CA2034656C - Structure for extracting water from a paper web in a papermaking process - Google Patents

Structure for extracting water from a paper web in a papermaking process

Info

Publication number
CA2034656C
CA2034656C CA 2034656 CA2034656A CA2034656C CA 2034656 C CA2034656 C CA 2034656C CA 2034656 CA2034656 CA 2034656 CA 2034656 A CA2034656 A CA 2034656A CA 2034656 C CA2034656 C CA 2034656C
Authority
CA
Canada
Prior art keywords
layer
web
water
outer layer
paper web
Prior art date
Legal status (The legal status 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 status listed.)
Expired - Fee Related
Application number
CA 2034656
Other languages
French (fr)
Inventor
Thomas G. Gulya
Michael C. Johnson
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Appleton Mills
Original Assignee
Appleton Mills
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 Appleton Mills filed Critical Appleton Mills
Application granted granted Critical
Publication of CA2034656C publication Critical patent/CA2034656C/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/065—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/024—Woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21F—PAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
    • D21F7/00—Other details of machines for making continuous webs of paper
    • D21F7/08—Felts
    • D21F7/083—Multi-layer felts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0278—Polyurethane
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/10—Fibres of continuous length
    • B32B2305/18—Fabrics, textiles
    • B32B2305/188—Woven fabrics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/38—Meshes, lattices or nets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/726—Permeability to liquids, absorption
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24273—Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
    • Y10T428/24322—Composite web or sheet
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24273—Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
    • Y10T428/24322—Composite web or sheet
    • Y10T428/24331—Composite web or sheet including nonapertured component
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249981—Plural void-containing components
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/10—Scrim [e.g., open net or mesh, gauze, loose or open weave or knit, etc.]
    • Y10T442/184—Nonwoven scrim
    • Y10T442/195—Including a foam layer

Abstract

STRUCTURE FOR EXTRACTING WATER FROM
A PAPER WEB IN A PAPERMAKING PROCESS
Abstract of the Disclosure A composite structure for extracting water from a wet paper web in a papermaking process. The structure includes a base or substrate and a layer of water permeable polymeric foam, such as polyurethane foam, is secured to a surface of the substrate and an outer web supporting layer of water permeable polymeric material is bonded to the outer surface of the foam layer. The outer polymeric layer provides a smooth web supporting surface having toughness and abrasion resistance.

Description

~034~

STR~CT~RE EOR EY~TRACTING I~ATER FRO'~
A PAPER ~EB Il~ A PAPERMAKING PROCESS
Background of the Invention A papermaker's felt is used in the press section of a papermaking machine to support the paper web as the web is passed through the nip between a pair of cooperating press rolls to extract water from the web.
During endless travel of the felt in the press section of the papermaking machine, the web-supporting surface of the felt is normally passed in direct contact with one or more uhle boxes or suction boxes, and may also ride against supporting rolls, both of which can cause abrasion to the web supporting sur-face. Additional abrasion can be caused by slippage of the felt, such as slippage between the felt and the paper web, slippage between the felt and rolls, and slippage between two felts. Thus the web carrying surface of the felt must have a certain flexibility and toughness to withstand this abrasive action.
In addition, the felt is subjected to sub-stantial compressive stress as it passes through the nip between the press rolls, and the web supporting surface of the felt must be resistant to the compres-sive stress to prevent tearing or rupture.
It has been proposed to utilize a polymeric foam material, such as polyurcthane foam, a-; a wcb-supporting component in a EeL~. ~lowever, ~he foam layer, if skived to thickness, has an outer web-supporting surface which is too weak to resist abrasion and other dynamic forces to which the felt is exposed in the papermaking process so that the foam material tends to abrade and tear away in large pieces which are detrimental to the paper machine operation.
-2- '~03~6S6 On the other hand, it is possible to form a polymeric foam layer with a relatively thick and rubbery surface skin, and while a skin of this type is capable of resisting abrasion, it lacks the necessary permeability to be used as a web-supporting surface in a papermaker's felt.
Summary of the Invention The invention is directed to a composite structure, such as a papermaker's felt, be used in a papermaking process for extracting water from a wet paper ~eb. In accordance with the invention, the composite structure includes a base or substrate that can be formed of natural or synthetic materials either in a woven, unwoven, or extruded form.
A layer of water permeable polymeric foam, such as polyurethane foam, is secured to a surface oE
the substrate, and a thin outer layer of water perme-able polymeric material is bonded to the outer surface of the foam layer.
The outer layer can be a latex or resin hav-ing a thickness generally in the range oE 1 to 40 mils.
The permeability for the outer layer can be achieved by preforming a sheet of the material with a mutliplicity of holes, or the outer layer can take the form of a latex or thermoplastic film having a natural, as-Eormed porosity. The outer layer pro~;cles ,a Elexiblo, tougll skin Eor the structure which will resisL clbrasion and tearing during service.
By preforming holes in the outer web-supporting layer, controlled permeability is obtained to provide more accurate control of the water extrac-tion from the paper web.
The outer polymeric layer provides a smooth web supporting surface which will not mar the web and thus provides a better quality of product.

_3_ ~03465fi The controlled porosity of the outer web supporting layer also reduces backflow through the felt. By proper selection of the pore or hole size in the outer layer, flow transmission can be limited to as little as vapor when pressures are reduced below 2Q
psi, thus minimizing back flow of water into the web as the web and felt emerge from the nip.
~ here a polymeric foam layer is employed as the web support, air is carried in the surface layer of the cells of the foam, and the air is pushed out under the paper web as the web and felt are converging in the nip which results in "blowing" of the sheet. As the felt structure of the invention has a relatively smooth outer surface or skin, there is less air carrying capacity, thereby minimizing "blowing" of the paper web.
Other objects and advantages will appear in the course of the following description:
Description of the Drawings The drawings illustrate the best mode presently contemplated of carrying out the invention.
In the drawings:
Fig. 1 is a transverse section showing the felt structure of the invention; and Fig. 2 is a schematic drawing of the method of producing tlle felt structure.
Description Of Thc-! Illusl:Lated l;'mt~o(3iment Fig. 1 illustrates a composite structure to be used for supporting a wet paper web or sheet in a papermaking process, and has particular application as a felt in the press section of the papermaking machine.
As illustrated in Fig. 1, the structure includes a base or substrate 1 and a layer of water permeable, polymeric foam 2 is secured to a surface of the base. A thin, flexible, water permeable layer of -4- ~ ~3465 polymeric material 3 is bonded to the outer surEace of the foam layer 2.
Substrate 1 can be formed of synthetic or natural materials and may consist of woven fabric, non-woven or randomly oriented fibrous material, needled batt, or non-woven extruded synthetic mesh.
Foam layer 2 is preferably an open or reticulated cell structure composed of a multiplicity of interconnected cells. The foam layer can be formed of a material, such as a polyurethane foam.
Alternately, the foam layer 2 can be constructed as described in ~.S. Patent 4,830,905 in which a closed cell foam is needled to the substrate 1, the needling acting to rupture the closed-cell structure to provide porosity for the foam layer.
The water permeable outer or skin layer 3 has a thickness in the range of 1 to 40 mils, and prefer-ably in the range of 10 to 20 mils. Outer layer 3 can take the form of a latex or a crosslinkable thermoplastic resin such as nylon, polyvinylchloride, acrylic, polyurethane or the like.
The water porosity of outer layer 3 can be provided by forming a multiplicity of holes or pores 4, preferably in a regular patern, in a sheet or film of the polymeric material. Alternately, certain films such as latex and polyvinylchloride, as Eorrnecl, are water permeable so that it ;s not necessary to punch or otherwise form holes in the material.
It is also contemplated that outer ]ayer 3 can take the form of spun bonded synthetic ~ibers, such as polyethylene or polypropylene fibers.
Outer layer 3 is flexible and tough and serves to support the paper web as the web is passed through the nip between cooperating press rolls.

_5 2034~S6 Fig. 2 represents schematically a manner of producing the felt structure of the inve~tion. As shown in Fig. 2, a pair of conveyor belts 5 and 6 formed of fabric, plastic, or metal, are each mounted for endless travel on a series of rollers 7. As shown in Fig. 2, the lower conveyor belt 5 projects beyond the end of the upper belt 6.
Layer 3, which can be in the form of a sheet or film of the polymeric material having a multiplicity of preformed pores or holes, is fed from a roll or coil into the projecting end of conveyor belt 5. A mixing head 8 is located above the projecting end of belt S
and a liquid foamable resin, such as polyurethane, is discharged from head 8 onto the upper surface of the sheet 3. After application of the foamable resin, the base or substrate 1 is applied to the upper surface of the foamable resin layer 2. The composite structure is then passed between the cooperating belts 5 and 6, and expansion or foaming of the liquid resin will cause the foam material to partially penetrate into the sub-strate, and to firmly bond to both the substrate and the layer 3. The belts 5 and 6 can be heated to accel-erate reaction of the components of the foamable resin composition.
As an alternate method, a coating of a liquid thermoplastic resin or latex can be apl-lied to th~
upper surface of a polymeric Eoam laycr which is honded to a substrate, and the latex will bond to the inter-mediate foam layer 2. However, this method requires accurate viscosity control of the resin or latex coat-ing to prevent clogging of the cells of the foam with the liquid resin or latex.
The structure of the invention has particular use as a felt in the press section of a papermaking machine in which the wet paper web is supported on the -6- X03~656 outer layer 3, as the paper web passes through the nip between a pair of cooperating press rolls. The holes or pores 4 in the outer layer 3 serve to regulate the water flow throuyh the felt, and it is preferred that the porosity of the outer layer 3 be slightly less than the porosity of the foam layer 2 and substrate 1, so that the outer layer 3 comprises the flow controlling component.
As the paper web and felt ernerge from the nip and the compressive force is released, there is a tendency for water to be drawn back into the web from the felt. By proper selection of the size of pores 4, backflow of water at reduced pressure can be minimi~ed or prevented.
The outer layer 3 has a relatively smooth surface which will not mar the paper web and will thus produce a more acceptable product.
As the outer layer 3 is flexible and tough, the felt structure is less susceptible to abrasion and tearing during use, thus providing a longer service life for the felt and correspondingly decreasing down-time of the papermakiny machine.

~)34656 Various modes of carrying out the invention are contemplated as being within the scope of the following claims particularly pointing o~t and distinctly claiming the subject matter of the invention:

Claims (18)

1. A structure to support a paper web in a papermaking process, comprising a substrate, a layer of water permeable polymeric foam secured to said sub-strate, and a tough, flexible, thin layer of water permeable polymeric material bonded to said foam layer and disposed to support a paper web in a papermaking process.
2. The structure of claim 1, wherein said outer polymeric layer has a thickness of 1 to 40 mils.
3. The structure of claim 1, wherein the outer layer is composed of a crosslinkable thermoplastic resin.
4. The structure of claim 1, wherein the outer layer is composed of spun bonded polymeric fibers.
5. The structure of claim 1, wherein said outer layer has a multiplicity of pores distributed in a regular pattern over the surface of the said outer layer.
6. The structure of claim 1, wherein said substrate comprises a needled fabric.
7. The structure of claim 1, wherein said substrate comprises a woven fabric.
8. The structure of claim 1, wherein said substrate comprises extruded synthetic mesh.
9. The structure of claim 1, wherein said foam layer comprises polyurethane foam having a multi-plicity of interconnected cells.
10. A structure to support a paper web in a papermaking process, comprising a substrate, a layer of water permeable polymeric foam secured to a surface of the substrate and having a plurality of innerconnected cells, and a flexible tough outer layer of water perme-able polymeric material bonded to said foam layer and having a thickness in the range of 1 to 40 mils.
11. The structure of claim 10, wherein said outer layer comprises a sheet having a multiplicity of pores extending therethrough.
12. The structure of claim 10, wherein the water permeability of said outer layer is less than the water permeability of said foam layer.
13. The structure of claim 11, wherein said structure is a press felt adapted to support a paper web as the felt and the web are subjected to a compres-sive stress to thereby extract water from said web and flow the extracted water through said structure.
14. The structure of claim 13, wherein the pores have a size such that back flow of water from said structure to said web on release of said compres-sive stress is substantially prevented.
15. A method of extracting water from a wet paper web, comprising the steps of forming a web-supporting structure composed of a base layer and an outer layer of water permeable polymeric material and an intermediate layer of water permeable polymeric foam material, supporting a wet paper web on said outer layer of said structure, extracting water from the paper web supported on said outer layer and flowing at least a portion of the water through said structure.
16. The method of claim 15, wherein the step of extracting water from the web comprises subjecting the web and the supporting structure to a compressive stress.
17. The method of claim 15, wherein the step of extracting water from the paper web comprises pass-ing the web supported on said outer layer through the nip between a pair of cooperating press rolls.
18. The method of claim 16, and including the steps of releasing the web and the supporting structure from said compressive stress, and selecting the perme-ability of said outer layer such that back flow of water from said structure to said web on release of said compressive stress is substantially prevented.
CA 2034656 1990-01-22 1991-01-21 Structure for extracting water from a paper web in a papermaking process Expired - Fee Related CA2034656C (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US07/468,222 1990-01-22
US07/468,222 US5071697A (en) 1990-01-22 1990-01-22 Structure for extracting water from a paper web in a papermaking process

Publications (1)

Publication Number Publication Date
CA2034656C true CA2034656C (en) 1994-12-27

Family

ID=23858910

Family Applications (1)

Application Number Title Priority Date Filing Date
CA 2034656 Expired - Fee Related CA2034656C (en) 1990-01-22 1991-01-21 Structure for extracting water from a paper web in a papermaking process

Country Status (6)

Country Link
US (1) US5071697A (en)
EP (1) EP0439280A1 (en)
AU (1) AU6944191A (en)
CA (1) CA2034656C (en)
FI (1) FI910134A (en)
NO (1) NO910236L (en)

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Also Published As

Publication number Publication date
FI910134A0 (en) 1991-01-10
FI910134A (en) 1991-07-23
AU6944191A (en) 1991-07-25
NO910236D0 (en) 1991-01-21
US5071697A (en) 1991-12-10
NO910236L (en) 1991-07-23
EP0439280A1 (en) 1991-07-31

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