An integrally-formed nonwoven object manufacturing method includes a raw material mixing step, a roller mixing step, a plastic sheet forming step, a foaming step, an embossing step, and a post-process step to manufacture a nonwoven object from TPU material such that the manufacturing process dispenses with a solvent to thereby effectuate environmental protection and reduce processing steps.

Filter media and related methods of foam forming the filter media are generally described herein.

Filter media and related methods of foam forming the filter media are generally described herein.

An apparatus for dispensing a reactive foam formulation to produce laminated panels includes a mixhead, a distribution system that defines multiple flowpaths for the reactive foam to outlets fitted with nozzles. The nozzles have multiple, spaced-apart outlets arranged at angles to each other to distribute the foam formulation evenly onto a moving bottom facing layer.

A method for continuous production of an endless string of polyurethane reactive plastic material including, a) conveying the reactive components to a mixer in a metered manner, b) mixing the reactive components into a reactive mixture, c) subsequently discharging the reactive mixture and d) coating a first sheet section made from a plane, flexible material which is conveyed continuously in a transporting direction with the reactive mixture. Further including: e) guiding the first sheet section across a guiding element, which has a concave section and a flat section which follows the concave section in the transporting direction; f) feeding two lateral sheet sections to the first sheet section, wherein the feeding occurs into the two lateral end sections of the first sheet section; g) merging the two lateral sheet sections and the first sheet section so that a bowl-shaped structure is formed for reception of the reactive mixture.

A method for continuous production of an endless string of polyurethane reactive plastic material including, a) conveying the reactive components to a mixer in a metered manner, b) mixing the reactive components into a reactive mixture, c) subsequently discharging the reactive mixture and d) coating a first sheet section made from a plane, flexible material which is conveyed continuously in a transporting direction with the reactive mixture. Further including: e) guiding the first sheet section across a guiding element, which has a concave section and a flat section which follows the concave section in the transporting direction; f) feeding two lateral sheet sections to the first sheet section, wherein the feeding occurs into the two lateral end sections of the first sheet section; g) merging the two lateral sheet sections and the first sheet section so that a bowl-shaped structure is formed for reception of the reactive mixture.

A method sets machine parameters of a foam production machine. The foam production machine includes an intermediate conveyance unit configured to receive a reactive mixture, a plurality of fall plates having vertically adjustable ends and configured to receive the reactive mixture from the intermediate conveyance unit, and a conveyor configured to receive the reactive mixture from the fall plates. The method includes executing software by a computer system, where executing the software includes importing characteristics of the foam production machine and a rise profile for the reactive mixture, and iteratively determining process and machine parameters, including reactive mixture flow rate, conveyor speed, a dimension of the intermediate conveyance unit, and vertical positions for the ends of each fall plate resulting in a predefined predicted profile of the reactive mixture on the plurality of fall plates.

A method sets machine parameters of a foam production machine. The foam production machine includes an intermediate conveyance unit configured to receive a reactive mixture, a plurality of fall plates having vertically adjustable ends and configured to receive the reactive mixture from the intermediate conveyance unit, and a conveyor configured to receive the reactive mixture from the fall plates. The method includes executing software by a computer system, where executing the software includes importing characteristics of the foam production machine and a rise profile for the reactive mixture, and iteratively determining process and machine parameters, including reactive mixture flow rate, conveyor speed, a dimension of the intermediate conveyance unit, and vertical positions for the ends of each fall plate resulting in a predefined predicted profile of the reactive mixture on the plurality of fall plates.

A method sets machine parameters of a foam production machine. The foam production machine includes an intermediate conveyance unit configured to receive a reactive mixture, a plurality of fall plates having vertically adjustable ends and configured to receive the reactive mixture from the intermediate conveyance unit, and a conveyor configured to receive the reactive mixture from the fall plates. The method includes executing software by a computer system, where executing the software includes importing characteristics of the foam production machine and a rise profile for the reactive mixture, and iteratively determining process and machine parameters, including reactive mixture flow rate, conveyor speed, a dimension of the intermediate conveyance unit, and vertical positions for the ends of each fall plate resulting in a predefined predicted profile of the reactive mixture on the plurality of fall plates.

A method sets machine parameters of a foam production machine. The foam production machine includes an intermediate conveyance unit configured to receive a reactive mixture, a plurality of fall plates having vertically adjustable ends and configured to receive the reactive mixture from the intermediate conveyance unit, and a conveyor configured to receive the reactive mixture from the fall plates. The method includes executing software by a computer system, where executing the software includes importing characteristics of the foam production machine and a rise profile for the reactive mixture, and iteratively determining process and machine parameters, including reactive mixture flow rate, conveyor speed, a dimension of the intermediate conveyance unit, and vertical positions for the ends of each fall plate resulting in a predefined predicted profile of the reactive mixture on the plurality of fall plates.