Machine system and method for producing random fiber webs

Abstract

A method for forming a random fiber web using an air-powered fiber feeding system is disclosed. The method includes providing a plurality of movable devices, including a licker-in and a feeder, where the licker-in is configured to pick up a plurality of fibers from a fiber mat fed proximate the licker-in by the feeder. The method also includes doffing the plurality of fibers from the licker-in at a doffing position within the system. The method also includes flowing an air supply and incorporating the plurality of fibers into the air supply after doffing. The method also includes controlling the air supply in a flow path between the licker-in and a collector. The method also includes collecting the plurality of fibers from the air supply on the collector to form a random fiber web.

Description

[Background technology]

[0001] The present disclosure relates to methods, systems, and machines for forming random fiber webs. More particularly, the present disclosure relates to machines, systems, and methods for making nonwoven airlaid webs.

[0002] Generally, various machines, systems, and methods are known for producing random fiber webs for random fiber articles used for various purposes. Cleaning and polishing equipment are formed in part from random fiber webs. In addition, disposable absorbent products, such as mortuary products, veterinary products, and personal care absorbent products, such as diapers, feminine napkins, adult incontinence products, and training pants, often include one or more layers of random fiber web material, particularly liquid-absorbent fibrous web material. [Brief explanation of the drawings]

[0003] [Figure 1] 1 is a schematic cross-sectional view of a portion of a machine for forming a random fiber web as known in the prior art; [Figure 2] FIG. 1 is a high-level schematic diagram tracking some modifications and / or additions to a system for forming a random fiber web according to one embodiment of the present disclosure. [Figure 3A] FIG. 1 shows a schematic cross-sectional view of a portion of a first machine for forming a random fiber web according to one embodiment of the present disclosure. [Figure 3B] FIG. 1 shows a schematic cross-sectional view of a portion of a first machine for forming a random fiber web according to one embodiment of the present disclosure. [Figure 4] FIG. 2 is a schematic cross-sectional view of a portion of a second machine for forming a random fiber web according to one embodiment of the present disclosure. [Figure 5] FIG. 10 is a schematic cross-sectional view of a portion of a third machine for forming a random fiber web according to one embodiment of the present disclosure. [Figure 6]FIG. 10 is a component diagram of a fourth machine for forming a random fiber web according to one embodiment of the present disclosure. [Figure 7A] 1 shows a diagram of a doffing plate and extended doffing bar for controlling airflow according to one embodiment of the present invention. [Figure 7B] 1 shows a diagram of a doffing plate and extended doffing bar for controlling airflow according to one embodiment of the present invention. [Figure 7C] 1 shows a diagram of a doffing plate and extended doffing bar for controlling airflow according to one embodiment of the present invention. [Figure 7D] 1 shows a diagram of a doffing plate and extended doffing bar for controlling airflow according to one embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0004] Aspects of the present disclosure relate to machines, systems, and methods for producing random fiber webs.

[0005] Aspects of the present disclosure are directed to machines, systems, and methods for producing nonwoven airlaid webs. One known machine 10 for making nonwoven airlaid webs is shown in connection with FIG. 1. Such a machine 10 relies on an initial random fiber mat that is fed, such as by a feed roll 14, to a rotating licker in 12. The licker in 12 is configured to comb individual fibers from the initial random fiber mat (not shown in FIG. 1). The licker in 12 then uses centrifugal force to dof the carded fibers from the licker in 12, and the carded fibers enter an air supply AS that flows past the licker in 12 and a sabre roll 16. The dofed fibers are entrained in an air supply (hereinafter, AS) and transported to a condenser 18. The fibers are deposited in a random manner on the condenser 18, forming a nonwoven fibrous web (not shown in FIG. 1).

[0006] Unfortunately, the machines described above often deposit fibers unevenly on the condenser 18. This has resulted in more costly processing steps to create a more uniform web deposition. For example, in the machine of FIG. 1, the uneven deposition of fibers on the condenser 18 can result in the removal of portions of the nonwoven fibrous web, such as portions along its cross-web edge regions.

[0007] The inventors have recognized a machine that modifies the machine of FIG. 1 to provide a more uniform deposition of fibers on the condenser 18. Such a machine can reduce processing costs and reduce the need for additional post-deposition steps. One recognition by the inventors was that the machine of FIG. 1 doffed an undesirable amount of carded fibers against one or both of the doffer plate 20 and the lower slide plate 22. These fibers were not captured in the air supply AS, but instead clumped and rolled down one or both of the doffer plate 20 and the lower slide plate 22 to the condenser 18. This was suspected as one cause of the uneven deposition described above. In response, the inventors propose various solutions, machines, etc., including those in which the doffer plate and / or the lower slide plate are eliminated or have modified geometries relative to the machine of FIG. 1.

[0008] The inventors have also recognized other components and machine embodiments that allow for improved and more uniform deposition of fibers on the capacitor, as described briefly herein and in more detail in International Application No. PCT / US2019 / 045603 (based on U.S. Provisional Application No. 62 / 717069), and International Application No. PCT / US2019 / 045604 (based on U.S. Provisional Application No. 62 / 717095), both filed August 8, 2019, and both incorporated by reference herein.

[0009] These components may variously include seals that are oriented opposite to the direction of rotation of the condenser, the addition of one or more ports in the housing of the machine to allow for visualization of the doffing of the fibers and / or the overlap of the fibers on the condenser, the addition of nose bars and / or nose bar extensions to change the doffing point of the fibers into the air stream, the addition of various air vent passages in the housing, doffer plates, and / or lower slide plates configured to facilitate venting and / or intake of air into and / or from the air supply, to name just a few. Additional component and machine embodiments are disclosed herein and described with reference to the figures.

[0010] FIG. 1 shows portions of a known machine 10 for forming random fiber webs, previously described above. In such a machine 10, the web is suitable for producing a nonwoven fabric by known chemical or mechanical bonding processes. For example, dry-formed structures can be chemically bonded by known means, such as applying adhesive by spraying or by impregnation, or bonding can be achieved by using fibers that have low melting points and can form bonds to non-adhesive fibers with heat and pressure. Mechanical bonding can be performed by needling, stitch bonding, print bonding, etc. The quality of any nonwoven fabric produced by these finishing methods depends on the quality and uniformity of the processed or finished web structure.

[0011] With further reference to FIG. 1 , the process described herein can be implemented in mass production. For example, in machine 10, doffed fibers can be discharged at an initial velocity of up to 5,000 feet per minute by licker-in 12, which can rotate at the same speed. Speeds of up to 20,000 feet per minute are not uncommon for licker-in 12. The doffed fibers can be entrained in an air supply AS passing near licker-in 12. The air supply AS, along with the doffed fibers entrained in the air supply AS, flows from the vicinity of licker-in 12 into a chamber 23 defined in part by a doffer plate 20 and a lower slide plate 22. These two plates typically initially have an angle of less than 15°. However, doffer plate 20 and lower slide plate 22 are angled relative to one another so that the cross-section of chamber 23 increases from the vicinity of licker-in 12 to the vicinity of condenser 18. The air supply AS may be controlled so that the doffed fibers are discharged into the air supply AS with the average velocity of the airflow within the air supply AS being 0.5 to 1.5 times the initial fiber velocity. The doffed fibers are preferably discharged onto the condenser 18 at a rate of 3 to 30 pounds per hour per inch of machine width or airflow width, although the machine 10 may be suitable for slower and faster operation. Typically, a large air volume is used as the air supply AS to transport the doffed fibers to the condenser 18. At standard density and temperature conditions (0.075 lbs. / cu.ft. at 70°F and 29.92"Hg), it is typical to operate at 20 to 30 times the weight of air relative to the weight of fiber processed per unit time.

[0012] It is desirable for the air supply AS to have a uniform velocity, low turbulence, and a vortex-free, steady airflow in the direction of motion of the licker-in 12. Unfortunately, this is not always the case in machines 10. Previously, it was thought that the design of the channel / chamber carrying the air supply AS should be shaped to create a venturi in the region 25 near the licker-in 12 where the fibers are doffed upstream of the chamber 23. Furthermore, the boundary layer formed around the surface of the licker-in 12 can be interrupted by the use of a doffing bar 24 located near the chamber 23 (sometimes called the expansion chamber) at the point of maximum shear just below the licker-in 12 at the beginning of the chamber 23. The doffing bar 24 is configured to provide a controlled, low level of turbulence in the air supply AS through which the doffed fibers pass.

[0013] A nose bar 26 may be utilized and positioned a short distance from the surface of the licker-in 12 to provide a narrow passageway through which the fibers are conveyed by hooks, protrusions, or portions of wire that overlie the cylindrical surface of the licker-in 12 to a discharge point (called the doffing point or doffing location) within the venturi 25 and air supply AS. A sabre roll 16 may be positioned near the nose bar 26 and the licker-in 12, and may be positioned within or near the air supply AS. The sabre roll 16 may be journaled for eccentric movement within the side housing of the machine 10. The sabre roll 16 widens the flow of the air supply AS and aids in doffing the fibers from the licker-in 12. The eccentric mounting of the sabre roll 16 allows for varying the space between the licker-in 12 and the sabre roll 16, confining the air supply AS to the doffing location.

[0014] As discussed above, the inventors have recognized components that modify the machine 10 of FIG. 1 to provide a more uniform deposition of fibers on the condenser. More specifically, the inventors have recognized that the machine 10 of FIG. 1 has an undesirable doffing position and doffing trajectory, causing at least a portion of the fibers to dofy toward, contact, and become entangled with the doffer plate 20 and / or lower slide plate 22, typically resulting in a non-uniform deposition of fibers on the condenser 18. Furthermore, the inventors have recognized that the machine 10 of FIG. 1 is susceptible to turbulence, airflow surges, and / or air vortices due to factors including the fully enclosed expansion chamber and other fully enclosed portions of the fully enclosed chamber and channels through which the air supply AS flows within the machine 10. The use of a venturi 25 at and immediately thereafter at the doffing position has also been found by the inventors to be unnecessary in all embodiments. The inventors also recognize that altering the geometry of the expansion chamber, and indeed removing or modifying the doffer plate 20 and / or lower slide plate 22, may be desirable in some cases.

[0015] FIG. 2 shows a highly schematic method 100 for forming a random fiber web using a pneumatic fiber feeding system. The method may include providing a plurality of rotatable rolls. These rotatable rolls may include a feed roll 104, a licker-in roll 106, and a saber roll 108. The term "roll," as used herein, is broadly defined to mean any movable, driven, or fed device, such as a belt, and thus is not limited to only rotatable devices such as rolls. The licker-in roll 106 may be configured with hooks, protrusions, and / or other features for picking up a plurality of fibers from a fiber mat fed adjacent the licker-in roll 106 by the feed roll 104. The saber roll 108 may be movably positioned adjacent the licker-in roll 106 (within less than one to a few inches of the licker-in roll 106).

[0016] The system 100 can include doffing a plurality of fibers from a licker-in roll at a doffing position within the system. The method 100 can further include flowing an air supply and entraining the plurality of fibers into the air supply after doffing. Additionally, the system 100 can include collecting the plurality of fibers from the air supply to form a random fiber web. Such collection of fibers can occur in a collector 110 (also referred to as a condenser). The collector can include a movable device, such as a roll or belt, that can operate to gather overlapping fibers as the fibers fall into the collector 110 to form a new random fiber web.

[0017] The air supply AS, with the plurality of fibers entrained therein, may pass through a channel (also referred to herein as a chamber, space, or volume) downstream (in the direction of flow of the air supply AS) from the vicinity of the licker-in roll 106 and the sabre roll 108. The channel may extend from the vicinity of the licker-in roll 106 and the sabre roll 108 to the vicinity of the collector 110. The channel may be at least partially defined by a housing 112 (which may include a doffer plate, a lower slide plate, and / or a side housing, as previously described herein).

[0018] As noted above, and as further described hereinafter, the inventors have modified the system 10 of FIG. 1. FIG. 2 illustrates some system and component modifications contemplated by the inventors. These modifications and components are further described with reference to FIGS. 3-7. Additional components and modifications are described in co-pending International Application Nos. PCT / US2019 / 045603 and PCT / US2019 / 045604, both filed August 8, 2019, the entire disclosures of which are incorporated herein in their entireties.

[0019] Specifically, as described in International Application PCT / US2019 / 045604, the nose bar assembly may include an extended nose bar between the feed roll 104 and the licker-in roll 106. The system 100 may also include providing an air deflector assembly disposed between the licker-in roll 106 and the saber roll 108. The air deflector assembly may be attached to the machine housing near the feed roll 104 and may extend into the space near the licker-in roll 106. The system 100 may also include providing a damper 118 near the saber roll 108 to control airflow around the saber roll 108. The system 100 may also include providing an airfoil that may be used in place of the saber roll 108.

[0020] Four other possible additions to the system 100 are described in International Application PCT / US2019 / 045603. Such additions may include providing a nose bar assembly that may include an extended nose bar between the feed roll 104 and the licker-in roll 106. The nose bar assembly, in some embodiments, may have texturing (i.e., may include surface features, such as from carding wire, etc.). The system 100 may include providing a vent in the saber roll assembly (i.e., a vent between the saber roll 108 and the saber roll end cap rotatably mounted in the side housing). The system 100 may include providing one or more viewing ports in the housing 112. These one or more viewing ports may be located, for example, near the doffing location (e.g., near the licker-in roll 106) and near the collector 110. These viewing ports allow, for example, to view / monitor the doffing of the fibers and / or to view / monitor the fibers as they fall onto the collector 110 to form the random fiber web. Additionally, the system 100 can provide a reverse seal that engages the collector 110 and is also attached to the lower slide plate. This reverse seal can be shaped to extend from the lower slide plate and can be oriented so that its tip extends in a direction generally opposite to the direction of rotation of the collector 110.

[0021] These additions may be utilized jointly, alone, or in various combinations as described in International Application No. PCT / US2019 / 045603. They may also be utilized in combination or in partial combination with the improvements of International Application No. PCT / US2019 / 045604. Furthermore, combinations or partial combinations of both International Application No. PCT / US2019 / 045603 and International Application No. PCT / US2019 / 045604 may be utilized with the improvements described herein.

[0022] 2 illustrates steps 150 and 160, including an open chamber 150 for airflow and a control device 160 for the airflow. In the system of FIG. 1, the airflow is supplied only from the air supply AS and collected in the collector 110 by vacuum. However, in at least some embodiments described herein, the housing 112 is designed with a less restrictive open chamber 150 for airflow. As discussed above, some problems with the design of FIG. 1 are the tendency for fibers to collide with either the doffer plate 20 or the lower slide plate 22. The more open chamber 150 in the housing 112 allows for less restrictive flow, reducing the likelihood that air or entrained fibers will collide with components of the system 100 between the licker-in roll 106 and the collector 110.

[0023] Additionally, in some embodiments, an air flow control device 160 is provided for air from an air supply, such as air supply AS. As shown in FIG. 1 , air is supplied from air supply AS between sabre roll 16 and licker-in roll 12 and routed to collector 18. In system 10, there are no additional air sources entering or exiting the system. This can cause the air flow within the housing to behave unpredictably, often resulting in entrapped fibers clumping and a non-uniform web. Therefore, in some embodiments, a static air control device is provided to allow air to enter or exit the system from sources other than air supply AS. Additionally, the direction of air flow within housing 112 can be controlled, at least in part, by dynamic air control mechanisms disposed within the housing.

[0024] 3A shows that the machine 220 may include a feeder (e.g., a rotatable feed roll 204), a licker-in (e.g., a licker-in roll 206), a sabre (e.g., a sabre roll 208), a channel 226, and a collector 210. The rotatable licker-in roll 206 may be configured to pick up a plurality of fibers from a fiber mat fed proximate the licker-in roll 206 by the feed roll 204. The licker-in roll 206 may be configured to doff the plurality of fibers from the licker-in roll 206. The rotatable sabre roll 208 may be positioned proximate the feed roll 204 and the licker-in roll 206. The channel 226 may allow an air supply AS to flow through a space 228 defined between the licker-in roll 206 and the sabre roll 208. The space 228 may include a doffing position where doffing of the plurality of fibers from the licker-in roll 206 occurs. A rotatable collector 210 can be positioned to capture the fibers once doffed into the air supply AS, which, when superimposed, form a random fiber web on the collector 210.

[0025] The air deflector assembly 216 may include a thin sheet of material disposed between the licker-in roll 206 and the sabre roll 208. The air deflector assembly 216 may be mounted in a housing portion 240 of the machine 220 near the feed roll 204 and may extend into the space 228 to the vicinity (less than an inch or less than a few inches) of the licker-in roll 204.

[0026] The embodiment of Figure 3A further shows a nose bar assembly 214 positioned near the licker-in roll 206 and extending along the licker-in roll 206 toward the sabre roll 208 of the machine 220. More specifically, the nose bar assembly 214 may include a nose bar 230 and a nose bar extension 232. The nose bar extension 232 and the nose bar 230 may be coupled to one another or may be a single component. The nose bar extension 232 may extend along the licker-in roll 206 and toward the sabre roll 208.

[0027] In the embodiment of FIG. 3A , the nose bar extension 232 may be separated from the space 226 by an air deflector assembly 216, which is positioned between the nose bar extension 232 (and actually extending between the licker-in roll 206 and the sabre roll 208) and the space 226. In FIG. 3A , the air deflector assembly 216 is positioned and configured to deflect the air supply AS away from the nose bar extension 232 and the doffing location (i.e., the location where a plurality of fibers are doffed from the licker-in roll 206). The doffing location may therefore be located within a second space 234 defined between the licker-in roll 206 and the air deflector assembly 216, near the termination point of the nose bar extension 232. The doffing location is therefore within the second space 234 due to the presence of the air deflector assembly 216, and not directly within the air supply AS in the space 228. In other words, in the embodiment of FIG. 3A, the doffing location is not located directly within the air supply AS, but is separated from the air supply AS by the air deflector assembly 216.

[0028] The nose bar assembly 214 may be positioned at least partially between the feed roll 204 and the licker-in roll 206 and may extend into the second space 234. The nose bar assembly 214 may be positioned near (within less than an inch or less than a few inches of) a portion of the outer periphery of the licker-in roll and may extend up to 170 degrees therearound. The nose bar assembly 214, and in particular the nose bar extension 232, may control the doffing position and trajectory. The nose bar extension 232 may be shaped and positioned to shift the doffing position and trajectory so that the fibers are better positioned to be entrained into the air supply AS after passing through the air deflector assembly 216, the doffer plate 20, and / or the lower slide plate 22 and over the end 236 of the air deflector assembly 216.

[0029] 3B shows a machine 320 having an air supply AS, a feeder (e.g., a rotatable feed roll 304), a licker-in (e.g., a licker-in roll 306), a sabre (e.g., a sabre roll 308), a channel 326 including a space 328, and a collector 310. The rotatable licker-in roll 306 may be configured to pick up a plurality of fibers from a fiber mat fed proximate the licker-in roll 306 by the feed roll 304. The licker-in roll 306 may be configured to doff the plurality of fibers from the licker-in roll 306. The rotatable sabre roll 308 may be positioned proximate the feed roll 304 and the licker-in roll 306. The channel 326 can channel the air supply AS into the space 328 defined between the licker-in roll 306 and the sabre roll 308. The space 328 can include a doffing position where doffing of the plurality of fibers from the licker-in roll 306 occurs. A rotatable collector 310 can be positioned to capture the fibers once doffed into the air supply AS, which, when superimposed, form a random fiber web on the collector 310.

[0030] The embodiment of FIG. 3B shows a nose bar assembly 314 positioned near the licker-in roll 306 and extending along the licker-in roll 306 toward the sabre roll 308 of the machine 320. FIG. 3B additionally shows a vent hole 315 in a sabre roll end cap 322 near the licker-in roll 306 of the machine 320. The sabre roll end cap 322 may be movable within the side housing so that the location of the vent hole 315 can be changed relative to the licker-in roll 306. FIG. 3B shows one or more view ports 316 in the side housing of the machine 320. The one or more view ports 316 may be positioned near the doffing location (e.g., near the licker-in roll 306) and near the collector 310. The apparatus 320 may include a reverse seal 318 extending from a lower slide plate 324 and shaped to engage the collector 310. The reverse seal 318 may be oriented so that its tip extends in a direction generally opposite to the direction of rotation of the collector 310 .

[0031] 3A and 3B both show embodiments in which fibers are doffed into an air supply AS and thrown toward a collector, while the entrained fibers pass through a housing having chamber barriers highlighted by box 250. Contact with any of these chamber barriers reduces the velocity of the moving fibers to zero, reducing the overall acceleration of the fibers and allowing the fibers to entangle with nearby fibers, creating clumps that result in regions of the resulting web with higher than desired fiber density.

[0032] In some embodiments, such as those shown in Figures 4-5, the chamber barriers create a wider path for airflow through the machine, making it more likely that entrained fibers will travel along a path directly from the doffing position to the collector without encountering an obstruction. The inventors have found that the various channel designs described herein are configured to spread the air supply AS more uniformly across each channel, with multiple fibers entrained within the air supply AS before it reaches the collector. This allows for a more uniform cross-web deposition on the collector when forming a random fiber web.

[0033] FIG. 4 illustrates one embodiment of a system 400 that is a portion of a machine 402 that includes a drum 404. In FIG. 4, the doffer plate is replaced by the drum 404. The drum 404 may be spaced from the licker-in roll and positioned near a collector 414. The drum 404 may include one or more passageways 406 in communication (e.g., via openings through the cylindrical wall of the drum 404) with a channel 408 that provides for the passage of the air supply AS to a collector 410 with a plurality of fibers entrained therein downstream of the doffing position. The one or more passageways 406 are configured to allow a quantity of the air supply AS to pass through the one or more passageways 406, if conditions within the system 400 and machine 402 so require. Alternatively, the one or more passageways are configured to allow ambient air from outside the machine 402 to enter the channel 408 through the one or more passageways.

[0034] The drum 404, in some embodiments, can provide a moving surface and can be configured to move relatively closer to or farther away from the collector 410 to change the size and shape of the channel 408 (defined in part by the drum 404). The drum 404 can rotate, as indicated by arrow R in FIG. 4 . Such rotation, in some embodiments, can be the result of the passage of ambient air or an air supply AS. In other embodiments, the drum 404 can be powered to facilitate the rotation indicated by arrow R. While FIG. 4 specifically illustrates a drum 404, other embodiments can contemplate plates, nips, belts, rolls, etc., or other types of devices that can be repositioned to change the size and shape of the channel 408. In still further embodiments, where a drum would be present for free air flow and exchange to and from the air supply AS, no device (e.g., housing, plate, nip, drum, belt, roll, etc.) may be provided so that the channel 408 is open to the ambient environment.

[0035] FIG. 5 illustrates one embodiment of a system 500 that is part of a machine 502 that includes a dynamic air control mechanism 560, shown in FIG. 5 as a rotatable doffing bar extension 560 that can rotate in the directions indicated by arrows 562, 564. In one embodiment, the doffing bar extension 560 can have a functional rotation range of more than 30°, more than 60°, more than 90°, more than 120°, or even more than 150°. In some embodiments, the doffing bar extension 560 can physically rotate further, but this does not provide a significant functional advantage. Varying the position of the extended doffing bar 560 affects the flow of air from the AS through the chamber 550. By varying the position of the doffing bar 560 and the position of the lower slide plate 568, the air flow path 566 can be affected, allowing for better control of the entrained fibers and greater uniformity in the cross-web direction as the fibers contact the collector 510.

[0036] The doffing bar 560 is shown in Figure 5 as extending over only a portion of the distance between the licker-in roll 506 and the collector 510. In some embodiments, the doffing bar extends over at least 5%, at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, or at least 45% of the distance between the licker-in roll 506 and the collector 510. In some embodiments, the doffing bar further extends over more than 50%, more than 55%, more than 60%, more than 65%, more than 70%, more than 75%, more than 80%, more than 85%, or more than 90% of the distance between the licker-in roll 506 and the collector 510.

[0037] Additionally, the doffing bar 560 is shown as having a straight bar extending from the rotating portion, however, in some embodiments the straight portion may be curved either towards or away from the slide plate 568.

[0038] The complete outermost periphery of chamber 550 is not shown in FIG. 5 . System 500, in some embodiments, may be combined with an upper drum, such as drum 404 of FIG. 4 , which may also allow for greater control of the movement of air and entrained fibers within flow channel 550. Alternatively, in some embodiments, a doffing plate, such as plate 20 of FIG. 1 , may provide an upper boundary on chamber 550. The upper boundary may also be a standard glass or metal housing in other embodiments. These and other suitable configurations are expressly contemplated. Other static and dynamic air control mechanisms, such as any of those described herein or in International Application No. PCT / US2019 / 045603 (based on U.S. Provisional Patent Application No. PCT62 / 717069), or International Application No. PCT / US2019 / 045604 (based on U.S. Provisional Patent Application No. 62 / 717095), may also be used in combination with extended doffing bar 560. For example, the position of the lower slide plate or sabre roll relative to the licker-in roll.

[0039] 6 shows a component diagram of a nonwoven web generating system 600. System 600 includes a fiber source 602 that supplies fibers to a fiber feeder 610. A licker-in roll 630 collects fibers from fiber feeder 610 using a fiber capture mechanism 634. Licker-in roll 630, in one embodiment, is a rotating licker-in roll 630 that rotates using a rotation mechanism 632. Licker-in roll 630 doffs the fibers, which are entrained in an air stream provided by an air source 620 and collected by a condenser 650. A vacuum 652 draws the fibers into position along the crossweb direction onto condenser 650, which rotates using a rotation mechanism 654.

[0040] The air flow from air supply 620 is controlled using air flow control mechanism 640. Air flow control mechanism 640 may include a static air controller 642, which, as used herein, is intended to describe a controller 642 that is generally not adjusted between operations and remains in a set operating position during operation. Air flow control mechanism 640, in some embodiments, may be a dynamic air control mechanism 644 that may be adjusted between operations. Dynamic air control mechanism 644, in some embodiments, may be adjustable during operation, although in situ adjustment is not recommended for safety reasons. The position, movement, and speed of movement, e.g., rotational speed, of licker-in roll or condenser 650 may, in some embodiments, be controlled by control system 660, which may be part of nonwoven web generating system 600 or may be connected to nonwoven web generating system 600 via a wired or wireless connection.

[0041] 7A-7D show diagrams of a doffing plate and extended doffing bar for controlling airflow according to one embodiment of the present invention. FIGS. 7A and 7B show diagrams of a prior art doffing plate, e.g., plate 20 from FIG. 1. When used in a prior art machine, the doffing plate 720 creates the upper boundary of the airflow chamber. As shown in FIG. 7A, the doffing assembly 700 includes a doffing plate 720 having a curvature, extending from point 704 where the doffing plate 720 connects to the licker-in roll to point 702 where the doffing plate 720 connects to the fiber collector. The doffing plate 720 connects to a doffing bar 710 that is in a fixed position 712 during system operation. The doffing plate 720 is intended to have some rotation so that a gap is formed at point 702 through which the formed fibrous web passes. The formed fibrous web closes the gap created by the doffing plate 720. The doffing plate 720 may be rotated a few degrees, for example, less than 10° or less than 15°, but any gap created is intended to be sealed by the fibrous web formed during operation of the assembly 700. Additionally, as mentioned above, the doffing plate 720 presents some issues with regard to free air flow from the doffing position to the collector.

[0042] In contrast, FIGS. 7C and 7D show diagrams of an extended doffing bar assembly 750. As shown in FIG. 7C, an extension portion 770 extends from a doffing bar 760, which is fixed within the system during operation. However, the extension portion 770 is rotatable about a rotation axis 780. As shown in FIGS. 7C and 7D, in some embodiments, the rotation is limited by a rotation path 782, which may include a range of approximately 150° about the rotation axis 780. However, in other embodiments, the rotation range may be greater, for example, limited only by the position of the doffing bar 760 and the licker-in roll, or the rotation range may be smaller. For example, the rotation range may be as little as 30°, 40°, 50°, 60°, 70°, 80°, 90°, 100°, 110°, 120°, 130°, or 140°. Additionally, the rotation range may be greater than 140° or greater than 150°. The rotation angle may also be expressed relative to a 0° position where the doffing bar 760 is positioned parallel to the slide plate. The rotation range may be, for example, from 0° to 30° or more in the direction toward the slide plate, or from 0° to 60° or more in the direction away from the slide plate.

[0043] 7C and 7D, the extended doffing bar assembly 750 does not function as a seal or upper boundary. In some embodiments, a separate boundary may also be included. In some embodiments, the separate boundary is porous or otherwise configured to allow air flow between the airflow channel and the surrounding environment.

[0044] A method for forming a random fiber web using an air-powered fiber feeding system is presented. The method includes providing a plurality of movable devices including a licker-in and a feeder. The licker-in is configured to pick up a plurality of fibers from a fiber mat fed proximate the licker-in by the feeder. The method also includes doffing the plurality of fibers from the licker-in at a doffing position within the system. The method also includes communicating an air supply and incorporating the plurality of fibers into the air supply after doffing. The method also includes controlling the air supply in a flow path between the licker-in and a collector. The method also includes collecting the plurality of fibers from the air supply on the collector to form a random fiber web.

[0045] Controlling the air supply in the flow path may include a static air control mechanism.

[0046] The static air control mechanism may include a vent in the sabre assembly, a chamber, a doffer plate, or a lower slide plate.

[0047] The static air control mechanism may include an extended nose bar between the feeder and the licker-in.

[0048] The static air control mechanism may include a reverse seal extending from the lower slide plate to the collector.

[0049] The static air control mechanism may include a drum that allows for the air supply to be interchanged with an ambient air source.

[0050] The drum may rotate.

[0051] The static air control mechanism may include an air deflection plate.

[0052] Controlling the air supply in the flow path may include a dynamic air control mechanism.

[0053] The dynamic air control mechanism may be adjustable only when the pneumatic fiber delivery system is inactive.

[0054] The dynamic air control mechanism may include an extended doffer bar.

[0055] The elongated doffer bar can be rotatable within the chamber of the pneumatic fiber delivery system, with rotation of the elongated doffer bar changing the air supply from a first air flow pattern within the chamber to a second air flow pattern within the chamber.

[0056] The dynamic air control mechanism includes an airfoil positioned to guide the air supply.

[0057] The method may further include controlling an amount of air supply to at least one of the doffing location and downstream of the doffing location defined by a flow direction of the air supply.

[0058] Controlling the amount of air supply may include providing one or more of a damper, a nose bar extension, an air deflector plate, an airfoil, and one or more passages within a housing of the system.

[0059] An air-powered fiber feeding system for forming a random fiber web is presented. The system includes a feeder. The system also includes a licker-in configured to take a plurality of fibers from a fiber mat fed by the feeder to a vicinity of the licker-in and to dof the plurality of fibers from the licker-in. The system also includes a channel for distributing an air supply to a space near the licker-in, the space including a doffing position where doffing of the plurality of fibers from the licker-in occurs. The system also includes a collector positioned to capture the plurality of fibers once doffed into the air supply, where the plurality of fibers form a random fiber web on the collector. The system also includes an air control mechanism within the channel.

[0060] The air control mechanism may be a static air control mechanism.

[0061] The air control mechanism may be a dynamic air control mechanism.

[0062] The static air control mechanism may include a vent in the sabre assembly, a vent in the chamber, the doffer plate, or the lower slide plate.

[0063] The static air control mechanism may include an extended nose bar between the feeder and the licker-in.

[0064] The static air control mechanism may include a reverse seal extending from the lower slide plate to the collector.

[0065] The static air control mechanism may include a drum that allows for the air supply to be interchanged with an ambient air source.

[0066] The drum may include an upper capacitor.

[0067] The upper capacitor may be rotated.

[0068] The static air control mechanism may include an air deflection plate.

[0069] The dynamic air control mechanism may include an extended doffer bar.

[0070] The elongated doffer bar can be rotatable within the chamber of the pneumatic fiber delivery system, with rotation of the elongated doffer bar changing the air supply from a first air flow pattern within the chamber to a second air flow pattern within the chamber.

[0071] The channel downstream of the doffing location can be defined by a flow direction of the air supply formed in part by a first plate having a substantially flat surface along the channel interfacing with a region of the first plate configured to be substantially aligned with the flow direction of the air supply.

[0072] The first end of the first plate extends beyond the extension doffer bar to a position adjacent the licker-in.

[0073] The system may also include one or more passageways in communication with the channel downstream of the doffing location. The one or more passageways may be configured to allow a volume of supply air to pass through the one or more passageways and also allow a volume of ambient air to pass through the one or more passageways and into the channel.

[0074] The one or more passages may be formed by a portion of the housing surrounding the channel.

[0075] The system may further include a deflector plate positioned near the licker-in and extending into the space, the deflector plate being positioned to keep the air supply and the plurality of fibers separated until after the doffing position.

[0076] The system may further include a nose bar assembly disposed between the licker in and the deflection plate. The nose bar assembly may be configured to extend the doffing position past the feed roll and into a second space defined between the licker in and the deflection plate.

[0077] The system may further include an airfoil disposed within the channel, the airfoil configured to be selectively movable toward and away from the deflection plate to selectively allow passage of at least a portion of the supply air into the second space.

[0078] The system may further include a damper disposed within the channel, the damper configured to be selectively movable toward and away from the saber roll to selectively allow passage of at least a portion of the supply air around a portion of the saber roll that does not interface with the licker-in.

[0079] An air-powered fiber feeding system for forming a random fiber web is presented. The system includes a plurality of movable devices, including a licker-in and a feeder. The licker-in is configured to pick up a plurality of fibers from a fiber mat fed by the feeder to a vicinity of the licker-in. The licker-in is configured to dof the plurality of fibers from the licker-in. The system also includes a channel for communicating an air supply to a space near the licker-in, the space including a doffing position where doffing of the plurality of fibers from the licker-in occurs. The system also includes a collector positioned to capture the plurality of fibers once doffed into the main air supply, where the plurality of fibers form a random fiber web on the collector. The system also includes an air control mechanism within the channel.

[0080] The system may also include one or more passages in communication with the drum, the channel downstream of the doffing position, or a restriction in the channel downstream of the doffing position and before the collector.

[0081] The air control mechanism may direct the air supply towards the collector.

[0082] The air control mechanism may be adjustable.

[0083] The air control mechanism may be rotatable.

[0084] The air control mechanism may extend within the channel towards the collector.

[0085] Adjusting the air control mechanism can change the flow path of the air supply through the channels.

[0086] The air control mechanism may extend to less than the midpoint between the licker-in and the collector.

[0087] The air control mechanism may extend beyond the midpoint between the licker-in and the collector.

[0088] The air control mechanism may include an extension portion that is substantially flat.

[0089] The air control mechanism may include a curved extension.

[0090] The air control mechanism extends from the doffing bar and is rotatable about an axis defined by the doffing bar.

[0091] The system may also include a deflector plate positioned near the licker-in and extending into the space, the deflector plate being positioned to keep the air supply and the plurality of fibers separated until after the doffing position.

[0092] The system may also include a nose bar assembly disposed between the licker in and the deflection plate. The nose bar assembly may be configured to extend the doffing position past the feed roll and into a second space defined between the licker in and the deflection plate.

[0093] The system may also include an airfoil disposed within the channel, the airfoil configured to be selectively movable toward and away from the deflection plate to selectively allow passage of at least a portion of the supply air into the second space.

[0094] The system may also include a damper disposed within the channel and configured to be selectively movable toward and away from the saber roll to selectively allow passage of at least a portion of the supply air around a portion of the saber roll that does not interface with the licker-in.

[0095] The system may also include a passage between the channel and a source of ambient air.

[0096] As used herein, The terms "a," "an," and "the" are used interchangeably with "at least one" and mean one or more of the elements being described.

[0097] The term "and / or" means either one or both. For example, "A and / or B" means A only, B only, or both A and B.

[0098] The terms "including," "comprising," or "having" and variations thereof are intended to encompass the items listed thereafter and equivalents thereof, as well as additional items.

[0099] The term "adjacent," as used herein, refers to the relative position of two elements, such as, for example, two layers that are in close proximity to one another, which may or may not be in contact with one another, and which may have one or more layers separating the two elements as understood by the context in which "adjacent" is used.

[0100] All scientific and technical terms used herein have meanings commonly used in the art unless otherwise specified. The definitions provided herein are intended to facilitate understanding of certain terms used frequently in this application and are not intended to preclude reasonable interpretations of such terms in the context of this disclosure.

[0101] Unless otherwise indicated, all numbers in the description and claims expressing feature dimensions (feature sizes), quantities, and physical properties used in the specification and claims should be understood as being modified in all instances by the term "about." Accordingly, unless specifically indicated to the contrary, the numerical parameters set forth in the above specification and appended claims are approximations that may vary depending upon the desired properties sought to be obtained by one of ordinary skill in the art using the teachings disclosed herein. At the very least, each numerical parameter should be construed in light of the number of reported significant digits and by applying ordinary rounding techniques; however, this is not intended to limit the application of the doctrine of equivalents to the scope of the claims. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the present disclosure are approximations, the numerical values ​​set forth in the specific examples are reported as precisely as possible. However, any numerical value inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements.

[0102] The term "substantially" means within 20 percent (sometimes within 15 percent, in still other cases within 10 percent, and in still other cases within 5 percent) of the referenced attribute. Thus, value A is "substantially similar" to value B if value A is within one or more of 5%, 10%, 20% of value A, plus / minus.

[0103] The features and advantages of the present disclosure will be further understood by consideration of the detailed description and appended claims.

[0104] The recitation of numerical ranges by endpoints includes all numbers subsumed within that range (e.g., a range of 1 to 5 includes, for example, 1, 1.5, 2, 2.75, 3, 3.80, 4, and 5) and any range within that range.

[0105] Although the present disclosure has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes can be made in form and detail without departing from the spirit and scope of the disclosure. In addition to the above embodiment, the following aspects are added. (Appendix 1) 1. A method for forming a random fiber web using a pneumatic fiber delivery system, comprising: providing a plurality of movable devices including a licker-in and a feeder, the licker-in configured to pick up a plurality of fibers from a fiber mat fed into the vicinity of the licker-in by the feeder; doffing the plurality of fibers from the licker-in at a doffing location within the system; passing an air supply through the air supply and incorporating the plurality of fibers into the air supply after the doffing; controlling the air supply in a flow path between the licker-in and a collector; collecting the plurality of fibers from the air supply onto a collector to form the random fiber web; A method comprising: (Appendix 2) 2. The method of claim 1, wherein controlling the air supply in the flow path includes a static air control mechanism. (Appendix 3) 3. The method of claim 2, wherein the static air control mechanism comprises a vent, a chamber, a doffer plate, or a lower slide plate in a sabre assembly. (Appendix 4) 3. The method of claim 2, wherein the static air control mechanism includes an extended nose bar between the feeder and the licker-in. (Appendix 5) 3. The method of claim 2, wherein the static air control mechanism includes a reverse seal extending from a lower slide plate to the collector. (Appendix 6) 3. The method of claim 2, wherein the static air control mechanism includes a drum that allows for interchange of the air supply with an ambient air source. (Appendix 7) 7. The method of claim 6, wherein the drum rotates. (Appendix 8) 3. The method of claim 2, wherein the static air control mechanism includes an air deflection plate. (Appendix 9) 2. The method of claim 1, wherein controlling the air supply in the flow path includes a dynamic air control mechanism. (Appendix 10) 10. The method of claim 9, wherein the dynamic air control mechanism is adjustable only when the pneumatic fiber delivery system is in an inoperative state. (Appendix 11) 10. The method of claim 9, wherein the dynamic air control mechanism includes an extended doffer bar. (Appendix 12) 10. The method of claim 9, wherein the elongated doffer bar is rotatable within a chamber of the pneumatic fiber delivery system, and wherein rotation of the elongated doffer bar changes the air supply from a first air flow pattern within the chamber to a second air flow pattern within the chamber. (Appendix 13) 10. The method of claim 9, wherein the dynamic air control mechanism includes an airfoil positioned to guide the air supply. (Appendix 14) 2. The method of claim 1, further comprising controlling an amount of the air supply to at least one of the doffing position and a downstream portion of the doffing position defined by a flow direction of the air supply. (Appendix 15) 15. The method of claim 14, wherein controlling the amount of air supply includes providing one or more of a damper, a nose bar extension, an air deflector plate, an airfoil, and one or more passages within a housing of the system. (Appendix 16) 1. A pneumatic fiber feeding system for forming a random fiber web, comprising: A feeder; a licker-in configured to take a plurality of fibers from a fiber mat fed by the feeder to a vicinity of the licker-in and configured to doff the plurality of fibers from the licker-in; a channel for distributing an air supply to a space adjacent the licker-in, the space including a doffing position where the doffing of the plurality of fibers from the licker-in occurs; a collector positioned to capture the plurality of fibers once doffed into the air supply, the plurality of fibers forming the random fiber web on the collector; an air control mechanism within the channel; A pneumatic fiber delivery system comprising: (Appendix 17) 17. The system of claim 16, wherein the air control mechanism is a static air control mechanism. (Appendix 18) 17. The system of claim 16, wherein the air control mechanism is a dynamic air control mechanism. (Appendix 19) 18. The method of claim 17, wherein the static air control mechanism comprises a vent in a sabre assembly, a chamber, a doffer plate, or a lower slide plate. (Appendix 20) 18. The method of claim 17, wherein the static air control mechanism includes an extended nose bar between the feeder and the licker-in. (Appendix 21) 18. The method of claim 17, wherein the static air control mechanism includes a reverse seal extending from a lower slide plate to the collector. (Appendix 22) 18. The method of claim 17, wherein the static air control mechanism includes a drum that allows for interchange of the air supply with an ambient air source. (Appendix 23) 23. The method of claim 22, wherein the drum includes an upper capacitor. (Appendix 24) 24. The method of claim 23, wherein the upper capacitor rotates. (Appendix 25) 18. The method of claim 17, wherein the static air control mechanism includes an air deflection plate. (Appendix 26) 19. The method of claim 18, wherein the dynamic air control mechanism includes an extended doffer bar. (Appendix 27) 19. The method of claim 18, wherein the elongated doffer bar is rotatable within a chamber of the pneumatic fiber feeding system, and wherein rotation of the elongated doffer bar changes the air supply from a first air flow pattern within the chamber to a second air flow pattern within the chamber. (Appendix 28) 28. The system of claim 27, wherein the channel downstream of the doffing position defined by the direction of flow of the air supply is formed in part by a first plate having a substantially flat surface along the channel that interfaces with a region of the first plate configured to be substantially aligned with the direction of flow of the air supply. (Appendix 29) 29. The system of claim 28, wherein a first end of the first plate extends beyond the extension doffer bar to a vicinity of the licker-in. (Appendix 30) 17. The system of claim 16, further comprising one or more passages in communication with the channel downstream of the doffing position, the one or more passages configured to allow a volume of the supply air to pass through the one or more passages and also to allow a volume of ambient air to pass through the one or more passages and enter the channel. (Appendix 31) 28. The system of claim 27, wherein the one or more passages are formed by a portion of a housing surrounding the channel. (Appendix 32) 17. The system of claim 16, further comprising a deflector plate positioned near the licker-in and extending into the space, the deflector plate positioned to maintain the air supply and the plurality of fibers separated until after the doffing position. (Appendix 33) 33. The system of claim 32, further comprising a nose bar assembly disposed between the licker-in and the deflection plate, the nose bar assembly configured to extend the doffing position past the feed roll and into a second space defined between the licker-in and the deflection plate. (Appendix 34) an airfoil disposed within the channel, the airfoil configured to be selectively movable toward and away from the deflection plate to selectively allow passage of at least a portion of the supply air into the second space; or a damper disposed within the channel, the damper configured to be selectively movable toward and away from the servile roll to selectively allow passage of at least a portion of the supply air around a portion of the servile roll that does not interface with the licker-in; 17. The system of claim 16, further comprising one of: (Appendix 35) 1. A pneumatic fiber feeding system for forming a random fiber web, comprising: a plurality of movable devices including a licker-in and a feeder, the licker-in configured to pick up a plurality of fibers from a fiber mat fed into the vicinity of the licker-in by the feeder, and configured to doff the plurality of fibers from the licker-in; a channel for distributing an air supply to a space adjacent the licker-in, the space including a doffing position where the doffing of the plurality of fibers from the licker-in occurs; a collector positioned to capture the plurality of fibers once doffed into the main air supply, the plurality of fibers forming the random fiber web on the collector; an air control mechanism within the channel; A pneumatic fiber delivery system comprising: (Appendix 36) 36. The system of claim 35, further comprising a drum, one or more passages in communication with the channel downstream of the doffing position, or a restriction in the channel downstream of the doffing position and prior to the collector. (Appendix 37) 36. The system of claim 35, wherein the air control mechanism directs the air supply toward the collector. (Appendix 38) 36. The system of claim 35, wherein the air control mechanism is adjustable. (Appendix 39) 39. The system of claim 38, wherein the air control mechanism is rotatable. (Appendix 40) 36. The system of claim 35, wherein the air control mechanism extends within the channel toward the collector. (Appendix 41) 39. The system of claim 38, wherein adjusting the air control mechanism changes the flow path of the air supply through the channel. (Appendix 42) 36. The system of claim 35, wherein the air control mechanism extends to less than a midpoint between the licker-in and the collector. (Appendix 43) 36. The system of claim 35, wherein the air control mechanism extends beyond a midpoint between the licker-in and the collector. (Appendix 44) 36. The system of claim 35, wherein the air control mechanism includes an extension portion that is substantially flat. (Appendix 45) 36. The system of claim 35, wherein the air control mechanism includes a curved extension. (Appendix 46) 36. The system of claim 35, wherein the air control mechanism extends from a doffing bar and rotates about an axis defined by the doffing bar. (Appendix 47) 36. The system of claim 35, further comprising a deflector plate positioned near the licker-in and extending into the space, the deflector plate positioned to maintain the air supply and the plurality of fibers separated until after the doffing position. (Appendix 48) 48. The system of claim 47, further comprising a nose bar assembly disposed between the licker-in and the deflection plate, the nose bar assembly configured to extend the doffing position past the feed roll and into a second space defined between the licker-in and the deflection plate. (Appendix 49) an airfoil disposed within the channel, the airfoil configured to be selectively movable toward and away from the deflection plate to selectively allow passage of at least a portion of the supply air into the second space; or a damper disposed within the channel, the damper configured to be selectively movable toward and away from the servile roll to selectively allow passage of at least a portion of the supply air around a portion of the servile roll that does not interface with the licker-in; 49. The system of claim 48, further comprising: (Appendix 50) 50. The system of claim 49, further comprising a passage between the channel and a source of ambient air.

Claims

1. 1. A pneumatic fiber feeding system for forming a random fiber web, comprising: A feeder; a licker-in configured to take a plurality of fibers from a fiber mat fed by the feeder to a vicinity of the licker-in and configured to doff the plurality of fibers from the licker-in; a channel for distributing an air supply to a space adjacent the licker-in, the space including a doffing position where the doffing of the plurality of fibers from the licker-in occurs; a collector positioned to capture the plurality of fibers once doffed into the air supply, the plurality of fibers forming the random fiber web on the collector; an air control mechanism within the channel; Equipped with the air control mechanism is a dynamic air control mechanism; The dynamic air control mechanism has a doffing bar provided near the licker-in and a slide plate disposed opposite the doffing bar, a doffing bar having a shaft portion and an extension portion extending from the shaft portion, the extension portion being pivotable about the shaft portion within a chamber of the pneumatic fiber feeding system through a predetermined angular range, thereby being pivotable both toward and away from the slide plate relative to a position in which the slide plate and the extension portion are arranged parallel to each other, and the pivoting of the extension portion directly changes the air flow pattern in the chamber from a first air flow pattern in the chamber to a second air flow pattern in the chamber.

2. 2. The system of claim 1, wherein the channel downstream of the doffing location defined by the flow direction of the air supply is formed in part by the slide plate, the slide plate having a substantially flat surface along the channel that interfaces with a region of the slide plate configured to be substantially aligned with the flow direction of the air supply.

3. 1. A pneumatic fiber feeding system for forming a random fiber web, comprising: a plurality of movable devices including a licker-in and a feeder, the licker-in configured to pick up a plurality of fibers from a fiber mat fed into the vicinity of the licker-in by the feeder, and configured to doff the plurality of fibers from the licker-in; a channel for distributing an air supply to a space adjacent the licker-in, the space including a doffing position where the doffing of the plurality of fibers from the licker-in occurs; a collector positioned to capture the plurality of fibers once doffed into the main air supply, the plurality of fibers forming the random fiber web on the collector; an air control mechanism within the channel; Equipped with a doffing bar provided near the licker-in and a slide plate disposed opposite the doffing bar, the doffing bar having a shaft portion and an extension extending from the shaft portion, the extension portion pivoting about the shaft portion within a predetermined angular range within a chamber of the pneumatic fiber feeding system to be pivotable both toward and away from the slide plate relative to a position where the slide plate and the extension portion are arranged parallel to each other, and the pivoting of the extension portion directly changes the air flow pattern within the chamber from a first air flow pattern within the chamber to a second air flow pattern within the chamber.

4. The system of claim 3 , wherein the air control mechanism extends within the channel toward the collector.

5. The system of claim 3 , wherein adjusting the air control mechanism changes the flow path of the air supply through the channel.

6. The system of claim 3 , wherein the air control mechanism extends to less than a midpoint between the licker-in and the collector.

7. The system of claim 3 , wherein the air control mechanism extends beyond a midpoint between the licker-in and the collector.

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