Machine, system and method for making random fiber web

Abstract

Methods, apparatuses, and systems for forming a random fiber web using a pneumatic fiber transport system are disclosed. In one embodiment, a method can optionally include providing a plurality of movable devices including a lickerin configured to remove a plurality of fibers from a mat of fibers transported by a conveyor to a vicinity of the lickerin, causing the plurality of fibers to be dislodged from the lickerin at a dislodgement location within the system, communicating a gas source to entrain the plurality of fibers with the gas source after dislodgement, and collecting the plurality of fibers from the gas source to form the random fiber web.

Description

Background Technology

[0001] This disclosure relates to methods, systems, and machines for forming random fiber webs. More specifically, the present invention relates to machines, systems, and methods for forming nonwoven air-laid webs.

[0002] Generally, various machines, systems, and methods are known for preparing random fiber webs for random fiber products used for a variety of purposes. Cleaning and abrasive devices are partially formed from random fiber webs. Additionally, disposable absorbent products such as those used in morgues and veterinary clinics, as well as personal care absorbent products such as diapers, feminine pads, adult incontinence products, and training pants, typically include one or more layers of random fiber web material, especially liquid absorbent fiber web material. Summary of the Invention

[0003] This disclosure relates to various aspects of machines, systems, and methods for preparing nonwoven airflow webs. (See also...) Figure 1 A known machine 10 for forming a nonwoven air-laid web is shown. This machine 10 relies on an initial random fiber mat, such as one fed to a rotating licker-in roller 12 via a conveyor roller 14. The licker-in roller 12 is configured to comb through the initial random fiber mat (…). Figure 1 Individual fibers (not shown). The carded fibers are then detached from the carding roller 12 using centrifugal force and enter the air source AS flowing through the carding roller 12 and the cutter roller 16. The detached fibers are carried and entrained in the air source AS to the condenser 18. The fibers are deposited on the condenser 18 in a random manner to form a nonwoven fiber web ( Figure 1 (Not shown in the image).

[0004] Unfortunately, the aforementioned machines typically exhibit uneven fiber deposition on condenser 18. This necessitates further costly processing steps to form a more uniform mesh deposition. For example, utilizing... Figure 1 The machine allows for the removal of portions of the nonwoven fiber web (such as portions along its transverse edge regions) due to uneven deposition of fibers on the condenser 18.

[0005] The inventor has recognized the modification Figure 1 The machine is designed to provide more uniform fiber deposition on the condenser. Such a machine reduces processing costs and can reduce the need for further post-deposition steps. One implementation by the inventors is... Figure 1 The machine abuts against one or both of the doffing plate 20 and the lower slide plate 22 to dislodge unwanted amounts of carded fibers. These fibers do not become trapped in the air source AS and aggregate, thus rolling down one or both of the doffing plate 20 and the lower slide plate 22 to the condenser 18. This is suspected to be one cause of the uneven deposition discussed above. In response, the inventors have proposed various solutions, machines, etc., including removing the doffing plate and / or the lower slide plate or having a relative to the doffing plate and / or the lower slide plate. Figure 1Those machines that modify geometry.

[0006] The inventors have also recognized other components and machine embodiments that allow for improved, more uniform fiber deposition on the condenser. These components include, in various ways, the addition of seals having an opposite orientation to the condenser's rotational direction; one or more openings in the machine housing allowing observation of fiber shedding and / or fiber stacking on the condenser; the addition of pressure gauges and / or pressure gauge extensions that alter the shedding point of the fiber entering the airflow; various air venting passages added to the housing; and doffing plates and / or lower slides configured to facilitate ventilation and / or the introduction of air into and / or the expulsion of air from the air source (to name just a few). Further components and machine embodiments are disclosed and discussed herein with reference to the accompanying drawings.

[0007] This invention discloses various embodiments, including a method for forming a random fiber web using a pneumatic fiber conveying system. The method may optionally include: providing a plurality of movable devices including a licker-in roller and a conveyor, the licker-in roller being configured to remove multiple fibers from a fiber pad conveyed by the conveyor to the vicinity of the licker-in roller; causing the multiple fibers to detach from the licker-in roller at a detachment location within the system; connecting an air source to entrain the multiple fibers after detachment; and collecting the multiple fibers from the air source to form the random fiber web.

[0008] In another embodiment, a pneumatic fiber conveying system for forming a random fiber web is disclosed. The system optionally includes: a rotatable conveyor roller; a rotatable licker-in roller configured to remove multiple fibers from a fiber pad conveyed by the conveyor roller to the vicinity of the licker-in roller and configured to cause the multiple fibers to detach from the licker-in roller; a rotatable cutter roller positioned adjacent to the conveyor roller and the licker-in roller; a channel connecting an air source to a space defined between the licker-in roller and the cutter roller, the space including a detachment location where the multiple fibers detach from the licker-in roller; and a collector positioned to capture the multiple fibers once they detach into the air source, the multiple fibers forming the random fiber web on the collector.

[0009] In another embodiment, a pneumatic fiber conveying system for forming a random fiber web is disclosed. The system optionally includes: a plurality of movable devices including a licker-in roller and a conveyor, the licker-in roller being configured to remove multiple fibers from a fiber pad conveyed by the conveyor to a vicinity of the licker-in roller, wherein the licker-in roller is configured to cause the multiple fibers to detach from the licker-in roller; a channel connecting an air source to a space adjacent to the licker-in roller, the space including a detachment location where the multiple fibers detach from the licker-in roller; a collector positioned to capture the multiple fibers once they detach into the main air source, the multiple fibers forming the random fiber web on the collector; and the following. At least one of the following: a pressure gauge assembly, which is at least partially positioned between the conveyor roller and the spiked roller and extends into the space; a vent, which is located in a cutter roller assembly adjacent to the spiked roller and communicates with the air source; a seal, which is coupled to the plate at the mounting portion and extends to contact the collector, wherein the seal extends from the mounting portion to an end in a direction opposite to the rotation direction of the collector; or one or more observation ports, which are along the channel and include locations adjacent to the detachment location and one or more of the collector. Attached Figure Description

[0010] Figure 1 This is a schematic cross-section of a part of a machine known in the prior art for forming a random fiber web;

[0011] Figure 2 It is a high-level schematic diagram of some modifications and / or additional components of a system for forming a random fiber web according to an embodiment of this disclosure;

[0012] Figure 3 This is a schematic cross-section of a portion of a first machine for forming a random fiber web according to an embodiment of this disclosure;

[0013] Figure 4 This is a schematic cross-section of a portion of a second machine for forming a random fiber web according to an embodiment of this disclosure;

[0014] Figure 5 This is a perspective view of the end cap of the cutter roller according to an embodiment of the present disclosure;

[0015] Figure 6 The enlarged schematic cross section shows the licker-roller and pressure gauge assembly of a third machine for forming a random fiber web according to an embodiment of the present disclosure;

[0016] Figure 7 It is based on the implementation scheme of this disclosure. Figure 6 A perspective view of the pressure gauge assembly;

[0017] Figure 8 The enlarged schematic cross-section shows the condenser, seals, and lower slide plate of a fourth machine for forming a random fiber web according to an embodiment of the present disclosure;

[0018] Figures 9 to 11 One or more ports are shown in the housing of a fifth machine forming a random fiber web according to an embodiment of the present disclosure. Detailed Implementation

[0019] This disclosure relates to machines, systems, and methods for manufacturing random fiber webs. For reference, Figure 1 A portion of a known machine 10 for forming a random fiber web is shown, and has previously been discussed with reference to the above-described invention. In such a machine 10, the web is suitable for producing a nonwoven fabric through known chemical or mechanical bonding treatments. For example, the structure formed by drying can be chemically bonded by known methods, such as by applying an adhesive through spraying or saturation, or bonding can be achieved by using fibers that may have low melting points and are bonded to non-adhesive fibers through heat and pressure. Mechanical bonding can be carried out by needle punching, stitch bonding, printing bonding, etc. The quality of any nonwoven fabric produced by these finishing methods depends on the quality and uniformity of the web structure being treated or finished.

[0020] See still Figure 1The process described herein may be operated on a large scale. For example, using machine 10, detached fibers can be projected by licker-in roller 12 at an initial speed of up to 5,000 ft / min, which may rotate at the same speed. Speeds of up to 20,000 ft / min are not uncommon for licker-in roller 12. The detached fibers may be entrained along with an air source AS passing through an adjacent licker-in roller 12. The air source AS (with the detached fibers entrained) is transferred from the vicinity of licker-in roller 12 into chamber 23, which is partially defined by doffing plate 20 and lower slide plate 22. These two plates typically have an initial angle of less than 15°. However, the doffing plate 20 and lower slide plate 22 are angled relative to each other, such that the cross-section of chamber 23 increases from the vicinity of licker-in roller to the vicinity of condenser 18. The air source AS can be controlled such that the detached fibers are projected into the air source AS, wherein the average velocity of the airflow in the air source AS is between 0.5 and 1.5 times the initial fiber velocity. The shed fibers are preferably projected onto the condenser 18 at a rate between 3 psi and 30 psi, but the machine 10 can be adapted to slower and higher operating rates. A large volume of air is typically used as the air source AS to deliver the shed fibers to the condenser 18. Operation is typical under standard density and temperature conditions (0.075 psi, at 70℉ and 29.92" Hg) with the weight of air being 20 to 30 times the weight of the fibers processed per unit time.

[0021] Ideally, the air source AS should have a uniform velocity, low turbulence, and a stable, vortex-free airflow in the direction of movement of the licker-in roller 12. Unfortunately, this is not always the case with respect to machine 10. It was previously thought that the design of the channel / chamber connecting the air source AS should be shaped to form a Venturi tube 25 in the region adjacent to the licker-in roller 12, where the fiber detaches upstream of chamber 23. Furthermore, the boundary layer formed around the surface of the licker-in roller 12 can be interrupted by using a detachment bar 24 located near chamber 23, at the point of maximum shear just below the licker-in roller 12 at the beginning of chamber 23 (sometimes referred to as the expansion chamber). The detachment bar 24 is configured to provide a controlled level of low turbulence in the air source AS through which the detached fiber passes.

[0022] A pressure gauge 26 can be used and positioned at a small distance from the surface of the licker-in roller 12 to provide a narrow passage in which fibers are carried onto hooks, protrusions, or sheets on the thread cover or the cylindrical surface of the licker-in roller 12 to a protrusion point (referred to as the drop point or drop position) and thus enter the venturi tube 25 and the air source AS. The cutter roller 16 can be positioned adjacent to the pressure gauge 26 and the licker-in roller 12, and can be positioned in and near the air source AS. The cutter roller 16 can be journal-connected to allow eccentric movement within the side housing of the machine 10. The cutter roller 16 expands the flow of the air source AS and facilitates fiber removal from the licker-in roller 12. The eccentric mounting of the cutter roller 16 allows for alteration of the space between the licker-in roller 12 and the cutter roller 16 to confine the air source AS to the drop position.

[0023] As discussed above, the inventor has recognized the modifications. Figure 1 Machine 10 is a machine for providing more uniform fiber deposition on the condenser. More specifically, the inventors recognize that using Figure 1 In machine 10, the drop location and drop trajectory are undesirable, and because at least some fibers drop towards and come into contact with the doffing plate 20 and / or the lower slide plate 22, and become tangled and intertwined, this generally results in uneven fiber deposition on the condenser 18. Furthermore, the inventors recognize that... Figure 1 Machine 10 is susceptible to turbulent airflow, air currents, and / or eddies due to factors including the completely enclosed expansion chamber within machine 10 and other completely enclosed portions of the passage connecting to the air source AS. In all embodiments, the inventors have also determined that the use of the Venturi tube 25 at and immediately after the dropout position is unnecessary. The inventors also recognize that modifications to the geometry of the expansion chamber, and indeed, in some cases, the elimination or modification of the doffing plate 20 and / or the lower slide plate 22, may be desirable.

[0024] Figure 2 A highly schematic method 100 for forming a random fiber web using a pneumatic fiber conveying system 102 is shown. The method may include the arrangement of multiple rotatable rollers. These rotatable rollers may include a conveyor roller 104, a licker-in roller 106, and a cutter roller 108. As used herein, the term "roller" is broadly defined to mean any movable, driven, or conveying device such as a belt, and is therefore not limited to rotatable devices such as rollers. The licker-in roller 106 may be configured to have hooks, protrusions, and / or other features to remove multiple fibers from a fiber pad conveyed by the conveyor roller 104 to the vicinity of the licker-in roller. The cutter roller 108 may be movably positioned adjacent to the licker-in roller 106 (within less than one inch to several inches).

[0025] Method 100 may include detaching multiple fibers from the licker-in roller at a detachment location within system 102. Method 100 may also include communicating with an air source to entrain multiple fibers after detachment. Additionally, method 100 may include collecting multiple fibers from the air source to form a random fiber web. Such collection of fibers may occur at collector 110 (also referred to as a condenser). The collector may include movable devices (such as rollers or belts) movable to gather stacked fibers, thereby forming a new random fiber web as the stacked fibers fall into collector 110.

[0026] An air source AS carrying multiple fibers can pass through a channel (also referred to herein as a chamber, space, or volume) located downstream of the licker-in roller 106 and the cutter roller 108 (in relation to the flow direction of the air source AS). This channel can extend from the vicinity of the licker-in roller 106 and the cutter roller 108 to the vicinity of the collector 110. The channel can be at least partially defined by a housing 112 (which may include a doffing plate, a lower slide plate, and / or a side housing as previously described herein).

[0027] As previously discussed and will be further discussed herein, the inventors have modified the [material / material] from [source / component]. Figure 1 Methods and machine methods 100 and system 102. Figure 2 Only some system and component modifications conceived by the inventors are shown. (Refer to...) Figures 3 to 11 These modifications and components are further described below. Additional components and modifications are discussed in co-pending application 62 / 717,095, filed on the same day as this application, entitled “Machines, Systems and Methods for Manufacturing Random Fiber Webs,” the entire disclosure of which is incorporated herein by reference.

[0028] Specifically, Figure 2 Four possible additions to method 100 and system 102 are shown. These additions can be used individually or in various combinations (e.g., Figure 3(As shown). Such additions may include providing a pressure gauge assembly 114, which may include an extended pressure gauge between the conveyor roller 104 and the licker-in roller 106. In some embodiments, the pressure gauge assembly 114 may have a textured structure (i.e., include surface features such as those from carding lines). Method 100 and system 102 may include providing a vent 115 in the cutter roller assembly (i.e., a vent between the cutter roller 108 and a cutter roller end cap rotatably mounted in a side housing). Method 100 and system may include providing one or more observation ports 116 in the housing 112. For example, these one or more observation ports 116 may be located adjacent to the dropout location (e.g., adjacent to the licker-in roller 106) and adjacent to the collector 110. For example, these observation ports allow observation / monitoring of fiber dropout and / or observation / monitoring of fibers as they fall and form a random fiber web on the collector 110. Additionally, method 100 and system 102 may provide a reverse seal 118 that engages with the collector 110 and is further mounted to the lower slide plate. The reverse seal 118 can be shaped to extend from the lower slide plate and can be oriented with an end that extends in a direction substantially opposite to the direction of rotation of the collector 110.

[0029] Figure 3 References are shown Figure 2 The four additions discussed in system 102 and method 100 are used together in machine 120 with a gas source AS. (As...) Figure 2 In the discussion, Figure 3 In this design, machine 120 may include a conveying device (e.g., a rotatable conveyor roller 104), a licker-in roller (e.g., a licker-in roller 106), a cutter roller (e.g., a cutter roller 108), a channel 126 including a space 128, and a collector 110. The rotatable licker-in roller 106 may be configured to remove multiple fibers from a fiber pad conveyed by the conveyor roller 104 to the vicinity of the licker-in roller 106. The licker-in roller 106 may be configured to cause multiple fibers to detach from the licker-in roller 106. The rotatable cutter roller 108 may be positioned adjacent to the conveyor roller 104 and the licker-in roller 106. The channel 126 may connect an air source AS to the space 128 defined between the licker-in roller 106 and the cutter roller 108. The space 128 may include a detachment location where multiple fibers detach from the licker-in roller 106. The rotatable collector 110 may be positioned to capture the multiple fibers once they have detached into the air source AS. The multiple fibers form a random fiber web on collector 110 during the layup process.

[0030] Figure 3 The embodiment shows a pressure gauge assembly 114 positioned adjacent to the licker roller 106 and extending along the licker roller 106 toward the cutter roller 108 of the machine 120. Figure 3Also shown is a vent 115 in the cutter end cap 122 adjacent to the guillotine roller 106 of the machine 120. Since the cutter end cap 122 is movable in the side housing, the position of the vent 115 can be changed relative to the guillotine roller 106. Figure 3 One or more viewing ports 116 are shown in the side housing of machine 120. The one or more viewing ports 116 may be located adjacent to the detachment location (e.g., adjacent to the licker roller 106) and adjacent to collector 110. Machine 120 may include a reverse seal 118 shaped to extend from the lower slide plate 124 to engage with collector 110. The reverse seal 118 may be oriented using an end that extends generally in a direction opposite to the direction of rotation of collector 110.

[0031] Figure 4 The system 200, which is a machine 202, includes only the portion with the vent 115 as described above. Figure 5 A perspective view of the cutter roller end cap 122 is shown. A vent 115 is defined by the cutter roller end cap 122 and the cutter roller 108. The position of the vent 115 can be changed relative to the needle roller 106 because the cutter roller end cap 122 and the cutter roller 108 are movable relative to the needle roller 106. Specifically, the cutter roller end cap 122 is configured to eccentrically position the cutter roller 108 within a space 128. Figure 4 As shown in the embodiment, the vent 115 communicates with the channel 126, allowing a certain amount of air source AS to pass through the vent and / or a certain amount of ambient air from outside the machine 202 side housing to enter the channel 126 through the vent. As specified by operating conditions, the vent 115 provides access to either a certain amount of air from the air source AS to the surrounding environment or a certain amount of ambient air to the air source AS. The inventors have discovered that the use of the vent reduces turbulent airflow within the channel 126, including space 128. Furthermore, by venting at or near the cutter roller end cap 122, the lateral deposition of the multi-fiber web can be more uniform, especially along the edges of the web formed by the machine 202.

[0032] like Figure 5 As shown, the first portion 130 of the cutter roller end cap 122 can be configured to receive and support the cutter roller 108. Figure 4 The second portion 132 of the cutter roller end cap 122 may define the first edge 134 of the vent 115. (Back) Figure 4 In some cases, the second edge 136 of the vent 115 may be defined by the outer diameter of the cutter roller 108. For example... Figure 4As shown, the vent 115 can be formed as a tapered slit 138 having a cross-sectional area that increases along its length in the direction of rotation of the cutter roller 108 and the cutter roller end cap 122. In some embodiments, the length of the tapered slit 138 may be between 0 degrees and 170 degrees of the circumference of the cutter roller 108. In other embodiments, the tapered slit 138 may have an extension between 60 degrees and 160 degrees of the circumference of the cutter roller 108. The slit 138 may have a taper from a width of 0 inches at the first end to a width of approximately 3 inches at the second end. In still other embodiments, the taper may be less aggressive and may simply be from a width of 0 inches at the first end to a width of approximately 1 inch at the second end.

[0033] Figure 6 A pressure gauge assembly 114 portion of system 300, which is part of machine 302, is shown. Pressure gauge assembly 114 is positioned adjacent to licker-in roller 106 and extends along licker-in roller 106 toward cutter roller 108 of machine 302. More specifically, pressure gauge assembly 114 may include pressure gauge 304 and pressure gauge extension 306. Pressure gauge extension 306 and pressure gauge 304 may be coupled together. Pressure gauge extension 306 extends along licker-in roller 106 and toward cutter roller 108, and extends into a space 128 defined between licker-in roller 106 and cutter roller 108, such that the drop-off position is in an air source AS within space 128. Pressure gauge assembly 114, and specifically pressure gauge extension 306, controls the drop-off position (i.e., the position where multiple fibers drop off licker-in roller 106) and trajectory. Pressure gauge extension 306 is shaped to deflect the drop-off position and trajectory, so that multiple fibers cross doffing plate 20 and lower slide plate 22 (see...). Figure 1 ), and is better positioned as entrained in the gas source AS.

[0034] according to Figure 6 In one embodiment, the pressure gauge assembly 114 is at least partially positioned between the conveyor roller 104 and the licker roller 106 and extends into the space 128. The pressure gauge assembly 114 may be positioned adjacent to the licker roller (within a few inches) and may extend around the circumference of the licker roller 106 from 1 degree to 170 degrees. In another embodiment, the pressure gauge assembly 114 may extend around the circumference of the licker roller 106 between 1 degree and 70 degrees. In still some other embodiments, the pressure gauge assembly 114 may extend around the circumference of the licker roller 106 between 1 degree and 32 degrees.

[0035] Figure 7 Another embodiment of the pressure gauge assembly 414 is shown, which has a configuration that is connected to the licker roller 106 ( Figure 6 ) The joint surface 402. In Figure 7 In one embodiment, surface 402 may be formed by a pressure gauge extension 406 and a pressure gauge 404. Figure 7In the implementation scheme, the surface has a textured structure 408 to facilitate the movement of the licker-in roller 106 ( Figure 6 The texturing structure 408 may include, for example, multiple interruptions (such as protrusions and / or recesses) in the surface 402 that are configured to cause impact, redirection, and / or untangling of the fibers as they pass through the surface 402. Figure 7 In the example shown, the textured structure 408 includes a series of teeth, but it should be understood that such a textured structure 408 may include any structure suitable for the purposes described in this paragraph. Although the pressure gauge extension 406 and the pressure gauge 404 are... Figure 7 Both are shown as having a textured structure 408, but in other embodiments, only one or a portion of the surface 402 of the ruler extension 406 and the ruler 404 may have a textured structure 408. According to one embodiment, the depth of the textured structure may be between 0.005 inches and 0.1 inches. In some embodiments, the depth of the textured structure may be between 0.005 inches and 0.2 inches.

[0036] Figure 8 A reverse seal 118 is shown as part of a system 500 that is part of machine 502. The reverse seal 118 is shaped to extend from the lower slide plate 124 to engage with the collector 110. The reverse seal 118 can be mounted to the lower slide plate 124 at a mounting portion 503. The reverse seal 118 can be oriented to extend from the mounting portion to an end 504 in a direction generally opposite to the direction of rotation of the collector 110 (indicated by arrow A). The reverse seal 118 may have a curved body portion 506 configured to engage with the collector 110 along its surface. The reverse seal 118 is configured such that no surface protrudes into the chamber 508 defined by the portion of the lower slide plate 124, and virtually no portion of the reverse seal 118 protrudes above the surface of the lower slide plate 124. This configuration of the reverse seal 118 eliminates or reduces the possibility of multiple fibers falling onto or being captured by the reverse seal 118. According to one embodiment, the reverse seal 118 may have a length between 0.5 inches and 3.0 inches (inclusive) from the mounting portion 503 to the end 504.

[0037] Figure 9 , Figure 10 and Figure 11 System 600, which is part of machine 602, is shown. System 600 includes one or more observation ports 116 in the side housing 604 of machine 602. Figure 9 and Figure 11 (as shown in the diagram). One or more observation ports 116 may include locations adjacent to the detachment site (e.g., adjacent to...). Figure 10 and Figure 11The first observation port 116A, located in the spiked roller 106, and the adjacent collector 110 ( Figure 10 and Figure 11 The second observation port 116B is positioned. Figure 10 and Figure 11 One or more observation ports 116 can be used to monitor the shedding of multiple fibers into the airflow AS. Figure 10 ), and can be used to monitor collector 110 ( Figure 10 and Figure 11 Multiple fibers are stacked on the machine 602. For example, a camera can be mounted to capture images through the observation port 116. The observation port 116 may have a thermoplastic sheet such as polycarbonate or another light-transmitting material sheet mounted therein to allow observation but keep the air source and multiple fibers within the machine 602.

[0038] As used in this article:

[0039] The terms “a,” “an,” “the,” and “the” are used interchangeably, wherein “at least one” means one or more of the elements described.

[0040] The term "and / or" means either or both. For example, "A and / or B" means only A, only B, or both A and B.

[0041] The terms “including,” “comprising,” or “having,” and their variations, are intended to cover the items listed thereafter and their equivalents, as well as additional items.

[0042] As understood in context, the term “adjacent” refers to the relative position of two elements (such as, for example, two layers) that are close to each other and may or may not need to be in contact with each other or may have one or more layers separating the two elements.

[0043] Unless otherwise specified, all scientific and technical terms used herein have their common meaning in the art. The definitions provided herein are intended to aid in understanding certain terms frequently used in this application and are not intended to exclude reasonable interpretations of those terms within the context of this disclosure.

[0044] Unless otherwise specified, all numerical values ​​in the specification and claims expressing characteristic dimensions, quantities, and physical properties should in all cases be understood to be modified by the term "about". Therefore, unless stated to the contrary, the numerical parameters listed in the foregoing specification and appended claims are approximations, which may vary depending on the desired characteristics sought by a person skilled in the art using the teachings disclosed herein. At a minimum, and without attempting to limit the application of the doctrine of equivalence to the scope of the claims, each numerical parameter should be interpreted at least according to the number of significant digits reported and by applying customary rounding. While the numerical ranges and parameters that set forth the broad scope of this disclosure are approximations, the values ​​listed in the specific embodiments are reported as precisely as possible. However, any numerical value inherently contains a certain degree of error, which must be caused by the standard deviation present in their respective experimental measurements.

[0045] The term "substantially" means within 20 percent of the attribute being mentioned (in some cases within 15 percent, in others within 10 percent, and in still others within 5 percent). Therefore, if value A is within ±5%, 10%, or 20 percent of value A, then value A is "substantially similar" to value B.

[0046] The features and advantages of this disclosure will be further understood upon consideration of the specific embodiments and the appended claims.

[0047] The range of numbers expressed by the endpoints includes all numbers included in the range (for example, the range of 1 to 5 includes, for example, 1, 1.5, 2, 2.75, 3, 3.80, 4, and 5) and any range within the range.

[0048] Although this disclosure is described with reference to preferred embodiments, those skilled in the art will recognize that changes in form and detail may be made without departing from the spirit and scope of this disclosure.

[0049] Various notes and examples

[0050] In Embodiment 1, a method for forming a random fiber web using a pneumatic fiber conveying system is disclosed. The method may optionally include: providing a plurality of movable devices including a licker-in roller and a conveyor, the licker-in roller being configured to remove multiple fibers from a fiber pad conveyed by the conveyor to the vicinity of the licker-in roller; causing the multiple fibers to detach from the licker-in roller at a detachment location within the system; connecting an air source to entrain the multiple fibers after detachment; and collecting the multiple fibers from the air source to form the random fiber web.

[0051] In Embodiment 2, the method according to Embodiment 1 may optionally include providing a pressure gauge assembly that extends between a portion of the conveyor and the spiked roller and into the air source adjacent to the detachment location.

[0052] In Embodiment 3, according to the method described in Embodiment 2, the pressure gauge assembly may have a textured structure along the surface that intersects with the needle roller.

[0053] In Embodiment 4, the method according to any one or any combination of Embodiments 1 to 3 may optionally include providing a vent in the cutter roller assembly and communicating the vent with the air source.

[0054] In Example 5, according to the method described in Example 4, the vent hole is movable as the cutter roller assembly moves away from and toward the detachment position.

[0055] In Embodiment 6, the method according to any one or any combination of Embodiments 1 to 5 may optionally include providing one or more observation ports in the housing, the one or more observation ports being located adjacent to one or more of the detachment location and the collection location of the plurality of fibers.

[0056] In Embodiment 7, the method according to any one or any combination of Embodiments 1 to 6 may optionally include providing a reverse seal that is mounted to the lower slide plate and engages with a collector that performs the collection of the plurality of fibers and is further mounted to the lower slide plate, wherein the reverse seal is oriented to have a range from the mounting portion to the end, the end extending in a direction substantially opposite to the rotation direction of the collector.

[0057] In Embodiment 8, a pneumatic fiber conveying system for forming a random fiber web is disclosed. The system optionally includes: a rotatable conveyor roller; a rotatable licker-in roller configured to remove multiple fibers from a fiber pad conveyed by the conveyor roller to the vicinity of the licker-in roller and configured to cause the multiple fibers to detach from the licker-in roller; a rotatable cutter roller positioned adjacent to the conveyor roller and the licker-in roller; a channel connecting an air source to a space defined between the licker-in roller and the cutter roller, the space including a detachment location where the multiple fibers detach from the licker-in roller; and a collector positioned to capture the multiple fibers once they detach into the air source, the multiple fibers forming the random fiber web on the collector.

[0058] In embodiment 9, the system according to embodiment 8 may optionally include a pressure gauge assembly, which is at least partially positioned between the conveying roller and the spiked roller and extends into the space.

[0059] In Example 10, according to the system described in Example 9, the pressure gauge assembly can wrap around the circumference of the needle roller by 1 degree to 170 degrees.

[0060] In Example 11, the system according to any one or any combination of Examples 8 to 10, wherein the pressure gauge assembly may have a surface that interacts with the needle roller, and wherein the surface has a textured structure to separate the multiple fibers.

[0061] In Example 12, according to the system of any one or any combination of Examples 8 to 11, the pressure gauge assembly may be configured such that the detachment position extends through the conveyor roller and into the space defined between the piercing roller and the cutter roller.

[0062] In embodiment 13, the system according to any one or any combination of embodiments 8 to 12, wherein the cutter roller is coupled to a movable end plate configured to eccentrically position the cutter roller within the space, and wherein the end plate includes a passage communicating with the channel, such that a certain amount of supply air can pass through the passage or a certain amount of ambient air can pass through the passage into the channel.

[0063] In embodiment 14, the system according to embodiment 13, wherein the passage may include a tapering slit having a cross-sectional area that increases along the length of the slit in the direction of rotation of the cutter roller and the end plate, and wherein the length of the slit is between 1 degree and 170 degrees of the circumference of the cutter roller.

[0064] In Embodiment 15, the system according to any one or any combination of Embodiments 8 to 14 may optionally include: one or more plates extending between the vicinity of the cutter roller and the vicinity of the collector; and a seal that is coupled to an end portion of the one or more plates at a mounting portion and extends to contact the collector, wherein the seal extends from the mounting portion to the end in a direction opposite to the direction of rotation of the collector.

[0065] In Embodiment 16, the system according to any one or any combination of Embodiments 8 to 15 further includes one or more observation ports along the channel, the one or more observation ports including locations adjacent to the detachment location and one or more of the collector.

[0066] In Embodiment 17, a pneumatic fiber conveying system for forming a random fiber web is disclosed. The system optionally includes: a plurality of movable devices including a licker-in roller and a conveyor, the licker-in roller being configured to remove multiple fibers from a fiber pad conveyed by the conveyor to the vicinity of the licker-in roller, wherein the licker-in roller is configured to cause the multiple fibers to detach from the licker-in roller; a channel connecting an air source to a space adjacent to the licker-in roller, the space including a detachment location where the multiple fibers detach from the licker-in roller; a collector positioned to capture the multiple fibers once they detach into the main air source, the multiple fibers forming the random fiber web on the collector; and the following. At least one of the following: a pressure gauge assembly, which is at least partially positioned between the conveyor roller and the spiked roller and extends into the space; a vent, which is located in a cutter roller assembly adjacent to the spiked roller and communicates with the air source; a seal, which is coupled to the plate at the mounting portion and extends to contact the collector, wherein the seal extends from the mounting portion to an end in a direction opposite to the rotation direction of the collector; or one or more observation ports, which are along the channel and include locations adjacent to the detachment location and one or more of the collector.

[0067] In embodiment 18, according to the system of embodiment 17, the pressure gauge assembly may be configured such that the detachment position extends through the conveyor and into the space defined between the licker roller and the cutter roller assembly.

[0068] In Example 19, the system according to any one or any combination of Examples 17 to 18, wherein the vent may be tapered and have a cross-sectional area that increases along the length of the vent in the rotational direction of the cutter roller assembly.

[0069] In Example 20, the system according to any one or any combination of Examples 17 to 19, wherein the pressure gauge assembly may have a surface that interacts with the needle roller, and wherein the surface has a textured structure to separate the multiple fibers.

Claims

1. A method for forming a random fiber web using a pneumatic fiber conveying system, the method comprising: Provided multiple movable devices including a licker-in roller and a conveyor, the licker-in roller being configured to remove multiple fibers from a fiber pad conveyed to the vicinity of the licker-in roller by the conveyor; The multiple fibers are detached from the licker-in roller at a detachment location within the system, wherein the detachment location is located in the space where the air source is located, so that once the multiple fibers are detached from the licker-in roller, they enter the air source and flow in a direction directly toward the collector. A pressure gauge assembly is provided, which extends between a portion of the conveyor and the licker-in roller and into the space, wherein the pressure gauge assembly includes a pressure gauge extension, and a passage for the multiple fibers to pass through is formed between the pressure gauge extension and the licker-in roller. The air source is connected to entrain the multiple fibers after they exit the passage, wherein the pressure gauge assembly is positioned between the needle roller and the air source; and The multiple fibers are collected from the gas source to form the random fiber web, wherein the collector is a condenser. The method further includes providing a vent in the cutter roller assembly defined by a cutter roller end cap and a cutter roller, and communicating the vent with the air source, wherein a first portion of the cutter roller end cap is configured to receive and support the cutter roller, a second portion of the cutter roller end cap defines a first edge of the vent, and a second edge of the vent is defined by the outer diameter of the cutter roller. The pressure gauge assembly is positioned adjacent to the barbed roller and extends along the barbed roller toward the cutter roller, such that the detachment location is shielded by the pressure gauge assembly and avoids the air source until the end of the pressure gauge extension.

2. The method of claim 1, wherein the pressure gauge assembly has a textured structure along the surface intersecting with the needle roller.

3. The method of claim 1, wherein the vent is movable as the cutter roller assembly moves away from and toward the detachment position.

4. The method according to any one of claims 1 to 3, further comprising providing one or more observation ports in the housing, the one or more observation ports including locations adjacent to one or more of the detachment location and the collection location of the plurality of fibers.

5. The method according to any one of claims 1 to 3, further comprising providing a reverse seal, the reverse seal being mounted to a lower slide plate and engaging with the collector, the collector performing collection of the plurality of fibers and further mounted to the lower slide plate, wherein the reverse seal is oriented to have a range from the mounting portion to an end, the end extending in a direction opposite to the rotation direction of the collector.

6. A pneumatic fiber conveying system for forming a random fiber web, the system comprising: Rotatable conveyor rollers; A rotatable licker-in roller, the licker-in roller being configured to remove multiple fibers from a fiber pad conveyed to the vicinity of the licker-in roller by the conveyor roller, and being configured to cause the multiple fibers to fall off the licker-in roller; A rotatable cutter roller, positioned adjacent to the conveyor roller and the piercing roller; A channel connects an air source to a space defined between the licker-in roller and the cutter roller, the space including a detachment location where the multiple fibers detach from the licker-in roller and enter the air source once detached from the licker-in roller, flowing directly toward the collector. A pressure gauge assembly, which is at least partially positioned between the conveyor roller and the spiked roller and extends into the space; and The collector is positioned to capture the plurality of fibers once they detach into the air source, the fibers forming the random fiber web on the collector. The pressure gauge assembly includes a pressure gauge extension that extends along the spiked roller toward the cutter roller, such that the detachment location is shielded by the pressure gauge assembly from the air source up to the end of the pressure gauge extension. The system further includes a vent in the cutter roller assembly defined by the cutter roller and a cutter roller end cap, the vent communicating with the air source, wherein a first portion of the cutter roller end cap is configured to receive and support the cutter roller, a second portion of the cutter roller end cap defines a first edge of the vent, and a second edge of the vent is defined by the outer diameter of the cutter roller, and wherein the cutter roller end cap is movable, and movement of the cutter roller end cap causes a change in the position of the vent.

7. The system of claim 6, wherein the pressure gauge assembly wraps around the circumference of the needle roller by 1 degree to 170 degrees.

8. The system according to any one of claims 6 to 7, wherein the pressure gauge assembly has a surface that interacts with the needle roller, and wherein the surface has a textured structure to separate the plurality of fibers.

9. The system according to any one of claims 6 to 7, wherein the pressure gauge assembly is configured such that the detachment position extends through the conveyor roller and into the space defined between the spiked roller and the cutter roller.

10. The system according to any one of claims 6 to 7, wherein the cutter roller is coupled to the cutter roller end cap, the cutter roller end cap being configured to eccentrically position the cutter roller within the space, and wherein the vent is in communication with the channel such that a certain amount of supply air can pass through the vent or a certain amount of ambient air can pass through the vent into the channel.

11. The system of claim 10, wherein the vent is formed as a tapering slit having a cross-sectional area that increases along the length of the slit in the direction of rotation of the cutter roller and the cutter roller end cap, and wherein the length of the slit is between 1 degree and 170 degrees of the circumference of the cutter roller.

12. The system according to any one of claims 6 to 7, further comprising: One or more plates extending between the vicinity of the cutter roller and the vicinity of the collector; and A seal that is coupled to the end portion of the one or more plates at the mounting portion and extends to contact the collector, wherein the seal extends from the mounting portion to the end in a direction opposite to the direction of rotation of the collector.

13. The system according to any one of claims 6 to 7, further comprising one or more observation ports along the channel, the one or more observation ports including locations adjacent to the detachment location and one or more of the collectors.

14. A pneumatic fiber conveying system for forming a random fiber web, the system comprising: Multiple movable devices, including a licker-in roller and a conveyor, wherein the licker-in roller is configured to remove multiple fibers from a fiber pad conveyed by the conveyor to the vicinity of the licker-in roller, and wherein the licker-in roller is configured to cause the multiple fibers to fall off the licker-in roller; The channel connects the air source to a space adjacent to the licker-in roller, the space including a detachment location where the multiple fibers detach from the licker-in roller and, once detached from the licker-in roller, enter the air source and flow directly toward the collector. The collector is positioned to capture the multiple fibers once they fall into the air source, the multiple fibers forming the random fiber web on the collector; A pressure gauge assembly, which is at least partially positioned between the conveyor and the licker-in roller and extends into the space; as well as A vent is provided, located in the cutter roller assembly adjacent to the licker roller and in communication with the air source. The vent in the cutter roller assembly is defined by a cutter roller end cap and a cutter roller. A first portion of the cutter roller end cap is configured to receive and support the cutter roller. A second portion of the cutter roller end cap defines a first edge of the vent, and a second edge of the vent is defined by the outer diameter of the cutter roller. The cutter roller end cap is movable, and movement of the cutter roller end cap causes a change in the position of the vent. The pressure gauge assembly includes a pressure gauge extension that extends along the spiked roller toward the cutter roller, such that the detachment location is shielded by the pressure gauge assembly and avoids the air source up to the end of the pressure gauge extension.

15. The system of claim 14, wherein the pressure gauge assembly is configured such that the detachment position extends through the conveyor and into the space defined between the spiked roller and the cutter roller assembly.

16. The system according to any one of claims 14 to 15, wherein the vent is tapered and has a cross-sectional area that increases along the length of the vent in the rotational direction of the cutter roller assembly.

17. The system according to any one of claims 14 to 15, wherein the pressure gauge assembly has a surface that interacts with the needle roller, and wherein the surface has a textured structure to separate the plurality of fibers.

18. The system of claim 14, further comprising a seal that is coupled to the plate at the mounting portion and extends to contact the collector, wherein the seal extends from the mounting portion to an end in a direction opposite to the direction of rotation of the collector.

19. The system of claim 14, further comprising one or more observation ports along the channel and including locations adjacent to the detachment location and one or more of the collectors.

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