Abstract: The present invention relates to a method of producing an absorbent member comprising feeding a superabsorbent polyer and pul fiber both in the form of a dispersion in an air stream, depositing the superabsorbent polymer and the pulp fiber in a recess by suction through a plurality of suction holes provided in the bottom of the recess and releasing the deposited aggregate from the recess. The bottom of the recess (50) has a first suction region having an open area ratio R1 of 40 to 80% and a second suction region having an open area ratio R2 of 2 to 20% with the ratio of R1 to R2 ranging from 70/30 to 99/1. The superabsorbent polymer and the pulp fiber are deposited on both the first and the second suction regions. The present invention also relates to an absorbent member comprising a superabsorbent polymer and pulp fiber.

Abstract: A method for the manufacture of compacts from comminuted material (12) such as lignocellulose material and/or other combustible material for burning in hearths, wherein the material (12) is placed into openings (11) of a mold (4) and then compressed to form compacts. The filling of a mold (4) with the material (12) and the compaction of the material (10) to form compacts (10) is performed in the pressing chamber (18) of a multi-platen press (1) with plungers (7) plunging into many openings (11) of a mold (4), and after compaction the mold (4) with the ram (3) is raised and additionally urged against the ram, while the finished compacts are driven out of the mold and then are pushed out of the press chamber (18) into a container (16) by an ejecting device. Moreover, an installation for the practice of the method includes a hopper (9) and a multi-platen press (1) with a mold raising-and-lowering device (14).

Abstract: An apparatus and a method for manufacturing an absorbent core for an absorbent product containing a first material and a second material dispersed throughout at least a portion of said first material. A rotating forming wheel produces the absorbent core in a mold provided on its circumferential surface and the forming wheel has a rotating air pervious belt along at least a part of the circumferential surface for keeping fibers and particles of the formed layer or layers in place on the wheel.

Abstract: Apparatus for forming an air formed 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 with a pocket for making a thicker portion of the fibrous web such as for a liquid holding formation of the absorbent core. The pocket has a bottom surface which is shaped so that additional material will be deposited in the pocket. A form member and an absorbent core made using the apparatus are also disclosed.

Abstract: An apparatus and method for forming tow-based absorbent structures having a single casing sheet are disclosed. The apparatus has a tow supply mechanism for providing tow material, a particulate matter supply mechanism for providing particulate matter, and a casing sheet supply mechanism for providing casing sheet material. The apparatus also has a vacuum draw roll having a foraminous center surface that has a width defined by a first edge and a second edge and is rotatable about a first axis. The vacuum draw roll is positioned to receive the tow material, the particulate matter and the casing sheet material to form a open core composite supply. The apparatus also has one or more angled surfaces positioned to create one or more obtuse angles in the open core composite supply, and one or more folders to further fold the one or more obtuse angles in the open core composite supply to form a folded core composite supply.

Abstract: Nonwoven webs having substantially aligned fibers can be formed in an apparatus having a direction of motion corresponding to the direction of web formation. The web is formed in the presence of at least one secondary fluid stream that oscillates the filaments or resulting attenuated fibers to and fro generally in and against the direction of motion so that a majority of the collected fibers are aligned within ±20° of the direction of motion and fibers having lengths of about 1-10 cm can be teased from the web. The resulting nonwoven webs are especially useful for forming pleated filtration media having pleats generally transverse to the direction of motion.

Abstract: A method for filling a receiver with expanded fibers includes the steps of feeding at least one bundle of fibers from at least one roving; introducing the at least one bundle into a portable tool having a manual gripping element, a spray nozzle, an air supply device connected for supplying air to the nozzle, an extraction system configured to hold the at least one bundle and feed the at least one bundle to the nozzle, and an inlet guide positioned to guide the at least one bundle to the extraction system; and using the air supply device to expand the fibers of the at least one bundle in said spray nozzle, and spray the expanded fibers into the receiver.

Abstract: An automated assist apparatus is provided in a system for forming a molded article from a composition comprised of a plurality of chopped mineral fibers and a binder applied to at least one portion of a perforated mold and initially held in place by a vacuum drawn through the perforations before undergoing a curing process. The assist apparatus includes at least one device for holding the composition applied to at least one portion of the perforated mold in place prior to and during the curing process and a motive device for automatically moving the holding device from a first retracted position away from the mold to a second position for holding the composition in place. The vacuum is released when the holding device is in the second position. The composition undergoes curing and the holding device is automatically moved to the first retracted position for removing the cured molded article.

Abstract: A glass preform having a living hinge section that is formed by introducing a continuous strand of fibrous material onto a portion of a screen and overspraying the strand and the rest of the screen with a chopped string binder material, therein forming a matted structure. The matted structure is subsequently heated to fuse together the binder material of adjacent chopped string binders to form the preform having a living hinge section. The preform may then be molded to form a three dimensional composite part such as a truck box. The living hinge section of the preform improves the flexibility of the preform during the molding process, thereby allowing for the preparation of complex three dimensional shapes.

Abstract: A method and an apparatus for forming air-laid fibrous absorbent cores comprises a first supply of air-entrained fibrous material and a first air-laying element connected with the first supply of air-entrained fibrous material and having a movable first perforated forming element for forming a first air-laid component of the absorbent core. Further, a supply of air-entrained fibrous material and discrete particles of absorbent material and a second air-laying element connected with the supply of air-entrained fibrous material and discrete particles is provided. The second air-laying element has a movable second perforated forming element for forming a second air-laid component of the absorbent core comprising a mixture of dispersed fibrous material and discrete particles and the second air-laying element is positioned with respect to the first air-laying element such as to transfer a formed second component from the second forming element onto a formed first component on the first forming element.

Abstract: A flexible structure comprises a plurality of starch filaments. The structure comprises at least a first region and a second region, each of the first and second regions having at least one common intensive property selected from the group consisting of density, basis weight, elevation, opacity, crepe frequency, and any combination thereof. The common intensive property of the first region differs in value from the common intensive property of the second region.

Abstract: A forming receptacle and method for receiving particulate material thereon, and thereby fabricating particulate congregates for use as absorbent cores in personal care absorbent articles is disclosed. The forming receptacle can comprise sheet material defining bottom and side walls of the receptacle. The bottom and side wall have first and second major surfaces and a thickness. The forming receptacle also comprises an array of apertures connecting first and second major surfaces, and further comprises a matrix of sheet material between apertures defining outer perimeters of respective apertures. Respective aperture walls taper from the first major surface toward the second major surface. Aperture walls of adjacent apertures intersect the second major surface without intersecting each other. The array of apertures can be arranged in a series of parallel rows wherein spacing between apertures is substantially constant from row to row.

Abstract: A manufacturing method of composite wood that arbitrary amount of wood can be used, nailing is possible and a product with arbitrary configuration is easily manufactured is provided.

Abstract: A method and apparatus (20) for forming a fibrous web (50) includes a movable, foraminous forming surface (22) and a substantially stationary, vacuum-commutator duct system (24) which is located substantially subjacent the forming surface (22). The vacuum-commutator duct system (24) has an entrance opening (26) that changes in configuration along a longitudinal dimension (30) of the entrance opening (26).

Abstract: A powder pressing apparatus comprises an upper punch and a lower punch for compression of a powder in a cavity formed in a through hole of a die. A gap between a side surface of the lower punch and a side surface of the through hole of the die is sealed by a sealing member. A lubricant is supplied with a gas from a nozzle in the side surface of the lower punch to the side surface of the through hole, and the lubricant applied to the side surface of the through hole is spread by an absorbing member. The cavity is filled with the powder while the cavity is under suction by a reduced pressure provided from the nozzle in the side surface of the lower punch. During the suction, a filtering member provides filtration for the lower punch not to draw the powder in.

Abstract: An automated assist apparatus is provided in a system for forming a molded article from a composition comprised of a plurality of chopped mineral fibers and a binder applied to at least one portion of a perforated mold and initially held in place by a vacuum drawn through the perforations before undergoing a curing process. The assist apparatus includes at least one device for holding the composition applied to at least one portion of the perforated mold in place prior to and during the curing process and a motive device for automatically moving the holding device from a first retracted position away from the mold to a second position for holding the composition in place. The vacuum is released when the holding device is in the second position. The composition undergoes curing and the holding device is automatically moved to the first retracted position for removing the cured molded article.

Abstract: The invention relates to a screen pipe to be used in dry forming of web material in order to distribute fiber material blown into the screen pipe through a jacket (2) of the pipe onto a wire arranged to move under the pipe. The fiber material provided inside the screen pipe is made to move for example by means of a spiked roll placed inside the pipe, so that the movement of the fiber material has both a radial and a tangential component with respect to the jacket (2) of the screen pipe. The jacket comprises on its inner surface profiled grooves (8) in the pipe's axial direction. The edge (8a) of the profiled groove is situated downstream with respect to the tangential component of the fiber flow. The upstream edge (8b) of the groove is positioned downstream with respect to the tangential component of the fiber flow. The bottoms of the profiled grooves comprise holes or slots (9) through which the fibers are discharged from the screen pipe.

Abstract: A method of producing a non-woven fabric having a high recovery after elongation and a substantially uniform surface including the steps of microcrepeing the fabric between about 20% and 35%, and heat setting the fabric to a temperature between its glass transition temperature and its melting temperature. A non-woven fabric having a recovery of at least 40% after five cycles of 35% elongation is made from a microcreped fabric of basis weight from 1-3.5 osy. The non-woven fabric has a uniform surface that is substantially free of bunching, gathering, and that is otherwise substantially flat to the eye and touch.

Abstract: A nonwoven fabric from spun fibers wherein the density of the spun fibers in the fabric varies between strips of relatively high density and strips of relatively low density. The strips extend along the length of the fabric in the machine direction in an alternating pattern, with the high density strips separated from each other by low density strips. The alternating high density and low density strips provide the fabric with a higher percent elongation in the cross direction than in the machine direction. The alternating pattern is achieved through use of a pattern screen defining a plurality of elongated air permeable regions separated by elongated substantially or relatively air impermeable regions, the elongated regions extending in the machine direction in an alternating pattern, with the air permeable regions separated from each other by the substantially or relatively air impermeable regions.

Abstract: A method and apparatus are disclosed for making a reconsolidated or reconstituted wood product from a charge of wood components and binder using steam injection pressing to consolidate and bind the charge into a mat in which the wood components are bound to each other to form the wood product. The charge is compressed into the mat by operation of at least the one pressing member in the form of a heated movable platen. The method and apparatus are characterized by the pressure being applied to the charge or mat from the steam injection pressing being independent of the compressing force applied to the charge or mat by the pressing member. The invention is particularly adapted to form beams of relatively large cross section, such as for example in excess of 30 mm, preferably larger than 40 mm.

Abstract: A nonwoven fabric from spun fibers wherein the density of the spun fibers in the fabric varies between strips of relatively high density and strips of relatively low density. The strips extend along the length of the fabric in the machine direction in an alternating pattern, with the high density strips separated from each other by low density strips. The alternating high density and low density strips provide the fabric with a higher percent elongation in the cross direction than in the machine direction. The alternating pattern is achieved through use of a pattern screen defining a plurality of elongated air permeable regions separated by elongated substantially or relatively air impermeable regions, the elongated regions extending in the machine direction in an alternating pattern, with the air permeable regions separated from each other by the substantially or relatively air impermeable regions.

Abstract: A nonwoven fabric from spun fibers wherein the density of the spun fibers in the fabric varies between strips of relatively high density and strips of relatively low density. The strips extend along the length of the fabric in the machine direction in an alternating pattern, with the high density strips separated from each other by low density strips. The alternating high density and low density strips provide the fabric with a higher percent elongation in the cross direction than in the machine direction. The alternating pattern is achieved through use of a pattern screen defining a plurality of elongated air permeable regions separated by elongated substantially or relatively air impermeable regions, the elongated regions extending in the machine direction in an alternating pattern, with the air permeable regions separated from each other by the substantially or relatively air impermeable regions.

Abstract: This invention provides preforms of continuous glass fiber strands for use as the sound absorbing material in an engine exhaust muffler. Preferably, the material is made of glass fibers of E glass compositions. With this invention, the strands are fluffed up, not directly in the muffler, but in a cavity that is made of a perforated shell matching the muffler shape. During this operation, a powder binder also is blown in with the fibers. This blowing operation is completed by forcing hot air through the preform which melts or cures the binder and allows it to bond the fibers together.

Abstract: The effects of interfacial transition between organic and inorganic layers of a multilayer construction are ameliorated by incorporating an inorganic component within the matrix of the organic layer. In a first aspect, a construction having adjacent organic and inorganic layers is fabricated by depositing a curable polymer, softening the polymer, and integrating an inorganic material therewith. The polymer is then cured to immobilize the integrated deposition material, and the desired inorganic layer is applied over the deposited inorganic material (and any exposed portions of the polymer). In a second aspect, a graded structure is built up on a substrate in successive deposition steps. Both polymer precursors and an inorganic filler material are deposited in stages, with each stage containing a desired ratio of polymer to filler.

Abstract: The present invention provides fibril system fibers which may be employed in filter applications and in artificial leather applications, and also provides an industrially superior manufacturing method for such fibril system fibers, and a spinning nozzle. The fibril fibers of the present invention include at least one macromolecular polymer having a film forming ability, and they have a structure in which fibrillated fibers having a diameter of 10 micrometers or less branch from main fibers having a width within a range of 0.1 micrometers-500 micrometers, and a length within a range of 10 micrometers-10 cm.

Abstract: A powder feed system for delivering a quantity of particulate material to a die cavity of a powder press is provided. The powder press has a table-like platen surface which is flush with and surrounds a die in which the die cavity sits, an upper punch appending from an upper ram and a lower punch. The powder feed delivery system includes a receptacle for receiving and delivering particulate material to the cavity. The receptacle has an ingress through which particulate material is received under pressure and an egress for registering with the interior of the cavity and through which particulate material is delivered under pressure from a feed conduit to the cavity. The feed conduit is attached at a first end to the receptacle ingress. At least one pressure generator is attached to a top end of a pressure vessel attached at a second end to the feed conduit.

Abstract: This process and apparatus use at least one chopper unit. The fiber choppers may be laser beam choppers or existing standard chopper units. The process and apparatus for producing a fiber-reinforced molded composite comprises providing a moldable composition, sequentially spraying a moldable composition into the mold, subsequently providing chopped fibers to the moldable composition and depositing the moldable composition and chopped fibers in mold and molding the moldable composition and fibers in the apparatus under heat and pressure to form the molded composite. One industrial application for these choppers is compression molding of interior trim panels for automobile doors. The choppers spray chopped glass fiber strands into a resin mixture. The glass and a polyol, isocyanate (—NCO) urethane resin mixture at the proper glass loading, distribution and pattern is fed to the mold.

Abstract: A method of making a headliner assembly includes providing a porous member having first and second sides. A negative pressure is developed on the second side of the porous member, and particulate material is selectively deposited proximate the first side of the porous member to form a particulate layer having an outline that corresponds with a desired outline of the headliner assembly. The particulate material is drawn toward the first side of the porous member by the negative pressure developed on the second side of the porous member. The particulate layer is then thermoformed to form the headliner assembly.

Abstract: A method for making an absorbent member is disclosed. The method includes introducing fibers into an air stream to form an air-fiber mixture. This air-fiber mixture is then directed to a porous media having a first surface. The air-fiber mixture contacts the first surface and the fibers collect on the first surface and forms a fibrous mat. The air passes through the first surface and can be recovered and recycled, if desired. The air-fiber mixture is then terminated or diverted so that the fibrous mat can be removed from the first surface. The fibrous mat is wetted by water to obtain a desired moisture content. Finally, the wetted fibrous mat is compressed to a predetermined thickness to form an absorbent member, which has unique expansion properties.

Abstract: This invention provides a method for producing a cushion structure having excellent quality in a short time by the final heat-molding of a fiber aggregate containing binder fibers by compression molding a fiber aggregate in multiple stages leaving the thermal shrinkage margin, passing hot gas through a by-pass channel on the side wall part of the molded article to eliminate the problem of insufficient heating of the side face of the molded article and detecting the completion of the filling of the fiber aggregate into the mold cavity by the pressure variation in the mold cavity.

Abstract: A technique for forming self-supporting structures with thermoplastic material incorporates a plasma-heated spray of thermoplastic material with glass fiber reinforcement, such as glass fibers. The material is sprayed into a mold which is shaped to create the desired form and configuration of the self-supporting structure. A mixture of thermoplastic powder and reinforcing fibers is carried by a stream of inert gas through a plasma region. The thermoplastic material is melted as it passes through the plasma region and the resulting plasma is sprayed against the surface of a form mold. The thickness of the resulting structure can be varied from region to region by changing the speed of movement of a spray nozzle relative to the form, using a plurality of spray nozzles that can be selectively activated and deactivated, or by providing a plurality of coats of sprayed thermoplastic material, one after another.

Abstract: An absorbent core for use in an absorbent article for absorbing discharged bodily fluid comprises a first absorbent material dispersed throughout the core, and a second absorbent material provided in a discrete strip, and substantially surrounded by the first absorbent material. An apparatus and method for producing such cores comprises a mold support advanceable in a predetermined direction and having at least one mold therein, and a tubular conduit for the second material alignably positioned such that a portion of the conduit will pass through at least a portion of the mold as the mold support is advanced. The mold support may comprise a forming drum or a forming belt. The tubular conduit has a distal end through which the second absorbent material may be expelled.

Abstract: A water soluble core comprising iggregate particles of an inert material and water soluble polyvinyl alcohol (PVA) binder results in an improved core composition having a longer shelf life and better release properties than other water soluble cores. The resultant core can be produced in less time and with less energy than other seater soluble cores, but is just as effectively remove d from the molded product upon exposure to water.

Abstract: A method for producing high performance components by the consolidation of powdered materials under conditions of hot isostatic pressure. The method uses the inclusion of reactive materials mixed into pressure-transmitting mold materials and into the powder to be consolidated to contribute to in-situ materials modification including purification, chemical transformation, and reinforcement. The method also uses encapsulation of the mold in a sealed container to retain the mold material in position, and to exclude air and contaminants.

Abstract: A method and apparatus for molding a cushion member from a fiber mixture by a filling process comprising filling a fiber mixture composed of synthetic matrix fibers and binder fibers dispersed therein into a mold cavity of an air-permeable mold by a transportation air stream and a heat-treatment process comprising making a molding air stream for heating and/or cooling the fiber mixture filled in the mold cavity to pass through the fiber mixture, wherein a contact surface of the mold with the fiber mixture is divided into a plurality of contact sections, and a flow rate and/or pressure of an air stream passing through each of the contact sections are regulated to a predetermined condition so that the air stream in the mold cavity is differently controlled in the filling process and the heat-treatment process.

Abstract: An improvement in the preparation of fiber preforms in which binder and fibers are dispersed to contact on vacuum-supplied screens is disclosed, comprising particularly (a) selecting a particulate binder material which is solid at 25.degree. C; (b) heating the binder material, during initial contact with the fibers, to a viscosity and for a time which is the same as or proportional to 1,000 centipoise for one second; and (c) dispersing the binder material and the fibers such that the preform exhibits a variation in the ratio of fibers and binder which correlates to a coefficient of variation which is less than or equal to about 5 percent. The resulting preform shows superior compaction and uniformity of constitution even when it is prepared in sections or in asymmetric configurations.

Abstract: A process for forming a preform includes drawing a vacuum through a porous overform (16) from its outer surface toward its inner surface; providing retractable pins (32) that protrude through vertical extending sections (34) of the overform when in an extended position; depositing chopped fibers onto the outer surface of the overform such that the vertical extending sections of the overform have the fibers retained against sag by protruding sections (35) of the pins while said preform is formed; and retracting the pins from the vertical extending sections of the overflow in order to remove said preform from said overflow after cure. The invention is also directed to an apparatus for the use in manufacturing fibrous preforms that incorporates a porous overform (16) for receiving chopped fibers and binder material thereon and a plurality of pins (32) protruding through a vertically extending section (34) of the overform for engaging and supporting chopped fibers deposited onto the overform.

Abstract: A powder feed system for delivering a quantity of particulate material to a die cavity of a powder press is provided. The powder press has a table-like platen surface which is flush with and surrounds a die in which the die cavity sits, an upper punch appending from an upper ram and a lower punch. The powder feed delivery system includes a receptacle for receiving and delivering particulate material to the cavity. The receptacle has an ingress through which particulate material is received under pressure and an egress for registering with the interior of the cavity and through which particulate material is delivered under pressure from a feed conduit to the cavity. The feed conduit is attached at a first end to the receptacle ingress. At least one pressure generator is attached to a top end of a pressure vessel attached at a second end to the feed conduit.

Abstract: A preform of complex three-dimensional shape is prepared by a directed fiber preforming process in which a flow of chopped fibers are drawn by vacuum against a foraminous screen having a shape corresponding to that of preform to be made. The screen has depressed regions that are susceptible to excessive build-up of the chopped fibers. To counteract the build-up in these areas, a baffling system is provided behind the screen having baffle plates which are extendable into and out of blocking engagement with the backside of the problem depressed regions to govern the vacuum draw and hence the deposit and build-up of fibers across the depressed regions.

Abstract: A unique method of producing a reinforced moulded sheet having one continuously planar face and having a plurality of ribs or thickened areas which provide a corresponding plurality of prominences directed outwardly of the other face, said prominences having predetermined shapes, locations and dimensions to serve as reinforced areas for said sheet. And a series of new or improved composite hollow moulded panels, each comprised of at least two co-extensive elements, each of said panels being reinforced and improved by the provision of at least one of said reinforced moulded sheets as an external element of said at least two co-extensive elements, the ribs or thickened areas of said reinforced sheet being glued internally of said hollow panel to the adjacent co-extensive element thereof.

Abstract: An EMI shield for personal computers, cellular telephones, and other electronic devices is constructed from thermoformable polymeric material which is then metallized on all surfaces by vacuum metallization techniques to provide an inexpensive, lightweight, yet effective EMI shield.

Abstract: A method for consolidating powdered material to near net shape and full density is provided. The method includes the steps of: mixing a particulate material with an organic or inorganic binder to form a mold material; shaping the mold material into a mold having a shape and including an external surface and an interior cavity and being of sufficient solidity to maintain its shape yet being compressible under pressure; filling the interior cavity with a powdered material to be consolidated; heating the mold with the powdered material therein to form a heated filled mold; applying pressure to the external surface of the mold sufficient to compress the mold material and transfer a pressurizing force to the powdered material within the mold cavity so as to consolidate the powder and form an article; and removing the article from the mold. In an alternative method, the mold material is made of a particulate material which is held in the shape of the mold by a vacuum.

Abstract: A distinctive method and apparatus (20) for forming a composite fibrous web (22) includes a web supply (24, 25), which provides at least two appointed fiber layer sections (26, 28) of desired fiber material. Each of the layer sections (26, 28) has a selected composition. A fiberizer (30) disintegrates each of the fiber layer sections (26, 28) into individual, laterally adjacent fiber streams (32, 33) while substantially maintaining a lateral separation of the fiber streams while the fiber streams (32, 33) are moving through the fiberizer (30). A directing channel (34) delivers the fiber streams (32, 33) from the fiberizer (30) to a forming chamber (40). The forming chamber (40) is configured to substantially maintain the separation of the fiber streams.

Abstract: An apparatus and method are disclosed for forming a sanitary napkin having a multi-segment core. Such a core is formed using a mold having a deposition cavity which is divided into cavity segments by at least one partition. Each partition can comprise a passageway for interconnecting adjacent cavity segments.

Abstract: The present invention provides a method and apparatus for applying discrete particles of absorbent material to a predetermined location on a fibrous web. The apparatus comprises a continuously rotating mask, and a means for directing a supply stream of absorbent particles to form an acute included angle with a diverting surface on the rotating mask. The mask diverting surface splits the supply stream of absorbent particles into a first intermittent stream passing through the mask and a second intermittent stream deflected by the diverting surface. The absorbent particles in one of the first and second intermittent streams is directed to the fibrous web.

Abstract: An apparatus (10) for use in manufacturing a fibrous preform with a narrow channel flange includes a foraminous preform screen (12), a fiber nozzle (28) that blows a stream of chopped fibers onto the screen (12) and binder nozzles (32) that spray binder into the fiber stream. Air blown from air nozzles (30) helps guide the fibers and a ducted fan (26) helps draw and hold them onto the screen (12). The screen (12) is formed with a narrow channel flange (16) having a shape identical to the narrow channel flange of the fibrous preform to be manufactured. The screen's flange (16) has a channel floor (36) extending laterally outward from the screen's main body (14) and a channel outer wall (38) projecting perpendicularly away from the channel floor (36) toward the fiber nozzle (28). A hinge (40) connects the channel floor (36) to the channel outer wall (38). To allow the nozzles to deposit a more uniform layer (42) of fibers, the outer wall (38) is rotated outward to lie parallel with the channel floor (36).

Abstract: An automotive interior trim part (10) is made by molding a substrate retainer layer (16), forming a skin layer (12) and forming an intermediate layer (14). The intermediate layer (14) is formed from a plurality of clusters of entangled high melt and low melt kinked fibers of polyethylene terephthalate (PET). The PET layer is blown into a partially closed mold that has the skin and retainer positioned in each mold die. The mold undergoes induced vibrations to promote tightening of the packed clusters. The mold is then fully closed to compress the PET fibers into full density. Heated air is then blown into the mold to soften the low melt fibers to adhere them to the retainer layer and skin. Cool air is then blown into the mold to resolidfy the clusters and form the intermediate layer into its molded shape.

Abstract: A method of producing a patterned shaped article which includes the steps of placing on a base surface, a form made of at least one partition member defining the boundary of the patterned to be produced, a peripheral frame surrounding the partition member at a prescribed spacing therefrom and a cover closing the upper ends of the partition member and the peripheral frame. The method also includes the steps of supplying dry particles to a pattern space enclosed by the partition member and a pattern space between the partition member and the peripheral frame, removing the form from the base surface forming a particle course having a prescribed pattern and causing the particles to set into an integral mask.

Abstract: In a process for preparing a molding from fibers and/or flakes and thermoplastic binder, the material is introduced into a mold, compacted, and bonded by thermal effect. To make it possible to introduce the material rapidly and such that a consistently equal density or a density changing in a defined pattern will be obtained, a filling contour calculated for the given molding is formed by a first mold disk set. After filling the filling contour, a first finished contour mold is positioned against it. A second mold disk set, whose disks are displaceable between the disks of the first mold disk set and form the second finished contour of the molding, is subsequently displaced in the first mold disk set against the first finished contour mold, while the material present in the filling contour is compacted. The material is subsequently fixed by thermal effect.

Abstract: A process for compacting foundry molding material is proposed, the molding material being introduced into a molding device with a pattern plate with a pattern frame and a molding and filing frame mounted on it, by means of a compressed gas, the compressed gas being used at least for precompaction, the pressure surge used for the precompaction being released into the molding floor with a low, then a higher pressure gradient.