MXPA01001616A - Process and apparatus for making papermaking belt - Google Patents

Abstract

A process and an apparatus for making a papermaking belt are provided, the belt comprising a reinforcing structure (40) and a resinous framework (50A) joined together. The preferred continuous process comprises the steps of depositing a flowable resinous material (50) onto a patterned molding surface (21);continuously moving the molding surface and the reinforcing structure at a transport velocity such that at least a portion of the reinforcing structure is in a face-to-face relationship with a portion of the molding surface;transferring the flowable resinous material from the molding surface onto the reinforcing structure;causing the flowable resinous material and the reinforcing structure to join together;and solidifying the resinous material thereby forming the resinous framework joined to the reinforcing structure. The apparatus comprises a molding member having a patterned molding surface comprising a plurality of molding pockets to carry a flowable resinous material therein;a means for depositing the flowable resinous material into the molding pockets of the molding surface;a means for moving the reinforcing structure in a predetermined direction;a means for moving the molding member in a predetermined direction such that the flowable resinous material is transferred from the molding pockets onto the reinforcing structure.

Description

PROCESS AND APPARATUS TO MANUFACTURE A TAPE FOR THE PREPARATION OF PAPER FIELD OF THE INVENTION The present invention relates generally to papermaking belts useful in paper making machines for making strong, soft, absorbent paper products. The invention also relates to a method for making such tapes for papermaking. More particularly, the invention relates to papermaking belts comprising a resinous framework and a reinforcement structure attached thereto. BACKGROUND OF THE INVENTION In general, a process for papermaking involves several stages. Typically, an aqueous pulp of fibers for papermaking is formed in an embryonic tissue in a member with perforations such as, for example, a Fourdrinier wire. After the initial formation of the paper tissue in the Fourdrinier wire mesh, or forming wires, the paper tissue is brought through a drying process or several drying processes into another piece of papermaking cloth in form of a continuous tape that is often different from Fourdrinier wire or forming wires. This other fabric is often referred to as a drying cloth or tape. While the fabric is in the drying belt, the process of drying or removing water can involve water removal in vacuum, drying by applying hot air through the fabric, mechanical processing, or a combination of the same. In the air-drying processes developed and marketed by the present beneficiary, the drying fabric may comprise what is known as a deviating member having a microscopically monoplanar, continuous crosslinked surface, and preferably in pattern and non-random form which defines several discrete diversion conduits, isolated from each other. Alternatively, the deflection member may comprise several discrete protuberances isolated therebetween by a substantially continuous deflection conduit, or else be semi-continuous (ie, comprising a continuous and discrete network combination). The embryonic tissue is associated with the deviation member. During the papermaking process, the papermaking fibers in the fabric are diverted into the bypass conduits and water is removed from the fabric through the bypass conduits. The fabric is then dried and reduced, if desired by crinkling. The deviation of the fibers in the deflection conduits of the papermaking belt can be induced, for example, by the application of a differential fluid pressure on the embryonic tissue of paper. A preferred method of applying a differential pressure is the exposure of the tissue to a fluid pressure differential through the drying fabric comprising the biasing member. Paper tissues dried by air passage may be made in accordance with any of the following commonly assigned U.S. Patent Documents incorporated herein by reference: No. 4,529,480 issued to Trokhan on July 16, 1985; No. 4,637,859 granted to Trokhan on January 20, 1987; No. 5,364,504, issued to Smurkoski et al., November 15, 1994; No. 5,259,664, issued to Trokhan et al. on June 25, 1996; and No. 5,679,222, issued to Rasch et al. on October 21, 1997. Generally, a method for making a diverting member comprises the application of a photosensitive liquid resin coating on a surface of an element with perforations, the thickness control of the coating at a preselected value, the exposing the coating of the photosensitive liquid resin to light at an activation wavelength through a mask, thus avoiding or reducing the curing of selected portions of the photosensitive resin. After the uncured portions of the photosensitive resin are typically removed through the washing by showers. Several commonly assigned US patents incorporated herein by reference disclose methods for the manufacture of papermaking belts: 4,514,345, issued April 30, 1985, to Jonson 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 January 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 .; 5,496,624, 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. e it has been found that the curing of the photosensitive resin was an effective way of manufacturing the papermaking belt, the search for improved methods and products continued. Now, it is believed that the bypass member can be manufactured at least through several other methods that do not necessarily require the use of curing radiation. Accordingly, it is an object of the present invention to provide a novel process for the manufacture of a papermaking belt by first forming a desired pattern of flowable resin in a molding member, and then transferring the resin from the molding member towards the reinforcement structure and solidifying the resin with pattern. Another object of the present invention is to provide a process that reduces the amount of resin that is required to build the papermaking belt comprising a reinforcing structure and a resinous patterned frame. Another object of the present invention is to provide an apparatus comprising a molding member for forming a desirable pattern of the resin and subsequently transferring the patterned resin to the reinforcing structure of the tape in construction. These and other objects of the present invention will be more easily taken into account the following description, in combination with the accompanying drawings. SUMMARY OF THE INVENTION A papermaking belt that can be manufactured through a process and apparatus of the present invention comprises a reinforcing structure and a resinous framework with pattern attached thereto. The reinforcing structure has a first side and a second opposite side. Preferably, but not necessarily, the reinforcing structure comprises a fluid-permeable element, such as a woven fabric or a screen having several open areas therethrough. The reinforcing structure may also comprise a felt. The resinous frame has an upper side and a lower side, the upper and lower sides correspond to the first side and the second side of the reinforcing structure, respectively. The resinous framework may also have a substantially continuous pattern, a discrete pattern, or a combination thereof (ie, a "semi-continuous pattern"). A process for making the belt comprises the following steps: providing a reinforcing structure having a first side, a second side opposite the first side, and a thickness between them; supply a resinous material that can flow; providing at least one molding member having a molding surface comprising a preselected pattern of molding bags structures and designed to carry the resinous material that can flow there; continuously moving the molding surface at a transport speed; deposit the resinous material that can flow in the molding bags of the molding surface; continuously transporting the reinforcing structure to the transport speed in such a way that at least a part of the reinforcing structure is in a face-to-face relationship with at least a part of the molding surface; transferring the resinous material that can flow from the molding pockets of the molding surface to the reinforcing structure; cause the resinous material that can flow and the reinforcement structure to join; and solidifying the resinous material thereby forming the resinous framework attached to the reinforcing structure. Preferably, the resinous material is transferred from the molding bags in the reinforcing structure in the predetermined pattern corresponding to the pattern of the molding bags. Preferably, a step is provided for the treatment of the molding surface with a release agent before depositing the resinous material on the molding surface or within said molding surface. When the reinforcing structure is in a face-to-face relationship with the molding surface, preferably the reinforcing structure comes into contact with the flowable resinous material placed in the molding bags for a predetermined period of time sufficient to cause the resinous material that can flow and the reinforcing surface to be joined at least partially. The transfer of the resinous material from the molding surface to the reinforcing structure can be assisted by pressing the molding surface and the reinforcing structure against each other. An apparatus for the manufacture of the papermaking belt has a machine direction and comprises a molding member having a patterned molding surface comprising several molding bags. The molding bags are structured and designed to carry a resinous material that can flow there. In one embodiment, the molding member comprises a rotating molding roller having a circumference and a longitudinal axis of rotation perpendicular to the machine direction. The circumference of the molding roll comprises the molding surface. In another embodiment, the molding member comprises a continuous molding belt adapted to move continuously in the machine direction. The apparatus further comprises a means for depositing the resinous material that can flow into the mold bags of the mold surface, a means for moving the reinforcing structure in the machine direction such that at least a part of the portion of the reinforcing structure is in a face-to-face relationship with at least a portion of the molding surface, and a means for moving the molding member in the machine direction in such a way that the resinous material which can flow be transferred from the molding bags to the reinforcing structure, preferably in a preselected pattern. The apparatus further preferably comprises a means for solidifying the fluid resin material to form the resin framework attached on the reinforcing structure. In one embodiment, the molding pouches of the molding surface form a substantially continuous pattern. In this case, the resinous material is transferred on the reinforcing surface in a substantially continuous pattern. In another embodiment, the molding bags of the molding roll form a pattern of discrete molding bags, in this case the resinous material is transferred into the reinforcing structure in a pattern comprising discrete resinous protuberances. A modality is contemplated in which the mold or molding surface bags form a combination of the substantially continuous pattern and the discrete pattern, which is known as a "semi-continuous" pattern. The resinous material may, in some embodiments, extend outwardly from the first side of the reinforcing structure after the resinous material has been deposited in the reinforcing structure. The molding bags have a depth that may be different in the different parts of the molding surface. The present invention allows the manufacture of the tape in which the resinous frame has a different thickness through the plane of the tape. At the same time, the present invention allows the construction of a tape in which the upper side of the resinous frame and the first side of the reinforcing structure are substantially in the same plane. The flowable resinous material is preferably selected from the group consisting of epoxies, silicones, urethanes, polystyrenes, polyolefins, polysulfides, nylons, butadienes, photopolymers, and any combination thereof. In a preferred embodiment, the resinous material that can flow comprises a photosensitive resin. The resinous material that can flow can comprise a thermosensitive resin, such as for example a thermo-hardening or thermo-plastic material. Preferably, the resinous material that can flow is provided in a liquid state. The flowable resinous material can be deposited on the molding surface or inside the molding surface first by contacting the molding surface with the resinous material that can flow and secondly by removing the excess of resinous material that can flow. flow from the molding surface as the molding surface moves. The apparatus further comprises a device for pressing the reinforcing structure onto the molding surface for a predetermined period of time thus facilitating the transfer of the resinous material from the molding surface towards the reinforcing structure. In one embodiment, the apparatus comprises a backup roller juxtaposed to the molding surface to form a constriction therebetween. In another embodiment, the apparatus comprises a backing sheet juxtaposed relative to the molding surface. The backing sheet is structured and designed to move in a face-to-face contact relationship with at least a portion of the reinforcing structure. Preferably, the backing sheet is under tension. In one embodiment, the molding surface comprises a predetermined pattern of recesses. The recesses are structured and designed to receive the reinforcement structure there. This embodiment offers the tape in which a substantial portion of the bottom side of the resinous frame is raised above 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 bottom side of the resinous frame. During a papermaking process, this distance provides leakage between the belt and the water removal equipment to make paper, thus eliminating a sudden application of fluid pressure differential to a paper web placed on the belt and mitigating this It forms a phenomenon known as pin molars. "The distance between the second side of the reinforcing structure and the underside of the resinous frame may be different through the plane of the tape.The apparatus may further comprise a device for solidifying the resinous material that can flow, such as for example a curing device comprising a source of UV radiation for curing the resinous material comprising a photosensitive resin, Optionally, a step and a device for controlling the thickness of the resinous material bonded on the reinforcement structure at least a pre-selected value SHORT DESCRIPTION OF THE DRAWINGS Figure 1 is a schematic side elevational view of one embodiment of a process and apparatus of the present invention, the illustrated process comprising a multi-stage process illustrated in Figure 1. Figure 2 is a more detailed schematic side elevational view of a fragment 2 of figure 1 showing a papermaking belt under construction in a first stage of the multi-stage process illustrated in figure 1. Figure 2A is a simplified top plan view, along lines 2A - 2A of Figure 2. Figure 3 is a schematic and more detailed side elevational view of a fragment 3 of Figure 1, showing a papermaking belt in construction in a second stage of the multi-stage process illustrated in Figure 1. Figure 3A is a simplified top plan view, along lines 3A-3A of the figure 3. Figure 4 is a partial and schematic side elevational view of one embodiment of the process and apparatus of the present invention, showing a molding roll and a tape in construction. Figure 5 is a schematic and partial side elevational view of another embodiment of the process and the apparatus of the present invention, the apparatus comprises a molding choke formed between the molding roll and a backing roll. Figure 6 is a schematic and partial side elevational view of another embodiment of the process and apparatus of the present invention, the apparatus comprising two backing rolls and a support sheet wrapped around the molding roll. Figure 7 is a schematic side elevational view of another embodiment of the process and apparatus of the present invention, showing a reinforcing structure wrapped around a portion of the circumference of the molding roll and fully retracted therein. Figure 7A is a schematic and more detailed view of a fragment 7A of Figure 7, showing the papermaking belt in construction employing the process and the apparatus illustrated in Figure 7. Figure 7B is a fragmentary planar representation and schematic of a view taken in the direction of arrow 7B of figure 7, showing an exemplary embodiment of the circumference of the molding roll, comprising a pattern of molding bags for receiving a fluid resin, and a pattern of recesses to receive the reinforcing structure, the two patterns interpose each other and have equal depths. Figure 8 is a schematic and partial side elevational view of another embodiment of the process and of the apparatus of the present invention, showing the reinforcing structure enveloping a portion of the circumference of the molding roll and partially retracted, the apparatus comprising 3 rolls of backing juxtaposed with the molding roller and in contact with the reinforcement structure. Figure 8A is a schematic and more detailed side elevational view of a fragment 8A of Figure 8. Figure 8B is the fragmentary and schematic planar representation of a view taken along lines 8B-8B of Figure 8A, which shows an exemplary embodiment of the circumference of the molding roll, comprising a pattern of molding bags for receiving a fluid resin, and a pattern of recesses for receiving the reinforcing structure, the two mutually interposed patterns, the molding bags having a depth greater than the depth of the recesses of the reinforcing structure. Fig. 9 is a schematic partial cross-sectional view, taken along lines 9-9 of Fig. 9A, of an exemplary embodiment of the papermaking belt that can be made employing the process and apparatus of the present invention, The belt comprises a substantially continuous frame attached to the reinforcing structure, and several discrete deflection conduits. Figure 9A is a schematic top plan view along lines 9A-9A of Figure 9. Figure 10 is a schematic partial cross-sectional view of an exemplary embodiment of the molding roll of the present invention, comprising several molding bags that have different depths. Figure 10A is a schematic planar representation of a plan view along lines 10A-10A of the figure . Figure 11 is a schematic partial cross-sectional view, taken along lines 11-11 of Figure HA, of an exemplary embodiment of the papermaking belt that can be made using the molding roller illustrated in Figure 10, Tape comprises several discrete protuberances that have different overloads. Figure HA is a schematic top plan view along lines 11A-11A of Figure 11. Figure 12 is a schematic side elevational view of another embodiment of the process and apparatus of the present invention, the apparatus comprises a continuous molding tape. DETAILED DESCRIPTION OF THE INVENTION A representative belt 90 for making the paper that can be manufactured according to the present invention is illustrated schematically in Figures 9, 9A, 11 and HA. As used herein, the term "papermaking belt", or simply "tape", refers to a structure substantially microscopically onoplanar designed to support and preferably carries a fabric there during at least one stage of a manufacturing process of paper. Typically, modern processes on an industrial scale employ continuous papermaking belts, but it should be understood that the present invention can be used to make discrete portions of the belt 90 to stationary plates that can be used to manufacture fabric sheets, drums , rotating, etc. As shown in Figures 9 and 11, the belt 90 has a side in contact with fabric 91 and a back side 92 opposite the side in contact with the fabric 91. The papermaking belt 90 is known as macroscopically monoplanar due to the fact that part of the belt 90 is placed in a planar configuration, the fabric side 91, observed as a whole, is essentially in a plane. It is said to be "essentially" monoplanar to recognize the fact that deviations from absolute planarity are tolerable, although not preferred, while deviations are not important enough to negatively affect the performance of the tape 90 for the purposes of a process particular papermaking. The papermaking belt 90 that can be made in accordance with the present invention generally comprises two primary elements: a frame 50 (preferably a hardened polymeric resin framework made from a fluid polymeric resinous material 50) and a reinforcing structure. 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 41 is in contact with the papermaking fibers during the papermaking process. 42 typically is in contact with papermaking equipment such as a vacuum pick-up shoe and a multiple-slot vacuum box (not illustrated). The reinforcing structure 40 can have several different shapes. It may comprise a woven element, a nonwoven element, a screen, a net, a strip, a plate, etc. 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 direction, as shown in figures 9 and 9A. More particularly, the woven reinforcement structure 40 may comprise a woven element with perforations as disclosed in U.S. Patent No. 5,334,289, issued to 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. The joint North American Patent No. 5,679,222, issued by Rasch et al., on October 21, 11997, is incorporated herein by reference. The joint North American patent No. 5,496,624, issued March 5, 1996 in the name of Stelljes, Jr et al., Is incorporated herein by reference to show an adequate reinforcing structure 40. The papermaking belt 90 can also be made using the reinforcing structure 40 comprising a felt, for example, as a co-assigned patent application no. serial 08 / 391,372, filed on February 15, 1995 in the name of Trokhan et al., and entitled "Method of Applying to Curable Resin to Substrate for Use in Papermaking" (Method for applying a Curable Resin to a Substrate for its Use in Papermaking), said application is incorporated herein by reference. The reinforcing structure 40 of the belt 90 reinforces the resinous frame 50A and preferably has a suitable projected area in which the papermaking fibers can deflect under pressure. In accordance with the present invention, the reinforcing structure 40 can be fluid permeable as well as non-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 for making a paper fabric with air-pass drying. An example of the non-permeable reinforcement structure 40 is shown in Figures 11 and HA. As shown in Figures 9, 9a, 11, lia, the reinforcing structure 40 is attached to the resinous frame 50a. The resinous framework 50a comprises a solidified resinous material 50 that is, the resinous framework 50 is a solid phase of the flowable resinous material 50a. In this regard, the term "resinous material 50" and the term "resinous frame 50a" can be used interchangeably if appropriate in the context of the description. The resinous frame 50a has an upper side 50 and a lower side 52 opposite the upper side 51. During the papermaking process, the upper side 51 of the frame 50a comes into contact with the papermaking fibers and consequently defines the pattern of the paper tissue produced. The bottom side 52 of the frame 50a can, in some embodiments (FIGS. 7 and 7a), be in contact with the papermaking equipment, in said embodiments, the bottom side 52 of the frame and the second side 42 of the structure reinforcement can be placed in the same macroplane. Alternatively, a distance Z can be formed between the bottom side 52 of the frame 50a and the second side 42 of the reinforcing structure (Figure 8A). Another embodiment (not illustrated) of the frame 50a may comprise the bottom side 52 having a network of passages that provide irregularities in the rear side surface structure, in accordance with that described in co-assigned US Patent 5,275,700 issued on 4 January 1994 to Trokhan, said patent is incorporated herein by reference. The last two embodiments of the frame 50a - one embodiment having the distance Z between the bottom side 52 of the frame 50a and the other embodiment having the texture irregularities on the back side - beneficially offer leakage between the bottom side 52 of the frame 50a. frame 50 and a surface of the papermaking equipment that are mutually in contact. The leak reduces or even completely eliminates a sudden application of vacuum pressure on the paper tissue, thus mitigating a phenomenon known as pinhole formation. A first process step in accordance with the present invention comprises the provision of a reinforcing structure 40. As explained above, the reinforcement structure 40 is a substrate that can comprise several different shapes, such as for example a woven fabric, a felt, a screen, a strip, etc. A more detailed description of the reinforcing structure 40, especially a structure comprising a woven element, is found in commonly assigned US Patent No. 5,275,700 which is incorporated herein by reference. Regardless of the specific embodiment, the reinforcing structure 40 has a first side 41 and a second side 42, as best shown in Figures 4, 7, 7A and 11. In the formed papermaking belt 90, the first side 41 faces (and in some embodiments may be in contact) with the papermaking fibers during the papermaking process, while the second side 42, opposite the first side 41, faces (and is typically in contact) to 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 embodiment (ie, before, during and after the incorporation) of the reinforcing structure 40 in the papermaking belt 90. A distance between the first side 41 and the second side 42 of the reinforcing structure forms a thickness of the reinforcing structure, designated here as "h" (figure 9).

In a preferred continuous process of the present invention, the reinforcing structure 40 is continuously moved in the machine direction, 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 the term refers to a direction that is parallel to the flow of paper tissue 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. The next step of the process of the present invention comprises the provision of a flowable resinous material 50. As used herein, the term "flowable resinous material" refers to a wide range of polymer resins and plastics that can achieve and maintaining under certain conditions and / or for a certain period of time, a sufficiently fluid or liquid state to be molded into a structure having a desired configuration, and then solidifying and preferably cured to form the frame 50a, as explained above. The flowable 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, photopolyres, and combinations thereof. Examples of the suitable liquid resinous material 50 comprising silicones, include, without limitation: "Smooth-Sil 900," "Smooth-Sil 905," "Smooth-Sil 910," and "Smooth-Sil 950." Examples of the suitable liquid resinous material 50 comprising polyurethanes, include, without limitation: "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, "" A60, "" PMC-770, "" PMC-780, "" PMC-790. " All of the exemplary materials mentioned above are available from S ooth-On, Inc., 2000 St. John Street, Easton, PA, 18042. Other examples of the liquid resinous material 50 include multi-component materials such as a liquid plastic of two. components "Smooth-Cast 300," and a liquid rubber compound "Clear Flex 50," both commercially available from Smooth-On, Ine. Photosensitive resins can also be used as the resinous material 50. The photosensitive resins are usually polymers that cure, or crosslink, under the influence of radiation, typically ultraviolet light (ÜV). References that contain more information about liquid photosensitive resins include Green et al., "Photocross-Linkage Resin Systems," J. Macro-Sci. Revs Macro Chem. C21 (2), 187-273 (1981-82); Bayer, "A Review of Ultraviolet Curing Technology", Tappi Paper Synthetics Conf. Proc., Sept. 25-27, 1978, pp. 167-172; and Schmidle, "Ultraviolet Curable Flexible Coatings," J. Of Coated Fabrics, 8, 10-20 (July 1978). The three above references are incorporated herein by reference. Especially preferred liquid photosensitive resins are found in the Merigraph series of resins manufactured by Hercules Incorporated, Wilmington, Del. An especially preferred resin is Merigraph EPD 1616 resin. Examples of the thermosensitive resins which may comprise the resinous material 50 of the present invention include, but are 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 flowable resinous material 50 is provided in liquid form. The present invention, however, contemplates the use of the flowable resinous material provided in solid form. In the latter case, an additional step of fluidization of the resinous material 50 is required. The flowable resinous material 50 is preferably supplied in a source 55 which offers suitable conditions (such as temperature) to maintain the resinous material 50 in been fluid. As used herein, the term "fluid" refers to a condition, condition or phase, of the resinous material 50, in which condition the resinous material 50 can flow and allow the resinous material 50 to be deposited on a surface with a three-dimensional pattern. in such a way that the resinous material 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 slightly 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 illustrated schematically in several drawings of the present application. The channel may have a closed end bottom and closed side walls and side wall outwards. The side wall into the channel may be open allowing the flowable resinous material placed there to be in freely contact and communicate with a molding member 20, in accordance with what is described below. If the resinous material comprises a thermoplastic resin, the source 55 and the molding surface 21 are preferably heated to prevent premature solidification of the liquid resinous material 50. The next stage of the process comprises the supply of a molding member 20. As shown in FIG. employed herein, the "molding member" 20 is a structure designed to receive the resinous material that can flow 50, and then transfer the resinous material 50 into the reinforcement structure in a predetermined pattern. In the preferred continuous process, the molding member 20 may comprise several different embodiments. In embodiments illustrated in Figures 1, 4-8, and 10, the molding member 20 comprises a molding roll 20a, while in a manner illustrated in Figure 12, the molding member 20 comprises a molding strip 20b. Regardless of its mode, the molding member 20 has a molding surface 21 having a three-dimensional pattern there, and structured and designed to receive the flowable resinous material 50 such that the resinous material that can flow 50 substantially adapts to the three-dimensional pattern. Preferably, the molding surface 21 comprises a preselected pattern of molding bags 22 there, as best shown in Figures 4, 7, 7B, 8 and 10. As used herein, the term "molding surface" 21 is a generic term that refers to all of the exposed surfaces of the molding member 20, including an inherent surface such as for example an external surface (the highest) of the strip 20b (figure 12), or an outer circumference 21a ( corresponding to a larger diameter) (figures 4, 8, 10) of the roller 20a, as well as internal surfaces of the bags 22 (figures 4, 7, 8, 10). The molding surface 21 is a surface on which the flowable resinous material 50 is deposited. In a preferred continuous process of the present invention, the molding member 20 is continuously moved at a transport speed thereby bringing the resinous material 50. It will be readily apparent to one skilled in the art that in the embodiments (Figures 1-8, and 10) comprising the rotating molding roll or the rotating molding rolls 20a (20a '), the transport speed comprises a surface velocity measured at one of the circumferences of the molding surface 21. In FIGS. 1 4-7, and 8, a direction of rotation of the molding roll or of the molding rolls 20a is indicated. (20a ') through an arrow "A". In the embodiment (Figure 12) comprising the molding strip 20b, the transport speed is a speed of the strip 20b measured between the support rolls 25 and 26. As used herein, the term "molding bags" 22 is refers to a pattern of depressions, or cavities, in the molding surface 21, designed to transfer the resinous material that can flow 50 from the source 55 to the reinforcing structure 40, and to deposit the resinous material that can flow 50 in the reinforcing structure 40 in a predetermined pattern. The molding bags 22 can comprise a substantially continuous pattern on the molding surface 21, as best shown in Figure 7B; in this case, the resinous material 50 is transferred to the reinforcing structure 40 in a substantially continuous pattern. 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 process of the present invention nor the performance and desired qualities the final product - the papermaking belt 90. Figures 2A and 9A show two different exemplary embodiments of the papermaking belt 90 having a substantially continuous resinous frame 50a, made by using the continuous pattern of the molding bags 22. Alternatively, the molding bags 22 may comprise a pattern of discrete depressions or cavities. In the latter case, the resinous material 50 is transferred from the molding bags 22 to the reinforcing structure 40 in a pattern comprising a plurality of discrete protuberances. An exemplary papermaking belt 90 having the resinous framework 50a comprising several discrete protrusions extending outwardly from the first side 41 of the reinforcing structure 40, is shown schematically in Figures 10, 11 and HA. A pattern (not shown) comprising a combination of substantially continuous molding bags 22 and discrete molding bags 22 is also contemplated in the present invention. The frame 50a which "presents an angle" with respect to the first surface 41 of the reinforcing structure 40 is contemplated in the present invention. As used herein, the term frame "presenting angle" refers to a frame 50a in which, if seen in section - has acute angles formed between the first surface 41 of the reinforcing structure 40 and the longitudinal axes of any discrete deflection duct - in the case of the continuous frame 50a, or discrete protuberances - in the case of the frame 50a comprising several discrete protuberances. These modalities are disclosed in co-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 Mending Of Making the Belt, "(Cellulose tissue, method and apparatus to manufacture it using papermaking belts that have an angled cross-sectional structure, and methods to manufacture the tape), and presented to Larry L. Huston on May 19, 1997, whose disclosures are incorporated herein by reference. The molding bags 22 have at least one depth designated here by the symbol "D". The depth D generally defines a thickness of the resinous material 50 deposited from the molding bags 22 in the reinforcing structure 40. As used herein, the term "depth" of the molding bag (s) 22 indicates the extension of the geometrically distinct depression (s) in the molding member 20. By way of example, Figures 10 and 10A show a fragment of the molding member 20, consisting of a molding roll 20a , which has several discrete molding bags 22. An inherent portion 21a of the molding surface 21 is the portion of the external circumference of the roller not affected by the molding bags 22, typically a portion of the roller circumference corresponding to the diameter roller greater In Figures 10 and 10A, the inherent portion 21a is a continuous portion of the outer circumference that spans the discrete molding bags 22. Figures 10 and 10A also show that each molding bag comprises two geometrically distinct depressions, a first depression 22a (relatively larger) that has the shape of a rhombus, and a second depression 22b (relatively smaller) that has the shape of a circle, as can be seen better in Figure 10A. The first depression 22a has the first depth Dl, and the second depression 22b has the second depth D2 greater than the first depth Dl, and therefore the molding bags 22 have two depths Dl and D2, as shown in Figure 10. It will be understood that the foregoing examples are for the purpose of illustrating the invention only and not limiting it. Virtually, in the present invention, an unlimited number of shapes and their permutations of the molding bags 22 having differential depths can be employed. While Figures 10 and 10A show the geometrically symmetrical molding bags 22, it is understood that geometrically asymmetric configurations (in plan view as well as in cross section) can be employed if desired (not shown). The "angled" configurations of the molding bags 22 can be used to produce the "angled" pattern of the resinous frame 50a, as explained above. In addition, there may be embodiments (not illustrated) of the molding bags 22 wherein the relationship between a specific depth D and a geometrically distinct configuration is not apparent, or even impossible to establish. The process of the present invention allows a person to profitably create almost any desired shape of resinous frame 90 by providing the molding surface 21 accordingly. The next step of the present invention comprises depositing the resinous material that can flow into the molding pockets 22 of the molding surface 21. Generally, in a preferred continuous process, this step comprises first contacting the surface of molding 21 with the flowable resinous material 50, and then removing the excess resinous material 50 from the molding surface 21 as the molding surface 21 moves. Preferably, the excess of the flowable resinous material 50 is removed at the source (channel) 55 of the resinous material 50, thereby reducing or eliminating waste from the resinous material 50. Any suitable deposition device known in the art can be employed in the apparatus 10 of the present invention to perform this step. As used herein, the term "depositing device" refers to any device capable of transferring the resinous material that can flow from a bulk amount to the molding surface 21 in required dosage. The term "deposit" refers to a transfer of the resinous material that can flow from the bulk form (provided, for example, into channel 55, described above) and the dose of resinous material that can flow into the surface. of molding 21 and / or in the molding bags 22, in such a way that the flowable resinous material 50 fills the molding bags 22 substantially uniformly. The removal of the excess resinous material 50 from the molding surface 21 can be achieved by shaking and / or scraping the excess material from the molding surface 21. The next two steps comprise the continuous transport of the reinforcing structure 40 to the transport speed in such a way that at least a portion of the reinforcing structure 40 is in a face-to-face relationship with at least a portion of the molding surface 20, and the transfer of the resinous material that can flow 50 from the molding bags 22 of the molding surface 20 on the reinforcing structure 40 in the preselected pattern. Preferably, the portion of the reinforcing structure 40 facing the molding surface 20 is in contact with the molding surface 20 for a predetermined period of time. In the embodiments in which the molding member 20 comprises the molding roller 20a, the predetermined period of time during which the molding surface is in contact with the reinforcing structure 40 is defined by the transport speed., diameter of the molding roll 20a, and a lambda wrap angle, as shown in Figures 1 and 4-6. With reference to figure 4, as used herein, the term "wrapping angle" defines an included lambda angle formed between two imaginary radii rl and r2, the radius rl is connected to the longitudinal axis (or center of rotation) F of the molding roll 20a at a point fl in which the reinforcing structure 40 first comes into contact with the molding surface 21, and the radius r2 connecting the longitudinal axis (or center of rotation) F of the molding roll 20 a at a point f2 in which the reinforcing structure 40 is in ultimate contact with the molding surface 21. A part of the circumference between the point fl and the point f2 defines a resulting contact zone K, i.e. an area of contact between the molding surface 21 and the reinforcing structure 40. In the embodiment of Figure 12, wherein the molding member 20 comprises the tape 20a, the resulting contact zone K comprises a first contact zone (circumferential) Kl and a second contact area (planar) K2 The resulting contact zone K preferably comprises a solidification segment of the process, that is to say a segment in which the resinous material 50 solidifies in such a way that it sufficiently adheres to the reinforcing structure 40 and retains its shape after disengagement. of the molding surface 21. The resinous material 50 does not have to completely solidify in the solidification segment and may retain a certain flowability after leaving the solidification segment, insofar as the resinous material 50 can sufficiently preserve its acquired shape while the resinous material 50 was associated with the molding bags 22. In accordance with the present invention, the resinous material 50 is maintained in a sufficiently fluid state prior to its deposit in the molding surface 21. Preferably, the material resinous 50 must be sufficiently fluid to uniformly fill the molding bags 22. In c In some embodiment, the solidification of the resinous material 50 can start directly after the resinous material 50 has filled the molding bags 22. In FIG. 4, an angle alpha schematically indicates a pre-solidification segment of the molding surface 21 after the depositing the resinous material 50 on the molding surface 21 and before the reinforcing structure 40 and the molding surface 21 come into contact in a face-to-face relationship (before reaching point fl). One skilled in the art will note that for a given resinous material 50, the desired level of viscosity of the resinous material 50 before reaching the point fl is defined by several factors, including the design and transport speed of the molding surface. , with respect to the geometry of the reinforcing structure 40 and the molding surface 21, the length of the resulting contact zone K, and other process conditions and parameters of the apparatus 10. Preferably, the viscosity of the resinous material 50 is greater in the segment before the solidification of the molding surface 21, which is defined through the angle alpha, especially when the resinous material 50 reaches the point fl relative to the viscosity of the resinous material in the channel 55. In accordance with The present invention contemplates a mode in which the resinous material 50 placed in the molding bags 22 solidifies in such a way that the surface of the material The sinus 50 which is in direct contact with the inner surface of the molding bags 22 solidifies first, while the rest of the resinous material 50 placed in the molding bags 22 is still in the fluid state. Then the surface of the resinous material 50, at least partially solidified, functions as a shell for the rest of the resinous material 50 which is still in the fluid state. This embodiment can be especially beneficial in the process using the reinforcing structure 40 having hollow spaces there such as for example a woven reinforcement structure 40. When the reinforcing structure 40 comes into contact with the resinous material 50, pressure can be used to press the reinforcing structure 40 and the resinous material relative to one another, thereby "pushing" the resinous material 50 through the threads of the reinforcing structure 40, said threads forming their first side 41, and at the reinforcing structure 40 without unduly distorting the shape of the resinous material 50 deposited in the reinforcing structure 40. Preferably, the time during which the molding surface 20 faces (and preferably in contact) with the structure of the reinforcement 40. reinforcement 40 should be sufficient for the resinous material 50 to be transferred from the molding bags 22 to the reinforcing structure 40. More preferably, this time must be sufficient for the resinous material 50 to, at least partially, with the reinforcing structure 40 in a pre-selected pattern (corresponding to the pattern of the molding surface 21). For the successful transfer of the resinous material 50 from the molding bags 22 to the reinforcing surface 40, various devices may be employed, alone or in combination, according to the present invention. Preferably, a surface energy of the molding bags 22 is smaller than a surface energy of the reinforcing structure 40. There are several ways to create a difference in surface energy between the molding bags and the reinforcing structure 40. A material that comprises the molding surface 21 may inherently have a relatively low surface energy. Or it can be treated to decrease its surface energy. Alternatively, or additionally, the molding surface 21 can be treated with a release agent 60 prior to the step of depositing the resinous material 50 in the molding bags 22. Examples of the release agent 60 include, without limitation: " Ease Reléase ™ "," Permarelease TM, Aqualease TM "Actilease", available in Smooth-On, Ine, Even though a source 65 of the release agent 60 is shown schematically through a channel in several drawings, it will be understood that the release agent 60 may be brushed, sprayed, or rubbed onto the molding surfaces, in these cases, the Source 65 may comprise a brush, a nozzle, or any other device known in the art. Figure 4, for example, shows the source 65 comprising a nozzle. In some applications, it may be necessary to apply two or more layers of the release agent 60 on the molding surface 21. In some embodiments in which the molding surface has microscopic pores there it may be desirable to heat the release agent 60 or / and the molding surface 21 to facilitate the penetration of the release agent 60 into the mold surface 21 thus sealing the pores before depositing the resinous material 50 on the molding surface 21. Other ways of causing the resinous material 50 to be bonded at least partially with the reinforcing structure 40 includes the application of a pressure difference to press the reinforcing structure 40 relative to the molding surface 21 in the contact zone K in order to cause a sufficient engagement between the material resinous 50 and reinforcing structure 40. Typically, even though not necessarily, resinous material 50 does not "stick" on the stoma reinforcement structure 40 but wraps around the structural elements of the reinforcing structure 40 (such as for example individual yarns in a woven reinforcement structure 40), so as to be "fixed" around them thereby enclosing at least partially some of them. The easy pressure of the penetration of the resinous material 50 fluid or partially solidified between the structural elements of the reinforcing structure 40. Figure 5, for example, shows a backing roller 30 juxtaposed with the molding roller 20a to form a throttle 23 among them. The reinforcing structure 40 moves through the throttle 23 and is preferably pressed by the backing roller 30 against the molding surface 21 of the molding roll 20a. Preferably, the backing roller 30 rotates at a surface velocity substantially equal to the transport speed of the reinforcing structure 40 in the throttle 23. This embodiment can be beneficially employed with the molding roll 20a having the molding surface 21 comprising a deformable material, and preferably of constant volume, in accordance with that described in commonly assigned US Patent No. 5,275,700 and incorporated herein by reference. The deformable molding surface 21, preferably of constant volume, provides an effective contact between the reinforcing structure 40 and the resinous material 50 since the reinforcing structure 40 can be "pressed" under pressure into the molding surface 21, facilitating thus the union of the resinous material 50 and of the reinforcing structure 40. Alternatively, a circumference of the backing roller 30 may comprise a layer (not shown) of a deformable material of constant volume. A barrier film 70 can be provided, as shown in Figure 5, to protect the surface of the backing roll 30 from contamination by resinous material 50. The barrier film 70 may also comprise a deformable material, preferably of constant volume . Alternatively, the barrier film 70 is a flexible, smooth, and planar material that easily adapts to the transport configuration formed by the backing roll 30 and the support rolls 70a and 70b around which the barrier film travels. 70 in the direction indicated by arrow "C". The barrier film is described in sufficient detail in commonly assigned U.S. Patent No. 5,275,700 and incorporated herein by reference. In figures 6 and 12, the reinforcing structure 40 is pressed against the molding surface 21 by a backing sheet 77 under tension. In the embodiment of figure 6, the backing sheet 77 is wrapped around a part of the molding roll 20a. In the embodiment of Figure 12, the backing sheet 77 is substantially planar and travels within the second contact zone K2. In both embodiments (of figures 6 and 12), the backing sheet 77 is supported by support rollers 77a, 77b, 77c, 77d and travels around said support rollers in a direction indicated by an arrow "C" . In these embodiments, one or more additional support roller (s) (not shown) can be provided between the rollers 77a and 77b for additional support of the backing sheet 77 and / or to further press the reinforcing structure 40 against the molding surface 21. Figures 7 and 8 show other exemplary embodiments comprising two (Figure 7) and three (Figure 8) back-up rolls 30. In such embodiments comprising more than a back-up roll 30, the pressure applied on the reinforcing structure 40 may vary between the backing rolls. For example, in Figure 7, a first back-up roll 30a applies a first pressure Pl in a first throttle 23a, and a second back-up roll 30b applies a second pressure P2 in a second throttle 23b on the backing structure 40. If if desired, the pressure P2 may be greater than the pressure Pl, or vice versa. Analogously, in Figure 8, the backup rollers 30a, 30b and 30c can apply a differential pressure on the reinforcing structure 40 in corresponding constrictions 23a, 23b, 23c, respectively. Figures 7-8B show two exemplary embodiments of the apparatus 10, wherein the reinforcing structure 40 is recessed in the molding surface 21. The molding surfaces 21 shown in Figures 7-8B have predetermined recess patterns 24 for receiving the reinforcing structure 40. In the embodiment of Figures 7-7B, the reinforcing structure 40 is fully inserted into the recesses 24 of the "molding 21" surface, the recesses 24 have a depth no less than the thickness h of the reinforcing structure and preferably equal to the thickness h of the reinforcing structure 40. In the embodiment of Figures 8-8B, the reinforcing structure 40 is only partially inserted into the recesses 24, the depth of the recesses 24 to receive the reinforcing structure is less than the thickness h of the reinforcing structure 40. The pattern of the molding bags 22 for receiving the flowable resinous material 50 is overlapped e to the recess pattern 24 for receiving the reinforcing structure 40. In Figures 7-8B, a portion of the molding surface 24, said portion supporting the reinforcing structure 40 is designated as 21R.; and a portion of the molding surface 21 provides support to the resinous material 50 and receives the designation 21S. Preferably, a step of adjusting the reinforcing structure 40 is performed with the recesses 24 in the modalities mainly illustrated in Figures 7-8A. The method of the process illustrated in Figures 7-7B offers a novel and effective way of constructing a paper making belt 90 having an "overload 0". As used herein, the term "overload" refers to the magnitude of the elevation of the resinous frame 50 relative to the reinforcing structure 40. More particularly, the overload may comprise a distance formed between the upper part 51 of the resinous frame 50 and the first side 41 of the reinforcing structure 40, as best illustrated in Figure 9, where the overload is designated "OB", the thickness of the reinforcing structure 40 is designated "h", and a gauge of the tape of paper making 90 is designated "H". When the resinous structure 50a extends outside the structure of 40, the tape is said to be overloaded. The term "overload 0" indicates that the side in contact with the tissue 41 of the resinous frame 50 and the first side 42 of the reinforcing structure 40 lie in the same plane. Since in the embodiment of FIGS. 7-7B the recesses 24 have the same depth as the molding bags 22, the surface portions 21S and 21R are located in a regular manner in relation to the larger external circumference 21a (or in to the longitudinal axis of rotation) of the molding roll 20. Accordingly, when the reinforcing structure 40 corresponds to the recesses 24, and when the resinous material 50 is deposited in the molding bags 22, the resinous material 50 can not extend further. beyond the surface portion 21R, and therefore can not extend beyond the first side 41 of the reinforcing structure 40 in the belt 90 being processed, as shown in Figure 7A. Figures 8-8B illustrate another advantage offered by the present invention. Since in the embodiment of Figures 8-8B the reinforcing structure 40 is partially inserted within the recesses 24, there is a distance "Z" formed between the second side 42 of the reinforcing structure 40 and the back side of the frame resinous 50 when the tape 90 is formed. In a papermaking belt with air passage drying, the distance "Z" creates a leak between the surface of the back side of the tape 92 which is in contact with the processing equipment of paper (such as a vacuum box or collection shoe) and the surface in contact with the tape of said equipment. The leak mitigates a sudden vacuum depression application on the paper web placed on the belt 90 and thereby reduces or totally eliminates what is known as pinhole formation. One skilled in the art will recognize that the term "pinhole formation" refers to the formation of a pin-sized hole, or "pinholes" in the tissue from which the water is being removed as a result of the application. sudden pressure of vacuum on the tissue and the subsequent separation of a certain amount of tissue fibers. Some of the fibers can pass completely through the papermaking belt, thus causing, in addition to the pinhole formation, the clogging of the vacuum water removal machinery with the papermaking fibers. Several US patents commonly assigned and incorporated herein by reference disclose various ways of mitigating or eliminating pin hole formation: US Patent No. 5,776,311 issued July 7, 1998 in the name of Trokhan et al., US Patent No. ,744,007 issued April 28, 1998 in the name of Trokhan et al., US Patent No. 5,741,402 issued April 21, 1998 in the name of Trokhan et al., US Patent No. 5,718,806 issued February 17, 1998 to from Trokhan et al. , and U.S. Patent No. 5,679,222 issued October 21, 1997 in the name of Rasch., are examples of this patent. The present invention offers another effective device for mitigating the undesired formation of pinholes. One skilled in the art will note that the pattern of the resinous material 50 transferred from the molding surface 21 to the reinforcing structure 40 reflects the pattern of the molding surface 21. thus, if the molding surface 21 comprises a substantially continuous pattern of the molding bags 22, as shown in Figures 7B and 8B. The resinous material 50 is transferred into the reinforcing structure 40 in a substantially continuous pattern. On the other hand, if the molding surface 21 comprises a plurality of discrete molding pouches 22, as best shown in Figure 10a, the resinous material 50 is transferred to the reinforcing structure 40 in a pattern comprising several resinous protuberances, figure HA. The next step of the process of the present invention comprises the solidification of the resinous material 50 bound on the reinforcing structure 40. As used herein, the term "solidification" and derivations thereof refers to a process for altering a fluid to a state solid or partially solid. Typically, the solidification includes a phase change from a liquid phase to a solid phase. The term "curing" refers to a solidification in which cross-linking occurs. For example, photosensitive resins can be cured by UV radiation in accordance with that described in 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. The thermoplastic and thermo-hardening resins require a certain temperature for solidification. Preferably, the solidification step comprises curing the resinous material 50. In some embodiments, the solidification process of the resinous material 50 may begin as soon as immediately after the resinous resinous material 50 has been deposited on the molding surface. 21. Preferably, the solidification proceeds while the reinforcing structure 40 and the molding surfaces 21 are in a face-to-face relationship (schematically shown as the resulting contact area K in the exemplary embodiment of Figure 4, and as the contact areas Kl and K2 in the exemplary embodiment of figure 12). A method for solidifying the resinous material 50 depends on its nature. If a thermoplastic or thermo-hardening resin is used, the solidification embraces the cooling of the resinous material 50 transferred onto the reinforcing structure 40. Photopolymer resins can be cured through a curing process described in commonly assigned US Pat. assigned 4,514,345; and 5,275,700, which are incorporated herein by reference and referred to above. The resinous material 50 comprising the resins of multiple components or plastics can naturally solidify, for a certain predetermined period of time, by virtue of their mixing. As an example, figures 6 and 12 schematically show a curing device 79 juxtaposed with the second side 42 of the reinforcing structure 40. It will be understood by a person skilled in the art that, according to the nature of the resinous material 50 and the solidification method, the curing device can be placed in other locations, for example, it can be juxtaposed to the resinous frame 50a, as shown schematically in Figure 4. Examples of the curing device 79 include, but are not limited to: a heater for increasing the rates of curing. cross-linking reaction or condensation rates in the case of polymer condensation; a cooler to solidify thermoplastics; several apparatuses that provide an infrared light curing radiation, a microwave curing radiation; or a ratio of ultraviolet light curing; and similar. The commonly assigned patent application, no. of series 08 / 799,852, entitled "Apparatus for Generating Parallel Radiation for Curing Photosensitive Resin" (Apparatus for Generating Parallel Radiation for Photosensitive Resin Curing), filed in the name of Trokhan on February 13, 1997; and the commonly assigned patent application, no. of series 08 / 858,334 entitled "Apparatus for Generating Controlled Radiation for Curing Photosensitive Resin" (Apparatus for Generating Controlled Radiation for Photosensitive Resin Curing), presented in the name of Trokhan et al, on February 13, 1997 and its continuation 08 / 958,540 filed October 24, 1997 are hereby incorporated by reference for the purpose of showing various embodiments of the curing device 79 which may be employed to solidify the resinous material 50 comprising a photosensitive resin. Optionally, a step may be provided to control the H gauge (FIG. 9) of the tape 90 in the process of the present invention. The caliber H can be controlled to a preselected value by controlling the OB overload, as explained above. Likewise, the caliber H can be controlled by controlling the depth of the recesses 24 for the reinforcing structure 40 (FIG. 8a). Another way to control gauge H involves changing the thickness of the resinous material 50 after the resinous material 50 has been transferred from the molding surface 21 to the reinforcing structure 40, and after the resinous frame has been at least partially formed. For example, the thickness of the resinous material 50 can be adjusted by mechanical devices known in the art. Figures 1 and 5 schematically show an 80 gauge control device comprising two mutually juxtaposed rollers forming a clearance 88 therebetween. By adjusting the clearance 88 between the rollers of the device 80, the gauge of the tape in construction can be controlled. In embodiments in which the resinous framework 50a is only partially solidified after having been formed between the molding surface 21 and the reinforcing structure, the gauge of the partially formed tape can be slightly adjusted causing the partially formed tape to move Alternatively, or additionally, the gauge control device may comprise a rotating sanding roller, a smoothing blade, a laser, or any other device known in the art and suitable for purpose of controlling the gauge of the belt 90. The process and apparatus of the present invention significantly reduce the amount of flowable resin required in the construction of the belt 90 and therefore offer an economic benefit. The methods of the prior art for manufacturing the tape, which employ a photosensitive resin and curing radiation, require the application of a coating of the photosensitive resin on the reinforcing structure, the curing of the selected portions of the resinous coating, and then the removal (typically, washing) of the uncured portions of the resinous coating. The amount of the washed resin is about 25% to 75% relative to the amount of the whole resinous coating. In the present invention, the exact amount of the resinous material 50, which is required for the resinous framework 50a is formed in a predetermined pattern of the molding pouches 22 of the molding member 20. The excess resinous material 50 deposited on the outer surface (inherent) 21a of the molding member 20 can be easily recycled (and preferably is recycled), by any means known in the art, to the source 55 of the resinous material 50, thereby completely eliminating the waste of resinous material 50. In addition, the process and apparatus of the present invention allow the creation of a virtually unlimited number of three-dimensional patterns of the resinous frame 50a. The process of the present invention may have two or more steps. Figure 1 shows schematically a two-step process. In a first step, a resinous material 50 is deposited on a first molding surface 21 of a first molding member 20a, and then transferred to the reinforcing structure 40 to form a first resinous frame 50a (best shown in Figures 2) and 2a). Optionally, the gauge of the belt in manufacturing process can be adjusted through the gauge control device 80. In the second step, a resinous material 50 'is deposited on a second molding surface 21' of a second molding member 20a ', and then transferred to the surface in contact with tissue 51 of the resinous frame 50a in order to form a second resinous frame 50a '(best shown in Figures 3 and 3A). These steps can be repeated as desired.

Claims (13)

1. CLAIMS A process for manufacturing a papermaking belt comprising a reinforcing structure and a resinous bonded frame, the process comprising the steps of: (a) providing a reinforcement structure having a first side, a second side opposite the first side, and a thickness between them; (b) provide a resinous material that can flow; (c) providing at least one molding member having a molding surface comprising a preselected pattern of molding bags to carry the resinous material that can flow there; (d) constantly moving the molding surface at a transport speed; (e) depositing the resinous material that can flow in the molding pouches of the molding surface, step (e) preferably comprises: contacting the molding surface with the resinous material that can flow, and removing the excess from the molding surface. resinous material which can flow from the molding surface as the molding surface is displaced; (f) continuously transporting the reinforcing structure to the transport speed in such a way that at least a part of the reinforcing structure is in a face-to-face relationship with at least a part of the molding surface, preferably the . { The reinforcing structure is in contact with the resinous material that can flow placed in the molding bags for a predetermined period of time sufficient to cause the resinous material that can flow and the reinforcing surface to at least partially join together; (g) transferring resinous material that can flow from the molding pouches of the molding surface to the reinforcing structure, preferably in the preselected pattern; (h) causing the resinous material that can flow and the reinforcing structure to join together; and (i) solidifying the resinous material thereby forming the resinous framework attached to the reinforcing structure, whereby the papermaking belt is formed.
2. The process according to claim 1, further comprising the step of: providing at least one backing roll juxtaposed with the molding surface to form a constriction therebetween to receive the reinforcing structure therein; and rotating the backing roller at a surface velocity substantially equal to the transport surface velocity of the reinforcement structure in the constriction.
3. The process according to claims 1 and 2, further comprising a step of controlling the thickness of the resinous material bonded onto the reinforcing structure in at least one preselected value.
4. The process according to claims 1, 2, and 3, wherein, in step (g) the resinous material is transferred to the reinforcing structure in a substantially continuous pattern, in a pattern comprising several discrete protuberances, or in a pattern comprising any combination thereof .
5. The process according to claims 1, 2, 3, and 4, wherein in step (a) the reinforcing structure comprises a fluid-permeable element, and preferably, a woven fabric or a screen having several open areas.
6. The process according to claims 1, 2, 3, 4, and 5, wherein in step (a) the reinforcing structure comprises a felt.
7. The process according to claims 1, 2, 3, 4, 5 and 6, wherein in step (b) the resinous material that can flow comprises a material selected from the group consisting of epoxies, silicones, urethanes, polystyrenes, polyolefins, polysulfides, nylons, butadienes, photopolymers, and any combination thereof.
8. An apparatus for manufacturing a papermaking belt comprising a reinforcing structure and a resinous frame joined therebetween, the apparatus having a machine direction and comprising: a molding member having a patterned molding surface comprising a plurality of molding bags designed to carry a resinous material that can flow there; a device for depositing the resinous material that can flow in the molding pockets of the molding surface; a device for displacing the reinforcing structure in the machine direction such that at least a part of the reinforcing structure is in a face-to-face relationship with at least a part of the molding surface; a device for moving the molding member in the machine direction such that the resinous material that can flow is transferred from the molding bags to the reinforcing structure. .
9. The apparatus according to claim 8, further comprising a device for solidifying the resinous material that can flow in order to form the resinous framework attached on the reinforcing structure.
10. The apparatus according to claims 8 and 9, wherein the molding pouches of the molding surface form a substantially continuous pattern, a pattern of discrete molding pouches, or any combination thereof.
11. The apparatus according to claims 8, 9, and 10, wherein at least some of the molding bags have different depths.
12. The apparatus according to claims 8, 9, 10, and 11, further comprising a device for pressing the reinforcing structure and the molding surface therebetween for a predetermined period of time, and further comprising preferably at least one backup roller juxtaposed with the molding surface to form a constriction therebetween.
13. 13. The apparatus according to claim 8, 9, 10, 11, and 12, further comprising a backing sheet juxtaposed to the molding surface, the backing sheet is structured and designed to move in a face-to-face contact relationship with at least a portion of the backing. reinforcement structure. The apparatus according to claims 8, 9, 10, 11, 12 and 13, further comprising a gauge control device designed to control the gauge of the belt under construction. The apparatus according to claims 8, 9, 10, 11, 12, 13, and 14, wherein the molding surface further comprises a predetermined pattern of recesses for receiving the reinforcing structure. SUMMARY OF THE INVENTION A process and apparatus for manufacturing a papermaking belt is provided, the belt comprising a reinforcing structure (40) and a resinous frame (50A) joined together. The preferred continuous process comprises the steps of depositing a resinous material that can flow (50) onto a patterned molding surface (21); the continuous movement of the molding surfaces and the reinforcing structure at a transport speed such that at least a part of the reinforcing structure is in a face-to-face relationship with a part of the molding surface; the transfer of the resinous material that can flow from the molding surface to the reinforcing structure; cause the resinous material that can flow and the reinforcement structure to join; and solidifying the resinous material thereby forming the resinous framework attached to the reinforcing structure. The apparatus comprises a molding member having a patterned molding surface comprising a plurality of molding bags for carrying a resinous material that can flow there; a device for depositing the resinous material that can flow in the molding pockets of the molding surface; a device for moving the reinforcing structure in a predetermined direction; a device for moving the molding member in a predetermined direction such that the resinous material that can flow is transferred from the molding bags to the reinforcing structure.