WO2010058084A1

WO2010058084A1 - Methods and apparatuses for manufacturing material web, system and fibre material product

Info

Publication number: WO2010058084A1
Application number: PCT/FI2009/050940
Authority: WO
Inventors: Pekka Koivukunnas
Original assignee: Innovaatiopalvelu Pekka Koivukunnas Oy
Priority date: 2008-11-21
Filing date: 2009-11-20
Publication date: 2010-05-27
Also published as: FI20086105A0; FI20086105A

Abstract

In a method for manufacturing a material web (W) such as a fibre web, manufacturing two sub-webs (W1, W2) and joining said sub-webs (W1, W2) from open sides of the sub-webs (W1, W2). The apparatus for manufacturing the material web (W) such as a fibre web comprises a first forming surface (110a, 210a) for manufacturing a first sub-web (W1) and a second forming surface (120a, 220a) for manufacturing a second sub-web (W2) and a contact area (N1, N2, N3) for joining said sub-webs (W1, W2) from the open sides of the sub-webs (W1, W2). The system comprises the manufacturing apparatus of the material web (W) according to any embodiment of the invention and a processing apparatus of the material web (W) connected after it. A fibre material product (W), such as a reelable fibre web or sheet, comprises a first surface substance layer (11) and a second surface substance (12) formed of material components, which surface substance layers form outer surfaces of the fibre material product (W) on opposite sides of the fibre material product (W), and the material components of each surface substance layer (11, 12) are evenly distributed in each surface substance layer in the thickness direction of the surface substance layer.

Description

METHODS AND APPARATUSES FOR MANUFACTURING MATERIAL WEB, SYSTEM AND FIBRE MATERIAL PRODUCT

FIELD OF INVENTION

The invention relates to manufacturing web-like material. Particularly, though not exclusively, the invention relates to a method and apparatuses for manufacturing a material web such as a fibre web and to a fibre material product.

BACKGROUND OF THE INVENTION

The current paper manufacturing process consists of multiple sequential unit processes which can be roughly divided in processes related to manufacturing of base paper and finishing processes. Unit processes related to manufacturing of base paper and corresponding apparatuses are among others manufacturing pulp, distributing pulp as an even flow in the head box, removing excess water and forming a web on the wire section, further removing water by mechanically pressing, evaporation drying the paper with drying cylinders and reeling.

In the paper manufacturing manner, in accordance with prior art, there is a problem that fine particles added to paper pulp, such as short fibres and fillers, tend to leave the paper on the wire section and in the pressing phase with the departing great amount of water. A desired property is to make fine particles stay in the surface of the forming paper but on the other hand an efficient water removal is desired. These aims conflict with each other. In the paper manufacturing manner, in accordance with known technique, fine particles drift with the flowing water towards the surface of the paper, but to stop them, a fabric with finest possible mesh is needed. On the other hand, for the removal speed of water a fabric with largest possible mesh is preferred. In addition, chemicals, so- called retention substances, are used, that help fine particles to stay in the paper web. The development of the current paper manufacturing process has thus been searching for a compromise between the aforementioned conflicting aims. In the present-day paper manufacturing process, several different chemicals, at worst tens of different ones, are used to solve other problems or to remove symptoms, as well. Removing chemicals from waste water is problematic, as well.

As is known, in the paper manufacturing process, in for example wire, pressure and drying sections, numerous different fabrics are used, such as wires, felts and belts, that are worn, are sensitive to damage and, in addition, are expensive.

In the paper manufacturing manner in accordance with known technique, the need for the finishing of the paper web is initiated already during the forming of the paper web on the wire section where a great amount of water is removed from the forming paper web through the forthcoming surfaces of the paper and the wires supporting them. On one hand, the wire should be as smooth as possible for achieving a good surface quality, but on the other hand the wire has to be as permeable to water as possible. The aforementioned requirements for the wire are in conflict with each other, and in practise, the wires that usually are manufactured by weaving polymeric fibres are always somewhat uneven of their surface. This leads to the surface of the base paper practically always being more or less uneven and serving as such only to few uses. Cockling emerging during the drying process of the paper web partly adds to the unevenness of the surface of the paper web.

Unit processes in accordance with finishing are among others coating and calendering. The aim of finishing phases is in some applications to improve the quality of the base paper to suite different purposes, such as a printing base. The process and apparatus of paper manufacturing as a whole are complex, sensitive and expensive. When considering e.g. the unit process calendering, conflicting requirements are perceived in accordance with it. On one hand, the paper needs calendering, i.e. thermo-mechanical pressure processing for achieving a desired level of smoothness and gloss for the surface, but on the other hand, the paper should be calendered as little as possible or rather not at all because calendering deteriorates several product qualities such as thickness and stiffness of the paper.

In solutions in accordance with known technique, the applying of a coating substance on the paper web may cause breaks in the paper manufacturing process, in other words the processed paper web may sometimes break and thus deteriorate the efficiency of the whole manufacturing process.

As such, the water processing, such as purifying raw water, pumping, heating, waste water purifying etc. is expensive and additionally, in the usual paper manufacturing a great portion of water has to be removed from the paper by evaporating which consumes a lot of energy. As is known, the dry solids content of the pulp fed to the wire section is typically 1-2 %. As is known, water is also removed by mechanically pressing, which requires expensive devices, as well.

In manufacturing an uncoated paper web, formed using base paper, and in coating a paper web a problem is that, when drying, the moisture that is removed from inside the paper has to flow through the outer surfaces of the paper, in which case the surface of the forming paper web will not become dense. At its worst, the paper may peel, i.e. divide in two parts, or the coating layer may depart from the base paper locally, in a so-called blistering phenomenon, if the surface of the paper is dense and water is tried to be removed by bringing in too much energy, because the vapour pressure forming inside the paper breaks the paper.

Known apparatuses, with which the desired level of quality will be achieved, are expensive to invest and use. Paper manufacturing industry is in trouble with the producing cost of high-quality fibre webs being high when compared to the selling price of the product.

Thus there has been established a need for a new manner of manufacturing paper in which the desired quality properties are achieved with an essentially simpler and cheaper method and apparatus.

SUMMARY

According to a first aspect of the invention a method for manufacturing a material web such as a fibre web is established, comprising:

- manufacturing two sub-webs; and

- joining said sub-webs from the side of the open surfaces of said sub-webs. An open surface may signify for instance a non-supported i.e. free surface of the sub-web. The open surface of the sub-web may be the surface of the sub-web opposite to the surface of the sub-web against a forming surface.

According to an embodiment of the invention, manufacturing a sub-web is started from manufacturing a surface forthcoming to the material web.

According to an embodiment of the invention, manufacturing a sub-web is started by applying surface substance onto the forming surface.

Surface substance may be liquid-like acting surface substance pulp or paste-like acting surface substance pulp.

According to an embodiment of the invention, an inner layer coming to the material web is applied on top of a surface substance layer. According to an embodiment of the invention, the inner layer coming to the material web is applied with the same forming surface as the surface substance layer before joining the sub-webs.

The dry solids content of the surface substance being applied depends on the embodiment in question. In some embodiments the dry solids content of the surface substance pulp being applied to the forming surface is at least 30 %. If the dry solids content is low, the drying need of the sub-web is greater, but yet significantly smaller than in applications in accordance with prior art, in which the dry solids content of the source substance is around a couple of per cent. When the dry solids content increases the drying need of the sub-web diminishes, which in its part enables speeding of the manufacturing process.

In some embodiments, surface substance is applied to the forming surface, which surface substance has a dry solids content of preferably 50-70 %, when the surface substance mass typically still acts liquid-like. In some embodiments, surface substance is applied to the forming surface, which surface substance has a dry solids content of preferably 60-80 %, when the surface substance mass acts more solid-like, for instance paste-like. In some embodiments, surface substance is applied to the forming surface, which surface substance has a dry solids content preferably 70-80 %. In some embodiments, depending on the source substance, even higher dry solids contents may be used.

When the dry solids content of the surface substance is increased, typically over 70-80 % depending on the material consistency, the viscosity of the surface substance increases and the surface substance changes in a certain dry solids content from a liquid state to a stiff/solid/paste-like state, where material no more streams freely.

In known technique, the dry solids content of coating substances, when applied, is typically so low that it acts like liquid. In known technique the using of high dry solids contents is restricted among others by the fact that coating substance is applied directly on top of the base paper. Because the viscosity of coating substances that have a high dry solids content is so high, applying them and removing redundant material may cause to the base paper a great shear force that may exceed the strength of the base paper, in which case it breaks and causes disturbance in the production. Additionally, smoothing the surface of a coating substance that has a high dry solids content is difficult with coating devices in accordance with known technology, because scratches and stripes left in the surface by the doctoring device are left on the outer surface of the paper.

According to some embodiments of the invention, higher than present dry solids contents and viscosities may be used; even so high that the surface substance acts stiff/solid/paste-like and is not in a free streaming, liquid-like state, because the surface substance is applied onto a strong forming surface, made of metal or other material, which practically cannot break. Additionally, the surface from which redundant surface substance is doctored off in some embodiments, stays in the web and possible unevennesses are not left to be seen outside the web.

According to an embodiment of the invention, a contact area is in contact with said forming surfaces of sub-web.

According to an embodiment of the invention, a first and a second forming surface form a contact area for joining a first and a second sub-web. Preferably, web material (sub-webs -> a material web) goes through the contact area without water removal happening in the contact area.

According to an embodiment of the invention:

- applying a first surface substance layer onto a first forming surface for forming a first sub-web and a first outer surface of a material web; and

- applying a second surface substance layer onto a second forming surface for forming a second sub-web and a second outer surface of a material web; and

- joining said sub-webs to a material web from the side of open surfaces.

According to an embodiment of the invention, at least one inner layer is applied onto an open surface of at least one of said sub-webs before joining said sub- webs.

According to an embodiment of the invention, a joining substance layer is applied onto an open surface of at least one of said sub-webs before joining said sub- webs. Preferably, the sub-webs are joined by forcing them against each other.

According to an embodiment of the invention, at least one sub-web is being dried before joining the sub-webs. Preferably, at least one sub-web is being dried to a desired moisture, preferably leaving at least one sub-web partly moist or preferably by over-drying at least one sub-web. Preferably, at least one sub-web is being dried without water removal by pressing. Preferably, at least one sub-web is being dried without water removal through a forming surface.

Preferably, the material web is being dried after joining the sub-webs, preferably only after the contact area. Preferably, the material web is being dried to a desired end moisture. Preferably, the material web is being dried on the first forming surface or on the second forming surface. Preferably, the material web is being dried between forming surfaces after the contact area.

According to an embodiment of the invention, the material web is a reelable material web. According to an embodiment of the invention, a material sheet is manufactured from the reelable material web.

According to an embodiment of the invention, at least one forming surface is arranged to be impermeable to liquid. According to an embodiment of the invention, all forming surfaces are impermeable to liquid. Preferably, at least one forming surface is sealed, i.e. impermeable to both liquid and gas.

According to an embodiment of the invention, the sub-web is being dried by evaporating solvent such as water.

According to an embodiment of the invention, the evaporating takes place substantially only through the open surface of the sub-web.

According to an embodiment of the invention, at least one sub-web is being heated with help of the forming surface and/or the open surface of at least one sub-web is being heated.

Preferably, at least one forming surface is being heated from inside and/or outside. Preferably, a certain sub-web or material web is being heated by using heating technology applying streaming heat transfer substance, water, steam, hot oil, induction, micro wave technique or infra-red technique.

Preferably, the layer being applied is applied by blade coating, rod coating, curtain coating, multi-layer curtain coating, spray coating, roll coating, airbrush coating, or extruder.

Preferably, at least one web-like material is added between the first sub-web and the second sub-web in the joining phase of said sub-webs.

According to an embodiment of the invention:

- a first surface substance is applied onto a movable first forming surface for forming a first surface substance layer and

- the first surface substance layer is being dried, for forming a first sub-web and for forming a first outer surface of the material web using the first forming surface; and

- a second surface substance is applied onto a movable second forming surface for forming a second surface substance layer and - the second surface substance layer is being dried, for forming a second sub-web and for forming a second outer surface of the material web using the second forming surface; and

- the first sub-web and the second sub-web are moved towards each other and said sub-webs are joined to a material web from the open sides of the sub-webs.

According to an embodiment of the invention, a material web is manufactured without manufacturing base paper.

According to an embodiment of the invention, at least one sub-web is manufactured without water removal through the forthcoming outer surfaces of the material web.

According to a second aspect of the invention, an apparatus is provided for manufacturing a material web such as a fibre web, which apparatus comprises:

- a first forming surface for manufacturing a first sub-web; and

- a second forming surface for manufacturing a second sub-web; and

- a contact area for joining said sub-webs from the open sides of the sub- webs.

According to an embodiment of the invention, the apparatus comprises:

- a first forming surface and

- at least one first applying device for applying a first surface substance layer onto the first forming surface for manufacturing a first sub-web and for forming a first outer surface of the material web; and

- a second forming surface and

- at least one second applying device for applying a second surface substance layer onto the second forming surface for forming a second sub-web and for forming a second outer surface of the material web; and said forming surfaces are arranged to be towards each other for forming a contact area of said sub-webs.

According to an embodiment of the invention, the apparatus comprises at least one inner layer applying device which is arranged in the direction of movement of the forming surface after the surface substance applying device before the contact area.

According to an embodiment of the invention, the apparatus comprises at least one surface substance applying device which is arranged in the direction of movement of the forming surface after the surface substance applying device before the contact area.

According to an embodiment of the invention, the apparatus comprises at least one drying device for drying the material web after the contact area.

Preferably, drying of the material web has been executed using a belt being pressed towards the forming surface, which belt is preferably heatable.

According to an embodiment, the control of the curving of the material web is arranged. Preferably, the contact area comprises two forming surfaces, which are arranged against each other to a direction opposite to the tendency to curve of the material web, into a curved position. Preferably, forming surfaces residing against each other are in an optional distance from each other and/or movable towards each other.

According to an embodiment of the invention, the apparatus comprises at least one forming surface which is impermeable of liquid (or waterproof).

According to an embodiment of the invention, at least one forming surface is heatable from the inside and/or from the outside. According to an embodiment of the invention, the apparatus comprises at least one drying device in connection with a forming surface outside the forming surface.

According to an embodiment of the invention, the apparatus comprises at least one drying device in connection with a forming surface inside the forming surface.

Preferably, said drying devices are applicable for using for drying the sub-web and/or for drying the material web. Preferably, said drying devices comprise a device applying streaming heat transfer substance, water, steam, hot oil, induction, micro wave technique or infrared technique.

According to an embodiment of the invention, the forming surface comprises a forming belt which preferably, optionally, has a structured surface. According to an embodiment of the invention, the forming surface comprises a forming cylinder which preferably, optionally, has a structured surface. Preferably, at least one forming surface comprises metallic or polymeric material. Preferably, at least one forming surface comprises a coating or surface treatment. Preferably, the apparatus comprises a reeling device arranged after the contact area. Preferably, the flow of the material web is arranged without unsupported transfers.

According to an embodiment of the invention, the apparatus comprises a forming belt and a forming cylinder and a contact area formed by these.

According to an embodiment of the invention, the apparatus comprises two forming cylinders and a contact area formed by these.

According to an embodiment of the invention, the apparatus comprises two forming belts and a contact area formed by these.

Preferably, the apparatus comprises:

- a movable first forming surface,

- at least one first applying device for applying a first surface substance onto the first forming surface to the first surface substance layer, for forming a first sub-web and for forming a first outer surface of the material web, using the first forming surface; and

- a movable second forming surface,

- at least one other applying device for applying a second surface substance onto the second forming surface to a second surface substance layer, for forming a second sub-web and for forming a second outer surface of a material web, using the second forming surface; and the first forming surface and the second forming surface are adapted to being movable towards each other for accomplishing the contact area and for joining the sub-webs to the material web by pressing the open surfaces of the sub-webs in the contact against each other.

According to a third aspect of the invention, a system is provided, which system comprises an apparatus for manufacturing a material web according to any embodiment of the invention and a processing apparatus connected after it.

According to an embodiment of the invention, in the system, the processing apparatus of a material web is chosen from a group of a reeler, a slitter-winder, a cross-directional cutter of a material web such as a sheet cutter, a printing press.

According to a fourth aspect of the invention, a fibre material product such as a reelable fibre web or a sheet is provided, which fibre material product comprises:

- a first surface substance layer and a second surface substance layer formed of material components, which surface substance layers form the outer surfaces of the fibre material product on opposite sides of the fibre material product, and

- the material components of each surface substance layer are evenly distributed in each surface substance layer in the thickness direction of the surface substance layer.

The material components may comprise for instance some of the following: pigment, binding material, fibre.

In some embodiments, the material components are evenly distributed in other directions as well, such as cross and longitudinal direction.

In some embodiments, the drying direction of the surface substance layer is inside the surface substance layer from the outer surface to inside.

In some embodiments, there are fibres at least in one surface substance layer. Preferably, the fibres are bonded in the surface substance layer by chemical bonds substantially without hydrogen bonds.

In some embodiments, the fibre material product is uncoated.

In some embodiments, the fibre material product comprises at least one inner layer where the material components are evenly distributed.

In some embodiments, the fibre material product comprises an inner layer with fibres but with less fibres than 50 volume percent.

In some embodiments, the material components in all the layers of the fibre material product are evenly distributed.

In some embodiments, the fibre material product comprises an accurate surface structure substantially without non-desired deviations. In the traditional paper manufacturing manner, due to the nature of the process, the surface structure of the surface layer is formed to be sporadic and the surface substance is not evenly distributed on the surface of the base paper.

In some embodiments, the fibre material product comprises a plane-like surface as its outer surface, for preferably the non-uniform thickness is compensated inside the fibre material product for instance with the interfaces of the layers. In the traditional paper manufacturing manner, due to the nature of the process, in the scale of inspection, the outer surface of the surface layer is not formed to be plane-like but uneven because the base paper is not even.

In some embodiments, the surface layer of the fibre material product defines the form of the inner layer/s, because it has been manufactured before manufacturing the inner layer/s.

According to an embodiment of the invention, material from the group of pigment, binding material, fibre, is arranged to the surface substance layer of the fibre material product. Preferably, material from the group of pigment, binding material, fibre, is arranged to the joining substance layer of the fibre material product. Preferably, material from the group of pigment, binding material, fibre, recycled material, is arranged to the inner layer of the fibre material product.

In some embodiments, each surface substance layer of the fibre material product comprises an amount of fine particles which is substantially the same as the amount of fine particles applied to each surface layer as a source substance.

According to an embodiment of the invention, the fibre material product is formed through water suspension.

According to an embodiment of the invention, the fibre material product comprises two uniform and (directly or preferably, through intermediate layers) to each other attached surface layers formed of a surface substance compound that comprises water and at least one of the following: fibres and fine particles, in which the z- directional (= being in perpendicular direction regarding to the material web or sheet) particle size distribution is constant from the outer surface of the material web at least halfway to the thickness of the layer. Preferably, the z-directional particle size distribution of each surface layer is undisturbed, starting from the outer surface of the material web at least halfway to the thickness of the layer.

In some embodiments, the fibre material product is manufactured of sub-webs by joining with a method according to the first aspect of the invention or an embodiment of the first aspect. In some embodiments, the fibre material product is manufactured of sub-webs by an apparatus according to the second aspect of the invention or an embodiment of the second aspect. In some embodiments, the fibre material product comprises in its outer surface a desired surface pattern or surface topography. Said surface pattern or surface topography may be tri-dimensional. Said surface pattern or surface topography may be copied from the forming surface in connection with manufacturing the sub-web. Said surface pattern or surface topography may be an optical grid structure.

In some embodiments, the fibre material product contains at least one layer which has fibres. In some embodiments, the fibre material product comprises plant- based fibres, in some embodiments, specifically wood fibres. In some embodiments, the fibre material product is a paper-like product. In some embodiments, the fibre material product is a cartonboard-like product. In some embodiments, the fibre material product has a plane layer structure. In some embodiments, the layers of the plane layer structure reach in the longitudinal and cross direction of the fibre material product substantially from the outer edge of the product to the other.

The embodiments in connection with the fibre material product presented in the foregoing may also act as an individual aspect alone or in a suitable combination with some other embodiment without dependence of the afore-presented fourth aspect of the invention.

In embodiments of the invention, for applying the method and apparatuses for manufacturing a material web in practice, a number of devices and process steps needed is smaller than in manufacturing material web according to known technique. In embodiments of the invention, a difference with methods for manufacturing web-like material according to prior art, is that in embodiments of the invention, a material web like a fibre web is manufactured without base paper. Thus the apparatuses needed for manufacturing base paper and the cost in accordance with building it is left out. Specifically the handling of water and chemicals associated with manufacturing the base paper are left out.

In embodiments of the invention, there is an advantage that in them only little water is used, which saves a lot of energy. In embodiments of the invention, in general, there can be used relatively less fibres and more filler substances in comparison with the conventional paper manufacturing, in which case the material cost is lower.

In embodiments of the invention, there is an advantage that a substantial amount of affordable recycled materials can be added inside the material web.

Other advantages become apparent from the following description and claims.

Aforementioned embodiments of the invention are described or have been described only with reference to one or more aspects of the invention. It will be evident to a person skilled in the art that any embodiment of any aspect can be applied in the same aspect and other aspects of the invention as such or in combination with other embodiments.

SHORT DESCRIPTION OF DRAWINGS

The invention will now be described by way of example only with reference to the accompanying drawings, in which:

Fig. 1 shows from a side an apparatus for manufacturing a material web according to a first embodiment of the invention,

Fig. 2 shows from a side an apparatus for manufacturing a material web according to a second embodiment of the invention, Figs. 3A and 3B show from a side apparatuses for manufacturing a material web according to a third and a fourth embodiment of the invention,

Fig. 3C shows from a side the apparatus according to Fig. 2, equipped with a belt circulation against the forming cylinder,

Fig. 4 shows from a side the apparatus for manufacturing material web W according to the second embodiment of the invention, equipped with blade coating devices and doctor blades,

Fig. 5 shows a preferred application for extending the contact time of joined sub- webs,

Figs. 6A and 6B show a preferred embodiment for controlling curving of a material web,

Fig. 7A shows a first example of a layer structured material web according to an embodiment,

Fig. 7B shows a second example of a layer structured material web according to an embodiment,

Fig. 7C shows an example of a multi-layer material web according to an embodiment,

Fig. 8 shows a preferred application for forming a multi-layer material web based on an apparatus of the type in Fig. 1 , Fig. 9 shows a preferred application for forming a multi-layer materia) web based on an apparatus of the type in Fig. 4,

Fig. 10 shows a preferred application in which solid web-like material is added between sub-webs in the joining phase, and

Figs. 11 and 12 show some preferred embodiments of manufacturing apparatuses of a material web, in connection with which there are coupled process devices for processing the material web.

DETAILED DESCRIPTION

In the following description like references denote like parts. It shall be understood that the presented Figures are not in entirely to scale, and that they mostly serve to illustrate embodiments of the invention.

A manufacturing process of a fibre web and especially a manufacturing process of paper are mainly used as examples of a method and apparatus for a manufacturing process of a material web in the following description.

The manufacturing processes of a material web, such as a fibre web, for instance paper, in accordance with the embodiments of the invention, substantially deviate from the manufacturing processes in accordance with the prior art. Thus, when according to prior art, base paper is made first and then it is for instance for achieving a smooth surface, coated and calendered, in methods according to embodiments of the invention, manufacturing of the base paper is not required at all, but first sub-webs comprising the surfaces of the future material web, such as paper, are manufactured, and thereafter the sub-webs are joined such that the surfaces comprising desired qualities form outer surfaces of the joined material web. We can speak of a so-called reversed manufacturing process of a material web, such as paper. In this type of reversed manufacturing process, in a way the surfaces are manufactured first and only thereafter the web itself is formed. A remarkable advantage in methods and apparatuses according to embodiments of the invention is that they consume only little water.

Some manufacturing apparatuses for a material web W in accordance with some preferred embodiments are presented in the Figures accompanying the description. The manufacturing apparatuses preferably comprise a manufacturing apparatus for a first sub-web W1 and a manufacturing apparatus for a second sub- web W2.

The first sub-web W1 comprising a first surface W11 which is formed to a manufactured material web, such as paper, is manufactured by first applying a desired layer of a first surface substance 11 onto a first forming surface which has desired surface qualities such as surface topology being for instance smooth, which first forming surface is movable and preferably heatable, for instance in Fig. 1 , a belt-like first forming surface 110a or in Fig. 2, a cylindrical first forming surface 210a. Next a first surface substance layer 11 applied onto the first forming surface 110a, 210a is dried on the first forming surface for forming the first sub- web W1. Preferably, the drying takes place by evaporating. Preferably, the first surface substance layer 11 is dried to a desired moisture, according to a preferred embodiment over-dry.

Correspondingly a second sub-web W2 , comprising a second surface W12 which is formed to the manufactured material web W, such as paper, may be manufactured by first applying a desired layer of a second surface substance 12 onto a second forming surface which has desired surface qualities such as surface topology being for instance smooth, which second forming surface is movable and preferably heatable, for instance in Fig. 1 , a belt-like second forming surface 120a or in Fig. 2, a cylindrical second forming surface 220a. Preferably the drying takes place by evaporating. Next, a second surface substance layer 12 applied onto the second forming surface 120a, 220a is dried on the second forming surface for forming the second sub-web W2. Preferably the drying takes place by evaporating. Preferably the second surface substance layer 12 is dried to a desired moisture, for instance over-dry.

In the Figs., moving directions of movable first forming surfaces and first sub-webs W1 have been denoted as M1 and moving directions of movable second forming surfaces and second sub-webs have been denoted as M2.

The surface substance 11 , 12 denotes in this description material that is applied onto a forming surface, which forming surface defines form qualities of the visible surface W11 , W12 of the forthcoming material web. Surface substances, similar or different by their composition, may be used on separate surfaces of the material web, in other words the sub-webs W1 , W2, as is explained in the following.

The surfaces W11 and W12 of the joined material web W, defined by the forming surfaces 110a, 120a, 210a, 220a, may be implemented ready in its surface qualities for the end use of the material web W, and the material web W may be implemented by applying the presented method with uniform thickness. Thus applying the presented method has an advantage that calendering or coating of the material web is not needed.

In some embodiments of the invention, a surface substance mixed with fibre material is used as surface substance 11 , 12 in distinction to known coating substances.

After the sub-webs W1 and W2 have been formed, the first sub-web W1 may be joined to, by its qualities, a similar or a different sub-web W2. According to a preferred embodiment, the joining takes place by applying onto at least either one of the sub-webs, a layer of joining substance 13 and by bringing the sub-webs in contact with each other and keeping them in contact so long that the joining substance 13 keeps the open surfaces of the sub-webs together, which surfaces in the joining process stay inside the material web. The joining substance 13 for joining comprises binding material and if needed, material with some technical or esthetical effect, such as fibre material and possibly water or other solvent substance. Different supplementary materials for the joining substance 13 and their effects on the qualities of the forthcoming material web are explained in closer detail in the following.

According to yet another preferred embodiment, drying of at least one sub-web is partly implemented. In this embodiment, the upper open surface of at least one sub-web is arranged to be moist enough for accomplishing the joining of the sub- webs when the sub-webs W1 and W2 are brought in contact with each other and kept in contact so long that the surfaces of the sub-webs W1 and W2, which surfaces are left inside the material web W, stay attached to each other. Thus for instance the surface substance layer 11 of the first sub-web W1 applied onto the first forming surface may be partly dried, and the joining substance 13 is not applied onto either of the sub-webs W1 , W2, then the first sub-web W1 and the second sub-web W2 may be moved towards each other, joining said sub-webs by pressing them against each other. The joining of sub-webs may be implemented without the joining substance 13 (Fig. 7B). Said preferably partly dried open surface being on top of said at least one sub-web, may be the open surface of the surface substance layer 11 , 12, the joining layer 13 or the inner layer 14.

After joining the sub-webs VV1 and W2, preferably the material web W, such as paper web, is still kept in contact with at least one forming surface, in Fig. 1 to the belt-like first forming surface 110a, so long that the material web W dries to the desired end moisture. Alternatively, the material web may be dried by a manner known as such. When the desired end moisture of the material web W is achieved, the material web W is disentangled from the said at least one forming surface for instance with a reel drum 310 of a reeling devices 300, and the completed material web W is reeled to a machine reel 320 around a reel core 330 with continuous action.

In embodiments of the invention, manufacturing methods of a material web and manufacturing apparatuses of a material web are simple and less devices and process steps are needed for applying them than in the manufacturing of a fibre web in accordance with the known technique. The methods can be implemented for instance by arranging the apparatuses for manufacturing each surface substance 11 , 12 and if needed, a joining substance 13, an applying device for said substances, forming surfaces for forming the sub-webs (for instance in Fig. 1 two forming belts, in Fig. 2 two forming cylinders, in Figs. 3A and 3B a forming belt and a forming cylinder), drying devices of sub-webs and a combination web, a reeling device, measurement, control and automation devices and cleaning devices for the forming surfaces. A doctor blade, that presents a cleaning device, is described for instance in connection with Fig. 4. Applying devices can be added on demand for applying desired inner layers 14, 14' (Fig. 7C) to the open surface of desired sub-webs.

In an exemplary implementation in Fig. 1 , the manufacturing method of a material web W is applied in a manufacturing apparatus of a material web, where the manufacturing apparatus 101 of a first sub-web W1 comprises a first applying device 111 (for instance a coating beam, a curtain coater, a multi-layer curtain coater) for applying a first surface substance 11 ; a third applying device 113 for applying joining substance 13 on top of the first surface substance 11 ; a movable first forming belt 110, which comprises a first forming surface 110a for forming a first sub-web W1 ; a first drying device 114 for drying the first sub-web W1 ; a drying device 121 for the joined web W; and first guide rolls 116 for movably supporting the first endless forming belt; and in which manufacturing apparatus, the manufacturing apparatus 102 of the second sub-web W2 comprises a second applying device 112 for applying a second surface substance 12; a movable second forming belt 120 which comprises a second forming surface 120a for forming the second sub-web W2; a second drying device 117 for drying the second sub-web W2; and second guide rolls 119 for movably supporting the second forming belt 120; and the manufacturing apparatus comprises a reeling devices 300 in connection with the first forming belt 110 for reeling the dried material web W to a material web reel 320 around a reel core 330 for instance with a reel cylinder 310 from the first forming belt 110 preferably without unsupported web transfer.

According to a preferred embodiment, the manufacturing apparatus for a certain sub-web comprises only one applying device with which the surface substance layer 11 , 12 and if desired, several other layers, for instance one inner layer 14 and a joining layer 13, can be applied. This way simple structures and multi-layer structures of the material web W may be implemented with one applying or coating unit such as a multi-layer curtain coater.

According to a preferred embodiment, the manufacturing apparatus for a certain sub-web comprises an applying device with which the surface substance layer 11 , 12 may be applied, and a separate applying device of the joining layer is not arranged in the manufacturing apparatus of the sub-web. The manufacturing apparatus of the material web W, formed with the manufacturing apparatus of the sub-web in accordance with this embodiment, may be used for manufacturing for instance the material web presented in Fig. 7B.

In case of Fig. 1 , when joining the sub-webs W1 and W2, they may preferably be brought in a light contact with each other e.g. by placing the sub-webs W1 and W2 through the forming belts 110 and 120 and the guide rolls 116, 119 inside the belt circulations to a light nip contact with each other in a joining nip N1. Using the nip in joining the sub-webs is beneficial, because in the nip, the thickness of the material web can be affected and the material web can be calibrated even in its thickness. A light nip contact in this connection may denote for instance that the sub-webs are not exactly pressed against each other in the nip N1 , but rather the sub-webs are managed such that they are merely forced against each other without specific pressing.

The contact time of the sub-webs W1 and W2 in the joining point can be elongated such that the forming belt circulations are arranged to partly touch each other according to Fig. 5. In Fig. 5, the manufacturing apparatuses 101 and 102 of the sub-webs W1 and W2 are described with reference to Fig. 1. In the case of Fig. 5, when joining the sub-webs W1 and W2, they are brought in contact with each other by arranging the first forming belt 110 and the second forming belt 120 overlapped, when the sub-webs W1 and W2 are joined between the forming belts 110 and 120 in a longer-lasting contact than in the manufacturing apparatus of Fig. 1. In an exemplary embodiment in Fig. 2, a manufacturing method of a material web W is applied in another manufacturing apparatus of a material web, where a manufacturing apparatus of a first sub-web W1 comprises a first applying device 211 for applying a first surface substance 11 ; a third applying device 213 for applying a joining substance 13 on top of the first surface substance 11 ; a first forming cylinder 210, which comprises a first forming surface 210a for forming the first sub-web W1; and in which manufacturing apparatus a manufacturing apparatus 202 of a second sub-web W2 comprises a second applying device 212 for applying a second surface substance 12; a second forming cylinder 220, which comprises a second forming surface 220a for forming the second sub-web W2; and the manufacturing apparatus comprises a reeling devices 300 in connection with the second forming cylinder 220 for reeling the dried material web to a material web reel 320 around a reel core 330 for instance with a reel cylinder 310 from a second forming belt 220 preferably without unsupported web transfer. Drying devices outside the preferably heatable forming surfaces of the forming cylinders for the first sub-web W1 and the second sub-web W2 and the material web W are not presented in connection with Fig. 2. Exterior drying devices suitable for use in connection with Fig. 2 are explained among others in connection with Fig. 4.

In case of Fig. 2, when joining the sub-webs W1 and W2, they may be arranged in a light contact with each other for instance by arranging the sub-webs W1 and W2 through the forming cylinders 210 and 220 in a light nip contact with each other in the joining nip N2.

Fig. 3A presents from side an apparatus according to a third embodiment of the invention for manufacturing a material web W. The apparatus in Fig. 3A comprises a first forming belt 110 such as the one presented in Fig. 1 for forming a first sub- web W1 , and a reeling devices 300 in connection with the forming belt 110, and the apparatus comprises a second forming cylinder 220 such as the one presented in Fig. 2 for forming a second sub-web W2, where an applying unit 212 of an second surface substance is preferably a blade coating device. Blade coating is explained in closer detail in connection with Fig. 4. Fig. 3B presents from side an apparatus for a manufacturing material web W according to a fourth embodiment of the invention. The apparatus in Fig. 3B comprises a first forming cylinder 210 such as the one presented in Fig. 2 for forming a first sub-web W1 (from which when compared to Fig. 2 an applying device of joining substance is reduced) and a reeling devices 300 in connection with this first forming cylinder 210, and the apparatus comprises a second forming belt 120 such as the one presented in Fig. 1 for forming a second sub-web W2, to connection of which, when compared to Fig. 1 , a third applying device 113 for applying joining substance 13 on top of a second surface substance layer 12 is added.

In cases of Figs. 3A and 3B, when joining the sub-webs W1 and W2, they may be arranged in a light contact with each other e.g. by arranging the sub-webs W1 and W2 in a light nip contact in a joining nip N3 through a guide roll of a forming belt and a forming cylinder. Another way of accomplishing a joining contact is to arrange the forming belt to touch the forming cylinder in a different place than where the guide roll of the forming belt lies, in which case a so-called long nip can be formed between the belt and the roll.

In the apparatuses in Figs. 1 , 3A and 3B, the circulation of each forming belt may also comprise more than the presented two guide rolls, for instance for elongating the forming belt circulation such that the drying time of a certain sub-web or the material web W is elongated, or for suitably applying some process device, such as a heating device or an applying device or a cleaning device or an equivalent, to the apparatus.

By reviewing the apparatuses in Figs. 1 , 2, 3A and 3B, it can be observed, that for forming the first sub-web W1 and the second sub-web W2 both a belt and a cylinder type of forming surface can be used in their various combinations. Correspondingly, it can be observed, that in connection with both the belt and the cylinder type of forming surface a reeling 300 for the dried material web W may be arranged, and as explained in the following, for instance such devices that in the conventional paper manufacturing process are as distinctive sub-processes after the paper machine.

The applying of the surface substance 11 , 12 onto the forming surfaces 110a, 120a, 210a, 220a may be implemented in the presented manufacturing process and manufacturing apparatuses through techniques known as such and commonly used technologies, such as blade coating, rod coating, curtain coating, multi-layer curtain coating, spray coating, roll coating, airbrush coating or extruder. The applying of the surface substance onto the first and second forming surface does not have to take place through the same technology but different technologies may be used, for instance depending on the applying technology suitable for a certain different surface substance. Methods known as such, such as mixers, filters and pumps etc. may be used for manufacturing the surface substance.

Correspondingly, the applying technology of the joining substance 13 and one or more inner layers explained in the following can be chosen from the body of the aforementioned techniques known as such and commonly used technologies, for instance depending on the applying technology suitable for a certain joining substance 13 and the supplementary material that the joining substance 13 includes. The applying technology of the surface substance 11 , 12 and the joining substance 13 may be same or different technology.

In the manufacturing apparatuses in Figs. 1 , 2, 3A and 3B, it is possible to use more than one drying device for producing heat to a certain forming surface as well, i.e. for drying the sub-web with this certain forming surface or for producing heat to this sub-web from outside this certain forming surface. This kind of a need may arise for instance when the sub-web comprises several layers, the drying of which requires more efficacy. According to an embodiment, drying devices may be arranged such that at least one resides inside the forming surface and at least one outside the forming surface.

Fig. 3C presents from side the manufacturing apparatus according to Fig. 2 equipped with a belt circulation 350 lying against the forming surface such as the forming cylinder. Preferably the belt circulation 350 comprises a belt 355 and for instance three belt guide rolls, of which the first belt guide roll 351 and the second belt guide roll, guide between them an endless metallic belt 355 to be pressed towards the forming surface, such as the forming cylinder 220, and the third belt guide roll 353 among other things guides the remainder of the belt to stay apart off the section of the belt that lies against the forming cylinder 220. A supporting effect may be directed to the material web W following the forming surface 220a of the forming cylinder 220 with the belt 355, for intensifying the heat transfer from the forming cylinder 220 to the material web W and thus promoting the drying of the material web W and improving the joining of the sub-webs W1 and W2 to each other. Preferably, the belt 355 is a heatable metallic belt, with which the drying process and the process of joining the sub-webs W1 and W2 to each other can be further intensified. The belt may be of polymeric material as well. There may be more than three belt guide rolls.

Fig. 4 presents from side an apparatus for manufacturing material web W equipped with blade coating units and doctor blades, according to a second embodiment of the invention. The apparatus in Fig. 4 comprises a first forming cylinder 210 such as the one presented as the manufacturing apparatus 201 of the first sub-web W1 in Fig. 2. A first applying device 211 is arranged in connection with the first forming cylinder 210, in which device blade coating technology is adapted for applying the first surface substance 11. The first applying device 211 comprises a first application roll 214 for applying the surface substance 11 onto the first forming surface 210a of the first forming cylinder 210; a first doctor blade

215 for doctoring the excess first surface substance 11 from the first forming surface 210a and for levelling the surface substance after the application; and a first pool 216 for storing the surface substance 11 where from the application roll

214 raises surface substance 11 and where surface substance 11 can return after blade doctoring.

In Fig. 4, the apparatus comprises a second forming cylinder such as the one presented in Fig. 2 as a manufacturing apparatus 202 of the second sub-web W2. The second applying device 212 is arranged in connection with the second forming cylinder 220, in which device blade coating technology is applied for applying the second surface substance 12 onto the second forming surface 220a of the second forming cylinder 220. The second applying device 212 comprises a second application roll 217 for applying the second surface substance 12 onto the second forming surface 220a; a second doctor blade 218 for doctoring the excess second surface substance 12 from the second forming surface 220a and for levelling the surface substance after the application; and a second pool 219 for storing the surface substance 12 where from the second application roll 217 raises surface substance 12 and where surface substance 12 may return after blade doctoring. The joining substance 13 may be applied by a known applying technology onto at least one of the sub-webs before the joining nip N2 formed by forming cylinders 210 and 220 between them, for which a third applying device 213 for applying the joining substance 13 on top of the second surface substance 12 is arranged in connection with the second forming cylinder 220.

In Fig. 4, the manufacturing apparatus of material web comprises a reeling devices 300 in connection with the second forming cylinder 220 for reeling the dried material web W to a material web reel 320 for instance with a reel cylinder 310 from the second forming cylinder 220.

In Fig. 4, a first exterior drying device 221 for drying the first sub-web W1 is arranged in connection with the first forming cylinder 210, in the area between the first doctor blade 215 and the joining nip N2, and the first forming surface 210a is heatable. A second exterior drying device 222 for drying the second sub-web W2 is arranged in connection with the second forming cylinder 220, in the area between the second doctor blade 218 and the third applying device 213, and the second forming surface 220a is heatable. Exterior drying devices are explained in closer detail in the following.

In Fig. 4, corresponding doctor blades 231 and 232 for doctoring the forming surface free of the sub-web are arranged next to the coating devices 211 and 212, when reviewed from the entry direction of the forming surface before corresponding application rolls 214 and 217. The doctor blades 231 and 232 are preferred examples of cleaning devices of the forming surfaces. Any known cleaning device for surface, such as a brush cleaning device or an apparatus based on spraying high-pressure liquid such as water can be used as cleaning devices. An advantage in using the blade doctoring 215, 218 and the application roll 214, 217 is that a separate cleaning device to keep the forming surface clean is not necessarily needed because the doctor blade 215, 218 also doctors possible impurities from the forming surface and the filter preferably arranged in the recycling system of the surface substance 11 , 12 can remove them from circulation. Additionally, the doctor blade technology enables an especially high dry solids content, approximately 70-80 %. As high dry solids content of the surface substance as possible is preferred in order to have the time and amount of energy needed for drying the surface substance as small as possible and to have the apparatus as small and simple as possible.

As presented in the foregoing, a rolling cylinder 210, 220 may be used as an implementing forming member in addition to the movable belt 110, 120, when the forming surface preferably comprises metallic material. The forming member implementing the forming surface may be of a coated type, for instance with polymeric material. Said forming member may comprise metal or polymeric composite. The first forming surface and the second forming surface in the manufacturing apparatus of the material web may be formed of similar or different material or a combination of materials, preferably depending on for instance a desired surface smoothness or patterning of a certain sub-web or a heating/drying need of a certain sub-web. Preferably the forming surface 110a, 120a, 210a, 220a of the forming member is impermeable of liquid.

The afore-presented forming member (a belt, a cylinder) 110, 120, 210, 220 implementing the forming surface may be of type that is heatable from inside and in heating the forming members, the sub-webs W1 , W2 and the joined material web W any known heating technology may be used, such as heating technology applying streaming heat transfer substance, water, steam, hot oil, induction, micro wave technique or infra-red technique. The same heating technologies may be used as well in heating some guide rolls 116, 119 arranged in the belt circulation for heating the forming belt 110, 120, and for heating the belt circulation 350 and the belt guide rolls 351 , 352, 353 (Fig. 3) that are against the forming surface such as the forming cylinder. As presented in the foregoing, one or more heaters may be placed as a drying device outside the forming member 110, 120, 210, 220 implementing the forming surface. This kind of an additional heater may use any known heating technology, such as blowing hot air on top, infra-red heating or induction heating. When using a metallic belt, e.g. an induction heater may be placed inside the belt circulation.

Any known heating technology may be placed outside the belt circulation as well as outside the cylinder. If something else than a metallic belt is used, the belt may be heated from inside only by the limits set by the material. For instance, blowing of hot air on top or infra-red heaters may be used as the heating outside the belt.

According to some embodiments, a drying device is not especially arranged for a certain sub-web but the sub-web is dried resulting from evaporating. Then preferably the drying of the sub-web in either or both manufacturing apparatuses of the sub-web, of the manufacturing apparatus of the material web, is arranged to take place without a specific drying device.

In methods according to embodiments of the invention, the surface structure of the forming surface 110a, 120a, 210a, 220a becomes exactly copied to the surface of the forming material web W such as paper without separate surface treatment phases. An advantage is that the forming surface 110a, 120a, 210a, 220a may be manufactured in advance to correspond with the desired surface qualities of the material web W such as paper. These traditional surface qualities of paper are gloss and smoothness and as an "opposite" to gloss, being matt-like. By implementing embodiments of the invention some new surface qualities or structures can be easily produced. As an example, among others different grid structures (a diffractive grid) affecting the optical qualities of the surface of the paper can be mentioned. If the forming surface 110a, 120a, 210a, 220a is metallic, different surface structures can be machined on it for instance by mechanically grinding and glazing, electrolytically glazing, electrolytically coating (e.g. chromating), spark machining, laser machining, mechanically shaping or by other ways of machining known as such, or by ceramically coating. If a metallic belt is used as the forming member 110, 120, it may be made of, in addition to the usual steel, electrolytically grown nickel, in which case it may have aforementioned optical grid structures manufactured in a manufacturing method known as such.

In embodiments of the invention, the surface substance 11 , 12 is first applied as a layer onto the forming surface 110a, 120a, 210a, 220a, and the surface substance 11 , 12 is arranged to detach from the forming surface after it has been dried.

During the drying a moisture gradient is formed in which case the surface substance residing against the forming surface of the sub-web dries first, in which case the sub-web can be detached even if the second surface of the sub-web was still moist. Preferably, the surface substance 11 , 12 is applied as an even and uniform layer.

The curving of the material web W such as paper being manufactured may be controlled for instance by ways presented in Figs. 6A and 6B such that the sub- webs W1 and W2 are joined in a contact area longer than the usual roll nip or the usual belt nip formed through guide rolls in the location of the guide rolls. The manufacturing apparatus in Fig. 6A mainly corresponds with the manufacturing apparatus presented in Fig. 1 , yet with the distinction that the manufacturing apparatus of the first sub-web and the manufacturing apparatus of the second sub-web are placed away from the same line, in other words to an inclined angular position towards each other. The contact area presented as a part enlargement in Fig. 6B is preferably formed by one forming belt pressed against the second forming surface. In Figs. 6A and 6B the second forming belt circulation 120 is placed below the first forming belt circulation 110, in which case the second belt area of the forming belt circulation 120 presses the first forming belt 110 upwards and preferably (not necessarily) touches the area of the guide roll 116 of the first forming belt circulation 110. In that case, the first forming belt 110 circulates the second forming belt 120 around the guide roll 119 for a distance of the curvature sector α. In Figs. 6A and 6B, the contact area of joining the sub-webs W1 and W2 comprises a curvature sector α, in the area of which, the material web W is curved to an opposite direction to the curving tendency of the material web such as paper. Deviating from the presentation in Figs. 6A and 6B, the curvature of the material web W, in a curved contact area arranged in the opposite direction, is also affected by for instance in a corresponding way such that the material web W is placed with the guide roll 116 of the first forming belt 110 surrounded by the second forming belt circulation 120 for a distance of the curvature sector α. Naturally the forming surface may be a cylindrical forming surface in which case correspondingly the material web W is arranged to circulate between the forming belt and the cylindrical forming surface for a distance of the curvature sector α.

It is advisable that the moulding pressure in the contact area of joining the sub- webs is just and just the size that the sub-webs W1 and W2 can be joined enough, i.e. that the joining substance 13 is arranged to a sufficient contact with the inner surface of both sub-webs (in other words the surface that stays inside the material web). Then the possible non-desired compression can be avoided and the adhesion of the sub-webs after the joining is achieved. It is advisable to choose the size of the moulding pressure pressing the sub-webs W1 and W2 towards each other such that the joining substance layer 13 is adjusted to correspond with the small unevennesses of the inner surfaces of the sub-webs W1 , W2, which unevennesses are always arisen in a free unsupported surface. Also the joining substance layer 13 itself may be a little uneven after the applying. In embodiments of the invention there is an advantage that the aforementioned unevennesses may be levelled inside the material web W, when the unevennesses are not shown for instance in the surface of the finished paper W, but the surfaces of the finished material web W preferably correspond with the forming surfaces 110a, 120a, 210a, 220a by their smoothness and other surface qualities.

Water or other solvent in the joining substance 13, that is unnecessary for instance in the joining process or in a combination structure web, may be removed by first evaporating from the sub-web W1 , W2 and if needed, the evaporating from the material web W is continued after the joining nip N1 , N2, N3. Preferably, the evaporating is accomplished by heating the sub-web W1 , W2 with a heatable forming surface 110a, 120a, 210a, 220a and with possible exterior heating devices that may heat the sub-web W1 and/or W2 from its open surface. An alternative way to drive the process is such that the sub-webs W1 , W2 are first over-dried and the water residing in the joining substance 13 is absorbed to the sub-webs after the joining of the sub-webs W1 , W2 and the moisture of the material web W becomes even in the z direction of the material web W and thus the desired end moisture is achieved. Here the z direction denotes the perpendicular direction with respect to the material web or sheet i.e. the thickness direction.

With the presented method, it is also possible to implement different cross- sectional structures i.e. different layer structures of the material web W such as paper. With the layer structure, the qualities of the material web W such as a fibre web, such as thickness, stiffness, strength, brightness, transparency, absorption of liquids, etc. may be affected. Layer structures may be implemented by first applying a surface substance layer 11 , 12 as a surface layer on top of the forming surface 110a, 120a, 210a, 220a and then on top of this surface layer, in addition to the needed joining substance layers 13 (or without the joining substance layer) one or more inner layers 14 before joining the first sub-web W1 and the second sub-web W2. The inner layers denote the material layers arranged between the surface substance i.e. the surface layers 11 , 12.

Fig. 7 A presents a diagrammatic first example of a layer structured material web W, the layers of which listed from above downward are a first surface substance layer 11 i.e. a first surface layer 11 , a joining layer 13 and a second surface substance layer 12 i.e. a second surface layer 12. By way of example, both the surface layers comprise fibres but either or both surface layers may be implemented without fibres as well.

Fig. 7B presents a second diagrammatic example of a layer structured material web W, the layers of which listed from above downward are a first surface substance layer 11 i.e. a first surface layer 11 and a second surface substance layer 12 i.e. a second surface layer 12. By way of example, both the surface layers comprise layers but either or both surface layers may be implemented without fibres as well.

Fig. 7C presents a diagrammatic example of a material web W, with as an example an asymmetrical multi-layer structure, and the structures of the material web W listed from above downward are the first surface substance layer 11 i.e. the first surface layer 11 , a first inner layer 14 and a second inner layer 14', the joining layer 13 (that may be in either of the sub-webs) comprised by the first sub-web W1 and the second surface substance layer 12 i.e. the second surface layer comprised by the second sub-web W2. By way of example, only one surface layer 12 comprises fibres, but the second surface layer could comprise fibres as well, or both the surface layers may be implemented without fibres. Preferably the strength of the first sub-web W1 has been increased by the fibre content of one inner layer 14.

In Figs. 7A-7C, between fibres and the substances of the layers, chemical bonds have been formed between the fibres and the other substances of the layers, which has been illustrated by presenting the fibres emphasised distinctive of each other. The layer comprising fibres forms a matrix that comprises binding material and filler/pigment as well, in which case the fibres are not significantly in contact with each other like in the known technique but there is for instance binding material and filler/pigment between them.

Figs. 8 and 9 present apparatuses in manufacturing a multi-layer structured material web.

Fig. 8 presents a preferred application for forming a multi-layer structured material web based on the manufacturing apparatus of the type in Fig. 1 , with one inner layer applying device added to the manufacturing apparatuses 101 and 102 of both the sub-webs W1 and W2, for enabling applying of the inner layer 14, 14' on top of the surface substance layer of both said sub-webs. In Fig. 8 the manufacturing apparatus 101 of the first sub-web W1 comprises a first inner layer applying device 141 for applying a first inner layer 14 on top of the first surface substance 11 , and the manufacturing apparatus 102 of the second sub-web W2 comprises a second inner layer applying device 142 for applying a second inner layer 14' on top of the second surface substance 12.

Fig. 9 presents a preferred application for forming a multi-layer structured material web based on the manufacturing apparatus of the type in Fig. 4, with one inner layer applying device added to the manufacturing apparatuses 201 and 202 of both the sub-webs W1 and W2, for enabling applying of the inner layer 14, 14' on top of the surface substance layer of both said sub-webs. In Fig. 9 the manufacturing apparatus 201 of the first sub-web W1 comprises a first additional layer applying device 241 for applying a first inner layer 14 on top of the first surface substance 11. The first additional layer applying device 241 is arranged in the direction of movement M1 of the sub-web after the blade coating device 211 and before the exterior heating device 221. The manufacturing apparatus 202 of the second sub-web W2 comprises a second additional layer applying device 242 for applying the second inner layer 14' on top of the second surface substance 12. The second additional layer applying device 242 is arranged in the direction of movement M2 of the second sub-web W2 after the blade coating device 212 and before the exterior heating device 222. The first and second additional layer applying device 241 , 242 are preferably of spray coating type of devices but some other coating technology is possible as well in a suitable location of the forming surface.

Naturally, more than one inner layer may be made to one sub-web, for instance in Fig. 7C.

It is possible to add at least one solid web-like material 30 between the first sub- web W1 and the second sub-web W2 for instance in the joining phase of these sub-webs. In Fig. 10, there is presented a manufacturing apparatus of a material web W applying this kind of method, which manufacturing apparatus is described with reference to Fig. 3A and the description below.

Although in embodiments of the invention, the manufacturing of base paper is not required at all, on the other hand, the embodiments do not prevent using another web-like product 30 in connection with the embodiments. One or more inner layers 14 may be replaced by a web manufactured beforehand, that may be for instance laminated on top of the other or both surface layers. The laminating may preferably be made when the surface substance of the surface layer is still a little wet or moist from its inner surface, when it may attach to the web being laminated and separate adhesive substance does not need to be added. The beforehand manufactured web-like material 30 may be uncoiled for instance from a reel 31 or it may be manufactured with methods according to known technique, for instance with a paper machine instantly before the laminating. The web-like material 30 may be for instance paper, fibre fabric, textile, metallic, plastic, glass (fibreglass mat) or other known web-like material. This kind of material may be totally or partly electricity conducting or semi-conducting material.

In Fig. 10 solid web-like material 30 is reeled open from a reel 31 and conveyed to a joining nip N3, where the sub-webs are joined. The apparatus in Fig. 10 can be used in manufacturing a multi-layer structured material web in Fig. 7C as well, in which case by adding solid web-like material 30 such as a thin plastic or metallic membrane between the surface substance layers 11 , 12 forming the outer surfaces of the material web W₁ it is possible to implement various special layer structures for instance for forming specialty papers and specialty boards. Then the needed joining substances 13 for achieving the bonds of the sub-webs W1 , W2 and at least one web-like material 30 are arranged between said webs.

The material composition of each layer (the surface substance layers i.e. the surface layers 11 , 12, the joining layer 13 and when desired additional inner layer/s 14) of the material web W may typically comprise the following main components', pigment, binding material and fibre. Additionally, in the material pulp of each layer, there may be different additional, filling and accessory agents such as water, foaming inhibitor, agent promoting forming of membrane, agent affecting surface chemistry. In embodiments of the invention, typically all pigments, binding materials and fibres according to the prior art may be used. As a pigment e.g. calcium carbonate, kaolin, talc, gypsum or titanium oxide may be used. As a binding material e.g. latex or starch based substances may be used. As fibres wood, polymeric, glass, carbon, aramid or other known fibres may be used. Different micro and nano fibres may be used as well. As an example of these kinds of fibres we can mention micro or nano fibres obtained by splitting wood fibre or carbon-made nano fibres. Fibres may be hollow or electricity conducting as well.

In the paper manufacturing process according to the prior art, there is the problem with using recycled paper that only the fibres that have stayed long and in good condition can be used of it, because certain strength qualities are needed for manufacturing base paper. Split fibres, surface substance components, such as pigments and binding materials, and printing ink have to be separated and disposed of as waste because they do not increase the strength of the base paper. In embodiments of the invention, there is an advantage that the aforementioned materials can be almost completely utilised. There is an advantage that considerable amounts of affordable recycled materials such as fibres and reject fractions (pigment, short and broken fibres, printing ink) generated in conventional paper recycling can be added to at least one joining layer 13 and the inner layers 14 of the materia) web W such as fibre web.

Varied using of recycled material in the material web W is based on two facts. First, the inner layer/s 14 of the material web W such as fibre web, may be darker than in known processes based on base paper, because the outermost surface substance layer 11 , 12 is throughout an average of more uniform thickness than the coating layer of processes based on base paper. In known processes based on base paper the thickness variation is greater in which case the brightness of the base paper has to be chosen by the thinnest parts of the coating layer to avoid so-called mottling phenomenon, i.e. the patchiness of the surface of the paper, discernible to the eye. An additional advantage that is obtained is the lower transparency of the material web W such as a fibre web, because the preferably dark particles of the middle or inner layer 14 absorb light more efficiently. Lower transparency enables relatively thinner papers which saves among others raw materials and energy.

On the other hand the paper manufacturing process itself in embodiments of the invention does not require very great strength from the material web W, unlike in solutions according to the prior art, where the paper has to be transferred across and through various process phases and rolls etc unsupported, using so-called unsupported transfer. Preferably, according to embodiments of the invention, it is easy to arrange that the material web W such as paper being manufactured is supported to some surface all the time and in that case there are no unsupported transfers. This enables a good efficiency for the manufacturing process, because there are not to be expected many web breaks. Additionally, the manufacturing apparatus of the material web W presented can be implemented significantly shorter and including significantly less different process phases. Preferably, proportions of different mixture materials are optimised. In the surface layer 11 , 12 (the surface substance material 11 , 12) of the material web W there may be only few or no fibres. A great amount of fibres in the surface layer 11 , 12 causes weakening of the surface quality of the material web W such as paper. In inner layers such as the joining substance layer 13 and the inner layers 14 there may be relatively lot of fibre for obtaining the needed strength qualities. In the joining substance layer 13, when needed, there may also be a different amount of fibres when compared to other layers. If the material web W such as paper consists of the surface layers 11 , 12 and the joining layer 13 only, it is advisable to arrange so much fibres in the joining layer 13 that the desired strength of the material web W is obtained.

If the material web W such as paper has one or more inner layers 14, with the presented method and apparatus, the necessary amount of fibres for the strength can be placed in these inner layers 14, and the joining substance layer 13 may consist of only binding material. If the first sub-web W1 and/or the second sub-web W2 have more layers, the material of the layers may be further applied with coating devices according to the prior art as such, as explained in the foregoing. Several layers can be applied simultaneously and in the same place of a certain forming surface for instance with a so-called multi-layer curtain coater.

For obtaining a sufficient inner strength of the surface substance it is preferred to use a suitable amount of fibres in the surface substance, but it is also possible in a more traditional manner to increase the ratio of the amount of the binding material with the amount of the fillers and pigments, for obtaining the inner strength of the surface substance.

The typical relative proportions of different components in the known coating substances are: pigment 80-90%, binding material 20-10%, additives 1-2%.

Pigments are divided in two groups: main pigments (proportion over 50%) and additional pigments. Main pigments are among others kaolin, ground calcium carbonate, talc and gypsum. Additional pigments are among others titanium dioxide, satin white, aluminium hydroxide, precipitated calcium carbonate, sodium silico aluminate, plastic pigments and calcinated kaolin.

Binding materials are typically divided in three groups: natural binding materials, the most important of which are starch, casein and protein, synthetic binding materials i.e. PVA and CMC and latexes, which are styrene, butadiene, vinyl acetate and acrylate latexes.

In the paper coating process according to the prior art there is the problem of so- called wandering of binding material, which means that the binding material is enriched right on the surface of the paper and the interface of the paper and the coating. This comes from the binding material first penetrating to the base paper with the liquid phase and later in the drying drifting towards the heat source and at the same time towards the surface of the coating. In the coating process according to the prior art, the typical dry solids content of the coating substance is 50-60%. In embodiments of the invention, significantly less dwelling of binding substance takes place, because according to some preferred embodiments the dry solids content of the surface substance is higher, preferably 60-80%, and the surface substance layer 11 , 12 is dried separately before joining the sub-webs in which case binding material can not dwell into the inner layers 14 in significant amounts and because the moisture in the surface substance according to some embodiments dwells only to one direction. Generally, the moisture in the surface substance dwells significantly towards the open surface of each sub-web before joining the sub-webs.

Additives may be used in embodiments of the invention typically for following purposes: for preventing the surface substance from foaming, for improving the preserving of the surface substance, as lubrication material, for controlling the acidity, for controlling the viscosity, for dispersing, as colour substances and as detaching substances to ease the reliable detaching of the sub-web from the forming surface.

Each layer of the material web W (surface, joining substance, inner layer) may have a detached coating device. The sub-webs W1 and W2 may have a similar or different layer structure and structure of individual layers. Printing papers typically have a symmetric structure but many specialty papers, e.g. release papers and container boards are asymmetric such as the multi-layer structure presented in Fig. 7C. All in all, in the presented method in general, there may be used relatively less fibres and more fillers when compared with the usual paper manufacturing, in which case the material cost is lower.

Some of the layers may consist of wood fibre only. In manufacturing such a layer, preferably HC pulp may be used (HC = high concistency i.e. high dry solids content).

One possible technology in connection with methods and apparatuses in accordance with embodiments of the invention is air web forming (Air Dynamic Forming, ADF) by using of which dry fibres may be formed to a web. A little moisture is used in the air web forming technology for obtaining hydrogen bonds between fibres, and it may be possible to manage without binding substance. According to some embodiments, by using dry fibres with air web forming, there may be obtained a good fibre formation and a good web strength in the inner layer.

According to an example applying air web forming technology, the surface substance layers 11 and 12 of the sub-webs W1 and W2, applied when moist, are suitably dried and inner layers 14 are formed on top of these surface substance layers by air web forming dry fibre, after which in the joining nip N1 heat is given to the material web W being formed and the heat treatment is continued to the joined material web W for strengthening the fibre bonds for instance with the additional heating device arranged below the first forming belt 110. The presented first example corresponds with the embodiment in Fig. 1 added with an exterior additional heater of the forming belt after the joining nip N1.

According to another example applying air web forming, the heat treatment of the joined material web W is continued between the surface of the forming cylinder 220 and the heatable forming belt 110 strained towards this surface, after the joining nip N3. For instance for this other example, the embodiment in Fig. 3B may be treated such that the forming belt 110 is placed below the forming cylinder 220 and to circulate the forming cylinder for forming a longer contact sector. In that case according to an embodiment, the long contact time between the hot metallic belt 110 and the hot cylinder 220 and the light pressure generate favourable circumstances for generating nitrogen bonds between fibres in the material web W and prevent excessive compression of the material web W.

According to some embodiments, it is advisable that each forming surface 110a, 120a, 210a, 220a residing towards the material web W being formed and having been formed, is kept clean and undamaged, because in the apparatus, the surface structure of the forming surface is directly copied onto the surface of the material web W such as paper. Thus copying of impurity particles and damages onto the fore-coming visible surface of the material web W is prevented.

For keeping the belt and correspondingly the cylinder arranged to a forming surface 110a, 120a, 210a, 220a clean, they may be coated with a suitable e.g. chemical coating, the qualities of which preferably also comprise suitable qualities for enabling the applied surface substance 11 , 12 (that is dry or moist or wet) to reliably attach onto the forming surface and for enabling the dried surface substance, that is the surface layer of the material web W, to reliably detach from the forming surface. For easing the sub-web to detach from the forming surface it is possible to use detaching agents that are known e.g. from cast coating technology.

According to some embodiments, the usual paper winder or corresponding may be completely left out and instead of it place such devices, that in the usual paper manufacturing process are as detached sub-processes after the paper machine.

An example of this kind of device is the slitter-winder. Examples of this kind of devices used in connection with the manufacturing apparatus of material web W applying the presented method are presented in Figs. 11 (a sheet cutter) and 12 (a printing press).

In an embodiment, a slitter-winder according to the prior art as such, can be placed in connection with a paper manufacturing device according to the invention. The slitter-winder may be of any known type such as a two-drum slitter-winder or a multi-station slitter-winder. Paper rolls suitable for a printing press are made with the slitter-winder and the reeler section attached to it.

In Figs. 11 and 12, by way of example, the manufacturing apparatus presented in Fig. 4 represents the manufacturing apparatus of the material web with the exception that the reeling devices 300 coupled after the manufacturing apparatus is replaced with another type of processing apparatus of the material web W.

In some embodiments of the invention, sheets are made of the material web W. This is done e.g. by cross-directional and/or longitudinal directional cutting.

In Fig. 11 , it is presented how the material web W such as paper may be cut to a given length preferably by a sheet cutter 400, in which case finished sheets suitable for a sheet pressing print are obtained. The material web W wider than the desired sheet end product may first be slitted in two or more longitudinal sub-webs longitudinally and thereafter the longitudinal sub-webs may be cut to a given length with the cross-directional cutter of the material web, such as the sheet cutter 400, in which case finished sheets suitable for a sheet pressing print are obtained. In Fig. 11 , it is presented a belt circulation 450 arranged between the forming cylinder 220 and the sheet cutter 400 as a support for the material web W so that there is not so-called unsupported transfer or the unsupported transfer is as short as possible.

The apparatus and method presented in Fig. 11 have an advantage that the paper manufacturing process as such does not cause extra strength or other requirements for the paper. In a special case, the whole manufacturing apparatus of a material web may be arranged to produce the material web W of the exact desired width in which case longitudinal slitting is not needed at all. There is an advantage of quick times of delivery for the printing products that are reprocessed products of the material web W, without the need of temporary storage of paper rolls. For instance when the orderer of the printing product desires different printing products to be printed on papers of different thicknesses, with the method of the invention, it may be implemented fast and easily only by controlling the thickness and number of the surface substance layers. Longitudinal slitting and cross-directional cutting 400 can be placed in connection with a device of the invention because the operating speed of the apparatus is not high. Operating speed of a paper machine according to the present-day prior art is around 1800- 2000 metres per minute.

A printing press 500 is connected with a manufacturing apparatus of material web W presented in another embodiment presented in Fig. 12. The material web W such as paper may be slitted longitudinally in two or more sub-webs before the printing press or after it. The paper is cut cross-directionally in sheets either before the printing press or immediately after it as presented in Fig. 12 with a sheet cutter 400. In Fig. 12, there is presented the belt circulation 450 arranged between the forming cylinder 220 and the printing press 500 as support for the material web W so that there is not so-called unsupported transfer or the unsupported transfer is as short as possible. The printing press 500 may be one device corresponding with the overall width of the paper web or it may contain several press units 500 corresponding with the width of the sub-webs. The printing press 500 or the printing presses may be of any known type such as an offset printing press, gravure printing press or digital printing press. The digital printing press may be e.g. an ink jet printing press or a laser printing press. There is an advantage of quick times of delivery of the printing products without the need of temporary storage of paper rolls. For instance when the orderer of the printing product desires different printing products to be printed on papers of different thicknesses, with the presented method it may be implemented fast and easily only by controlling the thickness and number of the surface substance layers. When using a digital printing press the content and the desired qualities of the paper may be fed to the computer controlling the device through a network connection and the device will perform all the needed adjustments etc. automatically.

In the afore-presented manner, the manufacturing process of a material web W such as paper may be connected as an expanded part of Print-on-demand production i.e. requirement printing. Print-on-demand technology denotes the digitisation of the publishing process. This denotes the whole publishing process: generating the publication, printing, marketing, storage and delivery. The methods and apparatuses for manufacturing a material web such as paper presented in embodiments of the invention may be estimated to be significantly less straining for the environment than earlier. The building of the apparatus requires significantly less raw materials and materials. The apparatus has smaller need for care and maintenance. The methods consume significantly less water and energy and produce less carbon dioxide emissions. Also virgin wood fibres are needed less. Transporting and temporary storing of paper rolls is left out. Additionally, a production plant applying the methods is easily placed in industrial estates of big towns, close to the end-users and recycled material sources in which case the need for transportation is minimised.

In embodiments of the invention, significantly low production cost per grammage of produced paper can be obtained although the operating speed of the presented apparatus is lower when compared with the operating speed of a paper machine according to the prior art. According to an estimate, one afore-presented apparatus unit has such a low investment cost that even when an investment cost of an amount of apparatuses needed for total production corresponding with a present-day paper machine is counted, it is still a fraction of the investment cost of a present-day paper machine. The same applies to needed buildings and estates because it has to be noted that there is no need to invest in apparatus related to the earlier significant amount of water and chemical processing and parts of building they require. When it is additionally noted the possibility to connect the apparatus applying the method according to embodiments of the invention to other sub-processes, such as slitting and printing, following the web manufacturing, the apparatus is cost-efficient. The possibility to produce paper cost-efficiently with significantly smaller apparatus units than known eases the investment decisions made in the branch and enables a larger entrepreneur group to participate in paper production. When using small apparatus units, with fluctuating demand, it is easy for the manufacturer of a material web W to start and close individual small apparatus units and implement flexible production batches according to customer demands.

The foregoing description provides non-restricting examples of some embodiments of the invention. It is clear to a person skilled in the art that the invention is not restricted to the presented details but that the invention can be implemented in other equivalent means.

Some of the features of the presented embodiments may be used to advantage without the corresponding use of other features. As such, the foregoing description shall be considered as merely illustrative of the present invention, and not in limitation thereof. Hence, the scope of the invention is only restricted by the appended patent claims.

Claims

1. A method for manufacturing a material web (W) such as a fibre web, characterised by: - manufacturing two sub-webs (W1 ,W2); and

- joining said sub-webs (W1 ,W2) from the side of open surfaces of said sub- webs (W 1 ,W2).

2. The method according to claim 1 , characterised by starting the method from manufacturing the surface (W11 ,W12) which will come to the material web

(W).

3. The method according to claim 1 or 2, characterised by starting manufacturing a sub-web by applying surface substance (11 ,12) to a forming surface.

4. The method according to any one of claims 1 to 3, characterised in that an inner layer (13,14,14') coming to the material web (W) is applied on top of a surface substance layer (11 ,12).

5. The method according to any one of claims 1 to 4, characterised in that the dry solids content of the surface substance pulp (11 ,12) being applied to the forming surface is at least 30 %.

6. The method according to any one of claims 1 to 5, characterised by:

- applying a first surface substance layer (11) onto a first forming surface (110a, 210a) for forming a first sub-web (W1) and a first outer surface (W11) of the material web (W); and

- applying a second surface substance layer (12) onto a second forming surface (120a, 220a) for forming a second sub-web (W2) and a second outer surface (W12) of the material web (W); and

- joining said sub-webs (W1 ,W2) to the material web (W) from the side of open surfaces of the sub-webs (W1 ,W2).

7. The method according to any one of claims 1 to 6, characterised by applying at least one inner layer (14,14') onto the open surface of at least one of said sub-webs (W1 , W2) before joining said sub-webs.

8. The method according to any one of claims 1 to 7, characterised by applying a joining substance layer (13) onto an open surface of at least one of said sub-webs (W1 , W2) before joining said sub-webs.

9. The method according to any one of claims 1 to 8, characterised in that at least one sub-web (W1 , W2) is being dried before joining the sub-webs (W1 , W2).

10. The method according to any one of claims 1 to 9, characterised by arranging at least one forming surface (110a,120a,210a,220a) to be impermeable to liquid.

11. The method according to any one of claims 1 to 10, characterised in that the sub-web (W 1 ,W2) is being dried by evaporating solvent such as water.

12. The method according to claim 11 , characterised in that the evaporating takes place substantially only through the open surface of the sub-web (W1 ,W2.).

13. The method according to any one of claims 1 to 12, characterised in that at least one sub-web (W1.W2) is being heated with help of the forming surface (110a,120a,210a,220a) and/or the open surface of at least one sub-web (W1 ,W2) is being heated.

14. The method according to any one of claims 1 to 13, characterised by:

- applying the first surface substance (11) onto a movable first forming surface (110a, 210a) for forming the first surface substance layer (11) and - and in that the first surface substance layer (11 ) is being dried, for forming the first sub-web (W1) and for forming the first outer surface (W11) of the material web (W) using the first forming surface (110a, 210a); and

- applying the second surface substance (12) onto a movable second forming surface (120a, 220a) for forming the second surface substance layer (12) and

- in that the second surface substance layer (12) is being dried, for forming the second sub-web (W2) and for forming the second outer surface

(W12) of the material web (W) using the second forming surface (120a, 220a); and - in that the first sub-web (W1) and the second sub-web (W2) are moved towards each other and said sub-webs (W1 ,W2) are joined to a material web (W) from the open sides of the sub-webs.

15. The method according to any one of claims 1 to 14, characterised by manufacturing the material web (W) without manufacturing base paper.

16. The method according to any one of claims 1 to 15, characterised by manufacturing at least one sub-web (W1 ,W2) without water removal through the forthcoming outer surfaces (W11 ,W12) of the material web.

17. An apparatus for manufacturing a material web (W) like a fibre web, characterised in that the apparatus comprises:

- a first forming surface (110a, 210a) for manufacturing a first sub-web (W1); and - a second forming surface (120a, 220a) for manufacturing a second sub- web (W2); and

- a contact area (N1 ,N2,N3) for joining said sub-webs (W1 ,W2) from open sides of the sub-webs (W1 ,W2).

18. The apparatus according to claim 17, characterised in that the apparatus comprises:

- the first forming surface (110a, 21 Oa) and

- at least one first applying device (11 1 , 211) for applying a first surface substance layer (11 ) onto the first forming surface (110a₁ 21 Oa) for manufacturing the first sub-web (W1) and for forming a first outer surface (W11) of the material web (W); and

- a second forming surface (120a, 220a) and

- at least one second applying device (112, 212) for applying a second surface substance layer (12) onto the second forming surface (120a, 220a) for forming the second sub-web (W2) and for forming a second outer surface (W12) of the material web (W); and

- said forming surfaces (110a,210a; 120a,220a) are arranged to be towards each other for forming the contact area (N1 ,N2,N3) of said sub-webs (W1.W2).

19. The apparatus according to claim 17 or 18, characterised in that the apparatus comprises at least one inner layer (14,14') applying device 141 ,142,241 ,242) which is arranged in the direction of movement of the forming surface (110a,120a,210a,220a) after the surface substance applying device (111 ,112,211 ,212) before the contact area (N1 ,N2,N3).

20. The apparatus according to any one of claims 17 to 19, characterised in that the apparatus comprises at least one joining substance (13) applying device (113, 213) arranged in the direction of movement of the forming surface (110a,120a,210a,220a) after the surface substance applying device (111 ,112,211 ,212) before the contact area (N1 ,N2,N3).

21. The apparatus according to any one of claims 17 to 20, characterised in that the apparatus comprises one drying device (121 ,110,210,220,350) for drying the material web (W) after the contact area (N 1 ,N2,N3).

22. The apparatus according to any one of claims 17 to 21 , characterised in that the apparatus comprises at least one forming surface (110a,120a,210a,220a) which is impermeable of liquid.

23. The apparatus according to any one of claims 17 to 22, characterised in that at least one forming surface (110a,120a,210a,220a) is heatable from the inside and/or from the outside.

24. The apparatus according to any one of claims 17 to 23, characterised in that the apparatus comprises at least one drying device (221 ,222) in connection with the forming surface (110a,120a,210a,220a) outside the forming surface.

25. The apparatus according to any one of claims 17 to 24, characterised in that the apparatus comprises at least one drying device (114,117) in connection with the forming surface (110a,120a,210a,220a) inside the forming surface.

26. The apparatus according to any one of claims 17 to 25, characterised in that the forming surface comprises a forming cylinder which has an optionally structured surface of a forming belt (110, 120) or of a forming cylinder (210, 220).

27. A system, characterised in that the system comprises the apparatus according to any one of claims 17 to 26 and a subsequently connected processing apparatus of the material web (W).

28. The system according to claim 27, characterised in that the processing apparatus of the material web (W) is chosen from a group of a reeler, a slitter- winder, a cross-directional cutter of the material web (W) such as a sheet cutter, and a printing press.

29. A fibre material product (W) such as a reelable fibre web or sheet, which fibre material (W) comprises: - a first surface substance layer(11) and a second surface substance layer

(12) formed of material components, which surface substance layers form the outer surfaces of the fibre material product (W) on opposite sides of the fibre material product (W), characterised in that - the material components of each surface substance layer (11 ,12) are evenly distributed in each surface substance layer in the thickness direction of the surface substance layer.