A nonwoven web and method of preparing a novel nonwoven web of synthetic
fiber are disclosed. An aqueous solution amide crosslinked synthetic
precursor polymer is extruded under defined conditions through a plurality
of die orifices to form a plurality of threadlines. The threadlines are
attenuated with a defined primary gaseous source to form fiber under
conditions of controlled macro scale turbulence and under conditions
sufficient to permit the viscosity of each threadline, as it leaves a die
orifice and for a distance of no more than about 8 cm, to increase
incrementally with increasing distance from the die, while substantially
maintaining uniformity of viscosity in the radial direction, at a rate
sufficient to provide fiber having the desired attenuation and mean fiber
diameter without significant fiber breakage. The attenuated threadlines
are dried with a defined secondary gaseous source. The resulting fibers
are deposited randomly on a moving foraminous surface to form a
substantially uniform web. The moving foraminous surface is positioned
about 10 to about 100 cm from the last gaseous source to contact the
threadlines. The fibers have a mean fiber diameter in the range of about
0.1 to 30 .mu.m and are substantially free of shot. The attenuating and
drying steps are carried out under conditions of controlled macro scale
turbulence.
