US20200270812A1 - Structured papermaking fabric - Google Patents

Structured papermaking fabric Download PDF

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Publication number
US20200270812A1
US20200270812A1 US16/612,177 US201816612177A US2020270812A1 US 20200270812 A1 US20200270812 A1 US 20200270812A1 US 201816612177 A US201816612177 A US 201816612177A US 2020270812 A1 US2020270812 A1 US 2020270812A1
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US
United States
Prior art keywords
structuring elements
elements
papermaking fabric
structuring
cross
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Abandoned
Application number
US16/612,177
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English (en)
Inventor
Jeffrey Dean Holz
Kenneth John Zwick
Mark William Sachs
Kevin Joseph Vogt
Mike Thomas Goulet
Mark Alan Burazin
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Kimberly Clark Worldwide Inc
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Kimberly Clark Worldwide Inc
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Publication date
Application filed by Kimberly Clark Worldwide Inc filed Critical Kimberly Clark Worldwide Inc
Priority to US16/612,177 priority Critical patent/US20200270812A1/en
Publication of US20200270812A1 publication Critical patent/US20200270812A1/en
Abandoned legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
    • D21H27/002—Tissue paper; Absorbent paper
    • D21H27/004—Tissue paper; Absorbent paper characterised by specific parameters
    • D21H27/005—Tissue paper; Absorbent paper characterised by specific parameters relating to physical or mechanical properties, e.g. tensile strength, stretch, softness
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D1/00—Woven fabrics designed to make specified articles
    • D03D1/0094—Belts
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D3/00—Woven fabrics characterised by their shape
    • D03D3/08—Arched, corrugated, or like fabrics
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21F—PAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
    • D21F11/00—Processes for making continuous lengths of paper, or of cardboard, or of wet web for fibre board production, on paper-making machines
    • D21F11/006—Making patterned paper
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21F—PAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
    • D21F11/00—Processes for making continuous lengths of paper, or of cardboard, or of wet web for fibre board production, on paper-making machines
    • D21F11/14—Making cellulose wadding, filter or blotting paper
    • D21F11/145—Making cellulose wadding, filter or blotting paper including a through-drying process
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21F—PAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
    • D21F7/00—Other details of machines for making continuous webs of paper
    • D21F7/08—Felts
    • D21F7/086—Substantially impermeable for transferring fibrous webs
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
    • D21H27/002—Tissue paper; Absorbent paper
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
    • D21H27/02—Patterned paper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2555/00—Personal care
    • D03D2700/0162—
    • D03D2700/02—

Definitions

  • absorbent tissue products are frequently embossed in a subsequent operation after their manufacture on the paper machine, while the dried tissue web has a low moisture content, to impart consumer preferred visually appealing textures or decorative lines.
  • absorbent tissue products having both desirable physical properties and pleasing visual appearances often require two manufacturing steps on two separate machines.
  • the present inventors have now discovered a means of improving tissue web drying by supporting the nascent web on a papermaking fabric comprising a plurality of structuring elements disposed on a carrier structure. More specifically the present inventors have discovered that certain desirable tissue product properties such as caliper and smoothness may be optimized without negatively affecting drying of the tissue product by providing a papermaking fabric having structuring elements having a perimeter less than 3.6 mm, such as less than about 3.0 mm, such as from about 1.4 to 3.6 mm, such as from about 1.6 to about 2.4 mm, wherein the structuring elements cover more than about 28 percent, such as from about 28 to about 35 percent, of the surface area of the web contacting surface of the fabric.
  • the amount of the nascent web that contacts the structuring elements and is molded into a smooth surface is maximized without exacerbating the negative affect to drying commonly associated with occluding a large portion of the surface area of the papermaking fabric.
  • relatively narrow structuring elements such as elements having a width of 0.7 mm or less, such as from 0.3 to 0.7 mm, have limited negative affect on drying, particularly the normalized drying rate, even when the elements cover a relatively large percentage of the papermaking surface area, such as more than 28 percent and in some instances more than 30 percent. This is counter to what was previously believed.
  • an increase in the percentage of fabric covered by structuring elements resulted in a commensurate reduction in heat transfer, based on the theoretical drying rate:
  • q is the heat transfer in W/m 2
  • ⁇ is the latent heat of the water dried in j/g
  • DR is the drying rate in g/s m 2
  • h is the heat transfer coefficient in W/m 2 C
  • A is the area open to the flow in m 2 /m 2
  • T is temperature.
  • the present invention provides a papermaking belt comprising a woven carrier structure having a machine contacting surface and an opposite web contacting surface and a plurality of structuring elements, which may be formed from a liquid and air impervious material such as silicone or polyurethane, disposed on the web contacting surface.
  • the structuring elements are preferably shaped and sized to enable molding of the nascent web and to minimize negative impacts to drying and as such generally have a cross-sectional perimeter less than 3.6 mm, such as less than about 3.0 mm, such as less than about 2.4 mm, such as less than about 2.0 mm, such as from about 1.4 to 3.6 mm, such as from about 1.6 to about 3.0 mm.
  • the structuring elements When viewed in the cross-section perpendicular to the X-Y plane of the papermaking belt the structuring elements may have any number of different cross-sectional shapes such as, for example, polygonal, semicircular or elliptical.
  • the structuring member has a polygonal cross-sectional shape such as, for example, a trapezoid, a parallelogram, a rectangle, a rhombus, or a square.
  • the structuring elements generally have a cross-sectional perimeter less than 3.6 mm, such as less than about 3.0 mm, such as less than about 2.4 mm, such as less than about 2.0 mm, such as from about 1.4 to 3.6 mm, such as from about 1.6 to about 3.0 mm.
  • Structuring elements can provide a means for deflecting papermaking fibers in the Z-direction as the nascent web is molded and dried while supported by the fabric.
  • the amount of fiber deflection and the physical properties of the resulting tissue web such as caliper, density and surface topography may be affected to some extent by the size and shape of the structuring elements.
  • the structuring member may have a Z-directional height greater than about 0.4 mm, such as greater than about 0.5 mm, and more preferably greater than about 0.6 mm, such as from about 0.4 to about 1.2 mm and more preferably from about 0.4 to about 0.8 mm.
  • the structuring member have width, generally measured in the cross-machine direction (CD) across the widest portion of the element and parallel to the upper surface plane of the carrier structure, of 0.7 mm or less, such as less than about 0.6 mm, such as less than about 0.5 mm, such as from about 0.4 to 0.7 mm.
  • fiber deflection and the physical properties of the resulting tissue web such as caliper, density and surface topography, as well as the effective drying of the web may be affected by the aspect ratio of the structuring member, or the ratio of the width to Z-directional height.
  • the aspect ratio which is generally the ratio of the element height to the element width, may be from about 2:1 to 2:3, such as from 1.5:1 to about 1:1.
  • the physical properties of the resulting tissue web, as well as the drying of the web may be influenced by the relative percentage of the carrier structure that is covered by the structuring elements. For example, it may be desirable to provide the finished tissue web with a plurality of relatively smooth, elevated portions that are brought in contact with a user's skin in-use, yet at the same time minimize the amount of the web that is contacted by the structuring elements, which are generally impermeable to air and water, so as not to impede drying.
  • the relative area of the carrier structure that may be covered by structuring elements may be relatively high such as greater than about 28 percent, such as greater than about 30 percent and more preferably greater than about 32 percent, such as from about 28 to about 35 percent and more preferably from about 30 to about 32 percent, without negatively affecting drying of the nascent web.
  • a finished tissue web having a relatively high degree of relatively smooth, elevated portions may be produced without negatively affecting drying of the nascent web.
  • FIG. 1 is a perspective view of a papermaking fabric useful in the manufacture of tissue webs according to one embodiment of the present invention
  • FIG. 2 is top view of a papermaking fabric useful in the manufacture of tissue webs according to one embodiment of the present invention
  • FIG. 3 is a cross section view of a papermaking fabric taken through line 3-3 of FIG. 2 ;
  • FIG. 4 is a cross-sectional image of a papermaking fabric taken using a Keyence VHX-5000 Digital Microscope (Keyence Corporation, Osaka, Japan) at a magnification of 20 ⁇ ;
  • FIG. 5 is a top view of a papermaking fabric taken using a Keyence VHX-5000 Digital Microscope (Keyence Corporation, Osaka, Japan) at a magnification of 20 ⁇ ;
  • FIG. 6 is an image of the papermaking fabric of FIG. 5 that has been processed to calculate the element coverage area as described in the Test Method section;
  • FIG. 7 is a plot of the heat transfer coefficient (drying rate normalized by the through-air dryer supply temperature) versus element coverage area (x-axis) at a through-air dryer supply temperature of 300° F. for through-air drying fabrics having structuring elements having widths of 0.9 mm ( ⁇ ), 0.8 mm (x), 0.7 mm ( ⁇ ), and 0.6 mm ( ⁇ );
  • FIG. 8 is a plot of the heat transfer coefficient (drying rate normalized by the through-air dryer supply temperature) versus element perimeter (x-axis) at a through-air dryer supply temperature of 300° F. for through-air drying fabrics having structuring elements having widths of 0.9 mm ( ⁇ ), 0.8 mm (x), 0.7 mm ( ⁇ ), and 0.6 mm ( ⁇ ); and
  • FIG. 9 is a plot of the drying loss factor (y-axis) versus element coverage area (x-axis) at a through-air dryer supply temperature of 300° F. for through-air drying fabrics having structuring elements having widths of 0.9 mm ( ⁇ ), 0.8 mm (x), 0.7 mm ( ⁇ ), and 0.6 mm ( ⁇ ).
  • papermaking fabric means any woven fabric used for making a cellulosic web such as a tissue sheet, either by a wet-laid process or an air-laid process.
  • Specific papermaking fabrics within the scope of this invention include forming fabrics; transfer fabrics conveying a wet web from one papermaking step to another, such as described in U.S. Pat. No. 5,672,248; molding, shaping, or impression fabrics where the web is conformed to the structure through pressure assistance and conveyed to another process step, as described in U.S. Pat. No. 6,287,426; creping fabrics as described in U.S. Pat. No. 8,394,236; embossing fabrics as described in U.S. Pat. No.
  • the fabrics of the invention are also suitable for use as molding or air-laid forming fabrics used in the manufacture of non-woven, non-cellulosic webs, such as baby wipes.
  • machine direction is the direction parallel to the flow of the fibrous web through the web-making equipment.
  • cross machine direction is the direction perpendicular to the machine direction in the X-Y plane.
  • width when referring to a structuring member generally refers to the widest portion of a cross-sectional portion of the element in the cross-machine direction (CD). Generally width is measured at the widest point of the element and parallel to the upper surface plane of the carrier structure.
  • the term “height” when referring to a structuring member is the Z-direction height of a member extending from the carrier structure and is generally measured between the upper surface plane of the carrier structure and the upper surface plane of the element.
  • the term “aspect ratio” when referring to a structuring member is the ratio of the element height to the element width.
  • the terms “effective perimeter” and “perimeter” when referring to a structuring member is the total perimeter of a cross-sectional portion of the element. Generally the perimeter of a cross-sectional portion of the element is a continuous line forming the boundary of a closed geometric figure.
  • cover area generally refers to percentage of the carrier structure's upper surface area that is covered by structural elements as measured using a Keyence VHX-5000 Digital Microscope (Keyence Corporation, Osaka, Japan) and described in the Test Methods section below.
  • the term “line element” refers to structuring elements in the shape of a line, which may be a continuous, discrete, interrupted, and/or partial line with respect to the carrier structure on which it is present.
  • the line element may be of any suitable shape such as straight, bent, kinked, curled, curvilinear, serpentine, sinusoidal, and mixtures thereof that may form regular or irregular periodic or non-periodic lattice work of structures wherein the line element exhibits a length along its path of at least 10 mm.
  • the line element may comprise a plurality of discrete elements, such as dots and/or dashes for example, that are oriented together to form a line element.
  • the term “continuous” when referring to a structuring member generally refers to an element disposed on a carrier structure useful in forming a tissue web that extends without interruption throughout one dimension of the carrier structure.
  • discrete element when referring to a structuring member generally refers to separate, unconnected elements disposed on a carrier structure useful in forming a tissue web that do not extend continuously in any dimension of the support structure or the tissue web as the case maybe.
  • curvilinear element when referring to a structuring member generally refers to any structuring member that contains either straight sections, curved sections, or both that are substantially connected visually. Curvilinear structuring elements may appear as undulating lines, substantially connected visually, forming signatures or patterns.
  • curvilinear structuring elements As used herein “decorative pattern” refers to any non-random repeating design, figure, or motif. It is not necessary that the curvilinear structuring elements form recognizable shapes, and a repeating design of the curvilinear structuring elements is considered to constitute a decorative pattern.
  • the papermaking fabric 10 comprises a carrier structure 30 having a web contacting surface 64 and a machine contacting surface 62 .
  • web contacting surface 64 is generally the side of the fabric 10 on which fibers, such as papermaking fibers, are deposited.
  • the web contacting surface forms an X-Y plane, where X and Y can correspond generally to the cross-machine direction (CD) and machine direction (MD), respectively, when using the belt in the manufacturing of tissue webs.
  • X designate a system of Cartesian coordinates, wherein mutually perpendicular “X” and “Y” define a reference plane formed by the web contacting surface 64 of the papermaking fabric 10 when disposed on a flat surface, and “Z” defines a direction orthogonal to the X-Y plane.
  • plane does not require absolute flatness or smoothness of any portion or feature described as planar.
  • a portion of the web contacting surface of the fabric may consist of a woven fabric having a textured upper surface, which may be useful in imparting patterns or physical properties to a tissue web, yet be defined as being generally planar or as having a surface plane.
  • Z-direction designates any direction perpendicular to the X-Y plane.
  • Z-dimension means a dimension, distance, or parameter measured parallel to the Z-direction and can be used to refer to dimensions such as the height of discrete primary elements or the thickness (or height or caliper), of the secondary elements. It should be carefully noted, however, that an element that “extends” in the Z-direction does not need itself to be oriented strictly parallel to the Z-direction; the term “extends in the Z-direction” in this context merely indicates that the element extends in a direction which is not parallel to the X-Y plane.
  • an element that “extends in a direction parallel to the X-Y plane” does not need, as a whole, to be parallel to the X-Y plane; such an element can be oriented in the direction that is not parallel to the Z-direction.
  • any given structuring member may not necessarily have an upper surface that is substantially flat throughout its entire length, yet the upper most portion of the member may generally define a plane. Irregularities in the upper surface of structuring elements may result from the elements being manufactured by depositing a polymeric material, which may be flowable to a certain extent, onto a woven carrier structure having an upper surface of which is not entirely flat, but has a degree of texture. Nonetheless, as illustrated in FIG. 1 and discussed herein, the structuring member 40 being disposed on a carrier structure 30 having a substantially flat upper surface 48 and the macroscopic “X-Y” plane is conventionally used herein for the purpose of describing relative geometry of several elements of the structuring member 40 .
  • the structuring elements 40 are provided in the form of substantially similarly shaped continuous line elements. Each structuring element 40 extends in the Z-direction on the web contacting side 64 of the carrier structure 30 .
  • the structuring elements 40 have a generally square cross-sectional shape with spaced apart relatively straight, parallel sidewalls 45 , 47 . While the illustrated structuring elements have a generally square cross-sectional shape, the invention is not so limited and the elements may have a variety of shapes such as, for example, polygonal, semicircular or elliptical.
  • the line elements have a polygonal cross-sectional shape such as, for example, a trapezoid, a parallelogram, a rectangle, a rhombus, or a square.
  • the structuring element sidewalls 45 , 47 and top surfaces 48 can be relatively straight and planar, such as illustrated in FIG. 1 , or they may be curved, partially straight and partially curved, or irregular when viewed in cross-section. It should be noted that the drawings schematically show the sidewalls 45 , 47 and top surface 48 as straight lines for ease of illustration only.
  • each of the structuring elements 40 have similar shapes and dimensions, the invention is not so limited, and a variety of different shapes and sizes may be employed.
  • each of the line elements can be individually sized, shaped, and spaced.
  • the illustrated structuring elements 40 are continuous line elements, each having a generally flat distal portion 48 (portion distal from the carrier structure 30 ) providing the papermaking fabric 10 with a relatively uniform second upper surface plane 74 (as illustrated in FIG. 3 ). In this manner each of the structuring elements 40 have a Z-direction height (h), measured from the upper surface plane 72 of the web contacting surface 64 of the carrier structure 30 .
  • the structuring elements may also vary in relation to one another in terms of height or width. Further, the height and width of a given line element need not be uniform along its entire length, but can vary depending on the method of manufacturing the element or according to the desired physical properties of the finished tissue web.
  • the structuring elements There are virtually an infinite number of shapes, sizes, spacing and orientations that may be chosen for the structuring elements.
  • the actual shapes, sizes, orientations, and spacing can be specified and manufactured by additive manufacturing processes based on the desired properties of the finished tissue web such as caliper, sheet bulk, surface smoothness and aesthetic appearance.
  • the improvement of the present invention is that the shapes, sizes, spacing, and orientations of the structuring element are such that they provide the finished tissue web with desirable physical properties, such as caliper, sheet bulk and surface smoothness, without negatively affecting drying of the tissue web.
  • the structuring elements are generally designed such that a sufficient amount of the nascent web is contacted by and molded into the elements, but the amount of the web that is effectively rendered impermeable because of its contact with the elements is minimized.
  • the shape of the elements may be modified such that the cross-sectional perimeter is less than 3.6 mm, such as less than about 3.0 mm, such as less than about 2.4 mm, such as less than about 2.0 mm, such as from about 1.4 to 3.6 mm, such as from about 1.6 to about 3.0 mm.
  • the aspect ratio may be modified to promote drying and impart the resulting web with the desired physical properties and aesthetic appearance.
  • optimal drying and physical properties of the tissue product may be obtained by using a through-air drying fabric having structuring elements with an aspect ratio, which is generally the ratio of the element height to the element width, from about 2:1 to 2:3, such as from 1.5:1 to about 1:1.
  • the carrier structure 30 comprises a pair of opposed major surfaces—a web contacting surface 64 from which the structuring elements 40 extend and a machine contacting surface 62 .
  • Machinery employed in a typical papermaking operation is well known in the art and may include, for example, vacuum pickup shoes, rollers, and drying cylinders.
  • the belt comprises a through-air drying fabric useful for transporting an embryonic tissue web across drying cylinders during the tissue manufacturing process.
  • the web contacting surface 64 supports the embryonic tissue web, while the opposite surface, the machine contacting surface 62 , contacts the through-air dryer.
  • the structuring element 40 is disposed on the web-contacting surface 64 for cooperating with, and structuring of, the wet fibrous web during manufacturing.
  • the web contacting surface 64 comprises a plurality of spaced apart three-dimensional elements 40 distributed across the web-contacting surface 64 of the carrier structure 30 such that the relative area of the carrier structure covered by the elements may be relatively high such as greater than about 28 percent, such as greater than about 30 percent and more preferably greater than about 32 percent, such as from about 28 to about 35 percent and more preferably from about 30 to about 32 percent, without negatively affecting drying of the nascent web.
  • elevated portions may be produced without negatively affecting drying of the nascent web.
  • the web-contacting surface 64 preferably comprises a plurality of continuous landing areas 60 .
  • the landing areas 60 are generally bounded by the elements 40 and coextensive with the upper surface plane 72 of the web contacting surface 64 .
  • Landing areas 60 are generally permeable to liquids and allow water to be removed from the cellulosic tissue web by the application of differential fluid pressure, by evaporative mechanisms, or both when drying air passes through the embryonic tissue web while on the papermaking belt 10 or a vacuum is applied through the belt 10 .
  • differential fluid pressure by evaporative mechanisms, or both when drying air passes through the embryonic tissue web while on the papermaking belt 10 or a vacuum is applied through the belt 10 .
  • the arrangement of elements and landing areas allow the molding of the embryonic web causing fibers to deflect in the z-direction and generate the caliper of, and patterns on the resulting tissue web.
  • the carrier structure 30 has two principle dimensions—a machine direction (“MD”), which is the direction within the plane of the belt 10 parallel to the principal direction of travel of the tissue web during manufacture and a cross-machine direction (“CD”), which is generally orthogonal to the machine direction.
  • MD machine direction
  • CD cross-machine direction
  • the carrier structure 30 is generally permeable to liquids and air.
  • the carrier structure is a woven fabric.
  • the carrier structure may be substantially planar or may have a three dimensional surface defined by ridges.
  • the carrier structure is a substantially planar woven fabric such as a multi-layered plain-woven fabric 30 having base warp yarns 32 interwoven with shute yarns 34 in a 1 ⁇ 1 plain weave pattern.
  • a suitable substantially planar woven fabric is disclosed in U.S. Pat. No.
  • the carrier structure comprises a substantially planar woven fabric wherein the plain-weave load-bearing layer is constructed so that the highest points of both the load-bearing shutes 34 and the load-bearing warps 32 are coplanar and coincident with the upper surface plane 72 of the web contacting surface 64 .
  • a plurality of structuring elements 40 that may, such as in the embodiments illustrated in FIGS. 1-3 , comprise a plurality of continuous line elements having a substantially rectangular cross-section, are disposed on the web-contacting surface 64 of the carrier structure 30 .
  • Each structuring element 40 has a first dimension in a first direction (x) in the plane of the top surface area, a second dimension in a second direction (y) in the plane of the top surface area, the first and second directions (x, y) being at right angles to each other.
  • the extent of the element 40 in the first direction (x) generally defines the element width (w).
  • the continuous element 40 further comprises a top surface 48 extending substantially along the second direction (y) and a pair of opposed sidewalls 45 , 47 extending in the z-direction and having a mean height (h). These dimensions being defined when the belt is in an uncompressed state.
  • the structuring elements 40 generally extend in the z-direction (generally orthogonal to both the machine direction and cross-machine direction) above the upper surface plane 72 of the web contacting surface 64 .
  • the elements 40 may have straight, parallel sidewalls 45 , 47 providing the structuring elements 40 with a width (w), and a height (h) and the elements 40 may be similarly sized.
  • the elements may have a Z-directional height greater than about 0.4 mm, such as greater than about 0.5 mm, and more preferably greater than about 0.6 mm, such as from about 0.4 to about 1.2 mm and more preferably from about 0.4 to about 0.8 mm.
  • the height of the elements is substantially similar and ranges from about 0.4 to about 1.2 mm and more preferably from about 0.4 to about 0.8 mm.
  • the structuring elements 40 may have a width (w), generally measured in the cross-machine direction (CD) across the widest portion of the element and parallel to the upper surface plane of the carrier structure, of 0.7 mm or less, such as less than about 0.6 mm, such as less than about 0.5 mm, such as from about 0.4 to 0.7 mm.
  • w width
  • CD cross-machine direction
  • the elements may be varied, it is generally preferred that the elements have a cross-sectional perimeter less than 3.6 mm, such as less than about 3.0 mm, such as less than about 2.4 mm, such as less than about 2.0 mm, such as from about 1.4 to 3.6 mm, such as from about 1.6 to about 3.0 mm. In other instances the elements have a height (h) and width (w) such that the aspect ratio is from about 2:1 to 2:3, such as from 1.5:1 to about 1:1.
  • the structuring elements 40 have planar sidewalls 45 , 47 such that the cross-section of the element has an overall square or rectangular shape.
  • the design element may have other cross-sectional shapes, such as a trapezoid or a parallelogram, which may also be useful in producing high bulk tissue products according to the present invention.
  • the structuring elements 40 preferably have planar sidewalls 45 , 47 and a square cross-section where the width (w) and height (h) are equal and are 0.7 mm or less, such as less than about 0.6 mm, such as less than about 0.5 mm, such as from about 0.4 to 0.7 mm.
  • the spacing and arrangement of the structuring elements relative to one another may vary depending on the desired tissue product properties and appearance.
  • a plurality of elements extend continuously throughout one dimension of the belt and each element in the plurality is spaced apart from the adjacent element.
  • the elements may be spaced apart across the entire cross-machine direction of the belt, may endlessly encircle the belt in the machine direction, or may run diagonally relative to the machine and cross-machine directions.
  • the directions of the elements alignments (machine direction, cross-machine direction, or diagonal) discussed above refer to the principal alignment of the elements.
  • the elements may have segments aligned at other directions, but aggregate to yield the particular alignment of the entire elements.
  • the elements are spaced apart from one another so as to define a landing area there-between.
  • the spacing of elements is such that the web maintains a relatively uniform density. This arrangement provides the benefits of improved web extensibility, increased sheet bulk, better softness, and a more pleasing texture.
  • the resulting sheet may have excessive pinholes and insufficient compression resistance and cross-machine direction physical properties, such as stretch, and be of poor quality. Further, tensile strength may be degraded if the span between elements greatly exceeds the fiber length. Conversely, if the spacing between adjacent elements is too small the tissue will not mold into the landing areas without rupturing the sheet, causing excessive sheet holes, poor strength, and poor paper quality.
  • the shape of the element may also be varied.
  • the elements are substantially sinusoidal and are arranged substantially parallel to one another such that none of the elements intersect one another.
  • the adjacent sidewalls of individual elements are equally spaced apart from one another.
  • the center-to-center spacing of design elements (also referred to herein as pitch or simply as p) may be greater than about 1.0 mm apart, such as from about 1.0 to about 20 mm apart and more preferably from about 2.0 to about 10 mm apart.
  • the continuous elements are spaced apart from one-another from about 2.5 to about 4.0 mm apart. This spacing will result in a tissue web which generates maximum caliper when made of conventional cellulosic fibers. Further, this arrangement provides a tissue web having three dimensional surface topography, yet relatively uniform density.
  • the continuous elements may occur as wave-like patterns that are arranged in-phase with one another such that the pitch (p) is approximately constant.
  • elements may form a wave pattern where adjacent elements are offset from one another. Regardless of the particular element pattern, or whether adjacent patterns are in or out of phase with one another, the elements are separated from one another by some minimal distance.
  • the distance between continuous elements is greater than 0.5 mm and in a particularly preferred embodiment greater than about 1.0 mm and still more preferably greater than about 2.0 mm such as from about 2.0 to about 6.0 mm and still more preferably from about 2.5 to about 4.0 mm.
  • the elements have an amplitude (A) and a wavelength (L).
  • the amplitude may range from about 2.0 to about 200 mm, in a particularly preferred embodiment from about 10 to about 40 mm and still more preferably from about 18 to about 22 mm.
  • the wavelength may range from about 20 to about 500 mm, in a particularly preferred embodiment from about 50 to about 200 mm and still more preferably from about 80 to about 120 mm.
  • the structuring elements are continuous the invention is not so limited. In other embodiments the elements may be discrete.
  • the discrete elements will be referred to herein as protuberances.
  • the protuberances are discrete and spaced apart from one another. Each protuberance is joined to a carrier structure and extends outwardly from the web contracting plane of thereof. In this manner the protuberances contact the tissue web during manufacture.
  • the protuberances may have a square horizontal and lateral (relative to the plane of the carrier structure) cross-sectional shape, however, the shape is not so limited.
  • the protuberance may have any number of different horizontal and lateral cross-sectional shapes.
  • the horizontal cross-section may have a rectangular, circular, oval, polygonal or hexagonal shape.
  • a particularly preferred protuberance has planar sidewalls which are generally perpendicular to the plane of the carrier structure.
  • the protuberances may have a tapered lateral cross-section formed by sides that converge to yield a protuberance having a base that is wider than the distal end.
  • the individual protuberances may be arranged in any number of different manners to create a decorative pattern.
  • protuberances are spaced and arranged in a non-random pattern so as to create a wave-like design.
  • spaced between the decorative patterns are landing areas that provide a visually distinctive interruption to the decorative pattern formed by the individual spaced apart protuberances.
  • the protuberances are spaced apart so as to form a visually distinctive curvilinear decorative element that extends substantially in the machine direction. Taken as a whole the discrete elements form a wave-like pattern.
  • the protuberances may be spaced and arranged so as to form a decorative figure, icon or shape such as a flower, heart, puppy, logo, trademark, word(s), and the like.
  • the design elements are spaced about the support structure and can be equally spaced or may be varied such that the density and the spacing distance may be varied amongst the design elements.
  • the density of the design elements can be varied to provide a relatively large or relatively small number of design elements on the web.
  • the design element density measured as the percentage of background surface covered by a design element, is from about 10 to about 35 percent and more preferably from about 20 to about 30 percent.
  • the spacing of the design elements can also be varied, for example, the design elements can be arranged in spaced apart rows. In addition, the distance between spaced apart rows and/or between the design elements within a single row can also be varied.
  • the plurality of protuberances defining a given design element may be spaced apart from one another so as to define landing areas there between.
  • the landing areas are generally bounded by the designs and coextensive with the top surface plane of the carrier structure. Landing areas are generally permeable to liquids and allow water to be removed from the cellulosic tissue web by the application of differential fluid pressure, by evaporative mechanisms, or both when drying air passes through the embryonic tissue web while on the papermaking belt or a vacuum is applied through the belt.
  • the elements may be formed from a polymeric material, or other material, applied and joined to the carrier structure in any suitable manner.
  • elements are formed by extruding, such as that disclosed in U.S. Pat. No. 5,939,008, the contents of which are incorporated herein by reference in a manner consistent with the present invention, or printing, such as that disclosed in U.S. Pat. No. 5,204,055, the contents of which are incorporated herein by reference in a manner consistent with the present invention, a polymeric material onto the carrier structure.
  • the design element may be produced, at least in some regions, by extruding or printing two or more polymeric materials.
  • the polymeric material may be silicone or polyurethane, or a combination thereof.
  • the papermaking fabrics of the present invention are particularly useful in making through-air dried tissue webs and products.
  • Through-air drying manufacturing processes are well known in the art and may be either creped through-air drying (CTAD) or uncreped through-air drying (UCTAD) processes.
  • CTAD creped through-air drying
  • UTAD uncreped through-air drying
  • the fabrics are useful in an UCTAD manufacturing process such as that described in U.S. Pat. No. 5,607,551.
  • a twin wire former having a papermaking headbox such as a layered headbox, injects or deposits a stream of an aqueous suspension of papermaking fibers onto a forming fabric positioned on a forming roll.
  • the forming fabric serves to support and carry the newly-formed wet web downstream in the process as the web is partially dewatered to a consistency of about 10 dry weight percent. Additional dewatering of the wet web can be carried out, such as by vacuum suction, while the wet web is supported by the forming fabric.
  • the wet web is then transferred from the forming fabric to a transfer fabric.
  • the transfer fabric can be traveling at a slower speed than the forming fabric in order to impart increased stretch into the web. This is commonly referred to as a “rush” transfer.
  • the transfer fabric can have a void volume that is equal to or less than that of the forming fabric.
  • the relative speed difference between the two fabrics can be from 0 to 60 percent, more specifically from about 15 to 45 percent. Transfer is preferably carried out with the assistance of a vacuum shoe such that the forming fabric and the transfer fabric simultaneously converge and diverge at the leading edge of the vacuum slot.
  • the web is then transferred from the transfer fabric to the through-air drying fabric with the aid of a vacuum transfer roll or a vacuum transfer shoe, optionally again using a fixed gap transfer as previously described.
  • the through-air drying fabric can be traveling at about the same speed or a different speed relative to the transfer fabric. If desired, the through-air drying fabric can be run at a slower speed to further enhance stretch. Transfer can be carried out with vacuum assistance to ensure deformation of the sheet to conform to the through-air drying fabric, thus yielding desired bulk and texture.
  • the side of the web contacting the through-air drying fabric is typically referred to as the “fabric side” of the paper web.
  • the fabric side of the paper web as described above, may have a shape that conforms to the surface of the through-air drying fabric after the paper web is dried in the throughdryer.
  • the opposite side of the paper web is typically referred to as the “air side.”
  • the level of vacuum used for the web transfers can be from about 3 to about 15 inches of mercury (75 to about 380 millimeters of mercury), preferably about 5 inches (125 millimeters) of mercury.
  • the vacuum shoe (negative pressure) can be supplemented or replaced by the use of positive pressure from the opposite side of the web to blow the web onto the next fabric in addition to or as a replacement for sucking it onto the next fabric with vacuum.
  • a vacuum roll or rolls can be used to replace the vacuum shoe(s).
  • the web While supported by the through-air drying fabric, the web is dried to a consistency of about 94 percent or greater by the throughdryer and thereafter transferred to a carrier fabric.
  • the dried basesheet is transported to the reel using the carrier fabric.
  • Suitable carrier fabrics for this purpose are Albany International 84M or 94M and Asten 959 or 937, all of which are relatively smooth fabrics having a fine pattern.
  • the base sheet may be subjected to additional converting steps such as reel calendering, off-line calendering or embossing.
  • Fabric images were acquired and analyzed using a Keyence VHX-5000 Digital Microscope (Keyence Corporation, Osaka, Japan) equipped with VHX-5000 Communication Software Ver. 1.5.1.1.
  • the lens is an ultra-small, high performance zoom lens, VH-Z20R/Z20T.
  • Structuring element dimensions were measured using the Keyence software. For example, element height was measured by first drawing a line approximately along the top surface plane of the carrier structure with the line tangent to at least two filaments forming the web contacting surface of the carrier structure. A second parallel line has been drawn approximately along the top surface plane of the structuring element with the line tangent to the top surface of the element. With the two lines drawn, each corresponding to a surface plane of the fabric, the digital microscope software was instructed to calculate the distances between the planes.
  • Element width was measured by determining the widest portion of the element and using the software to draw a first line through the widest point, the line being substantially parallel to the web contacting surface plane of the carrier structure. A pair of lines were then drawn perpendicular to the first line tangent to the point that the first line intersected the element, the digital microscope software was instructed to calculate the distances between the pair of lines.
  • the surface area of the carrier structure covered by the structuring elements was measured using a Keyence Microscope and image analysis software described above.
  • the sample of carrier structure for measurement should be an undamaged, flat fabric swatch approximately 3 ⁇ 3 inches in size.
  • FIG. 6 illustrates the output of the foregoing measurement method. The measurement was repeated for 3 distinct areas of the fabric sample and an arithmetic average Area Ratio Percent of the measurements was reported as the Area Ratio Percent.
  • the base sheets were produced from a furnish comprising northern softwood kraft and eucalyptus kraft using a layered headbox fed by three stock chests such that the webs having three layers (two outer layers and a middle layer) were formed.
  • the two outer layers comprised eucalyptus (each layer comprising 30 percent weight by total weight of the web) and the middle layer comprised softwood and eucalyptus.
  • the amount of softwood and eucalyptus kraft in the middle layer was maintained for all inventive samples—the middle layer comprised 29 percent (by total weight of the web) softwood and 11 percent (by total weight of the web) eucalyptus.
  • Strength was controlled via the addition of starch and/or by refining the softwood furnish.
  • the tissue web was formed on a Voith Fabrics TissueForm V forming fabric, vacuum dewatered to a consistency ranging from about 30 to about 33 percent and then subjected to rush transfer when transferred to the transfer fabric.
  • the transfer fabric was the fabric described as “Fred” in U.S. Pat. No. 7,611,607 (commercially available from Voith Fabrics, Appleton, Wis.).
  • the web was then transferred to a through-air drying fabric comprising a printed silicone pattern disposed on the sheet contacting side.
  • the silicone formed a wave-like pattern on the sheet contacting side of the fabric.
  • Inventive papermaking fabrics are shown in FIGS. 4 and 5 .
  • the pattern properties of the various fabrics are summarized in Table 1, below.
  • the tissue web was dried to a final consistency of about 98 percent by passing the web over first and second through-air dryers while supported by the through-air drying fabric.
  • the exhaust temperature of the first through-air dryer was controlled to about 300° F. It was discovered that through-air drying fabrics having narrower structuring elements, which are impermeable to air and water, were able to produce tissue webs having a sufficient degree of smooth flat surfaces without negatively affecting drying.
  • the plot shown in FIGS. 7 and 8 shows the heat transfer coefficient (shown in the equation below) calculated over the first through-air dryer for each fabric of the present example.
  • the percent of coverage area was varied by altering the spacing of the elements relative to one another.
  • the structuring elements had a substantially square cross-sectional shape and an aspect ratio of 1:1. It was expected that the main factor affecting heat transfer coefficient would be the relative area of the fabric occluded by the elements and that for every one percent increase in coverage there would be a one percent reduction in heat transfer. It was surprisingly discovered however, that the dimensions of the elements was a dominant factor affecting drying rate, and that using elements having a width of 0.7 mm or less the coverage area could be increased with very little adverse effect on drying rate.
  • the drying benefit may also be determined by calculating the Drying Loss Factor that compares the loss in drying rate measured for a given fabric having impermeable structuring elements (DR occluded ) to the drying rate of a fabric devoid of such elements (DR open ):
  • FIG. 9 shows the Drying loss factor measured for the fabrics of the present example compared to commercially available through-air drying fabric that is void of structuring elements (designated as T-1205-2 and described previously in U.S. Pat. No. 8,500,955).
  • the Drying Loss Factor increases as the width of the structuring element increases, however, for elements having a width of 0.8 Drying Loss Factor increases more rapidly compared to elements having a width of 0.7 mm or less.
  • the present invention provides a papermaking fabric comprising a woven carrier structure having a machine and a cross-machine direction and a first side with a plurality of substantially machine direction oriented structuring elements disposed thereon, the structuring elements having a cross-sectional height and width, wherein the width is 0.7 mm or less and the aspect ratio is from about 2:1 to about 2:3
  • the present invention provides the papermaking fabric of the first embodiment wherein the structuring elements are continuous line elements and have a polygonal cross-sectional shape.
  • the present invention provides the papermaking fabric of the first or the second embodiments wherein the structuring elements have a cross-sectional shape selected from the group consisting of a trapezoid, a parallelogram, a rectangle, a rhombus, and a square.
  • the present invention provides the papermaking fabric of the first through the third embodiments wherein the structuring elements have a height from about 0.4 to 0.7 mm.
  • the present invention provides the papermaking fabric of the first through the fourth embodiments wherein the structuring elements have a perimeter from about 1.6 to about 2.4 mm.
  • the present invention provides the papermaking fabric of the first through the fifth embodiments wherein the structuring elements are impermeable to air and water and comprise silicone or polyurethane.
  • the present invention provides the papermaking fabric of the first through the sixth embodiments wherein the structuring elements cover from about 28 to about 32 percent of the surface area of the first side of the carrier structure.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Paper (AREA)
  • Sanitary Thin Papers (AREA)
  • Nonwoven Fabrics (AREA)
  • Absorbent Articles And Supports Therefor (AREA)
  • Laminated Bodies (AREA)
US16/612,177 2017-05-22 2018-05-21 Structured papermaking fabric Abandoned US20200270812A1 (en)

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PCT/US2018/033611 WO2018217603A1 (fr) 2017-05-22 2018-05-21 Tissu structuré pour la fabrication de papier
US16/612,177 US20200270812A1 (en) 2017-05-22 2018-05-21 Structured papermaking fabric

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GB2577823B (en) 2023-02-15
US20190299562A1 (en) 2019-10-03
AU2018273337B2 (en) 2022-07-28
KR20200011429A (ko) 2020-02-03
AU2018273341A1 (en) 2019-12-05
AU2018273341B2 (en) 2022-07-28
MX2019012901A (es) 2019-12-16
KR20200010276A (ko) 2020-01-30
GB2577220A (en) 2020-03-18
MX2019012663A (es) 2020-01-21
GB2577823A (en) 2020-04-08
GB201917983D0 (en) 2020-01-22
WO2018217599A1 (fr) 2018-11-29
US20200094513A1 (en) 2020-03-26
WO2018217603A1 (fr) 2018-11-29
US10538053B2 (en) 2020-01-21
KR102577464B1 (ko) 2023-09-12

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