Patent ID: 8871059

Claim:
A process for making a fluff pulp sheet, comprising: creating a pulp slurry which includes fluff pulp fibers suspended in a liquid, the pulp slurry containing multiple fiber bundles formed from fluff pulp fibers which are bonded together and dispersed within the pulp slurry; applying an amount of the pulp slurry onto a moving bottom forming wire to form a web thereon, the pulp slurry being dispensed by a headbox; applying a top forming wire onto the web and dewatering the web through the top forming wire; applying high pulsating shear forces on the web sufficiently large to break some of the fluff pulp fiber bundles using a top set of blades and a bottom set of blades, at least one of the top set of blades and bottom set of blades being movable, the top set of blades adapted to contact the top forming wire and the bottom set of blades adapted to contact the bottom forming wire, movement of the at least one of the top and bottom sets of blades causing the web to move in an acute upward and downward fashion, wherein the bottom blades move the bottom forming wire upward causing the top forming wire to come into contact with the top set of blades; and controlling the cross-directional weight basis of the web by varying the concentration of the pulp slurry being deposited from the headbox onto the bottom forming wire.