Kimberly-clark Worldwide, Inc.

Peter Wallace

Charles Wilson Colman

Jian Qin

Donald Eugene Waldroup

Cathleen Mae Uttecht

Joseph Kenneth Baker

Deborah Joy Calewarts

A method for producing a high-bulk, foam-formed substrate includes producing an aqueous-based foam including at least 1% by weight crimped synthetic fibers and at least 1% by weight binder fibers; forming a wet sheet from the aqueous-based foam; and drying the wet sheet to obtain the foam-formed substrate. A substrate includes an aqueous-based polymer foam including at least 1% by weight crimped synthetic fiber and at least 1% by weight binder fiber, wherein the substrate is free of superabsorbent material. A method for producing a high-bulk, foam-formed substrate includes producing an aqueous-based foam including at least 2% by weight crimped binder fibers; forming a wet sheet from the aqueous-based foam; and drying the wet sheet to obtain the foam-formed substrate, wherein the foam-formed substrate is free of superabsorbent material, and wherein the substrate has a dry density between 0.02 g/cc and 0.1 g/cc.

Foam-formed fibrous sheets with crimped staple fibers

A process for foam forming webs is described herein. A foamed suspension of fibers is fed into a mixing chamber and then directed through a narrow constriction where the velocity of the foamed suspension of fibers is increased. From the narrow constriction, the foamed suspension of fibers enters a forming chamber which causes the foamed suspension of fibers to rapidly decrease in velocity. In one embodiment, for example, the foamed suspension of fibers undergoes a hydraulic jump resulting in significant fiber reorientation. Through the process, fiber orientation can be controlled. For example, webs can be produced that have comparable fiber orientation in the machine direction in comparison to the cross-machine direction.

Process and system for reorienting fibers in a foam forming process

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Penzance, United Kingdom

Peter Wallace