Abstract: A method of forming a fibrous web useful for compression molding stiff, board-like structural substrates for panels by thoroughly intermixing a 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: The throughput of an apparatus for processing fibrous materials is increased by a fiber outlet portion consisting essentially of a plurality of dividers oriented in a direction perpendicular to the direction of travel of the impact elements (such as hammers and rotor blades), said dividers having a leading surface which is inwardly slanted in the direction of travel of the impact elements and dividers being separated by continuous or semi-continuous slots.

Abstract: The invention generally provides for formation of meltblown material containing wood fiber on to a continuous foraminous belt. During formation a polymer and wood fiber first layer is applied to a moving belt from at least one bank of meltblown forming apparatus. This first layer does not contain superabsorbent. The belt carrying the first layer passes beneath at least one further source of meltblown fiber into which superabsorbent is added along with the wood fibers. This provides at least one additional layer integrally connected to the first-formed layer and having superabsorbent properties. The first layer acts to aid in trapping of any superabsorbent which is not immediately entangled in the meltblown and wood fibers and prevents it passing through the forming belt.

Abstract: Methods and apparatus for producing three-dimensional structural members having one flat side from wood fibers utilizing flow deposition of the fibers onto a support. The support includes resilient deformable mold inserts. The mold inserts are formed of silicone rubber and may be blocks of the material, or may be a membrane which can be inflated to form the mold inserts. Pressing is done with a force normal to the support, and the mold inserts create response forces at varying directions to thus shape and hold the three-dimensional finished part. Heat drying also may be used.

Abstract: The present invention provides an improved apparatus and method for forming a fibrous web. In accordance with the invention, a distributor housing delimits a fiberizing zone, and a delivery mechanism supplies a fiberizable material into the fiberizing zone. A moveable striking mechanism located in the fiberizing zone contacts the fiberizable material to initially separate the material into individual fibers. A discharging mechanism exits the fibers from the fiberizing zone into a web forming zone and toward a foraminous web forming layer. A gas delivering mechanism forces a stream of gas into the fiberizing zone to entrain the fibers therein and to eject a moving stream of the gas and fibers through the discharging mechanism into the web forming zone. The gas-fiber stream moves at a velocity sufficient to draw an induced supplementary gas flow past the discharging mechanism and toward the foraminous forming layer.

Abstract: Dry laid board comprising peat moss is provided and made by harvesting peat moss having a degree of decomposition of H-1 value as measured by the Modified Von Post Scale, individualizing the harvested peat moss, drying the individualized peat moss and entraining the peat moss in a gas stream. The entrained peat moss is then condensed to form a low density peat moss containing board which is subsequently calendered for use in such products as dressings, diapers and sanitary napkins.

Abstract: A dense, resilient, non-woven staple polymer fiber batt is formed of either of a plurality of overlayed, relatively thin webs or at least one relatively thick web. The web or webs comprise at least first and second staple polymer fiber constituents blended to form a homogenous mixture. The first fiber constituent has a relatively low melting temperature and the second fiber constituent has a relatively high melting temperature. The fibers of the first fiber constituent are fused by heat to themselves and to fibers of a second fiber constituent to interconnect the fibers while in a vacuum-compressed state. The heat is sufficient to melt the fibers of the first fiber constituent but not high enough to melt the fibers of the second fiber constituent.

Abstract: A process for providing film tubes with anti-blocking means in that the film tube is cooled internally by an aqueous suspension containing a suspended release agent directly after extrusion, the excess suspensions are sucked from the interior and the tube, which is additionally cooled on the exterior in a water bath, is freed of remaining liquid by squeezing rollers.

Abstract: There is provided an absorption pad having a C-shaped cross section and a perabsorbent layer embedded therein, said pad being blunted at its forward and rearward ends in the nature of a truncated pyramid. In a process for the manufacture of the absorption pad, the absorption pad blanks are shaped on a flake wheel and subsequently finished as absorption pads by pressing and folding. Prior to the folding step, a superabsorbent material is applied.

Abstract: A system for forming an air laid web of fibers and/or particles on a moving foraminous carrier. Fibers and/or particles are blended, and while supported in an air stream, introduced into a distributor unit. The distributor unit includes a rotatable cylinder formed with classification apertures of a predetermined shape, number, and size as specifically related to the types of fibers and/or particles utilized. A rotatable shaft with radially extending wire-like members agitates the fibers and/or particles and throws them outwardly through the apertures. Downwardly directed air flow transports the refined fibers and/or particles so as to form a homogeneous, still further refined, web on the surface of the carier. A variety of adjustments and alternations can be made to the system and its components to control the composition and thickness of the end product, and to attain maximum capacity for any combination of fibers and/or particles.

Abstract: The invention relates to the forming of felts, the fibres of which are disposed in random directions.These felts are obtained by depositing the fibres which are carried by a current of gas on a gas-permeable conveyor, the fibres, prior to being deposited, being coated with a binder composition. The felt constituted on the conveyor is subject to at least a longitudinal compression, the intensity of which is regulated in such a way that no creases form on the surface.The felts obtained are highly resistant to compression, to tearing and to flexion.

Abstract: An apparatus for the manufacture of fibrous webs comprises a forming wire and a distributor for depositing dry fibers on the wire. The distributor comprises at least one cylindrical chamber having its axis extending transversely of and in a plane parallel to the wire. The lower semicylindrical wall of the chamber is perforate for distributing fibers on the wire and the upper semicylindrical wall includes a fiber inlet. A helically bladed rotor in the chamber has its axis substantially coincident with the chambers axis of curvature, and upon rotation operates to drive fibers through the screen while evenly distributing them across the wire. Disposition of a pair of chambers in tandem with a common central fiber inlet operates further to create a racetrack fiber distribution across the wire.

Abstract: An apparatus for depositing a uniform web of dry fibers on a foraminous wire moving at speeds greater than 500 feet per minute including offset suction and air deflecting means within a fiber distributor for imparting a horizontal velocity component to the deposited fibers in the direction of the moving wire, also a method for depositing a uniform web of dry fibers onto a moving foraminous wire including imparting a horizontal velocity component to fibers deposited onto the wire in the direction of the wire by inducing a pressure gradient and baffling the air flow within a fiber distributor.

Abstract: The invention relates to a method and an apparatus for producing layers of dry fibres and/or particles on a forming surface pervious to air. According to the invention, the material is distributed in air and passed to a forming unit where a turbulence with high intensity is effected in that air is injected through separate nozzles.

Abstract: A method for producing a fabric item comprising the steps of producing a perforated substrate in the shape of the desired fabric item, supplying fibers to the perforated substrate, causing the fibers to engage the perforations in the substrate, and retaining the fibers in the perforations.

Abstract: Disclosed in accordance with the invention is a method for fiberboard manufacture comprising the steps of steaming and grinding woodchips to obtain a wood pulp, using said wood pulp to prepare a slurry of wood pulp in water, mixing said slurry with a binder, a cure catalyst for the binder, a water-repellent additive, peat, and carbamide to obtain a mixture, casting said mixture and dewatering said mixture to obtain a mat, and compacting said mat to obtain fiberboard which is subjected to heat treatment, in which method the peat used has a moisture content of between 25 and 70 percent and the peat content in said mixture is between 2.5 and 50 percent by mass, with the ratio of absolutely dry peat to said binder equal to between 1.0-7:1.0, respectively, while the carbamide content in said mixture is between 0.2 and 2.0 percent by mass, with the ratio of said carbamide to said binder equal to between 0.02-1:1, respectively.

Abstract: Hydrogen bonding between cellulosic fibriles can be improved in an air-laid process by injecting ammonia or organo-amine catalysts and steam into the cellulosic fibrile mass after such fibers have been reduced to fibrile form and prior to their dispersion in air to form a fibrous mat. Prior to and subsequent to the injection of the catalytic bearing steam, the fibers may be combined with other paper forming material, resins, additives and processed in an air-laid paper making process to form a felted fibrous product with a minimal amount of water content and with acceptable strength and density. Suitable catalysts include gaseous ammonia, ammonium hydroxide, or the organo-amines such as triethanol amine, methyl amine, ethyl amine, cyclohexyl amine, or aniline and the homologous series derivatives thereof.

Abstract: Improvement to the die and method of forming meltblown fibers and webs using a relatively cool fluid for meltblowing. Thermoplastic polymers such as polyolefins, polyamides, polyesters and the like are spun in accordance with the meltblowing process and contacted by a fluid which forms fibers and attenuates them. In accordance with the invention, the fluid is substantially cooler than the molten polymer and permits formation of webs at shorter forming distances greatly improving web formation. In addition, the costs of manufacture are improved since heating of the attenuating fluid may be reduced or avoided. In a particularly preferred embodiment, the die is provided with insulation between the attenuating fluid and the polymer chamber to avoid or reduce the tendency of the molten polymer to cool and cause plugging of the die. Alternatively, the die may, itself, be formed from an insulating material.

Abstract: The present invention provides a method for manufacturing polypropylene spun-bonded fabrics, which method involves preparing a polypropylene melt at a temperature of about 240.degree. to 280.degree. C. and forming polypropylene filaments by extruding this melt through a spinning nozzle at an extrusion velocity of about 0.02 meter/second to 0.2 meter/second. The spinning nozzle, or spinneret, has holes with a diameter less than 0.8 millimeter. The filaments thus formed are subsequently quenched by transversely blowing air at a temperature between about 20.degree. to 40.degree. C. The filaments are also aerodynamically withdrawn by means sufficient to create a filament withdrawal velocity between about 20 meters/second and 60 meters/second. The ratio of the extrusion velocity to the withdrawal velocity (herein defined as the deformation ratio) is between about 1:200 and 1:1000. These aerodynamically withdrawn filaments are then deposited onto a moving porous support in order to form a continuous web.

Abstract: An apparatus for the production of a fibrous web comprising a fiber distributor with a housing having an inlet for dry defibrated fibrous material and a perforated bottom wall, and at least two closely spaced rows of stirrers, each comprising impellers which are rotatably mounted within the housing, an air-permeable forming wire, a mechanism for advancing the wire below the bottom wall of said fiber distributor and a suction box mounted below the rows of stirrers and the forming wire.

Abstract: A method for making an air-laid batt of fibers which utilizes a plurality of scarfing rolls to remove material from the surface of the batt, wherein the batt is reformed between at least two of the scarfing rolls in order to produce a more homogeneous web.

Abstract: A method for making acoustical tile having a pattern of raised portions and portions in relief on the tile surface is provided by contacting deformable, acoustical tile fiber composition pulp with a hollow embossing roll containing the pattern in reverse and interstices communicating from the surface of the roll into the hollow interior of the roll; pressing the roll against the deformable pulp with sufficient force as to dispel the pulp; vent air, between the roll and the pulp surface, through the roll and produce the reversed pattern of the roll upon the pulp surface; and releasing the pulp from the surface of the roll by rotation of the roll.

Abstract: A process and apparatus are provided for the production of a non-woven fabric by melt-blowing wherein one or more yarns, e.g. monofilaments, are added or charged into the fabric stream between the extruder and collector by means of a supporting and drawing pressure gas stream. In one embodiment means are provided to regulate flow of the gas stream. In another embodiment means are provided to reciprocate or to rotate through a small arc the one or more charging means.

Abstract: A mixture of binder and fibrous material is introduced into the upper regions of a mat-forming zone. The mixture is intersected by a horizontally or upwardly directed air stream and entrained therein, then layered onto at least one foraminous wire by exhausting the entraining air through said foraminous wire or wires. By reducing turbulence and by controlling the manner in which the particulate matter is deposited upon the foraminous wires, uniform non-woven webs can be obtained which may be used in a variety of ways to form versatile building products.

Abstract: The present invention provides for a shaped body comprising a settable mineral material such as cement or gypsum with reinforcement fibers embedded therein. The reinforcement fibers, which are endless and consist of an organic polymer material, are processed as a nonwoven fabric characterized by a parallelized scatter texture.

Abstract: A molding mixture comprising a filler, such as wood particles and a resin binder, is pressed under light pressure on a flat bed to produce a mat with a density between 1/15 and 1/3 of the material in the finished article to be made by pressure molding. A molding preform is then made from a piece of such mat having a suitable contour, by sculpturing one side of the mat with suction devices to provide a thickness variation over the mat area corresponding to the requirements of the molding step.

Abstract: A process for producing thermal-insulating nonwoven bulky product characterized by its structural make up of substantially continuous single filaments of from about 0.01 to 2 denier which are stabilized on themselves in the product by a surface binder on the filaments.

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

Abstract: A method therefor for forming an air-laid web of dry fibers suitable for use in a wide variety of products ranging from bath and facial tissues to towels having basis weights on the order of 13 lbs./2880 ft..sup.2 to 50 lbs./2880 ft..sup.2 on a high-speed production basis, wherein the web is characterized by random array of individualized fibers substantially undamaged by mechanical action and having a controlled cross-directional profile, and by its freedom from nits, pills, rice and the like, thereby improving both the appearance and the tensile strength of the web. The full-width feeding of dry fibers to a 2-dimensional flow control and fiber screening system is described wherein substantially no cross-flow forces are created in the system, ensuring a uniform cross-directional basis weight profile.

Abstract: Methods for pre-forming and feeding a lightly compacted batt of individualized fibers having a controlled cross-directional profile directly to a rotary fiber orienting and screening mechanism across the full width thereof so as to maintain a controlled cross-directional profile in an air-laid web of dry fibers formed in a high speed dry web forming system.

Abstract: A process for producing a thermoplastic nonwoven fabric having a uniform thickness and optionally napped fibers according to a melt blowing method, which comprises blowing a fiber stream consisting of melt blown fibers and a gas at a high speed onto a plate within a valley-like fiber-collecting zone formed by two plates having a large number of pores, to form a uniform nonwoven fabric without scattering fibers.

Abstract: Method for improving fiber throughput in a high speed production system for forming an air-laid web of dry fibers and wherein individual fibers are separated from aggregated fiber masses in an enclosed, pressurized rotor chamber comprising forming a segment of the chamber wall with a plurality of closely spaced, elongated, narrow slots oriented parallel to the axis of the rotor chamber.

Abstract: Method and apparatus for forming filaments are provided by centrifugally forming a veil of primary fibers or streams of material and moving a fluid along a path within the veil at a velocity sufficient to attenuate said primary fibers into filaments.

Abstract: A lofted mat of filaments is produced from process and apparatus including: supplying a plurality of streams of molten polymeric material; attenuating said streams of material into continous filaments through the action of a stream of fluid moving from an attenuation means; said filaments being entrained in said fluid moving from said attenuation means, said filaments having non-uniform residual stresses established therein; moving said stream of fluid and filaments along a first surface positioned intermediate said attenuation means and a foraminous surface; establishing a vacuum at said foraminous surface; directing said stream of fluid and filaments into said foraminous surface obliquely oriented with respect to said first surface such that a first portion of said fluid separates from the filaments and passes through said foraminous surface and a second portion of said fluid moves said filaments along the foraminous surface; collecting said filaments in a randomly dispersed, substantially uniform layer hav

Abstract: A process is disclosed for producing a non-woven, boron nitride fiber mat, suitable for use as an electric cell separator in a lithium-sulfide battery. Molten boron oxide is centrifugally spun into strands and attenuated by an annular gas stream into fibers which are compacted at a controlled relative humidity into a mat. The mat of fibers passes through a needler, which repeatedly drives arrays of needles into the mat from either one or both sides, to reorient and intertwine the fibers, producing additional mechanical bonds thereamong. The needled mat then is heated in an anhydrous ammonia atmosphere to convert boron oxide in the fibers into boron nitride (BN). In an alternate embodiment the boron oxide fibers within the mat are converted into boron nitride before being passed through the needler.

Abstract: Method for the deposition of a uniform layer of dry fibers on a foraminous forming surface which comprises passing the fibers through a perforated wall having zones of different aperture sizes in order to provide an even cross-direction basis weight profile.

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

Abstract: An improved method and apparatus for forming nonwoven webs by spinning filaments into a quench chamber where they are contacted with a quenching fluid, then utilizing the quench fluid to draw the filaments through a two-dimensional nozzle spanning the full machine width, and collecting the filaments as a web on a porous surface. In contrast with the prior art, low motive fluid pressures can be used, and a non-eductive drawing means utilized to minimize air turbulence and the resulting filament entanglement in the drawing means while maintaining substantially constant cross machine filament distribution. The apparatus and process reduce problems relating to filament breakage and spreading and result in increased productivity and improved web formation. Other advantages include the ability to continuously spin highly pigmented polymer filaments and reduced hazards associated with high noise levels.

Abstract: Method for the manufacture of a fibrous web comprises provision of a conduit having a plurality of outlets for discharging classified fibers onto a linearly movable planar section of an endless screen. The fibers pass through openings in the screen and land on an underlying planar section of a forming wire, in formation of the fibrous web, with the aid of an underlying vacuum box. Uniformity of fiber distribution is provided by parallel banks of brushes that engage the planar section of the endless screen and are rapidly oscillated in short, non-synchronous strokes transversely of the direction of screen movement.

Abstract: A method of forming an air laid web of hydrogen bonded wood pulp fibers is disclosed. More specifically, a paper producing method is disclosed wherein microencapsulated hydrogen bond promoting material is thoroughly premixed with wood pulp fibers. The mixture is then air laid on a moving screen to form a three dimensional continuum. The microcapsules may then be ruptured by heat and/or pressure to release the hydrogen bond promoting material evenly throughout the continuum. The continuum may then be heated or pressed to further consolidate the web.

Abstract: In an improved die-nose assembly for a melt-blowing process wherein molten resin is extruded from a series of die-holes while heated gas is blown out through slots on either side of the die nose associated therewith, spacers which are movable widthwise of the die assembly are provided in the gas slots to provide effective uniformity in the gas streams across the width of the die.

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

Abstract: Method and apparatus for forming filaments are provided by centrifugally forming a veil of primary fibers or streams of material and moving a fluid along a path within the veil at a velocity sufficient to attenuate said primary fibers into filaments.

Abstract: Thermoplastic materials are converted directly into thermally bonded, coherent fibrous products by melt blowing techniques. The fibrous product is in the form of a rod having a relatively dense, rigid skin in which the fiber portions are oriented primarily in a longitudinal direction with respect to the axis of the product, and a less dense core where the fiber portions are oriented primarily in a transverse direction with respect to the axis of the product. The products are made by melt blowing fibers and intercepting them by a fiber collecting and forming device which permits a relatively heavy build-up of fiber mass in the central portion and a relatively light build-up of fibers in a lip portion surrounding the central portion.

Abstract: A fiber-reinforced cementitious sheet is formed by first co-mixing in an air current reinforcing fibers such as glass fibers, and cementitious mineral materials in finely particulate form such as calcium sulfate hemihydrate, both in substantially dry form, depositing the mixture on a moving foraminous surface by means of the air current to form a sheet, applying water as by spraying in at least an amount which is stoichiometrically sufficiently to hydrate the calcium sulfate hemihydrate to the dihydrate form and to provide the necessary degree of plasticity to the mixture, densifying the sheet by compression, and setting and drying the sheet. A pair of sheets may be utilized as face sheets and, prior to setting, combined with a core formed of for example a calcium sulfate hemihydrate slurry, and the sheets and core then set and dried to form a paper-free gypsum board having excellent strength, surface hardness, and fire-resistant properties.

Abstract: A process for producing a consolidated sheet of substantially dry fibrous material, for example wood pulp, comprising supplying fibrous material, having a moisture content of not more than 30 percent by weight on the total weight of the fibrous material, to a hopper and onto a gas-pervious conveyor while drawing gas through the conveyor (and through the fibrous material thereon), carrying the dry fibrous material on the conveyor surface from the hopper beneath means for reducing upward protrusions therefrom to form a layer of the fibrous material and applying pressure to said layer to consolidate the fibrous material to form a coherent sheet.

Abstract: Polymeric material in the form of fibrids is produced by preparing (1) a homogeneous liquid phase of a first polymeric material and solvent and (2) a second phase of other polymeric material which is incompatible with the first polymeric material and solvent. Phases (1) and (2) are mixed together in such proportions that the quantity by weight of the first polymeric material is greater than that of the second polymeric material in the mixture. The mixture is furnished with sufficient energy to render it flashable and is then subjected to a flash-spinning so that polymeric material in the form of fibrids is produced and those fibrids are thereafter collected.

Abstract: A fiber-reinforced cementitious sheet is formed by first co-mixing in an air current reinforcing fibers such as glass fibers, and cementitious mineral materials in finely particulate form such as calcium sulfate hemihydrate, both in substantially dry form, depositing the mixture on a moving foraminous surface by means of the air current to form a sheet, applying water as by spraying in at least an amount which is stoichiometrically sufficient to hydrate the calcium sulfate hemihydrate to the dihydrate form and to provide the necessary degree of plasticity to the mixture, densifying the sheet by compression, and setting and drying the sheet. A pair of sheets may be utilized as face sheets and, prior to setting, combined with a core formed of for example a calcium sulfate hemihydrate slurry, and the sheets and core then set and dried to form a paper-free gypsum board having excellent strength, surface hardness, and fire-resistant properties.

Abstract: A nonwoven fabric having alternating stripes of high fiber density and low fiber density is made in such a manner that the high fiber density stripes run across the fabric and maximize the cross direction strength to a point that the cross direction/machine direction strength ratio approaches unity. This advantageous and desirable characteristic can be achieved by hydroforming card web; first disposing the carded web on a relatively fine mesh screen and placing a finger-like striping bars over the web with the axis of the bars at 90.degree. to the card web's general fiber orientation. Water was then sprayed over the assembly with sufficient force to rearrange the fibers in the web thereby producing the nonwoven fabric of this invention.

Abstract: Method for making a laminated ballistic helmet from plural, continuous filament resin-coated layers. A continuous filament bundle, yarn or end is deposited on a plurality of different sized helmet-shaped preforms. A resin is coated upon or impregnated into the continuous filament bundle, yarn or end, either before or after deposition. The resulting resin containing preforms are stacked in nested relation and then molded to produce a bonded, laminated ballistic helmet.