Apparatus and method for forming fibrous structures comprising predominantly short fibers

Claim 1

An apparatus for dry-forming a fibrous structure, said apparatus including: A. a rotatable main drum having projections on its outer periphery, said drum having a fiber release zone; B. an inlet means outside of said release zone and including feed means for directing a fibrous feed into engagement with the outer periphery of the main drum, whereby rotation of said drum past the inlet means separates the fibers from the feed; C. a fiber working section between said inlet means and said release zone for individualizing fibers as they are directed in a downstream direction from said inlet means to said release zone by movement of the periphery of the main drum, said fiber working section including a movable satellite member having projections on its outer periphery and a housing positioned about said satellite member, the outer periphery of said satellite member being movable along a path in which the projections are directed close to the periphery of the main drum to cooperate with said main drum for individualizing fibers; D. a movable foraminous forming surface for intercepting the fibers after they leave the release zone of the main drum, whereby a fibrous structure is formed on said forming surface; E. a baffle means disposed adjacent the satellite member between said satellite member and the release zone, said baffle means including a lower air-directing section positioned close to the outer periphery of the main drum, said air-directing section including an upstream air-diverting surface means for (1) intercepting air conveyed to the air-directing section by movement of the outer periphery of the main drum past the satellite member, (2) diverting a first portion of the intercepted air away from the periphery of the main drum into the region between the satellite member and baffle means, and (3) diverting a second portion of said intercepted air through a constriction provided between the outer periphery of the main drum and a lower peripheral surface segment of the air-directing section; F. said baffle means being sealed against top and side walls of the housing to provide a barrier to the downstream movement of said first portion of diverted air to increase the static pressure adjacent the satellite member.

Claim 2

An apparatus for dry-forming a fibrous structure, said apparatus including: A. a rotatable main drum having projections on its outer periphery, said drum having a fiber release zone; B. an inlet means outside of said release zone and including feed means for directing a fibrous feed into engagement with the outer periphery of the main drum, whereby rotation of said drum past the inlet means separates the fibers from the feed; C. a fiber working section between said inlet means and said release zone for individualizing fibers as they are directed in a downstream direction from said inlet means to said release zone by movement of the periphery of the main drum, said fiber working section including a movable satellite member having projections on its outer periphery and a housing positioned about said satellite member, the outer periphery of said satellite member being movable along a path in which the projections are directed close to the periphery of the main drum to cooperate with said main drum for individualizing fibers; D. a movable foraminous forming surface for intercepting the fibers after they leave the release zone of the main drum, whereby a fibrous structure is formed on said forming surface; E. a baffle means disposed adjacent the satellite member between said satellite member and the release zone, said baffle means including a lower air-directing section positioned close to the outer periphery of the main drum, said air-directing section including an upstream air-diverting surface means for (1) intercepting air conveyed to the air-directing section by movement of the outer periphery of the main drum past the satellite member, (2) diverting a first portion of the intercepted air away from the periphery of the main drum into the region between the satellite member and baffle means, and (3) diverting a second portion of said intercepted air through a constriction provided between the outer periphery of the main drum and a lower peripheral surface segment of the air-directing section; F. said baffle means being sealed against top and side walls of the housing to provide a barrier to the downstream movement of said first portion of diverted air to increase the static pressure adjacent the satellite member.

Claim 12

An apparatus for dry-forming a fibrous structure, said apparatus including: A. a rotatable main drum having projections on its outer periphery, said drum having a fiber release zone; B. an inlet means outside of said release zone and including feed means for directing a fibrous feed into engagement with the outer periphery of the main drum, whereby rotation of the drum past the inlet means separates fibers from the feed; C. a fiber working section between said inlet means and said release zone for individualizing fibers as they are directed in a downstream direction from said inlet means to said release zone by movement of the peripheral surface of the main drum, said fiber working section including adjacent sets of rotatable satellite rolls and a housing positioned about said sets, each set including a rotatable worker roll and a rotatable turner roll with projections on their outer peripheries, the worker roll of each set being positioned beyond its respective turner roll in the direction of movement of the outer periphery of the main drum during rotation of said drum, the rolls in each set of satellite rolls being positioned close to each other and to the periphery of the main drum for cooperating with said main drum and with each other to individualize fibers conveyed past the sets of satellite rolls by movement of the outer periphery of the main drum; D. an outlet orifice positioned beyond the satellite rolls in the direction of movement of the outer periphery of the main drum during rotation of said drum, said outlet orifice being adapted to direct fibers to the fiber release zone from the fiber working section; E. a foraminous forming surface for intercepting the fibers after they leave the release zone of the main drum, whereby a fibrous structure is formed on said forming surface; F. a baffle means being sealed against the top and side walls of the housing and being disposed between the worker roll of one set of satellite rolls, which set is closest to the inlet means, and the turner roll of an adjacent set of satellite rolls; the improvement wherein said baffle means includes a lower air-directing section positioned close to the outer periphery of the main drum and having an air-diverting surface adjacent the worker roll of said one set of satellite rolls, said air-diverting surface intercepting air conveyed to it by the outer periphery of the main drum during rotational motion of said drum and diverting a first portion of the intercepted air in a first direction away from the periphery of the main drum into the region between the worker roll of said one set of satellite rolls and the baffle means, said baffle means providing a barrier to the downstream movement of said first portion of diverted air to increase the static pressure adjacent the downstream end of the worker roll of said one set of satellite rolls, said air-diverting surface also diverting a second portion of the intercepted air through a constriction provided between the outer periphery of the main drum and a peripheral surface segment of the air-directing section for conveying the second portion of air between the main drum and the turner roll of the adjacent set of satellite rolls.

Claim 13

An apparatus for dry-forming a fibrous structure, said apparatus including: A. a rotatable main drum having projections on its outer periphery, said drum having a fiber release zone; B. an inlet means outside of said release zone and including feed means for directing a fibrous feed into engagement with the outer periphery of the main drum, whereby rotation of the drum past the inlet means separates fibers from the feed; C. a fiber working section between said inlet means and said release zone for individualizing fibers as they are directed in a downstream direction from said inlet means to said release zone by movement of the peripheral surface of the main drum, said fiber working section including adjacent sets of rotatable satellite rolls and a housing positioned about said sets, each set including a rotatable worker roll and a rotatable turner roll with projections on their outer peripheries, the worker roll of each set being positioned beyond its respective turner roll in the direction of movement of the outer periphery of the main drum during rotation of said drum, the rolls in each set of satellite rolls being positioned close to each other and to the periphery of the main drum for cooperating with said main drum and with each other to individualize fibers conveyed past the sets of satellite rolls by movement of the outer periphery of the main drum; D. an outlet orifice positioned beyond the satellite rolls in the direction of movement of the outer periphery of the main drum during rotation of said drum, said outlet orifice being adapted to direct fibers to the fiber release zone from the fiber working section; E. a foraminous forming surface for intercepting the fibers after they leave the release zone of the main drum, whereby a fibrous structure is formed on said forming surface; F. a baffle means being sealed against the top and side walls of the housing and being disposed between the worker roll of one set of satellite rolls, which set is closest to the inlet means, and the turner roll of an adjacent set of satellite rolls; the improvement wherein said baffle means includes a lower air-directing section positioned close to the outer periphery of the main drum and having an air-diverting surface adjacent the worker roll of said one set of satellite rolls, said air-diverting surface intercepting air conveyed to it by the outer periphery of the main drum during rotational motion of said drum and diverting a first portion of the intercepted air in a first direction away from the periphery of the main drum into the region between the worker roll of said one set of satellite rolls and the baffle means, said baffle means providing a barrier to the downstream movement of said first portion of diverted air to increase the static pressure adjacent the downstream end of the worker roll of said one set of satellite rolls, said air-diverting surface also diverting a second portion of the intercepted air through a constriction provided between the outer periphery of the main drum and a peripheral surface segment of the air-directing section for conveying the second portion of air between the main drum and the turner roll of the adjacent set of satellite rolls.

Claim 32

An apparatus for forming a fibrous structure, said apparatus including: A. a rotatable main drum having projections on its outer periphery; B. feed means for directing a fibrous feed into engagement with the outer periphery of the main drum, whereby rotation of the main drum past the feed means separates fibers from the feed; C. a fiber release zone on the main drum at which fibers are released from the periphery of said main drum, said release zone being spaced from said feed means; D. a movable foraminous forming surface for intercepting the flow of fibers that leaves the periphery of the main drum at the fiber release zone to form a fibrous structure thereon; E. a formation section between the release zone and forming surface for receiving the fiber flow from the release zone and for permitting said flow to increase in thickness as it is directed to the foraminous forming surface; and F. an outlet orifice through which the fibers are directed from the fiber working section to the release zone, the improvement wherein said orifice is provided by the outer periphery of the main drum and an air-flow confining surface spaced from said outer periphery, said orifice including an upstream end adjacent the fiber working section and a downstream end adjacent the fiber release zone, the downstream end of said orifice being provided between a lower downstream end of the air-flow confining surface and the periphery of the main drum, the depth of the orifice adjacent the upstream end being greater than the depth adjacent the downstream end for reducing the thickness of the flow of air and fibers to accelerate said flow as said flow is directed from the working section to the fiber release zone, said flow thereafter being increased in thickness as it moves through the formation section to the forming surface, the lower end of the confining surface extending in the axial direction of the main drum and being spaced at varying distances from the main drum in said axial direction for controlling the cross-machine-direction basis weight of the fibrous structure formed on the forming surface.

Claim 33

An apparatus for forming a fibrous structure, said apparatus including: A. a rotatable main drum having projections on its outer periphery; B. feed means for directing a fibrous feed into engagement with the outer periphery of the main drum, whereby rotation of the main drum past the feed means separates fibers from the feed; C. a fiber release zone on the main drum at which fibers are released from the periphery of said main drum, said release zone being spaced from said feed means; D. a movable foraminous forming surface for intercepting the flow of fibers that leaves the periphery of the main drum at the fiber release zone to form a fibrous structure thereon; E. a formation section between the release zone and forming surface for receiving the fiber flow from the release zone and for permitting said flow to increase in thickness as it is directed to the foraminous forming surface; and F. an outlet orifice through which the fibers are directed from the fiber working section to the release zone, the improvement wherein said orifice is provided by the outer periphery of the main drum and an air-flow confining surface spaced from said outer periphery, said orifice including an upstream end adjacent the fiber working section and a downstream end adjacent the fiber release zone, the downstream end of said orifice being provided between a lower downstream end of the air-flow confining surface and the periphery of the main drum, the depth of the orifice adjacent the upstream end being greater than the depth adjacent the downstream end for reducing the thickness of the flow of air and fibers to accelerate said flow as said flow is directed from the working section to the fiber release zone, said flow thereafter being increased in thickness as it moves through the formation section to the forming surface, the lower end of the confining surface extending in the axial direction of the main drum and being spaced at varying distances from the main drum in said axial direction for controlling the cross-machine-direction basis weight of the fibrous structure formed on the forming surface.

Claim 41

A method for dry-forming a fibrous structure including short fibers under 1/4 inch in length as the predominate fiber component, said method including the steps of: A. rotating a main drum having projections on its outer periphery; B. directing a fibrous feed into engagement with the rotating outer periphery of the main drum, whereby rotation of the drum past the fibrous feed separates fibers from said feed, said fibrous feed including short fibers under 1/4 inch in length as the predominate fiber component; C. directing fibers which have been separated from the fibrous feed into a working section including a movable satellite member positioned adjacent the main drum and having projections on its outer periphery, whereby the projections on the outer peripheries of the satellite member and main drum cooperate to individualize fibers that are directed through the working section; D. conveying the individualized fibers from the fiber working section to a release zone on the periphery of the main drum at which the individualized fibers are released from the periphery of said main drum for subsequent conveyance to a foraminous forming surface upon which the fibrous structure is formed, said individualized fibers being directed to the release zone by the rotation of the main drum, the improvement of; E. directing a flow of air along the periphery of the main drum as said periphery moves in a downstream direction through the working section, intercepting the flow of air after said flow has been directed between the satellite member and main drum and before it exits the working section, diverting a first portion of the intercepted air away from the periphery of the main drum and adjacent the satellite member, providing a substantially sealed barrier to the downstream movement of said first portion of air to increase the static pressure adjacent the satellite member and diverting a second portion of the intercepted air along the periphery of the main drum for conveyance by rotation of the main drum to the fiber release zone.

Claim 42

A method for dry-forming a fibrous structure including short fibers under 1/4 inch in length as the predominate fiber component, said method including the steps of: A. rotating a main drum having projections on its outer periphery; B. directing a fibrous feed into engagement with the rotating outer periphery of the main drum, whereby rotation of the drum past the fibrous feed separates fibers from said feed, said fibrous feed including short fibers under 1/4 inch in length as the predominate fiber component; C. directing fibers which have been separated from the fibrous feed into a working section including a movable satellite member positioned adjacent the main drum and having projections on its outer periphery, whereby the projections on the outer peripheries of the satellite member and main drum cooperate to individualize fibers that are directed through the working section; D. conveying the individualized fibers from the fiber working section to a release zone on the periphery of the main drum at which the individualized fibers are released from the periphery of said main drum for subsequent conveyance to a foraminous forming surface upon which the fibrous structure is formed, said individualized fibers being directed to the release zone by the rotation of the main drum, the improvement of; E. directing a flow of air along the periphery of the main drum as said periphery moves in a downstream direction through the working section, intercepting the flow of air after said flow has been directed between the satellite member and main drum and before it exits the working section, diverting a first portion of the intercepted air away from the periphery of the main drum and adjacent the satellite member, providing a substantially sealed barrier to the downstream movement of said first portion of air to increase the static pressure adjacent the satellite member and diverting a second portion of the intercepted air along the periphery of the main drum for conveyance by rotation of the main drum to the fiber release zone.

Claim 49

A method of dry-forming a fibrous structure including short fibers under 1/4 inch in length as the predominate fiber component, said method including the steps of: A. rotating a main drum having projections on its outer periphery; B. directing a fibrous feed into engagement with the rotating outer periphery of the main drum, whereby rotation of the drum past the fibrous feed separates fibers from said feed, said fibrous feed including short fibers under 1/4 inch in length as the predominate fiber component; C. directing separated fibers in a downstream direction through a working section by rotation of the main drum, said working section including adjacent sets of rotating satellite rolls, each set including a rotating worker roll and a rotating turner roll with projections on their outer peripheries, the worker roll of each set being positioned beyond its respective turner roll in the direction in which the main drum is rotating, the roll in each set of satellite rolls being positioned close to each other and to the periphery of the main drum for cooperating with said main drum and with each other to individualize fibers conveyed through the working section by the rotating main drum; D. conveying the individualized fibers from the fiber working section to a release zone on the main drum where the individualized fibers are released from the periphery of said main drum for subsequent conveyance to a foraminous forming surface upon which the fibrous structure is formed, said individualized fibers being directed to the release zone by the rotation of the main drum; and E. intercepting a flow of air after it has been directed past a first set of the adjacent sets of rotating satellite rolls, and before it is directed into a second set of the adjacent sets of satellite rolls; (1) diverting a first portion of the intercepted air away from the periphery of the main drum and adjacent to the worker roll of the first set of satellite rolls; (2) providing a substantially sealed barrier to downstream movement of said first portion of air to thereby increase the static pressure adjacent the worker roll of said first set of satellite rolls; and (3) diverting a second portion of the intercepted air along the periphery of the main drum for conveyance between the main drum and the turner roll of the second set of satellite rolls.

Claim 50

A method of dry-forming a fibrous structure including short fibers under 1/4 inch in length as the predominate fiber component, said method including the steps of: A. rotating a main drum having projections on its outer periphery; B. directing a fibrous feed into engagement with the rotating outer periphery of the main drum, whereby rotation of the drum past the fibrous feed separates fibers from said feed, said fibrous feed including short fibers under 1/4 inch in length as the predominate fiber component; C. directing separated fibers in a downstream direction through a working section by rotation of the main drum, said working section including adjacent sets of rotating satellite rolls, each set including a rotating worker roll and a rotating turner roll with projections on their outer peripheries, the worker roll of each set being positioned beyond its respective turner roll in the direction in which the main drum is rotating, the roll in each set of satellite rolls being positioned close to each other and to the periphery of the main drum for cooperating with said main drum and with each other to individualize fibers conveyed through the working section by the rotating main drum; D. conveying the individualized fibers from the fiber working section to a release zone on the main drum where the individualized fibers are released from the periphery of said main drum for subsequent conveyance to a foraminous forming surface upon which the fibrous structure is formed, said individualized fibers being directed to the release zone by the rotation of the main drum; and E. intercepting a flow of air after it has been directed past a first set of the adjacent sets of rotating satellite rolls, and before it is directed into a second set of the adjacent sets of satellite rolls; (1) diverting a first portion of the intercepted air away from the periphery of the main drum and adjacent to the worker roll of the first set of satellite rolls; (2) providing a substantially sealed barrier to downstream movement of said first portion of air to thereby increase the static pressure adjacent the worker roll of said first set of satellite rolls; and (3) diverting a second portion of the intercepted air along the periphery of the main drum for conveyance between the main drum and the turner roll of the second set of satellite rolls.

Claim 59

An apparatus for dry-forming a fibrous structure, said apparatus including: A. a rotatable main drum having projections on its outer periphery, said drum having a fiber release zone; B. an inlet means outside of said release zone and including feed means for directing a fibrous feed into engagement with the outer periphery of the main drum, whereby rotation of said drum past the inlet means separates fibers from the feed; C. a fiber working section between said inlet means and said release zone for individualizing fibers as they are directed from said inlet means to said release zone by movement of the periphery of the main drum, said fiber working section including a movable satellite member having projections on its outer periphery, the outer periphery of said satellite member being movable along a path in which the projections are directed close to the periphery of the main drum to cooperate with said main drum for individualizing fibers; D. a foraminous forming surface for intercepting the fibers after they leave the release zone of the main drum, whereby a fibrous structure is formed on said forming surface; E. a baffle means disposed adjacent the satellite member and between said satellite member and the release zone, said baffle means including a lower air-directing section positioned close to the outer periphery of the main drum, said air-directing section including an upstream air-diverting surface means for (1) intercepting air conveyed to the air-directing section by movement of the outer periphery of the main drum past the satellite member, (2) diverting a first portion of the intercepted air away from the periphery of the main drum into the region between the satellite member and baffle means, and (3) diverting a second portion of said intercepted air through a constriction provided between the outer periphery of the main drum and a lower peripheral surface segment of the air-directing section; and F. an outlet orifice through which the fibers are directed from the fiber working section to the release zone, said orifice being provided by the outer periphery of the main drum and an air-flow confining surface spaced from said outer perphery, said orifice including an upstream end adjacent the fiber working section and a downstream end adjacent the fiber release zone, the depth of the orifice adjacent the upstream end being greater than the depth adjacent the downstream end for accelerating the flow of air and fibers as said flow is directed from the working section to the fiber release zone, said air flow confining surface having a lower downstream end which is spaced from the periphery of the main drum to provide the downstream end of the orifice, the lower end of said confining surface extending in the axial direction of the main drum and being spaced at varying distances from the main drum in said axial direction for controlling the cross-machine-direction basis weight of the fibrous structure formed on the forming surface.

Claim 60

An apparatus for dry-forming a fibrous structure, said apparatus including: A. a rotatable main drum having projections on its outer periphery, said drum having a fiber release zone; B. an inlet means outside of said release zone and including feed means for directing a fibrous feed into engagement with the outer periphery of the main drum, whereby rotation of said drum past the inlet means separates fibers from the feed; C. a fiber working section between said inlet means and said release zone for individualizing fibers as they are directed from said inlet means to said release zone by movement of the periphery of the main drum, said fiber working section including a movable satellite member having projections on its outer periphery, the outer periphery of said satellite member being movable along a path in which the projections are directed close to the periphery of the main drum to cooperate with said main drum for individualizing fibers; D. a foraminous forming surface for intercepting the fibers after they leave the release zone of the main drum, whereby a fibrous structure is formed on said forming surface; E. a baffle means disposed adjacent the satellite member and between said satellite member and the release zone, said baffle means including a lower air-directing section positioned close to the outer periphery of the main drum, said air-directing section including an upstream air-diverting surface means for (1) intercepting air conveyed to the air-directing section by movement of the outer periphery of the main drum past the satellite member, (2) diverting a first portion of the intercepted air away from the periphery of the main drum into the region between the satellite member and baffle means, and (3) diverting a second portion of said intercepted air through a constriction provided between the outer periphery of the main drum and a lower peripheral surface segment of the air-directing section; and F. an outlet orifice through which the fibers are directed from the fiber working section to the release zone, said orifice being provided by the outer periphery of the main drum and an air-flow confining surface spaced from said outer perphery, said orifice including an upstream end adjacent the fiber working section and a downstream end adjacent the fiber release zone, the depth of the orifice adjacent the upstream end being greater than the depth adjacent the downstream end for accelerating the flow of air and fibers as said flow is directed from the working section to the fiber release zone, said air flow confining surface having a lower downstream end which is spaced from the periphery of the main drum to provide the downstream end of the orifice, the lower end of said confining surface extending in the axial direction of the main drum and being spaced at varying distances from the main drum in said axial direction for controlling the cross-machine-direction basis weight of the fibrous structure formed on the forming surface.

Claim 63

An apparatus for dry-forming a fibrous structure, said apparatus including: A. a rotatable main drum having projections on its outer periphery, said drum having a fiber release zone; B. an inlet means outside of said release zone and including feed means for directing a fibrous feed into engagement with the outer periphery of the main drum, whereby rotation of the drum past the inlet means separates fibers from the feed; C. a fiber working section between said inlet means and said release zone for individualizing fibers as they are directed from said inlet means to said release zone by movement of the peripheral surface of the main drum, said fiber working section including adjacent sets of rotatable satellite rolls, each set including a rotatable worker roll and a rotatable turner roll with projections on their outer peripheries, the worker roll of each set being positioned beyond its respective turner roll in the direction of movement of the outer periphery of the main drum during rotation of said said drum, the rolls in each set of satellite rolls being positioned close to each other and to the periphery of the main drum for cooperating with said main drum and with each other to individualize fibers conveyed past the sets of satellite rolls by movement of the outer periphery of the main drum, the turner roll of each set of satellite rolls being closer to the main drum than to its cooperating worker roll and the worker roll of each set being spaced closer to its cooperating turner roll than to the main drum; D. an outlet orifice positioned beyond the satellite rolls in the direction of movement of the outer periphery of the main drum during rotation of said drum, said outlet orifice being adapted to direct fibers to the fiber release zone from the fiber working section; E. a foraminous forming surface for intercepting the fibers after they leave the release zone of the main drum, whereby a fibrous structure is formed on said forming surface; F. a baffle means disposed between the worker roll of one set of satellite rolls, which set is closest to the inlet means, and the turner roll of an adjacent set of satellite rolls, the worker roll of the one set of satellite rolls being closer to the main drum than the turner roll of the adjacent set of satellite rolls, said baffle means includes a lower air-directing section positioned close to the outer periphery of the main drum and having an air-diverting surface adjacent the worker roll of said one set of satellite rolls, said air-diverting surface intercepting air conveyed to it by the outer periphery of the main drum during rotational motion of said drum and diverting a portion of the intercepted air in a first direction away from the periphery of the main drum into the region between the worker roll of said one set of satellite rolls and the baffle means, said air-diverting surface also diverting a second portion of the intercepted air through a constriction provided between the outer periphery of the main drum and a peripheral surface segment of the air-directing section for conveying the second portion of air between the main drum and the turner roll of the adjacent set of satellite rolls.

Claim 64

An apparatus for dry-forming a fibrous structure, said apparatus including: A. a rotatable main drum having projections on its outer periphery, said drum having a fiber release zone; B. an inlet means outside of said release zone and including feed means for directing a fibrous feed into engagement with the outer periphery of the main drum, whereby rotation of the drum past the inlet means separates fibers from the feed; C. a fiber working section between said inlet means and said release zone for individualizing fibers as they are directed from said inlet means to said release zone by movement of the peripheral surface of the main drum, said fiber working section including adjacent sets of rotatable satellite rolls, each set including a rotatable worker roll and a rotatable turner roll with projections on their outer peripheries, the worker roll of each set being positioned beyond its respective turner roll in the direction of movement of the outer periphery of the main drum during rotation of said said drum, the rolls in each set of satellite rolls being positioned close to each other and to the periphery of the main drum for cooperating with said main drum and with each other to individualize fibers conveyed past the sets of satellite rolls by movement of the outer periphery of the main drum, the turner roll of each set of satellite rolls being closer to the main drum than to its cooperating worker roll and the worker roll of each set being spaced closer to its cooperating turner roll than to the main drum; D. an outlet orifice positioned beyond the satellite rolls in the direction of movement of the outer periphery of the main drum during rotation of said drum, said outlet orifice being adapted to direct fibers to the fiber release zone from the fiber working section; E. a foraminous forming surface for intercepting the fibers after they leave the release zone of the main drum, whereby a fibrous structure is formed on said forming surface; F. a baffle means disposed between the worker roll of one set of satellite rolls, which set is closest to the inlet means, and the turner roll of an adjacent set of satellite rolls, the worker roll of the one set of satellite rolls being closer to the main drum than the turner roll of the adjacent set of satellite rolls, said baffle means includes a lower air-directing section positioned close to the outer periphery of the main drum and having an air-diverting surface adjacent the worker roll of said one set of satellite rolls, said air-diverting surface intercepting air conveyed to it by the outer periphery of the main drum during rotational motion of said drum and diverting a portion of the intercepted air in a first direction away from the periphery of the main drum into the region between the worker roll of said one set of satellite rolls and the baffle means, said air-diverting surface also diverting a second portion of the intercepted air through a constriction provided between the outer periphery of the main drum and a peripheral surface segment of the air-directing section for conveying the second portion of air between the main drum and the turner roll of the adjacent set of satellite rolls.

Claim 65

An apparatus for dry-forming a fibrous structure, said apparatus including: A. a rotatable main drum having projections on its outer periphery, said drum having a fiber release zone; B. an inlet means outside of said release zone and including feed means for directing a fibrous feed into engagement with the outer periphery of the main drum, whereby rotation of the drum past the inlet means separates fibers from the feed; C. a fiber working section between said inlet means and said release zone for individualizing fibers as they are directed from said inlet means to said release zone by movement of the peripheral surface of the main drum, said fiber working section including adjacent sets of rotatable satellite rolls, each set including a rotatable worker roll and a rotatable turner roll with projections on their outer peripheries, the worker roll of each set being positioned beyond its repective turner roll in the direction of movement of the outer periphery of the main drum during rotation of said drum, the rolls in each set of satellite rolls being positioned close to each other and to the periphery of the main drum for cooperating with said main drum and with each other to individualize fibers conveyed past the sets of satellite rolls by movement of the outer periphery of the main drum; D. an outlet orifice positioned beyond the satellite rolls in the direction of movement of the outer periphery of the main drum during rotation of said drum, said outlet orifice being adapted to direct fibers to the fiber release zone from the fiber working section; E. a foraminous forming surface for intercepting the fibers after they leave the release zone of the main drum, whereby a fibrous structure is formed on said forming surface; F. a baffle means disposed between the worker roll of one set of satellite rolls, which set is closest to the inlet means, and the turner roll of an adjacent set of satellite rolls; the improvement wherein said baffle means includes a lower air-directing section positioned close to the outer periphery of the main drum and having an air-diverting surface adjacent the worker roll of said one set of satellite rolls, said air-diverting surface intercepting air conveyed to it by the outer periphery of the main drum during rotational motion of said drum and diverting a portion of the intercepted air in a first direction away from the periphery of the main drum into the region between the worker roll of said one set of satellite rolls and the baffle means, said air-diverting surface also diverting a second portion of the intercepted air through a constriction provided between the outer periphery of the main drum and a peripheral surface segment of the air-directing section for conveying the second portion of air between the main drum and the turner roll of the adjacent set of satellite rolls, wherein the distance between the outer periphery of the main drum and the segment of the periphery of the air directing section that is closest to the outer periphery of the main drum is no greater than about 0.2 inches.

Claim 66

An apparatus for dry-forming a fibrous structure, said apparatus including: A. a rotatable main drum having projections on its outer periphery, said drum having a fiber release zone; B. an inlet means outside of said release zone and including feed means for directing a fibrous feed into engagement with the outer periphery of the main drum, whereby rotation of the drum past the inlet means separates fibers from the feed; C. a fiber working section between said inlet means and said release zone for individualizing fibers as they are directed from said inlet means to said release zone by movement of the peripheral surface of the main drum, said fiber working section including adjacent sets of rotatable satellite rolls, each set including a rotatable worker roll and a rotatable turner roll with projections on their outer peripheries, the worker roll of each set being positioned beyond its repective turner roll in the direction of movement of the outer periphery of the main drum during rotation of said drum, the rolls in each set of satellite rolls being positioned close to each other and to the periphery of the main drum for cooperating with said main drum and with each other to individualize fibers conveyed past the sets of satellite rolls by movement of the outer periphery of the main drum; D. an outlet orifice positioned beyond the satellite rolls in the direction of movement of the outer periphery of the main drum during rotation of said drum, said outlet orifice being adapted to direct fibers to the fiber release zone from the fiber working section; E. a foraminous forming surface for intercepting the fibers after they leave the release zone of the main drum, whereby a fibrous structure is formed on said forming surface; F. a baffle means disposed between the worker roll of one set of satellite rolls, which set is closest to the inlet means, and the turner roll of an adjacent set of satellite rolls; the improvement wherein said baffle means includes a lower air-directing section positioned close to the outer periphery of the main drum and having an air-diverting surface adjacent the worker roll of said one set of satellite rolls, said air-diverting surface intercepting air conveyed to it by the outer periphery of the main drum during rotational motion of said drum and diverting a portion of the intercepted air in a first direction away from the periphery of the main drum into the region between the worker roll of said one set of satellite rolls and the baffle means, said air-diverting surface also diverting a second portion of the intercepted air through a constriction provided between the outer periphery of the main drum and a peripheral surface segment of the air-directing section for conveying the second portion of air between the main drum and the turner roll of the adjacent set of satellite rolls, wherein the distance between the outer periphery of the main drum and the segment of the periphery of the air directing section that is closest to the outer periphery of the main drum is no greater than about 0.2 inches.

Claim 68

A method for dry-forming a fibrous structure including short fibers under 1/4 inch in length as the predominate fiber component, by weight, and longer reinforcing fibers, said method including the steps of: A. rotating a main drum having projections on its outer periphery at a surface speed in excess of 10,000 feet/minute; B. directing a fibrous feed into engagement with the rotating outer periphery of the main drum to separate fibers from said feed, said feed including a predominant fiber component, by weight, of short fibers under 1/4 inch in length and a minor fiber component, by weight, of longer reinforcing fibers; C. directing the separated fibers into a fiber working section by rotation of the drum, said fiber working section including a rotating satellite member having projections on its outer periphery for cooperating with the projections on the rotating main drum to individualize fibers in said working section, said rotating satellite member moving fibers around it in its direction of rotation; D. controlling the pressure in the working section to minimize undesirable air-flow in a direction counter to the direction of fiber flow on the rotating satellite member, said undesirable air-flow being caused, at least in part, by the high speed rotation of the main drum; E. directing the individualized fibers from the fiber working section to a release zone on the main drum where they are released from the periphery of said main drum; and F. conveying the released fibers to a foraminous forming surface to form the fibrous structure.

Claim 69

A method for dry-forming a fibrous structure including short fibers under 1/4 inch in length as the predominate fiber component, by weight, and longer reinforcing fibers, said method including the steps of: A. rotating a main drum having projections on its outer periphery at a surface speed in excess of 10,000 feet/minute; B. directing a fibrous feed into engagement with the rotating outer periphery of the main drum to separate fibers from said feed, said feed including a predominant fiber component, by weight, of short fibers under 1/4 inch in length and a minor fiber component, by weight, of longer reinforcing fibers; C. directing the separated fibers into a fiber working section by rotation of the drum, said fiber working section including a rotating satellite member having projections on its outer periphery for cooperating with the projections on the rotating main drum to individualize fibers in said working section, said rotating satellite member moving fibers around it in its direction of rotation; D. controlling the pressure in the working section to minimize undesirable air-flow in a direction counter to the direction of fiber flow on the rotating satellite member, said undesirable air-flow being caused, at least in part, by the high speed rotation of the main drum; E. directing the individualized fibers from the fiber working section to a release zone on the main drum where they are released from the periphery of said main drum; and F. conveying the released fibers to a foraminous forming surface to form the fibrous structure.