Abstract: In the continuous production of mineral wool nonwoven fabrics, fiber/gas/air mixtures (3, 4) produced by several shredding units (14 to 17) are directed onto collecting conveyor units (19, 21) with suction surfaces (c, d) running in a curve and being under suction pressure for the formation of a wool nonwoven fabric (25). In this case the arrangement is such that an imaginary suction surface, increasing in its size in the conveying direction, is assigned to each fiber/gas/air mixture formed by the individual shredding units (14 to 17), actually d is larger than c. As a result it is possible, in a space-saving method of construction and per collecting conveyor unit to produce mineral wool nonwoven fabrics from rock wool with constant suction pressure with bulk densities even under 25 kg/m.sup.3 in good product quality. By series connection of several units or an oscillating deposit of an individual nonwoven fabric multilayer felt webs can further be formed.

Abstract: An insulation panel comprises a mineral fiber board having a density between 8 and 28 pounds per square foot, the fibers having no organic binder thereon, and between 5 and 40 percent by weight of particulate material packed in the interstices of the board, and a gas-tight envelope encapsulating the board, the envelope being evacuated to a vacuum between 10.sup.-4 Torr and 10 Torr.

Abstract: The present invention relates to a method and an apparatus for manufacturing a fiber slab (32), in which a fiber/air suspension is blown through a nozzle into a forming space (9). The forming space is defined by two mutually facing belt parts of two endless belts (10, 11). For the purpose of manufacturing the novel fiber slab, there is generated between the nozzle exit orifice (8') and the forming chamber a mist of highly liquid adhesive, and the fibers are imparted kinetic energy of such high value that the fibers pass essentially rectilinearly through the mist and into the forming chamber, where they collect on the slab end surface (36) earlier formed in the forming chamber and facing the nozzle.

Abstract: A method for forming a dry web on the wire, with the fibre material being fed into at least one perforated drumlike forming element that covers essentially the whole width of the web to be formed, in which forming element fibres are conveyed in the drum along the width of the web and screened through the mantle of the forming element onto the wire. To achieve such web formation as has as few disturbances as possible, the fibre material is fed into the drumlike forming element in such a way that the bulk of the fibres, when advancing in the feeding direction toward the other end of the forming element, get screened from the forming element onto the wire, and that those fibres that do not get screened, but travel through the forming element are removed from the forming element and returned for a new defibration.

Abstract: The invention relates to the reception of fibers under fibering machines to obtain a mat of mineral wool. It proposes assigning to each fibering machine its own collecting zone, the surfaces of the collecting zones increasing in the direction of the increase of base weight. The invention also proposes a device characterized by the presence of two reception drums for three fibering machines.

Abstract: A polyolefin BMF web made from a mixture of polypropylene and surfactant can have high wet strength when a) the surfactant is nonionic and b) the surfactant is mixed with the polypropylene at a static mixer that interconnects the extruder and the BMF die. By so postponing the addition of the surfactant, it is protected from both the exceedingly high temperatures of the extruder and from the high shearing forces within the extruder. The surfactant also is heated to high temperatures for a much shorter time than if it were premixed with the polypropylene.

Abstract: Method and apparatus for supplying binder to newly formed mineral wool fibres by means of several distribution means like nozzles or spreaders (30-33, 36-36, 41-43) while said mineral wool fibres are suspended in an air or gas stream on their way to a collection means (29), which in one or more steps form a final mineral wool path (F-J), whereby the binder or binder mixtures from the different distribution means (30-33, 35-36, 41-43) are supplied to different parts of the fibre suspension and in such amounts--in relation to the fibre flow in that part of the fibre suspension, which is actuated by the respective distribution means--that different layers (e.g. F+J, G+I, H) of the final mineral wool path get different content of binder.

Abstract: An apparatus for forming a zoned distribution of particulate material within a fibrous web includes a conveying mechanism for providing a gas entrained supply of the particulate material and a segregating mechanism for centrifugally directing at least a portion of the particulate material into an accumulation region of the apparatus. A transferring mechanism selectively directs particulate material from the accumulation region into a delivery gas stream to provide an intermittent flow volume of a selected quantity of particulate material from the accumulation region through a delivery conduit and into a web forming chamber. A fiberizing mechanism provides a flow of a selected fibrous material into the web forming chamber, and a directing mechanism controls the intermittent flow of particulate material from the delivery conduit into the forming chamber.

Abstract: The process for making a spun-filament fleece from at least two stretched thermoplastic monofilaments made of a thermoplastic material includes feeding thermoplastic material to at least two spinnerets each including a separate group or plurality of spinning nozzles arranged in rows over a rectangular cross section, then exposing each band or group of thermoplastic filaments issuing from each group of spinning nozzles separately to a transverse flow of cooling air in a blower shaft, next stretching the bands or groups of thermoplastic filaments jointly in a common central stretching shaft by outflowing stretching air, then depositing jointly the thermoplastic filaments which have been stretched in a spun band moving below the stretching shaft continuously to form the spun-filament fleece and drawing a suction air flow through the spun band and/or the spun-filament fleece being formed.

Abstract: An improved process is provided for flash-spinning plexifilamentary film-fibril strands of fiber-forming polyolefin from a small group halocarbon liquids that, if released to the atmosphere, present a greatly reduced ozone depletion hazard, as compared to the halocarbon currently-used commercially for making the strands. The preferred halocarbon for this purpose is 1,1-dichloro-2,2,2-trifluoroethane.

Abstract: In a process for producing fibrous mats as a starting material for compression moulded articles, fiberized waste materials are mixed with thermoplastic and/or thermoset or thermosetting binders, the mixture is spread onto an air-permeable conveyor belt to give a first fleece layer, on said fleece layer is loosely placed a polyester fabric or lattice with at least partly multifilament threads, a mesh size between 4 and 7 mm and a thermoset or thermosetting finish, then a second fleece layer is spread onto the fabric or lattice and then the layers are compressed at elevated temperature and under pressure to give a transportable mat, from which individual moulded articles are produced by compression moulding at temperatures between 180.degree. and 220.degree. C., the polyester fabric undergoing thermal conditioning prior to its use at temperatures roughly corresponding to the mould temperature.

Abstract: A method and apparatus for forming a non-woven pad consisting of fibrous material in which highly moisture-absorbent particles are intermixed with the fibrous material throughout a predetermined portion of the thickness of the non-woven pad. The non-woven pad is formed atop a conveyor moving through a chamber which has a duct connected to a source of vacuum operable to draw fibrous material injected into the chamber onto the conveyor. A spray gun or an extension thereof is positioned within the chamber relative to the fibrous material atop the conveyor, and is operated to discharge moisture-absorbent material at a predetermined velocity, such that the moisture-absorbent material is intermixed with the fibrous material throughout preferably a center layer of the thickness of the non-woven pad while forming boundary layers on either side of the center layer which are substantially free of moisture-absorbent material.

Abstract: A process for manufacturing mineral wool products according to which the mineral wool is collected to form a mattress on a conveyor belt, carried to a conforming and binder polymerizing chamber consisting of two complementary calibrating and transport conveyors consisting of a plurality of articulated perforated elements of pallet type. The speeds of the two conveyors are different, the difference in speed corresponding along the entire length of the chamber to a staggering of a length equivalent to at least the width of one pallet so that one of the faces of the mattress is smoothed during conformation of the mineral wool product.

Abstract: A method of making fiber reinforced composite articles from stabilized dry fiber preforms which are impregnated with a thermosetting resin by the resin transfer molding method. The dry fiber preforms may be stabilized prior to molding by dispersing a polymeric binder between adjacent dry fabric plies of the preform. Hot air is passed through the preform after it has been compressed to fuse the binder and bind the dry fabric plies together, forming a stabilized high density fiber preform. Forming a preform by this method is significantly less labor and time intensive than methods currently in use.

Abstract: In the fabrication of wood material panels, processed wood particles are coated with a binder free of a hardener and then are spread in a fleece on a support surface. The fleece is then compacted and pressed to form the panel. Before the compacting step, microcapsules are introduced into the fleece. The microcapsules have enclosing walls that do not react with the binder and contain a hardener in the gaseous phase or in the binary phase with a gaseous carrier agent. When the fleece is compacted, the capsule walls are destroyed and the hardener is released into the fleece. The microcapsules containing the hardener are produced in a device located adjacent to the inlet end of the press so that there is only a short distance between the device and a mixing station where the microcapsules and the bonded processed wood particles are mixed. The mixing station is located just ahead of or at the spreading station where the mixed wood particles and microcapsules are formed into the fleece.

Abstract: A spray head attachment adapted for use with a flow metering device such as a metering gear head is effective to discharge a plurality of spiral spray patterns of hot melt adhesive, in elongated strands or fibers, onto the backing sheet of a hygienic article. The spray head attachment includes a manifold having adhesive passageways connected to outlets of the metering gear head, air passageways connected to a source of pressurized air and recirculation passageways connected to a source of hot melt adhesive. Outlets of the adhesive and air passageways, and inlets of the recirculation passageways, are formed on a discharge surface of the manifold in groups or arrays, so that nozzles mounted to the manifold are each connected to one array of adhesive, air and recirculation passageways.

Abstract: Apparatus for forming highly isotropic web products includes an elevator that adjustably positions a former head and an associated air and fiber supply with respect to a product condenser for varying the width and density of an isotropic web formed thereon. The process of the present invention includes selectively directing individual fibers into first and second vertical air curtains the first of which is intercepted by a backwardly inclined condenser for forming a first feed mat which is stripped to form the fiber supply for the second vertical air curtain and wherein the velocity and the height of the second vertical air curtain are controlled to control the density and width of a resultant isotropic web structure formed on a continuous belt type condenser.

Abstract: Process for preparing subdenier fiber and structures thereof from lyotropic liquid crystalline polymers comprising extruding a stream of the polymer into a chamber, introducing a pressurized gas into the chamber, directing the gas in the flow direction of and in surrounding contact with the stream within the chamber, passing both the gas and the stream into a zoner of lower pressure at a velocity sufficient to attenuate the stream and fragment it into fibers, and contacting the fragmented stream in the zone with a coagulating fluid.

Abstract: Nonwoven web comprising thermoplastic meltblown fibers or filaments predominantly present as agglomerates or multiple fused fiber areas. Such agglomerates in the web act as columns and impart a desired degree of strength and resistance to compaction. In contrast to prior art webs where such agglomerates have been considered undesirable, the webs of the present invention find particular utility when formed into cylinders as filter plugs for smoking articles. In smoking articles of the invention, the filter plugs have a desired pressure drop while demonstrating an unexpected degree of firmness, all at an economically attractive cost. Preferred embodiments include those where the machine direction strength to cross machine direction grab tensile ratios in the range of from about 1:1 to 4:1 and the fibers or filaments are made from polypropylene. Other embodiments include webs and filter plugs containing additives distributed throughout the web.

Abstract: A web or structure is formed by feeding separate supplies of fibrous material into contact with two separate lickerins that are parallel to each other and rotated toward each other. The fibers from the two lickerins pass through a mixing zone and are accumulated on a moving conveying screen that is moved parallel to the axes of the lickerins. Segmented baffle plates may be inserted into the mixing zone to control the lateral or cross-sectional composition of a web formed by the fibers accumulated on the screen. A segmented feed may be used to advantageously deliver different fiber materials at different rates to each lickerin. Radially layered composite web structures having circular cross-sections may be formed with the same apparatus by forming the conveying screen into a U-shape and selectively controlling the air flow through the screen.

Abstract: The production of mineral fiber felt into which an additional product is introduced. The felt is made partly of freshly formed fibers and partly of recycled fibers which are conveyed into a receiving chamber in which the felt is formed. The additional product is introduced with the recycled fibers. One advantageous application includes applying a surface active agent to the recycled edges to form a supporting material for hydroponic culture.

Abstract: A web or structure is formed by feeding separate supplies of fibrous material into contact with two separate lickerins that are parallel to each other and rotated toward each other. The fibers from the two lickerins pass through a mixing zone and are accumulated on a moving conveying screen that is moved parallel to the axes of the lickerins. Segmented baffle plates may be inserted into the mixing zone to control the lateral or cross-sectional composition of a web formed by the fibers accumulated on the screen. A segmented feed may be used to advantageously deliver different fiber materials at different rates to each lickerin. Radially layered composite web structures having circular cross-sections may be formed with the same apparatus by forming the conveying screen into a U-shape and selectively controlling the air flow through the screen.

Abstract: A nonwoven web is formed by feeding separate supplies of fibrous material into contact with two separate lickerins that are parallel to each other and rotated toward each other. The fibers from the two lickerins pass through a mixing zone and are accumulated on a moving conveying screen that is moved parallel to the axes of the lickerins. A baffle plate may be inserted into the mixing zone and acts to control the lateral or cross-sectional composition of a web formed by the fibers accumulated on the screen. When different fibrous materials are fed to the lickerin along their length, the vertical composition of the web is altered.

Abstract: A distinctive apparatus for forming an absorbent body includes a forming chamber, and a fiber delivering mechanism for providing a flow of fibrous material within the forming chamber. A forming layer, which is located in the forming chamber and is movable therein, receives deposit of the fibrous material thereon. A conduit mechanism supplied a flow of dispersed bodies of high-absorbency material, which enter the forming chambers and intermix with the flow of fibrous material thereon. A regulating mechanism controls a velocity of the flow of high-absorbency material into the flow of fibrous material to thereby form a selected distribution of high-absorbency material within the fibrous material deposited onto the forming layer.

Abstract: A process for making a melt-blown nonwoven polymeric web for use as a liquid filter medium includes increasing the air (fluid) flow and the forming distance to produce a filter medium that is more bulky and more permeable and therefore resists plugging. The melt-blown process parameters include a polymer through-put between 1.8 and 2.9 PIH, a polymer melt temperature between 530.degree. and 600.degree. F., and air flow rate between 200 and 265 SCFM per square inch, air temperature between 500.degree. and 600.degree. F., forming distance between 12 and 23 inches, and a collector vacuum between 0.5 and 1.0 inch of water.

Abstract: Fibre material is defibrated and dispersed in an air flow and introduced through an inlet (2) into a forming head (1). In the forming head (1) the inlet transforms to a single-curved convex surface (5), which leads all the way to an accept outlet (6). A screen (7) is located at adjustable distance from the curved surface (5) for dividing ingoing fibre/air flow into accept and reject. An outlet (10) for the reject is located behind the screen (7). At a distance of 10-150 mm from the accept outlet (6) a running air-pervious support (27) is located, on which the web precipitates.

Abstract: A web or structure is formed by feeding separate supplies of fibrous material into contact with two separate lickerins that are parallel to each other and rotated toward each other. The fibers from the two lickerins pass through a mixing zone and are accumulated on a moving conveying screen that is moved parallel to the axes of the lickerins. Segmented baffle plates may be inserted into the mixing zone to control the lateral or cross-sectional composition of a web formed by the fibers accumulated on the screen. A segmented feed may be used to advantageously deliver different fiber materials at different rates to each lickerin. Radially layered composite web structures having circular cross-sections may be formed with the same apparatus by forming the conveying screen into a U-shape and selectively controlling the air flow through the screen.

Abstract: A nonreinforced microfiber fabric is disclosed. The fabric has minimum grab tensile strength to weight ratio greater than 0.8 N per gram per square meter and a minimum Elmendorf tear strength to weight ratio greater than 0.04 N per gram per square meter. The fibers in the fabric have an average length greater than 10 centimeters and at least 80% of the fibers have a diameter of 7 microns or less. The fabric is made by thermally embossing a microfiber web which is made with a minimum of degradation to the polymer and employing high velocity secondary air to maintain air flow uniformity and fiber length.

Abstract: Apparatus for and methods of forming, from a single column of fibers, an airlaid fibrous web having a multiplicity of components.

Abstract: Apparatus for and methods of forming airlaid fibrous webs having a multiplicity of layers and/or discrete particles of absorbent gelling material dispersed through at least a portion of the web. The apparatus is of the type which includes a laydown drum having a foraminous forming element, a primary vacuum chamber, and a dusting layer vacuum chamber; a primary hood; and a dusting layer hood. The dusting layer of fibers formed on the laydown drum acts to block the passage of particles or fibers entrained in a first fiber stream which is airlaid over the dusting layer so as to minimize equipment plugging problems and the loss of particles or fibers through the foraminous forming element. The primary vacuum chamber of the laydown drum preferably spans the primary hood and a portion of the dusting layer hood so that the dusting layer is not sheared off, damaged, or destroyed as the laydown drum rotates to the position where the first fiber stream is deposited over the dusting layer.

Abstract: A lickerin and feed mechanism create a supply of individual fibers which follow the rotation of the lickerin. These fibers are deflected from the lickerin in the form of a stream by means of a plate arranged parallel to the lickerin. A conveying screen intercepts the stream of fibers and accumulates them into a web without the use of a high velocity stream of air to doff the fibers from the lickerin or to capture fibers on the conveyor. Further, the housing for the apparatus is opened so that there are no seals to compress the web after it is produced. Multiple lickerins and feed mechanisms may be spaced along the conveying screen to create multiple-layer or blended products. The feed mechanisms may include devices for spraying particulate material on previously formed layers or blending it with fibers as a layer is formed.

Abstract: A method wherein there is provided a source of fiber forming material, with said fiber forming material being pumped into a die having a plurality of spinnerets about its periphery. The die is rotated at a predetermined adjustable speed, whereby the liquid is expelled from the die so as to form fibers. It is preferred that the fiber forming material be cooled as it is leaving the holes in the spinnerets during drawdown. The fibers may be used to produce fabrics, fibrous tow and yarn through appropriate take-up systems. The pumping system provides a pumping action whereby a volumetric quantity of liquid is forced into the rotational system independent of viscosity or the back pressure generated by the spinnerets and the manifold system of the spinning head, thus creating positive displacement feeding. Positive displacement feeding may be accomplished by the extruder alone or with an additional pump of the type generally employed for this purpose.

Abstract: A nonwoven web is prepared from a polymeric blend comprising at least one elastomer and at least one thermoplastic resin. The nonwoven web comprises fibers produced by melt blowing the polymeric blend. Conventional techniques are used to accomplish the melt blowing but due to high viscosity of certain elastomers it is frequently necessary to degrade the polymer blend priior to melt blowing. The nonwoven web exhibits improved extensibility, texture and hand.

Abstract: A method for forming a fiber web and fibrous web useful for compression molding stiff, board-like structural substrates for panels is formed of a thoroughly intermixed blend of wood fibers and synthetic plastic fibers with a dry, powdery, resinous molding material uniformly disbursed throughout the blend. The mass of intermixed fibers and resinous molding material is covered with a thin, randomly oriented, fibrous scrim material and the fibers are locked to each other and to the scrim mechanically by means of needling them together.

Abstract: A process for the production of a fiber web on a movable, gas-permeable surface of a continuous laydown belt which is under vacuum and which forms a distribution chamber. After the fibers are mechanically opened, the fiber flow is conducted into the distribution chamber by means of an air current and additional air currents are delivered to the distribution chamber. An additional air current is introduced into the distribution chamber for the purpose of preventing a lumping together of fibers prior to the laydown in the web while the carrying air current is delivered to the distribution chamber in a nozzle-shaped chute. After the fibers have been laid down in a web, the web is precompressed by means of a controllable vacuum.

Abstract: A nonwoven web is prepared by the method of forming a nonwoven web from a composition composed of at least one thermoplastic polymer and at least one defined siloxane-containing additive, which method involves the steps of (A) forming fibers by extruding a molten thermoplastic composition through a die; (B) drawing the fibers; (C) collecting the fibers on a moving foraminous surface as a web of entangled fibers; and (D) heating the web at a temperature of from about 27.degree. to about 95.degree. C. for a period of time sufficient to cause additional additive to move to the surfaces of the fibers. The method of the present invention is particularly useful for the preparation of nonwoven webs, the fibers of which have at least one surface characteristic which is different from the surface characteristics of the polymer component of the thermoplastsic composition.

Abstract: Superabsorbent articles in the form of soft, nonwoven fibrous webs are produced from aqueous fiber-forming polymer solutions by forming the polymer into water soluble filaments, contacting the filaments with a primary air stream having a velocity effective to attenuate and to partially dry the filaments, contacting the attenuated filaments with a secondary air stream having a velocity effective to fragment the filaments into fibers and to transport the fibers to a web-forming zone while also further attenuating and drying the fibers, collecting the fibers in reticulated web-form in the web-forming zone and curing the web to a water insoluble state. The temperature and air stream velocities are controlled with respect to ambient humidity and water content of the fiber during the fiber and web formation such that the fibers are collected without sticking. Collection is preferably on a wire belt followed by transport through a curing oven to compacting rolls and web take-up.

Abstract: To produce non-woven materials, endless filaments in the form of a warp are drawn off a filament draw-off nozzle to which are joined a filament offlet, a filament guide tube and a spreading extruder. An amount of compressed air under high pressure is admitted to the filament draw-off nozzle. By means of the invention the amount of compressed air at the filament draw-off nozzle is reduced and at the same time an additional amount of compressed air under relatively low pressure is admitted between the filament guide tube and the spreading extruder by means of a propelling nozzle. In spite of an additional amount of compressed air at the propelling nozzle the reduction at the filament draw-off nozzle is so large that for the isothermal compression output as a whole a considerable savings in energy of almost 30% can be achieved, and this while maintaining the important filament draw-off force necessary for the drawing of the filaments inside the filament offlet.

Abstract: The process for making the spun fleece proceeds in a filament-spinning unit having a spinning nozzle system, a cooling shaft, a stretching aperture, a diffuser shaft, a continuously moving fleece recovery conveyor and a device for feeding process air and for drawing outflowing air through the fleece recovery conveyor. The cooling shaft has a shaft wall provided with a plurality of air orifices. That allows process air required for cooling to be fed into the cooling shaft. That air flow at least partially is drawn through the fleece recovery conveyor. The thickness of the spun fleece is measured on the fleece recovery conveyor in the transport direction downstream of the diffuser shaft. The measured value is compared with a predetermined set value. On deviation of the measured value from the set value the setting angle of the air control flap or flaps which are located adjacent the entrance of the stretching aperture is changed.

Abstract: A thermoplastic material extrusion mechanism is provided which includes a die head having a centrally disposed high velocity gas delivery means adapted to continuously emit a jet of a gas having shear layers, at least one chamber for the thermoplastic material, thermoplastic material delivery means arranged at least partially surrounding the centrally disposed high velocity gas delivery means for directing extruded thermoplastic material emitted from the thermoplastic material delivery means toward the gas jet, causing the extruded thermoplastic material to be introduced into the shear layers of the gas jet, and a thermoplastic material conduit which communicates the at least one chamber with each of the thermoplastic material extrusion openings.

Abstract: Consolidated nonwoven fabrics and the process of producing theme is disclosed. The fabrics absorb water and substances with oleophilic and/or lipophilic properties. The inventive process includes blow-spinning a melt or a solution of a spinnable polymeric material to textile fibers and/or filaments, preferably having a diameter of 0.1 to 6 .mu.m, more preferably 0.5 to 3 .mu.m, transforming these textile fibers and/or filaments to a nonwoven fabric, consolidating this fabric and applying a wetting agent to the fabric. Consolidation is accomplished by means of water jets, then a zwitterionic or cationic surfactant is applied to the fabric in a wet-in-wet procedure during or immediately after the water-jet consolidation, and the fabric is dried; these procedures are performed continuously. A polyester or a polyamide is used preferentially as the polymeric material.

Abstract: A process for producing a non-woven web of thermoplastic polymer fibers comprises extruding a thermoplastic polymer through a series of die openings while passing a stream of hot gas from both sides of the die openings to impinge and attenuate the molten extruded resin fibers, wherein the gas is passed through a plurality of flow distribution holes and through a flow detector to intermix gas jets discharging from the holes.

Abstract: A large number of melt blown carbon fibers from petroleum pitch through a multi-orifice die under continuous formation, are fed onto the periphery of a continuously moving endless conveyor surface whose surface speed is matched to the linear velocity of the melt blown carbon fibers to cause the fibers to be deposited in parallel alignment on the conveyor surface and to be maintained in fiber axial alignment to form a non-woven mat of aligned carbon fibers. The speed of the conveyor surface may be slightly less than the linear speed of the fibers to form a loose fiber mat to facilitate subsequent fiber oxidation and carbonization by permitting gas flow through the aligned fiber mat. The endless conveyor may comprise a cylindrical drum whose surface is perforated to facilitate gas flow and oxidation of the carbon fibers subsequent to non-woven mat formation.

Abstract: A molded article, for example, a filter or a preform used in the manufacture of fiber-reinforced composites, is manufactured from an air laid batt from a single fiber type or a mixture of fibers. The batt is either resinated with a thermoplastic material or includes a thermoplastic binder fiber. The batt is formed into the desired shape of the molded article in a through-air mold and heated sufficiently to set the thermoplastic material, so that the resulting article retains the desired shape. If the article is to be used as a fluid filter, it can be used either as it is removed from the mold if a filter of uniform density is desired, of the article can be further processed in a compression mold to densify portions of the article to thereby form, for example, a fluid impervious portion used as a gasket. If the article is to be used as a preform for a structural composite, it is then to be transferred to a resin injection mold.

Abstract: A lickerin and feed mechanism create a supply of individual fibers which follow the rotation of the lickerin. These fibers are deflected from the lickerin in the form of a stream by means of a plate arranged parallel to the lickerin. A conveying screen intercepts the stream of fibers and accumulates them into a web without the use of a high velocity stream of air to doff the fibers from the lickerin or to capture fibers on the conveyor. Further, the housing for the apparatus is opened so that there are no seals to compress the web after it is produced. Multiple lickerins and feed mechanisms may be spaced along the conveying screen to create multiple-layer or blended products. The feed mechanism may include devices for spraying particulate material on previously formed layers or blending it with fibers as a layer is formed.

Abstract: A fibrous web comprising fibers which have been differentially cooled to provide a crimped fiber conformation thereto and then thermally relaxed to a sufficient degree to at least partially decrimp the fibers and increase the loft and decrease the density of the web. Also disclosed is a process for forming a web of such type, comprising the steps of forming a web of fibers, bonding the fibers to form a bonded web, differentially cooling the fibers to provide a crimped fiber conformation thereto, and thermally relaxing the fibers to a sufficient degree to at least partially decrimp the fibers and increase the loft and decrease the density of the web, wherein the differential cooling step preferably is carried out prior to bonding of the fibers to form the bonded web and the thermal relaxing step is carried out after bonding of the fibers to form such web.

Abstract: Apparatus and method for forming an integral laid fibrous web from multiple fiberizable components, characterized by generally discrete homogeneous compositional zones therein. The system comprises a housing having in its outer surface (i) inlet slot(s) for introduction of fiberizable materials into the housing and (ii) a discharge slot generally laterally coextensive with and translationally spaced from the inlet slot(s), for discharge of fiberized materials from the housing. A translatable body is positioned in the housing for translation therein, having a plurality of blades on its outer surface. The outer surface of the translatable body and the housing have a space therebetween wherein the blades travel during translation of the translatable body. First and second fiberizable components are fed to inlet slot(s) wherein the respective fiberizable components are at least partially laterally isolate relative to each other during the feeding.

Abstract: Disclosed herein are a process for producing a carbon fiber mat, having excellent production and energy efficiencies, comprising successively melt-spinning a fiber-forming pitch by a centrifugal spinning machine having a horizontal axis of rotation (parallel to the plane on which the spinning machine is placed), forming a mat by the thus spun pitch fibers, bringing the mat into an infusibilized state in an air atmosphere containing NO.sub.2 and calcining the thus infusibilized mat in an inert atmosphere, and an apparatus for carrying out the above-mentioned process.

Abstract: The present invention provides an improved apparatus for forming a fibrous web, and includes a fibrous supply mechanism for providing fibers of web material. The fibers are deposited onto a foraminous web forming layer which may optionally have a pocket recess formed therein. A foraminous spacing mechanism supports the web forming layer while allowing a substantially unrestricted gas flow from a region immediately adjacent to and downstream from the web forming layer. A gas flow regulating layer has a selected pattern of apertures therethrough, and is fixedly positioned in adjacent facing relation with the foraminous spacing means. The regulating layer provides a selected pattern of gas flow through the web forming layer. The regulating layer, the foraminous spacing mechanism and the gas flow regulating layer are constructed to form an installable and replaceable assembly, and a flow forcing mechanism provides a flow of gas through the web forming layer.

Abstract: Fiber mats formed by attenuating molten streams of attenuable mineral material by subjecting the streams to the action of a hot attenuating gas blast. The gas blast induces gas from the surrounding atmosphere, and the combined blast and induced gas forming a fiber-carrying current. The current is directed toward a preforated fiber-collecting conveyor on which the fibers are deposited in the form of a mat and the gas of the current passes through the conveyor. Provision is made for withdrawing a peripheral portion of the fiber-carrying current at a point intermediate the zone of attenuation and the perforated fiber-collecting conveyor.