CN100532708C - 制造干燥织物的方法及具有背面排气性以获得提高的纸幅稳定性的干燥织物 - Google Patents
制造干燥织物的方法及具有背面排气性以获得提高的纸幅稳定性的干燥织物 Download PDFInfo
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Abstract
一种造纸织物或工业织物的制造方法,例如用于造纸机干燥部的干燥织物,该方法包括使用压电喷头阵列将聚合树脂材料施加至基材背面上的预选位置上,该压电喷头阵列以具有10μ(10微米)或更大平均直径的液滴来沉积聚合树脂材料,以在预选位置上累积高度约有0.5mm的离散不连续的聚合树脂材料沉积物。预选位置可为结节,其由构成织物的纱线交织形成。使用沉积物的目的是将干燥织物的背面从例如干燥转筒表面或转向辊表面的表面分开,沉积物使集中在干燥织物与该表面之间的空气能够沿平行于该表面的纵向及横向排出,而非被迫穿过该织物,或者造成“掉落”现象。聚合树脂材料通过适合于其组分的方式定形,并且可视需要进行选择性研磨,以使沉积物在基材表面上具有均匀高度。
Description
技术领域
本发明涉及造纸技术。更具体地说,本发明涉及用于造纸机干燥部,且特别是用于单程干燥部(single-run dryer section)上的造纸织物。这种织物通常称为干燥织物。
背景技术
如本领域技术人员所公知的,在造纸机成形部中,造纸过程首先将纤维浆即纤维素纤维的水分散液沉积至移动的成形织物上。在此过程中,浆体中大量的水分通过成形织物排出,而纤维网则留在成形织物的表面上。
刚形成的纤维网从成形部进入压榨部,压榨部包括一系列压榨压区。纤维网由压榨织物支撑,或者通常情况下位于两层压榨织物之间,通过压榨压区。在压榨压区内,纤维网受到压缩力的作用,该压缩力将其中的水分挤出,并使网中的纤维成分彼此粘附,使得纤维网转变为纸幅。从纤维网中挤出的水分由一层或多层压榨织物所吸收,并且理想的情况是不回到纸幅中去。
纤维网现在为纸幅,最终进入干燥部,干燥部至少包括一个可转动的干燥转鼓系列或转筒系列,这些转鼓或转筒由蒸汽在内部进行加热。干燥织物引导纸幅本身以弯曲路径依次绕行该系列中的每个转鼓,且干燥织物将纸幅紧紧地贴在至少部分转鼓的表面。加热的转鼓通过蒸发作用降低纸幅的水分含量至所需的水平。
应该了解的是,成形、压榨及干燥织物都在造纸机上采用无端环(endless loop)的形式,并且都起到输送带的作用。应该进一步了解的是,纸张生产是一种以相当快的速度进行的连续过程。也就是说,在成形部内,纤维浆连续地沉积到成形织物上,而刚生产出的纸幅在离开位于造纸机下游末端的干燥部后,就被连续地卷绕到辊筒上。
现在更具体地谈及干燥部,在干燥部中,干燥转筒可排列成顶行/层和底行/层。底层转筒与顶层转筒相对交错,而非呈严格的垂直关系。当纸幅通过干燥部时,纸幅交替通过顶层和底层的转筒,首先绕过两层之一层中的干燥转筒,然后绕过另一层的干燥转筒,循序前进直到通过干燥部。
顶层和底层的干燥转筒可各自套有单独的干燥织物。在这种情况下,进行干燥的纸幅在未受支撑的情况下横越各干燥转筒与另一层中的相邻干燥转筒间的空间或“口袋”。
在单层干燥部中,可采用单行转筒及许多转向筒或转向辊。转向辊可为实心的或为透气的。
为了提高生产速度,并使纸幅所受干扰最小化,采用单程干燥部,以高速运送进行干燥的纸幅。在单程干燥部中,使用单一的干燥织物运送纸幅,该单一的干燥织物沿弯曲路径依次绕行顶层和底层的干燥转筒。
应了解的是,在单程干燥部中,干燥织物将进行干燥的纸幅直接贴在两层之一的干燥转筒上,通常为顶层干燥转筒上,但载着纸幅环绕底层的干燥转筒。该织物的回程在顶层干燥转筒上面。另一方面,一些单程干燥部具有相反的结构,在该结构中,干燥织物将纸幅直接贴在底层干燥转筒上,但载着纸幅环绕顶层转筒。在这种情况下,该织物的回程在底层转筒下面。无论是哪一种情况,在移动的干燥织物靠近干燥转筒的狭窄空间内,由移动的干燥织物背面所携载的空气形成压缩楔形。由此导致压缩楔形中气压增大,使空气穿过干燥织物向外流动。接着,此气流将纸幅推离干燥织物的表面,此种现象称作“掉落”。“掉落”造成边缘破损而降低所制造的纸制品的品质,“掉落”若导致纸幅断裂还会降低纸机效率。
许多造纸厂通过对干燥转筒或干燥辊切削沟槽,或通过对那些干燥辊加设真空源的办法来解决此项问题。两种权益之计都使收集于压缩楔形的空气不穿过干燥织物而被除去,但都较昂贵。
关于这一点,织物制造者也已经使用对织物施加涂料的方法,例如“纸幅约束法(sheet restraint method)”,以赋予织物附加的功能。作为一种附加此功能性的方法,施加涂料对于织物,例如干燥织物的重要性,已由Luciano-Fagerholm(发明名称为“Dryer Fabric WithHydrophilic Paper Contacting Surface”的美国专利5,829,488(Albany))所引证。
Luciano和Fagerholm已证实,对织物使用亲水性表面处理可赋予织物保持纸幅的性能,同时保持与最初的渗透性相接近。然而,这种处理织物表面的方法,虽然成功地赋予纸幅约束力,但仍需提高涂层的亲水性及耐久性。WO专利97/14846也认可纸幅约束法的重要性,并涉及使用硅酮涂覆材料完全覆盖并浸渍织物,使织物基本不能渗透。然而,这种渗透性的大幅降低对干燥织物的应用来说,是无法接受的。美国专利5,397,438也对纸幅约束力进行了论述,该专利涉及将粘合剂施加至织物的面面区域,以避免纸幅收缩。其他相关的现有技术包括美国专利5,731,059,其报道了仅在织物边缘使用硅酮密封剂,用于高温及防拆散保护;以及美国专利5,787,602,其涉及将树脂施加至织物的结节上。所有上述参考的专利均以引用方式并入本文。
本发明以具有背面排气性的干燥织物形式提供了另一种解决此问题的方法,该背面排气性让收集于压缩楔形的空气不必穿过干燥织物而排出。本发明还包括一种制造该干燥织物的方法。
发明内容
因此,本发明主要涉及干燥织物,但其也可应用于造纸机的成形部、压榨部及干燥部中所用的任何织物中,以及应用于制造非织造织物所用的工业织物中。同样,造纸织物或工业织物包括基材,该基材采用无端环的形式,并且具有背面及纸幅接触面。多个离散不连续的聚合树脂材料的沉积物布置在背面上的预选位置上。这些沉积物相对于背面具有至少0.5mm的高度,所以当织物绕过干燥转筒或转向辊时,通过该量,可使织物背面与干燥转筒或转向辊的表面分开。沉积物使收集在背面与干燥转筒表面之间的空气沿平行于该表面的纵向及横向排出,而非穿过织物,以减轻“掉落”问题。
离散不连续的聚合树脂材料的沉积物的预选位置可为结节,该结节在织物一个方向的纱线通过另一个方向的纱线上方处形成。或者,预选位置可为结节之间的“凹部”,此替代方案具有如下优点:可使两根相交纱线在交叉点处相互粘结。又或者,预选位置可为两个或更多个沿机器方向或机器横向对齐的相邻结节及其间的一个或多个凹部。当预选位置沿机器方向对齐时,此替代方案具有可改善排气性的优点。沉积物优选只位于纱线的结节上或只位于纱线背面表面上,在此处沉积物不会影响织物的渗透性。此外,当沉积物在背面上形成一种不连续涂层时,沉积物不会影响到织物的弯曲性能或弯曲中性轴的位置。最后,通过此方式改善织物背面控制空气的能力,而非通过使用精细且复杂的组织图案向织物背面提供气道,基材所用的底布组织结构可具有其他特征,例如具有开孔,由此为织物提供更高的渗透性以提高干燥速度,并且可更简单以及成本更低地进行制造及缝合。
本发明还提供了一种制造造纸织物或工业织物例如干燥织物的方法。该方法包括提供织物基材的第一步骤。
聚合树脂材料以平均直径为10μ(10微米)或更大的液滴沉积至基材的预选位置上,以累积离散不连续的聚合树脂材料的沉积物,直到相对于基材表面至少高0.5mm。可至少使用一个压电喷头将聚合树脂材料沉积至基材上,但其他沉积该尺寸液滴的装置为本领域的技术人员所公知,或在未来可开发出。然后,以适当方式将聚合树脂材料定形或固定。
如上所述,预选位置可为结节,该结节由织物的纱线交织而形成在织物表面上。
随后,可选择研磨聚合树脂材料的沉积物,以在基材表面上使沉积物具有均匀高度。
现将参照以下附图对本发明进行更完整详细的说明。
附图说明
图1为根据本发明的方法制造造纸织物及工业织物所用装置的示意图;
图2为本发明的干燥织物沿其纵向截取的剖视图;
图3为如图2所示沿其横向截取的干燥织物的剖视图;
图4为干燥织物背面的立体图;
图5为干燥织物的替代实施例沿其纵向截取的剖视图;
图6为干燥织物的另一实施例沿其纵向截取的剖视图;以及
图7为所沉积材料的各种代表形状的立体图。
具体实施方式
制造本发明的造纸织物或工业织物的方法首先为提供基材。通常,基材是由单丝纱线织成的织物。然而,更广泛地说,基材可为机织物、非织造织物或针织物,这些织物由纸机织物生产或用于制造非织造物及非织造织物的工业织物生产所用的任何种类的纱线构成,例如单丝纱线、捻合单丝纱线、复丝纱线及捻合复丝纱线。这些纱线可由本领域技术人员为此目的而使用的任意一种聚合树脂材料挤出获得。因此,可使用下列树脂族中的材料:聚酰胺、聚酯、聚氨酯、芳香族聚酰胺、聚烯烃及其他树脂。
或者,基材可由网眼织物组成,例如共同转让给Johnson的美国专利4,427,734中所示,其所教导的内容以引用方式并入本文。基材还可为多种螺旋链结的皮带,其示出于许多美国专利中,例如Gauthier的美国专利4,567,077,其所教导的内容以引用方式并入本文。
此外,基材可根据共同转让给Rexfelt等人的美国专利5,360,656所示的方法,通过螺旋缠绕机织带、无纺带、针织带或网眼织物带的方式制造,该专利所教导的内容以引用方式并入本文。因此基材可由螺旋缠绕带构成,其中每个螺旋捻圈都通过连续接缝与下一个连接,使得该基材在纵向为环形。
上述内容不应视为基材的唯一可能形式。可以选择性地使用由纸机织物及其相关技术领域的技术人员所使用的任意一种基材。
一旦提供基材,可通过本领域中的普通技术人员所熟知的方法,可选择将一层或多层短纤维毛层附于基材的一面或两面上。也许最为人熟知且最常使用的方法为针刺法,其中毛层中的各短纤维由多根往复的刺针刺入基材结构中。或者,各短纤维可通过水刺法连接到基材,其中细高压水柱执行与上述往复的刺针同样的功能。可以认识到,通过这些或其他本领域技术人员所公知的方法,一旦使短纤维毛层与基材连接,则基材具有的结构将与多种压榨织物的相同,压榨织物通常用于在造纸机压榨部使湿纸幅脱水。
不论是否在基材的一面或两面附加短纤维毛层材料,一旦提供基材后,就将其安装在图1示意性示出的装置10上,这样可依据本发明将聚合树脂材料沉积至基材的背面上。应该理解的是,基材在安装于造纸机上的过程中,可为环状形式或可缝成环状形式。因此,图1所示的基材12应理解为基材12的整体长度的较短部分。基材12若为环状形式,则最实用的方法是将其绕装在一对辊上,该辊虽未示于图中,但为纸机织物技术领域中的技术人员所熟知。在此情况下,装置10设在基材12的两个走向中的其中一个上,最方便的是顶部走向上,该基材12位于两个辊之间。但是,不论是否为环状,在制造过程中优选将基材12置于适度的张力下。此外,为了避免松垂,在基材12穿过装置10时,可用水平支撑件从底下对其进行支撑。最后应观察到,基材12若为环状,则在根据本发明施加聚合树脂材料之后,可能需要将其倒置,即将其内外翻转,以确保聚合树脂材料留在基材12的背面上。
此外,对于某些应用,可能需要将树脂图案施加至纸幅接触面。并且,可想见应将用于空气控制的树脂以相同或不同的图案施加至织物的两面。
现在更具体地参照图1,其中在实施本发明的方法时,基材12示为以向上的方向穿过装置10,装置10包括一连串的数个站,基材12可逐步通过各站而制成织物。
各站显示如下:
1.可选的聚合物沉积站14;
2.成像/聚合物精确沉积站24;
3.可选的定形站36;以及
4.可选的研磨站44。
在第一站,可选的聚合物沉积站14中,压电喷头阵列16安装在横轨18、20上,并在横轨上沿横交于基材12通过装置10的运动方向移动,也可在横轨之间平行于基材12的运动方向来移动,可利用压电喷头阵列16在基材12静止的同时将聚合树脂材料沉积在基材12上或其内。可视需要利用可选的聚合物沉积站14将聚合树脂材料比利用例如喷涂等常规技术达成者更加均匀地沉积在基材上。
压电喷头阵列16至少包括一个但优选包括多个由计算机控制的独立的压电喷头,各喷头发挥泵的作用,其动作构件为压电元件。若技术上许可,则实施时可利用多达256个压电喷头或更多喷头所组成的阵列。动作构件为晶体或陶瓷,通过施加电信号使之物理变形。此变形能使该晶体或陶瓷发挥泵的作用,在每次接收到适当的电信号时就会机械地喷出一滴液体材料。这样,使用压电喷头响应计算机控制的电信号来重复地供应所需材料液滴,从而以所需形状累积所需材料量的方法,通常称为“按需喷滴”法。
喷头沉积材料的精确度将取决于所要形成的结构的尺寸和形状。所用的喷头类型和所施加材料的粘度也会影响所选喷头的精确度。
再参照图1,压电喷头阵列16从基材12的一边开始,或优选从纵向延伸于其中的基准线开始,贯穿基材12进行纵向和横向移动,而基材12则静止不动,将标称直径为10μ(10微米)或更大例如50μ(50微米)或100μ(100微米)的极小液滴形式的聚合树脂材料沉积在基材12上。压电喷头阵列16相对于基材12的纵向与横向移动,以及从阵列16的各压电喷头喷出的聚合树脂材料液滴的沉积,都是以受控方式由计算机控制的,使得在基材12长、宽和深或高(x、y、z维度或方向)的三个平面内,及需要时也可在基材12每一单位面积上,以受控的形状施加所需量的聚合树脂材料。此外,材料沉积不但可横越基材的运动,也可平行于此运动方向,相对于此运动方向呈螺旋形,或为任何其他适合此目的的方式。
在本发明中,压电喷头阵列用于在基材12表面之上或其中沉积聚合树脂材料,聚合树脂材料的选择受限,必须符合在输送时,即,当聚合树脂材料在压电喷头的喷嘴中准备沉积时,粘度为100cps(100厘泊)或更少的要求,使得各压电喷头能以固定的液滴输送速度提供聚合树脂材料。在这点上,聚合树脂材料在输送点的粘度及喷头的尺寸对于界定形成在基材12上的液滴尺寸及形状,以及及时达到最终的图案分辨率都很重要。限制聚合树脂材料的选择的另一个要求为:在其作为液滴从压电喷头落向基材12期间或在其落在基材12上之后,必须部分定形,以防止聚合树脂材料流动,并且保持对聚合树脂材料的控制,以确保其在落在基材12上的位置处仍保持液滴形式。满足这些标准及具有优选的耐磨性能的合适的聚合树脂材料为:
1.热熔性材料及湿气固化的热熔性材料;
2.基于聚氨酯及环氧树脂的两组分反应体系;
3.由聚氨酯、聚酯、聚醚和硅酮所衍生的反应性丙烯酸酯单体及丙烯酸酯低聚物组成的感光聚合物组合物;以及
4.包括丙烯酸树脂与聚氨酯的水性胶乳和水性分散物以及微粒填充混合物。
应该理解的是,聚合树脂材料在沉积于基材上之后,需要固定于基材12上或其内。用来定形或固定聚合树脂材料的方式取决于其本身的物理及/或化学要求。感光聚合物用光来固化,而热熔性材料则通过冷却来定形。水性胶乳和分散物先干燥再加热固化,而反应性体系则受热固化。因此,聚合树脂材料可通过固化、冷却、干燥或其任何组合来定形。
为了控制聚合树脂材料在基材12内的渗入及分布,即,将该材料控制并限制于基材12的所需范围内,必须将其适当固定。这种控制对防止基材12表面底下的渗渍与扩散都是极为重要的。例如,这种控制可通过将基材12保持在一定温度而实现,这种温度会使聚合树脂材料在接触时快速定形。也可在具有一定开孔率的基材上使用某些材料来实现控制,这种材料具有已知或明确的固化或反应时间,因此聚合树脂材料还来不及扩散超出基材12的所需范围,就已经定形。
在基材12之上可使压电喷头阵列16通过一次或多次,以沉积所需量的材料,并制成所需形状。在这点上,沉积物可采用如图7概括示出的任意一种形状。该形状可为方形、圆锥形、矩形、卵形、梯形等具有较粗的底部而向上逐渐变细的形状。当喷头重复通过沉积区域时,依照所选的设计方案而定,所沉积的材料量会以递减的方式层叠。
当已经在横轨18、20之间的区带中横贯基材12的每一单位面积上施加了所需聚合树脂材料量时,基材12则纵向前进与该区带等宽的量,并重复上述过程,从而在与之前已完成的区带相邻的新区带上施加该聚合树脂材料。以此重复方式,可使整个基材12的每一单位面积上都具有所需聚合树脂材料量。
或者,压电喷头阵列16仍从基材12的边缘开始,或优选从纵向延伸于其中的基准线开始,并相对于横轨18、20保持在固定位置,而基材12则在该阵列之下移动,从而在环绕基材12的纵向条带中的每一单位面积上施加聚合树脂材料的任何所需量。当完成该纵向条带后,压电喷头阵列16会在横轨18、20上横向移动与该纵向条带等宽的量,并重复上述程序,从而在与之前已完成的条带相邻的新的纵向条带上施加聚合树脂材料。如果需要,则可以以此重复方式,使整个基材12的每一单位面积都具有所需聚合树脂材料量。
注意,该图案可为随机的图案,在基材上重复的随机图案,或在皮带之间重复的随机图案,以控制品质。
在横轨18、20的一端,设有喷头检查站22,以检测从压电喷头阵列16中的各压电喷头喷出的聚合树脂材料的流量。在该处净化和清洁压电喷头,从而使任何有故障的压电喷头单元自动恢复操作。
在第二站,本发明中唯一不是可选的成像/聚合物精确沉积站24中,横轨26、28支撑数码相机30和压电喷头阵列32,相机可横贯基材12的宽度移动,压电喷头阵列可横贯基材12的宽度移动并可在两根横轨26、28之间相对于横轨纵向移动,而基材12保持不动。
数码相机30检查基材12的表面,以定位结节,该结节形成在基材12一个方向纱线越过另一个方向纱线的交织处。在织造过程中,这些交叉点虽然依据组织图案而定位在很接近预定或规则的间隔处,但其会产生变化。因此,若只试图以离散间隔来沉积聚合树脂材料,将无法确保所有或所需数量的交叉点都会接收到沉积物。因此,通过与数码相机30一起操作的图案快速识别(FPR)处理器,对实际表面与其所需外形之间实时做出比较。FPR处理器发信号给压电喷头阵列32,其将聚合树脂材料沉积在所需位置上,以符合所需外观。在本发明中,将聚合树脂材料沉积在织物背面的结节上,以在其上累积离散不连续的聚合树脂材料的沉积物。或者,将其沉积在结节之间的凹部上,或是在与机器方向或机器横向对齐的两个或更多个相邻结节上以及其间的凹部上。本质上,提供沉积物是为了使织物背面与干燥转筒或转向辊分开,所以由织物背面携载至压缩楔形中的空气可沿着背面表面在纵向及横向排出,而非被迫穿过织物并造成“掉落”。理想上,在压电喷头阵列32的多次通过中,通过沉积来自压电喷头的聚合树脂材料液滴而逐渐地累积沉积物,以获得高于结节0.5mm至1.0mm标称范围的高度,从而使织物背面以该值与干燥转筒或转向辊分开。通过压电喷头阵列32的多次通过,可精细地控制沉积物的形状,而不影响干燥织物的渗透性。也就是说,通过以重复图案来沉积液滴,即,将液滴层叠在相邻液滴的顶部,基材12上的聚合物树脂材料的高度或z-方向可受到控制,并可为均匀的、变化的或其它按需调整的。此外,可使用压电喷头阵列中的部分独立的压电喷头来沉积一种聚合树脂材料,而使用其他独立的压电喷头来沉积一种不同的聚合树脂材料,以产生具有不止一种类型聚合树脂材料的微区的表面。这种精确沉积可避免在所沉积的聚合树脂材料上为获得单面表面而进行的研磨步骤。当然,如果需要,也可进行研磨步骤。
如同可选的聚合物沉积站14,在横轨26、28的一端,设有压电喷头检查站34,以检测从各压电喷头喷出的材料的流量。在该处净化和清洁压电喷头阵列32中的各压电喷头,从而使任何有故障的压电喷头单元自动恢复操作。
在第三站,可选的定形站36中,横轨38、40支撑定形装置42,该装置在使所用的聚合树脂材料定形时会需要。定形装置42可为热源,例如,红外线、热空气、微波或激光源;冷空气;或紫外光或可见光源,其选择取决于所使用聚合树脂材料的要求。
最后,第四站及最后一站为可选的研磨站44,在此采用适当的研磨,以使基材12表面上的任何聚合树脂材料具有均匀厚度。可选的研磨站44可包括具有研磨表面的辊筒,以及设在基材12的另一面上的另一个辊筒或支撑表面,以确保研磨可形成均匀厚度。
现在作为实例来参照图2,图2为根据本发明的干燥织物50沿其纵向截取的剖视图,干燥织物50具有沉积在其背面表面上的结节上的聚合树脂材料,以形成离散不连续的沉积物60。干燥织物50以双层组织由纵向纱线52及横向纱线54织成,但应理解所显示的特定组织仅为实例,但本发明并不局限于此。
图3为如图2所示沿其横向截取的剖视图。如图2及图3所示,纵向纱线52及横向纱线54均具有矩形横截面,但也应理解其仅为实例,但本发明并不局限于此。
干燥织物50的背面56为图2及图3所示视图中的下侧。根据本发明,在纵向纱线52交织于较低的横向纱线54之上所形成的结节58具有离散不连续的聚合树脂材料的沉积物60,其由成像/聚合物精确沉积站24所沉积的小液滴累积而成。显而易见,沉积物60可将结节58从任何表面例如干燥转筒的表面分开,并且相对于此表面提高整个干燥织物50。如图2及图3的视图所示,沉积物60能够使空气在干燥织物50的背面56与干燥转筒之间沿纵向及横向流动,以使携载至压缩楔形中的空气通过移动的干燥织物50排出,而非向外穿过干燥织物50。如上所述,沉积物60相对于其所布置处的结节58具有0.5mm到1.0mm标称范围的高度。
图4为干燥织物50的背面56的立体图,图中示出了由纵向纱线52所形成的结节58上的沉积物60。结节58及沉积物60形成背面56上的斜纹线,但本领域技术人员将认识到这种排列由图2至图4所示的特定组织图案产生,而并非为本发明所有干燥织物的必要特征。简而言之,在制造过程的最后步骤中,可将沉积物60施加至任何干燥织物50的背面,包括例如申请人为Gauthier的美国专利4,567,077所示的螺旋链结类型的干燥织物,其所教导的内容以引用方式并入本文。
在某种意义上,在干燥织物50的背面56上形成不连续涂层的沉积物60的优点是不影响干燥织物50的弯曲性能,因为其不连续地驻留在表面上,所以其既不影响干燥织物50的坚挺性,也不影响其弯曲中性轴的位置。
在本发明的可替代实施例中,可选的聚合物沉积站14、成像/聚合物精确沉积站24及可选的定形站36也可调整为以螺旋技术由基材12制成织物,而非通过如上所述定向在机器横向。在螺旋技术中,可选的聚合物沉积站14、成像/聚合物精确沉积站24及可选的定形站36从基材12的一个边缘开始,例如从图1中的左侧边缘开始,并且在基材12沿图1所示方向移动时,逐渐地横越基材12进行移动。将站14、24、36及基材12的移动速度设成,使成品织物所需的聚合树脂材料以连续方式在基材12上螺旋。在此可替代的方案中,当各螺圈通过可选的定形装置42底下时,由可选的聚合物沉积站14和成像/聚合物精确沉积站24所沉积的聚合树脂材料可部分定形或固定,并在整个基材12通过装置10处理后,完全定形。
或者,可选的聚合物沉积站14、成像/聚合物精确沉积站24及可选的定形站36均可保持在彼此对齐的固定位置上,而基材12在它们之下移动,使得成品织物所需的聚合树脂材料施加到环绕基材12的纵向条带上。当完成该纵向条带时,可选的聚合物沉积站14、成像/聚合物精确沉积站24及可选的定形站36横向移动与该纵向条带等宽的量,并在与之前已完成的纵向条带邻近的新纵向条带上重复该过程。以此重复方式,可根据需要完全处理整个基材12。
应该注意的是,该材料并不需要是全宽度的皮带,也可为例如在Rexfelt的美国专利5,360,656中所披露的材料条,然后再制成全宽度的皮带,该专利所披露内容在此以引用方式并入本文。在完全加工后,材料条可为未缠绕的,并将其卷在一组辊筒上。可收存这些成卷的制带材料,然后可采用例如刚刚提到的上述美国专利中的教导内容,来制成环状的全宽度结构物。
图5为根据本发明的干燥织物70沿其纵向截取的剖视图,干燥织物70具有沉积在其背面表面上所谓凹部上的聚合树脂材料,以形成离散不连续的沉积物。干燥织物70由纵向纱线72及横向纱线74以平纹组织交织而成,但应理解本发明并不限于这种平织。干燥织物70的背面76为其在图5所示图面中的下侧。在此处所示实施例中,纵向纱线72交织于下方的横向纱线74的下方而形成的结节80之间的凹部78具有通过沉积小液滴而累积的离散不连续的聚合树脂材料的沉积物82。沉积物82可将织物70的背面76从任何表面例如干燥转筒或转向辊的表面分开,并且相对于此表面提高整个干燥织物70。沉积物82还在交叉点处粘结纵向纱线72及横向纱线74。如上所述,沉积物82相对于结节80具有从0.5mm到1.0mm标称范围的高度。
图6为干燥织物90沿其纵向截取的剖视图,干燥织物90的背面表面上具有聚合树脂材料,聚合树脂材料沉积在机器方向对齐的两个相邻结节上及结节之间的凹部上,以在其背面表面上形成离散不连续的沉积物。干燥织物90由纵向纱线92及横向纱线94以平纹组织交织而成,但应理解本发明并不限于这种平织。干燥织物90的背面96为其在图6所示视图中的下侧。在此处所示实施例中,在纵向纱线92上,离散不连续的沉积物98在相邻的结节100之间延伸并且覆盖结节之间的凹部102,结节100在纵向纱线92交织于横向纱线94的下方的交织处形成。沉积物98通过沉积聚合树脂材料的小液滴进行累积,并且其可将织物90的背面96从任何表面例如干燥转筒或转向辊的表面分开,并且相对于此表面提高整个干燥织物90。沉积物98相对于结节100具有从0.5mm到1.0mm标称范围的高度。虽然图6示出了沉积物98只从结节100延伸至下一结节,但应理解其也可延伸任何所需要的长度,即任何所需数量的结节100。
还应该理解的是,不论离散不连续的沉积物60、82、98采用何种形式(例如方形、矩形、圆柱形、梯形等,参见图7),沉积物不必施加至每个结节、凹部、或依情况施加的其他部分。相反,在机器方向或机器横向上,沉积物可由任意数量的位于其间的结节或凹部彼此分开,以在织物的背面形成所需图案。
最后,如上所述,基材12若为环状,则当使用装置10将聚合树脂材料沉积在所通过的基材12的顶部走向上时,可能需要将其倒置,即,将其内外翻转,使离散不连续的聚合树脂材料的沉积物布置在其背面上。基材12若不是环状,则当基材12在干燥部上缝合成环状时,最终将具有离散不连续的沉积物的一面放置在内侧上。无论是如上所述的哪种情况,除了背面外,还存在将树脂施加至纸幅接触面的情况。此外,作为替代方案,可考虑以所需图案来沉积牺牲材料,以大体上形成可供随后沉积的树脂材料所用的模型。这种牺牲材料例如可为蜡或水溶性物质,随后将其移除而在织物上留下以所需图案定形的树脂。
此外,也可需要通过阵列中不同的喷头将不同的聚合树脂材料施加至同一织物的不同位置上。
虽然本发明根据其特定的实施例加以描述,但是对于本领域技术人员来说,可以容易地对上述实施方案进行多种修改和改进,或应用于其他领域,而不偏离本发明的目的、精神和范围。所有这些改动均在本发明权利要求范围内。具体地说,虽然上述披露了用压电喷头在基材上以预选位置沉积聚合树脂材料,但其他在所需尺寸范围内沉积液滴的装置,可为本领域技术人员所公知,或在将来开发出并可用于实施本发明。使用这种装置也在本发明的权利要求范围内。
Claims (28)
1.一种造纸织物或工业织物的制造方法,所述方法包括以下步骤:
a)提供所述织物的基材;
b)以受控方式将多个聚合树脂材料液滴沉积至所述基材上的预选离散位置上,以在所述预选离散位置累积高度约0.5mm的离散不连续的所述聚合树脂材料的单元;以及
c)至少部分定形所述聚合树脂材料。
2.根据权利要求1所述的方法,其中所述液滴具有10微米或更大的标称直径。
3.根据权利要求1所述的方法,其中所述步骤b)及c)在横向延伸贯穿所述基材的连续区带上依次进行。
4.根据权利要求1所述的方法,其中所述步骤b)及c)在纵向延伸环绕所述基材的连续条带上依次进行。
5.根据权利要求1所述的方法,其中所述步骤b)及c)螺旋环绕所述基材进行。
6.根据权利要求1所述的方法,其中所述基材织造而成,以及在所述步骤b)中,所述基材上的所述预选离散位置为结节,该结节由所述基材的纵向纱线通过横向纱线上方形成。
7.根据权利要求1所述的方法,其中所述基材织造而成,以及在所述步骤b)中,所述基材上的所述预选位置为结节,该结节由所述基材的横向纱线通过纵向纱线上方形成。
8.根据权利要求1所述的方法,其中所述基材织造而成,以及在所述步骤b)中,所述基材上的所述预选位置为结节之间的凹部,该结节由所述基材的纵向纱线通过横向纱线上方形成。
9.根据权利要求1所述的方法,其中所述基材织造而成,以及在所述步骤b)中,所述基材上的所述预选位置为结节之间的凹部,该结节由所述基材的横向纱线通过纵向纱线上方形成。
10.根据权利要求1所述的方法,其中所述基材织造而成,以及在所述步骤b)中,所述基材上的所述预选位置在两个相邻结节之间延伸、并且包括其间的凹部,该结节由所述基材的纵向纱线通过横向纱线上方形成。
11.根据权利要求1所述的方法,其中所述基材织造而成,以及在所述步骤b)中,所述基材上的所述预选位置在两个相邻结节之间延伸、并且包括其间的凹部,该结节由所述基材的横向纱线通过纵向纱线上方形成。
12.根据权利要求1所述的方法,其中,在所述步骤b)中,所述聚合树脂材料通过压电喷头阵列进行沉积,该压电喷头阵列至少包括一个计算机控制的压电喷头。
13.根据权利要求1所述的方法,其中所述步骤b)包括以下步骤:
i)实时检测所述基材的表面,以定位所述预选离散位置,并使所述聚合树脂材料沉积在其上,从而累积所述离散不连续的单元;以及
ii)将所述聚合树脂材料沉积在需要聚合树脂材料的所述预选位置上,以使所述单元具有所需高度。
14.根据权利要求13所述的方法,其中所述检测步骤由与数码相机配合操作的图案快速识别处理器实时进行。
15.根据权利要求14所述的方法,其中所述沉积步骤通过连接于所述图案快速识别处理器的压电喷头阵列进行。
16.根据权利要求1所述的方法,其中所述聚合树脂材料选自由以下材料组成的组:
(1)热熔性材料及湿气固化的热熔性材料;
(2)基于聚氨酯及环氧树脂的两组分反应体系;
(3)由聚氨酯、聚酯、聚醚和硅酮所衍生的反应性丙烯酸酯单体及丙烯酸酯低聚物组成的感光聚合物组合物;以及
(4)包括丙烯酸树脂与聚氨酯的水性胶乳和水性分散物以及微粒填充混合物。
17.根据权利要求1所述的方法,其中所述定形步骤通过将所述聚合树脂材料暴露于热源而进行。
18.根据权利要求1所述的方法,其中所述定形步骤通过将所述聚合树脂材料暴露于冷空气而进行。
19.根据权利要求1所述的方法,其中所述定形步骤通过将所述聚合树脂材料暴露于光化辐射而进行。
20.根据权利要求12所述的方法,其中所述压电喷头阵列包括多个由计算机控制的单独的压电喷头,以及,其中部分所述由计算机控制的单独的压电喷头沉积一种聚合树脂材料,而其他由计算机控制的单独的压电喷头则沉积不同的聚合树脂材料。
21.根据权利要求1所述的方法,还包括对沉积在所述基材上的所述聚合树脂材料进行研磨的可选步骤,以使所述基材表面平面上方的所述聚合树脂材料具有均匀厚度。
22.根据权利要求1所述的方法,其中沉积第一聚合树脂材料,以及沉积与所述第一聚合树脂材料不同的第二聚合树脂材料。
23.一种造纸织物或工业织物,包括:
基材,采用具有背面及纸接触面的无端环形式;以及
多个离散不连续的聚合树脂材料的单元,由位于所述背面上的预选离散位置上的多个液滴形成,所述单元相对于所述背面具有约0.5mm的高度。
24.根据权利要求23所述的造纸织物或工业织物,其中所述基材由纵向纱线及横向纱线交织而成,以及,其中所述预选位置为所述背面上的结节,该结节由所述纱线形成。
25.根据权利要求23所述的造纸织物或工业织物,其中所述基材由纵向纱线及横向纱线交织而成,以及,其中所述预选位置为所述背面上的结节之间的凹部,该结节由所述纱线形成。
26.根据权利要求23所述的造纸织物或工业织物,其中所述基材由纵向纱线及横向纱线交织而成,以及,其中所述预选位置至少包括所述背面上的两个相邻结节及其间的凹部,该结节由所述纱线形成。
27.根据权利要求23所述的造纸织物或工业织物,其中所述织物为干燥织物。
28.根据权利要求23所述的造纸织物或工业织物,其中所述基材为螺旋链结带。
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/334,212 | 2002-12-31 | ||
US10/334,212 US7005043B2 (en) | 2002-12-31 | 2002-12-31 | Method of fabrication of a dryer fabric and a dryer fabric with backside venting for improved sheet stability |
Publications (2)
Publication Number | Publication Date |
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CN1732305A CN1732305A (zh) | 2006-02-08 |
CN100532708C true CN100532708C (zh) | 2009-08-26 |
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CNB2003801081190A Expired - Fee Related CN100532708C (zh) | 2002-12-31 | 2003-11-19 | 制造干燥织物的方法及具有背面排气性以获得提高的纸幅稳定性的干燥织物 |
Country Status (16)
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US (1) | US7005043B2 (zh) |
EP (2) | EP1579059B1 (zh) |
JP (1) | JP4817662B2 (zh) |
KR (1) | KR101159110B1 (zh) |
CN (1) | CN100532708C (zh) |
AU (1) | AU2003291098B2 (zh) |
BR (1) | BR0317840B1 (zh) |
CA (2) | CA2511374C (zh) |
ES (1) | ES2606371T3 (zh) |
MX (1) | MXPA05007191A (zh) |
NO (1) | NO20053698L (zh) |
NZ (1) | NZ540830A (zh) |
RU (1) | RU2324024C2 (zh) |
TW (1) | TWI313313B (zh) |
WO (1) | WO2004061208A1 (zh) |
ZA (1) | ZA200505035B (zh) |
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RU2324024C2 (ru) | 2008-05-10 |
ES2606371T3 (es) | 2017-03-23 |
CA2969921C (en) | 2020-04-14 |
TW200422483A (en) | 2004-11-01 |
NZ540830A (en) | 2006-02-24 |
BR0317840B1 (pt) | 2014-09-09 |
CN1732305A (zh) | 2006-02-08 |
NO20053698L (no) | 2005-09-28 |
JP2006512504A (ja) | 2006-04-13 |
NO20053698D0 (no) | 2005-07-29 |
CA2511374C (en) | 2017-07-18 |
AU2003291098B2 (en) | 2008-08-21 |
KR20050088487A (ko) | 2005-09-06 |
BR0317840A (pt) | 2005-11-29 |
EP1579059B1 (en) | 2016-09-07 |
WO2004061208A1 (en) | 2004-07-22 |
EP1579059A1 (en) | 2005-09-28 |
AU2003291098A1 (en) | 2004-07-29 |
EP3088602A1 (en) | 2016-11-02 |
KR101159110B1 (ko) | 2012-06-25 |
CA2511374A1 (en) | 2004-07-22 |
US20040126545A1 (en) | 2004-07-01 |
US7005043B2 (en) | 2006-02-28 |
CA2969921A1 (en) | 2004-07-22 |
RU2005120643A (ru) | 2006-01-27 |
TWI313313B (en) | 2009-08-11 |
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