MXPA00012873A - Papermaking belt having reinforcing piles - Google Patents

Abstract

A woven papermaking belt having a paper contacting top surface plane (24) and an opposed backside (26). The belt comprises a fabric (22) having yarns disposed, in part, in the top surface plane to form knuckles (36). The belt further comprises reinforcing piles (40) extending from a proximal end (42) to a distal end (44). The distal ends (44) of the reinforcing piles (40) are disposed between the top surface plane (24) of the papermaking belt and the backside (26) of the papermaking belt. The reinforcing piles (40) resist applied loads and may prevent deflection ofthe knuckles (36) during the papermaking process. The applied loads may either be normal to the belt, as occurs during imprinting, within the plane of the belt, which causes sleaziness of the belt, or both. The belt according to the present invention may have piles (40) with proximal ends (42) disposed at two or more different elevations, as well as distal ends (44), which are disposed at two or more elevations. This arrangement provides a belt which imprints different densities onto paper during papermaking, according to the ability of the piles (40) to resist compressive loads applied normal to the plane of the belt. In one alternative embodiment, the piles (40) may be disposed between the first and second layers of a multi-layer papermaking belt. The belt according to the present invention is particularly suitable for woven papermaking fabrics having long, unsupported knuckles.

Description

PAPER BAND THAT HAS REINFORCEMENT PADS FIELD OF THE INVENTION This invention relates to paper webs, and more particularly to webs having increased resistance to compression perpendicular to the plane of the web and / or decreased poor quality within the plane of the web.

BACKGROUND OF THE INVENTION Air drying is well known in the paper industry. Drying by air passage has advantageously been performed with commercial success using bands having two components, a foraminate element and a resinous framework. These bands are disclosed in the patents of the United States jointly assigned: 4,514,345, granted on April 30, 1985 to Johnson et al .; 4,528,239, granted on July 9, 1985 to Trokhan; 5,098,522, granted on March 24, 1992; 5,260,171, issued November 9, 1993 to Smurkoski et al .; 5,275,700, granted on January 4, 1994 to Trokhan; 5,328,565, issued on the 12th of January 1994 to Rasch et al .; 5,334,289, issued on August 2, 1994 to Trokhan et al .; 5,431,786, granted on July 11, 1995 to Rasch et al .; 5,496,624, granted on March 5, 1996 to Stelljes, Jr. et al .; 5,500,277, issued March 19, 1996 to Trokhan et al .; 5,514,523, issued May 7, 5 1996 to Trokhan et al .; 5,554,467, issued September 10, 1996, to Trokhan et al., 5,566,724, issued October 22, 1996 to Trokhan et al .; 5,624,790, granted on April 29, 1997 to Trokhan et al., 5,628,876, granted on May 13, 1997 to Ayers et al., And 5,679,222 issued October 21, 1997 to Rasch et al. all of which are incorporated herein by reference. Papermaking using two bands is also known in the art. Each band may have a foraminate element and a patterned frame. One band is used for the forming mesh and one is used for the drying band. The technique also shows discrete pattern elements in the frame, particularly for the forming mesh.

Suitable examples are found in United States patents assigned jointly 5,503,715 issued on April 2, 1996 to Trokhan et al. and 5,614,061 issued on March 25, 1997 to Phan et al., are incorporated herein. for reference.

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A common feature with each of these Patents is the presence of the patterned frame in the plane of the foraminate element or above it. The foraminous element serves as a reinforcement structure for the resinous framework. The patterned frame provides deflection conduits for the embryonic webs during the papermaking process, and prints a high density pattern on the paper formed therein. The conduits of Deflection can be discrete, semicontuous or continuous. Recently, attempts have been made to design air-pass drying bands that do not depend on a resinous frame to provide deflection ducts or print the paper. For example, PCT Application WO 95/27821, published October 19, 1995 in the name of Chiu et al., And European Patent Application 0 677 612 A2, published October 18, 1995 in the name of Wendt. et al. they expose air-drying fabrics which supposedly impart to the resultant product a significantly increased transverse direction extension capacity, while at the same time supposedly also supply high volume. These fabrics can have ^^^^^^^^ ¡¿igg ^ ^^ g | an upper layer dominated by large warp knuckles, and no knitted weft knuckles on the upper surface. Many of these large warp knuckles do not have support frames 5 below to provide the compressive strength that occurs during papermaking, particularly during printing. The presentations of the Wendt and Chiu applications are incorporated herein as a reference for the purpose limited to show how to make papermaking fabrics that have a similar pattern to the jacquard. Paper fabrics woven on a "dobby" loom or multiple-loom may also be suitable for use with the invention claimed. Also, cloths woven on most typical looms may also be suitable for use with the claimed invention. A problem that seems inherent in this approach, or any approach that has warps (or silk frames) with large stretches without support, is the deflection of the warps (or silk wefts) during the papermaking process. This deflection can avoid completely printing the fabric paper. The collapse of the cloth will have a damaging effect on the embryonic plot, the probable reduction of its volume. The printing increases fiber-to-fiber bonding and is typically carried out in conjunction with a Yankee dryer drum, but can also be carried out with other suitable roller / contact point 5 combinations or other rigid surfaces. For example, extended nip presses or shoe presses can be used for printing. The printing has been commercially successful to improve the tissue softness / strength ratio. This commercial success is due to the acceptance by the consumer of tissue paper of multiple regions created by the combination of the impression and the deflection conduits. Wendt et al. they appear to avoid the problem 15 associated with the deflection of long stretches by not printing the paper. To do this, Wendt et al. they avoided the Yankee drum dryer and the creping operation. However, this approach is not feasible for the large number of existing paper mills 20 that depend on a Yankee drum dryer to complete the drying process. In addition, not creping the paper can make it difficult to impart proper lay in the machine direction for the final product. In addition, the absence of printed regions (25 high density) often provide a role fe- - - ^. ,? mff? ^ - Mtef- • ^ mmi tissue with a weaker softness / resistance ratio. Wendt et al. they appear to overcome the problems associated with the absence of creping by allegedly producing a micro-contoured sheet dried by air passage without creping. The micro-shrinkage is known from the commonly assigned U.S. Patent 4,440,597, issued April 3, 1984 to Wells et al., Which is incorporated herein by reference. The micro-shrinkage occurs when the paper is transferred from a faster moving fabric, such as, for example, a forming mesh, to a slower moving fabric, such as, for example, a drying cloth or a fabric transfer. However, micro shrinkage inherently delays the papermaking process at the speed limit of the slower moving fabric. Delaying the papermaking process increases the manufacturing cost and limits the capacity of the paper machinery. The micro-contraction of the paper also tends to deteriorate the durability and the tensile strength. A different problem known in the art and associated with drying bands by air passage is poor quality. Poor quality refers to the movement of the silk weft warp yarns with the plane of the band in relation to each other. More frequently, poor quality is presented in fabrics with estimated higher separation. This problem is aggravated in those fabrics having large floats as illustrated in the Wendt et al., Application mentioned above. In addition, fabrics that have low density screenings (projected area up or large hollow volume) are also prone to poor quality problems. Poor quality can also occur with multilayer fabrics. Multilayer fabrics include double layer fabrics and triple layer fabrics. Double fabrics layer have stacked warps tied together by silk frames or vice versa. A triple layer fabric has first and second independent layers juxtaposed in a face-to-face relationship and held in place by attached threads. In a multilayer fabric poor quality can be presented with the movement of a layer of the fabric in relation to the other layer of the fabric and / or with the movement of the warps the silk wefts in relation to other warps and wefts of silk with the same layer.

Still another problem known in the art and associated with paper webs is the strength at the seams. Fabrics produced on conventional looms are sewn to provide an endless band suitable for use in papermaking. The resistance to the failure in the machine direction of the seam in tension is known as resistance in the seams. The strength at the seams is particularly critical in the fabrics mentioned above that have high separation counts, low density and large floats. Accordingly, in one aspect, this invention can provide a paper web having knuckles suitably supported for printing paper. Furthermore, in one aspect, this invention can provide a paper web having either large warp knuckles, knitted weft knuckles, or both, which are suitably supported. In one aspect, this invention can further provide this band which can be used with a Yankee drying drum or other means for printing the tissue paper. In addition, in one aspect, this invention can provide both single-layer and multi-layer papermaking webs that have poor poor quality for a particular web.

BRIEF DESCRIPTION OF THE INVENTION The invention comprises a paper web. The paper web has a top surface plane and a back side opposite the top surface plane. The web comprises a web having a plurality of interwoven threads. The band further comprises a plurality of fluffs, each fluff extending from a proximal end to a distal end. The proximal end may be juxtaposed with the rear side of the web or at an elevation above the back side of the web. The distal end is in the middle of the posterior side and the upper surface plane of the band. The fluff can intercept a yarn, according to which the yarn arches the thread of the normal deflection towards the plane of the band and / or inside it. The paper web can be a multi-layer paper web. In a multi-layer web, a first plurality of threads forms a first layer and a second plurality of threads forms a second layer. The fluffs may extend from the proximal ends juxtaposed with the back side of the band toward the distal ends. The distal ends of the fluffs may be juxtaposed with the first layer of threads, the second yarn layer, other suitable lifts or a combination thereof. Similarly, the proximal ends of the fluffs may be juxtaposed with the back side of the band, with the first or second layer of yarns, other suitable elevations or a combination thereof.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a top plan view of a band according to the present invention. Figure 2 is a vertical sectional view taken along lines 2-2 of Figure 1, and having fluffs with proximal ends coincident with the back side of the band and a fluff with the proximal end coinciding with the plane medium of the second layer of the fabric. The distal end of the fluff having the proximal end coinciding with the lateral part is juxtaposed with the knuckles. The distal end of the fluff having the proximal end coincident with the median plane of the second layer is juxtaposed with the upper sub-surface of the first strand of the layer. However, it must be recognized that the configuration illustrated in Figure 2 can be reversed.

Figure 3 is a vertical sectional view of an alternative embodiment according to the present invention showing a fabric that can be woven in a jacquard loom and has the proximal end of the fluff coincident with the first layer of the fabric underneath of the knuckle Figure 4 is a vertical sectional view of an alternative embodiment according to the present invention showing a multilayer fabric having attached threads attached, with first fluffs having the proximal and distal ends juxtaposed with the median planes of the two layers of the fabric, and second fluffs having the proximal ends juxtaposed with the rear side of the band. Figure 5 is a vertical sectional view taken along lines 5-5 of Figure 3.

DETAILED DESCRIPTION OF THE INVENTION Referring to Figure 1, the present invention comprises a paper web 20 having a web 22 and reinforcement fluff 40. The web 22 comprises interwoven yarns 30. The yarns 30 comprise warps 32 and silk webs 34. , mainly oriented in the machine direction and in the direction transverse to the machine, respectively. According to the present invention, the paper web 20 may be a forming mesh, a backing mesh for a double-mesh former, a transfer fabric, a felt base for a press felt or a through-drying fabric. The paper web 20 will be discussed below as a through-drying fabric, although it should be recognized that other interpretations for the claimed invention are feasible. The band 20, according to the present invention, is macroscopically monoplane. The plane of the band 20 defines the XY directions. Perpendicular to the XY directions and to the plane of the band 20 is the Z direction of the band. Also, the paper made on the web 20 according to the present invention can be considered as macroscopically mono-flat and resting on an XY plane. The Z direction of the paper is perpendicular to the XY directions and to the paper side. The paper belt 20 of Figures 1 and 2 has knuckles 36 and preferably large knuckles 36 which impart the impressions mentioned above. A "knuckle" refers to any ^ .a-áafe -. &^. ^ - a-, ^ »A-ASjta.bg - ^ - aas - thread in contact with the paper in the upper surface plane 24. A" large knuckle "refers to the knuckle of a warp 32 or silk weft 34 having a sufficient length for two or more wefts 34 of transverse silk or warps 32, respectively. The "upper surface plane 24" of the band 20 refers to the surface in contact with the paper of the band 20. On the contrary, the "side part 26" of the band 20 is on the surface in contact with the machine of the band 20. The paper made in the band 20 and according to the process of the present invention can have a basis weight of 10 to 70 grams per square meter and 3-300 of 10. to 150 knuckle prints per square inch and more preferably 10 to 50 knuckle prints per square inch. Each impression corresponds to the position and pattern provided by a knuckle 36 and preferably a large knuckle 36 in the band paper bin 20 of the present invention. It should be recognized that the warps 32 and the silk webs 34 can be comparatively provided in a pattern that prints the paper with relatively complex impressions such as, for example, Christmas trees, fish, butterflies, flowers, etc.

The most complex impressions can be created by weaving fabric 22 into a jacquard or "dobby" loom. Complex designs can also be woven in a high-batch count loom or a loom that has one or more loom frames for loom as are known in the art. For example, a batch loom 24 may be suitable. Various fabrics 22 may be used for the web 20 according to the present invention. The individual layer fabrics 22 are found in United States patents assigned jointly 3,905,863 granted on September 16, 1975 to Ayers and 4,239,065 issued on December 16, 1980 to Trokhan, which are incorporated herein by reference. reference. Other suitable fabrics 22 include multilayer fabrics 22, commonly referred to as double and triple layer fabrics 22, as shown in Figs. 2 and 4. Referring to Fig. 4, one type of multilayer fabric 22 has the yarns. 30 tissues together to form the first and second layers 52, 54 independently. These layers 52, 54 are tied together in face-to-face relationship. A first plurality of yarns 30 is woven to form the first layer 52. The first layer 52 of the web 22 is juxtaposed with the upper surface plane 24 of the web 20 and preferably defines the same plane. A second plurality of yarns 30 is woven to form the second layer 54 of the fabric 22. The second layer 54 of the fabric 22 is juxtaposed with the back side 26 of the band 20 and preferably defines the same. The first layer 52 and the second layer 54 of the fabric 22 are joined together in a face-to-face relationship using tied threads 30, as is well known in the art. The upper surface plane 24 and the lateral part 26 in this manner are defined by the outwardly facing surfaces of the first and second layers 52, 54, respectively of the multilayer fabric 22. Any of the integral threads or attachments may be used to join the two layers 52, 54. Referring to FIGS. 1 and 2, another type of multilayer fabrics 22 has the woven threads together without the first and second layers 52, 54 independent. In these fabrics, the first plurality of yarns 30 placed closer to the upper surface plane 24 of the band acts as a first evident layer 52 providing support to the paper placed thereon. A second plurality of wires 20 is placed closer to the part side 26 of the fabric 22. The second plurality of threads acts as a second evident layer 54, which provides a surface in contact with the machine and supports any threads 30 placed therein. In an alternative embodiment, the fluff 40 can not only increase but replace the tied threads. By cutting the fluff 40 the first and second layers 52, 54 of the fabric can be held. 22 of multiple layers in face-to-face relationship without relying on the tied threads. The multilayer fabrics 22 are set forth in United States Patents assigned jointly 5,664,724 issued on October 22, 1996 to Trokhan et al .; 5,500,277 granted on March 19, 1996 to Trokhan et al., 5,496,624 granted on March 5, 1996 to Stelljes, Jr. et al., they are incorporated herein by reference. With additional reference to Figure 2, The reinforcement fluff 40 is applied to any of the fabrics 22 discussed above or to any other suitable fabric 22. Each fluff 40 extends from a proximal end 42 juxtaposed with the back side 26 of the band 20, or even coinciding therewith at a distal end 44. The and the distal end 44 of the fluff 40 can intersect one of the knuckles 36 of the fabric 22. As discussed above, the distal ends 44 of FIG. the fluff 40 does not extend outwards, or above the upper plane 24 of the fabric 22. Posed alternatively, the ends 44 of the fluff 40 are in the intermediate part of the upper surface plane 24 and the lateral part 26 of the Fabric 22. By "intermediate part" it is to be understood that the distal end 44 of the fluff 40 is positioned between the lateral part 26 and the upper surface plane 24. The fluff 40 may comprise a frame having a substantially continuous pattern, as illustrated in US Pat. No. 4,637,859 mentioned above and incorporated, a semi-continuous pattern as illustrated in the aforementioned U.S. Patent 5,628,876 and incorporated or preferably in a discrete pattern as illustrated in U.S. Patent 4,514,345 and 5,245,025 mentioned above and incorporated. Discrete patterns are preferred for reinforcement fluffes 40, because discrete patterns can provide the least restriction to airflow through band 20. ; i ^ .- itfér- - ^ for a given amount of support for the knuckles 36. In addition, the discrete fluffs 40 are already placed in their positions to support the knuckles 36, in the intermediate positions of the knuckles 36, or in combinations thereof. In the bands according to the prior art, the frame extends towards the upper plane of the fabric or above it. These arrangements are contemplated to be outside the present invention. It is preferred that the knuckles 36 of the warp 32 (the large unsupported silk weft 34) are supported by the fluff 40. By "unsupported" it should be understood that no structural element is present between the knuckles 36 and the rectum of the fabric 22 for resisting compression of the knuckle 36 in the direction perpendicular to the plane of the band 20, although it should be recognized that the sub-upper surface crossings may exist where a silk 34 or warp 32 weave crosses the knuckle 36 without making contact or resistance to compression of the knuckle 36. In accordance with the present invention, a fluff 40 may be present between the lower side of the knuckle 36 and the back side 26 of the band 20. The fluff 40 supports the knuckle 36. This support of the fluff 40 minimizes the deflection of the knuckle 36 under compression loads applied perpendicular to the plane of the band 20. Preferably, in accordance with the present invention, to support the knuckles 36. particularly the knuckles 36, the fluff 40 does not extend above the upper plane 24 of the fabric 22. In this arrangement the fluff 40 only needs to extend from the lateral part 26 of the fabric 22 to an elevation where the distal end 44 is below or It coincides with the upper surface plane 24 of the band 20. It should be recognized that a fluff 40 can be used to support any portion of any yarn 30, and particularly the portion of this yarn 30 that forms part of the upper surface plane 24 of the fabric 22. However, it is believed that the fluff 40 will be more useful for supporting the knuckles 36, and particularly the large knuckles 36 of the fabric 22. Of greater preference In order to prevent the fluff 40 from forming part of the printing pattern of the band 20, the fluff 40 extends from the side part 26 of the band 20 to 1 * -, '? -i-faith • i-iis xa? * ..., ... - ,,. * .- * -. -3 an elevation coinciding with the median plane 60 of the warps 32 or of the silk weft 34 forming the knuckles 36. The median plane 60 is that plane through the center (without considering the cross sectional shape 5) of the yarn 30 comprising the knuckle 36. This arrangement protects the knuckle 36 in the upper surface plane 24 of the band 20 while providing a column to resist deflection of the knuckle 36. The fluff 40 acts as a column, which supports in a compressible manner the knuckle 36 against the back side 26 of the fabric and finally against the papermaking machinery supporting the fabric 22. According to the present invention, the fabric of the cloth for drying through forms knuckles 36 and with this the pattern of printing, if any, on the paper. It must be recognized that, in addition, an additional printing pattern can be provided by having a patterned frame coinciding with the knuckle elevation 36 of the upper surface plane 24. This additional patterned frame can be produced according to any one of U.S. Patents 4,637,859; 5,628,876; and / or 5,143,345 mentioned above and incorporated as is known in the art.

The fluff 40 can be provided and installed in the band 20 in one or more of several ways. The fluff 40 may comprise resin. The resin can be cured by actinic radiation, it can be cured thermally, or it can be cured by any other suitable means. In the first form, liquid resin, fabric 22, and a mask having transparent and opaque regions are provided, as set forth in U.S. Patents 4,514,345: 4,528,239; 5,098,522; 5,275,700; and the 5,334,289 mentioned above and incorporated. The mask has transparent regions in register with the desired locations of the fluff 40, and opaque regions where it is not desired to have fluff 40. The cloth 22 is immersed in the liquid resin. The ream is then provided at a depth sufficient to support the desired yarn 30 but does not extend above the upper plane 24 of the fabric 22. The resin is then cured on the fluff 40 as described in Patents 4,514,345; 4,528,239; 5,098,522; 5,275,700; and the 5,334,289 mentioned above to produce fluff 40 in the desired position and height. The proximal ends 42 of the fluff 40 can be '* - - »• ** £ - *. - - ^ - ** lrt ** ^ ^ «*? ***?« - ». > MJ ^., ^ Provide with a texture of the back side, as is known in the art. The X-Y position of the fluff 40 is determined by the transparent regions of the mask. The height of the Z direction of the fluff is determined by the depth of the resin before curing. The resin cures inside the fluffs by passing actinic radiation through the transparent regions of the mask and curing the liquid resin underneath in the solid fluffs. The transparent regions of the mask can be in register with the large knuckles either visually or by creating a pattern of Moaré interference. When creating this Moire interference pattern, the mask is preprinted with transparent regions in register with the size, spacing and total geometry of the large knuckles. The transparent regions is then in register with these knuckles 36 in a position that minimizes the pattern of interference on the knuckles 36. It should be understood that the knuckles 36 or any other portions of the threads 30, where it is desired to place the fluff 40 in an XY position they must be transparent for actinic radiation. This transparency allows sufficient curing of any photosensitive resin below. If a multi-layered fabric is used with the present invention, as is known in the art, the second layer 54 may have a plurality of opaque threads 30. The opaque threads prevent curing of the photosensitive resin below. And still in In another embodiment, the first layer 52 of the fabric 22 can be provided with a plurality of opaque threads 30 for the same purpose. Of course, someone with regular experience recognizes that the threads 30 in any layer 52, 54 of a multiple fabric 22 layers or the threads 30 of a single layer fabric 22 may be opaque, if desired. If thermally curable resin is used, the knuckles 36 can be provided for heat transmission, while the others regions of the fabric 22 insulate the resin from the heat, preventing it from healing. The resin that remains uncured, either from actinic radiation or heat, is then washed by irrigation, providing flow to through the area on the cloth 22. It is important that the band 20 allow sufficient air flow in order to obtain efficient drying. Alternatively, the uncured resin is selectively vacuum or air cut with positive pressure of the fabric 22 prior to curing. Particularly, the resin can be selectively vacuum-stripped from regions where fluff 40 is not desired. Prophetically, this process will remove the resin of the large foramin between the yarns in the yarn. plane X-Y, although it will allow the resin to remain trapped between the wires 30 separated in the Z direction. Alternatively, it is not necessary for the curable resin to be used for the fluff 40.

The fluffes 40 can be provided through an externally introduced means for supporting the knuckles 36. Examples of fluffes 40 inserted externally include thermoplastic material applied from the back side 26 of the band 20 and printed to the rise of the band coinciding with the knuckles 36. The epoxies, moldable clays or waterproof clays can be applied in a similar way and introduced externally. Alternatively, wires may be used 30 dual-melting bicomponents to weave the Fabric 22. These threads 30 have an outer cover and an inner core. The core has a higher melting point than the cover. To manufacture the web 20 of the present invention, first the web 22 is woven from the biocomponent threads 30. The fabric 22 is then placed on a horizontal, rigid and flat support surface with the front side 26 facing downwards. The heat is applied locally to the fabric 22, but is limited to the juxtaposed regions with the knuckles 36. The heat melts the cover of the threads 30, in the XY positions coinciding with the knuckles 36 or in any other desired position. The material of the cured cover flows down to the horizontal support surface. The horizontal support surface acts as a heat reducer. Therefore, the cover material solidifies again, forming a fluff 40 between the bottom of the knuckles 36 and the back side 26 of the band 20. Referring to Figures 3, 4 and 5, it will be apparent to someone With experience in the art, various variations in the paper web 20 are contemplated according to the present invention.

For example, if a multi-ply web 22 for paper web 20 is used, it is only necessary that the webs 40 extend between the threads 30 comprising the first layer 52 of the web 22 and the threads 30 comprise the second web 54 of the web. the web 22. This web 20 can be produced prophetically by first providing a multilayer fabric 22. The web 22 is then back-loaded to the desired elevation with a removable material. This elimination of materials avoids the: uring of the resin below the desired elevation. In the sense in which it is used herein, "lift" refers to the distance in the Z direction from the back side 26 of the band 20, to the upper plane 24 of the strip 20. The backload is exposed in the patent US ceded joint manner 5,629,052, issued May 13, 1997 to Trokhan et al., and 5,674,663 issued 7 October 1997 cFarland et al., which is incorporated herein by reference. The resin that is formed from the fluff 40 is then provided at the desired elevation in the first layer 52 of the fabric 22 for manufacturing ?F? ? ÉfÉfff-1 '-: -.. - - * "* - ~ ^^' * ^ - ^^^^ paper The resin is cured material is subsequently removed retrocarga From the above analysis, be recognized that the yarns 30 comprising the second layer 54 of the cloth 22 have a median plane 60. Referring to Figure 5, in a particular embodiment, the backfill material is provided at an elevation that intersects the median plane 60 of the threads 30 of the second layer 54. Similarly, the resin is provided at a depth originating from the median plane 60 of the threads 30 of the second layer 54 and intersecting it.Of course, the resin can then be provided at an elevation where the distal ends 44 of the fluff 40 intersect the median plane 60 of the first layer 52 of the fabric 22. This arrangement provides knuckles 36 which provide a local column support for the paper band 20. This support is limited to the portion of the band 20 defined between the first layer 52 of the band 20 and the second layer 54 of the band 20 and between them. Compression loads normally applied to the plane of the band 20 are transferred from the first layer 52 through the fluff 40 to the second layer 54 and finally to the »* IM £ J **», -. - -r ^. . ... AfeA ^^. ^. "-., - .. ^ A ^ a. ^, .-" ^ - Mia paper making machinery making contact with the back side 26 of the band 20. This mode provides the advantage of flexibility in the first layer 52 while still reinforcing the knuckles 36 against the five second layer 54. referring to Figure 4, the proximal ends 42 of a first plurality of fluffs 40 may be juxtaposed with the backside 26 the fabric 22. In particular, some of the fluff 40 may have the proximal ends 42 coincident with the side portion 26. The proximal ends 42 of a second plurality of ribs 40 may be juxtaposed with the second layer 54 of the fabric 22. The distal ends 44 of the fluff 40 may have a common elevation (as shown) or may be placed at different elevations. For example, the distal ends 44 of the first plurality of fluffs 40 may be coincident with the surface plane upper 24 of the band 20 or coincident with the median plane 60 of the threads 30 that form the knuckles 36, or placed at some other elevation. The elevations of the distal ends 44 of the other plurality of fluffs 40 may be placed at an elevation different from that of the distal ends 44 of the first plurality of ridges 43. The arrangement shown in Figure 4, which has fluff 40 with proximal ends 42 and distal end 44 at different elevations, may be provided as follows. First, the curing resin in the fluff 40 having proximal ends 42 coincident with the back side 26 of the band is provided at sufficient depth and is cured. The uncured resin is washed, producing fluffs 40 having proximal ends 42 coincident with the back side 26 of the fabric 22 and distal ends 44 at the desired elevation. The backfill material is then added as discussed above. The liquid resin is again emptied to the desired depth and cured in the fluffs 40 having the proximal ends 42 placed at a relatively high elevation in the fabric 22, (as, for example, the median plane 60 of the second layer 54). Alternatively, the process can be reversed. The backfill material can be added and the fluffs 40 having the proximal ends 42 placed at a relatively high elevation can be emptied first. The uncured resin and the "# * ..-> 30 Backfill material is washed then. The resin is then added coincident with the back side 26 of the fabric 22 and cured in the fluff 40 having proximal ends 42 coincident with the back side 26 as shown, or placed at any other suitable elevation. The depth of previous curing of the resin again determines the elevation of the distal ends 44 of the fluff 40. This process provides a band 20 having fluff 40 with proximal ends 42 juxtaposed not only with the back side 26 of the band 20, but also have proximal ends 42 juxtaposed with the second layer 54 of the fabric 22 of band 20. This hybrid arrangement provides the benefit of a band 20 having regions of first and second resistors different from the applied compression. The regions coincident with the fluffs 40 having the proximal ends 42 coinciding with the back side 26 of the band 20 will have a greater resistance to compression than the regions of the band 20 having fluff 40 with proximal ends 42 supported by other yarns 30 of the fabric 22.

This hybrid web 20 will have different first and second printing densities. A first and higher printing density will be provided by the fluff 40 having the proximal ends 42 juxtaposed with the back side 26 of the strip 20. A second and lower printing density will be provided by the fluff 40 having proximal ends juxtaposed by strands 30 on the fabric 22 and particularly on the yarns 30 on the second layer 54 of the fabric 22. It should be recognized that the actual printing on the paper is provided by the knuckles 36 of the web 20. However, the printing density of the knuckles 36 is determined, in part, by the elevation of the proximal end 42 of the fluff 40 in register with that knuckle 36. The benefit of a band 20 having an array of hybrid fluff 40 is that the first fluff 40, having the ends next 42 coinciding with the back side 26 of the web will provide a solid print against the Yankee dryer drum, or other solid surface. The second fluff 40 having the proximal ends 42 placed at elevations above the back side 26 of the band 20 will not provide . .,. < "'• ^ fe-- - •' '.M-JHM ---- M? - ^. Llff.fl * s. ~ ^« - • - T'.-Ila-a'flrh-t'rlr a print solid, although they will still contribute to flex paper to the low density region of a multi-density paper.The hybrid web 20 provides two different print densities 5 on paper.The two different printing densities can be arranged to provide any pattern aesthetically pleasing, for example, the first and highest printing density can be provided in an pattern of decorations such as, for example, hearts, flowers, butterflies, party decorations, etc. The second and lower printing density can be provided in a grid, trellis or matrix that provides a quilted appearance for the paper. The grid, lattice or matrix can form an array of cells. One of the decorative modalities can be placed in each cell. Alternatively, a plurality, but less than all the cells, may have an impression decorative in it. For example, one third to one half of the cells can have a decorative impression on them. Referring to Figure 3, still in another embodiment the fluff 40 can be extended from a proximal end 42 coincident with the The first layer 52 of the fabric 22. The distal ends 44 of the fluff 40 can intersect the knuckles 36 and preferably the median plane 60 of the knuckles 36. It will be evident that the fluff 40 also becomes visible. they can provide with the proximal ends 42 and the distal ends 44 at other suitable elevations. Still in another alternative embodiment (not shown) the proximal ends 42 of the fluff 40 can extend outwardly beyond the lower plane of the fabric 22. In this embodiment, the back side 26 of the band 20 is still defined by the proximal ends 42 of the fluff 40. However, the fabric 22 rises above the back side 26 of the paper band 20. In this embodiment, the fabric 22 could seldom, if ever, contacting the papermaking machinery used to produce paper on the band 20 according to the present invention. The fluff 40 can be used to withstand the deformation of the band 20 in the X-1 plane and thereby mitigate the poor quality. For example, fluffs 40 may be juxtaposed over the areas of band 20 anticipated to have the highest poor quality. In particular, the fluff 40 they can be juxtaposed with the regions of band 20 without having close threads. This arrangement provides a band 20 having fluff 40 that mitigates and / or reduces poor quality with the plane of either a single layer band 20 or a multiple layer band 20. Prophetically, the fluff 40 can also provide improved strength at the seams for the band 20. The fluffs 40 attached together with adjacent threads 30 in the machine direction, prevent these threads 30 from unraveling or otherwise separating at the seam. As noted in the above, the elevations of the distal ends 44 of the fluffs 40 can be placed at suitable and predetermined elevations. For example, the distal ends 44 of the fluff 40 may intersect the yarns 30. Alternatively, the proximal ends 42 of the fluff 40 may is to thread threads 30. This arrangement can be used with multi-layered fabrics 22 having integral tied threads 30, together with threads 30, or both. Of course, it must be recognized that the distal ends 44 of the fluff 40 can have different XY geometries. For example, the distal ends 44 of some fluffs 40 may be sized to provide support throughout the length of the knuckle machine direction 36. Alternatively, the distal end 44 of a single fluff 40 may be sized to support two or more knuckles 36. All of these variations are contemplated to be within the scope of the present invention. 10 ÍA < ^^^^^^^^^^^^^^ g ^^^^^^^ - ^ - | --j ^^ ..- ^ - ^^ -----------. - ^ ------- ^^^^^^ | ^^^^^^^^^ - ^^^^^ ¿b - ^ ----- ^^^

Claims (10)

1. CLAIMS: 1. A paper web having a top surface plane and a back side opposite thereto, the web comprises: a web having a plurality of interwoven webs; and a plurality of fluffs, each fluff extends from a proximal end to a distal end, the distal end is intermediate on the posterior side and the upper surface plane, the fluff intersects a yarn, whereby the fluff supports deflection of the yarn. .
2. 2. A band according to claim 1, where each fluff intersects a yarn, the fluffs support the deflection of the yarns with the plane of the band or the deflection normal to the plane < from the band.
3. 3. A band according to claims 1 and 2, where the fluffs are discrete.
4. 4. A band according to claims 1, 2 and 3, wherein the fabric comprises woven warp and weft in a pattern provided with knuckles U_¿¡rftg $ £ '•' l • '- ** - ****! ** - "***" ~ ^. Large knuckles, the large knuckles comprise a warp or a silk weft and are of sufficient length to measure two silk or two warp wefts, respectively, preferably the fluffs are in register with the large knuckles.
5. 5. A band according to claims 2, 3 and 4, wherein the proximal ends are juxtaposed with the back side of the band.
6. 6. A multi-layer paper web having a top surface plane and a back side opposite thereto, the web comprises: a first plurality of woven webs for 15 forming a first layer defining the upper surface plane; a second plurality of yarns woven to [form a second layer defining the side part, the first layer and the second layer are joined in a 20 face to face relationship; and a plurality of fluffs, the fluffs extend from the proximal ends to the distal ends, the distal ends are intermediate with the posterior side and the plane ? iMft lil - ^^ - *** ^^ * '- * - - ~ - - .. ----- .. ^.; a¿S¿ £ -.; A., ... ^ gi &; ..i. i \ 38 upper surface, whereby the fluffs support yarns of the first layer.
7. 7. A band according to claim 6 in which the proximal ends of the fluff intersect the yarns of the second layer.
8. 8. A band according to claim 6, wherein the proximal ends of the fluffs are juxtaposed with the rear side of the band.
9. 9. A band according to claims 6, 7 and 8 having a first plurality of fluffs, wherein the distal ends of the first plurality of fluffs are placed at a first elevation above the back side of the band, the band further comprising a second plurality of fluffs, the second plurality of fluffs having distal ends placed in a second elevation above the rear side of the band, the second elevation is different from the first levation. . ¿^ ^^ --- ^ - ^^ 1 - ^^ - »~, ^ y ^^^^^^^ sj ^^^^ a ^ g XsX ± ^^^ j ^
10. 10. One paper web, the web has a top surface plane and a back side opposite thereto, the web comprises: a multi-layer web, the web has a first plurality of threads in a first web and a second plurality of threads in a second web; and a plurality of fluffs do not extend outwardly beyond the upper surface plane, fluffs connect portions of the first yarn olurality with portions of the second plurality of yarns in register therewith, preferably the yarn prints the paper in the yarns. With two different printing densities, a first printing density and a second printing density, the first printing density is greater than the second printing density. SUM OF THE INVENTION A woven paper web having a top surface plane (24) in contact with the paper and a back side (26) opposite it. The band comprises a fabric (22) having strands placed, in part, on the upper surface plane to form knuckles (36). The band further comprises reinforcing hairs (40) extending from a proximal end (42) to a distal end (44). The distal ends (44) of the reinforcement fluff (40) are placed between the upper surface plane (24) of the paper web and the back side (26) of the paper web. The reinforcing fluffes (40) resist applied loads and can prevent deflection of the knuckles (36) during the papermaking process. The applied loads can be either normal to the band, as it occurs during printing, within the plane of the band, which causes the poor quality of the band or both. The wave according to the present invention can have fluffs (40) with proximal ends (42) placed at two or more different elevations, as well as distal ends (44), which are placed at two or more elevations. This arrangement provides a web that prints different densities on paper during papermaking, according to the ability of the fluff (40) to resist the compressive loads applied to the plane of the web. In an alternative embodiment, the fluff (40) can be placed between the first and second layers of a multi-layer paper web. The web according to the present invention is particularly suitable for woven paper fabrics having large, unsupported knuckles.