the single fabric layer comprises a plurality of different fiber types, the system comprising:

• a first polymer source configured to provide a stream of a molten or semi-molten first polymer;
• a second polymer source configured to provide a stream of a molten or semi-molten second polymer, wherein the first polymer and the second polymer are of a different type;
• a spin beam in fluid communication with the first and second polymer sources, the spin beam including a zoned distribution plate disposed upstream of a spinneret, the zoned distribution plate comprising a plurality of distribution apertures arranged in zones, wherein each zone is configured and arranged to extrude a plurality of polymer streams that are of a different polymer type than polymer streams extruded by an adjacent zone to the spinneret, wherein the zoned distribution plate comprises a first zoned distribution configuration comprising first and second distribution zones in fluid communication with the first polymer source, the first and second distribution zones of the first zoned distribution configuration being configured to produce a first fiber type, and a third distribution zone disposed between the first and second distribution zones of the first zoned distribution configuration, the third distribution zone being in fluid communication with the second polymer source, and being configured to produce a second fiber type that is different from the first fiber type;
• and
• a collection surface disposed below the spinneret onto which continuous filaments are deposited to form a single layer comprising two or more types of fibers that are of a different type from each other.