Abstract: Methods and apparatuses for producing a substrate are described. A method and apparatus for introducing a component into a fluid supply is also presented. A method can include providing a first fluid supply. The fluid supply can be configured as a foam in some embodiments. The method can also include providing a component feed system and a supply of the component. The method can include introducing the component to a fluid supply in an eductor in some aspects. A resultant slurry including a fluid supply and the component can be transferred through a headbox. The resultant slurry can be dewatered to provide a substrate including the component.

Abstract: Apparatuses and processes for producing a substrate are described. A headbox is also provided. The headbox can include at least one flow section. The at least one flow section can include a constriction zone; a slice zone; an expansion zone; and a formation zone. A process for producing a web is also provided. The process can include depositing a slurry of fibers into a constriction zone. The slurry of fibers can then be flowed from the constriction zone through a slice zone and into an expansion zone. The slurry of fibers can then be flowed from the expansion zone into a formation zone. The slurry can be conveyed on a moving forming surface. Fluids may be drained from the slurry of fibers through the forming surface within the formation zone to form an embryonic web. The embryonic web may be dried.

Abstract: Methods and apparatuses for producing a substrate are described. A method and apparatus for introducing a component into a fluid supply is also presented. A method can include providing a first fluid supply. The fluid supply can be configured as a foam in some embodiments. The method can also include providing a component feed system and a supply of the component. The method can include introducing the component to a fluid supply in an eductor in some aspects. A resultant slurry including a fluid supply and the component can be transferred through a headbox. The resultant slurry can be dewatered to provide a substrate including the component.

Abstract: Apparatuses and processes for producing a substrate are described. A headbox is also provided. The headbox can include at least one flow section. The at least one flow section can include a constriction zone; a slice zone; an expansion zone; and a formation zone. A process for producing a web is also provided. The process can include depositing a slurry of fibers into a constriction zone. The slurry of fibers can then be flowed from the constriction zone through a slice zone and into an expansion zone. The slurry of fibers can then be flowed from the expansion zone into a formation zone. The slurry can be conveyed on a moving forming surface. Fluids may be drained from the slurry of fibers through the forming surface within the formation zone to form an embryonic web. The embryonic web may be dried.

Abstract: Methods and apparatuses for producing a substrate are described. A method and apparatus for introducing a component into a fluid supply is also presented. A method can include providing a first fluid supply. The fluid supply can be configured as a foam in some embodiments. The method can also include providing a component feed system and a supply of the component. The method can include introducing the component to a fluid supply in an eductor in some aspects. A resultant slurry including a fluid supply and the component can be transferred through a headbox. The resultant slurry can be dewatered to provide a substrate including the component.

Abstract: Methods for foam forming a multi-layer substrate can include providing a first foam supply including a first supply of fibers and providing a second foam supply. The method can also include providing a supply of particulates. The method can include providing a headbox and a forming surface. The method can include transferring the first foam supply to a first z-directional layer of the headbox and transferring the second foam supply and the supply of particulates to a second z-directional layer of the headbox. The method can include transferring the first supply of fibers, the supply of particulates, and the second supply of fibers through an outlet of the headbox to the forming surface to form a resultant slurry. The resultant slurry can be configured such that the first supply of fibers are directly against the forming surface.

Abstract: Methods and apparatuses for producing a substrate are described. A method and apparatus for introducing a component into a fluid supply is also presented. A method can include providing a first fluid supply. The fluid supply can be configured as a foam in some embodiments. The method can also include providing a component feed system and a supply of the component. The method can include introducing the component to a fluid supply in an eductor in some aspects. A resultant slurry including a fluid supply and the component can be transferred through a headbox. The resultant slurry can be dewatered to provide a substrate including the component.

Abstract: Methods and apparatuses for drying web substrates are described. In one embodiment, a method of drying a web substrate may comprise supplying air to a first dryer head located proximate a web conveyer, the air within the first dryer head having a temperature of less than 176 degrees C., directing air from the first dryer head toward the web conveyer at a velocity greater than 1000 m/min and forming a first drying region, and advancing the web substrate in a first direction on the web conveyer and through the first drying region.

Abstract: Absorbent materials described herein can include an intake layer and an absorbent layer. The absorbent material can include a saturation capacity greater than 125 grams, and a second intake time of less than 50 seconds and a wet thickness of less than 17 mm according to the Modified Fluid Intake Under Pressure Test as described herein. In some aspects, the intake layer and the absorbent layer can provide an integrated material including an interface between the intake layer and the absorbent layer. The interface can include at least some fibers of the intake layer mixed with at least some fibers of the absorbent layer.

Abstract: Absorbent substrates including a high percentage of superabsorbent material and method of manufacturing such absorbent substrates are disclosed. An absorbent substrate can include an intake layer including a first plurality of fibers and an absorbent layer. The absorbent layer can include superabsorbent material providing greater than 80% of the absorbent layer by total weight of the absorbent layer. The intake layer and the absorbent layer can provide an integrated material including an interface between the intake and absorbent layers. The interface can include at least some of the first plurality of fibers of the intake layer mixed with at least some of the absorbent layer.

Abstract: Methods and apparatuses for producing a substrate are described. A method and apparatus for introducing a component into a fluid supply is also presented. A method can include providing a first fluid supply. The fluid supply can be configured as a foam in some embodiments. The method can also include providing a component feed system and a supply of the component. The method can include introducing the component to a fluid supply in an eductor in some aspects. A resultant slurry including a fluid supply and the component can be transferred through a headbox. The resultant slurry can be dewatered to provide a substrate including the component.

Abstract: Methods and apparatuses for producing a substrate are described. A method and apparatus for introducing a component into a fluid supply is also presented. A method can include providing a first fluid supply. The fluid supply can be configured as a foam in some embodiments. The method can also include providing a component feed system and a supply of the component. The method can include introducing the component to a fluid supply in an eductor in some aspects. A resultant slurry including a fluid supply and the component can be transferred through a headbox. The resultant slurry can be dewatered to provide a substrate including the component.

Abstract: Absorbent materials described herein can include an intake layer and an absorbent layer. The absorbent material can include a saturation capacity greater than 125 grams, and a second intake time of less than 50 seconds and a wet thickness of less than 17 mm according to the Modified Fluid Intake Under Pressure Test as described herein. In some aspects, the intake layer and the absorbent layer can provide an integrated material including an interface between the intake layer and the absorbent layer. The interface can include at least some fibers of the intake layer mixed with at least some fibers of the absorbent layer.

Abstract: Absorbent substrates including a high percentage of superabsorbent material and method of manufacturing such absorbent substrates are disclosed. An absorbent substrate can include an intake layer including a first plurality of fibers and an absorbent layer. The absorbent layer can include superabsorbent material providing greater than 80% of the absorbent layer by total weight of the absorbent layer. The intake layer and the absorbent layer can provide an integrated material including an interface between the intake and absorbent layers. The interface can include at least some of the first plurality of fibers of the intake layer mixed with at least some of the absorbent layer.

Abstract: Methods and apparatuses for producing a substrate are described. A method and apparatus for introducing a component into a fluid supply is also presented. A method can include providing a first fluid supply. The fluid supply can be configured as a foam in some embodiments. The method can also include providing a component feed system and a supply of the component. The method can include introducing the component to a fluid supply in an eductor in some aspects. A resultant slurry including a fluid supply and the component can be transferred through a headbox. The resultant slurry can be dewatered to provide a substrate including the component.

Abstract: Methods and apparatuses for producing a substrate are described. A method and apparatus for introducing a component into a fluid supply is also presented. A method can include providing a first fluid supply. The fluid supply can be configured as a foam in some embodiments. The method can also include providing a component feed system and a supply of the component. The method can include introducing the component to a fluid supply in an eductor in some aspects. A resultant slurry including a fluid supply and the component can be transferred through a headbox. The resultant slurry can be dewatered to provide a substrate including the component.

Abstract: Methods and apparatuses for producing a substrate are described. A method and apparatus for introducing a component into a fluid supply is also presented. A method can include providing a first fluid supply. The fluid supply can be configured as a foam in some embodiments. The method can also include providing a component feed system and a supply of the component. The method can include introducing the component to a fluid supply in an eductor in some aspects. A resultant slurry including a fluid supply and the component can be transferred through a headbox. The resultant slurry can be dewatered to provide a substrate including the component.

Abstract: Methods and apparatuses for producing a substrate are described. A method and apparatus for introducing a component into a fluid supply is also presented. A method can include providing a first fluid supply. The fluid supply can be configured as a foam in some embodiments. The method can also include providing a component feed system and a supply of the component. The method can include introducing the component to a fluid supply in an eductor in some aspects. A resultant slurry including a fluid supply and the component can be transferred through a headbox. The resultant slurry can be dewatered to provide a substrate including the component.

Abstract: Methods and apparatuses for producing a substrate are described. A method and apparatus for introducing a component into a fluid supply is also presented. A method can include providing a first fluid supply. The fluid supply can be configured as a foam in me embodiments. The method can also include providing a component feed system and a supply of the component. The method can include introducing the component to a fluid supply in an eductor in some aspects. A resultant slurry including a fluid supply and the component can be transferred through a headbox. The resultant slurry can be dewatered to provide a substrate including the component.

Abstract: Methods and apparatuses for drying web substrates are described. In one embodiment, a method of drying a web substrate may comprise supplying air to a first dryer head located proximate a web conveyer, the air within the first dryer head having a temperature of less than 176 degrees C., directing air from the first dryer head toward the web conveyer at a velocity greater than 1000 m/min and forming a first drying region, and advancing the web substrate in a first direction on the web conveyer and through the first drying region.