Abstract: A dry-formed web is transferred at speeds in excess of 300 feet per minute onto a stable, porous, endless belt and both the dry-formed web and the belt are conveyed through the embossing nip. The combination of the dry-formed web and the belt are guided into the embossing nip so that the web and belt partially wraps the embossing roll before entering the embossing nip. As the embossing roll contacts the web, some of the air in the web is forced through the porous belt.

Abstract: An apparatus for testing the permeability of porous web materials. The porous web 12 is placed against a surface of a test head 10 of the apparatus. The test head 10 contains at least one aperture 28 and a vacuum source 87 connected to the test head 10 causes air to be drawn through the web 12 and then through the aperture 28. The test head 10 also includes at least one static port 32 that communicates with the aperture 28. The static port 32 is located very close to the web 12 and measures the static pressure within the aperture 28 before it leaves the aperture 28. A pressure transducer 46 is connected to the static port 32 and provides a measurement of the pressure drop across the web 12. If the volumetric flow rate of air through the web 12 is kept constant, the pressure transducer 46 output 52 is representative of the permeability of the web 12.

Abstract: A dry-formed nonwoven fabric; preferably an air lay web; including a fiber composition which is at least 50%, by weight, wood pulp fiber less than about 0.635 cm (1/4 inch) in length with 25% or more of the fiber composition in the web, by weight, being kraft wood pulp fibers, and under 50%, by weight, reinforcing fibers intermixed with the wood pulp fibers throughout the web structure; an embossment in the web providing a plurality of compressed, densified valley regions and less-dense high loft regions; the web including no more than about 5.1 g/m.sup.2 (3.0 lbs per ream of 2,880 ft..sup.2) of a binder and having a cross machine direction wet tensile strength no lower than about 0.09 Kg/cm (0.5 lbs/inch), and preferably at least 0.107 Kg/cm (0.6 lbs/inch). A higher cross-machine direction wet tensile strength in excess of 0.267 Kg/cm (1.5 lbs/inch) can be established at a binder level less than 8.5 g/m.sup.2 (5 lbs/ream), and preferably at a binder level between 6.8-8.5 g/m.sup.2 (4-5 lbs/ream).

Abstract: An apparatus for increasing the width, or cross-machine-direction dimension of a fluid-entrained (e.g., air-entrained) stream of fibers to form a fibrous web that is wider than the stream of fibers. A rotatable spreading roll having a foraminous outer surface obliquely intercepts the open downstream end of a conveying duct through which the fluid-entrained stream of fibers is directed, and an intermediate web, wider than the stream of fiber in the first conveying duct, is deposited on this foraminous surface. The spreading roll is rotated to direct the intermediate web into communication with the upstream end of a second conveying duct, and a pressure differential established through the apparatus functions to relaunch the fibers of the intermediate web into the second conveying duct, and ultimately onto a foraminous forming surface to form a fibrous web product that is wider than the initially formed stream of fibers in the first conveying duct.

Abstract: An apparatus for increasing the width, or cross-machine-direction dimension of a fluid-entrained (e.g. air-entrained) stream of fibers prior to depositing the fibers on a foraminous forming surface to form a fibrous web structure. A rotatable spreading roll intercepts the open downstream end of a conveying duct through which the fluid-entrained stream of fibers is directed, and this roll includes a plurality of axially spaced disks providing flow-directing channels between them. The rotational axis of the spreading roll is oriented obliquely to the duct so that the lateral dimension of flow-directing channels between laterally spaced-apart duct sidewalls is greater than the width of the duct at its open downstream end, as measured generally normal to the direction of fiber flow through the duct.

Abstract: An apparatus and method for fluid-forming (e.g., air-forming) a fibrous structure, such as a fibrous web, employs a conveying duct through which a stream of fluid-entrained fibers is directed, and a foraminous surface intercepting the downstream end of the duct to collect the fibrous structure on its surface. The improvement resides in establishing an oblique orientation between the foraminous surface and the direction of fiber flow through the duct so that the width of the foraminous surface intercepting the open end of the duct is greater than the width of the downstream end of the duct, as measured between laterally spaced sidewalls in a direction generally normal to the direction of material flow through the duct. In accordance with this invention the width of the fibrous structure deposited on the foraminous surface is greater than the width of the stream of fluid-entrained fibers confined within the conveying duct.

Abstract: Method and apparatus for separating fibers from a stack of fibrous sheets, either in roll or bale form, by directing the stack of sheets into engagement with a fiberizing means employs a differential feed system for directing the bottom sheet, or sheets, of the stack into engagement with the fiberizing means at a different speed relative to other sheets of the stack. Preferably the bottom sheet of the stack is fed into the fiberizing means at a slower speed relative to other sheets of the stack to minimize clump generation in the fiberizing operation.

Abstract: Clump-removal devices are disclosed for separating unacceptably large clumps from an air stream containing both clumps and substantially individualized fibers.