Equipment and processes for the application of atomized fluid to a web substrate

An apparatus for the application of steam and embossing to a permeable, web material comprising a wet-laid substrate, the apparatus comprising:

• a source plenum comprising a fluid inlet configured to supply air;
• a receipt plenum positioned adjacent to and above the source plenum, wherein the source plenum and the receipt plenum define an opening therethrough;
• a permeable belt extending through the opening between the source plenum and the receipt plenum, wherein the permeable belt comprises a first side and a second side opposite the first side, wherein the source plenum is in facing relationship to the first side of the permeable belt and the receipt plenum is in facing relationship to the second side of the permeable belt, wherein the web material comprising a wet-laid substrate is disposed on the first side of the permeable belt and in facing relationship with the source plenum;
• a fluid source disposed within the source plenum, wherein the fluid source supplies steam such that the steam engages the web material comprising a wet-laid substrate and a portion of steam passes through the first side of permeable belt to the second side of the permeable belt and into the receipt plenum, and wherein the fluid source comprises an atomizer disposed in proximate fluid contact with the web material comprising a wet-laid substrate so that the cumulative volume median drop size of the fluid source is about 30 microns or less;
• an exhaust operatively connected to the receipt plenum, wherein the exhaust provides a negative pressure causing the steam to pass through the web material comprising a wet-laid substrate and the permeable belt and into the receipt plenum;
• an embossing unit situated downstream from the source and receipt plenums;
• wherein the steam increases the temperature and the humidity of the web material comprising a wet-laid substrate;
• and
• wherein the web material comprising a wet-laid substrate is embossed via the embossing unit downstream of the application of steam so that a deformation height from embossing is higher than that without the application of steam.