Foam formation system and method for foam formation

Description

41 FOAM FORMATION SYSTEM AND METHOD FOR FOAM FORMATION FUNDAMENTALS

[001] 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.

[002] To improve various characteristics of woven blankets, they have also been formed according to a foaming process. During the foaming process, a suspension of foamy 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. In addition to woven 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.

[003] In certain conventional foaming systems, one or more fan pumps transport foam from a separation silo to a standing water tank via a short channel. This arrangement can have disadvantages. For example, large fan pumps and / or vacuum assist may be required to provide sufficient suction pressure from the low-density foam in the separation silo. As another example, the compressibility of the foam in the separation silo may limit the vacuum applicable in the separation silo.

[004] A system to improve the handling of foam between a separation silo and a standing water tank would be useful. Petition 870250087383, dated 09 / 26 / 2025, page 12 / 66 / 41 SUMMARY

[005] In general, the present disclosure is directed to an improved process and system for flowing foam between a separator and a tank. A pump is operable to flow foam from the separator to the tank. The pump can be controlled to maintain a foam level in the separator based on a signal from a sensor that detects the foam level in the separator. The processes and systems of the present disclosure can advantageously assist in reducing or preventing excessive or insufficient drainage of foam from the separator. Furthermore, excessive drainage of foam from the separator can drag large air bubbles into the foam flow from the separator, which can decrease the foam density and impede foam flow. In contrast, insufficient drainage of foam from the separator can cause vacuum loss in the separator, foam formation in the separator, and introduction of foam into a vacuum source.These negative effects of excessive and insufficient drainage can be limited or avoided by operating the pump to maintain the foam level in the separator. The processes and systems of this disclosure can also advantageously assist in providing a consistent residence time for the foam in the separator, which can improve foam stability.

[006] In one embodiment, a foaming system includes an inlet box and a tank. A separator is disposed between the inlet box and the tank along a foam flow path between the inlet box and the tank. The separator includes an inlet for the foam, a first outlet for the foam, and a second outlet for the foam-free air. The foaming system also includes a pump. A sensor is operable to determine the foam level in the separator. A controller is configured to receive a signal from the sensor corresponding to the foam level in the separator and, based at least in part on the foam level in the separator, operate the pump to maintain the foam level. Petition 870250087383, dated 09 / 26 / 2025, page 13 / 66 / 41 foam within a defined range inside the separator.

[007] In another embodiment, a foam-making system includes a tank. A vacuum separator includes an inlet for foam, a first outlet for the foam, and a second outlet for the foam-free air. The vacuum separator is coupled to the tank via the first outlet, so that the foam can flow from the vacuum separator to the tank. A pump is operable to flow the foam from the vacuum separator to the tank. A sensor is operable to determine the foam level in the vacuum separator. A controller is configured to determine the foam level in the vacuum separator based, at least in part, on a signal from the sensor and to operate the pump to maintain the foam level within a determined range within the vacuum separator based, at least in part, on the determined foam level in the vacuum separator.

[008] In another embodiment, a method for foam formation includes: flowing foam from an inlet box into a vacuum separator; flowing free air from the foam out of the vacuum separator through a vacuum outlet of the vacuum separator; and operating a pump to flow the foam out of the vacuum separator through a foam outlet of the vacuum separator. The operation of the pump includes determining the foam level in the vacuum separator with a sensor and adjusting the pump flow rate to maintain the foam level within a determined range within the vacuum separator based, at least in part, on the determined foam level in the vacuum separator.

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

[0010] A full and informative disclosure of this disclosure is set out, more particularly, in the remainder of the descriptive report, including reference to the attached figures, in which: Petition 870250087383, dated 09 / 26 / 2025, p. 14 / 66 / 41 FIG. 1 is a schematic view of a system and process according to an exemplary embodiment of the present disclosure for forming mats from a foamed suspension of materials; FIG. 2 is a schematic view of a system and process according to an exemplary embodiment of the present disclosure for depositing a foamy suspension of materials onto a forming surface according to the present disclosure; and FIG. 3 is a schematic view of a system and process according to an exemplary embodiment of the present disclosure for separating free air from a foam stream during foaming of a nonwoven mat.

[0011] FIG. 4 is a flow diagram of a process according to an example embodiment of the present disclosure for separating free air from a foam stream during foaming of a nonwoven mat.

[0012] The repeated use of reference characters in this descriptive report and in the drawings is intended to represent features or elements that are the same as, or analogous to, the present invention. DEFINITIONS

[0013] When introducing the elements of this disclosure or the preferred embodiment(s) thereof, the articles “a / an”, “the” and “said” are intended to indicate that there is one or more of the elements. As used herein, the terms includes and including are intended to be inclusive in a manner similar to the term comprising. Similarly, the term “or” is generally intended to be inclusive (i.e., “A or B” is intended to mean “A or B or both”). Approximate language, as used herein throughout the descriptive report and claims, is applied to modify any quantitative representation that may permissibly vary without resulting in an alteration of the basic function to which it relates. Petition 870250087383, dated 09 / 26 / 2025, p. 15 / 66 / 41 Consequently, a value modified by a term or terms, such as “about,” “approximately,” and “substantially,” should not be limited to the precise value specified. In at least some cases, approximate language may correspond to the precision of an instrument for measuring the value. For example, approximate language may refer to being within a ten percent (10%) margin.

[0014] 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.

[0015] 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.

[0016] 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.

[0017] 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.

[0018] As used herein, the term “layer” refers to a structure that provides an area of ​​a substrate in a height direction from the substrate that is composed of similar components and structure.

[0019] 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.

[0020] As used in this document, unless expressly indicated otherwise, when used in relation to material compositions, the terms percentage, %, percentage by weight or Petition 870250087383, dated 09 / 26 / 2025, page 16 / 66 / 41. Percentage by weight refers to the quantity by weight of a component as a percentage of the total, unless expressly stated otherwise.

[0021] The term “absorbent personal care article” refers here to an article intended and / or adapted to be placed against or close to (i.e., contiguous to) the user’s body to absorb and contain various liquid, solid and semi-solid exudates discharged from the body. Examples include, but are not limited to, diapers, pull-up diapers, training diapers, diapers for grown children, swim pants, feminine hygiene products, including, but not limited to, menstrual pads or panties, incontinence products, medical gowns, surgical compresses and dressings, and so forth.

[0022] The term superabsorbent material, as used herein, refers to organic or inorganic materials that are swollen in water and insoluble in water, including superabsorbent polymers and compositions of superabsorbent polymers capable, under the most favorable conditions, of absorbing at least about ten times (10X) their weight, or at least about fifteen times (15X) their weight, or at least about twenty-five times (25X) their weight in an aqueous solution containing nine tenths (0.9) percent by weight of sodium chloride.

[0023] 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 web.

[0024] The term direction opposite to the machine, as used here, refers to the direction perpendicular to the machine direction defined above.

[0025] The term pulp, as used herein, refers to fibers from natural sources, such as woody and non-woody plants. Woody plants include, for example, deciduous and coniferous plants. Non-woody plants include, for example, cotton, flax, esparto grass, sow thistle, straw, jute, hemp. Petition 870250087383, dated 09 / 26 / 2025, page 17 / 66 / 41 and bagasse. Cellulose fibers may include hardwood fibers, softwood fibers, and mixtures thereof.

[0026] The term average fiber length, as used in this document, refers to an average length of fibers, fiber bundles, and / or fiber-like materials determined by measurement using microscopic techniques. A sample of at least 20 randomly selected fibers is separated from a liquid fiber suspension. The fibers are placed on a microscope slide prepared to suspend fibers in water. A dyeing agent is added to the suspended fibers to color the cellulose-containing fibers so that they can be distinguished from or separated from synthetic fibers. The slide is placed under a Fisher Stereomaster II microscope - Series S19642 / S19643. Measurements of 20 fibers in the sample are made at 20X linear magnification using a 0-20 mils 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: Petition 870250087383, dated 09 / 26 / 2025, page 18 / 66 / 41 where k = maximum fiber length xi = fiber length ni = number of fibers with length xin = total number of fibers measured.

[0027] 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.

[0028] 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, bicomponent, multicomponent, molded, hollow or similar cross-sections. DETAILED DESCRIPTION

[0029] 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.

[0030] In general, the present disclosure relates to a system and method for foaming a nonwoven mat. In the system, a separator silo is separated from a standing water tank, and a pump can be set up to flow foam from the separator silo to the standing water tank. The pump can be controlled to maintain a level range. Petition 870250087383, dated 09 / 26 / 2025, page 19 / 66 / 41 consistent for the foam in the separator silo. Furthermore, the foam level in the separator silo can be measured by a sensor, such as a capacitive rod, and the pump can be controlled based on the sensor measurements. The separator silo can be configured to operate under vacuum, and the standing water tank can be set to ambient pressure.

[0031] The system and process of the present disclosure can provide several advantages and benefits. For example, the system may include a separate fan pump configured to propel foam from the standing water tank to an inlet box. The fan pump can operate more efficiently and robustly by utilizing the pump to maintain a consistent level range for the foam in the separator silo. Thus, a suction height for the fan pump can be improved and / or a centrifugal pump can be used in the fan pump instead of a vacuum-assisted centrifugal pump. As another example, the vacuum level within the overall system can be increased, and the desired vacuum level can be decoupled from the machine height.Thus, a height difference between a free foam surface in the separator silo and a free foam surface in the standing water tank can be substantially reduced by using the pump to maintain a consistent level range for the foam in the separator silo. As another example, using the pump to maintain a consistent level range for the foam in the separator silo can help reduce or prevent excessive or insufficient drainage of foam from the separator silo. This can prevent the entry of large air bubbles into the foam flow from the separator silo and / or the introduction of foam into a vacuum source for the separator silo. As another example, using the pump to maintain a consistent level range for the foam in the separator silo can help provide a consistent residence time for the foam in the separator, which can improve foam stability. Petition 870250087383, dated 09 / 26 / 2025, p. 20 / 66 / 41

[0032] Referring to FIGS. 1 and 2, an example embodiment of a system and process according to aspects of the present disclosure is shown. In general, during the process, solid material, such as fibers and / or superabsorbent particles, water, and a foaming agent are added to a tank and mixed until the desired air content, bubble size / foam stability, and solid dispersion are achieved, such as a fiber dispersion. The fiber-containing foam can then be optionally diluted during the process, especially when a recycling stream is present. In one example aspect, the air content of the foamed suspension is between about thirty percent (30%) and about sixty-five percent (65%). As will be described below, exemplary aspects of the process and system of the present disclosure are directed to the separation of foam from free air and to the management of foam, for example, during the foaming of a nonwoven mat.

[0033] FIG. 1 illustrates a system and process for producing a foamed fiber suspension and for forming mats from the foamed fiber suspension. It is understood that the example system shown in FIG. 1 is provided by way of example and that any suitable mat-forming system may be used in accordance with this disclosure. As shown in FIG. 1, the system may include a mixing tank 12 configured to form the foamed fiber suspension. The foamed fiber suspension may then be fed into an inlet box or mat-forming system 10 which deposits the foamed fiber suspension onto a porous forming surface 26 to form a mat 14. The mixing tank 12 may be in communication with a water supply 22 to feed the tank with water and a foaming agent or surfactant supply 24 to feed a surfactant to the tank 12.A fiber supply can also be fed to tank 12 and combined with the water. Petition 870250087383, dated 09 / 26 / 2025, page 21 / 66 / 41 the surfactant. The aqueous solution formed by combining the surfactant and water can be agitated and transformed into a foam to form a foamy suspension of fibers. As described above, in addition to fibers, various other materials can be combined in tank 12. These other materials, for example, may include superabsorbent particles or similar.

[0034] The surfactant or foaming agent, for example, may include any suitable surfactant. In one exemplary embodiment, for example, the foaming agent may include sodium lauryl sulfate, which is also known as sodium lauryl ether sulfate or sodium laureth sulfate. Other foaming agents include sodium dodecyl sulfate or ammonium lauryl sulfate. In other exemplary embodiments, the foaming agent may include 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. In one exemplary embodiment, a nonionic surfactant is used. The nonionic surfactant, for example, may include an alkyl polyglycoside. In one aspect, for example, the surfactant may be a C8 alkyl polyglycoside, a C10 alkyl polyglycoside, or a mixture of C8 and C10 alkyl polyglycosides.

[0035] The foaming agent may be combined with water generally in an amount greater than about one tenth of one percent (0.1%) by weight, as in an amount greater than about half a percent (0.5%) by weight, as in an amount greater than about seven tenths of one percent (0.7%) by weight. One or more foaming agents may generally be present in an amount from about one hundredth of one percent (0.01%) by weight to about five percent (5%) by weight, as in an amount up to about two percent (2%) by weight.

[0036] When the foaming agent and water are combined, the Petition 870250087383, dated 09 / 26 / 2025, page 22 / 66 / 41. A mixture can be mixed or subjected to forces capable of forming a foam. A foam generally refers to an aggregate of hollow cells or bubbles.

[0037] The density of the foam may vary depending on the particular application and several factors, including the fiber used. In one example embodiment, for instance, the density of the foam may be greater than about two hundred grams per liter (200 g / L), such as greater than about two hundred and fifty grams per liter (250 g / L), such as greater than about three hundred grams per liter (300 g / L). The density of the foam is generally less than about six hundred grams per liter (600 g / L), such as less than about five hundred grams per liter (500 g / L), such as less than about four hundred grams per liter (400 g / L), such as less than about three hundred and fifty grams per liter (350 g / L).In one example embodiment, for instance, a lower density foam is used having a foam density generally less than about three hundred and fifty grams per liter (350 g / L), such as less than about three hundred and forty grams per liter (340 g / L), such as less than about three hundred and thirty grams per liter (330 g / L). The foam may generally have an air content greater than about forty percent (40%), such as greater than about fifty percent (50%), such as greater than about sixty percent (60%), for example, at standard temperature and pressure (TPP). The air content is generally less than about seventy-five percent (75%) by volume, as well as less than about seventy percent (70%) by volume, such as less than about sixty-five percent (65%) by volume.

[0038] Foam can be formed in the presence of a fiber supply or, alternatively, foam can be formed first and then combined with a fiber supply. In general, any fiber capable of forming a base sheet, such as a woven mat or other similar type of nonwoven, can be used. Petition 870250087383, dated 09 / 26 / 2025, p. 23 / 66 / 41

[0039] Fibers suitable for the manufacture of blankets include any natural or synthetic cellulosic fibers, including but not limited to: non-woody fibers such as cotton, abaca, kenaf, sabai grass, flax, esparto 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. Cellulose fibers may be prepared in high 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.

[0040] A portion of the fibers, such as up to one hundred percent (100%) or less by dry weight, or from about five percent (5%) to about thirty percent (30%) by dry weight, may be synthetic fibers, such as rayon, polyolefin fibers, polyester fibers, bicomponent 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 three millimeters (3 mm) to about one hundred and fifty millimeters (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.

[0041] 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 be used, such as mercerized pulps, chemically hardened or cross-linked fibers, or sulfonated fibers. To obtain good properties Petition 870250087383, dated 09 / 26 / 2025, page 24 / 66 / 41. Regarding the mechanical properties of fibers used in papermaking, it may be desirable for the fibers to be relatively intact and largely unrefined or only lightly refined. While recycled fibers may be used, virgin fibers are generally useful for their mechanical properties and lack of contaminants. Mercerized fibers, regenerated cellulosic fibers, cellulose produced by microbes, rayon, and other cellulosic materials or cellulosic derivatives may be used. Fibers suitable for papermaking may also include recycled fibers, virgin fibers, or mixtures thereof. In certain examples of embodiments capable of high volume and good compression properties, the fibers may have a Canadian Standard Freedom of at least two hundred (200), more specifically at least three hundred (300), more specifically still at least four hundred (400), and more specifically at least five hundred (500).

[0042] Other papermaking fibers that may be used include recycled paper or fibers and high-yield fibers. High-yield cellulose fibers are those papermaking fibers produced by pulping processes that provide a yield of about sixty-five percent (65%) or more, more specifically about seventy-five percent (75%) or more, and even more specifically from about seventy-five percent (75%) to about ninety-five percent (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 relative to sulfite pulps. Petition 870250087383, dated 09 / 26 / 2025, page 25 / 66 / 41 typical chemically reduced to cellulose.

[0043] The mat can also be formed without a substantial amount of bonding strength between internal fibers. In this sense, the fiber used to form the base mat can be treated with a chemical debonding agent. The debonding agent can be added to the foamed fiber pulp during the pulping process or can be added directly to the headbox. Suitable debonding agents that can be used include cationic debonding agents such as dialkyl fatty quaternary amine salts, monoalkyl fatty tertiary amine salts, primary amine salts, imidazoline quaternary salts, silicon quaternary salt and unsaturated alkyl fatty amine salts. Other suitable debonding agents are disclosed in Patents No. 5,529,665 to Kaun, the entirety of which is incorporated herein by reference. In particular, Kaun discloses the use of various cationic silicon compositions as debonding agents.

[0044] In one embodiment, the debonding agent used in the process of the present disclosure may be 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 one kilogram per metric ton (1 kg / ton) to about ten kilograms per metric ton (10 kg / ton) of fiber present in the pulp.

[0045] In an alternative embodiment, the detaching agent may be an imidazoline-based agent. The imidazoline-based detaching agent may be obtained, for example, from Witco Corporation. The imidazoline-based detaching agent may be added in an amount between two kilograms per metric ton. Petition 870250087383, dated 09 / 26 / 2025, p. 26 / 66 / 41 (2.0 kg / ton) and approximately fifteen kilograms per metric ton (15 kg / ton).

[0046] Other optional chemical additives may also be added to the aqueous papermaking feedstock or to the formed embryonic web to impart additional benefits to the product and process. The following materials are included as examples of additional chemicals that may be applied to the web. The chemicals are included as examples and are not intended to limit the scope of the disclosure. Such chemicals may be added at any point in the papermaking process.

[0047] Additional types of chemicals that can be added to the paper blanket include, but are not limited to, absorption aids generally in the form of cationic, anionic or non-ionic surfactants, humectants and plasticizers, such as low molecular weight polyethylene glycols, and polyhydroxylated compounds, such as glycerin and propylene glycol. Materials that provide benefits to skin health, such as mineral oil, aloe vera extract, vitamin E, silicone, lotions in general and the like, can also be incorporated into the finished products.

[0048] Other examples of such materials include, but are not limited to, odor control agents such as odor absorbers, activated carbon fibers and particles, baby powder, 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.

[0049] Returning to FIG. 2, once the foamy fiber suspension is formed in tank 12 (FIG. 1), the foamy fiber suspension can be fed to the mat forming system 10. As illustrated in Petition 870250087383, dated 09 / 26 / 2025, page 27 / 66 / 41 FIG. 2, the blanket formation system 10 may include one or more formation zones. In the exemplary embodiment of FIG. 2, three formation zones are shown, including the first formation zone 50, the second formation zone 52, and the third formation zone 54. The formation zones 50, 52, and 54 are positioned along the porous formation surface 26. In an exemplary 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 be oriented at an angle to the horizontal greater than about ten degrees (10°), such as greater than about twenty degrees (20°), such as greater than about thirty degrees (30°), and generally less than about sixty degrees (60°), such as less than about fifty degrees (50°).Each formation zone 50, 52, and 54 can be configured to receive a separate and independent flow of the foamed fiber suspension to deposit the foamed fiber suspension onto the formation surface 26. For example, the first formation zone 50 can deposit a foamed fiber suspension directly onto the formation 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 can be 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.

[0050] As shown in FIG. 2, each formation zone 50, 52 and 54 may be in fluid communication with a separate and independent fibrous foam supply line. For example, the first formation zone 50 may be in communication with a first line of Petition 870250087383, dated 09 / 26 / 2025, page 28 / 66 / 41 supply of fibrous foam 56, the second formation zone 52 may be in fluid communication with a second supply line of fibrous foam 58, and the third formation zone 54 may be in fluid communication with a third supply line of fibrous foam 60. The first, second and third supply lines 56, 58 and 60 may be configured to feed a foamy fiber suspension to each of the respective formation zones 50, 52 and 54 at a determined and selected flow characteristic, which may be, for example, flow rate, such as volumetric flow rate, pressure, air content and / or density. In this respect, each of the supply lines 56, 58 and 60 may be in fluid communication with the mixing tank 12, as shown in FIG. 1.For example, the first supply line 56 may include a first injection line 62 that is connected to the mixing tank 12. Similarly, the second supply line 58 may include a second injection line 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 10 may include separate mixing tanks, and each of the first, second, and third injection lines 62, 64, and 66 may be connected to a different mixing tank to feed the foamed fiber suspension to the mat forming system 10.

[0051] 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 monitoring device. Petition 870250087383, dated 09 / 26 / 2025, page 29 / 66 / 41 of density. The density monitoring device, for example, may be part of one of the other devices, such as part of the flow meter. Alternatively, the density of the foamy fiber suspension may be calculated using information received from other instruments.

[0052] For example: the first fibrous foam supply line may include a first pumping device 68, a first flow meter 74, a first pressure monitoring device 80 and a first temperature monitoring device 81; the second fibrous foam supply line 58 may include 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 may include a third pumping device 72, a third flow meter 78, a third pressure monitoring device 84 and a third temperature monitoring device 85.Pumping devices 68, 70, and 72 can be adjusted so that the foamed fiber suspension can be independently fed to each formation zone 50, 52, and 54 at a desired and selected 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 foamed fiber suspension flow at the formation surface.

[0053] In one embodiment, flow meters 74, 76 and 78, pressure monitoring devices 80, 82 and 84, temperature monitoring devices 81, 83 and 85 can be placed in communication with one or more controllers. The controllers may include microprocessors or any suitable programmable device. The Petition 870250087383, dated 09 / 26 / 2025, page 30 / 66 / 41 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 to each formation zone 50, 52 and 54 at a flow rate within the desired set points and / or at a pressure within the desired set points to optimize the formation of a mat on the formation surface 26.

[0054] The 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.

[0055] As shown in FIG. 2, opposite the first formation zone 50 along the formation surface 26 there may be a first drainage device 86 in fluid communication with a first Petition 870250087383, dated 09 / 26 / 2025, p. 31 / 66 / 41 drainage line 92. Opposite the second formation zone 52 there may be a second drainage device 88 in fluid communication with a second drainage line 94. Similarly, opposite the third formation zone 54 there may be a third drainage device 90 in communication with a third drainage line 96. The first, second and third formation zones 50, 52 and 54 may be adjacent to each other along the formation surface 26 and may be positioned on one side of the formation surface 26. Drainage devices 86, 88 and 90 may also be adjacent to each other and may be positioned on the opposite side of the formation surface 26 in alignment with formation zones 50, 52 and 54.As the foamed fiber suspension is deposited on the forming surface of each forming zone 50, 52, and 54, a mat 14 can be formed, and excess fluids can enter the corresponding drainage devices 86, 88, and 90. The drainage devices can be any suitable static or dynamic drainage device capable of draining fluids from the mat or forming surfaces. The drainage device can be a static or vacuum suction box. Alternatively, the drainage device can be a drum, such as a rotating drum that applies suction.

[0056] As shown in FIG. 2, each drain line 92, 94, and 96 may include a corresponding flow control device, flow meter, temperature monitoring device, and pressure monitoring device. For example: the first drain line 92 may include 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 drain line 94 may include a second flow control device 100, a second flow meter 106, a second temperature monitoring device 107, and a second pressure monitoring device 110. Petition 870250087383, dated 09 / 26 / 2025, pp. 32 / 66 / 41, pressure monitoring device 112; and the third drainage line 96 may include 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 flow control devices 98, 100, and 102 may be any device suitable for controlling flow through the line and may be an adjustable valve or a pump. Pumps, for example, may be used to apply suction to the formation surface. Alternatively, drainage may occur by gravity. In another embodiment, each flow control device 98, 100, and 102 may be a combination of a pump and an adjustable valve.

[0057] In one embodiment, the system 10 may further include one or more controllers 116. The controllers 116 may include 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 116 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 drainage devices 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, from temperature monitoring devices 105, 107 and 109 and / or from... Petition 870250087383, dated 09 / 26 / 2025, page 33 / 66 / 41. Optional density monitoring devices can be used to quantify the discharge flows of fluids containing gases and liquids. In one embodiment, controller 116 can use the above information to calculate a flow rate, such as a volumetric flow rate, at the formation surface and control the volumetric flow rate based on at least one characteristic of the frothing 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.

[0058] In examples of embodiments, 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 may be non-fibrous.A sealing fluid can be fed into the sealing fluid zone 120 at a flow rate and / or pressure such that the sealing fluid deposited on the forming surface 26 forms a fluid seal that prevents airflow in an 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... Petition 870250087383, dated 09 / 26 / 2025, page 34 / 66 / 41 foam on the formation surface.

[0059] 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 opposite a sealing drainage device 130 connected to a sealing drainage line 132. The sealing drainage line 132 may include a flow control device 134, a flow meter 136, a temperature monitoring device 137, and a pressure sensing device 138, all of which may be in communication with the controller 116. In this way, the drainage flow rate of the sealing fluid can be controlled based on the flow rate or pressure at which the sealing fluid enters or exits the sealing zone 120. By including the sealing zone 120, better formation of the blanket 14 occurs opposite the first formation zone 50.

[0060] 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 may be in fluid communication with a drainage line 142 which may include a pressure monitoring device 144. The suction zone 140 serves to draw fluids through the embryonic mat 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 foamed fiber suspension being drained through one or more drainage devices can be controlled so that excess fluid from one or more formation zones enters the suction zone 140. Ideally, the suction zone 140 facilitates the drainage of fluids from the network 14 without causing any detrimental effects.

[0061] As shown in FIG. 2, all drain lines 92, 94, 96, 132 and 142 can be fed to a separator tank 150. The separator tank 150 can be configured to separate free gases from Petition 870250087383, dated 09 / 26 / 2025, page 35 / 66 / 41 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 include 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 into the process via supply lines 56, 58, 60, and 122.

[0062] Returning to FIG. 1, after the embryonic mat 14 is formed from the mat-forming system or headbox 10, the mat 14 can be fed into several different subsequent processes. FIG. 1 represents only one exemplary embodiment of a process for drying the mat 14 after it has been formed. As shown, the mat 14 is formed on the forming surface 26 and transported downstream. The infinite motion forming fabric 26, for example, can be supported and driven by rollers 28.

[0063] Once formed in the forming fabric 26, the formed blanket 14 may have a consistency of less than about fifty percent (50%), such as less than about twenty percent (20%), such as less than about ten percent (10%), such as less than about five percent (5%). In fact, the consistency of formation may be less than about two percent (2%), such as less than about one and eight tenths percent (1.8%), such as less than about one and a half percent (1.5%). The consistency of formation is generally greater than about half percent (0.5%), such as greater than about eight tenths percent (0.8%).

[0064] Once the wet blanket 14 is formed on the forming fabric 26, the blanket 14 is transported downstream and optionally further dehydrated. For example, the process may optionally include a Petition 870250087383, dated 09 / 26 / 2025, p. 36 / 66 / 41 plurality of vacuum devices 16, such as vacuum and vacuum rollers. Vacuum boxes assist in removing moisture from the newly formed blanket 14.

[0065] 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 box 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 blanket 14, causing the water in the blanket to drain more easily, especially in conjunction with the vacuum rollers 20. From the forming fabric 26, the newly formed blanket 14 is conveyed downstream and dried. The blanket 14 can be dried using any suitable drying device. For example, the blanket 14 can be air-dried or placed in a heated drying drum and creased or left uncreased. In FIG. 1, for example, the formed blanket 14 is placed in contact with two heated drying drums 38 and 40.In an exemplary embodiment, from drying drums 38 and 40, blanket 14 can be fed into an air dryer before being rolled onto a roll.

[0066] The embodiment in FIG. 2 is for forming multilayer mats. In another aspect, the process of the present disclosure can be used to create single-layer mats from a foamy suspension of materials.

[0067] Returning now to FIG. 3, a system 200 for separating foam from the open air and managing foam, for example, during the foaming of a nonwoven mat, according to an example of embodiments of the present disclosure is shown. It is understood that the system 200 can be used in or with any foaming system or process to form mats from a suspension of foamed fibers. For example, the system 200 can be used in or with the systems and processes of Petition 870250087383, dated 09 / 26 / 2025, page 37 / 66 / 41 example shown in FIGS. 1 and 2 and described above. Thus, system 200 is described in more detail below in the context of the example systems and processes shown in FIGS. 1 and 2. However, it should be understood that system 200 can be used in or with other systems and processes to form mats from a foamed fiber suspension in examples of alternative embodiments.

[0068] As shown in FIG. 3, the system 200 includes a separator 210 and a tank 230. The separator 210 can be arranged between an inlet box, such as the blanket forming system 10 (FIG. 1), and the tank 230. Furthermore, the separator 210 can be arranged along a foam flow path between the inlet box and the tank 230. Thus, the separator 210 can receive foam flowing from the inlet box to the tank 230. The separator 210 can be configured to separate free gases from the foam in the separator 210. The inlet box and the separator 210 can be connected by means of pipes, tubing, conduits, etc.

[0069] The separator 210 may include an inlet 220, a first outlet 222, and a second outlet 224. The inlet 220 may be in fluid communication with the inlet box, and a foam flow FF may enter the separator 210 through the inlet 220. As shown, the separator 210 may include a plurality of inlets 220 in example embodiments. Each of the inlets 220 may be connected to and in fluid communication with one of the respective drain lines 92, 94, 96, 132, and 142 (FIG. 2). Thus, foam from various portions of the blanket-forming system 10 can enter the separator 210 through one of its respective inlets 220. In other embodiments, two or more foam streams from the blanket-forming system 10 can be combined upstream of the separator 210 and enter the separator 210 through a single inlet.

[0070] The first output 222 may be in fluid communication. Petition 870250087383, dated 09 / 26 / 2025, page. 38 / 66 / 41 with tank 230, and the foam flow FF can exit separator 210 through the first outlet 222. Thus, the foam flow FF can pass through the first outlet 222 on the foam flow path between the inlet box and tank 230. The second outlet 224 can be in fluid communication with a vacuum source 270, and a free air flow FA can exit separator 210 through the second outlet 224. Furthermore, the vacuum source 270 can be operable to generate a vacuum within an internal volume 216 of separator 210. The vacuum within the internal volume 216 of separator 210 can aspirate and remove large air bubbles from within the foam in separator 210. The free air from the large air bubbles can then exit separator 210 through the second outlet 224. In contrast, the air trapped in the foam as gas bubbles Dispersed particles can remain within the FF foam stream and exit separator 210 through the first outlet 222.

[0071] As noted above, separator 210 can be configured to remove free air from the foam flow FF passing through separator 210 between the inlet box and tank 230. Gravity can facilitate the separation of free air from the foam within separator 210. Furthermore, the relatively denser foam can settle towards the lower portion 212 of separator 210, and the relatively less dense free air can rise towards the upper portion 214 of separator 210 aided by the vacuum within the internal volume 216 of separator 210. To aid in the separation of free air from the foam flow FF, the first and second outlets 222, 224 can be spaced in separator 210. For example, separator 210 can extend between a lower portion 212 and an upper portion 214, for example, along a vertical direction V.The first outlet 222 can be positioned in the lower portion 212 of the separator 210, and the second outlet 224 can be positioned in the upper portion 214 of the separator 210. Thus, for example, the first and second outlets 222, 224 can be spaced along the vertical direction V in the separator 210 and / or positioned. Petition 870250087383, dated 09 / 26 / 2025, page. 39 / 66 / 41 opposite each other along the vertical direction V in separator 210. Furthermore, the first outlet 222 can be positioned to receive the relatively denser foam that settles towards the lower portion 212 of separator 210, and the second outlet 224 can be positioned to receive the relatively less dense free air that rises towards the upper portion 214 of separator 210. The inlet(s) 220 can be positioned between the first and second outlets 222, 224, for example, along the vertical direction V. Thus, the foam flow FF can enter the internal volume 216 of separator 210 between the first and second outlets 222, 224 and / or in an intermediate portion of separator 210.

[0072] Tank 230 may be in fluid communication with separator 210. Furthermore, the FF foam flow may exit separator 210 through the first outlet 222 and flow into tank 230. Separator 210 and tank 230 may be connected by means of piping, tubing, conduits, etc. Inside tank 230, water, surfactant(s) or other fluids may be added to the foam in tank 230. Tank 230 may also be in fluid communication with the headbox, for example, blanket forming system 10 (FIG. 2), so that the foam in tank 230 may be reintroduced into the headbox for foaming a non-woven blanket in the headbox. Thus, tank 230 may be configured to recycle the FF foam flow back into the foaming process. Tank 230 and the inlet box can be connected by means of pipes, tubing, conduits, etc.In certain embodiments, an internal volume 232 of tank 230 may be contiguous with the ambient atmosphere. Thus, for example, the pressure within the internal volume 232 of tank 230 may be greater than the vacuum within the internal volume 216 of separator 210 during the operation of system 200. In other embodiments, the internal volume 232 of tank 230 may be contiguous with the ambient atmosphere by means of a valve 234. Petition 870250087383, dated 09 / 26 / 2025, page 40 / 66 / 41 modalities, the upper portion of tank 230 may include an opening or other connection to the ambient atmosphere. The internal volume 232 of tank 230 may be greater than the internal volume 216 of separator 210. For example, the internal volume 232 of tank 230 may be not less than twice (2X) greater, not less than five times (5X) greater, not less than ten times (10X) greater than the internal volume 216 of separator 210.

[0073] System 200 also includes features for maintaining an LF level of foam in separator 210. As shown in FIG. 3, system 200 includes a pump 240 and a sensor 250. Pump 240 can be arranged along the foam flow path between the inlet box and tank 230. For example, pump 240 can be arranged downstream of the first outlet 222, for example, between separator 210 and tank 230. Pump 240 can be operated to flow foam out of the internal volume 216 of separator 210 through the first outlet 222. In addition, foam flow FF can exit separator 210 at the first outlet 222 during operation of pump 240. In certain embodiments, pump 240 can be a positive displacement pump, such as a rotary, reciprocating, or linear positive displacement pump.The use of a positive displacement pump can advantageously assist in pumping foam from separator 210 through the first outlet 222 during the operation of pump 240, for example, due to the ability of positive displacement pumps to handle viscous fluids more efficiently than centrifugal pumps. Since the foam in the foam stream FF may be non-Newtonian, the density and viscosity of the foam in the foam stream FF may change based on location and process. Thus, pump 240 may be particularly suitable for pumping foam when pump 240 is a positive displacement pump. However, it should be understood that pump 240 may be a centrifugal pump in alternative embodiments. Petition 870250087383, dated 09 / 26 / 2025, page 41 / 66 / 41

[0074] Sensor 250 can be operated to determine the LF foam level in separator 210. For example, sensor 250 can detect and / or measure a height of the LF foam level within the internal volume 216 of separator 210, for example, along the vertical direction V. The LF foam level can correspond to a boundary between the foam and the free air within the internal volume 216 of separator 210. For example, as noted above, separator 210 can separate the free air from the foam within separator 210. The free foam surface facing the upper portion 214 of separator 210 can correspond to the LF foam level in separator 210. Sensor 250 can be configured to detect the LF foam level. As an example, sensor 250 could be a capacitive rod mounted on separator 210 and extending into the internal volume 216 of separator 210.For example, the capacitive rod can be mounted on the separator 210 at the upper portion 214 of the separator 210 and can extend downwards along the vertical direction V towards the lower portion 212 of the separator 210. The capacitive rod can detect a change in capacitance that varies as a function of the LF foam level in the separator 210 and can emit a signal that corresponds to the LF foam level in the separator 210. Other sensors can also be used to detect the LF foam level in the guide 210. For example, sensor 250 can include an optical sensor, a camera, an ultrasonic sensor, a radar sensor, etc., configured to detect the LF foam level in the separator 210 and emit a signal that corresponds to the LF foam level in the separator 210.

[0075] System 200 may also include or be in operational communication with a processing device or controller 260 that may be configured in a general way to facilitate the operation of at least part of System 200. In this sense, pump 240, sensor 250, and other components of System 200 may be in communication with controller 260. Thus, for example, controller 260 may receive inputs from the sensor. Petition 870250087383, dated 09 / 26 / 2025, page 42 / 66 / 41 250 and can adjust the operation of pump 260 based, at least in part, on the inputs from sensor 250. Pump 240, sensor 250, and other system components 200 may communicate with the controller 260 by means of, for example, one or more shared signal lines or communication buses. In this way, input / output (“I / O”) signals can be routed between the controller 260 and various operating components of system 200.

[0076] As used herein, the terms “processing device,” “computing device,” “controller,” or similar terms may generally refer to any suitable processing device, such as a general-purpose or special-purpose microprocessor, a microcontroller, an integrated circuit, an application-specific integrated circuit (ASIC), a digital signal processor (DSP), a field-programmable gate array (FPGA), a logic device, one or more central processing units (CPUs), graphics processing units (GPUs), processing units that perform other specialized calculations, semiconductor devices, etc. Furthermore, such “controllers” are not necessarily restricted to a single element but may include any suitable number, type, and configuration of integrated processing devices arranged in any manner suitable to facilitate the operation of the apparatus.Alternatively, the 260 controller can be built without using a microprocessor, for example, by using a combination of discrete analog and / or digital logic circuits (such as switches, amplifiers, integrators, comparators, flip-flops, AND / OR gates and the like) to perform the control functionality instead of relying on software.

[0077] The 260 controller may include, or be associated with, one or more computer-readable non-transient memory or storage media, such as RAM, ROM, EEPROM, EPROM, Petition 870250087383, dated 09 / 26 / 2025, page 43 / 66 / 41 flash memory devices, magnetic disks, or other suitable memory devices (including combinations thereof). These memory devices may be a separate component of the processor or may be included within the processor. Furthermore, these memory devices may store information and / or data accessible by one or more processors, including instructions that may be executed by one or more processors. It should be noted that instructions may be written in software in any suitable programming language or may be implemented in hardware. Additionally, or alternatively, instructions may be executed logically and / or virtually using separate threads on one or more processors.

[0078] For example, the controller 260 may be operable to execute programming instructions or microcontroller code associated with an operational cycle of the system 200. In this sense, the instructions may be software or any set of instructions that, when executed by the processing device, cause the processing device to perform operations, such as running one or more software applications, adjusting the operating parameters of the pump 240, etc. Furthermore, it should be noted that the controller 260, as disclosed herein, is capable of and may be operable to execute any methods, steps of methods, or parts of methods, as disclosed herein. For example, in some example embodiments, the methods disclosed herein may be incorporated into programming instructions stored in memory and executed by the controller 260.

[0079] Memory devices may also store data that can be retrieved, manipulated, created, or stored by one or more processors or parts of the 260 controller. The data may include, for example, data to facilitate the performance of the methods described herein. The data may be stored locally (e.g., in the 260 controller) in one or more databases and / or may be split so that the data Petition 870250087383, dated 09 / 26 / 2025, pp. 44 / 66 / 41, may be stored in multiple locations. Furthermore, or alternatively, one or more databases may be connected to the controller 260 via any suitable network, such as via a high-bandwidth local area network (LAN) or wide area network (WAN). In this respect, for example, the controller 260 may further include a communication module or interface that can be used to communicate with one or more other components of the system 200, controller 260, or any other suitable device, for example, via any suitable communication lines or networks and using any suitable communication protocol. The communication interface may include any components suitable for interacting with one or more networks, including, for example, transmitters, receivers, ports, controllers, antennas, or other suitable components.

[0080] Controller 260 can be configured to control the operation of pump 240 in order to maintain the foam level LF within separator 210. For example, controller 260 can receive a signal from sensor 250 corresponding to the foam level LF in separator 210. Based at least in part on the foam level LF in separator 210, controller 260 can operate pump 240 to maintain the foam level LF within a determined range within separator 210. As an example, controller 260 can adjust the operation of pump 240 to increase the flow rate of foam FF from separator 210 in response to the detected foam level LF from sensor 250 being greater than the determined range R. Conversely, controller 260 can adjust the operation of pump 240 to decrease the flow rate of foam FF from separator 210 in response to the detected foam level LF from sensor 250 being greater than the determined range R. sensor 250 being smaller than the determined range R.The determined range R can be selected to limit or prevent excessive and / or insufficient foam drainage from separator 210. For example, a lower value of the determined range R can be positioned above the first outlet 222 along the vertical direction V, and a higher value of the range... Petition 870250087383, dated 09 / 26 / 2025, page 45 / 66 / 41, a determined R can be positioned below the second outlet 224 along the vertical direction V. As a specific example, the lower value of the determined R range can be positioned not less than twenty-five centimeters (25 cm) above the first outlet 222 along the vertical direction V, and the upper value of the determined R range can be positioned not less than twenty-five centimeters (25 cm) below the second outlet 224 along the vertical direction V. Such spacing can advantageously help to limit or prevent excessive and / or insufficient drainage of foam from the separator 210. In examples of embodiments, the determined R range can be less than fifty centimeters (50 cm), less than twenty-five centimeters (25 cm), less than ten centimeters (10 cm), etc. along the vertical direction V.This sizing of the determined interval R can help provide a consistent residence time for the foam in separator 210 during system operation 200.

[0081] As shown in FIG. 3, system 200 may also include an additional pump 280. The additional pump 280 may be arranged downstream of tank 230. The additional pump 280 may be operable to flow foam from tank 230 to the inlet box, for example, blanket forming system 10 (FIG. 2). In embodiments, the additional pump 280 may include a fan pump. By maintaining the foam level LF within the determined range R, the additional pump 280 may operate with greater efficiency and robustness. Furthermore, in embodiments, the additional pump 280 may not utilize vacuum assistance because pump 240 maintains the foam level LF within the determined range R.

[0082] FIG. 4 illustrates a method 400 for foam formation according to an exemplary embodiment of the present subject. As an example, method 400 can be used in or with system 200 (FIG. 3) to assist in maintaining a foam level within a separator. Petition 870250087383, dated 09 / 26 / 2025, page 46 / 66 / 41 vacuum. The 260 controller of system 200 can be programmed or configured to implement method 400. Although method 400 is described in more detail below in the context of system 200, it will be understood that method 400 can be used in or within any suitable system or process in alternative example embodiments.

[0083] In 410, the foam can flow from an inlet box, such as the blanket forming system 10 (FIG. 2), to a vacuum separator, such as separator 210 (FIG. 3). Thus, the foam flow FF can enter separator 210 in 410. In 420, the free air from the foam can flow out of the vacuum separator, for example, through the second outlet 224.

[0084] In 430, a foam level in the vacuum separator can be determined. For example, sensor 250 can detect and / or measure the LF foam level within the internal volume 216 of separator 210 in 430, and sensor 250 can output a signal corresponding to the LF foam level. In 440, the LF foam level can be compared to a determined range. For example, controller 260 can compare the determined LF foam level from sensor 250 with the determined range.

[0085] Method 400 may also include the operation of a pump controller based on a comparison of the foam level with a determined range. For example, in 450, an operating parameter of the pump may be adjusted to change the foam flow rate from the vacuum separator when the detected foam level is outside the determined range. In certain embodiments, in 450, the controller 260 may increase the operating speed of pump 240 to increase the foam flow rate FF from separator 210 when the detected foam level LF from sensor 250 is greater than the determined range R. Conversely, in such embodiments, the controller 260 may decrease the operating speed of pump 240 in 450 to decrease the foam flow rate FF from separator 210 when the detected foam level LF from sensor 250 is greater than the determined range R. Petition 870250087383, dated 09 / 26 / 2025, page 47 / 66 / 41 for less than the determined range R. In 460, the operating parameter of the pump can be kept constant to maintain the foam flow rate of the vacuum separator when the detected foam level is within the determined range. In certain embodiments, in 460, the controller 260 can maintain the operating speed of the pump 240 to keep the foam flow rate FF of the separator 210 constant when the detected foam level LF of the sensor 250 is within the determined range R.

[0086] In embodiments, the average residence time of the foam in the vacuum separator can be substantially constant during method 400. Thus, for example, the average residence time of the foam in separator 210 can vary by less than one minute (1 min), less than thirty seconds (30 s), less than ten seconds (10 s), etc. during method 400. This consistent residence time can advantageously improve the stability of the foam during method 400.

[0087] During method 400, the interior of the vacuum separator may be under vacuum. Thus, for example, the vacuum source 270 may operate during method 400 to generate a vacuum within the internal volume 216 of the separator 210 and thus extract and remove large air bubbles from within the foam in the separator 210. During method 400, an internal volume of a still water tank receiving the foam flow from the vacuum separator may be contiguous with the ambient atmosphere. Thus, for example, the internal volume 232 of tank 230 may be contiguous with the ambient atmosphere during method 400, as the foam flow FF exits the separator 210 and flows into tank 230.

[0088] FIG. 4 illustrates steps performed in a specific order for illustrative and discussion purposes. Those skilled in the art, using the disclosures provided herein, will understand that the steps of any of the methods discussed herein may be adapted, rearranged, expanded, omitted, or modified in various ways without departing from the scope of Petition 870250087383, dated 09 / 26 / 2025, pages 48 / 66 / 41, is hereby published.

[0089] These and other modifications and variations of the present invention may be practiced 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. EXAMPLE OF MODALITIES

[0090] First embodiment: A foam-forming system comprising: an inlet box; a tank; a separator disposed between the inlet box and the tank along a foam flow path between the inlet box and the tank, the separator comprising an inlet for the foam, a first outlet for the foam and a second outlet for foam-free air; a pump; an operable sensor to determine a foam level in the separator; and a controller configured to receive a signal from the sensor corresponding to the foam level in the separator and, based at least in part on the foam level in the separator, operate the pump to maintain the foam level within a determined range within the separator.

[0091] Second embodiment example: The foam formation system of the first embodiment example, further comprising an additional pump disposed downstream of the tank in a foam flow path between the tank and the inlet box, the additional pump operable to flow the foam along the flow path between the inlet box and the tank.

[0092] Third example of a modality: The training system of Petition 870250087383, dated 09 / 26 / 2025, page 49 / 66 / 41 foam of the second embodiment example, in which the additional pump comprises a fan pump.

[0093] Fourth example of embodiment: The foam-forming system of any of the first to third exemplary embodiments, in which the inlet is arranged between the first and second outlets along a vertical direction.

[0094] Fifth example of embodiment: The foam formation system of any of the first to fourth exemplary embodiments, wherein the first outlet is positioned in a lower portion of the separator, and the second outlet is positioned in an upper portion of the separator.

[0095] Sixth embodiment: The foaming system of any of the first through fifth embodiments, further comprising a vacuum source coupled to the separator by means of the second outlet of the separator, the vacuum source operable to generate a vacuum within an internal volume of the separator.

[0096] Seventh embodiment example: The foam-forming system of the sixth embodiment example, in which an internal volume of the tank is contiguous to the ambient atmosphere.

[0097] Eighth example embodiment: The foam-making system of any of the first to seventh example embodiments, wherein the pump comprises a positive displacement pump.

[0098] Ninth example of embodiment: The foam-forming system of any of the first through eighth exemplary embodiments, wherein the sensor comprises a capacitive rod.

[0099] Tenth example of embodiment: The foam formation system of any of the first through ninth exemplary embodiments, wherein a tank volume is greater than a separator volume.

[00100] Eleventh example of a modality: A system of Petition 870250087383, dated 09 / 26 / 2025, page 50 / 66 / 41 foam formation, comprising: a tank; a vacuum separator comprising an inlet for foam, a first outlet for foam and a second outlet for foam-free air, the vacuum separator coupled to the tank by means of the first outlet so that the foam can flow from the vacuum separator to the tank; an operable pump to flow the foam from the vacuum separator to the tank; an operable sensor to determine a foam level in the vacuum separator; and a controller configured to determine the foam level in the vacuum separator based, at least in part, on a signal from the sensor, and to operate the pump to maintain the foam level within a determined range within the vacuum separator based, at least in part, on the determined foam level in the vacuum separator.

[00101] Twelfth embodiment: The foam-making system of the eleventh embodiment, further comprising an additional pump disposed downstream of the tank, the additional pump operable to flow the foam from the tank.

[00102] Thirteenth embodiment: The foam-forming system of the eleventh or twelfth embodiment, in which the inlet is arranged between the first and second outlets along a vertical direction.

[00103] Fourteenth example embodiment: The foaming system of any of the eleventh to thirteenth example embodiments, wherein the first outlet is positioned in a lower portion of the vacuum separator, and the second outlet is positioned in an upper portion of the vacuum separator.

[00104] Fifteenth embodiment: The foam-forming system of any of the eleventh to fourteenth embodiments, further comprising a vacuum source coupled to the vacuum separator by means of the second outlet of the vacuum separator, the vacuum source operable to generate a vacuum within a volume Petition 870250087383, dated 09 / 26 / 2025, page 51 / 66 / 41 internal vacuum separator.

[00105] Sixteenth embodiment: The foam-forming system of the fifteenth embodiment, in which an internal volume of the tank is contiguous to the ambient atmosphere.

[00106] Seventeenth embodiment: A method for foam formation, comprising: flowing foam from an inlet box to a vacuum separator; flowing free air from the foam out of the vacuum separator through a vacuum outlet of the vacuum separator; and operating a pump to flow the foam out of the vacuum separator through a foam outlet of the vacuum separator, wherein the operation of the pump comprises determining a foam level in the vacuum separator with a sensor and adjusting a pump flow rate to maintain the foam level within a determined range within the vacuum separator based, at least in part, on the determined foam level in the vacuum separator.

[00107] Eighteenth embodiment: The method of the seventeenth embodiment, in which the interior of the vacuum separator is under vacuum.

[00108] Nineteenth embodiment: The seventeenth embodiment or eighteenth embodiment method, in which the residence time of the foam in the vacuum separator is substantially constant. Petition 870250087383, dated 09 / 26 / 2025, pp. 52 / 66

Claims

1 / 4 CLAIMS 1. Foam formation system, characterized in that it comprises: an inlet box; a tank; a separator disposed between the inlet box and the tank along a flow path for foam between the inlet box and the tank, the separator comprising an inlet for the foam, a first outlet for the foam and a second outlet for foam-free air; a pump; an operable sensor to determine the foam level in the separator; and a controller configured to receive a signal from the sensor corresponding to the foam level in the separator, and based at least in part on the foam level in the separator, operate the pump to maintain the foam level within a determined range within the separator.

2. Foam formation system according to claim 1, characterized in that it further comprises an additional pump disposed downstream of the tank in a flow path for foam between the tank and the inlet box, the additional pump being operable to flow the foam along the flow path between the inlet box and the tank.

3. Foaming system according to claim 2, characterized in that the additional pump comprises a fan pump.

4. Foam-forming system according to claim 1, characterized in that the inlet is arranged between the first and second outlets along a vertical direction. Petition 870250087383, dated 09 / 26 / 2025, page 63 / 66 2 / 4 5. Foaming system according to claim 1, characterized in that the first outlet is positioned in a lower portion of the separator, and the second outlet is positioned in an upper portion of the separator.

6. Foaming system according to claim 1, characterized in that it further comprises a vacuum source coupled to the separator via the separator's second outlet, the vacuum source being operable to generate a vacuum within an internal volume of the separator.

7. Foaming system according to claim 6, characterized in that an internal volume of the tank is contiguous to the ambient atmosphere.

8. Foam-forming system according to claims 1 to 7, characterized in that the pump comprises a positive displacement pump.

9. Foam-forming system according to claims 1 to 8, characterized in that the sensor comprises a capacitive rod.

10. Foaming system according to claims 1 to 9, characterized in that the volume of the tank is greater than the volume of the separator.

11. Foam formation system, characterized in that it comprises: a tank; a vacuum separator comprising an inlet for foam, a first outlet for foam and a second outlet for foam-free air, the vacuum separator coupled to the tank by means of the first outlet so that the foam can flow from the vacuum separator to the tank; an operable pump for flowing the foam from the vacuum separator to the tank; an operable sensor for determining a foam level in the vacuum separator; and a controller configured to determine the foam level in the vacuum separator based, at least in part, on a signal from the sensor, and to operate the pump to maintain the foam level within a determined range within the vacuum separator based, at least in part, on the determined foam level in the vacuum separator.

12. Foam formation system according to claim 11, characterized in that it further comprises an additional pump disposed downstream of the tank, the additional pump being operable to flow the foam from the tank.

13. Foam-forming system according to claim 11, characterized in that the inlet is arranged between the first and second outlets along a vertical direction.

14. Foaming system according to claim 11, characterized in that the first outlet is positioned in a lower portion of the vacuum separator, and the second outlet is positioned in an upper portion of the vacuum separator.

15. Foaming system according to claim 11, characterized in that it further comprises a vacuum source coupled to the vacuum separator via the second outlet of the vacuum separator, the vacuum source being operable to generate a vacuum within an internal volume of the vacuum separator.

16. Foam-forming system according to claim 15, characterized in that an internal volume of the tank is contiguous to the ambient atmosphere.

17. Method for foam formation, characterized by the fact that it comprises: foam flowing from an inlet box to a vacuum separator; free airflow from the foam out of the vacuum separator through a vacuum outlet of the vacuum separator; and operating a pump to make the foam exit the vacuum separator through a foam outlet of the vacuum separator, wherein the operation of the pump comprises determining a foam level in the vacuum separator with a sensor and adjusting a pump flow rate to maintain the foam level within a determined range within the vacuum separator based, at least in part, on the determined foam level in the vacuum separator.

18. Method according to claim 17, characterized in that the interior of the vacuum separator is under vacuum.

19. Method according to claim 17, characterized in that the residence time of the foam in the vacuum separator is substantially constant. Petition 870250087383, dated 09 / 26 / 2025, pp. 66 / 66

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