EP0511185A1 - Procédé et dispositif pour la fabrication de carton cellulosique à couches multiples et les articles ainsi obtenus - Google Patents

Procédé et dispositif pour la fabrication de carton cellulosique à couches multiples et les articles ainsi obtenus Download PDF

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Publication number
EP0511185A1
EP0511185A1 EP92850092A EP92850092A EP0511185A1 EP 0511185 A1 EP0511185 A1 EP 0511185A1 EP 92850092 A EP92850092 A EP 92850092A EP 92850092 A EP92850092 A EP 92850092A EP 0511185 A1 EP0511185 A1 EP 0511185A1
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EP
European Patent Office
Prior art keywords
fibers
fabric
layer
web
slurry
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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EP92850092A
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German (de)
English (en)
Inventor
Wayne R. Self
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International Paper Co
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International Paper Co
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Filing date
Publication date
Application filed by International Paper Co filed Critical International Paper Co
Publication of EP0511185A1 publication Critical patent/EP0511185A1/fr
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    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21F—PAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
    • D21F11/00—Processes for making continuous lengths of paper, or of cardboard, or of wet web for fibre board production, on paper-making machines
    • D21F11/02—Processes for making continuous lengths of paper, or of cardboard, or of wet web for fibre board production, on paper-making machines of the Fourdrinier type
    • D21F11/04—Processes for making continuous lengths of paper, or of cardboard, or of wet web for fibre board production, on paper-making machines of the Fourdrinier type paper or board consisting on two or more layers

Definitions

  • This invention relates to multiply cellulosic, e.g. paper, board which is particularly suitable for use in the manufacture of containers for liquid food products, and more particularly for disposable milk cartons, and to methods and apparatus for the manufacture of such board.
  • Disposable containers for liquid food products have long been manufactured from cellulosic board that is formed using conventional fourdrinier papermaking machines. Such board is most usually single ply and of a basis weight in excess of about 150 lb./3000 ft2. Of recent there has been considerable effort exerted toward producing multiply board for use in such disposable containers in an effort to reduce the overall cost of the board, while maintaining those board properties that are essential for its successful use in disposable liquid food containers. Systems such as those shown in U.S. Patent Nos. 3,681,193, 3,891,501, 4,004,968 and 4,472,244 have been suggested for use in making multiply paper board. In these patents the apparatus and methods disclosed for the manufacture of multiply board, i.e.
  • first and second streams of cellulosic pulps are deposited substantially simultaneously onto a forwardly moving foraminous papermaking fabric, e.g. a fourdrinier wire, to develop first and second layers of a multiply web.
  • a forwardly moving foraminous papermaking fabric e.g. a fourdrinier wire
  • These overlaid layers are dewatered to a consistency of between about 1.8% and about 3.5%, by weight, and thereupon are mechanically integrated at their interface and their formation enhanced.
  • Such mechanical integration further conditions the upper surface of the second layer for the receipt of a third layer of pulp.
  • Such third layer is developed by depositing a stream of cellulosic pulp onto the upper surface of the second layer at a location just down-stream of the wet line of the bilayered web on the wire.
  • the three layers are captured between the initial forming fabric and a further formaminous forming fabric that is overlaid onto the top surface of the third layer.
  • the multilayered web is dewatered upwardly through the several layers of the web to hydraulically integrate the second and third layers and enhance the integration of the first and second layers.
  • the web is further dewatered, dried and collected.
  • the web is dried and fed through a size press prior to final drying to develop a surface size on opposite surfaces of the web, and then calendered.
  • the composition of the second layer of fibers includes less expensive fibrous matter, such as a larger percentage of hardwood fibers, and the total quantity of fibers deposited as the second layer preferably is between about 0% and about 300% greater than the quantity of the fibers deposited in forming either the first or third outer layers.
  • the apparent bulk of the second (inner) layer preferably is greater than that of either of the first or third layers, but the overall caliper of the board product is maintained at about the same caliper as single ply board made from the same total weight of fibers.
  • the multiply board of the present invention exhibits pertinent properties that are equal to or superior to the same properties of single ply board.
  • the present board exhibits the modulus, stiffness, bulge resistance, and other properties of a single ply board, and does so with the present board containing between about 9% and 11% less fiber content, by weight.
  • FIG. 1 there is depicted a preferred embodiment of apparatus for carrying out the method of the present invention and comprises a continuous loop fourdrinier wire 10 which is trained about a breast roll 12, a couch roll 14, and one or more idler rolls 16 and 18.
  • the wire includes an upper run 20 which is supported as by a plurality of suction devices 22 and/or foils 24, all as are well known in the art.
  • the wire is moved in a forward direction, by drive means not shown, as indicated by arrow 26.
  • a headbox 28 Adjacent the breast roll 12, there is provided a headbox 28 which in the preferred embodiment comprises two flow channels 30 and 32, each of which is in fluid communication with its respective source of cellulosic pulp (not shown).
  • Pulp streams from the respective channels 30 and 32 are maintained as separate streams until substantially the moment of their discharge from a dual slice 34. These two streams are deposited substantially simultaneously as separate layers of pulp onto the wire 12 as it is moving forwardly to form a bilayered web 35 on the wire, such web comprising first and second layers, 31 and 33, respectively.
  • a bilayered web 35 on the wire such web comprising first and second layers, 31 and 33, respectively.
  • the thickness of the layers on the wire 10 are exaggerated for purposes of illustration.
  • One suitable headbox is a Strataflo unit manufactured by Beloit Corporation of Beloit, Wisconsin. As the bilayered web on the wire is move forwardly, it is partially dewatered as by the suction devices 22 and the foils 24.
  • the bilayered web is contacted by a dandy roll 36.
  • a dandy roll 36 preferably comprises an open mesh formed into a cylindrical geometry and positioned with its length transversely of the direction of forward movement of the web.
  • the roll 36 is preferably driven at a tangential speed that is substantially equivalent to the forward lineal speed of the wire, e.g., 100% ⁇ 5%.
  • the roll 36 is mounted so that it can be forced into pressurized contact with the upper surface of the web 35, such that between about 2 to 4 inches of the circumferential dimension of the roll is in contact with the web as the web moves forwardly.
  • This 2 to 4 inch “footprint” of the roll 36 extends across the full width of the web 35.
  • the open mesh character of the roll 36 serves to mechanically engage the fibers of the web and enhance the integration of the first and second layers of the web at their interface as well as enhancing the overall formation of the web. Further, the open mesh smooths and conditions the top surface of the second layer 33 for receiving a further layer of pulp thereon.
  • One suitable dandy roll is formed of phosphor bronze wire having a mesh count of 15 x 13 cm, an open area of about 39.5%, a warp yarn diameter of 0.26 mm, and a weft yarn diameter of 0.25 mm.
  • a further, i.e. third, layer of pulp is deposited onto the upper surface of the web as from a secondary headbox 38.
  • This headbox may be of conventional single-slice design.
  • the pulp deposited onto the web from the secondary headbox preferably is substantially equivalent in composition and quantity as the pulp deposited onto the wire from the channel 32 of the headbox 28, thereby causing the first and third layers of the web to be substantially identical in a preferred embodiment.
  • the trilayered web is captured between a further foraminous papermaking fabric 40 which is trained about a plurality of rolls 42, 44, 46 and 48.
  • fabric 40 is a part of a device known in the art as a Bel Bond unit, manufactured by Beloit Corporation of Beloit, Wisconsin.
  • the Bel Bond unit includes one or more suction devices 50 disposed on that side of the wire 40 opposite the web 35 and adapted to withdraw water from the web in an upward direction. This action serves to hydraulically integrate the second and third layers of the web, as well as to further dewater the web.
  • the partially dewatered web is withdrawn from the wire 12 at the couch roll 14 and directed through a wet press 62.
  • the web 35 is first contacted by a suction pick up roll 66 about which there is trained a first felt 68.
  • the web is next captured between the first felt 68 and a second felt 70 and directed through a first press nip 72 between a grooved roll 74 and a suction roll 76.
  • the web while still on the first felt 68 and trained about the suction roll 76, is passed through a second press nip 78 developed between a suction roll 76 and a hard-surfaced roll 80.
  • the web is again captured between the first felt 68 and a third felt 82 and conveyed through a third press nip 84 established between a further grooved roll 86 and a smooth roll 88.
  • Pressure loads in the press nips of 200, 300, and 600 p.l.i., respectively, have been found suitable.
  • Other wet press designs known in the art would also suffice.
  • the web exiting the wet press section is conveyed through a dryer section 64 within which the web is passed over a series of heated rolls 90 and dried.
  • a water solution or slurry of sizing material may be deposited on the surface of the sheet in a size press 60.
  • Surface sizing further strengthens the sheet surface layer and can include materials that promote a hydrophobic nature of the sheet surface.
  • the web 35 is fed over a roll 61, then through the nip 71 between a pair of rolls 63 and 65.
  • Sizing solution is fed into the nip 71 from one or both of sources 67 and 69 of sizing solution, depending upon whether one or both surfaces of the web are to receive sizing.
  • the sized web is fed through a second dryer 64' which includes heated rolls 90'.
  • the dried web may be passed through one or more nips (calendered) to improve surface smoothness.
  • the dry web is collected in a roll 92.
  • a turned-up corner portion 94 of a web 35 produced in accordance with the present method is depicted in Figure 3.
  • the depicted web comprises a first (bottom) layer 31, a second (inner) layer 32 and a third (top) layer 33.
  • the several layers are delineated for purposes of illustration, but it is to be recognized that the interfaces between layers are not so pronounced in the actual web.
  • the preferred embodiment of the method of the present invention comprises the steps of preparing first, second, and third slurries of cellulosic fibers in an aqueous medium, depositing a stream of the first slurry onto a forwardly moving papermaking fabric at a first velocity sufficient to form a first layer of fibers on said fabric, substantially simultaneously depositing a stream of the second slurry onto the upper surface of the first layer of fibers at a velocity sufficient to deposit onto said first layer between about 0% and 300% greater quantity of fibers from the second slurry than the quantity of fibers deposited from the first slurry, commencing dewatering of the bilayered web and when it has achieved a consistency of between about 1.8% and about 3.5%, mechanically integrating the first and second layers at their interface, depositing a stream of the third slurry onto the upper surface of the integrated bilayered web at a location immediately down-stream of the wet line of the web on the forming fabric, substantially immediately after deposition of the third layer, capturing the web between the first forming
  • the pulp slurries employed in the present invention are selected to develop first and third outer layers of the present board that capture therebetween a second, i.e. inner, layer which exhibits an apparent bulk that is substantially greater than the apparent bulk of the outer layers. In this manner, the overall caliper of the board is developed with less fibrous content of the board than for single ply board formed from like fibers.
  • the pulp used for the first and third layers is of the same composition, namely about 75% softwood and 25% hardwood fibers, at a consistency of about 0.8% by weight, based on oven dried fibers and a C.S.F. of about 500.
  • the preferred composition of the inner layer is about 25% softwood and 75% hardwood fibers, at a consistency of about 0.8% and a C.S.F. of about 610.
  • the greater percentage of softwood fibers in the pulp for the outer layers provides for the development of strength in these layers, good surface smoothness of the board product, and other properties.
  • the quantity of fibers for the inner layer deposited on the wire is between about 0% and 300% greater than the quantity of fibers deposited in the formation of each of the outer layers.
  • the inner layer develops an apparent bulkiness which aids in imparting to the board product a final caliper that is equivalent to the caliper of a single ply board, but whose total fiber content is about 9% to 11% less than the fiber content of a single ply board.
  • the present invention provides the means for producing more board product with less fibers, and doing so without loss of the desired properties of the board.
  • the relative volume of the pulp for forming the inner ply varies below about 0% or above about 300% there is a noticeable decrease in the desired properties of the board.
  • Table I shows the average apparent density, average stiffness constant and calculated yield improvement of various boards made in accordance with the present method:
  • the consistency of the pulp may be the same for each layer, preferably from about 0.5 to about 0.8%, the consistency of pulp for each layer may be selected to be of a specific value for that layer.
  • the average consistency of the pulps used for formation of the first and second layers may range from between about 0.6% to about 1.1%, depending upon the desired basis weight of the board product.
  • the pulp consistency employed to obtain a particular basis weight of product is also a function of the wire speed. Table II presents the data from a series of tests employing the present method to produce board product of various basis weights.
  • Board product useful in the manufacture of containers for liquid food products preferably contain a starch size on the opposite outer surfaces of the board. Accordingly, it is preferred in the present method to pass the formed web through a size press containing a conventional starch size to thereby deposit between about 1 and about 3 lb (based on 3000 ft2) of sizing onto each of the opposite surfaces of the web. In a typical mill run, about 35 lb of starch per ton of fibers, produces a suitable sizing of the web. Other sizes, combinations of sizes, and/or quantities of sizes may be employed to obtain specific results.
  • the sized web may be calendered as desired.
  • Paper board manufactured in accordance with the present invention was converted to quart-size and half-gallon-size milk cartons and tested. Prior to its conversion, boards having a basis weight of 180, 200 and 220 lb/3000 ft2 were passed through an extruder and coated with about 16.7 lb of matte polyethylene on the outer surface of the third layer of the boards and about 10.7 lb. of gloss polyethylene on the outer surface of the first (wire) layer of the boards. Boards having a basis weight of 250 and 280 lb/3000 ft2 were coated with 18.9 lb. of matte PE on their third layer surfaces and 11.1 lb of gloss PE on their wire sides. The results of testing of converted milk cartons are given in Tables VII and VIII. These data show that the cartons made from the multiply board of the present invention compared favorably to like cartons made from single ply board.

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EP92850092A 1991-04-23 1992-04-23 Procédé et dispositif pour la fabrication de carton cellulosique à couches multiples et les articles ainsi obtenus Withdrawn EP0511185A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US69051891A 1991-04-23 1991-04-23
US690518 1991-04-23

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EP (1) EP0511185A1 (fr)
JP (1) JPH05239788A (fr)
CA (1) CA2066812A1 (fr)
FI (1) FI921812A (fr)

Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1999002777A1 (fr) * 1997-07-07 1999-01-21 Stora Kopparbergs Bergslags Ab Carton a grande rigidite et emballage a base de ce carton
US5935382A (en) * 1996-05-31 1999-08-10 Valmet-Karlstad Ab Method and board machine for manufacturing a paperboard web
US6540873B2 (en) 1999-09-06 2003-04-01 Metso Paper Karlstad Ab Board machine and method of manufacturing a multilayer cardboard web
US6699361B1 (en) 1999-09-07 2004-03-02 Metso Paper Karlstad Ab Papermaking device for producing a multilayer liner and associated methods
US6833055B2 (en) * 2002-03-08 2004-12-21 Rock-Tenn Company Multi-ply paperboard prepared from recycled materials and methods of manufacturing same
WO2006084883A1 (fr) * 2005-02-10 2006-08-17 Stora Enso Ab Carton de grande qualite et produits fabriques a partir de celui-ci
CN102182106A (zh) * 2011-05-07 2011-09-14 昌乐新迈纸业有限公司 一种涂布白面牛卡纸生产设备及生产方法
CN102182105A (zh) * 2011-05-07 2011-09-14 山东世纪阳光纸业集团有限公司 用于生产涂布牛卡纸的四叠网成形设备及生产方法
CN102182098A (zh) * 2011-05-07 2011-09-14 山东世纪阳光纸业集团有限公司 一种轻涂白面牛卡纸生产设备及生产方法
CN102242519A (zh) * 2011-06-08 2011-11-16 玖龙纸业（太仓）有限公司 一种牛卡纸造纸机，其成形部和造纸方法
CN102369324A (zh) * 2009-03-31 2012-03-07 日本制纸株式会社 纸容器用原纸及使用该纸容器用原纸的纸容器用层压片材
US20180171560A1 (en) * 2015-07-07 2018-06-21 Stora Enso Oyj Shaped tray or plate of fibrous material and a method of manufacturing the same

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4371632A (en) * 1981-04-24 1983-02-01 Empire Enterprises, Inc. Compositions, processes, and writing elements employing resins of the thermosetting type
FI982372A0 (fi) * 1998-11-02 1998-11-02 Enso Oyj Päällystetty kartonki, menetelmä sen valmistamiseksi sekä siitä saatuja tuotteita
JP2009242999A (ja) * 2008-03-31 2009-10-22 Nippon Paper Industries Co Ltd 液体容器用原紙
JP7192669B2 (ja) * 2019-06-07 2022-12-20 トヨタ車体株式会社 成形品及びその製造方法

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4145249A (en) * 1976-04-29 1979-03-20 Jwi Ltd. Shearing means for penetrating pulp stock on Fourdrinier machine
EP0029269A1 (fr) * 1979-11-13 1981-05-27 THE PROCTER & GAMBLE COMPANY Papier à couches multiples, ayant une surface douce, lisse et veloutée, et procédé pour sa fabrication
WO1984001176A1 (fr) * 1982-09-13 1984-03-29 Eastman Kodak Co Produit de papier composite stratifie et son procede de production

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4145249A (en) * 1976-04-29 1979-03-20 Jwi Ltd. Shearing means for penetrating pulp stock on Fourdrinier machine
EP0029269A1 (fr) * 1979-11-13 1981-05-27 THE PROCTER & GAMBLE COMPANY Papier à couches multiples, ayant une surface douce, lisse et veloutée, et procédé pour sa fabrication
WO1984001176A1 (fr) * 1982-09-13 1984-03-29 Eastman Kodak Co Produit de papier composite stratifie et son procede de production

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
TAPPI JOURNAL. vol. 67, no. 4, April 1984, ATLANTA US pages 64 - 67; D. HOPE AND J.D. PEEL: 'Improvements in linerboard manufacture using Bel Bond Formers and extended nip press' *

Cited By (17)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5935382A (en) * 1996-05-31 1999-08-10 Valmet-Karlstad Ab Method and board machine for manufacturing a paperboard web
WO1999002777A1 (fr) * 1997-07-07 1999-01-21 Stora Kopparbergs Bergslags Ab Carton a grande rigidite et emballage a base de ce carton
US6221212B1 (en) 1997-07-07 2001-04-24 Stora Kopparbergs Bergslags Ab Cardboard having great reigidity
US6540873B2 (en) 1999-09-06 2003-04-01 Metso Paper Karlstad Ab Board machine and method of manufacturing a multilayer cardboard web
US6699361B1 (en) 1999-09-07 2004-03-02 Metso Paper Karlstad Ab Papermaking device for producing a multilayer liner and associated methods
US6833055B2 (en) * 2002-03-08 2004-12-21 Rock-Tenn Company Multi-ply paperboard prepared from recycled materials and methods of manufacturing same
WO2006084883A1 (fr) * 2005-02-10 2006-08-17 Stora Enso Ab Carton de grande qualite et produits fabriques a partir de celui-ci
US7897011B2 (en) 2005-02-10 2011-03-01 Stora Enso Ab High quality paperboard and products made thereof
CN102369324A (zh) * 2009-03-31 2012-03-07 日本制纸株式会社 纸容器用原纸及使用该纸容器用原纸的纸容器用层压片材
CN102182105A (zh) * 2011-05-07 2011-09-14 山东世纪阳光纸业集团有限公司 用于生产涂布牛卡纸的四叠网成形设备及生产方法
CN102182098A (zh) * 2011-05-07 2011-09-14 山东世纪阳光纸业集团有限公司 一种轻涂白面牛卡纸生产设备及生产方法
CN102182106A (zh) * 2011-05-07 2011-09-14 昌乐新迈纸业有限公司 一种涂布白面牛卡纸生产设备及生产方法
CN102242519A (zh) * 2011-06-08 2011-11-16 玖龙纸业（太仓）有限公司 一种牛卡纸造纸机，其成形部和造纸方法
CN102242519B (zh) * 2011-06-08 2014-05-07 玖龙纸业（太仓）有限公司 一种牛卡纸造纸机和造纸方法
US20180171560A1 (en) * 2015-07-07 2018-06-21 Stora Enso Oyj Shaped tray or plate of fibrous material and a method of manufacturing the same
EP3320141A4 (fr) * 2015-07-07 2019-01-23 Stora Enso Oyj Plateau ou plaque façonné en matière fibreuse et son procédé de fabrication
US10711403B2 (en) * 2015-07-07 2020-07-14 Stora Enso Oyj Shaped tray or plate of fibrous material and a method of manufacturing the same

Also Published As

Publication number Publication date
JPH05239788A (ja) 1993-09-17
FI921812A (fi) 1992-10-24
CA2066812A1 (fr) 1992-10-24
FI921812A0 (fi) 1992-04-23

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