Abstract: A nonwoven web contains an even distribution of its composite materials by the separate application of particulate material such as superabsorbent particles into a forming head outside the air stream for deposition of thermoplastic fibers in the forming head. The thermoplastic fibers are distributed by air entertainment through tubular forming screens having rotary distribution members therein. The particulate absorbents are generally placed in the forming box by distribution units which may have metering devices and outlet chutes extending into the forming head.

Abstract: The method and apparatus for forming composite wood products particularly composite veneer like products which may be intermediate products and laminated to form the final composite product. Strands are fed from a source of supply at a metered rate, entrained in an air stream and carried along a confined path between an entrainment zone and the source of supply. Strands are condensed onto a surface to form a veneer lay-up of at least one layer of strands on the forming surface and this veneer lay-up is carried from the path and deposited onto a collecting surface and later consolidated into a composite product. Entraining air and strands not forming veneer are separated in the supply station, the strands fall onto the supply of strands and energy is added to the separated entraining air and it is returned to the entraining zone.

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: The method and apparatus for forming composite wood products particularly composite veneer like products which may be intermediate products and laminated to form the final composite product. Strands are fed from a source of supply at a metered rate, entrained in an air stream and carried along a confined path between an entrainment zone and the source of supply. Strands are condensed onto a surface to form a veneer lay-up of at least one layer of strands on the forming surface and this veneer lay-up is carried from the path and deposited onto a collecting surface and later consolidated into a composite product. Entraining air and strands not forming veneer are separated in the supply station, the strands fall onto the supply of strands and energy is added to the separated entraining air and it is returned to the entraining zone.

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: An arrangement used for filtering out conveying air when supplying fiber material to a processing machine is provided. The arrangement has an essentially vertical filling chute for the fiber material, the chute having an upper intake opening and a lower exit opening, a device with pneumatic fiber feed at the upper intake opening, and a floccule-forming device at the lower exit opening including a system of draw-in rolls and a fast-rotating opening roll. The chute includes at least one air-permeable surface for separating the fiber material from the conveying air. An evacuating device evacuates the filtered out conveying air. An exhaust air device is coupled to the evacuating device and has an air stream regulator which is connected to a control and regulating device. The conveying air stream is guided along the opening roll, and a partial air stream of the filtered out conveying air is guided into the exhaust air device.

Abstract: A unit for making pre-shaped absorbent pads for sanitary items is equipped with a continuous conveyor belt with an operating branch which defines a line for pad forming and feed; the branch extends along a straight path, along which there are three successive stations for feeding absorbent material and a plurality of seats designed to accept and retain a given quantity of the absorbent material.

Abstract: In an apparatus for and method of producing absorbent pads from a flock-air mixture which is fed through a feed conduit to a shaping recess carrier to form the respective absorbent pad, the carrier rotates or circulates in a predetermined direction of operation. For excess air in the region of the flock-laying device is to be sucked away in a simple fashion without adversely affecting the process of shaping the absorbent pad, the feed conduit feeding the flock-air mixture to the carrier is branched into at least first and second conduits, the first conduit carrying a first partial flow of the mixture and the second conduit carrying a second partial flow thereof. The first and second conduits are directed on to the carrier in such a way that the second partial flow meets the carrier substantially downstream of the first partial flow in the direction of operation of the carrier.

Abstract: A nonwoven web contains an even distribution of its composite materials by the separate application of particulate material such as superabsorbent particles into a forming head outside the air stream for deposition of thermoplastic fibers in the forming head. The thermoplastic fibers are distributed by air entertainment through tubular forming screens having rotary distribution members therein. The particulate absorbents are generally placed in the forming box by distribution units which may have metering devices and outlet chutes extending into the forming head.

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 process for making high aspect ratio metal flakes comprises applying a multi-layer sandwich of vapor deposited metal and release coats in alternating layers to a rotating chilled drum or suitable carrier medium contained in a vapor deposition chamber. The alternating metallized layers are applied by vapor deposition and the intervening release layers are preferably solvent-soluble materials applied by suitable coating or vapor deposition sources contained in the vapor deposition chamber. The release coat materials can be a thermoplastic solvent-soluble polymer. The multi-layer sandwich built up in the vacuum chamber is removed from the drum or carrier and treated with a suitable solvent to dissolve the release coating from the metal in a stripping process that leaves the metal flakes essentially release coat free.

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: Methods and systems for the manufacture of reinforcing preforms for structural composite products. Minimum contact eyelets reduce friction in the supply system for string reinforcing materials. Also, preforms of various configurations and thicknesses can be produced.

Abstract: Methods and systems for the manufacture of reinforcing preforms for structural composite products. The air flows for the manufacturing stations are optimized by providing a separate air system for each cell and providing seals between the net-edge blocks and the mold portions. An adjustable valve in the air system to the material applicator (chopper-gun) allows use of different materials and manufacture of preforms having different thickness and configurations.

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

Abstract: The invention relates to a method and to an apparatus for perforating a web of material intended to form an outer casing sheet of absorbent articles. As the web is advanced, the web is first provided with a large number of mutually separated cuts in the nip defined between raised plateaus on a matrix cylinder and circumferentially extending knife-edges of a cutting cylinder. The web is then deformed transversely to its plane at parts which border on each cut. The invention also relates to a perforated outer casing sheet which includes recesses in the form of mutually adjacent elongated channel-like grooves.

Abstract: An apparatus and method are provided for molding clusters of fibers, including at least some thermoplastic fibers, into products at a cost, quality, and performance level acceptable for commercial production. The clusters are dedensified 10 and then placed 12 into an empty mold 20. The mold 20 has apertures 28 to facilitate the transfer of thermal energy through the mold 20. A linear conveyor 32 is used to transport the mold through a plurality of process locations on a continuous or semi-continuous basis. Included is a heating location 48 wherein the mold 20 is heated 14, providing an influx of thermal energy sufficient to fuse the thermoplastic fibers to form a heated product. A cooling location 50 follows the heating location 48, wherein the mold 20 and the heated product contained therein are cooled 16 to produce a cooled product. The cooled product is then ejected 18 from the mold 520.

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 three-dimensional object from fibers includes attaching a mold made at least in part of elastomeric material to a porous support. The mold comprises a first mold member defining at least one channel in fluid communication with the porous support. Each channel has within it at least one second mold member. A mixture of fibers and fluid carrier is poured onto the mold. Thereafter, a pressure differential is created across the mold to create a flow of the mixture toward the porous support via the second mold members. This flow causes the fluid carrier to pass through the porous support, thus depositing the fibers within the recessed parts of the second mold members in the mold. Thereafter, the mold is compressed sufficiently to deform the mold and to provide uniform, normal pressure to the fibers which have been deposited in the second mold members.

Abstract: This process and apparatus use at least two chopper units. 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, a first fiber chopper providing chopped fibers to the apparatus from a first direction, a second fiber chopper providing chopped fibers to the apparatus from a second direction, wherein the first direction is different from the second direction 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.