This disclosure relates to air-assisted spinnerets and spinneret arrays for electrospinning. In some embodiments, the air-assisted spinnerets and spinneret arrays are incorporated in electrospinning systems and/or electrospinning machines. Methods of making and using the same are also described herein.

This disclosure relates to air-assisted spinnerets and spinneret arrays for electrospinning. In some embodiments, the air-assisted spinnerets and spinneret arrays are incorporated in electrospinning systems and/or electrospinning machines. Methods of making and using the same are also described herein.

An apparatus for making filaments has a spinneret plate having a row of holes from which emerge filaments. A manifold distributes a supplied plastic melt over a starting spinning width. A filter plate is downstream of the manifold. A pack of distributor plates is downstream of the filter plate. The distributor plates each have a plurality of distributor holes distributed over a manifold width. The distributor holes receive the plastic melt emerging from the filter plate. The spinneret plate is downstream of the distributor-plate pack and has a row of spinneret passages extending over a final spinning width aligned with the spinneret holes. An output face of the filter plate turned toward the distributor-plate pack and/or an inlet face of the spinneret plate turned toward the distributor-plate pack is curved or crowned at least in sections.

An apparatus for making filaments has a spinneret plate having a row of holes from which emerge filaments. A manifold distributes a supplied plastic melt over a starting spinning width. A filter plate is downstream of the manifold. A pack of distributor plates is downstream of the filter plate. The distributor plates each have a plurality of distributor holes distributed over a manifold width. The distributor holes receive the plastic melt emerging from the filter plate. The spinneret plate is downstream of the distributor-plate pack and has a row of spinneret passages extending over a final spinning width aligned with the spinneret holes. An output face of the filter plate turned toward the distributor-plate pack and/or an inlet face of the spinneret plate turned toward the distributor-plate pack is curved or crowned at least in sections.

One or more aspects of the disclosure provides a nonwoven fabric comprising a single layer in which the single fabric layer comprises a plurality of different fibers in which each fiber type has desired functionality. In one aspect, 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, is provided. The system includes a spin beam having a zoned distribution plate disposed upstream of a spinneret, the zoned distribution plate includes 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 to form a single layer having two or more types of fibers that are of a different type from each other.

A method and apparatus for fabricating a conjugate fiber. Resins having different properties, for example, resins of the same or different components including functional pigments or substances are continuously and alternatively discharged in an endless state by operating a spinning nozzle unit in a melting state, thereby fabricating the conjugate fiber having the different properties in the longitudinal direction of the fiber, and having various surface effects and patterns in the longitudinal direction of the fiber. A conjugate fiber fabricated by the above apparatus and method is also provided.

A method and apparatus for fabricating a conjugate fiber. Resins having different properties, for example, resins of the same or different components including functional pigments or substances are continuously and alternatively discharged in an endless state by operating a spinning nozzle unit in a melting state, thereby fabricating the conjugate fiber having the different properties in the longitudinal direction of the fiber, and having various surface effects and patterns in the longitudinal direction of the fiber. A conjugate fiber fabricated by the above apparatus and method is also provided.

A method of making nonwoven webs comprising providing a spinneret wherein the spinneret includes a pattern of conduits, the pattern of conduits forming an extrusion region; directing only a first stream of molten propylene polymer having a first temperature into a region adjacent of the first side of the spinneret, directing only a second stream of molten propylene polymer having a second temperature into a region distal to the first side of the spinneret, extruding only the first stream of molten propylene polymer through the exit openings in a first zone; extruding only the second stream of molten propylene polymer through the exit openings of a second zone; the second zone is distal to the first side with the first zone being between the second zone and the first side.

A method of making nonwoven webs comprising providing a spinneret wherein the spinneret includes a pattern of conduits, the pattern of conduits forming an extrusion region; directing only a first stream of molten propylene polymer having a first temperature into a region adjacent of the first side of the spinneret, directing only a second stream of molten propylene polymer having a second temperature into a region distal to the first side of the spinneret, extruding only the first stream of molten propylene polymer through the exit openings in a first zone; extruding only the second stream of molten propylene polymer through the exit openings of a second zone; the second zone is distal to the first side with the first zone being between the second zone and the first side.

The invention relates to a melt conductor (1), in particular a melt distributor or melt mixer, for an extruding die (2) of an extrusion facility (3), comprising a melt conductor block (4) with a multi-channel system (5), the multi-channel system (5) being arranged inside the melt conductor block (4) with three-dimensional extension and having at least one input (6) and at least one output (7) for polymer melt, between one input (6) and one output (7) fluidically connected to the input (6) several branchings (8) arranged in series and several levels (9a) of sub-branches (10) being formed over several levels (12a, 12b) of divided melt channels (11a, 11b); with m melt channels (11a) of the a.sup.th level (12a) with X.sup.th local cross-sections and n melt channels (11b) of the b.sup.th level (12b) with y.sup.th local cross-sections being present, wherein n>m if b>a, the y.sup.th local cross-sections of the melt channels (11b) of the b.sup.th level (12b) being smaller than the X.sup.th local cross-sections of the melt channels (11a) of the a.sup.th level (12a). The invention further relates to an extruding die, an extrusion facility and to a method of operating the extrusion facility.