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: 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 fiber fluff generator includes a housing having three substantially cylindrical portions, each of which mounts and contains a rotor having a rotor shaft and a plurality of rotor pins extending radially therefrom. The rotor pins are arranged in rows spaced incrementally along the length of the shaft with gaps therebetween, each row including plural rotor pins arranged in spoke-like fashion. The rotor shafts preferably are mounted parallel to one another and lie in a common vertical plane. The rotor pins on one rotor shaft are axially offset from and overlap with the rotor pins on the adjacent rotor shaft(s) so that the rotor pins collectively are interleaved to provide a cross-combing effect. Stator pins fastened to the housing extend radially inwardly into the gaps between the rows of rotor pins to provide further cross-combing interaction.

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.