Process and apparatus for forming a composite product

A - Human Necessities – 61 – F

Patent

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A61F 13/15 (2006.01) D04H 13/00 (2006.01)

Patent

CA 2051163

Composite products, comprising a wad of fibrous material sandwiched between a non-woven fabric carrier and a liquid-impervious backing are formed by forming the wad on the carrier, moulding the wad and carrier to have a desired configuration, stabilizing the wad and bonding it to the carrier, applying the backing and cutting the wad with a border of carrier and backing from the rest of the carrier and the backing. The carrier is sheet-like and a number of the wads are formed thereon in a continuous manner. The wads are stabilized by means of a foamed acrylic binder that is sprayed onto the wads and sucked through the wads and onto the carrier by a suction applied to the underneath of the carrier. The wads and carrier are then heated to cure the binder. Instead, the wad can include thermoplastic particles so that the wad is stabilized and bonded by being heated.

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