Patent Grant
9771683
The present invention relates to a wet paper web transfer belt (also referred to as transfer belt) used in papermaking machines.
A papermaking machine for removing moisture from the source material of paper generally comprises a wire part, a press part and a dryer part. The wire part, the press part and the dryer part are arranged along the transfer direction of a wet paper web.
In one type of papermaking machine, the wet paper web is passed from one part to another in an open-draw. In the press part of this open-draw papermaking machine, there are a number of places in which the wet paper web is not supported by any roll or by papermaking equipment such as a felt or a belt; in other words, places in which the wet paper web is travelling on its own. In these places, problems such as “web breaks” tend to occur. The risk of this problem occurring increases as the papermaking machine is operated at high speed; therefore, there are limitations to operating an open-draw papermaking machine at high speed.
In recent years, most papermaking machines have therefore come to be of the type in which the wet paper web is passed in a closed-draw. In the press part of this closed-draw papermaking machine, the wet paper web is transferred while being placed on a papermaking felt or a wet paper web transfer belt; therefore, there are no places in which the wet paper web travels on its own as in an open-draw papermaking machine. As a result, it has become possible to operate papermaking machines at still higher speed and to stabilize operations.
Hereinafter an example of the press part of a closed-draw papermaking machine will be explained in detail.
The wet paper web W is transferred by being passed from the wire part to the press part 3 and from there to the dryer part 4. After dewatering the wet paper web in the press part 3, it is finally dried in the dryer part 4. A wet paper web transfer belt 1 is arranged in the press part 3 of the papermaking machine 2 for transferring the wet paper web W in the direction of arrow B.
The wet paper web W is transferred in the direction of arrow B while being supported by press felts 5, 6, the wet paper web transfer belt 1 and a dryer fabric 7, respectively. The press felts 5, 6, the wet paper web transfer belt 1 and the dryer fabric 7 are respectively endless belts supported by guide rollers 8.
In a typical closed-draw papermaking machine, a shoe press mechanism 13 is arranged in a position facing press roll 10. The shoe press mechanism 13 comprises a concave press shoe 9 facing the press roll 10; via a shoe press belt 11, the shoe 9 constitutes a press section 12 together with the press roll 10.
The wet paper web W is passed from the wire part (not shown in the figure) to the press part 3; thereafter, it is passed from the press felt 5 to the press felt 6. Then, the wet paper web W is transferred by the press felt 6 to the press section 12 of the shoe press mechanism 13. In the press section 12, the wet paper web W is compressed by the shoe 9 via the shoe press belt 11 and by the press roll 10 while being sandwiched by the press felt 6 and the wet paper web transfer belt 1. As a result thereof, the moisture in the wet paper web W is dewatered. Compared to the wet paper web transfer belt 1, the press felt 6 is configured to have high water permeability; therefore, in the press section 12, the moisture from the wet paper web W moves to press felt 6. In the press part 3, the wet paper web W is thus dewatered and its surface is smoothened.
Immediately after exiting the press section 12, the wet paper web W, the press felt 6 and the wet paper web transfer belt 1 swell in volume because they are suddenly released from pressure. Due to this swelling and because of the capillary action of the pulp fibers constituting the wet paper web W, the so-called “rewetting phenomenon” occurs in which part of the moisture in the press felt 6 moves to the wet paper web W. Nevertheless, since the water permeability of the wet paper web transfer belt 1 is low, the amount of moisture held inside it is small. Consequently, there is almost no rewetting phenomenon in which moisture moves from the wet paper web transfer belt 1 to the wet paper web W, and the wet paper web transfer belt 1 contributes to improving the dewatering of the wet paper web W.
Having passed through the press section 12, the wet paper web W is transferred by the wet paper web transfer belt 1 in the direction indicated by arrow B. Then, the wet paper web W is sucked up by a suction roll 14 and transferred by the dryer fabric 7 to the dryer part 4, where it is dried.
Here, the adhesive and releasing properties of the wet paper web contacting surface in relation to the wet paper web are among important functions required by the wet paper web transfer belt. In other words, the wet paper web transfer belt 1 requires that the wet paper web W positively adheres to the wet paper web contacting surface of the wet paper web transfer belt 1 immediately after it exits from the press section 12, while allowing the wet paper web W to smoothly release (detach) from the wet paper web transfer belt 1 when it is passed to the dryer fabric. In case these requirements are not fulfilled, the phenomenon of paper robbing and floating edges (damp edges) can occur.
The phenomenon called paper robbing occurs, for example, when the adhesive force of the wet paper web contacting surface of the wet paper web transfer belt 1 is weak and the wet paper web W having passed through the press section 12 remains on the press felt 6 instead of being passed from the press felt 6 to the wet paper web transfer belt 1, or when the adhesive force of the wet paper web contacting surface of the wet paper web transfer belt 1 is strong and the wet paper web W remains on the wet paper web transfer belt 1 instead of being passed to the dryer fabric 7. The phenomenon called floating edges occurs when the end parts (edges) of the wet paper web detach from the wet paper web transfer belt 1 or the press felt 6 and become to float.
When paper robbing occurs, operations need to be interrupted and the setting of the device needs to be modified so that the wet paper web is appropriately transferred. Further, when the floating edges phenomenon occurs, it is possible that quality problems occur such as wrinkles in the wet paper web; moreover, the problem of a break in the wet paper web (sheet break) or operational problems may occur such as the need to reduce the operating speed of the papermaking machine so as to avoid a break in the wet paper web (or the occurrence of floating edges).
Further, another important function of the wet paper web transfer belt is the wear resistance of the wet paper web contacting surface and the machine contacting surface of the wet paper web transfer belt. In other words, it becomes possible to use the wet paper web transfer belt over an extended period of time by improving the wear resistance of the wet paper web contacting surface and the machine contacting surface of the wet paper web transfer belt 1.
Various wet paper web transfer belts have been proposed in the prior art to fulfill the above functions.
For example, JP 06-057678 A discloses a wet paper web transfer belt in which a wet paper web contacting surface formed on the upper surface of a base (wet paper web side) is formed by an impermeable polymer coating layer and a lower surface of the base (roll side) is formed by a fibrous web. Particles with a higher hardness than the polymer coating are mixed in the impermeable polymer coating layer and the particles are made to protrude from the surface by such means as polishing the wet paper web contacting surface. Furthermore, U.S. Pat. No. 6,962,885, JP 2007-530800 and WO 2013/020745 similarly propose belts in which various fillers have been added to the resin layer.
The hydrophilic properties and the surface roughness of the wet paper web transfer belt surface are two major factors influencing the wet paper web adhesive properties of the wet paper web transfer belt. Adding a filler, as in the wet paper web transfer belts mentioned in the above-cited prior art, is an effective means for adjusting the hydrophilic properties and the surface roughness of the wet paper web transfer belt surface. However, further improvement has been desired in view of prevention of paper robbing and floating edges.
The object of the present invention is to provide a wet paper web transfer belt, wherein the adhesive properties and the releasing properties of the wet paper web contacting surface with the wet paper web are improved and paper robbing and floating edges do not occur.
The present invention, in order to solve the above problems, has employed the technology described below in a wet paper web transfer belt, wherein a reinforcing base material comprising a wet paper web-side surface and a machine-side surface and a water-impermeable resin are integrated with each other, and wherein at least the wet paper web-side surface of the reinforcing base material is embedded in the water-impermeable resin, and an outer circumferential layer comprising a wet paper web contacting surface is constituted by some of the water-impermeable resin.
(1) A wet paper web transfer belt in which a reinforcing base material comprising a wet paper web-side surface and a machine-side surface and a thermosetting polyurethane are integrated with each other, at least the wet paper web-side surface of the reinforcing base material is embedded in the polyurethane, an outer circumferential layer comprising a wet paper web contacting surface is constituted by some of the polyurethane; wherein, at least the outer circumferential layer comprises two different types of fillers including a high-roundness filler with a relatively high roundness and a low-roundness filler with a relatively low roundness, the difference between the high-roundness filler and the low-roundness filler is 0.1 or more.
(2) A wet paper web transfer belt according to (1); wherein the roundness of the high-roundness filler is 0.6 or more and the roundness of the low-roundness filler is less than 0.6.
(3) A wet paper web transfer belt according to (1); wherein the roundness of the high-roundness filler is 0.7 or more and the roundness of the low-roundness filler is less than 0.7.
(4) A wet paper web transfer belt according to (1); wherein the roundness of the high-roundness filler is 0.8 or more and the roundness of the low-roundness filler is less than 0.8.
(5) A wet paper web transfer belt according to (1) to (4); wherein the specific surface area of the high-roundness filler is 10 m2/g or less.
(6) A wet paper web transfer belt according to (1) to (5); wherein the specific surface area of the low-roundness filler is 12 m2/g or more.
(7) A wet paper web transfer belt according to (1) to (6); wherein the high-roundness filler comprises one or more filler(s) selected from inorganic fillers.
(8) A wet paper web transfer belt according to (1) to (7); wherein the low-roundness filler comprises one or more filler(s) selected from inorganic fillers or carbon-based fillers.
(9) A wet paper web transfer belt according to (1) to (8); wherein the two different fillers are only comprised in the outer circumferential layer.
(10) A wet paper web transfer belt according to (1) to (9); wherein the content of the high-roundness filler is from 5 wt % or more to 55 wt % or less in relation to the total weight of the outer circumferential layer (the total weight of the polyurethane, the filler(s) and other additives), and the content of the low-roundness filler is from 5 wt % or more to 55 wt % or less in relation to the total weight of the outer circumferential layer (the total weight of the polyurethane, the filler(s) and other additives).
(11) A wet paper web transfer belt according to (1) to (10); wherein the total content of the two different fillers is from 10 wt % or more to 60 wt % or less in relation to the total weight of the outer circumferential layer (the total weight of the polyurethane, the fillers and other additives).
(12) A wet paper web transfer belt according to (1) to (11); wherein the low-roundness filler is one or more types of filler selected from amorphous particulate fillers, needle-like fillers, fibrous fillers, plate-like fillers.
(13) A wet paper web transfer belt according to (1) to (12); wherein the average particle diameter of the high-roundness filler is 1.0 to 100 μm.
(14) A wet paper web transfer belt according to (1) to (13); wherein the average particle diameter of the low-roundness filler is 1.0 to 100 μm.
(15) A wet paper web transfer belt according to (1) to (14); wherein the reinforcing base material is a composite reinforcing base material in which short fibers have been intertwiningly integrated by needle punching with at least the machine-side surface of the reinforcing base material.
(16) A wet paper web transfer belt according to (15); wherein an inner circumferential layer comprising a machine contacting surface is constituted by some of the short fibers integrated with the machine-side surface.
(17) A wet paper web transfer belt according to (1) to (15); wherein an inner circumferential layer comprising a machine contacting surface is constituted by some of the polyurethane.
By adopting the above-described constitution, the present invention can provide a wet paper web transfer belt wherein the adhesive properties and releasing properties of the wet paper web with the wet paper web contacting surface of conventional wet paper web transfer belts have been further improved, and paper robbing and floating edges do not occur.
Hereinafter, the embodiments of the present invention will be explained in detail while referring to the drawings. The present invention is a wet paper web transfer belt 1 used in the press part of the papermaking machine shown in
A wet paper web transfer belt 1 shown in
A wet paper web transfer belt 1 shown in
A wet paper web transfer belt 1 shown in
The reinforcing base material 24 is generally a fabric woven with a weaving machine, or the like, from warp and weft yarns; however, a grid-like structure made by superposing warp and weft columns can also be used.
Examples of materials for the reinforcing base material 24 and the short fibers 33 include polyester (polyethylene terephthalate, polybutylene terephthalate, and the like), aliphatic polyamide (polyamide 11, polyamide 12, polyamide 612, and the like), aromatic polyamide (aramid), polyvinylidene fluoride, polypropylene, polyether ether ketone, polytetrafluoroethylene, polyethylene, wool, cotton, metal, and the like.
Examples of alternative materials for the polyurethane 25 include thermosetting resins such as epoxy, acrylic, and the like, or thermoplastic resins such as polyamide, polyarylate, polyester, and the like; preferably urethane resin is used.
The roundness (X) of the filler particles can be expressed by formula (1) below; wherein, A and C are respectively the particle projected area and the perimeter measured on an image taken of a filler particle by an electron microscope, B is the area of a perfect circle corresponding to the perimeter C, r is the particle radius, and π is the circular constant.
X=A/B=A/(πr2)=A/{π×(C/2π)2}=A×4 π/C2 (1)
Examples of materials for the high-roundness filler 29 include inorganic fillers such as silica, glass, calcium carbonate, iron, stainless steel, alumina, aluminum, zinc, tin, titanium and the like; the average particle diameter can be in the range from 1.0 μm to 300 μm. The specific surface area of the high-roundness filler 29 can be 10 m2/g or less.
Examples of materials for the low-roundness filler 29′ include inorganic fillers such as silica, glass, kaolin, calcium carbonate, iron, stainless steel, alumina, aluminum, zinc, tin, titanium and the like, and carbon-based fillers such as carbon black. The specific surface area of the low-roundness filler 29′ can be 12 m2/g or more. Moreover, in view of giving the surface of the wet paper web transfer belt a degree of roughness via the shape of the low-roundness filler 29′, it is also possible to use amorphous particulate fillers, needle-like fillers, fibrous fillers and plate-like fillers.
In case only one type of filler with a relatively high roundness (for example, a roundness of 1) is used as filler added to the outer circumferential layer of the wet paper web transfer belt, the surface of the wet paper web transfer belt may become too smooth because it is difficult to give the surface of the wet paper web transfer belt roughness by this filler, and the adhesive properties of the wet paper web may become excessive. Moreover, in case only one type of filler with a relatively low roundness (for example, a roundness of less than 0.6) is used as filler added to the outer circumferential layer of the wet paper web transfer belt, the surface of the wet paper web transfer belt may become too rough because this filler gives the surface of the wet paper web transfer belt too much roughness, and the adhesive properties of the wet paper web may be insufficient.
In the wet paper web transfer belt according to the present invention, the amount of high-roundness filler and low-roundness filler varies according to the type of paper to be made and according to the papermaking conditions; however, in order to ensure the sheet adhesion properties, it is preferred to introduce, into the outer circumferential layer 27, between 5 wt % or more and 55 wt % or less of the high-roundness filler and between 5 wt % or more and 55 wt % or less of the low-roundness filler in relation to at least the total weight of the outer circumferential layer (the total weight of the polyurethane, the fillers and other additives). Moreover, in order to prevent contamination in parts where lipophilic contaminants (from pitch, sizing agents, and the like) are abundant, it is necessary to make the surface hydrophilic by introducing a relatively large amount of fillers; however, if the amount of fillers exceeds 60% of the total weight (the total weight of the polyurethane, the fillers and other additives), the wet paper web transfer belt becomes too hard and there is the risk of cracks occurring. Further, in parts where fine pulp fibers with high adhesiveness are used, there is the risk of malfunctioning occurring in which the fine pulp fibers adhere to the surface of the wet paper web transfer belt if too much filler is introduced. Consequently, the total amount of the high-roundness filler 29 and the low-roundness filler 29′ in each layer is preferably 10 wt % to 60 wt % of the total weight of the layer (the total weight of the polyurethane, the fillers and other additives). Other additives such as pigments and anti-foaming agents can be appropriately added according to design.
Thus, by adopting the above-described constitution in the wet paper web transfer belt 1, it is possible to provide a wet paper web transfer belt in which the adhesive and releasing properties of the wet paper web with the wet paper web contacting surface of conventional wet paper web transfer belts are further improved and in which paper robbing and floating edges do not occur.
Hereinafter, a specific example of a production method of a wet paper web transfer belt according to the present invention will be explained.
Next, the outer circumferential layer 27 of the wet paper web transfer belt 1 can be formed by again coating polyurethane from the resin discharge opening 42 onto the wet paper web-side surface 22 of the reinforcing base material 24 while rotating the rolls 40, and by layering the polyurethane by the coater bar 41 and by curing the polyurethane (
Moreover, the wet paper web transfer belts 1 shown in
Hereinafter, the present invention will be described by means of the Examples and Comparative Examples.
The Reinforcing Base Material
The reinforcing base materials of the wet paper web transfer belts according to Examples 1 to 9 and Comparative Examples 1 to 8 used the following constitution.
The Polyurethane
The polyurethane of the wet paper web transfer belts of Examples 1 to 9 and Comparative Examples 1 to 8 was obtained by reacting a mixture of tolylenediisocyanate (TDI) and polytetramethylene glycol (PTMG), as urethane prepolymer, with dimethylthiotoluenediamine (DMTDA), as curing agent.
In Examples 1 to 9, the wet paper web transfer belt shown in
The conditions of the fillers included in the outer circumferential layer of the wet paper web transfer belts of Examples 1 to 9 and Comparative Examples 1 to 8 are shown in Table 1.
The floating edges condition of the wet paper web after passing the nip and the occurrence of paper robbing due to the felt 6 or due to the wet paper web transfer belt after the wet paper web W had passed the press nip 12 under the conditions listed hereinafter and by using the device shown in
The Pressing Conditions
The Constitution of the Press Felt 6
Base Fabric
The Batt Fibers needle-punched to the Base Fabric
The Wet Paper Web (Handsheet)
Further, the paper robbing due to the felt 6 or the wet paper web transfer belt after passing the nip was evaluated with the help of a video camera. The evaluation results are shown in Table 2.
As shown in Table 2, the adhesive and releasing properties of the wet paper web on the wet paper web contacting surface was further improved in the wet paper web transfer belts of Examples 1 to 9, in which paper robbing and floating edges did not occur.
Explanation of the Reference Characters
W: wet paper web, 1: wet paper web transfer belt, 2: closed-draw papermaking machine, 3: press part, 4: dryer part, 5, 6: press felt, 7: dryer fabric, 8: guide rolls, 9: shoe, 10: press roll, 11: shoe press belt, 12: press section, 13: shoe press mechanism, 14: suction roll, 22: wet paper web-side surface, 23: machine-side surface, 24: reinforcing base material, 25: polyurethane, 26: wet paper web contacting surface, 27: outer circumferential layer, 28: inner circumferential layer, 29: high-roundness filler, 29′: low-roundness filler, 30: machine contacting surface, 31: intermediate layer, 32: composite reinforcing base material, 33: short fibers, 40: rolls, 41: coater bar, 42: resin discharge opening
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