US3871952A - Manufacture of non-woven fibrous material from a foamed furnish - Google Patents

Manufacture of non-woven fibrous material from a foamed furnish Download PDF

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Publication number
US3871952A
US3871952A US348596A US34859673A US3871952A US 3871952 A US3871952 A US 3871952A US 348596 A US348596 A US 348596A US 34859673 A US34859673 A US 34859673A US 3871952 A US3871952 A US 3871952A
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United States
Prior art keywords
foamed
mixer
surface active
active agent
dispersion
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Expired - Lifetime
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US348596A
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English (en)
Inventor
Neil George Douglas Robertson
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Arjo Wiggins Ltd
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Wiggins Teape Research and Development Ltd
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Publication date
Priority claimed from GB1621072A external-priority patent/GB1395757A/en
Priority claimed from GB1534473A external-priority patent/GB1397378A/en
Application filed by Wiggins Teape Research and Development Ltd filed Critical Wiggins Teape Research and Development Ltd
Application granted granted Critical
Publication of US3871952A publication Critical patent/US3871952A/en
Anticipated expiration legal-status Critical
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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

Definitions

  • ABSTRACT Non-woven fibrous material is manufactured from a foamed fibre dispersion fed to a foraminous support and the invention resides in forming the foamed fibre dispersion by applying a vacuum to the underside of the support to recover a major part of the liquid from the dispersion on the support, delivering the recovered liquid to a mixer and mixing the recovered liquid in the mixer with fibres, a air, and a surface active agent to obtain a mixture thereof which is fed to a foaming device in which the foamed fibre dispersion is formed for feeding to the support.
  • the degree of uniformity, or the lack of uniformity, of the web may be controlled to some extent by the exercise of the machine operators skill and by the design of the machine.
  • the formation of acceptably uniform webs from fibres which have an excessive tendency to flocculate, or clump together such as long synthetic fibres, or long, lightly beaten cotton or wood fibres, or other long natural fibres from animal, vegetable or mineral sources, requires that the fibres be dispersed in very large volumes of liquid. The subsequent drainage of such large volumes of liquid cannot be ac complished on conventional paper-making machines but requires costly modifications thereto.
  • a less common known method of manufacturing fibrous material is that in which fibres are first dispersed in a liquid medium of high viscosity, such as an aqueous solution of sugar, or of natural gums, the dispersion then being drained through the wire of a paper-making machine thereby to form a fibrous web on the wire.
  • a liquid medium of high viscosity such as an aqueous solution of sugar, or of natural gums
  • This method has the advantage that when the dispersing action ceases, the fibres very quickly cease their motion in the liquid medium, and become immobile before they can become flocculated and clumped together to any appreciable extent.
  • the fibres in such a liquid medium remain well dispersed until the liquid medium is drained from the dispersion and the web formed.
  • due to the always high viscosity of the liquid medium initial dispersion of fibres therein is difficult, and its drainage through the forming web and through the supporting wire is slow and difficult, so that this known method is not well suited to the largescale continuous manufacture of fibrous material.
  • Known foamed fibre dispersion forming apparatus as described above, while being effective to form dispersions having required properties, has the disadvantage that it comprises relatively moving parts, i.e. the impeller and the casing, and thus requires an input of power to provide the necessary movement. Further, the relative movement of the parts results in wear in the apparatus.
  • fibrous material having a higher degree of uniformity of fibre dispersion throughout the material than can be produced at the same weight consistency using only water as the dispersion medium can be manufactured using a foamed liquid medium having an air content above a lower limit less than secondly that there is an air content level for the foamed liquid medium above which although the dispersion of fibres in the foamed liquid medium is more uniform than can be obtained at the same weight consistency using only water as the dispersion medium, nevertheless the fibres in the foamed liquid medium have a tendency to agglomerate; and thirdly that the size distribution of the bubbles in the foamed liquid medium is of considerable importance.
  • foamed liquid media comprising air bubbles dispersed in a liquid containing a surface active agent are useful for dispersing fibres, and in fact that certain foamed liquid media can be used to produce agglomeration of fibres (and particles) rather than dispersion thereof, albeit that the overall fibre dispersion may be better than could be obtained at the same weight consistency using water only as the dispersion medium.
  • volume percentage of air therein, and that the possible volume percentage of air range (ie. 0% to about 999%) can be divided into three subranges two of which, namely up to about 55% and over about can be used to effect agglomeration of fibres and/or particles, and the other, namely from about 55% to about 75%, can be used to effect substan tially uniform dispersion of generally discrete fibres.
  • the volume percentage of air required to effect the most uniform dispersion of any particular fibres and/or particles is generally dependent upon the shape, size, physical properties and concentration of the fibres and- /or particles.
  • the relationship between the size of the fibres and/or particles and the arithmetic mean diameter of the air bubbles is also relevant in determining the most uniform dispersion of any particular fibres and/or particles.
  • the fibres are dispersed substantially, uniformly throughout the foamed liquid medium.
  • the volume percentage of air in a foamed liquid medium is less than about 55%, the air is contained in a relatively few relatively wide diameter range bubbles which divide the medium into pockets of liquid in which the fibres collect, and as the viscosity of the liquid (normally water) is relatively low, the fibres are free to move and thus agglomerate within the liquid pockets.
  • the packing density of the bubbles is so high that the bubbles are deformed from their normally spherical shape into polyhedrally shaped bubbles.
  • surface tension effects result in forces in the planes of the inter-bubble lamellae, the forces being directed towards the line of intersection of the lamellae and into the points of intersection of the lines of intersection of the lamellae. These forces move fibres into the lines of intersection of the lamellae and the fibres become aligned in bundles in these lines.
  • the effect on the viscosity of the medium of the bubble size distribution is thought to result from the fact that the volume percentage of air required for close packing of the bubbles is less if the bubbles have a substantially uniform size distribution.
  • the chemical nature of the surface active agent used is not critical provided that it is able to produce a foamed liquid medium having the specified properties.
  • the surface active agent may be anionic, cationic, or nonionic, and it has been found that proprietary surface active agents such as that sold under the name ACE" liquid, this being an anionic substance, by Industrial Soaps Ltd., that sold as TEXOFOR (Registered Trade Mark) FN 15, a non-ionic substance by Glover Chemicals Ltd., and that sold as AMINE I Fbl9, a cationic substance, by Float-Ore Ltd. are all suitable.
  • Other surface active agents that have been used are oxtylphenoxypolyethoxy ethanol, and commercial grade dodecyl benzene sulfonate.
  • the arithmetic mean diameter of the bubbles in a foamed liquid medium can be determined by plunging a microscope slide cooled to about 70C into the medium, and then removing the slide with a sample of the medium frozen thereto and placing the slide into a freezing stage of a microscope. Photomicrographs at say lOO'X magnification can then be taken and the arithmetic mean diameter of the visible bubbles then determined therefrom.
  • This method has the advantage that a sample of the medium is taken from within the medium mass, and it is no only the outer layer of bubbles that is examined.
  • a method of manufacturing non-woven fibrous material for example paper, by feeding to a foraminous support from a foaming device a foamed fibre dispersion formed by the foaming device, said method including the steps of forming the foamed fibrous dispersion which is fed to the support by recovering a major part of the foamed water from foamed fibre dispersion on the support by connecting the input side of a vacuumcreating device to the underside of the support and the output side to a mixer, introducing fibres into the mixer, together with recovered foamed water, a air and surface active agent, and following mixing thereof in the mixer feeding the air/water/fibre/surface active agent mixture to the foaming device.
  • a machine for manufacturing non-woven fibrous material which machine includes a foraminous support on which the material is formed, apparatus comprising a closed foaming device arranged to form a foamed fibre dispersion and to feed the dispersion for deposition on the support; a mixer; vacuum-creating means to drain liquid from foamed water from foamed fibre dispersion on the support, the negative pressure side of the vacuum-creating means being connected to the underside of the support and the positive pressure side being connected to the mixer; means operable to deliver to the mixer foamed water drained from foamed fibre dispersion on the support; and means connecting the mixer with the foaming device to deliver thereto a water/fibre/air/surface active agent mixture formed in the mixer.
  • FIG. 1 illustrates diagrammatically apparatus for carrying into effect the method according to the invention
  • FIG. 2 illustrates diagrammatically, in plan, one form of apparatus for forming a foamed fibre dispersion
  • FIG. 3 is a section diagrammatically illustrating a part of the apparatus of FIG. 2.
  • the reference 1 indicates a foraminous support, being the wire of a Fourdrinier paper-making machine, on which there is deposited from a head box 2 a foamed fibre dispersion, not shown, from which a non-woven fibrous material is formed by draining water, generally in a foamed condition, from the dispersion through the foraminous support 1. Draining is effected, in known manner by vacuum-creating means 3 and 4 the negative pressure sides of which are connected to the underside of the support 1. As can be seen from FIG. 1, the vacuum-creating means 3 and 4 are spaced apart along the support and between the means 3 and 4 the support 1 passes over what are known as table rolls 5.
  • the vacuum-creating means are associated respectively with what are usually termed wet vacuum boxes 12 and dry vacuum boxes 13.
  • the positive pressure sides of the vacuum-creating means are respectively connected by pipes 14 and 15 with a pipe 16 in which drained foamed water containing surface active agent meets and becomes infused with a mixture of air/water/fibres/surface active agent fed to the pipe 16 by a pump 17 at a pressure of about 25 to 30 pounds per square inch.
  • the pipe 16 is connected with an in-line mixer 18, of any suitable kind which effects a coarse mixing of the mixture to provide a fairly homogeneous mixture which passes from the mixer through an inlet pipe 19 to an in-line foaming device 20 in which a foamed fibre dispersion, having desired properties as referred to above, is formed for delivery through an outlet pipe 21 to the head box 2.
  • the foaming device may be of any suitable closed kind, but is preferably of the kind described below with reference to FIG. 2 because this does not utilise any mechanical moving parts, it is not open to atmosphere, and it is possible to admit metered quantities of air and surface active agent to a water/fibre dispersion as the latter approaches the mixer.
  • the fibre is first beaten with water in a conventional beater 22, such as a Hollander beater, to form stock having a consistency of about 4% by weight based on bone dry fibre.
  • the stock is pumped by a pump 23 to chests 24 where it is held to provide bulk storage for the apparatus, the fibre being kept substantially uniformly in suspension by conventional agitators 25.
  • the stock is pumped along a line 26 by a pump 27 to a refiner 28 from which the stock passes to a thickener 29.
  • the thickener serves to dewater the stock so that it leaves the thickener at a consistency which is usually between 20% and 30% by weight based on bone dry fibre, but should be sufficiently high to minimise the input of fresh water into the apparatus while achieving the required dryness for the web that is removed from the foraminous support 1 prior to drying.
  • Water extracted from the stock in the thickener 29 is removed through a drain pipe 30 and may either go to drain or be re-directed for reuse in the beater 22.
  • the thickened stock is delivered to a pulper 31 in which it is mixed by conventional agitating means 32 with water which is stored in a tank 33 which receives drained foamed water from pipe 14 through a valve 34, and with broke pumped to tank 33 from the broke tank 11 by a pump 35, passing if desired through a broke deflaker 36.
  • Surface active agent may, if desired, be added to the water in tank 33 but it is preferred to admit both air and surface active agent to the water/fibre dispersion as it flows through a pipe 37 to the pipe 16.
  • the pump 17 is included in pipe 37 and the air and surface active agent are delivered into pipe 37, preferably on the output side of pump 17, through metering devices 38, 39 respectively.
  • a deflaker 40 which serves to disperse clumps of fibres is also included in pipe '37.
  • the preferred kind of foaming device 20 mentioned above comprises a plurality of foam-forming pipes 41, which may consist of flexible tubes, each of which has at least one internal region of constricted cross-section formed by a tubular insert 42 which may be circular or of other desired cross-section.
  • An inlet manifold, formed by a housing 43, and an outlet manifold, formed by a housing 44, are connected one to the other by the foam-forming pipes 41.
  • the inlet manifold is connected to the inlet pipe 19 by a flange 45 and the outlet manifold is connected to the outlet pipe 21 by a flange 46.
  • Each foam-forming pipe 41 extends laterally from a housing and is coiled, as at 47, between the ends thereof connected respectively to the inlet and the outlet housing.
  • the housings 43, 44 are circular and the foam-forming pipes extend radially therefrom.
  • each end of each of the foam-forming pipes is connected to a housing 43, 44 through a manually operable valve 48 connected to a stub pipe 49 extending laterally from the housing.
  • the tubular inserts 42 are connected to the valves 48 and the foam-forming pipes 41 are fitted over the inserts 42 as illustrated in FIG. 3.
  • One end 50 of the inlet housing 43 is open to comm unicate with the inlet pipe 19 and the end ofthe housing opposite said open end is closed by a plug 51, FIG. 3, having a conical configuration 52 extending into the housing to prevent the formation of air pockets in the inlet housing 43.
  • foam-forming pipes 41 There may be forty-eight foam-forming pipes 41 arranged in four ranks or banks each of twelve pipes and the housings 43, 44 are preferably independently supported so that little or no vibration is transmitted between the inlet and outlet manifolds.
  • the number of foam-forming pipes to be used is selected by manipulation of the valves 48. If desired, the number of foam-forming pipes 41 in use can be changed during operation of the apparatus by manipulation of the valves 48.
  • a mixture of air, water and fibre, and surface active agent fed to the manifold 41 is substantially equally divided into each foam-forming pipe and the tubular inserts 42 set up turbulence in the mixture which effects foaming and dispersion of the fibres, to provide a foamed fibre dispersion having desired properties as referred to above.
  • recovered drained liquid is continuously recycled through a loop formed by the pipes 14, 15, 16 mixer 18, pipe 19, and foaming device 20, thus reducing the quantity of make-up surface active agent required, and that by using the described preferred form of foaming device it is possible, by metering air and surface active agent into the approach flow system, to provide control over the air content and thus the viscosity of the foam.
  • a process for manufacturing a non-woven fibrous material from a foamed fiber dispersion fed to a foraminous support from a foaming device wherein the amount of surface active agent required is reduced comprising:
  • a closed circuit system for manufacturing nonwoven fibrous material from a foamed fiber dispersion wherein the amount of surface active agent required is reduced comprising:
  • pipe means for deliverying said mixture from said mixer to said closed foaming device
  • feeding means for feeding said foamed fiber dispersion effected by said closed foaming device to a foraminous support on which said non-woven fibrous material is formed;
  • vacuum drain means including vacuum box means, for recovering a major part of the liquid, generally in a foamed condition, from said foamed fiber dispersion on said foraminous support;
  • pump means operable to recycle said liquid so recovered generally in a foamed condition directly from said vacuum box means through said pulp delivery pipe means to said mixer; and metering means operable to introduce into said pulp delivery pipe means upstream of said mixer metered quantities of air and make-up surface active agent.

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  • Paper (AREA)
  • Nonwoven Fabrics (AREA)
  • Chemical Or Physical Treatment Of Fibers (AREA)
  • Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)
  • Reinforced Plastic Materials (AREA)
US348596A 1972-04-07 1973-04-06 Manufacture of non-woven fibrous material from a foamed furnish Expired - Lifetime US3871952A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB1621072A GB1395757A (en) 1972-04-07 1972-04-07 Apparatus for producing a foamed fibre dispersion
GB1534473A GB1397378A (en) 1973-03-30 1973-03-30 Manufacture of non-woven fibrous material

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US3871952A true US3871952A (en) 1975-03-18

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US348596A Expired - Lifetime US3871952A (en) 1972-04-07 1973-04-06 Manufacture of non-woven fibrous material from a foamed furnish

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US (1) US3871952A (no)
AR (2) AR199395A1 (no)
AT (1) AT324825B (no)
CA (1) CA983300A (no)
DD (2) DD104581A5 (no)
DE (1) DE2317402C3 (no)
ES (1) ES413439A1 (no)
FI (2) FI65459C (no)
FR (1) FR2179205B1 (no)
IT (1) IT980789B (no)
NL (1) NL171733C (no)
NO (1) NO142678C (no)
SE (1) SE395489B (no)

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Cited By (113)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
USRE29770E (en) * 1973-09-14 1978-09-19 Isorel S.A. Manufacture of fiberboard according to the wet method with closed backwater system
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FR2179205A1 (no) 1973-11-16
DE2317402A1 (de) 1973-10-18
NL171733C (nl) 1983-05-02
DE2317402B2 (de) 1980-10-16
DD104582A5 (de) 1974-03-12
DD104581A5 (no) 1974-03-12
AT324825B (de) 1975-09-25
NL171733B (nl) 1982-12-01
FR2179205B1 (no) 1975-12-26
NO142678B (no) 1980-06-16
FI65459C (fi) 1984-05-10
NO142678C (no) 1980-09-24
SE395489B (sv) 1977-08-15
FI56869C (fi) 1980-04-10
NL7304817A (no) 1973-10-09
AR202457A1 (es) 1975-06-13
ES413439A1 (es) 1976-06-01
AR199395A1 (es) 1974-08-30
FI65459B (fi) 1984-01-31
IT980789B (it) 1974-10-10
FI56869B (fi) 1979-12-31
DE2317402C3 (de) 1981-07-02
CA983300A (en) 1976-02-10

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