Method and apparatus for spinning a web of mixed fibers, and products produced therefrom

A method of forming plural-component synthetic fibers from plural respective dissimilar molten/solution polymer components, said method comprising the steps of:

• (a) flowing said plural components, mutually separated, in a structure having plural parts;
• and
• (b) in said structure, distributing each separate component to an array of spinneret orifices defined at a peripheral edge of at least one spinneret plate such that each component flows into each spinneret orifice to provide, in each spinneret orifice, a combined flow containing each of said plural components, said spinneret plate being one of said plural parts of said structure;
• wherein said fibers are issued in a first direction edgewise from said spinneret plate as respective streams from spinneret orifices;
• and
• wherein step (b) comprises the steps of:
• (b.1) providing at least one distributor plate, having upstream and downstream surfaces, said at least one distributor plate having multiple surface grooves formed therein to a depth that is less than the thickness of that plate;
• (b.2) positioning said at least one distributor plate in said structure so that the upstream and downstream surfaces are parallel to said first direction and in a position requiring said plural components to flow through said multiple distribution flow paths formed therein so that at least one of said plural components has at least one instance of flow which is parallel to said first direction;
• and
• (b.3) directing the mutually separated components through said distribution flow paths to combine said components in a predetermined manner at a plurality of said inlet holes.

A fiber spinning method comprising the steps of:

• (a). flowing a plurality of different polymer materials through a series of surface-to-surface abutting plates having aligned outlet edges in a first direction perpendicular to the plate surfaces;
• (b). flowing the plurality of different polymer materials along respective separated surface grooves defined in a least one plate;
• (c) delivering the flowing different polymer material from said grooves to a plurality of spinneret orifices defined at the outlet edge of a plate;
• and
• (d) extruding the polymer from said spinneret orifices as fibers.

A fiber extrusion spin pack assembly for forming synthetic fibers comprising:

• supply means for delivering plural mutually separated flowable polymer components under pressure;
• in fluid flow communication with said supply means, primary distribution means for delivering the mutually separated components to prescribed locations in said assembly;
• a spinneret plate having an array of multiple spinneret orifices defined in an edge thereof for issuing said synthetic fibers from said spin pack assembly in a first direction parallel to said spinneret plate, each spinneret orifice having an each upstream end inlet;
• and
• at least a first distributor plate positioned parallel to said spinneret plate and between said primary distribution means and said spinneret plate, and having multiple distribution flow paths for precisely delivering from one to multiple component streams of the one or more mutually separated components from said primary distribution means to pre-selected points at any or all of said spinneret orifices, wherein said distribution flow paths include surface grooves defined in at least one surface of said distributor plate to a depth of less than the thickness of the distributor plate.

A fiber spinning process comprising the steps of:

• (a) providing at least two independent sources of polymer materials;
• (b) feeding said polymer material from each of said independent sources into a series of distribution plates together defining separated distribution paths, each of which receives polymer material from one of said independent sources;
• (c) directing at least two of said polymer materials in said separated distribution paths until said polymer materials approach the inlets to spinneret orifices defined by at least one of said distribution plates;
• (d) extruding an array of fibers from said spinneret orifices such that at least one of the fibers formed has a cross section wherein the at least two polymer materials are longitudinally coextensive with one another in substantially distinct domains substantially throughout the length of said fiber,
• (e) attenuating said array of fibers extruded from said spinneret orifices;
• and
• (f) forming a web of said attenuated fibers.

A fiber spinning device comprising:

• at least two independent sources of polymer materials and pumps for feeding polymer material from each of said independent sources;
• a series of distribution plates together defining separated distribution paths, each of said paths being positioned to receive polymer material from one of said independent sources;
• at least one of said distribution plates having a plurality of spinneret orifices defined therein;
• said distribution paths being configured and disposed to direct said polymer materials from said independent sources into said spinneret orifices, wherein at least one spinneret orifice receives at least two of said polymers such that the fiber formed from the at least one spinneret orifice has a cross section wherein the at least two polymer materials are longitudinally coextensive with one another in substantially distinct domains substantially throughout the length of said fiber;
• means for extruding said fibers as a web from said spinneret orifices and
• means for attenuating said fibers as the fibers are extruded in molten form from said spinneret orifices.