1. A process for making a fibrous structure, the process comprising the steps of:
a) providing a fibrous material in the form of roughly graded material;
b) providing a plurality of apertured, cylindrical drums; each of the drums having an inlet and being rotatably mounted about an longitudinal axis, and wherein the inside of each drum comprises one ore more rotatable needle rolls, each needle roll having a longitudinal axis arranged in parallel with the longitudinal axis of the corresponding apertured, cylindrical drum; and each needle roll having a shaft and a plurality of needles extending radially outwardly from the shaft;
c) providing a foraminous carrier underneath the plurality of apertured, cylindrical drums, wherein the apertured, cylindrical drums are positioned consecutively one after the other such that the longitudinal axis of each drum is transverse to the moving direction of the foraminous carrier;
d) providing a low-pressure below the foraminous carrier;
e) supplying the roughly graded material into the apertured, cylindrical drums through the inlet of each drum, wherein the roughly graded material is transported in an air-stream;
f) rotating the roughly graded material inside the apertured, cylindrical drums, whereby the roughly graded material is agitated within the drums by the needle rolls, thereby separating the fibers, and transporting the fibers through the apertures of the drums; and
g) drawing the fibers onto the foraminous carrier whereby the fibers are deposited to form a fibrous structure on the foraminous carrier, the fibrous structure having a width of from about 4 cm to about 25 cm.
2. The process of claim 1 wherein the roughly graded material is introduced into the rotatable, apertured, cylindrical drums at a total fiber throughput of from about 70 kgh to about 420 kgh.
3. The process of claim 1 wherein the foraminous carrier moves at a speed of from about 750 mmin to about 450 mmin.
4. The process of claim 1 wherein the apertured, cylindrical drums have a diameter of from about 200 mm to about 500 mm.
5. The process of claim 4 wherein the apertured, cylindrical drums have a longitudinal dimension of from about 40 mm to about 250 mm.
6. The process of claim 1 wherein the fibrous structure is made in-line with the manufacture of absorbent articles and the fibrous structure is introduced directly into the absorbent articles on the same manufacturing line.
7. The process of claim 6 wherein the fibrous structure is not cut along the longitudinal direction of the fibrous structure prior to introducing it into the absorbent articles.
8. The process of claim 1 wherein the needle rolls are counter rotating with the rotation of the apertured, cylindrical drums.
9. The process of claim 7 wherein the fibrous structure has a basis weight of from about 20 gm2 to about 500 gm2.
10. The process of claim 4 wherein the apertured, cylindrical drums are arranged in an arc-like configuration to form an arc-shaped drum assembly.
11. The process of claim 1 wherein the foraminous carrier 1 is in the form of a rotating foraminous drum and wherein the low-pressure is provided inside the foraminous drum, such that the fibers are drawn on the part of the foraminous drum which is directly adjacent the apertured, cylindrical drums.
12. The process of claim 11, wherein the foraminous carrier drum has a diameter of from about 400 mm to about 800 mm.
13. The process of claim 1 wherein the process does not include a step of bonding the fibrous structure.
14. The process of claim 1 wherein the fibers are deposited on the foraminous carrier such that the fibrous structure is shaped along its longitudinal side edges, wherein the widest width of the fibrous structure is less than about 25 cm and smallest width of the fibrous structure is more than about 4 cm.
15. The process of claim 1 wherein the apertured, cylindrical drums do not have an outlet, such that the fibers can only leave the apertured, cylindrical drums through the apertures.
16. The process of claim 15 wherein the inlets of all apertured cylindrical drums are oriented on the same side of the drums.
17. The process of claim 1 wherein the apertured cylindrical drums are not interconnected with each other.
18. The process of claim 17, wherein at least two different kinds of fibers are introduced into the apertured, cylindrical drums such that a layered fibrous structure deposited on the foraminous carrier.
The claims below are in addition to those above.
All refrences to claim(s) which appear below refer to the numbering after this setence.
1. A method of applying a heat insulation layer to a surface, comprising
providing a mixture containing:
a hydraulic bonding agent comprising 80-90 wt. % of total solid materials of the mixture, the hydraulic bonding agent containing alpha-hemihydrate, beta-gypsum, or a mixture of alpha-hemihydrate and beta gypsum,
an aluminum powder-limestone flour mixture comprising 5-14.95 wt. % of the total solid materials, the aluminum powder-limestone flour mixture having a ratio of about 90% limestone flour to about 10% aluminum powder,
lime comprising 0.5-5.0 wt % of the total solid materials,
citric acid comprising about 0.05 wt % of the total solid materials, and
water,
wherein the mixture has a pH of 11.8 or more; and
applying the mixture in liquid or paste form onto the surface, wherein a waterbonding agent factor is about 0.35-0.65%.
2. The method according to claim 1, wherein the surface is a floor surface.
3. The method according to claim 1, wherein the surface is a wall surface and that the mixture is of a pasty consistency.
4. The method according to claim 1, wherein the providing comprises mixing the mixture at a place of installation.
5. The method according to claim 1, wherein the provided mixture is of such a consistency that it is self-leveling.
6. The method according to claim 1, wherein the applied mixture introduces a heat insulation layer to the surface, and wherein the introduced heat insulation layer hardens to reach its final strength after about 24 hours.
7. The method according to claim 1, wherein the mixture is 100% recyclable.
8. A method of providing a heat insulation layer for a surface, comprising:
mixing a bonding agent, a pore former, lime, and citric acid with an addition of water to provide a mixture having a pH of 11.8 or more, the bonding agent comprising 80-90 wt. % of total solid materials, the pore former comprising 5-14.95 wt. % of the total solid materials, the lime comprising 0.5-5.0 wt. % of the total solid materials, and the citric acid comprising about 0.05 wt. % of the total solid materials; and
applying the mixture in liquid or paste form onto the surface to provide the heat insulation layer, wherein a waterbonding agent factor is about 0.35-0.65%;
wherein the hydraulic bonding agent contains alpha-hemihydrate, beta-gypsum, or a mixture of alpha-hemihydrate and beta gypsum; and
wherein the pore former comprises blended aluminum powder and limestone flour having a ratio of about 90% limestone flour to about 10% aluminum powder.
9. The method according to claim 8, wherein said mixing takes place at a place of use.
10. The method according to claim 8, further comprising:
allowing the heat insulation layer to harden, wherein the heat insulation layer hardens to its final strength after about 24 hours.
11. The method according to claim 8, wherein the surface is a floor surface.
12. The method according to claim 8, wherein the surface is a wall surface.
13. The method according to claim 6, wherein the heat insulation layer includes a highly uniform pore structure; and
wherein the heat insulation layer is open to vapor diffusion.
14. The method according to claim 1, wherein after applying the mixture, the aluminum powder reacts to form aluminate and hydrogen, wherein heat is developed; and
wherein the heat development creates water vapor, the water vapor loosening a solid structure of the mixture and leaving pores in the solid structure, the pores being filled with air.
15. The method according to claim 6, wherein the final strength in the applied mixture is maintained after hardening.