WO2012013781A1 - Toile fibreuse formée sur un tissu structuré - Google Patents

Toile fibreuse formée sur un tissu structuré Download PDF

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Publication number
WO2012013781A1
WO2012013781A1 PCT/EP2011/063101 EP2011063101W WO2012013781A1 WO 2012013781 A1 WO2012013781 A1 WO 2012013781A1 EP 2011063101 W EP2011063101 W EP 2011063101W WO 2012013781 A1 WO2012013781 A1 WO 2012013781A1
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WO
WIPO (PCT)
Prior art keywords
fabric
float
yarns
weave pattern
weave
Prior art date
Application number
PCT/EP2011/063101
Other languages
English (en)
Inventor
Scott Quigley
Original Assignee
Voith Patent Gmbh
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Voith Patent Gmbh filed Critical Voith Patent Gmbh
Publication of WO2012013781A1 publication Critical patent/WO2012013781A1/fr

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Classifications

    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21F—PAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
    • D21F11/00—Processes for making continuous lengths of paper, or of cardboard, or of wet web for fibre board production, on paper-making machines
    • D21F11/006—Making patterned paper
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21F—PAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
    • D21F1/00—Wet end of machines for making continuous webs of paper
    • D21F1/0027—Screen-cloths
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
    • D21H27/02—Patterned paper
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
    • D21H27/002—Tissue paper; Absorbent paper

Definitions

  • the present invention relates generally to papermaking, and relates more specifically to a fibrous web formed on a structured fabric employed in papermaking.
  • a water slurry, or suspension, of cellulosic fibers (known as the paper "stock") is fed into a gap between two endless woven wires that travels between two or more rolls.
  • At least one of the wires are often referred to as a "structured fabric” that provides a papermaking surface on the upper surface of its upper run which operates as a filter to separate the cellulosic fibers of the paper stock from the aqueous medium, thereby forming a wet paper web.
  • the aqueous medium drains through mesh openings of the structured fabric, known as drainage holes, by gravity or vacuum located on the lower surface of the upper run (i.e., the "machine side") of the fabric.
  • the paper web is transferred to a press section of the paper machine, where it is passed through the nips of one or more pairs of pressure rollers covered with another fabric, typically referred to as a "press felt.” Pressure from the rollers removes additional moisture from the web; the moisture removal is often enhanced by the presence of a "batt" layer of the press felt.
  • the paper is then transferred to a dryer section for further moisture removal . After drying, the paper is ready for secondary processing and packaging.
  • Typically, papermakers' fabrics are manufactured as endless belts by one of two basic weaving techniques.
  • fabrics are flat woven by a flat weaving process, with their ends being joined to form an endless belt by any one of a number of well- known joining methods, such as dismantling and reweaving the ends together (commonly known as splicing), or sewing on a pin-seamable flap or a special oldback on each end, then reweaving these into pin-seamable loops.
  • a number of auto-joining machines are available, which for certain fabrics may be used to automate at least part of the joining process.
  • the warp yarns extend in the machine direction and the filling yarns extend in the cross machine direction.
  • Effective sheet and fiber support are important considerations in papermaking, especially for the forming section of the papermaking machine, where the wet web is initially formed. Additionally, the structured fabrics should exhibit good stability when they are run at high speeds on the papermaking machines, and preferably are highly permeable to reduce the amount of water retained in the web when it is transferred to the press section of the paper machine.
  • tissue and fine paper applications i.e., paper for use in quality printing, carbonizing, cigarettes, electrical condensers, and the like
  • the papermaking surface comprises a very finely woven or fine wire mesh structure.
  • the sheet In a conventional tissue forming machine, the sheet is formed flat. At the press section, 100% of the sheet is pressed and compacted to reach the necessary dryness and the sheet is further dried on a Yankee and hood section. The sheet is then creped and wound-up, thereby producing a flat sheet.
  • a sheet is formed on a structured or molding fabric and the sheet is further sandwiched between the structured or molding fabric and a dewatering fabric.
  • the sheet is dewatered through the dewatering fabric and opposite the molding fabric.
  • the dewatering takes place with aiiflow and mechanical pressure.
  • the mechanical pressure is created by a permeable belt and the direction of air flow is from the permeable belt to the dewatering fabric. This can occur when the sandwich passes through an extended pressure nip formed by a vacuum roll and the permeable belt.
  • the sheet is then transferred to a Yankee by a press nip. Only about 25% of the sheet is slightly pressed by the Yankee while approximately 75% of the sheet remains unpressed for quality.
  • the sheet is dried by a Yankee/Hood dryer arrangement and then dry creped.
  • the ATMOSTM system one and the same structured fabric is used to carry the sheet from the headbox to the Yankee dryer.
  • the sheet reaches between about 35 to 38% dryness after the ATMOSTM roll, which is almost the same dryness as a conventional press section.
  • this advantageously occurs with almost 40 times lower nip pressure and without compacting and destroying sheet quality.
  • a big advantage of the ATMOS 1 M system is that it utilizes a permeable belt which is highly tensioned, e.g., about 60 kN/ni. This belt enhances the contact points and intimacy for maximum vacuum dewatering.
  • the belt nip is more than 20 times longer than a conventional press and utilizes aiiflow through the nip. which is not the case on a conventional press system.
  • TAD through-air drying
  • Absorbency capacity is also 30% ⁇ higher than with conventional TAD fonned towel fabrics. The results are the same whether one uses 100% virgin pulp up to 100% recycled pulp. Sheets can be produced with basis weight ratios of between 14 to 40 g/m 2 .
  • the ATMOSTM system also provides excellent sheet transfer to the Yankee working at 33 to 37% dryness.
  • a key aspect of the ATMOSTM system is that it forms the sheet on the molding fabric and the same molding fabric carries the sheet from the headbox to the Yankee dryer. This produces a sheet with a uniform and defined pore size for maximum absorbency capacity.
  • the fabric utilizes an at least three float warp and weft structure which, like the prior art fabrics, is symmetrical in form.
  • U.S. Pat. No. 5,429,686 to CHIU et al. discloses structured forming fabrics which utilize a load-bearing layer and a sculptured layer.
  • the fabrics utilize impression knuckles to imprint the sheet and increase its surface contour.
  • This document does not create pillows in the sheet for effective dewatering of TAD applications, nor does it teach using the disclosed fabrics on an ATMOSTM system and/or forming the pillows in the sheet while the sheet is relatively wet and utilizing a hi-tension press nip.
  • the invention provides a fibrous web including a fibrous construct having at least one formed surface feature.
  • the surface feature including a topographical pattern reflective of a weave pattern in a fabric used in a papermaking machine having a through-air drying system.
  • the fabric including a single layer of yarns arranged in a repeating weave pattern, each weave pattern including a plurality of waip yarns substantially oriented in a machine direction (MD) defining MD yarns; and a plurality of weft yarns substantially oriented in a cross machine direction (CD) defining CD yarns.
  • MD yarns each having at least one long float within the weave pattern. Each long float being adjacent to at least one other long float of an MD yarn.
  • the weave pattern being a plain weave apart from the long floats.
  • Fig. 1 shows a repeating weave pattern having a square shape of a top side or paper facing side of an embodiment of a structured fabric of the present invention, each ' X ' indicating a location where a warp MD yarn passes over a weft CD yarn;
  • Fig. 2 shows the weave pattern of the structured fabric of Fig. 1 ;
  • Fig. 3 shows a repeating weave pattern having a square shape of a top side or paper facing side of another embodiment of a structured fabric of the present invention, each "X v indicating a location where a warp MD yarn passes over a weft CD yarn;
  • Fig. 4 shows the weave pattern of the structured fabric of Fig. 3;
  • Fig. 5 shows a repeating weave pattern having a square shape of a top side or paper facing side of yet another embodiment of a structured fabric of the present invention, each K X V indicating a location where a warp MD yam passes over a weft CD yam;
  • Fig. 6 shows the weave pattern of the structured fabric of Fig. 5;
  • Fig. 7 shows a repeating weave pattern having a square shape of a top side or paper facing side of yet another embodiment of a structured fabric of the present invention, each V X V indicating a location where a waip MD yarn passes over a weft CD yarn;
  • Fig. 8 shows the weave pattern of the structured fabric of Fig. 7;
  • Fig. 9 shows a repeating weave pattern having a square shape of a top side or paper facing side of yet another embodiment of a structured fabric of the present invention, each V X V indicating a location where a warp MD yarn passes over a weft CD yarn;
  • Fig. 10 shows the weave pattern of the structured fabric of Fig. 9;
  • Fig. 1 1 shows a repeating weave pattern having a square shape of a top side or paper facing side of yet another embodiment of a structured fabric of the present invention, each * X" indicating a location where a warp MD yam passes over a weft CD yam;
  • Fig. 12 shows the weave pattern of the structured fabric of Fig. 1 1 ;
  • Fig. 13 shows a repeating weave pattern having a square shape of a top side or paper facing side of yet another embodiment of a structured fabric of the present invention, each K X" indicating a location where a warp MD yarn passes over a weft CD yam;
  • Fig. 14 shows the weave pattern of the structured fabric of Fig. 1 3;
  • Fig. 15 shows a repealing weave pattern having a square shape of a top side or paper facing side of yet another embodiment of a structured fabric of the present invention, each V X V indicating a location where a waip MD yam passes over a weft CD yam;
  • Fig. 16 shows the weave pattern of the structured fabric of Fig. 15;
  • Fig. 17 shows a repeating weave pattern having a square shape of a top side or paper facing side of yet another embodiment of a structured fabric of the present invention, each ⁇ X V indicating a iocation where a warp MD yarn passes over a weft CD yam;
  • Fig. 18 shows the weave pattern of the structured fabric of Fig. 17;
  • Fig. 19 shows a repeating weave pattern having a square shape of a top side or paper facing side of yet anoiher embodiment of a structured fabric of the present invention, each ⁇ X" indicating a location where a warp MD yarn passes over a weft CD yam;
  • Fig. 20 shows the weave pattern of the structured fabric of Fig. 19;
  • Fig. 21 shows a repeating weave pattern having a square shape of a top side or paper facing side of yet another embodiment of a structured fabric of the present invention, each ⁇ X ⁇ indicating a location where a watp MD yam passes over a weft CD yarn;
  • Fig. 22 shows the weave pattern of the structured fabric of Fig. 21 ;
  • Fig. 23 shows a repeating weave pattern having a square shape of a top side or paper facing side of yet another embodiment of a structured fabric of the present invention, each "X" indicating a location where a warp MD yarn passes over a weft CD yarn;
  • Fig. 24 shows the weave pattern of the structured fabric of Fig. 23;
  • Fig. 25 shows a repeating weave pattern having a square shape of a top side or paper facing side of yet another embodiment of a structured fabric of the present invention, each V X ⁇ indicating a location where a warp MD yarn passes over a weft CD yam;
  • Fig. 26 shows the weave pattern of the structured fabric of Fig. 25;
  • Fig. 27 shows a repeating weave pattern having a square shape of a top side or paper facing side of yet another embodiment of a structured fabric of the present invention, each V X V indicating a location where a waip MD yam passes over a weft CD yarn;
  • Fig. 28 shows the weave pattern of the structured fabric of Fig. 27;
  • Fig. 29 illustrates a schematic cross-sectional view of an embodiment of an ATMOS papennaking machine
  • FIG. 30 illustrates a schematic cross-sectional view of another embodiment of an ATMOSTM papennaking machine
  • FIG. 3 J illustrates a schematic cross-sectional view of another embodiment of an ATMOSTM papennaking machine
  • FIG. 32 illustrates a schematic cross-sectional view of another embodiment of an ATMOS 1 papennaking machine
  • FIG. 33 illustrates a schematic cross-sectional view of another embodiment of an ATMOSTM papennaking machine:
  • FIG. 34 illustrates a schematic cross-sectional view of another embodiment of an ATMOS papennaking machine
  • FIG. 35 illustrates a schematic cross-sectional view of another embodiment of an ATMOSTM papennaking machine
  • Fig. 36 illustrates a schematic cross-sectional view of another embodiment of an ATMOSTM papennaking machine
  • Fig. 37 is a schematic process flow diagram of a throughdrying process in accordance with this invention, illustrating an iincreped throughdrying process with only one throughdryer
  • Fig. 38 is a schematic process flow diagram of a throughdrying process in accordance with this invention, illustrating an uncreped throughdrying process having two horroughdryers in series;
  • Fig. 39 shows another schematic view of an apparatus for practicing the present invention product and process.
  • the present invention relates to a structured fabric for a papermaking machine, a former for manufacturing a paper web, and also to a former which utilizes the structured fabric, and in some embodiments a belt press, in a papermaking machine.
  • the present invention also relates to a twin wire former ATMOS system which utilizes the structured fabric which has good resistance to pressure and excessive tensile strain forces, and which can withstand wear/hydrolysis effects that are experienced in an ATMOSTM system.
  • the system may also include a permeable belt for use in a high tension extended nip around a rotating roil or a stationary shoe and a dewatering fabric for the manufacture of premium tissue or towel grades.
  • the fabric has key parameters which include permeability, weight, caliper, and certain compressibility.
  • Fig. 1 depicts a weave pattern 10 from a top pattern view of the web facing side of the fabric (i.e., a view of the papermaking surface).
  • the numbers 1 -20 shown on the bottom of the pattern identify the warp, machine direction (MD) yarns while the right side numbers 1 -20 show the weft, cross-direction (CD) yarns.
  • the symbol X illustrates a location where a waip yarn passes over a weft yarn and an empty box illustrates a location where a waip yarn passes under a weft yarn.
  • Fig. 1 depicts a weave pattern 10 from a top pattern view of the web facing side of the fabric (i.e., a view of the papermaking surface).
  • the numbers 1 -20 shown on the bottom of the pattern identify the warp, machine direction (MD) yarns while the right side numbers 1 -20 show the weft, cross-direction (CD) yarns.
  • the symbol X illustrates a location where a waip yarn passes over
  • the areas that are shaded indicate long float waip yarns, which float over at least two weft yarns.
  • the shaded areas form a MD float pattern, while the non-shaded areas represent a plain weave pattern.
  • the weave patterns of Figs. 3, 5. 7, 9, 1 1 , 1 3, 15. 17, 19. 21 , 23, 25. and 27 illustrate other embodiments of the present invention.
  • Fig. 2 illustrates the weave pattern of the MD yarns relative to the CD yarns with the CD yarns being represented in each line as the numbers, with the line being the pattern of the MD yarn.
  • Fig. 4 corresponds to Fig 3 and so on with the even numbered figures through Fig. 28, corresponding to the odd numbered figure that is numerically one less than the even numbered
  • the embodiments shown in Figs. 1 -28 are illustrative of the invention and the invention is not limited to the weave patterns shown therein.
  • the fabric of Figs. 1 -28 illustrates a repeating weave pattern square of the fabric that encompasses twenty MD warp yarns (yarns 1 -20 numbered along the bottom of each pattern) and twenty weft yarns (yarns 1 -20 that are numbered along the right side of each pattern).
  • the MD warp yam float is over at least four or even over at least five weft yarns.
  • the MD waip yarns have there long float they are always adjacent to at least one other MD warp yarn that is also undergoing a long float.
  • the float beginning and ending are offset in the MD by one weft yarn position.
  • the contiguous adjacent MD warp yarns form an MD yam float pattern, with at least one being present in each weave pattern 10.
  • the MD yarn float patterns are replicated in weave pattern 10, and includes mirror-image or reflected MD yarn float patterns.
  • the MD yarn float patterns can be symmetrical or asymmetrical. For example, in Fig.
  • Fig. 3 there are MD yam float patterns that are mirror-images and are symmetrical.
  • the MD yarns float over three weft yarns and are three MD yarns wide.
  • the weave of the single layer fabric is a simple weave pattern.
  • the plain weave pattern surrounds the MD yam float patterns, in some weave patterns, such as those of Figs. 1 7 and 19. the simple weave patterns appear surrounded by MD vara float patterns.
  • the parameters of the structured fabric shown in Figs. 1-28 can have a mesh (number of warp yarns per inch) and a count (number of weft yarns per inch) of any amount.
  • the single- layered fabric should have a high penneability value due to the nature of a single layer fabric and the way it is woven.
  • the particular size of the yarns is typically governed by the mesh of the papermaking surface and the yarn size can be selected based upon the intended use. Fabrics employing these yarn sizes may be implemented with polyester yarns or with a combination of polyester and nylon yarns.
  • the structured fabric can also be treated and/or coated with an additional polymeric material that is applied by, e.g., deposition.
  • the material can be added cross-linked during processing in order to enhance fabric stability, contamination resistance, drainage, wearability, improve heat and/or hydrolysis resistance and in order to reduce fabric surface tension. This aids in sheet release and/or reduced drive loads.
  • the treatment/coating can be applied to
  • the topographical pattern in the paper web can be changed and manipulated by use of different single -layer weaves. Further enhancement of the pattern can be attained by adjustments to the specific fabric weave by changes to the yarn diameter, yam counts, yarn types, yarn shapes, permeability, caliper and the addition of a treatment or coating etc.
  • a printed design such as a screen-printed design, of polymeric material can be applied to the fabric to enhance its ability to impart an aesthetic pattern into the web or to enhance the quality of the web.
  • one or more surfaces of the fabric or molding belt can be subjected to sanding and/or abrading in order to enhance surface characteristics.
  • the characteristics of the individual yarns utilized in the fabric of the present invention can vary depending upon the desired properties of the final papermakers' fabric.
  • the materials comprising yarns employed in the fabric of the present invention may be those commonly used in papermakers' fabric.
  • the yarns may be formed of polypropylene, polyester, nylon, or the like. The skilled aitisan should select a yarn material according to the particular application of the final fabric.
  • the structured fabric is a single-layered woven fabric which can withstand high pressures, heat, moisture concentrations, and which can achieve a high level of water removal and also mold or emboss the paper web. These characteristics provide a structured fabric appropriate for the Voith ATMOS ' papermaking process.
  • the fabric preferably has a width stability and a suitable high permeability and preferably utilizes hydrolysis and/or temperature resistant materials, as discussed above.
  • the fabric is preferably a woven fabric that can be installed on an ATMOSTM machine as a pre-joined and/or seamed continuous and/or endless belt. Alternatively, the structured fabric can be joined in the
  • ATMOSTM machine using, e.g., a pin-seam arrangement or can otherwise be seamed on the machine.
  • the invention also provides for utilizing the structured fabric disclosed herein on a machine for making a fibrous web, e.g., tissue or hygiene paper web. etc.. which can be, e.g.. a twin wire + a permeable belt ATMOSTM system.
  • a fibrous web machine including a headbox 22 that discharges a fibrous slurry between a forming fabric 26 and a structured fabric 28 having a weave pattern 10.
  • structured fabric 28 is an embodiment of the structured fabric discussed above in connection with Figs. 1 -28.
  • Rollers 30 and 32 direct fabric 26 in such a manner that tension is applied thereto, against slurry 24 and structured fabric 28.
  • Structured fabric 28 is supported by forming roll 34 which rotates with a surface speed that matches the speed of structured fabric 28 and forming fabric 26. Structured fabric 28 has peaks and valleys as defined by weave pattern 10, which give a corresponding structure to web 38 formed thereon. Structured fabric 28 travels in a web direction, and as moisture is driven from the fibrous slurry, structured fibrous web 38 takes form. The moisture that leaves the slurry travels through forming fabric 26.
  • the fibrous slurry is formed into a web 38 with a structure that matches the shape of structured fabric 28.
  • Forming fabric 26 is porous and allows moisture to escape during forming. Further, water is removed through dewatering fabric 82. The removal of moisture through fabric 82 does not cause compression of web 38 traveling on structured fabric 28.
  • Structured fabric 28 carries a three dimensional structured fibrous web 38 to an advanced dewatering system 50, past vacuum box 67 and then to a position where the web is transferred to Yankee dryer 52 and hood section 54 for additional drying and creping before winding up on a reel (not shown).
  • a shoe press 56 is placed adjacent to structured fabric 28, holding fabric 28 in a position proximate Yankee dryer 52. Structured fibrous web 38 comes into contact with Yankee dryer 52 and transfers to a surface thereof, for further drying and subsequent creping.
  • a vacuum box. 58 is placed adjacent to structured fabric 28 to achieve improved solids levels. Web 38, which is carried by structured fabric 28, contacts dewatering fabric 82 and proceeds toward vacuum roll 60. Vacuum roll 60 operates at a vacuum level of -0.2 to -0.8 bar with a preferred operating level of at least -0.4 bar. Hot air hood 62 is optionally fit over vacuum roll 60 to improve dewatering.
  • a steam box can be installed instead of the hood 62 supplying steam to the web 38.
  • the steam box preferably has a sectionalized design to influence the moisture re-dryness cross profile of the web 38.
  • the length of the vacuum zone inside the vacuum roll 60 can be from 200 mm to 2,500 mm, with a preferable length of 300 mm to 1 ,200 mm and an even more preferable length of between 400 mm to 800 mm.
  • the solids level of web 38 leaving suction roll 60 is 25% to 55% depending on installed options.
  • a vacuum box 67 and hot air supply 65 can be used to increase web 38 solids after vacuum roll 60 and prior to Yankee dryer 52.
  • Wire turning roll 69 can also be a suction roll with a hot air supply hood.
  • roll 56 includes a shoe press with a shoe width of 80 mm or higher, preferably 120 mm or higher, with a maximum peak pressure of less than 2.5 MPa.
  • shoe press with a shoe width of 80 mm or higher, preferably 120 mm or higher, with a maximum peak pressure of less than 2.5 MPa.
  • Belt press 64 includes a permeable belt 66 capable of applying pressure to the machine side of structured fabric 28 that carries web 38 around vacuum roll 60.
  • Fabric 66 of belt press 64 is also known as an extended nip press belt or a link fabric, which can run at 60 KN/m fabric tension with a pressing length that is longer than the suction zone of roll 60.
  • Belt 66 is a specially designed extended nip press belt 66, made of, for example reinforced pol vurethane and/or a spiral link fabric. Belt 66 also can have a woven construction. Such a woven construction is disclosed, e.g., in EP 1837439. Belt 66 is permeable thereby allowing air to flow there through to enhance the moisture removing capability of belt press 64. Moisture is drawn from web 38 through dewatcring fabric 82 and into vacuum roll 60.
  • FIG. 31 there is shown another embodiment of the present invention which is substantially similar to the embodiment shown in Fig. 30 with the addition of hot air hood 68 placed inside of belt press 64 to enhance the dewatering capability of belt press 64 in conjunction with vacuum roll 60.
  • Fig. 32 there is shown yet another embodiment of the present invention, which is substantially similar to the embodiment shown in Fig. 30, but including a boost dryer 70 which encounters structured fabric 28.
  • Web 38 is subjected to a hot surface of boost dryer 70. and structured web 38 rides around boost dryer 70 with another woven fabric 72 riding on top of structured fabric 28.
  • On top of woven fabric 72 is a thermally conductive fabric 74, which is in contact with both woven fabric 72 and a cooling jacket 76 that applies cooling and pressure to all fabrics and web 38.
  • the pressing process does not negatively impact web quality.
  • the drying rate of boost dryer 70 is above 400 kg/hr m 2 and preferably above 500 kg/hr nr.
  • boost dryer 70 provides sufficient pressure to hold web 38 against the hot surface of the dryer thus preventing blistering.
  • Steam that is formed at the knuckle points of fabric 28 passes through fabric 28 and is condensed on fabric 72.
  • Fabric 72 is cooled by fabric 74 that is in contact with cooling jacket 76, which reduces its temperature to well below that of the steam.
  • cooling jacket 76 reduces its temperature to well below that of the steam.
  • the condensed water is captured in woven fabric 72, which is de-watered by dewatering device 75. It has been shown that depending on the size of boost dryer 70. the need for vacuum roll 60 can be eliminated. Further, depending on the size of boost dryer 70, web 38 may be creped on the surface of boost dryer 70, thereby eliminating the need for Yankee dryer 52.
  • FIG. 33 there is shown yet another embodiment of the present invention substantially similar to the invention disclosed in Fig. 30 but with an addition of an air press 78, which is a four roll cluster press that is used with high temperature air and is referred to as a High Pressure Through Air Dryer (HPTAD) for additional web drying prior to the transfer of web 38 to Yankee dryer 52.
  • An air press 78 which is a four roll cluster press that is used with high temperature air and is referred to as a High Pressure Through Air Dryer (HPTAD) for additional web drying prior to the transfer of web 38 to Yankee dryer 52.
  • Four-roll cluster press 78 includes a main roll, a vented roll, and two cap rolls. The purpose of this cluster press is to provide a sealed chamber that is capable of being pressurized. The pressure, chamber contains high temperature air.
  • the high-pressure hot air passes through an optional air dispersion fabric, through web 38 and fabric structured 28 into a vent roll.
  • the air dispersion fabric may prevent web 38 from following one of the cap rolls.
  • the air dispersion fabric is very open, having a permeability that equals or exceeds that of fabric structured 28.
  • the drying rate of the HPTAD depends on the solids content of web 38 as it enters the HPTAD.
  • the preferred drying rate is at least 500 kg/hr nr. which is a rate of at least twice that of conventional TAD machines.
  • the compact size of the HPTAD allows for easy retrofitting to an existing machine.
  • the compact size of the HPTAD and the fact that it is a closed system means that it can be easily insulated and optimized as a unit to increase energy efficiency.
  • FIG. 34 there is shown another embodiment of the present invention. This is significantly similar to the embodiments shown in Figs. 30 and 33 except for the addition of a two-pass HPTAD 80.
  • two vented rolls are used to double the dwell time of structured web 38 relative to the design shown in Fig. 33.
  • An optional coarse mesh fabric may be used as in the previous embodiment.
  • Hot pressurized air passes through web 38 carried on structured fabric 28 and onto the two vent rolls. It has been shown that depending on the configuration and size of the HPTAD, more than one HPTAD can be placed in series, which can eliminate the need for roll 60.
  • a conventional twin wire former 90 may be used to replace the crescent former shown in previous examples.
  • the forming roll can be either a solid or open roll. If an open roll is used, care must be taken to prevent significant dewatering through the structured fabric to avoid losing basis weight in the pillow areas.
  • the outer forming fabric 93 can be either a standard forming fabric or one such as that disclosed in U.S. Pat. No. 6,237,644.
  • the inner fabric 91 should be a structured fabric that is much coarser than the outer forming fabric 90.
  • inner fabric 91 may be similar to structured fabric 28.
  • a vacuum roll 92 may be needed to ensure that the web stays with structured fabric 91 and does not go with outer wire 90.
  • Web 38 is transferred to structured fabric 28 using a vacuum device,
  • the transfer can be a stationary vacuum shoe or a vacuum assisted rotating pick-up roll 94.
  • the second structured fabric 28 is at least the same coarseness and preferably coarser than first structured fabric 91 .
  • the process from this point is the same as the process previously discussed in conjunction with Fig. 30.
  • the registration of the web from the first structured fabric to the second structured fabric is not perfect, and as such some pillows will lose some basis weight during the expansion process, thereby losing some of the benefit of the present invention.
  • this process option allows for running a differential speed transfer, which has been shown to improve some sheet properties. Any of the arrangements for removing water discussed above as may be used with the twin wire former arrangement and a conventional TAD.
  • FIG. 36 there is illustrated another ATMO$ 1 M system having many elements as discussed above.
  • the ATMOSTM system of Fig 36 is further described in WO 2010/069695 having a priority date of December 19, 2008.
  • Belt press 64 constitutes a first pressing zone where web 38 is pressed.
  • Web 38 proceeds to a second pressing zone 65 where web 38 is pressed again.
  • Figs. 37-39 illustrate types of TAD systems, specifically those described in the patent record of Kimberly-Clark ( See WO 2005/073461 A l ) and Procter & Gamble ( See WO 2005/073461 A l ) and Procter & Gamble ( See WO 2005/073461 A l ) and Procter & Gamble ( See WO 2005/073461 A l ) and Procter & Gamble ( See WO
  • FIG. 37 illustrates one of many papermaking processes to which the invention is applicable. Shown is an uncreped throughdried tissue process in which a twin wire former having a layered papermaking headbox 205 injects or deposits a stream of an aqueous suspension of papermaking fibers between two forming fabrics 206 and 207.
  • Forming fabric 207 being the same as structured fabric 28, discussed above. Forming fabric 207 serves to support and carry the newly-formed wet web 208 downstream in the process as the web is partially dewatered to an appropriate consistency, such as about 10% dry weight percent.
  • profiling of the web in accordance with this invention takes place at the point in the process where the exhaust gas recovery plenum 21 1 and the vacuum box(es) 210 are positioned.
  • Additional dewatering of the wet web can be carried out. such as by vacuum suction, using one or more steam boxes in conjunction with one or more vacuum suction boxes (not shown) while the wet web is supported by the forming fabric 207.
  • the wet web 208 is then transferred from the forming fabric 207 to a transfer fabric 213 traveling at a slower speed than the forming fabric 207 in order to impart increased MD stretch into the web.
  • the transfer is carried out to avoid compression of the wet web, preferably with the assistance of a vacuum shoe 214.
  • the profiling it is within the scope of this invention for the profiling to take place at any point while the web is supported by the transfer fabric as well as the forming fabric 207.
  • the web is then transferred from the transfer fabric 213 to the throughdrying fabric 220 with the aid of a vacuum transfer roil 215 or a vacuum transfer shoe. Transfer is preferably carried out with vacuum assistance to ensure deformation of the sheet to conform to the throughdrying fabric, thus yielding desired bulk, flexibility. CD stretch and appearance.
  • the vacuum shoe (negative pressure) can be supplemented or replaced by the use of positive pressure from the opposite side of the web to blow the web onto the next fabric in addition to or as a replacement for sucking it onto the next fabric with vacuum.
  • a vacuum roll or rolls can be used to replace the vacuum shoe(s).
  • the web While supported by the throughdrying fabric 220. the web is dried to a final consistency, typically about 94 percent or greater, by the rulingoughdryer 225 and thereafter transferred to a carrier fabric 230.
  • the dried basesheet 227 is transported to the reel 235 using carrier fabric 230 and an optional carrier fabric 231.
  • An optional pressurized turning roll 233 can be used to facilitate transfer of the web from carrier fabric 230 to fabric 23 1.
  • reel calendering or subsequent off-line calendering can be used to improve the smoothness and softness of the basesheet.
  • the hot air used to dry the web while passing over the throughdryer is provided by a burner 240 and distributed over the sutface of the throughdrying drum using a hood 241.
  • the air is drawn through the web into the interior of the throughdrying drum via fan 243 which serves to circulate the air back to the burner.
  • fan 243 which serves to circulate the air back to the burner.
  • a portion of the spent air is vented 245. while a proportionate amount of fresh make-up air 247 is fed to the burner.
  • the exhaust gas recycle stream 250 provides exhaust gas to the exhaust gas recovery plenum 21 1 operatively positioned in the vicinity of one or more vacuum suction boxes 210, such that exhaust gas fed to the exhaust gas recovery plenum is drawn through the web, through the papermaking fabric and into the vacuum box(es) in order to control the consistency profile the web.
  • the humidity of the recycled exhaust gas can be about 0.15 pounds of water vapor or greater per pound of air, more specifically about 0.20 pounds of water vapor or greater per pound of air, and still more specifically about 0.25 pounds of water vapor or greater per pound of air.
  • Fig. 38 is a schematic process flow diagram of another throughdrying process in accordance with this invention, similar to that illustrated in Fig. 37, but in which two
  • fhroughdryers are used in series to dry the web.
  • the components of the second throughdryer are given the same reference numbers used for the first throughdryer, but distinguished with a "prime".
  • the exhaust gas from the first (primary) throughdryer is recycled to the exhaust gas recovery plenum 2 1 1 because of its relatively greater heat value.
  • the exhaust gas from the second throughdryer can be used for the recycle stream to the exhaust gas recovery plenum 21 1.
  • exhaust gas from the second throughdryer can be used to heat and/or profile the dewatered web by providing an exhaust gas recycle stream 255 which, as shown, is directed to exhaust gas recovery plenum 256 opposite vacuum roll or shoe 257.
  • exhaust gas recycle stream 255 which, as shown, is directed to exhaust gas recovery plenum 256 opposite vacuum roll or shoe 257.
  • Any of the web- contacting or sheet-contacting rolls in the vicinity of vacuum roll or shoe 257 are also suitable locations for introducing the exhaust gas for purposes of profiling in accordance with this invention should these rolls be equipped with vacuum.
  • a vacuum box can be placed within the loop of fabric 2 13 and the plenum 256 can be placed operative] ⁇ ' opposite this vacuum box to profile the web.
  • one fibrous structure useful in achieving the fibrous structure paper product of the present invention is the through-air-dried (TAD), differential density structure described in U.S. Pat. No. 4,528,239.
  • TAD through-air-dried
  • the apparatus 300 includes a head box 310, a Fourdrinier section 320 comprising a Fourdrinier wire 322, a press section 330 comprising a TAD carrier fabric 332, which is the same as structured fabric 28 discussed above and a Yankee Dryer 340.
  • the papermaking machine such that there is a differential velocity between the TAD carrier fabric 332 and the Fourdrinier wire 322 to provide increased fibers in the pillow regions of the fibrous web.
  • the Fourdrinier wire 322 may even run at a higher speed than the TAD carrier fabric 332.
  • Fourdrinier wire is from about 0% to about -6% of the TAD earner fabric (wire-to-press draw of from about 0% to about -6%).
  • a resin coated belt may be used instead of a TAD carrier fabric.

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Abstract

L'invention concerne une toile fibreuse comprenant une structure fibreuse ayant au moins une caractéristique formée sur sa surface, la caractéristique de surface comprenant un motif topographique ressemblant à un dessin d'armure dans un tissu utilisé dans une machine de fabrication de papier comportant un système de séchage traversant, le tissu comprenant une couche unique de fils organisés en un dessin d'armure répétitif, ledit dessin d'armure comprenant une pluralité de fils de chaîne pratiquement orientés dans la direction de la machine (MD) définissant des fils MD et une pluralité de fils de trame pratiquement orientés dans la direction perpendiculaire à la machine (CD) définissant des fils CD, les fils MD comportant chacun au moins un long flotté dans le dessin d'armure, chaque long flotté étant adjacent à au moins un autre long flotté d'un fil MD, le dessin d'armure étant une armure toile excepté pour les longs flottés.
PCT/EP2011/063101 2010-07-30 2011-07-29 Toile fibreuse formée sur un tissu structuré WO2012013781A1 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US12/847,519 US20120024489A1 (en) 2010-07-30 2010-07-30 Structured fabric
US12/847,519 2010-07-30
US12/969,849 US20120024487A1 (en) 2010-07-30 2010-12-16 Fibrous web formed on a structured fabric
US12/969,849 2010-12-16

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WO2012013781A1 true WO2012013781A1 (fr) 2012-02-02

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PCT/EP2011/063101 WO2012013781A1 (fr) 2010-07-30 2011-07-29 Toile fibreuse formée sur un tissu structuré
PCT/EP2011/063093 WO2012013778A1 (fr) 2010-07-30 2011-07-29 Toile fibreuse formée sur un tissu structuré
PCT/EP2011/063084 WO2012013773A1 (fr) 2010-07-30 2011-07-29 Tissu structuré

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PCT/EP2011/063093 WO2012013778A1 (fr) 2010-07-30 2011-07-29 Toile fibreuse formée sur un tissu structuré
PCT/EP2011/063084 WO2012013773A1 (fr) 2010-07-30 2011-07-29 Tissu structuré

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DE202014001502U1 (de) * 2013-03-01 2014-03-21 Voith Patent Gmbh Gewobenes Sieb mit flachen Kettfäden
SE537959C2 (sv) 2013-03-27 2015-12-08 Valmet Aktiebolag Rullstol och förfarande för upprullning av en pappersbana itorränden av en pappersmaskin
SE537744C2 (sv) * 2013-04-26 2015-10-13 Valmet Aktiebolag Rullstol för upprullning av en pappersbana till en rulle ochförfarande för upprullning av en pappersbana för att bildaen rulle
MX368475B (es) 2013-09-09 2019-10-04 Valmet Oy Bobinadora y método para enrollar en un rollo una membrana de papel y para iniciar un nuevo rollo.
EA038862B1 (ru) 2013-11-14 2021-10-29 Джиписипи Айпи Холдингз Элэлси Способ определения характеристик ткани (варианты)
WO2015149992A1 (fr) * 2014-04-02 2015-10-08 Voith Patent Gmbh Tissu pour machine à papier
WO2017139786A1 (fr) * 2016-02-11 2017-08-17 Structured I, Llc Courroie ou tissu comprenant une couche polymère pour machine à papier
DE102016206387A1 (de) 2016-04-15 2017-10-19 Voith Patent Gmbh Verfahren und Formierband zur Herstellung einer Faserstoffbahn
DE102018114748A1 (de) 2018-06-20 2019-12-24 Voith Patent Gmbh Laminierte Papiermaschinenbespannung
WO2022106385A1 (fr) * 2020-11-23 2022-05-27 Voith Patent Gmbh Tissu structuré tissé ayant des lignes de sergé qui se croisent

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US3974025A (en) * 1974-04-01 1976-08-10 The Procter & Gamble Company Absorbent paper having imprinted thereon a semi-twill, fabric knuckle pattern prior to final drying
US4191609A (en) * 1979-03-09 1980-03-04 The Procter & Gamble Company Soft absorbent imprinted paper sheet and method of manufacture thereof
US4528239A (en) 1983-08-23 1985-07-09 The Procter & Gamble Company Deflection member
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US20070175534A1 (en) * 2006-01-31 2007-08-02 Astenjohnson, Inc. Single layer papermakers fabric
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WO2009069046A1 (fr) 2007-11-26 2009-06-04 The Procter & Gamble Company Produit de structure fibreuse formé à l'état humide
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US20120024487A1 (en) 2012-02-02
US20120024486A1 (en) 2012-02-02
WO2012013778A1 (fr) 2012-02-02
US20120024489A1 (en) 2012-02-02

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