Abstract: A method and apparatus for impregnating a porous substrate with a solids-bearing saturant first introduces the saturant into the substrate from a first side, and then introduces a displacement material into the substrate from the first side. This displacement material forces at least some of the saturant in the substrate farther into the substrate, away from the first side. A wide variety of devices can be used for introducing the saturant and the displacement material into the substrate, including pressure saturators, converging chamber pressure saturators, roller coaters, blade coaters, and the like. By pushing the saturant away from the first side with the displacement material, the first side can be made more suitable for further processing such as adhesive bonding.

Abstract: A saturator of the type comprising a chamber situated between a chamber defining element and a mandrel, in which a web is moved between the chamber defining element and the mandrel to impregnate the web with a saturant contained in the chamber includes at least one saturant delivery port which extends across substantially the entire width of the chamber or the entire width of one of the saturating zones if the chamber defines a plurality of saturating zones. In this way, uniformity of saturation across the chamber is improved. An insert is removably mounted to the chamber defining element such that a surface of the insert defines a wall of the chamber.

Abstract: A pressure saturator system includes a grooved mandrel and an opposed element which define a converging chamber therebetween. A web is passed through the chamber with a first side of the web adjacent the mandrel. A liquid saturant is introduced into the chamber such that the saturant contacts the second side of the web and impregnates the web as the web passes through the chamber. A gas receiving belt is passed through the chamber with the belt interposed between the web and the mandrel and in contact with the first side of the web. The belt receives gases and any excess saturant form the first side of the web as the saturant enters the web in the chamber, thereby facilitating the removal of gases from the web, improving the saturation process, and protecting the mandrel from undesired contact with the saturant. In alternate embodiments the betls is formed of a porous material or defines an array of gas receiving slots positioned against the first side of the web.

Abstract: A saturator of the type comprising a chamber situated between a chamber defining element and a mandrel, in which a web is moved between the chamber defining element and the mandrel to impregnate the web with a saturant contained in the chamber includes at least one saturant delivery port which extends across substantially the entire width of saturation zone which extends only partially across the web if the chamber defines a plurality of saturating zones. In this way, uniformity of saturation across the chamber is improved.

Abstract: An apparatus for processing a self-supporting web includes a rotatable mandrel and a stationary block member which defines a recess adjacent the mandrel. The recess is shaped to form a converging chamber between the mandrel and the block member, which converges in the direction of motion of the self-supporting web. A belt is mounted for movement through the chamber and is positioned between the self-supporting web and the block member. The chamber is sized to compress the self-supporting web between the block member and the mandrel, thereby reducing the thickness of the self-supporting web as it passes through the chamber. This apparatus can be used for laminating, liquid removal, or caliper reduction operations on the self-supporting web.

Abstract: A saturator of the type which includes a chamber situated between a chamber defining element and a mandrel, in which a web is moved through the chamber to impregnate the web with a saturant contained in the chamber, includes a chamber defining element which defines an array of grooves. The grooves are separated by raised surfaces. The raised surfaces cooperate with the mandrel to pressurize the saturant in a high pressure zone which causes a relatively large amount of saturant to enter the web. The grooves define respective low pressure zones, which cause a reduced amount of saturant or no saturant to impregnate the web. A desired pattern of impregnation of the web can be obtained by properly positioning the grooves with respect to the raised surfaces on the chamber defining element.

Abstract: A saturator of the type comprising a chamber situated between a chamber defining element and a mandrel, in which a web is moved between the chamber defining element and the mandrel to impregnate the web with a saturant contained in the chamber includes a stencil having at least one impermeable region shaped to cover less than the entire web. The stencil is passed through the chamber at the same speed as the web with the stencil juxtaposed against the web such that portions of the web aligned with the at least one impermeable region are not impregnated with the saturant, while other exposed portions of the web are impregnated with the saturant.

Abstract: A pressure saturator for impregnating a substrate with a saturant is disclosed, having a block member with an arcuate, sloping upper surface that is graduated from a relatively deep portion to a relatively shallow portion. Rollers are disposed on each side of the block member for conveying the substrate into and out of the saturator, and a mandrel is disposed between the rollers for guiding the substrate through the saturator. The lower portion of the mandrel is spaced from the block member and extends into the recess formed by the arcuate surface to define a chamber therebetween. The chamber has an inlet and an outlet for admitting the substrate and the saturant, and converges in depth from the inlet region to the outlet region to pressurize the solution and force the saturant into the interstices of the substrate.

Abstract: A pressure saturator for impregnating porous substrate materials with solids in solution, in which a reservoir contains the saturant solution and has a base member with a portion forming a depression therein. A mandrel is disposed within the depression in spaced relation to the surface of the depression. Preferably, the distance between the surface of the depression and the mandrel is three times the thickness of the substrate material. Heating elements are disposed in the base and heat the portion of the base member forming the depression, thereby heating the solution between the mandrel and the surface of the depression. The substrate is fed into the saturator from a supply roll and is passed through the space between the depression and the mandrel. The heated solution causes solids from the solution to replace the air in the interstices of the substrate in a near 100 percent weight-to-weight saturation.