Patent ID: 8206640

Claim:
A process for preparing a fiber batt from blow spun fibers comprising: a) heating a spinnable substance to a temperature sufficient to allow the spinnable substance to flow; b) forming at least one fiber by passing the spinnable substance into a spinning apparatus and through at least one capillary located within the spinning apparatus, wherein said at least one fiber has an initial velocity; c) contacting said at least one fiber with at least one flowing stream of gas; d) contacting said at least one fiber with at least one additional flowing stream of gas to place said fiber under tension, wherein the velocity of said at least one additional flowing stream of gas is greater than said initial velocity of the at least one fiber; e) passing said at least one fiber and said additional flowing stream of gas into a venturi; f) thereafter passing said at least one fiber into a diffuser, comprising an upper portion and a lower portion, wherein the diffuser is shaped so that its walls curve outwards to provide for a horizontal component and an upward vertical component to the gas flow thereby dissipating the at least one additional flowing stream of gas to reduce the velocity of the at least one additional flowing stream of gas thereby reducing the velocity of the at least one fiber to a final velocity; g) passing said at least one fiber out of said diffuser at said final velocity; and, h) collecting said at least one fiber to form a fiber batt.