Process for producing a blanket, and system for producing blankets

Description

55 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 / 492,095, 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 solids, gases, and liquids. The gases represent compressible portions, Petition 870250086510, dated 09 / 24 / 2025, page 12 / 90 / 55, while liquids are relatively incompressible. Thus, foam suspensions are subject to volume changes when subjected to changes in pressure or temperature. Furthermore, these suspensions function as non-Newtonian fluids and are subject to changes in viscosity 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 controlling the drainage flow through a forming surface. During the process, the suspension Petition 870250086510, dated 09 / 24 / 2025, page 13 / 90 / 55. Foamed fiber is fed into a forming zone. According to the present disclosure, in one aspect, a plurality of drainage devices can be positioned in alignment with the forming zone to drain excess fluids from the forming surface. Each drainage device can be controlled independently. In this way, the process and system of the present disclosure can control fluid drainage and create a desired drainage profile. The plurality of drainage devices, for example, can be operated independently and can be used not only to create a uniform fiber formation in a mat, but can also be used to improve fiber mixing within the mat.

[008] For example, in one aspect, the system and process of the present disclosure can be used to form single-layer or multi-layer blankets. The plurality of drainage devices can be used to control mixing within each layer and between layers. In this way, the resulting multi-layer blanket can have better mechanical properties, better absorption characteristics, and at the same time prevent certain materials from migrating to the surface of the blanket in an undesirable manner.

[009] In one aspect, the present disclosure is directed to a process for producing a mat. The process includes the flow of a foamy suspension of materials into a forming zone. The foamy suspension is fed into the forming zone at an initial flow rate. The foamy suspension of materials fed into the first forming zone is deposited adjacent to at least one mobile porous forming surface to form a layer of an embryonic mat. In one aspect, only one layer of the embryonic mat is fed into each forming zone. Excess fluid is drained through the porous forming surface to a first drainage device and to a second device. Petition 870250086510, dated 09 / 24 / 2025, page 14 / 90 / 55 drainage. The first and second drainage devices are positioned in alignment with the first formation zone along at least one porous formation surface. A flow rate of drainage fluids drained through the first drainage device is controlled and a flow rate of drainage fluids drained through the second drainage device is controlled in the formation of the mat. The embryonic mat is then dried.

[0010] In one aspect, in addition to two drainage devices, the formation zone may be aligned with three drainage devices, four drainage devices, five drainage devices, and generally less than ten drainage devices, such as less than six drainage devices, such as less than five drainage devices.

[0011] In one aspect, the flow rate of drainage fluids drained through the first drainage device and the flow rate of drainage fluids drained through the second drainage device are controlled based on at least one characteristic of the flow of the foamed material suspension being fed into the forming zone. At least one characteristic of the flow of the foamed material suspension may comprise a temperature, a pressure, a mass flow rate, a volumetric flow rate, or a density of the foamed material suspension. The flow rate of drainage fluids drained through the first drainage device may be controlled independently of the flow rate of drainage fluids drained through the second drainage device.

[0012] In one aspect, the first drainage device may be positioned upstream and adjacent to the second drainage device, and the flow rate of drainage fluids drained through the first drainage device may be greater or less than the flow rate of drainage fluids drained through the second drainage device. In another aspect, the flow rate of drainage fluids through the first drainage device and Petition 870250086510, dated 09 / 24 / 2025, p. 15 / 90 / 55 through the second drainage device may be approximately the same. For example, the fluid flow rate through the first drainage device and the fluid flow rate through the second drainage device may differ by no more than about 20%, as by no more than about 15%, as by no more than about 10%, as by no more than about 5%, as by no more than about 3%, as by no more than about 1%. For example, in one embodiment, the first drainage device and the second drainage device may comprise vacuum boxes that apply suction to the mat being formed. The amount of suction through each drainage device may be controlled so as to produce a desired flow rate.Matching the flow rate between the first drainage device and through the second drainage device can provide several advantages and benefits, including the production of a better-formed and / or more uniform drainage mat.

[0013] When forming multilayer mats, the process may also include 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 may be fed to the second formation zone at a second flow rate. The foamed suspension of materials fed into the second formation zone may be deposited adjacent to at least one mobile formation surface, so that a second layer of material is formed below or over the materials deposited adjacent to the formation surface of the first formation zone to form a multilayer mat. A third drainage device may be positioned aligned with the second formation zone. It is possible to control the flow rate of the drainage fluids that are drained through the third drainage device.The second formation zone can be positioned downstream of the first formation zone, and the first drainage device and the second. Petition 870250086510, dated 09 / 24 / 2025, page 16 / 90 / 55 drainage devices can be positioned upstream of where the second layer is formed. Alternatively, the second formation zone can be positioned upstream of the first formation zone and the first drainage device and the second drainage device can be positioned downstream of where the second layer is formed.

[0014] In another embodiment, the process may include the step of flowing the foamed suspension of materials to a third formation zone positioned adjacent to one of the other formation zones. The foamed suspension of materials may be fed to the third formation zone at a third flow rate. The foamed suspension of materials fed into the third formation zone is deposited adjacent to at least one mobile porous formation surface, so that a third layer of materials is formed in the multilayer mat. A stream of drainage fluid is drained through a fourth drainage device positioned in alignment with the third formation zone.

[0015] When the process includes a second formation zone or a third formation zone, each of the above formation zones can be lined with a plurality of drainage devices, such as between two and four drainage devices that can be independently controlled to manage drainage through the multilayer blanket.

[0016] In one aspect, the process may further include the step of flowing a fluid into a sealing zone. The sealing zone may be positioned adjacent to and upstream of the first forming zone. The fluid being fed into the sealing zone may be emitted onto the mobile, porous forming surface 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. Petition 870250086510, dated 09 / 24 / 2025, p. 17 / 90 / 55

[0017] Fluids can also be aspirated through the embryonic mat into a suction zone adjacent to and downstream of one or more forming zones. The drainage flow rates of the foamed fiber suspension being drained through one or more forming zones can enter the suction zone. In one aspect, the drainage flow rate of the foamed fiber suspension being drained through one or more drainage devices can be controlled so that excess fluid from one or more forming zones enters the suction zone to control the liquid and air mixture that is collected by the suction zone.

[0018] In one embodiment, the process is operated in such a way that the flow rate of fluids through one or more drainage devices aligned with a formation zone is less than the flow rate of the foamed suspension of materials being fed into the corresponding formation zone.

[0019] In one aspect, the foamed fiber suspension can be pumped to each or more formation zones individually, so that the fluid pressure within each supply line to each formation zone can be controlled independently of the other formation zones. In one aspect, for example, the foamed fiber suspension is pumped to the first formation zone at a first pressure, and the flow rate of the drainage fluids drained through the first drainage device and through the second drainage device is controlled based on the first pressure. The flow rate of the drainage fluids drained through the drainage devices can be monitored independently by a flow meter and a pressure monitoring device downstream of the formation surface and each drainage device.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 one. Petition 870250086510, dated 09 / 24 / 2025, page 18 / 90 / 55 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 and through the second drainage device based on the calculated discharge flow rate. Each flow control device, for example, could be an adjustable valve.

[0020] In one embodiment, the moving forming surface is operated at an inclination 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.

[0021] Blankets can be made with high-volume or low-volume characteristics. The volume, for example, can generally be greater than about 3 cm3 / g, as well as greater than about 5 cm3 / g, as greater than about 7 cm3 / g, as greater than about 9 cm3 / g, as greater than about 11 cm3 / g, as greater than about 14 cm3 / g and generally less than about 20 cm3 / g, as 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.

[0022] The blankets made according to 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 may be made exclusively of cellulose fibers or may be made of cellulose fibers mixed with other fibers, such as synthetic fibers and / or particles or superabsorbent fibers. The synthetic fibers, for example, may be present in the woven blanket in an amount greater than about 5% by weight, as well as in an amount greater than about 15% by weight. Petition 870250086510, dated 09 / 24 / 2025, page 19 / 90 / 55, as in an amount greater than about 20% by weight, 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.

[0023] The foamed fiber suspension can be formed according to the present disclosure by combining a foam with a fiber material. 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.

[0024] This disclosure also applies to a system for producing mats. The system includes a forming zone positioned relative to at least one porous forming surface. The forming zone is in communication with a fibrous foam supply line. The fibrous foam supply line includes a pumping device to flow a foam suspension of materials to the respective forming zone. The fibrous foam supply line also includes a flow meter, a pressure monitoring device, a temperature monitoring device, or combinations thereof. The fibrous foam supply line serves to feed 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 given flow rate, pressure, or both.The system also includes an initial drainage device positioned in relation to at least one porous formation surface. Petition 870250086510, dated 09 / 24 / 2025, page 20 / 90 / 55 aligned with the formation zone. The first drainage device is in fluidic communication with a corresponding first drainage line. The system also includes a second drainage device adjacent to the first drainage device and also positioned in alignment with the formation zone, the second drainage device being in fluidic communication with a corresponding second drainage line.

[0025] In one aspect, the first drainage line includes a first flow control device to control the flow rate of fluid being drained to the first drainage device. The first drainage line further includes a first flow meter, a first pressure monitoring device, a first temperature monitoring device, or combinations thereof. The second drainage line includes a second flow control device to control the flow rate of fluid being drained to the second drainage line. The second drainage line further includes a second flow meter, a second pressure monitoring device, a second temperature monitoring device, or combinations thereof. The system also comprises one or more controllers communicating with the flow control devices associated with the first drainage line and the second drainage line.One or more controllers are configured to control the flow rate of fluids being drained to the first and second drainage devices in relation to a flow rate or pressure of the foamed material suspension being fed into the forming zone.

[0026] In one aspect, to form multilayer mats, the system includes a plurality of forming zones. Each forming zone is in communication with a separate fibrous foam supply line. Each fibrous foam supply line includes a pumping device to flow a foam suspension of materials to a Petition 870250086510, dated 24 / 09 / 2025, p. 21 / 90 / 55 respective formation zone. Each fibrous foam supply line also includes a flow meter, a pressure monitoring device, a temperature monitoring device, or combinations thereof. Each fibrous foam supply line serves to feed 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 formation zone forms a separate layer in a multilayer network.

[0027] For each formation zone, there is at least one corresponding drainage device. Each formation zone may include a single drainage device or a plurality of drainage devices. For example, each formation zone may include two drainage devices, three drainage devices, or four drainage devices. Each drainage device may be 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 to each corresponding drainage device. Each drainage line also includes a flow meter, a pressure monitoring device, a temperature monitoring device, or combinations thereof.

[0028] One or more controllers may be in communication with each of the flow control devices associated with the drainage lines. One or more controllers may be 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 foamed material slurry being fed to each of the forming zones.

[0029] As described above, each formation zone in the system may be aligned with two or more drainage devices. The zone of Petition 870250086510, dated 24 / 09 / 2025, p. 22 / 90 / 55 formation, in one aspect, may have a length in which at least one of the drainage devices aligned with the formation zone may extend beyond a length of the formation zone. The drainage device, for example, may extend beyond the length of the formation zone by less than about 20%, such as less than about 15%, such as less than about 10%, such as less than about 5%. In an alternative embodiment, the plurality of drainage devices aligned with the formation zone are all positioned within the length of the formation zone.

[0030] 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.

[0031] 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 foam in the production of larger quantities of foamed fiber suspension. In another embodiment, the system may further include a suction zone adjacent to and downstream of the plurality of forming zones to draw air through mats formed on the forming 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.

[0032] Other features and aspects of this publication are discussed in more detail below. BRIEF DESCRIPTION OF THE FIGURES

[0033] A complete and informative disclosure of the present Petition 870250086510, dated 09 / 24 / 2025, page 23 / 90 / 55 disclosure is established, 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 foamed fiber suspension; Figure 2 is a schematic diagram of a system and process for depositing a foamed fiber suspension onto a forming surface according to the present disclosure; Figure 3 is a schematic diagram of another embodiment of a system and process for depositing a foamed fiber suspension onto a forming surface according to the present disclosure; Figure 4 is a schematic diagram of another embodiment of a system and process for depositing a foamed fiber suspension onto a forming surface according to the present disclosure; Figure 5 is a schematic diagram of another embodiment of a system and process for depositing a foamed fiber suspension onto a forming surface according to the present disclosure; Figure 6 is a schematic diagram of another embodiment of a system and process for depositing a foamed fiber suspension onto a forming surface according to the present disclosure; Figure 7 is a schematic diagram of another embodiment of a system and process for depositing a foamy fiber suspension onto a forming surface according to the present disclosure; and Figure 8 is a cross-sectional view of one type of training zone that can be used in the process and system of this disclosure.

[0034] 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. Petition 870250086510, dated 09 / 24 / 2025, page 24 / 90 / 55 DEFINITIONS

[0035] 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.

[0036] 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.

[0037] 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. Suitable foaming fluids include, but are not limited to, water.

[0038] 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.

[0039] 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.

[0040] 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.

[0041] As used in this document, unless expressly stated otherwise, when used in relation to material compositions, the terms “percentage”, “%”, “percentage by weight” or “percentage by weight” refer to the amount by weight of a component as a percentage of the total, except as expressly stated otherwise.

[0042] The term “absorbent personal hygiene article” refers here to an article intended and / or adapted to be placed against or close to the Petition 870250086510, dated 09 / 24 / 2025, page 25 / 90 / 55 body (i.e., contiguous to the body) of the user 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 pants, feminine hygiene products, including, but not limited to, menstrual pads or panties, incontinence products, medical clothing, surgical compresses and dressings, and so forth.

[0043] 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 favorable conditions, of absorbing at least about 10 times their weight, or at least about 15 times their weight, or at least about 25 times their weight in an aqueous solution containing 0.9 percent by weight of sodium chloride.

[0044] 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 mat.

[0045] The term “direction opposite to the machine”, as used here, refers to the direction perpendicular to the machine direction defined above.

[0046] 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, sawdust, straw, jute, hemp, and bagasse. Cellulose fibers may include hardwood fibers, softwood fibers, and mixtures thereof.

[0047] 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 techniques Petition 870250086510, dated 09 / 24 / 2025, page 26 / 90 / 55 microscopic. A sample of at least 20 randomly selected fibers is separated from a liquid suspension of fibers. 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 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 (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 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 Petition 870250086510, dated 09 / 24 / 2025, page 27 / 90 / 55 ni = number of fibers with length Xi n = total number of fibers measured.

[0048] 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.

[0049] 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 may be treated as hydrophilic. Staple fibers may be staple fibers or similar. Staple fibers may have round, two-component, multi-component, molded, hollow or similar cross-sections. DETAILED DESCRIPTION

[0050] 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.

[0051] 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 foamy fiber suspension. According to the present disclosure, both the supply flow and the drainage flow of a foamy fiber suspension being deposited on a porous forming surface can be 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 foamy fiber suspension. The inlet pressure and / or inlet flow rate Petition 870250086510, dated 09 / 24 / 2025, page 28 / 90 / 55: The foamed fiber suspension in at least one discrete formation zone can be coordinated with the drainage flow through the porous formation surface to control mat formation. When producing multilayer mats, the process and system can result in the mixing of layers to create multilayer mats with enhanced physical properties.

[0052] The drainage flow through the porous forming surface can be controlled using one or more drainage devices. In one aspect, a single drainage device is placed in alignment with each corresponding forming zone. In another aspect, however, several advantages and benefits can be obtained if more than one drainage device is placed in alignment with a single forming zone. Having multiple drainage devices aligned with a forming zone can allow greater control over fluid drainage. In general, greater drainage using multiple drainage devices can remove moisture from the mat being formed and reduce energy costs in subsequent mat drying. Having a plurality of drainage devices opposite a forming zone, for example, can remove significant amounts of moisture, especially from superabsorbent materials.Reducing the amount of interstitial water in a layer containing superabsorbent materials, for example, can positively impact the mat's formation characteristics and drastically reduce the energy required to dry it.

[0053] Controlling fluid drainage across the porous formation surface using a plurality of drainage devices can also provide control over fiber mixing. For example, when producing a single-layer mat, the desired fiber mixing can occur within the layer. When producing multi-layer mats, fluid drainage can be controlled to cause mixing between the different layers of the mat. Petition 870250086510, dated 09 / 24 / 2025, p. 29 / 90 / 55 blanket without sacrificing overall uniform formation. For example, in one aspect, the process and system can be used to produce multilayer blankets that include a plurality of discrete blanket-forming zones that can be positioned adjacent to each other along the porous forming surface. When forming the multilayer blanket, the drainage flow rate in each of the discrete forming zones can be controlled to produce blankets with stable sheet formation and enhanced structure and interface stability.

[0054] In one aspect, a supply of a foamed fiber suspension is fed into an inlet box where at least one discrete forming 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 overdrainage during changes in process conditions and raw material inputs. In one embodiment, the drainage flow from the porous forming surface is controlled with adjustable flow control devices such as valves and / or pumps (including vacuum devices) 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 for 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.

[0055] The system and process of the present disclosure may provide several advantages and benefits. For example, during the process, the orientation of the fibers and / or the mixing of the fibers may be Petition 870250086510, dated 09 / 24 / 2025, page 30 / 90 / 55 controlled. Consequently, the system and process of this disclosure can also be used to produce blankets with customized properties for a specific end-use application. For example, through the process of this disclosure, it is possible to form blankets 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.

[0056] In addition to the above, the system and process of this disclosure minimize any detrimental effects that may occur due to the application of vacuum or suction force to the foamed fiber suspension or embryonic mat being formed. Overall, the alignment of inlet pressure and drainage flow in various formation zones can achieve stable layer formation.

[0057] 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.

[0058] 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. As the Petition 870250086510, dated 09 / 24 / 2025, page 31 / 90 / 55. Foam suspensions are not Newtonian; the density and viscosity of the foam change based on location and process. According to this disclosure, several parameters of the foamed suspension can be 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 calculated. Knowing at least some of the above parameters allows one to calculate changes in the 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 formation surface. In this way, the fluid drainage rate across the formation surface can be calculated and controlled based on the flow rate of the foamed suspension onto the formation surface, to control and optimize the formation of a mat with uniform properties. In particular, monitoring parameters of the foam going to the formation surface and being drained from the formation surface can be used to prevent under- or over-drainage of the mat on the formation surface, producing mats without interruptions, imperfections, or other irregularities in the fiber mat that may be caused by unbalanced shear forces exerted on the mat.

[0059] 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 and the size of the Petition 870250086510, dated 09 / 24 / 2025, page 32 / 90 / 55 bubble / stability of the foam 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 velocity of the foamed suspension at the forming surface. Below the moving forming surface there is one or more drainage devices that can apply vacuum to the mat as it is formed and that pull excess foam through the forming surface to control sheet formation.In the drainage lines positioned downstream of the formation 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 formation surface is then controlled and adjusted based on the volumetric flow rate of the foamed suspension fed onto the formation 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 multi-layer mats, shear forces can be controlled and / or minimized to improve the boundaries between layers.

[0060] 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 Petition 870250086510, dated 24 / 09 / 2025, p. 33 / 90 / 55 foam fiber suspension. The foam fiber suspension is then fed into a mat forming system 10 or headbox which deposits the foam fiber suspension onto a porous forming surface 26 to form a mat 14. According to the present disclosure, the mat forming system or headbox 10 includes one or more adjacent forming zones in combination with one or more drainage devices and corresponding drainage lines to control and coordinate the influx of the aqueous fiber suspension with the drainage flow through the forming surface 26 to control mat formation. The mat forming system 10 is more particularly illustrated in FIG. 2.

[0061] 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.

[0062] 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 foam 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.

[0063] The foamy fiber suspension can be subjected to dehydration at an almost simultaneous rate through both Petition 870250086510, dated 09 / 24 / 2025, p. 34 / 90 / 55 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.

[0064] Returning to FIG. 1, 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 surfactant to tank 12. A fiber supply is fed to tank 12 and combined with the 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 fiber suspension. 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.

[0065] 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.

[0066] 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 Petition 870250086510, dated 09 / 24 / 2025, page 35 / 90 / 55 C10 alkyl polyglycosides.

[0067] 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.

[0068] Once the foaming agent and water are combined, the mixture is combined or otherwise subjected to forces capable of forming a foam. A foam generally refers to an aggregate of hollow cells or bubbles.

[0069] 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.

[0070] Foam can be formed in the presence of a fiber supply or, alternatively, 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 this disclosure, can be Petition 870250086510, dated 09 / 24 / 2025, p. 36 / 90 / 55 used.

[0071] Fibers suitable for making blankets comprise any natural or synthetic cellulosic fibers, including but not limited to non-wood 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 eucalyptus, maple, birch and poplar. Pulp fibers may be prepared in high-yield or low-yield forms and may be pulped by any known method, including kraft, sulfite, high-yield pulping methods and other known pulping methods. Fibers prepared from organosolv pulping methods may also be used.

[0072] 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.

[0073] Types of synthetic cellulose fibers 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 celluloses, chemically hardened or cross-linked fibers, or sulfonated fibers. To obtain good mechanical properties of the fibers for papermaking, it is desirable that Petition 870250086510, dated 09 / 24 / 2025, page 37 / 90 / 55, the fibers are relatively undamaged, largely unrefined, or only slightly refined. Although recycled fibers may be used, virgin fibers are generally useful for their ideal mechanical properties and lack of contaminants. Mercerized fibers, regenerated cellulose fibers, cellulose produced by microbes, rayon, and other cellulosic or cellulose-derived materials may be used. Fibers for suitable papermaking may also include recycled fibers, virgin fibers, or blends thereof. In some embodiments capable of 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 most specifically at least 500.

[0074] 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. These pulping processes include bleached thermo-chemical-mechanical pulp (BCTMP), thermo-chemical-mechanical pulp (CTMP), thermomechanical pressure / 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.

[0075] The blanket can also be formed without a quantity Petition 870250086510, dated 09 / 24 / 2025, page 38 / 90 / 55 substantial bond 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, imidazoline quaternary salts, 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 publicizes the use of various cationic silicone compositions as debonding agents.

[0076] 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.

[0077] 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.

[0078] Other optional chemical additives may also be added to the aqueous papermaking feedstock or to the formed embryonic mat to impart additional benefits to the product and Petition 870250086510, dated 09 / 24 / 2025, page 39 / 90 / 55 of the process. The following materials are included as examples of additional chemicals that can be applied to the blanket. The chemicals are included as examples and are not intended to limit the scope of the invention. Such chemicals can be added at any point in the papermaking process.

[0079] Other types of chemicals that can be added to the paper blanket include, but are not limited to, absorbency aids generally in the form of cationic, anionic or non-ionic surfactants, 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, can also be incorporated into the finished products.

[0080] 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.

[0081] Once the foam fiber suspension is formed in tank 12, the foam 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, the second forming zone 50, and the second forming zone 50. Petition 870250086510, dated 09 / 24 / 2025, p. 40 / 90 / 55 formation 52, and third formation zone 54. Formation zones 50, 52, and 54 are positioned along the porous formation surface 26. In one embodiment, as shown in FIG. 2, the porous formation surface 26 may be inclined relative to the horizontal. For example, the porous formation surface 26 may have an angle with the horizontal greater than about 10°, as greater than about 20°, as greater than about 30°, and generally less than about 60°, as less than about 50°. Each forming zone 50, 52, and 54 is designed to receive a separate and independent flow of fiber foam suspension to deposit the fiber foam suspension onto the forming surface 26. For example, the first forming zone 50 can deposit a fiber foam suspension directly onto the forming surface 26.The second formation zone 52, however, can be configured to deposit a second flow of the foamed fiber suspension onto the fibers deposited by the first formation zone 50. Similarly, the third formation zone 54 can deposit a flow of the aqueous fiber suspension onto the fibers deposited by the first formation zone 50 and the second formation 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 formation zone to form single-layer mats.

[0082] 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. Supply lines 56, 58, and 60 are configured to feed a foam suspension of Petition 870250086510, dated 09 / 24 / 2025, p. 41 / 90 / 55 fibers for each of the corresponding formation zones 50, 52, and 54 in 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 which is connected to the mixing tank 12. Similarly, the second supply line 58 may include a second injection line 64, while the third supply line 60 may be in communication with a third injection line 66. The injection lines 62, 64, and 66 may all be in communication with the mixing tank 12 to feed the foamed 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 can be connected to a different mixing tank to feed the fiber foam suspension to the mat forming system 10.

[0083] 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.

[0084] For example, the first fibrous foam supply line includes a first pumping device 68, a first flow meter 74, a first pressure monitoring device Petition 870250086510, dated 09 / 24 / 2025, pp. 42 / 90 / 55 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 present disclosure, the pumping devices 68, 70, and 72 can be adjusted so that the fiber foam suspension can be independently fed to each forming zone 50, 52, and 54 at a desired flow rate and / or pressure.Flow meters 74, 76, and 78, pressure monitoring devices 80, 82, and 84 (e.g., volumetric flow rate), and 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 foamed fiber suspension at the formation surface.

[0085] 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. Petition 870250086510, dated 09 / 24 / 2025, pp. 43 / 90 / 55 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 blanket on the forming surface 26.

[0086] 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 foamed fiber suspension at the measurement location. Furthermore, the density of the foamed fiber suspension can be measured or calculated from the information received from the various instruments. This information, in one embodiment, can be sent to the controllers to then calculate at least one characteristic of the foamed fiber suspension at the formation surface. In particular, the controller can be programmed to correct the volumetric flow rate determined at the formation 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 formation 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.

[0087] 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. Petition 870250086510, dated 09 / 24 / 2025, pages 44 / 90 / 55

[0088] 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 feedstock, the 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.

[0089] 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.

[0090] 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 Petition 870250086510, dated 09 / 24 / 2025, page 45 / 90 / 55 calculated by dividing the flow rate (L / min) of the raw material by the fraction of the liquid volume. The gas flow rate of the foamed suspension can be determined by subtracting the liquid flow rate (L / min) from the flow rate of the foamed suspension (L / min). All the above determinations are made at the location of the measurements in FIG. 2.

[0091] To calculate changes in density and volumetric flow rate of foam at other points in the system, such as at the formation surface, the pressure difference must be accounted for due to the expansion or 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 change in temperature. Alternatively, temperature changes within the system can be measured, calculated, or estimated and thus 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.

[0092] 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. Base 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 Petition 870250086510, dated 09 / 24 / 2025, page 46 / 90 / 55 mass flow rate of 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.

[0093] 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 compared to the predefined value. Based on the 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 forming surface and / or the basis weight of the layer being formed.

[0094] 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.

[0095] In the embodiment illustrated in FIG. 2, several characteristics of Petition 870250086510, dated 09 / 24 / 2025, page 47 / 90 / 55: Drainage fluid is 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.

[0096] For example, as shown in FIG. 2, opposite each formation zone 50, 52, and 54 is a corresponding drainage device in fluid communication with a corresponding drainage line. In the embodiment illustrated in FIG. 2, each formation zone is aligned with a single drainage device and is provided for explanation of one embodiment of the process. In FIGS. 4-7, on the other hand, other systems and processes are shown in which several drainage devices are aligned with at least one formation zone. As will be evident from FIGS. 4-7, several advantages and benefits can be obtained when more than one drainage device is aligned with at least one formation zone within the system.

[0097] 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 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.

[0098] As shown in FIG. 8, a second foamy suspension of materials is also being fed into the process from a second inlet box. In the embodiment illustrated in FIG. 8, two Petition 870250086510, dated 09 / 24 / 2025, page 48 / 90 / 55 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.

[0099] The first flow of the foamy material suspension 302 is fed into the formation zone 300 and deposited on the moving porous forming 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 forming surface 308 to where the partition or lamella 306 ends. As shown in FIG. 8, the formation zone 300 has length L.

[00100] According to the present disclosure, a drainage device is aligned with the formation zone provided that the drainage device does not extend more than 20% beyond the length L of the formation zone. In other embodiments, the drainage device or a 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%.

[00101] 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, the formation zones 50, 52, and Petition 870250086510, dated 09 / 24 / 2025, pp. 49 / 90 / 55 are adjacent to each other along 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 formation surface 26 from formation zones 50, 52, and 54. As the foamy fiber suspension is deposited on the formation surface of each formation zone 50, 52, and 54, a mat 14 is formed and the excess fluid enters the corresponding drainage devices 86, 88, and 90. The drainage devices may be any suitable static or dynamic drainage device capable of draining fluid from the mat or formation surfaces. The drainage device may be a static or vacuum suction box. Alternatively, the drainage device may be a drum, such as a rotating drum that applies suction.

[00102] As shown in FIG.2. Each drainage line 92, 94, 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.The optional flow control devices 98, 100, and 102 can be any suitable device 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... Petition 870250086510, dated 09 / 24 / 2025, pp. 50 / 90 / 55 formation surface. Alternatively, drainage may occur by gravity. In yet another embodiment, each flow control device 98, 100, and 102 may be a combination of a pump and an adjustable valve.

[00103] In an 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 may be adjusted and controlled based on at least one characteristic of the foamed fiber suspension that may 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 may be based on the volumetric flow rate of the foamed fiber suspension being fed into 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, may 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 fluid flow rate (mass or volumetric) can be controlled through each drainage device using different techniques and methods. For example, flow control devices 98, 100, and 102 can 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. Petition 870250086510, dated 09 / 24 / 2025, pp. 51 / 90 / 55 50, 52, and 54. In one aspect, for example, flow control devices may comprise suction devices that apply suction to the formation surface to drain fluids. The flow rate of fluids drained through each drainage device may be controlled by adjusting the amount of suction applied to the formation surface. In another aspect, the suction applied to the formation surface may be constant, and a downstream valve or other device may be used to control the drainage. In another embodiment, fluids may be drained by gravity, and a valve or similar device may be used to control the flow.

[00104] 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.

[00105] 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 with the controller 116. The controller may receive information from the flow meters 104, 106, and 108, the temperature monitoring devices 105, 107, and 109, the optional density monitoring devices and / or the pressure monitoring devices 110, 112, and 114 to make adjustments to the flow control devices 98, 100, and 102 to control the flow rate at which fluids are drained from each of the devices. Petition 870250086510, dated 09 / 24 / 2025, pp. 52 / 90 / 55, regarding drainage 86, 88, and 90. The combination of receiving information from flow control devices 98, 100, and 102, which may be volumetric flow meters, from pressure monitoring devices 110, 112, and 114, temperature monitoring devices 105, 107, and 109, and / or optional density monitoring devices may be used to quantify the discharge flows of fluids containing gases and liquids. In one embodiment, the controller 116 may 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.

[00106] 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. In this embodiment, controller 116 can determine a reference pressure from information received from all downstream measuring devices and instruments. Controller 116 can then adjust the reference pressure on the formation surface based on a characteristic of the foamed suspension, such as the volumetric flow rate of the foamed suspension.

[00107] 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 Petition 870250086510, dated 09 / 24 / 2025, page 53 / 90 / 55 uniform characteristics and improved properties.

[00108] 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.

[00109] 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.

[00110] For example, as shown in FIG. 2, by controlling the discharge flow rates relative to the inlet flow rates, the foamy fiber suspension fed into each formation zone 50, 52, and 54 can be caused to spread in a unique manner on the formation surface 26. 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 suspension. Petition 870250086510, dated 09 / 24 / 2025, page 54 / 90 / 55 foamed fibers being fed to each of the formation zones 50, 52, and 54. Creating a pressure differential where formation zones 50, 52, and 54 intersect with formation surface 26 can create mixing and reorientation of fibers and longitudinal flow, as shown in FIG. 2.

[00111] 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 received from the flow meter 126, the pressure monitoring device 128, the temperature monitoring device 129, and optionally a density monitoring device can be used to calculate the volumetric flow rates of the foam on the forming surface.

[00112] 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 device of Petition 870250086510, dated 09 / 24 / 2025, page 55 / 90 / 55 flow control 134, a flow meter 136, a temperature monitoring device 137, and a pressure detection device 138 which may all 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.

[00113] 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.

[00114] In one embodiment, one or more drainage devices 86, 88, and 90 are operated so that the foamy suspension of fibers fed into formation zones 50, 52, and 54, and particularly into the third formation zone 54, causes the excess liquid to flow longitudinally out of a perimeter of the third formation zone 54 to be collected in suction zone 140.

[00115] In one embodiment, as shown in FIG. 2, all drainage lines 92, 94, 96, 132, and 142 can be fed to a separator tank 150. The separator tank 150 can be configured to Petition 870250086510, dated 09 / 24 / 2025, page 56 / 90 / 55 to separate free gases from foam. As shown, the separator tank 150 may 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 may comprise a mixture of water and surfactant. As shown in FIG. 2, a pumping device 156 may be used to pump liquids from the separator tank 150 to a liquid tank 158 which may also be placed in communication with a water source 160. The liquid tank 158 may be used to recycle the water and surfactant mixture back to the process via supply lines 56, 58, 60, and 122.

[00116] The mat formation 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 formation 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 formation zones achieves stable sheet formation and can produce multilayer mats with controlled and / or optimized mixing between the different mat layers.

[00117] Referring to FIG. 1, after the embryonic mat 14 is formed from the mat forming system or headbox 10, the mat can be fed to several different downstream processes. FIG. 1 represents only one embodiment of a process for drying the mat after it has been formed. As shown, the mat 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.

[00118] 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 Petition 870250086510, dated 24 / 09 / 2025, p. 57 / 90 / 55 In truth, the consistency of formation may be less than about 2%, as well as less than about 1.8%, as well as less than about 1.5%. The consistency of formation is generally greater than about 0.5%, as well as greater than about 0.8%.

[00119] 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.

[00120] 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 blanket 14 is placed in contact with two heated drying drums 38 and 40. In one embodiment, from the drying drums 38 and 40, the blanket can be fed to an air dryer before being rolled onto a roll.

[00121] As described above, in one aspect, at least one formation zone in the system can be placed in alignment with a plurality of drainage devices. The use of a plurality of drainage devices can better control the amount of fluid or moisture drained from the blanket. Placing a plurality of drainage devices aligned with a single formation zone can also be Petition 870250086510, dated 09 / 24 / 2025, pp. 58 / 90 / 55 used to control fiber characteristics. Drainage devices, for example, can be used to cause fiber mixing and / or control fiber alignment.

[00122] Referring to FIG. 4, for example, an embodiment of a blanket formation system made in accordance with the present disclosure is shown, in which the system includes a single formation zone positioned in alignment with three drainage devices. Similar reference numbers have been used to indicate similar elements.

[00123] 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.

[00124] Opposite formation zone 50 are positioned three drainage devices 86A, 86B, and 86C which are aligned with the formation zone. Each drainage device 86A, 86B, and 86C is in communication with a corresponding drainage line 92A, 92B, and 92C. Each drainage line 92A, 92B, and 92C includes a corresponding flow control device 98A, 98B, and 98C, a flow meter 104A, 104B, and 104C, a temperature monitoring device 105A, 105B, and 105C, and a pressure monitoring device 110A, 110B, and 110C. All instruments can be in communication with a controller 116 which may comprise one or more microprocessors.

[00125] In the embodiment illustrated in FIG. 4, each drainage device 86A, 86B, and 86C can be operated independently of the others. Petition 870250086510, dated 09 / 24 / 2025, page 59 / 90 / 55 drainage devices. 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.

[00126] In one embodiment, for example, a greater amount of drainage may occur through drainage device 86A compared with drainage devices 86B and 86C in order to initially remove as much fluid as possible.

[00127] Alternatively, less drainage may occur between drainage devices 86A and 86B while greater amounts of drainage may occur in drainage device 86C. In this embodiment, a beneficial amount of fiber mixing may occur to produce a blanket with one or more desired properties.

[00128] In another embodiment, greater drainage can occur through drainage device 86B than occurs through drainage devices 86A and 86C. Drainage device 86B, for example, can be used for primary drainage while the other drainage devices 86A and 86C can be there to supplement drainage.

[00129] In another aspect, the system and process of the present disclosure can be configured so that the drainage or flow rate of fluids through each drainage device can be approximately the same. For example, the amount of suction applied to the forming fabric can be varied in front of each drainage device to create approximately the same flow rate through each drainage device. As shown in FIG. 4, for example, the mat being formed will generally contain a greater amount of fluid opposite drainage device 86A than the amount of fluid contained in the network opposite the Petition 870250086510, dated 09 / 24 / 2025, page 60 / 90 / 55 drainage device 86B and drainage device 86C. To maintain relatively equal flow rates, less suction can be applied by drainage device 86A compared to drainage device 86B and drainage device 86C in order to produce drainage flows that are approximately the same. In one embodiment, maintaining approximately the same drainage flow rates can provide several benefits and advantages, including better and / or more uniform formation of the blanket.

[00130] For example, in one embodiment, the drainage flow rate between each drainage device 86A, 86B, and 86C may vary by no more than about 20%, as by no more than about 15%, as by no more than about 10%, as by no more than about 5%, as by no more than about 3%. In a specific embodiment, the flow rate through each drainage device opposite a single formation zone may vary by at most 1%. In this way, the drainage flow rate profile may be constant or substantially constant along the length of a single formation zone.

[00131] Having more than one drainage device positioned in alignment with formation zone 50 can provide excellent control over fluid drainage to produce a drainage profile along formation zone 50 that yields a desired result. In the embodiment illustrated in FIG. 4, formation zone 50 is aligned with three drainage devices 86A, 86B, and 86C. In other embodiments, however, the system may include only two drainage devices, four drainage devices, five drainage devices, six drainage devices, or even seven drainage devices aligned with formation zone 50.

[00132] The process and system as illustrated in FIG. 4 is generally for forming a single-layer blanket. Referring to FIGS. Petition 870250086510, dated 09 / 24 / 2025, pages 61 / 90 / 55 Figures 5-7 show other embodiments of systems according to the present disclosure, which are designed to form multilayer mats. In each system illustrated in Figures 5-7, at least one forming zone is placed in alignment with two drainage devices to control fluid drainage through the mat as it is formed.

[00133] In FIGS. 5-7, as well as reference numerals, similar elements were used. As shown in FIGS. 57, each 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.

[00134] 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.

[00135] In the embodiment illustrated in FIG. 5, the first formation zone 50 is aligned with two drainage devices 86A and 86B. Similarly, the second formation zone 52 is aligned with two drainage devices 88A and 88B. The third formation zone 54, on the other hand, is aligned with a single drainage device 90. Petition 870250086510, dated 09 / 24 / 2025, pages 62 / 90 / 55 As shown, drainage devices 86A and 86B are in fluid communication with the corresponding drainage lines 92A and 92B. Each drainage line is in communication with a flow control device 98A and 98B, a flow meter 104A and 104B, a temperature monitoring device 105A and 105B, and a pressure monitoring device 110A and 110B.

[00136] Drainage devices 88A and 88B are each in communication with corresponding drainage lines 94A and 94B. Drainage lines 94A and 94B are in communication with corresponding flow control devices 100A and 100B, flow meters 106A and 106B, temperature monitoring devices 107A and 107B, and pressure monitoring devices 112A and 112B.

[00137] Similar to FIG. 2, the drainage device 90 in alignment with the formation zone 54 is in communication with a drainage line 96 which includes a flow control device 102, a flow meter 108, a temperature monitoring device 109, and a pressure monitoring device 114.

[00138] In the embodiment illustrated in FIG. 5, a greater number of drainage devices are positioned at the upstream end of the formation surface. Thus, a higher concentration of drainage devices is located adjacent to where the blanket is first formed. In this way, fluids can be drained more efficiently from the blanket after the first and second layers have been deposited on the formation surface.

[00139] Alternatively, drainage devices 86A, 86B, 88A, and 88B can be used to promote fiber mixing. For example, 86B and 86A can be operated to drain less fluid from the mat compared to drainage devices 86A and 88B. In this way, mixing can occur between the first layer and the second layer. The mixing between Petition 870250086510, dated 09 / 24 / 2025, p. 63 / 90 / 55 layers can occur using a plurality of drainage devices without causing fiber mixing to the point where the layers are no longer discernible.

[00140] Referring to FIG. 6, another embodiment of a blanket formation system is shown according to this disclosure. FIG. 6 is identical to FIG. 5 except the third formation zone 54 is placed in alignment with two drainage devices 90A and 90B. Drainage devices 90A and 90B are in communication with corresponding drainage lines 96A and 96B. Each drainage line 96A and 96B includes corresponding flow control devices 102A and 102B, flow meters 108A and 108B, temperature monitoring devices 109A and 109B, and pressure monitoring devices 114A and 114B.

[00141] FIG. 6 provides similar control over fluid drainage as FIG. 5 except for more control opposite the third formation zone 54. Including two drainage devices 90A and 90B opposite formation zone 54, for example, the system can be controlled to promote fiber mixing between the second and third layers of the mat. For example, less drainage can occur through drainage devices 88A and 88B compared to the drainage that occurs in drainage devices 86B and 90A to promote some fiber mixing between adjacent layers.

[00142] In another embodiment, all drainage devices 86A, 86B, 88A, 88B, 90A, and 90B can be used to remove as much fluid and moisture as possible before further processing.

[00143] Referring to FIG. 7, another embodiment of a process and system according to this disclosure is shown. In this embodiment, the first formation zone 50 is aligned with a first drainage box 86 which is in fluid communication with a drainage line 92. The second formation zone 52 is also in Petition 870250086510, dated 09 / 24 / 2025, p. 64 / 90 / 55 communication with a single drainage device 88 that is in fluid communication with a drainage line 94.

[00144] The third formation zone, on the other hand, is aligned with two drainage devices 90A and 90B. Drainage devices 90A and 90B are in fluid communication with the corresponding drainage lines 96A and 96B. Located along drainage lines 96A and 96B are flow control devices 102A and 102B, flow meters 108A and 108B, temperature monitoring devices 109A and 109B, and pressure monitoring devices 114A and 114B. A controller 116, which may comprise one or more microprocessors, may be used to control the different components to increase or decrease the flow rate of fluids drained through each drainage device 86, 88, 90A, and 90B and in the corresponding drainage line 92, 94, 96A, and 96B.

[00145] Having a plurality of drainage devices 90A and 90B in alignment with the third forming zone 54 can provide several advantages and benefits. For example, in one embodiment, less drainage through drainage devices 88, 90A, and / or 90B can promote fiber mixing between the second and third layers. If the second layer contains superabsorbent materials, for example, some of the superabsorbent materials may be in the third layer without also being on the surface of the finished mat. In this way, fluids that come into contact with the mat during use can have greater access to the superabsorbent particles without them remaining on the surface of the product and causing lint or creating more friction on the outer surface.

[00146] Alternatively, drainage devices 90A and 90B can be used to increase fluid drainage at the end of the forming surface while the third layer is being formed. Increasing drainage at the end can reduce the energy required to dry the mat.

[00147] Blankets made in accordance with this disclosure may Petition 870250086510, dated 09 / 24 / 2025, pp. 65 / 90 / 55, can be used in all different types of products. For example, the fabric blanket can be used to produce toilet paper, facial tissues, paper towels, industrial wipes, and the like. In one embodiment, the blankets made according to this disclosure may contain substantial amounts of superabsorbent particles. For example, at least one layer of the blanket may contain superabsorbent particles in an amount greater than about 50% by weight and up to about 90% by weight, including all 1% by weight increments between them. These types of blankets are particularly suitable for incorporation into absorbent personal hygiene articles. For example, the blankets can be used as absorbent cores positioned between a liquid-permeable lining and a liquid-impermeable outer covering.

[00148] 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 870250086510, dated 09 / 24 / 2025, pp. 66 / 90

Claims

1 / 15 CLAIMS 1. A process for producing a mat, characterized in that it comprises: flowing a foamy suspension of materials into at least one formation zone, the foamy suspension being fed into a first formation zone at a first flow rate; depositing the foamy suspension of materials fed into the first formation zone adjacent to at least one mobile porous formation surface to form a layer of an embryonic mat; draining the excess fluids through the porous formation surface to a first drainage device and to a second drainage device, the first and second drainage devices positioned in alignment with the first formation zone along at least one porous formation surface;and controlling a flow rate of drainage fluids drained through the first drainage device and controlling a flow rate of drainage fluids drained through the second drainage device, wherein the flow rate of drainage fluids drained through the first drainage device is controlled independently of the flow rate of drainage fluids drained through the second drainage device.

2. Process according to claim 1, characterized in that the flow rate of drainage fluids drained through the first drainage device and the flow rate of drainage fluids drained through the second drainage device are controlled based on at least one characteristic of the flow of the foamed material suspension being fed to the first forming zone, the at least one characteristic of the flow of the foamed material suspension comprising a temperature, a pressure, a mass flow rate, a volumetric flow rate or a density of the foamed material suspension. Petition 870250086510, dated 09 / 24 / 2025, p. 67 / 90 2 / 15 3. Process according to claim 1 or 2, characterized in that at least one of the layers of the embryonic mantle is the only layer formed in a respective formation zone.

4. A process according to any of the preceding claims, characterized in that the first drainage device is positioned upstream and adjacent to the second drainage device, and in which the flow rate of drainage fluids drained through the first drainage device is greater than the flow rate of drainage fluids drained through the second drainage device.

5. A process according to any one of claims 1 to 3, characterized in that the first drainage device is positioned upstream and adjacent to the second drainage device, and in which the flow rate of drainage fluids drained through the first drainage device is less than the flow rate of drainage fluids drained through the second drainage device.

6. A process according to any one of claims 1 to 3, characterized in that the flow rate of drainage fluids drained through the first drainage device and the flow rate of drainage fluids drained through the second drainage device are substantially the same, such that the flow rate of drainage fluids drained through the first drainage device and the flow rate of drainage fluids drained through the second drainage device vary by no more than about 20%, such as by no more than about 15%, such as by no more than about 10%, such as by no more than about 5%, such as by no more than about 3%.

7. A process according to any of the preceding claims, characterized in that it further comprises the step of flowing the foamy suspension of materials into a second formation zone positioned adjacent to the first formation zone, the foamy suspension of materials being fed into the second formation zone at a second flow rate; depositing the foamy suspension of materials fed into the second formation zone adjacent to at least one mobile porous formation surface, so that a second layer of material is formed below or over the deposited materials adjacent to the formation surface of the first formation zone to form a multilayer mat; and controlling a flow rate of drainage fluids drained through a third drainage device positioned in alignment with the second formation zone.

8. Process according to claim 7, characterized in that the second formation zone is positioned downstream of the first formation zone and in that the first drainage device and the second drainage device are positioned upstream of where the second layer is formed.

9. Process according to claim 7, characterized in that the second formation zone is positioned upstream of the first formation zone and in that the first drainage device and the second drainage device are positioned downstream of where the second layer is formed.

10. Process according to any one of claims 7 to 9, characterized in that it further comprises the step of flowing the foamed suspension of materials to a third formation zone positioned adjacent to one of the other formation zones, the foamed suspension of materials being fed to the third formation zone at a third flow rate; depositing the fed foamed suspension of materials into the third formation zone adjacent to at least one mobile porous formation surface so that a third layer of materials is formed in the multilayer mat; and controlling a flow rate of drainage fluids drained through a fourth drainage device positioned in alignment with the third formation zone.

11. Process according to any one of claims 1 to 6, characterized in that the process includes only the first forming zone to produce single-layer blankets.

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

13. Process according to claim 12, characterized in that the sealing zone positioned adjacent to and upstream of all formation zones emits a fluid towards at least one porous formation surface to inhibit airflow.

14. A process according to any of the preceding claims, characterized in that the first formation zone has a length and in which at least one of the first drainage device or the second drainage device extends beyond the length of the first formation zone.

15. Process according to any one of claims 7 to 10, characterized in that the foamed suspension of materials is pumped into each formation zone individually, so that the fluid pressure upstream of each formation zone can be controlled independently of the other formation zones.

16. Process according to any of the preceding claims, characterized in that the foamed suspension of materials is pumped to the first formation zone and in that, 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 the first drainage device and the second drainage device being controlled based on the calculated flow rate.

17. 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 first flow meter and a first pressure monitoring device, the first flow meter and the first pressure monitoring device sending information to a controller that calculates a discharge flow rate, the controller being in communication with a first 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, and in that the flow rate of drainage fluids drained through the second drainage device is monitored by a second flow meter and a second pressure monitoring device,The second flow meter and the second pressure monitoring device send information to a controller that calculates a discharge flow rate. The controller is in communication with a second adjustable flow control device to control the flow rate of drainage fluids drained through the second drainage device based on the calculated discharge flow rate.

18. A process according to any of the preceding claims, characterized in that the forming surface is inclined with respect to the horizontal.

19. 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 about 350 g / L to about 600 g / L and / or containing about 40% to about 80% by volume of air, such as about 40% to about 65% by volume of air.

20. A 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.

21. A 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.

22. 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.

23. 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.

24. 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 a flow meter, a Petition 870250086510, dated 09 / 24 / 2025, page.72 / 90 7 / 15 temperature monitoring device and a pressure monitoring device, wherein the information received from at least one of the flow meter, the pressure monitoring device or the temperature monitoring device is used to calculate a flow rate of fluids being drained through the first drainage device at the formation surface, and wherein the fluids drained through the second drainage device are also monitored downstream of the formation surface by at least one of a flow meter, a temperature monitoring device and a pressure monitoring device, and wherein the information received from at least one of the flow meter, the pressure monitoring device or the temperature monitoring device is used to calculate a flow rate of fluids being drained through the second drainage device at the formation surface.

25. A process according to any one of the preceding claims, characterized in that the first drainage device and the second drainage device comprise vacuum boxes.

26. A process according to any one of claims 1 to 24, characterized in that the first drainage device and the second drainage device comprise drainage rollers.

27. System for producing mats, characterized in that it comprises: a first forming zone positioned in relation to at least one porous forming surface, the first 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 for Petition 870250086510, dated 09 / 24 / 2025, page 1.73 / 90 8 / 15 respective first formation zone, the first formation zone being configured to form only a single layer of a blanket; a first drainage device positioned in relation to at least one porous formation surface in alignment with the first formation zone, the first drainage device being in fluid communication with a corresponding first drainage line; and a second drainage device adjacent to the first drainage device and positioned in relation to at least one porous formation surface, also in alignment with the first formation zone, the second drainage device being in fluid communication with a corresponding second drainage line.

28. System according to claim 27, characterized in that the fibrous foam supply line further includes a flow meter, a pressure monitoring device, a temperature monitoring device, or combinations thereof; the fibrous foam supply line feeds a foam suspension of materials to the 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, temperature, pressure, or combinations thereof; and wherein the first drainage line includes a first flow control device to control the flow rate of a fluid being drained to the first drainage device; the first drainage line further includes a first flow meter, a first pressure monitoring device, a first temperature monitoring device, or combinations thereof.and wherein the second drainage line includes a second flow control device to control the flow rate of a fluid being drained to the second drainage device, the second drainage line further includes a second flow meter, a second pressure monitoring device, a second temperature monitoring device or combinations thereof, the system further comprising one or more controllers communicating with the flow control devices associated with the first drainage line and the second drainage line, or one or more controllers being configured to control the flow rate of fluids being drained to the first and second drainage devices in relation to a flow rate, temperature or pressure of the foamed material slurry being fed to the first forming zone.

29. A system according to claim 27 or 28, characterized in that it comprises a plurality of formation zones, 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 specified flow rate, temperature, pressure or both,each formation zone forming a separate layer in a multilayer blanket on at least one porous formation surface; wherein for each formation zone there is at least one corresponding drainage device, each drainage device being in fluidic 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 Petition 870250086510, dated 09 / 24 / 2025, page 75 / 90 10 / 15 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,being 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, temperature, or pressure of the foamed material suspension being fed to each of the forming zones.

30. System according to claim 29, 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.

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

32. System according to any one of claims 27 to 31, characterized in that the first formation zone has a length and in which at least one of the first drainage device or of the second drainage device extends beyond the length of the first formation zone.

33. Process for producing a mat, characterized in that it comprises: flowing a foamy suspension of materials into at least one formation zone, the foamy suspension being fed into a first formation zone at a first flow rate; depositing the foamy suspension of materials fed into the first formation zone adjacent to at least one mobile porous formation surface to form a layer of an embryonic mat; draining the excess fluids through the porous formation surface to a first drainage device and to a second drainage device, the first and second drainage devices positioned in alignment with the first formation zone along at least one porous formation surface;and controlling a flow rate of drainage fluids drained through the first drainage device and controlling a flow rate of drainage fluids drained through the second drainage device, wherein the flow rate of drainage fluids drained through the first drainage device and the flow rate of drainage fluids drained through the second drainage device are controlled based on at least one characteristic of the flow of the foamed material suspension being fed to the first forming zone, at least one characteristic of the flow of the foamed material suspension comprising a temperature, a pressure, a mass flow rate, a volumetric flow rate or a density of the foamed material suspension.

34. Process according to claim 33, characterized in that the flow rate of drainage fluids drained through the first drainage device is controlled independently of the flow rate of drainage fluids drained through the second drainage device.

35. Process according to claim 33, characterized in that the first drainage device is positioned upstream and adjacent to the second drainage device, and in which the flow rate of drainage fluids drained through the first drainage device is greater than the flow rate of drainage fluids drained through the second drainage device.

36. Process according to claim 33, characterized in that the first drainage device is positioned upstream and adjacent to the second drainage device, and wherein the flow rate of drainage fluids drained through the first drainage device is less than the flow rate of drainage fluids drained through the second drainage device.

37. Process according to claim 33, characterized in that the flow rate of drainage fluids drained through the first drainage device and the flow rate of drainage fluids drained through the second drainage device are substantially the same, such that the flow rate of drainage fluids drained through the first drainage device and the flow rate of drainage fluids drained through the second drainage device vary by no more than about 20%, such as by no more than about 15%, such as by no more than about 10%, such as by no more than about 5%, such as by no more than about 3%.

38. Process according to claim 33, characterized in that it further comprises the step of flowing the foamed suspension of materials into a second formation zone positioned adjacent to the first formation zone, the foamed suspension of materials being fed into the second formation zone at a second flow rate; depositing the fed foamed suspension of materials into the second formation zone adjacent to at least one mobile porous formation surface, so that a second layer of material is formed below or over the deposited materials adjacent to the formation surface of the first formation zone to form a multilayer mat; and Petition 870250086510, dated 24 / 09 / 2025, p. 78 / 90 13 / 15 controlling a flow rate of drainage fluids drained through a third drainage device positioned in alignment with the second formation zone.

39. A process according to claim 38, characterized in that it further comprises the step of flowing the foamed suspension of materials into a third formation zone positioned adjacent to one of the other formation zones, the foamed suspension of materials being fed into the third formation zone at a third flow rate; depositing the fed foamed suspension of materials into the third formation zone adjacent to at least one mobile porous formation surface so that a third layer of materials is formed in the multilayer mat; and controlling a flow rate of drainage fluids drained through a fourth drainage device positioned in alignment with the third formation zone.

40. Process according to claim 33, characterized in that the first formation zone has a length and in which at least one of the first drainage device or the second drainage device extends beyond the length of the first formation zone.

41. Process according to claim 33, 38 or 39, characterized in that the foamed suspension of materials is pumped to each formation zone individually, so that the fluid pressure upstream of each formation zone can be controlled independently of the other formation zones.

42. Process according to claim 33, characterized in that the foamed suspension of materials is pumped to the first formation zone and in that, 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 the first drainage device and the second drainage device being controlled based on the calculated flow rate.

43. A process according to claim 33, characterized in that the flow rate of drainage fluids drained through the first drainage device is monitored by a first flow meter and a first pressure monitoring device, the first flow meter and the first pressure monitoring device sending information to a controller that calculates a discharge flow rate, the controller being in communication with a first 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, and in that the flow rate of drainage fluids drained through the second drainage device is monitored by a second flow meter and a second pressure monitoring device, the second flow meter and the second pressure monitoring device sending information to a controller that calculates a discharge flow rate,The controller is in communication with a second adjustable flow control device to control the flow rate of drainage fluids drained through the second drainage device based on the calculated discharge flow rate.

44. Process according to claim 33, characterized in that the materials contained in the blanket comprise at least about 5% by weight of cellulose fibers, as at least about 10% by weight of cellulose fibers, as at least about 15% by weight of cellulose fibers optionally combined with non-fibrous particles, such as superabsorbent particles.

45. Process according to claim 33, characterized in Petition 870250086510, dated 09 / 24 / 2025, pp. 80 / 90 15 / 15, in that the fluids drained through the first drainage device are monitored downstream of the formation surface by at least one of a flow meter, a temperature monitoring device, and a pressure monitoring device, and wherein the information received from at least one of the flow meter, the pressure monitoring device, or the temperature monitoring device is used to calculate a flow rate of fluids being drained through the first drainage device at the formation surface, and wherein the fluids drained through the second drainage device are also monitored downstream of the formation surface by at least one of a flow meter, a temperature monitoring device, and a pressure monitoring device.and wherein the information received from at least one of the flow meter, pressure monitoring device, or temperature monitoring device is used to calculate a flow rate of fluids being drained through the second drainage device at the formation surface.

46. ​​Process according to claim 33, characterized in that at least one of the layers of the embryonic mantle is the only layer formed in a respective formation zone.

47. Process according to claim 33, characterized in that only one of the layers of the embryonic mantle is formed in a respective formation zone. Petition 870250086510, dated 09 / 24 / 2025, pp. 81 / 90

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