Method and apparatus for producing a zoned and/or layered substrate

A method for manufacturing a substrate, the method comprising:

• providing a first supply of fibers;
• providing a second supply of fibers;
• providing a headbox, the headbox comprising:
• a machine direction;
• a cross direction;
• an inlet;
• an outlet;
• a first z-directional layer having a height;
• and
• a first cross-directional divider that separates a first zone of the headbox from a second zone of the headbox in a cross-directional manner in the first z-directional layer, the first cross-directional divider including a height that is at least 90% of the height of the first z-directional layer;
• transferring the first supply of fibers to the first zone of the headbox at the inlet and transferring the second supply of fibers to the second zone of the headbox at the inlet;
• and
• transferring the first supply of fibers and the second supply of fibers through the headbox to the outlet to provide the substrate.

A headbox for manufacturing a substrate, the headbox including a machine direction and a cross direction, the headbox comprising:

• an inlet;
• an outlet;
• an internal chamber;
• and
• a divider at least partially within the internal chamber, the divider comprising:
• a first surface;
• a second surface, the second surface being opposite from the first surface;
• a width defined in the cross direction that is at least 90% of a width of the internal chamber of the headbox;
• a length defined in the machine direction;
• and
• a first cross-directional divider extending away from the first surface of the divider, the first cross-directional divider comprising a cross-directional thickness and a machine-directional length;
• wherein the divider separates a first z-directional layer of the headbox from a second z-directional layer of the headbox;
• and
• wherein the first cross-directional divider separates a first zone of the headbox from a second zone of the headbox in a cross-directional manner, the first zone and the second zone being in the first z-directional layer.

A method for manufacturing a substrate including a first layer and a second layer, the method comprising:

• providing a first supply of fibers;
• providing a supply of particulates;
• providing a headbox, the headbox comprising:
• a machine direction;
• a cross-direction;
• a z-direction, the z-direction being perpendicular to a plane defined by the machine direction and the cross-direction;
• and
• a divider comprising a first surface, a second surface opposite the first surface, a width extending in the cross-direction, and a length extending in the machine direction, the divider separating a first z-directional layer of the headbox from a second z-directional layer of the headbox;
• setting a z-directional position of the divider in the headbox to provide a target relative thickness setting of the second z-directional layer of the headbox;
• transferring the first supply of fibers and the supply of particulates to the headbox such that the first supply of fibers enter the first z-directional layer of the headbox and the supply of particulates enter the second z-directional layer of the headbox;
• and
• controlling the first supply of fibers and the supply of particulates through the headbox to a forming surface such that a relative thickness of the second layer of the substrate is provided with less than 20% variation of the target relative thickness setting of the second z-directional layer of the headbox.