Apparatus for preparing air-laid nonwoven webs from combined streams

Web forming apparatus comprising:

• frame means;
• means for feeding a fibrous material to a first fiberizing station at a first location on said frame means;
• means for feeding a fibrous material to a second fiberizing station at a second location on said frame means;
• means defining a first mixing zone between said first and second fiberizing stations, said mixing zone having a fiber inlet end and a fiber outlet end;
• means adjacent the inlet end of said first mixing zone for opening said first mentioned material at said first fiberizing station and producing a supply of individualized fibers that enter said first mixing zone through said inlet end;
• means adjacent the inlet end of said first mixing zone for opening said second mentioned material at said second fiberizing station and producing a supply of individualized fibers that enter said first mixing zone through said inlet end;
• means for providing gaseous streams for initially directing said supplies of individualized fibers toward one another and to said first mixing zone;
• a flow controlling member;
• means mounting said flow controlling member for movement relative to said first mixing zone to control the extent to which said gaseous streams intermix to produce a first combined gaseous stream;
• means for feeding a fibrous material to a third fiberizing station at a third location on said frame means;
• means for feeding a fibrous material to a fourth fiberizing station at a fourth location on said frame means;
• means defining a second mixing zone between said third and fourth fiberizing stations, said second mixing zone having a fiber inlet end and a fiber outlet end;
• means adjacent the inlet end of said second mixing zone for opening said third mentioned material at said third fiberizing station and producing a supply of individualized fibers that enter said second mixing zone through its said inlet end;
• means adjacent the inlet end of said second mixing zone for opening said fourth mentioned material at said fourth fiberizing station and producing a supply of individualized fibers that enter said second mixing zone through its said inlet end;
• means for providing gaseous streams for initially directing said supplies of individualized fibers toward one another and to said second mixing zone;
• a second flow controlling member;
• means mounting said second flow controlling member for movement relative to said second mixing zone to control the extent to which said last mentioned gaseous streams intermix to produce a second combined gaseous stream means defining a third mixing zone between said first and second mixing zones and communicating with the outlet ends thereof, said third mixing zone having a fiber inlet end and a fiber outlet end;
• third flow controlling member;
• means mounting said third flow controlling member for movement relative to said third mixing zone to control the extent to which said first and second combined gaseous steams intermix to produce a third combined gaseous stream;
• and fiber collecting means adjacent the fiber outlet end of said third mixing zone for accumulating fibers to form a web.