EP1045937A1 - Fabrication, selon le procede par mousse, de bandes de papier pour filtres ou autres a partir de pate mecanique - Google Patents

Fabrication, selon le procede par mousse, de bandes de papier pour filtres ou autres a partir de pate mecanique

Info

Publication number
EP1045937A1
EP1045937A1 EP98943914A EP98943914A EP1045937A1 EP 1045937 A1 EP1045937 A1 EP 1045937A1 EP 98943914 A EP98943914 A EP 98943914A EP 98943914 A EP98943914 A EP 98943914A EP 1045937 A1 EP1045937 A1 EP 1045937A1
Authority
EP
European Patent Office
Prior art keywords
filter
web
automotive
recited
paper
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.)
Withdrawn
Application number
EP98943914A
Other languages
German (de)
English (en)
Inventor
Jan Ahlstrom Paper Group KAUKOPAASI
Kay RÖKMAN
H kan Ahlstrom Glassfibre Oy SABEL
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Ahlstrom Glassfibre Oy
Original Assignee
Ahlstrom Glassfibre Oy
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Ahlstrom Glassfibre Oy filed Critical Ahlstrom Glassfibre Oy
Publication of EP1045937A1 publication Critical patent/EP1045937A1/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • 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
    • D21F11/002—Processes for making continuous lengths of paper, or of cardboard, or of wet web for fibre board production, on paper-making machines by using a foamed suspension

Definitions

  • the invention relates to the utilization of the foam process of making non-woven webs using particular raw materials, and for making particular end products.
  • the foam process according to the invention is basically as described in U.S. patents 3,716,449, 3,871 ,952, and
  • the foam process of web making is used for making webs using mechanical cellulose pulp, typically at least 50% mechanical pulp and desirably from about 60- substantially 100% mechanical pulp. While the details of the invention will be described with respect to CTMP (chemi thermo mechanical pulp), it is to be understood that other mechanical pulps are also suitable, including CMP (chemi mechanical pulp), TMP (thermo mechanical pulp), and ground wood pulp.
  • CTMP chemi thermo mechanical pulp
  • the invention also relates to the production of filter paper, particularly for automotive use.
  • Filter paper started to be used in automobiles some 40-50 years ago, and today is standard equipment in every car with a combustion engine.
  • the applications for filter papers can today be divided into the following grade categories: auto air, oil, heavy duty air (HDA), fuel media, and cabin air.
  • the auto air media/filter paper is designed to trap the particles entering the engine with the air.
  • the HDA filter paper has the same function, but is designed for a more demanding environment with large amounts of dust in the air (e.g. earth moving machines, etc.).
  • An oil media/filter paper is designed to take the particles out of the oil stream entering the engine.
  • the fuel media/filter paper is designed to filter particles from gasoline on diesel fuel before it enters the engine.
  • the cabin air media/filter paper is designed to trap the outside particle before they come into the cabin or compartment where the passengers are sitting.
  • filter papers are also other applications for such filter papers.
  • automotive filter papers are produced according to the wet-laid process, which dates back to the early part of this century. In this process the fibers are broken up under agitation in a pulper.
  • the fibers are then pumped in a liquid slurry through deflakers and refiners to the paper machine.
  • the deflakers and refiners help disperse the fibers, and give them a better surface for generating bonding strength.
  • the main components on the paper machine are the wet end and the dry end. Between the pulper and the wet end various types of wet and dry strength enhancing chemicals are also added.
  • the wet end comprises a headbox and dewatering elements.
  • the headbox has a flat fourdrinier, incline wire, or cylinder type foraminous element.
  • the dewatering elements are designed to suck out water from the slurry to dewater it from roughly a 0.05% fiber consistency to a 25% fiber consistency on a moving wire (foraminous element).
  • After the wet end the media enters the dry end. The objective there is to dry the media from 25% to about a 98-99% fiber consistency.
  • the media is now either impregnated "in-line” on the same paper machine, or rolled up and impregnated "off-line” on a separate impregnation machine.
  • the objective of the impregnation process is to fully saturate the media with a resin or latex (thermosetting or thermoplastic), and thereby give the media its final mechanical strength as well as making it convertable into a filter.
  • the impregnation process basically includes an impregnation unit followed by dryers.
  • the impregnation unit can be a size-press, roll coater, curtain coater, or the like, and the dryers any conventional contact/non-contact types.
  • the oil and HDA media types are grooved, giving them a continuous S-shape in the machine direction.
  • the reason for this is to increase the overall filtration surface, and help keep the subsequently formed pleats separated when pleating the media and building the filter element.
  • cellulose fibers are suitable for filter paper since high porosity (or bulk) is needed.
  • Northern/Southern softwoods (3-4.5 mm length, 30-45 micron diameter), Hardwood (1-2 mm length, 20-30 micron diameter), and Eucalyptus (1-2 mm length, 6-15 micron diameter) are often used. If the cellulose is mercerized or flash- dried more porosity is gained.
  • ⁇ PZ mercerized Southern Softwood
  • Synthetic fibers are to some extent also used, mainly polyester (6 mm length, 1.7 dtex diameter) for enhancing the strength requirements.
  • the most important quality factors for filter paper are the filtration efficiency, life/capacity, and the mechanical strength. These characteristics are dependent on the following important physical properties: basis weight (g/m 2 ), thickness (mm), Bubble Point (mmWC), Porosity (mmWC), Stiffness (mg), and Burst Strength (kPa).
  • basis weight g/m 2
  • thickness mm
  • mmWC Bubble Point
  • mmWC Porosity
  • Stiffness mg
  • Burst Strength Burst Strength
  • Basis 110 100 105 120 weight
  • filter paper may be made that is entirely suitable for all of the automotive applications set forth above, as well as numerous other applications where particles are to be filtered from an air or liquid stream containing the particles, using less expensive material.
  • mechanical pulp is utilized as anywhere from at least 50% to substantially 100% of the filter paper. It is possible to achieve an acceptable filter paper using at least 50% mechanical pulp only because the filter paper is formed by the foam process of web formation, not the conventional water laid process.
  • the foam process utilized according to the invention gives far better web formation. This means better air flow/pore size relationship, which enhances filtration.
  • the superior formation of the web also should have a positive impact on the pleating process, resulting in less breaks when the filter paper is fed through conventional pleating machines.
  • Another enormous advantage of the invention is the ability to provide enough porosity/thickness (especially for air and oil applications) using less expensive material, i.e. mechanical pulp.
  • Conventional cellulose fibers that provide more porosity (less restriction to flow) and/or thickness command a premium price [e.g. HPZ, cotton, wool, and/or rayon fibers].
  • HPZ high-Z, cotton, wool, and/or rayon fibers
  • a method of producing a non-woven web of fibrous material is provided.
  • the method comprises: (a) forming a foam slurry of air, water, surfactant, and fibers, at least 50% of the fibers by weight being mechanical pulp fibers; (b) passing the foam slurry into contact with a moving foraminous element; and (c) forming a fibrous web on the foraminous element by removing foam from the slurry through the foraminous element, and drying the web.
  • the method may further comprise impregnating the web with resin or latex suitable for forming the web into automotive filter paper, and/or grooving the web so that the web is suitable for use as automotive filter paper, and/or pleating the web so that it is suitable for use as automotive filter paper.
  • the resin or latex may be cured, which impregnates the web so that the web is, again, suitable for use as automotive filter paper. Pleating and curing may be practiced remote from (a) - (c), and after the web has been cut into sheets.
  • the invention also relates to a paper element having at least 50% mechanical pulp made by (a) - (c) above.
  • a paper filter element comprising: A sheet of fibrous material having at least 50%, by weight, mechanical pulp fibers.
  • the sheet Impregnated with cured resin or latex making it suitable for use as a particle filter.
  • the sheet having a plurality of pleats so as to be suitable for use as a particle filter.
  • the paper filter element may further comprise a plurality of grooves in the sheet extending substantially perpendicular to the pleats so as to facilitate use of the sheet as a particle filter, and may be in combination with an automotive oil filter casing, an automotive air filter casing, an automotive fuel filter casing, or an automotive cabin filter casing.
  • the sheet preferably comprises at least 60% mechanical pulp, and at least 5% long fibers.
  • the long fibers may be rayon, HPZ, cotton, wool, and mixtures thereof.
  • the sheet may comprise about 65% CTMP and about 35% HPZ.
  • FIGURE 1 is a schematic illustration of a method for producing filter paper for automotive uses, according to the invention
  • FIGURE 2 is a schematic illustration like FIGURE 1 only for an alternative embodiment of a method according to the invention.
  • FIGURE 3 is a schematic illustration of an automotive filter utilizing filter paper according to the invention.
  • a filter paper was made by the foam process containing about 65% CTMP and about 35% HPZ, compared to a conventional 60-80% HPZ and 20-40% Skogcell Flash (flash dried Northern pine, a chemical pulp) formulation when made by a water laid process.
  • the foam process filter paper so produced has properties comparable to the conventional 60-80% HPZ paper, and was certainly suitable for most automotive air and oil filtering applications. Since CTMP typically costs $350-$380 per ton while HPZ costs roughly $1200 per ton, a 40% fiber cost savings can be achieved by producing fiber paper from the foam process using at least about 50% mechanical pulp.
  • Filter papers produced according to the invention can be produced with using a wide variety of fiber mixtures. For example Skogcell, synthetic, or other fibers may be used in blends with mechanical pulp fibers to produce filter papers according to the invention.
  • Desirable filter papers are produced when the difference between the first and second values for the BP (Bubble Point) test are the smallest. Desirable filter properties are also typically provided by low density, and the "air flow index" and the “mechanical air flow index” values on the enclosed tables are attempts to utilize one number to indicate the general total desirability of a particular paper for use in filtering.
  • the foam process produced webs have a number of advantages. As one example, compare the 100% HPZ furnish on Table 1 , which when produced by the wet laid process has a BP of 88/106, whereas when produced by the foam process has a BP of 94/102, indicating many fewer pin holes using the foam process. Both the "air flow index” and “mechanical air flow index” are also significantly higher for the foam process sheet.
  • CTMP sheet test in Table 2 The CTMP sheet produced by the wet laid process does not have acceptable properties, the density being too high, the BP being completely unacceptable, and both the air flow index and the mechanical air flow index being too low. Note however that the CTMP sheet - produced from fibers having about one-quarter the cost of the HPZ sheet -- have comparable, and in one case even better, properties than the HPZ sheet.
  • the CTMP sheet produced by the foam process has an acceptable density, a better BP value than the 100% HPZ sheet produced by the wet laid process, and air flow index and mechanical flow index numbers within the same range (e.g. compare 305 for the mechanical air flow index for the foam process 100% CTMP with 327 for the 100% HPZ formed by the wet laid process).
  • Filter papers produced by the foam process also allow more flexibility in raw material usage. With the wet laid process one is limited to 6 mm length fibers (at some mill locations 12 mm is manageable) in order not to lose control of formation and generate "roping problems" (the fibers making a long string or rope). It is expected that longer fibers (e.g. lengths of 18 mm - 28 mm, or more, for polyester fibers) can be used in the foam process as it has earlier successfully been demonstrated. The benefit of longer fibers is that one can make a stronger sheet. Further, compared to the wet laid process less energy is needed in the foam process because one can disperse the fibers at a higher consistency.
  • longer fibers e.g. lengths of 18 mm - 28 mm, or more, for polyester fibers
  • FIGURE 1 schematically illustrates the practice of the method according to the present invention for the production of filter paper for automotive uses, in an on-line manner.
  • First the web is formed using the foam-laid process as indicated at 10, in which a slurry of air, water, surfactant, and fibers (at least about 50% of which are mechanical pulp fibers) are moved into contact with a moving foraminous element, and then foam is removed from the slurry through the element to form a non- woven web. Drying and other conventional steps are also practiced.
  • FIGURE 1 illustrates the rest of the steps in FIGURE 1 only with off-line impregnation and grooving, as indicated by boxes 15 and 16.
  • impregnation and grooving steps 11 , 12 may also be practiced, but the steps 15, 16 are practiced at a facility remote from where the foam-laid web formation step 10 takes place.
  • FIGURE 3 very schematically illustrates an automotive filter 20 that can be made utilizing filter paper produced according to the invention.
  • the filter paper 21 (having at least 50% mechanical pulp) is produced by the foam process as described in co-pending application Serial No. 08/923,900, filed September 4, 1997 (atty. dkt. 30-441), and conventional grooves that are formed therein are illustrated schematically at 22 in FIGURE 2, while the conventional pleats that are formed therein using conventional pleating machines are illustrated schematically at 23 in FIGURE 3.
  • the pleated and grooved filter paper 21 is then placed in a suitable canister 24, the exact mechanism for locating the filter paper 21 within the canister 24, or the details of the canister and how the filter paper 21 is disposed in the canister, being conventional and depending upon the application or a customer's particular preference.

Landscapes

  • Paper (AREA)
  • Filtering Materials (AREA)

Abstract

Des bandes non tissées en matière fibreuse sont obtenues, selon le procédé par mousse, à l'aide de pâte mécanique (par ex. pâte chimico-thermomécanique, pâte chimicomécanique, pâte thermomécanique ou pâte mécanique de défibreur), typiquement d'au moins 50 % de pâte mécanique et de préférence d'environ 60 à 100 % de pâte mécanique. Les bandes obtenues sont de préférence transformées en papier filtre pour les automobiles, par exemple par imprégnation de résine ou de latex, par rainurage, par pliage, par cuisson de la résine ou du latex, etc. Par exemple, une feuille fabriquée selon le procédé par mousse peut comporter au moins 60 % de pâte mécanique et au moins 5 % de fibres longues qui peuvent être de la rayonne, du HPZ, du coton, de la laine et des mélanges de ces matières. L'élément filtre est typiquement placé en combinaison avec un boîtier de filtre à huile, un boîtier de filtre à air, un boîtier de filtre à carburant ou un boîtier de filtre d'air de l'habitacle dans une automobile.
EP98943914A 1997-09-19 1998-09-09 Fabrication, selon le procede par mousse, de bandes de papier pour filtres ou autres a partir de pate mecanique Withdrawn EP1045937A1 (fr)

Applications Claiming Priority (5)

Application Number Priority Date Filing Date Title
US5955997P 1997-09-19 1997-09-19
US59559P 1997-09-19
US9845898A 1998-06-17 1998-06-17
US98458 1998-06-17
PCT/FI1998/000706 WO1999015730A1 (fr) 1997-09-19 1998-09-09 Fabrication, selon le procede par mousse, de bandes de papier pour filtres ou autres a partir de pate mecanique

Publications (1)

Publication Number Publication Date
EP1045937A1 true EP1045937A1 (fr) 2000-10-25

Family

ID=26738903

Family Applications (1)

Application Number Title Priority Date Filing Date
EP98943914A Withdrawn EP1045937A1 (fr) 1997-09-19 1998-09-09 Fabrication, selon le procede par mousse, de bandes de papier pour filtres ou autres a partir de pate mecanique

Country Status (5)

Country Link
EP (1) EP1045937A1 (fr)
JP (1) JP2001522946A (fr)
KR (1) KR20010030634A (fr)
CN (1) CN1270648A (fr)
WO (1) WO1999015730A1 (fr)

Families Citing this family (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6531078B2 (en) * 2001-02-26 2003-03-11 Ahlstrom Glassfibre Oy Method for foam casting using three-dimensional molds
CN101967769B (zh) * 2009-07-27 2012-05-30 苏州新业造纸有限公司 一种食品油滤纸的生产工艺
CN102400410A (zh) * 2011-09-28 2012-04-04 浙江鑫丰特种纸业股份有限公司 医用皱纹包装纸及生产工艺
FI124556B (en) 2012-04-26 2014-10-15 Stora Enso Oyj A hydrophobic bonded fibrous web and a method of making a bonded web
CN102788393B (zh) * 2012-08-23 2016-01-20 深圳市中纺滤材无纺布有限公司 一种环保可重复使用的湿帘及其加工方法
FI125024B (fi) * 2012-11-22 2015-04-30 Teknologian Tutkimuskeskus Vtt Muotoiltava kuitutuote ja menetelmä sen valmistamiseksi
FI127368B (fi) 2013-06-20 2018-04-30 Metsae Board Oyj Menetelmä kuituradan valmistamiseksi sekä kuitutuote
BR112018007748B1 (pt) 2015-11-03 2022-07-26 Kimberly-Clark Worldwide, Inc. Produto de tecido de papel, produto de limpeza, e, artigo absorvente de cuidado pessoal
BR112019010678B1 (pt) 2016-12-22 2023-01-17 Kimberly-Clark Worldwide, Inc Processo para produzir um produto de papel tissue
KR102165232B1 (ko) 2017-11-29 2020-10-13 킴벌리-클라크 월드와이드, 인크. 개선된 특성을 갖는 섬유 시트
KR102299453B1 (ko) 2018-07-25 2021-09-08 킴벌리-클라크 월드와이드, 인크. 3차원 폼-레이드 부직포 제조 공정

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1129757A (en) * 1966-05-31 1968-10-09 Wiggins Teape Res Dev Method of producing a thixotropic liquid suspending medium particularly for the forming of non-woven fibrous webs

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See references of WO9915730A1 *

Also Published As

Publication number Publication date
WO1999015730A1 (fr) 1999-04-01
KR20010030634A (ko) 2001-04-16
CN1270648A (zh) 2000-10-18
JP2001522946A (ja) 2001-11-20

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