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Abstract

A method of forming a fibrous material includes creating a mixture of pulp, liquid, and a debonder. Drying the mixture produces pulp, which is generally mixed with binder fibers, where each binder fiber has a core and an outer layer. The core has a first melting temperature and the outer layer has a second melting temperature lower than the first melting temperature. The method includes providing the pulp and binder fibers to a dry-lay machine to form a layer of base fibrous material. In one embodiment, the layer of base fibrous material is heated to at least partially melt the binder fibers' outer layers. The method includes applying a bonding material to the layer; creping the layer; and curing the layer to form the fibrous material. Alternatively, the method includes embossing the layer of base fibrous material; and spraying a chemical bonder to the layer of base fibrous material.

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First Claim