Unitized composite fabrics with cross machine wave-like shaping and methods for making same

Abstract

A manufacturing method for producing a unitized composite material has been discovered. An assembly of loose fibers or fiber and fabric combinations is formed where at least one of the layered elements contains a bondable material such as a thermally sensitive bonding fiber. The un-bonded layered assembly is shaped into a wavy form having a repeating wave-like pattern of the desired amplitude and wavelength. The amplitude and wavelength of the repeating waves can be altered such as by changing the relative speeds of a transfer device and an oven wire and the height of the transfer device relative to the height of the oven wire using simple machinery control settings. The shaped assembly is subsequently bonded in an oven or other activation step preserving the wave-like shaping when cooled or removed from the activation effect.

1 . An apparatus for production of a composite comprising:
 a substrate for receiving material and conveying material;   one or more heads for deposition of material onto said substrate; and   a wire for conveying material from the substrate to an activation machine for processing the material to obtain a unitized composite, wherein a portion of said substrate adjacent to said wire is at a different height in the z direction relative to wire.   
   
   
       2 . The apparatus of  claim 1  wherein said wire conveys material more slowly than said portion of said substrate. 
   
   
       3 . The apparatus of  claim 2  wherein said portion of said substrate is a transfer device. 
   
   
       4 . The apparatus of  claim 3  wherein the speed of said transfer device relative to said wire, and the z direction distance between said wire and said transfer device determine the shape of said material when it is on said wire. 
   
   
       5 . The apparatus of  claim 3  wherein the speed of said transfer device relative to said wire can be varied independently of said z direction distance between said wire and said transfer device. 
   
   
       6 . The apparatus of  claim 3  wherein the z direction distance between said wire and said transfer device can be varied independently of said speed of said transfer device relative to said wire. 
   
   
       7 . The apparatus of  claim 3  wherein said transfer device is a suction roll.