Apparatus for forming controlled density fibrous pads for diapers and the other absorbent products

An apparatus for forming discrete fibrous pads, said apparatus compromising:

• a. a drum constructed from a multiplicity of self contained pad formation pocket modules, said modules containing contiguous pad forming pockets, wherein said pockets have a three-dimensional configuration describing the pad to be formed therein, and being defined by a three-dimensional foraminous pad forming layer and which is supported by a lower foraminous support layer;
• and,
• b. a gas flow regulating system comprising a multiplicity of precisely positioned cross directional airflow control louvers which are fixed beneath the pad forming layer in a laterally radial position;
• and,
• c. a top plate and sub-plate assembly which defines the periphery of said pad forming pocket and which holds and contains within the top plate and sub-plate said three-dimensional foraminous pad forming layer and said lower foraminous support layer, said plate assembly being fixed to said end rails and to said side rails on said rail's outer edges by an attachment means, wherein said plates, which extend the full length of said side rail, thereby secure said airflow control louvers in place in said radial slots located in said side rail's inner surfaces;
• and
• d. a secondary gas regulating system created by off-setting the inner circumferential edges of said sub-plates towards the outer circumferential edge of the frame rails by distance of up to 10 millimeters;
• and,
• e. a gas flow regulating device wherein the inner cross-directional radial edge of each of said end-rails, which describes the ends of the pad forming pockets, are tapered such that the angle of the taper is at least 15 degrees but no greater than 45 degrees as measured from the lateral radial surface of said end rail and wherein the land formed at the other outermost radial edge is at least 0.060 inches in width.