US5004579A — Methods and apparatus for selective placement of …

Claim 1

Independent Claim 270 words

Apparatus for forming fibrous articles having at least two distinct potions of fibrous materials, comprising: (a) first means for defiberizing a first fibrous material; (b) duct means for entraining and transporting the defiberized first fibrous material to a first airlaying location; (c) second means for defiberizing a second fibrous material; (d) duct means for entraining and transporting the defiberized second fibrous material to a second airlaying location; (e) airlaying apparatus, comprising: (i) first forming chamber in communication with a duct means, creating a first airlaying location; (ii) second forming chamber in communication with a duct means, creating a second airlaying location; (iii) cavity transport means, having an interior section; (iv) a plurality of deposition cavities disposed on the cavity transport means, at least a portion of each of the deposition cavities comprising a foraminous surface; (v) vacuum chamber means, disposed in the interior section of the cavity transport means, in communication with a least a portion of the foraminous surface of a deposition cavity; (vi) air handling means for creating a controlled pressure differential between the airlaying locations and the interior section of the cavity transport means; and (f) ejection means for removing a fibrous article from the airlaying apparatus whereby the first defiberized material is deposited in at least a portion of a deposition cavity and the second defiberized material is deposited in at least a portion of the same deposition cavity resulting in an article having at least two distinct portions of fibrous materials having a greater proportion of one of said fibrous materials in one lateral planar portion of said article than in another lateral co-planar portion.

Claim 2

Dependent Claim 270 words

Apparatus for forming fibrous articles having at least two distinct potions of fibrous materials, comprising: (a) first means for defiberizing a first fibrous material; (b) duct means for entraining and transporting the defiberized first fibrous material to a first airlaying location; (c) second means for defiberizing a second fibrous material; (d) duct means for entraining and transporting the defiberized second fibrous material to a second airlaying location; (e) airlaying apparatus, comprising: (i) first forming chamber in communication with a duct means, creating a first airlaying location; (ii) second forming chamber in communication with a duct means, creating a second airlaying location; (iii) cavity transport means, having an interior section; (iv) a plurality of deposition cavities disposed on the cavity transport means, at least a portion of each of the deposition cavities comprising a foraminous surface; (v) vacuum chamber means, disposed in the interior section of the cavity transport means, in communication with a least a portion of the foraminous surface of a deposition cavity; (vi) air handling means for creating a controlled pressure differential between the airlaying locations and the interior section of the cavity transport means; and (f) ejection means for removing a fibrous article from the airlaying apparatus whereby the first defiberized material is deposited in at least a portion of a deposition cavity and the second defiberized material is deposited in at least a portion of the same deposition cavity resulting in an article having at least two distinct portions of fibrous materials having a greater proportion of one of said fibrous materials in one lateral planar portion of said article than in another lateral co-planar portion.

Claim 3

Dependent Claim 20 words

The apparatus of claim 1, further comprising environmental control means to regulate the temperature and humidity within the duct means.

Claim 4

Dependent Claim 29 words

The apparatus of claim 1, further comprising scarfing means for removing airlaid material extending beyond the boundaries of the deposition cavity, prior to the ejection of the fibrous article.

Claim 5

Dependent Claim 20 words

The apparatus of claim 3, further comprising means for collecting the removed airlaid material and transporting it to a duct.

Claim 6

Dependent Claim 65 words

The apparatus of claim 1, further comprising: at least three mill means for defiberizing a fibrous material; duct means for entraining and transporting the defiberized fibrous material to at least three airlaying locations; and a plurality of forming chambers in communication with a duct means creating at least three airlaying locations, whereby fibrous articles having a plurality of distinct portions of fibrous materials are formed.

Claim 7

Dependent Claim 45 words

The apparatus of claim 1, wherein the portion of said deposition cavities comprising a foraminous surface is comprised of a surface which forms a major surface of the airlaid article and further comprises at least a portion of the adjacent lateral portion of the cavity.

Claim 8

Dependent Claim 22 words

The apparatus of claim 1, further comprising baffle means for regulating the airflow and pressure of distinct portions of said deposition cavities.

Claim 9

Dependent Claim 32 words

The apparatus of claim 1, further comprising honeycomb means for channeling the airflow through deposition cavities, the honeycomb means disposed between the foraminous surface of the deposition cavity and the vacuum source.

Claim 10

Dependent Claim 33 words

The apparatus of claim 1, further comprising apparatus for creating a positive pressure in a first portion of a deposition cavity and a negative pressure in a second portion of a deposition cavity.

Claim 11

Dependent Claim 18 words

The apparatus of claim 1, wherein said first forming chamber deposits airlaid material in a substantially radial manner.

Claim 12

Dependent Claim 63 words

The apparatus of claim 1, further comprising a neutral zone chamber within the airlaying apparatus having a circumferential length approximately equal to the length of the deposition cavity, said neutral zone disposed between said first forming chamber and said second forming chamber, the vacuum pressure in the neutral zone being substantially less than the vacuum pressure in said first and second forming chambers.

Claim 13

Dependent Claim 22 words

The apparatus of claim 1, further comprising transfer drum means for receiving and transporting the airlaid articles away from the airlaying apparatus.

Claim 14

Dependent Claim 19 words

The apparatus of claim 1, further comprising ejector means for removing an airlaid article from within a deposition cavity.

Claim 15

Dependent Claim 28 words

The apparatus of claim 13, said ejector means comprising means for controlling a source of compressed air and directing the stream of compressed air against the airlaid article.

Claim 16

Dependent Claim 96 words

Deposition cavity apparatus for forming an airlaid article, in communication with a duct carrying a stream of air-entrained fibrous material to an airlaying location, comprising: a frame portion in sealing engagement with the duct; and a foraminous portion, foramen in said foraminous portion being of a size sufficient to retain the air-entrained fibrous materials, whereby an airlaid article is formed in the region of the foraminous portion and further comprising apparatus for creating a negative pressure in a first portion of a deposition cavity and a positive pressure in a second portion of a deposition cavity.

Claim 17

Dependent Claim 96 words

Deposition cavity apparatus for forming an airlaid article, in communication with a duct carrying a stream of air-entrained fibrous material to an airlaying location, comprising: a frame portion in sealing engagement with the duct; and a foraminous portion, foramen in said foraminous portion being of a size sufficient to retain the air-entrained fibrous materials, whereby an airlaid article is formed in the region of the foraminous portion and further comprising apparatus for creating a negative pressure in a first portion of a deposition cavity and a positive pressure in a second portion of a deposition cavity.

Claim 18

Independent Claim 199 words

A method of forming fibrous articles having at least two distinct portions of fibrous materials, comprising the steps of: (a) defiberizing a first fibrous material; (b) entraining and transporting the defiberized first fibrous material to a first airlaying location; (c) defiberizing a second fibrous material; (d) entraining and transporting the defiberized second fibrous material to a second airlaying location; (e) airlaying the fibrous materials by transporting the first fibrous material to a first forming chamber in communication with a duct means, creating a first airlaying location; transporting the second fibrous materials to a second forming chamber in communication with a duct means, creating a second airlaying location; creating a controlled pressure differential between the airlaying locations and a vacuum chamber; passing the first and second air entrained fibers through a deposition cavity, at least a portion of the deposition cavity comprising a foraminous surface; and ejecting the fibrous article from the airlaying apparatus, whereby the first defiberized material is deposited in at least a portion of a deposition cavity and the second defiberized material is deposited in at least a portion of a deposition cavity resulting in an article having at least two distinct co-planar portions of fibrous materials.

Claim 19

Independent Claim 199 words

A method of forming fibrous articles having at least two distinct portions of fibrous materials, comprising the steps of: (a) defiberizing a first fibrous material; (b) entraining and transporting the defiberized first fibrous material to a first airlaying location; (c) defiberizing a second fibrous material; (d) entraining and transporting the defiberized second fibrous material to a second airlaying location; (e) airlaying the fibrous materials by transporting the first fibrous material to a first forming chamber in communication with a duct means, creating a first airlaying location; transporting the second fibrous materials to a second forming chamber in communication with a duct means, creating a second airlaying location; creating a controlled pressure differential between the airlaying locations and a vacuum chamber; passing the first and second air entrained fibers through a deposition cavity, at least a portion of the deposition cavity comprising a foraminous surface; and ejecting the fibrous article from the airlaying apparatus, whereby the first defiberized material is deposited in at least a portion of a deposition cavity and the second defiberized material is deposited in at least a portion of a deposition cavity resulting in an article having at least two distinct co-planar portions of fibrous materials.

Claim 20

Dependent Claim 19 words

The method of claim 16, further comprising the step of regulating the temperature and humidity within a duct means.

Claim 21

Dependent Claim 29 words

The method of claim 16, further comprising the step of removing airlaid material extending beyond the boundaries of the deposition cavity, prior to the ejection of the fibrous article.

Claim 22

Dependent Claim 21 words

The method of claim 18, further comprising the step of collecting the removed airlaid material and transporting it to a duct.

Claim 23

Dependent Claim 62 words

The method of claim 16, further comprising the steps of: defiberizing at least three fibrous materials; entraining and transporting the defiberized fibrous materials to at least three airlaying locations; and providing a plurality of forming chambers in communication with a duct means creating at least three airlaying locations, whereby fibrous articles having a plurality of distinct portions of fibrous materials are formed.

Claim 24

Dependent Claim 22 words

The method of claim 16, further comprising the step of regulating the airflow and pressure of distinct portions of said deposition cavities.

Claim 25

Dependent Claim 31 words

The method of claim 16, further comprising the step of channeling the airflow through deposition cavities, using means disposed between the foraminous surface of the deposition cavity and the vacuum source.

Claim 26

Dependent Claim 34 words

The method of claim 16, further comprising the step of creating a positive pressure in a first portion of a deposition cavity and a negative pressure in a second portion of a deposition cavity.

Claim 27

Dependent Claim 24 words

The method of claim 16, wherein said the deposition of material into a first forming chamber is carried out in a substantially radial manner.

Claim 28

Dependent Claim 21 words

The method of claim 16, further comprising the step of receiving and transporting the airlaid articles away from the airlaying apparatus.

Claim 29

Dependent Claim 18 words

The method of claim 16, further comprising the step of removing airlaid articles from within a deposition cavity.

Claim 30

Dependent Claim 27 words

The method of claim 26, wherein said removal step comprises controlling a source of compressed air and directing the stream of compressed air against an airlaid article.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1994-04-01	1994-10-01	1995-04-02	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1998-04-01	1998-10-01	1999-04-02	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2002-04-01	2002-10-01	2003-04-02	$7700.00	Window Closed / Lapsed

Methods and apparatus for selective placement of fibrous material in formed fibrous articles

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