US 12,270,135 B2
Nonwoven fabric having a single layer with a plurality of different fiber types, and an apparatus, system, and method for producing same
Marc Newman, Simpsonville, SC (US); Fabio Baldissera, Simpsonville, SC (US); Rene Ruschel, Greer, SC (US); and Yu Xin, Greer, SC (US)
Assigned to Fitesa Simpsonville, Inc., Simpsonville, SC (US)
Filed by Fitesa Simpsonville, Inc., Simpsonville, SC (US)
Filed on Jan. 5, 2024, as Appl. No. 18/405,722.
Application 18/405,722 is a continuation of application No. 17/572,271, filed on Jan. 10, 2022, granted, now 11,913,151.
Claims priority of provisional application 63/136,122, filed on Jan. 11, 2021.
Prior Publication US 2024/0183088 A1, Jun. 6, 2024
This patent is subject to a terminal disclaimer.
Int. Cl. B32B 37/15 (2006.01); D01D 5/08 (2006.01); D01D 5/22 (2006.01); D01D 5/32 (2006.01); D01D 5/34 (2006.01); D01D 7/00 (2006.01); D04H 3/005 (2012.01); D04H 3/007 (2012.01); D04H 3/033 (2012.01); D04H 3/16 (2006.01)
CPC D04H 3/033 (2013.01) [D01D 5/082 (2013.01); D04H 3/007 (2013.01); D04H 3/16 (2013.01); B32B 2250/20 (2013.01); B32B 2262/0253 (2013.01); B32B 2305/18 (2013.01)] 23 Claims
OG exemplary drawing
 
1. 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 comprises a first distribution zone configured to produce non-crimping or low crimping filaments and a second distribution zone configured to produce crimped filaments.