MXPA01001615A - Papermaking belt and process and apparatus for making same - Google Patents

Abstract

The invention comprises a method for applying a curable resin (50) to a reinforcing structure (40) and an apparatus therefor. The apparatus comprises a working surface (72) having a pattern of recesses therein structured and designed to at least partially receive a reinforcing structure (40), a means for disposing the reinforcing structure (40) in the pattern of recesses of the working surface, a means (55) for applying a fluid resinous material to the reinforcing structure disposed in the recesses of the working surface, and a means for solidifying the fluid resinous material to provide a patterned resinous framework joined to the reinforcing structure. The process comprises the steps of at least partially disposing the reinforcing structure in the recesses of a working surface, applying the fluid resinous material to the reinforcing structure, and then solidifying the fluid resinous material to form a patterned resinous framework joined to the reinforcing structure. Preferably, the reinforcing structure has voids, penetrable by the fluid resinous material, intermediate the first and second sides, and the resinous material occupies at least some of the voids in the reinforcing structure. The finished belt comprises a patterned resinous framework joined to the reinforcing structure such that a substantial portion of a bottom side of the resinous framework is between two opposite sides of the reinforcing structure.

Description

TAPE FOR PROCESSING PAPER AND PROCESS AND APPARATUS FOR MANUFACTURING FIELD OF THE INVENTION The present invention relates to processes for manufacturing papermaking belts. More particularly, the present invention relates to a method for manufacturing a belt comprising a reinforcement structure and a resinous framework attached to the reinforcement structure. BACKGROUND OF THE INVENTION [0002] In general, papermaking processes with air passage drying include several steps. An aqueous dispersion of papermaking fibers is formed in an embryonic tissue in a member with perforations, such as a Fourdrinier metal mesh. This embryonic tissue is related to a deviation member having a macroscopically planar crosslinked surface, and preferably with a non-random pattern which defines within the deviation member various fluid-permeable bypass conduits. In a continuous process of papermaking, this biasing member is in the form of a continuous papermaking belt. If the patterned surface of the deflection member is substantially continuous, the various deflection conduits comprise discrete conduits insulated therebetween. If the patterned surface of the deflection member comprises several insulated protuberances therebetween, the various conduits form a substantially continuous area. The papermaking fibers are diverted into the bypass conduits, and water is removed through the bypass conduits, thereby forming an intermediate fabric. The intermediate fabric is then dried and, if desired, reduced by creping. The papermaking belt comprising the deviation member is described in several commonly assigned US Patents: 4,514,345, issued April 30, 1985 to Johnson et al .; 4,528,239, issued July 9, 1985 to Trokhan; 5,098,522, issued March 24, 1992; 5, 260,171, issued November 9, 1993 to Smurkoski et al .; 5,275,700, issued on June 4, 1994 to Trokhan; 5,328,565, issued July 12, 1994 to Rasch et al .; 5,334,289, issued August 2, 1994 to Trokhan et al .; 5,431,786, issued July 11, 1995 to Rasch et al .; 5,486,624, issued 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, 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, issued April 29, 1997 to Trokhan et al .; 5,628,876, issued May 13, 1997 to Ayers et al .; 5,679,222, issued October 21, 1997 to Rasch et al .; and 5,714,041, issued February 3, 1998 to Ayers et al., whose disclosures are incorporated herein by reference. The deviation of the papermaking fibers in deflection conduits of the deflection member can be introduced, for example, by the application of a differential fluid pressure on the embryonic tissue. A preferred method of applying the differential pressure comprises exposing the embryonic tissue to a vacuum through the biasing conduits of the biasing member. A sudden application of the differential fluid pressure on the fibers tends to separate some of the deflected fibers in the deflection conduits from the tissue and between them. In addition, as a result of a sudden application of the pressure differential on the tissue, some fibers with partial removal of water separated from the embryonic tissue could pass completely through the conduits of the deviating member. These phenomena cause the formation of what are known as "pinholes" in the finished paper fabric, and can also cause the vacuum water removal machinery to clog with the separated fibers of tissue. This undesirable creation of the pin holes can be mitigated by providing a leak between the biasing member and the paper making equipment creating the fluid pressure differential. One way to create such a leakage comprises the supply of surface texture irregularities in the cross-linking of the back side of the deflection member. North American patents commonly assigned Nos. 5, 098,522 issued on March 24, 1992 to S urkoski et al.; and 5,364,504 issued on November 15, 1994 to Smurkoski et al. present a process for manufacturing the tape with textured back side comprising the casting of a photosensitive resinous material on a reinforcing structure and through said structure while the reinforcing structure is moved on a textured work surface. The co-assigned US Patent No. 5,275,700 issued on January 4, 1994 to Trokhan et al. discloses a process for manufacturing a tape with textured back side, said process comprises the application of a coating of a photosensitive resin on the reinforcing structure and the pressing of the reinforcing structure on a deformable surface in such a way that the deformable surface forms protrusions They exclude the resin from certain areas, creating in this way a back side of the textured tape. United States Patent No. 5, 334, 289 co-assigned issued August 2, 1994 to Trokhan et al. discloses a process for manufacturing a tape with a textured back side, comprising the application of a photosensitive resin coating on a reinforcing structure having opaque portions, and then exposing the resin to a curing irradiation through the structure of reinforcement. The aforementioned patents are incorporated herein by reference. Another way of mitigating the undesirable creation of the pinholes, developed by the present beneficiary, comprises making the tape having deflection conduits such that a substantial portion of each conduit is not less than about 1143 mm (45 mils) inch) in each dimension of the conduit (measured in the general plane of the belt, ie, an XY plane), in accordance with that disclosed in co-assigned United States Patent No. 5,679,222 issued on October 21 from 1997 to Rasch et al., which is incorporated herein by reference. However, the search for improved products has continued. The present invention offers a novel process for making an improved papermaking belt comprising a reinforcing structure and a resinous framework attached thereto. It is a benefit of the present invention to offer a novel process for the manufacture of a textured papermaking belt on the back side. Another benefit of the present invention is that it offers a novel process for manufacturing a papermaking belt wherein the depth of penetration of the resin into the reinforcing structure is controllable in such a way that the resin penetrates a predetermined part of the thickness of the resin. the reinforcement structure in order to provide an acceptable bonding of the resin on the reinforcement structure, while maintaining the flexibility of the reinforcement structure, as well as the air and water permeability. Another benefit of the present invention is that it offers a process for reducing the amount of resinous material that is required to manufacture the tape. SUMMARY OF THE INVENTION A papermaking belt that can be made by a process and apparatus of the present invention comprises a reinforcing structure and a patterned resinous frame attached thereto. The reinforcing structure has a first side and a second opposite side. The resinous frame has an upper side and a lower side, the upper side and the lower side correspond to the first side and second side of the reinforcing structure, respectively. The resinous framework and the reinforcing structure are joined in such a way that a substantial portion of the underside of the resinous framework is raised on the second side of the reinforcing structure. That is, the tape has a distance formed between the second side of the reinforcing structure and the substantial portion of the underside of the resinous frame. During a papermaking process, this distance provides leakage between the tape and a water removal equipment in papermaking, thus eliminating a sudden application of fluid pressure differential to a paper tissue placed on the belt and mitigating a phenomenon known as "pinhole formation". The distance between the second side of the reinforcing structure and the underside of the resinous frame may be different in the plane of the tape. An apparatus for manufacturing the papermaking belt comprises a work surface having a recess pattern there, a device for placing the reinforcement structure in the recess pattern of the work surface, a device for applying a flowable resinous material on the reinforcement structure by placing on the recesses of the work surface, and a device for solidifying the flowable resinous material in order to provide a resinous framework with pattern attached on the reinforcement structure. The pattern of recesses is structured and designed in such a way that it receives at least partially the reinforcement structure there. In a preferred continuous process, the apparatus further comprises a device for continually moving the reinforcing structure in a machine direction. A process for manufacturing the tape comprises the following steps. A flowable resinous material is provided. The fluid resinous material is preferably selected from the group consisting of epoxies, silicones, urethanes, polyethylars, polyolefins, polysulfides, nylons, I butadienes, photopolymers, and any combination thereof. In a preferred embodiment, the fluid resinous material comprises a photosensitive resin. In another preferred embodiment, the fluid resinous material comprises a thermosensitive resin. Preferably the fluid resinous material is provided in a liquid state. The next step comprises the provision of a reinforcing structure having a first side, a second side opposite the first side, and a thickness defined therebetween. Preferably, a fluid-permeable structure is used, such as a woven reinforcement structure. However, the use of the reinforcing structure not permeable to fluids is also contemplated within the framework of the present invention. Preferably, the reinforcing structure has gaps between its first side and second side, said gaps being penetrated by the fluid resinous material. The next step involves the supply of a work surface. The work surface comprises an external surface and a pattern of recesses there. The recesses have a depth and are structured and designed to receive the reinforcement structure there. The next step comprises the at least partial placement of the reinforcing structure in the recesses of the work surface. Various devices, such as, for example, support rollers and pressure rollers, can be used to facilitate the placement of the reinforcing structure in the recesses. Due to the flexible nature of the reinforcing structure, the reinforcing structure can be placed only partially in the recesses. In some embodiments, the reinforcement structure is placed in the recess pattern to extend beyond the outer surface of the work surface. In these cases, it is preferred that at least a portion of the penetrable voids by the fluid resinous material extend beyond the outer surface of the work surface. The next step comprises the application of the fluid resinous material on the reinforcement structure. Preferably, the resinous material occupies at least a certain portion of the gaps in the reinforcing structure in such a way as to "latch" or "enclose" portions of the reinforcing structure to effectively form a link therebetween. Alternatively, the resinous material can be fixed on the reinforcing structure, without surrounding the portions thereof. In the latter case, the first side of the reinforcing structure preferably has sufficient roughness and / or is sufficiently adhesive, which can be achieved through a special treatment of the reinforcement structure.

The fluid resinous material can be applied on the reinforcing structure in the form of a substantially uniform layer, or alternatively, according to a predetermined pattern. The first mode is especially relevant for photosensitive curable resinous materials, while the latter mode - for processes employing a patterned molding surface for depositing the resinous material in said reinforcing structure. In the latter case, the process further comprises the steps of providing a pattern molding surface juxtaposed with the reinforcing structure, and the deposit of the fluid resinous material in the molding pouches of the molding surface. The molding surface has a pattern of molding bags there, said bags are structured and designed to receive the fluid resinous material and then to deposit it in the reinforcing structure. The various molding bags may comprise a substantially continuous pattern, a discrete bag pattern, or a semi-continuous pattern comprising a combination of substantially continuous pattern and discrete bag pattern. The molding surface may comprise a rotating molding roller surface or a surface of a continuous molding belt. The next step comprises the solidification of the flowable resinous material to form a patterned resinous framework attached on the reinforcing structure, the nature of the resinous material imposing a solidification method. Preferably, the solidification comprises curing (i.e., a process involving cross-linking) of the resinous material. Photosensitive resinous materials can be cured by curing radiation, typically UV. Some thermosensitive resinous materials can be cured naturally, for a certain period of time. After the solidification of the resinous material, it forms a resinous framework firmly attached to the reinforcing structure, thus forming the papermaking belt. DESCRIPTION OF THE DRAWINGS While the specification concludes with the claims that specifically and clearly present what is claimed in the present invention, the invention will be better understood from the following description taken in combination with the accompanying drawings, wherein similar elements are designated by the same reference number, and: Figure 1 is an illustration of a process for manufacturing a paper web with a papermaking belt made in accordance with the present invention. Figure 2 is a schematic and partial plan view of an exemplary embodiment of the papermaking belt manufactured in accordance with a process of the present invention, the belt includes a reinforcing structure and a continuous resinous frame attached on the structure of reinforcement. Figure 3 is a cross-sectional view taken along lines 3-3 of Figure 2. Figure 4 is a schematic side elevational view illustrating one embodiment of the process and the apparatus in accordance with the present invention for manufacturing the papermaking belt comprising a curable photosensitive resinous material. Figure 4A is a schematic cross-sectional view taken along lines 4A-4A of Figure 4. Figure 4B is a schematic cross-sectional view taken along lines 4B-4B of Figure 4. Figure 4C is a schematic and more detailed cross-sectional view of an element of the recess pattern of the work surface, which is illustrated in Figure 4B. Figure 5 is a schematic side elevational view illustrating another embodiment of the process and apparatus according to the present invention for manufacturing the papermaking belt, the apparatus comprising a molding member. DETAILED DESCRIPTION OF THE INVENTION In the representative papermaking machine illustrated schematically in Figure 1, the papermaking belt that could be made in accordance with the present invention takes the form of a continuous ribbon, a papermaking belt 10. The papermaking belt 10 has one side in contact with fabric 11 and a back side 12 opposite the side in contact with fabric 11. The papermaking belt 10 has a woven fabric. paper (or "fiber-woven") 27 through several stages of the papermaking process. Processes for the formation of embryonic tissues are described in several references as for example in the North American Patent No. 3,301,746 issued to Sanford and Sisson on January 31, 1974; and in U.S. Patent No. 3,994,771 issued to Morgan and Rich on November 30, 1976, both patents are incorporated herein by reference. The papermaking belt 10 is moved in the direction indicated by the direction arrow B around the return rows 19a and 19b, printing throttle roller 19k, return rolls 19c, 19d, 19e, and 19f, and a emulsion distribution roller 19g. The loop around which the papermaking belt 10 travels includes a device for applying a fluid pressure differential on the embryonic tissue 27, such as for example a vacuum collection shoe 18a and a multi-slot vacuum box 18b . In Figure 1, the papermaking belt 10 also travels around a pre-dryer, such as a through-flow dryer, 33 and passes through a constriction formed between the print choke roller 19k and a drying drum, such as for example a Yankee drying drum, 28. Although the preferred embodiment of the papermaking belt 10 is in the form of a continuous ribbon illustrated in FIG. Figure 1, the belt 10 can be incorporated in several other forms including, for example, stationary plates for use in the manufacture of sheets, or rotary drums for use with other types of continuous processes. Regardless of the physical form that the papermaking belt 10 can take, the tape 10 generally has certain physical characteristics presented below. As can be seen better in Figures 2 and 3, the tape 10 is essentially macroscopically monoplanar, and has the side in contact with the fabric 11 and the back side 12 opposite the side in contact with the fabric 11. paper 10 is macroscopically monoplanar since when a portion of the tape 10 is placed in a planar configuration, the side in contact with the fabric 11, viewed globally, is essentially in a plane. It is said to be "essentially" macroscopically monoplanar to recognize the fact that deviations from an absolute planarity are tolerable, although not preferred, insofar as the deviations are not important enough to negatively affect the performance of the tape 10 for the purposes of a specific papermaking process. The papermaking belt 10 that can be made according to the present invention generally comprises two primary elements: a frame 50a (preferably a hardened polymeric resin framework made from a fluid resinous material 50) and a reinforcing structure 40. The reinforcing structure 40 has a first side 41 and a second side 42 opposite the first side 41. The first side 41 can be in contact with the papermaking fibers during the papermaking process, while the second side 42 typically it is in contact with the paper making equipment, such as for example a vacuum pick-up shoe 18a and a multiple-slot vacuum box 18b (both are illustrated in Figure 1). The reinforcing structure 40 can have several different shapes. It may comprise a woven element, a non-woven element, a screen, a net, a ribbon, a plate, etc. The preferred reinforcing structure 40 is permeable to air, but it should be understood that an air impermeable reinforcing structure 40 is also contemplated within the scope of the present invention. In a preferred embodiment, the reinforcing structure 40 comprises a woven element formed of several yarns in the direction in the machine between fabrics with several yarns in a transverse direction relative to the machine, as shown in figures 2 and 3. More in particular, the woven reinforcement structure 40 may comprise a foraminous woven element, as for example disclosed in the commonly assigned US Patent No. 5, 334,289, issued in the name of Trokhan et al., On August 2, 1994, and incorporated herein by reference. The reinforcing structure 40 comprising a woven element may be formed of one or more layers of interwoven yarns, the layers being substantially parallel to each other and interconnected in a face-to-face contacting relationship. Co-assigned U.S. Patent No. 5,679,222, issued by Rasch et al., On October 21, 1997, is incorporated herein by reference. The co-assigned US Patent No. 5,496,624, issued March 5, 1996 in the name of Stelljes, Jr et al., Is incorporated herein by reference to show a suitable reinforcing structure 40. The reinforcing structure 40 of the tape 10 reinforces the resinous frame 50a and preferably has a suitable projected area in which the papermaking fibers can deflect under pressure. According to the preferred embodiment of the present invention, the reinforcing structure 40 is permeable to fluids. As used herein, the term "fluid permeable" refers to a condition of the reinforcing structure 40, said condition allows fluids, such as water and air, to pass through the reinforcing structure 40 in at least one address As will be readily recognized by a person skilled in the art, tapes comprising fluid-permeable reinforcement structures are typically employed in processes of making a paper fabric with air-pass drying. As shown in Figures 2 and 3, the reinforcing structure 40 is attached to the resinous frame 50a. The resinous framework 50a comprises a solidified resinous material 50 and preferably cured, that is to say, the resinous framework 50 is a solid phase of the fluid resinous material 50a. In this regard, the term "resinous material 50" and the term "resinous frame 50a" may be used interchangeably where appropriate in the context of the present application. The resinous frame 50a has an upper side 50 and a lower side 52 opposite the upper side 51. A person skilled in the art will note that the terms "upper" and "lower" are conventionally employed herein for definition purposes, and in current context are descriptive only in relation to the tape 10 illustrated in figure 3. During the papermaking process the upper side 51 of the frame 50a is in contact with the papermaking fibers, thus defining the pattern of the paper tissue produced. In the end tape 10, the side in contact with the fabric 11 comprises the upper side 51 of the resinous frame 50 a. In some embodiments, portions of the lower side 52 of the frame and the second side 42 of the reinforcing structure can be placed in the same plane. In these cases, the lower side portions 52 of the frame 50a may be in contact with the papermaking equipment. In accordance with the present invention, a substantial portion of the lower side 52 of the frame 50a is not in contact with the papermaking equipment. On the contrary, the substantial portion of the lower side 52 is raised on the surface of the papermaking equipment in such a way that a distance Z is formed between them, as will be explained in more detail below. The substantial portion of the lower side 52 lies between the first side 41 and the second side 42 of the reinforcing structure 40. The term "substantial portion" refers to a portion of the lower side 52, said portion not being placed therein. plane in which the second side 42 of the reinforcing structure 40 is located, and a relative size of said portion is defined as the projected area of this portion in the general plane of the tape 10. That is, the substantial portion of the side bottom 52 of resinous frame 50a is raised (as shown in figure 3) on second side 42 of reinforcing structure 40, and distance Z (which can vary) is formed between them). A) Yes, during the papermaking process, the substantial portion of the underside of the resinous frame 50a is not in contact with the surface of the papermaking water removal equipment. The substantial portion of the lower side 52 (seen as an area projected toward the general plane of the belt 10) is preferably at least about 45%, more preferably at least about 65%, and especially preferably so less than about 85%, relative to the entire projected area of the underside 52. It will be understood that the projected areas formed by the yarns of the reinforcement structure 40 are not counted. It will be understood that the distance Z may vary (not shown) between different parts of the end tape 10. A desirable size of the substantial portion of the bottom side 52 is defined by the relative geometry of the tape 10 and the water removal equipment. , the magnitude of the distance Z and other parameters of a particular papermaking process. For a particular belt 10, the substantial portion of the bottom side 52 must be sufficient to provide leakage between the surface of the papermaking equipment creating a fluid pressure differential on the back side 12 of the papermaking belt 10. The desired size of the substantial portion is preferably defined by a desired leak between the tape 10 and the papermaking equipment providing the fluid differential during the papermaking process. A leak of at least about 35 Marlatts with a pressure differential of 17.78 cm (7 inches) of mercury is preferred. A conversion of Marlatts in standard cubic centimeters / minute can be done by inserting the measured reading in Marlatts in the following equation where x is the reading in Marlatts and is the corresponding value in standard cubic centimeters / minute: Y = 36,085 + 52,583x - .7685x2 This equation for converting Marlatts into standard cc / min was developed by calibrating the flowmeter to standard cc / min using a Buck Optical Soap Bubble Meter. US Pat. No. 5,334,289 co-assigned and incorporated herein describes in more detail the test methods and a device used to make leakage measurements (US Patent No. 5,334,289, to 65: 8 -68: 7). The device described in US Pat. No. 5,334,289 can be used to measure the texture leakage from the back side of the papermaking belt 10 made in accordance with the present invention. The deflection conduits 60 (Figures 2 and 3) extend between the upper side 51 and the lower side 52 of the resinous frame 50. In a preferred embodiment, which is shown in Figures 2 and 3, the various discrete deflection conduits are distributed in a non-random pre-selected pattern through the resinous framework 50a substantially continuous, the patterns of the distribution of conduits, as well as the shapes of the conduits may vary as understood by one skilled in the art. Another embodiment (not illustrated) of the tape 10 comprises a substantially continuous (non-discrete) duct 60 encompassing a plurality of discrete portions of the resinous frame 50a. In the latter case, preferably the plurality of the discrete portions of the resinous frame 50a comprises a plurality of protrusions extending outward from the first side 41 of the reinforcing structure 40 and distributed throughout the substantially continuous conduit 60 in a pre-selected pattern not random. As used herein, a pattern is said to be "substantially" continuous to indicate that minor deviations from absolute continuity can be tolerated to the extent that these deviations do not adversely affect the performance or desired qualities of the final product - the production ribbon paper 10. The papermaking belt 10 comprising a combination of the two previous modes (ie, which comprises the plurality of conduits described and the substantially continuous conduit) is also contemplated in the present invention. Commonly assigned US Patent No. 5,245,025 issued September 14, 1993 in the name of Trokhan et al., Is incorporated herein by reference. The frame 50a may comprise the underside 52 having a network of passages that provide irregularities in relation to the surface texture of the back side, in accordance with that described in commonly assigned US Patent No. 5,275,700 on January 47, 1994 to Trokhan. , said patent is incorporated by reference herein. The two frame modalities 50a - one modality "having the distance Z between the rear side 52 and the frame 50a, and the other mode having the irregularities in the texture of the rear side - beneficially offer leakage between the tape 10 and a surface of the papermaking equipment creating the fluid pressure differential.The leak reduces and can even completely eliminate a sudden application of vacuum pressure on the paper tissue, thus mitigating a phenomenon known as pit formation. The frame 50a which "presents an angle" in relation to the first surface 41 of the reinforcing structure 40 is contemplated within the framework of the present invention, as used herein, the term "presenting an angle" with respect to the frame 50a "refers to a frame 50a in which, if seen in cross section - presents sharp angles between the first surface 41 of the reinforcing structure 40 and long axes of any of the discrete deflection conduits - in the case of the continuous frame 50a, or discrete protuberances - in the case of the frame 50a comprising a plurality of discrete protuberances. These modalities are disclosed in the commonly assigned patent applications Serial No. 08 / 858,661; and not . series 08 / 858,662, both applications entitled "Cellulosic Web, Method and Apparatus for Making the Same Using Papermaking Belt Angled Cross-sectional Structure, and Method of Making the Belt" (Cellulosic Fabric, Method and Apparatus for Manufacturing them Using a Production Tape of Paper having an Angled Cross Section, and Method of Making the Ribbon) and filed in the name of Larry L. Huston on May 19, 1997 whose disclosures are incorporated herein by reference. A first step of the papermaking tapemaking process 10 according to the present invention comprises the supply of a fluid resinous material 50. As used herein, the term "fluid resinous material" refers to a wide range of polymer resins and similar materials that can achieve and maintain under certain conditions a sufficient fluid state to be deposited on the reinforcing structure 40 having holes there, and for it to penetrate at least partially into these recesses in such a way that the reinforcing structure 40 and the resinous material can be joined. The flowable resinous material 50 can be solidified under certain conditions, and preferably, the flowable resinous material 50 can be cured. The term "curing" refers to the solidification of the fluid resinous material 50a, during said solidification cross-linking occurs. The fluid resinous material 50 of the present invention may comprise a material selected from the group consisting of: epoxies, silicones, urethanes, polystyrenes, polyolefins, polysulfides, nylons, butadienes, photopolymers and combinations thereof. Examples of the suitable liquid resinous material 50 comprise silicones, including, but not limited to: "Smooth-Sil 900", "Smooth-Sil 905", "Smooth-Sil 910", and Smooth-Sil 950. Examples of the resinous material suitable liquid 50 comprising polyurethanes include, but not limited to: "CP-103 Supersoft", "Formula 54-290 Soft", "PMC-121/20", "PL-25", "PMC-121/30", "BRUSH-ON 35", "PMC-121/40", "PL-40", "PMC-724", "PMC-744", "PMC-121/50", "BRUSH-ON 50", "64 -2 Clear Flex "," PMC-726"," PMC-746"," AßO "," PMC-770"," PMC-780"," PMC-790"All exemplary materials are commercially available in Smooth -On, Inc., 2000 St. John Street, Easton, PA, 18042. Other examples of liquid resinous material 50 include multi-component materials such as a two-component liquid plastic "Smooth-Cast 300", and a composite liquid rubber "Clear Flex 50", both commercially available from Smooth-On, Inc. Photosensitive resins can also be employed as the resinous material 50. An exemplary embodiment of the process employing the photosensitive resin as resinous material 50 is shown in Figure 4. The photosensitive resins are usually polymers that cure or crosslink under the influence of radiation, typically ultraviolet light ( UV). References that contain more information about photosensitive liquid resins include Green et al., "Photocross-Linkage Resin Systems," (Photo Reticulation Resin System), by J. Macro-Sci. Revs Macro Chem. C21 (2), 187-273 (1981-82); Bayer, "A Review of Ultraviolet Curing Technology" (A Review of Ultraviolet Light Curing Technology), Tappi Paper Synthetics Conf. Proc., September 25-27, 1978, pages 167-172; and Schmidle "Ultraviolet Curable Flexible Coatings" (Curable Flexible Coatings with Ultraviolet Light), J. of Coated Fabrics, 8, 10-20 (July 1978). The three above references are incorporated herein by reference. Especially preferred liquid photosensitive resins are included in the Merigraph series of resins manufactured by Hercules Incorporated, Wilmington, Del. A most preferred resin is Merigraph EPD 1616 resin. Examples of thermosensitive resins which may comprise the resinous material 50 of the present invention include , not limited to: a group of Hytrel® thermoplastic elastomers, (such as Hytrel® 4056, Hytrel® 7246, and Hytrel® 8238); and Zytel® Nylon (such as Zytel® 101L, and Zytel® 132F), commercially available from DuPont Corporation of Wilmington, DE. Preferably, the fluid resinous material 50 is provided in liquid form. The present invention, however, also contemplates the use of fluid resinous material 50 which is provided in solid form. In the latter case, an additional step of fluidization of the resinous material 50 is required. The fluid resinous material 50 is preferably supplied to a source 55 which offers the appropriate conditions (such as temperature) to maintain the resinous material 50 in a fluid state. As used herein, the term "fluid" refers to a condition or phase condition of the resinous material 50, in which condition the resinous material 50 can flow and this allows the resinous material 50 to be deposited on a surface with a three-dimensional pattern. in such a way that the resinous surface 50 substantially adapts to a three-dimensional pattern of the patterned surface. If thermoplastic or thermosetting resins are used as the resinous material 50, typically a temperature above the melting point of the material is desired to maintain the resin in a fluid state. The material is considered at the "melting point" or above the "melting point" if the material is fully in the fluid state. A suitable source 55 is a channel shown schematically in various drawings of the present application. The channel may have a bottom with a closed end and closed side walls and a side wall facing out. The side wall inward of the channel may be open allowing the fluid resinous material 50 placed there to freely contact and communicate with a molding member 70 (Fig. 5) in accordance with what is described below. If the resinous material comprises a thermoplastic resin, the source 55 and the molding member 70 are preferably heated to prevent premature solidification of the fluid resinous material 50. In the embodiment of the process of the present invention, illustrated in Figure 5, a Proper source 55 is a channel. The channel may have a closed end bottom and closed side walls and a side wall facing outward. The side wall inward of the channel may be open allowing the fluid resinous material 50 placed there in contact freely and communicate with a molding member 70 in accordance with what is described below. In the embodiment of the process illustrated in Figure 4, a coating of fluid resinous material 50 is applied to the reinforcing structure 40 by means of the source comprising a nozzle.

The second step of the process according to the present invention comprises the provision of a reinforcing structure 40. As explained above, the reinforcing structure 40 is a substrate that can comprise several different shapes, such as for example a woven fabric, a screen, a tape, etc. A more detailed description of the reinforcing structure 40, particularly of a reinforcement structure with woven element, can be found in the US Patent NO. 5,275,700 commonly assigned incorporated herein by reference. In the formed papermaking belt 10, the first side 41 faces (and in some embodiments may be in contact) the papermaking fibers during the papermaking process, while the second side 42, opposite to the papermaking process. first side 41, faces (and is typically in contact) with the papermaking team. As used herein, the first side 41 and the second side 42 of the reinforcing structure 40 are consistently known through these respective names independently of the incorporation (i.e., before, during and after incorporation) of the structure of reinforcement 40 in the papermaking belt 10. A distance between the first side 41 and the second side 42 of the reinforcing structure 40 defines its thickness and is referred to herein as "H" (figure 3) in accordance with the present invention , the preferred reinforcing structure 40 has intermediate recesses 49 between the first side 41 and the second side 42, as shown in Figure 3. In the reinforcing structure 40 comprising a woven element (as shown in Figure 3) , the recesses 49 may be a natural occurrence of a woven pattern. The recesses 49 are such that the fluid resinous material 50 can penetrate the recesses 49 such that the resinous material 50 and the reinforcing structure 40 are securely joined together after the solidification of the resinous material 50 and its transformation into the framework. resinous 50a. That is, the combination of viscosity of the fluid resinous material 50 and dimensions and shapes of the recesses 49 preferably allows the fluid resinous material 50 to penetrate the recesses 49 and "attach" around at least part of the reinforcement structure. 40 in such a way that an effective "bond" is formed with the reinforcing structure 40. While the reinforcing structure 40 having recesses 49 is preferred here, the present invention contemplates the use of the reinforcement structure having no such recesses or holes. well having the holes not penetrable by the liquid resinous material 50. In this case, the reinforcing structure 40, especially its first side 41 is such that the resinous material 50 can be fixed there to sufficiently join the reinforcing structure. For this purpose, the reinforcing structure 40, especially its first side 41, preferably has a sufficient roughness, either inherently or as a result of a special treatment. Alternatively or additionally, the first side of the reinforcing structure can be treated with a suitable adhesive to cause the resilient material 50 to be held on the reinforcing structure 40. In the preferred continuous process of the present invention, the reinforcing structure 40 is It moves continuously in one direction of the machine, which is indicated in several figures as "MD". The use of the term "machine direction" here is consistent with the traditional use of the term in papermaking, where this term refers to a direction that is parallel to the flow of the tissue of the paper through the processing equipment. paper. As used herein, the "machine direction" is a direction parallel to the flow of the reinforcing structure 40 during the process of the present invention. Any device known in the art and suitable for a given process can be used to provide the continuous movement of the reinforcing structure 40. Since some types of the resinous material 50 require a relatively longer solidification time compared to a "time of use". ", that is, the time during which the resinous material 50 can be maintained in a liquid state, the movement of the reinforcing structure 40 can be adjusted, if desired, in such a way that the tape 10 is constructed part by part, as will easily recognize an expert in the field. The next step comprises the provision of a work surface 21. As used herein, the term "work surface" refers to a surface of a work member 20, structured and designed to provide support to the reinforcement structure 40 when the reinforcing structure 40 receives the resinous material that can flow there. The work member 20 may comprise several structures. Figure 4 shows the work member 20 in the form of a rotating roller 20a that rotates in a direction indicated by a directional arrow "A", while in figure 5 the work member 20 comprises a continuous belt 20b that moves in the address of the MD machine. Regardless of a specific mode of the work member 20, the work surface 21 has certain characteristics, in accordance with the present invention. More importantly, Figures 4A and 4B show that the work surface 21 has a pattern of recesses 24 that can receive the reinforcement structure 40. The pattern of recesses 49 is structured and designed in such a way that the reinforcement structure 40 can at least partially embedded in recesses 24, as best shown in Figure 4B. The recesses 49 can be formed in any manner known in the art such as by engraving, molding, extrusion, etc. As used herein, the term "work surface" 21 is a generic term that refers to all exposed surfaces in contact with the reinforcing structure 40, including an external (or higher) surface 22 and one (s) surface (s) of recesses 24. It is conventionally said that recesses 24 have a "bottom" 25 and "walls" 26, as shown schematically in Figure 4C. In Figure 4A, the work surface 21a comprises an outer surface 22a (or a surface corresponding to a larger diameter of the roll 20a) and internal surfaces 23a of the recesses 24. In Figure 5, the work surface 21b comprises an outer surface 22b and internal surfaces 23b of the recesses 24 in the belt 20b. It is said that the reinforcing structure 40 is "at least partially" recessed in the recess pattern 24 to recognize that due to the flexibility of the reinforcing structure 40, in some embodiments, portions of the reinforcement structure 40 may not be fully embedded within the recesses 24, which may be tolerable insofar as it does not adversely affect the process and the final product of the present invention. According to the present invention, the recesses 24 have at least one depth "D" (figures 4B and 4C) which is preferably smaller than the thickness h of the reinforcement structure 40. The difference between the thickness h of the structure of reinforcement 40 and the depth D of the recesses 24 ensures that the reinforcing structure 40 extends further (or "up" with reference to Figure 4B) of the work surface 21. Preferably, the reinforcement structure is extends beyond the outer surface 22 of the work surface 21 such that at least a portion of the recesses 49 into which the flowable resinous material 50 can penetrate also extend beyond the outer surface 22 of the work surface 20, as best shown in Figure 4B. By way of illustration only, in Figure 4B, a symbol "V" schematically designates a "vertical" dimension of a type of the holes 49 between one of the yarns of the woven reinforcement structure 40 and the outer surface 22a of the surface of work 21a. That is, if the reinforcing structure 40 comprises a woven element, there is preferably a clearance between at least the upper thread of the reinforcing structure 40 and the outer surface 22 of the work surface 21, as best shown in Figures 4A and 4B. If desired, the recesses 49 may have different depths. It will be understood that while the embodiment in which the depth D of the recesses 49 is smaller than the thickness h of the reinforcing structure 40 is preferred, it is not necessary that it be so. In the present invention, embodiments are contemplated in which the depth D of the recesses 49 is equal to or greater than the thickness h of the reinforcing structure 40, as will be explained in more detail below. The next step in the process of the present invention comprises depositing the reinforcing structure 40 in the recesses 49 of the work surface 20. Any means known in the art can be employed for this step. In Figure 5, a pressure roller 27 and several support rollers 27a facilitate the adjustment of the reinforcing structure 40 within the recesses 24 of the recess structure 21a. The process of the present invention can be adjusted in such a way as to allow a correspondence of a part of the reinforcing structure 40 which makes contact with the work surface 20, and then the movement of the work surface 21 having the portion of the reinforcement structure 40 recessed to the next location, where the resinous material that can flow 50 is applied to reinforcement structure 40, and then the process is repeated. This embodiment is not specifically illustrated but can easily be contemplated by a person skilled in the art based on the various drawings of the present application. The next step comprises the application of the resinous material that can flow 50 on the reinforcing structure 40. According to a specific embodiment of the process of the present invention, the fluid resinous material 50 can be applied using several devices. In the embodiment of Figure 4, the fluid resinous material 50 is applied to the reinforcing structure 40 through the nozzle 55 to form a layer of fluid resinous material 50. In this case, it is preferred that the resinous material 50 be applied to in a regular manner across the width of the reinforcing structure 40, thereby forming a substantially uniform layer of the resinous material in contact with the reinforcing structure 40. In Figure 4, the reinforcing structure 40 moves in the direction of the MD machine towards above, on and around the rotating roller 20a, and return rollers 29a, 29b, and 29c. The thickness of the resinous material 50 applied on the reinforcing structure 40 can be controlled to a preselected value according to the expected use of the tape 10 under construction. Any suitable device for controlling the thickness can be used, for example, in Figure 4, a roller 28a is juxtaposed with the working member 20 comprising the roller 20a to form a constriction therebetween. A clearance between the roller 28a and the working surface 21a of the roller 20a can be controlled mechanically by devices not illustrated. If the resinous material 50 is selected from photosensitive resins, a mask 15 juxtaposed to the layer of resinous material 50 may be employed in order to protect certain areas of the photosensitive liquid resin from exposure to the curing radiation, as described in the commonly assigned North American Patents 4,514,345; and 5,275,700, which are incorporated herein by reference and mentioned above. In Figure 4, the mask preferably comprises an endless loop that moves in the direction indicated by the directional arrows Dl around the rollers 28a and 28b. In the embodiment illustrated in Figure 4, the thickness control of the resinous material 50 applied on the reinforcing structure 40 and the juxtaposition of the mask 15 relative to the resinous material 50 occur simultaneously. Figure 5 shows the embodiment of the process of the present invention, wherein the fluid resinous material 50 is applied on the reinforcing structure 40 through a molding member 70. As used herein, the "molding member" 70 is a pattern structure designed to first receive the fluid resinous material 50 thereby forming a predetermined pattern of the resinous material there, and then transfer the resinous material 50 to the reinforcement structure in a predetermined pattern. In the preferred continuous process, the molding member 70 may comprise several different embodiments. In the embodiment illustrated in Figure 5, the molding member 70 comprises a continuous belt, a portion of said belt moving in juxtaposition to the reinforcing structure 40 and work surface 20. One skilled in the art will understand, however, that the molding member 70 may comprise a rotating roller (not shown). Regardless of its mode, the molding member 70 comprises a molding surface 71 having a three-dimensional pattern. The molding surface 71 is a surface on which / within which the fluid resinous material 50 is deposited. The molding surface 71 is structured and designed to receive the flowable resinous material 50 in such a way that the resinous material which flow 50 can be substantially adapted to the three-dimensional pattern of the molding surface 71. Preferably, the molding surface 71 comprises a preselected pattern of molding bags 72 therein. In a preferred continuous process of the present invention, the molding member 70 is continuously moved at a transport speed thereby bringing the resinous material 50. A person skilled in the art will readily see that in the embodiments comprising the rotating molding roller or the various rotating molding rolls, the transport speed consists of a surface speed measured at the circumferences of the molding surface. In the embodiment of figure 5, which comprises the molding member 70 in the form of the continuous belt, the transport speed is a belt speed.

As used herein, the term "molding bags" 72 refers to a pattern of depressions, or cavities, in the molding surface 71, designed to receive there the fluid resinous material • 50 from a source 55, and then for transferring the fluid resinous material 50 towards the reinforcing structure 40 in order to deposit the fluid resinous material 50 in the reinforcing structure 40 in a predetermined pattern. The molding bags 72 may comprise a substantially continuous pattern on the molding surface 71; in this case, the resinous material 50 is transferred in the reinforcing structure 40 in a substantially continuous pattern to form a substantially continuous resinous frame 50a, in accordance with what is described above. Alternatively, the molding bags 72 can comprise a pattern of discrete depressions or cavities. In the latter case, the resinous material 50 is transferred from the molding bags 72 to the reinforcing structure 40 in a pattern comprising a plurality of discrete protuberances, as described above. A pattern (not illustrated) comprising a combination of substantially continuous molding bags and discrete molding bags (ie, what is known as a "semi-continuous" pattern) is also contemplated in the present invention. The structure 50a having an "angle" in relation to the first surface 41 of the reinforcing structure 40 is contemplated within the framework of the present invention. As used herein, the term structure having an "angle" 50a refers to a structure 50a in which - if observed in cross section - acute angles are formed between the first surface 41 of the reinforcing structure 40 and longitudinal axes of any discrete deflection conduit - in the case of the continuous structure 50a or discrete protuberances - in the case of the structure 50a comprising several discrete protuberances. These embodiments are disclosed in the commonly assigned patent applications Serial No. 08 / 858,661, and Serial No. 08 / 858,662, both of which are entitled "Cellulosic Web, Method and Apparatus for Making the Same Using Papermaking Belt Having Angled Cross-sectional Structure, and Method of Making the Belt ", (cellulose tissue, method and apparatus for making it using papermaking ribbons that have a transverse structure presenting angles, and method to make such a ribbon) and presented on behalf of Larry L. Huston on the day May 19, 1997, whose disclosures are incorporated herein by reference. The molding bags 72 have at least one depth. In the embodiment illustrated in Figure 5, the depth of the molding bags 72 generally defines a thickness of the resinous material 50 deposited from the molding bags 72 in the reinforcing structure 40. As used herein, the term "depth" "of the molding bag or of the molding bags 72 indicates the magnitude of the depression (the depressions) geometrically distinct (s) in the molding member 70. Virtually, an unlimited number of shapes and their permutations of the molding bags 72 having differential depths may be employed in the present invention. The "angle" configurations of the molding bags 72 can be used to produce the "angled" pattern of the resinous frame 50a as explained above. The embodiment of the process of the present invention illustrated in FIG. 5 allows to advantageously create almost any desired shape of the resinous frame 90 by supplying the correspondingly shaped molding surface 71. The pattern of the molding bags 72 can be made by any known method in the art, including, but not limited to, engraving, and molding / casting. The molding surface 71 can be constructed by using an existing papermaking belt 10 having a desirable pattern of the resinous frame 50a. In this case, the tape 10 is used as a template in which a suitable molding material can be applied to form, after solidification, a molding surface 71. It is known in the art that this molding surface 71 can be affixed to the molding member 71. molding 70 through any suitable device. Obviously, where applicable, the entire molding member can be constructed in accordance with what is described above. An example of the molding materials that may be employed is "Brush-On 50", commercially available from Smooth-On, Inc., but not limited to this material. In Figure 5, the flowable resinous material 50 is deposited in the molding pouches 72 of the molding surface 71 generally by first contacting the molding surface 71 with the flowable resinous material 50, and then by removing the excess resinous material 50 from the molding surface 71 as the molding surface 71 is displaced. Preferably, the excess of the flowable resinous material 50 is removed at the source (channel in Figure 5) 55, thus reducing or even eliminating the waste of resinous material 50. Any suitable deposition device known in the art can be employed in the apparatus 10 of the present invention to effect this step. Removal of the excess resinous material 50 from the molding surface 71 can be achieved by cleaning and / or scraping the excess material from the molding surface 71. In Fig. 5, the step of applying the fluid resinous material 50 on the reinforcing structure 40 comprises the continuous transport of the reinforcing structure 40 to the transport speed in such a way that a portion of the reinforcing structure 40 is in a face-to-face relationship with a portion of the molding surface. , and the transfer of the resinous material that can flow 50 from the molding bags 72 of the molding surface 71 onto the reinforcement structure 40 in the preselected pattern. If desired, the molding bags 72 can be treated with a release agent 60 prior to the step of depositing the resinous material 50 in the molding bags 72 to facilitate the transfer of the resinous material 50 from the molding bags 72 towards the reinforcing structure 40. In Figure 5, the working member 20, comprising the belt 20, moves in the direction of the machine MD around the support rollers 29a and 29b that rotate in the direction indicated by the arrow Directional "A". The reinforcing structure 40 comes into contact with the work surface 71 and engages the work surface 21 in a constriction formed between the support roll 29a and a press roll 27. In FIG. 5, the reinforcement structure 40 it is also supported by rollers 27a. The molding member 70 travels around the rollers 79a, 79b, 29b, 79c, 79d, and 79f. The reinforcing structure 40 arrives at a face-to-face relationship with the molding surface in a constriction formed between the support roll 79b and the tape 20b. Starting at this point, the corresponding portions of the reinforcing structure 40 fitted within the work surface 21 and the molding surface 71 move in a face-to-face relationship, preferably with face-to-face touch, over a period of time. predetermined time sufficient to cause the resinous material 50 to be transferred from the molding pouches 72 of the molding surface 71 to the reinforcing structure 40 and to at least partially solidify in such a manner as to retain the form after separation from the mold. the molding surface 71 of the reinforcing structure. In an embodiment of Figure 5, the transfer of the resinous material 50 from the molding surface 71 onto the reinforcing structure 40 is advantageously facilitated by gravity, since at least at some point the molding surface 71 is located above the reinforcing structure 40. It will be understood that the resinous material 50 may be partially solidified while being associated with the molding surface 71 and before the resinous material 50 is transferred from the molding surface 71 to the reinforcing structure 40. In some modalities, a change in viscosity of the resinous material 50 is contemplated, before it is deposited in the reinforcing structure 40. However, as has been emphasized above, the resinous material 50 must retain a sufficient viscosity to allow the resinous material 50 and the reinforcement structure 40 join. Preferably, the portion of the reinforcing structure 40 facing the molding surface 71 is in contact with the molding surface 71 for a predetermined period of time. The process employing the molding surface 71, mainly illustrated in Figure 5, is described - in more detail in the commonly assigned and co-pending application entitled "Papermaking Belt and Process for Making the Same" (papermaking belt and process for manufacture) filed in the name of Ampulski on the same date as the present Application, said application is incorporated herein by reference. Regardless of a specific method for the application of the resinous material 50 on the reinforcing structure 40, in the preferred embodiment, the fluid resinous material 50 has a viscosity that allows the fluid resinous material 50 to penetrate at least a portion of the voids. 49 of the reinforcing structure 40. In accordance with the present invention, a portion of the fluid resinous material 50 must penetrate beyond the first side 41 of the reinforcing structure 40 to reach the recesses 49 in such a way as to at least partially fit. or "hook", portions of the reinforcing structure 40 and to thereby form a secure connection between the resinous frame 50a and the reinforcing structure 40 in the finished tape 10.

In the preferred embodiment, wherein the reinforcing structure 40 comprises a woven element, the resinous material 50 must at least partially fit the yarns forming the first surface 41 in order to create a secure connection therebetween. In the embodiment in which a part of the recesses 49 extends beyond the outer surface 22 of the work member 20, the fluid resinous material 50 easily fills the exposed recesses 49, thereby fitting the corresponding portions of the structure of reinforcement 40. However, it is believed that in the embodiments in which the thickness h of the reinforcing structure 40 is equal to or less than the depth D of the recesses 49, the viscosity of the fluid resinous material 50 must be selected to allow the Resinous material 50 partially penetrates the recesses 24, thereby filling the recesses 49. Due to the woven nature of the reinforcing structure 40, some hollow spaces exist between the reinforcement structure yarns 40 and the walls of the recesses 24. Accordingly, given a sufficient viscosity of the fluid resinous material 50, the fluid resinous material 50 can penetrate between the threads of the reinforcing structure 40 and the walls of the recesses 24, as well as between the individual interwoven strands of the reinforcing structure 40. In the embodiments of Figures 4B-5, wherein portions of the recesses 49 where the fluid resinous material 50 can penetrate extends beyond of the outer surface 22 of the work member 20, a substantial portion of the fluid resinous material 50 can not reach beyond the external surface 22 of the work surface 20. Therefore, after the solidification of the resinous material 50, it is created a distance Z between the second side 42 of the reinforcing structure 40 and the bottom side 51a of the resinous frame 50a. Obviously, relatively small amounts of fluid resinous material 50 can still in some embodiments penetrate between the individual threads of the reinforcing structure 40 and between the threads of the reinforcing structure 40 and the walls of the recesses 24 and still reach a "bottom" of the recesses 49. It will be understood by a person skilled in the art that due to said penetration of the fluid resinous material 50 into the recesses between the reinforcing structure yarns 40 and / or the walls of the recesses 49, the distance Z may be different in length. the plane of the tape 10 under construction, which is acceptable insofar as the average distance Z is sufficient to provide a leak between the belt 10 and the vacuum equipment and to eliminate the sudden application of vacuum pressure on the fabric placed on the tape 10, as explained above. The next step in the process of the present invention comprises the solidification of the fluid resinous material 50. As used herein, the term "solidification" and derivatives thereof refer to a process for altering a fluid to a solid state. Typically, the solidification includes a phase change, from a liquid phase to a solid phase. The term "curing" refers to a solidification in which a crosslinking occurs. Preferably, the solidification of the resinous material 50 comprises curing. A method for solidifying the resinous material 50 depends on its nature. For example, photosensitive resins can be cured by UV radiation, in accordance with that described in the commonly assigned US Patents 5,334,289; 5,275,700; 5,364,504; 5,098,522; 5,674,663; and 5,629,052, all of which are incorporated herein by reference. Thermoplastic resins and thermosetting resins require a certain temperature for solidification. The resinous material 50 comprising multi-component or plastic resins naturally solidifies, for a certain predetermined period of time, by virtue of their joint mixing. In some modalities, the solidification process of the resinous material 50 can start as soon as immediately after the fluid resinous material 50 has been deposited on the molding surface 71, Figure 5. Preferably, the solidification proceeds while the reinforcing structure 40 and the surface molding 71 are in a face-to-face relationship. As an example, Figure 5 schematically shows a curing device 80 juxtaposed with the opposite surface of the working surface 21b of the tape 20b. One skilled in the art will understand that, depending on the nature of the resinous material 50 and the method of its solidification, the curing device 80 can be placed in other locations. Examples of the curing device 79 include, but are not limited to: a heater for increasing the rates of crosslinking reaction or condensation rates in the case of condensation polymers; a cooler to solidify thermoplastics; several devices that offer radiation for curing with infrared light, a microwave curing radiation, or a curing ratio with ultraviolet light; and similar. In the exemplary embodiment of Figure 4, the photosensitive resinous material 50 is cured by its exposure to curing radiation, i.e., the light of the activating wavelength through the mask, thereby inducing curing of the material resinous 50 in the portions that are not protected by the non-transparent regions of the mask 50. A curing device 80 that includes a curing radiation source 16 may comprise an exposure lamp that provides illumination primarily at the wavelength that causes the curing of liquid photosensitive resin 50. Any suitable source of illumination, such as mercury arc, pulsed xenon, electrodeless and fluorescent lamps, may be employed. The commonly assigned patent application Serial No. 08 / 799,852, entitled "Apparatus for Generating Parallel Radiation for Curing Photosensitive Resin" (apparatus for generating parallel radiation for the curing of photosensitive resin), filed under the name Trokhan et al. on February 13, 1997; and the commonly assigned patent application with a Serial No. 08 / 858,334, entitled "Apparatus for Generating Controlled Radiation for Curing Photosensitive Resin" (apparatus for generating controlled radiation for the curing of photosensitive resin), filed in the name of Trokhan et al. . on February 13, 1997, and its continuation 08 / 958,540, filed on October 24, 1997, are incorporated herein by reference for the purpose of showing various embodiments of the curing radiation apparatus 16 that can be used for the solidification of the resinous material 50 comprising a photosensitive resin. In the embodiment of Figure 4, a step of removing from the reinforcement structure 40 substantially all of the uncured resinous material 50, ie, the resinous material 50 which was protected by the non-transparent regions of the mask 15 against exposure to curing radiation. A vacuum can be applied from a vacuum apparatus 18a to a composite of the reinforcing structure 40 and partially cured resinous material 50 to remove a substantial amount of liquid (ie, uncured) resinous material from the composite. Then, a sprinkler 17 may be employed to wash the residue of the uncured resinous material 50 from the composite. The vacuum can then be applied again, from a vacuum apparatus 18b in order to remove any residual liquid resinous material 50 and shower liquid. Optionally, there may be a second exposure (not illustrated) of the resinous material 50 to the curing radiation to complete the curing of the resinous material 50 and to increase the hardness and durability of the resinous frame 50a of the tape 10 under construction. The process continues until the entire length of the reinforcing structure 40 has been treated and converted into the tape 10. The heat-sensitive resinous material 50 can be naturally solidified at room temperature. In the embodiment illustrated in Figure 5, the solidification step of the fluid resinous material 50a can be provided by keeping the resinous material 50 associated with the reinforcing structure 40 and the patterned molding surface 71 for a predetermined period of time. During this period, the resinous material 50 solidifies sufficiently to retain its desired shape after separation from the molding surface 70. In the embodiment of Fig. 5, the solidification process of the resinous material 50 may begin immediately after the fluid resinous material 50 has been deposited on the molding surface 71. The solidification proceeds while the reinforcing structure 40 and the molding surface 71 are in a face-to-face relationship, starting at the constriction formed between the support roll 79b and the tape 20b. From this point on, the corresponding portions of the reinforcement structure 40 in recess within the work surface 21 and the molding surface 71 move in a face-to-face relationship for a predetermined period of time sufficient to cause the Resinous material 50 is transferred from the molding bags 72 of the molding surface 71 to the reinforcing structure 40 and solidifies at least partially in such a way that it retains its shape after the molding surface 71 has been separated from the structure of reinforcement. Optionally, solidification accelerators may be employed to accelerate the solidification process of the resinous material 50. As used herein, "solidification accelerators" refer to materials which, when added to the resinous material 50, shorten the time necessary for solidification, and preferably curing, of the resinous material 50. Such solidification accelerators should not adversely affect, preferably, the final physical properties of the resinous framework 50a under construction. Examples of solidification accelerators include, but are not limited to: "SO-CURE Accelerator Cure" ("C-1506," "C-1508," "C-1509," and "C-1511"); and "KICK-IT Cure Accelerator" ("PMC-724," "PCM-726," "PMC-121/30," "PMC-121/50," "PMC-744," "PMC-780,") all of which are commercially available from Smooth-On, Inc., 2000 St. John Street, Easton, PA, 18042. Optionally, a gauge control step of the tape 10 can be provided in the process of the present invention. The gauge can be controlled by controlling the depth of the recesses 24 in the work surface 21. Another way of controlling the gauge involves changing the thickness of the resinous material 50 after the resinous material 50 has sufficiently bonded onto the reinforcement structure 40. , and after the resinous framework 50a has been formed at least partially. For example, the thickness of the resinous material 50 can be adjusted by mechanical means known in the art, and therefore not illustrated here. For example, a pair of mutually juxtaposed rollers that form a constriction between them can be used to control the gauge of the belt 10. By adjusting a throttling clearance between the rollers, the gauge of the belt 10 under construction can be controlled. Alternatively or additionally, the gauge control device may comprise a rotating grinding roller, a smoothing blade, a laser, or other devices known in the art and suitable for the purpose of controlling the gauge of the belt. .

Claims (1)

1. CLAIMS A process for manufacturing a papermaking belt comprising a reinforcing structure and a resinous framework attached to said structure, the process comprising the steps of: (a) providing a flowable resinous material; (b) providing a reinforcement structure having a first side, a second side opposite the first side, and a thickness defined therebetween, where preferably the reinforcing structure has gaps between the first side and the second side, the recesses may to be penetrated by the fluid resinous material; (c) providing a work surface comprising an external surface and a recess pattern there, the recess pattern having a depth and is structured and designed to receive the reinforcement structure there; (d) placing at least partially the reinforcement structure in the recesses of the work surface, wherein preferably the reinforcement structure is placed in the recess pattern to extend beyond the external surface of the work surface and more preferably at least a portion of the voids that can be penetrated by the fluid resinous material extends beyond the outer surface of the work surface; (e) applying the flowable resinous material to the reinforcing structure, preferably the resinous material occupies at least a part of the gaps in the reinforcing structure; Y (f) solidifying the flowable resinous material to form a patterned resinous frame attached to the reinforcing structure. The process according to claim 1, wherein in step (b) the reinforcing structure comprises a woven element. The process according to claims 1 and 2, wherein in step (a) the fluid resinous material is selected from the group consisting of epoxies, silicones, urethanes, polystyrenes, polyolefins, polysulfides, nylons, butadienes, photopolymers and combinations thereof. The process according to claims 1, 2, and 3, wherein in step (a) the fluid resinous material comprises a photosensitive resin, a thermosensitive resin, or a combination thereof. The process according to claim 1, 2, 3, and 4 wherein in step (e) the fluid resinous material is applied to the reinforcement structure in a non-random pre-selected pattern. The process according to claim 1, 2, 3, 4, and 5, further comprising a step of substantially changing a viscosity of at least a portion of the fluid resinous material applied on the reinforcing structure before the step of solidifying the fluid resinous material. A process for manufacturing a papermaking belt comprising a reinforcing structure and a resinous framework attached thereto, the process comprising the steps of: (a) provide a flowable resinous material; (b) providing a reinforcing structure comprising at least a plurality of yarns in the machine direction interwoven with at least a plurality of yarns in the transverse direction relative to the machine, the reinforcement structure having a first side , a second side opposite the first side, a thickness defined between them, and gaps between the first side and the second side, the holes can be penetrated by the fluid resinous material; (c) providing a work surface comprising an outer surface and a recess pattern there, the recess pattern having a depth less than the thickness of the reinforcement structure, the recess pattern is structured and designed to receive the structure of recesses. reinforcement there; (d) placing the reinforcing structure in the recesses such that a portion of the recesses where the fluid resinous material can penetrate extends beyond the outer surface of the work surface; (e) applying the fluid resinous material to the reinforcement structure to occupy at least a portion of the recesses in the reinforcing structure; and (f) solidifying the flowable resinous material to form a patterned resinous frame attached to the reinforcing structure. An apparatus for manufacturing a papermaking belt comprising a reinforcing structure having gaps there and a thickness, and a resinous framework attached to the reinforcing structure, the apparatus comprises: (a) a work surface comprising an external surface and a pattern of recesses there structured and designed to receive at least partially the reinforcing structure there; (b) a device for placing the reinforcing structure in the recess pattern of the work surface; (c) a device for applying a fluid resinous material on the reinforcement structure placed in the recesses of the work surface; (d) a device for solidifying the fluid resinous material to provide a resinous patterned frame attached to the reinforcing structure. The apparatus according to claims 1, 2, 3, 4, 5, 6, 7, and 8, wherein the molding surface comprises a rotating molding roller, or a continuous molding tape. A papermaking belt comprising: a reinforcement structure comprising at least several machine-direction yarns interwoven with at least several yarns in the transverse direction relative to the machine, the reinforcing structure having a first side , a second side opposite the first side, a thickness defined between them, and gaps between the first side and the second side; and a patterned resinous frame comprising an upper side and a lower side opposite the upper side, and several deflection conduits extending between the upper side and the underside, the patterned resinous frame is attached to the reinforcement structure of such that a substantial portion of the bottom side of the resinous frame is found between the first side and the second side of the reinforcing structure. SUMMARY OF THE INVENTION The invention comprises a method for applying a curable resin (50) onto a reinforcing structure (40) and an apparatus for this purpose. The apparatus comprises a work surface (72) having a pattern of recesses structured therein and designed to at least partially receive a reinforcing structure (40) a device for positioning the reinforcement structure (40) in the recess pattern of the work surface, a device (55) for applying a resinous fluid material on the reinforcement structure placed in the recesses of the work surface, and a device for solidifying the flowable resinous material in order to provide a resinous framework with pattern attached to the reinforcement structure. The process comprises the steps of at least partially positioning the reinforcing structure in the recesses of a work surface, applying the flowable resinous material to the reinforcement structure, and then solidifying the flowable resinous material to form a resinous framework with attached pattern. to the reinforcement structure. Preferably, the reinforcing structure has gaps where the fluid resinous material can penetrate, between the first side and the second side, and the resinous material occupies at least a portion of the gaps in the reinforcing structure. The finished tape comprises a patterned resinous frame attached to the reinforcing structure such that a substantial portion of a bottom side of the resinous frame is between two opposite sides of the reinforcing structure.