Apparatus and die cartridge assembly adapted for use therewith, and process for producing fibrous materials

An apparatus for producing fibrous material comprising fibers, comprising:

• a polymer extrusion body through which molten polymer is directed for delivery to an elongated polymer cavity at a lower portion of said extrusion body,
• at least one gas source for supplying pressurized gas generally beneath said extrusion body;
• and
• a removable die cartridge assembly removably positioned beneath said extrusion body for effecting formation of said fibrous material by fibrillation of polymer films, and wherein said cartridge assembly defines:
• a plurality of annular film forming walls, and
• a plurality of polymer passages communicating with said polymer cavity for directing said polymer onto said plurality of annular film forming walls defined by said cartridge assembly, and
• a plurality of gas passages communicating with said gas source arranged for directing pressurized gas from said gas source against molten polymer in the form of a film on said plurality of annular film forming walls for effecting formation of fibrous material comprising fibers from each of said film forming walls.

An apparatus for producing fibrous material comprising fibers, comprising:

• a polymer extrusion body through which molten polymer is directed for delivery to an elongated polymer cavity at a lower portion of said extrusion body,
• at least one gas source for supplying pressurized gas generally beneath said extrusion body;
• and
• a removable die cartridge assembly removably positioned beneath said extrusion body for effecting formation of said fibrous material by fibrillation of polymer films, and wherein said cartridge assembly defines:
• at least one polymer passage communicating with said polymer cavity for directing said polymer onto at least one non-annular film forming wall defined by said cartridge assembly, and
• at least one gas plenum chamber communicating with said gas source, with pressurized gas being directed from said gas plenum chamber against molten polymer in the form of a film on said at least one non-annular film forming wall for effecting formation of said fibrous material comprising fibers.

An apparatus for producing fibrous material comprising fibers, comprising:

• a polymer extrusion body through which molten polymer is directed for delivery to an elongated polymer cavity at a lower portion of said extrusion body,
• at least one gas source for supplying pressurized gas generally beneath said extrusion body;
• and
• a removable die cartridge assembly removably positioned beneath said extrusion body for effecting formation of said fibrous material by fibrillation of polymer films, and wherein said cartridge assembly defines:
• at least one polymer passage communicating with said polymer cavity for directing said polymer onto at least one linear film forming wall defined by said cartridge assembly, and
• at least one gas passage communicating with said gas source arranged for directing pressurized gas from said gas source against molten polymer in the form of a film on said at least one linear film forming wall for effecting formation of said fibrous material comprising fibers, and
• wherein said die cartridge assembly includes at least one heating element for heating said die cartridge assembly independently of said extrusion body.

An apparatus for producing fibrous material comprising fibers, comprising:

• a polymer extrusion body through which molten polymer is directed for delivery to an elongated polymer cavity at a lower portion of said extrusion body,
• at least one gas source for supplying pressurized gas generally beneath said extrusion body;
• and
• a removable die cartridge assembly removably positioned beneath said extrusion body for effecting formation of said fibrous material by fibrillation of polymer films, and wherein said cartridge assembly defines:
• a pair of linear film forming walls arranged in converging relationship to each other, and in parallel relationship to said polymer cavity,
• at least one polymer passage communicating with said polymer cavity for directing said polymer onto said pair of linear film forming walls defined by said cartridge assembly, and
• at least one gas passage communicating with said gas source arranged for directing pressurized gas from said gas source against molten polymer in the form of a film on said pair of linear film forming walls for effecting formation of said fibrous material comprising fibers.

An apparatus for producing fibrous material comprising fibers, comprising:

• a polymer extrusion body through which molten polymer is directed for delivery to an elongated polymer cavity at a lower portion of said extrusion body,
• at least one gas source for supplying pressurized gas generally beneath said extrusion body;
• and
• a removable die cartridge assembly removably positioned beneath said extrusion body for effecting formation of said fibrous material by fibrillation of polymer films, and wherein said cartridge assembly defines:
• a pair of linear film forming walls arranged in parallel relationship to each other,
• at least one polymer passage communicating with said polymer cavity for directing said polymer onto said pair of linear film forming walls defined by said cartridge assembly, and
• a pair of gas passages communicating with said gas source and arranged in converging relationship for each directing pressurized gas from said gas source against molten polymer in the form of a film on a respective one of said film forming walls for effecting formation of said fibrous material comprising fibers.