Abstract: Methods for forming an absorbent fibrous composite containing absorbent material dispersed in bands through the composite and along the composite's length are disclosed. The methods generally include depositing a fibrous slurry on a foraminous support to form a web and depositing or injecting absorbent material into the web across its width to provide a web having absorbent material in bands along the composite's length. Drying the web provides a fluted absorbent composite. In one embodiment, the method is a wetlaid method and in another embodiment, the method is a foam-forming method. Preferably, the methods are twin-wire forming methods.

Abstract: Methods for forming an absorbent fibrous composite containing absorbent material dispersed in bands through the composite and along the composite's length are disclosed. The methods generally include depositing a fibrous slurry on a foraminous support to form a web and depositing or injecting absorbent material into the web across its width to provide a web having absorbent material in bands along the composite's length. Drying the web provides a fluted absorbent composite. In one embodiment, the method is a wetlaid method and in another embodiment, the method is a foam-forming method. Preferably, the methods are twin-wire forming methods.

Abstract: Methods for forming an absorbent fibrous composite containing absorbent material dispersed in bands through the composite and along the composite's length are disclosed. The methods generally include depositing a fibrous slurry on a foraminous support to form a web and depositing or injecting absorbent material into the web across its width to provide a web having absorbent material in bands along the composite's length. Drying the web provides a fluted absorbent composite. In one embodiment, the method is a wetlaid method and in another embodiment, the method is a foam-forming method. Preferably, the methods are twin-wire forming methods.

Abstract: An absorbent composite having a reticulated core and a fibrous stratum is disclosed. The core and stratum are integrally formed, and the stratum is coextensive with a surface of the core. In one embodiment, the composite includes strata on opposing surfaces of the core. The core includes a fibrous matrix and absorbent material. The fibrous matrix defines voids and passages between the voids, which are distributed throughout the composite. Absorbent material is located within some of the voids. On wetting, absorbent material located in these voids is expandable into the void. Methods for forming the composite and absorbent articles that include the composite are also disclosed.

Abstract: An apparatus is disclosed for preparing a quantity of individual treated fibers from one or more fiber mats. The apparatus comprises a fiber treatment zone, and a conveyor for conveying each mat through the fiber treatment zone. In the treatment zone each mat is impregnated by an applicator with a treatment material, such as a crosslinking substance, and conveyed directly to an attrition device. The attrition device fiberizes the mats to form a fiber output having a low nit level, such as no more than about three, and a dryer both dries the fiber output and cures the crosslinking substance. The fiberizer is configured to minimize the accumulation of fiber at locations therein. Fiber is transported from the attrition device to the dryer at a high velocity under reduced pressure to promote drying. A heated retention bin is provided after drying to increase curing time in the system. A thermobonding agent may be added to the dried and cured fibers to enhance the wet strength of webs made from the fiber.

Abstract: Disclosed is a process for making reduced odor individualized, crosslinked fibers which includes the steps of providing cellulosic fibers, contacting the fibers with a solution containing a C.sub.2 -C.sub.9 polycarboxylic acid crosslinking agent, mechanically separating the fibers into substantially individual form, drying the fibers and reacting the crosslinking agent with the individualized fibers to form intrafiber crosslink bonds. The individualized cellulosic fibers are then contacted with a strong alkaline solution and strong oxidizing agent to reduce the odor and increase the brightness. Preferably, the crosslinking agent is citric acid, and preferably, between about 1.0 weight % and about 12.0 weight % of the crosslinking agent reacts to form the intrafiber crosslink bonds. Preferably, the alkaline solution is an aqueous solution of sodium hydroxide, and preferably, about 0.09 weight % of the sodium hydroxide, on a dry fiber weight basis, is applied to the crosslinked fibers.

Abstract: An apparatus is disclosed for preparing a quantity of individual treated fibers from one or more fiber mats. The apparatus comprises a fiber treatment zone, and a conveyor for conveying each mat through the fiber treatment zone. In the treatment zone each mat is impregnated by an applicator with a treatment material, such as a crosslinking substance, and conveyed directly to an attrition device. The attrition device fiberizes the mats to form a fiber output having a low nit level, such as no more than about three, and a dryer both dries the fiber output and cures the crosslinking substance. The fiberizer is configured to minimize the accumulation of fiber at locations therein. Fiber is transported from the attrition device to the dryer at a high velocity under reduced pressure to promote drying. A heated retention bin is provided after drying to increase curing time in the system. A thermobonding agent may be added to the dried and cured fibers to enhance the wet strength of webs made from the fiber.

Abstract: A method is disclosed for preparing a quantity of individual treated fibers from one or more fiber mats in a treatment apparatus. The apparatus comprises a fiber treatment zone, a conveyor for conveying each mat through the fiber treatment zone, wherein each mat is impregnated by an applicator with a crosslinking substance, and directly to an attrition device. The attrition device fiberizes the mats to form a fiber output having a low nit level, such as no more than about three, and a dryer for both drying the fiber output and curing the crosslinking substance. The fiberizer is configured to have minimize the accumulation of fiber at locations therein. An optional component of the fiberizer is a novel fluff generator comprised of multiple rotors each having plural longitudinally extended rows of radially extending rotor pins that rotate past groups of shorter pins mounted on the inside surface of the fluff generator housing.

Abstract: A fiberizer is described having a rotor to which plural hammers are mounted for fiberizing a sheet of fibers delivered to the rotor as the rotor is rotated. A feed mechanism utilizing a pair of seal rollers, at least one of which is driven, is configured for effective delivery of both wet or dry sheets to the fiberizer. The hammers are configured to minimize dead spaces within the fiberizer. In addition, air flow is directed through the fiberizer to minimize accumulations of fibers therein. Furthermore, an optional liquid flushing mechanism is provided for periodically cleaning the fiberizer during use.

Abstract: Restrained bales are formed for transporting high-bulk, crosslinked cellulose fiber in a reduced volume. A limited amount of force is used in compressing the fiber into the bales so that the fiber is not damaged. The limited amount of force used allows the bale, when restraints are released, to expand to about twice its restrained volume. Fiber damage is further minimized by limiting the amount of compression to the minimum required so that a transport container is completely filled to its volume and payload capacities.

Abstract: Restrained bales are formed for transporting high-bulk, crosslinked cellulose fiber in a reduced volume. A limited amount of force is used in compressing the fiber into the bales so that the fiber is not damaged. The limited amount of force used allows the bale, when restraints are released, to expand to about twice its restrained volume. Fiber damage is further minimized by limiting the amount of compression to the minimum required so that a transport container is completely filled to its volume and payload capacities.