Systems and methods for manufacturing dry molded fiber components

Abstract

A system for manufacturing dry molded fiber components includes an infeed station configured to supply a base material, a milling station to fiberize the base material into a plurality of fibers; a forming station to arrange the plurality of fibers into a fiber mat, and a press that compresses the fiber mat to form a final molded component.

Description

SYSTEMS AND METHODS FOR MANUFACTURING DRY MOLDED FIBER COMPONENTSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application 63 / 604,748 filed on Nov. 30, 3023, which is hereby incorporated by reference in its entirety.STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH

[0002] Not applicable.BACKGROUND

[0003] The present disclosure relates to the production of dry molded fiber components. More specifically, the present disclosure relates to systems and methods for forming mats from fibers (e.g., cellulose fibers) and for reducing system waste.

[0004] Plastic food containers, bags, and other disposal products have become a ubiquitous part of our modern lives, but they come with a host of environmental, health, and sustainability problems. Plastic food containers, for example, cause significant environmental problems because they are not biodegradable, and therefore generate a substantial amount of waste. While some plastic food containers can be recycled, the rates of recycling are generally low due to various factors, including the complexity of recycling different types of plastics, contamination issues, and the lack of infrastructure for recycling in many areas.

[0005] Plastic containers are also a significant contributor to marine pollution. When not properly disposed of, plastic containers can end up in rivers and oceans, where they break down into smaller particles called microplastics. These microplastics harm marine life, as they are often ingested by aquatic animals and can disrupt ecosystems.

[0006] Some plastics used in food containers, moreover, may contain harmful chemicals like phthalates, per-and polyfluoroalkyl substances (PFAS), and bisphenol A (BPA). These chemicals can leach into the food or liquids they hold, posing health risks when consumed. Over time, as plastic containers degrade, these chemicals may also be released into the environment.

[0007] Because of these problems, efforts to limit the use of plastic food containers have been ongoing for several years. These efforts have taken various forms, including legislation, regulations, and voluntary initiatives. Many countries, states, and cities have implemented bans or restrictions on single-use plastic products, including plastic food containers, utensils, and straws.

[0008] Fiber food containers and utensils, which can be made from materials like recycled paper, molded paper pulp or biodegradable plant-based plastics, can provide moreeco-friendly alternatives to traditional plastic containers, and these types of containers have been particularly important in replacing plastic containers and implements. While fiber products offer ecological advantages, however, they currently suffer from a number of problems and limitations. For example, current fiber containers and utensils are generally less durable and less sturdy as compared to plastic or foam utensils and containers. They can easily deform or break if subjected to pressure or rough handling, and it is challenging to create utensils with the necessary structural integrity to withstand the rigors of everyday use. Ensuring that containers and utensils can hold their shape and withstand pressure without breaking or deforming, however, is crucial for consumer satisfaction.

[0009] Additionally, fiber materials may have limitations in terms of the shapes and designs that can be achieved. Complex or intricate designs, for example, can be difficult to create with fibers, and this can restrict the creativity of designs.

[0010] The current disclosure addresses these and other issues.SUMMARY

[0011] In one aspect of the disclosure, a system for manufacturing dry molded fiber components is provided. The system may include an infeed station configured to supply a base material; a milling station including a mill configured to receive and fiberize the base material into a plurality of fibers; and a forming station configured to receive the plurality of fibers. The forming station comprises a drum core connected to a vacuum source, the drum core including a plurality of baffles arranged to define a plurality of vacuum regions; a forming drum rotatably coupled around the drum core, an outer forming surface of the forming drum comprising a plurality of openings for supplying vacuum from the vacuum source to the plurality of fibers, a strength of the vacuum source applied to the plurality of fibers being individually controlled at each of the plurality of vacuum regions, wherein the vacuum source causes the fibers from the milling station to be deposited on and secured to the forming drum to form a fiber mat; and a press configured to receive the fiber mat and compress the fiber mat to form a final molded component.

[0012] In other aspects, the mill may be configured to receive trim of the fiber mat from an outfeed side of the press, and to re-fiberize the trim with the base material. The mill may include a rotor with a plurality of blades rotationally fixed to a shaft, each of the plurality of blades including a plurality of teeth, and the plurality of blades may be rotationally fixed so that the teeth of the plurality of blades are in a helical arrangement about the shaft. The mill may include a housing receiving a rotor that rotates therein, the housing defining a trim slot configured to receive the trim material, a plurality of additional base material slots configured to receive the base material, and a duct configured to eject the fiber to the forming station. The plurality of base material slots may be arranged between the trim slot and the duct so that, as a rotor rotates within the housing, a toothof the rotor passes from the trim slot to the plurality of base material slots and then the duct. The trim slot may be arranged between the plurality of base material slots so that, as a rotor rotates within the housing, a tooth of the rotor passes from a first of the base material slots to the trim slot, then to a second of base material slots, and then the duct. Relative to the rotation of the rotor, the trim slot may be spaced from a first of the plurality of base material slots by at least 45 degrees and a second slot of the plurality of base material slots may be spaced from the duct by at least 45 degrees. The plurality of base material slots may comprise a first base material slot configured to receive a first web of the base material and a second base material slot configured to receive a second web of the base material, the second base material slot being arranged between the first base material slot and the duct.

[0013] In yet other aspects of the disclosure, the press may include an infeed side and an outfeed side, and the outfeed side of the press may be located closer to the mill than the infeed side of the press. The outfeed side of the press may also or alternately be located closer to the forming station than the infeed side of the press.

[0014] In still other aspects of the disclosure, the forming station may include a scarfing roller configured to remove excess fiber from the fiber mat to control a thickness of the fiber mat. The forming drum may rotate relative to the drum core. The plurality of openings in the forming drum may be perforations that are defined in an outer circumferential surface of the drum. The forming drum may include a forming plate coupled to the drum, the forming plate defining a cavity configured to receive the plurality of fibers from the milling station. The cavity may have a variable depth to form a fiber mat with a corresponding variable thickness.

[0015] In other aspects of the disclosure, the drum core may include a plurality of ducts, each of the plurality of ducts corresponding to one of the plurality of vacuum regions, wherein the ducts are in communication with the vacuum source, and wherein the vacuum to the plurality of ducts is controllable so that a strength of the vacuum at each of the plurality of vacuum regions is independently controllable. The plurality of ducts may be configured to be selectively opened or closed. The system may further include a plurality of adjustable gates coupled to the ducts, the adjustable gates moveable between an open position and a closed potion to control the vacuum to the plurality of ducts. The drum core may also comprise a plurality of baffles, the baffles dividing an interior of the drum core into the plurality of vacuum regions. At least one outlet of the plurality of ducts may be received a first and a second of the plurality of baffles.

[0016] In other aspects of the disclosure, the system may comprise a festooning station configured to accumulate the fiber mat from the forming station and to selectively meter the fiber mat to an infeed side of the press in accordance with a press cycle. The festooning station may comprise a belt configured to convey the fiber mat to the press. The festooningstation may be sized to enable at least two meters of fiber mat accumulation during a press cycle. The system may further comprise a conveyor configured to move the fiber mat from an upstream side of the press to an opposing downstream side of the press adjacent the festooning station, and the festooning station may be configured to receive the fiber mat from the conveyor and to feed the fiber mat back to the press. The conveyor may be positioned beneath the press. The festooning station may also comprise a carriage translating between a first position adjacent the press and a second position offset from the press. The festooning station may further comprise a belt operating on an idler wheel, and wherein the conveyor is configured to provide the fiber mat to the belt and to drive the fiber mat over the idler wheel and into the press.

[0017] In another aspect of the disclosure, a forming drum assembly for producing a fiber mat from loose fibers may be provided. The forming drum assembly can include a forming drum having an outer circumferential surface comprising a plurality of openings, the forming drum defining an interior cavity; and a drum core received within the interior cavity of the forming drum, the drum core including a plurality of baffles arranged to define a plurality of vacuum zones within the interior cavity of the forming drum, each of the plurality of vacuum zones configured to couple to an independently controllable vacuum at the respective vacuum zone, wherein the forming drum is rotatably coupled to the drum core, and when vacuum is applied through the plurality of openings, the loose fibers form a mat on the outer circumferential surface of the forming drum. Each of the plurality of vacuum zones may be configured to couple to a corresponding duct of a vacuum source to provide the independently controllable vacuum at the respective vacuum zone. The forming drum may comprise at least one a forming plate coupled to the drum, the forming plate defining at least one cavity that receives the fibers. The at least one cavity may have a variable depth to form a fiber mat with a corresponding variable thickness. The at least one cavity may comprise one of a plurality of continuous cavities and a plurality of discrete cavities extending around a circumference of the outer circumferential surface of the forming drum. The plurality of baffles may define at least four vacuum zones, or six vacuum zones. The plurality of baffles may define a plurality of vacuum zones, the baffles being spaced across an interior of the drum core between first and second end plates to form a plurality of vacuum regions within the drum core. Each of the vacuum zones may be coupled to a separately controlled vacuum source. Each of the vacuum zones may also be coupled to a vacuum source duct that is controlled by a sliding gate. The plurality of baffles may be provided on an insert that is removably coupled to an interior of the forming drum.

[0018] In still another aspect of the disclosure, a mill for producing fibers may be provided. The mill may include a feed unit configured to receive a trim fiber source; a plurality of infeed guides configured to receive a plurality of base material fiber sources; a housing defining a first trim slot configured to receive the trim fiber source, a plurality ofbase material slots configured to receive a corresponding plurality of base material fiber sources, and a duct configured to eject the fibers produced from each of the trim fiber source and the base material fiber source; and a rotor configured to rotate within the housing to fiberize the trim fiber source and the base material fiber sources, the rotor including a plurality of blades that are rotationally fixed to a shaft, each of the plurality of blades including a plurality of teeth. The plurality of blades may be arranged so that the teeth of the plurality of blades are in a helical arrangement about the shaft. The rotor may be configured to rotate from the first slot toward the duct and the second slot is arranged between the first slot and the duct. The feed unit may comprise a pair of rolls receiving a web of trim material therebetween. The pair of rolls may be nip rolls sandwiching the web of trim material therebetween. The feed unit may comprise a regrind mill configured to break the trim material into a stream of discrete pieces received by a pneumatic feed unit or a mechanical feed unit. The mechanical feed unit may be a conveyor or a feed screw. The plurality of infeed guides may comprise a first infeed guide comprising a support surface configured to receive a first base material fiber source and a second infeed guide comprising a support surface configured to receive a second base material fiber source. A respective breaker bar may be positioned at each of the first slot and the plurality of additional slots. A seal may be positioned in each slot opposite the respective breaker bar. Each infeed guide may comprise a support surface configured to receive a base material fiber source and a second pair of rolls.

[0019] In yet still another aspect of the disclosure, a method for producing dry molded fiber components may be provided. The method may comprise the steps of fiberizing a base material; feeding the fiberized base material to an air permeable forming surface in communication with a vacuum source to form a fiber mat; controlling a strength of the vacuum source at selected regions of the perforated forming surface to vary a depth of the fiber mat at selected locations; and compressing the mat to form a multi-dimensional molded component. The method may further comprise the steps of cutting the multidimensional molded component from the mat, fiberizing a trim portion of the mat after the cutting step and feeding the fiberized trim onto the perforated forming surface with the fiberized material, providing cavities in a surface of the forming surface to vary a depth of the mat formed at the cavity, and / or applying a mold to the mat. The multi-dimensional molded component may also be formed as a discrete part.

[0020] In still a further aspect of the disclosure, a festooning station for accumulating a fiber mat may be provided. The festooning station may comprise a festoon carriage, the festoon carriage comprising a linear block movably coupled to a pair of rails, and a carriage drive source coupled to the linear block and configured to drive the linear block along the pair of rails; a belt assembly comprising: an idler drum rotatably coupled to the linear block of the festoon carriage, an outer surface of the idler drum comprising a continuous radiusof curvature outer shell; at least one belt drive roll coupled to the linear block of the festoon carriage; a belt received on the idler drum and the drive roll; and a drive source coupled to the belt drive roll and configured to drive the belt along a belt travel path defined by the idler drum and the drive roll, wherein as the carriage drive source drives the linear block along the pair of rails in the festoon carriage, the belt assembly is moveable between at least a first and a second position along the rails of the festooning carriage, the position of the festooning station extending a path followed by a fiber mat enabling accumulation of the fiber mat. The festooning station may further comprise at least one idler roll, the idler roll positioned along the belt travel path between the belt drive roll and the idler drum and positioned to extend the belt travel path, and / or a plurality of idler rolls, the plurality of idler rolls positioned along the belt travel path receiving the belt, and extending a path followed by the belt. The idler roll may comprise a steel, aluminum, or carbon fiber construction and / or may have an outer wall of the idler roll has a thickness of 2 mm to 3 mm. The belt of the festooning station may receive a fiber mat from a conveyor system beneath the idler drum and the belt drives the fiber mat over the idler drum reversing the direction of travel of the mat. The conveyor may be configured to receive the fiber mat from a forming drum and to transfer the fiber mat to a press. The drive belt travel path may cause a delay in the motion of the fiber mat of between six and ten seconds. The continuous outer shell has a thickness of between substantially 2 mm and 7 mm, may be one of steel and aluminum, and may be one of solid and perforated.

[0021] In other aspects of the disclosure, a method is provided for operating a system for manufacturing dry molded fiber components is provided that includes an infeed station configured to supply a base material, a milling station including a mill configured to receive and fiberize the base material into a plurality of fibers, a forming station configured to receive the plurality of fibers, and to form a fiber mat through the application of a vacuum source, a backer material supply system configured to provide backer material to the fiber mat, and a press configured to receive the fiber mat and compress the fiber mat to form a final molded component. The method includes the following steps: in a dry-run mode, activating the backer material supply system, deactivating the press and feeding the backer material through the press and to the milling station to be recycled; in a start-up mode subsequent to the dry-run mode, activating the infeed station and the milling station feeding the base material from the infeed station to the milling station to form the fiber mat, feeding the fiber mat onto the backer material, feeding the fiber mat through the deactivated press back to the milling station to be recycled, and continuing to feed backer material and base material until a leading edge of the fiber mat reaches one of the press and the milling station; and in a production mode subsequent to the start-up mode, activating the press and pressing the fiber mat into dry molded fiber components, and feeding trim from the fiber mat to the milling station.

[0022] In yet another aspect of the disclosure, a system for manufacturing dry molded fiber components includes an infeed station configured to supply a base material, a milling station including a mill configured to receive and fiberize the base material into a plurality of fibers, a forming station configured to receive the plurality of fibers, and to form a fiber mat through the application of a vacuum source, a backer material supply system configured to provide backer material to the fiber mat, and a press configured to receive the fiber mat and compress the fiber mat to form a final molded component. The system also includes a controller programmed to: in a dry-run mode, deactivate the press and feed the backer material through the press and to the milling station; in a start-up mode subsequent to the dry-run mode, activate the infeed station and the milling station, feed the base material from the infeed station to the milling station to form the fiber mat, feed the fiber mat onto the backer material, feed the fiber mat through the deactivated press back to the milling station, and continue to feed backer and base material until receiving feedback that the fiber mat has reached a pre-determined weight; and in a production mode subsequent to the start-up mode, activate the press and pressing the fiber mat into dry molded fiber components, and feed trim from the fiber mat to the milling station.BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The features, aspects and advantages of the disclosure will become apparent when consideration is given to the following detailed description thereof. Such detailed description makes reference to the following drawings.

[0024] FIG. 1 is a schematic view of a system for manufacturing a dry molded fiber component.

[0025] FIG. 2A is a side view of an infeed station and tensioner of the system of FIG. 1.

[0026] FIG. 2B is a side view of a milling station and a forming station of the system of FIG. 1.

[0027] FIG. 2C is a side view of a combining station, festooning station, and a press of the system of FIG. 1.

[0028] FIG. 3 is a perspective view of the festooning station of FIG. 2C, according to an embodiment.

[0029] FIG. 4 is a perspective view of the milling station of FIG. 2B.

[0030] FIG. 5 is a top view of the milling station of FIG. 2B.

[0031] FIG. 6 is a section view of the milling station, taken through line VI-VI in FIG.5.

[0032] FIG. 7 is a detail view of the milling station of FIG. 2B, taken about line VII-VII in FIG. 6.

[0033] FIG. 8 is a partial cross-sectional view of the milling station of FIG. 7.

[0034] FIG. 9 is a side view of a blade configured for use with the milling station of FIG. 7.

[0035] FIG. 10 is a detail view of the mill, taken about line X-X in FIG. 7.

[0036] FIG. 11 is a perspective view of the forming station of FIG. 2B.

[0037] FIG. 12 is a perspective view of a forming drum of the forming station of FIG.2B and vacuum connections to the forming drum.

[0038] FIG. 12A is front view of the forming drum of FIG. 12, illustrating rings mounted on the forming surface to narrow a width of a fiber mat formed on the forming drum.

[0039] FIG. 12B is front view of the forming drum of FIG. 12, illustrating rings mounted on the forming surface to increase the thickness of a fiber mat formed on the forming drum.

[0040] FIG. 12C is a front view of the forming drum of FIG. 12, illustrating rings for masking portions of the forming surface to provide a defined shape of the fiber mat formed on the forming surface of the forming drum.

[0041] FIG. 12D is a front view of the forming drum of FIG. 12, illustrating a cover plate that includes masking portions that extend across the forming surface to define discrete fiber mat components.

[0042] FIG. 13A is an exploded side view of the forming drum of FIG. 12.

[0043] FIG. 13B is a perspective side view of the forming drum of FIG. 12.

[0044] FIG. 14 is a side view of the forming drum of FIG. 12.

[0045] FIG. 15 is a section view of the forming drum, taken through line XV-XV in FIG.14.

[0046] FIG. 16 is a section view of the forming drum, taken through line XVI-XVI in FIG. 14.

[0047] FIG. 17 is a section view of the forming drum, taken through line XVII-XVII in FIG. 14.

[0048] FIG. 18 is a partial schematic view of the forming drum of FIG. 12 with a cover plate installed thereon, according to one embodiment.

[0049] FIG. 19 is a partial perspective view of a portion of the forming drum of FIG. 12 with a series of cover plates installed thereon, according to another embodiment.

[0050] FIG. 20 is a partial perspective view of a portion of the forming drum of FIG. 12 with a series of cover plates installed thereon, according to yet another embodiment.

[0051] The following detailed description is to be read with reference to the figures, in which like elements in different figures have like reference numerals.DETAILED DESCRIPTION

[0052] As generally mentioned above, the present disclosure relates to systems and methods for manufacturing dry molded fiber components. Dry molded fiber componentsare those formed from dry fibers or pulp (e.g., cellulose fibers) that can be pressed together to form complex, three-dimensional shapes. For example, dry molded fiber components can be formed with undercuts, snap-fit features, etc., that may be too complex or cost prohibitive to manufacture with conventional fiber molding techniques. With conventional dry molded fiber processes, dry fibers are typically arranged into a two-dimensional mat. The mat can be placed or formed on a conveyer (e.g., with a wire mesh belt) that transfers the fiber mat into a press. The press can include a die that compresses and cuts portions the fiber mat into the shape of the final component, which is then ejected from the system.

[0053] The present disclosure can provide improvements upon conventional processes utilized to manufacture dry molded fiber as well as disposable absorbent product such as adult incontinence products, diapers, and feminine hygiene products. In particular, the present disclosure relates to improved mill configurations that allow for more efficient fiberization of a base material, as well as for the reuse and re-fiberization of trim left over from the production of other dry molded fiber components. Additionally, the present disclosure relates to mat forming systems for creating a three-dimensional fiber mat (e.g., a fiber mat with variable thickness) to allow for the production of more complex geometries, as compared with conventional mat forming systems.

[0054] FIG. 1 depicts a non-limiting example of a system 100 for manufacturing dry molded fiber component (e.g., a machine or assembly line configured to produce dry molded fiber components). The system 100 can include, by way of example, an infeed station 104 configured to supply a base material 106 to a milling station 108 for fiberizing the base material 106, a forming station 120 for forming the fibers into a mat, a combining station 134 for applying backers to the mat, a festooning station 136 for supplying the fiber mat to a press 140, which is activated to press the mat into a dry molded fiber component. Each of these stages will be described more fully below.

[0055] Referring still to FIG. 1, as described above, an infeed station 104 configured to supply a base material 106 for molding is provided at the input of the system 100. The base material 106 can be, for example, provided on a roll which is continually fed into the fiberizing process. Metering of the base material 106 can be controlled by an electronic controller 105 in accordance with a downstream demand of the system 100. The electronic controller 105 can be, for example, a programmable logic controller (PLC), a computer, or an application specific device comprising a microprocessor, memory, and communication components, such as transceivers, wireless communication devices, etc. which can be configured to communicate via network communications, internet protocols, through cellular communications or other types of communications. The electronic controller 105 may be configured to control a plurality or all of the stages of system 100. Alternatively, a plurality of electronic controllers can be provided. For example, each station may includean electronic controller, which may be in communication with other electronic controllers in the system 100, or with a master controller.

[0056] Referring still to FIG. 1, the base material 106 can be made of cellulose fiber or another type of fibrous material. For example, in some cases, the base material 106 can be provided as paperboard (i.e., pre-compressed cellulose fiber or kraft pulp) that is formed into rolls. The particular length of the fibers within base material 106 can be selected to allow for fiber entanglement, which can affect the strength and rigidity of the final molded component. An exemplary range of fiber lengths is 0.5mm to 6mm. Referring now also to FIG. 2A, a side view of a non-limiting example of an infeed station 104 is shown. As illustrated here, the infeed station 104 includes a mounting structure 103 for mounting two rolls 106A and 106B of base material 106, each of which are fed to an optional material handling system 110. The base material 106 that is provided on the rolls 106A and 106B may be the same base material or may be different materials used in the forming process. Although, as illustrated here, infeed station 104 includes a mounting structure for two rolls of material, in some cases the infeed station 104 can be configured to support a single roll or three or more rolls. Base material 106 may be fed to the system 100 as a single layer from a single roll, or material from multiple rolls of material may be simultaneously fed to the system to produce a fluff mat with multiple material types, such as, for example, treated, untreated bleached, unbleached, softwood (e.g., pine), hardwood, or eucalyptus. In cases where multiple material types are utilized, infeed station 104 may be controlled to vary the infeed rate of one material type relative to another to process varying ratios of mixing. Infeed station 104 is configured such that once a first roll 106A runs out, the infeed station 104 can automatically switch to the second roll 106B to provide a continuous supply of base material 106 to the system 100. Correspondingly, this allows the first roll 106A to be replaced while base material 106 is being supplied from the second roll 106B, and vice versa. Switching may be effected, for example, by the electronic controller 105 based on feedback received from proximity or optical sensors configured to monitor the roll of base material 106. Density and / or weight of the fluff produced in the system may also be monitored using one or more sensors 145, such as those available from Hossbach Sensor Technologie, Fu rth, Germany, and the feedback may be used by the controller 105 to adjust the infeed speed at infeed station 104 and control the grams per square meter of the fiber mat. A splicing table, not shown, may be included to enable splicing of an expiring roll of base material with a new roll of base material.

[0057] Referring still to FIGS. 1 and 2A, the infeed station 104 can supply the base material 106 to a milling station 108. In some cases, an optional material handling system 110 can be provided between the infeed station 104 and the milling station 108 to provide sound deadening and tracking functionality for the base material 106. Additionally, the material handling system 110, in conjunction with the infeed station 104, can be configuredto control a rate of supply of the base material 106 to the milling station 108. As illustrated in FIG. 2A, the material handling system 110 can comprise one or more rollers configured to guide or track the base material 106 to the milling station 108. The rollers preferably have a high mass construction with a resilient outer surface such that roller contact with the base material 106 dampens vibration and energy transmitted through the base material 106 reducing the sound power level in the mill area. The rollers can be mounted on a frame structure, and, in some applications, can be manually adjusted via an operator turning a handwheel to adjust roller orientation. Typically, one of the rollers serves in the material handling system as the drive roll and can be connected to a motor or other power source. This roller is responsible for pulling the web material through the system. The second roller can be an idler roll, which is positioned opposite the drive roll. The idler roll provides a counterforce to the drive roll, creating the necessary tension in the web material. While a two-wheel system is described herein, system 100 may include any other known style of web handling units. One or more optional manual splicing tables (not shown) may be provided in place of or in addition to material handling system 110.

[0058] System 100 may also include an optional water spray or atmospheric humidification system (not shown) to impart moisture onto the base material 106 to aid in reducing static, etc. The spray or humidification system can include vision systems or sensors that can measure moisture content and provide feedback to controller 105 which can adjust the flow rate of nozzles associated with the spray. For example, near infrared sensors, such as those available from Finna Sensors of Denver, CO., KPM Analytics of Westborough, MA., or Moisttech Corp, of Sarasota, FL. can be used. Infeed station 104 may further include an optional automated pulp tracking system (not shown) with an active tracking system including a tracking table with web guide sensors such as a FIFE web guiding system commercially available from Maxcess and / or vision sensors, active driven tension control and dancer feedback. In some embodiments, infeed station 104 may include an optional slitting system comprising one or more knife units that slit the base material 106 into narrower web segments to a narrower infeed width of the milling station 108.

[0059] Referring still to FIG. 1 and now also to FIG. 2B, as described in greater detail below, the milling station 108 includes a mill 112 (see e.g., FIGS. 6-8) configured to fiberize the base material 106 into a plurality of fibers 116 for use in later processes of the system 100. The mill 112 can be any type of mill configured to fiberize the base material 106, which may depend, at least in part, on the type of fiber of the base material 106 and any additives (e.g., wax, bonding agents, colorants, etc., which can be in the form of granules or liquids) that are added to the mill 112 during fiberization of the base material 106. For example, in some systems, the mill 112 can be a hammer mill, sawtooth mill, disk mill, or another type of mill. In any case, the mill 112 is generally configured to mechanically breakor tear apart the base material 106 into individual fibers and to mix those fibers together. While a single mill 112 is shown in the figures, it is contemplated that some systems may include multiple mills to provide for increased fluff throughput, to produce a fiber mat having a high grams per square meter (GSM), multiple fiber layers, and / or wider width. A fiber mat with a high GSM may alternatively achieved increasing the number of rolls of base material 106 in the infeed station 104 and feeding stacked sheets of base material into a common infeed of the mill 112.

[0060] The fibers from the mill 112 can be supplied to the forming station 120 where the fibers 116 can be arranged to form a fiber mat 122. More specifically, the loose fibers 116 are output (e.g., as a stream of loose or entangled fibers) through a discharge or duct 124 extending between the milling station 108 and the forming station 120. The discharge 124 of mill 112 may be horizontally oriented, as shown in FIG. 6, or oriented vertically (up or down) or at an alternative angle relative to forming drum 130 in alternate embodiments. In some cases, mill 112 may include one or more optional infeed ports (not shown) to permit additives such as solid granules (e.g., wax) and / or loose fibers (e.g., bi-component "BICO") and / or fibers and tissues that are pneumatically transported from a regrind or reclaim station to be added to the stream in the duct 124 to mix with the fibers 116. The optional infeed port(s) may include manually or electrically controllable values (not shown) to permit intermittent dosing of the additives and / or regrind material.

[0061] Once at the forming station 120, the fibers 116 can be deposited to form a fiber mat 122. For example, and as described in greater detail below, the fiber mat 122 can be formed by depositing fibers 116 onto a forming drum 130, which rotates as the fibers 116 are being deposited. In some cases, a diverter structure (not shown) can be used to control the deposition of the fibers 116 onto the forming drum 130, for example, to control a width or concentration of deposited fibers 116. Correspondingly, the forming drum 130 can be coupled to a forming vacuum zone 125 in communication with one or more vacuum sources 240 (FIG. 11) to secure the deposited fibers 116 on an outer circumferential surface defining a forming surface 234 of the forming drum 130 that is air permeable via a plurality of openings therein, and further control the shape and other parameters of the fiber mat 122. In one exemplary embodiment, vacuum source 240 may be a centrifugal industrial fan. The vacuum level of the forming station can be controlled by changing the speed of the fan, such as, for example, via VFD motor control. In embodiments with multiple vacuum sources 240, the sources may be arranged to individually control vacuum in the machine direction 102, the cross-machine direction 107, and / or other directions between the machine direction 102 and cross-machine direction 107.

[0062] For example, the forming drum 130 can be used to form a continuous fiber mat, or a series of discrete fiber mats. Discrete fiber mats can minimize fiber usage and reduce waste, and improve system efficiency, such as by improving press performance at latersteps in the process. Additionally, the fiber mat can be formed as a two-dimensional sheet with a substantially uniform thickness or density, or as a three-dimensional mat having regions of varying thickness or density, or with varying width or other geometric features (e.g., channels or openings) as described in more detail below with respect to FIGS. 11- 20. The ability to form regions of varying thickness or density can allow for the formation of deep drawn parts and other complex shapes that are typically not possible with two- dimensional fiber mats. Moreover, increased fiber entanglement can be achieved, as compared with conventional systems that merely deposit fibers onto a moving conveyor, which can result in increased mat integrity and strength of the final molded component. Relatedly, the increased fiber entanglement can also result in greater mat density, which can reduce cracking when the fiber mat 122 is pressed at later steps to form the final molded component.

[0063] Referring now to FIGS. 12A - 12C, the forming drum 130 can include first and second rings 254A and B that can be mounted to the forming surface 234 on opposing sides adjacent the outer rim 252 which can be used to shape the fiber mat formed on the forming surface. The forming surface 234 can include one or more holes or apertures that align with offset sets of holes or apertures 256A and 256B in the corresponding rings 254A and 254B and enable threaded fasteners such as screws or bolts, or other types of fasteners, to couple the rings 254A and 154B to the forming drum 130. The rings 254A and 254B coupled to the surface of the forming drum 130 can be constructed in different ways and / or connected to the forming drum in different positions to enable the construction of webs or fiber mats with different characteristics. Referring first to FIG. 12A, here the rings 254A and 254B are coupled to the forming drum 130 offset a distance from the outer rim 252 selected to narrow the width of the fiber mat formed on the forming surface 234. The forming drum 130 can include multiple sets of apertures 256A, 256B to enable movement of the ring 254 to different positions on the forming surface 234, thereby enabling the construction of fiber mats of varying widths.

[0064] Referring now to FIG. 12B, the rings 254A and 254B illustrated here includes a thicker construction and / or a higher sidewall 259A, 259B height than the rings 254A and 254B in FIG. 12A. This construction increases the outer diameter of the rings 254A and 254B relative to the forming surface 234, which enables a thicker web or fiber mat 122 to be developed on the forming surface 234.

[0065] Referring now to FIG. 12C, the rings 254A and 254B may alternatively or additionally be formed to include a rounded or stepped interior edge 300, the stepped interior edge 300 illustrated here including a base edge 302 located at a first diameter, and one or more masking portion 303A, 303B, 3030, 303D that extends from the base edge 302 to a masking edge 305 that is located closer to the center of the forming surface 234. The masking portion 303 of one of the rings 254A and B may cover the forming surface234, and therefore provide a mask that prevents a fiber mat from forming, therefore enabling the production of a fiber mat 122 with a specific predefined shape. As illustrated here, the masking edge 305 can include rounded and / or rectangular shapes. It will be apparent, however, that many different shapes and configurations of masking can be provided to enable the construction of mats of varying shapes, sizes, and thicknesses, depending on the position, thickness, and edge configuration of the rings 254A, 254B attached to the forming surface 234. Although the rings 254A, 254B are described above as separate components from the forming drum 130, ring structures of the type described above may also be integrally formed on the forming surface 234 of the drum 130. Although the rings 254A, 254B described above form a continuous fiber mat, in some applications, the masking portion 303 may extend across the entire forming surface 234, thereby defining a discrete fiber mat 122 between each masking portions 303A, B, C, D and a subsequent masking portion 303, as illustrated in FIG. 12D.

[0066] Alternatively, rather than separate rings 254A, 254B a cover plate 250 may be provided as a single, continuous piece or may be provided in segments of the type described below and illustrated in FIGs. 17 - 19, that are coupled to both sides of the forming drum 130 and include a masking edge in the form of sidewalls forming three- dimensional cavities or depressions on the forming surface 234. The cover plate 250 may also be formed integrally with the forming drum 130. Alternatively, one ring 254A may be a ring with straight edges as described and illustrated with reference to FIGs. 12A or 12B, and the opposing ring 254B may include both a base edge 302 and a masking portion 303 that extends across the forming surface 234 to the inner edge 305 of the opposing ring 254A. Opposing rings 254A and B may also be mirror images of one another, with masking edges meeting substantially at the center of the forming surface 234. The rings 254A and B and cover plates 250 that provide masking may be adjusted to have higher sidewalls to form thicker fiber mats, be adjustable or moveable on the forming drum 130 to adjust a width of the mat, or be mounted in different locations on the forming surface 234 to adjust the parameters of the fiber mat formed on the forming surface 234.

[0067] In some cases, to help achieve a desired thickness and / or uniformity, the forming station 120 can further include one or more scarfing rollers 132. A single scarfing roller 132 is included in the embodiment illustrated in FIG. 11, however, it is contemplated that multiple scarfing rollers may be positioned side by side in the cross-machine direction or in series in the machine direction according to alternate embodiments. The scarfing roller 132 can be configured to remove excess fibers 116 from the fiber mat 122 on the outer, exposed surface that is opposite the forming drum 130. Accordingly, the scarfing roller 132 can be configured to shape the exposed surface of the fiber mat 122 into a desired shape (e.g., planar, stepped, curviplanar, etc.). The scarfing roller 132 may have a width substantially equal to the width of the forming surface or have a narrower widththat permits the scarfing roller 132 to project below the top surface of the outer rim 252 closer to the perforations in the forming surface 234. In the illustrated non-limiting example, scarfing roller 132 includes a central shaft with a plurality of projections of uniform length extending radially outward from the shaft. Such an embodiment may be used to shape a planar fiber mat 122 with a uniform thickness. In alternate embodiments, the length of the projections may be varied to form a shaped or profiled scarfing roll configured to provide higher or lower regions in the fiber mat 122. According to various embodiments, the projections may be rigid or flexible pins, blades, bars, bristles, or other geometric protrusions extending outward from the shaft. The distance between the projections and the forming drum 130 can be used to control the thickness of the fiber mat 122. Correspondingly, in some cases, the scarfing roller 132 can be movable to adjust the thickness of the fiber mat 122. System 100 may include an optional closed loop scarf return duct (not shown) to transfer scarfed fiber back into the mill 112. An optional tucking roll 133 (see FIG. 2B) may be positioned downstream from the scarfing roller 132 to aid in retaining the fiber mat 122 against the forming drum 130 and remove air from the fiber mat 122 as it exits the forming chamber 121 and to seal the forming chamber 121 from air infiltration. A vacuum transfer roll 147 is positioned to transfer the fiber mat 122 off the forming drum 130.

[0068] In the embodiment described above, the fluff mat 122 is formed, at least in part, from fibers ground from a rigid or semi-rigid base material 106 such as a sheet of pulp. Alternatively base material 106 may be metered into an infeed port of the mill 112 as a loose fiber to be blended with trim regrind.

[0069] Referring still to FIG. 1, and now also to FIG. 2C, in some cases, the integrity of the fiber mat 122 can be further improved by applying a reinforcing layer or "backer" (e.g., as a web layer, film, and / or spray) to the fiber mat 122. Accordingly, once the fiber mat 122 is formed, it can be transported to an optional combining station 134, where one or more backers 135 can be applied to the fiber mat 122 via a corresponding backer material supply system 137, which may include any combination of optional metering rolls, tensioning rolls, dancer rolls, tracking web guides or turn bars, splicing systems (for example zero-speed splicing units, at speed splicing units, or other known web splicing technologies), printing systems (e.g., flexographic, ink jet, or other known printing technologies), web registration systems, and / or liquid application units (e.g., flexographic, gravure, or other known deposition units). While two backers 135 are illustrated in FIG. 20, alternative embodiments may include three or more backers, a single backer, or backers may be omitted entirely. The backer can be paper, tissue, nonwoven, a plastic film (e.g., poly), barrier spray, or other material that can be secured (e.g., sprayed, attached via an adhesive, or initially placed in contact and later secured by pressure applied by the press 140) to one or both sides of the fiber mat 122. Backer may be a single layer on aside of the fiber mat 122 or a multi-layer composite such as, for example, a tissue layer coupled to a plastic film layer, to provide a variety of desired barrier properties. In other cases, the backer can be arranged in other ways, for example, between two fiber mats.

[0070] A discrete backer layer, i.e., a series of discrete pieces of backer layer, may also be applied to one or both sides the fiber mat 122 via one or more slip-and-cut applicators (not shown), each comprising a rotating anvil and rotating knife roll. The continuous backer 135 is fed at a relatively low speed along the vacuum face of the rotating anvil, which is moving at a relatively higher surface speed and upon which the backer 135 is allowed to "slip." A knife-edge, mounted on the rotating knife roll, cuts a segment of backer 135 against the anvil face. This knife-edge is preferably moving at a surface velocity similar to that of the circumference of the anvil. Once cut, the discrete backer segment is held by vacuum drawn through holes on the face of the anvil as it is carried at the anvil's speed downstream to the transfer point where the backer segment is transferred to the traveling fiber mat 122. Alternatively, a rotary knife roll similar to that described above may be provided in combination with a downstream discrete segment turning device (not shown) that includes vacuum pucks, which rotate and place the series of backer segments on the traveling fiber mat 122 at an angle, such as 90 degrees for example, relative to the running continuous backer web. The turning device may be, for example a rotary pad turner of the types more fully described in U.S. Pat. No. 5,25,910 and U.S. Pub. 20120186944, which are incorporated herein by reference.

[0071] In some cases, the backer can be configured to provide a desired property in the final molded component. For example, a backer can be a waxed paper material or a hydrophobic spray that can help to repel liquids and prevent or slow the rate at which liquid is absorbed into the final molded product. In some cases, the backer can include a decorative elements or logos. Depending on the applied backer, therefore, the combining station can include one or more additive stations 139, which may comprise one or more spray nozzles oriented, for example, in a vertical down, horizontal, or other angle spray configuration, slot-coating applicators, brush or roll application devices, extrusion systems for applying materials in the form of beads, dots, or lines, hot melt adhesive systems, screen printing systems, lamination devices, or other known deposition systems alone or in combination. Additive station(s) 139 may be configured to provide a continuous application of barrier material or be provided with an optional control system 141 including controllable valves or other known flow control devices to enable intermittent application of the barrier material to select regions of the fiber mat 122 corresponding approximately to the mold or final product shapes thereby minimizing unnecessary barrier material consumption and the amount of barrier material present in the recycled trim material. System 100 may also include an optional embossing unit (not shown) comprising one or two patterned rolls and configured to impart a pattern into one or both surfaces of the fibermat 122. Embossing unit may be positioned upstream of the backer material supplies 137 to create an embossed pattern on the fiber layer alone, or positioned downstream of the backer material supplies 137 to impart the embossed pattern through the backer layer(s). The emboss pattern may be designed to provide defined bend lines to assist with the fiber mat 122 conforming to the press mold cavities and / or to provide a visual feature in the final part. System 100 may also include an optional die unit (not shown) comprising a patterned knife roll and mating anvil roll to create a series of discontinuous cuts and / or perforations within the fiber mat 122 in the machine direction 102 and / or cross-machine direction 107 to improve conformance and alignment of the fiber mat 122 within the press mold cavities.

[0072] Referring still to FIG. 2C and again to FIG. 2B, once the fiber mat 122 is formed, the fiber mat 122 can be driven off of the forming drum 130 by pressure from a vacuum source applied in a transfer vacuum zone 127 of forming drum 130 and the fiber mat 122 can then be transported (e.g., via a driven conveyor or roller system 326 and / or a dead plate) to a press 140. In some cases, the press 140 may be configured to operate continuously (e.g., similar to a roller), or to operate cyclically to produce batches of molded components. Where a press 140 is configured to produce batches of molded components, the feed of the fiber mat 122 can be metered to allow the continued production of fiber mat 122 while allowing the press to complete a cycle. Accordingly, a festooning station 136 can be provided to selectively supply fiber mat 122 to the press 140 for each press cycle. The festooning station 136 can act as an accumulator that can accumulate fiber mat 122 while a press cycle is conducted and then provide the accumulated fiber mat 122 to the press 140 once the previous press cycle is complete. The festooning station 136 can include, by way of example, conveyor systems, bins, or roll accumulators.

[0073] An embodiment of festooning station 136 is shown in FIG. 3 and includes an idler drum 312 with a rotary shaft 304 positioned on a festoon carriage 306. The idler drum 312 includes an outer surface with a continuous radius of curvature that provides a consistent, unform contact with the fiber mat 122, which aids in preventing defects, irregularities, and variations in the formed mat 122. The outer surface of idler drum 312 may also help maintain a more uniform surface on the fiber mat 122, preventing surface irregularities. Having a continuous drum surface also helps to maintain constant belt tension within the system. In some applications, a sheet material 313, such as aluminum or other known lightweight and rigid material, may wrap the outer circumference of idler drum 312. The outer surface of the idler drum 312 may be solid, or may be perforated or formed with small holes or apertures. The size of any hole formed in the outer surface is selected to maintain the consistent contact and pressure on the fiber mat 122.

[0074] Referring still to FIG. 3, a series of idler rolls 308, one or more drive rolls 310, and the idler drum 312 define an adjustable travel path of a belt 314 that supports andconveys the fiber mat 122. Idler rolls 308 may have a light-weight construction, for example a thin steel, aluminum, or carbon fiber shell, to reduce inertia. For example, in one application a WINertiaTM double rolled idler roller having a weight of one hundred pounds per inch from Maxcess®, of Oakbrook Illinois was successfully employed. Although a specific arrangement is shown, the illustrated arrangement of idler rolls and drive roll(s) is exemplary only and alternative configurations are within the scope of the disclosure.

[0075] Referring still to FIG. 3, a servo drive 327, a screw drive, a magnetic drive, a gear drive, a pneumatic drive or other known drive source is coupled to drive roll 310 and controls movement of belt 314. Belt 314 serves as a support surface that aids in maintaining the uniform integrity of the fiber mat 122 as it is transported to the press 140. Belt 314 may be constructed from any known metal or polymer screen or mesh materials. In one exemplary embodiment, the belt 314 includes a base polyester mesh structure coated with a secondary friction-enhancing material, such as a synthetic elastomer. Additionally, or as an alternative to the coating material, a surface texture may be applied to or formed on the outward-facing surface of the mesh structure to further enhance performance. In some embodiments, such as when the fiber mat 122 is formed with a continuous construction, belt 314 operates without applied vacuum. In alternative embodiments, such as when the fiber mat 122 is formed as discrete mat segments or without facing backers, belt 314 is operated with applied vacuum to aid in transport.

[0076] A linear block 316, coupled to the festoon carriage 306, rides on a set of rails 318. A servo drive 320 or other known carriage drive source drives movement of the linear block 316 via a belt 324, which causes festoon carriage 306 to translate back and forth along a travel direction 322. Fiber mat 122 travels on the conveyor system 326, which may include one or multiple driven conveyors in alternative embodiments, that carries fiber mat 122 from the combining station 134, underneath the press 140, and to the belt 314 of festooning station 136. As shown in FIGS. 20 and 3, conveyor system 326 is positioned below idler drum 312. Festooning station 136 accumulates a length of fiber mat 122 as it travels away from the drive side 328 of festooning station 136 and delivers an accumulated length of fiber mat 122 to the press 140 as it travels toward the drive side 328. The fiber mat 122 therefore travels from conveyor system 326 below the press 140, around idler drum 312 and back toward the press 140 from a top of the idler drum 312, reversing direction of motion as the fiber mat 122 approaches the press 140, as shown by machine direction arrow 102 of FIG. 20. The path followed by the fiber mat 122 provides increased accumulation of mat material before entry to the press 140. In one embodiment, festooning station 136 is sized to enable at least two meters of fiber mat 122 accumulation to accommodate up to a ten second dwell time and preferably at least a six second dwell period within the press 140. In alternate embodiments, festooning station 136 may be replaced with a linear accumulating assembly similar to linear accumulator 148, festooningbelts or festooning conveyors as known in the industry, a dancer roll assembly or other known tension control unit.

[0077] After exiting festooning station 136, the fiber mat 122 is metered into the press 140 through a pair of infeed nip rolls 159 so that a molded component 150 can be formed from the fiber mat 122. The infeed nip rolls 159 may be configured to permit adjustment of the infeed location of the fiber mat 122 in the cross-machine direction 107. In instances where the width of the fiber mat 122 is smaller than operational width of the press 140, such adjustment may be advantageous to decrease cycle time by enabling the die cavities to be positioned in close proximity to the extraction robot (not shown). The press 140 can include a mold (not shown) that is configured in accordance with the shape of the final molded component 150. That is, the mold can define one or more cavities that are formed as the negative shape of the molded component 150. Accordingly, when the press 140 is closed over the fiber mat 122, the mat material positioned within the die cavities is compressed into the shape of the molded component 150. In some cases, prior to entering the press 140, the fiber mat 122 can be debulked at one or more optional debulking stations 142, each including a driven roll positioned adjacent an anvil. Driven roll may have a smooth surface, to uniformly compress the fiber mat 122, or have a pattern of raised portions, to compress select regions of the fiber mat 122 more than other regions. Debulking of the fiber mat 122 can increase the density of the fiber mat 122, which can provide a more uniform, planar surface for receiving barrier spray and increase conformity of the fiber mat 122 with the die cavity, thus improving press performance and dimensional accuracy of the molded component 150 and, in cases of a patterned roll impart a three- dimensional pattern in the fiber mat 122 to create regions of different density in the fiber mat 122.

[0078] System 100 may include an optional preheating unit (not shown) to heat the fiber mat 122 before it enters the press 140. The preheating unit may be configured as a contact heating unit such as, for example, a pair of heated rolls that heat the fiber mat 122 as it passes between the rolls, or a non-contact unit that heats the fiber mat 122 indirectly, such as by directing heated air toward the fiber mat 122 or that heats the fiber mat 122 via infrared. The preheating unit may be positioned between the festooning station 136 and the infeed of the press 140 or at a location upstream of the festooning station 136 and downstream of the backer material supplies 137. System 100 may also include one or more optional inspection systems such as, for example, a vision system configured to analyze characteristics such as uniformity and density in the fiber mat 122 and / or detect irregularities or defects.

[0079] In some cases, particularly where the molded component 150 is formed form a continuous fiber mat, the molded component 150 can be cut from the fiber mat 122 as part of the press process so it can be ejected or extracted from the system 100 as a finishedpart. Correspondingly, the remnants of the fiber mat 122, that is, the trim 144, can be transported back to the milling station 108 where it can be reintroduced into the mill 112 to be re-fiberized with the base material 106. A pair of press outfeed nip rolls 155, which may be independently driven or driven via a common drive means such as, for example, a servo drive, aid in transitioning the trim 144 out from the press 140. In an alternate embodiment, nip rolls 155 may be replaced with one or more servo-driven conveyors. Trim 144 may be directed through an optional debulking station 157 prior to being reintroduced to the mill 112. The illustrated embodiment further includes an optional dancer roll assembly 153 or other known tension control unit positioned between the debulking station 157 and the mill 112.

[0080] Because the trim 144 may have holes where the molded component 150 was removed, the structural integrity of the trim 144 can vary along its length. Accordingly, as illustrated in FIG. 2B, the milling station 108 can include a feed unit 146 to feed the trim 144 into the mill 112. The feed unit 146 can be a set of nip rolls or double-sided conveyor configured to receive the trim 144 in a sandwiched configuration between opposed conveyor belts. In this way, more consistent pressure can be applied to the trim 144 to reduce the chance of the trim 144 bunching or tearing. Relatedly, to account for varying feed rates resulting from press 140 cycling, an accumulating station 148 can be positioned between the press 140 and the feed unit 146 to allow for substantially constant feed rate of trim 144 into the feed unit 146, and thus, the mill 112. System 100 may also include an optional volume-based feed system control to control feed rate of the trim 144 to the mill 112 based on a trim volume determined, for example, by a vision system or a gravimetric feed system. In the embodiment shown, accumulating station 148 is a linear accumulator that includes a belt driven carriage assembly 149 that oscillates in a translation direction 151 to accumulate and deliver trim 144 as the press 140 cycles. In alternate embodiments, linear accumulator 148 may be replaced with a festooning drum assembly, similar to festooning station 136, festooning belts or festooning conveyors as known in the industry, a dancer roll assembly, or other known tension control unit.

[0081] As discussed above, a milling station 108 is configured to receive a source of fibers, from new base material 106 and optionally from trim 144 left over from a pressing process. Referring now to FIGS. 4 and 5 a non-limiting example of a milling station 108 is shown. The milling station 108 includes a mill 112 that is configured to receive fiber from multiple sources, including new base material 106 (e.g., via one or more rolls 106A, 106B of base material 106) and trim 144 from the press 140. Correspondingly, the milling station 108 can include one or more infeed guides 160A, B configured to support and align the base material 106 as it enters the mill 112, as well as a feed unit 146 configured to support and align the trim 144 as it enters the mill 112. The illustrated embodiment includes two infeed guides 160A and B. Alternate embodiments may include a single guide 160 or threeor more guides 160, each with corresponding support surfaces 161 and pairs of rolls 163. Each infeed guide may comprise a support surface 161 configured to receive a base material fiber source and a pair of rolls 163. The illustrated embodiment includes support surfaces 161A and B and a pair of rolls 163A and B. Referring now also to FIG. 6, the mill 112 can also include a housing 164, which can be supported on a frame 168 of the milling station 108. The housing 164 can define an interior space that is configured to receive a rotor 172 therein. The rotor 172 can be rotated about a rotor axis 174 by a motor 178 or another power source. Here, the motor 178 is operatively coupled to the rotor 172 via an optional belt drive 179. As seen in FIGS. 2B and 6, milled fiber 116 exits the mill 112 through duct 124.

[0082] The mill 112 can be a rotary-type mill that is configured to fiberize the base material 106 and the trim 144. That is, the mill 112 can be configured to mechanically break apart the condensed fibers within the base material 106 and the trim 144 into loose fibers 116 that can be reconstructed into a comparatively lower density fiber mat. With additional reference to FIGS. 6-8, the mill 112 is shown in a horizontal orientation relative to a direction of gravity, but the mill 112 can be oriented differently in other applications, for example in a vertical orientation to deliver loose fibers downward, or in an orientation that facilitates a delivery of fibers at an upward or downward angle.

[0083] Referring still to FIGS. 6 - 8, and now also to FIG. 9, depending on the type of fiber being processed, the rotor 172 can be operated differently to optimize fiberization. In the illustrated non-limiting example, the rotor 172 can be configured as a blade-type rotor having a plurality of fixed blades 180 that are secured to a shaft 182. Each blade 180 can define a plurality of teeth 184 (FIGS. 7, 9, and 10) that extend radially outward from the shaft 182. In the illustrated non-limiting example, each blade 180 includes eight teeth; however, blades can be configured to have more or fewer teeth. Each tooth 184 includes a tip 186 that is configured to engage with the base material 106 or the trim 144 to cause fiberization thereof. In some cases, the tip 186 can be configured as a carbide tip that can improve fiberization efficiency and longevity of the rotor. To further improve fiberization efficiency, the blades 180 can be arranged into a stacked configuration. Correspondingly, each blade 180 can define a kerf thickness and the blades 180 can be stacked so that the kerfs of each adjacent blade abut or overlap one another. Accordingly, fiberization can occur along the entire length of the blade stack.

[0084] In some cases, the blades 180 can be arranged so that the tips 186 are in a helical or spiral configuration about the rotor axis 174, which can increase fiberization efficiency while also reducing power consumption, noise, and vibration. To rotationally lock the blades 180 with the tips 186 in a desired configuration such as helical, spiral, chevron, or a random blade orientation, the blades 180 can be rotationally locked to the shaft 182 with a key 188 that is received by a slot 190 formed in the shaft 182 and a correspondingnotch 192 formed in each blade 180 (see FIG. 7). Correspondingly, the blades 180 can arranged into sets of blades that are each configured to be rotationally locked at different angles. Referring now to FIG. 9, the angle 194 of a blade can be measured as the angle between a first radial line 196 extending through the notch 192 and a second radial line 198 extending along the first tooth 184 in either clockwise or anti-clockwise direction from the first radial line 196. The second radial line 198 may be defined as the radial line that bisects the tooth 184. In an alternative rotor configuration, the blades 180 are locked rotationally via rod bolts (not shown) that clamp the blades 180 together and lock the blades 180 to the shaft 182.

[0085] Referring again to FIG. 7, in the illustrated non-limiting example, the blades 180 are arranged into eight sets of blades 180A-H, with each set being at a unique angle. For example, the sets of blades can be at angles of 0 degrees, 5.625 degrees, 11.25 degrees, 16.875 degrees, 22.5 degrees, 28.125 degrees, 33.75 degree, and 39.375 degrees, respectively, to achieve consistent spacing between sets. In other examples, the sets of blades can be arranged at different angles.

[0086] In some cases, blades of a rotor can be configured to act as a fan that creates turbulent airflow within a housing of a mill. The turbulent air can aid in fiberization and entanglement of the fibers. Depending on desired airflow for fiber transport and / or if design specifications dictate a reduced fiber / air dilution rate, additional air can be introduced into the system via optional passive air inlets (not shown) or an optional fan (not shown).

[0087] With continued reference to FIGS. 7 and 8 and also to FIG. 10, housing 164 of the mill 112 can include one or more slots 210A, B, C to allow a fiber source (e.g., the base material 106 or a trim fiber source referred to hereafter as the trim 144) to pass into the interior space of the mill 112 where it can be fiberized by the rotor 172. In the illustrated non-limiting example, a slot 210A, B, and C is provided for each of the fiber sources, including base material slot 210A receiving a first web of base material from the first roll 106A, a base material slot 210B receiving a second web of base material from the second roll 106B, and trim slot 2100, receiving trim 144 from the press 140. The slots 210A, B, and C can be circumferentially spaced about the rotor axis 174 and the number, construction and location of the slots 210A, 210B, and 2100 can vary by the particular application.

[0088] Relatedly, where trim 144 is being reintroduced to the mill 112 for re- fiberization, it can be beneficial to insert the trim 144 into the trim slot 2100 that is circumferentially furthest from the exit duct 124, as illustrated in this example. By doing so, the trim 144, which may have hardened regions and openings from the press 140, is contacted by a tooth 184 of the blade 180 first, and is more likely to be contacted with a clean blade 180, thereby improving fiberization of the trim 144. Moreover, by fiberizing the trim 144 before the new base material 106, the fibers from the trim 144 can be moreevenly distributed throughout the fiber 116 exiting the mill 112 through duct 124. In some applications, it may be beneficial to feed the trim 144 into a trim slot 210C that is arranged between two or more base material slots 210A and 210B. In this configuration, as a rotor rotates within the housing 164, a tooth 184 of the rotor 172 passes from a first base material slot 210A to the trim slot 210C receiving the trim 144, then to a second additional base material slot 210B, and then to the exit duct 124.

[0089] To further aid in fiberization, breaker bars 214 can be provided at each slot 210A, B, and C. The breaker bars 214 can support the fiber source, which is typically formed as a non-rigid web of material, at the instant of the blade impact so that it can be more efficiently separated into fibers by the rotor 172. Correspondingly, a seal 213 can be provided in the corresponding slot 210 A, B, or C opposite the breaker bar 214. The seal 213 can control the size of the corresponding slot 210 in accordance with the thickness of the fiber source. Accordingly, the seal 213 can help ensure that the fiber source remains in contact with the breaker bar 214 as it enters the mill 112 and can also help to prevent separate fibers from exiting the mill 112 via the slots 210A, B and C. An optional screen panel (not shown) with a pattern of openings (e.g., slots or holes) formed therein may be positioned at the outlet of the mill 112, with the openings sized to a target size of the fluff fibers of the formed fiber mat 122. Airflow within the mill 112 will redirect any clumps of fluff (e.g., knots or knits) back through the mill 112, thus breaking any clumps into smaller pieces before they exit the mill 112.

[0090] With reference to FIG. 10, the breaker bar 214 can include a breaker 216 formed as a protruding edge that extends toward the rotor 172. The breaker 216 can act as a cutting or shearing surface that causes fiberization of the fiber source as the rotor 172 passes the breaker 216. In some cases, a recess 218 can be formed behind the breaker 216, relative to a rotational direction of the rotor 172 to allow fibers to more easily clear the rotor teeth 184. In some cases, the breaker bar 214 can be adjustable to control a gap 220 between the breaker 216 and the tips 186 of the teeth 184. That is, the width of the gap 220 can be controlled by moving the breaker bar 214 radially closer to or away from the rotor axis 174. The width of the gap 220 can be adjusted to control the length of the fibers being formed by accounting for variations in material type and thickness of the fiber source (e.g., the base material 106 or the trim 144), minimize undesirable excess heat generation resulting from the cutting process and undue fiber damage via reduction in fiber length and generation of excess fine fibers.

[0091] In the embodiment described above, the continuous trim 144 is introduced directly into the mill 112 where it is refiberized by the rotor 172. In an alternative embodiment, the trim 144 may be refiberized in a two-stage process that begins with an optional, additional regrind mill (not shown) such as, for example, a small chopper mill unit equipped with a screen, that breaks the continuous trim 144 into a stream of discretepieces. In such an embodiment feed unit 146 would be configured as a pneumatic feed unit or a mechanical feed unit such as a conveyor or feed screw according to exemplary, nonlimiting examples to transport the discrete pieces into the trim slot 210C of mill 112. The discrete pieces are then fiberized by the mill 112 and mixed with newly fiberized fibers from the base material 106. In yet another alternative embodiment, the backer 135 and fluff components of the trim 144 are segmented into separate streams after the trim 144 exits the press. The backer component may then be fed into the optional, additional regrind mill prior to being reintroduced to the mill 112 while the fluff component may be fed directly into the mill 112. Alternatively, the backer component may be collected for disposal, such as in cases where the backer is a non-fiberizable material (e.g., poly). System 100 may also include an optional reject system (not shown) that monitors for and rejects defective products. These defective products may be fed into an additional regrind mill such as that described above and thus recycled back into the production stream.

[0092] As discussed above, the fibers 116 produced by a mill 112 can be transported to a forming station 120 to be arranged into a fiber mat 122 that can be pressed to form a final molded component. Referring now to FIGS. 2B and 11, the forming station 120 can include the forming drum 130, upon which the fibers 116 from the forming chamber 121 are deposited to form the fiber mat 122. While a top section of forming chamber 121 is illustrated in FIG. 11, the side panels thereof have been removed for clarity. The forming drum 130 can be rotatably supported on a frame 230 to rotate about an axis 232. More specifically, the forming drum 130 can include an outer forming surface 234 that is configured to support the fiber mat 122 and that rotates to allow for a continuous fiber mat 122 to be formed on the outside of the forming surface 234. In this case, the fiber 116 is deposited proximate a portion of the forming surface 234 facing the exit duct 124 to form the fiber mat 122, which is then carried clockwise around the forming drum 130 (e.g., by rotation of rotary shaft 231 about axis 232) to be ejected for optional light compression, laminating, coating, spraying, and for use at the press 140.

[0093] To keep the fiber mat 122 secured to the forming surface 234 of the forming drum 130, the forming surface 234 is air permeable, and can, for example include perforations through which a vacuum source 240 can be applied. The vacuum source 240 can draw the fibers 116 onto the forming surface 234 to form the fiber mat 122 and to carry the fiber mat 122 on the forming surface 234 until it is transferred away from the forming surface 234 to be used in downstream processes. It is appreciated that the vacuum may be applied along a portion of the forming surface 234, and more specifically, a region 236 (i.e., a deposition region or area) of the forming surface 234 corresponding to the area at which the fibers 116 are deposited. The size of the deposition region 236 may vary depending on the particular application.

[0094] With additional reference to FIGS. 12-17, to apply the vacuum source 240, the forming drum 130 includes an opening 235 configured to receive a drum core 238 therein. The core 238 can be configured to couple to the vacuum source 240 to supply a vacuum at one or more openings (e.g., perforations) in the forming surface 234. Correspondingly, the core 238 can include one or more ducts 248 to couple the vacuum source 240 to the forming surface 234, which are illustrated in FIGS. 12 - 17 as 248A - 248F. The strength of the applied vacuum source 240 can affect the distribution of fibers 116 onto deposition region 236 of the forming surface 234, and thus a local density or thickness of the resulting fiber mat 122. Due to losses in the vacuum system, the strength of the vacuum may vary across the deposition region 236, which can result in undesired variations in local thickness or density of the fiber mat 122.

[0095] Referring now to FIGS. 2B, 13A, 13B, and 14-17, to help direct, control and / or equalize the uniformity of air flow or consistent static pressure drop across the deposition region 236, the forming vacuum zone 125 of the core 238 can be divided into individual vacuum regions 244 spaced in the cross-machine direction 107 using internal baffles 270. Referring first to FIG. 13A, as described above, the forming vacuum zone 125 is a sector or "pie"-shaped portion of the drum core 238, and can be defined by a first vacuum zone sector wall 245 which extends from a first inner mounting point adjacent the rotary shaft 231 to a first outer mounting point extending between the outer rings 284 and 286 of the drum core 238, and a second vacuum zone sector wall 247 that extends from a second inner mounting point adjacent the rotary shaft 231 to a second outer mounting point coupled to the outer rings 284 and 286 of the drum core 238. A plurality of parallel vacuum region dividing walls 270A - E can extend between the first and second vacuum zone sector walls 245 and 247, dividing the forming vacuum zone 125 into a plurality of individual vacuum regions 244A - F, as illustrated in FIG. 15. Referring now to FIGS. 13B, 14 and 15, vacuum ducts 248A - F can be routed to the individual vacuum regions 244A - F, respectively, through apertures 272 formed in the vacuum zone sector walls 245 and 247 between pairs of dividing baffles 270. As illustrated in FIGS. 15 and 16, the duct apertures 272 can be provided in both the first and second vacuum zone sector walls 245 and 247, and can be staggered, such that a duct 248 is received between every other pair of dividing baffles 270 on each vacuum zone sector wall 245 or 247. The duct apertures 272 in vacuum sector wall 245 are also offset from the duct apertures 272 in vacuum sector wall 247, such that the ducts 248A, C, and E connect to the apertures 272 in the vacuum sector wall 245 and provide a vacuum source to vacuum regions 244A, 2440, and 244E, while the ducts 248B, D, and F connect to duct apertures 272 in vacuum sector wall 247 and provide a vacuum source to vacuum regions 244B, 244D, and 244F. Referring now to FIG. 13B, the ducts 248A, C, and E are illustrated routed through the drum to the vacuum zone sectorwall 245, while the ducts 248B, 238D, and 248F are routed to vacuum zone sector wall 247.

[0096] Referring again to FIG. 13A, as illustrated here, the vacuum region dividing baffles 270 can be formed as part of a vacuum region insert 274 that is mounted between the first and second vacuum region sector walls 245 and 247. The vacuum region insert 274 can, as shown here, be removably coupled to the drum core 238 using threaded fasteners such as screws, bolts, or similar devices.

[0097] The vacuum region insert 274 can include outer walls 276 and 278 that are angled to correspond to the angle of the vacuum zone sector walls 245 and 247, and that can have apertures formed therein to align with apertures 272 in the vacuum zone sector wall. The vacuum region insert 274 also has a lower surface 271 that is curved to match the curvature of the rotary shaft 231. The vacuum region dividing baffles 270A - E extend between the opposed outer walls 276 and 278, divide the vacuum region insert 274 into the plurality of individual vacuum regions 244A - F. A substantially flat upper plate 288 extends between a top edge of the outer wall 276 and a top edge of the outer wall 278. The flat upper plate 288 includes a plurality of apertures 290A - F, which are aligned above the vacuum regions 244A - F, and form horizontal baffles or flanges 292 and 294 that extend inward toward a center of each of the vacuum regions 244A - F from opposing sides, reducing a size of the air flow path in the vacuum regions 244A - F and helping to equalize differences in flow that can result from the ducts 248A, C, and E being positioned on opposing sides of the forming vacuum zone 125 from ducts 248B, D, and F. Baffles 242, which are sized and dimensioned to extend between walls 245 and 247 can be coupled above each of the vacuum insert divider baffles 270, and can extend to a position substantially parallel with outer rings 284 and 286 defining the core 238. The individual vacuum regions can isolate each vacuum region 244A - F from the others so that the vacuum strength at each vacuum region 244 can be individually controlled. Although six vacuum regions 244A - F are defined in the forming vacuum zone 125 illustrated here, it will be apparent that this number can be changed depending on the application. Further, the size and shape of the apertures 290 can be varied to adjust flow in the vacuum regions 244A - F.

[0098] As described above, each vacuum region 244 can be coupled to a corresponding duct 248 that connects the vacuum region 244 to the vacuum source 240. Referring again to FIG. 12, a vacuum interconnect 267 providing ducts for interconnecting individual vacuum ducts to the vacuum regions 244, is shown. As described above, the vacuum source 240 can apply vacuum to each duct 248 individually at the desired strength by connecting the ducts 248A - F in the drum core 238 to corresponding vacuum ducts 249A - F, which are in direct communication with the vacuum source 240. The vacuum supplied to the ducts 248A - F can also be controlled with an optional valve or flap, such as an aircontrol blast gate or perforated or solid slide gate 251, that can be moved to adjust the air flow into the corresponding duct 248. A slide gate 251, as illustrated here, can include a blade 253 that is moved selectively into and out of a housing 255 to close or open the corresponding duct 249. Alternatively, the slide gate 251 can be coupled to and directly open or close ducts 248. The slide gate 251 may be positioned on each duct 248 at a location proximate the vacuum interconnect 267 or at a location proximate the forming drum 130, depending on space constraints. Alternatively, the slide gates 251 may be positioned within the drum core 238 atop the flat upper plate 288, with a slide gate 251 covering each aperture 290 corresponding to each vacuum region 244 to control vacuum therein. In either embodiment, the position of slide gates 251 may be adjusted manually or via electronic control, for example in combination with a closed-loop system that uses a vision system or other detection means to monitor and correct for undesirable thickness variations in the fiber mat 122. Slide gates 251 may be solid panels, as shown in FIG. 12, or include a pattern of openings. When the slide gates 251 are located within the drum core 238, an access panel (not shown) may be provided on the drum core 238 to permit operator access to the slide gates 251 for manual adjustment. Furthermore, when the slide gates 251 are located within the drum core 238 the number of ducts 248 may be reduced such that two or more vacuum regions are coupled to a common duct. Although a slide gate 251 is illustrated on each duct in FIG. 12, it will be apparent that slide gates 251 may be provided on any selected number of ducts, and that some ducts may include a slide gate and other ducts may not, depending on the application. Also, different types of gates may be provided on different ducts, depending on the application. Further, the slide gates 251 may also be opened, closed and adjusted using sensor technology. For example, a sensor or sensors 145 may be mounted to monitor the density, thickness, and / or weight of the fiber mat on the forming drum 130, and feedback from the sensor(s) may be used by a controller such as controller 105 to adjust the slide gates 251. The basis weight of the fiber mat may also be monitored, for example, in the cross-machine direction, and used to adjust the position or rate of vacuum flow applied via slide gates 251. Sensors that can be used in this process include weight and fleece detection sensors available from Hossbach Sensor Technologie, Forth, Germany. Near infrared spectroscopy can also be used to monitor fluff and the fiber mat.

[0099] In the illustrated non-limiting example, the core 238 includes six vacuum regions 244A - F, each of which is coupled to a corresponding duct 248A - F. The vacuum regions 244 are distributed along the axial direction of the forming drum 130. In other nonliming examples, baffles 242 can be arranged differently to create more or fewer vacuum regions and to distribute the vacuum regions differently along the deposition region 236. For example, baffles 242 could be arranged to control vacuum strength for a group of ducts248, rather than a single duct. In other embodiments baffles 242 are eliminated entirely thus defining a single vacuum region at the deposition region 236.[O1OO] When included, vacuum region dividing baffles 270 and baffles 242 allow for greater control over the vacuum, thus the thickness and density of a fiber mat 122 can be controlled to have tighter tolerances, thereby reducing waste and allowing for more accurate formation of the molded component. In alternate embodiments, uniform pressure drop across the deposition region 236 may be accomplished by varying the pattern and size of openings within the surface 234 of the forming drum 130, for example by using smaller openings in a central portion of the deposition region 236 and larger opening in the side portions of the deposition region 236 adjacent the rim 252 and increasing the density of the pattern of openings in the side portion of the deposition region 236. In yet another alternative embodiment, uniform pressure drop is achieved by dividing the core 238 into separate drive side and operator side volumes with a circular plate (not shown) positioned at the center line of the drum core 238 and separately supplying vacuum to each volume separately via a duct coupled to each volume. In addition, the ability to control vacuum strength can also allow for more complex fiber mats 122 to be formed. In particular, controlling the vacuum strength can allow mats to be formed with intentional variations in thickness or density, which can be helpful when producing complex shapes and deep drawn parts. In addition, this allows for more efficient use of fibers to minimize waste. Furthermore, the surface 234 of forming drum 130 can include a uniform spacing of openings / perforations (such as 50% open area in one exemplary and non-limiting example), or varying hole sizes and / or spacing to provide a surface with multiple open area densities. Varying the size and patterns of the openings within the surface 234 of the forming drum 130 can thus be used to control the thickness and density of a fiber mat 122.

[0101] In some embodiments a backer is fed onto the forming surface 234 of the forming drum 130 at a location upstream of the exit duct 124 such that fiber is deposited onto the backer rather than directly onto the forming surface 234. This "form-on" backer may replace a backer 135 supplied at the combining station 134 or may be provided in addition thereto. The form-on backer may be provided as a tissue pre-coated or otherwise pre-treated with a barrier material or a barrier material may be blended with the fiberized fluff within the mill 112. Alternatively, or in addition thereto, an additive station 139 may be positioned to apply barrier material on the outward facing surface of the form-on backer before fiber is introduced thereon. The barrier material may be applied using any suitable application technique or techniques, including a spray application, a slot-coat application, or other appropriate application technique.

[0102] With additional reference to FIGS. 18 - 20, in some cases the forming surface 234 is configured to include one or more depressions or cavities 258 defined on the circumferential surface thereof to provide even greater control over the shape and densityof a fiber mat 122. The one or more cavities 258 may extend and / or may be aligned along the circumferential dimension of the forming drum 130. In some embodiments, a plurality of discrete cavities 258 are defined in the forming surface 234 and aligned in the circumferential dimension in which discrete fiber mat portions are formed, as shown in FIG. 19. These discrete fiber mat portions may be sized to correspond to the mold cavities of the press 140 and thus reduce the volume of trim material exiting the press 140. In other embodiments, a single, continuous cavity 258 may be defined on the forming surface 234 to form a continuous fiber mat 122. Multiple continuous cavities 258 may also be provided on the forming surface 234 spaced apart across the width 260 of the forming surface 234 as shown in FIG. 20 to create a fiber mat 122 of multiple side-by-side continuous lanes. These continuous cavities 258 may be sized to correspond to the width of mold cavities within the press 140 to minimize the volume of fiber trim exiting the press 140 and / or to enable pleating of the backer 135 between the fiber lanes for deep draw products. The cavity(ies) 258 can have a generally uniform depth in instances where a two-dimensional fiber mat 122 is desired, or a depth that varies in the machine direction 102 and / or crossmachine direction 107 to form a three-dimensional fiber mat 122.

[0103] In order to define the cavity(ies) 258 in the forming surface 234, an arrangement of cover plates 250 are attached to the forming surface 234. The cover plates 250 can be secured to the forming surface 234 with any suitable attachment mechanism, including fasteners (e.g., screws, nuts and bolts, clamps, magnets, etc.), easily permitting different sized and / or shaped cover plates 250 to be incorporated into the system 100 for product changeover. In other embodiments, the entire forming drum 130 may be changed out with a different forming drum having different cavity(ies). The cover plates 250 define the cavity(ies) 258 and provide for communication of the vacuum at the locations of the cavity(ies) 258, with the cover plates 250 allowing for differently shaped continuous or discrete fiber mats to be formed on the forming drum 130 depending on the specific configuration or construction of the cover plates 250.

[0104] As shown in FIGS. 19 and 20, cover plates 250 are configured to define a three- dimensional depression or cavity 258 that is defined by one or more side walls 402 and a floor 404. The side walls 402 define the shape of the depression 258 (and of the resulting fiber mat that is produced), and the walls 402 may be formed as vertical walls or as sloped walls, according to embodiments. The height of the walls 402, and corresponding depth of each cavity 258, may vary depending upon the particulars of the manufacturing process for forming the fiber mat, including the dimensions and / or type of backers and the desired wall thickness of the molded product, as examples. The floor 404 of each cavity 258, and optionally the walls 402, includes a baffle or screen 406 that permits airflow therethrough, such that a vacuum can be communicated through the forming surface 234 (i.e., vacuumopenings) and through the floor 404 (and optionally the walls 402) so that fiber particles that are deposited into the cavity 258 are retained on the forming surface 234.

[0105] Optional protrusions or inserts 408 may be provided in the cavity 258 to form regions of fiber mat 122 with a decreased fiber thickness or that are free or substantially free of fibers 116. In the illustrated embodiment, one insert 408 is included in each cavity 258, but it is recognized that multiple inserts 408 could alternately be provided. The inserts 408 extend radially outward from the floor 404 and have a height less than or equal to a height of the side walls 402. In the illustrated embodiment, the inserts 408 have a generally linear shape, but it is envisioned that the inserts 408 could alternatively have a non-linear shape.

[0106] In general, the cover plate 250 can define a cavity 258 corresponding to a general shape, width, and thickness of the fiber mat 122. Accordingly, the depth of the cavity 258 can be varied based on a desired GSM of the fiber mat 122. The width of the cavity 258 can be varied based on a desired overall width of the fiber mat 122. For example, as illustrated in FIG. 18, the regions of the cavity 258 corresponding to vacuum regions 244B, 244E have a first depth, the regions of the cavity 258 corresponding to vacuum regions 244D, 2440 have a second depth that is less than the first depth, and the regions of the cavity 258 corresponding to vacuum regions 244A, 244F have a third depth that is less than the second depth. As a result, the fiber mat 122 will have a greater thickness in the center and become thinner moving toward the edges. Correspondingly, to help attract more fibers 116 to the thicker areas, a larger vacuum can be applied at vacuum regions 244B, 244E than at vacuum regions 244D, 244C, and a larger vacuum can be applied at vacuum regions 244D, 244C than at vacuum regions 244A, 244F. In some cases, the forming drum 130 can include a rim 252, which can help to secure and locate the forming plate 250 on the forming drum 130. Scarfing roller 132 may be particularly advantageous when forming fiber mat sections with relatively deep cavities to aid in redistributing fiber into the deep cavities.

[0107] Referring again to FIGS. 2B, 12, and 13B, once the fiber mat 122 is formed, the fiber mat 122 can be driven off of the forming drum 130 by pressure from a vacuum source applied in a transfer vacuum zone 127 of the forming drum 130. Referring now to FIG, 12, vacuum is provided to transfer vacuum zone 127 through a duct 257, which can be connected to a vacuum source duct 261 in the vacuum interconnect 267. The vacuum source duct 261 and / or transfer zone duct 257 can also be controlled by a sliding gate 251 of the type described above. As illustrated here, the vacuum interconnect 267 can also include vacuum supply and return ducts 263 and 265 which can also be controlled by a sliding gate 251.

[0108] Referring again to FIG. 1, in operation, the system 100 can be operated in a dry-run mode, a start-up mode, and a production or continuous run mode. The dry-runand start-up modes enable testing and calibration of the system when the system 100 is not being used to produce dry molded fiber products, and verification of proper mat formation before a continuous production mode is entered. Each of these modes can be activated by providing control signals to the controller 105 through a user interface. For example, in some applications, specific pushbuttons, a keyboard and corresponding graphic display, or a personal device such as a cellphone, a laptop, or similar device in wired or wireless communication with the controller 105 can be used to select between the modes. Alternatively, changes in operational mode can be triggered by process feedback from sensors in communication with controller 105, as described below.

[0109] Referring now also to FIG. 2C, in the dry-run or web-up mode, a backer material 135, such as a tissue, can be fed from the backer material supply 137 and through the press 140 station, which is deactivated, along with the spray nozzles at additive station 139. The backer material 135 can be routed back to the milling station 108 by feed unit 146 along the route for trim 144, as illustrated in FIG. 1, enabling a user to verify proper operation of the conveyors and rollers in the corresponding portions of system 100. The backer material 135 can be recycled at the milling station 108, if appropriate.[O11O] When the backer material 135 has been routed to the milling station 108, the start-up mode can be entered, in which all of the stages except for the press 140 and any optional additive spray that may be in the system, are activated. As described above, a user can activate the start-up mode through a user interface. Alternatively, one or more sensors 143, such as optical or weight sensors, can identify when the backer material 135 from the web-up stage approaches the press 140 or milling station 108, and the controller 105 can receive a signal indicating that the backer material has reached the milling station 108 and activate the start-up mode (i.e., switch from the dry-run mode to the start-up mode) without further user intervention. In the start-up mode, base material 106 for forming the fluff mat is provided from infeed station 104. The base material 106 can be, for example, provided on a roll which is continually fed to the fiberizing process. In this stage, because the milling station 108 is activated, a continuous fiber mat is formed and faced with one or more backers, but not pressed or cut by the press 140. The backer-faced fiber mat is routed through the non-operative press and fed by feed unit 146 back to the milling station 108 where it can be recycled into the system. Because the fiber mat is continuous, the start-up mode enables the system to begin operation on a mat of a consistent weight and thickness. During this stage, sprayers associated with the additive stations 139 can be activated, either by user input, or by use of sensors such as weight sensors, optical sensors, or vision systems. In one example, the sprayers associated with additive stations 139 can be activated by user input or by the use of one or more sensors 165 when the fluff mat 122 reaches the sprayers associated with the downstream additive station.

[0111] When a leading edge of the fiber mat reaches the press 140, reaches a predetermined position downstream of the press 140 such as a position proximate nip rolls 155, debulking station 157, or has reached the milling station 108 for recycling, or when the fiber mat is of a pre-determined weight or thickness, the production mode can be entered. In the production mode, the press 140 is activated, enabling the production of molded components 150. Again, the production mode can be activated by a user through a user interface, or by one or more sensors 167, which can be optical sensors identifying a position and / or weight of the fiber mat, by way of example. Sensor(s) 167 may be positioned upstream of the press 140 as shown in FIG. 2C, or proximate nip rolls 155, debulking station 157, and / or milling station 108 as examples. When the press 140 is activated, the fiber mat is pressed into dry molded fiber components 150, and the feed unit 146 now provides trim to the milling station 108 for recycling, Because the amount of material that is being recycled is greater as compared to the start-up mode, the controller 105 adjusts the infeed speed of the base material 106 to the milling station 108 to account for the increased input. The adjustments to the feed rate of the base material 106 can be made automatically based, for example, on stored data regarding a size of the product produced, or optical or weight sensors. Alternatively, user input can be used to adjust the material feed rate into the mill 112.

[0112] The described system enables the production of molded components in complex and multidimensional shapes, while maintaining a high level of structural integrity and strength. As described above, this type of construction is useful in producing food containers, tableware, and utensils. There are, however, many other applications for these types of constructions, including, for example, food packaging such as plates, bowls, utensils, lids, caps, cups, boxes, as non-limiting examples; packaging for consumer and industrial products; molded paper cushioning for packaging houseware products including frames, vases, and decorative items; molded automotive and industrial products; gift packaging and decorations; pharmaceutical products, electronics, and many other products.

[0113] Within this specification, embodiments have been described in a way which enables a clear and concise specification to be written, but it is intended and will be appreciated that embodiments may be variously combined or separated without parting from the disclosure. For example, it will be appreciated that the features described herein are applicable to all aspects of the embodiments described herein. Further, it is to be understood that the present disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the description or illustrated in the drawings. The present disclosure is capable of other configurations and of being practiced or of being carried out in various ways. For example, although a specific ordered series of steps is described above, the order of these steps can be varied. For example, insome applications reinforcing or backing materials can be applied at alternate stages of the process. In addition to the types of coatings and materials described above, reinforcing layers or backers can include wax coatings; polymer coatings, such as polyethylene and polypropylene; varnish and other sealants; laminated layers, such as plastic laminate; prelaminated, pre-coated, and / or printed layers; fiberglass reinforcements; and anti-microbial coatings, including silver and copper-based coatings, zinc oxide coatings, and natural antimicrobial extracts such as tea tree oil, oregano oil, or neem oil.

[0114] Additionally, although specific compression stages at debulking station 142 and debulking station 157 are shown and described, in some applications, additional compression stages may be added to the system. For example, compression may be provided at debulking stations 142 and 157, at nip rolls 155 and 159, and / or feed unit 146. Compression can also be provided between exit of the press 140 and the infeed at milling station 108. Compression stages can be used to control the thickness of the fiber mat, prevent delamination of the backer materials, and provide positive draw points to control the transport of the fiber mat through the process. Compression stages can also isolate web tension variation, for example compression applied at nip rolls 155 and 159 isolate the variations in the fluff mat web tension as the press 140 cycles. In instances where a liquid binder or adhesive is applied to the backers or fluff mat to reduce delaminating of the backer during use (e.g., in instances where the final product is exposed to hot liquids), compression stages can assist with bonding of the material layers prior to the press 140.

[0115] Further, although a removable internal structure is shown for dividing the vacuum zone into individual vacuum regions, it will be apparent that various configurations of internal baffles can be mounted directly to the drum core. Further, an internal structure of the type described can be provided with various numbers and shapes of baffles for directing the vacuum source to form specific structures. Additionally, although the insert is described as removably coupled to the drum core, it will be apparent that the insert can be adhered in other ways which are readily or not readily removable, using adhesives, welds, rivets, and other methods of interconnection.

[0116] Additionally, although one or two rolls of material are illustrated at the infeed if the system above, it will be apparent that, in some applications, additional materials may be desirable, and three or more rolls of material may be provided at the input of the process.

[0117] Further, although a hammer mill is described above for use in milling station 108, various types of processes may be applied including, by way of example, disc refiners, attrition mills, grinders, beater machines, and fiberizers. In some applications, multi-stage high frequency refiners may also be used.

[0118] Additionally, although specific tensioning devices for tensioning web materials in the system 100 have been described, it will be apparent that various types of manualand automatic tensioners can be used including, for example, pneumatic tensioners; mechanical tensioners employing springs, levers, or weights; and dancer tensioners.

[0119] Further, while a single vacuum source is described above, it will be apparent that, in some applications, dedicated, individual vacuum sources for each duct could also be employed. Proximity sensors or optical sensors could be used to identify when a desired mat depth is reached, and vacuum sources could be turned off to specific areas of a mat either by mechanical means or through deactivation of one or more vacuum sources.

[0120] Thus, it will be appreciated by those skilled in the art that, while the disclosure has been described above in connection with particular non-limiting examples and examples, the disclosure is not necessarily so limited, and numerous other nonembodiments, examples, uses, modifications and departures from the non-limiting examples, examples and uses are intended to be encompassed by the claims attached hereto. The figures, similarly, depict selected configurations and are not intended to limit the scope of the present disclosure. The present disclosure is to be accorded the widest scope consistent with the principles and features disclosed herein.

[0121] Various features and advantages of the disclosure are set forth in the following claims.

Claims

CLAIMS1. A system (100) for manufacturing dry molded fiber components, the system (100) including: an infeed station (104) configured to supply a base material; a milling station (108) including a mill (112) configured to receive and fiberize the base material into a plurality of fibers; a forming station (120) configured to receive the plurality of fibers, the forming station comprising: a drum core (238) connected to a vacuum source (240), the drum core including a plurality of baffles (242) arranged to define a plurality of vacuum regions (244A-F); a forming drum (130) rotatably coupled around the drum core, an outer forming surface (234) of the forming drum comprising a plurality of openings for supplying vacuum from the vacuum source (240) to the plurality of fibers, a strength of the vacuum source applied to the plurality of fibers being individually controlled at each of the plurality of vacuum regions, wherein the vacuum source causes the fibers from the milling station to be deposited on and secured to the forming drum to form a fiber mat; and a press (140) configured to receive the fiber mat and compress the fiber mat to form a final molded component.

2. The system (100) of claim 1, wherein the mill (112) is configured to receive trim of the fiber mat from an outfeed side of the press (140), and re-fiberize the trim with the base material.

3. The system (100) of claim 2, wherein the mill (112) includes a housing (164) receiving a rotor (172) that rotates therein, the housing defining a trim slot (210C) configured to receive the trim, a plurality of base material slots (210A,210B) configured to receive the base material, and a duct (124) configured to eject the plurality of fibers to the forming station (120).

4. The system (100) of claim 3, wherein the plurality of base material slots (210A, 210B) are arranged between the trim slot (210C) and the duct (124) so that, as a rotor (172) rotates within the housing (164), a tooth (184) of the rotor (172) passes from the trim slot to the plurality of base material slots and then the duct.

5. The system (100) of claim 3, wherein the trim slot (210C) is arranged between the plurality of base material slots (210A,210B) so that, as a rotor (172) rotates within the housing, a tooth (184) of the rotor (172) passes from a first of the base materialslots (210A) to the trim slot (210C), then to a second of base material slots (210B), and then the duct (124).

6. The system (100) of claim 3, wherein, relative to the rotation of the rotor (172), the trim slot (210C) is spaced from a first slot (210A) of the plurality of base material slots (210A,210B) by at least 45 degrees and a second slot (210B) of the plurality of base material slots (210A,210B) is spaced from the duct (124) by at least 45 degrees.

7. The system (100) of claim 3, wherein the plurality of base material slots (210A, 210B) comprises a first base material slot (210A) configured to receive a first web of the base material and a second base material slot (210B) configured to receive a second web of the base material, the second base material slot being arranged between the first base material slot and the duct (124).

8. The system (100) of claim 1, wherein the press (140) includes an infeed side and an outfeed side, and wherein the outfeed side of the press is located closer to the mill (112) than the infeed side of the press.

9. The system (100) of claim 1, wherein the press (140) includes an infeed side and an outfeed side, and wherein the outfeed side of the press is located closer to the forming station (120) than the infeed side of the press.

10. The system (100) of claim 1, wherein the forming station (120) includes a scarfing roller (132) configured to remove excess fiber from the fiber mat to control a thickness of the fiber mat.

11. The system (100) of claim 1, wherein the forming drum (130) rotates relative to the drum core (238).

12. The system (100) of claim 1, wherein the plurality of openings in the forming drum (130) are perforations that are defined in an outer circumferential surface (234) of the forming drum.

13. The system (100) of claim 7, wherein the forming drum (130) includes a forming plate (250) coupled to the drum, the forming plate (250) defining a cavity (258) configured to receive the plurality of fibers from the milling station (108).

14. The system (100) of claim 13, wherein the cavity (258) has a variable depth to form a fiber mat with a corresponding variable thickness.

15. The system (100) of claim 1, wherein the drum core (238) includes a plurality of ducts (248), each of the plurality of ducts corresponding to one of the plurality of vacuum regions (244A-F), wherein the ducts are in communication with the vacuum source (240), and wherein the vacuum to the plurality of ducts is controllable so that a strength of the vacuum at each of the plurality of vacuum regions is independently controllable.

16. The system (100) of claim 15, wherein the plurality of vacuum regions (244A-244F) are spaced in the cross-machine direction (107).

17. The system (100) of claim 10, wherein at least one outlet of the plurality of ducts (248) is received a first and a second of the plurality of baffles (242).

18. The system (100) of claim 10, wherein the plurality of ducts (248) are configured to be selectively opened or closed.

19. The system (100) of claim 10, further comprising a plurality of adjustable gates (251) coupled to the ducts (248), the adjustable gates moveable between an open position and a closed potion to control the vacuum to the plurality of ducts.

20. The system (100) of claim 1, wherein the drum core (238) comprises a plurality of baffles (242), the baffles dividing an interior of the drum core into the plurality of vacuum regions (244A-244F).

21. The system (100) of claim 1, wherein the mill (112) includes a rotor (172) with a plurality of blades (180) rotationally fixed to a shaft (182), each of the plurality of blades including a plurality of teeth (184); and wherein the plurality of blades is rotationally fixed so that the teeth of the plurality of blades are in a helical arrangement about the shaft.

22. The system (100) of claim 1, further comprising a festooning station (136) configured to accumulate the fiber mat from the forming station (120) and to selectively meter the fiber mat to an infeed side of the press (140) in accordance with a press cycle.

23. The system (100) of claim 22, wherein the festooning station (136) comprises a belt (314) configured to convey the fiber mat to the press (140).

24. The system (100) of claim 22, wherein the festooning station (136) is sized to enable at least two meters of fiber mat accumulation during a press cycle.

25. The system (100) of claim 22, wherein the festooning station (136) comprises a carriage (306) translating between a first position adjacent the press (140) and a second position offset from the press (140).

26. The system (100) of claim 22, further comprising a conveyor (326) configured to move the fiber mat from an upstream side of the press (140) to an opposing downstream side of the press adjacent the festooning station (136), and wherein the festooning station is configured to receive the fiber mat from the conveyor and to feed the fiber mat back to the press.

27. The system (100) of claim 26, wherein the festooning station (136) comprises a belt (314) operating on an idler drum (312), and wherein the conveyor (326) is configured to provide the fiber mat to the belt and to drive the fiber mat over the idler drum and into the press (140).

28. The system (100) of claim 26, wherein the conveyor (326) is positioned beneath the press (140).

29. A forming drum assembly for producing a fiber from loose fibers comprising: a forming drum (130) having an outer circumferential surface (234) comprising a plurality of openings, the forming drum defining an interior cavity (258); a drum core (238) received within the interior cavity of the forming drum, the drum core including at least first and second vacuum zone sector walls (245,247) arranged to define a vacuum zone (125) within the interior cavity of the forming drum, the vacuum zone configured to be coupled to an independently controllable vacuum; and a plurality of baffles (242) extending between the first and second vacuum zone sector walls to define a plurality of individual vacuum regions (244A-244F) within the vacuum zone, wherein the forming drum is rotatably coupled to the drum core, and when vacuum is applied through the plurality of openings, the loose fibers form a fiber mat on the outer circumferential surface (234) of the forming drum.

30. The forming drum assembly of claim 29, further comprising at least one forming plate (250) coupled to the forming drum (130), the forming plate defining at least one cavity (258) that receives the loose fibers.

31. The forming drum assembly of claim 30, wherein the at least one cavity (258) has a variable depth to form a fiber mat with a corresponding variable thickness.

32. The forming drum assembly of claim 30, wherein the at least one cavity (258) comprises one of a plurality of continuous cavities and a plurality of discrete cavities extending around a circumference of the outer circumferential surface (234) of the forming drum (130).

33. The forming drum assembly of claim 29, wherein each of the plurality of individual vacuum regions (244A-244F) is configured to couple to a corresponding duct (248A-248F) of a vacuum source (240) to provide the independently controllable vacuum at the respective vacuum regions.

34. The forming drum assembly of claim 29, wherein the plurality of baffles (242) define at least four vacuum regions (244A-244F).

35. The forming drum assembly of claim 29, wherein the plurality of baffles (242) define six vacuum regions (244A-244F).

36. The forming drum assembly of claim 29, wherein each of the vacuum regions (244A-244F) is coupled to a separately controlled vacuum source (240).

37. The forming drum assembly of claim 29, wherein the plurality of baffles (242) are provided on an insert (408) that is removably coupled to an interior of the forming drum (130).

38. The forming drum assembly of claim 29, wherein each of the vacuum regions (244A-244F) is coupled to a vacuum source (240) duct that is controlled by a sliding gate (251).

39. The forming drum assembly of claim 38, further comprising a sensor (145) for monitoring a density, a thickness, and / or a weight of the fiber mat formed on the outer circumferential surface (234) of the forming drum (130), the sensor providing feedback to a controller (105) that is configured to adjust a position of the sliding gate (251).

40. The forming drum assembly according to any one of claims 29-39, further comprising first and second rings (254A,254B) coupled to opposing edges of the outer circumferential surface (234) adjacent an outer rim (252), the first and second rings defining a width of the fiber mat.

41. The forming drum assembly of claim 40, wherein the first and second rings (254A,254B) comprise offset sets of holes (256A,256B) that selectively align with holes in the outer circumferential surface (234) to adjust the width of the fiber mat.

42. The forming drum assembly according to any one of claims 40 and 41, wherein a sidewall (259A,259B) height of the first and second rings (254A,254B) defines a thickness of the fiber mat formed on the outer circumferential surface (234) of the forming drum (130).

43. The forming drum assembly of claim 42, wherein the first and second rings (254A,254B) include a stepped interior edge (300) facing a center of the outer circumferential surface (234), the stepped interior edge providing a defined shape to the outer circumferential surface of the forming drum (130).

44. The forming drum assembly of claim 43, wherein the stepped interior edge (300) comprises at least one of a rectangular and a rounded edge.

45. The forming drum assembly according to any one of claims 43 and 44, wherein at least a portion the stepped interior edge (300) of the first ring (254A) abuts the stepped interior edge (300) of the second ring (254B).

46. The forming drum assembly according to any one of claims 40-45, wherein the first and second rings (254A,254B) are integral to the outer circumferential surface (234) of the forming drum (130).

47. The forming drum assembly according to any one of claims 29-46, further comprising a cover plate (250) coupled to the outer circumferential surface of the forming drum, the cover plate (250) comprising at least one opening (235) that defines a shape of the fiber mat.

48. The forming drum assembly of claim 47, wherein the cover plate (250) comprises a plurality of segments coupled to the outer circumferential surface (234) of the forming drum (130).

49. The forming drum assembly according to any one of claims 47 and 48, wherein the cover plate (250) is integral with the outer circumferential surface (234) of the forming drum (130).

50. A mill (112) for producing fibers, the mill including: a feed unit (146) configured to receive a trim fiber source; a plurality of infeed guides (160) configured to receive a plurality of base material fiber sources; a housing (164) defining a first trim slot (210C) configured to receive the trim fiber source, a plurality of base material slots (210A,210B) configured to receive a corresponding plurality of base material fiber sources, and a duct (124) configured to eject the fibers produced from each of the trim fiber source and the base material fiber source; and a rotor (172) configured to rotate within the housing to fiberize the trim fiber source and the base material fiber sources, the rotor (172) including a plurality of blades (180) that are rotationally fixed to a shaft (182), each of the plurality of blades including a plurality of teeth (184).

51. The mill (112) of claim 50, wherein the plurality of blades (180) are arranged so that the teeth (184) of the plurality of blades are in a helical arrangement about the shaft (182).

52. The mill (112) of claim 50, wherein the rotor (172) is configured to rotate from a first slot (210A) of the plurality of base material slots (210A,210B) toward the duct (124) and a second slot (210B) of the plurality of base material slots is arranged between the first slot and the duct (124).

53. The mill (112) of claim 50, wherein the feed unit (146) comprises a pair of rolls receiving the trim therebetween.

54. The mill (112) of claim 53, wherein the pair of rolls are nip rolls sandwiching the trim therebetween.

55. The mill (112) of claim 50, wherein the feed unit (146) comprises a regrind mill configured to break the trim into a stream of discrete pieces received by a pneumatic feed unit.

56. The mill (112) of claim 50, wherein the feed unit (146) comprises a regrind mill configured to break the trim into a stream of discrete pieces received by a mechanical feed unit.

57. The mill (112) of claim 56, wherein the mechanical feed unit (146) is a conveyor or a feed screw.

58. The mill (112) of claim 50, wherein the plurality of infeed guides (160) comprises a first infeed guide (160A) comprising a support surface (161A) configured to receive a first base material fiber source and a second infeed guide (160B) comprising a support surface (161B) configured to receive a second base material fiber source.

59. The mill (112) of claim 50, further comprising a respective breaker bar (214) positioned at each of the first trim slot (210C) and the plurality of base material slots (210A,210B).

60. The mill (112) of claim 59, further comprising a respective seal (213) positioned in each slot (210A-210C) opposite the respective breaker bar (214).

61. The mill (112) of claim 50, wherein each infeed guide (160) comprises a support surface (161) configured to receive a base material fiber source and a pair of rolls (163).

62. A method for producing dry molded fiber components, the method comprising the following steps: fiberizing a base material; feeding the fiberized base material to an air permeable forming surface (234) in communication with a vacuum source (240) to form a fiber mat; controlling a strength of the vacuum source at selected regions of the forming surface to vary a depth of the fiber mat at selected locations; and compressing the fiber mat to form a multi-dimensional molded component.

63. The method of claim 62, further comprising the step of cutting the multidimensional molded component from the fiber mat.

64. The method of claim 63, further comprising the step of fiberizing a trim portion of the fiber mat after the cutting step and feeding the fiberized trim onto the forming surface (234) with the fiberized base material.

65. The method of claim 62, further comprising the step of providing cavities (258) in a surface of the forming surface (234) to vary a depth of the fiber mat formed at the cavities.

66. The method of claim 62, wherein the step of compressing the fiber mat comprises applying a mold to the fiber mat.

67. The method of claim 62, wherein the multi-dimensional molded component is a discrete part.

68. A festooning station (136) for accumulating a fiber mat, the festooning station comprising: a festoon carriage (306), the festoon carriage comprising a linear block (316) movably coupled to a pair of rails (318), and a carriage drive source (320) coupled to the linear block and configured to drive the linear block along the pair of rails; a belt assembly comprising: an idler drum (312) rotatably coupled to the linear block of the festoon carriage, an outer surface of the idler drum comprising a continuous radius of curvature; at least one belt drive roll (310) coupled to the linear block of the festoon carriage; a belt (314) received on the idler drum and the belt drive roll; and a drive source (327) coupled to the belt drive roll and configured to drive the belt along a belt travel path defined by the idler drum and the belt drive roll, wherein as the carriage drive source drives the linear block along the pair of rails in the festoon carriage, the belt assembly is moveable between at least a first and a second position along the pair of rails of the festoon carriage, the position of the festooning station extending a path followed by a fiber mat enabling accumulation of the fiber mat.

69. The festooning station (136) of claim 68, further comprising at least one idler roll (308), the idler roll positioned along the belt travel path between the belt drive roll (310) and the idler drum (312) and positioned to extend the belt travel path.

70. The festooning station (136) of claim 69, further comprising a plurality of idler rolls (308), the plurality of idler rolls positioned along the belt travel path receiving the belt (314), and extending a path followed by the belt.

71. The festooning station (136) of claim 68, wherein the idler drum (312) comprises a steel, aluminum, or carbon fiber construction.

72. The festooning station (136) of claim 68, wherein an outer wall of the idler drum (312) has a thickness of 2 mm to 3 mm.

73. The festooning station (136) of claim 68, wherein the belt (314) receives a fiber mat from a conveyor system (326) beneath the idler drum (312) and the belt drives the fiber mat over the idler drum reversing the direction of travel of the fiber mat.

74. The festooning station (136) of claim 73, wherein the conveyor system (326) is configured to receive the fiber mat from a forming drum (130) and to transfer the fiber mat to a press (140).

75. The festooning station (136) of claim 68, wherein the drive belt travel path causes a delay in the motion of the fiber mat of between six and ten seconds.

76. The festooning station (136) of claim 68, wherein the outer surface of the idler drum (312) has a thickness of between substantially 2 mm and 7 mm.

77. The festooning station (136) of claim 68, wherein the outer surface of the idler drum (312) is one of steel and aluminum.

78. The festooning station (136) of claim 68, wherein the outer surface of the idler drum (312) is one of solid and perforated.

79. The festooning station (136) according to any one of claims 68-76, wherein the belt (314) comprises a screen or a mesh material.

80. The festooning station (136) according to any one of claims 68-79, wherein the belt (314) comprises a metal or a polymer material.

81. The festooning station (136) according to any one of claims 68-80, wherein the belt (314) comprises a polyester mesh coated with a synthetic elastomer.

82. The festooning station (136) according to any one of claims 68-81, wherein the belt (314) comprises a surface texture applied to or formed on an outward-facing surface of the belt.

83. A method for operating a system (100) for manufacturing dry molded fiber components, the system including, an infeed station (104) configured to supply a base material; a milling station (108) including a mill (112) configured to receive and fiberize the base material into a plurality of fibers; a forming station (120) configured to receive the plurality of fibers, and to form a fiber mat through the application of a vacuum source (240); a backer material supply system (137) configured to provide backer material to the fiber mat; a press (140) configured to receive the fiber mat and compress the fiber mat to form a final molded component, the method comprising the following steps: in a dry-run mode, activating the backer material supply system, deactivating the press (140) and feeding the backer material through the press and to the milling station to be recycled; in a start-up mode subsequent to the dry-run mode, activating the infeed station and the milling station feeding the base material from the infeed station to the milling station to form the fiber mat, feeding the fiber mat onto the backer material, feeding the fiber mat through the deactivated press back to the milling station to be recycled, and continuing to feed backer material and base material until a leading edge of the fiber mat reaches one of the press and the milling station; and in a production mode subsequent to the start-up mode, activating the press and pressing the fiber mat into dry molded fiber components, and feeding trim from the fiber mat to the milling station.

84. The method of claim 83, further comprising the step of activating a sprayer of an additive station (139) to add an additive during the start-up mode.

85. The method according to any one of claims 83 and 84, further comprising the step of activating a sprayer of an additive station (139) to add an additive during the production mode.

86. The method according to any one of claims 83-85, further comprising the steps of adjusting an infeed speed from the infeed station (104) after the press (140) is activated in the production mode.

87. The method of claim 86, wherein the infeed speed is adjusted based on feedback from a weight sensor (145).

88. The method according to any one of claims 83-87, further comprising activating the production mode when a leading edge of the fiber mat reaches the press (140) or a pre-determined position downstream of the press.

89. A system (100) for manufacturing dry molded fiber components, the system including, an infeed station (104) configured to supply a base material; a milling station (108) including a mill (112) configured to receive and fiberize the base material into a plurality of fibers; a forming station configured to receive the plurality of fibers, and to form a fiber mat through the application of a vacuum source (240); a backer material supply system (137) configured to provide backer material to the fiber mat; a press (140) configured to receive the fiber mat and compress the fiber mat to form a final molded component; and a controller (105), the controller programmed to: in a dry-run mode, deactivate the press and feed the backer material through the press and to the milling station; in a start-up mode subsequent to the dry-run mode, activate the infeed station and the milling station, feed the base material from the infeed station to the milling station to form the fiber mat, feed the fiber mat onto the backer material, feed the fiber mat through the deactivated press back to the milling station, and continue to feed backer and base material until receiving feedback that the fiber mat has reached a pre-determined weight; and in a production mode subsequent to the start-up mode, activate the press and pressing the fiber mat into dry molded fiber components, and feed trim from the fiber mat to the milling station.

90. The system (100) of claim 89, further comprising a sensor (143) for sensing material entering the milling station (108), and wherein the controller (105) is programmedto switch from the dry-run mode to the start-up mode when a signal is received indicating that the backer material has reached the milling station (108).

91. The system (100) according to any one of claims 89 and 90, further comprising a sensor for sensing a material of the fiber mat, and wherein the controller (105) is programmed to activate the press (140) and enter the production mode when a signal is received indicating that the fiber mat has reached a pre-determined weight or a pre-determined thickness, has reached the press, or has reached a pre-determined position downstream of the press.

92. The system (100) according to any one of claims 89-91, wherein the controller (105) is further programmed to activate a nozzle of an additive station (139) to provide a spray to the backer material in the start-up mode.

93. The system (100) according to any one of claims 89-92, wherein the controller (105) is further programmed to activate a nozzle of an additive station (139) to provide a spray to the backer material in the production mode.

94. The system (100) according to any one of claims 89-93, wherein the controller (105) is further programmed to activate the production mode when a leading edge of the fiber mat reaches the press (140).

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