Sheet slitting forming belt for nonwoven products

Abstract

A forming fabric for use in the production of nonwoven products comprising a plurality of protuberances having a predetermined size and shape, wherein the protuberances are arranged in a pattern that defines a size and shape of nonwoven sheets formed therefrom.

1 . A forming fabric for use in the production of nonwoven products comprising a plurality of protuberances having a predetermined size and shape, wherein said protuberances are arranged in a pattern or grid and wherein said pattern defines a size and shape of nonwoven sheets formed therefrom.  
     
     
         2 . The forming fabric as claimed in  claim 1 , wherein said fabric is woven or nonwoven.  
     
     
         3 . The forming fabric as claimed in  claim 1 , wherein said plurality of protuberances are on a web forming side of said forming fabric.  
     
     
         4 . The forming fabric as claimed in  claim 1 , wherein said plurality of protuberances are impermeable to air.  
     
     
         5 . The forming fabric as claimed in  claim 1 , wherein said plurality of protuberances are formed of a polymeric resin material.  
     
     
         6 . The forming fabric as claimed in  claim 5 , wherein said polymeric resin material is selected from the group consisting of polyamide, polyester, polyetherketone, polypropylene, polyolefin; polyurethane, polyketone, and polyethylene terephthalate resins.  
     
     
         7 . The forming fabric as claimed in  claim 1 , wherein said plurality of protuberances are formed of a thermoplastic material, silicone or rubber.  
     
     
         8 . The forming fabric as claimed in  claim 1 , wherein said plurality of protuberances are individual strips or pieces of material.  
     
     
         9 . The forming fabric as claimed in  claim 8 , wherein said plurality of protuberances are attached to said forming fabric.  
     
     
         10 . The forming fabric as claimed in  claim 9 , wherein said plurality of protuberances are attached to said forming fabric using a mechanical attachment means selected from the group consisting of gluing with an adhesive, melt bonding, stitching and hook and loop fastening.  
     
     
         11 . The forming fabric as claimed in  claim 1 , wherein said plurality of protuberances are formed as a coating, an extrusion or as a resin deposition.  
     
     
         12 . The forming fabric as claimed in  claim 1 , wherein said plurality of protuberances have a cross-sectional shape selected from the group consisting of square, triangular, rectangular and rectangular having chamfered corners.  
     
     
         13 . A method of forming individual nonwoven sheets comprising the steps of: 
 providing an air permeable forming fabric;    selectively closing a plurality of areas on said forming fabric to air flow in a desired pattern or grid on a web forming surface of said forming fabric;    providing a vacuum means adjacent to a non-web forming side of said forming fabric;    depositing fibers on said forming fabric; and    wherein said pattern defines a size and shape of the individual nonwoven sheets formed on said forming fabric.    
     
     
         14 . The method as claimed in  claim 13 , wherein the forming fabric is woven or nonwoven.  
     
     
         15 . The method as claimed in  claim 13 , wherein said vacuum means provides a suction to the forming fabric thereby urging said fibers onto air permeable areas of said forming fabric.  
     
     
         16 . The method as claimed in  claim 13 , wherein said plurality of areas on said forming fabric are rendered impermeable to air with the addition of an impermeable material to said web forming surface of said forming fabric.  
     
     
         17 . The method as claimed in  claim 16 , wherein said impermeable material is formed of a polymeric resin material.  
     
     
         18 . The method as claimed in  claim 17 , wherein said polymeric resin material is selected from the group consisting of polyamide, polyester, polyetherketone, polypropylene, polyolefin, polyurethane, polyketone, polyethylene terephthalate resins.  
     
     
         19 . The method as claimed in  claim 16 , wherein said impermeable material is formed of a thermoplastic material, silicone or rubber.  
     
     
         20 . The method as claimed in  claim 13 , wherein said pattern or grid is constructed from individual strips or pieces of impermeable material.  
     
     
         21 . The method as claimed in  claim 20 , wherein said individual strips or pieces of impermeable material are attached to said forming fabric.  
     
     
         22 . The method as claimed in  claim 21 , wherein said individual strips or pieces of impermeable material attach to said forming fabric using a mechanical attachment means selected from the group consisting of gluing with an adhesive, melt bonding, stitching and hook and loop fastening.  
     
     
         23 . The method as claimed in  claim 18 , wherein said impermeable material is formed as a coating, an extrusion or as a resin deposition.  
     
     
         24 . The method as claimed in  claim 16 , wherein said impermeable material has a cross-sectional shape selected from the group consisting of square, triangular, rectangular, and rectangular having chamfered corners.