Method of forming a web of air-laid dry fibers

Abstract

A method therefor for forming an air-laid web of dry fibers suitable for use in a wide variety of products ranging from bath and facial tissues to towels having basis weights on the order of 13 lbs./2880 ft..sup.2 to 50 lbs./2880 ft..sup.2 on a high-speed production basis, wherein the web is characterized by random array of individualized fibers substantially undamaged by mechanical action and having a controlled cross-directional profile, and by its freedom from nits, pills, rice and the like, thereby improving both the appearance and the tensile strength of the web. The full-width feeding of dry fibers to a 2-dimensional flow control and fiber screening system is described wherein substantially no cross-flow forces are created in the system, ensuring a uniform cross-directional basis weight profile. The fibers are subjected to only minimal mechanical disintegrating action at all stages of the process subsequent to hammermilling and, thus, shortening, curling and/or rolling of the fibers to aggregated fiber masses is minimized. The aggregated fiber masses which are present in the fiber stream fed to the system are centrifugally and tangentially separated from individualized fibers and soft fiber flocs and removed from the system while maintaining relatively low fiber separation and/or recycling on the order of less than 10%.