Patent ID: 6982052

Claim:
Apparatus for air forming an article having a plurality of superimposed fibrous layers, said apparatus comprising: first and second substantially discrete forming chambers, a foraminous forming surface movable through said first and second forming chambers along a forming path length, a first fiber feed mechanism for introducing a fibrous material into said first forming chamber, a first vacuum source in communication with said first forming chamber for drawing said fibrous material in said first forming chamber onto said forming surface to form a first layer on said forming surface, a first removing and directing mechanism for removing a portion of said first layer and directing the portion removed back into said first forming chamber, a second fiber feed mechanism for introducing a fibrous material into said second forming chamber, and a second vacuum source in communication with said second forming chamber for drawing said fibrous material in said second forming chamber onto said forming surface to form a second layer on said forming surface superimposed on said first layer.