US3716449A - Method and apparatus for forming a non-woven fibrous web from a foamed fiber furnish - Google Patents

Method and apparatus for forming a non-woven fibrous web from a foamed fiber furnish Download PDF

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US3716449A
US3716449A US00091104A US3716449DA US3716449A US 3716449 A US3716449 A US 3716449A US 00091104 A US00091104 A US 00091104A US 3716449D A US3716449D A US 3716449DA US 3716449 A US3716449 A US 3716449A
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foam
web
fibers
surfactant
containing water
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A Gatward
B Radvan
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Arjo Wiggins Ltd
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Wiggins Teape Research and Development Ltd
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    • 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
    • D21F11/002—Processes for making continuous lengths of paper, or of cardboard, or of wet web for fibre board production, on paper-making machines by using a foamed suspension

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  • Att0rneylmirie and Smiley ABSTRACT Improvements are afforded in method and apparatus for making non-woven fibrous webs including paper from a foamed aqueous furnish containing a surfactant in that the foam acquires and has imparted thereto physical characteristics as regards attainment of such a highly emulsified state that the bubbles are scarcely visible to the naked eye, as regards viscosity build-up of the foam to at least 22 seconds as measured with a Ford Cup Type B-4 and as regards the specific gravity being no greater than 0.35.
  • Other improvements pertain to vortical mixing in the production of the foam, to combining the method and apparatus with conventional methods and apparatus and to handling the surfactant-containing water when in the foamed furnish and likewise as drained from the formed web.
  • the invention relates to the forming of non-woven fibrous webs and in particular to the production of such webs utilizing a liquid suspending medium in the form of an aqueous foam in which the fibers are dispersed and suspended and from which they are formed into a layer on the wire of a paper-making machine, which layer is then collapsed and drained to form the web.
  • a less common known method of producing relatively uniform dispersions of fibers in a liquid medium, and hence substantially uniform fibrous webs is that by which the fibers are dispersed in a liquid medium of high viscosity, such as aqueous solutions of sugar, or of natural gums.
  • a liquid medium of high viscosity such as aqueous solutions of sugar, or of natural gums.
  • fibers to be formed into a web are dispersed in foamed surfactant-containing water which has been brought to such a state of extreme emulsification of air therein that the inadequacies of prior proposals for the employment of foam in a web-forming operation have been successfully over- 'come.
  • a thick, viscous emulsion is formed bydispersing air in an aqueous solution of an emulsifying agent in the form of bubbles, so small that even the largest is barely visible to the naked eye.
  • the number average bubble diameter as determined in the manner hereinafter described, should be no greater than about 0.2 mm.
  • the foam should contain at least 65 percent of air or, in other words, the specific gravity of the foam should not be greater than 0.35. Moreover, the viscosity of the foam emulsion should not be less than 22 seconds as measured at 20 C using Ford Cup Type 8-4 in the manner called for by British Standard 1733.
  • the vortical foaming action is continued until the desired emulsification of air is attained in the region adjacent the base of the vortex from which the foam is taken for deposit on the webforming foraminous surface of the web-forming machine;
  • the fibers to be formed into the web are dispersed in the foam so as to be present in the highly emulsified foam taken to the headbox of the web-forming machine.
  • features of the invention relate to the sources of fibers and of surfactant-containing water and their introduction, preferably concurrently from separate sources, into the foam-producing means. Still other features relate to the manner of reutilizing the surfactantcontaining water that drains from the foam when the foam collapses to form a fibrous web on the wire or other foraminous support of the webiorming machine and its reintroduction directly into the foam-producing means, said reintroduction preferably being controlled responsive to the liquid level occurring in the foamproducing means.
  • surfactantcontaining liquid drained from the web during its formation is returned to the foam-producing means partly substantially fiber-free and partly with fibers dispersed thereinv
  • Another feature of the invention relates to balancing introduction of fresh water in a thickened fiber dispersion in relation to the dryness of the web that is removed from the web-forming machine whereby maximum conservation of surfactant may be afforded.
  • Still other feature relate to apparatus.
  • apparatus which comprises vortion with conventional tex type foam-producing means so combined with webforming means that foamed fiber furnish deposited on the wire of the web-forming machine is taken from adjacent the base of the vortex that occurs in vortical type foam-producing means.
  • Other features relate to the apparatus that is employed in utilizing and pumping surfactant-containing water drained from the web.
  • Materials formed in this manner have the advantage of very uniform distribution of fibers over their area, as compared with those obtained by methods known heretofore, especially if the fibers are long or liable to clump and flocculate together.
  • Another advantage is that the suspension of fibers in an emulsion of air can be obtained at a consistency, that is ratio of fiber to liquid, substantially higher than is practicable with the previously known methods.
  • Yet another advantage is that the deposition and drainage of the suspensions in order to form a fibrous web may be accomplished using currently available papermaking machinery with only slight' I .modifications.
  • new machinery can be constructed to form fibrous webs from the suspension, which machinery is substantially more simple in design and operation than is conventional paper-making machinery.
  • the chemical nature of the emulsifying agent used is found not to be critical provided that it has an emulsifying power sufficient to produce a thick, viscous emulsion of very small air bubbles.
  • the emulsifying agent may be anionic, cationic, or non-ionic and it has been found that proprietary surfaceactive agents such as that sold under the name ACE" liquid, this being an anionic substance, by Industrial Soaps Ltd., that sold as TEXOFOR FN 15, a non-ionic substance, by Glover Chemicals Ltd., and that sold as AMINE Pb 19, a cationic substance, by Float-Ore Ltd., are allsuitable for makingthe required viscous emulsion.
  • Another nonionic emulsifying agent that has been used is octylphenoxypolyethoxy ethanol.
  • One of the most useful emulsifying agents is commercial grade dodecyl benzene sulfonate.
  • Soapflakes may also be used. Itis, however, to be understood that the emulsifying agent used may depend on the properties which it may impart to a finished fibrous material.
  • the emulsifying agent is mixed with water and the use of hot water may be an advantage in preparing the emulsion but hot water is not essential.
  • the emulsion may be prepared in any suitable kind of emulsifying apparatus subject to the proviso that the apparatus is capable of emulsifying air in the form of very small bubbles, the largest of which is barely visible to the naked eye, in the liquid and of maintaining this dispersion. In general, simply stirring the liquid does not produce a sufficiently vigorous emulsifying action.
  • the concentration of the emulsifying agent be sufficiently high and that the action of the emulsifying apparatus be sufficiently vigorous to produce a finely dispersed emulsion of air in water. .It will be understood that if the concentration of the emulsifying agent is too low only a thin fluid emulsion will be obtained which will soon separate into a liquid layer and a coarse froth, and that if the concentration is sufficiently high but the emulsifying action of the apparatus is insufficiently vigorous a thick, viscous emulsion may not form at all.
  • a satisfactory emulsion is one which has a viscosity greater than 22 seconds, when measured by Ford Cup Type B-4 according to British Standard 1733, and the air content of the foam is not less than 65 percent by volume, that is, the foam has a specific gravity not greater than 0.35, provided that the largest bubble is barely visible to the naked eye.
  • the reference is to the viscosity of foam produced in the absence of the fibers, but under conditions corresponding precisely with the conditions that prevail when producing the foamed furnish, the reason being that the presence of the fibers interferes with obtaining an accurate measurement of viscosity.
  • the extent to which the largest bubble may be visible to the naked eye may be determined by examination of the foamed furnish.
  • the number average diameter of the bubbles in a foam is determined by placing a drop of foam produced in the absence of fibers but produced under conditions precisely corresponding with those that prevail during the formation of the foamed furnish on a microscope slide.
  • Photomicrographs are taken at 100 magnification at successive intervals of 1 minute. The number of bubbles visible in the field of view on each photomicrograph is counted. It is found that the number of visible bubbles appears to decrease exponentially with time to a constant value, that is:
  • the value of No is determined graphically by plotting log (N-X) against T, value of X being adjusted until the graph forms the best possible straight line. Extrapolating the graph to T 0, namely, the value of No at the intersection of the line with the log (N-X) axis, one may obtain No, the supposed number of bubbles at the time when the sample was taken. Dividing the area of the field of view by No, one obtains the number average area per bubble, and hence the number average bubble diameter.
  • the preferred method of effecting dispersion of fibers in the liquid emulsion is to transfer the prepared liquid medium from the apparatus in which it is prepared to another apparatus and there to add to it and to disperse in it a suspension of fibers in a small quantity of water.
  • the prepared, substantially uniform, suspension of fibers flows or is pumped to and deposited as a layer on the moving wire of a Fourdriner type paper-making machine, ,or the surface of a cylinder type board machine, or the web-forming area of other suitable forms of apparatus known in the art of paper making.
  • a Fourdriner type paper-making machine or the surface of a cylinder type board machine, or the web-forming area of other suitable forms of apparatus known in the art of paper making.
  • While spreading of the suspension of fibers on the wire and the collapsing and draining of the resulting layer of emulsion can be effected by any of the methods known in the art, the spreading is may be permitted by a sensing device that is responsive to liquid level in the foam-producing means.
  • Fiber may be introduced separately either dry or in the form of a thickened slurry.
  • the fresh water content of the slurry is controlled in balanced relation to the water content of the web as it is removed from the web-forming machinei
  • Part of the drained water may be mixed with edge trim or other fibers and separately introduced into the foam-producing means.
  • Erratic pumping action 00- casioned by the presence of foam in the surfactant-con preferably effected by the use of an enclosed flow spreader of relatively low volume, for example, of the kind described in British Pat. No. 1,075,103, and is then collapsed by means of suction applied to the underside of the wire, after which the formed web is handled as in a usual paper-making process.
  • Surfactant-containing water drained from-the foam during formation on the foraminous support of the web-forming machine is effectively reutilized and at least a part thereof is returned directly to the foamproducing means as, for example, so as to be introduced adjacent the mouth of the vortex of a vortical foam-producing unit, and in order to control the consistency of the foamed fibers furnish its introduction taining water is successfully overcome preferably by the employment of a positive displacement pump whose capacity preferably is greatly increased in a novel way by sucking additional liquid into a jet stream of the output of said pump.
  • An advantage of the process according to the invention is that multilayer sheets may be formed without difficulty.
  • Several layers of fibrous suspension may be collapsed and drained consecutively upon an already formed mat, that is, by using several headboxes suspended above and along part of the length of the wire. The position of each headbox would coincide with a bank of suction boxes positioned on the underside of the wire.
  • this would necessitate large quantities of water from the second and successive headboxes being drained through the previously formed mats, resulting in poor formation.
  • little liquid has to be drained through the previously formed mats and collapsing and draining of the emulsion does not unduly disturb the formation. Because of the high viscosity of the foamed suspension its drainage may be accelerated at a more controlled rate, namely, on a larger number of suction boxes, without the disadvantage of the stock flocculating.
  • FIG. I is a schematic side elevation of one type of system embodying features of this invention wherein a foam emulsion of the character aforesaid is produced and utilized according to this invention in the production of a non-woven web;
  • FIG. 2 is a side elevation of a preferred foam-producing means that is employed according to this invention for producing a fibrous foam suspension, the foamproducing means being shown on a larger scale as compared with the showing in FIG. 1;
  • FIG. 3 is a plan view of the foam-producing means shown in FIG. 2;
  • FIG. 4 is a detail sectional elevation through a foamproducing means of the type shown in FIGS. 2 and 3;
  • FIG. 5 is a side elevation, largely schematic, of the web-forming means wherein the foamed fiber furnish is formed into a web on the wet end of a machine of the Fourdrinier type, this portion of the system being shown in greater detail than the showing in FIG. 1;
  • FIG. 6 is a detail view on a larger scale of the headbox end of the Fourdrinier machine shown in FIG. 5;
  • FIG. 7 is an enlarged view of the positive displacement type pump which preferably is used at different locations in the system for pumping surfactant-containing water.
  • FIG. 8 is a block flow diagram showing an overall system which may be selectively operated in conventional formation of a non-woven web or utilizing aqueous foam.
  • the fiber to be formed into the non-woven web is first beaten with water and water-containing stock after thickening is mixed with water containing surfactant to form a dilute fiber suspension wherein the fibers are entrained in a foam emulsion having the properties and characteristics hereinabove mentioned.
  • the fiber which is introduced into the system is beaten or otherwise refined in a conventional beater 10, such as a Hollander beater, to form a stock consistency at about 4 percent by weight based on bone dry fiber.
  • the stock is dropped by the line 11 controlled by the valve 12 to the machine chest 13 where it is held so as to provide bulk storage for the system, the fiber being kept uniformly in suspension as by the use of a conventional agitator 14.
  • the stock is directed by the line 15 containing the pump 16 to the constant headbox 17 which maintains its desired head by an overflow over a weir back into the chest 13 via line 18.
  • the stock in the headbox 17 is passed through a conventional refiner l9 and back into the headbox from which it finally flows at a constant head by line 20 into the thickener 21.
  • the thickener serves to de-water the stock to an extent which facilitates reuse of surfactant-containing liquid by balancing the amount of liquid entering the system with that removed from the system whereby surfactant containing water drained from the web during its formation on the web-forming machine may be conserved and reused.
  • the consistency of the stock as it leaves the thickener is usually between 12 and 20 percent by weight based on bone dry fiber, but should be sufficiently high to minimize the input of fresh water into the system, depending upon the dryness of the web that is removed from the web-forming step prior to drying.
  • Water extracted from the stock in the thickener 21 is removed through the drain line 22 and may either go to drain or re-directed into mill back-water for reuse in the initial beating step.
  • the foam-producing means comprises a plurality of vortical mixing units arranged for sequential foam production and withdrawal of foamed furnish in the manner to be described.
  • the foam-producing means comprises a succession of open top'compartments A, B, C and D.
  • Each of compartments A, C and D contains two vortical foam-producing units. Two are shown in each compartment and, while there are four compartments, this particular arrangement is not essential in the practice of this invention.
  • the thickened stock from thickener 21 and the supply of surfactant-containing water from sources to be described are shown as being introduced into compartment A so that the foaming and the fiber dispersion occur simultaneously in this compartment.
  • the surfactant-containing water may be introduced 5 into compartment A and the thickened stock may be introduced into compartment C whereby the foam is initially produced to a substantial extent in the absence of the fiber and the production of the foam is completed while being blended with the fiber stock.
  • the vortical foaming unit which is preferably employed in the practice of this invention is, as aforesaid, a modification of foaming equipment designed for use in froth-type mineral separation by the Denver Equipment Co.
  • the modified vortical unit which is preferably employed in the practice of this invention effects vortical mixing under conditions such that the coarse bubbles rise to the surface without overflowing and with reintroduction into the vortex along with such air as may be necessary to provide the desired specific gravity so as to be further emulsified at the foot of the vortex; and when foam is taken from the foam-producing means it is taken froma region adjacent the base of the vortex of one of the vortical foaming units immediately after the emulsifying action of the impeller means at the base of the vortex by which the air is caused to be emulsified in the form of minute bubbles.
  • Each of the vortical foaming units comprises a bladed impeller 24 which is rotated at a suitable speed such as from 300 to 500 rpm. by means of the driven shaft 25 which rotates in bearings mounted within the housing 26.
  • the impeller or rotor 24 is interposed between the floor 27 of the foaming unit and the stator 28 and there is upstanding from the stator 28 a collar 29 on the first two units only.
  • the distance between the impeller 24 and stator 28 is chosen so that the fluid passing therebetween is subjected to a high rate of shear. In practice this distance is in the range 0.010 to 0.125 inch.
  • the fiber to water consistency in ordinary practice is about I to 2 percent and the liquid level is substantially above the upper extremity of the collar 29.
  • the foam produced in controls the liquid level in compartment A into comcompartment A flows over the top of weir 30 which 5 line 31 and return it into the vortex of the vortical foaming unit at the inlet 32 of each unit in compartment A to be further acted upon to emulsify air therein.
  • the foamed furnish flows under baffle 33 into compartment C in which there are two vortical foaming units, indicated generally by the reference character 34, whose construction is the same as that of the units in compartment A except for the omission of the collar 29 and inlet 32.
  • the vortical units serve to further emuls'ify the air so as to reduce the bubble size and, again, such coarse bubbles as there may be tend to rise to the surface and become sucked into the vortex again for further emulsification.
  • the foamed fiber furnish In flowing from compartment C to compartment D the foamed fiber furnish passes through apertures 35 which are disposed below the level maintained in compartment C, with the result that coarse bubbles in compartment C at the surface are not transferred to compartment D and only the more minutely emulsified bubbles pass into compartment D through the apertures 35.
  • compartment D there is another pair of vortical foaming units, indicated generally by the reference character 36, which are identical in construction and operation as compared with the units contained in compartment C.
  • compartment D such coarse bubbles as there may be again rise to the surface where they are recycled into the vortex for further emulsification and the foam is taken from the foam-producing means by the outlet conduit 37.
  • Baffles 38 assist in maximizing the emulsified characteristics of the foamed furnish as it is withdrawn through the outlet conduit 37.
  • the fineness of the bubble size of the emulsified air may vary somewhat responsive to different rates of rotation of the impeller in the vortical foaming units. It is well,-therefore, before instituting a commercial run to make adjustments in the rotational speed of the impellers in the respective vortical foaming units in order to determine the most effective rotational speed for the impeller conditions otherwise prevailing during the operation in question.
  • the foam is of the highly viscous character hereinabove mentioned wherein the individual bubbles are scarcely I visible to the naked eye.
  • the foam is taken by the conduit 37, controlled by the-valve 39 to the headbox 40' of the Fourdrinier type web-forming machine, as shown in FIG. 1 and in greater detail in FIGS. 5 and 6.
  • the headbox 40 may be provided with a simple open type Vee box and may be provided with a slice of known design.
  • the water content will be less than in the normal paper-making process, typically percent instead of 82 percent (that is 25 percent instead of 18 percent by weight based on bone dry fiber), corresponding with the water content of the thickened pulp which is introduced into the foam-producing means and commingled with the surfactant-containing water to make the foam.
  • the thickened pulp introduced into the foam-producing means should be dewatered at least to such an extent that nearly all of the surfactant-containing backwater may be returned to be commingled therewith, and only very little of the said back-water needs to be disposed of. If the pulp is dewatered to a sufficient extent, no back-water needs to be disposed of, and the system is then balanced.
  • the vacuum maintained in the vacuum boxes 43 and 45 is provided by a conventional vacuum pump 47.
  • Surfactant-containing liquid from the wet vacuum box 43 disposed closest to the breast roll 42 is removed therefrom by the line 48 under the influence of the applied vacuum to a separator tank 49 wherein the liquid becomes separated from air and the air is taken into the vacuum pump 47 by the line 50 from which it is discharged into the atmosphere.
  • Surfactant-containing water is directed from the bottom of the tank 49 to the pump 51 by which it is pumped by the line 52 to the back-water tank 53.
  • the pumping of water containing surfactant in a quantity adapted to produce a viscous foam presents a special problem inasmuch as a conventional centrifugal pump is not adapted to handle liquid that contains air. Accordingly, in order that the surfactant-containing water may be effectively pumped a special type of positive displacement pump is employed.
  • a pump which is commercially known as type F Mono pump has been found to be suitable.
  • the pump 51 is a pump of the positive displacement type wherein, as shown in detail in FIG. 7, the rotation of the rotatable sinusoidal part 54 effects positive displacement pumping to produce a continuous unfluctuating stream.
  • the exit of the pump 51 is provided with a jet 55 which creates in the surrounding chamber 55A a suction imposed on line 56 which communicates with the other two wet vacuum boxes 43. ln this manner the relatively small capacity positive displacement pump is used so as to greatly increase its capacity for withdrawing surfactant-containing water from the wet boxes 43 and directing the water to the back-water tank 53.
  • the drained water which during travel of the wire drains therefrom in the region of the table rolls 41 and likewise in the region of the table rolls 44 is collected by the collector 57 from which it drains to pump 58 which pumps the surfactant-containing water by the line 59 to the back-water tank 53.
  • Surfactant-containing water is directed from tank 53 to compartment A of the foam-producing means by line 88, the amount being controlled by passage through the pump 89.
  • a sensing device 1 which is responsive to liquid level in compartment D of the foam-producing means 23 regulates the speed of operation of .the pump 89 so as to maintain the level in compartment D substantially constant. When make-up sur factant is needed it is metered into compartment A of the foam-producing means 23.
  • Vacuum provided by the vacuum pump 47 also communicates with the separator tank 60 into which surfactant-containing water is taken from dry vacuum boxes 45 by the line 61.
  • the surfactant-containing water from the bottom of the tank 60 is pumped by the pump 61, which is of the same type as the pump 51 which has previously been described. Part of the water is pumped directly through the pump 61 and thence to a jet in the jet region 62 which serves to suck the balance of the water from bank 60into the stream being pumped.
  • the surfactant-containing water so propelled is directed by the line 63 so as to go into the hogpit 64.
  • the hogpit also normally receives the surplus trim width of the web and during any wet end break any such web material also falls into the hogpit wherein it is slushed by means of conventional agitating means such as the agitator 65.
  • the slushed fiber in the hogpit is maintained at a consistencywhich is desired for being pumped by pump 66 and line 67 into the foam-producing means 23.
  • the pump 66 again is of the positive displacement type in order to effectively pump the fibers slushed with surfactant-containing water back into the foam-producing means.
  • a vacuum box 68 preferably is installed to extract the moisture from the interstices of the wire and any such collected surfactant-containing water is directed by line 69, which communicates with the line 61 leading to the separator tank 60, and any such liquid eventually goes into the hogpit.
  • water sprays may be used for washing the wire and, in order that fresh water may not be introduced into the system via the wire, a further vacuum box 70 is applied to the wire immediately in front of the breast roll and fresh water discharged therefrom is allowed to go to drain along with the wash water from water sprays 71 which is collected by the collector 72 and directed to the drain 73.
  • EXAMPLE 1 A web of filter paper grade was produced as above described. The furnish consisted of 50 percent bleached kraft, 25 percent sulfite and 25 percent cotton linters. The fibers were beaten and stored and after thickening as aforesaid were supplied to the foamproducing means at a consistency level of about 1 percent. The viscosity of the foam was 23 seconds. Its specific gravity was 0.3 and the number average diameter of the bubbles was less than 0.2 mm. The take-off moisture for the web was 73 percent, or 27 percent dry. The suction maintained in the suction boxes was about 10 inches Hg and that in the suction couch roll about l4 inches Hg.
  • the surfactant solution fed into the mixing means contained about 0.2 percent ofoctylphenoxypolyethoxy ethanol as the emulsifying surfactant.
  • the weight of the finished paper was approximately 120 g/sq.m. and it was formed into a web about 84 inches wide at the rate of about ft. per minute.
  • the mean residence time in association with each pair of vortical forming units was about 60 seconds.
  • the fiber forma- EXAMPLE 2 Paper-making stock was prepared by known methods by disintegrating cotton linter fibers in water and heating to 18 Schopper-Riegler. The stock was treated in the normal way with a wet strength resin, that used being 2 percent melamine formaldehyde by weight of fiber.
  • An emulsion of air in water was prepared by continuously pumping a 0.2 percent by weight solution of TEXOFOR FN l5 (a polyoxyalkylene condensate) in water through a modified Denver flotation cell of the kind hereinabove described at such a rate that the mean residence time in the cell was 15 seconds.
  • the admission of air to the impeller of the cell was restricted so that little coarse froth formed at the surface of the emulsion and was not allowed to overflow into the launder of the cell in the manner used in the froth flotation process.
  • the emulsion and the prepared stock were taken pumped into another Denver cell at such rates of flow that the mean residence time was 45 seconds and the proportion of fiber to water in the suspension was 2 parts by weight of fiber to 100 parts of water.
  • the admission of air to the cell was restricted so that little of the coarse top froth was formed and the suspension did not overflow into the launder of the cell.
  • the specific gravity of the suspension was 0.3 and the viscosity and bubble size were substantially as in Example 1.
  • the suspension was pumped from the bottom of the second cell adjacent the base of the vortex maintained in the cell and spread and deposited in a layer on the wire of a Fourdrinier type paper-making machine through a V-shaped nozzle of the kind described in British Pat. No. l,075,l03, the thickness of the layer of suspension being approximately 1% cm.
  • the V-shaped nozzle was suspended over the wire at a position such that the suspension was deposited on the wire directly above the suction boxes and on passage over the surfaces of the suction boxes the layer collapsed and drained to form a web of fiber of a substance of I g/sq. cm.
  • the suction in the boxes was approximately 1% to 3 inches Hg and that in the suction couch wasl 2 to 14 inches Hg.
  • the fibrous web was then transferred from the wire to the succeeding sections of the paper-making machine in the normal manner.
  • the liquid and froth collected from the suction boxes was largely separated from the air in a cyclone type separator of known kind.
  • the air was exhausted by a wet vacuum pump and the separated liquid and froth were returned to the Denver cell.
  • the uniformity of the resulting material was much greater than that of the usual material made from similar fibrous stock with the resulting advantage of more uniform distribution of the size of open pores in the material, and a superior filtering performance.
  • Example 3 The process followed was that of Example 2 but the stock consisted of 67 percent of free beaten sulfite pulp and 33 percent of an artificial latex such as is referred to in British Pat. specification No. 920.848.
  • the latex was added to the suspension in the second Denver type cell.
  • the web formed had a substance of 40 g/sqm. and the proportion of latex retained in the web was 85 percent to 90 percent as compared with 70 percent retained when a web is made by the usual known papermaking processes.
  • a suspension prepared inaccordance with the invention there can be obtained an increased retention of loadings and other additives within the fibrous web.
  • EXAMPLE 4 Cotton linter stock as in Example 2 had added to it in the beater a proportion of percent Terylene fibers 1 inch long and 1S denier. The stock was then pumped continuously through a thickener into a modified hydrapulper dispersing machine having a vortical mixing action very similar to that hereinabove described as produced when using the modified Denver cell, the hydrapulper screen having been removed. In the hydrapulper the furnish was dilutedto a consistency of 1 percent and it had a proportion of 0.2 percent by weight of liquid of TEXOFOR FN added to it.
  • a further feature of this invention resides in using in combination with a Fourdrinier type machine or other web-forming machine apparatus which may be selectively employed either for the production of paper or other non-woven web material in the conventional manner or for utilizing fibers which have been dispersed in foam that is fed to the headbox of the webforrning machine.
  • Such apparatus combination is illustrated in the block flow diagram of FIG. 8. In this flow diagram the operating components have' been indicated generally.
  • Means for preparing a fiber stock suspension is indicated at 74 and prepared stock is transferred to the thick stock storage means 75.
  • the wet end of a paperor other web-forming machine is indicated at 76.
  • the thick stock from storage means 75 is directed through the mixing means 77 wherein the furnish of desired dilution is produced that is fed into the headbox of the webforming machine.
  • Transfer of the thick stock to the mixing stage is controlled by valve 78 and transfer of the furnish to the headbox of the web-forming machine is controlled by valve 79.
  • Water drained from the web during its formation may be directed to the back-water tank 80 so that it may be fed back into the mixing stage 77.
  • the flow of water into the back-water tank is controlled by the valve 81.
  • the valves 78, 79 and 81 are open and the valves 82, 83 and 84 are closed.
  • valves 82, 83 and 84 are opened and the valves 78, 79 and 81 are closed.
  • the valve 82 is open, thick stock from the storage means 75 is transferred to the stock thickener 85 which corresponds with the stock thickener 21 shown in FIG. 1.
  • Thick stock from the stock thickener 85 is directed to the foam-producing means 86 which in the flow diagram corresponds with the foam-producing means 23 shown in FIG. 1.
  • the foamed fiber furnish may then be directed through open valve 83 to the headbox of the web-forming machine.
  • Method of producing a non-woven fibrous web which comprises a. forming by a vigorous shearing action an aqueous foam consisting essentially of air dispersed in the form of very small bubbles in an aqueous solution containing a surface active agent, the number average diameter of said bubbles being not more than substantially 0.2mm, said foam having a viscosity of at least 22 seconds as measured'by Ford Cup Type B-4 at 20 C and having an air content by volume of at least about 65 percent;
  • Method of producing a non-woven fibrous web which comprises a. forming a foam of surfactant-containing water,
  • said foam being formed by a vigorous shearing action and consisting essentially of air dispersed in the form of very small bubbles, the average diameter of said bubbles being not more than substantially 0.2 mm, said foam having a viscosity of at least 22 seconds is measured by Ford Cup Type B- 4 at C, and having an air content by volume of at least about 65 percent, by subjecting water containing an effective amount of a foam-producing surfactant to the vortical foaming action of an impeller which creates a vortex of liquid drawn towards the impeller at the base of the vortex together with some air that is emulsified by the action of the impeller with return flow of foam to the mouth of the vortex carrying with it coarse bubbles which at least in part are drawn into the vortex;
  • Method of producing a non-woven fibrous web which comprises a. forming a suspension of fibers in water;
  • foaming the dilute furnish by subjecting the furnish to vigorous shearing action to produce therein an aqueous foam consisting essentially of air in the form of very small bubbles in an aqueous solution containing a surfactant, the number average diameter of said bubbles being not more than substantially 0.2 mm, said foam having a viscosity of at least 22 seconds as measured by Ford Cup Type 8-4 at 20 C and having an air content by volume of at least about percent;
  • step (e) a portion of the surfactant-containing water drained from the web during its formation in step (e) is added to the surfactantcontaining water that is introduced substantially free of fibers into the foam producing step (d); another portion of surfactant-containing water drained from the web is admixed with waste portions of the formed web to form a dispersion of fibers in surfactant-containing water; and said fiber dispersion is introduced into the foam-producing step.
  • Apparatus for making a non-woven fibrous web which comprises in combination:
  • web-forming means provided with a foraminous support on which an aqueous fiber furnish is deposited with formation of fibrous web and drainage of aqueous liquid therefrom;
  • foam-producing means including a casing having means for admission of air thereto, a blade impeller mounted within said casing so as to be rotatable about an axis at right angles to the upper surface of the casing, the upper edge of said impeller being situated closely adjacent to the upper inner surface of said casing so as to produce a vortex in the aqueous liquid supplied thereto, the distance between said upper edge of the impeller and the surface of the casing being in the range 0.010 inch to 0.125 inch and such as to form a foam wherein the number average diameter of the bubbles is not more than substantially 0.2 mm, by vigorous shearing action on said aqueous liquid;
  • g'. means for directing aqueous liquid drained from said web-forming means selectively to said mixing means and to said foam-producing means.
  • fiber stock selectively directed to said foam-producing means from said fiber stock supply means is directed from said fiber stock supply means to stock thickening means and from said stock thickening means to said foam-producing means.
  • a web-forming apparatus including a travelling foraminous support on which an aqueous'fiber furnish is deposited with formation of a fibrous web;
  • Apparatus according to claim 19 which comprises a reservoir, means for directing surfactant-containing liquid drained from said web during its formation on said foraminous support into said reservoir, and
  • the apparatus of claim 17, which further includes a reservoir for supplying surfactant-containing water to said foam-producing means, means for directing surfactant-containing water from said reservoir into said foam-producing means, means for collecting surfactant-containing water drained from said web-forming means, means for directing surfactant-containing water from said collecting means into said reservoir, and means for depositing foam produced by said foamproducing means having fibers disposed therein onto said foraminous support.
  • said collecting means comprises a first collecting means for collecting a first portion of said surfactant-containing water drained from said web-forming means, and a second collecting means for collecting a second portion of surfactant-containing water from said web-forming means, and wherein said means for directing water from said collecting means into said reservoir comprises a mixing reservoir, means for directing surfactant-containing water into said mixing reservoir, means for introducing fibrous stock into said mixing reservoir,
US00091104A 1966-05-31 1970-11-19 Method and apparatus for forming a non-woven fibrous web from a foamed fiber furnish Expired - Lifetime US3716449A (en)

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GB24125/66A GB1129757A (en) 1966-05-31 1966-05-31 Method of producing a thixotropic liquid suspending medium particularly for the forming of non-woven fibrous webs

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DE (1) DE1696278A1 (xx)
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ES (1) ES341080A1 (xx)
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SE326888B (xx) 1970-08-03
DE1696278A1 (de) 1972-01-05
BE699159A (xx) 1967-11-29
GB1129757A (en) 1968-10-09
FI51851C (fi) 1977-04-12
NL6707589A (xx) 1967-12-01
FI51851B (xx) 1976-12-31
NO131735B (xx) 1975-04-07
NO131735C (xx) 1975-07-16
AT288152B (de) 1971-02-25
NL152037B (nl) 1977-01-17
DK123785B (da) 1972-07-31
ES341080A1 (es) 1968-06-16

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