MXPA01002522A - Process and apparatus for making papermaking belt using fluid pressure differential - Google Patents

Abstract

A process and an apparatus for making a papermaking belt (90) are provided, the belt comprising a reinforcing structure (40) and a resinous framework (50) joined together. The preferred continuous process comprises the steps of depositing a flowable resinous material onto a patterned molding surface (20);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;applying a fluid pressure differential to transfer the flowable resinous material from the molding surface onto the reinforcing structure and 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 preferably 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 and the molding member in a predetermined direction;and a means for creating a fluid pressure differential sufficient to transfer the flowable resinous material from the molding member to the reinforcing structure.

Description

jfjtí PROCESS AND APPARATUS TO MANUFACTURE A BAND FOR PAPER MANUFACTURING, USING A FLUID PRESSURE DIFFERENTIAL FIELD OF THE INVENTION The present invention relates in general to bands for the manufacture of paper useful in paper machines for manufacturing absorbent paper products, soft and resistant. More particularly, the invention relates to bands for the manufacture of paper, hereinafter, paper strips, comprising a resinous framework and a reinforcement structure attached thereto.

BACKGROUND OF THE INVENTION In general, a process for papermaking includes several steps. Normally, an aqueous pulp of paper fibers becomes an embryonic web on a foraminous member, such as, for example, a Fourdrinier mesh. After the initial formation of the paper web in the Fourdrinier Mesh, or in forming meshes, the paper web is conducted through a drying process or processes in another piece of the paper cloth, in the form of an endless band, which is often different from the Fourdrinier mesh or the forming meshes. This other cloth is commonly referred to as __i_¿_7? ___._ l ^^ a tej band or fabric drying. While the web is on the drying web, the dewatering or drying process may involve vacuum dewatering, blow-drying with hot air through the web, mechanical processing or a combination thereof. In air drying processes, developed and marketed by the present assignee, the drying fabric may comprise a so-called diversion member having a network surface. macroscopically monoplane, continuous and, preferably with pattern and non-random, defining a multitude of discrete and discretely isolated deviation conduits. Alternatively, the deflection member may comprise a multitude of discrete protuberances isolated from each other by means of a virtually continuous or semi-continuous deflection conduit. The embryonic plot is associated with the deviation member. During the paper manufacturing process, the paper fibers in the weft are diverted to the diversion conduits and the water is removed from the weft. through the diversion conduits. The web is then dried and can be shortened, for example, by creping. The deviation of the fibers towards the diversion channels of the paper web can be induced by, for example, the application of differential fluid pressure. in the embryonic paper web. A preferred method for f * í. f _____ da = __fr'-s__k. .... i? t á ^^ k ^^! í! "¡£ ¡^ jteS ^ -í ^ * _te = _». applying differential pressure is exposing the web to a fluid pressure differential through the drying fabric comprising the biasing member. Interleaved dried paper webs may be prepared in accordance with any of the patents of the United States assigned in a joint manner and incorporated herein by reference: No. 4,529,480 issued to Trokhan on July 16, 1985; No. 4,637,859 issued to Trokhan on January 20, 1987; No. 5,364,504, issued to Smurkoski et al. on 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. granted on October 21, 1997. In general, a method for manufacturing the diverting member comprises applying a coating of photosensitive liquid resin to a surface of a foraminate element, controlling the thickness of the coating at a preselected value, exposing the coating of the liquid resin photosensitive to light at an activating wavelength through a mask, thus avoiding or reducing the curing of selected portions of the photosensitive resin. Then, uncured portions of the photosensitive resin are usually washed by stripping with showers. Several United States Patent, assigned in a joint manner, which is _ ^ * ».__ &. h ^ .L ^ ag. incorporated herein by reference, reveal paper webs and methods for making the bands: 4,514,345, issued April 30, 1985 to Johnson et al .; 4,528,239, granted on July 9, 1985 to Trokhan; 5,098,522, granted on March 24, 1992; 5,260,171, issued on November 9, 1993 to Smurkoski et al; 5,275,700, granted on January 4, 1994 to Trokhan; 5,328,565, issued on July 12, 1994 to Rasch et al .; 5,334,289, granted on August 2, 1994 to Trokhan et al .; 5,431,786, issued July 11, 1995 to Rasch et al .; 5,496,624, granted on March 5, 1996 to Stelljes, Jr. and collaborators; 5,500,277, granted on March 19, 1996 to Trokhan et al .; 5,514,523, granted on May 7, 1996 to Trokhan et al .; 5,554,467, issued September 10, 1996, to Trokhan et al .; 5,566,724, issued October 25, 1996 to Trokhan et al .; 5,624,790, granted on April 29, 1997 to Trokhan et al .; 5,628,876 granted on May 13, 1997 to Ayers et al; 5,679,222 issued October 21, 1997 to Rasch et al .; and 5,714,041 granted on February 3, 1998 to Ayers et al., whose disclosures are incorporated herein by reference. While curing photosensitive resin has proven to be an effective way to manufacture the paper web, the search for improved methods and products has continued. Currently, it is believed that the bypass member can be manufactured by at least several other methods that do not necessarily require the use of curing radiation. In accordance with the foregoing, the present invention provides a novel process for manufacturing a paper web by first forming a desired pattern of a resinous fluid material in a molding member, and then by transferring the resinous material of the molding member to the reinforcing structure and by solidifying the patterned resinous material. The present invention also provides a process wherein the transfer of the The resinous material of the molding member to the reinforcing structure is aided by the application of a fluid pressure differential. The present invention also provides a process that reduces the amount of resinous material required to build the paper web, which comprises a reinforcing structure and a patterned resinous frame. The present invention also provides an apparatus comprising a molding member to form a desirable pattern of the resinous material and subsequently transferring the patterned resinous material to the reinforcing structure of the band being manufactured. , _- & _._. These and other objects of the present invention will be more readily apparent when considered with reference to the following description, together with the accompanying drawings.

SUMMARY OF THE INVENTION A paper web that can be manufactured by a process and apparatus of the present invention comprises a reinforcing structure and a resinous frame with pattern attached thereto. The reinforcing structure has a first side and a second opposite side. Preferably, although not necessarily, the reinforcing structure comprises a fluid-permeable element, such as, for example, a woven fabric or a mesh having a multitude of 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 and second sides of the reinforcing structure, respectively. The resinous framework can have an almost continuous pattern, a discrete pattern, or a semi-continuous pattern. A process for manufacturing a paper web comprising a reinforcing structure and a resinous framework attached thereto, includes the following steps: providing a reinforcement structure having a first go* . . , * __? ___ a _____ É_ side, a second side opposite the first side and a thickness between them; provide a flowable resinous material; providing a molding member at least partially fluid permeable; depositing the fluid resinous material 5 on or within the molding member, preferably in a preselected pattern; juxtaposing the reinforcing structure to the molding member; applying a fluid pressure differential to the fluid resinous material associated with the molding member, thereby transferring the material resinous fluid of the molding member to the reinforcing structure, preferably practically in the preselected pattern and, causing the fluid resinous material and the reinforcing structure to join; and solidify the resinous material forming the frame in this way resinous attached to the reinforcement structure. Preferably, the process further comprises a step to pre-solidify the fluid resinous material before the step of applying a fluid pressure differential, so that the resinous material reaches a condition in the which can sufficiently retain the desired shape during the passage of the application of the fluid pressure differential. The fluid resinous material preferably penetrates within the thickness of the reinforcing structure. Preferably, this penetration occurs during the step of applying the pressure differential of fluid and is sufficient for the resinous material to effectively join the reinforcing structure, ensuring the individual elements thereof. The apparatus of the present invention preferably comprises a means for pre-solidifying and / or solidifying the flowable resinous material, which means that it depends on the nature of the resinous material. The step of depositing the fluid resinous material on or within the molding member preferably comprises contacting the molding member with the fluid resinous material and then removing the excess of the fluid resinous material from the molding member. Any means known in the art can be used to deposit the fluid resinous material on or within the molding member. Examples include: a tundish, a spray, an extruder. Preferably, the fluid resinous material is deposited on or within the molding member in a preselected pattern. The molding member has a molding surface preferably comprising a plurality of fluid-permeable molding cavities, structured to receive the fluid resinous material therein. The molding cavities can form a substantially continuous pattern, a pattern of discrete molding cavities or a semi-continuous pattern. In some - »a * toM_» ».., _ ^» «^ 4_i_ < < ^ a__ ".. .. ^ .. ^". "___ ,.". «_ • .. mmí i &? á iá *! és &. ,? ^^? Í2 ^^ & ^^^ S ^ i ^^ Xá ^ & embodiments, at least some of the molding cavities may have differential depths. The molding member may further comprise a pattern of recesses or recesses for receiving therein the reinforcing structure. In another embodiment, the molding member comprises a molding roll having a circumference and a longitudinal axis perpendicular to the machine direction, the molding roll can be rotated about its longitudinal axis. In another embodiment, the molding member comprises at least one endless band structured and designed to travel continuously in a predetermined direction. A method is contemplated in which the molding cavities are formed by holes, through at least a portion of the molding member. In another embodiment, the molding member comprises a first band having holes therethrough, and a second band, wherein a portion of the first band is in a face-to-face contact relationship with a portion of the second band. . When the fluid resinous material is deposited on or within the molding member, the fluid resinous material is located within the holes of the first band and may be supported by the second band. Then, at a certain point in the process, the bands and first and second separate, so that, i.jfi * á!, *. < KL • < _ ^ - a ^ j ^ afe, _ .. preference, only the first band is juxtaposed to the reinforcement structure. The preferred fluid resinous material comprises a material selected from the group consisting of 5 epoxides, silicones, urethanes, polystyrenes, polyolefins, polysulfides, nylons, butadienes, photopolymers and any combination thereof. The fluid resinous material is preferably supplied and deposited on the molding member or therein in liquid form. Energy The surface area of the molding surface in contact with the resinous material is preferably less than the surface energy of the reinforcing structure. Before depositing the resinous material on or within the molding member, the molding surface of the limb member The molding can be treated with a releasing agent or release agent, to reduce the surface energy of the molding surface. In the preferred continuous process, the additional step of continuously moving the molding member is required and to the reinforcing structure at a transport speed, such that at least a portion of the reinforcing structure is in a face-to-face relationship with at least a portion of the molding member. Preferably, the reinforcement structure contacts the molding member. The reinforcement structure and / or the J__¡¿B ».ifesg - s. If the molding surface can be supported by a support roller or by an endless support band, the support roller is preferably juxtaposed to the molding member to form a line between them. contact point The support band is preferably juxtaposed to the molding member and is structured to move in a face-to-face contact relationship with at least a portion of the reinforcing structure and / or the molding member. preferred apparatus of the present The invention has a machine direction and comprises a means for moving the reinforcing structure and the molding member and, preferably, a means for moving the support roller or band in the machine direction such that a portion of the reinforcement structure is in a face-to-face and, preferably, contact relationship, with a portion of the molding member. The apparatus may have optional means for pressing the reinforcing structure and the molding surface together for a predetermined period of time. The means for creating a fluid pressure differential can include any means known in the art, for example a vacuum apparatus. The fluid pressure differential must be sufficient to transfer the fluid resinous material from the molding member to the reinforcement structure. í7 12 Preferably, the process includes the step of controlling the gauge of the band being manufactured and, more specifically, the thickness of the resinous material bonded to the reinforcing structure, at least at a preselected value. The thickness of the resinous material can be controlled by a gauge controlling device that includes, enunciatively, a pair of juxtaposed rolls forming between them a gap or any other means known in the art, such as by example, a laser beam, a blade, etc. Preferably, the fluid resinous material is transferred from the molding member to the reinforcing structure, practically in a preselected pattern. Depending on the desired pattern of the resinous framework of the As the band being manufactured, the resinous material can be transferred to the reinforcing structure in a substantially continuous pattern, in a pattern comprising a multitude of discrete protuberances or in a semi-continuous pattern. Preferably, the resinous material extends out from the first side of the reinforcing structure, after the resinous material has been bonded to the reinforcing structure. The reinforcing structure can comprise a variety of shapes. A preferred reinforcement structure comprises a woven fabric or a mesh having a * «Multitude of open areas & through it. Another preferred reinforcement structure comprises a felt. A reinforcement structure comprising a combination of woven fabric and felt is also contemplated. 5 BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a schematic side elevational view of a continuous process mode and apparatus of the present invention. Figure IA is a schematic cross-sectional side view of a fragment IA of Figure 1, and showing one embodiment of a molding member. Figure 2 is a schematic side elevational view of another embodiment of a continuous process and an apparatus of the present invention, comprising a support band. Figure 2A is a schematic cross sectional side view of a fragment 2A of Figure 2. Figure 2B is a side view in schematic cross section 20, similar to that of Figure 2A, and showing another embodiment of the molding member . Figure 2C is a schematic cross-sectional side view of another embodiment of the molding member. 25 Figure 3 is a side elevational view '"*" - • * »• ^^ A ^ A ,,,,». . ..._, ... 7. . Schematic diagram of another embodiment of a continuous process and of an apparatus of the present invention, comprising a composite molding member, formed by two endless bands. Figure 3A is a schematic cross-sectional side view of the fragments 3A of Figure 3, showing the composite molding member formed by the two endless bands. Figure 4 is a schematic side elevation view of another embodiment of the process and apparatus of the present invention, showing a molding member supported by a roller. Figure 5 is a schematic side elevational view of another embodiment of the process and apparatus of the present invention, showing a molding member comprising a roll. Figure 6 is a fragmentary and schematic planar representation of an exemplary embodiment of the molding member, comprising a pattern of molding cavities for receiving the fluid resin and a pattern of recesses or recesses for receiving the structure of reinforcement, the two patterns are mutually interposed and have differential depths. Figure 6A is a side view in partial cross section of the paper web that can manufactured using the process and apparatus of the present invention, the band has a distance formed between a second side of the reinforcing structure and a lower side of the resinous frame. Figure 7 is a schematic partial cross-sectional view (taken along lines 7-7 of Figure 7A) of an exemplary embodiment of the paper web that can be manufactured using the process and apparatus of the present invention, The band comprises a substantially continuous frame attached to the reinforcing structure and a plurality of discrete deflection conduits. Figure 7A is a schematic top plan view taken along lines 7A-7A of Figure 7. Figure 8 is a schematic partial cross-sectional view of an exemplary embodiment of the molding member of the present invention, which it comprises a multitude of molding cavities having differential depths. Figure 8A is a schematic plan view of a plan view taken along lines 8A-8A of Figure 8. Figure 9 is a schematic partial cross-sectional view (taken along lines 9-9 from i - and .- * ... - .fifeiife * «&" _ * _. «_. i _.-_, _ > - i. and ^ s_s_ __; fgtea '~ 3 ^ _ Figure 9A) of another exemplary embodiment of the paper web that can be manufactured using the process and apparatus of the present invention, the web comprises a multitude of discrete protrusions having differential overloads. . Figure 9A is a schematic top plan view, taken along lines 9A-9A of Figure 9.

DETAILED DESCRIPTION OF THE PREFERRED MODALITIES Paper web A representative paper web 90 that can be manufactured in accordance with the present invention is shows schematically in Figures 7, 7A, 9, and 9A. As used herein, the term "paper web" or simply "web" refers to a virtually monoplane structure at the microscopic level, designed to support and, preferably, transport over it a plot during at least one stage of the papermaking process. Normally, modern industrial processes use endless paper webs, although it will be understood that the present invention can be used to make discrete portions of web 90. or stationary, as well as rotating, plates that can The * a ^ ¿R. £ Maar -.- g_ used to make handmade frames, rotating drums, etc. As shown in Figures 7 and 9, the band 90 has a side 91 of contact with the weft and a reverse or back side 92 opposite the side 91 of contact with the weft. The paper web 90 is said to be macroscopically monoplane, because when a portion of the web 90 is put into a flat configuration, the side of the web 91, observed as a whole, is essentially in a plane. It is said to be "essentially" monoplane, to recognize the fact that deviations from complete planarity are tolerated, although it is not preferred, and as long as these deviations are not enough and important enough to affect adversely affects the performance of band 90 for the purposes of a particular papermaking process. The paper web 90 that can be manufactured in accordance with the present invention, generally comprises mainly two elements: a frame 50a (from Preferably, a hardened polymer resinous frame made of a fluid polymeric resinous material 50) and a reinforcing structure 40. The reinforcing structure 50a and the resinous frame 40 are joined. The reinforcing structure 40 has a first side 41 and a second side 42 opposite the first side 41. The first side 41 can do contact with the paper fibers during the papermaking process, while the second side 42 normally contacts the papermaking equipment, such as, for example, a vacuum capture shoe and a multi-slot vacuum box (not none is shown). The reinforcing structure 40 can take any of several different forms. It may comprise a woven element, a non-woven element, a mesh, a net, a band, a plate, etc. In a preferred embodiment, the reinforcing structure 40 comprises a woven element formed by a multitude of interwoven yarns as shown in Figures 7 and 7A. More particularly, the woven reinforcement structure 40 may comprise a foraminate woven element, such as disclosed in the United States Patent assigned jointly with No. 5,334,289, issued in the name of Trokhan et al. August 1994 and incorporated herein by reference. The reinforcement structure 40 comprising a woven element, can be formed by one or several layers of interwoven yarns, the layers are practically parallel to each other and are interconnected in a face-to-face contact relationship. The United States Patent assigned jointly, No. 5,679,222, granted to Rasch et al. On October 21, 1997; The Patent of the ^^^? n ^ ¡fej jaü ^ JJtaa ^? iíí »t ^, S-_ai_¡ ^ < Jump up ^ "United States Assigned in Joint Manner No. 5,496,624, granted on March 5, 1996 in the name of Stelljes, Jr. and collaborators; and the patent application, assigned jointly, with serial No. 08 / 696,712 filed in the name of Boutilier on August 14, 1996 and entitled "Papermaking Belt Having Bilaterally and Alternating Tie Yarns", are incorporated herein by reference. The paper web 90 can also be manufactured using the reinforcing structure 40 comprising a felt, as set forth in the Patent Application, assigned in a joint manner, with Serial No. 08 / 391,372, filed on February 15, 1995, in the name of Trokhan et al. entitled "Method of Applying to Curable Resin to Substrate for Use in Papermaking ", such request is incorporated herein by reference. The reinforcing structure 40 of the web 90 reinforces the resinous framework 50a and, preferably, has a suitable projected area in which the papermaking fibers can deviate under pressure during the papermaking process. In accordance with the present invention, the reinforcing structure 40 is preferably fluid permeable. As used herein, the term "fluid permeable" refers, in the context of the reinforcing structure 40, to a condition of the reinforcing structure 40, this condition allows it through the structure of Fluids such as water and air pass in at least one direction. As will be readily recognized by those skilled in the art, webs comprising fluid-permeable reinforcement structures are normally used in the manufacturing processes of a through-air drying paper web. As shown in Figures 7, 7a, 9, 9a, the reinforcing structure 40 is attached to the resinous frame 50a. The resinous framework 50a comprises a solidified resinous material 50, that is to say, the resinous framework 50a is a solid phase of the fluid resinous material 50. In this sense, the terms "resinous material 50" and "resinous framework 50a" can be used interchangeably when is appropriate in the context of the present description. The resinous frame 50a has an upper side 51 and a lower side 52 opposite the upper side 51. During the papermaking process, the upper side 51 of the frame 50a is in contact with the papermaking fibers and thus defines the pattern of the paper web that will be 0 produced The lower side 52 of the frame 50a can, at least in some embodiments (Figures 7 and 7A), be in contact with the papermaking equipment, in these embodiments, the lower side 52 of the frame 50a and the second side 42 5 of the reinforcing structure 40 can be located in the same macro-plane. Alternatively, between the lower side 52 of the frame 50a and the second side 42 of the reinforcing structure can be formed a distance Z, as shown in Figure 6A. Another embodiment (not shown) of the frame 50a may comprise the lower side 52 having a network of passages that provide textural irregularities in the backside or reverse surface, as described in the United States Patent, assigned in a joint manner, 5,275,700, granted on January 4, 1994 to Trokhan, is patent is incorporated herein by reference. The last two embodiments of the frame 50a, which has the distance between the lower side 52 of the frame 50a and the second side 42 of the reinforcing structure 40 (Figure 6A), and the other having textural irregularities on the reverse, provide in Beneficial way outlets or leaks between the underside 52 of the frame 50 and a surface of the paper equipment. The leaks reduce, or even eliminate, along with the sudden application of vacuum pressure to the paper web during the papermaking process, thus mitigating the phenomenon known as pitting. The frame 50a that is "angled" with respect to the first surface 41 of the reinforcing structure 40 is contemplated in the present invention. As used herein, the term frame 50a "angled" . &Sfc, ~ - - _fr, refers to the frame 50a, wherein, if observed in cross section, sharp angles are formed between the first surface 41 of the reinforcing structure 40 and the longitudinal axes of either the conduits of discrete deviation 5 (in the case of the continuous frame 50 a), or of the discrete protuberances (in the case of the frame 50 a comprising a multitude of discrete protuberances). These modalities are revealed in patent applications, assigned jointly, with Serial No. 08 / 858,661, and Serial No. 08 / 858,662, both applications entitled "Cellulosic Web, Method and Apparatus for Making the Same Using Papermaking Belt Having Angled Cross-sectional Structure, and Method of Making the Belt" and submitted on behalf of Larry L. Huston on May 19, 1997, the disclosures of these applications are incorporated herein by reference.

Process and. Apparatus The first step of the process according to the present invention comprises providing a reinforcing structure 40. As explained above, the reinforcing structure 40 is a substrate that can comprise a variety of different shapes, such as, for example, a woven fabric, felt, mesh, band 25, etc. In the United States Patent, assigned in No. 5,275,700, incorporated herein by reference, is a more detailed description of the reinforcing structure 40, particularly one comprising a woven element. Regardless of its specific embodiment, the reinforcing structure 40 has a first side 41 and a second side 42, as best seen in Figures 6A, 7, and 9. In the formed paper web 90, the first side 41 it is oriented towards the paper fibers (and in some embodiments may be in contact with them) during the papermaking process, while the second side 42, opposite the first side 41, is oriented towards the papermaking equipment (and usually contacts the papermaking equipment). East) . As used herein, reference will be made consistently to the first side 41 and the second side 42 of the reinforcing structure 40 by these respective names, without regard to incorporation (i.e., before, during and after incorporation). ) of the reinforcement structure 40 in the paper web 90. The distance between the first side 41 and the second side 42 of the reinforcing structure forms the thickness of the reinforcement structure, designated herein as "h" (FIGS. 7 and 9). In the preferred continuous process of the present invention, the reinforcing structure 40 moves continuously in the machine direction, indicated in several figures as "MD". Use in £ Syífe gffr * tí? Ifc- »- ** • v * j« F *. ** «* Í» J; ¿^ > , * ^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^ The term "machine direction" is consistent with the traditional use of the term in papermaking, where this term refers to an address that is parallel to the flow of the paper web through papermaking equipment. 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. It should be understood that the machine direction is a relative term defined with respect to the movement of the reinforcing structure 40 at a particular point in the process. Therefore, the machine address may change several times (and indeed it does) during a particular process of the present invention. In various embodiments of the preferred continuous process, shown schematically in Figures 1, 2, 3, and 3A, the reinforcing structure 40 moves in the machine direction around a roller 71 and through a line or point of contact formed between the roller 71 and roller 70b. In the embodiments of Figures 2 and 3, the reinforcing structure 40 further travels through a line or point of contact between the roller 70b and the roller 72b and additionally through a contact point between the roller 70a and the roller 72a. In the modalities of Figures 2 and 3, the reinforcement structure 40 is also supported by an endless support band 80, between the point of contact between the rollers 70b and 72b and the contact point formed between the rollers 70a and 72a. The support band 80 travels continuously around the support rollers 72a and 72b. In Figures 1, 2, and 3, the rollers 71, 72a, and 72b rotate counterclockwise, in the direction indicated by the arrow "B" and the rollers 70a and 70b rotate in the direction of clockwise, in the direction indicated by the arrow "A". In one embodiment of Figure 4, the reinforcing structure 40 is supported, between the rollers 70a and 70b, by a roller 15 that rotates counterclockwise in the direction of the direction arrow "B". In a embodiment shown in Figure 5, the reinforcing structure 40 is supported by a molding member 20 comprising a molding roll that rotates clockwise (in the direction indicated by arrow "A") and it passes through a first contact point formed between the molding roller and the roller 70e and a second contact point formed between the molding roller and the roller 70f. The rollers 70e and 70f rotate counterclockwise in the "B" direction. The next step of the process of this ^^^^ ___ a? «A _____ t * _... fc. ^ .__ t_ ^ -. ^^^ ^. ^ .. ¿^ ^ X ^. ^ SSS ^ S ^^ 7 ^ '^ & ^; A ^^. ^. invention comprises providing a fluid resinous material 50. As used herein, the term "fluid resinous material" refers to a wide variety of polymeric resins and plastics which under certain conditions and / or over a period of time, may reaching and retaining a fluid or liquid state, such that the resinous material 50 can be molded sufficiently, becoming a structure having a desired configuration and then solidifying and, after Preferably, cure, to form the frame 50a, as explained hereinabove. The fluid resinous material 50 of the present invention may comprise a material selected from the group consisting of: epoxides, silicones, urethanes, polystyrenes, polyolefins, polysulfides, nylons, butadienes and any combination thereof. Examples of suitable liquid resinous material 50 comprising silicones, include but are not limited to: "Smooth-Sil 900," "Smooth-Sil 905," "Smooth-20 Sil 910" and "Smooth-Sil 950." Examples of the suitable liquid resinous material 50 comprising polyurethanes, include, but are 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," "A60," "PMC-770," "PMC-780," "PMC-790." All of the above exemplary materials can be obtained commercially from Smooth-On, Inc., Easton, PA, 18042. Other examples of the liquid resinous material 50 include multi-component materials, such as, for example, a two-component liquid plastic. Smooth-Cast 300, "and a liquid rubber compound" Clear Flex 50, "both can be obtained commercially from Smooth-On, Inc. 10 Photosensitive resins can also be used as resinous material 50. Photosensitive resins are usually curing polymers , or crosslink under the influence of radiation, usually ultraviolet (UV) light. References that contain more information about of photosensitive liquid resins include Green et al., "Fotocross-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. 167-20; and Schmidle, "Ultraviolet Curable Flexible Coatings," J. of Coated Fabrics, 8, 10-20 (July 1978). The three preceding references are incorporated herein by reference. Especially preferred photosensitive liquid resins are included in the series of Merigraph resins, manufactured by MacDermid, Inc., of íijs? Éli, ^ ¿^ á ^ tá áSSSib Waterbury, CT. 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 5 Hytrel® thermoplastic elastomers (such as Hytrel® 4056, Hytrel® 7246 and Hytrel® 8238); and Zytel® Nylon (such as Zytel® 101 L, and Zytel® 132F), which can be obtained commercially from DuPont Corporation of Wilmington, DE. Preferably, the fluid resinous material 50 is provides in liquid or fluid form. However, the present invention contemplates the use of the fluid resinous material 50 which is supplied in solid form. In the latter case, an additional step of the fluidization of the resinous material 50 is required. The material fluid resinous 50 is preferably supplied to a source 55 (Figures 1, 2, 3, 4 and 5) which provides the appropriate conditions (such as, for example, temperature) to maintain the fluid resinous material 50 in the fluid state. As used herein, the The terms "fluid" and "liquid" refer to a condition, condition or phase of the resinous material 50, in this condition, the resinous material 50 has the ability to flow and allows the resinous material 50 to be deposited on a surface or inside. of the same one that has a pattern three-dimensional, so that the resinous material 50 e "" 29 it practically adapts or adjusts to the three-dimensional pattern of the patterned surface. If thermoplastic resins or thermosets are used as the resinous material 50, a temperature slightly above the melting point of the resinous material 50 will normally be desired to keep the resin in a fluid state. It is considered that the resinous material 50 is at or above the "temperature or melting point" if the resinous material 50 is completely in the fluid state. The suitable source 55 is a trough shown schematically in the various drawings of the present application. The tundish may have a bottom or closed end bottom and closed sidewalls and an outermost sidewall. The innermost side wall of the trough may be opened allowing the fluid resinous material 50 placed therein to freely contact the molding member 20. If the resinous material comprises a thermoplastic resin, the source 55 and the molding surface 21 preferably they are heated to prevent premature solidification of the liquid resinous material 50. The next step of the process comprises providing a molding member 20, which is fluid permeable. As used herein, the "molding member" 20 is a structure designed to receive the fluid resinous material 50 and then transfer the _ < , "" And '• < v., - _. ??? 9S7- ~ 7 * ^^^ * «£ *? *« - ** - | ^ atiaafe -.-.-Y - * ... - The resinous material 50 towards the reinforcing structure 40, preferably practically "a pre-selected pattern." The molding member 20 is "fluid permeable", because at least a portion or portions of the molding member 20 allows fluids such as water and air to pass through the molding member 20, at least in one direction. "fluid-permeable" term, in the context of the molding member 20, refers to the condition of at least one portion or portions of the molding member 20, this condition allows the portion or portions to provide fluid communication through the same, i.e., between opposite sides 21 and 22 of the molding member 20. In accordance with the present invention, at least a partial fluid permeability of the molding member 20 must be sufficient for to allow effective application of a fluid pressure differential through the molding member 20, such as to transfer the resinous material 50 from the molding member 20 to the reinforcing structure 40, as will be explained in more detail below. In the preferred continuous process, the molding member 20 can comprise a variety of different modalities. In the embodiments shown in Figures 1 to 4, the molding member 20 comprises an endless molding band, while in the embodiment shown in FIG.

In the figure IfP, the molding member 20 comprises a gipotable molding roller. Regardless of its mode, the molding member 20 has a molding surface 21 which preferably has a three-dimensional pattern and is structured and designed to receive the fluid resinous material 50, such that the fluid resinous material 50 practically fits or adjust to the three-dimensional pattern. Preferably, the molding surface 21 comprises a pre-selected pattern of molding cavities 25, permeable to fluid, As best seen in Figures 3A, 5, 6, and 8. As used herein, the term " molding surface "21 is a generic term that refers to all surfaces of the molding member 20, including an inherent surface, such as an external surface (the highest) of the molding band or an outer circumference (corresponding to a larger diameter) of the molding roll, as well as internal surfaces of the cavities 25. The molding surface 21 is a surface on (or inside) from which the fluid resinous material 50 is deposited. In a preferred continuous process of the present invention, the molding member 20 moves continuously at a transport speed, thereby carrying the resinous material 50. Those skilled in the art will readily appreciate that in the embodiment (Figure 5) comprising the rotating molding roller, the speed of The transport comprises a surface velocity measured at one of the circumferences of ®, molding surface 21. In Figure 5, the direction of rotation of the molding roll is indicated by the direction arrow "A". In the embodiments of Figures 1, 2, 3 and 4, the molding member 20, comprising a molding band, is supported by at least one pair of support rollers 70a and 70b, which rotate in the clockwise direction (one direction of rotation of the support rollers indicated by the arrow "A"). In Figure 4, the molding band is also supported by support rollers 70c and 70d. As used herein, the term "molding cavities" 25 refers to a pattern of depressions (or niches), or holes in the molding surface 21, which are designed to receive the fluid resinous material 50 from the source 55 and after for depositing the fluid resinous material 50 on the reinforcing structure 40 in a pre-determined pattern. The molding cavities 25 may comprise a substantially continuous pattern on the molding surface 21, as best seen in Figure 6; in this case, the material resinous 50 is transferred onto the reinforcement structure 40 in a practically continuous pattern. As used herein, a pattern is said to be "practically" continuous to indicate that minor deviations from absolute continuity can be tolerated, provided that these deviations do not adversely affect the process of the present invention and performance and qualities. Desired from the final product, the paper web 90. Figures 7 and 7A show an exemplary embodiment of the paper web 90 having a resinous frame 50a Practically continuous, made using the continuous pattern of the molding cavities 25. Alternatively or additionally, the molding cavities 25 may comprise a pattern of discrete depressions or holes. In the latter case, the material resinous 50 is transferred from the molding cavities 25 to the reinforcing structure 40 in a pattern comprising a multitude of discrete protuberances. An exemplary paper web 90 having the resinous framework 50a comprising a multitude of discrete protrusions that are extend outward from the first side 41 of the reinforcing structure 40, is shown schematically in Figures 9, and 9A. A pattern (not shown) comprising a combination of the substantially continuous molding cavities and the discrete molding cavities, as well as a semi-continuous pattern, is also contemplated in the present invention. In some embodiments, the molding cavities 25 may comprise holes extending through the molding member 20, between the mutually opposite surfaces 21 and 22, as shown in Figures IA and 2A. In a preferred embodiment shown in Figures 3 and 3A, the molding member 20 comprises an endless composite band formed by a first band 20a and a second band 20b. The first band 20a has a multitude of holes extending through the thickness of the first band 20a. These holes form the molding cavities 25. In the continuous process of Figure 3, a portion of the first band 20a is in a face-to-face contact relationship with a portion of the second band 20b, such that the second band 20b "closes" the holes of the first band 20a on one side of the first band 20a, as best seen in Figure 3A. When the fluid resinous material 50 is deposited in the holes of the first band 20a, the second band 20b prevents the resinous material 50 from leaking through the holes of the first band 20a. When the reinforcing structure 40 is juxtaposed to the first band 20a (Figure 3A), the resinous material 50 is within the holes of the first band 20a and, at the same time, between the reinforcing structure 40 and the second band 20b. Finally, in the process, the first band 20a and the second band 20b are separated, while the reinforcing structure 40 preferably continues closely associated with the first band 20a. Now, a fluid pressure differential can be effectively applied to the resinous material 50 to transfer the resinous material 50 from the holes of the first band 20a to the reinforcing structure., as will be explained in more detail later. In the embodiment of Figures 3 and 3A, the second band 20b may be fluid permeable or non-fluid permeable. In the latter case, the fluid permeability of the molding member 20 is achieved only after the first band 20a and the second band 20b have been separated. A less preferred embodiment of the molding member 20 is possible and shown in Figures IA and 2A, in this embodiment, the molding member 20 comprises a single band which through therethrough has holes. In this case, the viscosity of the fluid resinous material 50, the dimensions and shape of the holes through the molding band 20, the time during which the resinous material 50 is within the holes and other relevant process parameters should be selected. so as to prevent the flowable resinous material 50 from prematurely leaking (ie, before the molding band 20 is juxtaposed to the reinforcing structure 40) through i &áj __ £ __ é < tj. _ ^ _ ^ ¡¡_í__: __3s¡ of the holes of the molding member 20. Any person skilled in the art will understand that the above parameters are interdependent and individual for a particular process and apparatus of the present invention. Figure 2B shows another embodiment of the molding member 20. In Figure 2B, the molding member 20 has the pattern molding surface 21, as explained above. The molding cavities 25 are structured to receive the fluid resinous material 50 therein. In Figure 2B, at least portions 29 of the molding member are fluid permeable. The fluid-permeable portions 29 are the portions corresponding to the molding cavities 25 in the desirable application direction of the fluid pressure differential for the purposes of the transfer of the resinous material 50 from the molding member 20 to the reinforcing structure 40. Figure 2C shows another embodiment of the molding member 20 comprising a fluid-permeable support element 20c, relatively thin and a pattern element 20d attached to support element 20c. The portions of the support element 20c, whose portions do not have corresponding portions in the patterned element 20d provide therethrough fluid permeability. The element with pattern 20d »^ Gfe • ** - * / -fe, .. *. & _É__É_ÍÉ «--i *. ' It can be permeable to fluids or not. The fluid-permeable molding member 20 (or the fluid-permeable portions of the molding member 20) can be manufactured using a variety of suitable fluid-permeable materials and known in the art. Examples include, but are not limited to: fluorocarbon polymers, such as, for example, polytetrafluoroethylene (or PTFE, also known as Teflon®); GoreTex® obtainable in commercial form 10 from W. L. Gore & Associates, Inc. of Newark, DE; microporous materials, which can be obtained commercially from Millipore Corp. of Bedford, MA; micropore ribbons manufactured by 3M Corporation of St. Paul, MN; various sintered materials, such as, for example, Porna Dynapore® porous stainless steel wire mesh laminates manufactured by Martin Kurtz & Co. , Inc. of Mineola, NY; and sintered alloys available from National Sintered Alloys, Inc. of Clinton, CT; and woven metal wire fabrics, which can be obtained in commercial form from Haver & 20 Boecker from Oelde, Germany and Haver Standard India Pvt. Ltd. (HAST) of Bombay, India. The molding cavities 25 have at least one depth designated in the present by the symbol "D" (Figure 8). The depth D generally defines a thickness (although not necessarily equal to this) of the Pfcr, -. , ... sM. ",, ..______., * _ &_____». .-, _. _........-. ^. -, ...... .. .. *. J ^^ ... ^ »....... .. ^. ^^^. ^^: .- tf | .f-3y ^ feA; ^^ .. resinous material 50 deposited from the molding cavities 25 on the reinforcing structure 40. As used herein, the term "depth" of the molding cavities 25 indicates the extent of the 5 geometrically distinct depressions in the molding member 20 As an example, Figures 8 and 8A show a fragment of the molding member 20, comprising a molding roll, having a multitude of discrete molding cavities 25. An inherent portion 21a of the molding surface 21 is the portion of the outer circumference of the roller that is not affected by the molding cavities 25, usually a portion of the circumference of the roller corresponds to the larger diameter of the roller. In Figures 8 and 8A, the inherent portion 21a is a portion continuous of the outer circumference comprising the discrete molding cavities 25. Figures 8 and 8A also show that each molding cavity comprises two geometrically distinct depressions, a first depression 25a (relatively larger) having the shape exemplifies a diamond and a second depression 25b (relatively minor) having the exemplary shape of a circle, as best shown in Figure 8A. The first depression 25a has the first depth DI, and the second depression 25b has the second depth D2 greater that the first depth DI, or, to put it in a way # »Í« *? Fe ^^?, ^ ^^^.,. ^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^ - different, each of the molding cavities 25 shown in Figure 8, has two depths, the first depth DI and the second depth D2. Figures 9 and 9A schematically illustrate band 90, it is made using the molding member 20 shown in Figures 8 and 8A. The band 90 has the frame 50a comprising a multitude of discrete protuberances, each having two "heights": a first height hl corresponding to the first depth DI (although not necessarily equal) of the first depressions 25a, and a second height h2 corresponding to the second depth D2 (although not necessarily equal) of the second depressions 25b. It should be understood that the above examples are only intended to have illustrative purposes and are not intended to limit the invention. In the present invention, an unlimited number of shapes and their combinations and permutations of the molding cavities 25 having differential depths can be used virtually. While Figures 8 and 8A show geometrically symmetric molding cavities, it will be understood that geometrically asymmetric configurations (not shown) can be used if desired (in a plan view, as well as in cross section).

To produce the "angled" pattern of the resinous framework 50a, "angled" configurations of the molding cavities 25 can be used, as explained hereinabove. In addition, there may be embodiments (not shown) of the molding cavities 25 in which the relationship between a specific depth D and a geometrically distinct configuration is not obvious or even impossible to establish. The process of the present invention allows that advantageously create almost any desired shape of the resinous frame 90, providing the forming surface 21 shaped accordingly. The next step in the process of the present invention comprises depositing the fluid resinous material 50 on or within the molding member 20. Preferably, the fluid resinous material 50 is deposited within or on the molding member 20, in a practically pre-determined pattern. The fluid resinous material 50 is said to be deposited "inside" or "over" the molding member 20 to take into account that, in accordance with the present invention, the molding member 20 can have a variety of surface modalities. molding 21 (defined hereinabove) which receives the flowable resinous material 50. It is intended that the use of the conjunction "in or on" reflects the fact that the molding surface 21 can be practically * ¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡Flat, in which case, the fluid resinous material 50 is deposited "on" the molding member 20 or, it can preferably have a three-dimensional pattern comprising in the same molding cavities 24 (Figure 8), in which case, the fluid resinous material can be deposited "inside" the molding member 20. It is also intended that they reflect the different possible methods for depositing the fluid resinous material 50. For example , the fluid resinous material 50 can be deposited on the molding surface 21, which has mold cavities 24 and, then, the excess resinous material 50 is removed by milling or by any other technique known in the art. Alternatively or additionally, the resinous material 50 can be deposited directly into the molding cavities 24 of the molding surface 21. Those skilled in the art should also understand that in the present context, the "on or in" disjunction includes the conjunction "on and in". In general, in a preferred continuous process, the The step of depositing the fluid resinous material 50 first comprises contacting the molding surface 21 with the fluid resinous material 50 and then removing from the molding surface 21 the excess resinous material 50, as the surface is moving. of molding 21. Of In preference, the excess of the fluid resinous material 50 is t? & amp; amp; amp; amp; amp; amp; amp; amp; * i & . _ ..;: ____ «_ _-» - * J_tf; gft ___? &. Ate ____ lc __ ^ _ -a returns to the source (for example, to the trough) 55 of the resinous immaterial 50. By doing so, it can significantly reduce, and even virtually eliminate, the waste of resin material 50. In the apparatus 10 of the present invention any suitable means of depositing known in the art can be used to perform this step. As used herein, the term "means to deposit" refers to anything that has the ability to transfer the fluid resinous material 50 from a bulk amount to the molding surface 21 at the required dosage, such as for example , a trough capable of communicating with the molding member, with a nozzle, with an extruder and with other suitable means. The term "deposit" refers to the transfer of the fluid resinous material 50 from the mass of material (provided, for example, in the trough 55, described hereinabove) and the dosage of the fluid resinous material 50 on the molding surface. or within it and / or within the molding cavities 25, such that the fluid resinous material 50 fills the molding cavities 25 in a substantially uniform manner. The removal of the excess resinous material 50 from the molding surface 21 can be done by carving and / or scraping the excess material from the molding surface 21, or by any other methods 43 known in the art. The next pass has a high preference and is necessary in the continuous process and, comprises, continuously displacing the rolling member 20 and the reinforcing structure 40 at a transport speed, such that at least a portion of the reinforcing structure 40 is in face-to-face relationship with at least a portion of the molding member 20, particularly, with the molding surface 21 having associated therewith the fluid resinous material. Preferably, the portion of the reinforcing structure 40 that faces the molding surface 20 contacts the molding surface 20 for a predetermined period of time. This predetermined time period of preference should is sufficient for the resinous material 50 to be transferred from the molding member 20 to the reinforcing structure 40 under a fluid pressure differential, as explained below. In accordance with the present invention, the The resinous material 50 is maintained in a sufficiently fluid state before it is deposited on or within the molding member 20. Preferably, the resinous material 50 must be fluid enough to uniformly fill the molding cavities 25. In some modalities, the solidification of the material Resinous 50 may start just after the resinous material 50 has filled the molding cavities 25. A very preferred pre-solidification step may be required to allow the resinous material 50 to retain its shape in sufficient form during the next step of the application of the pressure differential to the resinous material 50 and transfer of the resinous material 50 from the molding member 20 to the reinforcing structure 40. As used herein, "pre-solidification" refers to the partial solidification of the resinous material 50, such that the resinous material 50 is able to sufficiently retain the desired shape and is still soft enough to effectively bond to the reinforcing structure 40. The degree of pre-solidification depends on the type of the resinous material. and its viscosity, of the relative geometry of the molding surface 21 and of the reinforcing structure 40, of the time during which the resinous material 50 will be transferred to the reinforcing structure 40, and of other relevant parameters of the process and apparatus of the present invention. invention. For the purposes of pre-solidification, a curing apparatus 100 may be used, as shown schematically in Figures 1 and 2. After the resinous material 50 associated with the molding member 20 has preferably pre-solidified, the next step comprises applying the fluid pressure differential to the fluid resinous material 50 to transfer the resinous material 50 from the molding member 20 to the reinforcing structure 40 and to cause the resinous material 50 to join the reinforcing structure 40. In accordance with the present invention, a mode is contemplated in which the resinous material 50, located in the molding cavities 25 pre-solidifies, such that the outer surface of the resinous material 50, which is in direct contact with the inner surface of the molding cavities 25 solidify first, while the rest of the resinous material 50 deposited in the molding cavities 25 is still in a substantially fluid state. Then, the external surface of the resinous material 50, which is at least partially solidified, functions as a shell for the rest of the resinous material 50, which is still at least partially fluid. This embodiment can be particularly beneficial in the process using the reinforcement structure 40 which has spaces voids therethrough, such as, for example, a woven reinforcement structure 40. In this embodiment, when the fluid pressure differential is applied to the partially solidified resinous material 50, the resinous material 50 is "pushed" through. of the threads of the reinforcement structure 40, which form their first side 41 and within the structure of 40, without distorting in a prohibitive manner the shape of the resinous material 50, so that the partially solidified "shell" retains the shape of the resinous material 50 that will be deposited in the reinforcing structure 40. Normally, although not necessarily , the resinous material 50 does not merely attach to the reinforcing structure 40, but wraps the structural elements of the reinforcing structure 40 (such as for example the individual yarns in a woven reinforcement structure 40), to ensure on them in an appropriate way, surrounding at least partially some of them in this way. The fluid pressure differential forces the resinous material 50 to penetrate between the 15 structural elements of the reinforcing structure 40. Preferably, the time during which the molding member 20 is oriented to the reinforcing structure 40 (and, for preference makes contact with it) should be sufficient for the resinous material 50 to be transferred with the application of the fluid pressure differential, of the molding member 20 on the reinforcing structure 40. More preferably, this time should be sufficient to that the resinous material 50 binds, at least partially, to the reinforcing structure 40, preferably in a desired pattern (which practically fc. , t r-r > ,, .- *.

? ^ Hjj '^ corresponds to the pattern of the molding surface 21). It is said that the resinous material 50 is attached to the reinforcing structure 40 preferably in a pattern that "practically" corresponds to eoh. the preselected pattern Ir 5 of the molding surface 21 to be taken into account that minor deviations or distortions of the absolutely correct pattern formed on the molding member 20 or within it, are tolerable, as long as these deviations or distortions do not interfere in any way important in the performance of the band that is being manufactured. It should also be understood that the pattern of the molding surface 21 can be designed in such a way as to compensate for the potential distortions of the pattern of the resinous material 50 during the transfer of the material. resinous 50 of the molding member 20 to the reinforcing structure. For example, assuming that during the transfer step, in some embodiments, the resinous material 50 may expand laterally while losing height, the dimensions of the molding cavities may vary. can be made smaller than the corresponding desired dimensions of the resinous frame 50a. A means 30 for creating and applying the fluid pressure differential to the resinous material 50 is well known in the art and includes, by way of illustration, and not limiting, devices such as: an apparatus vacuum, a fan, a hydraulic pump and the like. A hydraulic pump can be used to create the fluid pressure differential with liquid media such as oil and water. As used herein, the term "vacuum apparatus" is a generic term that refers to any device that has the ability to create a pressure differential between the mutually opposite sides 21 and 22 of the molding member 20. note that the The vacuum apparatus includes devices designed to create a "positive" pressure and devices designed to create a "negative" pressure. As used herein, the "positive" pressure is the pressure that is greater than the ambient pressure, that is, the atmospheric pressure; and the "negative" pressure is the pressure that is less than the atmospheric pressure. For example, if the resinous material 50 comprises a thermopolymer, gas can be used to create the positive pressure. As the gas expands, it cools, cooling and solidifying in this way resinous material 50. Gases containing free radical initiators could be used to cure certain types of resinous material 50. In some embodiments it may be desirable to control the application of the pressure differential of fluid to the resinous material 50, so as to avoid sudden application of a pressure that can prohibitively distort the pattern of the resinous material 50 that will be formed on or within the molding member 20. For example, a rate of application of the fluid pressure differential can be distributed to increase it gradually or discretely as the molding member 20 and the reinforcing structure 40 travel in the machine direction. Alternatively or additionally, the surface supporting the reinforcing structure 40 in the application area of the fluid pressure differential, if applicable, may be textured to provide a leak between the supporting surface and the reinforcing structure 40. Only for illustrative purposes, in Figures 2, 3, and 3A, this support surface comprises a surface of the support band 80; and in Figure 4, the support surface comprises a surface of the support roll 15. These and other methods for controlling the rate of application of the fluid pressure differential to the resinous material 50 are described in greater detail in the US Pat. United, assigned jointly 5,776,311, granted on July 7, 1998, to Trokhan et al., Whose disclosure is incorporated herein by reference in order to disclose the various methods for controlling the fluid pressure differential application regime. to the resinous material 50 associated with the bulb member 20. Preferably, the surface energy of the molding surface 21 associated with the resinous material 50 is smaller than the ground energy of the reinforcement structure 40. There are several ways to generate a surface energy differential. between the molding surface 21 and the reinforcing structure 40. The material comprising the molding surface 21 can inherently have a relatively low surface energy or can be treated to reduce its surface energy. Alternatively or additionally, the molding surface 21 can be treated with a release agent or demolding agent 60 prior to the step of depositing the resinous material 50 on or within the molding member 20. Examples of delivery agent 60 include, but are not limited to: "Ease Release ™," "Permarelease ™," "Aqualease ™," and "Actilease ™," which can be obtained from Smooth-On, Inc. Source 65 of the release agent 60 is shown schematically as a rolling nozzle in several drawings. However, it will be understood that the release agent 60 can also be applied by brush or by milling onto the molding surfaces, in these cases, the source 65 may comprise a brush, a tundish or any other suitable device known in the art. In some 25 applications, it may be necessary to apply to the surface "» ** "*." * - * ".«, ** '• **> * "' ^ .í * 'l ^ _f ^ _S__e-a-' 't" "* __ * iÉ? * .β of molding 21 two or more coatings, ie hands, of the release agent 60. In some embodiments in which the molding surface has microscopic pores, it may be desirable to heat the release agent 60 and / or the surface of molding 21 to facilitate the penetration of the release agent 60 into the molding surface 21 thereby sealing the pores before depositing the resinous material 50 on the molding surface 21. If desired, the molding member 20 can be structured to have a pattern of recesses or entrants 26 (Figure 6) to receive the reinforcing structure 40 therein. Then, when the reinforcing structure 40 is juxtaposed to the molding member 20, the reinforcing structure 40 is at least partially embedded in the molding surface 21. The reinforcing structure 40 can be fully embedded within the recesses 26 of the reinforcement. molding surface 21, in which case, the recesses 26 have a depth not less than, and preferably equal to, the thickness h of the reinforcing structure 40. Alternatively, the reinforcing structure 40 may be only partially embedded within the recesses. 26, in which case, the depth of the recesses 26 is less than the thickness h of the reinforcing structure 40. In Figure 6, the pattern of the molding cavities 25 for receiving the fluid resinous material 50 is superimposed on the pattern of aaa___g3E > * »> * • h - - -? &? _ S__MMBi_te¡_í_. recesses 26 for receiving reinforcing structure 40. In Figure 6, a portion of molding surface 21, this portion provides support for reinforcing structure 40 is designated 21S; and a portion of the molding surface 21 that provides support to the resinous material 50 is designated 21R. Preferably, the step is performed by registering the reinforcement structure 40 with the recesses 26. The reinforcement structure 40 can also be embedded (not shown), at least partially, in the support band 80. (Figures 2, 3, and 3A) or on the support roll 15 (Figure 4). In this case, a distance "Z" may be formed between the second side 42 of the reinforcing structure 40 and the lower side 52 of the resinous frame 50, when the band 90 is formed, as shown in Figure 6A. In a paper web for drying by air passage, the distance "Z" creates a leak between the surface of the back side 92 of the web that is in contact with paper equipment (such as, for example, a vacuum box or a brake shoe). capture) and the contact surface with the band of this equipment. The leaks mitigate the sudden application of vacuum pressure to the paper web placed in the band 90 and, thus, reduce, if not completely eliminate the so-called formation of pitting. Those skilled in the art will recognize that the term U_j_ft_fe ci "pitting" refers to the formation of pin-sized holes or "pitting" in the weave to be drained as a result of the sudden application of vacuum pressure to the plot and the consequent separation of a certain number of fibers from the weft. Some of the fibers can pass completely through the paper web, thus causing, in addition to the formation of pitting, the clogging of vacuum dewatering machinery due to paper fibers. Those skilled in the art will appreciate that the pattern of the resinous material 50 transferred from the molding member 20 to the reinforcing structure 40 reflects the pattern of the molding surface 21. Thus, if the molding surface 21 comprises a pattern practically Continuous of the molding cavities 25, as shown in Figure 6, the resinous material 50 is transferred to the reinforcing structure 40 in a substantially continuous pattern. On the other hand, if the molding surface 21 comprises a plurality of discrete molding cavities 25, as best seen in Figures 8 and 8A, the resinous material 50 is transferred to the reinforcing structure 40 in a pattern comprising a multitude of resinous protuberances, Figures 9 and 9A. The next step of the process of this The invention comprises the solidification of the resinous material «Fe ^ tA *» _ & ¿^ ^ ia¿, J ^ i ^ a ^ fe g. __j __- 50 attached to the reinforcing structure 40. As used herein, the term "solidification" and its derivations refer to the process of altering a fluid in a solid or in a partially solid state. Normally, solidification involves a phase change, from the liquid phase to the solid phase. The term "curing" refers to a solidification in which cross-linking occurs. For example, photosensitive resins can be cured by UV radiation, as described in commonly assigned United States 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 thermosets require a certain temperature for their solidification. Preferably, the step of solidification comprises curing the resinous material 50. As explained above, preferably the process of pre-solidification of the resinous material 50 can begin almost immediately after the fluid resinous material 50 has been deposited on the molding member 20 or within it. Preferably, the solidification continues while the reinforcing structure 40 and the molding surface 21 are in a face-to-face relationship. The method for solidifying the resinous material 50 depends on its nature. If it is O - «, -fi used a thermoplastic or thermosetting resin, the solidification comprising cooling the resinous material 50 transferred to the reinforcing structure 40. The photopolymer resins can be cured by a curing process described in United States Patents, assigned in pooled form, 4,514,345; and 5,275,700, incorporated herein by reference and referenced above. The resinous material 50 comprising multi-component resins or plastics can naturally solidify, for a certain predetermined period of time, by virtue of being a mixture. As an example, Figures 1 and 2 schematically show the curing apparatus 100 juxtaposed to the second side 42 of the reinforcing structure 40. Depending on the type of resinous material 50, examples of the curing apparatus 100 include, but are not limited to: a heater to increase the rates of crosslinking reaction or the condensation rates for the condensation polymers; a cooling to solidify thermoplastic; various apparatus providing infrared curing radiation, microwave curing radiation or ultraviolet curing radiation; and the similar. The patent application, assigned jointly with Serial No. 08 / 799,852, entitled "Apparatus for Generating Parallel Radiation For Curing Photosensitive Resin "filed in the name of Trokhan on February 13, 1997, and the patent application, assigned jointly with Serial No. 08 / 858,334, entitled" Apparatus for Generating Controlled Radiation for Curing Photosensitive Resin "filed on behalf of Trokhan et al., February 13, 1997, are incorporated herein by reference in order to show various embodiments of the curing apparatus 100 that can be used to solidify the resinous material 50 comprising a photosensitive resin. of the present invention a step can be provided to control the H gauge (Figure 7) of the 90 band. The H gauge can be controlled at a preselected value by controlling the OB cover (Figure 7), ie the distance between the side upper 51 of the resinous frame 50 and the first side 41 of the reinforcing structure 40. The caliber H can also be controlled by controlling the depth of the recesses 26 in the molding member 20 or the depth of the recesses in the support surface for the reinforcing structure 40. Another way of controlling the caliber H comprises changing the thickness of the resinous material 50 after the resinous material 50 has been transferred from the limb member. molding 20 to the reinforcing structure 40, and after the resinous frame has been formed, at least - ^^ »* ^ partially. For example *, the thickness of the resinous material 50 can be adjusted through mechanical means known in the art. Figure 3 schematically shows a control device 5 of caliber 5 comprising two mutually juxtaposed rollers forming a gap between them. By adjusting the spacing between the rollers of the device 85, the gauge of the band 90 being manufactured can be controlled. Alternatively or additionally, the controlling device of the gauge may comprise a rotating sander roller, a planing knife, a laser, or any other means known in the art and suitable for the purpose of controlling the gauge of the band 90. The process and apparatus of the present invention significantly reduce the amount of fluid resin that is required to be used during the manufacture of the band 90 and thus provides an economic benefit. The methods of the prior art for the manufacture of a band, using photosensitive resin and curing radiation, require the application of a photosensitive resin coating to the reinforcing structure, the curing of selected portions of the resinous coating, and then the removal (typically, by stripping) of the uncured portions of the coating. resinous. The amount of the resin that will be eliminated by washing is about 25% to 75% with respect to the amount of the complete resinous coating In the present invention, the exact amount of the resinous material 50, which is required for the resinous framework 50a can be formed on the molding member 20 or The excess resinous material 50 deposited on the external (inherent) surface 21a of the molding member 20 can be easily recycled (and preferably recycled), by any means known in the art, to the source 55 of resinous material 50, thereby completely eliminating the waste of resinous material 50. In addition, the process and apparatus of the present invention allows creating a virtually unlimited number of three-dimensional patterns of resinous framework 50a.

Claims (16)

1. REVIVALMENTS; A process for manufacturing a paper web comprising a reinforcing structure and a resinous frame attached thereto, the process comprising the steps of: (a) providing a reinforcing structure having a first side, a second side opposite to the first side and a thickness between these; (b) providing a flowable resinous material; (c) providing a molding member, the molding member is at least partially fluid permeable; (d) depositing the fluid resinous material on or within the molding member, preferably in a preselected pattern, preferably by contacting the molding member with the flowable resinous material, and removing excess material from the molding member. resinous fluid, whereby the resinous material is transferred to the reinforcing structure in a substantially continuous pattern, in a pattern comprising a multitude of discrete protuberances, or in a combination thereof; (e) juxtaposing the reinforcing structure to the molding member; (f) apply a fluid pressure differential .? - _ » the flowable resinous material - associated with the molding member, thereby transferring the flowable resinous material from the molding member to the reinforcing structure and causing the flowable resinous material and the reinforcing structure to join; and (g) solidifying the resinous material thereby forming the resinous framework attached to the reinforcing structure, thereby forming the paper web.
2. 2. A process for manufacturing a paper web comprising a reinforcing structure and a resinous framework attached thereto, the process comprising the steps of: (a) providing a fluid-permeable reinforcement structure having a first side, a second opposite side to the first side and a thickness between them; (b) providing a flowable resinous material; (c) providing a molding member that therein comprises a pattern of fluid-permeable molding cavities, the molding cavities being structured to receive therein the fluid resinous material; (d) depositing the resinous fluid material within the molding cavities of the molding member; (e) juxtaposing the reinforcing structure to the molding member; (f) apply a fluid pressure differential JtSr "* F-" to the fluid resinous material-located in the molding cavities of the molding member to transfer the fluid resinous material of the molding member to the reinforcing structure, such that the fluid resinous material and the structure of reinforcement join; and (g) solidifying the fluid resinous material transferred to the reinforcing structure, thereby forming the resinous framework attached to the reinforcing structure, whereby the paper web is formed.
3. 3. The process according to claims 1 and 2, further comprising the step of pre-solidifying the flowable resinous material, such that the resinous material retains enough of the preselected pattern during step (f).
4. 4. The process according to claims 1, 2, and 3, further comprising the step of controlling the thickness, in at least one preselected value, of the resinous material bonded to the reinforcing structure. The process according to claims 1, 2, 20 3, and 4, wherein in step (g) the resinous material extends outward from the first side of the reinforcing structure after the resinous material has been bonded to the reinforcement structure. 6. The process according to claims 1, 2, 25 3, 4, and 5, wherein the reinforcing structure comprises a woven fabric or a mesh qu !. It has a multitude of open areas through it. The process according to claims 1, 2, 3, 4, 5, and 6, wherein in step (b) of providing a flowable resinous material, it comprises providing a material selected from the group consisting of: epoxides, silicones, urethanes, polystyrenes, polyolefins, polysulfides, nylons, butadienes, photopolymers and any combination thereof. 8. An apparatus for manufacturing a paper web comprising a reinforcing structure and a resinous frame attached thereto, the apparatus comprising: a molding member having a pattern of fluid-permeable molding cavities, structured to receive and carry on they are a fluid resinous material, at least a portion of the molding member will be juxtaposed to at least a portion of the reinforcing structure, the molding cavities form a substantially continuous pattern, a pattern of discrete molding cavities, or a combination of them; a means for depositing the fluid resinous material within the molding cavities of the molding member; a means to generate a fluid pressure differential sufficient to transfer the resinous material fluid of the molding cavities of the molding member towards the reinforcing structure, the apparatus additionally has a machine direction and, preferably, comprises a means for displacing the reinforcing structure and the molding member in the machine direction, such so that at least a portion of the reinforcing structure is in a face-to-face relationship with at least a portion of the molding member. The apparatus according to claim 8, wherein at least some of the molding cavities have differential depths therein. The apparatus according to claims 8 and 9, further comprising means for pressing the reinforcing structure and the molding surface with respect to each other for a predetermined period of time. The apparatus according to claims 8, 9, and 10, further comprising at least one support roller juxtaposed to the molding surface to form between them a line or contact point and / or a support band juxtaposed to the molding surface, the support band is structured to move in a face-to-face contact relationship with at least a portion of the reinforcing structure. 12. The apparatus according to claims 8, 9, * * 64 10, and 11, wherein the molding further comprises a pattern of recesses for receiving therein the reinforcing structure. The apparatus according to claims 8, 9, 5, 10, 11 and 12, wherein the molding member comprises a roller having a circumference and a longitudinal axis perpendicular to the machine direction, the molding roller can rotate around the longitudinal axis or an endless band structured and designed to travel 10 continuously in machine direction. The apparatus according to claims 8, 9, 10, 11, 12 and 13, wherein at least some of the molding cavities comprise holes through at least a portion of the molding surface. 15. The apparatus according to claims 8, 9, 10, 11, 12, 13 and 14, wherein the molding member comprises at least one first band having holes therethrough and a second band, a portion of the first band will be in a relationship of 20 contact with a portion of the second band. 16. The apparatus according to claims 8, 9, 10, 11, 12, 13, 14, and 15, wherein the reinforcing structure comprises a felt. A process and an apparatus for manufacturing a paper web 90 are provided, the web comprises a reinforcement structure, a resinous framework 50 joined together. The preferred continuous process comprises the steps of depositing a fluid resinous material on a patterned molding surface (20); continuously displacing the molding surface and the support structure at a transport speed such that at least a portion of the reinforcing structure is in a face-to-face relationship with a portion of the molding surface; applying a fluid pressure differential to transfer the resinous fluid material from the molding surface to the reinforcing structure and causing the fluid resinous material and the reinforcing 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, preferably comprising a plurality of molding cavities for carrying therein a flowable resinous material; a means for depositing the fluid resinous material within the molding cavities of the molding surface; means for moving the reinforcing structure and the molding member in a predetermined direction; and a means to generate a fluid pressure differential sufficient to transfer the resin material? Fluid from the molding chamber to the reinforcing structure.