Method and apparatus for depositing moisture-absorbent and thermoplastic material in a substrate

• US 5,143,680 A
• Filed: 05/17/1990
• Issued: 09/01/1992
• Est. Priority Date: 05/17/1990
• Status: Expired due to Fees

• Current Assignee: Nordson Corporation
• Original Assignee: Nordson Corporation
• Inventors: Becker, Richard A., Fena, Ernest J., Fimmen, Charles L., Shlapak, Robert, Folden, David W., Schneider, Douglas A., Molnar, Julius J., Selestak, David M.
• Primary Examiner(s): THEISEN, MARY LYNN F
• Application Number:
  US07/525,880
• Time in Patent Office: 838 Days
• Field of Search: 264/518, 264/113, 264/510, 264/511, 264/6, 264/12, 425/80.1, 425/81.1, 425/82.1, 425/83.1
• US Class Current: 264/511
• CPC Class Codes: A61F 13/15658 Forming continuous, e.g. composite, fibrous webs, e.g. involving the application of pulverulent material on parts thereof
• CPC Class Codes: A61F 13/535 inhomogeneous in the plane of the pad, e.g. core absorbent layers being of different sizes A61F13/5323, A61F13/537 take precedence
• CPC Class Codes: D04H 1/54 by welding together the fibres, e.g. by partially melting or dissolving in combination with needling D04H1/485

Abstract

A method and apparatus for forming a non-woven pad of fibrous material is provided in which highly moisture-absorbent particles and fibers of thermoplastic material are intermixed with the fibrous material throughout one or more predetermined portions of the thickness of the non-woven pad while maintaining other portions of the thickness of the pad substantially free of highly moisture-absorbent particles and/or thermoplastic fiber material. The non-woven pad is formed on one side of a conveyor moving through a forming chamber which has a duct connected to a source of vacuum operable to draw fibrous material injected into the chamber onto the conveyor. One dispenser discharges the highly moisture-absorbent material at a predetermined location relative to the fibrous material being drawn onto the conveyor, and at least one other dispenser discharges the thermoplastic fiber material into the chamber at a location to intermix the thermoplastic fiber material with the fibrous material and highly moisture-absorbent material being drawn onto the conveyor at the predetermined location, and/or to intermix the thermoplastic fiber materials with the fibrous material in areas of the thickness of the non-woven pad on one or both sides of the highly moisture-absorbent material.

Claims

1. Apparatus for forming a non-woven pad of fibrous material with a first material and a thermoplastic material interspersed throughout a selected portion of the thickness of said non-woven pad, comprising:

a forming chamber having an interior;

pad support means for supporting said non-woven pad, said pad support means being movable in a first direction within said interior of said forming chamber;

means for introducing fibrous material into said interior of said forming chamber;

vacuum means for applying a vacuum to draw said fibrous material onto said pad support means, said fibrous material forming said non-woven pad on said pad support means which increases in thickness in said first direction of movement of said pad support means;

first dispenser means for intermixing said first material with a portion of said fibrous material being drawn onto said pad support means at a predetermined location within said forming chamber;

second dispenser means for forming thermoplastic fibers from said thermoplastic material and for dispensing said thermoplastic fibers into said forming chamber for intermixing with said first material and said fibrous material being drawn onto said pad support means at said predetermined location to form a layer of intermixed fibrous material, first material and thermoplastic fibers within a predetermined portion of said thickness of said non-woven pad while maintaining another portion of said thickness of said non-woven pad substantially free of said first material and said thermoplastic fibers.

2. The apparatus of claim 1 in which said pad support means is a conveyor.

3. Apparatus for forming a non-woven pad of fibrous material with a first material, a thermoplastic material and a third material interspersed throughout a selected portion of the thickness of said non-woven pad, comprising:

a forming chamber having an interior;

pad support means for supporting said non-woven pad, said pad support means being movable in a first direction within said interior of said forming chamber;

means for introducing fibrous material into said interior of said forming chamber;

vacuum means for applying a vacuum to draw said fibrous material onto said pad support means, said fibrous material forming said non-woven pad on said pad support means which increases in thickness in said first direction of movement of said pad support means;

first dispenser means for intermixing said first material with a portion of said fibrous material being drawn onto said pad support means at a predetermined location within said interior of said forming chamber;

second dispenser means for forming thermoplastic fibers from said thermoplastic material and for dispensing said thermoplastic fibers into said forming chamber for intermixing with said first material and said fibrous material being drawn onto said pad support means at said predetermined location;

third dispenser means for intermixing a third material with said fibrous material, first material and thermoplastic fibers being drawn onto said pad support means at said predetermined location to form a layer of intermixed fibrous material, first material, thermoplastic fibers and third material within a predetermined portion of said thickness of said non-woven pad while maintaining another portion of said thickness of said non-woven pad substantially free of said first material, thermoplastic fibers and third material.

4. The apparatus of claim 3 in which said pad support means is a conveyor.

5. Apparatus for forming a non-woven pad of fibrous material with a first material, a thermoplastic material and a third material interspersed throughout selected portions of the thickness of said non-woven pad, comprising:

a forming chamber having an interior;

a pad support means for supporting said non-woven pad, said pad support means being movable in a first direction within said interior of said forming chamber;

means for introducing fibrous material into said interior of said forming chamber;

means for introducing fibrous material into said interior of said forming chamber;

vacuum means for applying a vacuum to draw said fibrous material onto said pad support means, said fibrous material forming said non-woven pad on said pad support means which increases in thickness in said first direction of movement of said pad support means;

first dispenser means for intermixing said first material with a portion of said fibrous material being drawn onto said pad support means at a predetermined location within said interior of said forming chamber;

second dispenser means for forming thermoplastic fibers from said thermoplastic material and for dispensing said thermoplastic fibers into said forming chamber for intermixing with said fibrous material being drawn onto said pad support means at a location upstream from said predetermined location;

third dispenser means for intermixing said third material with said fibrous material being drawn onto said pad support means at a location downstream from said predetermined location, whereby said non-woven pad is formed with a first layer of intermixed fibrous material and thermoplastic fibers which is drawn onto said pad support means upstream from said predetermined location, a second layer of intermixed fibrous material and said first material which is drawn atop said first layer at said predetermined location, and a third layer of intermixed fibrous material and said third material which is drawn atop said second layer downstream from said predetermined location.

6. The apparatus of claim 5 in which said pad support means is a conveyor.

7. Apparatus for forming a non-woven pad of fibrous material with a first material and a thermoplastic material interspersed throughout a selected portion of the thickness of said non-woven pad, comprising:

a chamber having an inlet and an outlet;

a conveyor movable between said inlet and said outlet of said chamber, said conveyor having a first side and a second side;

means for introducing fibrous material into said chamber;

vacuum means located on said first side of said conveyor for applying a vacuum in said chamber to draw said fibrous material onto said second side of said conveyor, said fibrous material forming a non-woven pad on said second side of said conveyor which increases in thickness in a direction from said inlet of said chamber toward said outlet thereof, said non-woven pad having a bottom surface resting on said second side of said conveyor and a top surface which slopes upwardly relative to said conveyor from said inlet of said chamber toward said outlet thereof;

first dispenser means for intermixing said first material with a portion of said fibrous material being drawn onto said conveyor at a predetermined location relative to said upwardly sloping top surface of said non-woven pad;

second dispenser means for forming thermoplastic fibers from said thermoplastic material and for dispensing said thermoplastic fibers into said chamber for intermixing with said first material and said fibrous material being drawn onto said conveyor at said predetermined location to form a layer of intermixed fibrous material, first material and thermoplastic fibers within a predetermined portion of said thickness of said non-woven pad while maintaining another portion of said thickness of said non-woven pad substantially free of said first material and said thermoplastic fibers.

8. The apparatus of claim 7 in which said second dispenser means comprises:

a die head formed with at least one first passageway for transmitting thermoplastic material, and at least one second passageway for transmitting air;

a nozzle block formed with a first discharge plenum having a plurality of discharge outlets and at least one second discharge plenum having an outlet oriented at an angle relative to the axes of said discharge outlets, said nozzle block being mounted to said die head so that said first passageway transmits said thermoplastic material into said first discharge plenum and through said discharge outlets thereof, and so that said second passageway transmits air into said second discharge plenum and through said outlet thereof for engagement with said thermoplastic material ejected from said discharge outlets.

9. The apparatus of claim 8 in which said at least one first passageway of said die head includes an inlet passageway, a transfer passageway connected to said inlet passageway and a number of discharge ports each connected between said transfer passageway and said first discharge plenum in said nozzle block.

10. The apparatus of claim 8 in which said first discharge plenum is formed at the center of said nozzle block, and said at least one second discharge plenum comprises two air plenums located on opposite sides of said first discharge plenum, each of said air plenums being defined by a recess formed in one side of said nozzle block and a plate connected to said nozzle block over said recess.

11. The apparatus of claim 8 in which said die head is formed with an air chamber adapted to communicate with a source of air, said at least one second passageway of said die head including a group of discharge passageways located on one side of said die head and another group of discharge passageways located on the other side of said die head, each of said groups of discharge passageways extending between said air chamber and one of said air plenums formed in said nozzle block.

12. Apparatus for forming a non-woven pad of fibrous material with a first material, a thermoplastic material interspersed throughout a selected portion of the thickness of said non-woven pad at spaced locations therealong, comprising:

a chamber having an inlet and an outlet;

a conveyor movable between said inlet and said outlet of said chamber, said conveyor having a first side and a second side;

means for introducing fibrous material into said chamber;

vacuum means on said first side of said conveyor for applying a vacuum in said chamber to draw said fibrous material onto said second side of said conveyor, said fibrous material forming said non-woven pad on said conveyor which increases in thickness in a direction from said inlet of said chamber toward said outlet thereof, said non-woven pad having a bottom surface resting on said second side of said conveyor and a top surface which slopes upwardly relative to said conveyor from said inlet of said chamber toward said outlet thereof;

first dispenser means for intermittently mixing said first material with a portion of said fibrous material being drawn onto said conveyor at a predetermined location relative to said upwardly sloping top surface of said non-woven pad;

second dispenser means for forming thermoplastic fibers from said thermoplastic material and for intermittently dispensing said thermoplastic fibers into said chamber for mixing with said first material and said fibrous material being drawn onto said conveyor at said predetermined location to form a layer of intermixed fibrous material, first material and thermoplastic fibers within a predetermined portion of said thickness of said non-woven pad at spaced locations therealong while maintaining another portion of said thickness of said non-woven pad at spaced locations therealong substantially free of said first material and said thermoplastic fibers.

13. Apparatus for forming a non-woven pad of fibrous material with a first material and a thermoplastic material interspersed throughout a selected portion of the thickness of said non-woven pad, comprising:

a chamber having an inlet and an outlet;

a conveyor movable between said inlet and said outlet of said chamber, said conveyor having a first side and a second side;

means for introducing fibrous material into said chamber;

vacuum means located on said first side of said conveyor for applying a vacuum in said chamber to draw said fibrous material onto said second side of said conveyor, said fibrous material forming a non-woven pad on said conveyor which increases in thickness in a direction from said inlet of said chamber toward said outlet thereof, said non-woven pad having a bottom surface resting on said conveyor and a top surface which slopes upwardly relative to said conveyor from said inlet of said chamber toward said outlet thereof;

first dispenser means for intermixing said first material with a portion of said fibrous material being drawn onto said conveyor at a predetermined location relative to said upwardly sloping top surface of said non-woven pad;

second dispenser means for forming thermoplastic fibers from said thermoplastic material and for dispensing said thermoplastic fibers into said forming chamber for intermixing with said first material and said fibrous material being drawn onto said conveyor at said predetermined location to form a layer of intermixed fibrous material, first material and thermoplastic fibers within a predetermined portion of said thickness of said non-woven pad while maintaining another portion of said thickness of said non-woven pad substantially free of said first material and said thermoplastic fibers;

means for supplying said thermoplastic fibers to said second dispenser means;

control means for controlling the operation of said second dispenser means.

14. The apparatus of claim 13 in which said second dispenser means comprises:

a die head formed with at least one first passageway for transmitting said thermoplastic material, and at least one second passageway for transmitting air;

a nozzle block formed with a first discharge plenum having a plurality of discharge outlets and at least one second discharge plenum having an outlet oriented at an angle relative to the axes of said discharge outlets, said nozzle block being mounted to said die head so that said first passageway transmits said thermoplastic material into said first discharge plenum and through said discharge outlets thereof, and so that said second passageway transmits air into said second discharge plenum and through said outlet thereof for engagement with said thermoplastic material ejected from said discharge outlets.

15. The apparatus of claim 13 in which said thermoplastic material is thermoplastic, hot melt adhesive, said means for supplying said thermoplastic hot melt adhesive to said second dispenser means comprising an adhesive spray gun connected to a source of molten hot melt adhesive material, said adhesive spray gun discharging hot melt adhesive material into said first passageway of said die head of said second dispenser means.

16. The apparatus of claim 15 in which said control means is an adhesive applicator operatively connected to said adhesive spray gun, said adhesive applicator being effective to open said adhesive spray gun to permit the passage of hot melt adhesive material into said die head and to close said adhesive spray gun to terminate the flow of hot melt adhesive material into said die head.

17. Apparatus for use with a forming chamber having an inlet and an outlet, a conveyor movable between said inlet and said outlet, a vacuum device located on one side of said conveyor for applying a vacuum in said chamber to draw fibrous material introduced into said chamber onto the opposite side of said conveyor forming a non-woven pad on said conveyor which has a bottom surface resting on said conveyor and a top surface which slopes upwardly relative to said conveyor from said inlet of said chamber to said outlet thereof, said apparatus comprising:

first dispenser means for intermixing moisture-absorbent material with a portion of said fibrous material being drawn into said conveyor at a predetermined location relative to said upwardly sloping top surface of said non-woven pad;

supply means for supplying hot melt adhesive material;

second dispenser means connected to said supply means to receive said hot melt adhesive material;

control means for causing said second dispenser means to form and dispense hot melt adhesive fibers into said forming chamber for intermixing with said moisture-absorbent material and said fibrous material being drawn onto said conveyor at said predetermined location to form a layer of intermixed fibrous material, moisture-absorbent material and hot melt adhesive fibers within a predetermined portion of said thickness of said non-woven pad while maintaining another portion of said thickness of said non-woven pad substantially free of said moisture-absorbent material and said hot melt adhesive fibers.

18. The apparatus of claim 17 in which said second dispenser means comprises:

a die head formed with at least one first passageway for transmitting said hot melt adhesive material, and at least one second passageway for transmitting air;

a nozzle block formed with a first discharge plenum having a plurality of discharge outlets and at least one second discharge plenum having an outlet oriented at an angle relative to the axes of said discharge outlets, said nozzle block being mounted to said die head so that said first passageway transmits said hot melt adhesive material into said first discharge plenum and through said discharge outlets thereof, and so that said second passageway transmits air into said second discharge plenum and through said outlet thereof for engagement with said hot melt adhesive material ejected from said discharge outlets.

19. The apparatus of claim 18 in which said means for supplying hot melt adhesive material to said second dispenser means comprises an adhesive spray gun connected to a source of molten hot melt adhesive material, said adhesive spray gun discharging hot melt adhesive material into said first passageway of said die head.

20. The apparatus of claim 19 in which said control means is an adhesive applicator operatively connected to said adhesive spray gun, said adhesive applicator being effective to open said adhesive spray gun to permit the passage of hot melt adhesive material into said die head and to close said adhesive spray gun to terminate the flow of hot melt adhesive material into said die head.

21. Apparatus for forming a non-woven pad of a fibrous material with a first material and a thermoplastic material interspersed throughout a selected portion of the thickness of said non-woven pad, comprising:

a chamber having an inlet and an outlet;

a conveyor movable between said inlet and said outlet of said chamber, said conveyor having a first side and a second side;

means for introducing fibrous material in suspension into said chamber;

vacuum means located on said first side of said conveyor for applying a vacuum in said chamber to draw said fibrous material onto said second side of said conveyor, said fibrous material forming a non-woven pad on said conveyor which has a minimum thickness at said inlet of said chamber and which increases in thickness toward said outlet thereof as more of said fibrous material is drawn onto said conveyor;

first dispenser means for intermixing said first material with a portion of said fibrous material being drawn onto said conveyor at a predetermined location intermediate said inlet and outlet of said chamber;

second dispenser means for forming thermoplastic fibers from said thermoplastic material and for dispensing said thermoplastic fibers into said chamber for intermixing with said first material and said first material being drawn onto said conveyor at said predetermined location, whereby said non-woven pad is formed with a bottom layer of said fibrous material which is drawn onto said conveyor between said inlet of said chamber and said predetermined location, an intermediate layer of intermixed fibrous material, first material and thermoplastic fibers which is drawn atop said bottom layer of fibrous material at said predetermined location, and a top layer of fibrous material which is drawn onto said intermediate layer between said predetermined location and said outlet of said chamber, said bottom layer and said top layer of said non-woven pad being substantially free of said first material and said thermoplastic fibers.

22. The apparatus of claim 21 in which said first and second dispenser means are operative intermittently to intermix said first material and said thermoplastic fibers with a portion of said fibrous material being drawn onto said conveyor at said predetermined location to form said intermediate layer of intermixed fibrous material, first material and thermoplastic fibers within a predetermined portion of the thickness of said non-woven pad at spaced locations therealong.

23. The apparatus of claim 21 in which said first dispenser means is a spray gun which discharges highly moister-absorbent material.

24. The apparatus of claim 21 in which said dispenser means is a thermoplastic material die head which discharges said thermoplastic fibers.

25. Apparatus for forming a non-woven pad of fibrous material with a first material, a thermoplastic material and a third material interspersed throughout a selected portion of the thickness of said non-woven pad, comprising:

a chamber having an inlet and an outlet;

a conveyor movable between said inlet and said outlet of said chamber, said conveyor having a first side and a second side;

means for introducing fibrous material into said chamber;

vacuum means located on said first side of said conveyor for applying a vacuum in said chamber to draw said fibrous material onto said second side of said conveyor, said fibrous material forming a non-woven pad on said second side of said conveyor which increases in thickness in a direction from said inlet of said chamber toward said outlet thereof, said non-woven pad having a bottom surface resting on said second side of said conveyor and a top surface which slopes upwardly relative to said conveyor from said inlet of said chamber toward said outlet thereof;

first dispenser means for intermixing said first material with a portion of said fibrous material being drawn onto said conveyor at a predetermined location relative to said upwardly sloping top surface of said non-woven pad;

second dispenser means for forming thermoplastic fibers from said thermoplastic material and for dispensing said thermoplastic fibers into said chamber for intermixing with said first material and said fibrous material being drawn onto said conveyor at said predetermined location;

third dispenser means for intermixing said third material with said fibrous material, first material and said thermoplastic fibers being drawn onto said conveyor at said predetermined location to form a layer of intermixed fibrous material, first material, thermoplastic fibers and third material within a predetermined portion of said thickness of said non-woven pad while maintaining another portion of said thickness of said non-woven pad substantially free of said first material, thermoplastic fibers and said third material.

26. The apparatus of claim 25 in which said first dispenser means is a spray gun which discharges highly moisture-absorbent material.

27. The apparatus of claim 25 in which said second dispenser means is a thermoplastic material die head which discharges thermoplastic fibers having relatively high tensile strength.

28. The apparatus of claim 25 in which said third dispenser means is a thermoplastic material die head which discharges a thermoplastic material which maintains air gaps between said fibrous material within said intermediate layer of said non-woven pad.

29. Apparatus for forming a non-woven pad of fibrous material with a first material, a thermoplastic material and a third material interspersed throughout a selected portions of the thickness of said non-woven pad, comprising:

a chamber having an inlet and an outlet;

a conveyor movable between said inlet and said outlet of said chamber, said conveyor having a first side and a second side;

means for introducing fibrous material into said chamber;

vacuum means located on said first side of said conveyor for applying a vacuum in said chamber to draw said fibrous material onto said second side of said conveyor, said fibrous material forming a non-woven pad on said second side of said conveyor which increases in thickness in a direction from said inlet of said chamber toward said outlet thereof, said non-woven pad having a bottom surface resting on said second side of said conveyor and a top surface which slopes upwardly relative to said conveyor from said inlet of said chamber toward said outlet thereof;

first dispenser means for intermixing said first material with a portion of said fibrous material being drawn onto said conveyor at a predetermined location relative to said upwardly sloping top surface of said non-woven pad;

second dispenser means for forming thermoplastic fibers from said thermoplastic material and for dispensing thermoplastic fibers into said chamber for intermixing with said fibrous material being drawn onto said conveyor at a location upstream from said predetermined location;

third dispenser means for intermixing said third material with said fibrous material being drawn onto said conveyor at a location downstream from said predetermined location, whereby said non-woven pad is formed with a first layer of intermixed fibrous material and thermoplastic fibers which is drawn onto said conveyor upstream from said predetermined location, a second layer of intermixed fibrous material and said first material which is drawn atop said first layer at said predetermined location, and a third layer of intermixed fibrous material and said third material which is drawn atop said second layer downstream from said predetermined location.

30. The apparatus of claim 29 in which said first dispenser means is a spray gun which discharges highly moisture-absorbent particulate material.

31. The apparatus of claim 29 in which said second dispenser means is a thermoplastic material die head which discharges said thermoplastic fibers.

32. The apparatus of claim 29 in which said third dispenser means is a thermoplastic material die head which discharges thermoplastic material.

33. Apparatus for forming a non-woven pad of fibrous material with a first material and a thermoplastic material interspersed throughout a selected portion of the thickness of said non-woven pad, comprising:

a chamber having an inlet and an outlet;

a conveyor movable between said inlet and said outlet of said chamber, said conveyor having a first side and a second side;

means for introducing fibrous material into said chamber;

vacuum means located on said first side of said conveyor for applying a vacuum in said chamber to draw said fibrous material onto said second side of said conveyor, said fibrous material forming a non-woven pad on said second side of said conveyor which increases in thickness in a direction from said inlet of said chamber toward said outlet thereof, said non-woven pad having a bottom surface resting on said second side of said conveyor and a top surface which slopes upwardly relative to said conveyor from said inlet of said chamber toward said outlet thereof;

first dispenser means for intermixing said first material with a portion of said fibrous material being drawn onto said conveyor at a predetermined location relative to said upwardly sloping top surface of said non-woven pad;

second dispenser means for forming thermoplastic fibers from said thermoplastic material and for dispensing thermoplastic fibers into said chamber for intermixing with said first material and said fibrous material being drawn onto said conveyor at said predetermined location;

means for positioning a moisture-wicking substance at the exterior surface of said second material in an effective amount so that said exterior surface of said thermoplastic fibers is capable of wicking moisture, whereby a layer of intermixed fibrous material, first material and thermoplastic fibers having a moisture-wicking substance at the exterior surface thereof is formed within a predetermined portion of said thickness of said non-woven pad while maintaining another portion of said thickness of said non-woven pad substantially free of said first material and said thermoplastic fibers.

34. The apparatus of claim 33 in which said means for positioning said moisture-wicking substance comprises means for applying said moisture-wicking substance to the exterior surface of said thermoplastic material.

35. The apparatus of claim 33 in which said means for positioning said moisture-wicking substance comprises means for intermixing said moisture-wicking substance and said thermoplastic material to from a blend in which at least a portion of said moisture-wicking substance is located at the exterior surface of said thermoplastic material.

36. The apparatus of claim 33 in which said second dispenser means is a thermoplastic material die head which discharges said thermoplastic fibers, said means for positioning said moisture-wicking substance at the exterior surface of said thermoplastic material comprising a mixer block adapted to connect to a source of air and to a source of the moisture-wicking substance, said mixer block being formed with a passageway for intermixing and then discharging said air and said moisture-wicking substance into said thermoplastic material die head for combination with thermoplastic material supplied to said die head, whereby said die head discharges thermoplastic fibers which are a blend of said thermoplastic material and said moisture-wicking substance wherein at least a portion of said moisture-wicking substance is located at the exterior surface of said thermoplastic fibers.

37. The apparatus of claim 33 in which said second dispenser means is a thermoplastic material die head which discharges said thermoplastic fibers, said means for positioning said moisture-wicking substance at the exterior surface of said thermoplastic material comprising means for intermixing thermoplastic material and moisture-wicking material to form a blend which is supplied to said die head, whereby said die head discharges thermoplastic fibers formed of said blend wherein at least a portion of said moisture-wicking substance is located at the exterior surface of said thermoplastic fibers.

38. The apparatus of claim 33 in which said means for positioning said moisture-wicking substance comprises a spray gun adapted to connect to a source of moisture-wicking substance, said spray gun discharging said moisture-wicking substance into said chamber in the path of said thermoplastic material so that said moisture-wicking substance is applied onto at least a portion of the exterior surface of said thermoplastic material.

39. Apparatus for use with a forming chamber having an inlet and an outlet, a conveyor movable between said inlet and said outlet, a vacuum device located on one side of said conveyor for applying a vacuum in said chamber to draw fibrous material introduced into said chamber onto the opposite side of said conveyor forming a non-woven pad on said conveyor which has a bottom surface resting on said conveyor and a top surface which slopes upwardly relative to said conveyor from said inlet of said chamber to said outlet thereof, said apparatus comprising:

first dispenser means for intermixing moisture-absorbent material with a portion of said fibrous material being drawn onto said conveyor at a predetermined location relative to said upwardly sloping top surface of said non-woven pad;

thermoplastic material supply means for supplying hot thermoplastic material;

means for transmitting a moisture-wicking substance to said thermoplastic material supply means for intermixing with said thermoplastic material to form a blend;

second dispenser means connected to said supply means to receive said blend of thermoplastic material and moisture-wicking substance;

control means for causing said second dispenser means to form thermoplastic fibers of said blend in which at least a portion of said moisture-wicking substance is located at the exterior surface of said fibers, and for discharging said thermoplastic fibers into said forming chamber for intermixing with said moisture-absorbent material and said fibrous material being drawn into said conveyor at said predetermined location to form a layer of intermixed fibrous material, moisture-absorbent material and fibers of thermoplastic material and a moisture-wicking substance within a predetermined portion of said thickness of said non-woven pad while maintaining another portion of said thickness of said non-woven pad substantially free of said moisture-absorbent material and said thermoplastic fibers.

40. The apparatus of claim 39 in which said means for transmitting a moisture-wicking substance comprises a pressure pot and a pump connected to said pressure pot which pumps said moisture-wicking substance into said thermoplastic material supply means.

41. Apparatus for forming a non-woven pad of fibrous material with a first material, a thermoplastic material and a third material interspersed throughout a selected portion of the thickness of said non-woven pad, comprising:

a chamber having an inlet and an outlet;

a conveyor movable between said inlet and said outlet of said chamber, said conveyor having a first side and a second side;

means for introducing fibrous material into said chamber;

vacuum means located on said first side of said conveyor for applying a vacuum in said chamber to draw said fibrous material onto said second side of said conveyor, said fibrous material forming a non-woven pad on said second side of said conveyor which increases in thickness in a direction from said inlet of said chamber toward said outlet thereof, said non-woven pad having a bottom surface resting on said second side of said conveyor and a top surface which slopes upwardly relative to said conveyor from said inlet of said chamber toward said outlet thereof;

first dispenser means for intermixing said first material with a portion of said fibrous material being drawn onto said conveyor at a predetermined location relative to said upwardly sloping top surface of said non-woven pad;

second dispenser means for forming thermoplastic fibers from said thermoplastic material and for dispensing said thermoplastic fibers into said chamber for intermixing with said first material and said fibrous material being drawn onto said conveyor at said predetermined location;

third dispenser means for intermixing a third material with said fibrous material, first material and thermoplastic fibers being drawn onto said conveyor at said predetermined location;

means for positioning a moisture-wicking substance at the exterior surface of at least one of said thermoplastic material and third material in an effective amount so that said exterior surface of said thermoplastic fibers formed from said thermoplastic material and said exterior surface of said third material are capable of wicking moisture, whereby a layer of intermixed fibrous material, first material, thermoplastic fibers, third material and moisture-wicking substance is formed within a predetermined portion of said thickness of said non-woven pad while maintaining another portion of said thickness of said non-woven pad substantially free of said first material, said thermoplastic fibers and said third material.

42. The apparatus of claim 41 in which said means for positioning said moisture-absorbing substance comprises means for applying said moisture-absorbing substance to the exterior surface of at least one of said thermoplastic material and said third material.

43. The apparatus of claim 41 in which said means for positioning said moisture-absorbing substance comprises means for intermixing said moisture-absorbing substance with at least one of said thermoplastic material and said third material to form a blend in which at least a portion of said moisture-absorbing substance is located at the exterior surface of at least one of said thermoplastic material and said third material.

44. The apparatus of claim 41 in which said second and third dispenser means are thermoplastic material die heads which discharge thermoplastic fibers, said means for positioning said moisture-wicking substance at the exterior surface of at least one of said thermoplastic material and said third material comprising a mixer block adapted to connect to a source of air and a source of moisture-wicking substance, said mixer block being formed with a passageway for intermixing and then discharging said air and moisture-wicking substance into said die head for combination with thermoplastic material supplied to said die head, whereby said die head discharges fibers with are a blend of said thermoplastic material and said moisture-wicking substance wherein at least a portion of said moisture-wicking substance is located at the exterior surface of said fibers.

45. The apparatus of claim 41 in which said means for positioning said moisture-wicking substance comprises a first spray gun and a second spray gun each adapted to connect to a source of moisture-wicking substance, said first spray gun discharging said moisture-wicking substance into said chamber in the path of said thermoplastic fibers so that said moisture-wicking substance is applied onto at least a portion of the exterior surface of said thermoplastic fibers, and said second spray gun discharging said moisture-wicking substance in the path of said third material so that said moisture-wicking substance is applied onto at least a portion of the exterior surface of said third material.

46. Apparatus for forming a non-woven pad of fibrous material with a first material, a thermoplastic material and a third material interspersed throughout selected portions of the thickness of said non-woven pad, comprising:

a chamber having an inlet and an outlet;

a conveyor movable between said inlet and said outlet of said chamber, said conveyor having a first side and a second side;

means for introducing fibrous material into said chamber;

vacuum means located on said first side of said conveyor for applying a vacuum in said chamber to draw said fibrous material onto said second side of said conveyor, said fibrous material forming a non-woven pad on said second side of said conveyor which increases in thickness in a direction from said inlet of said chamber toward said outlet thereof, said non-woven pad having a bottom surface resting on said second side of said conveyor and a top surface which slopes upwardly relative to said conveyor from said inlet of said chamber toward said outlet thereof;

first dispenser means for intermixing said first material with a portion of said fibrous material being drawn onto said conveyor at a predetermined location relative to said upwardly sloping top surface of said non-woven pad;

second dispenser means for forming thermoplastic fibers from said thermoplastic material and for dispensing said thermoplastic fibers into said chamber for intermixing with said fibrous material being drawn onto said conveyor at a location upstream from said predetermined location;

means for positioning a moisture-wicking substance at the exterior surface of said thermoplastic material in an effective amount so that said exterior surface of said thermoplastic fibers formed therefrom are capable of wicking moisture;

third dispenser means for intermixing said third material with said fibrous material being drawn onto said conveyor at a location downstream from said predetermined location;

means for positioning a moisture-wicking substance at the exterior surface of said third material in an effective amount so that said exterior surface of said third material is capable of wicking moisture, whereby said non-woven pad is formed with a first layer of intermixed fibrous material and said thermoplastic fibers having moisture-wicking substance at the exterior surface thereof which is drawn onto said conveyor upstream from said predetermined location, a second layer of intermixed fibrous material and said first material which is drawn atop said first layer at said predetermined location, and a third layer of intermixed fibrous material and said third material having moisture-wicking substance at the exterior surface thereof which is drawn atop said second layer downstream from said predetermined location.

47. A method of forming a non-woven pad of fibrous material with a first material and a thermoplastic material interspersed throughout a selected portion of the thickness thereof, comprising:

introducing fibrous material into a chamber;

applying a vacuum to draw said fibrous material onto a pad support moving in a first direction within said chamber, said fibrous material forming a non-woven pad on said pad support which increases in thickness in said first direction of movement of said pad support;

intermixing said first material with a portion of said fibrous material being drawn onto said pad support at a predetermined location within said chamber;

forming thermoplastic fibers from said thermoplastic material in a dispenser means and dispensing said thermoplastic fibers from said dispenser means into said chamber for intermixing with said fibrous material and said first material being drawn onto said pad support at said predetermined location to form a layer of intermixed fibrous material, first material and thermoplastic fibers within a predetermined portion of said thickness of said pad while maintaining another portion of said thickness of said pad substantially free of said first material and said thermoplastic fibers.

48. The method of claim 47 in which said step of applying a vacuum comprises applying a vacuum in said chamber on one side of a conveyor to draw said fibrous material onto the opposite side of said conveyor to form said non-woven pad.

49. A method of forming a non-woven pad of fibrous material with a first material and a thermoplastic material interspersed throughout a predetermined portion of the thickness thereof, comprising:

introducing fibrous material into a chamber;

applying a vacuum to draw said fibrous material onto a pad support moving in a first direction within said chamber, said fibrous material forming a non-woven pad on said pad support which increases in thickness in said first direction of movement of said pad support;

intermittently intermixing said first material with a portion of said fibrous material being drawn onto said pad support at a predetermined location within said chamber;

forming thermoplastic fibers from said thermoplastic material in a dispenser means and intermittently dispensing said thermoplastic fibers from said dispenser means into said chamber for intermixing with said fibrous material and said first material being drawn onto said pad support at said predetermined location to form a layer of intermixed fibrous material, first material and thermoplastic fibers within a predetermined portion of said thickness of said non-woven pad at spaced locations along the length of said non-woven pad while maintaining another portion of said thickness of said non-woven pad substantially free of said first material and said thermoplastic fibers.

50. The method of claim 49 in which said step of applying a vacuum comprises applying a vacuum in said chamber on one side of a conveyor to draw said fibrous material onto the opposite side of said conveyor to form said non-woven pad.

51. A method of forming a non-woven pad of fibrous material with a first material, a thermoplastic material and a third material interspersed throughout selected portions of the thickness thereof, comprising:

introducing fibrous material into a chamber;

applying a vacuum to draw said fibrous material onto a pad support moving in a first direction within said chamber, said fibrous material forming a non-woven pad on said pad support which increases in thickness in said first direction of movement of said pad support;

intermixing said first material with a portion of said fibrous material being drawn onto said pad support at a predetermined location within said chamber;

forming thermoplastic fibers from said thermoplastic material in a dispenser means and dispensing said thermoplastic fibers from said dispenser means into said chamber for intermixing with said fibrous material and said first material being drawn onto said pad support at said predetermined location;

intermixing said third material with said fibrous material, said first material and said thermoplastic fibers being drawn onto said pad support at said predetermined location to form a layer of intermixed fibrous material, first material, thermoplastic fibers and said third material within a predetermined portion of said thickness of said non-woven pad while maintaining another portion of said thickness of said non-woven pad substantially free of said first material, thermoplastic fibers and said third material.

52. The method of claim 51 in which said step of applying a vacuum comprises applying a vacuum in said chamber on one side of a conveyor to draw said fibrous material onto the opposite side of said conveyor to form said non-woven pad.

53. A method of forming a non-woven pad of fibrous material with a first material, a thermoplastic material and a third material interspersed throughout selected portions thereof, comprising:

introducing fibrous material into a chamber;

applying a vacuum to draw said fibrous material onto a pad support moving in a first direction within said chamber, said fibrous material forming a non-woven pad on said pad support which increases in thickness in said first direction of movement of said pad support;

intermixing a first material with a portion of said fibrous material being drawn onto said pad support at a predetermined location within said chamber;

forming thermoplastic fibers from said thermoplastic material in a dispenser means and dispensing said thermoplastic fibers from said dispenser means into said chamber for intermixing with said fibrous material being drawn onto said pad support at a location upstream from said predetermined location;

intermixing said third material with said fibrous material being drawn onto said pad support at a location downstream from said predetermined location, whereby said non-woven pad is formed with a first layer of intermixed fibrous material and thermoplastic fibers which is drawn onto said pad support upstream from said predetermined location, a second layer of intermixed fibrous material and first material which is drawn atop said first layer at said predetermined location, and a third layer of intermixed fibrous material and third material which is drawn atop said second layer downstream from said predetermined location.

54. The method of claim 53 in which said step of applying a vacuum comprises applying a vacuum in said chamber on one side of a conveyor to draw said fibrous material onto the opposite side of said conveyor to form said non-woven pad.

55. A method of forming a non-woven pad of fibrous material with a first material and a thermoplastic material interspersed throughout a selected portion of the thickness thereof, comprising:

introducing fibrous material into a chamber;

applying a vacuum in said chamber to draw said fibrous material onto a conveyor moving through said chamber, said fibrous material forming a non-woven pad having a bottom surface resting on one side of said conveyor and a top surface which slopes upwardly relative to said conveyor from the inlet toward the outlet of said chamber;

dispensing said first material into said chamber at a predetermined location along said upwardly sloping top surface of said non-woven pad, said first material being intermixed with a portion of said fibrous material being drawn onto said conveyor at said predetermined location;

forming thermoplastic fibers from said thermoplastic material in a dispenser means and dispensing said thermoplastic fibers from said dispenser means into said chamber so that said thermoplastic fibers intermix with said fibrous material and said first material being drawn onto said conveyor at said predetermined location to form a layer of intermixed fibrous material, first material and thermoplastic fibers within a predetermined portion of said thickness of said pad while maintaining another portion of said thickness of said pad substantially free of said first and second materials.

56. The method of claim 55 in which said step of dispensing said first material comprises dispensing highly moisture-absorbent material.

57. The method of claim 56 in which said step of forming and dispensing said thermoplastic fibers includes dispensing fibers of thermoplastic material for intermixing with said fibrous material and said highly moisture-absorbent material at said predetermined location to form a layer of intermixed fibrous material, highly moisture-absorbent material and thermoplastic fibers wherein said thermoplastic fibers substantially retain said highly moisture-absorbent material with said layer of said non-woven pad.

58. A method of forming a non-woven pad of fibrous material with a first material and a thermoplastic material interspersed throughout a predetermined portion of the thickness thereof, comprising:

introducing fibrous material into a chamber;

applying a vacuum in said chamber to draw said fibrous material onto a conveyor moving through said chamber, said fibrous material forming a non-woven pad having a bottom surface resting atop said conveyor and a top surface which slopes upwardly relative to said conveyor from the inlet toward the outlet of said chamber;

intermittently dispensing said first material into said chamber at a predetermined location along said upwardly sloping top surface of said non-woven pad, said first material being intermixed with a portion of said fibrous material being drawn onto said conveyor at said predetermined location;

forming thermoplastic fibers from said thermoplastic material in a dispenser means and intermittently dispensing said thermoplastic fibers from said dispenser means into said chamber so that said thermoplastic fibers intermix with said fibrous material and said first material being drawn onto said conveyor at said predetermined location to form a layer of intermixed fibrous material, first material and thermoplastic fibers within a predetermined portion of said thickness of said non-woven pad at spaced locations along the length of said non-woven pad while maintaining another portion of the thickness of said non-woven pad substantially free of said first and second materials.

59. The method of claim 58 in which said step of dispensing said first material comprises dispensing highly moisture-absorbent material.

60. The method of claim 59 in which said step of forming and intermittently dispensing said thermoplastic fibers comprises intermittently dispensing fibers of thermoplastic material for intermixing with said fibrous material and said highly moisture-absorbent material at said predetermined location to form a layer of intermixed fibrous material, highly moisture-absorbent material and thermoplastic fibers at predetermined locations along the length of said non-woven pad wherein said thermoplastic fibers substantially retain said highly moisture-absorbent material within said layer of said non-woven pad.

61. A method of forming a non-woven pad of fibrous material with a first material, a thermoplastic material and a third material interspersed throughout selected portions of the thickness thereof, comprising:

introducing fibrous material into a chamber;

applying a vacuum in said chamber to draw said fibrous material onto a conveyor moving through said chamber between an inlet and outlet thereof, said fibrous material forming a non-woven pad on said conveyor which increases in thickness in a direction from said inlet of said chamber toward said outlet thereof, said non-woven pad having a bottom surface resting on said conveyor and a top surface which slopes upwardly relative to said conveyor from the inlet of said chamber toward said outlet thereof;

dispensing said first material into said chamber at a predetermined location relative to said upwardly sloping top surface of said non-woven pad for intermixing with a portion of said fibrous material being drawn onto said conveyor at said predetermined location;

forming thermoplastic fibers from said thermoplastic material in a dispenser means and dispensing said thermoplastic fibers from said dispenser means into said chamber for intermixing with said fibrous material and said first material being drawn onto said pad support at said predetermined location;

dispensing a third material into said chamber at said predetermined location for intermixing with said fibrous material, said first material and said thermoplastic fibers being drawn onto said conveyor thereat to form a layer of intermixed fibrous material, first material, thermoplastic fibers and third material within a predetermined portion of the thickness of said non-woven pad while maintaining another portion of said thickness of said non-woven pad substantially free of said first material, thermoplastic fibers and third material.

62. The method of claim 61 in which said step of forming and dispensing thermoplastic fibers into said chamber includes forming and dispensing thermoplastic fibers from thermoplastic material having properties which enhance the tear strength of said non-woven pad.

63. The method of claim 61 in which said step of forming and dispensing thermoplastic fibers into said chamber includes forming and dispensing thermoplastic fibers from a thermoplastic material which maintains air spaces within said fibrous material within said intermixed layer so that said non-woven pad has the desired loft.

64. The method of claim 61 in which said step of dispensing said first material into said chamber comprises dispensing a highly moisture-absorbent material for intermixing with said fibrous material within said layer of said non-woven pad.

65. A method of forming a non-woven pad of fibrous material with a first material, a thermoplastic material and a third material interspersed throughout selected portions thereof, comprising:

introducing fibrous material into a chamber;

applying a vacuum in said chamber to draw said fibrous material onto a conveyor moving through said chamber between an inlet and outlet thereof, said fibrous material forming a non-woven pad on said conveyor which increases in thickness in a direction from said inlet of said chamber toward said outlet thereof, said non-woven pad having a bottom surface resting on said conveyor and a top surface which slopes upwardly relative to said conveyor from the inlet of said chamber toward said outlet thereof;

dispensing a first material into said chamber at a predetermined location relative to said upwardly sloping top surface of said non-woven pad for intermixing with a portion of said fibrous material being drawn onto said conveyor at said predetermined location;

forming thermoplastic fibers from said thermoplastic material in a dispenser means and dispensing said thermoplastic fibers from said dispenser means into said chamber for intermixing with said fibrous material being drawn onto said conveyor at said predetermined location;

dispensing a third material into said chamber for intermixing with said fibrous material being drawn onto said conveyor at a location downstream from said predetermined location, whereby said non-woven pad is formed with a first layer of intermixed fibrous material and thermoplastic fibers which is drawn onto said conveyor upstream from said predetermined location, a second layer of intermixed fibrous material and first material which is drawn atop said first layer of said predetermined location, and a third layer of intermixed fibrous material and third material which is drawn atop said second layer downstream from said predetermined location.

66. The method of claim 65 in which said step of dispensing said first material comprises dispensing a highly moisture-absorbent material.

67. The method of claim 65 in which said step of dispensing said third material comprises dispensing thermoplastic fibers formed from a thermoplastic material.

68. A method of forming a non-woven pad of fibrous material with a first material and a thermoplastic material interspersed throughout a selected portion of the thickness thereof, comprising:

introducing fibrous material into a chamber;

applying a vacuum in said chamber to draw said fibrous material onto a conveyor moving through said chamber, said fibrous material forming a non-woven pad having a bottom surface resting on one side of said conveyor and a top surface which slopes upwardly relative to said conveyor from the inlet toward the outlet of said chamber;

dispensing said first material into said chamber at a predetermined location along said upwardly sloping top surface of said non-woven pad, said first material being intermixed with a portion of said fibrous material being drawn onto said conveyor at said predetermined location;

forming thermoplastic fibers from said thermoplastic material in a dispenser means and dispensing said thermoplastic fibers from said dispenser means into said chamber so that said thermoplastic fibers intermix with said fibrous material and said first material being drawn onto said conveyor at said predetermined location;

dispensing a moisture-wicking substance at the exterior surface of said thermoplastic material in an effective amount so that said exterior surfaces of said thermoplastic fibers formed therefrom are capable of wicking moisture, whereby a layer of intermixed fibrous material, first material and thermoplastic fibers having moisture-wicking material at the exterior surface thereof is formed within a predetermined portion of said thickness of said pad while maintaining another portion of said thickness of said pad substantially free of said first material and said thermoplastic fibers.

69. The method of claim 68 in which said step of positioning a moisture-wicking substance comprises applying a moisture-wicking substance onto the exterior surface of said thermoplastic material.

70. The method of claim 68 in which said step of positioning a moisture-wicking substance comprises intermixing said thermoplastic material and said moisture-wicking substance to form a blend in which at least a portion of said moisture-wicking substance is located at the exterior surface of said thermoplastic material.

71. The method of claim 68 in which said step of dispensing said thermoplastic fibers formed from said thermoplastic material comprises dispensing fibers having an exterior surface, said step of positioning a moisture-wicking substance comprises applying the moisture-wicking substance onto said exterior surface of said thermoplastic fibers.

72. The method of claim 68 in which said step of positioning a moisture-wicking substance comprises intermixing said thermoplastic material with said moisture-wicking material to form a blend which is supplied to at least one die head, said blend being discharged from said die head to form said thermoplastic fibers wherein at least a portion of said moisture-wicking substance is located at the exterior surface of said thermoplastic fibers.

73. A method of forming a non-woven pad of fibrous material with a first material, a thermoplastic material and a third material interposed throughout selected portions thereof, comprising:

introducing fibrous material into a chamber;

applying a vacuum in said chamber to draw said fibrous material onto a conveyor moving through said chamber between an inlet and outlet thereof, said fibrous material forming a non-woven pad on said conveyor which increases in thickness in a direction from said inlet of said chamber toward said outlet thereof, said non-woven pad having a bottom surface resting on said conveyor and a top surface which slopes upwardly relative to said conveyor from the inlet of said chamber toward said outlet thereof;

dispensing a first material into said chamber at a predetermined location relative to said upwardly sloping top surface of said non-woven pad for intermixing with a portion of said fibrous material being drawn onto said conveyor at said predetermined location;

forming thermoplastic fibers from said thermoplastic material in a dispenser means and dispensing said thermoplastic fibers from said dispenser means into said chamber for intermixing with said fibrous material being drawn onto said conveyor at a location upstream from said predetermined location;

positioning a moisture-wicking substance at the exterior surface of said thermoplastic material in an effective amount so that the exterior surfaces of said thermoplastic fibers formed from said thermoplastic material are capable of wicking moisture;

dispensing a third material into said chamber for intermixing with said fibrous material being drawn onto said conveyor at a location downstream from said predetermined location;

positioning a moisture-wicking substance at the exterior surface of said third material in an effective amount so that said exterior surface of said third material is capable of wicking moisture, whereby said non-woven pad is formed with a first layer of intermixed fibrous material and thermoplastic fibers having moisture-wicking substance at the exterior surface thereof which is drawn onto said conveyor upstream from said predetermined location, a second layer of intermixed fibrous material and first material which is drawn atop said first layer at said predetermined location, and a third layer of intermixed fibrous material and third material having moisture-wicking substance at the exterior surface thereof which is drawn atop said second layer downstream from said predetermined location.

74. The method of claim 73 in which said step of dispensing said first material comprises dispensing a highly moisture-absorbent material.

75. The method of claim 73 in which said step of dispensing said third material comprises dispensing a thermoplastic material.

76. The method of claim 73 in which said steps of positioning a moisture-wicking substance comprise intermixing said thermoplastic material and said moisture-wicking substance to form a blend in which at least a portion of said moisture-wicking substance is located at the exterior surface of said thermoplastic material, and intermixing said third material and said moisture-wicking substance to form a blend in which at least a portion of said moisture-wicking substance is located at the exterior surface of said third material.

77. The method of claim 73 in which said steps of dispensing said thermoplastic material and said third material each comprises dispensing fibers into said forming chamber having an exterior surface, said steps of positioning a moisture-wicking substance comprising applying the moisture-wicking substance onto said exterior surface of said fibers of thermoplastic material and said third material.

78. The method of claim 73 in which said steps of positioning a moisture-wicking substance comprise:

intermixing said thermoplastic material with said moisture-wicking material to form a blend which is supplied to a first die head, said blend being discharged from said die head to form said thermoplastic fibers wherein at least a portion of said moisture-wicking substance is located at the exterior surface of said thermoplastic fibers; and

intermixing said third material with said moisture-wicking material to form a blend which is supplied to a second die head, said blend being discharged from said die head to form fibers wherein at least a portion of said moisture-wicking substance is located at the exterior surface of said fibers.