Process for producing a blanket, and system for producing blankets

Description

/ 47 PROCESS FOR PRODUCING A BLANKET, AND SYSTEM FOR PRODUCING BLANKETS CROSS-REFERENCE TO RELATED ORDERS

[001] This application relates to and has priority rights to U.S. Provisional Patent Application No. 63 / 492,099, filed March 24, 2023, which is incorporated by reference in its entirety for all purposes. FUNDAMENTALS

[002] Many tissue paper products, such as facial tissues, toilet paper, paper towels, industrial cleaners and the like, are produced according to a wet-deposition process. Wet-deposited webs are made by depositing an aqueous suspension of cellulosic fibers onto a forming fabric and then removing the water from the newly formed web.

[003] To improve various characteristics of fabric blankets, they have also been formed according to a foam-forming process. During the foam-forming process, a suspension of foam fibers is created and spread on a moving porous conveyor belt to produce an embryonic blanket. Foam-formed blankets can demonstrate improvements in volume, elasticity, thickness, and / or absorption.

[004] In addition to fabric blankets, foaming can be used to make all different types of blankets and products. For example, relatively long fibers and synthetic fibers can be incorporated into blankets using a foaming process. In this way, foaming processes can be more versatile than many wet application processes.

[005] However, in the past, there have been problems controlling the formation of mats in a foaming process. For example, foam suspensions containing fibers are three-phase mixtures containing Petition 870250086500, dated 09 / 24 / 2025, page 12 / 74 / 47 solids, gases, and liquids. Gases represent compressible portions, while liquids are relatively incompressible. Thus, foam suspensions are subject to volume changes when pressure or temperature changes occur. Furthermore, these suspensions function as non-Newtonian fluids and are subject to viscosity changes as the shear rate changes. Due to at least these characteristics of foam suspensions, it can be difficult to control the behavior of the foam suspension fed onto a porous forming surface during mat formation. Additionally, excessive or insufficient drainage of fluids from a mat formed by a foam suspension can subject the mat to shear forces that cause defects and irregularities in the mat. These problems can be exacerbated when attempting to form multilayer structures.

[006] Therefore, there is currently a need for a system and process for producing foam-formed mats that allows for better control over mat formation, as the process is subject to natural variability under process conditions, which will significantly affect fluid behavior. Furthermore, there is also a need for a system and process for producing multilayer foam mats, where the process and system allow for control of the resulting mat formation and layer mixing. SUMMARY

[007] In general, the present disclosure is directed to an improved process and system for forming mats from a foamed fiber suspension. More particularly, the process and system of the present disclosure have been specifically designed to better control mat formation. In general, the system and method of the present disclosure are directed to controlling the supply flow of a foamed fiber suspension to an inlet box in combination with the control Petition 870250086500, dated 09 / 24 / 2025, page 13 / 74 / 47 of the drainage flow through a formation surface. During the process, the drainage flow from one or more formation zones is controlled based on the inlet flow rate and / or pressure for each formation zone. In this way, possible harmful effects caused by suction force on the embryonic mat and foam stock can be minimized.

[008] In one aspect, a two-phase fluid, such as a foam, is fed into a formation zone. Temperature, pressure, density, and / or volumetric flow rate are monitored upstream of the formation zone. Temperature, pressure, density, and / or volumetric flow rate are also monitored in the formation zone or downstream of the formation zone. Changes in temperature or pressure, for example, can affect the density / mass flow rate of the foam. By determining the drainage flow rate, physical changes in the two-phase fluid (e.g., density) can be calculated and accounted for. In this way, drainage flow rates can be adjusted to match the flow rates fed into the formation zone to facilitate mat formation.

[009] Through the process of the present disclosure, blankets can be produced with improved properties and characteristics. For example, blankets made according to the present disclosure can exhibit improved physical properties, including tensile strength properties and, particularly, more uniform strength properties when comparing the properties of the blankets in the machine direction relative to the transverse direction.

[0010] In one embodiment, the present disclosure relates to a process for producing a mat. The process includes the flow of a foamy suspension of materials, such as fibers, into one or more adjacent training zones. One or more training zones include at least one first training zone. The foamy suspension is fed into Petition 870250086500, dated 24 / 09 / 2025, p. 14 / 74 / 47 each formation zone independent of the other formation zones. The foamed suspension is fed to the first formation zone at an initial flow rate. The foamed suspension of materials fed into the first formation zone is deposited on a moving porous formation surface to form an embryonic mat. Excess fluids are drained through the porous formation surface to one or more drainage devices. Each formation zone includes a corresponding drainage device positioned in alignment with each formation zone along the porous formation surface. One or more drainage devices include at least one first drainage device positioned opposite the first formation zone along the porous formation surface.The flow rate of drainage fluids is controlled through each drainage device based on and in relation to at least one characteristic of the flow of the frothed material suspension being fed to the first forming zone. In one aspect, the flow rate of drainage fluids drained through the first drainage device is controlled based on and in relation to the first flow rate of the frothed material suspension being fed to the first forming zone.

[0011] In one embodiment, the process further includes the step of flowing the foamed suspension of materials to a second formation zone positioned adjacent to the first formation zone. The foamed suspension of materials can be fed to the second formation zone at a second flow rate. The foamed suspension of materials fed into the second formation zone is deposited on the moving formation surface and on the materials deposited on the moving formation surface of the first formation zone to form a multilayer mat. The flow rate of the drainage fluids drained through a second drainage device positioned opposite the second formation surface is controlled.

[0012] Similarly, the process may also include the step of Petition 870250086500, dated 24 / 09 / 2025, p. 15 / 74 / 47, to flow the foamed suspension of materials to a third formation zone positioned adjacent to the second formation zone. The foamed suspension of materials is fed to the third formation zone at a third flow rate. The foamed suspension of materials is deposited on the mobile formation surface in the third formation zone over the materials deposited on the formation surface of the first and second formation zones. According to this disclosure, the flow rate of drainage fluids through a third drainage device positioned opposite the third formation zone can be controlled based on the calculated third flow rate. In this way, a three-layer mat can be formed with controlled properties and, optionally, with fiber mixing between adjacent layers.

[0013] Optionally, the drainage flow rate can be controlled so that the foamy suspension of materials being fed to the first formation zone can flow longitudinally out of a perimeter of the first formation zone to improve the formation of the embryonic mat in certain embodiments. The drainage flow rate through the second drainage device and through the third drainage device can also be controlled so that the foamy suspension of materials being fed to the second formation zone is forced to flow longitudinally out of a perimeter of the second formation zone and that the foamy suspension of materials being fed to the third formation zone is forced to flow longitudinally out of a perimeter of the third formation zone.

[0014] The embryonic membrane is then dried to form a fibrous product.

[0015] In one aspect, the process may also include the step of flowing a fluid into a sealing zone. The sealing zone may be positioned adjacent to and upstream of the first formation zone. The fluid Petition 870250086500, dated 09 / 24 / 2025, p. 16 / 74 / 47, which is being fed into the sealing zone, may be emitted onto the surface of the mobile, porous formation to inhibit airflow in the longitudinal upstream direction. The fluid fed into the sealing zone, in one aspect, may be non-fibrous and may comprise a liquid, such as water, or may comprise a foamed fluid.

[0016] Fluids can also be aspirated through the embryonic blanket into a suction zone adjacent to and downstream of one or more formation zones. The drainage flow rates of the foamy suspension of materials being drained through one or more formation zones can enter the suction zone. In one aspect, the drainage flow rate of the foamy suspension of materials being drained through one or more drainage devices can be controlled so that excess fluid from one or more formation zones enters the suction zone to control the liquid-air mixture that is collected by the suction zone.

[0017] In one embodiment, the process is operated so that the fluid flow rate through the first drainage device is less than the first flow rate of the foamed material slurry being fed into the first formation zone. Similarly, the fluid flow rate through the second drainage device and / or the third drainage device may also be less than the flow rate of the foamed material slurry being fed into the corresponding formation zone.

[0018] In one aspect, the foamy suspension of materials can be pumped to each or more forming zones individually, so that the fluid pressure within each supply line to each forming zone can be controlled independently of the other forming zones. In one aspect, for example, the foamy suspension of materials is pumped to the first forming zone at a first pressure, and the flow rate of drainage fluids drained through the first drainage device is controlled based on the first pressure. The flow rate Petition 870250086500, dated 09 / 24 / 2025, page 17 / 74 / 47 of drainage fluids drained through the first drainage device can be monitored by a flow meter and a pressure monitoring device downstream of the formation surface. The flow meter and pressure monitoring device can send information to a controller that calculates a discharge flow rate at a reference pressure or flow rate. The controller, which can be any suitable microprocessor or programmable device, can be in communication with an adjustable flow control device to control the flow rate of drainage fluids drained through the first drainage device based on the calculated discharge flow rate. The flow control device, for example, can be an adjustable valve.

[0019] In one embodiment, the moving forming surface is operated at an angle relative to the horizontal. For example, the forming surface may be at an angle greater than about 10°, such as greater than about 20°, and generally less than about 60°, such as less than about 50°, relative to the horizontal.

[0020] Blankets can be made with high-volume or low-volume characteristics. Blankets, for example, can have a volume greater than about 3 cm3 / g, such as greater than about 5 cm3 / g, such as greater than about 7 cm3 / g, such as greater than about 9 cm3 / g, such as greater than about 11 cm3 / g, such as greater than 14 cm3 / g and generally less than about 20 cm3 / g. Alternatively, blankets can have a volume less than about 3 cm3 / g, such as less than about 1 cm3 / g, such as less than about 0.5 cm3 / g, such as less than about 0.08 cm3 / g and generally greater than about 0.03 cm3 / g.

[0021] Blankets made in accordance with this disclosure may have all different basis weights. For example, the basis weight may be from about 6 g / m2 to about 800 g / m2, as well as from about 10 g / m2 to about 200 g / m2, as well as from about 20 g / m2 to about 120 g / m2. The blankets Petition 870250086500, dated 09 / 24 / 2025, page 18 / 74 / 47, may be made exclusively of cellulose materials or may be made of cellulose materials mixed with other materials, such as synthetic fibers and / or particles or superabsorbent materials. Synthetic fibers, for example, may be present in the blanket in an amount greater than about 5% by weight, such as in an amount greater than about 15% by weight, such as in an amount greater than about 20% by weight, such as in an amount greater than about 25% by weight, and in an amount up to 100% by weight. Synthetic fibers may comprise polymeric fibers, such as polyester fibers. Alternatively, synthetic fibers may comprise regenerated cellulose fibers, such as rayon fibers, viscose fibers, and the like.

[0022] The foamed suspension of materials can be formed according to the present disclosure by combining a foam with a fiber coating. The foam can have a density of about 200 g / L to about 600 g / L, as well as about 350 g / L to about 600 g / L. The foamed suspension can be formed by combining a foaming agent with water. The foamed fiber suspension can contain from about 40% to about 80% by volume of air, as well as from about 40% to about 65% by volume of air.

[0023] This disclosure also applies to a system for producing mats. The system may include a plurality of adjacent forming zones positioned along a porous forming surface. Each forming zone may be in communication with a separate foamed fiber supply line. Each foamed fiber supply line may include a pumping device for pumping a foamed suspension of materials to a respective forming zone. Each foamed fiber supply line may further include a flow meter, a pressure monitoring device, a temperature monitoring device and / or a monitoring device. Petition 870250086500, dated 09 / 24 / 2025, page 19 / 74 / 47 density. Each foamed fiber supply line feeds a foamed suspension of materials to a corresponding forming zone to deposit the materials contained in the foamed suspension onto the porous forming surface at a determined flow rate (e.g., volumetric or mass flow rate) that can be calculated by a controller from receiving upstream flow rate, temperature, pressure, and / or density information.

[0024] The system further includes a plurality of adjacent drainage devices positioned along the porous formation surface opposite the plurality of adjacent formation zones. For each formation zone, there is a corresponding drainage device positioned aligned on an opposite side of the porous formation surface. Each drainage device is in fluid communication with a corresponding drainage line. Each drainage line includes a flow control device to control the flow rate of a fluid being drained from each corresponding drainage device. Each drainage line may also include a flow meter, a temperature monitoring device, a density monitoring device, a pressure monitoring device, or combinations thereof. One or more controllers are placed in communication with each of the flow control devices associated with the drainage lines.One or more controllers are configured to control the flow rate of fluids being drained from the drainage device in relation to the flow rate or pressure of the foamed material suspension being fed to each of the formation zones. For example, one or more controllers may be configured to control the flow rate of fluids drained from each drainage device based on information received from the corresponding pressure monitoring devices associated with each formation zone. The system of this disclosure can be used to produce single-layer mats or... Petition 870250086500, dated 09 / 24 / 2025, page 20 / 74 / 47 multilayer blankets.

[0025] In one embodiment, the system may also include a drying device positioned downstream of the formation zones to dry a mat formed on the porous formation surface.

[0026] In one embodiment, the system may further include a separator tank in fluid communication with each of the drainage lines to receive drainage fluid from each drainage device. The separator tank may separate free gases from the foam and may be configured to recycle the foam, producing larger quantities of foamed material suspension. In another embodiment, the system may further include a suction zone adjacent to and downstream of the plurality of formation zones to draw air through mats formed on the formation surface. The flow rate of fluids drained from each drainage device may be controlled by one or more controllers so that the suction zone collects a mixture of liquid and air from a mat that is being formed. The liquid and air mixture collected from the suction zone may also be fed to the separator tank.

[0027] Other features and aspects of this publication are discussed in more detail below. BRIEF DESCRIPTION OF THE FIGURES

[0028] A full and informative disclosure of this disclosure is set out, more particularly, in the remainder of the descriptive report, including reference to the attached figures, in which: Figure 1 is a schematic diagram of one embodiment of a process according to the present disclosure for forming mats from a foamy suspension of materials; Figure 2 is a schematic diagram of a system and process for depositing a foamy suspension of materials onto a forming surface according to the present disclosure; Petition 870250086500, dated 09 / 24 / 2025, p. 21 / 74 / 47 Figure 3 is another embodiment of a schematic diagram (partial view) of a system and process for depositing a foamy suspension of materials onto a forming surface according to the present disclosure; Figure 4 is another embodiment of a schematic diagram of a system and process for depositing a foamy suspension of materials onto a forming surface according to the present disclosure; Figure 5 is another embodiment of a schematic diagram of a system and process for depositing a foamy suspension of materials onto a forming surface according to the present disclosure; and Figure 6 is a cross-sectional view of a type of training zone that can be incorporated into the process and system of this disclosure.

[0029] The repeated use of reference characters in this descriptive report and in the drawings is intended to represent features or elements that are the same as, or analogous to, the present invention. DEFINITIONS

[0030] As used in this document, the term foam-formed product means a product formed from a suspension including a mixture of a solid, a liquid and dispersed gas bubbles.

[0031] As used in this document, the term foaming process means a process for manufacturing a product involving a suspension including a mixture of a solid, a liquid and dispersed gas bubbles.

[0032] As used in this document, the term foaming fluid means any one or more known fluids compatible with the other components in the foaming process. Foaming fluids Petition 870250086500, dated 09 / 24 / 2025, page 22 / 74 / 47 suitable include, but are not limited to, water.

[0033] As used herein, the term “foam half-life” means the time elapsed until half of the initial mass of the foam reverts to liquid water.

[0034] As used herein, the term “layer” refers to a structure that provides an area of ​​a substrate in a height direction of the substrate that is composed of similar components and structure.

[0035] As used herein, the term nonwoven blanket refers to a blanket with a structure of individual fibers or segments that are interposed, but not in a manner identifiable as an interwoven fabric.

[0036] As used in this document, unless expressly stated otherwise, when used in relation to material compositions, the terms percentage, %, weight percentage or percent by weight refer to the amount by weight of a component as a percentage of the total, except as expressly stated otherwise.

[0037] The term “absorbent personal hygiene article” refers here to an article intended and / or adapted to be placed against or close to (i.e., contiguous to) the user’s body to absorb and contain various liquid, solid and semi-solid exudates discharged from the body. Examples include, but are not limited to, diapers, pull-up diapers, training diapers, diapers for grown children, swim trunks, feminine hygiene products, including, but not limited to, menstrual pads or panties, incontinence products, medical gowns, surgical compresses and dressings, and so forth.

[0038] The term superabsorbent material, as used in this document, refers to water-insoluble and water-intumescent organic or inorganic materials, including superabsorbent polymers and compositions of superabsorbent polymers capable, under the most extreme conditions Petition 870250086500, dated 09 / 24 / 2025, p. 23 / 74 / 47 favorable, to absorb at least about 10 times its weight, or at least about 15 times its weight, or at least about 25 times its weight in an aqueous solution containing 0.9 percent by weight of sodium chloride.

[0039] The term machine direction, as used in this document, refers to the direction of movement of the forming surface on which the fibers are deposited during the formation of a nonwoven blanket.

[0040] The term direction opposite to the machine, as used here, refers to the direction perpendicular to the machine direction defined above.

[0041] The term pulp, as used herein, refers to fibers from natural sources, such as woody and non-woody plants. Woody plants include, for example, deciduous and coniferous plants. Non-woody plants include, for example, cotton, flax, esparto grass, sow thistle, straw, jute, hemp, and bagasse. Cellulose fibers may include hardwood fibers, softwood fibers, and mixtures thereof.

[0042] The term average fiber length, as used in this document, refers to an average length of fibers, fiber bundles, and / or fiber-like materials determined by measurement using microscopic techniques. A sample of at least 20 randomly selected fibers is separated from a liquid fiber suspension. The fibers are placed on a microscope slide prepared to suspend fibers in water. A dyeing agent is added to the suspended fibers to color the cellulose-containing fibers so that they can be distinguished from or separated from synthetic fibers. The slide is placed under a Fisher Stereomaster II microscope - Series S19642 / S19643. Measurements of 20 fibers in the sample are made at 20X linear magnification using a 0-20 mil scale, and an average length, minimum and maximum length, and a deviation or coefficient of variation are calculated.In some cases, the average fiber length will be calculated as a weighted average length of the fibers. Petition 870250086500, dated 24 / 09 / 2025, page 24 / 74 / 47 fibers (e.g., fibers, fiber bundles, fiber-like materials) determined by equipment such as, for example, a Kajaani Model No. FS-200 fiber analyzer, available from Kajaani Oy Electronics, Kajaani, Finland. According to a standard test procedure, a sample is treated with a macerating liquid to ensure that there are no fiber bundles or splinters. Each sample is disintegrated in hot water and diluted to a suspension of approximately 0.001%. Individual test samples are taken in portions of approximately 50 to 100 ml from the diluted suspension when tested using the standard Kajaani fiber analysis test procedure. The weighted average fiber length can be an arithmetic mean, a length-weighted average, or a weight-weighted average and can be expressed by the following equation: where k = maximum fiber length xi = fiber length ni = number of fibers with length xi n = total number of fibers measured.

[0043] A characteristic of the average fiber length data measured by the Kajaani fiber analyzer is that it does not discriminate between different fiber types. Thus, the average length represents an average based on the lengths of all the different types, if any, of fibers in the sample.

[0044] As used in this document, the term staple fibers means staple fibers made from synthetic polymers, such as polypropylene, polyester, post-consumer recycled (PCR) fibers, polyester, nylon and the like, and those that are not hydrophilic can be treated Petition 870250086500, dated 09 / 24 / 2025, page 25 / 74 / 47 as hydrophilic. Staple fibers can be staple fibers or similar. Staple fibers can have round, bicomponent, multicomponent, molded, hollow or similar cross-sections. DETAILED DESCRIPTION

[0045] It must be understood by those skilled in the art that the present discussion is a description of exemplary embodiments only and is not intended to limit the broader aspects of the present disclosure.

[0046] In general, the present disclosure relates to a system and process for forming mats, particularly nonwoven mats, including woven mats, absorbent cores, synthetic fiber mats and the like. According to the present disclosure, the mats are formed from a foamed fiber suspension. According to the present disclosure, both the supply flow and the drainage flow of a foamed fiber suspension being deposited on a porous forming surface are controlled. For example, the mat manufacturing system of the present disclosure includes at least one discrete forming zone positioned adjacent to the forming surface that receives a flow of a foamed fiber suspension. The inlet pressure and / or inlet flow rate of the foamed fiber suspension in at least one discrete forming zone is coordinated with the drainage flow through the porous forming surface to control mat formation.When producing multilayer blankets, the process and system can result in the mixing of layers to create multilayer blankets with enhanced physical properties.

[0047] In one aspect, a supply of a foamy fiber suspension is fed into an inlet box where at least one discrete formation zone is located, and the drainage flow from the inlet box can be converted into pressure to optimize sheet formation. Through the process and system of the present disclosure, the sheet formation conditions are controlled to prevent underdrainage and / or Petition 870250086500, dated 09 / 24 / 2025, page 26 / 74 / 47 overdrainage during changes in process conditions and raw material inputs. In one embodiment, the drainage flow from the porous formation surface is controlled with adjustable flow control devices such as valves and / or pumps, which in turn are controlled by a volumetric flow meter and / or a pressure transmitter and / or a temperature monitoring device. The use of a combination of flow meter, pressure transmitter and / or temperature monitoring device allows a fully quantified two-phase discharge flow profile that can then be converted into a reference value. In this way, the adjustable flow meter device can be controlled to achieve a discharge flow calculated at the reference value.

[0048] In one aspect, the process and system can be used to produce multilayer mats that include a plurality of discrete mat-forming zones that can be positioned adjacent to each other along the porous forming surface. When forming the multilayer mat, the drainage flow rate in each of the discrete forming zones can be controlled to produce mats with stable sheet formation and enhanced structure and interface stability.

[0049] The system and process of the present disclosure can provide several advantages and benefits. For example, during the process, the fiber orientation can be controlled. Consequently, the system and process of the present disclosure can also be used to produce mats with customized properties for a specific end-use application. For example, through the process of the present disclosure, it is possible to form mats with improved elasticity properties, improved absorption characteristics, greater volume if desired, greater thickness if desired, and / or greater basis weight. Furthermore, a combination of different properties can be enhanced and improved.

[0050] In addition to the above, the system and process of the present Petition 870250086500, dated 09 / 24 / 2025, page 27 / 74 / 47 disclosure minimizes any harmful effects that may occur due to the application of vacuum or suction force on the foamed fiber suspension or embryonic mat being formed. Overall, aligning the inlet pressure and drainage flow in various formation zones can achieve stable layer formation.

[0051] As described above, the process and system of this disclosure are particularly suitable for use in foaming processes for the production of fibrous mats. There are many advantages and benefits to a foaming process as described above. During a foaming process, water is replaced by foam as the carrier for the fibers that form the mat. The foam, which represents a large amount of air, is mixed with fibers and, optionally, other materials such as superabsorbent materials. Because less water is used to form the mat, less energy is required to dry the mat.

[0052] Although foaming processes and systems can offer several advantages, controlling the foam suspension during the mat production process is problematic. Foam suspensions, for example, are two-phase systems that include a compressible gas phase and a substantially incompressible liquid phase. Because foam suspensions are non-Newtonian, the density and viscosity of the foam change based on location and process. According to the present disclosure, several parameters of the foamed suspension are monitored or calculated during the process to determine the characteristics of the foamed suspension as it is deposited onto a forming surface and as fluids are drained from the forming surface. For example, the foamed suspension being fed onto the forming surface can be monitored for flow rate, such as volumetric flow rate, pressure, temperature, and / or density, which can be measured or Petition 870250086500, dated 09 / 24 / 2025, page 28 / 74 / 47 calculated. Knowing at least some of the above parameters allows for the calculation of changes in density and volumetric flow rate of the foam as the foamed suspension is fed through an inlet box and deposited onto a forming surface. According to this disclosure, all or some of the above parameters can also be determined on the drainage side of the forming surface. In this way, the fluid drainage rate across the forming surface can be calculated and controlled based on the flow rate of the foamed suspension onto the forming surface, to control and optimize the formation of a mat with uniform properties.In particular, monitoring parameters of the foam that goes to the forming surface and is drained from the forming surface can be used to prevent insufficient or excessive drainage of the mat at the forming surface, in order to produce mats without interruptions, imperfections, or other irregularities in the fiber mat that may be caused by unbalanced shear forces exerted on the mat.

[0053] Referring to FIGS. 1 and 2, an embodiment of a system and process according to the present disclosure are shown. In general, during the process, solid material, such as fibers and / or superabsorbent particles, water, and a foaming agent are added to a tank and mixed until the desired air content, bubble size / foam stability, and solid dispersion are achieved, such as a fiber dispersion. The fiber-containing foam can then be optionally diluted during the process, especially when a recycling stream is present. In one aspect, the air content of the foamed suspension is between about 30% and about 65%. As will be described below, the process and system of the present disclosure are particularly directed to measuring certain parameters of the foamed suspension in-line in order to calculate the volumetric flow rate, air content, basis weight, and / or the Petition 870250086500, dated 09 / 24 / 2025, page 29 / 74 / 47 speed of the foamed suspension on the forming surface. Under the moving forming surface there is one or more drainage devices that can apply vacuum to the mat while it is being formed and that pull excess foam through the forming surface to control sheet formation. In the drainage lines positioned downstream of the forming surface, several parameters of the drained foam are also measured to calculate a volumetric flow rate of the foam being drained from the surface. The volumetric flow rate of the foam drained from the forming surface is then controlled and adjusted based on the volumetric flow rate of the foamed suspension fed onto the forming surface to carefully control the properties of the nonwoven mat being formed. The process and system of the present disclosure are suitable not only for producing single-layer mats but also for producing multi-layer mats.When producing multilayer blankets, shear forces can be controlled and / or minimized to improve the boundaries between layers.

[0054] FIG. 1 illustrates a system and process for producing a foamed fiber suspension and for forming mats from the foamed fiber suspension. It should be understood that any suitable mat-forming system may be used in accordance with the present disclosure and FIG. 1 is provided for exemplary purposes only. As shown in FIG. 1, the system may include a mixing tank 12 which is used to form the foamed fiber suspension. The foamed fiber suspension is then fed into a mat-forming system 10 or headbox which deposits the foamed fiber suspension onto a porous forming surface 26 to form a mat 14.According to this disclosure, the mat or inlet box formation system 10 includes one or more adjacent formation zones in combination with one or more drainage devices and corresponding drainage lines to control and coordinate the influx of aqueous fiber suspension with the drainage flow through the. Petition 870250086500, dated 09 / 24 / 2025, p. 30 / 74 20 / 47 forming surface 26 to control blanket formation. The blanket formation system 10 is more particularly illustrated in FIG. 2.

[0055] In an alternative embodiment, the system for producing the mat may be a double yarn forming system. In a double yarn former, two yarns form loops respectively, and as they travel with the compressed material between them, fluids are removed by means of drainage devices, thus gradually a fiber mat grows and a blanket is formed. The double yarn former is characterized by eliminating a free stock surface as shown in FIG. 1, faster running speeds may be possible.

[0056] Referring to FIG. 3, a partial view of an embodiment of a double yarn forming system is shown. One or more layers of independent forming zones of a foamed fiber suspension are ejected from a head box 210 between two forming surfaces 226 and 228 to form a mat 214. The two forming surfaces may be guided by a forming roller and a chest roller, respectively. The formed mat 214 travels along an approximate curved line on a plurality of shoe blades spaced apart from each other on the side of the forming surface 226.

[0057] The foamy fiber suspension can be subjected to dewatering at an equal rate almost simultaneously through both formation surfaces 226 and 228. For example, as will be described in more detail below in relation to FIG. 2, drainage devices with controls to manage drainage rates can be positioned adjacent to formation surface 226 and adjacent to formation surface 228.

[0058] Returning to FIG. 1, the mixing tank 12 is in communication with a water supply 22 to feed the tank with water and a foaming agent or surfactant supply 24 to feed Petition 870250086500, dated 09 / 24 / 2025, p. 31 / 74 / 47 a surfactant to tank 12. A supply of fiber is fed to tank 12 and combined with water and surfactant. The aqueous solution formed by the combination of surfactant and water can be agitated and transformed into foam to form a foamy suspension of fibers. As described above, in addition to fibers, various other materials can be combined in tank 12. These other materials, for example, may include superabsorbent particles or similar.

[0059] The surfactant or foaming agent, for example, may comprise any suitable surfactant. In one embodiment, for example, the foaming agent may comprise sodium lauryl sulfate, which is also known as sodium laureth sulfate or sodium lauryl ether sulfate. Other foaming agents include sodium dodecyl sulfate or ammonium lauryl sulfate. In other embodiments, the foaming agent may comprise any suitable cationic and / or amphoteric surfactant. For example, other foaming agents include fatty acid amines, amides, amine oxides, quaternary fatty acid compounds and the like.

[0060] In one embodiment, a nonionic surfactant is used. The nonionic surfactant, for example, may comprise an alkyl polyglycoside. In one aspect, for example, the surfactant may be a C8 alkyl polyglycoside, a C10 alkyl polyglycoside, or a mixture of C8 and C10 alkyl polyglycosides.

[0061] The foaming agent is combined with water generally in an amount greater than about 0.1% by weight, such as in an amount greater than about 0.5% by weight, such as in an amount greater than about 0.7% by weight. One or more foaming agents are generally present in an amount of about 0.01% by weight to about 5% by weight, such as in an amount up to about 2% by weight.

[0062] Once the foaming agent and water are combined, the mixture is Petition 870250086500, dated 09 / 24 / 2025, page 32 / 74 / 47 combined or otherwise subjected to forces capable of forming a foam. A foam generally refers to an aggregate of hollow cells or bubbles.

[0063] The density of the foam may vary depending on the particular application and several factors, including the fiber used. In one embodiment, for example, the density of the foam may be greater than about 200 g / L, as greater than about 250 g / L, as greater than about 300 g / L. The density of the foam is generally less than about 600 g / L, as less than about 500 g / L, as less than about 400 g / L, as less than about 350 g / L. In another embodiment, for example, a lower density foam is used, with a foam density generally less than about 350 g / L, as less than about 340 g / L, as less than about 330 g / L. The foam will generally have an air content greater than about 40%, as greater than about 50%, as greater than about 60% (at standard temperature and pressure (TPP)). The air content is generally less than about 75% by volume, as well as less than about 70% by volume, and also less than about 65% by volume.

[0064] The foam can be formed in the presence of a fiber supply or, alternatively, the foam can first be formed and then combined with a fiber supply. In general, any fibers capable of forming a base sheet, such as a woven mat or other similar type of nonwoven, according to the present disclosure, can be used.

[0065] Fibers suitable for making blankets comprise any natural or synthetic cellulosic fibers, including, but not limited to, non-woody fibers such as cotton, abaca, kenaf, sabai grass, flax, sparta grass, straw, hemp-jute, bagasse, milkweed fibers and pineapple leaf fibers; and woody or cellulose fibers such as those obtained from deciduous and coniferous trees, including softwood fibers such as northern and southern softwood kraft fibers; hardwood fibers such as Petition 870250086500, dated 09 / 24 / 2025, page 33 / 74 / 47 eucalyptus, maple, birch and poplar. Pulp fibers can be prepared in high-yield or low-yield forms and can be pulped by any known method, including kraft, sulfite, high-yield pulping methods and other known pulping methods. Fibers prepared from organosolv pulping methods can also be used.

[0066] A portion of the fibers, such as up to 100% or less by dry weight, or from about 5% to about 30% by dry weight, may be synthetic fibers, such as rayon, polyolefin fibers, polyester fibers, two-component coating-core fibers, multicomponent binder fibers, and the like. The fibers may be virgin fibers or recycled fibers. The fibers may be staple fibers and may have an average length of about 3 mm to about 150 mm. An exemplary polyethylene fiber is Fybrel®, marketed by Minifibers, Inc. (Jackson City, Tenn.). By containing synthetic polymer fibers, the blanket may be thermally bonded where the fibers cross.

[0067] Synthetic cellulose fiber types include rayon in all its varieties and other fibers derived from viscose or chemically modified cellulose. Chemically treated natural cellulosic fibers can also be used, such as mercerized cellulose, chemically hardened or cross-linked fibers, or sulfonated fibers. To obtain good mechanical properties of fibers for papermaking, it is desirable that the fibers be relatively undamaged, largely unrefined, or only slightly refined. Although recycled fibers can be used, virgin fibers are generally useful for their ideal mechanical properties and absence of contaminants. Mercerized fibers, regenerated cellulose fibers, cellulose produced by microbes, rayon, and other cellulosic or cellulose-derived materials can be used. Fibers for suitable papermaking can also include recycled fibers, virgin fibers, or blends thereof.In some modalities capable of. Petition 870250086500, dated 09 / 24 / 2025, page 34 / 74 / 47, due to high density and good compression properties, the fibers may have a Canadian Drying Standard of at least 200, more specifically at least 300, even more specifically at least 400, and more specifically at least 500.

[0068] Other papermaking fibers that may be used in this publication include mill waste from paper mills, recycled fibers, and high-yield fibers. High-yield cellulose fibers are papermaking fibers produced by cellulose processes that provide a yield of about 65% or greater, more specifically about 75% or greater, and even more specifically from about 75% to about 95%. The term yield is the resulting amount of processed fibers expressed as a percentage of the initial wood mass. Such pulping processes include bleached thermo-chemical-mechanical pulp (BCTMP), thermo-chemical-mechanical pulp (CTMP), thermomechanical press / pressure pulp (PTMP), thermomechanical pulp (TMP), thermomechanical chemical pulp (TMCP), high-yield sulfite pulps, and high-yield Kraft pulps, which leave the resulting fibers with high levels of lignin.High-yield fibers are well known for their stiffness in both dry and wet states compared to typical chemically reduced cellulose fibers.

[0069] The mat can also be formed without a substantial amount of bonding strength between internal fibers. In this respect, the fiber assortment used to form the base web can be treated with a debonding agent. The debonding agent can be added to the foamed fiber suspension during the pulp production process or can be added directly to the headbox. Suitable debonding agents that can be used in this publication include cationic debonding agents such as fatty quaternary dialkylamine salts, monofatty alkyl tertiary amine salts, primary amine salts, salts Petition 870250086500, dated 09 / 24 / 2025, page 35 / 74 / 47 imidazoline quaternaries, silicone, quaternary alkyl salt and unsaturated fatty alkylamine salts. Other suitable debonding agents are disclosed in Patent No. 5,529,665 to Kaun, incorporated herein by reference. In particular, Kaun discloses the use of various cationic silicone compositions as debonding agents.

[0070] In one embodiment, the debonding agent used in the process of the present disclosure is an organic quaternary ammonium chloride and, in particular, a silicone-based amine salt of a quaternary ammonium chloride. For example, the debonding agent may be PROSOFT.RTM.TQ1003, marketed by Hercules Corporation. The debonding agent may be added to the fiber pulp in an amount of about 1 kg per metric ton to about 10 kg per metric ton of fiber present in the pulp.

[0071] In an alternative embodiment, the take-off agent may be an imidazoline-based agent. Imidazoline-based take-off agents may be obtained, for example, from Witco Corporation. Imidazoline-based take-off agents may be added in an amount between 2.0 and about 15 kg per metric ton.

[0072] Other optional chemical additives may also be added to the aqueous papermaking feedstock or to the formed embryonic web to impart additional benefits to the product and process. The following materials are included as examples of additional chemicals that may be applied to the web. The chemicals are included as examples and are not intended to limit the scope of the invention. Such chemicals may be added at any point in the papermaking process.

[0073] Other types of chemicals that can be added to the paper blanket include, but are not limited to, absorbency aids, usually in the form of cationic, anionic or non-ionic surfactants, Petition 870250086500, dated 09 / 24 / 2025, page 36 / 74 / 47 humectants and plasticizing agents, such as low molecular weight polyethylene glycols and polyhydroxy compounds such as glycerin and propylene glycol. Materials that provide benefits for skin health, such as mineral oil, aloe extract, vitamin E, silicone, lotions in general and the like may also be incorporated into finished products.

[0074] In general, the products of the present invention can be used in conjunction with any known materials and chemicals that are not antagonistic to their intended use. Examples of such materials include, but are not limited to, odor control agents such as odor absorbers, activated carbon fibers and particles, talc, sodium bicarbonate, chelating agents, zeolites, perfumes or other odor masking agents, cyclodextrin compounds, oxidants, and the like. Superabsorbent particles may also be employed. Additional options include cationic dyes, optical brighteners, humectants, emollients, and the like.

[0075] Once the foamy fiber suspension is formed in tank 12, the foamy fiber suspension can be fed to the mat forming system, as shown in FIG. 2. As illustrated in FIG. 2, the mat forming system 10 includes one or more forming zones. In the embodiment illustrated in FIG. 2, three forming zones are shown, including the first forming zone 50, second forming zone 52, and third forming zone 54. The forming zones 50, 52, and 54 are positioned along the porous forming surface 26. In one embodiment, as shown in FIG. 2, the porous forming surface 26 can be inclined relative to the horizontal. For example, the porous formation surface 26 may have an angle with the horizontal greater than about 10°, greater than about 20°, greater than about 30°, and generally less than about 60°, less than about 50°. Each formation zone 50, 52, and 54 is designed to receive a separate flow and Petition 870250086500, dated 09 / 24 / 2025, page 37 / 74 / 47 independent of the fiber foam suspension to deposit the fiber foam suspension on the forming surface 26. For example, the first forming zone 50 can deposit a foamed fiber suspension directly onto the forming surface 26. The second forming zone 52, however, can be configured to deposit a second flow of the foamed fiber suspension onto the fibers deposited by the first forming zone 50. Similarly, the third forming zone 54 can deposit a flow of the aqueous fiber suspension onto the fibers deposited by the first forming zone 50 and the second forming zone 52. In this way, a multilayer mat is formed. It should be understood, however, that the system and process of the present disclosure may include only a single forming zone to form single-layer mats.

[0076] As shown in FIG. 2, each formation zone 50, 52, and 54 is in fluid communication with a separate and independent fibrous foam supply line. For example, the first formation zone 50 is in communication with a first fibrous foam supply line 56, the second formation zone 52 is in fluid communication with a second fibrous foam supply line 58, and the third formation zone 54 is in fluid communication with a third fibrous foam supply line 60. The supply lines 56, 58, and 60 are configured to feed a foamy fiber suspension to each of the corresponding formation zones 50, 52, and 54 at a determined and selected flow characteristic, which may be, for example, flow rate, such as volumetric flow rate, pressure, air content, and / or density.In this sense, each of the supply lines 56, 58, and 60 may be in fluid communication with the mixing tank 12 as shown in FIG. 1. For example, the first supply line 56 may include a first injection line 62 that is connected to the mixing tank 12. Similarly, the second supply line 58 may include a second injection line. Petition 870250086500, dated 09 / 24 / 2025, page 38 / 74 / 47 injection line 64, while the third supply line 60 may be in communication with a third injection line 66. Injection lines 62, 64, and 66 may all be in communication with mixing tank 12 to feed the foam fiber suspension to each of the forming zones 50, 52, and 54. Alternatively, the system may include separate mixing tanks, where each injection line 62, 64, and 66 may be connected to a different mixing tank to feed the foam fiber suspension to the mat forming system 10.

[0077] As shown, each of the fibrous foam supply lines 56, 58, and 60 may include a pumping device, a flow meter, such as a volumetric flow meter, a pressure monitoring device, and / or a temperature monitoring device. Each fibrous foam supply line 56, 58, and 60 may also be in communication with a density monitoring device. The density monitoring device, for example, may be part of one of the other devices, such as the flow meter. Alternatively, the density of the fiber foam suspension may be calculated using information received from other instruments.

[0078] For example, the first fibrous foam supply line includes a first pumping device 68, a first flow meter 74, a first pressure monitoring device 80, and a first temperature monitoring device 81; the second fibrous foam supply line 58 includes a second pumping device 70, a second flow meter 76, a second pressure monitoring device 82, and a second temperature monitoring device 83; and the third fibrous foam supply line 60 includes a third pumping device 72, a third flow meter 78, a third pressure monitoring device 84, and a third temperature monitoring device 85. According to the Petition 870250086500, dated 09 / 24 / 2025, pp. 39 / 74 / 47, present disclosure, the pumping devices 68, 70, and 72 can be adjusted so that the fiber foam suspension can be independently fed to each formation zone 50, 52, and 54 at a desired flow rate and / or pressure. The flow meters 74, 76, and 78, the pressure monitoring devices 80, 82, and 84 (e.g., volumetric flow rate), and the temperature monitoring devices 81, 83, and 85 can monitor flow rates, pressures, and temperatures upstream of the formation surface to calculate at least one characteristic of the flow of the fiber foam suspension at the formation surface.

[0079] In one embodiment, flow meters 74, 76, and 78, pressure monitoring devices 80, 82, and 84, and temperature monitoring devices 81, 83, and 85 can be placed in communication with one or more controllers. The controllers may comprise microprocessors or any suitable programmable device. Pumping devices 68, 70, and 72 can also be placed in communication with one or more controllers. The controllers can be configured to adjust pumping devices 68, 70, and 72 based on information received from flow meters 74, 76, and 78, pressure monitoring devices 80, 82, and 84, and / or temperature monitoring devices 81, 83, and 85.In this way, the foamed fiber suspension can be fed into each forming zone 50, 52, and 54 at a flow rate within the desired set points and / or at a pressure within the desired set points to optimize the formation of a mat on the forming surface 26.

[0080] Information received from flow meters 74, 76, and 78, pressure monitoring devices 80, 82, and 84, and / or temperature monitoring devices 81, 83, and 85 can be used to determine the characteristics of the foamy fiber suspension at the measurement location. Furthermore, the density of the foamy fiber suspension Petition 870250086500, dated 09 / 24 / 2025, pp. 40 / 74 / 47, can be measured or calculated from information received from various instruments. This information, in one embodiment, can be sent to controllers to then calculate at least one characteristic of the foamed fiber suspension at the forming surface. In particular, the controller can be programmed to correct the volumetric flow rate determined at the forming surface based on changes in density, pressure, and temperature. For example, the foamed suspension may experience a pressure drop as it is emitted from the supply line to the forming surface, which alters the density of the foamed suspension. A method for calculating downstream values ​​of the foamed suspension, for example, is disclosed in U.S. Patent No. 4,764,253, which is incorporated herein by reference.

[0081] As described above, in one embodiment, the density of the foamed suspension is determined directly or calculated. In one aspect, a density monitoring device (e.g., a density meter) can be incorporated into the system illustrated in FIG. 2. The density monitoring device, for example, can be part of flow meters 74, 76, and 78. The density monitoring device can measure the density directly. Alternatively, the density can be measured in other ways. For example, the air content of the foamed suspension can be first determined and the density can be calculated based on the measured pressure.

[0082] In one aspect, the measured characteristics of the foamed suspension within supply lines 56, 58, and 60 can be combined with other known information to calculate one or more characteristics of the foamed suspension at the forming surface. For example, in one embodiment, in addition to measuring or determining the flow rate (mass flow rate and / or volumetric flow rate), density, temperature, and pressure of the foamed suspension, other information can be provided to the controller, including the amount of solid material or concentration contained in the raw material, the Petition 870250086500, dated 09 / 24 / 2025, page 41 / 74 / 47 width of the forming surface, the velocity of the forming surface and the desired basis weight of the layer to calculate and / or determine at least one setpoint, such as the volumetric flow rate of the foamed suspension that is fed to the forming surface.

[0083] Foam suspension is a two-phase fluid. The foam suspension includes a liquid volume fraction and a gas volume fraction. The gas volume fraction may also be called the air content by volume. The air content by volume can be determined by dividing the weight of one liter of foam by the weight of one liter of water (e.g., 1,000 g). The air content by volume of the foam suspension depends on the pressure. In other words, the air content by volume and the density of the foam suspension change as the pressure changes.

[0084] In one aspect, when performing calculations, the solid component of the foam can be neglected and assumed to be part of the liquid phase. The flow rate (L / min) of the foamed suspension can be represented as the sum of the liquid flow rate (L / min) combined with the gaseous phase flow rate (L / min). The liquid volume fraction of the foam is the percentage of the total foam volume that is liquid and can be determined by dividing the liquid flow rate (L / min) by the foam flow rate (L / min). The liquid volume fraction can also be calculated from the measured or calculated density of the foamed suspension. The total foam flow rate (L / min) can then be calculated by dividing the raw material flow rate (L / min) by the liquid volume fraction. The gas flow rate of the foamed suspension can be determined by subtracting the liquid flow rate (L / min) from the foamed suspension flow rate (L / min). All the above determinations are made at the measurement site in FIG. 2.

[0085] To calculate density changes and changes in volumetric foam flow rate at other points in the system, such as at the formation surface, the pressure difference must be accounted for due to expansion or Petition 870250086500, dated 09 / 24 / 2025, page 42 / 74 / 47 compression of the gas phase. The ideal gas law can be used to determine changes in density and volumetric flow rate of the foam, assuming no temperature change. Alternatively, temperature changes within the system can be measured, calculated, or estimated and therefore accounted for in the ideal gas law. In this way, one or more characteristics of the foamed suspension, including density and volumetric flow rate, can be determined at the location of flow meters 74, 76, and 78 illustrated in FIG. 2 and then calculated at the formation surface.

[0086] In addition to the measurements and calculations above, the basis weight of the layer or mat formed on the forming surface can also be calculated. Basis weight calculations can be determined based on the area formed per unit time and the weight of solid matter, such as fibers, delivered to the forming surface per unit time (e.g., fiber flow rate). The area of ​​the mat formed per unit time can be determined based on the width of the forming surface and the velocity of the forming surface. The desired solids or fiber flow rate can be calculated by multiplying the target basis weight by the area formed per unit time. To determine the actual mass flow rate of solids or fibers, one can assume that the weight of the water is the total mass of fluid moving through the system. The density differences between the fiber and the water and the effect of temperature on the density of the water can be neglected.Thus, the mass flow rate can be calculated by dividing the mass flow rate of the fiber fed to the system by the amount of fiber contained in the liquid phase of the foamed suspension. Alternatively, the mass flow rate of the fiber can be measured directly.

[0087] In one aspect, the controller can be programmed to have predetermined or pre-selected reference values ​​for at least one characteristic of the foamed suspension. For example, the controller can be programmed with a desired volumetric flow rate and / or mass flow rate value. These values ​​can be calculated by the controller and Petition 870250086500, dated 09 / 24 / 2025, pp. 43 / 74 / 47 compared to the predefined value. Based on comparisons between the predefined value and the calculated or measured value, the controller can be configured to control pumping devices 68, 70, and 72 in response to any deviation from the predefined value. In this way, the controller can control the volumetric flow rate of the foamed suspension to the formation surface and / or the basis weight of the layer being formed.

[0088] In addition to controlling the flow characteristics of the foamed suspension fed to the formation surface, the system and process of the present disclosure also contain similar components for measuring and / or determining similar characteristics of the drainage fluids that are drained through the formation surface. For example, the fluids drained from the formation surface are also in the form of a foam with a liquid phase and a gaseous phase. As shown in FIG. 2, the flow rate, temperature, pressure and / or density of the drainage fluids can also be measured, determined and / or calculated. A flow control device can be placed in each drainage line to then control the amount of fluid drained from the formation surface based on the flow characteristics of the foamed suspension that is fed to the formation surface. In this way, the formation of the mat can be controlled to optimize the mat properties.

[0089] In the embodiment illustrated in FIG. 2, several characteristics of the drainage fluid are measured and / or calculated downstream of the formation surface. These measurements are taken downstream of the formation surface and then used to calculate flow rates at the formation surface, taking into account changes in pressure, density and / or temperature.

[0090] For example, as shown in FIG. 2, opposite each formation zone 50, 52, and 54 is a corresponding drainage device communicating fluids with a corresponding drainage line. In the embodiment illustrated in FIG. 2, each formation zone is aligned with a Petition 870250086500, dated 09 / 24 / 2025, page 44 / 74 / 47 single drainage device.

[0091] As used herein, a drainage device is “aligned” with a formation zone when the drainage device is positioned relative to the length of the formation zone such that the drainage device does not extend beyond the length of the formation zone by more than about 20%. For example, an embodiment of a formation zone 300 is shown in FIG. 6 for exemplary and explanatory purposes. As shown, the formation zone 300 includes a first layer of a foamy suspension of materials 302 being deposited adjacent to an inclined porous formation surface 26. The first foamy suspension of materials 302 may be emitted from a first headbox.

[0092] As shown in FIG. 6, a second foamy suspension of materials is also being fed into the process from a second inlet box. In the embodiment illustrated in FIG. 6, two different flow streams are shown. The system and the process, however, may include only a single flow stream or may include more than two flow streams.

[0093] The first flow of the foamy material suspension 302 is fed into the formation zone 300 and deposited on the moving porous formation surface 26. The first flow of the foamy material suspension 302 is separated from the second flow of the foamy material suspension 304 by a partition or lamella 306. As used herein, the length of the formation zone is the distance from where the foamy material suspension is deposited on the moving porous formation surface 308 to where the partition or lamella 306 ends. As shown in FIG. 6, the formation zone 300 has length L.

[0094] According to the present disclosure, a drainage device is aligned with the formation zone, provided that the device Petition 870250086500, dated 24 / 09 / 2025, p. 45 / 74 / 47 drainage does not extend more than 20% beyond the length L of the formation zone. In other embodiments, the drainage device or plurality of drainage devices may be positioned within the length of the formation zone. Alternatively, one or more drainage devices may extend beyond the length of the formation zone by less than about 15%, such as less than about 10%, such as less than about 5%, such as less than about 2%.

[0095] Returning to FIG. 2, opposite the first formation zone 50 along the formation surface 26 is a first drainage device 86 in fluid communication with a first drainage line 92. Opposite the second formation zone 52 is a second drainage device 88 in fluid communication with a second drainage line 94. Similarly, opposite the third formation zone 54 is a third drainage device 90 in communication with a third drainage line 96. As shown in FIG. 2, formation zones 50, 52, and 54 are adjacent to each other along the formation surface 26 and are positioned on one side of the formation surface. Drainage devices 86, 88, and 90 are also adjacent to each other and are positioned on the opposite side of the formation surface 26 in alignment with formation zones 50, 52, and 54.As the foamy fiber suspension is deposited on the forming surface of each forming zone 50, 52, and 54, a mat 14 is formed and the excess fluids enter the corresponding drainage devices 86, 88, and 90. The drainage devices can be any suitable static or dynamic drainage device capable of draining fluids from the mat or forming surfaces. The drainage device can be a static or vacuum suction box. Alternatively, the drainage device can be a drum, such as a rotating drum that applies suction.

[0096] As shown in FIG. 2, each drainage line 92, 94, Petition 870250086500, dated 09 / 24 / 2025, pages 46 / 74 / 47 and 96, includes a corresponding flow control device, flow meter, temperature monitoring device, and pressure monitoring device. For example, the first drainage line 92 includes a first flow control device 98, a first flow meter 104, a first temperature monitoring device 105, and a first pressure monitoring device 110. The second drainage line 94 includes a second flow control device 100, a second flow meter 106, a second temperature monitoring device 107, and a second pressure monitoring device 112. The third drainage line 96 includes a third flow control device 102, a third flow meter 108, a third temperature monitoring device 109, and a third pressure monitoring device 114.Flow control devices 98, 100, and 102 can be any device suitable for controlling flow through the line and can be an adjustable valve or a pump. Pumps, for example, can be used to apply suction to the formation surface. Alternatively, drainage can occur by gravity. In yet another embodiment, each flow control device 98, 100, and 102 can be a combination of a pump and an adjustable valve.

[0097] In one embodiment of the present disclosure, each drainage line 92, 94, and 96 is controlled independently of the other drainage lines. The amount of flow or drainage from each drainage device 86, 88, and 90 through each corresponding drainage line 92, 94, and 96 can be adjusted and controlled based on at least one characteristic of the foamed fiber suspension that can be measured or calculated as described above and that is fed to each of the formation zones 50, 52, and 54. For example, in one embodiment, the amount of flow or drainage from each drainage device can be based on the volumetric flow rate of the foamed fiber suspension being fed to Petition 870250086500, dated 09 / 24 / 2025, page 47 / 74 / 47 each of the formation zones. For example, flow meters 104, 106, and 108 in combination with pressure monitoring devices 110, 112, and 114, temperature monitoring devices 105, 107, and 109, and / or optionally one or more density monitoring devices, can be used to quantify the drained fluids, which may be a two-phase discharge stream containing liquids and gases. The two-phase discharge flow can be converted into a reference pressure based on information received from flow meters 104, 106, and 108, pressure monitoring devices 110, 112, and 114, temperature monitoring devices 105, 107, and 109, and / or density monitoring devices.The flow control devices 98, 100, and 102 can then be adjusted and controlled to achieve an ideal or desired discharge flow rate, based on at least one characteristic of the foamed fiber suspension fed to each of the forming zones 50, 52, and 54.

[0098] In one aspect, for example, the characteristics of the two-phase drainage fluid flowing through drainage lines 92, 94, and 96 can be measured or calculated downstream of the formation surface. The same calculations described above can then be used to determine one or more characteristics of the foam being drained from the formation surface based on the measured and calculated characteristics of the foam downstream of the formation surface.

[0099] In one embodiment, the system may also include one or more controllers 116. The controllers may be microprocessors or any suitable programmable devices. As shown in FIG. 2, each flow control device 98, 100, and 102, each flow meter 104, 106, and 108, each temperature monitoring device 105, 107, and 109, each density monitoring device and / or each pressure monitoring device 110, 112, and 114 may be in communication. Petition 870250086500, dated 09 / 24 / 2025, page. 48 / 74 / 47 with controller 116. The controller can receive information from flow meters 104, 106, and 108, temperature monitoring devices 105, 107, and 109, optional density monitoring devices, and / or pressure monitoring devices 110, 112, and 114 to make adjustments to flow control devices 98, 100, and 102 to control the flow rate at which fluids are drained from each of the drainage devices 86, 88, and 90. The combination of receiving information from flow control devices 98, 100, and 102, which can be volumetric flow meters, from pressure monitoring devices 110, 112, and 114, from temperature monitoring devices 105, 107, and 109, and / or optional density monitoring devices can be used to quantify the discharge flows of fluids containing gases and liquids.In one embodiment, controller 116 can use the above information to calculate a flow rate, such as a volumetric flow rate, at the formation surface and control the volumetric flow rate based on at least one characteristic of the frothed slurry being fed to the formation surface. Controller 116 can then control flow control devices 98, 100, and 102 to achieve a calculated discharge flow rate through each drainage device and drainage line.

[00100] In one aspect, controller 116 can determine a volumetric flow rate of the foam being drained from the formation surface and can adjust the volumetric flow rate based on the volumetric flow rate of the foamed suspension being fed to the formation surface. Alternatively, the drainage system can apply vacuum to the formation surface at each of the drainage devices. Controller 116, in this embodiment, can determine a reference pressure from information received from all downstream measuring devices and instruments. Controller 116 can then adjust the reference pressure at the formation surface based on a characteristic of the foamed suspension, such as with Petition 870250086500, dated 09 / 24 / 2025, page 49 / 74 / 47 based on the volumetric flow rate of the foamed suspension.

[00101] Through the process of the present disclosure, foam drainage from the forming surface can be carefully controlled based on the amount of foam and fibers being fed onto the forming surface to produce mats without over- or under-draining the mats during formation. In this way, it is possible to produce mats with uniform characteristics and improved properties.

[00102] In the embodiment illustrated in FIG. 2, flow control devices 98, 100, and 102 are shown as valves. In other embodiments, however, flow control devices 98, 100, and 102 may be pumping devices for pumping fluids through the drain lines at the desired flow rates. In one aspect, each flow control device may be a combination of a pumping device and a valve.

[00103] According to the present disclosure, the drainage flow rates through each drainage line 92, 94, and 96 can be coordinated with the flow rates and / or pressures of the foamed fiber suspension fed into each of the forming zones 50, 52, and 54. By controlling the drainage flow rates based on the feed flow rates, the mat formation can be controlled to optimize properties. When producing multilayer mats, as shown in FIG. 2, the drainage flow rates can be controlled relative to the inlet pressures and / or flow rates to further improve the mixing between layers to further enhance the physical properties of the mats while they are being formed.

[00104] For example, as shown in FIG. 2, by controlling the discharge flow rates relative to the inlet flow rates, the foamy suspension of fibers fed to each forming zone 50, 52, and 54 can be caused to spread in a unique manner on the forming surface 26. Petition 870250086500, dated 09 / 24 / 2025, page 50 / 74 / 47 For example, as shown by the arrows, the foamy fiber suspension fed into each formation zone 50, 52, and 54 can be caused to flow laterally out of the perimeter of each formation zone, causing fiber reorientation and / or layer mixing. For example, in one embodiment, the drainage flow rates in drainage devices 86, 88, and 90 can be maintained at a flow rate lower than the flow rate of the foamy fiber suspension being fed into each of the formation zones 50, 52, and 54. The creation of a pressure differential where formation zones 50, 52, and 54 intersect with formation surface 26 can create fiber mixing and reorientation and longitudinal flow, as shown in FIG. 2.

[00105] In one embodiment, the process and system of the present disclosure may further include a sealing zone 120 positioned along the forming fabric 26 and in fluid communication with a sealing fluid supply line 122. As shown in FIG. 2, the sealing fluid supply line 122 may include a pumping device 124, a flow meter 126, a pressure monitoring device 128, and a temperature monitoring device 129. The sealing fluid supply line 122 serves to supply a fluid, particularly a liquid, to the sealing zone 120. The sealing fluid may be any suitable liquid. For example, the sealing fluid may be water, a solution of water and surfactant, or similar. In one embodiment, the sealing fluid is not fibrous.A sealing fluid is fed into the sealing fluid zone 120 at a flow rate and / or pressure such that the sealing fluid is deposited on the forming surface 26, forming a fluid seal that prevents airflow in the upstream longitudinal direction. Information is received from the flow meter 126, the pressure monitoring device 128, the temperature monitoring device 129, and optionally a monitoring device for... Petition 870250086500, dated 09 / 24 / 2025, page 51 / 74 / 47 density can be used to calculate volumetric flow rates of foam on the forming surface.

[00106] As shown in FIG. 2, the sealing zone 120 can be positioned upstream and adjacent to the plurality of formation zones. The sealing zone 120 can also be placed in front of a sealing drainage device 130 connected to a sealing drainage line 132. The sealing drainage line 132 may include a flow control device 134, a flow meter 136, a temperature monitoring device 137, and a pressure sensing device 138, all of which may be in communication with the controller 116. In this way, the drainage flow rate of the sealing fluid can be carefully controlled based on the flow rate or pressure at which the sealing fluid enters or exits the sealing zone 120. Including the sealing zone 120, better blanket formation 14 occurs in front of the first formation zone 50.

[00107] The mat formation system 10 as shown in FIG. 2 may also include a suction zone 140 adjacent to the plurality of formation zones and positioned downstream of the formation zones. The suction zone 140 is in fluid communication with a drainage line 142 which may include a pressure monitoring device 144. The suction zone 140 serves to extract fluids through the embryonic network 14 after the mat has been formed. The suction zone 140 serves to remove excess fluids, mainly liquids, from the mat 14. In one aspect, the drainage flow rate of the foamy fiber suspension being drained through one or more drainage devices is controlled so that excess fluid from one or more formation zones enters the suction zone 140. Ideally, the suction zone 140 facilitates the drainage of fluids from the mat 14 without causing any detrimental effects.

[00108] In one embodiment, one or more drainage devices 86, 88, and 90 are operated so that the foamy fiber suspension Petition 870250086500, dated 24 / 09 / 2025, p. 52 / 74 / 47 fed into formation zones 50, 52, and 54 and particularly into the third formation zone 54 causes excess liquid to flow longitudinally out of a perimeter of the third formation zone 54 to be collected in suction zone 140.

[00109] In one embodiment, as shown in FIG. 2, all drain lines 92, 94, 96, 132, and 142 can be fed to a separator tank 150. The separator tank 150 can be configured to separate free gases from the foam. As shown, the separator tank 150 can include a gas outlet 152 that can be connected to a vacuum source and a liquid outlet 154. The liquid collected in the separator tank 150 can comprise a mixture of water and surfactant. As shown in FIG. 2. A pumping device 156 can be used to pump liquids from the separator tank 150 to a liquid tank 158, which can also be connected to a water source 160. The liquid tank 158 can be used to recycle the water and surfactant mixture back into the process via supply lines 56, 58, 60, and 122.

[00110] The mat forming system illustrated in FIG. 2 can offer several advantages and benefits when forming mats from foamed fiber suspension. For example, by controlling the flow through the drainage lines relative to the flow of the foam fiber suspension to the forming zones, the detrimental effects of suction on the foam stock during mat formation can be minimized. Furthermore, aligning the inlet pressure and drainage flow in the multiple forming zones provides stable sheet formation and can produce multilayer mats with controlled and / or optimized mixing between the different mat layers.

[00111] Referring to FIG. 1, after the embryonic blanket 14 is formed from the blanket formation system or inlet box 10, the blanket Petition 870250086500, dated 24 / 09 / 2025, p. 53 / 74 / 47 can be fed into several different downstream processes. FIG. 1 represents only one embodiment of a process for drying the blanket after it has been formed. As shown, the blanket 14 is formed on the forming surface 26 and transported downstream. The endless travel forming fabric 26, for example, can be supported and driven by rollers 28.

[00112] Once formed in the forming fabric 26, the formed blanket may have a consistency of less than about 50%, such as less than about 20%, such as less than about 10%, such as less than about 5%. In fact, the forming consistency may be less than about 2%, as well as less than about 1.8%, as well as less than about 1.5%. The forming consistency is generally greater than about 0.5%, such as greater than about 0.8%.

[00113] Once the wet web is formed on the forming fabric 26, the web is conveyed downstream and optionally further dehydrated. For example, the process may optionally include a plurality of vacuum devices 16, such as vacuum and vacuum rollers. Vacuum boxes assist in removing moisture from the newly formed web 14.

[00114] As shown in FIG. 1, the forming fabric 26 can also be placed in communication with a steam oven 18 positioned above a pair of vacuum rollers 20. The steam oven 18, for example, can increase dryness and reduce cross-moisture variation. The steam applied by the steam box 18 heats the moisture in the wet web 14, causing the water in the web to drain more easily, especially in conjunction with the vacuum rollers 20. From the forming fabric 26, the newly formed web 14 is conveyed downstream and dried. The web can be dried using any suitable drying device. For example, the web can be air-dried or placed in a heated drying drum and wrinkled or left uncreped. In FIG. 1, for example, the formed web 14 is placed in contact with two heated drying drums. Petition 870250086500, dated 24 / 09 / 2025, p. 54 / 74 / 47 and 40. In one embodiment, of the drying drums 38 and 40, the blanket can be fed to an air dryer before being rolled onto a roll.

[00115] The embodiment in FIG. 2 serves to form multilayer blankets. In another aspect, the process of the present disclosure can be used to create single-layer blankets from a foamy suspension of materials.

[00116] Referring to FIG. 4, for example, an embodiment of a mat-forming system made according to the present disclosure is shown, in which the system includes a single forming zone positioned in alignment with a drainage device. Similar reference numbers have been used to indicate similar elements.

[00117] As shown, the system includes an injection line 62 for injecting a foamed fiber suspension into the system adjacent to a pump 68. The pump 68 transports the foamed fiber suspension to a forming zone 50. A flow meter 74, a pressure monitoring device 80, and a temperature monitoring device 81 can monitor flow rates, pressures, and temperatures upstream of the forming surface to calculate at least one characteristic of the flow of the foamed fiber suspension at the forming surface.

[00118] Opposite the formation zone 50 is positioned a drainage device 86 which is aligned with the formation zone. The drainage device 86 is in communication with a corresponding drainage line 92. The drainage line 92 includes a corresponding flow control device 98, a flow meter 104, a temperature monitoring device 105, and a pressure monitoring device 110. All instruments can be in communication with a controller 116 which may comprise one or more microprocessors.

[00119] In the embodiment illustrated in FIG. 4, the drainage device Petition 870250086500, dated 09 / 24 / 2025, page 55 / 74 / 47 can be operated to control drainage in a manner that controls mat formation. Thus, as the foamy fiber suspension is deposited on the formation surface, the amount of drainage that occurs along the formation surface within the formation zone 50 can be controlled, adjusted, and modified based on any desired outcome.

[00120] The process and system as illustrated in FIG. 4 is generally for forming a single-layer mat. Referring to FIG. 5, another embodiment of a system according to the present disclosure is shown which is designed to form multi-layer mats using a single drainage device.

[00121] In FIG. 5, reference numerals were used to indicate similar elements. As shown in FIG. 5, the system includes injection lines 62, 64, and 66 for injecting a foamed fiber suspension into the process adjacent to the corresponding pumps or pumping devices 68, 70, and 72. The pumping devices 68, 70, and 72 feed the foamed fiber suspension to the corresponding forming zones 50, 52, and 54.

[00122] Each pumping device 68, 70, and 72 is in communication with a corresponding fibrous foam supply line 56, 58, and 60. Each fibrous foam supply line 56, 58, and 60 is in communication with a flow meter 74, 76, and 78, a pressure monitoring device 80, 82, and 84, a temperature monitoring device 81, 83, and 85, and optionally a density monitoring device (not shown). The three fibrous foam supply lines 56, 58, and 60 are fed to the corresponding forming zones 50, 52, and 54 to form a three-layer mat. In one embodiment, for example, the intermediate layer may comprise a superabsorbent material that is sandwiched between two outer layers. Petition 870250086500, dated 09 / 24 / 2025, page 56 / 74 / 47

[00123] In the embodiment illustrated in FIG. 5, the formation zones 50, 52, and 54 are all aligned with a single drainage device 86. As shown, the drainage device 86 is in fluid communication with a corresponding drainage line 92. The drainage line 92 is in communication with a flow control device 98, a flow meter 104, a temperature monitoring device 105, and a pressure monitoring device 110.

[00124] In the embodiment illustrated in FIG. 5, the amount of drainage through the drainage device 86 can be based on all the information received by the controller 116 from the instruments associated with all three formation zones 50, 52, and 54. Furthermore, adjustment of the drainage rate through the drainage device 86 can also be controlled by the controller 116 in conjunction with information received from the flow control device 98, the flow meter 104, the temperature monitoring device 105, and / or the pressure monitoring device 110.

[00125] The mats made according to this disclosure can be used in all different types of products. For example, the fabric mat can be used to produce toilet paper, facial tissues, paper towels, industrial wipes and the like. In one embodiment, the mats made according to this disclosure may contain substantial amounts of superabsorbent particles. For example, at least one layer of the mat may contain superabsorbent particles in an amount greater than about 50% by weight and up to about 90% by weight, including all 1% weight increments between them. These types of mats are particularly suitable for incorporation into absorbent personal hygiene articles. For example, the mats can be used as absorbent cores positioned between a liquid-permeable lining and a liquid-impermeable outer covering. Petition 870250086500, dated 09 / 24 / 2025, page 57 / 74 / 47

[00126] These and other modifications and variations of the present invention may be carried out by those skilled in the art without departing from the spirit and scope of the present invention, which is more particularly set forth in the appended claims. Furthermore, it should be understood that the details of the various embodiments may be modified in whole or in part. In addition, persons of ordinary skill in the art will note that the description presented is for illustrative purposes only and should not be construed as a limitation of the invention, which is described in more detail in the appended claims. Petition 870250086500, dated 09 / 24 / 2025, pp. 58 / 74

Claims

1 / 9 CLAIMS 1. A process for producing a mat, characterized in that it comprises: flowing a foamy suspension of materials into one or more forming zones, including at least one first forming zone, the foamy suspension being fed into the first forming zone at a first flow rate; depositing the foamy suspension of materials fed into the first forming zone adjacent to at least one mobile porous forming surface to form an embryonic mat; draining excess fluids through the porous forming surface to at least one drainage device; and controlling a flow rate of drainage fluids drained through at least one drainage device based on at least one characteristic of the flow of the foamy suspension of materials being fed into the first forming zone; and drying the embryonic mat.

2. Process according to claim 1, characterized in that at least one feature of the flow of the foamed suspension of materials comprises a temperature, pressure, mass flow rate, volumetric flow rate or density of the foamed suspension of materials.

3. Process according to claim 1, characterized in that it further comprises the step of flowing the foamed suspension of materials to a second formation zone positioned adjacent to the first formation zone, the foamed suspension of materials being fed to the second formation zone at a second flow rate; depositing the foamed suspension of materials fed to the second formation zone onto the materials deposited adjacent to the formation surface of the first formation zone to form a multilayered mat; and controlling a flow rate of drainage fluids drained through at least one drainage device positioned in alignment with the second formation zone.

4. Process according to claim 3, characterized in that the drainage flow rate through at least one drainage device positioned in alignment with the second formation zone is controlled so that the foamed suspension of materials being fed to the second formation zone is forced to flow longitudinally out of a perimeter of the second formation zone.

5. A process according to claim 3 or 4, characterized in that it further comprises the step of flowing the foamed suspension of materials to a third formation zone positioned adjacent to the second formation zone, the foamed suspension of materials being fed to the third formation zone at a third flow rate; depositing the foamed suspension of materials fed into the third formation zone onto the deposited materials adjacent to the formation surface of the first and second formation zones; and controlling a flow rate of drainage fluids drained through at least one drainage device positioned in alignment with the third formation zone.

6. Process according to claim 5, characterized in that the drainage flow rate through at least one drainage device positioned in alignment with the third formation zone is controlled so that the foamed suspension of materials being fed to the third formation zone is forced to flow longitudinally out of a perimeter of the third formation zone. Petition 870250086500, dated 24 / 09 / 2025, p. 60 / 74 3 / 9 7. Process according to claim 1, characterized in that the process includes only the first forming zone to produce single-layer blankets.

8. A process according to any of the preceding claims, characterized in that a sealing zone is positioned adjacent to and upstream of the first forming zone to inhibit airflow in an upstream longitudinal direction.

9. Process according to claim 8, characterized in that the sealing zone positioned adjacent to and upstream of the first formation zone emits a fluid towards at least one porous formation surface to inhibit airflow.

10. Process according to claim 9, characterized in that the fluid emitted by the sealing zone comprises a foam.

11. A process according to any of the preceding claims, characterized in that the fluid flow rate through the first drainage device is less than the first flow rate of the foamed suspension of materials being fed into the first formation zone.

12. A process according to any one of the preceding claims, characterized in that the foamed suspension of materials is pumped into each or more formation zones individually, so that the fluid pressure upstream of each formation zone can be controlled independently of the other formation zones.

13. Process according to any of the preceding claims, characterized in that the foamed suspension of materials is pumped to the first formation zone, before the first formation zone, the temperature, pressure, flow rate and density of the foamed suspension of materials are determined to calculate a flow rate at the formation surface, the flow rate of the drainage fluids drained through Petition 870250086500, dated 09 / 24 / 2025, page 61 / 74 4 / 9 of the first drainage device being controlled based on the calculated flow rate.

14. A process according to any of the preceding claims, characterized in that the flow rate of drainage fluids drained through the first drainage device is monitored by a flow meter and a pressure monitoring device, the flow meter and the pressure monitoring device sending information to a controller that calculates a discharge flow rate, the controller being in communication with an adjustable flow control device to control the flow rate of drainage fluids drained through the first drainage device based on the calculated discharge flow rate.

15. A process according to any one of the preceding claims, characterized in that it further comprises the step of drawing fluids through the embryonic mantle into a suction zone that is downstream of one or more formation zones and corresponding drainage devices.

16. Process according to claim 15, characterized in that the drainage flow rate of the foamy suspension of materials being drained through one or more drainage devices is controlled so that excess fluid from one or more formation zones enters the suction zone.

17. Process according to any of the preceding claims, characterized in that the forming surface is inclined with respect to the horizontal.

18. Process according to any of the preceding claims, characterized in that the foamed suspension of materials is formed by combining a foam with a fiber, the foam having a density of about 200 g / L to about 600 g / L, such as from about 350 g / L to about 600 g / L and / or containing from about 40% to about 80% by volume of air, such as from about 40% to about 65% by volume of air.

19. Process according to any of the preceding claims, characterized in that the materials contained in the blanket comprise at least about 5% by weight of cellulose fibers, such as at least about 10% by weight of cellulose fibers, or at least about 15% by weight of cellulose fibers optionally combined with non-fibrous particles, such as superabsorbent particles.

20. Process according to any of the preceding claims, characterized in that the materials contained in the blanket comprise at least about 5% by weight of polymeric synthetic fibers, or at least about 10% by weight of polymeric synthetic fibers, or at least about 15% by weight of polymeric synthetic fibers.

21. Process according to claim 1, characterized in that the dry blanket has a density greater than about 0.03 g / cm3, such as greater than about 0.05 g / cm3, such as greater than about 0.1 g / cm3 and less than about 0.7 g / cm3, such as less than about 0.5 g / cm3.

22. Process according to claim 1, characterized in that the dry blanket has a basis weight of about 6 g / m2 to about 800 g / m2, such as from about 10 g / m2 to about 200 g / m2, such as from about 20 g / m2 to about 120 g / m2.

23. A process according to any of the preceding claims, characterized in that the fluids drained through the first drainage device are monitored downstream of the formation surface by at least one of the following: a flow meter, a temperature monitoring device, and a pressure monitoring device, and wherein the information received from at least one of the following: flow meter, pressure monitoring device, or temperature monitoring device is used to calculate a flow rate of fluids being drained through the first formation zone at the formation surface.

24. A process according to any one of the preceding claims, characterized in that at least one drainage device is positioned in alignment with at least one formation zone along at least one porous formation surface.

25. A process according to any one of the preceding claims, characterized in that the first drainage device comprises a vacuum box.

26. Process according to any one of claims 1 to 23, characterized in that the first drainage device comprises a drainage roller.

27. System for producing mats, characterized in that it comprises: a forming zone positioned in relation to at least one porous forming surface, the forming zone being in communication with a fibrous foam supply line, the fibrous foam supply line including a pumping device for flowing a foam suspension of materials to the respective forming zone, the fibrous foam supply line further including a flow meter, a pressure monitoring device, a temperature monitoring device, or combinations thereof, the fibrous foam supply line for feeding a foam suspension of materials to the corresponding forming zone to deposit the materials contained in the foam suspension adjacent to at least one porous forming surface at a determined flow rate, a pressure or both;at least one drainage device positioned to drain fluids from the porous formation surface, or at least one drainage device being in fluid communication with a corresponding drainage line, the drainage line including a flow control device to control a flow rate of a fluid being drained to the drainage device, the drainage line further including a flow meter, a pressure monitoring device, a temperature monitoring device, or combinations thereof; and one or more controllers in communication with the flow control device associated with the drainage line, or one or more controllers being configured to control the flow rate of fluids being drained to at least one drainage device in relation to a flow rate, temperature, or pressure of the frothed material slurry being fed into the formation zone.

28. System according to claim 27, characterized in that it comprises a plurality of formation zones and a plurality of drainage devices, each formation zone being in communication with a separate fibrous foam supply line, each fibrous foam supply line including a pumping device for flowing a foam suspension of materials to a respective formation zone, each fibrous foam supply line further including a flow meter, a pressure monitoring device, a temperature monitoring device or combinations thereof, each fibrous foam supply line for feeding a foam suspension of materials to a corresponding formation zone to deposit the materials contained in the foam suspension adjacent to at least one porous formation surface at a determined flow rate, pressure or both;each drainage device being positioned in alignment with at least one porous formation surface in coordination with the plurality of formation zones, wherein for each formation zone there is at least one corresponding drainage device, each drainage device being in fluid communication with a corresponding drainage line, each drainage line including a flow control device to control a flow rate of a fluid being drained to each corresponding drainage device, each drainage line further including a flow meter, a pressure monitoring device, a temperature monitoring device or combinations thereof;and wherein one or more controllers are in communication with each of the flow control devices associated with the drainage lines, with one or more controllers configured to independently control the flow rate of fluids being drained to each drainage device in relation to a flow rate or pressure of the frothed material suspension being fed to each of the forming zones.

29. System according to claim 28, characterized in that one or more controllers are configured to control the flow rate of fluids drained from each drainage device based on information received from the corresponding flow meter, pressure monitoring device and / or temperature monitoring device associated with each formation zone.

30. System according to claim 27, 28 or 29, characterized in that it further comprises a drying device positioned downstream for drying a mat formed on the porous formation surface.

31. System according to claim 28, characterized by the fact that the plurality of formation zones are positioned along at least one porous formation surface to form multilayer mats.

32. System according to claim 27, 28, 29, 30 or 31, characterized in that the movable forming surface is inclined relative to a horizontal.

33. System according to any one of claims 27 to 32, characterized in that it further comprises a separator tank in fluid communication with the drainage line to receive a drainage fluid from the drainage device, the separator tank separating free gases from the foam to recycle the foam in the production of the foamy suspension of materials.

34. System according to any one of claims 27 to 33, characterized in that it further comprises a suction zone adjacent to and downstream of the formation zone for drawing fluids through mats formed on the formation surface, the flow rate of fluids being drained to the drainage device being controlled by one or more controllers in a manner that causes the suction zone to collect fluid from a mat being formed. Petition 870250086500, dated 09 / 24 / 2025, pp. 67 / 74

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