Process and apparatus for air forming an article having a plurality of reinforced superimposed fibrous layers
AssigneeKimberly-Clark Worldwide, Inc.
InventorsDavid W. Heyn, Susan J. Daniels, Derek Paul Murphy, Michael Barth Venturino
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Abstract
A process and apparatus for air forming an article having a plurality of superimposed reinforced fibrous layers. The layers are formed in substantially discrete forming chambers by depositing fibrous materials on a forming surface which moves along a forming path through the chambers. A first layer is air-formed on the forming surface as the surface moves through the first forming chamber and a second layer is air-formed over the first layer as the surface moves through the second forming chamber. A reinforcing web is embedded in the article during the air-forming process.
Claims22
Apparatus for air forming a reinforced fibrous article having a plurality of layers, said apparatus comprising:
- first and second substantially discrete forming chambers, each forming chamber having an entrance and exit,
- a foraminous forming surface movable through said first and second forming chambers along a forming path length,
- a first fiber inlet for introducing a fibrous material into said first forming chamber,
- a second fiber inlet for introducing a fibrous material into said second forming chamber,
- one or more vacuum sources in communication with said first and second forming chambers for drawing said fibrous material in said first forming chamber onto said forming surface to form a first layer on said forming surface and for drawing said fibrous material in said second forming chamber onto said forming surface to form a second layer on said forming surface over said first layer,
- a source of reinforcing web located generally exterior to the first and second forming chambers,
- a delivery mechanism for delivering reinforcing web from the source for application of the web toward the forming surface at a location along said forming path length.
A process of forming a reinforced fibrous article having a plurality of layers, said method comprising moving a foraminous forming surface through first and second substantially discrete forming chambers along a forming path length, each forming chamber having an entrance and exit,
- introducing a fibrous material into said first forming chamber,
- vacuum drawing said fibrous material in said first forming chamber onto said forming surface to form a first layer on said forming surface,
- introducing a fibrous material into said second forming chamber,
- vacuum drawing said fibrous material in said second forming chamber onto said forming surface to form a second layer on said forming surface superimposed on said first layer, and
- overlaying a reinforcing web on fibers collected on said forming surface at a location along said forming path.
Dependencies are inferred from the claim text.