Abstract: A method and system for applying a foamed binding agent to a fibrous web is disclosed. The invention is characterized by the use of an extruder having an upper lip extending 1/16 to 1/4 inch beyond the lower lip, and by the drawing of a vacuum beneath the applied foam, said characteristics being critical to the formation of a uniform foam layer atop the web. A second, more substantial vacuum is then applied beneath the web to essentially completely draw the binding agent into the web thereby providing substantial inter-fiber bonding.

Abstract: A method and system for applying a foamed binding agent to a fibrous web is disclosed. The invention is characterized by the use of an extruder having an upper lip extending 1/16 to 1/4 inch beyond the lower lip, and by the drawing of a vacuum beneath the applied foam, said characteristics being critical to the formation of a uniform foam layer atop the web. A second, more substantial vacuum is then applied beneath the web to essentially completely draw the binding agent into the web thereby providing substantial inter-fiber bonding.

Abstract: Methods by which a dry-formed loose fibrous web is bonded by applying to one of its surfaces a low add-on level of a relatively high binder solids concentration bonding material to form a once-bonded web, and to the other side of the web, a greater add-on level of a relatively lower solids concentration bonding material, the first-applied emulsion preferably adding from about 20% to about 40% binder solids by weight, and the second-applied adding the rest of the total binder solids to be included in the fibrous web product. The bonding material can be a solution or emulsion. Preferably, the first and second-applied bonding materials are water-based latex emulsions, the solids concentration of the first-applied emulsion is from about 15% to about 25% by weight, that of the second-applied emulsion is from about 10% to about 20% by weight based on the total binder solids to be included in the fibrous web product, and a vacuum draws the second-applied bonding material into the web.

Abstract: A process for coloring nonwoven webs of fibrous material, particularly air-layed webs, in which solid, water insoluble particulate pigments are introduced and intermixed with the fibers of the web to provide the coloring thereof. An initial formed web of fibrous material has a suspension of insoluble pigment in a liquid applied thereto, is fiberized, and is reformed into a web and bonded with a binding liquid. Alternatively, the pigment may be mixed with the separated fibers after the fibrous material is fiberized and before reforming.

Abstract: A fibrous web is uniformly adhered to the surface of a smooth creping cylinder or other creping surface without causing substantial compression of the web. A raised pattern is pressed into the web toward the creping cylinder to cause the portions of the web that are pressed to adhere more strongly to the creping surface, while the portions of the web that are not pressed remain more lightly adhered to the creping surface. The web is creped from the creping surface with a creping blade, and the resulting product has a pattern creped appearance wherein the portions of the web that are pressed are finely creped while the portions of the web that were not so pressed are coarsely creped.