Apparatus and method for forming a layer of blended fibers into a continuous web

Abstract

The invention is directed a method and system for forming a layer of blended fibers into a continuous web. In one aspect, the apparatus includes blending apparatus for blending first and second fibers. The blended fibers are conveyed to a fiber collection station. A collecting and feeding apparatus at the fiber collection station has a feed chute that receives the blended fibers and an outlet for discharging the fibers. An accumulation chute between the inlet and outlet accumulates a column of the blended fibers. Fibers from the column are fed through the outlet as an initial layer of blended fibers to a forming station. A fiberizing apparatus at the forming station breaks up the initial layer into individual fibers. The individual fibers are deposited on a reforming conveyor as a reformed layer of blended fibers. The layer of blended fibers can be used in making absorbent pads, such as feminine protection pads.

1 . An apparatus for forming a layer of blended fibers into a continuous web, said apparatus comprising: 
 a blending apparatus for blending first and second fibers;    a collecting and feeding apparatus at a fiber collection station comprising a feed chute having an inlet for receiving a supply of said blended fibers, an outlet, an accumulation chute between the inlet and outlet for accumulating a column of blended fibers, and feed means at the outlet for feeding fibers from the column through the outlet as an initial layer of blended fibers to a forming station;    a fiberizing apparatus for breaking up said initial layer into small tufts and/or individual fibers; and    a reforming apparatus comprising a reforming conveyor on which said individual fibers are deposited as a reformed layer of blended fibers.    
     
     
         2 . The apparatus as set forth in  claim 1  wherein said initial layer is of substantially uniform width and thickness.  
     
     
         3 . The apparatus as set forth in  claim 1  wherein said feed means feeds fibers as an initial layer of blended fibers having a density between 0.005 and 0.050 g/cc.  
     
     
         4 . The apparatus as set forth in  claim 1  wherein said feed means feeds fibers as an initial layer of blended fibers having a density between 0.010 and 0.030 g/cc.  
     
     
         5 . The apparatus as set forth in  claim 1  wherein said feed means feeds fibers as an initial layer of blended fibers having a density between 0.013 and 0.019 g/cc.  
     
     
         6 . The apparatus as set forth in  claim 1  wherein said reforming apparatus comprises an air chamber having an inlet for receiving said individual fibers and an outlet adjacent said reforming conveyor, and an air system for generating a stream of air in the air chamber moving in a direction toward the reforming conveyor for directing fibers onto the conveyor.  
     
     
         7 . The apparatus as set forth in  claim 6  wherein said reforming apparatus further comprises apparatus for compressing the reformed layer into a continuous web of desired thickness.  
     
     
         8 . A method of forming a layer of blended fibers into a continuous blended-fiber web, said method comprising: 
 blending first and second fibers;    collecting a supply of said blended fibers;    feeding the fibers from the supply as an initial layer of blended fibers;    breaking up said initial layer into small tufts and/or individual fibers at a fiberizing station; and    reforming the individual fibers as a reformed layer of blended fibers on a moving conveyor.    
     
     
         9 . The method as set forth in  claim 8  wherein said initial layer is of substantially uniform width and thickness.  
     
     
         10 . The method as set forth in  claim 8  wherein said initial layer of blended fibers has a density between 0.005 and 0.050 g/cc.  
     
     
         11 . The method as set forth in  claim 8  wherein said initial layer of blended fibers has a density between 0.010 and 0.030 g/cc.  
     
     
         12 . The method as set forth in  claim 8  wherein said initial layer of blended fibers has a density between 0.013 and 0.019 g/cc.  
     
     
         13 . The method as set forth in  claim 8  wherein said feeding step comprises compressing the fibers to form said initial layer.  
     
     
         14 . The method as set forth in  claim 8  wherein said fibers are directed to said conveyor by an air chamber and an air stream in the air chamber flowing toward said conveyor.  
     
     
         15 . The method as set forth in  claim 8  wherein said fibers in said reformed layer are randomly oriented.  
     
     
         16 . The method as set forth in  claim 8  further comprising compressing the reformed layer into a continuous web of desired thickness.  
     
     
         17 . An interlabial pad made using the method of  claim 8 .  
     
     
         18 . An apparatus for forming a layer of blended fibers into a continuous web, said apparatus comprising: 
 means for blending first and second fibers;    means for collecting a supply of said blended fibers;    means for feeding the fibers from the supply as an initial layer of blended fibers;    means for breaking up said initial layer into small tufts and individual fibers at a fiberizing station; and    means for reforming the individual fibers as a reformed layer of blended fibers on a moving conveyor.