Abstract: A process for continuously forming a fibrous element in an elongate closed foraminous former during movement of the former through fluid extraction means, and which includes the steps of forming a fibrous dispersion, injecting the dispersion into said former, generating a pressure gradient across an extraction zone within said fluid extraction means and injecting the fibrous dispersion into the former at an injection velocity relative to the speed of the former (efflux ratio) to cause some of the fibres to build up as a fibrous mat on the inner surface of the former and the remainder to pack together to form a core so as to produce a continuous fibrous element having a fibrous core which is enclosed by a crust of greater density.

Abstract: A process for forming a mineral wool, resin-bound acoustical insulating fiberboard product is described, which includes steps for mixing mineral wool fibers and powdered thermosetting binder, the introduction of the mixture into an air stream, and the directing of the entrained mixture into a mat-forming zone formed by converging upper and lower forming wires, the exhausting of air through the wires to build up layers of fiber and binder thereon and the consolidation and heating of the layers to form a fiberboard product, the amounts of air exhausted through the forming wires being adjusted so that a resin-enriched layer of predominantly fine fibers is initially deposited on the upper forming wire. A preferred embodiment is disclosed wherein an open mesh glass fabric is positioned between the lower forming wire and the layer of fibers and resins being formed thereover, said fabric acting as a carrier for the board-forming mat.

Abstract: A continuous in-line method for forming an airlaid fibrous fluff web adjacent the uppermost and lowermost surfaces of a substantially planar internal reinforcing ply having substantially the same width as said fibrous web, said ply being substantially impervious to the passage of fibers from one surface thereof to the other, in a continuous fiber deposition zone is disclosed. In a preferred embodiment, a unique ply folding board is employed to permit continuous formation of an airfelt web having a reinforcing ply comprised of wet strength tissue paper located approximately mid-way between its uppermost and lowermost surfaces. Two adjacent vacuum chambers are preferably employed in the continuous forming zone to compensate for the increased airflow restriction encountered when forming the uppermost fibrous web portion over the reinforcing ply and the lowermost fibrous web position.

Abstract: A nonwoven, self-sustaining, absorbent fabric comprising a batt of randomly arranged, intermingled cellulosic fibers has a plurality of high loft, loosely compacted regions separated from each other by highly compressed regions. An adhesive material penetrates through the compressed regions to form bonded fiber networks extending completely through the batt, and said adhesive material only partially penetrates through said high loft regions whereby the fibers in the interiors of said high loft regions are unbonded by said adhesive so that said regions are highly absorbent. A method of manufacturing the above-described nonwoven fabric by moistening opposed surfaces of a loosely compacted, randomly oriented cellulosic fiber batt, embossing said moistened batt for providing a pattern in said surfaces, applying an adhesive to the patterned surfaces of the batt and setting said adhesive.