Apparatus for forming a substrate
Methods and apparatuses for producing a substrate are described. A method and apparatus for introducing a component into a fluid supply is also presented. A method can include providing a first fluid supply. The fluid supply can be configured as a foam in some embodiments. The method can also include providing a component feed system and a supply of the component. The method can include introducing the component to a fluid supply in an eductor in some aspects. A resultant slurry including a fluid supply and the component can be transferred through a headbox. The resultant slurry can be dewatered to provide a substrate including the component.
1. An apparatus for forming a substrate, the apparatus comprising:
a first pump configured for pumping a first fluid supply;
a component feed system comprising:
a component supply area for receiving a supply of a component; and
an outlet conduit;
an eductor in fluid communication with the outlet conduit of the component feed system and with a second fluid supply comprising water, wherein at least one of the first fluid supply and the second fluid supply comprises a plurality of fibers, the eductor comprising a first discharge;
a headbox in fluid communication with the first fluid supply and the first discharge of the eductor, wherein a resultant slurry comprises the first fluid supply, the second fluid supply, and the supply of the component; and
a forming surface configured to receive the resultant slurry transferred through the headbox.
2. The apparatus of claim 1 , wherein the eductor comprises:
a first inlet in fluid communication with the supply of the component;
a second inlet in fluid communication with the second fluid supply; and
a discharge.
3. The apparatus of claim 2 , wherein the outlet conduit comprises an outlet axis, and wherein the first inlet of the eductor comprises a first inlet axis, the first inlet axis being co-axial with the outlet axis.
4. The apparatus of claim 2 , wherein the outlet conduit comprises an outlet axis, and wherein the discharge comprises a discharge axis, the discharge axis being co-axial with the outlet axis.
5. The apparatus of claim 2 , wherein the eductor further comprises a venturi section, and wherein a distal end of the outlet conduit is disposed in the venturi section of the eductor.
6. The apparatus of claim 2 , wherein the second inlet is upstream of a distal end of the outlet conduit of the component feed system.
7. The apparatus of claim 1 , further comprising a second mixing junction in fluid communication with the first discharge of the eductor and with the first fluid supply, the second mixing junction comprising a second discharge, the second discharge in fluid communication with the headbox.
8. The apparatus of claim 7 , wherein the second discharge is integral to the headbox.
9. The apparatus of claim 1 , further comprising:
a second pump configured for pumping the second fluid supply;
a first tank configured for holding the first fluid supply, the first tank in fluid communication with the first pump; and
a second tank configured for holding the second fluid supply, the second tank in fluid communication with the second pump.
10. The apparatus of claim 1 , wherein the first fluid supply is a first foam, the first foam comprising the plurality of fibers, water, and a surfactant, wherein the second fluid supply is a second foam, and wherein the component is a particulate.
11. An apparatus for forming a substrate, the apparatus comprising:
a first pump configured for pumping a first fluid supply;
a component feed system comprising:
a component supply area for receiving a supply of a component; and
an outlet conduit comprising an outlet axis;
an eductor in fluid communication with the supply of the component through the outlet conduit of the component feed system and with a second fluid supply comprising water, the eductor comprising a first discharge;
a mixing junction in fluid communication with the first discharge of the eductor and with the first fluid supply, the mixing junction comprising a second discharge;
a headbox in fluid communication with the second discharge of the mixing junction, wherein a resultant slurry comprises the first fluid supply, the second fluid supply, and the supply of the component; and
a forming surface configured to receive the resultant slurry transferred through the headbox.
12. The apparatus of claim 11 , wherein the eductor further comprises:
a first inlet in fluid communication with the supply of the component; and
a second inlet in fluid communication with the second fluid supply.
13. The apparatus of claim 12 , wherein the first inlet of the eductor comprises a first inlet axis and the first discharge of the eductor comprises a discharge axis, wherein the discharge axis is co-axial with the first inlet axis.
14. The apparatus of claim 12 , wherein the eductor further comprises a venturi section, and wherein a distal end of the outlet conduit is disposed in the venturi section of the eductor.
15. The apparatus of claim 12 , wherein the second inlet is upstream of a distal end of the outlet conduit of the component feed system.
16. The apparatus of claim 11 , further comprising a second pump, the second pump configured for pumping the second fluid supply, wherein the second fluid supply is a foam.
17. An apparatus for forming a substrate, the apparatus comprising:
a first pump configured for pumping a first fluid supply comprising water;
a component feed system comprising:
a component supply area for receiving a supply of a component; and
an outlet conduit comprising an outlet conduit axis;
an eductor in fluid communication with the outlet conduit of the component feed system and with the first fluid supply, the eductor comprising a discharge;
a headbox in fluid communication with the discharge of the eductor, wherein a resultant slurry comprises the first fluid supply and the supply of the component; and
a forming surface configured to receive the resultant slurry transferred through the headbox.
18. The apparatus of claim 17 , wherein the eductor comprises:
a first inlet in fluid communication with the supply of the component; and
a second inlet in fluid communication with the first fluid supply.
19. The apparatus of claim 18 , wherein the discharge of the eductor comprises a discharge axis, and wherein the outlet axis of the outlet conduit is co-axial with the discharge axis.
20. The apparatus of claim 18 , wherein the eductor further comprises a venturi section, and wherein a distal end of the outlet conduit is disposed in the venturi section of the eductor.