CN1180392A - Method of applying curable resin to substrate for use in papermaking - Google Patents
Method of applying curable resin to substrate for use in papermaking Download PDFInfo
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- CN1180392A CN1180392A CN 96192981 CN96192981A CN1180392A CN 1180392 A CN1180392 A CN 1180392A CN 96192981 CN96192981 CN 96192981 CN 96192981 A CN96192981 A CN 96192981A CN 1180392 A CN1180392 A CN 1180392A
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Abstract
The invention comprises a method for applying a curable resin, such as a photosensitive resin, to a substrate such as a papermaker's dewatering felt (220). The method comprises the steps of providing a substrate; providing a curable liquid resin; providing a second material different from the curable liquid resin; applying the second material (2410) to the substrate to occupy at least some of the voids in the substrate intermediate the first (230) and second (232) surfaces of the substrate; applying the curable resin (1520) to the substrate; curing (3150) at least some of the resin to provide a resin layer on the substrate; and removing (3170, 2550) at least some of the second material from the substrate, wherein at least some of the second material is removed from the substrate after applying the curable resin to the substrate.
Description
The field of the invention
The invention provides a kind ofly, more particularly, the present invention relates to a kind ofly produce the device of pattern in the page carrier method to make the paper web that makes used in the papermaking with curable liquid is resin-coated curable resin-coated in the method for page carrier.
Background of the present invention
In existing paper technology, people have known coating such as cold coating and foamed coating have been coated the page carrier.For example, people have known with the pattern of preliminary election photosensitive resin have been coated on the multihole device used in the papermaking operation (foraminous member).People also know to provide to have coating, thereby obtain controlled pore volume and permeability as the Papermaker press felt of foamed coating.Following document description resin, filler, foam, laminate structures or the application of other coating in the paper making equipment manufacture process: be presented to the United States Patent (USP) 3,549,742 of Benz on December 22nd, 1970; Be presented to the United States Patent (USP) 4,446,187 of Eklund; Be presented to people's such as Johnson United States Patent (USP) 4,514,345 on April 30th, 1985; Be presented to the United States Patent (USP) 4,637,859 of Trokhan on January 20th, 1987; Be presented to the United States Patent (USP) 4,795,480 of Boyer etc. on January 3rd, 1989; Be presented to people's such as Smurkoski United States Patent (USP) 5,098,522 on March 24th, 1992; Be presented to the United States Patent (USP) 5,346,567 of Barnewall on September 13rd, 1994; Be presented to people's such as Trokhan United States Patent (USP) 5,334,289 on August 2nd, 1994; Open and transfer the PCT publication number WO91/14558 of SCAPA group with on October 3rd, 1991 with the name of Sayers etc.
People also know with resin and filler material and come impregnate fabric such as raphioid fiber fabric and blanket material.Following document description resin and/or the application of filler in fabric: the United States Patent (USP) 4,250,172 that is presented to people such as Mutzeuber; Be presented to the United States Patent (USP) 4,390,574 of Wood; Be presented to people's such as Dost United States Patent (USP) 4,464,432; Be presented to people's such as Sumii United States Patent (USP) 5,217,799; Be presented to people's such as Landis United States Patent (USP) 5,236,778; Be presented to Woo again on July 12nd, 1988 reissue patent 32,713.
For making papermaking apparatus, after the part resin solidification on the page carrier, preferably remove uncured resin from carrier.For making final papermaking apparatus have desired characteristic aspect its special papermaking purposes, it is very important removing uncured resin from carrier.Permeability and water the permeability by this device of the compressibility, air that these characteristics include, but not limited to pliability, the device of device by this device.For the papermaking apparatus (by opening, between sheet forming and dry period, air and/or water are carried) of pattern decorative resin surface, remove uncured resin particular importance with opening.Be retained in the permeability that uncured resin in the carrier can reduce carrier, thereby reduce by flowing at the opening of the resin surface of pattern decorative.
A kind of method of removing uncured resin comprises from carrier washes uncured resin off.For example, United States Patent (USP) 4,514,345 above-mentioned discloses from the multihole device that is made into by fibril (woven filament) and has washed uncured resin off, then removes the method for remaining cleaning fluid and uncured liquid from multihole device by vacuum.Yet only using washing and vacuum method is invalid to removing all uncured resins.
The foam carrier of woollen blanket or perforate can have a large amount of relatively little, can capture the inside hole of uncured resin.As described above, the uncured resin of capture can reduce the performance of papermaking apparatus.In addition, the resin of this capture is waste basically, only can increase the cost of resin casting technique.The number of times that increases washing and vacuum cycle is removed the cost that the resin that is captured also can increase this method.
In addition, in some coating, preferably can control the degree of depth that resin infiltrates carrier.For example, preferably make the resin bed of curing be seeped into the preset thickness part of carrier, thereby resin is meeted the requirements with combining of carrier, keep the pliability of carrier and carrier permeability simultaneously empty G﹠W.
Be presented to the United States Patent (USP) 3 of Benz on December 22nd, 1970,549,742 disclose and a kind of packing material have been filled in method in the drainage element hole, these holes finally be perforate to be used for drainage, then curable material is filled in the residual pore of the drainage element in the presumptive area, in this zone, can prevent that liquid from passing through flowing of drainage element.After curable materials is fixed or solidified, from the drainage element, remove packing material.The shortcoming of Benz method be filler before coating the drainage element, just place, and filler must be pressed into the drainage element, so that the presumptive area of drainage element does not contain filler with predetermined pattern.Therefore, wherein the curable material pattern that can be fixed to the drainage element is limited by the presumptive area of the drainage element that does not contain filler.
And Benz adopts pressure mechanically to force filler to enter the drainage element.Filler is pressed into carrier can produces following shortcoming: if carrier has many little internal voids, and be compressible relatively, so pressure being put on carrier can the carrier shrinkage or close part hole in the carrier, thereby makes filler to the infiltration of the carrier difficulty that becomes.
In addition, make filler be pressed into the blanket floor and can cause filler to flow into the blanket district, this means that these zones are perforates for curable material by the side.Therefore, being used for curable resin by the disclosed method of Benz is unfavorable in being coated with the cloth blanket layer.
Therefore, an object of the present invention is to provide a kind of with curable resin-coating in carrier to make the method for papermaking apparatus.
Another object of the present invention provides a kind of method that reduces uncured photosensitive resin amount, and these uncured photosensitive resins need be removed from the device that makes paper web produce pattern, and this device is suitable for making the page with the high-visible pattern of naked eyes.
Another object of the present invention provides a kind of method that makes paper web produce the device of pattern of making, this device has a dehydration blanket layer and the photosensitive resin layer with pattern decorative, and this photosensitive resin layer may penetrate into the surface of blanket layer and comes from the surface expansion of blanket layer.
Summary of the present invention
The present invention comprises a kind of with the method for curable resin-coating in the page carrier.Particularly this method can be used for making papermaking apparatus, as sheet forming blanket or the dry blanket of paper web.In one embodiment, method of the present invention can be used for photosensitive resin is coated dehydration blanket layer to make papermaking apparatus, and this device can be used for making paper web to produce pattern and dehydration.The paper web pattern that the papermaking apparatus of gained can comprise dehydration blanket layer and contain photosensitive resin forms layer (a web patterning layer), and this dehydration blanket layer has first highly to be faced the first blanket face of paper web and face the second blanket face of paper web in the opposite direction.Pattern forms layer and is penetrated into the first blanket face, and from the expansion of the first blanket face to be different from second end face that contacts with paper web of formation highly of the first blanket face height.
According to the present invention, this method makes and has produced a barrier in the carrier, thereby defines the degree of depth of curable liquid resin by the carrier thickness infiltration.This method comprises the following steps:
Provide to have first surface, the carrier of second surface and thickness, this carrier has hole between first and second surfaces;
Curable liquid resin is provided;
The second kind of material that is different from curable liquid resin is provided;
With second kind of material coat carrier with occupy in the carrier between first and second surfaces to the small part hole;
With curable resin-coated in carrier;
Make at least the part resin solidification on carrier, to form resin bed; With
From carrier, remove to second kind of material of small part, wherein with curable resin-coated after carrier, from carrier, removing to second kind of material of small part.
Remove to the step of second kind of material of small part and preferably include second kind of material coating carrier of removing at least about 50%, and more preferably, remove second kind of material that all coat carrier basically.
In one embodiment, carrier comprises papermaking dehydration woollen blanket and resin comprises photosensitive resin.
In one embodiment, this method comprises this step, promptly with resin-coated before carrier, reduce to coat the flowability of second kind of material of carrier.This method also comprises a step, promptly after part resin solidification at least, improves the flowability of second kind of material, so that remove second kind of material from carrier.
In one embodiment, this method is included in before the coating liquid photosensitive resin, changes the state of second kind of material coating carrier.In one embodiment, the liquid mixture of second kind of material Yi Shui and soap gelling agent is applied to the whole thickness of carrier.Cool off second kind of material so that it is frozen into gel.Make the second kind of material liquefaction of skim gelation or the dissolving of contiguous carrier first surface, remove by water spray then, be substantially free of second kind of material with the part carrier thickness that contiguous first surface is provided.
Then, liquid light maleate resin is coated the first surface of carrier so that it infiltrates carrier from first surface, and outside carrier, expand to the preset distance of carrier apart from first surface.Prepare actinic radiation sources and have opaque and the veil clear area.Thereby the actinic radiation that resin is exposed to by veil makes this liquid light maleate resin by predetermined pattern cured.Wash uncured liquid resin by the water spray off from the first surface of carrier then.Then by heating, heat water-spraying with vacuumize second kind of material liquefaction making the gelation that is retained in the carrier and get rid of from carrier.
Accompanying drawing is described
Though this specification is particularly pointing out and to explicitly call for claims of the present invention to finish, in conjunction with the accompanying drawings, following description will make the present invention be understood better, and similar portions is to be represented by same reference numbers in the accompanying drawing, and:
Fig. 1 is the plane of the device made of the method according to this invention, and this device comprises dehydration blanket layer and the photosensitive resin paper web pattern of the curing that links to each other with dehydration blanket layer forms layer, and has the continuous net-shaped paper web that contacts with end face.
Fig. 2 is the cross-sectional view of device shown in Figure 1.
Fig. 3 is the method schematic diagram that forms device papermaking with the paper web pattern, and this device is that the method according to this invention is made.
Fig. 4 A-4H is the schematic diagram that paper web pattern made according to the method for the present invention forms each step of device.
Fig. 5 is that the method according to this invention is made paper web pattern formation schematic representation of apparatus, and this device has woollen blanket dehydration layer and forms layer by the paper web pattern that photosensitive resin is made.
Fig. 6 is the micro-enlarged photograph of the device made of the method according to this invention.
Fig. 7 is the micro-enlarged photograph of the cross section of device shown in Figure 6.
Detailed description of the present invention
Fig. 1 and Fig. 2 are the schematic diagrames of papermaking paper web supporting arrangement 200, and this device is made with method of the present invention.Device 200 comprises carrier as dehydration blanket layer 220, forms layer 250 with the resin paper web pattern of the curing that links to each other with blanket layer 220 surface.Fig. 3 has illustrated the method for making paper web with the device 200 of Fig. 1 and 2.Fig. 4 A-4H explanation is made each step that the paper web pattern forms device 200 according to the present invention by photosensitive resin is solidificated on the carrier surface.Fig. 5 is the schematic diagram of an embodiment of method of the present invention.Fig. 6 and 7 is micro-enlarged photographs of the device 200 made with method of the present invention.
Paper web supporting arrangement (the web support apparatus)
Fig. 1,2 and 4H shown paper web supporting arrangement 200, it comprises drying and gives the continuous drying blanket of paper web pattern.Paper web supporting arrangement 200 has in the face of first 202 of paper web with in the opposite direction in the face of second 204 of paper web.In Fig. 1, observe paper web supporting arrangement 200 from first 202 angle towards the observer in the face of paper web.
Paper web supporting arrangement 200 comprises carrier, has hole between first and second surfaces of carrier.Preferably, the one side at least to small part hole and carrier is a fluid communication.For example, carrier comprises dehydration blanket layer 220, and it has the first blanket face 230 of facing paper web that is in first height, 231 (Fig. 2) and the second blanket face 232 of facing paper web in the opposite direction.Blanket layer 220 has a large amount of holes at first surface 230 and 232 of second surfaces.Paper web supporting arrangement 200 also comprises the paper web pattern that links to each other with the first surface 230 of facing paper web and forms layer 250.As shown in Figure 2, the paper web pattern form layer 250 from 230 expansions of the first blanket face to have the end face 260 of paper web contact at second height 261 different with first height 231.Difference in height 262 (Fig. 4 H) between first height, 231 and second height 261 is at least about 0.05 millimeter, and difference in height in one embodiment is between about 0.1 and 0.2 millimeter.
The paper web pattern forms layer 250 and comprises curable resin, and it can be with liquid deposition on the surface of carrier, and solidifies subsequently so that part paper web pattern forms the surface of layer penetrating carrier.Especially, the paper web pattern forms layer 250 can comprise photosensitive resin, and it can be with liquid deposition on first surface 230, and subsequently by radiation curing so that part paper web pattern forms layer 250 infiltration, thereby be firmly bonded to the first blanket face 230.Preferably, the paper web pattern forms layer 250 and does not expand to the whole thickness of blanket layer 220, but expands to half following thickness of about blanket layer 220, with the pliability and the compressibility of maintenance paper web supporting arrangement 200, and the particularly pliability and the compressibility of blanket layer 220.
The dehydration blanket layer 220 that is fit to comprises the fibrage (batt) 240 of natural or synthetic fiber, and it is to be connected to the supporting structure that is formed by the fibril 244 that is made into by acupuncture.Shown in Fig. 4 A.The suitable material that forms fibrage 240 includes, but is not limited to natural fabric such as wool and synthetic fiber such as polyester and nylon.The 1-20 dawn that the fiber of formation fibrage 240 has (about 1～20 gram of per 9000 meters fine line lengths).
The blanket layer 220 that is fit to is the Amplex 2 squeezing blankets by the Appleton papermaking equipment company manufacturing of state of Wisconsin Appleton.This blanket layer 220 has about 3 millimeters thickness, about 1400 gram/rice
2Quantitatively, about 20～30 standard feet
3The air permeability of/minute (scfm), and have double-deck supporting structure.This double-deck supporting structure has the horizontal weavy grain of monofilament of a fibril top more than 3 layers and bottom warp and one 4 layers strand flower.Fibrage 240 comprises nylon fiber, and it has the fineness at about 3 dawn at first surface 230, and the fibrage carrier under first surface 230 has the fineness at about 10～15 dawn.
The photosensitive resin that is fit to is disclosed in the United States Patent (USP) 4,514,345 that was presented to people such as Johnson on April 30th, 1985 and was presented on August 2nd, 1994 in people's such as Trokhan the United States Patent (USP) 5,334,289, and incorporating into own forces in this of these patents is for reference.The resin that solidifies has the hardness that is less than or equal to about 60ShoreD.This hardness is the mean value 1 * 2 * 0.025 inch five value not measuring on the photopolymerization resin coupon of decorative pattern, and this sample is to solidify forming under the identical condition of layer 250 with the paper web pattern.This hardness measurement is carried out under 25 ℃, and after shore D hardometer probe contacts 10 seconds with resin reading.The resin that obtains such hardness by curing is desired, and purpose is to make the paper web pattern form layer 250 some pliabilities and deformability are arranged.The resin that solidifies is preferably anti-oxidant.Uncured resin is 70 viscosity with about 5000～25000 centipoises, and this is convenient to resin and infiltrated through blanket layer 220 before solidifying.The liquid light maleate resin that is fit to is included in the Merigraph series plastics that the Hercules company of Delaware State Wilmington makes, and these resins also comprise antioxidant, and it is disclosed in the United States Patent (USP) 5,334,289 above-mentioned.The liquid light maleate resin that is fit to is the MEH-1000 resin, and it can have been bought from Hercules company.
The application of paper web supporting arrangement in papermaking
Fig. 3 has illustrated and has installed 200 application in paper web 20 manufacture processes.With the suspension (slurry) of paper fibre such as cellulosic wood pulp fibre from head box (headbox) 500 deposit to porous, on the fluid permeable forming net (forming belt) 542, to form initial paper web 543 by the paper fibre of forming net 542 supportings.Forming net 542 comprises continuous fourdrinier wire, or alternatively, can be arbitrary shape of various twin wire former (twin wire former) well known in the prior art.Then, paper web 543 is transferred to paper web supporting arrangement 200 by forming net 542, and initial paper web 543 is fixed on first 202 of paper web supporting arrangement 200.
The step that makes initial paper web 543 transfer to paper web supporting arrangement 200 can comprise in the opening 270 that makes part paper web 543 be deflected into paper web pattern formation layer 250 simultaneously to form the step of non-monoplane paper web 545.Make initial paper web 543 transfer to paper web supporting arrangement 200 and the step of initial paper web 543 deflections of part can be reached by the fluid pressure that 600 pairs of initial paper webs 543 of vacuum source apply differential at least in part.Back at initial paper web branchpoint also can be provided with one or more addition of vacuum sources 620.
Initial paper web 543 is shifted and deflection forming after the non-monoplane paper web 545, paper web 545 by 200 carryings of paper web supporting arrangement by at Yankee dryer cylinder 880 and 900 nips that form of roller (nip) 800.Paper web is transferred on drying cylinder 880 surfaces 875, and dry thereon, makes paper web wrinkling to form wrinkle paper web 20 from surface 875 by scraper 1000 then.Before paper web 545 is transferred to dryer cylinder 880, paper web is further dewatered, as by the squeezing or the hot blast impingement drying.For example, paper web can be squeezed at the nip 700 between paper web supporting arrangement 200 and the dehydration that the separates blanket 712, this is disclosed in Application No. is 08/358,661, denomination of invention is (Ampulski is in submit applications on December 19th, 1994) in " paper web of wet pressing and manufacture method thereof " patent.For the open paper web of how making with pattern decorative 20, following patent literature is all incorporated into own forces in this for reference: be presented to the United States Patent (USP) 4,529,480 of Trokhan on July 16th, 1985; The Application No. 08/268,154 that Trokhan submitted on June 29th, 1994, its denomination of invention is " the paper web pattern that comprises blanket layer and photosensitive resin layer forms device "; The Application No. 08/268 that people such as Trokhan submitted on June 29th, 1994,213, denomination of invention is " have trizonal at least page structure, these zones comprise with the interconnective transition region of relative thinner area that is in differing heights and make the apparatus and method of this page "; With the Application No. 08/358,661 that Ampulski submitted on December 19th, 1994, its denomination of invention is " wet pressed paper web and the method for making identical paper web ".
Be used in the photosensitive resin that solidifies on the blanket layer and make the paper web supporting arrangement
According to the present invention, paper web supporting arrangement 200 can be made with the step shown in Fig. 4 A-4H.Provide have first surface, the carrier of second surface and thickness, and this carrier has hole between first and second surfaces.In Fig. 4 A, the carrier that is provided is to take off blanket layer 220.Liquid light maleate resin and the second kind of material that is different from photosensitive resin also will be provided.
Referring to Fig. 4 B, the present invention includes this step, be about to second kind of material (being labeled as 2000) and coat blanket layer 220.Blanket layer 220 is with the operation of the direction shown in the arrow among Fig. 4 B.In one embodiment, before second kind of material coated blanket layer 220, blanket layer 220 ran to contiguous heat lamp 2310, and it is in the position of the first blanket face 230 of contiguous blanket layer 220.Heating lamp 2310 can be used for heating blanket layer 220.Using heating lamp 2310 is optionally, is not essential.
Then, blanket layer 220 runs to contiguous header box (header pipe) 2410, and it is fixed on the position of the second surface 232 of contiguous blanket layer 220.Header box 2410 has an opening, and whereby, second kind of material 2000 can be coated directly onto on the second surface 232 of blanket layer 220.Second kind of material is applied to blanket layer 220 with liquid condition, with occupy the surface 230 and 232 between the blanket layer to the small part hole.In Fig. 4 B, second kind of material is applied to blanket layer 200 with the whole blanket layer thickness between impermeable surface 230 and 232.The blanket layer 220 that deposits second kind of material 2000 is directly arrived whole blanket layer 220 thickness between the surface 230 and 232 by the nip between the roller 2,472 2470 to guarantee second kind of distribution of material.In addition, second kind of material 2000 can be applied to the first surface 230 of blanket layer 220.
Second kind of material 2000 filled the hole of blanket layer 220, thereby stoped the infiltration of liquid light maleate resin to whole blanket layer 220.The effect of second kind of material 2000 is that the resin of avoiding curable enters the specific part that contains hole blanket layer 220.Preferably, second kind of material is easy to coat carrier, and can be by curable resin from 220 displacement of blanket layer.After the resin solidification of coating blanket layer 220, second kind of material also preferably is easy to get rid of from blanket layer 220.
In one embodiment, second kind of material 2000 (1) relatively flow regime coat blanket layer 220 so that second kind of material 2000 is penetrated into whole blanket layer 220; (2) after it is applied to the blanket layer and photosensitive resin coat before the blanket layer 220, can make its flowability to its change, thereby stop second kind of material 2000 to be replaced by photosensitive resin with reduction; (3) after part resin solidification at least, can make its flowability to its change, thereby be convenient to of the eliminating of second kind of material from blanket layer 220 hole with increase.
In one embodiment, when at first being applied to carrier, second kind of material is flowable relatively.For example, when at first being applied to carrier, second kind of material can comprise liquid, is dissolved in the solute in the liquid flux, is dispersed in the solids in the liquid component of second kind of material, or the mixture of liquid reaction component.After second kind of material coated carrier, and in curable resin-coating before carrier, compare when at first coating carrier, second kind of material changed make it have less relatively flowability, thereby provide a barrier layer to infiltrate the predetermined portions of carrier to prevent curable resin.
Before carrier, preferably, second kind of material coating carrier becomes immobilising relatively by following method in curable resin-coating, for example: the viscosity that improves second kind of material; At least make second kind of material of part become solid-state by liquid state; The fluid components of second kind of material of evaporation is to form the fine-celled foam barrier layer of blocking film or sealing in carrier; Or the generation chemical reaction makes the liquid reaction component of second kind of material be transformed into the reactor product of full-bodied or solid.Although Fig. 4 B puts up with the second kind of material that forms gel to 4H and discusses, other example of the second kind of material that is fit to also provides as follows.
In one embodiment, the present invention includes this step, promptly change the state of second kind of material 2000 coating blanket layer 220.Phrase " changes the state of second kind of material " and refers to when certain temperature and pressure the discontinuous variation of certain performance of second kind of material.The state that changes second kind of material comprises makes second kind of material become liquid phase or solid phase by gas phase, makes second kind of material become gas phase or solid phase by liquid phase and makes second kind of material become gas or liquid phase by solid phase.The example of the state variation of second kind of material includes, but not limited to make the liquefaction of second kind of material, makes second kind of material distillation and by making second kind of material solidification or gelation make second kind of material cured.In one embodiment, second kind of material stood the phase transformation from the solid phase to the liquid phase, and this is to carry out under the temperature of the resin degraded that is lower than curing (i.e. the temperature that melts or decompose less than the resin that solidifies), and more preferably carries out in the time of about 50～150 °F.
Referring to Fig. 4 B, in one embodiment, second kind of material is at elevated temperatures, coats blanket layer 220 with the form of the liquid mixture of water and gelling agent.The liquid mixture of water and gelling agent is cooled off on blanket layer 220 to form solid gel second kind of material mutually, fill the hole in the blanket layer 220.
Before photosensitive resin is coated blanket layer 220, preferably remove (but not being whole) second kind of material from blanket layer 220.Referring to Fig. 4 C, the present invention includes from the first surface 230 of contiguous blanket layer 220 and get rid of the step of second kind of material, thereby the essentially no second kind of material of segment thickness of blanket layer 220 is provided.If second kind of material comprises gel, second kind of material of one deck of the first surface 230 of contiguous blanket layer 220 can use water injector 2510 to remove.In addition, can remove second kind of material layer from blanket layer 220 by mechanical cleaning.Second kind of material of one deck of removing contiguous first surface 230 provides the blanket layer 220 of predetermined portions thickness, photosensitive resin can coat this part and has been fixed in this at last.
Referring to Fig. 4 D, the present invention includes the step of curable resin-coating in carrier.In the embodiment illustrated, after surface 230 was got rid of, one deck liquid light maleate resin 2010 was applied to the first surface 230 of the exposure of blanket layer 220 at second kind of material of part.A kind of veil 3010 is fixed on contiguous this liquid resin layer 2010.Veil 3010 has opacity 3012 and clear area 3014.Pressure roller 3100 controls are deposited on the depth d of the resin bed 2010 on the blanket layer 220.Selected depth d makes the surface 260 of its resin bed that approximates curing 250 and the Desired Height between the blanket face 230 (Fig. 4 G) differ from 262 thickness that add second kind of material 2000 of that layer that the blanket layer from Fig. 4 C is got rid of.
Referring to Fig. 4 E, the present invention includes and to coat the partly solidified at least step of resin of carrier.In one embodiment of the present invention, Choice of Resin ground is solidified to form the resin bed with pattern decorative on carrier.In Fig. 4 E, resin solidification lamp 3150 provides actinic radiation sources in first curing schedule, so that small part is solidified the liquid light maleate resin layer 2010 that is deposited on the blanket layer 220.Veil 3010 is positioned in the middle of lamp 3150 and the liquid light maleate resin layer 2010.By veil 3010, liquid light maleate resin is exposed under the actinic radiation selectively, thereby makes the curing of photosensitive resin and align with the clear area 3014 of covering in 3010.First curing schedule provides the resin bed 250 with pattern decorative that solidifies at least in part on the first surface 230 of blanket layer 220.
Referring to Fig. 4 F, the present invention can comprise this step, promptly after first curing schedule shown in Fig. 4 E, gets rid of uncured resin from carrier.In Fig. 4 F, uncured resin is represented by 2010A.Veil 3010 can be removed from the resin bed 250 with pattern decorative.Use water injector 2530 to get rid of uncured resin 2010A then.Water injector is had a certain degree, can from opening 270, remove uncured resin 2010A like this with the resin bed 250 of pattern decorative.Solidified second kind of material 2000 can be avoided the whole thickness of uncured resin penetration blanket layer 220, and keeps the first surface 230 of the uncured contiguous blanket layer 220 of resin.Therefore, uncured resin 2010A is easy to use water injector 2530 to get rid of from the opening 270 of resin bed 250 relatively.Referring to Fig. 4 G, the present invention includes this step, promptly resin-coated after carrier, second kind of material 2000 of exclusive segment at least from the carrier.In embodiments, if second kind of material 2000 as by gel solidification, can be by second kind of material being heated to its temperature more than gelling temp, thereby being liquefied, second kind of material of gel remove second kind of material 2000.In Fig. 4 G, blanket layer 220 runs to contiguous heat lamp 3170, and it is positioned at the position of the first surface 230 of contiguous blanket layer 220.Second kind of material 2000 can be with heat lamp 3170 heating so that second kind of material fluidization.Then, available heat water spray system 2550 flushing blanket layers 220, and be placed directly on the vacuum tank 2570 to get rid of second kind of material and any uncured photosensitive resin that stays of fluidization.In Fig. 4 G, heat water-spraying's device 2550 directly washes facing to the first surface 230 of blanket layer 220.Vacuum tank 2570 has produced a vacuum at the second surface 232 of blanket layer 220, to get rid of second kind of material of fluidization from second surface 232.If necessary, can repeat to spray and vacuumize, to get rid of second kind of material of fluidizations from blanket layer 220.
Preferably, get rid of second kind of material 2000 coating carrier of at least 50%, and most preferably, from carrier, get rid of second kind of material 2000 that all coat carrier basically.Shown in Fig. 4 C and 4G, before liquid resin is coated carrier and after, all can get rid of second kind of material from carrier.In the illustrated embodiment, second kind of material getting rid of after liquid resin is coated carrier is than these resin-coated remove in the carrier front row many.
In Fig. 4 F and 4G, uncured liquid resin is to wash off before second kind of material eliminating of staying on the blanket layer 220.In addition, can get rid of all second kind of materials 2200, then wash uncured liquid resin off from blanket layer 220 from blanket layer 220.
Referring to Fig. 4 H, the method according to this invention can comprise from blanket layer 220 gets rid of the back curing schedule that is carried out behind all uncured liquid resin 2010A and all second kind of materials 2000 basically.An actinic radiation sources is positioned on the resin bed 250 so that the curing fully of resin bed 250 as cure lamp behind the resin 3180.Preferably before resin bed 250 is by lamp 3180 final curings, get rid of all second kind of materials and all uncured liquid resins from carrier, this can be avoided the accidental of resin in the part blanket layer 220 to solidify, and this a part of blanket layer 220 is air permeable and water preferably.As described below, back curing schedule can be by placing water-bath 1620 to carry out resin bed 250, thereby promote the photosensitive resin complete reaction.
The paper web supporting arrangement 200 of gained has the resin bed 250 of curing, the first surface 230 of its infiltration blanket layer 220, thus expand in the middle of first surface 230 and the second surface 232.The resin bed 250 that solidifies also can be from first surface 230 expansions highly to have an end face that contacts with paper web 260 at second of the height that is different from first surface 230.
Be used to fill the example of second kind of material of carrier mesopore
Many materials all are suitable for use as second kind of material 2000 of filling carrier mesopore to avoid the whole thickness of liquid resin penetrating carrier.Preferably, second kind of material is to coat carrier before liquid resin is coated carrier.Yet in another embodiment, second kind of material can be coated carrier, coated the liquid resin of carrier with the displacement front.Following example is illustrative, but is not limited to these.
In one embodiment, second kind of material can comprise water.If water is as second kind of material 2000, preferably use distilled water, be deposited on the carrier to avoid hard water.For example, water can be applied to blanket layer 220 by liquid, and keeps liquid in the whole steps of adding and solidified liquid photosensitive resin.In that resin-coated to keep water during in carrier be that the shortcoming that liquid has is if before resin solidification with liquid curable, part water (if not most of) can be replaced by liquid resin.
In another embodiment, water can be used as liquid and coats blanket layer 220, and solidifies before the liquid light maleate resin coating then.Can form one deck ice by the state that makes water-setting change water admittedly in the blanket layer, this can be avoided liquid resin to be penetrated into the whole thickness of blanket layer 220.
In another embodiment, compare with the viscosity of coating blanket layer 220 at first, second kind of material can be transformed into has the viscosity that increases considerably.The viscosity that increases considerably second kind of material is meant that the viscosity of second kind of material increases by 10 times at least, and preferably increases by 100 times.For example, second kind of material can comprise solvent and solute, as water and the mixture that is dissolved in the solute component in the water.Soluble component can comprise water soluble resin such as polyvinyl alcohol, and it coats the blanket layer with the temperature and the low-solid content that raise." be dissolved in the water " and be meant that this component can be dissolved in the deionized water 25 ℃ of amounts at least about 1.0%.
Specifically, second kind of material can comprise the aqueous solution of the Elvanol HV (can be from the DL state, the Dupont company in Wilmington city has bought) of 8% (by weight).Second kind of material can be coated carrier in about 160 temperature.This solution has the viscosity of about 250 centipoises and is easy to fill hole in the blanket layer 220.It is about 14% the concentration of solution to be brought up to by evaporation water, and the temperature of solution can be reduced to about 70 °F, so that the viscosity of second kind of material is increased to about 35,000 centipoises.After the photosensitive resin coating and solidifying, can preferably use hot water that Elvanol is dissolved again.
In another embodiment, second kind of material can comprise the hydrosol that is dissolved in the water.Preferred glue shows pseudoplastic behavior (shear thinning)." shear thinning " is meant when this material is subjected to shearing force, and its viscosity reduces.In one embodiment, the high viscosity guar gum aqueous solution of 1-3% is added the carrier that contains hole, this glue and the aqueous solution are subjected to the temperature of shear rate and rising simultaneously.Be higher than about 1/10 minute shear rate and at least about 60 ℃ temperature under, this glue and viscosity in aqueous solution can be reduced to is enough to make the glue and the aqueous solution easily to fill the hole of blanket layer 220.Eliminate the shear rate of the glue and the aqueous solution then, and make this solution be cooled to about 70 °F, to form glue and the aqueous solution of viscosity more than or equal to about 50,000 centipoises.Glue and viscosity in aqueous solution have avoided curable liquid resin to replace the glue and the aqueous solution from blanket layer 220.R.L.Davidson in 1980, " hydrosol and the resin handbook " that McGraw-Hill edits (handbook of water soluble gums and resins), 6-1 incorporates into own forces in this for reference to the 6-8 page or leaf, purpose is the hydrosol and the application that openly is fit to and measures shear rate.
In another embodiment, second kind of material can comprise the mixture of water and second kind of component, and wherein water is as removing from mixture by dry or evaporation.For example, second kind of material can be applied to blanket layer 220, thereby and water can provide a barrier layer to prevent that photosensitive resin from permeating this carrier as from second kind of material, getting rid of by evaporation.Then, use water injector flush away barrier layer from carrier, thereby get rid of the barrier layer from carrier.For example, second kind of material can comprise with the water of glycerine plasticizing and the solution of high molecular weight polyvinyl alcohol.This solution can be liquid in the time of 70 °F, and when the water in the solution evaporated, it can change film forming.The polyvinyl alcohol that is fit to comprises Elvanol 90-50 and Elavanol 71-30 (can be from the DL state, the Dupont company in Wilmington city has bought).The polyvinyl alcohol of the 6-8% (by weight) that the aqueous solution that is fit to comprises.Before in PVA mixed entry, can make the polyvinyl alcohol plasticizing by the mixture of making about 90～95% polyvinyl alcohol and about 5～10% (by weight) glycerine.Mixture with polyvinyl alcohol and glycerine is added in the water then, contains the aqueous solution of about 6-8% (by weight) polyvinyl alcohol with formation.
In another embodiment, second kind of material can comprise the solid that is dispersed in the liquid.For example, second kind of material can comprise the latex rubber that is dispersed in the low Tg in the water.This dispersion liquid can comprise the polyacrylic acid latex resin of about 40% (by weight) in water.The polyacrylic acid latex resin can comprise Roplex TR-520 polyacrylic acid latex resin, and it can have been bought from Robm and Haas company.In case evaporation of water in the dispersion liquid, solid gum milk-globule body condenses into rubbery membranes, if the temperature of film remains on below the crosslinking temperature of latex rubber, it is easy to water and disperses so.In addition, can add blowing agent in dispersion liquid, it can produce gas by heating.For example, diazonium urea can be added in latex resin and the aqueous dispersion, producing nitrogen by heating, thereby in case in the dispersion water evaporation form latex foam.
In a kind of embodiment scheme, second kind of material can comprise water miscible wax-like materials, as polyethylene glycol (PEG).PEG has the fusing point of the degradation temperature that is lower than curable photosensitive resin, this make second kind of material or be solid when being bordering on about 70 °F, and can below the degradation temperature of curable photosensitive resin, liquefy.For example, having the PEG that is higher than about 600 molecular weight is fit to.Especially specifically, second kind of material can comprise the PEG1500 that fusing point is about 46 ℃, and fusing point is about 56 ℃ PEG4000, and fusing point is about 60 ℃ PEG6000 and its mixture.In addition, second kind of material can comprise low-molecular-weight relatively PEG, and as PEG400, it can keep liquid condition in photosensitive resin coating and setting up period.
Second kind of material 2000 also can comprise the dispersible surfactant system of water soluble surfactant active and water.For example, second kind of material can comprise the liquid scrubbing agent solution, as comprises the detergent solution of anion and non-ionic surface active agent, a kind of ethanol partitioning agent and water.This detergent solution can be at the resin-coated carrier of coating before carrier.This detergent solution can be bought with Joy Brand Diswashing Liquid from the Procter § Gamble company of the city of Cincinnati, Russia last of the twelve Earthly Branches Florida State.
Second kind of material 2000 also can be included in and be the water soluble surfactant active of solid or the dispersible surfactant system of water below 70 °F.Water soluble surfactant active's example comprises the derivative of sulfosuccinic acid.These materials are coated with as the aqueous solution, can dryly form pliable and tough obstruction film (occlusivefilm), and this film is suitable for forming the barrier layer and permeates this carrier to prevent liquid light maleate resin.An example of anion surfactant is Aerosl OT-75 (can buy from the Cyanimid company of the U.S.).Aerosol OT surfactant is the dioctyl ester of sodium sulfosuccinate.
But the example of the water decentralized system that is fit to comprises the mixture of chain alkyl quaternary surfactant and PEG400 or glycerine.More particularly, the mixture of about 70% (by weight) two (butter of slight sclerosis) alkyl dimethyl ammonium chloride and about 30% (by weight) PEG400 (at about 70 is starchiness wax, is liquid at about 150) can be used for preparing second kind of material 2000.
In another embodiment, second kind of material can comprise the reaction combination, and it is a liquid in room temperature, or water-soluble solid water-soluble and that can be grouped to higher molecular weight or high viscosity paste.For example, second kind of material can comprise about by weight 10% acrylic acid, about 20% sodium acrylate, about 70% water and the mixture of radical initiator.This radical initiator can cause by heating.The example of radical initiator is V-50, a kind of 2,2 '-azo two (2-amidine propane) dihydrochloride, can buy from the Wako chemical company in Texas Dallas city.
In another embodiment, second kind of material can comprise gelling agent.The gelling agent that is fit to includes, but not limited to the plant gelling agent, for example pectin, carrageenan, agar, animal protein gelatin, aquogel polymerization gelling agent and soap gelling agent.Water soluble is a JELLO board gelatin with the example of the gelling agent that forms second kind of material 2000, can buy from the General Foods Corp. in White Plains city, New York.
The aquogel polymerization gelling agent that is fit to comprises partial cross-linked at least polymer, and it is by polymerisable unsaturated acidiferous monomer preparation, and this monomer is water-soluble or becomes water-soluble by hydrolysis.These monomers comprise the unsaturated compound of the olefinic with at least one hydrophilic group, and this comprises ethylenic unsaturated acid and the acid anhydrides that comprises the two keys of at least one carbon-to-carbon alkene.The Application No. 08/307 that people such as Trandai submitted on September 16th, 1994,951, the application for a patent for invention of " the moderate gel fragrance that comprises soap, polymeric hydrogel polymer and high water gaging is formed " by name is for reference at this, and purpose is open gelling agent.
The soap gelling agent that is fit to comprises and has 12～40 carbon atom (C
12-C
40) the monobasic slaine of aliphatic acid, and more preferably C
12-C
22Soap.The salt-forming cation that is fit to that is used in these gelling agents comprises slaine such as alkali metal, as sodium and potassium.In one embodiment, second kind of material comprises and is selected from fatty acid sodium salt, the soap of aliphatic acid sylvite and other composition.
The example that is used for the aliphatic acid of synthetic soap gelling agent comprises tetradecanoic acid, hexadecanoic acid, octadecanoid acid, oleic acid, linoleic acid, linolenic acid, Heptadecanoic acide and these sour mixtures.The source of above-mentioned aliphatic acid includes, but not limited to coconut oil, butter, lanolin, fish oil, beeswax, palm oil, peanut oil, olive oil, cottonseed oil, soya-bean oil, corn oil, rapeseed oil, rosin acid, lubricating grease, castor oil, Linseed oil, oiticica oil (Oiticica), neat's foot oil, safflower oil, sesame oil, Sorghum Oil, sunflower oil, appropriate chi oil, tung oil, butter, poultry oil, whale oil and rice bran oil.
Preferred fatty acid soaps gelling agent comprises sodium laurate, tetradecanoic acid sodium, hexadecanoic acid sodium, odium stearate, potassium laurate, potassium myristate, hexadecanoic acid potassium, and potassium stearate.In one embodiment, second kind of material 2000 comprises water-soluble tetradecanoic acid sodium solution.It is about by weight 5～30% that the solution that is fit to comprises, and more preferably from about 5～20% tetradecanoic acid sodium is dissolved in the water.This solution has about 90～120 gelation temperature.Tetradecanoic acid sodium can be by making tetradecanoic acid (C
13H
27COOH) form with the reactant aqueous solution of NaOH.React completely for making, alkali and acid add by stoichiometry.Be added to NaOH in the water and be heated to about 180 °F.Then tetradecanoic acid is added to gradually water/NaOH solution.This reaction will continue about 1 hour.Before being applied to blanket layer 220, make formed tetradecanoic acid sodium solution be cooled to about 140～160 °F then.
The advantage of the solution of this soap gelling agent and water is, with resin-coated before carrier, it can be solidified into gel phase at 50 °F～150 °F.Therefore, this gel phase can stop the displacement of liquid light maleate resin at room temperature (about 70), and does not need refrigerating plant to be cured.In addition, this solution mainly is water (when being applied to blanket layer 220, having 70% water (by weight) at least).Therefore, the eliminating of second kind of material removing from blanket layer 220 and handle just to become and oversimplified, and ambient influnence minimum.
Formation has the method for continuous operation band of the resin bed of blanket layer and pattern decorative
Fig. 5 schematically illustrates the method for making paper web supporting arrangement 220 according to one embodiment of the invention, and this device is the shape of continuous operation band, and it comprises the blanket layer 220 of the resin bed 250 with curing.In the embodiment depicted in fig. 5, blanket layer 220 can comprise the Amflex2 blanket, and it can be bought from the Appleton Paper Making Machinery Plant in Wisconsin Appeton city, and photosensitive resin can comprise the MEH-1000 resin, and it can be bought from the Hercules chemical company.
The building mortion 1513 of the roll form with working surface 1512 is provided.Make building mortion 1513 rotations by a driving arrangement (not shown).Provide counterdie 1503 by roller 1531, and received by roller 1532.Between roller 1531 and 1532, counterdie 1503 is taped against the working surface 1512 of building mortion 1513.The effect of counterdie is the working surface of protection building mortion 1513 and is convenient to the paper web supporting arrangement 200 disengaging building mortions 1513 that part is finished.Counterdie 1503 can be made by any suitable material, includes, but is not limited to thickness and be 0.01～0.1 millimeter polypropylene screen.
As shown in Figure 5, being the banded dehydration blanket layer 220 of continuous operation moves around shaping roller 1513 and many slewing rollers 1511 with closed path.Before second kind of material and liquid resin were coated blanket layer 220, dehydration blanket layer 220 can move by heat lamp 2310 so that 220 preheating of blanket layer.
Be applied to that second kind of material on the blanket layer 220 can be cooled to below 90 °F so that second kind of material cured cooled off second kind of material and can be made the tetradecanoic acid sodium in blanket layer 220 hole become the stabilizing gel phase.After the gel phase of second kind of material settling out formed, blanket layer 220 ran to the speed of about 2～4 feet per minutes and is adjacent to water injector 2510.This water injector has a nozzle, and it is positioned at apart from the about 3 inches position of the first surface 230 of blanket layer 220, is used for removing from blanket layer 220 second kind of material of part (but not being whole) gelation.Nozzle has produced many to be staggered to form the fan-shaped spray pattern of arrangement.Water injector 2510 sprays 1.5 gallons water approximately at the surface region of every square feet of blanket layer 220.This nozzle is Tee Jet board nozzles spray system 50015 types (Spray Systems Tee Jet brand), and its aperture is 0.031 inch.The water that is sprayed is carried by water injector 2510, and temperature is about 90 °F, and with about 500 pounds/inch
2Pressure be transported to nozzle.
Operation water injector 2510 to be removing second kind of material of contiguous first surface 230, thereby the essentially no second kind of material of segment thickness of blanket layer 220 is provided.Water injector 2510 can be used for getting rid of second kind of material that thickness is 0.002～0.2 inch layer of gel.The thickness of second kind of material of that layer gel of being got rid of is less than the thickness of blanket layer 220, this makes the thickness of blanket layer 220 of about 75%-98% still keep by second kind of material soaking of gel, and the thickness of the blanket layer 220 of 85%-95% maintenance second kind of material soaking of gel still after with water injector 2510 flushings most preferably from about.At the first surface 230 of blanket layer 220, vacuum head 2520 produces about 1-4 pound/inch
2Vacuum, with the second kind of material getting rid of fluidization and the water of sprinkling.
In case after obtaining the first surface 230 of blanket layer 220 from second kind of material preparation of blanket layer 220 exclusive segment (not being whole), just photosensitive resin can be applied to first surface 230.Dehydration blanket layer 220 is positioned at the position of contiguous counterdie 1503, and this makes counterdie 1503 between dehydration blanket layer 220 and building mortion 1513, and makes the second blanket face 232 of dehydration blanket layer 220 be positioned at the position of contiguous counterdie 1503.Liquid light maleate resin coating is coated on the first blanket face 230.Liquid light maleate resin coating 1502 can be coated with the first blanket face in any suitable manner.In Fig. 5, cold coating is coated with by nozzle 1520, forms a beach resin with the upstream of the nip that forms at pressure roller 3100 on blanket layer 220.
The resinous coat controllable thickness system of coating blanket layer 220 is to predetermined value, and this value forms the desirable difference in height 262 that contacts 260 of end faces with paper web of layer 250 corresponding to the first blanket face 230 and paper web pattern.In Fig. 5, resin-coated thickness can be controlled by the spacing of mechanically controlling between pressure roller 3100 and the building mortion 1513.Pressure roller 3100 tends to the smoothing resin surface and controls its thickness together with veil 3010 and veil guide roller 1542.Second kind of material of gel prevents part blanket layer 220 thickness that liquid light maleate resin infiltration is occupied by second kind of material of gel.
See through veil 3010, photosensitive resin is exposed under the actinic radiation of radiation wavelength, thus cause with that part of resin bed that aligns in the clear area of veil 3010 in resin partly solidified at least.In Fig. 5, the ultra-violet radiation with radiation wavelength is provided by first cure lamp 3150.Radiation wavelength is a characteristic of resin, and it can be provided by any suitable light source, as mercury-arc lamp, and xenon flash lamp, electrodeless lamp and fluorescent lamp.For the MEH-1000 resin, suitable cure lamp 3150 is F450 Fusion lamp that " D " or " H " bulb is housed, and can buy from the Fusion lamp system house in Rockville city, Md state.During curtain coating, blanket layer 220 runs to contiguous cure lamp 3150 with the speed of about 1-3 feet per minute.
Curing facing to the resin of the clear area of veil 3010 has shown the partly solidified of resin, and still keeps liquid facing to the unexposed portion resin of the opacity of veil 3010.For making the resin on the blanket layer 220 obtain uniform initial solidification, should be uniform on the width of whole blanket layer 220 to the energy that photosensitive resin provides by uviol lamp.From the energy of each cure lamp 3150 outputs should be coupling mutually, and is mutual in 5%.Cure lamp 3150 can be placed side by side along paper machine horizontal (vertical with the plane of Fig. 5).For example, three cure lamp 3150 can be placed side by side in paper machine direction.A pair of light hole plate places in the middle of lamp 3150 and the blanket layer 220, and on paper machine direction certain intervals is arranged, and to form the light hole gap, by this light hole gap, ultraviolet light can directly be radiated on the resin that is coated on the blanket layer 220 from lamp 3150.
The gross energy that directly is radiated blanket layer 220 can (lightbug) be measured by " the moving mark of light ", is the EIT UV Integrating Radiometer of UR 365CH1 as the model of being made by the electronic instrument technology company that is positioned at Sfirling Virginia (Electronic InstrumentationTechnologies).The moving mark of light can be fixed on the casting roller 1513, with mensuration be applied to blanket layer 220 whole energy (millijoule/centimetre
2).On the whole width of roller 1513, per 1/2 inch replication once so just can determine to be given by lamp 3150 Energy distribution of photosensitive resin.Even the light hole distance between plates along the width of roller 1513 is uniformly, but Energy distribution also is uneven usually.Spacing between the light hole plate can transversely change the position with the paper machine, thereby uniform Energy distribution is provided, and this is to be transported on the resin on the blanket layer 220 by lamp 3150.
After the resin bed of coating first surface 230 is partly solidified, can get rid of all uncured liquid resins basically from dehydration blanket layer 220.The mixture of available water or surfactant and water comes high-pressure spray wash blanket layer 220, thereby gets rid of uncured liquid resin from blanket layer 220.In the position of adjacent roll 1542, veil 3010 and counterdie 1503 and blanket layer 220 and partly solidified resin bed separate.Compound blanket layer 220 and partly solidified resin bed run to and close on water injector 2530.Adjust the angle of water injector 2530 and remove uncured resin 2010A from the opening of the resin bed of pattern decorative.
Then, compound blanket layer 220 and resin bed are by the water bath 1620 of distilled water or deionized water.At this moment, second of gel kind of material is also in the second blanket layer 220.Pass through water bath 1620 for the first time at compound blanket layer 220 and resin bed, close the back cure lamp 3180 that is positioned on the water bath 1620.Back cure lamp is that the final curing step that is described below is opened.
Behind the leaving water bath 1620, compound blanket layer and resin bed run to heat lamp 3170 and vacuum head 2560 centres with the speed of about 1-3 feet per minute.Heating lamp 3170 is heated to about 140 °F with second kind of material of gel, and this temperature is higher than the gelling temp of second kind of material, thereby all second kind of materials are liquefied so that get rid of from blanket layer 220 basically.Heating lamp 3170 is positioned at the position of the contiguous first blanket face 230, and vacuum head 2560 is the positions that are positioned at the contiguous second blanket face 232.Heating lamp 3170 also can be positioned at apart from the about 3 inches position of blanket layer 220.The heat lamp 3170 that is fit to is Prothern heating lamps of being made by ProcessThermal company, and has about 20 amperes rated power.At the second blanket face 232,1-5 pound/inch that vacuum head 2560 has produced
2Vacuum.
Then, compound blanket layer and resin bed run in the middle of hot-water spraying's the device 2550 and vacuum head 2570, and hot-water spraying's device 2550 directly sprays to the first surface 230 of blanket layer 220.About 140 distilled water of hot-water spraying's device 2550 usefulness Tee Jet board nozzles spray.The pressure that water injector produces is about 50～200 pounds/inch
2Vacuum head 2570 has produced about 1-5 pound/inch at the second surface 232 of blanket layer 220
2Vacuum, to get rid of second kind of material and any uncured liquid resin that stays of liquefaction from second surface 232.
Preferably, by heating lamp 3170, water injector 2550 and vacuum head 2560 and 2570, all second kind of materials have been got rid of from blanket layer 220 basically.If need, compound blanket layer 220 and resin bed can move around the closed path that is limited by roller 1513 and 1511, thereby can repeat by heating lamp 3170, water injector 2550 and vacuum head 2560 and 2570.Be to be understood that, get rid of second kind of material if be from blanket layer 220, multiple blanket layer 220 of group and resin bed have moved repeatedly around closed path, so this repeatedly by be at uncoated more second kind of material or liquid resin in blanket layer 220, and uviol lamp 3150 and 3180 is to carry out under the situation of closing.
Paper web supporting arrangement 220 can be checked with microscope, gets rid of from blanket layer 220 to confirm liquid resin and second kind of material that all are uncured.In addition, the cleannes of blanket layer 220 can be tested with drainage described below and measure.Paper web supporting arrangement 200 can be between Plexiglas up-hole plate with 3.25 inches openings and orifice plate.Up-hole plate and internal diameter are about 4 inches upright cylinder and link to each other.Distilled water is added in the cylinder so that keep about 4 inches high water columns in the cylinder.Measure 1 minute drainage time water yield by device 200.When the diverse location on paper web supporting arrangement 200 is measured, the drainage speed of paper web supporting arrangement 200 (centimetre
3/ second/foot
2) should be uniformly usually, and should not multiply by by the percentage of the projected area of the devices 200 of paper web pattern formation layer 250 covering at least about the drainage speed that equals blanket layer 220.
Implement final step of the present invention and comprise the second back curing schedule, purpose is that the resin bed on the first surface of blanket layer 220 is solidified fully.In case all second kind of materials and all uncured liquid resins are got rid of from blanket layer 220 basically, compound blanket layer 220 and resin bed just can pass through water bath 1620.The 3180 pairs of resin beds of back cure lamp that are positioned on the water bath 1620 have carried out last curing.Compound blanket layer 220 and resin bed are immersed in (preferably, water bath 1620 comprises water and reductant, as sodium sulfite) in the water bath 1620, and purpose is in order to get rid of the dissolved oxygen in the water, otherwise it will make the radically curing reaction in the water bath 1620 stop.
When back cure lamp 3180 was opened, compound blanket layer 220 and resin bed 250 passed through water bath 1620 with the speed of about 1-3 feet per minute.The back cure lamp 3180 that is fit to is top listed F450 lamps.Water in the water bath 1620 can make the actinic radiation from back cure lamp 1605 pass through, thereby is radiated resin bed 1521, has got rid of the oxygen that Raolical polymerizable is stopped simultaneously.The depth of water in the water bath 1620 is about the 1-4 inch.After water bath 1620 came out, compound blanket layer 220 and resin bed 250 (Fig. 4 H) moved on vacuum head to remove from blanket layer 220 and anhydrate.
After be cured as lamp 1605 when opening, make compound blanket layer 220 and the resin bed back curing schedule by water bath 1620 can repeat about 1-3 time till resin bed 250 is no longer sticking.At this moment, blanket layer 220 and the resin that solidifies have formed paper web supporting arrangement 200 together, and it has completely crued paper web patterned layer 250.When lamp 3150 is closed, move 1-3 time around roller 1513 and 1511 loops that form by making compound blanket layer 220 and resin bed, just can repeat the back curing schedule.
In one embodiment, can provide veil 1504 with continuous net-shaped clear area.This veil can be used for making paper web supporting arrangement 200, and this device has paper web patterned layer 250, and this layer has continuous netted paper web contact end face 260, has a large amount of discontinuous openings 270 in this surface, as shown in Figure 1.Form the conduit that forms in the layer 250 by the paper web pattern, each discontinuous opening 270 can communicate with the first blanket face 230.For opening 270, the shape that is fit to includes, but not limited to circle, in ellipse, polygon, irregularly shaped or its combined shaped of paper machine direction (MD shown in Figure 5) elongation.The proj ected surface areas of continuous net-shaped end face 260 be about paper web supporting arrangement 200 proj ected surface areas (as seen from Figure 1) 5～75%.And be preferably paper web supporting arrangement 200 (as seen from Figure 1) proj ected surface areas 20～60%.
In the embodiment depicted in fig. 1, contiguous network shape end face 260 can have approximately less than 700 discontinuous openings 270 in the proj ected surface areas of paper web supporting arrangement 200 per square inch, and preferably has about 70～700 discontinuous openings 270 in the proj ected surface areas of paper web supporting arrangement (as seen from Figure 1) per square inch.The continuous opening 270 of in the contiguous network shape end face each has about 0.5～3.5 millimeter effective free distance (free span), and effective free distance wherein is defined as 1/4 girth of the area of opening 270 divided by opening 270.Effective free distance can be 0.6～6.6 times of difference in height 262.There is the device of this configured openings 270 to can be used as the dry blanket on the paper machine or squeeze blanket, be used to make page structure with pattern decorative, this page structure has continuous network area (this continuous network area can for paper web contact end face 260 corresponding high tightness that compress, relative districts), and (these projectioies are corresponding with the position of surperficial 260 split sheds 270 with the projection of the many normally malcompressions that are dispersed in whole continuous networks regions.Preferably, in paper machine direction (MD) with cross paper machine direction (CD), discontinuous opening 270 is two-way staggered, as the United States Patent (USP) of issuing on January 20th, 1,987 4,637, described in 859, this patent is incorporated into own forces in this for reference.In the embodiment depicted in fig. 1, opening 270 is part overlap joints and two-way staggered, and opening has certain size and interval, this makes the edge of opening 270 in paper machine direction and laterally expansion mutually, and make be parallel to paper machine direction or laterally arbitrary drawn line all can pass through part opening 270 at least.
The mensuration of paper web supporting arrangement height
Measure the difference in height between the height 261 of the height 231 (Fig. 2) of the first blanket face 230 and paper web contact surface 260 with following method.The paper web supporting arrangement is placed on the flat horizontal surface, and makes paper web pattern formation aspect upwards.Circular contact surface is about recording needle that 1.3 square millimeters and vertical length be about 3 millimeters to be installed in and to make federal product size analyzer (Federal Products dimensiongauge) by federal Products Co., Ltd (Federal Products Company of Providenee, Rhode Ialand) and go up (regulating 432B-81 type amplifier uses to disconnect probe with EMD-4320 W1).This instrument can be proofreaied and correct by determining the voltage difference between two accurate partitions, and these two partitions have known thickness and known difference in height can be provided.For guaranteeing the free-running operation of recording needle, this instrument is in the height zeroing a little less than the first blanket face 230.Recording needle is placed on the height of being measured also to be reduced to measure.Recording needle has applied 0.24 gram/millimeter to measuring point
2Pressure.Highly locate at each, will measure at least three times, the difference of each height 231 and 261 average measurement is as difference in height 262.
Fig. 6 and 7 is micro-enlarged photographs of paper web supporting arrangement 200 constructed in accordance.Paper web supporting arrangement 200 among Fig. 6 and 7 is included in the resin bed 250 that solidifies on the dehydration blanket layer 220.The surface 230 of the resin bed 250 infiltration blanket layers 220 that solidify is so that the resin bed that solidifies expands to the part blanket layer thickness of adjacent surface 230.The resin bed 250 of this curing also can be from 230 expansions, so that 230 on the surface 260 of resin bed and surface produce certain intervals.
In above-mentioned described embodiment, carrier comprises dehydration blanket layer 220.Yet method of the present invention is used in the resin bed that forms pattern decorative on other carrier.For example, carrier can comprise paper making forming or dry blanket, and it comprises the fibril that is made into, and this blanket has about 300～1500 standard feet
3/ minute air permeability.The example of an indefiniteness of interchangeable carrier is to be described in to be presented to Trokhan and to incorporate paper machine blanket in this following United States Patent (USP) for reference into own forces: the United States Patent (USP) 4 that on March 4th, 1980 issued, 191, the United States Patent (USP) 4,239,065 that on December 16th, 609 and 1980 issued.
Claims (10)
1. one kind with curable resin-coated method on carrier, and this method comprises the following steps:
Provide have first surface, the carrier of second surface and thickness, this carrier has hole between first and second surfaces;
Curable liquid resin is provided;
The second kind of material that is different from curable liquid resin is provided;
Second kind of material coated carrier to occupy the hole of the part carrier between carrier first and second surfaces at least;
Before curable liquid resin is coated carrier, change the state of second kind of material of part at least;
With curable resin-coated in carrier;
Near small part resin solidification is to form resin bed on carrier; With
Removing from carrier to second kind of material of small part, is resin-coatedly to remove from carrier after carrier curable to second kind of material of small part wherein.
2. also be included in before the step with resin solidification according to the method for claim 1, near small part is coated the step of second kind of material cooled of carrier.
3. also be included in before the step of removing second kind of material from carrier according to the method for claim 1 or 2, near small part is coated the step of second kind of material heating of carrier.
4. according to claim 1,2 or 3 method, it is characterized in that the step of removing second kind of material from carrier comprises the following steps:
With resin-coated before carrier, from carrier remove the part rather than whole second kind of material; With
With resin-coated after carrier, remove to second kind of material of small part from carrier.
5. according to claim 1,2,3 or 4 method, it is characterized in that, thereby the step of coating liquid resin comprises with the first surface of resin-coated first surface penetrating carrier in carrier and from the first surface expansion of carrier; And the liquid resin step of curing is included selectively the resin bed of liquid resin step of curing with pattern decorative that a kind of first surface expansion from carrier is provided.
6. according to claim 1,2,3,4 or 5 method, it is characterized in that carrier comprises papermaking dehydration woollen blanket.
7. according to claim 1,2,3,4,5 or 6 method, it is characterized in that second kind of material comprises water.
8. according to claim 1,2,3,4,5,6 or 7 method, it is characterized in that second kind of material comprises the component that is selected from glycerine, polyethylene glycol, polypropylene glycol and composition thereof.
9. according to claim 1,2,3,4,5,6,7 or 8 method, it is characterized in that second kind of material comprises gelling agent.
10. according to claim 1,2,3,4,5,6,7,8 or 9 method, it is characterized in that second kind of material comprises the gelling agent that is selected from sodium laurate, tetradecanoic acid sodium, hexadecanoic acid sodium, odium stearate, potassium laurate, potassium myristate, hexadecanoic acid potassium, potassium stearate and composition thereof.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN 96192981 CN1180392A (en) | 1995-02-15 | 1996-01-24 | Method of applying curable resin to substrate for use in papermaking |
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US08/391,372 | 1995-02-15 | ||
| CN 96192981 CN1180392A (en) | 1995-02-15 | 1996-01-24 | Method of applying curable resin to substrate for use in papermaking |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN1180392A true CN1180392A (en) | 1998-04-29 |
Family
ID=5128569
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN 96192981 Pending CN1180392A (en) | 1995-02-15 | 1996-01-24 | Method of applying curable resin to substrate for use in papermaking |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN1180392A (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN106661838A (en) * | 2014-07-28 | 2017-05-10 | 福伊特专利有限公司 | Method for producing or machining a roller, roller and functional layer of a roller |
-
1996
- 1996-01-24 CN CN 96192981 patent/CN1180392A/en active Pending
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN106661838A (en) * | 2014-07-28 | 2017-05-10 | 福伊特专利有限公司 | Method for producing or machining a roller, roller and functional layer of a roller |
| CN106661838B (en) * | 2014-07-28 | 2019-07-23 | 福伊特专利有限公司 | It is used to prepare or the method for making roller, roller and function drum layer |
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