Claims
- 1. A segmented die assembly comprising:(a) a plurality of manifold segments, each having an inlet polymer flow passage and a polymer discharge flow passage formed therein; said manifold segments being interconnected in side-by-side relationship wherein said inlet polymer flow passages are in fluid communication, respectively, and each manifold segment including a rotary positive displacement pump for receiving a polymer melt from said inlet polymer flow passage and discharging the polymer melt into said polymer discharge flow passage, said positive displacement pump including a driven rotary member; (b) a shaft extending through said manifold segments and connected to said driven rotary member of each manifold segment, said shaft comprising a stub shaft mounted in each manifold segment, and said stub shafts being interconnected in end-to-end relationship; (c) a motor for driving said shaft so that said motor drives said interconnected stub shafts as a unit whereby said rotary positive displacement pump of each manifold segment pumps polymer melt into its respective polymer discharge flow passage; (d) a die module comprising (i) a die body mounted on each manifold segment and having a polymer flow passage in fluid communication with the polymer discharge flow passage of its associated manifold segment; and (ii) a nozzle mounted on the die body and having a polymer flow passage in fluid communication with said polymer flow passage of its associated die body for receiving the polymer melt and discharging a filament or filaments of the polymer melt therefrom; and (e) means for delivering a polymer melt to said inlet polymer flow passage of each manifold segment whereby the melt is distributed to said inlet polymer flow passages of the manifold segments and flows in each segment to said pump, said discharge flow passage and said flow passages of said die body and said nozzle.
- 2. The die assembly of claim 1, wherein at least two of said manifold segments are identical.
- 3. The die assembly of claim 1, wherein the positive displacement pump of each manifold segment comprises a gear pump.
- 4. The die assembly of claim 3, wherein each manifold segment includes a recess and wherein said gear pump of each manifold segment comprises a pair of intermeshed gears located internal to said recess of said manifold segment, said recess sealed by an adjacent manifold segment.
- 5. A segmented die assembly, comprising:(a) a plurality of manifold segments interconnected in side-by-side relationship, each manifold segment having (i) an inlet polymer flow passage formed therein; (ii) a rotary positive displacement pump mounted therein for receiving a polymer melt from its respective inlet polymer flow passage and discharging the polymer melt into a polymer discharge flow passage, said positive displacement pump including a driven rotary member; and (iii) a stub shaft drivingly connected to said driven rotary member; (b) a means for interconnecting said stub shafts in end-to-end relationship whereby rotation of said interconnected stub shafts rotates said rotary member in unison; (c) a motor for rotating said interconnected stub shafts whereby said rotary positive displacement pump of each manifold segment pumps polymer melt into its respective polymer discharge flow passage; (d) a die module comprising (i) a die body mounted on each manifold segment and having a polymer flow passage in fluid communication with said polymer discharge flow passage of its associated manifold segment; and (ii) a nozzle mounted on said die body and having a polymer flow passage in fluid communication with said polymer flow passage of its associated die body for receiving the polymer melt and discharging a filament or filaments of the polymer melt therefrom; and (e) means for delivering the polymer melt to said inlet polymer flow passage of each manifold segment whereby the melt is distributed to said inlet polymer flow passages of said manifold segments and flows in each segment to the pump, said discharge flow passage and said flow passage of said die body and said nozzle.
- 6. A die assembly manifold for operating a selectable number of die modules and a corresponding number of recirculation modules, said die assembly manifold comprising:(a) a plurality of manifold segments corresponding to the selectable number of die modules, said manifold segments being interconnected in side-by-side relationship, each manifold segment including: (i) a polymer inlet flow passage in fluid communication with an adjacent manifold segment forming a continuous polymer flow passage; (ii) a polymer discharge flow passage configured to provide a pressurized polymer melt to the die modules and the recirculation modules associated with the manifold segment; (iii) a rotary positive displacement pump for receiving a polymer melt from said polymer inlet flow passage and discharging the pressurized polymer melt into said polymer discharge flow passage; (iv) a first die module instrument air passage for one of the selectable number of die modules; and (v) a first recirculation module instrument air passage for one of the corresponding number of recirculation modules; (b) a pair of end plates laterally closing the plurality of manifold segments, said pair of end plates configured to provide the polymer melt to said continuous polymer flow passage; and (c) a pump drive shaft extending through said manifold segments and connected to each rotary positive displacement pump to drive each pump and maintain operating pressure of the polymer melt within said manifold segments.
- 7. The die assembly manifold of claim 6, wherein the die modules are pneumatically controllable by a die module pneumatic controller, and each manifold segment further comprises:a first input instrument air flow passage in gaseous communication with the other manifold segments to form a continuous instrument air input flow passage, said continuous instrument air input flow passage configured to provide instrument air to the die module pneumatic controller; a first exhaust instrument air flow passage in gaseous communication with the other manifold segments to form an exhaust instrument air continuous flow passage, said exhaust instrument air continuous flow passage configured to exhaust instrument air from the die module pneumatic controller; and a second die module instrument air passage, said first and second die module instrument air passages each configured to be in gaseous communication between the die module pneumatic controller and a selected one of the die modules for selectively opening and closing the selected one of the die modules.
- 8. The die assembly manifold of claim 7, wherein the recirculation modules are pneumatically controllable by a recirculation module pneumatic controller, each manifold segment further comprising:a second input instrument air flow passage in gaseous communication with the other manifold segments to form a second continuous instrument air input flow passage, said second instrument air input flow passage configured to provide instrument air to the recirculation module pneumatic controller; a second exhaust instrument air flow passage in gaseous communication with the other manifold segments to form a second exhaust instrument air continuous flow passage, said second exhaust instrument air continuous flow passage configured to exhaust instrument air from the recirculation module pneumatic controller; and a second recirculation module instrument air passage, said first and second recirculation module instrument air passages each configured to be in gaseous communication between the recirculation module pneumatic controller and a selected one of the recirculation modules for selectively opening and closing the recirculation module.
- 9. The die assembly manifold of claim 6, wherein each die module includes a meltblowing nozzle configured to discharge process air to displace a filament dispensed by the die module, the pair of end plates further configured to provide process air to said plurality of manifold segments, each manifold segment further comprising:a process air passage in gaseous communication with the other manifold segments to form a continuous process air flow passage, the process air flow passage configured to provide process air to a respective one of the die modules.
- 10. The die assembly manifold of claim 9, wherein said process air flow passage of each manifold segment comprises a plurality of holes, said pair of end plates including slots coupling said plurality of holes to form a continuous process air flow passage adapted to be heated during multiple passes of the process air through the plurality of manifold segments.
- 11. A die assembly for operating a selectable number of die modules and a corresponding number of recirculation modules, comprising:(a) a plurality of manifold segments corresponding to the selectable number of die modules, said manifold segments being interconnected in side-by-side relationship, each manifold segment including: (i) a polymer inlet flow passage in fluid communication with an adjacent manifold segment forming a continuous polymer flow passage; (ii) a polymer discharge flow passage configured to provide a pressurized polymer melt to the die modules and the recirculation modules associated with the manifold segment; (iii) a rotary positive displacement pump for receiving a polymer melt from said polymer inlet flow passage and discharging the pressurized polymer melt into said polymer discharge flow passage; (iv) a first die module instrument air passage for one of the selectable number of die modules; and (v) a first recirculation module instrument air passage for one of the corresponding number of recirculation modules; (b) a pair of end plates laterally closing the plurality of manifold segments, said pair of end plates configured to provide the polymer melt to said continuous polymer flow passage; (c) a pump drive shaft extending through said manifold segments and connected to each rotary positive displacement pump to drive each pump and maintain operating pressure of the polymer melt within said manifold segments; a motor operably coupled to said drive shaft to drive said plurality of rotary positive displacement pumps; and a plurality of die modules each comprising (i) a die body mounted on one of said manifold segments and having an inlet polymer flow passage in fluid communication with said polymer discharge flow passage of its associated manifold segment; and (ii) a nozzle mounted on said die body and having an inlet polymer flow passage in fluid communication with said inlet polymer flow passage of its associated die body for receiving the polymer melt and discharging a filament or filaments of the polymer melt therefrom.
- 12. The die assembly of claim 11, wherein said nozzles of each die module are arranged in a row, and each rotary positive displacement pump of each manifold segment includes a driven rotating member which rotates about an axis parallel to said row of nozzles.
- 13. The die assembly of claim 11, further including a recirculation module mounted on each manifold segment and having an inlet polymer flow passage in fluid communication with said polymer discharge flow passage of its associated manifold segment.
- 14. The die assembly of claim 13, wherein the assembly further includes a passage for recirculating the polymer melt from said recirculation module to a means for delivering polymer melt to said inlet polymer flow passage of each manifold segment.
- 15. A die assembly for operating a selectable number of die modules and a corresponding number of recirculation modules respectively configured for operation by a die module pneumatic controller and a recirculation module pneumatic controller, the die assembly comprising:(a) a plurality of manifold segments corresponding to the selectable number of die modules, said manifold segments being interconnected in side-by-side relationship, each manifold segment including: (i) a polymer inlet flow passage in fluid communication with an adjacent manifold segment forming a continuous polymer flow passage; (ii) a polymer discharge flow passage configured to provide a pressurized polymer melt to the die modules and the recirculation modules associated with the manifold segment; (iii) a rotary positive displacement pump for receiving a polymer melt from said polymer inlet flow passage and discharging the pressurized polymer melt into said polymer discharge flow passage; (iv) a first die module instrument air passage for one of the selectable number of die modules; and (v) a first recirculation module instrument air passage for one of the corresponding number of recirculation modules; (b) a pair of end plates laterally closing the plurality of manifold segments, said pair of end plates configured to provide the polymer melt to said continuous polymer flow passage; (c) a pump drive shaft extending through said manifold segments and connected to each rotary positive displacement pump to drive each pump and maintain operating pressure of the polymer melt within said manifold segments; (d) a first input instrument air flow passage in gaseous communication with the other manifold segments to form a continuous instrument air input flow passage, said continuous instrument air input flow passage configured to provide instrument air to a die module pneumatic controller; (e) a first exhaust instrument air flow passage in gaseous communication with the other manifold segments to form an exhaust instrument air continuous flow passage, said exhaust instrument air continuous flow passage configured to exhaust instrument air from the die module pneumatic controller; (f) a second die module instrument air passage, said first and second die module instrument air passages each configured to be in gaseous communication between the die module pneumatic controller and a selected one of the die modules for selectively opening and closing the selected one of the die modules; (g) a second input instrument air flow passage in gaseous communication with the other manifold segments to form a second continuous instrument air input flow passage, said second instrument air input flow passage configured to provide instrument air to a continuous recirculation module pneumatic controller; (h) a second exhaust instrument air flow passage in gaseous communication with the other manifold segments to form a second exhaust instrument air continuous flow passage, said second exhaust instrument air continuous flow passage configured to exhaust instrument air from the recirculation module pneumatic controller; (j) a second recirculation module instrument air passage, said first and second recirculation module instrument air passages each configured to be in gaseous communication between the recirculation module pneumatic controller and a selected one recirculation module for selectively opening and closing the recirculation module; (k) a motor operably coupled to said shaft to drive said plurality of rotary positive displacement pumps; (l) a die module mounted on each manifold segment and having an inlet polymer flow passage in fluid communication with said polymer discharge flow passage of its associated manifold segment; and (ii) a nozzle mounted on said die body and having an inlet polymer flow passage in fluid communication with said inlet polymer flow passage of its associated die body for receiving the polymer melt and discharging a filament or filaments of the polymer melt therefrom; and (m) a recirculation module comprising a die body mounted on each manifold segment, said die body having an inlet polymer flow passage in fluid communication with said polymer discharge flow passage of its associated manifold segment for receiving the polymer melt and discharging a recirculated polymer melt.
- 16. The die assembly of claim 15, further comprising:a die module pneumatic controller operably coupled to each manifold segment for controlling the associated die module; and a recirculation module pneumatic controller operably coupled to each manifold segment for controlling the associated recirculation module.
- 17. The die assembly of claim 16, wherein each pneumatic controller comprises a solenoid valve.
RELATED APPLICATION
This application is a continuation-in-part of Application Ser. No. 09/063,651, filed Apr. 20, 1998 (now abandoned), the disclosure of which is hereby fully incorporated by reference herein.
US Referenced Citations (19)
Foreign Referenced Citations (3)
Number |
Date |
Country |
68534594.6 |
Dec 1985 |
DE |
0820817 |
Jan 1988 |
EP |
WO 9401221 |
Jan 1994 |
WO |
Non-Patent Literature Citations (1)
Entry |
Trends (1993) The CF 800 Metered Head. |
Continuation in Parts (1)
|
Number |
Date |
Country |
Parent |
09/063651 |
Apr 1998 |
US |
Child |
09/141959 |
|
US |