Abstract: A low-weight infant diaper has a longitudinal direction and a width direction that intersect each other. The low-weight infant diaper includes: an exterior sheet disposed closer to a non-skin side than an absorbent body; and a belt including a first locking member on a first side in the width direction and a second locking member on a second side opposite to the first side in the width direction. The belt is locked to a non-skin side of the exterior sheet by the first locking member. The belt includes a first additional joining portion that causes a part of the belt to join the exterior sheet. The first additional joining portion is disposed in a region in the first side.

Abstract: A hair cleaning implement in the form of a laminate with surface properties specifically tailored to improve sebum removal from hair. The implement includes a nonwoven material joined to a film to form a laminate and a plurality of discrete protrusions extending from the surface of the nonwoven material. The protrusions are configured to provide the desired surface properties to the implement.

Abstract: A method of producing a partially separated fiber bundle includes a partial separation processing step for alternately forming separation-processed sections, each divided into a plurality of bundles, and not-separation-processed sections along the lengthwise direction of a fiber bundle, wherein a separation means provided with a plurality of projected parts is penetrated into the fiber bundle to create separation-processed parts, the separation means is removed from the fiber bundle, and the separation means is penetrated into the fiber bundle again, characterized in that a sizing agent is applied at an arbitrary timing during the production process of the partially separated fiber bundle. A partially separated fiber bundle is obtained by the production method, a fiber-reinforced resin molding material uses the partially separated fiber bundle, and a production method makes the fiber-reinforced resin molding material.

Abstract: A process is disclosed for creating air laid, high loft, non-woven, variable density web structures. The fiber manipulation and distribution necessary to produce a variable weight and density web is accomplished by creating variable, negative pressure regions across the surface of a condenser or other vacuum screen, which causes fibers to migrate toward areas of lower pressure. Also disclosed are embodiments of condenser and vacuum screens for producing such variable density web structures.

Abstract: A rotary drum for a fiber-stacking device includes a drum body, pattern plates each having a single fiber-stacking depression, and holding mechanisms each detachably holding a corresponding pattern plate on the outer circumferential surface of the drum body. Each holding mechanism has a fixed hook and a moveable hook. The fixed hook is immovably attached to one side of the drum body and forms a first groove with the drum body. The movable hook is attached to the other side of the drum body to be moveable between a holding position and a release position, forms a second groove with the drum body at the holding position, and opens the second groove at the release position. When the movable hook is at the holding position, the two side parts of the pattern plate are accommodated inside the first and second grooves.

Abstract: A SMC lamination line is disclosed that has an upper carrier film and a lower carrier film with oriented chopped fibers being deposited between the carrier films. Resin paste or adhesive is provided to retain oriented fibers on the lower carrier film. A guide roller guides the carrier film in close proximity to an in-feed conveyor that feeds oriented chopped fiber unto the lower carrier film. The guide roller is preferably less than the diameter of the end roller of the feed conveyor. The guide roller is also preferably within the arc of movement of the ends of the oriented chopped fibers to ensure a smooth and non-disruptive transfer of the oriented chopped fibers to the lower carrier film.

Abstract: A fleece-laying device for laying a fleece from a card web having a laying carriage movable above and transversely to an output conveyor belt, an upper carriage also movable transversely to the output conveyor belt, and a first card web conveyor belt and a second card web conveyor belt for guiding the card web via the upper carriage and the laying carriage into a laying nip formed in the laying carriage. The fleece-laying device includes a card web guiding area between the upper carriage and the laying carriage with two sections of the first and second card web conveyor belts holding the card web between them and being guided over at least one support roll mounted in a support carriage which is also movable transversely to the output conveyor belt.

Abstract: Apparatus for forming an air formed, reinforced fibrous web has a form member on which fluent fibrous material is deposited in an air formed deposition process. The fibrous web may be used as an absorbent core of an absorbent article. The form member has a forming surface which is shaped and arranged to contact and support a reinforcing member, such as a web of scrim. The forming surface is particularly formed to locate the reinforcing member at the proper position within the thickness of the fibrous web. No additional locating structure is needed and the reinforcing member can be placed on the forming surface prior to entry into the forming chamber where fibrous material is deposited onto the forming chamber. A form and a method for making a reinforced fibrous web are also disclosed.

Abstract: An apparatus and a method for preparing an absorbent article is disclosed. The apparatus has at least two forming surfaces which differ in terms of air permeability to allow the selective placement of fibrous material. The forming surface comprises a perforated forming screen. The forming screen has multiple zones with different amounts of open area through which air may pass. Particles carried in the air which flows through the open area are deposited on different zones of the forming screen resulting in different basis weights corresponding to the different air permeabilities. The apparatus and method thus provide an article having optimal zoned absorbency in a cost-effective manner.

Abstract: Method for the production of a fiber composite by placing fibers on a support, wherein long fibers are used at least as an essential component for the production of a nonwoven fabric (70). Said fibers are fed to at least one delivery head (A, A1, A2) substantially over the height of a material column and ejected in a sustantially horizontal manner therefrom. A long fiber-air suspension is generated by adding at least one aggregate. The suspension is directly applied on the support, which is especially shaped as a molding strip (14).

Abstract: A method and apparatus for forming an airlaid fibrous web on a moving surface can include a contoured foraminous member (62) having a first side portion (66), a laterally opposed second side portion (68), and a depth contour. A longitudinally extending, first side-masking member (52) can be located superjacent the first side portion (66) of the foraminous member (62), and can have a first inboard side wall surface (70). At least a second, separately provided, longitudinally extending, side-masking member (53) can be located superjacent the second side portion (68) of the foraminous member (62), and can have a second inboard side wall surface (72). Either or both of the first and second side-masking members (52, 54) are at least laterally movable relative to the foraminous member (62). A releasable attachment system (74) can selectively hold at least the first side-masking member (52) at a substantially fixed position relative to the foraminous member (62).

Abstract: The present invention provides an improved apparatus for forming a fibrous pad for absorbent products with improved density control. Fibers entrained in a high speed air flow are deposited onto the foraminous surface of a spaced, three-dimensional pad-forming pocket. The fine foraminous pad forming screen is supported on its periphery by two top plates, a coarse forming screen, two subplates and end rails which incorporate a device to hold the pad forming screen.A gas flow regulating system consisting of precisely placed cross directional fixed and adjustable airflow control louvers controls the air flow direction and reduces spill over and turbulence during the pad formation and especially during the transition of the forming pocket into and out of the air stream as the rotary former shell rotates through the filling position.

Abstract: A method for manufacturing an absorbent structure in an absorbent product such as a sanitary napkin, panty liner, diaper or similar product, which is manufactured by air-permeable forming elements. In the present method, the constituent fibres or similar material are given a certain electrical potential while the forming elements completely or partially are given an opposite potential or are grounded, the position and duration of the potential being variable. The material's orientation, distribution and location can be controlled so that the structure in the absorbent product can have the desired appearance.

Abstract: A method and apparatus for distributing reinforcement fibers includes a chute for supplying reinforcement fibers, the chute having an outlet end, and a metering belt mounted for endless travel along a first path at the outlet end of the chute. The metering belt has elongate members with tips extending outwardly from the metering belt, to define a volume between the tips and the metering belt. The tips of the metering belt pass sufficiently close to the chute so that fibers having penetrated the volume formed by the elongate members are carried away by the metering belt. The metering belt is also mounted for endless travel along a second path around a curved surface which causes adjacent elongate members to spread apart and diverge from each other, thereby causing the fibers to be discharged from the metering belt. A collection surface receives the discharged fibers.

Abstract: The present invention utilizes the smooth continuous motion of a masking belt to concentrate air-entrained absorbent materials on the surface of a moving fibrous substrate. Air flowing through the open areas of the masking belt carries the entrained material into the fibrous web. The fibrous web acts as a filter to separate the entrained material from the air stream. Substantially all dispensed material is captured by the fibrous web, and expensive and complex absorbent material recycle systems can be eliminated.

Abstract: A shaped nonwoven fabric comprises continuous spunbond filaments made by directly forming the spunbond filaments into a web in a single process. The fabric has an array of discrete surface features such as apertures or projections, or both. The spunbond filaments are bonded together with an adhesive polymeric component so that the shape of the fabric is retained. The fabric can be engineered to have particular fluid handling properties, strength properties, abrasive properties and aesthetic properties. Articles such as personal care products, garments, medical products and cleaning products are also disclosed.

Abstract: A distinctive method for contouring a fibrous web includes the steps of (a) providing a fibrous web which defines an interconnected series of appointed article segments along a length dimension of said web, and (b) conveying said web at a selected speed along an appointed machine direction. The method also includes the step of (c) removing predetermined quantities of fibers from selected regions of said fibrous web with a moving, outer peripheral scarfing surface, which is movable along a selected movement direction. The scarfing surface is constructed to provide each of the article segments with a selected contoured basis weight which varies along the length dimension of said segment in a selected correspondence with a predetermined scarfing pattern. The scarfing pattern is provided by the outer peripheral scarfing surface and is variably patterned along the movement direction of the scarfing surface.

Abstract: A distinctive apparatus for contouring a fibrous web includes a supplying mechanism for providing a fibrous web which defines an interconnected series of appointed article segments along a length dimension of the web. A conveying mechanism moves the web at a selected speed along an appointed machine direction. A scarfing mechanism removes predetermined quantities of fibers from selected regions of the fibrous web. The scarfing mechanism is constructed to provide each of the article segments with a selected contoured basis weight which varies at least along the length dimension of the segment in a selected correspondence with a predetermined scarfing pattern. The scarfing pattern is provided by an outer peripheral surface of the scarfing mechanism, and the pattern is configured to have a selected variation at least along a movement direction of the scarfing mechanism.

Abstract: There is disclosed a three dimensional nonwoven web consisting of drawn and unoriented thermoplastic fibers formed from a blend of polypropylene and polybutylene, wherein the blend by weight is from 90% to 70% polypropylene and from 10% to 30% polybutylene. The blend can be a blend of a homopolymer of polypropylene and a homopolymer of polybutylene; a homopolymer of polypropylene and a copolymer of polybutylene; a copolymer of polypropylene and a homopolymer of polybutylene; and a copolymer of polypropylene and a copolymer of polybutylene. In addition, ternary blends comprising polypropylene, polybutylene, and terpolymer (propylene, ethylene, and 1-butene) are useful. The resulting nonwoven webs have enhanced strength, toughness, and tear resistance.

Abstract: Apparatus for forming three dimensional shaped webs. The apparatus controls the flow of entraining air for an air laid web by restricting passage of the air through selected zones of a condensing surface. By limiting the open area in a zone of a suction plate the amount of fibers condensed over the zone is reduced permitting control of location of and amount of deposit. The duct work defining the conduit for the entraining air may also be shaped or provided with blocks to prevent scavenging of fibers which have already been deposited.

Abstract: A method of preparing a reinforcing web for a composite structure. A continuous strand is deposited in a bed of pins according to a desired pattern such as overlapped rows of shingled loops.

Abstract: For use in the making of slivers from a lap, an apparatus is proposed which comprises a plurality of tooth-carrying carding drums (3, 4, 5, 6), which succeed each other in the direction of travel of the lap. Each carding drum (4, 5, 6) which succeeds another constitutes a worker roller for cooperating with the preceding carding drum (3, 4, 5). The fibers which fly from the carding drums (3, 4, 5 and 6) into ejection ducts (10) are deposited in the form of strips on a collecting surface (7), to which a vacuum is applied only in zones.

Abstract: Nonwoven web and method of making including interbonded thermoplastic fibers in an array of hollow projections extending outwardly from at least one surface of said web. The projections are separated by land areas of interbonded fibers, and the fiber orientation is greater in the projections than in the land areas. Either the projections or the land areas may be perforated as desired for controlled porosity and fluid flow properties. The nonwoven webs of the invention may be made by a number of processes but, preferably, are made by forming directly on a surface with corresponding projections with or without apertures and a vacuum assist or by forming on an apertured surface with a pressure differential sufficient to draw the fibers through the apertures forming the projections.

Abstract: A robotized apparatus for forming a web to be used as a reinforcement in a plastic composite. The apparatus has a dispensing head including a freely rotatable tube which is moved according to a desired pattern. The tube terminates in a horn from which a continuous strand is delivered into a bed of pins.

Abstract: A method for the preformation of a cushion for a seat, characterized by feeding an aggregate of three-dimensional curled short-fiber filaments to conveyor means, causing said conveyor carring thereon said aggregate of filament to be advanced under a rotary member provided on the outer surface thereof with a multiplicity of raised needles and kept in rotation and allowing said needles to come into contact with said aggregate of filaments thereby scraping part of the filaments from said aggregate and giving to said aggregate of filaments a prescribed shape.

Abstract: An apparatus for forming a fiber lap to be processed by a carding machine includes a generally vertically oriented feed chute having generally parallel and vertically oriented front and rear walls. The chute has an opening at the top for receiving fiber tufts and an opening at the bottom for delivering a fiber lap. An air stream is introduced into the chute for flow in the direction of the bottom thereof. Air exit openings are provided in the zone of at least one of the walls allowing the air stream to leave the feed chute. The depth of the feed chute measured horizontally at the height level of the air exit openings varies along the chute width, whereby a fiber lap of varying thickness along the lap width is produced.

Abstract: A method and apparatus for collecting fibrous material (14) comprises distributing the fibrous material (14) onto a collection surface (18) to form a pack (20), and intercepting a portion of the fibrous material (14) during formation of the pack (20) with a plurality of spikes (24) extending from the collection surface (18). The spikes (24) partially penetrate the pack (20) and retain the intercepted fibrous material (14) in the upper portion (27) of the insulation pack (20).

Abstract: A novel adsorptive nonwoven fabric having good strength as well as good permeability and softness and a method of making the same is disclosed. This product consists essentially of supporting fibers containing a heat-fusible fiber and an adsorptive material, said supporting fibers being disintegrated in air before they are admixed with an adsorptive material, and a web is formed from the final mixture followed by being subjected to a heat treatment at a temperature above the melting point of said heat-fusible fiber to firmly fix said adsorptive material in the web by heat-fusion of the heat-fusible fiber.