Process and apparatus for air forming an article having a plurality of superimposed fibrous layers
First Claim
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1. Apparatus for air forming an article having a plurality of superimposed fibrous layers, said apparatus comprising:
- first and second substantially discrete forming chambers, a foraminous forming surface movable through said first and second forming chambers along a forming path length, a first fiber feed mechanism for introducing a fibrous material into said first forming chamber, a first vacuum source in communication with said first forming chamber for drawing said fibrous material in said first forming chamber onto said forming surface to form a first layer on said forming surface, a first removing and directing mechanism for removing a portion of said first layer and directing the portion removed back into said first forming chamber, a second fiber feed mechanism for introducing a fibrous material into said second forming chamber, and a second vacuum source in communication with said second forming chamber for drawing said fibrous material in said second forming chamber onto said forming surface to form a second layer on said forming surface superimposed on said first layer.
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Abstract
Process and apparatus for air forming an article having a plurality of superimposed fibrous layers. The layers are formed in substantially discrete forming chambers by depositing fibrous material on a forming surface which moves along an arcuate path through the chambers. A first layer is air-formed on the forming surface as the surface moves through the first forming chamber and a second layer is air-formed over the first layer as the surface moves through the second forming chamber.
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Citations
46 Claims
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1. Apparatus for air forming an article having a plurality of superimposed fibrous layers, said apparatus comprising:
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first and second substantially discrete forming chambers, a foraminous forming surface movable through said first and second forming chambers along a forming path length, a first fiber feed mechanism for introducing a fibrous material into said first forming chamber, a first vacuum source in communication with said first forming chamber for drawing said fibrous material in said first forming chamber onto said forming surface to form a first layer on said forming surface, a first removing and directing mechanism for removing a portion of said first layer and directing the portion removed back into said first forming chamber, a second fiber feed mechanism for introducing a fibrous material into said second forming chamber, and a second vacuum source in communication with said second forming chamber for drawing said fibrous material in said second forming chamber onto said forming surface to form a second layer on said forming surface superimposed on said first layer. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23)
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24. A process of forming an article having a plurality of superimposed fibrous layers, said process comprising:
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moving a foraminous forming surface through first and second substantially discrete forming chambers along forming path length, introducing a fibrous material into said first forming chamber, vacuum drawing said fibrous material in said first forming chamber onto said forming surface to form a first layer on said forming surface, removing a portion of said first layer and directing the portion removed back into said first forming chamber, introducing a fibrous material into said second forming chamber, and vacuum drawing said fibrous material in said second forming chamber onto said forming surface to form a second layer on said forming surface superimposed on said first layer. - View Dependent Claims (25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45)
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46. A process of forming an article having a plurality of superimposed fibrous layers, said process comprising:
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moving a foraminous forming surface through first and second substantially discrete forming chambers along an arcuate forming path length, said forming surface having a plurality of foraminous areas spaced at intervals along the forming surface, each foraminous area having a first section for collecting fibrous material to a first depth and a second section for collecting fibrous material to a second depth greater than said first depth, introducing a fibrous material into said first forming chamber, vacuum drawing said fibrous materiai in said first forming chamber onto said forming surface to form a first layer on said first and second sections of said forming areas, introducing a fibrous material into said second forming chamber, and vacuum drawing said fibrous material in said second forming chamber onto said forming surface to form a second layer on said first and sections of said forming areas superimposed on said first layer.
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Specification