Former Head Roller Projections for Fiber Dispersion

The patent introduces a screen as an intermediary element between the air stream and the fiber mass. The screen breaks up the fiber clumps into smaller aggregates before they reach the forming wire, reducing the need for high-velocity air to achieve proper fiber separation. This mediator approach allows effective fiber dispersion at lower air velocities, thereby reducing energy consumption while maintaining manufacturing precision.

The patent replaces the purely pneumatic system (relying on high-velocity air to separate fibers) with a mechanical system involving a rotating screen with openings. The mechanical action of the screen physically breaking up fiber clumps substitutes for the need for high air velocity, achieving fiber separation through mechanical means rather than relying solely on aerodynamic forces, thus reducing energy consumption.

The patent segments the fiber mass into smaller clumps using a screen with multiple openings arranged in a specific pattern. This segmentation approach breaks down large fiber aggregates into smaller, more manageable clusters that can be more easily dispersed and formed into a uniform nonwoven structure. The segmented approach achieves better fiber dispersion through a relatively simple screening mechanism rather than complex multi-component systems.

The rotating screen serves multiple functions simultaneously: it breaks up fiber clumps, distributes fibers evenly across the forming width, and controls the timing and location of fiber release. This multi-functional element achieves comprehensive fiber dispersion without requiring separate components for each function, thereby maintaining device simplicity while improving manufacturing precision.