Method for forming air formed adhesive bonded webs

Claim 1

A method of forming a continuous airlaid web of wood pulp fibers of a basis weight of about 5-50 lbs./2880 ft. 2 and having a three-dimensional fiber continuum interrupted by a pattern of bonded fiber areas, which method comprises: a. air laying wood pulp fibers onto a moving foraminous carrier to form a continuous three-dimensional continuum of substantially dry and uncompacted randomly deposited fibers, b. transferring the dry, uncompacted continuum from the carrier by contacting the surface of the continuum which is away from the carrier with a transfer member moving at substantially the same speed as the carrier and having adhesive disposed in a liquid printed on the surface thereof in a preselected pattern of discrete spots which are spaced less than an average fiber length apart, while supporting the continuum on the carrier and causing the liquid to penetrate the continuum, the clearance between the transfer member and the carrier being sufficient that the liquid penetrates the continuum without being forced through the continuum to the carrier side thereof, such penetration with the temporary binding effect on the continuum in combination with the preferential attraction of the liquid for the transfer member causing the continuum to transfer, substantially intact, from the carrier to the transfer member, and c. bonding said continuum by removing the liquid and leaving said adhesive while continuing to support the continuum until the adhesive bonds the fibers at the discrete spots of the preselected pattern.

Claim 2

A method of forming a continuous airlaid web of wood pulp fibers of a basis weight of about 5-50 lbs./2880 ft. 2 and having a three-dimensional fiber continuum interrupted by a pattern of bonded fiber areas, which method comprises: a. air laying wood pulp fibers onto a moving foraminous carrier to form a continuous three-dimensional continuum of substantially dry and uncompacted randomly deposited fibers, b. transferring the dry, uncompacted continuum from the carrier by contacting the surface of the continuum which is away from the carrier with a transfer member moving at substantially the same speed as the carrier and having adhesive disposed in a liquid printed on the surface thereof in a preselected pattern of discrete spots which are spaced less than an average fiber length apart, while supporting the continuum on the carrier and causing the liquid to penetrate the continuum, the clearance between the transfer member and the carrier being sufficient that the liquid penetrates the continuum without being forced through the continuum to the carrier side thereof, such penetration with the temporary binding effect on the continuum in combination with the preferential attraction of the liquid for the transfer member causing the continuum to transfer, substantially intact, from the carrier to the transfer member, and c. bonding said continuum by removing the liquid and leaving said adhesive while continuing to support the continuum until the adhesive bonds the fibers at the discrete spots of the preselected pattern.

Claim 4

A method of forming a continuous airlaid web of wood pulp fibers of a basis weight of about 5-50 lbs./2880 ft. 2 and having a three-dimensional fiber continuum interrupted by a pattern of bonded fiber areas, which method comprises: a. air laying wood pulp fibers onto a moving foraminous carrier to form a continuous three-dimensional continuum of substantially dry and uncompacted randomly deposited fibers, b. transferring the dry, uncompacted continuum from the carrier by contacting the surface of the continuum which is away from the carrier with a transfer roll having a patterned surface moving at substantially the same speed as the carrier and carrying adhesive disposed in a liquid on the raised areas of the pattern on the surface thereof which are spaced less than an average fiber length apart, while supporting the continuum on the carrier and causing the liquid to penetrate the continuum, the clearance between the transfer roll and the carrier being sufficient that the liquid penetrates the continuum without being forced through the continuum to the carrier side thereof, such penetration with the temporary binding effect on the continuum in combination with the preferential attraction of the liquid for the transfer roll causing the continuum to transfer, substantially intact, from the carrier to the transfer roll and c. bonding said continuum by removing the liquid while leaving said adhesive while continuing to support the continuum until the adhesive bonds the fibers at the discrete areas of the pattern.

Claim 5

A method of forming a continuous airlaid web of wood pulp fibers of a basis weight of about 5-50 lbs./2880 ft. 2 and having a three-dimensional fiber continuum interrupted by a pattern of bonded fiber areas, which method comprises: a. air laying wood pulp fibers onto a moving foraminous carrier to form a continuous three-dimensional continuum of substantially dry and uncompacted randomly deposited fibers, b. transferring the dry, uncompacted continuum from the carrier by contacting the surface of the continuum which is away from the carrier with a transfer roll having a patterned surface moving at substantially the same speed as the carrier and carrying adhesive disposed in a liquid on the raised areas of the pattern on the surface thereof which are spaced less than an average fiber length apart, while supporting the continuum on the carrier and causing the liquid to penetrate the continuum, the clearance between the transfer roll and the carrier being sufficient that the liquid penetrates the continuum without being forced through the continuum to the carrier side thereof, such penetration with the temporary binding effect on the continuum in combination with the preferential attraction of the liquid for the transfer roll causing the continuum to transfer, substantially intact, from the carrier to the transfer roll and c. bonding said continuum by removing the liquid while leaving said adhesive while continuing to support the continuum until the adhesive bonds the fibers at the discrete areas of the pattern.