US3772107A
Expired / Lapsed
US
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Method and apparatus for forming a nonwoven fibrous web
Assignee: Individual
•
Filing: 1971-11-03
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Granted: 1973-11-13
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Expires: 1991-11-03
Abstract
Abstract A method of forming a nonwoven fibrous web from multiple laps of staple fibers, the major proportion of fibers within each lap being substantially oriented in one direction. Laps of the staple fibers are fed into overlying relationship with the major proportion of oriented fibers in each lap disposed in the same direction. Air is entrapped between adjacent laps as they are fed into overlying relationship to create an air barrier between adjacent overlying laps. The overlying laps are spread transversely of the direction in which the major proportion of fibers are oriented, and fibers within overlying laps are reoriented transversely within the plane of the laps out of the direction in which the major proportion of fibers are oriented while maintaining the air barrier between the adjacent overlying laps. The laps are pressed together after the lap spreading and fiber reorienting steps to form a unitary nonwoven fibrous web and fibers of the unitary nonwoven fibrous web are then bonded together. An apparatus for forming a nonwoven fibrous web from multiple laps of staple fibers, the major proportion of fibers within each lap being substantially oriented in one direction. Lap forming means for forming the laps of staple fibers and for generating air currents. A lap-confining channel is defined in part by a lower, air-impervious conveyor belt, and a shield encloses the downstream end of each lap forming means and defines an enclosed flow path from the lap forming means to the lap-confining channel. The enclosed flow path permits the laps of staple fibers to be directed into overlying relationship with each other within the lap-confining channel and aids in establishing laminar flow of the air currents into the lap-confining channel to define air barriers between adjacent laps, and between the conveyor belt and lower lap. The conveyor belt feeds the overlying laps to a spreading and reorienting means disposed downstream of the lap forming means for spreading the overlying laps transversely of their direction of feed and for reorienting fibers within overlying laps transversely within the plane of respective laps out of the direction in which the major proportion of fibers are oriented while maintaining the air barrier between the adjacent overlying laps. Calendering means disposed downstream of the spreading and reorienting means for pressing the overlying laps together to form a unitary nonwoven fibrous web, and bonding means disposed downstream of the calendering means for bonding together fibers of the unitary nonwoven fibrous web.
Inventors
- 👤 A Gentile
- 👤 C Hauck
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-31 21:55
CPC Classifications
D; D04; D04H; D04H1/00; D04H1/70; D04H1/74; Y; Y10; Y10T; Y10T156/00; Y10T156/17; Y10T156/1702; Y10T156/1712; Y10T156/1798
Claims Analysis
Total Claims: 28
Claim 1
Independent Claim
160 words
A method for forming a nonwoven fibrous web from multiple laps of staple fibers at a speed in excess of 200 feet per minute, the major proportion of said staple fibers within each lap being substantially oriented in one direction, said method comprising the steps of: A. feeding the laps of staple fibers in a downstream direction into overlying relationship with each other with said major proportion of fibers in each lap disposed in the same direction; B. establishing laminar air flow in said downstream direction between adjacent overlying laps to create an air barrier between said adjacent overlying laps for preventing extensive clinging together of fibers between said adjacent overlying laps; C. reorienting fibers within the plane of overlying laps transversely out of said one direction while maintaining said air barrier between said adjacent overlying laps; D. pressing said laps together to form a unitary nonwoven fibrous web; and E. bonding together fibers of said unitary nonwoven fibrous web.
Claim 2
Independent Claim
160 words
A method for forming a nonwoven fibrous web from multiple laps of staple fibers at a speed in excess of 200 feet per minute, the major proportion of said staple fibers within each lap being substantially oriented in one direction, said method comprising the steps of: A. feeding the laps of staple fibers in a downstream direction into overlying relationship with each other with said major proportion of fibers in each lap disposed in the same direction; B. establishing laminar air flow in said downstream direction between adjacent overlying laps to create an air barrier between said adjacent overlying laps for preventing extensive clinging together of fibers between said adjacent overlying laps; C. reorienting fibers within the plane of overlying laps transversely out of said one direction while maintaining said air barrier between said adjacent overlying laps; D. pressing said laps together to form a unitary nonwoven fibrous web; and E. bonding together fibers of said unitary nonwoven fibrous web.
Claim 3
Dependent Claim
30 words
The method according to claim 1, including spreading said overlying laps in a direction transverse to said one direction simultaneously with reorienting fibers within the plane of said overlying laps.
Claim 4
Independent Claim
30 words
A method according to cliam 1, wherein the fibers within one of said overlying laps is reoriented to a different degree than the fibers within another of said overlying laps.
Claim 5
Independent Claim
30 words
A method according to cliam 1, wherein the fibers within one of said overlying laps is reoriented to a different degree than the fibers within another of said overlying laps.
Claim 6
Dependent Claim
51 words
The method to claim 1, wherein the fibers within said overlying laps are reoriented by reorienting the fibers within said overlying laps in successive stages, the successive stages of fiber reorientation in one of said overlying laps alternating with the successive stages of fiber reorientation in another of said overlying laps.
Claim 7
Dependent Claim
38 words
The method according to claim 1, including wet pressing said laps together to form said unitary nonwoven fibrous web, print bonding together fibers of said unitary nonwoven fibrous web and drying said nonwoven fibrous web after print bonding.
Claim 8
Dependent Claim
29 words
The method according to claim 5, including print bonding together fibers of said unitary nonwoven fibrous web in a discrete, discontinuous pattern of bonded areas separated by unbonded areas.
Claim 9
Dependent Claim
24 words
The method according to claim 6, wherein said bonded areas comprises less than 25 percent of the entire area of said nonwoven fibrous web.
Claim 10
Independent Claim
187 words
A method for forming a nonwoven fibrous web from multiple laps of staple fibers at a speed in excess of 200 feet per minute, the major proportion of said staple fibers within each lap being substantially oriented in one direction, said method comprising the steps of: A. directing the laps in a downstream direction into overlying relationship within a lap-confining channel with said major proportion of fibers in each lap being disposed in the same direction; B. establishing laminar air flow in said downstream direction between adjacent overlying laps within said lap-confining channel to form an air barrier between said adjacent overlying laps; C. feeding said adjacent overlying laps with the air barrier therebetween in said one direction between upper and lower sets of reorienting rolls, the rolls in one set being spaced in said one direction from the rolls of the other set for reorienting fibers within the plane of overlying laps transversely out of said one direction in successive stages; D. pressing said adjacent overlying lapS together to form a unitary nonwoven fibrous web; and E. bonding together fibers of said unitary nonwoven fibrous web.
Claim 11
Independent Claim
187 words
A method for forming a nonwoven fibrous web from multiple laps of staple fibers at a speed in excess of 200 feet per minute, the major proportion of said staple fibers within each lap being substantially oriented in one direction, said method comprising the steps of: A. directing the laps in a downstream direction into overlying relationship within a lap-confining channel with said major proportion of fibers in each lap being disposed in the same direction; B. establishing laminar air flow in said downstream direction between adjacent overlying laps within said lap-confining channel to form an air barrier between said adjacent overlying laps; C. feeding said adjacent overlying laps with the air barrier therebetween in said one direction between upper and lower sets of reorienting rolls, the rolls in one set being spaced in said one direction from the rolls of the other set for reorienting fibers within the plane of overlying laps transversely out of said one direction in successive stages; D. pressing said adjacent overlying lapS together to form a unitary nonwoven fibrous web; and E. bonding together fibers of said unitary nonwoven fibrous web.
Claim 12
Dependent Claim
32 words
The method according to claim 8, including spreading each of said overlying laps in a direction transverse to said one direction simultaneously with reorienting fibers within the plane of said overlying laps.
Claim 13
Dependent Claim
35 words
The method according to claim 8, wherein the number of rolls in the upper set differs from the number of rolls in the lower set for reorienting the fibers within overlying laps to different degrees.
Claim 14
Dependent Claim
39 words
The method according to claim 8, including wet pressing said adjacent overlying laps together to form said unitary nonwoven fibrous web, print bonding together fibers of said unitary nonwoven fibrous web and drying said nonwoven fibrous web after bonding.
Claim 15
Dependent Claim
29 words
The method according to claim 11, including print bonding together fibers of said unitary nonwoven fibrous web in a discrete discontinuous pattern of bonded areas separated by unbonded areas.
Claim 16
Dependent Claim
24 words
The method according to claim 12, wherein said bonded areas comprise less than 25 percent of the entire area of said nonwoven fibrous web.
Claim 17
Independent Claim
260 words
An apparatus for forming a nonwoven fibrous web from multiple laps of staple fibers at a speed in excess of 200 feet per minute, the major proportion of said staple fibers within each lap being substantially oriented in one direction, said apparatus comprising: A. lap forming means for forming said laps of oriented staple fibers and for generating air currents; B. a lap-confining channel being defined by a lower air-impervious conveyor, opposed air-impervious side members disposed closely to side margins of said air-impervious conveyor, a back member and an upper closure, said lap-confining channel being open at a downstream end thereof; C. shield means for defining an enclosed flow path between said lap forming means and said lap-confining channel, said laps and air currents being directed through said enclosed flow path into said lap-confining channel to form overlying laps with an air barrier between adjacent overlying laps and between the conveyor and its adjacent lap; D. means for driving said air-impervious conveyor for conveying said overlying laps in a downstream direction through the open downstream end of said lap-confining channel; E. fiber reorienting means disposed downstream of said lap forming means for reorienting fibers within the plane of overlying laps transversely out of said one direction while maintaining said air barrier between said adjacent overlying laps; F. calendering means disposed downstream of said fiber reorienting means for pressing said adjacent overlying laps together to form a unitary nonwoven fibrous web; and G. bonding means disposed downstream of said calendering means for bonding together fibers of said unitary nonwoven fibrous web.
Claim 18
Independent Claim
260 words
An apparatus for forming a nonwoven fibrous web from multiple laps of staple fibers at a speed in excess of 200 feet per minute, the major proportion of said staple fibers within each lap being substantially oriented in one direction, said apparatus comprising: A. lap forming means for forming said laps of oriented staple fibers and for generating air currents; B. a lap-confining channel being defined by a lower air-impervious conveyor, opposed air-impervious side members disposed closely to side margins of said air-impervious conveyor, a back member and an upper closure, said lap-confining channel being open at a downstream end thereof; C. shield means for defining an enclosed flow path between said lap forming means and said lap-confining channel, said laps and air currents being directed through said enclosed flow path into said lap-confining channel to form overlying laps with an air barrier between adjacent overlying laps and between the conveyor and its adjacent lap; D. means for driving said air-impervious conveyor for conveying said overlying laps in a downstream direction through the open downstream end of said lap-confining channel; E. fiber reorienting means disposed downstream of said lap forming means for reorienting fibers within the plane of overlying laps transversely out of said one direction while maintaining said air barrier between said adjacent overlying laps; F. calendering means disposed downstream of said fiber reorienting means for pressing said adjacent overlying laps together to form a unitary nonwoven fibrous web; and G. bonding means disposed downstream of said calendering means for bonding together fibers of said unitary nonwoven fibrous web.
Claim 19
Dependent Claim
52 words
The apparatus according to claim 14, wherein said calendering means is a wet press calendering means for wetting said adjacent overlying laps and pressing said adjacent overlying laps together to form a unitary nonwoven fibrous web, and drying means disposed downstream of said bonding means for drying the bonded, nonwoven fibrous web.
Claim 20
Dependent Claim
43 words
The apparatus according to claim 14, wherein said bonding means comprises opposed rolls, at least one of said opposed rolls having a discrete pattern therein for bonding together fibers of said unitary nonwoven fibrous web in a pattern corresponding to said discrete pattern.
Claim 21
Dependent Claim
36 words
The apparatus according to claim 14, wherein said upper closure of said lap-confining channel has entrance openings defined therethrough, said laps being directed through said enclosed flow cnannel and said entrance openings into said lap-confining channel.
Claim 22
Independent Claim
172 words
A method for forming a nonwoven fibrous web from multiple laps of staple fibers at a speed in excess of 200 feet per minute, said method comprising the steps of: a. feeding the laps in a downstream direction into oVerlying relationship within a lap-confining channel with the major proportion of the fibers in each lap substantially oriented in the feed direction; b. establishing laminar air flow in said downstream direction within the lap-confining channel simultaneously with the feeding of the laps into said lap-confining channel; c. feeding the overlying laps in said downstream direction between upper and lower sets of reorienting rolls prior to pressing said overlying laps together, the rolls in one set being spaced in the downstream direction from the rolls in the other set for reorienting fibers within the plane of overlying laps in successive stages transversely out of said downstream direction; d. pressing said adjacent overlying laps together after reorientation to form a unitary nonwoven fibrous web; and e. bonding together fibers of said unitary nonwoven fibrous web.
Claim 23
Independent Claim
172 words
A method for forming a nonwoven fibrous web from multiple laps of staple fibers at a speed in excess of 200 feet per minute, said method comprising the steps of: a. feeding the laps in a downstream direction into oVerlying relationship within a lap-confining channel with the major proportion of the fibers in each lap substantially oriented in the feed direction; b. establishing laminar air flow in said downstream direction within the lap-confining channel simultaneously with the feeding of the laps into said lap-confining channel; c. feeding the overlying laps in said downstream direction between upper and lower sets of reorienting rolls prior to pressing said overlying laps together, the rolls in one set being spaced in the downstream direction from the rolls in the other set for reorienting fibers within the plane of overlying laps in successive stages transversely out of said downstream direction; d. pressing said adjacent overlying laps together after reorientation to form a unitary nonwoven fibrous web; and e. bonding together fibers of said unitary nonwoven fibrous web.
Claim 24
Dependent Claim
35 words
The method according to claim 18, including spreading each of said overlying laps in a direction transverse to said downstream direction simultaneously with the reorienting of the fibers within the plane of said overlying laps.
Claim 25
Dependent Claim
35 words
The method according to claim 18, wherein the number of rolls in the upper set differs from the number of rolls in the lower set for reorienting the fibers within overlying laps to different degrees.
Claim 26
Dependent Claim
40 words
The method according to claim 18, including wet pressing said adjacent overlying laps together to form said unitary nonwoven fibrous web, print bonding together said fibers of said unitary nonwoven fibrous web and drying said nonwoven fibrous web after bonding.
Claim 27
Dependent Claim
29 words
The method according to claim 21, including print bonding together fibers of said unitary nonwoven fibrous web in a discrete discontinuous pattern of bonded areas separated by unbonded areas.
Claim 28
Dependent Claim
24 words
The method according to claim 22, wherein said bonded areas comprise less than 25 percent of the entire area of said nonwoven fibrous web.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1976-11-12 | 1977-05-14 | 1977-11-13 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1980-11-12 | 1981-05-14 | 1981-11-13 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1984-11-12 | 1985-05-14 | 1985-11-13 | $7700.00 | Window Closed / Lapsed |