IP Library › Granted Patent US 6,964,931
Granted Patent B2
US 6,964,931 · App. 09/793,360 · Granted Nov 15, 2005

Method of making continuous filament web with statistical filament distribution

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Quick Facts
Patent No.
US 6,964,931
App. No.
09/793,360
Granted
Nov 15, 2005
Kind
B2
Abstract

The present invention is directed to a method of making a substantially continuous filament web which includes providing a plurality of polymer extruders for supplying polymer streams of at least two different polymer compositions, and providing a spinneret assembly for receiving the polymer streams. The spinneret assembly includes a plurality of orifices from which the polymer streams are extruded for formation of substantially continuous filaments formed from the polymer compositions. The distribution of at least one of the polymer compositions within the spinneret assembly is selected to optimize selected physical characteristics of the resultant continuous filament web.

Claims (21)

1. A method of making a substantially continuous filament web, comprising the steps of:

providing a plurality of polymer extruders for supplying polymer streams of at least two different polymer compositions having differing melting points;

providing a single spinneret assembly for receiving said polymer streams of at least two different polymer compositions, said single spinneret assembly including a plurality of orifices from which said polymer streams are extruded for formation substantially continuous filaments formed from said polymer compositions, wherein at least some of said substantially continuous filaments are formed as polymer filaments from a single one of said polymer compositions and other ones of said substantially continuous filaments are formed as polymer filaments from: a single different one of said polymer compositions, or plural ones of said polymer compositions, and

thermal bonding said substantially continuous filaments to form said web,

wherein the distribution of at least one of said polymer compositions within said spinneret assembly is selected to optimize selected physical characteristics of said web.

2. A method of making a substantially continuous filament-web in accordance with claim 1 , wherein:

said thermal bonding step comprises thermal point bond calendering.

3. A method of making a substantially continuous filament-web in accordance with claim 1 , wherein:

said thermal bonding step comprises through-air bonding.

4. A method of making a substantially continuous filament-web in accordance with claim 1 , wherein:

said formation of said filaments includes forming at least some of said filaments as bi-component filaments each including at least two of said polymer compositions.

5. A method of making a substantially continuous filament-web in accordance with claim 4 , wherein:

said bi-component filaments comprise sheath-core bi-component filaments.

6. A method of making a substantially continuous filament-web in accordance with claim 4 , wherein:

said bi-component filaments comprise segmented pie bi-component filaments.

7. A method of making a substantially continuous filament-web in accordance with claim 4 , wherein:

said bi-component filaments comprise side-by-side bi-component filaments.

8. A method of making a substantially continuous filament-web in accordance with claim 1 , wherein:

said formation of said filaments includes forming at least some of said filaments as side-by-side bi-component filaments each including at least two of said polymer compositions, and other ones of said filaments as segmented pie bi-component filaments.

9. A method of making a substantially continuous filament-web in accordance with claim 1 , wherein

said formation of said filaments includes forming at least some of said filaments as hollow bi-component filaments.

Assignments (13)
RELEASE OF SECURITY INTEREST Recorded Oct 2, 2015
From: CITIBANK, N.A.
To: AVINTIV SPECIALTY MATERIALS, INC. (F/K/A POLYMER GROUP, INC.)
Reel/Frame 036743/0900 →
RELEASE OF SECURITY INTEREST Recorded Oct 2, 2015
From: WILMINGTON TRUST COMPANY
To: AVINTIV SPECIALTY MATERIALS, INC. (F/K/A POLYMER GROUP, INC.)
Reel/Frame 036743/0667 →
SECURITY AGREEMENT Recorded Mar 9, 2011
From: POLYMER GROUP, INC.
To: CITIBANK, N.A., AS COLLATERAL AGENT
Reel/Frame 025920/0089 →
SECURITY AGREEMENT Recorded Feb 8, 2011
From: POLYMER GROUP, INC.
To: WILMINGTON TRUST COMPANY, AS COLLATERAL AGENT
Reel/Frame 025757/0126 →
RELEASE OF SECURITY INTEREST Recorded Feb 7, 2011
From: CITICORP NORTH AMERICA, INC., AS COLLATERAL AGENT
To: POLYMER GROUP, INC.; CHICOPEE, INC.; PGI POLYMER, INC.
Reel/Frame 025754/0903 →
RELEASE OF SECURITY INTEREST IN PATENTS Recorded Dec 6, 2005
From: WILMINGTON TRUST COMPANY, AS SECOND LIEN COLLATERAL AGENT
To: BONLAM (S.C.), INC.; CHICOPEE, INC.; DOMINION TEXTILE (USA) INC.; FABPRO ORIENTED POLYMERS, INC.; FABRENE CORP.; FABRENE GROUP L.L.C.; FIBERGOL CORPORATION; FIBERTECH GROUP, INC.; FNA ACQUISITION, INC.; FNA POLYMER CORP.; LORETEX CORPORATION; PGI EUROPE, INC.; PGI POLYMER, INC.; PNA CORPORATION; POLY-BOND INC.; POLYLONIX SEPARATION TECHNOLOGIES, INC.; POLYMER GROUP, INC.; PRISTINE BRANDS CORPORATION; TECHNETICS GROUP, INC.
Reel/Frame 016851/0471 →
RELEASE OF SECURITY INTEREST IN PATENTS Recorded Dec 6, 2005
From: CITICORP NORTH AMERICA, INC., AS FIRST LIEN COLLATERAL AGENT
To: BONLAM (S.C.), INC.; CHICOPEE, INC.; DOMINION TEXTILE (USA) INC.; FABPRO ORIENTED POLYMERS, INC.; FABRENE CORP.; FABRENE GROUP L.L.C.; FIBERGOL CORPORATION; FIBERTECH GROUP, INC.; FNA ACQUISITION, INC.; FNA POLYMER CORP.; LORETEX CORPORATION; PGI EUROPE, INC.; PGI POLYMER, INC.; PNA CORPORATION; POLY-BOND INC.; POLYLONIX SEPARATION TECHNOLOGIES, INC.; POLYMER GROUP, INC.; PRISTINE BRANDS CORPORATION; TECHNETICS GROUP, INC.
Reel/Frame 016851/0436 →
SECURITY AGREEMENT Recorded Dec 6, 2005
From: POLYMER GROUP, INC.; CHICOPEE, INC.; FIBERTECH GROUP, INC.; PGI POLYMER, INC.; POLY-BOND INC.
To: CITICORP NORTH AMERICA, INC., AS COLLATERAL AGENT
Reel/Frame 016851/0624 →
SECURITY AGREEMENT Recorded Aug 12, 2004
From: CHICOPEE, INC.; FIBERTECH GROUP, INC.; POLY-BOND, INC.; POLYMER GROUP, INC.
To: WILMINGTON TRUST COMPANY, AS SECOND LIEN COLLATERAL AGENT
Reel/Frame 015778/0311 →
SECURITY AGREEMENT Recorded Aug 10, 2004
From: CHICOPEE, INC.; FIBERTECH GROUP, INC; POLY-BOND, INC.; POLYMER GROUP, INC.
To: CITICORP NORTH AMERICA, INC. AS FIRST LIEN COLLATERAL AGENT
Reel/Frame 015732/0080 →
RELEASE OF SECURITY INTEREST Recorded May 13, 2004
From: JPMORGAN CHASE BANK, AS ADMINISTRATIVE AGENT
To: FIBERTECH GROUP, INC.; POLYMER GROUP, INC.
Reel/Frame 015380/0798 →
SECURITY AGREEMENT Recorded Jun 26, 2003
From: POLYMER GROUP, INC.
To: JPMORGAN CHASE BANK
Reel/Frame 014192/0001 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Jun 15, 2001
From: CARLYLE, THOMAS SCOTT; STORZER, MARLENE
To: POLYMER GROUP INC.
Reel/Frame 011895/0440 →