Method for forming fibrous pads

Abstract

Method for the dry forming of fibrous pads employ a pad forming member closing the lower end of a pad forming area. The pad forming member preferably is in the form of a condenser roll having three-dimensional pockets, or cavities about the periphery thereof. Each cavity includes an opening into it, and the cavities are brought into communication with the pad forming area as the condenser roll is continuously driven during operation of the apparatus. Each cavity is defined by foraminous bottom and side surfaces, the surface area of which is greater than the surface area of the opening into it. An air suspension of fibers is formed in the pad forming area, and a vacuum is applied through the foraminous surfaces of each cavity when it is disposed in the pad forming area to pull the air of the suspension through the foraminous surfaces, and deposit the fibers carried in the air suspension onto the foraminous surfaces in the form of a fibrous layer. A transfer conveyer is fed in overlying relationship with the opening of each cavity downstream of the pad forming area, and a vacuum is applied through the transfer conveyer to transfer the fibrous layer from each cavity onto the transfer conveyer. The fibers deposited on the transfer conveyer are confined to an area substantially equal to the surface area of the opening into each cavity, and accordingly, the fibers are consolidated as they are transferred from each cavity onto the transfer conveyer to form fibrous pads having a greater basis weight than the basis weight of the fibrous layers formed within the cavities.

Dependencies are inferred from the claim text.