APPARATUS AND PROCESS FOR FORMING THREE-DIMENSIOAL FIBROUS PANELS

摘要

A fibrous panel is molded in two or more progressively formed mold members each comprising a porous support plate to which a plurality of rigid mold pieces are affixed. The mold pieces are truncated 3D tapered structures, and are arranged on the support plate in a regular array so that an intersecting gri d or lattice of channels is defined between them. A fiber stock is poured into a first mo ld member and the stock is compressed and dewatered to form a panel. The panel is removed from the first mold member and placed into a second mold member having narrower and shallower channels whose side walls are more upright tha n those of the first mold member. The panel is further compressed and dewatere d in the second mold member, and is densified in both the vertical and lateral directions by virtue of the progressive formation of the mold members.