RU2789713C1 - Methods for substrate formation - Google Patents

Abstract

FIELD: substrate production.

SUBSTANCE: methods and devices for obtaining a substrate are described. Also presented is a method and apparatus for introducing a component into a supplied amount of fluid. The method may include providing a first supplied amount of fluid. In some embodiments, the amount of fluid delivered may be in the form of foam. The method may also include providing a component loading system and providing a supply quantity of the component. In some aspects, the method may include introducing the component into the amount of fluid supplied in the ejector.

EFFECT: resulting slurry containing the supplied amount of fluid and the component can be transported through the headbox; resulting slurry may be dehydrated to provide a support containing the component.

24 cl, 11 dwg

Description

FIELD OF TECHNOLOGY

The present invention relates to methods and apparatus for forming substrates. In particular, the present invention relates to methods of production using foaming and devices for the formation of substrates.

BACKGROUND OF THE INVENTION

Personal care products such as diapers, diaper briefs, potty training briefs, adult incontinence products, and feminine hygiene products may contain a variety of substrates. For example, the diaper may comprise an absorbent structure, nonwovens, and films. Similarly, handkerchiefs, wet wipes and towels may also contain various substrates. Some of the substrates in these products may contain natural and/or synthetic fibers. In some products, some substrates may also contain different types of components to provide additional functionality to the substrate and/or the final product itself.

For example, one such component that it may be desirable to add to the substrate includes a superabsorbent material (SAM). SAM can be in particle or fiber form and is commonly used in substrates to increase absorbency. Absorbent systems for absorbent personal care products, such as a diaper, often contain SAM. There are SAM backing processes that involve using spin chambers to mix SAM particles or fibers with cellulosic fibers to form an absorbent core. These processes are typically performed in dry environments, as SAM can be difficult to process in wet conditions due to volume expansion due to fluid absorption and gelation, among other potential disadvantages. However, alternative substrate formation processes may use fluids, such as liquids, to provide the substrates with various other characteristics and capabilities in the manufacture and use of such substrates.

Thus, there is a need to develop methods and apparatus for incorporating a component into a feed amount of a substrate forming fluid. There is also a need to develop methods and devices for forming substrates containing components. There is also a need to develop improved headboxes for forming substrates.

SUMMARY OF THE INVENTION

In one embodiment, a method for the formation of a substrate containing component is provided. The method may include the provision of the first given quantity of fluid and the provision of the second submitted amount of fluid. At least one element from the first given amount of fluid and the second served amount of fluids can contain many fibers. The method may additionally include the provision of the component loading system. The method may include the provision of the submitted amount of the component for the component loading system. The component may include at least one particle and fiber element. The method can additionally include transportation of the first given quantity of fluid. Also, the method may include the introduction of the component into the second submitted amount of fluid in the ejector. The method can additionally include the transportation of the second submitted amount of a fluid medium containing the component. Also, part of the method may be mixing the first amount of fluid with a second submitted quantity of fluid, containing the component, to provide the suspension resulting from the suspension. The method can additionally include transportation of the suspension obtained as a result of a suspension by means of a pressure box on a forming surface. The method may also include dehydration obtained as a result of suspension to provide a substrate containing component.

In another embodiment, a method for forming a substrate containing a component is provided. The method may include providing a first fluid supply and providing a second fluid supply. At least one of the first fluid supply and the second fluid supply may comprise a plurality of fibers. The method may also include providing a component loading system. The method may further include providing a feed amount of the component to the component loading system. Additionally, the method may include transporting the first supplied amount of fluid. The method may include conveying a second fluid supply under a second fluid supply pressure. In addition, the method may include the introduction of a component in the second supplied amount of fluid in the mixing node. The method may further include transporting a second fluid supply containing the component through the outlet of the mixing unit, wherein the second fluid supply containing the component is transported under pressure at the outlet of the mixing unit. Also, the method may include controlling the pressure difference between the outlet pressure of the mixing unit and the supply pressure of the second fluid. It may also be part of the method to mix the first fluid feed with the second fluid feed containing the component to provide the resulting slurry. The method may further include transporting the resulting slurry via a headbox to the forming surface. The method may also include dehydrating the resulting slurry to provide a support containing the component.

In yet another embodiment, a method for forming a substrate containing a component is provided. The method may include providing a first supplied amount of fluid. The method may include providing a component loading system. The method may also include providing a feed quantity of the component to the component loading system. The component may include at least one particle and fiber element. The method may also further include transporting the first supplied amount of fluid. The method may include introducing a component into the first fluid supply in the ejector to provide the resulting slurry. Additionally, the method may include transporting the resulting slurry via a headbox to a forming surface. The method may also include dehydrating the resulting slurry to provide a support containing the component.

BRIEF DESCRIPTION OF GRAPHICS

The full and sufficient disclosure of the present invention, intended for a specialist in this field of technology, is set out more specifically in the rest of the description, which refers to the attached figures on which:

in fig. 1 is a process flow diagram for an exemplary method of introducing a component into a fluid supply and forming a substrate containing the component, in accordance with one embodiment of the present invention.

In FIG. 2 is a detailed diagram of the component loading system, two mixing assemblies, and two fluid supplies upstream of the headbox shown in the process diagram of FIG. 1.

In FIG. 3 is a cross-sectional view of the first mixing unit and outlet of the component loading system of FIG. 2.

In FIG. 4A is a process flow diagram for an alternative exemplary method for introducing a component into a fluid feed and forming a support containing the component, in accordance with yet another embodiment of the present invention.

In FIG. 4B is a process flow diagram for another alternative exemplary method for introducing a component into a fluid feed and forming a support containing the component, in accordance with yet another embodiment of the present invention.

In FIG. 4C is a process flow diagram for another alternative exemplary method for introducing a component into a fluid feed and forming a support containing the component, in accordance with another embodiment of the present invention.

In FIG. 5 is a front, top, and perspective view of an exemplary headbox, the top surface of which has been removed for clarity.

In FIG. 6 is a top plan view of the headbox of FIG. 5.

In FIG. 7 is a rear plan view of the headbox of FIG. 5.

In FIG. 8 is a side, top, perspective, and cross-sectional view taken along line 8-8 in FIG. 6 showing the top surface.

In FIG. 9 is a side view, in cross section, taken along line 8-8 in FIG. 6 showing the top surface.

The reuse of reference numbers in this specification and in the drawings is intended to represent the same or similar features or elements of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention relates to methods and devices by which a substrate containing a component can be obtained. While the present invention provides examples of substrates made by foaming, it is contemplated that the methods and apparatus described herein can be used to take advantage of wet and/or dry air molding manufacturing methods.

Each example is provided for the purpose of explanation and is not intended to be limiting. For example, features illustrated or described as part of one embodiment or figure may be used with respect to another embodiment or figure to obtain yet another embodiment. The present invention is intended to include such modifications and variations.

When presenting elements of the present invention or preferred embodiment(s) thereof, the use of the terms in the singular or plural, as well as with the word "specified" implies that there are one or more elements. The terms "comprising", "including" and "having" are intended to be inclusive and mean that there may be additional elements in addition to the listed elements. In the context of this document, the terms "first", "second", "third", etc. do not indicate a specific order, but are used as a means to distinguish between different cases when referring to different features in the present invention. Many modifications and variations of the present invention can be made without departing from its spirit and scope. Therefore, the exemplary embodiments described herein should not be used to limit the scope of the present invention.

Definitions

In the context of this document, the term "foaming product" means a product formed from a suspension containing a mixture of solid, liquid and dispersed gas bubbles.

In the context of this document, the term "foaming process" means a process for making a product containing a suspension that contains a mixture of solid, liquid and dispersed gas bubbles.

In the context of this document, the term "foaming fluid" means any of one or more known fluids that are compatible with other components in the process of obtaining using foaming. Suitable foaming fluids include, but are not limited to, water.

In the context of this document, the term "half-life of the foam" means the time elapsed before the reverse transformation of half of the original mass of the foam into liquid water.

In the context of this document, the term “layer” refers to a structure that provides the substrate area in the direction along the SAM axis, which consists of such components and has a similar structure.

In the context of this document, the term "non-woven fabric" means a fabric having a structure of individual fibers or filaments, which are interleaved, however, in an undetectable manner, as in the case of a knitted fabric.

In the context of this document, unless expressly indicated otherwise, each of the terms "percent", "%", "weight percent" or "percent by weight" used in relation to the composition of materials refers to the amount by weight of a component, expressed as a percentage value of the total, except where expressly stated otherwise.

The term “personal care absorbent article” as used herein refers to an article that is designed and/or adapted to be placed against or near the body (i.e., in contact with the body) of a wearer to absorb and contain various liquid, solid and semi-liquid secretions secreted by the body. Examples include, but are not limited to, diapers, diaper briefs, potty training briefs, teen briefs, briefs, feminine hygiene products including, but not limited to, menstrual pads or briefs, incontinence products, medical garments , surgical pads and bandages, etc.

The term "interlayer" refers to a discrete layer within a multilayer product, where individual layers can be located in contact with each other.

The term "superimposed" or "coupled" or "attached" as used herein refers to articulation, bonding, joining, bonding, or the like. two elements. Two elements will be considered superimposed, bonded, or connected together if they are articulated, glued, connected, bonded, or the like. directly with each other or indirectly with each other, for example, when each is directly connected to intermediate elements. The superimposition, linking or connection of one element with another can occur through continuous or interrupted links.

The term "superabsorbent material" as used herein refers to water-swellable, water-insoluble organic or inorganic materials, including superabsorbent polymers and superabsorbent polymer compositions, capable of absorbing at least about 10 times their weight under most favorable conditions. , or at least about 15 times its weight, or at least about 25 times its weight in an aqueous solution containing 0.9 weight percent sodium chloride.

Method and device

In one embodiment, the present invention relates to a method and apparatus 10 with which a substrate 12 can be formed. FIG. 1 is a diagram of an exemplary apparatus 10 that may be used as part of a foaming process to produce a substrate 12 that is a foamed product. The device 10 may include the first tank 14, configured to accommodate the first supplied amount 16 of the fluid. In some embodiments, the first fluid delivered 16 may be foam. The first fluid supply 16 may comprise fluid provided by the fluid supply 18. In some embodiments, the first fluid supply 16 may comprise a plurality of fibers provided by the fiber supply 20, however, in other embodiments, the first supply 16 the fluid may not contain a plurality of fibers. First fluid delivery 16 may also contain a surfactant provided by surfactant delivery 22. In some embodiments, first tank 14 may include a mixing device 24, as will be discussed in more detail below. The agitator 24 may mix (eg, agitate) the first fluid feed 16 to mix the fluid, fibers (if present) and surfactant with air or some other gas to create foam. The agitator 24 may also mix the foam with fibers (if present) to create a suspension of fibers in the foam in which the foam retains and separates the fibers to help distribute the fibers in the foam (for example, as an artificial means of the mixing process in the first tank 14 ). An even distribution of the fibers can contribute to the desired quality of the substrate 12, including, for example, the strength and appearance of the desired quality.

The device 10 may also include a second tank 26, configured to accommodate the second supplied amount 28 of the fluid. In some embodiments, the second fluid delivery 28 may be foam. Second fluid delivery 28 may comprise fluid provided by fluid delivery 30 and surfactant provided by surfactant delivery 32. In some embodiments, second fluid delivery 28 may comprise a plurality of fibers in addition to or as an alternative to the fibers present in the first supplied amount 16 of the fluid. In some embodiments, the implementation of the second tank 26 may contain a device 34 for mixing. The agitator 34 may mix the second fluid supply 28 to mix the fluid and surfactant with air or some other gas to create foam.

In the case of either or both of the first tank 14 and the second tank 26, the first fluid supply 16 or the second fluid supply 28 may be affected to form foam. In some embodiments, the foaming fluid and other components are affected to form a porous foam having an air content of more than about 50% by volume and, desirably, an air content of more than about 60% by volume. In certain aspects, a highly expandable foam is formed having an air content of from about 60% to about 95%, and in additional aspects from about 65% to about 85%. In certain embodiments, the foam can be manipulated to introduce air bubbles such that the expansion ratio (volume of air relative to other components in the expanded stable foam) is greater than 1:1 and in certain embodiments, the ratio of air to other components can be between about 1.1:1 to about 20:1, or about 1.2:1 to about 15:1, or about 1.5:1 to about 10:1, or even about 2:1 to about 5: 1.

Foam can be obtained using one or more means known from the prior art. Examples of suitable methods include, but are not limited to, vigorous mechanical agitation, such as using agitators 24, 34, compressed air injection, etc. Mixing the components using a high speed, high shear agitator is particularly well suited for use the formation of the required highly porous foams. Various high shear agitators are known in the art and considered suitable for use in the present invention. High shear agitators typically employ a tank containing the foam precursor and/or one or more pipes through which the foam precursor is directed. High shear agitators may use a series of screens and/or rotors to work with the precursor and to effect intensive mixing of the components and air. In a particular embodiment, a first tank 14 and/or a second tank 26 is provided, comprising one or more rotors or impellers and associated stators. The rotors or impellers rotate at high speeds to provide flow and shear. The air can, for example, be introduced into the tank at various positions or simply by being drawn in by the action of the mixing devices 24, 34. Although the specific design of the agitator may affect the speeds required to achieve the desired mixing and shear, in certain embodiments, suitable rotor speeds may be greater than about 500 rpm and, for example, range from about 1000 rpm to about 6000 rpm. /min, or from about 2000 rpm to about 4000 rpm. In certain embodiments of rotor-based high shear agitators, the agitator(s) 24, 34 can be operated with foam until swirling in the foam disappears or sufficient volume expansion is achieved.

In addition, it is noted that the foaming process can be carried out in a single foam step or in successive foam steps for the first tank 14 and/or the second tank 26. For example, in one embodiment, all components of the first fluid supply 16 in the first tank 14 (eg, the amount of fluid 18 supplied, fibers 20, and surfactant 22) can be mixed with each other to form a slurry from which foam is formed. Alternatively, one or more individual components can be added to the foaming fluid to form an initial mixture (e.g., dispersion or foam), after which the remaining components can be added to the initial foam slurry, and then all components are affected to form the final foam. In this regard, fluid 18 and surfactant 22 may be initially mixed and affected to form an initial foam prior to adding any solids. Fibers can then be added to the water/surfactant based foam as needed and then subjected to further exposure to form the final foam. As a further alternative, fluid 18 and fibers 20, such as high density pulp sheet, can be mixed vigorously at a higher density to form an initial dispersion, after which a foaming surfactant, additional water, and other components, such as synthetic fibers to form a second mixture which is then mixed and impacted to form a foam.

Foam density at foaming for the first fluid delivery 16 in the first tank 14 and/or at foaming for the second fluid delivery 28 in the second tank 26 may vary depending on the particular application and various factors such as the range of fibers used. In some embodiments, for example, the foam density may be greater than about 100 g/L, such as greater than about 250 g/L, such as greater than about 300 g/L. The foam density is typically less than about 800 g/L, such as less than about 500 g/L, such as less than about 400 g/L, such as less than about 350 g/L. In some embodiments, for example, a lower density foam is used having an overall foam density of less than about 350 g/L, such as less than about 340 g/L, such as less than about 330 g/L.

In some embodiments, the apparatus 10 may also include a first pump 36 and a second pump 38. The first pump 36 may be in fluid communication with the first fluid delivery 16 and may be configured to pump the first fluid delivery 16 to transport the first delivery. 16 fluid. The second pump 38 may be in fluid communication with the second fluid delivery 28 and may be configured to pump the second fluid delivery 28 to transport the second fluid delivery 28. In some embodiments, the first pump 36 and/or the second pump 38 may be an eccentric screw pump or a centrifugal pump, however, it is contemplated that other suitable types of pumps may be used. In addition, as further discussed below, in some embodiments, the apparatus may be provided with a single pump capable of pumping one fluid supply to the first fluid supply 16 and the second fluid supply 28.

As shown in FIG. 1 and 2, the device 10 may also include a component loading system 40. The component loading system 40 may include a component supply portion 42 for accommodating the amount of component 44 to be supplied, as shown in the partly cut portion of the component supply portion 42 shown in FIG. 2. The component loading system 40 may also include an outlet 46. The outlet 46 may have a circular cross-section or may be rectangular, such as with a slot. The component loading system 40 may also include a hopper 48. The hopper 48 may be connected to the component supply section 42 and may be used to replenish the amount of component 44 supplied at the component supply section 42.

In some embodiments, the component loading system 40 may include a bulk materials pump. Some examples of bulk solids pumps that may be used herein may include systems that use screws/screws, belts, vibratory chutes, rotating discs, or other known systems to handle and discharge the feed quantity of component 44. In component loading system 40 other types of loading devices may be used, such as, for example, an ingredient loading device such as one manufactured by Christy Machine & Conveyor, Fremont, Ohio. In some embodiments, the component loading system 40 may also be implemented as a conveyor system.

The component loading system 40 may also include a fluid management system 50. The fluid control system 50 may be configured to control the entrainment of gas into the fluid supply in which the component 44 is supplied. component loading system 40. In other embodiments, the fluid control system 50 may be formed as part of the design of the component loading system 40 itself, such that a separate enclosure 52 surrounding the component loading system 40 may not be required. As shown in FIG. 1 and 2, in some embodiments, the fluid control system 50 may also include a purge port 54.

The amount of component 44 supplied may be in the form of particles and/or fibers. In one embodiment, as described in this document, the submitted amount of component 44 may be a super -recruiting material (SAM) in the form of particles. In some embodiments, the SAM may be in the form of a fiber. Of course, as used in the device 10 and the methods described in this document, components of other types are also assumed, as described below. System 40 loading the component described in this document can be especially beneficial for the submitted amount of component 44, which is most advisable to maintain in a dry environment with the minimum effect of a fluid environment or foam used in the device 10 and methods described in this document.

With reference to FIG. 1-3, in some embodiments, the apparatus 10 and methods described herein may comprise a first mixing assembly 56 and a second mixing assembly 58. In preferred embodiments, the first mixing assembly 56 may be an ejector. The first mixing unit 56 may be in fluid communication with the outlet 46 of the component loading system 40 and be in fluid communication with the second fluid supply 28 . As shown in FIG. 3, the first mixing assembly 56 may include a first inlet 60 and a second inlet 62. The first inlet 60 may be in fluid communication with a feed quantity of the component 44 via an outlet 46. The second inlet 62 may be in fluid communication with the second feed quantity 28 fluid. The first mixing unit 56 may also include an outlet 64.

In preferred embodiments, the first mixing unit 56 can be made in the form of a coaxial ejector. For example, in the preferred version of the implementation, the first mixing unit 56 can be made so that the axis 66 of the first intake hole 60 of the first mixing assembly 56 is a coaxial one with an axis of 68 of the exhaust channel 46, which provides the submitted amount of component 44. The first mixing unit 56 can also be performed like this that the axis of the 70 issue 64 is a coaxial one with the exhaust axis 68 of the final channel 46. Thus, the first mixing unit 56 can be made that the axis 66 of the first intake hole 60 can be carved with an axis of 70 output 64 of the first mixing unit 56. The second intake of hole 62, which provides the second submitted amount of 28 turnover for the first mixing unit 56, can be arranged so as to enter the first mixing unit 56 on the side of the first mixing unit 56. This configuration of the supplied amount of component 44 to the first intake hole 60 is comprehensive with the axis. 70 issue, not the receipt of the second submitted quantity The 28 -fluid medium in the first intake hole 60 is the opposite of many configurations of ejectors in which the supplied quantity of fluid and the component is mixed using the driving force of the taxed amount of fluid, but provides the advantages of the first mixing unit 56 described in this document.

When configured as an ejector, the first mixing unit 56 can mix the feed amount of component 44 from the component loading system 40 with the second feed amount 28 of the fluid. By conveying the second fluid delivery 28 to the first mixing assembly 56 at the second inlet 62 and through the first mixing assembly 56, the second fluid delivery 28 provides a driving pressure for the delivery of component 44. The driving pressure can create a vacuum with respect to the delivery. component 44 and a component loading system 40 to help draw the mixing and entraining component 44 feed into the second fluid feed 28 . In some embodiments, the implementation of the driving pressure can create a vacuum of less than 1.5 inches of mercury in relation to the supplied amount of component 44. Art., however, in other embodiments, the implementation of the driving pressure can create a vacuum of 5 inches of mercury in relation to the supplied amount of component 44. Art. or more, or 10 inches Hg. Art. or more.

The fluid control system 50 may assist in controlling the proper distribution and entrainment of the component feed 44 into the second fluid feed 28, as well as controlling the fluid entrainment into the second fluid feed 28 downstream of the component loading system 40. For example, in the absence of enclosure 52 surrounding component loading system 40, additional fluid (e.g., ambient gas such as air) may be entrained in second fluid supply 28 as component supply 44 is metered into second fluid supply 28. It may also be that when the second fluid supply 28 creates a driving pressure against the component loading system 40, the vacuum attracting the component supply 44 may cause additional air to be entrained into the second fluid supply 28. Entrainment of additional air into the second fluid supply 28 may be desirable in some circumstances, however, in other circumstances it may be desirable to control the gas content in the second fluid supply 28 during introduction of the component feed 44 into the second fluid supply 28 in the first mixing unit 56. For example, in some circumstances where the second fluid supply 28 is foam, it may be desirable to maintain the gas content of the foam at a relatively constant level as the foam passes through the first mixing unit 56. Thus, the fluid control system 50 can assist in controlling the pressure exerted on the component loading system 40 and the flow of gas through it to help prevent or at least control the amount of gas entrained in the second fluid supply 28 when the component supply 44 mixes with the second fluid supply 28 and can assist in counteracting the driving pressure on the component supply 44 and the component loading system 40 that is created by the second fluid supply 28.

In some embodiments, the fluid control system 50 may include a closure for separating the component loading system 40. For example, as discussed above, the fluid control system 50 may include a casing 52 to provide insulation with respect to the component loading system 40. The isolation of the component loading system 40 can help prevent entrainment of additional air into the second fluid supply 28 when the component supply 44 is introduced into the second fluid supply 28 in the first mixing assembly 56.

However, in some embodiments, it may also be advantageous to include an additional capability in the fluid management system 50. For example, in some embodiments, the fluid control system 50 may include a purge port 54. The purge port 54 may be configured to purge a fluid stream, such as ambient air stream, to provide additional fluid flow control to the component loading system 40. Purge opening 54 may admit a gas flow (eg, air flow) into the housing 52 to help control the air flow and pressure within the housing 52 surrounding the component loading system 40. It has been found that by providing a purge port 54 to introduce some purge flow of atmospheric air into the component loading system 40, the backsurge of the second fluid supply 28 in the first mixing assembly 56 can be reduced or eliminated. the first mixing assembly 56 can help prevent the component loading system 40 from clogging or needing to be cleaned, particularly when the component loading system 40 can deliver dry particles such as SAM. In other process conditions, it may be desirable to completely isolate the component loading system 40 for similar reasons.

Additionally or alternatively, fluid control system 50 may be configured to supply additional gas flow (e.g., air flow) and/or provide positive pressure to prevent backfilling of component loading system 40 in some circumstances, such as when an obstruction occurs in device 10 downstream. flow behind the first mixing node 56. In the case where the obstacle creates an increased pressure, the second supplied amount of fluid 28 may tend to refill the system 40 loading component. Backfilling the component loading system 40 with fluid can be detrimental to processing, particularly when the amount of component 44 supplied is a dry component such as SAM. The fluid control system 50, configured to provide positive pressure to the component loading system 40, can help prevent such backfilling of the component loading system 40.

It is also contemplated that other additional aspects of the fluid control system 50 can be used to maintain gas flow and pressure at a level suitable for the component loading system 40, including but not limited to providing a vacuum to the component loading system 40 in addition to the purge air purge described above. orifice 54 and/or positive pressure, or as an alternative to them.

As shown in FIG. 3, in some embodiments, the first mixing assembly 56 may also include a venturi section 72. The venturi section 72 may be a narrowed region of the first mixing assembly 56 that can increase the speed of the second fluid supply 28 passing through the venturi section 72 and thus increase the vacuum pressure generated by the second supply 28 fluid in relation to the supplied amount of component 44 in the system 40 loading component, and can also contribute to the entrainment of the supplied amount of component 44 in the second supplied amount 28 of the fluid. In some embodiments, the distal end 74 of outlet 46 supplying the feed quantity of component 44 to first mixing assembly 56 may be located in section 72 in the form of a venturi. The location of the distal end 74 of the outlet 46 in the venturi section 72 can be adjusted as one way of controlling the pressure of both the second fluid supply 28 as it is discharged from the first mixing unit 56 and the component loading system 40.

The first mixing unit 56 may also provide pressure control to transport the second fluid supply 28 containing the component 44 as it exits the outlet 64 of the first mixing unit 56 compared to when the second fluid supply 28 enters the first mixing node 56. Before the first mixing node 56, the second supplied amount 28 of the fluid can be transported under the pressure of the second fluid. The second supplied amount 28 of the fluid containing a component of the supplied amount of the component 44 may exit the outlet 64 of the first mixing unit 56 under pressure at the outlet. The pressure drop between the pressure of the second fluid up to the first mixing unit 56 and the outlet pressure can be controlled. In some embodiments, this pressure drop can be controlled by changing the flow rate of the second fluid quantity 28 supplied. In some embodiments, this pressure drop can be controlled by locating the distal end 74 of outlet 46 in venturi section 72 of first mixing assembly 56. For example, if distal end 74 of outlet 46 moves further into venturi section 72, area is reduced. for the flow of the second fluid supply 28 through the venturi tube 72, and thus the supply pressure of the second fluid supply 28 is increased. If the distal end 74 of the outlet 46 moves further out of the venturi section 72 ( i.e., back towards the component loading system 40), the area for the second fluid supply 28 to flow through the venturi section 72 increases, and, thus, both the supply pressure of the second fluid supply 28 entering the first mixing unit 56 and the vacuum level in relation to the component loading system 40 are reduced. In some embodiments, it is preferable to control the pressure differential between the pressure of the second fluid upstream of the first mixing assembly 56 and the outlet pressure to be less than or equal to 25 psi, or more preferably less than 20 psi. sq. inch, or less than 15 psi inch, or less than 10 psi inch, or less than 5 psi inch.

Another feature of the first mixing unit 56 that can provide improved mixing and transport of the feed quantity of the component 44 to the second fluid feed quantity 28 in the first mixing assembly 56 may be that the second inlet 62 providing the second fluid feed quantity 28 is located upstream of the distal end 74 of an outlet 46 that supplies component 44 from component loading system 40 to first mixing assembly 56. In such a configuration, a second fluid supply 28 may enter first mixing assembly 56 upstream of component supply 44 to prevent the supplied amount of component 44 from coming into contact or sticking to the inner surface of the first mixing unit 56. Thus, in the embodiment shown in FIG. 3, the alignment of the axis 68 of the outlet channel 46 and the axis 70 of the outlet of the first mixing unit 56, as well as the entry of the second supplied amount of fluid 28 into the first mixing unit 56 upstream can create a hydraulic protection of the annular shape around the place of entry of the supplied amount of the component 44 as it entrainment in the second supplied amount 28 of the fluid in the first mixing unit 56.

It should be noted that although in FIG. 1-3 shows one outlet 46 of the component loading system 40 and one first mixing unit 56, it is contemplated that the outlet 46 may be divided into two or more channels to load two or more first mixing units 56 to mix the feed quantity of the component 44 with the second supplied amount 28 of the fluid. In such a configuration, the second fluid supply 28 may comprise as many channels as there are first mixing units 56. By having more than one outlet 46 and more than one first mixing unit 56 for mixing the component supply 44 with the second fluid supply 28 , it is possible to achieve a higher flow rate of the second supplied amount of fluid 28 containing a component from the supplied amount of component 44.

In some embodiments, it is also contemplated that the first mixing assembly 56 may be an ejector with a different configuration than the coaxial ejector described above. For example, it is contemplated that the first mixing unit 56 may be an ejector in the form of a slotted ejector.

With reference to FIG. 1, in some embodiments, the apparatus 10 may include a second mixing assembly 58. The second mixing assembly 58 may be operable to mix a second fluid delivery 28 containing a component from the component delivery 44 with the first fluid delivery 16. After the output of the second fluid supply 28, containing the component from the component supply 44, from the outlet 64 of the first mixing unit 56, it can be transported to the second mixing unit 58. The first fluid supply 16 can be delivered to the second mixing unit 58 using the first pump 36. The second mixing unit 58 may mix the first fluid supply 16 and any of its components (e.g., fluid 18, fibers 20, surfactant 22) with the second fluid supply 28 and any of its components (e.g., fluid 30, surfactant 32), as well as a component of the feed amount of component 44 to provide the resulting slurry 76. The resulting slurry 76 can be transported from the second mixing unit 58 through the outlet 78 of the second mixing unit 58 to the headbox 80 .In some embodiments, as shown in FIG. 3, there may be a separation between the outlet 78 of the second mixing unit 58 and the headbox 80. However, in other embodiments, the outlet 78 of the second mixing unit 58 may be integral with the headbox 80.

In FIG. 4A depicts an alternative embodiment of apparatus 110 and method for forming substrate 12. FIG. 4A shows the same components as those of the apparatus 10 and method described in FIG. 1-3 if not listed here. The device 110 of FIG. 4A contains only the first tank 14 to accommodate the first supply amount 16 of the fluid. The apparatus 110 and method of FIG. 4A does not include a second tank 26 containing a second supply 28 of fluid. The first fluid delivery 16 may comprise a fluid delivery 18, a fiber delivery 20, and a surfactant delivery 22. The device 110 may also include a component loading system 40, a fluid control system 50, and a mixing assembly 56 described above in with respect to FIG. 1-3. Based on this configuration, the first pump 36 can transport the first fluid supply 16 to the first mixing unit 56. The component loading system 40 can transport the component 44 supply to the first mixing unit 56 as previously described. In preferred embodiments, the first mixing unit 56 may be an ejector, more preferably a coaxial ejector as described with respect to FIG. 3. The first mixing assembly 56 may mix the first fluid feed 16 with a component from the component feed 44 and provide the resulting slurry 76 that exits the outlet 64 of the first mixing assembly 56 and is transported to the headbox 80. In some embodiments, the outlet 64 of first mixing assembly 56 may be separate from headbox 80, however, in some embodiments, outlet 64 of first mixing assembly 56 may be integral with headbox 80. In some embodiments, first fluid delivery 16 may comprise fluid 18 and surfactant 22 to be mixed with the feed amount of component 44 to provide the resulting slurry 76, but may not contain any fibers. In other embodiments, the first fluid feed 16 may comprise fluid 18, fibers 20, and surfactant 22 to be mixed with component feed 44 to provide the resulting slurry 76.

In FIG. 4B depicts yet another alternative embodiment of the device 210 and the method for forming the substrate 12. The device 10 may include a first pump 36 that can be in fluid communication with the first fluid quantity 16 to be delivered. The first fluid delivery 16 may comprise a fluid delivery 18 and a surfactant 22. The first fluid delivery 16 may be separated at the assembly 17. The first fluid delivery 16 may pass after the two control valves 23. The first delivery quantity 16, the fluid may flow after one of the control valves 23 in the channel 19 towards the headbox 80. The fiber feed 20 may be added to the first fluid feed 16 after the control valve 23. Preferably, the fiber feed 20 may be fed into the first feed quantity 16 fluid in such a supplied amount of fluid as foam.

When the first fluid supply is divided at the node 17, the first fluid supply 16 may be pumped after the second control valve 23 in the channel 21 towards the first mixing node 56. The fluid supply in this channel may be referred to as the second fluid supply 28. The second fluid delivery 28 may comprise the fluid delivery 18 and the surfactant 22 (which of the first fluid delivery 16). In some embodiments, it may be preferable to add the fiber feed 20' to the second fluid feed 28 as shown in FIG. 4B. Preferably, the fiber feed 20' may be supplied to the first fluid feed 16 in a fluid feed such as foam.

In the embodiment depicted in FIG. 4B, the feed quantity of component 44 may be added to the second fluid feed quantity 28 in the first mixing assembly 56 as described above. Device 210 may include outlet 65 of first mixing assembly 56 containing component 44 downstream of outlet 64 of first mixing assembly 64. The amount of fluid and component 44 supplied at outlet 65 of first mixing assembly 56 may provide first input 67 to headbox 80. The first fluid delivery 16 may provide a second inlet 69 into the headbox 80. The first inlet 67 may be separate from the second inlet 69 into the headbox 80. For example, in some embodiments, the first inlet 67 containing component 44 may be separate from the second input 69 having a Z-direction divider 71 (also referred to as a plate), and thus the fluid supplies 16, 28 can be separated from each other for at least a portion of the headbox 80 when the fluid supplies 16, 28 transported by headbox 80 to provide the resulting slurry 76. In this case, p the resulting slurry 76 may provide two different layers to provide a two-layer substrate 12.

Another alternative embodiment is shown in FIG. 4C. Fig. 4C is similar to the configuration shown in FIG. 2, however, in the configuration of FIG. 4C, a purge port 154 is provided that can provide a controlled flow of fluid to a feed quantity of component 44 after component 44 enters outlet 46 of component loading system 40, but upstream of first mixing assembly 56. Such a configuration can supply fluid (e.g., liquid, gas, or foam) into the component 44 feed to help control fluid entrainment into the second fluid feed 28 when the component feed 44 is mixed with the second fluid feed 28 in the first mixing assembly 56. For example, in one embodiment, adding a foam stream to the vent 154 can help prevent additional gas (eg, air) from being entrained in the component 44 feed as it mixes with the second fluid feed 28.

Regardless of whether the device 10, 110, 210 and method described herein is used to transport the resulting slurry 76, or another device and/or method, the resulting slurry 76 can be further transported to form the substrate 12. headbox 80. As shown in FIG. 5-9, the headbox 80 may have a machine direction 81 and a transverse direction 83. The machine direction 81 extends in the direction of transport of the resulting slurry 76 through the headbox 80. The resulting slurry 76 is not shown in FIG. 5-9 for clarity.

Headbox 80 may include at least one flow section 82. In the embodiment of headbox 80 shown in FIG. 5-9, headbox 80 includes two flow sections 82. As shown in FIG. 5, the flow sections 82 may be spaced apart in the lateral direction 83, but may be in the same common plane formed by the MD 81 and the lateral direction 83. It is contemplated that in some embodiments containing more than one flow section 82, these flow sections sections 82 may be positioned such that one flow section 82 is positioned on top of another flow section 82 in a z-direction 85 perpendicular to the plane formed by the machine direction 81 and the transverse direction 83. In some embodiments, comprising more than one flow section 82, two flow sections 82 may be substantially similar to each other. However, it is also contemplated that one flow section 82 may be configured differently from another flow section 82 depending on various factors such as, but not limited to, the characteristics of the substrate 12 to be formed. Additionally, although in the embodiment of FIG. 5-9 show two flow sections 82, it is contemplated that the headbox 80 may comprise three or more flow sections 82. The number of flow sections 82 can be adjusted to achieve different flow rates of the resulting slurry 76, the required width of the substrate 12, and/or the number of directional On the axis Z layers of the substrate 12.

Each flow section 82 may include a bottom surface 84 and an upper surface 86 (labeled in FIGS. 8 and 9). The upper surface is 86 in FIG. 5-7 have been removed for clarity of internal features of the headbox 80. The flow section 82 may also have a first side 87 and a second side 88. The second side 88 may be opposite the first side 87. In some embodiments, the first side 87 and the second side 88 can be configured to be symmetrical to each other about an axis parallel to machine direction 81. As best shown in FIG. 6, first side 87 and second side 88 may respectively comprise first portions 87a, 88a that are convex with respect to interior portion 89 of flow section 82. First side 87 and second side 88 may also comprise second portions 87b, 88b, respectively, that are concave along relative to interior 89 of flow section 82. In some embodiments, each of first side 87 and second side 88 may have a varying radius of curvature along the length of first portion 87a and second portion 88b in machine direction 81. First side 87 and second side 88 may be It is made that each side is 87, 88 contains the 90 bend segment. The kink segment 90 may serve as a transition between the first portions 87a, 88a and the second portions 87b, 88b of the first and second sides 87, 88, respectively. 5 and 6 (on which the segment 90 of the excess for identification is marked with a point).

Viewed from top to bottom of interior 89 as shown in FIG. 6, interior 89 may have a MD side profile that includes a first side profile 77 and a second side profile 79. First side profile 77 may be a first side profile 87 and second side profile 79 may be a second side profile 88 with considering the interior 89 in a top-down view. Each of the first side profile 77 and the second side profile 79 may respectively comprise the first parts 87a, 88a, which are convex with respect to the inner part 89 of the flow section 82, and each of them may contain, respectively, the second parts 87b, 88b, which are concave with respect to inside 89 of the flow section 82. For example, these side profiles 77, 79 can be obtained regardless of whether the first side 87, the second side 88, the top surface 86 and the bottom surface 84 are present, or whether these sides 87, 88 and the top and bottom surfaces 86, 84 are not clearly demarcated, for example, if the interior 89 of the flow section 82 is formed by smooth surfaces and curvature, such as in an oval-shaped cross section.

The pressure box 80 can be made in such a way that each flow section 82 contains the intake hole 91. Each running section 82 can also contain a final hole 92. As shown in the form of a pressure box of 80 in FIG. 7, in some embodiments, the intake hole 91 may have a round cross -sectional form so that it can be connected to the channel of the round cross section, which transports the as a result, the suspension of 76 into the pressure box 80. Of course, it is assumed that inlet foramen 91 may have others cross section shapes. Additionally, it is also assumed that the inventory 91 of the pressure box 80 can form part of the release 78 of the second mixing unit 58 or the first mixing unit 56.

As shown in FIG. 6 for the left flow section 82, the width W ₁ of the interior 89 at the inlet 91 may be less than the width W ₂ of the interior 89 at the outlet 92. For the purposes of this document, the widths W ₁ and W ₂ are defined as measured between the first side 87 and the second side 88 in a direction parallel to the transverse direction 83 of the headbox 80 and in the plane formed by the machine direction 81 and the transverse direction 83.

As shown in FIG. 9, the interior 89 of the flow section 82 may have a height H ₁ at the inlet 91 that is greater than the height H ₂ of the interior 89 at the outlet 92. For the purposes of this document, the heights H ₁ and H ₂ are defined as measured between bottom surface 84 and top surface 86 in a direction parallel to the Z-direction 85, which is perpendicular to the plane formed by the machine direction 81 and the transverse direction 83. As also shown in FIG. 9, the interior 89 of the flow section 82 is configured such that the top surface 86 and bottom surface 84 provide for a change in the flow path between inlet 91 and outlet 92 in the z-direction 85.

In some embodiments, each of the first side 87 and the second side 88 of the flow section 82 may respectively contain parts 87c, 88c for expanding the flow. The flow expansion portions 87c, 88c may be closer to the inlet 91 than the first portions 87a, 88a of the first side 87 and the second side 88, respectively. The first parts 87a, 88a of the first side 87 and the second side 88, respectively, may be closer to the inlet 91 than the second parts 87b, 88b of the first side 87 and the second side 88, respectively.

When the resulting slurry 76 enters the headbox 80 through each inlet 91, the resulting slurry 76 first enters the interior 89 of the flow section 82 and the flow expansion portions 87c, 88c of the first side 87 and the second side 88, respectively. At this point, the flow path of the resulting slurry 76 increases in width in the transverse direction 83. After passing through the first side 87 and second side 88 to expand the flow 87c, 88c, respectively, the resulting slurry 76 increases in width more substantially as it is conveyed. the first parts 87a, 88a of the first and second sides 87, 88, respectively. The resulting slurry stream 76 then passes a kink segment 90 on each of the first and second sides 87, 88 and is eventually conveyed by the second portions 87b, 88b of the first and second sides 87, 88, respectively. Importantly, this controlled increase in flow width of the resulting slurry 76 and the combination of first portions 87a, 88a and second portions 87b, 88b of first and second sides 87, 88, respectively, provides improved flow throughout the interior 89 of flow section 82, which reduces eddies and other turbulent properties of the resulting slurry 76 as it passes through the headbox 80. Thus, the side profiles 77, 79 of the interior 89 of the flow section 89 (e.g., the first and second sides 87, 88) form a configuration that is advantageous for minimizing the time that the resulting slurry 76 resides in the headbox 80 while expanding to the width and height required to form the substrate 12. dry elements, such as SAM, for which it is desirable to reduce minimizing exposure time to liquids forming part of the resulting slurry 76.

Additionally, the configuration of the varying height and width of the interior 89 of the flow section 82 is believed to help provide improved flow density of the resulting slurry 76 through the headbox 80. As described above, the width W ₁ of the interior 89 at the inlet 91 is less than the width W ₂ of the interior 89 at the outlet 92 to allow the resulting slurry 76 to expand in the transverse direction 83 to the desired width of the substrate 12. As the width of the interior 89 increases as the resulting slurry 76 passes through the headbox 80, the height of the interior 89 decreases. As noted above, the height H ₁ of interior 89 at inlet 91 is greater than the height H ₂ of interior 89 of flow section 82 at outlet 92. By reducing the height of interior 89 as the width of interior 89 increases, the resulting more laminar flow is maintained. slurry 76 through the interior 89 of headbox 80. It also helps to reduce the residence time of the resulting slurry 76 in the headbox 80, which, as noted above, can be advantageous when the resulting slurry 76 contains components from the feed amount of component 44 to dry cells, such as SAM, for which it is desirable to minimize exposure time to liquids.

It should also be noted that the arcuate shape in the z-direction 85 between the top surface 86 and the bottom surface 84 between inlet 91 and outlet 92 is believed to provide improved flow control of the resulting slurry 76 and may help reduce eddies or other turbulence. flow of the resulting slurry 76 through the headbox 80, which further adds to the component 44 feed component benefits noted above. , which is formed, in particular, when used in the production process using foaming.

With reference to FIG. 1 and 4, the device 10, 110, 210 may also include a forming surface 94 on which the resulting slurry 76 is deposited after exiting the outlet 92 of the headbox 80. The forming surface 94 may be a perforated sheet, such as a woven tape or screen, or any other suitable surface for receiving the resulting slurry 76. In some embodiments, the resulting slurry 76 may be deposited on another pre-formed substrate that may be on top of the forming surface 94. The apparatus 10, 110 may also include a dewatering system 96 that may be configured to remove liquid from the resulting slurry 76 on the forming surface 94. In some embodiments, the dewatering system 96 may be configured to apply vacuum to the resulting slurry 76 to draw liquid from the resulting slurry 76, and that In this way, it can convert the resulting slurry 76 containing a plurality of fibers 20 and component 44 into a substrate 12. In some embodiments, the device 10, 110, 210 may also include a drying system 98. Drying system 98 may be configured to further dry the resulting slurry 76 and/or substrate 12. In some embodiments, apparatus 10, 110, 210 may include a winding system 99 that may be configured to wind substrate 12 into a roll. In other embodiments, the device 10, 110, 210 may hang the substrate 12 or assemble the substrate 12 into any other suitable configuration.

foaming fluid

The foaming processes described herein may include a foaming fluid. In some embodiments, the foaming fluid may be from about 85% to about 99.99% foam (by weight). In some embodiments, the foaming fluid used to produce the foam may be at least about 85% foam (by weight). In certain embodiments, the foaming fluid may comprise from about 90% to about 99.9% foam (by weight). In certain other embodiments, the foaming fluid may comprise from about 93% to 99.5% foam, or even from about 95% to about 99.0% foam (by weight). In preferred embodiments, the foaming fluid may be water, however, it is contemplated that other processes may use other foaming fluids.

Foaming surfactant

The foaming processes described herein may use one or more surfactants. The fibers and surfactant, together with the foaming liquid and any additional components, can form a stable dispersion capable of substantially maintaining a high degree of porosity for a period longer than the duration of the drying process. In this regard, the surfactant is chosen to provide a foam having a foam half-life of at least 2 minutes, more preferably at least 5 minutes, and most preferably at least 10 minutes. Foam half-life can be dependent on surfactant types, surfactant concentrations, foam formulations/solid levels, and mixing intensity/air content of the foam. The foaming surfactant used in the foam may be selected from one or more substances known in the art that are capable of providing the desired degree of foam stability. In this regard, the foaming surfactant can be selected from anionic, cationic, nonionic and amphoteric surfactants, provided that they alone or in combination with other components provide the necessary foam stability or foam half-life. It should be appreciated that more than one surfactant may be used, including surfactants of different types, provided they are compatible, and more than one surfactant of the same type. For example, in some embodiments, due to their compatibility, a combination of a cationic surfactant and a nonionic surfactant, or a combination of an anionic surfactant and a nonionic surfactant, may be used. However, in some embodiments, the combination of a cationic surfactant and an anionic surfactant may not be suitable for combination due to incompatibility between these surfactants.

Anionic surfactants considered suitable for use in the present invention include, without limitation, anionic sulfate surfactants, alkyl ether sulfonates, alkylaryl sulfonates, or mixtures or combinations thereof. Examples of alkylarylsulfonates include, without limitation, alkylbenzenesulfonic acids and their salts, dialkylbenzenesulfonic acids and their salts, dialkylbenzenesulfonic acids and their salts, alkylphenolsulfonic acids/condensed alkylphenolsulfonic acids and their salts, or mixtures or combinations thereof. Examples of additional anionic surfactants that are considered suitable for use in the present invention include alkali metal sulfonates, sulfonated fatty acid esters of glycerol, such as sulfated coconut oil monoglycerides, salts of sulfated esters of monovalent alcohols, such as sodium oleyl isethionate, fatty acid metal soaps, amino sulfonic acid amides such as sodium oleylmethyl tauride, sulfated products of fatty acid nitriles such as palmitonitrile sulfonate, alkali metal alkyl sulfates such as sodium lauryl sulfate, ammonium lauryl sulfate or trimethylamine lauryl sulfate, ester sulfates containing alkyl groups of 8 or more carbon atoms such as sodium lauryl ether sulfate, ammonium lauryl ether sulfate, sodium alkylaryl ether sulfates and ammonium alkylaryl ether sulfates, polyoxyethylene alkyl ether sulfuric acid esters, sodium salts, potassium salts, and amine salts s alkylnaphthylsulfonic acid. Certain phosphate surfactants, including phosphate esters such as sodium lauryl phosphate esters or available from Dow Chemical Company under the trade name TRITON, are also considered suitable for use in this regard. A particularly popular anionic surfactant is sodium dodecyl sulfate (SDS).

Cationic surfactants are also considered suitable for use in conjunction with the present invention for the manufacture of some embodiments of the substrates. In some embodiments, such as embodiments containing a superabsorbent material, cationic surfactants may be less preferred for use due to the potential interaction between the cationic surfactant(s) and the superabsorbent material that may be anionic. Foaming cationic surfactants include, without limitation, monocarbylammonium salts, dicarbylammonium salts, tricarbylammonium salts, monocarbylphosphonium salts, dicarbylphosphonium salts, tricarbylphosphonium salts, carbylcarboxysalts, quaternary ammonium salts, imidazolines, ethoxylated amines, quaternary phospholipids, and the like. Examples of additional cationic surfactants include a variety of amines and fatty acid amides and their derivatives, as well as salts of amines and fatty acid amides. Examples of aliphatic fatty acid amines include dodecylamine acetate, octadecylamine acetate and tallow fatty acid amine acetates, aromatic amine homologues containing fatty acids such as dodecylanaline, fatty amides derived from aliphatic diamines such as undecylimidazoline, fatty amides derived from aliphatic diamines such as undecylimidazoline, fatty amides derived from disubstituted amines such as oleylaminodiethylamine, ethylenediamine derivatives, quaternary ammonium compounds and their salts, examples of which are trimethylammonium tallow chloride, dioctadecyldimethylammonium chloride, didodecyldimethylammonium chloride, dihexadecylammonium chloride, alkyltrimethylammonium hydroxides, dioctadecyldimethylammonium thallium hydroxide, trimethylammonium hydroxide, methylpolylxyethylenecoammonium chloride and dipalmitylhydroxyethylammonium methosulfate, amide derivatives of amino alcohols such as beta-hydroxyethylstearylamide, and long chain amine salts fatty acids. Additional examples of cationic surfactants considered suitable for use in the present invention include benzalkonium chloride, benzethonium chloride, cetrimonium bromide, distearyldimethylammonium chloride, tetramethylammonium hydroxide, and the like.

Nonionic surfactants considered suitable for use in the present invention include, without limitation, ethylene oxide condensates with a long chain fatty alcohol or fatty acid, ethylene oxide condensates with an amine or amide, ethylene and propylene oxide condensates, fatty acid alkylolamide, and fatty amine oxides. . Various additional examples of nonionic surfactants include stearyl alcohol, sorbitan monostearate, octyl glucoside, octaethylene glycol monododecyl ether, lauryl glucoside, cetyl alcohol, MEA cocamide, monolaurin, polyoxyalkylene alkyl ethers such as long chain polyethylene alkyl ether (12-14C), polyoxyalkylene sorbitan esters, polyoxyalkylene alkoxylate ethers, polyoxyalkylene alkylphenol ethers, ethylene glycol-propylene glycol copolymers, polyvinyl alcohol, alkyl polysaccharides, polyethylene glycol sorbitan monooleate, octylphenol ethylene oxide, etc.

The foaming surfactant may be used in varying amounts as needed to achieve desired foam stability and foam air content. In certain embodiments, the foaming surfactant may comprise from about 0.005% to about 5% foam (by weight). In certain embodiments, the foaming surfactant may comprise from about 0.05% to about 3% foam, or even from about 0.05% to about 2% foam (by weight).

fibers

As noted above, the apparatus 10, 110 and methods described herein may include providing fibers from a fiber feed 18. In some embodiments, the fibers may be suspended in a fluid feed 16, 28, which may be foam. The fibrous foam slurry may provide one or more fiber deliveries. In some embodiments, the fibers used herein may include natural fibers and/or synthetic fibers. In some embodiments, the fiber feed amount 18 may contain only natural fibers or only synthetic fibers. In other embodiments, the fiber feed quantity 18 may comprise a mixture of natural fibers and synthetic fibers. Some of the fibers used herein may be absorbent while other fibers used herein may be non-absorbent. Non-absorbent fibers can provide features for substrates that are formed using the methods and devices described herein, such as improved absorption or distribution of fluids.

A wide variety of cellulosic fibers are considered suitable for use herein. In some embodiments, the fibers used may be conventional papermaking fibers, such as wood pulp fibers formed by a variety of pulping processes, such as kraft pulp, sulfite pulp, bleached chemothermomechanical pulp (BCTMP), chemothermomechanical pulp (CTMP) , pressure applied thermomechanical pulp (PTMP), thermomechanical pulp (TMP), thermomechanical chemical pulp (TMCP), etc. By way of example only, wood pulp fibers and methods for making wood pulp fibers are disclosed in US 4,793,898 to Laamanen et al. .; US 4,594,130 issued to Chang et al.; US 3585104, issued in the name of Kleinhart; US 5595628, issued in the name of Gordon et al.; No. 5,522,967 to Shet, etc. In addition, the fibers can be any of long to medium length wood pulp, short to medium length wood pulp, or mixtures thereof. Examples of suitable long and medium length wood pulps include softwood fibers such as, but not limited to northern softwood, southern softwood, mahogany, red cedar, hemlock, pine (e.g. southern pines), spruce (for example, black spruce), etc. Examples of suitable short to medium length cellulose fibers include hardwood fibers such as, but not limited to, eucalyptus, maple, birch, aspen, and the like.

Moreover, recycled fibers such as pulp from sources such as newsprint, recycled cardboard and office waste can be used if desired. In a particularly preferred embodiment, refined fibers are used in the paper based web in such a way that the total amount of wet fibers and/or long and medium fiber lengths such as softwood fibers can be reduced.

Regardless of the origin of the wood pulp fiber, wood pulp fibers preferably have an average fiber length of greater than about 0.2 mm and less than about 3 mm, such as from about 0.35 mm to about 2.5 mm, or from about 0. 5 mm to about 2 mm, or even from about 0.7 mm to about 1.5 mm.

Additionally, other cellulosic fibers that can be used in the present invention include non-wood fibers. In the context of this document, the term "non-wood fiber" usually refers to cellulosic fibers obtained from non-wood stems of monocots or dicots. Non-limiting examples of dicots that can be used to produce non-wood fiber include kenaf, jute, flax, ramie, and hemp. Non-limiting examples of monocots that can be used to produce non-wood fiber include cereal straw (wheat, rye, barley, oats, etc.), stalks (corn, cotton, sorghum, Hesperaloe funifera, etc.), vines (bamboo, sisal, bagasse, etc.) and herbs (miscanthus, esparto, lemon tree, sabai, millet, etc.). In still other specific cases, the non-wood fiber can be obtained from aquatic plants such as water hyacinth, microalgae such as spirulina, marine macroalgae such as red or brown algae.

Moreover, other cellulosic fibers for making substrates according to this document may include synthetic types of cellulose fibers formed by spinning, including rayon fiber in all its varieties, and other fibers derived from viscose or chemically modified cellulose, for example, available under trade names LYOCELL and TENCEL.

In some embodiments, non-wood and synthetic cellulosic fibers may have a fiber length greater than about 0.2 mm, including, for example, an average fiber size from about 0.5 mm to about 50 mm, or from about 0.75 to about 30 mm, or even from about 1 mm to about 25 mm. In general terms, when using relatively longer average fiber lengths, it can often be advantageous to vary the amount and type of foaming surfactant. For example, in some embodiments, if relatively longer average fiber lengths are used, it may be preferable to use relatively large amounts of foaming surfactant to help produce foam with the desired foam half-life.

Additional fibers that can be used in the present invention include foam fluid resistant fibers, namely fibers that are non-absorbent, the flexural stiffness of which is substantially unaffected by the presence of a foam fluid. As noted above, typically the foaming fluid comprises water. As a non-limiting example, water resistant fibers include fibers such as polymer fibers containing polyolefin, polyester (PET), polyamide, lactic acid polymer, or other fiber forming polymers. Polyolefin fibers such as polyethylene (PE) and polypropylene (PP) are particularly well suited for use in the present invention. In some embodiments, the non-absorbent fibers may be recycled fibers, biodegradable fibers, and/or marine-degradable fibers. In addition, highly crosslinked cellulosic fibers having little absorbent properties can also be used herein. Because of this, due to very low levels of water absorbency, water resistant fibers do not undergo significant change in flexural stiffness when in contact with an aqueous fluid and are therefore able to maintain an open composite structure when wetted. The fiber diameter can contribute to the increase in bending stiffness. For example, PET fiber has higher flexural rigidity than polyolefin fiber in both dry and wet states. The higher the denier of the fiber, the higher the bending stiffness that the fiber exhibits. The water resistant fibers preferably have a water holding capacity (WRV) of less than about 1, and even more preferably from about 0 to about 0.5. In certain aspects, it is preferred that the fibers, or at least a portion thereof, comprise non-absorbent fibers.

Synthetic and/or water resistant fibers may have a fiber length greater than about 0.2 mm, including, for example, an average fiber size of from about 0.5 mm to about 50 mm, or from about 0.75 to about 30 mm, or even from about 1 mm to about 25 mm.

In some embodiments, the synthetic and/or water resistant fibers may be pleated to enhance the bulking capacity of the foamed fibrous substrate. For example, corrugated PET staple fiber can be configured to be thicker (or can result in low sheet density) than straight PET staple fiber of the same fiber diameter and length.

In some embodiments, the total fiber content may be from about 0.01% to about 10% foam (by weight) and in some embodiments from about 0.1% to about 5% foam (by weight).

binder

In some embodiments, the amount of fluid supplied 16, 28 may contain binders. Binder materials that can be used in the present invention may include, without limitation, thermoplastic binder fibers such as PET/PE bicomponent binder fiber, and water-compatible adhesives such as, for example, latexes. In some embodiments, the binder materials used herein may be in powder form, such as, for example, thermoplastic PE powder. It is important to note that the binder may include an agent that is insoluble in water on the dried substrate. In certain embodiments, the latexes used in the present invention may be cationic or anionic to facilitate application and adhesion to cellulosic fibers that may be used herein. For example, latexes considered suitable for use include, without limitation, anionic styrene-butadiene copolymers, polyvinyl acetate homopolymers, vinyl acetate-ethylene copolymers, vinyl acetate-acrylic acid copolymers, ethylene-vinyl chloride copolymers, ethylene-vinyl chloride-vinyl acetate terpolymers, acrylate copolymers, and polyvinyl chloride, acrylic polymers, nitrile polymers, as well as other suitable anionic latex polymers known in the art. Examples of such latexes are described in US 4,785,030 issued to Hager, US 6,462,159 issued to Hamada, US 6,752,905 issued to Chuang et al., etc. Examples of suitable thermoplastic binder fibers include, without limitation, monocomponent and multicomponent fibers containing at least one thermoplastic polymer with a relatively low melting point, such as polyethylene. In certain embodiments, polyethylene/polypropylene sheath/core staple fibers may be used. The binder fibers may have lengths corresponding to the fibers described herein above with respect to synthetic cellulose fibers.

Binders in liquid form, such as latex emulsions, may comprise from about 0% to about 10% foam (by weight). In certain embodiments, the non-fibrous binder may comprise about 0.1% to about 10% foam (by weight) or even about 0.2% to about 5%, or even about 0.5% to about 2% foam ( by weight). When used, binder fibers can be added in proportion to the other components to achieve the desired ratios of fibers and structure, while maintaining the total solids content of the foam below the above amounts. By way of example, in some embodiments, the binder fibers may comprise from about 0% to about 50% of the total weight of the fibers, and more preferably in some embodiments from about 5% to about 40% of the total weight of the fibers.

Foam stabilizers

In some embodiments, if the fluid supply 16, 28 is in the form of a foam, the foam may optionally also contain one or more foam stabilizers known in the art that are compatible with the foam components and do not further interfere with the formation of hydrogen bonds between the cellulose fibers. Foam stabilizers considered suitable for use in the present invention are, without limitation, one or more zwitterionic compounds, amine oxides, alkylated polyalkylene oxides, or a mixture or combination thereof. Specific examples of foam stabilizers include, without limitation, cocoamine oxide, isononyldimethylamine oxide, n-dodecyldimethylamine oxide, and the like.

In some embodiments, the implementation of the foam stabilizer when used can be from about 0.01% to about 2% foam (by weight). In certain embodiments, the foam stabilizer can be from about 0.05% to about 1% foam, or even from about 0.1% to about 0.5% foam (by weight).

Components

In the methods described herein, the foaming process may include adding one or more components as additional additives to be included in the composition of the substrate 12. For example, one additional additive that may be added during the formation of the substrates 12 described herein, may be superabsorbent materials (SAM). Typically, SAM is provided in particulate form, and in certain aspects may include polymers of unsaturated carboxylic acids or derivatives thereof. These polymers are often rendered insoluble but swellable in water by crosslinking the polymer with a di- or polyfunctional internal crosslinker. These internally cross-linked polymers are at least partially neutralized and typically contain pendant anionic carboxyl groups on the polymer backbone which give the polymer the ability to absorb aqueous fluids such as body fluids. Typically, SAM particles are post-processed to crosslink the pendant anionic carboxyl groups on the surface of the particle. SAMs are made using known polymerization techniques, preferably aqueous solution polymerization using gel polymerization. The products of this polymerization process are aqueous polymer gels, i.e. SAM hydrogels, which are reduced in size to small particles by mechanical forces, then dried using drying procedures and apparatus known in the art. The drying process is followed by pulverization of the resulting SAM particles to the desired particle size. Examples of superabsorbent materials include, without limitation, the superabsorbent materials described in US 7396584 Azad et al. US 7935860 Dodge et al. US 2005/5245393 Azad et al. US 2014/09606 Bergam et al. et al. etc. In addition, to facilitate processing, SAM can be processed to make the material temporarily non-absorbent during foam formation and high expansion foam formation. For example, in one aspect, the SAM may be treated with a water-soluble protective coating having a dissolution rate such that the SAM is not substantially exposed to an aqueous carrier until a highly expandable foam is formed and drying operations are initiated. Alternatively, to prevent or limit premature expansion during processing, SAM may be introduced into the process at low temperatures.

In some embodiments involving SAM, the SAM may comprise from about 0% to about 40% foam (by weight). In certain embodiments, the SAM may comprise from about 1% to about 30% foam (by weight) or even from about 10% to about 30% foam (by weight).

Other additional means may include one or more wet strength additives that may be added to the foam or fluid feed 16, 28 to help improve the relative strength of the ultra-low density cellulosic composite material. Such strength additives suitable for use with papermaking and tissue paper fibers are known in the art. Temporary wet strength additives may be cationic, nonionic, or anionic. Examples of these temporary wet strength additives include PAREZ™ 631 NC and temporary wet strength resins PAREZ(R) 725, which are cationic glyoxylated polyacrylamides available from Cytec Industries, located in West Paterson, New Jersey. These and similar resins are described in US Pat. No. 3,556,932 to Coscia et al. and US Pat. No. 3,556,933 to Williams et al. Additional examples of temporary wet strength additives include dialdehyde starches and other aldehyde-containing polymers such as those described in US 6224714 to Schroeder et al., US 6274667 to Shannon et al., US 6287418 to Schroeder et al., Et al. 6365667, issued in the name of Shannon et al. etc.

Also in the present invention, permanent wet strength agents containing cationic oligomeric or polymeric resins can be used. Resins of the polyamide-polyamine-epichlorohydrin type, such as KYMENE 557H sold by Solenis, are the most widely used permanent wet strength agents and are suitable for use in the present invention. Such materials have been described in the following documents: US 3700623 to Keim, US 3772076 to Keim, US 3855158 to Petrovich et al., US 3899388 to Petrovich et al., US 4129528, Petrovich et al., US 4,147,586 Petrovich et al., US 4,222,921 van Eenam, etc. Other cationic resins include polyethyleneimine resins and aminoplast resins made by reacting formaldehyde with melamine or urea . Permanent and temporary wet strength resins can be used together in the manufacture of the composite cellulosic products of the present invention. Additionally, dry strength resins may also optionally be used with respect to the composite cellulosic webs of the present invention. Such materials may include, without limitation, modified starches and other polysaccharides such as cationic, amphoteric, and anionic starches, and guar and locust bean gums, modified polyacrylamides, carboxymethyl cellulose, sugars, polyvinyl alcohol, chitosan, and the like.

When used, such wet and dry strength additives can range from about 0.01% to about 5% by dry weight of the cellulosic fibers. In certain embodiments, strength additives can be from about 0.05% to about 2% by dry weight of the cellulose fibers, or even from about 0.1% to about 1% by dry weight of the cellulose fibers.

Also, other additional components can be added to the foam, as long as they do not significantly interfere with the formation of a highly expandable stable foam, the formation of hydrogen bonds between cellulose fibers, or other desired properties of the web. By way of example, if desired, additional additives may include one or more of pigments, opacifiers, antimicrobial agents, pH modifiers, skin benefit agents, odor absorbers, fragrances, thermally expandable microspheres, foam particles (such as spray particles). foam), etc. to impart or enhance one or more physical or aesthetic qualities. In certain embodiments, the composite cellulose webs may contain agents beneficial to the skin, such as, for example, antioxidants, astringents, conditioners, emollients, deodorants, topical analgesics, film formers, humectants, hydrotropes, pH modifiers, surface modifiers. , skin protection products, etc.

When used, the various components preferably comprise less than about 2% foam (by weight) and even more preferably less than about 1% foam (by weight) and even less than about 0.5% foam (by weight).

In some embodiments, the implementation of the solids content, including fibers or contained particles, preferably is not more than about 40% of the foam. In certain embodiments, cellulosic fibers may comprise from about 0.1% to about 5% foam, or from about 0.2% to about 4% foam, or even from about 0.5% to about 2% foam.

The methods and devices 10, 110, 210 described herein may be advantageous for forming one or more components of personal care products. For example, in one embodiment, the substrates 12 described herein may be an absorbent core for an absorbent article such as, but not limited to, a diaper, adult incontinence garment, or feminine hygiene product. The substrates 12 described herein may also be advantageous for use in other products such as, but not limited to, handkerchiefs, wipes, and towels.

IMPLEMENTATION OPTIONS

Embodiment 1 A method for forming a support containing a component, the method comprising: providing a first supply amount of a fluid; providing a second fluid delivery, wherein at least one of the first fluid delivery and the second fluid delivery comprises a plurality of fibers; providing a component loading system; providing a feed amount of a component to a component loading system, wherein the component includes at least one particle and fiber element; transporting the first supplied amount of fluid; the introduction of the component in the second supplied amount of fluid in the ejector; transporting a second supplied amount of fluid containing the component; mixing the first fluid feed with the second fluid feed containing the component to provide the resulting slurry; conveying the resulting slurry via the headbox to the forming surface; and dehydrating the resulting slurry to provide a support containing the component.

Embodiment 2 The method according to Embodiment 1, wherein the first fluid supplied is a first foam, the first foam containing a plurality of fibers, water, and a surfactant.

Embodiment 3 The method according to Embodiment 1 or 2, wherein the second fluid supply is a second foam, the second foam containing water and a surfactant.

Embodiment 4 The method according to any of the previous embodiments, wherein the ejector comprises: a first inlet in fluid communication with the supplied amount of the component; a second inlet in fluid communication with the second supplied amount of fluid; and release.

Embodiment 5 The method according to Embodiment 4, wherein the component loading system comprises an outlet, wherein the outlet comprises an axis of the outlet, and wherein the first inlet of the ejector comprises an axis of the first inlet, the axis of the first inlet is coaxial with the axis of the outlet. .

Embodiment 6 The method according to Embodiment 4 or 5, wherein the component loading system comprises an outlet, wherein the outlet comprises an outlet axis, and the outlet comprises an outlet axis, wherein the outlet axis is coaxial with the outlet axis.

Embodiment 7 The method according to any one of Embodiments 4 to 6, wherein the second fluid supply is conveyed under the pressure of the second fluid before introducing the second component into the second fluid supply, and wherein the second fluid supply containing the component exits from the outlet of the outlet pressure ejector, the method further comprising: controlling a pressure differential between the outlet pressure and the supply pressure of the second fluid.

Embodiment 8 The method of any of the previous embodiments, wherein the component is particulate.

Embodiment 9 The method according to Embodiment 8, wherein the particles are a superabsorbent material.

Embodiment 10 A method for forming a support containing a component, the method comprising: providing a first supply amount of fluid; providing a second fluid delivery, wherein at least one of the first fluid delivery and the second fluid delivery comprises a plurality of fibers; providing a component loading system; providing a feed amount of the component to the component loading system; transporting the first supplied amount of fluid; transporting the second supplied amount of fluid under the pressure of supplying the second fluid; introducing the component into the second supplied amount of fluid in the mixing unit; transporting a second fluid supply containing the component through the outlet of the mixing unit, wherein the second fluid supply containing the component is transported under pressure at the outlet of the mixing unit, controlling the pressure difference between the outlet pressure of the mixing unit and the supply pressure of the second fluid; mixing the first fluid feed with the second fluid feed containing the component to provide the resulting slurry; conveying the resulting slurry via the headbox to the forming surface; and dehydrating the resulting slurry to provide a support containing the component.

Embodiment 11 The method according to Embodiment 10, wherein controlling the differential pressure between the outlet pressure of the mixing unit and the supply pressure of the second fluid comprises maintaining the differential pressure between the outlet pressure of the mixing unit and the supply pressure of the second fluid such that it is less than or equal to 25 pounds per square inch.

Embodiment 12 The method according to Embodiment 10 or 11, wherein the mixing unit comprises an ejector.

Embodiment 13 The method according to Embodiment 12, wherein the ejector comprises: a first inlet in fluid communication with the supplied amount of the component; a second inlet in fluid communication with the second supplied amount of fluid; and release.

Embodiment 14 The method according to Embodiment 13, wherein the component loading system comprises an outlet, wherein the outlet comprises an axis of the outlet, and wherein the first inlet of the ejector comprises an axis of the first inlet, the axis of the first inlet is coaxial with the axis of the outlet. .

Embodiment 15 The method according to any one of Embodiments 10-14, wherein the first fluid quantity supplied is a first foam, wherein the first foam comprises a plurality of fibers, water, and a surfactant, and wherein the second fluid quantity supplied is a second foam, and the second foam contains water and a surfactant.

Embodiment 16 The method according to any one of Embodiments 10-15, wherein the component is particulate.

Embodiment 17 The method according to Embodiment 16, wherein the particles are a superabsorbent material.

Embodiment 18 A method for forming a substrate containing a component, the method comprising: providing a first supply amount of fluid; providing a component loading system; providing a feed amount of a component to a component loading system, wherein the component comprises at least one particle and fiber element; transporting the first supplied amount of fluid; introducing a component into the first fluid supply in the ejector to provide the resulting slurry; conveying the resulting slurry via the headbox to the forming surface; and dehydrating the resulting slurry to provide a support containing the component.

Embodiment 19 The method according to Embodiment 18, wherein the first supplied amount of fluid comprises a plurality of fibers.

Embodiment 20 The method of Embodiment 19, wherein the first fluid supplied is a first foam, the first foam contains a plurality of fibers, water, and a surfactant, and the component is particles.

Embodiment 21 The method according to any one of Embodiments 18-20, wherein the first fluid supply is supplied to the ejector at supply pressure of the first supply, the resulting slurry exits the ejector at outlet pressure, the method further comprising: controlling the pressure difference between the outlet pressure and the supply pressure of the first quantity to be supplied.

Embodiment 22 The method according to any one of Embodiments 18-21, wherein the ejector comprises: a first inlet in fluid communication with the supplied amount of the component; a second inlet in fluid communication with the first supplied amount of fluid; and release.

Embodiment 23 The method according to Embodiment 22, wherein the component loading system comprises an outlet, wherein the outlet comprises an axis of the outlet, and wherein the first inlet of the ejector comprises an axis of the first inlet, the axis of the first inlet is coaxial with the axis of the outlet. .

Embodiment 24 The method according to Embodiment 22 or 23, wherein the component loading system comprises an outlet, wherein the outlet comprises an outlet axis, and wherein the outlet comprises an outlet axis, wherein the outlet axis is coaxial with the outlet axis.

All documents mentioned in the detailed description, in appropriate part, are incorporated herein by reference, and the mention of any document should not be construed as an admission that it is prior art with respect to the present invention. If any meaning or definition of a term in this written document conflicts with any meaning or definition of a term in a document incorporated by reference, then the meaning or definition in which the term is used in this written document shall prevail.

While specific embodiments have been illustrated and described, it should be apparent to those skilled in the art that various other changes and modifications may be made without departing from the spirit and scope of the present invention. Therefore, it is intended that the appended claims should cover all such changes and modifications that fall within the scope of the present invention.

Claims (64)

1. A method for forming a substrate containing a component, the method comprising: providing a first supplied amount of fluid; providing a second fluid delivery, the second fluid delivery comprising water, and wherein at least one of the first fluid delivery and the second fluid delivery comprises a plurality of fibers; providing a component loading system; providing a feed amount of a component to a component loading system, wherein the component comprises at least one particle and fiber element; transporting the first supplied amount of fluid; introducing the component into the second supply of fluid in the ejector; transporting a second supplied amount of fluid containing the component; mixing the first fluid feed with the second fluid feed containing the component to provide the resulting slurry; conveying the resulting slurry via the headbox to the forming surface; And dehydrating the resulting slurry to provide a support containing the component. 2. The method of claim. 1, characterized in that the first supplied amount of fluid is a first foam, and the first foam contains a plurality of fibers, water and surfactant. 3. The method of claim. 1, characterized in that the second supplied amount of fluid is a second foam, and the second foam contains water and a surfactant. 4. The method according to p. 1, characterized in that the ejector contains: a first inlet in fluid communication with the supplied amount of the component; a second inlet in fluid communication with the second supplied amount of fluid; And release. 5. The method according to claim. 4, characterized in that the component loading system contains an outlet channel, and the outlet channel contains the axis of the outlet channel, and the first inlet of the ejector contains the axis of the first inlet, and the axis of the first inlet is coaxial with the axis of the outlet channel. 6. Method according to claim 4, characterized in that the component loading system comprises an outlet channel, wherein the outlet channel comprises an outlet channel axis, and the outlet comprises an outlet axis, wherein the outlet axis is coaxial with the outlet channel axis. 7. The method according to claim 4, characterized in that the second fluid supply is conveyed under the pressure of the second fluid before the second component is introduced into the second fluid supply, and the second fluid supply containing the component exits the outlet of the ejector under outlet pressure, the method further comprising: controlling the pressure difference between the outlet pressure and the supply pressure of the second fluid. 8. The method according to claim 1, characterized in that the component is particles. 9. The method according to claim 8, characterized in that the particles are a superabsorbent material. 10. A method for forming a substrate containing a component, the method comprising: providing a first supplied amount of fluid; providing a second fluid delivery, wherein at least one of the first fluid delivery and the second fluid delivery comprises a plurality of fibers; providing a component loading system; providing a feed amount of the component to the component loading system; transporting the first supplied amount of fluid; transporting the second supplied amount of fluid under the pressure of supplying the second fluid; introducing the component into the second supplied amount of fluid in the mixing unit; transporting a second supplied amount of fluid containing the component through the outlet of the mixing unit, and the second supplied amount of fluid containing the component is transported under pressure at the outlet of the mixing unit; controlling the pressure difference between the outlet pressure of the mixing unit and the supply pressure of the second fluid; mixing the first fluid feed with the second fluid feed containing the component to provide the resulting slurry; conveying the resulting slurry via the headbox to the forming surface; And dehydrating the resulting slurry to provide a support containing the component. 11. The method according to claim 10, characterized in that the control of the pressure difference between the outlet pressure of the mixing unit and the supply pressure of the second fluid includes maintaining the pressure difference between the outlet pressure of the mixing unit and the supply pressure of the second fluid so that it is less than or equal to 25 psi. 12. The method according to p. 10, characterized in that the mixing unit contains an ejector. 13. The method according to p. 12, characterized in that the ejector contains: a first inlet in fluid communication with the supplied amount of the component; a second inlet in fluid communication with the second supplied amount of fluid; And release. 14. The method according to claim. 13, characterized in that the component loading system contains an outlet channel, and the outlet channel contains the axis of the outlet channel, and the first inlet of the ejector contains the axis of the first inlet, and the axis of the first inlet is coaxial with the axis of the outlet channel. 15. The method according to p. 10, characterized in that the first supplied amount of fluid is a first foam, and the first foam contains a plurality of fibers, water and a surfactant, and while the second supplied amount of fluid is a second foam, and the second foam contains water and a surfactant. 16. The method according to p. 10, characterized in that the component is a particle. 17. The method according to claim 16, characterized in that the particles are a superabsorbent material. 18. A method for forming a substrate containing a component, the method comprising: providing a first fluid delivery, the first fluid delivery comprising water; providing a component loading system; providing a feed amount of a component to a component loading system, wherein the component comprises at least one particle and fiber element; transporting the first supplied amount of fluid; introducing a component into a first fluid supply in an ejector to provide the resulting slurry, wherein the ejector is configured such that the first fluid supply provides a driving pressure to the component supply to help draw the mixing and entrainment component supply into the first the supplied amount of fluid; conveying the resulting slurry via the headbox to the forming surface; And dehydrating the resulting slurry to provide a support containing the component. 19. The method according to claim 18, characterized in that the first supplied amount of fluid contains a plurality of fibers. 20. The method of claim. 19, wherein the first amount of fluid supplied is a first foam, and the first foam contains a plurality of fibers, water and a surfactant, and the component is particles. 21. The method according to claim 18, characterized in that the first supply amount of fluid is supplied to the ejector at the supply pressure of the first supply amount, while the resulting slurry exits the ejector under pressure at the outlet, and the method further includes: control of the differential pressure between the outlet pressure and the supply pressure of the first quantity to be supplied. 22. The method according to p. 18, characterized in that the ejector contains: a first inlet in fluid communication with the supplied amount of the component; a second inlet in fluid communication with the first supplied amount of fluid; And release. 23. The method according to claim. 22, characterized in that the component loading system contains an outlet channel, and the outlet channel contains the axis of the outlet channel, and the first inlet of the ejector contains the axis of the first inlet, and the axis of the first inlet is coaxial with the axis of the outlet channel. 24. The method of claim. 22, characterized in that the component loading system includes an exhaust channel, and the outlet channel contains an axis of the outlet channel, and the outlet contains an outlet axis, and the outlet axis is coaxial with the axis of the outlet channel.

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