Patent Grant
7662260
1. Field of the Invention
The present invention relates to a method and to an apparatus for the manufacture of a fiber web, and, more particularly, to a method and an apparatus for the manufacture of a tissue web or a hygienic paper web, provided with a three-dimensional paper structure.
2. Description of the Related Art
The imprinting of a three-dimensional structure into the surface of a paper web, in particular of a tissue web or of a hand tissue, is known, see, for example, WO 99/47749 and WO 01/18307. It is further known that a very good paper quality can be achieved by a so-called throughflow air drying (TAD=through air drying). It is, however, disadvantageous that the use of TAD dryers is very complex and correspondingly expensive.
What is needed in the art is a simple, more economical way of providing a high quality structural tissue.
The present invention provides an improved method and an improved apparatus to form a high quality structured tissue in an economic and correspondingly cost-favorable manner, without the use of a larger TAD drying apparatus. The expected quality level is achieved with respect to the water retention capability, the water absorption speed and the volume (bulk), etc.
In accordance with one embodiment the present invention, a method is disclosed for the manufacture of a fiber web, specifically a tissue web or a hygienic paper web, with a three-dimensional surface structure. The fiber web is pressed, for example by vacuum drawing it, onto an imprinting fabric at a dry content <35% by way of a first pressure field. The web is thereby pre-imprinted and is then subsequently pressed onto an imprinting fabric a further time by way of a further pressure field for the further dewatering and drying of the web in order to fix the three-dimensional surface structure and the strength.
A sustainable three-dimensional surface structure is produced in the relevant fiber web, which remains present in the desired manner in the web, after the drying process. The use of a complex and correspondingly expensive TAD method is no longer required. In particular, a sustainable surface structure of, for example, a tissue web or a hygienic paper web can now be produced after the forming region, or forming zone, even without a TAD drying device.
An imprinting screen or an imprinting membrane is used as the imprinting band or structured band also, respectively known as “imprinting fabric” and “structured fabric”. The fiber web is generally pre-imprinted after the forming zone.
It is often an advantage for the fiber web to be formed on the imprinting fabric that is used for the pre-imprinting. The fiber web can also be transferred to the imprinting fabric used for the preimprinting.
Another embodiment of the method of the present invention is characterized in that at least three throughflow apparatuses are utilized and they are arranged in series in the web running direction. In the region of each throughflow apparatus the fiber web is exposed to a respective throughflow, in particular to an air throughflow, with the throughflow directions, as they relate to the fiber web, being at least partly different or opposite to one another in the different throughflow apparatuses. In particular at least three throughflow apparatuses are used in which the throughflow direction of at least one throughflow apparatus differs, with respect to the web, from the throughflow direction of the other throughflow apparatuses, which may be located on an upper side or lower side of the web.
In this embodiment each throughflow apparatus includes a suction device. Alternatively, at least one of the throughflow apparatuses may include a suction device and at least one of the throughflow apparatuses may include an air press. For example, in the web running direction, a first throughflow apparatus can include a suction device, a second throughflow apparatus can include an air press and a third throughflow apparatus can again include a suction device.
A respective suction device can in particular include a suction roll, a suction box and/or the like in each case.
Advantageously, at least one suction device is used in which the pressure difference (Δp) lies in a range of from approximately 0.2 up to approximately 0.4 bar. The temperature is preferably <220° C., in particular ≦180° C. and preferably ≦150° C. The airflow speed through the fiber web is preferably less than ≦15 m/s, particularly with very fine clothings. The result is a much lower energy requirement and a much lower complexity of the technical plant than with the conventional TAD process. The dwell time of the fiber web in the suction zone is advantageously ≦0.5 s, in particular ≦0.4 s and preferably ≦0.3 s.
In accordance with another embodiment of the present invention, at least the first pressure field is produced by way of a suction element arranged on the side of the imprinting fabric remote from the fiber web in order to suck the fiber web into the surface structure of the imprinting fabric. In particular a so-called wet suction box can be used as the suction element.
It is also of advantage for the fiber web to be further pressed gently in the pressure field, preferably over a path extending in the web running direction.
The further pressure field is produced by way of a press nip. To effect a pressing of the web, which is as gentle as possible, this press nip can be produced, for example, between a drying cylinder and a counter element. The fiber web is guided through the press nip and is in contact with the surface of the drying cylinder on one side and the other side is in contact with the imprinting fabric. In particular, a so-called Yankee cylinder can be used as the drying cylinder. A shoe press unit, which includes a flexible fabric guided over a shoe press in the region of the press nip, can be used as a counter element cooperating with the drying cylinder. A shoe press roll, provided with a flexible roll jacket, is preferably used as the shoe press unit in this process.
Advantageously, a soft fabric or a clothing with fine pores and a capillary effect (capillary fabric), in particular felt, is provided inside the loop of the imprinting fabric to guide the web through the press nip, thereby producing the further pressure field. The soft felt can, for example, be a felt with a foamed layer, which as will be explained in more detail below, contributes to the dewatering of the fiber web, due to its capillary effect.
Another practical embodiment of the method of the present invention is characterized in that the pre-imprinted fiber web is dried on a drying or a Yankee cylinder, the fiber web is subsequently creped and/or wound up.
In accordance with one of the embodiments of the method in accordance with the present invention, the dry content at which the fiber web is pre-imprinted, and/or the dry content at which the three-dimensional surface structure is fixed, is selected to be <35%, preferably <30% and more preferably <25%. In this process the water retention capability and the bulk is thus sustainably increased, which means that the desired imprint is still present even on the use of the end product, such as the tissue or hygienic paper web. In particular, the advantage of a higher water retention capability for a hand towel tissue or a paper towel is apparent in the use of the respective end product.
In accordance with one of the embodiments of the method in accordance with the present invention, a device subject to suction is used between the suction element that produces the first pressure field and the press nip that produces the further pressure field. The fiber web is guided, together with an imprinting fabric, over both the device subject to suction and through the press nip. It is advantageous for the device subject to suction, to have a curved surface, and for the fiber web and the imprinting fabric to be guided over this curved surface. A suction roll can, for example, be used as the device subject to suction.
A felt is expediently guided through the press nip between the imprinting fabric and the flexible fabric of the shoe press unit.
In specific cases, it is advantageous for the felt, which is particularly soft, to be guided over the device subject to suction. The suction effect of the device subject to suction is correspondingly reduced in this process, a hood standing under overpressure is associated with it in order to support the underpressure effect of the device subject to suction.
Further advantages result from the relatively long common guidance of the felt and of the imprinting fabric, since the capillary effect of the felt is utilized for the dewatering of the fiber web over the longer path.
The felt can, for example, be conditioned by way of a suction device, in particular by a suction box, before it is joined with the imprinting fabric to support the fiber web. In particular the dry content of the felt can be increased and the felt can be cleaned by appropriate conditioning.
The imprinting fabric is guided over the suction element, or over the wet suction box, prior to the device subject to suction, i.e. prior to the suction roll, in order to suck the fiber web into the three-dimensional surface structure of the imprinting fabric and thus to imprint this structure onto the fiber web. At the same time, the respective suction element brings about a corresponding increase in dry content.
In accordance with another embodiment of the method in accordance with the present invention, the felt is joined with the imprinting fabric supporting the fiber web, after the web passes the device subject to suction. The device subject to suction therefore does not have the felt wrapped around it, whereby the suction effect of this device is increased and the dry content is increased accordingly. The wet imprinting effect (wet molding effect) is maintained by the gentle dewatering of the so-called TissueFlex process, which, in contrast to a shoe press roll, works at a lower pressure and with a longer dwell time.
It is also advantageous for the length of the press nip of the shoe press that includes the drying cylinder and the shoe press unit, in the web running direction, to be larger than a value of approximately 80 mm. Additionally, the shoe press is designed such that a pressure profile results over the press nip length having a maximum pressing pressure, which is lower than or equal to a value of approximately 2.5 MPa. A gentle pressing is thus ensured, which avoids a smoothing out of the structure produced in the fiber web. As previously discussed, a suction roll, with which a pressure hood is associated, can be used between the suction element producing the first pressure field and the press nip.
In accordance with another embodiment of the method in accordance with the present invention, at least one dewatering screen with zonally different screen permeability is used in the forming zone. The respective dewatering screen can be provided as an external screen. This is in particular an advantage in the manufacture of hand towel tissue. The screen produces a fine structure, which increases the water absorption speed and which brings about an increased water retention capability in conjunction with the imprinting.
It is an advantage for a former to have two peripheral dewatering fabrics, which run together while forming a material inlet gap and are guided over a forming element such as a forming roll and for a dewatering screen, with zonally different screen permeability. The dewatering fabrics can be used as an external fabric that does not come into contact with the forming element and as an internal fabric. An imprinting fabric can be used as the internal fabric and a dewatering screen with zonally different screen permeability can be used as the external fabric in this process. It is, for example, also possible for the fiber web to be passed from the internal fabric to an imprinting fabric.
During wet molding in a tissue machine, that utilizes an imprinting fabric, it is a particular goal to achieve a desired dry content. The web can be wet molded by way of the imprinting fabric, for example, by way of a suction box prior to the press. To avoid disrupting the three-dimensional structure, which was pre-imprinted by the wet molding in the region of the wet suction box, by a shortterm high pressure in the press nip, an imprinting fabric, such as, an imprinting screen or an imprinting membrane, is guided through the press nip. The imprinting fabric is structured such that a surface portion has raised or closed zones, which are small in comparison with the surface portion of recessed zones or bores of the web and, accordingly, a smaller surface portion of the fiber web is pressed in the press nip. The smaller surface portion of raised or closed zones results in web zones of high density for strength. The larger surface portion of recessed zones or bores remains at least substantially unpressed, and results in the desired water absorbing capability and the desired bulk, such as was previously only achieved by the complex and expensive TAD drying.
An imprinting fabric can advantageously be used in which the surface portion of raised or closed zones are ≦40% of the surface area and preferably lies in a range from approximately 25% to approximately 30%. The imprinting fabric may have raised zones and recessed zones that result from offsets, such as, by intersection points of weft and warp threads, of a screen fabric. As already mentioned, an imprinting membrane can also be used, in which the raised and recessed zones result from bores therein. In this case, it is of advantageous that 100% of the surface except for the bore area is pressed and a higher strength results.
The respective imprinting fabric is guided together with the fiber web over, for example, a drying cylinder, in particular over a Yankee cylinder. A shoe press unit is used as the counter element cooperating with the drying cylinder. The length of the press nip and the pressure profile resulting over the press nip length can be selected as has previously been recited.
It has been shown that a water absorption capability (g H20/g fibers) is higher by 50% and bulk (cm3/g) is higher by 100% as a result of using the method in accordance with the invention, at the same tensile strength, when an imprinting fabric is used instead of a conventional felt in the press nip prior to the creping. By creping the web, the water absorption capability can be improved by 50% and a water absorption capability of TAD hand towel quality can be achieved.
The improved quality of the paper results as a consequence of the lower pressure pressing of the web as a consequence of the smaller surface portion of raised zones and not by a TAD drier. The permeability of the web results by the stretching of the web into the fabric structure by way of the suction element, whereby so-called pillows are produced, which increase the water absorption capability and the bulk accordingly. A relatively complex and correspondingly expensive TAD drier is therefore no longer required for this purpose.
The function of the TAD drum and of the air throughflow system consists of drying the web. The appropriate dry content must be achieved in order to be able to carry out the wet molding in a conventional machine, i.e. in particular in a conventional tissue machine.
In contrast to the TAD system, in order to reduce the rewetting and to keep the desired dry content, in accordance with a preferred embodiment of the method of the present invention, at least one clothing with fine pores and with a capillary effect is used for the dewatering of the web and this can be e.g. a felt or a screen with a foamed layer. The foam coating is chosen such that pores result in a range from approximately 3 μm up to approximately 6 μm. The corresponding capillary effect is utilized for the dewatering. The respective clothing, such as a felt, can be provided with a special foam layer, which gives the surface very small pores whose diameter lie in the range of from approximately 3 μm up to approximately 6 μm. The air permeability of this clothing is very low. The natural capillary effect is utilized for the dewatering of the web while it is in contact with the clothing.
A clothing with fine pores, such as a screen or a felt with a foamed layer, is guided together with an imprinting fabric and a fiber web lying therebetween about a suction roll, with the clothing with fine pores preferably being in contact with the suction roll. The clothing with fine pores can, wrap around a suction roll with a diameter from approximately 2 to 3 m, or around a plurality of suction rolls with smaller diameters, preferably around suction rolls with a diameter in each case of, approximately 2 m. The dwell time of the web in the region of the suction rolls or should be longer than approximately 0.15 sec. and shorter than approximately 0.40 sec.
The respective suction roll can be acted on by a vacuum on its lower side or a suction roll with associated siphon extraction can be used. The water can also be centrifuged into a gutter by centrifugal force, in particular with a lower diameter roll.
Dewatering utilizing the capillary effect is described in U.S. Pat. No. 5,701,682. The respective capillary element is, however, part of the suction roll in the present invention. The use of a clothing with fine pores and with a capillary effect results in the following advantages in comparison with a roll:
Despite the utilization of the capillary effect for dewatering, a hood standing under overpressure can be associated with the device subject to suction in order to support the underpressure effect of the device subject to suction.
In accordance with a further embodiment of the method in accordance with the present invention, the fiber web is guided, together with an imprinting fabric for the expulsion of water by means of gas pressure, at least once, preferably twice, through a pressure space. The pressure space is bounded by at least four rolls arranged in parallel and into which a gas under pressure is introduced. The fiber web is guided through the pressure space together with the imprinting fabric and a membrane. The basic principle of such a displacement press, in which the water in the fiber web is displaced by air, is described in German Patent DE 199 46 972.
In accordance with another embodiment of the method in accordance with the present invention, a vacuum dewatering of the fiber web takes place in which the pressure difference (Δp) is ≧0.1 bar, preferably ≧0.2 bar and more preferably ≧0.3 bar. The pressure difference (Δp) can in particular lie in a range from approximately 0.2 bar up to approximately 0.4 bar. In contrast to the conventional TAD method, an open surface of approximately 20% is advantageously provided. A clothing with fine pores, such as a screen or a felt with a foamed layer, is used for the vacuum dewatering. The open surface in this process is, however, preferably very small such that a very small air volume flow results.
In accordance with still another embodiment of the method in accordance with the present invention, the vacuum dewatering takes place such that an air volume flow ≦50 m3/m2·min, in particular ≦20 m3/m2·min, in particular ≦5 m3/m2·min and preferably ≦1 m3/m2·min (to practically zero m3/m2·min) results.
A corresponding “Spectra” membrane, which can be used for vacuum dewatering, allowing an airflow of 15 m/s so a higher vacuum is needed.
The apparatus in accordance with another embodiment of the present invention for the manufacture of a fiber web, in particular a tissue web or a hygienic paper web, provided with a three-dimensional surface structure is accordingly characterized in that the fiber web is pressed e.g. by suction onto an imprinting fabric at a dry content <35% by way of a first pressure field. The web being thereby pre-imprinted and subsequently pressed onto an imprinting fabric a further time by way of a further pressure field for further dewatering and drying in order to fix the three-dimensional surface structure and the strength thereof.
The invention can in particular be used with Crescent Formers, Duo Formers, C Wrap Formers, S Wrap Formers and in the manufacture of multi-layer and multi-ply tissue.
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 embodiments of the invention taken in conjunction with the accompanying drawings, wherein:
Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate one preferred embodiment of the invention, in one form, and such exemplifications are not to be construed as limiting the scope of the invention in any manner.
Referring now to the drawings, and more particularly to
Fiber web 12 is pressed, e.g. sucked, onto an imprinting fabric 14, also known as a structured fabric 14, at a dry content <35% by way of a first pressure field I and is thereby pre-imprinted. Fabric web 12 is subsequently pressed once again onto imprinting fabric 14 by way of a further pressure field II, for the further dewatering and drying of web 12 in order to fix the three-dimensional surface structure and the strength. In particular, an imprinting screen can be provided as imprinting fabric 14.
In one embodiment of the present invention, imprinting fabric 14 is provided for the imprinting and for the fixing of the surface structure.
First pressure field I is produced by way of a suction element 16 arranged on the side of imprinting fabric 14 remote from fiber web 12. Fiber web 12 is sucked into the surface structure of imprinting fabric 14. Suction element 16 can in particular be embodied as a suction box 16 or as a wet suction box 16.
In further pressure field II, fiber web 12 is pressed, preferably gently, and in particular, over a path extending in a web running direction L. Further pressure field II is produced by way of a press nip 18, which is formed between a drying cylinder 20 and a counter element 22. Fiber web 12 is guided through press nip 18 and is in contact with surface 20′ of drying cylinder 20. Web 12 contacts imprinting fabric 14 on its other side.
Specifically, a Yankee cylinder can be provided as drying cylinder 20.
A shoe press unit 22, which includes a flexible fabric 26 guided over a press shoe 24, in the region of press nip 18, can preferably be provided as a counter element 22 cooperating with drying cylinder 20. A shoe press roll with a flexible roll jacket 26 is provided as shoe press unit 22. Press nip 18 extends in web running direction L, whereby a relatively gentle pressing of fiber web 12 is achieved.
A fabric 28, preferably a soft fabric, or a clothing with fine pores and with a capillary effect (capillary fabric), in particular a soft felt or a soft foamed felt, can be guided through press nip 18, inside the loop of imprinting fabric 14. This soft fabric 28 or clothing 28 with fine pores runs between imprinting fabric 14 and flexible fabric 26 of shoe press unit 22.
Fiber web 12 can be dried on drying cylinder 20, such as, for example, on a Yankee cylinder. Fiber web 12 can moreover be creped. Web 12 can be wound up by an appropriate device.
The dry content at which fiber web 12 is pre-imprinted and/or the dry content at which the three-dimensional surface structure is fixed is, as already mentioned, <35% and preferably be <30 and more preferably <25.
A device subject to suction 30, which can in particular be a suction roll 30, is provided between suction element 16 and press nip 18. Fiber web 12 is guided together with imprinting fabric 14 both over the device subject to suction 30 and through press nip 18. Clothing 28 with fine pores such as felt 28, is guided through press nip 18 between imprinting fabric 14 and flexible fabric 26 of shoe press unit 22.
Felt 28 is not only guided through press nip 18, but also over the device subject to suction 30. Since the suction effect of device 30 is reduced by the resistance of felt 28, a hood standing under overpressure is associated with the device subject to suction 30 to support the underpressure effect of the device subject to suction 30.
A suction device 32 such as a suction box 32, or the like, is provided for the conditioning of felt 28. As can be recognized with reference to
Water is removed from fiber web 12 over a longer path by the capillary effect of felt 28 due to the relatively long common guidance of felt 28 and of imprinting fabric 14. Felt 28 is conditioned beforehand via suction device 32, whereby its dry content is increased and felt 28 is cleaned.
Imprinting fabric 14 is guided over suction element 16 in front of the device subject to suction 30, which in addition to an increase in dry content brings about a pre-imprinting of fiber web 12. Fiber web 12 is sucked into the three-dimensional surface structure of imprinting fabric 14 or of imprinting screen 14, whereby the structure is imprinted onto the web.
Now, additionally referring to
As in the embodiment shown in
Now, additionally referring to
Clothing 36 with fine pores is guided together with imprinting fabric 14 and fiber web 12 lying therebetween about suction roll 38, with clothing 36 being in contact with suction roll 38. The suction roll 38, which is wrapped around by clothing 36, can have a diameter of approximately 2 m up to approximately 3 m. The lower side of suction roll 38 is acted on by a vacuum. Siphon extraction can generally also be associated with suction roll 38. The respective vacuum device is designated by “40” in
At least one dewatering screen with zonally different screen permeability is provided in the forming zone.
A former with two peripheral dewatering fabrics 14 and 42 is provided, with internal fabric 14 simultaneously serving as the imprinting fabric 14. Dewatering fabrics 14 and 42 run together thereby forming a material inlet gap 44 and are guided over forming element 46 such as forming roll 46.
Imprinting fabric 14 is formed as the internal fabric of the former coming into contact with forming element 46. External fabric 42 that does not come into contact with forming element 46, serves as a dewatering screen with a zonally different screen permeability.
A pulp suspension is introduced into material inlet gap 44 by way of a head box 48. A pick-up element 50 also known as partition element 50 is positioned after forming element 46 and web 12 is thereby held to imprinting fabric 14 upon the separation of dewatering fabric 42. Suction element 16 (solid-line representation) is provided in front of device 34 with a capillary effect and fiber web 12 is pressed onto imprinting fabric 14 by it. Suction element 16 can, however, also be arranged s shown by suction element 16′, between device 34 and suction roll 30.
A soft fabric 28 or a clothing 28 with fine pores and having a capillary effect such as felt 28, is guided, together with fiber web 12 and imprinting fabric 14, through press nip 18 formed between drying cylinder 20 and shoe press unit 22. Soft fabric 28 is also guided about suction device 30. As already mentioned, this soft fabric 28 can, for example, be a clothing 28 with fine pores having a capillary effect, such as felt 28 having a corresponding capillary effect, also known as capillary felt 28. Felt 28 is conditioned via a suction device 28 or a so-called UHLE box. Drying cylinder 20 is a Yankee cylinder 32. Drying hood 52 can be associated with drying cylinder 20.
The dry content of fiber web 12 in front of dewatering unit 34 amounts to approximately 10% up to approximately 25%. In the region following device 34 the dry content is approximately 30% to approximately 40%.
Now, additionally referring to
A pick-up 50 or partition element 50 is within the loop of imprinting fabric 14 and fiber web 12 is held to imprinting fabric 14 upon the separation or internal fabric 54 of the former.
Suction element 16 is within the loop of imprinting fabric 14 and is arranged in front of dewatering device 34 with a capillary effect. However, suction element 16 may be arranged after device 34. Additionally, felt 28 is not utilized in this embodiment.
The dry content of fiber web in the present embodiment amounts to approximately 10% up to approximately 25% in the region of pick-up element 50, to approximately 15% up to approximately 30% in the region of dewatering device 34 and to approximately 35% up to approximately 45% in the region after device 34.
Now, additionally referring to
After passing air press 56, fiber web 12 is guided, together with imprinting fabric 14, over device subject to suction 30, in particular over a suction roll 30, and through press nip 18 formed between drying cylinder 20 and shoe press unit 22. Drying hood 52 is associated with drying cylinder 20 also known as Yankee cylinder 20.
First pressure field I, by which fiber web 12 is pressed onto imprinting fabric 14, at a dry content of <50% and is correspondingly pre-imprinted, is produced, by air press 56.
Now, additionally referring to
Raised zones 68 and the recessed zones can result, for example, by offsets, at intersection points of weft and warp threads of a screen fabric. In the case of the press membrane illustrated in the right hand part of
A thickness d of imprinting membrane 14 is shown in the right hand part of
While this invention has been described as having a preferred design, 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 |
|---|---|---|---|
| 101 29 613 | Jun 2001 | DE | national |
This is a divisional of U.S. patent application Ser. No. 10/739,470; now U.S. Pat. No. 7,291,249, entitled “METHOD AND AN APPARATUS FOR THE MANUFACTURE OF A FIBER WEB PROVIDED WITH A THREE-DIMENSIONAL SURFACE STRUCTURE,” filed Dec. 18, 2003, which is a continuation of PCT Application No. PCT/EP02/05808, entitled “METHOD AND DEVICE FOR PRODUCING A FIBRE STRIP PROVIDED WITH A THREE-DIMENSIONAL SURFACE STRUCTURE”, filed May 27, 2002.
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| Number | Date | Country | |
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| Parent | 10739470 | Dec 2003 | US |
| Child | 11845828 | US |
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| Parent | PCT/EP02/05808 | May 2002 | US |
| Child | 10739470 | US |
