PAPER MACHINE CLOTHING AND METHOD OF PRODUCING THE CLOTHING

Abstract

A paper machine clothing has a substrate with an upper side, a lower side, two lateral edges and a usable region between the two lateral edges. The usable region is formed with a multiplicity of through-channels that extend through the substrate from the upper side to the lower side. The through-channels are non-cylindrical with a cross sectional area becoming smaller when going in a thickness direction of the substrate from the upper side to a middle region of the substrate between the upper side and the lower side. An upper rim of at least one of the plurality of through-channels directly contacts an upper rim of at least one other neighboring through-channel of the plurality of through-channels. There is also described a method of producing such a paper machine clothing.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the priority, under 35 U.S.C. § 119, of European patent application EP 18168641.1, filed Apr. 23, 2018; the prior application is herewith incorporated by reference in its entirety.

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention concerns a paper machine clothing comprising a substrate with an upper side, a lower side, two lateral edges and an usable region between the two lateral edges, wherein the usable region comprises a plurality of through-channels extending through the substrate and connecting the upper side with the lower side, wherein the through-channels are non-cylindrical with a cross sectional area becoming smaller when going in a thickness direction of the substrate from the upper side to a middle region of the substrate between the upper side and the lower side. Another aspect of the present invention concerns a method of producing such a paper machine clothing.

In the sense of the present invention the term “paper machine clothing”, abbreviated “PMC,” refers to any kind of a rotating clothing or fabric used to transport a nascent or already formed fiber web in a machine that is designed to continuously produce and/or finish a fiber web, such as paper, tissue or board material. For historical reasons, PMC is sometimes also called wire, felt or fabric. In particular, PMC can be a forming wire or a dryer fabric or a press felt, depending upon its intended use in the corresponding machine. Furthermore, in the sense of the present invention the term PMC may also refer to any kind of clothing used in wet and/or dry production of fibrous nonwovens.

The term “substrate,” as used herein, refers to some kind of foil material made of plastic. The substrate itself is usually impermeable to water, so that through-channels are needed to obtain a desired permeability, e.g. for dewatering the nascent fiber web or further drying the already formed fiber web. The substrate can be formed monolithic or comprise several layers that might be co-extruded or produced separately and laminated together afterwards. After joining the longitudinal ends of the substrate to each other, e.g. by laser welding, to obtain some kind of an endless belt, the perforated substrate may already represent the final product, for example a forming wire. For other applications, further steps might be necessary to produce the final PMC, such as permanently attaching fibers thereto to form a press felt. Furthermore, the substrate may comprise a reinforcing structure, such as yarns, that may be imbedded therein. After joining the longitudinal ends of the substrate to each other, the “upper side” of the substrate shall be the radially outer side, sometimes also referred to as “paper side”, whereas the “lower side” of the substrate shall be the radially inner side, sometimes also referred to as “machine side”.

The concept of producing a PMC from a substrate that is perforated, especially by using a laser, has been known for quite a long time in the prior art and was described, e.g. in the 1980's and 1990's in U.S. Pat. Nos. 4,541,895 and 5,837,102, respectively. Those disclosures are herewith incorporated by reference. FIG. 1 illustrates the processes of perforating a substrate via laser drilling according to U.S. Pat. No. 5,837,102. FIG. 1 only shows a portion of a substrate 20′ used to produce a PMC forming fabric. The substrate 20′ has a first surface 22′ and an opposite second surface that is not shown in the figure. Even though the first surface 22′ may be embossed it can be considered as being substantially plane and parallel to the second surface. The substrate 20′ is perforated using a laser beam LB from a laser that is connected to a controller so as to drill a plurality of discrete through-channels 30′ into the substrate 20′. The through-channels 30′ connect the side of the first surface 22′ with the side of the opposite second surface of the substrate 20′. The through-channels 30′ extend in the thickness direction TD of the substrate 20′, i.e. perpendicular to the first surface 22′ and the second surface.

In the sense of the present invention the term “usable region” refers to a region of the PMC that is actually used for the production and/or finishing of the fiber web. The usable region may span the complete width of the PMC, i.e. may reach from one lateral edge to the other lateral edge thereof. Alternatively, the usable region may refer only to a region that is located between the two lateral edges and is spaced apart from the two lateral edges. In the latter case, the PMC may have another configuration, such as permeability and thickness, outside the usable region compared to the usable region.

The term “cross sectional area” of a through-channel in the sense of the present invention refers to an area of the through-channel that is obtained by cutting the through-channel with a plane that is perpendicular to the thickness direction of the substrate.

The term “non-cylindrical” in the sense of the present invention means that there are at least two different cross sectional areas of a through-channel. For example, in the case of a non-cylindrical through channel that is substantially conical, a cross sectional area taken at a first plane perpendicular to the thickness direction of the substrate may be substantially circular having a first radius, whereas another cross sectional area taken at a second plane perpendicular to the thickness direction of the substrate may be also substantially circular but having a second radius that differs from the first radius.

A paper machine clothing that is pertinent with regard to the claimed invention is disclosed in U.S. Pat. No. 4,446,187 and in German published patent application DE 10 2010 040 089 A1. The disclosures are herewith incorporated by reference. FIGS. 2, 3A, 3B and 3C are based on the disclosure of the U.S. Pat. No. 4,446,187 A reference.

FIG. 2 shows a substrate 20′ that is placed under tension between two rollers R. The substrate 20′ has a radially outer, first surface 22′ and an opposite, radially inner, second surface 24′, as can be seen in FIGS. 3a, 3b and 3c. The first surface 22′ and the second surface 24′ are planar and parallel to each other. The thickness direction TD is oriented perpendicular to the first surface 22′ and the second surface 24′. The substrate 20′ further comprises a first lateral edge 26′ and a second lateral edge 28′. In this example, the usable region of the substrate 20′ extends in width direction WD of the substrate 20′ the full way from the first lateral edge 26′ to the second lateral edge 28′. In the usable region the substrate 20′ is perforated by a laser that is drilling a plurality of discrete through-channels 30′ into the substrate 20′. As indicated in FIG. 2 the laser first makes the through-channels 30′ close to the first lateral edge 26′ in a first row and continues moving across the substrate 20′ to the through-channel 30′ close to the second lateral edge 28′ at the end of the same row. Thereafter, the laser is displaced by one row to make another through-channel 30′ close to the first lateral edge 26′ in a next row.

FIGS. 3A, 3B and 3C show different possible configurations of the through-channels 30′. In FIG. 3A the through-channel is cylindrical having the same cross sectional area at any location along the thickness direction TD of the substrate 20′. In FIG. 3B the through-channel 30′ is conical wherein the cross sectional area of the through-channel 30′ close to the first surface 22′ is larger than the cross sectional area of the through-channel 30′ close to the second surface 24′. In FIG. 3C the through-channel 30′ is neither cylindrical nor conical. Instead it resembles a hyperboloid having a cross sectional area that is also always circular, like in the previous two examples, but the radius of this circle is first decreasing when going in thickness direction TD from the first surface 22′ to a middle region MR of the substrate 20′ situated in the thickness direction TD between the first surface 22′ and the second surface 24′, and is then increasing again when further going from the middle region MR of the substrate 20′ to the second surface 24′.

Fiber retention, permeability and the degree of marking are characteristic parameters of a PMC that are important in view of the quality of the fiber web that is to be produced and/or finished on the PMC. With the paper machine clothing known from the prior art there is still room for improvement.

SUMMARY OF THE INVENTION

It is accordingly an object of the invention to provide a paper machine clothing and a production method which overcome the above-mentioned and other disadvantages of the heretofore-known devices and methods of this general type and which provide for improved characteristics compared to the prior art paper machine clothing, thereby allowing to produce a fiber web of very high quality.

With the foregoing and other objects in view there is provided, in accordance with the invention, a paper machine clothing, comprising:

a substrate having an upper side, a lower side, two lateral edges and a usable region between said two lateral edges;

said usable region having a plurality of through-channels formed therein extending through said substrate and connecting said upper side with said lower side;

said through-channels being non-cylindrical, with a cross sectional area becoming smaller in a thickness direction of said substrate from said upper side to a middle region of said substrate between said upper side and said lower side; and

an upper rim of at least one of said plurality of through-channels directly contacting an upper rim of at least one neighboring through-channel of said plurality of through-channels.

In other words, the objects of the invention are achieved in a paper machine clothing in which an upper rim of at least one of the plurality of through-channels directly contacts an upper rim of at least one other neighboring through-channel of the plurality of through-channels. In a preferred implementation of the invention, this applies substantially to all through-channels and to all their neighboring through-channels formed within the usable region of the substrate. In the sense of the present invention the term “neighboring” could be replaced by the term “adjacent”, meaning that there is no other through-channel placed between two neighboring or adjacent through-channels. Furthermore, in the sense of the present invention the term “upper rim” of a through-channel refers to the rim of the through-channel on the upper side of the substrate. The rim itself may be defined as a closed line where the sidewall of the through-channel ends. In view of the previously described examples of the prior art, the upper rim can be easily identified, always being completely surrounded by the first surface 22′. To be more specific, in these examples, the upper rim is always a circular line lying within the plane of the first surface 22′ of the substrate 20′. In contrast, according to the present invention, the upper rim of a through-channel may not lie within a plane. This is particularly true when two neighboring through-channels partially “intersect” or “overlap” each other on the upper side of the substrate. The upper rim may then partially be surrounded or defined by portions of the still existing first surface of the substrate and partially by the sidewall of at least one neighboring through-channel. In an alternative embodiment of the present invention, the upper rim of a through-channel may be even completely surrounded or defined by the respective upper rims of the neighboring trough-channels. In the latter case, the original first surface of the substrate, i.e. the surface that was substantially plane and parallel to the second surface of the substrate before the perforation of the substrate, may have been completely lost in the usable region of the substrate. The topography of the substrate after the perforation process may somehow resemble the topography of an egg carton.

In the known prior art, the through-channels are always formed as discrete holes being clearly spaced apart from one another with the respective upper rims of the through-channels being fully surrounded or defined by the first surface of the substrate. Such a configuration was believed mandatory to maintain the required structural integrity of the substrate.

It is to the credit of the inventors to have overcome this prejudice of the prior art by decreasing the distance of non-cylindrical through-channels to such an extent that the neighboring through-channels “overlap” each other on the upper side of the substrate. It was surprisingly found out that it is possible to do so without unduly reducing the structural integrity of the substrate. With the present invention it is thus possible to increase the open area of the upper side of the substrate. It is a further to the credit of the inventors to have found out that by doing so the quality of the fiber web to be produced and/or finished on the PMC can be significantly improved.

In a preferred embodiment of the present invention at least 90%, preferably all, of the through-channels in the usable region of the substrate have an upper rim that directly contacts an upper rim of at least one other neighboring through-channel, preferably of all other neighboring through-channels, of the plurality of through-channels in the usable region of the substrate.

Furthermore, it is advantageous if less than 20%, preferably less than 10%, and more preferably less than 5%, of a surface on the upper side of the substrate is flat and substantially orthogonal to the thickness direction of the substrate. In other words, it is preferred if hardly any portion of the original first surface of the substrate, that was existing before the perforation process, is left after the perforation process.

In contrast to the first surface, with respect to the second surface of the substrate, it is advantageous, if between 70% and 90%, preferably between 75% and 85%, and more preferably about 80%, of a surface on the lower side of the substrate is flat and substantially orthogonal to the thickness direction of the substrate. Such a result can be achieved if the cross sectional area of the through-channels is smaller on the lower side of the substrate compared to the upper side of the substrate. For example, the through-channels may be substantially funnel-shaped tapering to the lower side of the substrate.

According to one embodiment of the present invention, the cross sectional area of at least one through-channel, preferably of all through-channels, of the plurality of through-channels in the usable region of the substrate may continuously decreases when going in the thickness direction of the substrate from the upper side to the lower side of the substrate.

According to an alternative embodiment of the present invention, the cross sectional area of at least one through-channel, preferably of all through-channels, of the plurality of through-channels in the usable region of the substrate continuously increases again when going in the thickness direction of the substrate from the middle region of the substrate between the upper side and the lower side to the lower side of the substrate. With such a configuration, the respective through-channel resembles the through-channel shown in FIG. 3C and the dewatering capability of the PMC may be enhanced by using the effect of a nozzle.

It is also possible to have in the same substrate a mixture of trough-channels according to the two previously described embodiments.

Another important finding of the inventors concerns the aspect that a shape of the cross sectional area of at least one through-channel, preferably of all through-channels, of the plurality of through-channels changes when going in the thickness direction of the substrate from the upper side to the lower side. In particular the shape of the cross sectional area is advantageously more elliptical in an upper region of the through-channel than in a lower region of the through-channel and/or the shape of the cross sectional area is advantageously more circular in a lower region of the through-channel than in an upper region of the through-channel. In view of the through-channels 30′ described with respect to FIGS. 3A, 3B and 3C, the basic shape of the cross sectional area of the through-channels 30′ is always the same, i.e. circular. However, it turned out to be advantageous—for reasons explained in more detail below—if the cross sectional area of the through-channels 30′ changes along the thickness direction of the substrate, in particular if the cross sectional area is more elliptical close to the upper side of the substrate and more circular close to the lower side of the substrate. If the through-channels are drilled by a laser, such a form of the through-channels can be achieved for example by not shutting off of the laser or by at least not shutting off completely the laser when advancing with the laser from one through-channel to the next neighboring through-channel in a row. Applying this method can result in that the upper rim of a through-channel is deeper below the original first surface of the substrate at a point between two neighboring through-channels in the direction of advancement of the laser compared to a point between two neighboring through-channels in a direction perpendicular thereto.

With the above described aspect of the present invention it is possible to impart anisotropic properties to the substrate in a beneficial way. For example, it is proposed that the shape of the cross sectional area in the upper region of the through-channel has a first dimension extending in cross-machine direction and a second dimension extending in machine direction, wherein the first dimension is smaller than the second dimension. With such a configuration of the through-channels the substrate, and thus the final paper machine clothing, can stand higher stress in the machine direction compared to the cross machine direction, wherein stresses that act on the paper machine clothing are usually in fact much higher in the machine direction than in the cross machine direction. As it is clear to those skilled in the art, the term “machine direction” refers to the longitudinal direction of the PMC, i.e. the direction of transportation of the fiber web or the fibrous nonwoven when the PMC is installed in a corresponding machine, whereas the term “cross machine direction” refers to a direction within the plane of the PMC that is perpendicular to the machine direction.

In an alternative embodiment it is proposed that the shape of the cross sectional area in the upper region of the through-channel has a first dimension extending in cross-machine direction and a second dimension extending in machine direction, wherein the first dimension is larger than the second dimension. Such a form of the through-channels is particularly beneficial if the fiber retention on the paper machine clothing, in particular a forming fabric, shall be enhanced.

The first dimension and the second dimension preferably differ from each other by at least 5%, more preferably by at least 10%, and even more preferably by at least 15%, of the respective smaller dimension.

Preferably, on the lower side of the substrate the shape of the cross sectional area is substantially circular.

In order to increase the density of through-channels in the usable region of the substrate, and thus, to enhance the dewatering capability of the paper machine clothing, it is suggested that at least 90% of all through-channels in the usable region of the substrate are arranged in a non-checkered pattern. The term “checkered pattern” in the sense of the present invention means that all through-channels have the same distance to all their neighboring through-channels and all through-channels are arranged in rows that are oriented perpendicular to each other.

According to another aspect, the present invention also refers to a method of producing the paper machine clothing as previously described comprising the following steps: providing a substrate having a first surface and a second surface, wherein the first surface and the second surface are preferably planar and parallel to each other; and forming a plurality of non-cylindrical through holes into a usable region of the substrate, wherein at least some, preferably all, of the plurality of through holes that are neighboring each other are formed at such a close distance that they partially overlap each other.

The term “through hole” in the sense of the present invention refers to the form of a hole that is formed in the substrate neglecting the neighboring through holes that may partially overlap. In contrast, the term “through-channel” refers to the geometric form of the channels in the finally drilled substrate. Due to the fact that neighboring through holes may overlap each other according to the present invention, its form, especially in view of its upper rim, can differ from the form of the through-channels.

According to one embodiment of the present invention it is proposed that, when all the through holes have been formed into the usable region of the substrate, at least one of the first surface and the second surface in the usable region has disappeared by at least 90%, preferably by 100%. As result the finally drilled substrate has none or hardly any opposite surface portions that are planar and parallel to each other. Preferably the substrate, before it is perforated, has a caliper in its usable region between 0.5 mm and 1.5 mm and even more preferable between 0.8 mm and 1.2 mm. After perforating the substrate in its usable region, the caliper thereof may be different. In some embodiments the caliper of the perforated substrate may be smaller compared to the substrate before perforation. This may be particularly true when at least one of the first surface and the second surface in the usable region has completely disappeared. However, in other embodiments, the caliper of the perforated substrate may be even greater compared to the substrate before perforation. This can happen if part of the material that is evaporated e.g. by means of a laser condensates again, thereby forming some kind of hills or ridges. Anyway, as previously mentioned, the topography of the substrate after the perforation process may somehow resemble the topography of an egg box.

Preferably the plurality of through holes is formed into the substrate by using a laser, wherein preferably cold air is blown onto the substrate during the step of forming the through holes into the substrate. The cold air inhibits overheating and damaging of the substrate material, which is particularly important for the material region between two neighboring through holes when the laser is advancing form the first of the two through holes to the second one.

Other features which are considered as characteristic for the invention are set forth in the appended claims.

Although the invention is illustrated and described herein as embodied in a paper machine clothing and a method of producing the same, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.

The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

FIG. 1 is a schematic illustrating a prior art process of perforating a substrate via laser drilling according to U.S. Pat. No. 5,837,102;

FIG. 2 is a plan view showing a substrate under tension according to the prior art represented by U.S. Pat. No. 4,446,187;

FIGS. 3A, 3B and 3C are sectional side views illustrating cross sections of laser-bored through channels according to U.S. Pat. No. 4,446,187;

FIG. 4 shows a section of a substrate comprising a single through hole of a first type;

FIG. 4A shows an enlarged view of the through hole in FIG. 4;

FIG. 5 shows a section of a substrate comprising a single through hole of a second type;

FIG. 5A shows an enlarged view of the through hole in FIG. 5;

FIG. 6 shows a sectional view along lines A-A and B-B in FIG. 4 and along line C-C in FIG. 5;

FIG. 7 shows a sectional view along line D-D in FIG. 5;

FIG. 8 shows a section of a substrate comprising a plurality of through holes of the first type;

FIG. 9 shows a section of a substrate comprising a plurality through holes of the second type;

FIG. 10 shows a sectional view along lines E-E and F-F in FIG. 8 and along line G-G in FIG. 9;

FIG. 11 shows a sectional view along line H-H in FIG. 9;

FIG. 12 shows a sectional view similar to the sectional view of FIG. 10, but with a third type of through holes;

FIG. 13 shows a section of a substrate similar to the one shown in FIG. 8, but with the through holes arranged in a non-checkered pattern; and

FIG. 14 shows a section of a substrate similar to the one shown in FIG. 9, but with the through holes arranged in a non-checkered pattern.

DETAILED DESCRIPTION OF THE INVENTION

Referring now once more to the figures of the drawing in detail, FIG. 4 shows a section of a substrate 20 which section is indicated by a dashed square. The substrate 20 comprises a first surface 22 and an opposite second surface 24 (see FIG. 6), wherein the first surface 22 and the second surface 24 are substantially planar and parallel to each other.

A single through hole 31 of a first type is provided in the center of the section of the substrate 20. FIG. 6 shows a cross sectional view which is taken through the through hole 31 along line A-A or line B-B of FIG. 4. As can be seen from FIGS. 4 and 6, the through hole 31 extends through the substrate 20 in its thickness direction TD along a central axis CA of the through hole 31, the central axis CA being indicated by a dashed line in FIG. 6. Thus, the through hole 31 connects the first surface 22 with the second surface 24 of the substrate 20. The through hole 31 is substantially funnel shaped with a cross sectional area becoming continuously smaller when going in the thickness direction TD from the first surface 22 to the second surface 24. The cross sectional area of a through hole 31 is obtained by cutting the through hole 31 with a plane that is oriented perpendicular to the thickness direction TD of the substrate 20. In this embodiment the shape of the cross sectional area of the through hole 31 is always circular, no matter at which height level of the substrate the cross sectional area is taken.

The through hole 31 has a circular upper rim 34 where a side wall of the through hole 31 ends and the flat first surface 22 begins. The circular upper rim 34 has a diameter A, as shown in FIG. 4A. Furthermore, the through hole 31 has a circular lower rim 36 where the side wall of the through hole 31 ends and the flat second surface 24 begins. The circular lower rim 36 has a diameter a, as also shown in FIG. 4A. Diameter A of the upper rim is larger than diameter a of the lower rim.

FIG. 5 shows another section of a substrate 20 which section is also indicated by a dashed square. The substrate 20 comprises a first surface 22 and a second surface 24 (see FIG. 7), wherein the first surface 22 and the second surface 24 are substantially planar and parallel to each other.

A single through hole 32 of a second type is provided in the center of the section of the substrate 20. FIG. 6 shows a cross sectional view which is taken through the through hole 32 along line C-C of FIG. 5 and FIG. 7 shows a cross sectional view which is taken through the through hole 32 along line D-D of FIG. 5. As can be seen from FIGS. 5, 6 and 7, the through hole 32 extends through the substrate 20 in its thickness direction TD along a central axis CA of the through hole 32, the central axis CA being indicated by a dashed line in FIGS. 6 and 7. Thus, the through hole 32 connects the first surface 22 with the second surface 24 of the substrate 20. The through hole 32 is substantially funnel shaped with a cross sectional area becoming continuously smaller when going in a thickness direction TD from the first surface 22 to the second surface 24. The cross sectional area of the through hole 32 is obtained by cutting the through hole 32 with a plane that is oriented perpendicular to the thickness direction TD of the substrate 20. In this embodiment the shape of the cross sectional area of the through hole 32 is not constant but changes when going along the thickness direction TD of the through hole 32. In an upper region of the substrate 20, i.e. in a region close to the first surface 22, the through hole 32 is more oval or elliptical, whereas in a lower region of the substrate 20, i.e. in a region close to the second surface 24, the through hole 32 is more or completely circular. The shape of the cross sectional area of the through hole 32 preferably changes continuously along the thickness direction TD of the substrate 20.

Thus, the through hole 32 has an elliptical upper rim 35 where a side wall of the through hole 32 ends and the flat first surface 22 begins. The elliptical upper rim 35 has a first diameter A and a second diameter B measured orthogonally thereto, as indicated in FIG. 5A. Furthermore, the through hole 32 has a circular lower rim 36 where the side wall of the through hole 32 ends and the flat second surface 24 begins. The circular lower rim 36 has a diameter a, as also shown in FIG. 5A. The second diameter B of the upper rim 35 is larger than the first diameter A of the upper rim 35. The first diameter A of the upper rim 35 is larger than the diameter a of the lower rim 36. Preferably, the second diameter B of the upper rim 35 is at least 5%, more preferably at least 10%, even more preferably at least 15% larger than the first diameter A of the upper rim 35.

According to the idea of the present invention, several of such non-cylindrical through holes are arranged in such a close relationship that they partially overlap each other in the substrate. Examples of such arrangements for the through holes 31 of the first type and the through holes 32 of the second type are shown in FIGS. 8 and 9, respectively. To be more precise, nine corresponding through holes 31, 32 arranged in a checkered pattern are shown in these figures. The through holes 31, 32 each have a respective lower rim 36. Furthermore, for the sake of clarity, also the corresponding upper rims 34, 35 of the through holes 31, 32 are shown, even though these upper rims 34, 35 do not exist anymore as such in the final product. Instead, in the final product, i.e. in the finally perforated substrate 20, through-channels 30 are formed having a respective upper rim 38 that is at least partially delimited by the upper rim 38 of a neighboring through-channel 30. As shown in FIGS. 8 and 9, the originally existing flat or planar first surface 22 of the substrate 20 has almost completely disappeared after the perforation of the substrate 20 in the usable region UR thereof. In alternative embodiments it may have completely disappeared. One reason for the complete disappearance of the originally flat first surface 22 of the substrate 20 could be that the distance between the through holes 31, 32 is chosen even smaller than shown in FIGS. 8 and 9 (as will be explained below in view of FIGS. 13 and 14). An additional or alternative reason for the complete disappearance of the originally flat first surface 22 of the substrate 20 could be that the through holes 31, 32 have been laser-drilled and that the material of the substrate 20 that has been evaporated by the energy of the laser at least partially condensates again on the first surface 22, thus forming some kind of hill or ridge thereon. As a consequence, the upper rim 38 of a corresponding through-channel 30 does not necessarily extend within a plane but is rather a closed line that extends three-dimensionally. It should be noted that the upper rim 38 of the through-channel 30 may extend partially below the originally flat first surface 22 of the substrate 20 and/or extend partially above the originally flat first surface 22 of the substrate 20.

FIGS. 10 and 11 represent views similar to the ones shown in FIGS. 6 and 7, respectively, but now with several neighboring through holes 31, 32 that form the through-channels 30 in the substrate 20 of the final product. In FIG. 10 a location (see reference sign 38) of the upper rim 38 of the through-channel 30 of FIG. 8 is shown that represents an absolute minimum of the upper rim 38. In other words, the upper rim 38 has the largest distance to the originally flat first surface 22 of the substrate 20 which surface 22 is indicated by a dotted line in FIG. 10. The surface of the substrate 20 has a saddle point at this location of the upper rim 38.

In FIG. 11 a location (see reference numeral 38) of the upper rim 38 of the through-channel 30 of FIG. 9 is shown (according to the section along line H-H of FIG. 9) that represents an absolute minimum of the upper rim 38 of this through-channel 30. In other words, the upper rim 38 has the largest distance to the originally flat first surface 22 of the substrate 20 which surface 22 is also indicated by a dotted line in FIG. 11. The surface of the substrate 20 has a saddle point at this location of the upper rim 38. A section along line G-G of FIG. 9 is represented by the drawing of FIG. 10. At the location of the upper rim 38 shown in this figure, the upper rim only has a local minimum. Thus, the ridges that separate two neighboring through-channels 30 from each other are higher when following the line G-G compared to the ridges when following the line H-H of FIG. 9. Consequently, the substrate has anisotropic properties.

These anisotropic properties can be used in a beneficial way. For example, the substrate that is perforated in a way as shown in FIGS. 9, 10 and 11 is more stress resistant in the direction parallel to line H-H compared to the direction parallel to line G-G. If line H-H substantially represents the machine direction of the final paper machine clothing the relatively high forces in the machine direction can be absorbed by the substrate 20 while at the same time the substrate 20 provides a relatively large open area on its upper side. Alternatively, if line H-H substantially represents the cross machine direction of the final paper machine clothing the nascent paper web in a forming section can adhere better to the substrate 20 since ridges formed in the substrate 20 between neighboring rows of through channels 30 that extend in cross machine direction are higher than those extending in the machine direction. Consequently, the properties of the substrate 20 can be adjusted to the intended use or the requirements of the paper machine clothing.

FIG. 12 shows a sectional view similar to the cross sectional view of FIG. 10, but of a third type of through holes. This third type of through holes differs from the first and second type of through holes 31, 32 in that the cross sectional area of the through hole of the third type and, thus, the cross sectional area of the corresponding through-channel 30 that is created thereof, continuously increase again when going in the thickness direction TD of the substrate 20 from the middle region MR of the substrate 20 between the upper side and the lower side to the lower side of the substrate 20. In an extreme case, neighboring through holes may not only partially overlap each other on the first side 22 of the substrate 20 but also on the second side 24 thereof.

Finally, FIGS. 13 and 14 show a section of a substrate 20 similar to the one shown in FIGS. 8 and 9, respectively, with the difference that the through holes 31, 32 are arranged in a non-checkered pattern. In FIGS. 8 and 9 each through hole 31, 32 has eight neighboring other through holes 31, 32 wherein the distance to four of these eight neighboring through holes 31, 32 is larger than the distance to the remaining four neighboring through holes 31, 32. Small areas of the originally flat first surface 22 of the substrate 20 are still left.

In contrast, in the examples shown in FIGS. 13 and 14, each through hole 31, 32 has six neighboring other through holes 31, 32 wherein the distance to all these neighboring through holes 31, 32 is substantially the same (for example corresponding to the smaller distance of the embodiments shown in FIGS. 8 and 9). These six neighboring through holes 31, 32 are arranged in a honeycomb pattern around a corresponding through hole 31, 32 in the middle thereof. No areas of the originally flat first surface 22 of the substrate 20 are left after the perforation processes. With such an arrangement, the density of through-channels 31 in the final substrate 20 can be increased, as well as the open area on the upper side of the substrate 20.

The following is a summary list of reference numerals and the corresponding structure used in the above description of the invention:

20′, 20 substrate

22, 22′ first surface

24, 24′ second surface

26′ first lateral edge

28′ second lateral edge

30′, 30 through-channel

31 through hole of first type

32 through hole of second type

34 circular upper rim of through hole

35 elliptical upper rim of through hole

36 circular lower rim of through hole

38 upper rim of through-channel

a, b diameter of lower rim

A, B diameter of upper rim

CA central axis

LB laser beam

MR middle region

R roller

TD thickness direction

WD width direction

Claims

1. A paper machine clothing, comprising: a substrate having an upper side, a lower side, two lateral edges and a usable region between said two lateral edges;said usable region having a plurality of through-channels formed therein extending through said substrate and connecting said upper side with said lower side;said through-channels being non-cylindrical, with a cross sectional area becoming smaller in a thickness direction of said substrate from said upper side to a middle region of said substrate between said upper side and said lower side; andan upper rim of at least one of said plurality of through-channels directly contacting an upper rim of at least one neighboring through-channel of said plurality of through-channels.

2. The paper machine clothing according to claim 1, wherein at least 90%, preferably all, of the through-channels in said usable region of said substrate have an upper rim that directly contacts an upper rim of at least one neighboring through-channel.

3. The paper machine clothing according to claim 2, wherein said upper rims of all of said through-channels in said usable region contact all directly neighboring through-channels in said usable region of said substrate.

4. The paper machine clothing according to claim 1, wherein less than 20% of a surface on said upper side of said substrate is flat and substantially orthogonal to the thickness direction of said substrate.

5. The paper machine clothing according to claim 4, wherein less than 5% of the surface on said upper side of said substrate is flat and substantially orthogonal to the thickness direction of said substrate.

6. The paper machine clothing according to claim 1, wherein between 70% and 90% of a surface on said lower side of said substrate is flat and substantially orthogonal to the thickness direction of said substrate.

7. The paper machine clothing according to claim 6, wherein about 80% of the surface on said lower side of said substrate is flat and substantially orthogonal to the thickness direction of said substrate.

8. The paper machine clothing according to claim 1, wherein the cross sectional area of at least one of said through-channels in said usable region of said substrate continuously decreases along the thickness direction of said substrate from said upper side to said lower side of said substrate.

9. The paper machine clothing according to claim 8, wherein the cross sectional area of all of said through-channels of the plurality of through-channels in said usable region of said substrate continuously decreases along the thickness direction of said substrate from said upper side to said lower side of said substrate.

10. The paper machine clothing according to claim 1, wherein the cross sectional area of all of said through-channels of the plurality of through-channels in the usable region of said substrate continuously increases in the thickness direction of said substrate from said middle region of said substrate to said lower side of said substrate.

11. The paper machine clothing according to claim 1, wherein a shape of the cross sectional area of at least one of said through-channels changes along the thickness direction of said substrate from said upper side to said lower side.

12. The paper machine clothing according to claim 11, wherein the shape of the cross sectional area of all of said through-channels of the plurality of through-channels changes along the thickness direction of said substrate from said upper side to said lower side.

13. The paper machine clothing according to claim 11, wherein the shape of the cross sectional area is more elliptical in an upper region of said through-channel than in a lower region of said through-channel and/or the shape of the cross sectional area is more circular in a lower region of said through-channel than in an upper region of said through-channel.

14. The paper machine clothing according to claim 13, wherein the shape of the cross sectional area in the upper region of said through-channel has a first dimension extending in cross-machine direction and a second dimension extending in a machine direction, and wherein the first dimension is smaller than the second dimension.

15. The paper machine clothing according to claim 13, wherein the shape of the cross sectional area in the upper region of said through-channel has a first dimension extending in cross-machine direction and a second dimension extending in machine direction, and wherein the first dimension is greater than the second dimension.

16. The paper machine clothing according to claim 11, wherein the shape of the cross sectional area on said lower side of said substrate is substantially circular.

17. The paper machine clothing according to claim 1, wherein at least 90% of said through-channels in said usable region of said substrate are arranged in a non-checkered pattern.

18. A method of producing a paper machine clothing according to claim 1, the method comprising: providing a substrate having a first surface and a second surface, wherein the first surface and the second surface are substantially planar and parallel to each other; andforming a plurality of non-cylindrical through holes into a usable region of the substrate,with at least some of the plurality of through holes that are neighboring each other are formed at such a close vicinity to partially overlap each other.

19. The method according to claim 18, wherein, with all of the through holes formed in the usable region of the substrate, at least one of the first surface or the second surface in the usable region has disappeared by at least 90%.

20. The method according to claim 18, which comprises forming the plurality of through holes into the substrate by using a laser and blowing cold air onto the substrate during the step of forming the through holes into the substrate.