A method for manufacturing a compact includes a mixing step of mixing a fiber and a powder of a binder to obtain a mixture; an accumulating step of accumulating the mixture to form a web; a humidifying step of adding water to the web; and a forming step of heating and pressurizing the water-added web to obtain a compact. The binder binds between fiber molecules by the addition of water. The powder has an average particle diameter (D50) of 20.0 μm or less.

A method for manufacturing a compact includes a mixing step of mixing a fiber and a powder of a binder to obtain a mixture; an accumulating step of accumulating the mixture to form a web; a humidifying step of adding water to the web; and a forming step of heating and pressurizing the water-added web to obtain a compact. The binder binds between fiber molecules by the addition of water. The powder has an average particle diameter (D50) of 20.0 μm or less.

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.

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.

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.

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.

A method for consolidating a fibrous material of plant-based fibers, such as cellulose fibers and/or poly-lactic acid fibers, the method including: applying to the fibrous material an aqueous solution including a cellulose derivative, and/or a salt thereof, and an acid, the aqueous solution having a pH within the range of from 3 to 7, optionally within the range of from 3 to 6, optionally within the range of from 3 to 4.5; and drying the bonded fibrous material, optionally at 100° C. or higher. Also, a fibrous material formed by the method, an aqueous binder solution including a cellulose derivative, and/or a salt thereof, and an acid, and a nonwoven material including airlaid plant-based fibers being consolidated by a bio-based binder in the presence of a carboxylic acid, the bio-based binder being a cellulose derivative, and/or a salt thereof.

A method for consolidating a fibrous material of plant-based fibers, such as cellulose fibers and/or poly-lactic acid fibers, the method including: applying to the fibrous material an aqueous solution including a cellulose derivative, and/or a salt thereof, and an acid, the aqueous solution having a pH within the range of from 3 to 7, optionally within the range of from 3 to 6, optionally within the range of from 3 to 4.5; and drying the bonded fibrous material, optionally at 100° C. or higher. Also, a fibrous material formed by the method, an aqueous binder solution including a cellulose derivative, and/or a salt thereof, and an acid, and a nonwoven material including airlaid plant-based fibers being consolidated by a bio-based binder in the presence of a carboxylic acid, the bio-based binder being a cellulose derivative, and/or a salt thereof.

The present invention is generally related to a high capacity, high efficiency nonwoven filtration media comprising a gradient pore structure. In particular, the filtration media can comprise thermoplastic synthetic microfibers, fibrillated fibers, staple fibers, and a binder. Furthermore, the filtration media may be produced without the use of glass fibers or microglass fibers. Consequently, the filtration media of the present invention does not cause the same issues as conventional filtration media that comprises glass fibers and/or microglass fibers. Moreover, the filtration media can be used to treat fuel, lubrication fluids, hydraulic fluids, and various other industrial gases.

The present invention is generally related to a high capacity, high efficiency nonwoven filtration media comprising a gradient pore structure. In particular, the filtration media can comprise thermoplastic synthetic microfibers, fibrillated fibers, staple fibers, and a binder. Furthermore, the filtration media may be produced without the use of glass fibers or microglass fibers. Consequently, the filtration media of the present invention does not cause the same issues as conventional filtration media that comprises glass fibers and/or microglass fibers. Moreover, the filtration media can be used to treat fuel, lubrication fluids, hydraulic fluids, and various other industrial gases.