Patent Application
20120193058
1. Field of the Invention
The current invention relates to a combination of a press felt with a pressure roll covering and/or a suction roll covering which can be used in the press section of a paper making machine, or in a machine for the production of a web material, for example paper or cardboard.
2. Description of the Related Art
During the production of paper a substantial part of the liquid, generally water, which is contained in the base material provided for the production of paper, is removed in a press section. The base material is carried on one, or respectively between two press felts through generally several press nips which are used in conjunction with a pressure roll and/or suction roll. The aim of this process is to remove the greatest possible volume of liquid from the material whereby at the same time the energy expenditure, primarily for the production of a vacuum in the region of one or several suction rolls, is to be reduced.
What is needed in the art is a press felt and roll covering that provides improved dewatering with a lower expenditure of energy.
It is therefore the objective of the current invention to cite a combination of a press felt with a pressure roll covering and/or a suction roll covering for a paper making machine which provides improved dewatering characteristics and lower energy expenditure.
According to one embodiment of the present invention this objective is met by a combination of a press felt with a pressure roll covering and/or a suction roll covering for a paper machine, whereby the combination includes:
a) a porous press felt with a carrier structure and polyurethane material embedded in the carrier structure and/or with at least one layer of non-woven material,
b) a pressure roll covering with a circumferential groove surface structure having a groove width in the range of 0.5 mm to 1.5 mm, a distance between grooves in the range of 1.5 to 2.5 mm and a groove depth in the range of 1.5 mm to 4 mm, whereby the percentage of an open surface in relation to the overall surface of the pressure roll covering is in the range of 20% to 50%, and/or a suction roll covering with a circumferential groove surface structure having a groove width in the range of 0.5 mm to 1.5 mm, a distance between grooves in the range of 1.5 mm to 2.5 mm and a groove depth in the range of 1.5 mm to 4 mm, and an arrangement or holes with a plurality of suction holes completely penetrating through the suction roll covering, whereby the percentage of an open surface in relation to the overall surface of the suction roll covering is in the range of 30% to 50%.
It was noticed that with the combination of a specially constructed press felt which possesses a comparatively low porosity, in other words a comparatively low hollow space volume and a cover constructed for a pressure roll or respectively a suction roll as previously described, very good dewatering characteristics are achieved, while at the same time the energy used to produce the vacuum or respectively to remove liquid by means of the vacuum can be reduced in particular in the region of a suction roll due to the comparatively open design of the roll covering.
Further improvement of the liquid absorption capacity, of the pressure roll covering is obtained by an arrangement of holes with a plurality of blind holes which are open facing the top side of the pressure roll covering. The pressure roll covering has a circumferential groove surface structure and the holes do not completely penetrate there through with the open surface being provided by the circumferential groove surface structure and the disposition of the holes.
The suction roll covering may also provide that its hole arrangement includes a plurality of blind holes which do not completely penetrate the covering and which are open facing the top side of the suction roll covering which has a circumferential groove surface structure.
In order to further improve absorption of liquid in the hole arrangement, it is suggested that the holes in the hole arrangement of the suction roll covering and/or in the hole arrangement of the pressure roll covering have a diameter in the range of 2 mm to 5 mm.
In one variation of the present invention, which is very advantageous in regard to the liquid absorption capacity it is suggested that the pressure roll covering and/or the suction roll covering has a modulus of elasticity in the range of 50N/mm2 to 500N/mm2. It has been found that such a low modulus of elasticity, which has a comparatively good deformability of the construction material further improves the liquid absorption capacity. Also, a hollow space volume share in the range of 200 to 1500 cm3/m2 contribute to the liquid absorption capacity.
The pressure roll covering, or respectively the suction roll covering is preferably made of polyurethane material whereby the desired deformability is combined with the necessary durability under constant pressure load.
Moreover, the thickness of the pressure roll covering, or respectively also the suction roll covering, is in the range of 10 mm to 13 mm.
In order to ensure that the press felt according to the inventive combination of the present invention is constructed with a comparatively low hollow space volume whereby it can be achieved that the greater portion of water pressed from the paper, which is to be manufactured, reaches the roll covering it is suggested that polyurethane material is integrated into at least one layer of the press felt that consists of non-woven material. The provision of polyurethane material in the non-woven material reduces the hollow space volume of the non-woven material, whereby this material already possesses a clearly reduced hollow space volume share than for example that of a woven material.
The basis weight content of the polyurethane material in the press felt is in a range of 50 g/m2 to 700 g/m2. The press felt has a hollow space volume content of less than 600 cm3/m2, preferably less than 500 cm3/m2, most preferably of less than 400 cm3/m2. This at least one layer of non-woven material or respectively fiber-/thread-material and/or the carrier structure may be a laid scrim, formed fabric or a warp knit fabric.
In the provision of a carrier structure with therein integrated polyurethane material, the comparatively low hollow space volume share can, for example, also be achieved if woven material is utilized as a carrier structure and the porosity is provided by way of a coating of polyurethane material carried by and therefore incorporated in this carrier structure.
The present invention further relates to a papermaking machine with a press section in which the inventive combination is provided.
The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of an embodiment of the invention taken in conjunction with the accompanying drawings, wherein:
Corresponding reference characters indicate corresponding parts throughout the several views. The exemplification set out herein illustrates one embodiment of the invention, in one form, and such exemplification is not to be construed as limiting the scope of the invention in any manner.
Referring now to the drawings, and more particularly to
Moreover, a hole arrangement 16 is disposed in suction roll covering 10, which is, for the purpose of illustration, only illustrated in a portion of the top view in
Hole arrangement 16 further includes a plurality of blind or pocket holes 20, which like suction holes 18 are open to top side 22 which; however, do not penetrate completely through suction roll covering 10 which is constructed having a thickness ‘d’ in the range of 10 to 13 mm.
As is shown in
Through the circumferential groove surface structure 12 and holes 18 and 20, which are open facing top side 22, an open surface is provided whose percentage in relation to the overall surface, which is substantially formed by a cylindrical circumferential surface of the suction roll covering, is in a range of 30% to 50%. With this comparatively large surface component, through which liquid can be directly removed, an excellent dewatering capacity is achieved together with the liquid absorption volume formed by the groove structuring and different holes 18, 20. In this embodiment of the present invention the hollow space volume share in suction roll covering 10 is preferably in a range from 200 to 1500 cm3/m2.
A pressure roll covering, which for the purpose of discussion can be considered a pressure roll covering 10, for a pressure roll 54 for use in a press section 52 of a papermaking machine 50 can be designed as shown in
In order to provide the required elasticity for suction roll cover 10 or respectively also for the appropriately designed pressure roll covering, roll coverings of this type may for example be constructed with polyurethane and have a modulus of elasticity in the range of 50N/mm2 to 500N/mm2.
Now, additionally referring to
This hollow space volume is provided in press felt 28 that includes at least one layer of non-woven fiber-/thread-material, for example composed of monofilaments or respectively conventional yarns. Non-woven material of this type can, for example, include a single- or multi-layer laid scrim, a non-woven material or a warp knit structure. Also the use of a composite material of a multitude of spiral or helix wound elements connected by a pintle wire represents the use of non-woven material in the sense of the current invention.
Basically, press felt 28 may also be multi-layered and include thereby at least one such layer of non-woven material.
Non-woven material of this type, in particular if it is a fibrous or warp knit structure, compared to a woven fiber or yarn material possesses a comparatively low porosity. This can be further supported by introducing polyurethane material into the non-woven material or into at least one layer thereof, thereby further lowering the hollow space volume share. This is illustrated in
One can see the fibrous material 30 indicated by solid line cross hatched area which is made up, for example, as non-woven material into which interconnected polyurethane material 32 is embedded. This can be produced in that small polyurethane particles 34 are brought into the non-woven fibrous material and are then fused by means of heat and/or pressure so that a substantially coherent bond is created through appropriate deformation of the polyurethane particles 34, which also maintains a pore structure in the thereby composed press felt 28.
Due to the integration of polyurethane material into the non-woven fibrous material, which in this case is used as a carrier structure, not only is the porosity influenced, but also the elasticity of press felt 28 is adjusted so that interaction with the previously discussed roll coverings leads to improved dewatering characteristics. It has been shown that, in particular when the polyurethane material is provided at a base weight of 50 g/m2 to 700 g/m2, excellent dewatering characteristics with comparatively low remoistening can be achieved.
An alternative embodiment of a press felt 28 of the present invention can basically also be designed, for example, with a woven carrier structure into which polyurethane material is integrated, either in the previously discussed sense so that the warp threads and/or weft threads of the woven structure being used as carrier structure are encased with the polyurethane while maintaining a certain porosity, or so that a substantially tight bond is produced with the polyurethane material on at least one side of the carrier structure.
With the inventive combination of a press felt 28 of the previously discussed construct with a pressure roll covering and/or a suction roll covering also of the discussed construct a constant nip pressure in a press section of a paper machine is produced due to the comparatively wide and deep groove structure, the comparatively low modulus of elasticity of the utilized polyurethane material, the comparatively large open surface share, the comparatively large hollow space volume share, in particular in the roll coverings or respectively also the provided hole arrangements.
On the other hand, dewatering through the roll coverings, in particular through the suction roll covering is clearly improved. A substantial contribution hereto is that the utilized press felt 28 has clearly reduced remoistening characteristics due to its structure or respectively, also due to its porosity with a preferably lower hollow space volume share than the press roll covering and/or the suction roll covering and therefore also facilitates separation of press felt 28 from the paper layer which is initially transported on it and subsequently separated from it. A press felt 28 which includes one or several polyurethane layers, possibly on one carrier structure, which have a lower hollow space volume than a press felt 28 produced through needling may in particular contribute to these desirable characteristics.
Tests have shown that the surface structure of suction roll covering 10, its open area as well as the construct of press felt 28 for the dewatering efficiency and also for the dry content of the paper are important. With the same open area of suction roll covering 10 and the same hollow space volume of press felt 28 the dewatering characteristic, the dry content of the paper and the so-called sheet bulk, in other words the paper thickness are influenced.
In addition to the surface structuring of the rolls 54 and the design of press felt 28, the design of the press section of the paper machine also influences dewatering respective to the dry content of the web. Two basic concepts are known here, the so-called “nip-dewatering”, in other words dewatering in the press nip, and suction through a so-called Uhle-box outside the press nip. Both possibilities are sufficiently known so that a detailed description can be foregone.
The vacuums which are applied in a suction- or suction press roll 54 in a known manner, for example, through at least one suction box in at least two zones, can be reduced or even turned off with a suitable combination of press felt 28 and roll covering 10, whereby dewatering remains the same or may even be improved. It is therefore possible to achieve the same dry content or even an increase of the dry content in spite of a lower vacuum in a first suction zone of a suction press roll 54, so that a lowering of the vacuum in a second suction zone of the suction press roll 54 may occur. This was confirmed in trials with all suction press roll surface designs and all press felts. It is therefore possible to now provide the vacuum in only one suction zone. Suction in additional zones can be eliminated which has a positive effect on the use of energy.
The suction power can also be significantly reduced when using the Uhle-box. With the surface design with suction holes 18 and circumferential groove surface structure 12 the Uhle-box may even be turned off.
In regard to line loads during nip-dewatering, the highest loads can be achieved with suction press rolls having a surface design which has suction holes 18, circumferential groove surface structure 12 and blind holes 20. As expected, a lowering of the line load in this case leads to a lower dry content.
Overall dewatering can be kept substantially neutral with presses having several press nips when using suction press roll coverings with suction holes 18 and circumferential groove surface structure 12.
Considering the energy consumption of the roll drives, an insignificant increase can be observed at the same machine speed and same vacuum. This is however at least compensated for by the lowering of the vacuums as already discussed above.
When using suction rolls 10 with suction holes 18 and circumferential groove surface structure 12, low consumption of drive power is registered.
Overall, in trials at the same speed of the paper machine a dry content of up to 1.5% higher could be achieved, whereby suction- or suction press rolls with a design incorporating suction holes 18 and a circumferential groove surface structure 12 achieve the best results. The paper bulk can be increased by up to 6% with the same surface design and the same machine speed.
While this invention has been described with respect to at least one embodiment, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 10 2009 028 215.7 | Aug 2009 | DE | national |
This is a continuation of PCT application No. PCT/EP2010/056173, entitled “COMBINATION OF A PRESS FELT WITH A PRESSURE ROLLER COVERING AND/OR A SUCTION ROLLER COVERING FOR A PAPER MACHINE”, filed May 6, 2010, which is incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/EP2010/056173 | May 2010 | US |
| Child | 13364715 | US |
