Method and apparatus for producing nonwoven fibrous fabric at high rate of speed

Abstract

In the production of a nonwoven fabric of thermally bonded fibers, a heavy web of fibers is continuously fed to a toothed cylinder at a slow speed to form a layer of fibers, and a portion of this layer is removed and formed into a lightweight uniform web at a faster speed. The second web is conveyed without draw to a calender having a bonding nip, and the fibers of the web are rearranged by compression and heating and are supported on a hot surface of one of the calender rolls prior to entering the nip to additionally improve uniformity.

What is claimed is:  
     
         1 . Apparatus for making a uniform web of fibers, said apparatus comprising a rotating toothed roll, means for supplying a first web of fibers to said toothed roll at a first basis weight and providing a layer of fibers on said toothed roll, and means for removing from said toothed wall a portion of said layer of fibers and forming a second web of fibers having a basis weight lower than said first basis weight.  
     
     
         2 . The apparatus of    claim 1    wherein said first web moves at a first speed and said second web moves at a second speed faster than said first speed.  
     
     
         3 . The apparatus of    claim 1    wherein said tooth roll rotates at a surface speed substantially faster than said means for removing a portion of said layer of fibers.