Patent ID: 7785444

Claim:
A cylindrical suction box assembly for applying an embossed pattern to at least a portion of a continuous sheet of non-woven fabric produced by a water-entanglement process, the cylindrical suction box assembly comprising: (a) a cylindrical suction box having a substantially cylindrical outer wall with a plurality of longitudinal slots configured in said outer wall, said suction box being substantially hollow with at least one interior dividing partition configured to divide an interior volume of said suction box into at least first and second suction chambers such that at least a first of said plurality of longitudinal slots opens into said first suction chamber and at least a second of said plurality of longitudinal slots opens into said second suction chamber; (b) at least one fluid injector deployed proximal to an outer surface of said suction box and aligned with at least a first one of said plurality of longitudinal slots, said at least one fluid injector configured to deliver a flow of fluid to a surface of the substantially continuous sheet of non-woven fabric, said fluid then passing through said first of said plurality of longitudinal slots into said first suction chamber; and (c) an embossing roller having a patterned outer surface having a plurality of embossing-indentations, said embossing roller deployed about said suction box such that during rotation at least a portion of said embossing roller: (i) passes between said fluid injector and said first of said plurality of longitudinal slots so as to force a portion of the non-woven fabric into at least some of said plurality of embossing-indentations; and (ii) subsequently passes over said second of said plurality of longitudinal slots such that a de-watering process is performed while said portion of the non-woven fabric remains in said plurality of embossing-indentations, and at least a portion of water being carried by the non-woven fabric is drawn into said second suction chamber.