Patent ID: 7998384
Filing Date: 2011-08-16
Classification: D01F,D04H,Y02P,Y10T

Abstract:
1. A process for producing spunbond nonwoven fabric, comprising the steps of: separately melting two or more polypropylene polymer components, at least one component including reclaimed polypropylene recovered from previously spun polypropylene fiber or webs comprised of previously spun polypropylene fiber, and wherein at least one component comprises virgin polymer separately directing the two or more molten polypropylene polymer components through a distribution plate configured so that the separate molten polymer components combine at a multiplicity of spinnerette orifices to form bicomponent filaments containing the two or more polymer components, the polymer components being arranged in a sheath-core cross-sectional configuration, with the polymer component containing reclaimed polypropylene being present in the core, and the reclaimed polypropylene being in an amount up to 100% by weight, and with the total amount of reclaimed polypropylene in the filaments being 25% by weight or greater; extruding the multicomponent filaments from the spinnerette orifices into a quench chamber; directing quench air from a first independently controllable blower into the quench chamber and into contact with the filaments to cool and solidify the filaments; directing the filaments and the quench air into and through a filament attenuator and pneumatically attenuating and stretching the filaments; directing the filaments from the attenuator into and through a filament depositing unit; depositing the filaments from the depositing unit randomly upon a moving continuous air-permeable belt to form a nonwoven web of substantially continuous filaments; applying suction from a second independently controllable blower beneath the air-permeable belt so as to draw air through the depositing unit and through the air-permeable belt; and directing the web through a bonder and bonding the filaments to convert the web into a coherent nonwoven fabric.