Abstract: A fusion bonded fiber product is made by compressing between heated dies a mat of moisture-containing fibers of the type that change irreversibly to an amorphous nonglassy state that permits fiber-to-fiber bonding at a characteristic critical temperature. The further compression of the partially compacted mat is stopped or slowed when the mat is a small multiple of the desired caliper for the bonded product for a period of time sufficient to vaporize the moisture content of the mat. During this time period, most of the vaporized moisture content of the mat is expelled as saturated steam through the mat surfaces while the temperature of the mat is still well below the critical temperature. Then, the compression of the mat is continued under continuous consolidation to the final density and caliper of the fusion bonded product while the mat is heated to a temperature above the critical temperature.

Abstract: A chopped mixture derived from municipal solid waste, free of ferrous metal is fed into the open upper end of a vertical rotor chamber for contact sequentially by an upper and lower high-speed rotor, with the rotor blades of the rotors further chopping the mixture and imparting centrifugal force to the mixture particles. Selectifier screens concentrically surround the rotor blades at the upper and lower rotor positions and have mesh openings which effect ballistic separation and elimination of glass, grit, sand, dust and fiber elements at these levels dependent upon the screen size openings. The two rotors are separated to form an intermediate treatment zone permitting liquid or solid spray of the mixture particles passing vertically downward from the upper rotor zone to the lower rotor zone.