Method for foam casting using three-dimensional molds
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United States of America Patent
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Mar 11, 2003
Grant Date -
Aug 29, 2002
app pub date -
Feb 26, 2001
filing date -
Feb 26, 2001
priority date (Note) -
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Abstract
Disclosed is a method of producing a non-woven web of fibrous or particulate material comprising: formation of a foam slurry; deposition of that slurry onto a foraminous element having a three-dimensional mold; and formation of a web having a three-dimensional shape that is not substantially planar by removal of foam from the slurry through the foraminous element and drying the web. An apparatus therefor is also disclosed. The method may be used in production a variety of products, including automotive pleated fluid and air filters, pleated heating and/or air conditioning (HVAC) filters, shaped breathing mask filters and bacterial filters, laminated cleaning products with super-absorbent middle layers, such as a mop wipe shape to fit a cleaning mop head, and other products.
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