This application is a 371 of PCT/EP2012/003352 filed 20 Jul. 2012
The present invention relates to fabrics for paper machines and refers in particular to nonwoven fabrics and the production thereof.
Paper machines are used to produce fibrous nonwoven webs such as papers of an extremely wide range of grades, boards, paperboards and similar nonwoven materials. In this document, the term “paper” will be used as representative of these types of fibrous nonwoven webs.
The production of a fibrous nonwoven web begins in the forming section of a paper machine with the application of a fibrous suspension to a fabric or with the introduction of a fibrous suspension into the gap formed between two fabrics. Fabrics are normally implemented in the form of endless strips which, deflected over rolls, each run around within a specific part or section of the paper machine. The paper-side surface of the fabric bears the fibrous suspension or the fibrous web or fibrous nonwoven web produced there from by dewatering. The surface of the fabric that is led over the rolls will be designated below as the running side, the paper-side surface, provided to transport the fibrous suspension or web will be designated as the useful side. For the purpose of dewatering, the fabrics have passages, via which the water can be sucked away from the paper-side surface toward the running side.
The fabrics currently used as forming fabrics in the forming section of paper machines consist of woven material. Woven fabrics have regular structures with a repeating basic pattern. The forming fabrics are normally built up from a plurality of woven layers of different thread thickness and thread guidance. On account of their different woven structure, the individual layers of such fabrics not only have permeabilities for water that differ from one another but, since the openings or passages formed in the paper-side layers are regularly covered by yarns of woven layers lying underneath, also lead to laterally varying permeabilities of the forming fabric and therefore to a locally varying dewatering rate of the fibrous web. The result is visible markings of the paper web with a regular arrangement following the weaving pattern. Since less dewatered regions of a paper web furthermore also have a lower fiber density, lateral permeability fluctuations can impair the quality of the paper web to be produced.
Woven fabrics also have a low flexural rigidity and therefore frequently tend to form creases as they circulate in paper machines. The use of monofilaments of different materials, such as for example a combination of yarns made of polyethylene terephthalate (PET) and polyamide (PA), on the running side of a fabric, because of the different characteristics of these materials with respect to water uptake, stretch, etc, often leads to forming fabric edges that stand up or stick out.
Since fabrics cannot be woven as an endless strip, the two ends of a finitely long woven strip have to be joined to each other in order to form an endless strip. In order to avoid irregularities at the joint, which can lead to markings of the paper web, the joining is carried out via a complicated woven seam structure, in which the ends of associated ends of warp and weft threads that are assigned to each other are spliced to one another with an offset in accordance with a specific pattern at the joint of the woven strip. This joining technique is very complicated and is reflected in correspondingly high production costs for woven endless fabrics.
As an alternative to woven fabrics, fabrics have been proposed which are produced from nonwoven material webs. In the patent specifications CA 1 230 511 and U.S. Pat. No. 4,541,895, for example, a fabric is specified which is formed from a laminate made of a plurality of layers of nonwoven, water-impermeable materials. Openings are introduced into the laminate for the purposes of dewatering. The individual layers of the laminate are joined flat by means of, for example, ultrasonic welding, high-frequency welding, thermal welding, adhesive bonding or chemical pre-treatment of the layers. The dewatering holes are introduced into the laminate, preferably by means of laser drilling. The spliced seam of a layer can be arranged to be offset from the other layers; the spliced seams can furthermore also be arranged at an angle to the running direction of the endless strip, in order to avoid noticeable thickenings of the fabric. However, producing such film laminates in the dimensions required for forming fabrics entails a great deal of effort. In addition, such multilayer film laminates are relatively stiff and tend to delaminate under the conditions prevailing during use in the forming section of a paper machine.
If polymer strips are used for producing fabrics for paper machines, said strips have to be oriented in the running direction of the fabric, otherwise the fabric will be stretched irreversibly under the tensile stresses prevailing in operation and thus become unusable after a short time. However, appropriately unidirectionally oriented polymer strips are not available in the widths which are usual for fabrics of paper machines used on an industrial scale. In order to produce a fabric, it is therefore necessary for a plurality of polymer strips subsequently to be joined to one another laterally beside one another. In order to obtain a fabric in the form of an endless strip, the ends of the strip additionally have to be joined together. At the connecting points or joints, the material is not oriented, which means that the fabric at these points exhibits a correspondingly lower mechanical stability.
In order to solve this problem, patent application US 2010/0230064 proposes a fabric for use in paper machines which is produced from a spirally wound polymer strip. The width of the polymer strip is substantially smaller than the width of the fabric produced there from, the longitudinal direction of the polymer strip, apart from the oblique position given by the height of the windings, coinciding with the running direction of the fabric. The side edges respectively opposite one another of adjacent windings of the polymer strip are welded to one another in order to form a closed running surface. Since the welded seam is arranged at a relatively small angle with respect to the running direction of the fabric, the components of the tensile stress acting transversely with respect to the welded seam are low, so that, in the ideal case, the non-oriented material of the welded seam is not loaded excessively. The production of a fabric from a spirally laid polymer strip is very complicated, however, since it requires a special welding apparatus in which either the welding apparatus has to be guided repeatedly around the fabric with high precision along the welding line, or the fabric has to be displaced with the circulating welding line relative to the welding apparatus. In addition, after the welding operation, the edges of the fabric have to be trimmed in order to obtain a uniformly wide fabric. As a result, the welded seam abuts one of the side edges of the fabric at an acute angle, which means that, on account of the welded seam that is structurally weaker as compared with the polymer strip, a point of attack for tearing of the fabric is provided.
On the basis of that explained, it is therefore desirable to specify a fabric for paper machines which is formed in the shape of a film, has a high mechanical stability and tensile strength, is sufficiently wide for use in industrially used paper machines and can be fabricated by using conventional means.
Embodiments of such fabrics for a paper machine have two or more endless strips, which are each formed by a film-like web closed along a joint to form a film-like web that is endless in the direction of circulation of the fabric, wherein the endless strips are connected to one another at the side edges such that the joints of two endless strips that are connected to each other are arranged to be offset in relation to one another with respect to the direction of circulation of the fabric.
In this connection, it is pointed out that the terms “comprise”, “have”, “include”, “contain”, and “with” used in this text and in the claims in relation to the enumeration of features, and also the grammatical modifications thereof, generally designate a non-final enumeration of features, such as method steps, apparatuses, regions, sizes and the like, and in no way rule out the presence of further and other features or groupings of other or additional features.
The joint in a film-like web has properties that differ from the remaining web material, which manifest themselves in a lower tensile strength and higher extensibility of the joint. As a result of the offset of the joints, a tensile force acting on the fabric in the area of the joint of one of the endless strips is absorbed by the adjacently arranged non-joined film material of an adjacent endless strip and, in this way, overloading and stretching of the joint is effectively prevented.
In advantageous embodiments, the film-like webs are formed from a polymer that is oriented unidirectionally in the direction of circulation of the fabric, which achieves a high dimensional stability of the fabric in proper use. In order to be suitable for use in paper machines, film-like webs in embodiments of the fabric are formed on the basis of a material which is chosen from polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polyphenylene sulfide (PPS), polyether ether ketone (PEEK), polyamide (PA) or polyolefines. For use in paper machines, the thickness of the film-like webs in embodiments is further preferably chosen from the range from 300 to 1600 μm and in particular preferably from the range from 500 to 800 μm.
It is conceivable for the film-like webs to be formed from a non-oriented polymer and, in order to provide the tensile strength of the fabric, for threads extending in the direction of circulation of the fabric, in particular spirally wound threads, to be provided.
The film-like webs in embodiments are preferably at least partially integrally connected at the joints, in order to avoid the joint opening, for example with the effect of gap formation during use of the fabric. An integral connection is understood to mean the connecting partners being held together by atomic or molecular forces. In further embodiments, the endless strips are connected integrally to one another, in order to create a seamless transition between the mutually adjoining endless strips.
In advantageous embodiments, the active surfaces of a joint and/or of a lateral connecting point are arranged in the form of a staircase, so that part of the connecting surface is not penetrated perpendicularly by the tensile forces that occur, and in this way the dimensional stability of the connecting point is increased. In this case, the active surfaces designate the surfaces adjoining one another at the connecting point. In order to enlarge the connecting surface and in order to increase their ability to be irradiated, at least one active surface of a joint and/or of a lateral connecting point is arranged as a surface inclined with respect to the surfaces of the fabric.
According to a further embodiment of the invention, at least one joint extends along a line, in particular a straight line, extending diagonally in relation to the direction of circulation. In this way, the length of the joint can be made greater than the width of the film-like web, which means that the tensile force acting on the joint is distributed to a longer joint. In this way, the durability of the joint can be improved. A further advantage in the diagonal course of the joint is that, as the fabric passes through a nip, the entire joint does not pass through the nip at the same time, instead only a small section in each case. In this way, any markings possibly caused by the joint are reduced, and the run of the fabric in the machine also becomes more stable.
It is also conceivable for the fabric to comprise a plurality of film-like webs arranged one above another and connected flat to one another. In this connection, it is in particular conceivable for the joints of film-like webs arranged one above another to extend diagonally with respect to the direction of circulation and to enclose different angles with the direction of circulation.
Further features of the invention can be gathered from the following description of exemplary embodiments in conjunction with the claims and the appended figures. It should be pointed out that the invention is not restricted to the versions of the exemplary embodiments described but is determined by the scope of the appended patent claims. In particular, in embodiments according to the invention, the features listed in the exemplary embodiments explained below can be implemented in numbers and combinations differing from the examples. In the following explanation of some exemplary embodiments of the invention, reference is made to the appended figures, in which:
In the figures, the same or similar designations are used for functionally equivalent or similar characteristics, irrespective of specific embodiments.
The individual film-like webs 10, 20 and 30 are constructed monolithically, which in this text is to be understood to mean that the webs, apart from any possible surface coating, consist of one piece, i.e. are in particular not built up in several plies. The film webs 10, 20 and 30 can be perforated, depending on the intended purpose, i.e. they can have vertically penetrating holes, for example for dewatering the fibrous web.
Each of the film webs used to produce a fabric 1 has two side edges delimiting its extent in the transverse direction QR, as shown in the illustrations a) and b) of
To form an endless fabric 1, preferably each of the individual film-like webs 10, 20 and 30 are firstly joined along a joint 11, 21 and 31, respectively, to form an endless strip. The schematic illustration of
The ends of a film web 10 can be joined by using different joining techniques, such as for example adhesive bonding, calendaring and in particular welding. In order to weld the two web ends, an ultrasonic welding method or a transmission laser welding method can be used. In the transmission laser welding method, the touching surfaces of the two web ends are melted by means of an NIR laser (laser with an emission wavelength in the near infrared range) and pressed onto one another. Since the material of the film strips 10, 20, 30 does not absorb the light from an NIR laser, the surfaces to be melted must previously be provided with an absorber coating; it is generally sufficient to coat only one of two surfaces touching at the joint with a material absorbing the NIR laser light. The absorber coating absorbs the light from the NIR laser used for the welding, heats up as a result and consequently melts the surface regions of the web ends adjacent thereto. By means of pressing the molten regions onto one another, an integral connection is ultimately produced.
Suitable lasers for NIR transmission welding are, for example, diode lasers with emission wavelengths in the range from 808 to 980 nm and Nd:YAG lasers with an emission wavelength of 1064 nm. Preferably, lasers with emissions in the range from 940 to 1064 nm are used.
The two end edges of a film-like web 10 can be joined end-to-end or by using profiling of the ends forming the same. Here, end-to-end is to be understood to mean the ends of a film web 10 running at right angles or obliquely with respect to the useful or running side meeting each other.
Via profiling the ends 14 and 15, the area of the joint 11 can be enlarged further and the stretching thereof under tensile loading can be reduced further. In the example illustrated in
A further example of butt edge profiling is shown by
When joining the film web ends with the aid of an NIR transmission welding method, the individual film strips are preferably made of a polymer which is transparent to the light wavelengths used for the welding. The film-like webs used are therefore advantageously flat substrates produced by extrusion or casting, for example, made of thermoplastics such as for example polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polyphenylene sulfide (PPS), polyether ether ketone (PEEK), polyamide (PA), polyolefines and polyimides (PI). These materials are known in the form of uniaxially oriented plates or roll products and are obtainable on the market. For the production of fabrics 1 for paper machines, film web thicknesses from the range from 150 up to 1600 μm and in particular from the range from 500 to 800 μm are preferably used.
When welding the ends of uniaxially oriented film webs 10, the material structure within the joining zone 11 is destroyed, for example by re-crystallization, which means that the joining zone can be loaded less mechanically and chemically and, as a result, it is possible for undesired corrugations and distortions at the joining zone 11 to occur during proper use. During the production of endless fabrics 1, the joining zones 11, 21 and 31 of the individual endless strips 10, 20 and 30 etc are therefore arranged offset relative to one another with respect to the direction of circulation LR of the fabric, as illustrated in
The tensile forces acting on the fabric 1 at right angles to the direction of circulation LR are substantially lower than those acting longitudinally with respect thereto, so that during normal operation no stretching of the connecting points between the individual endless strips 10, 20 and 30 occurs. The connection of mutually adjacent endless strips can be carried out, like the joining of the end edges of the film-like webs, by means of ultrasonic welding or transmission laser welding. Two side edges 13, 14 can be connected end-to-end in a manner analogous to the end edges of a film web or by using profiling of the edge surfaces forming the side edges.
The schematic illustration of
In an alternative transmission laser welding method, as illustrated schematically in
A fabric 1 made from a plurality of film-like webs joined in accordance with the above explanations can be made in any desired width and therefore matched to the requirement of a respective paper machine by using conventional joining techniques. A fabric 1 made as explained previously exhibits high mechanical stability and tensile strength and, in proper operation, does not tend to form corrugations or distortions.
Number | Date | Country | Kind |
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10 2011 079 517 | Jul 2011 | DE | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/EP2012/003352 | 7/20/2012 | WO | 00 | 1/21/2014 |
Publishing Document | Publishing Date | Country | Kind |
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WO2013/010678 | 1/24/2013 | WO | A |
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Number | Date | Country | |
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20140166224 A1 | Jun 2014 | US |