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    • 专利摘要:
    PROCESS FOR PREPARING A FLUFF PASTE BLADE An improved process for preparing fluff pulp blades by mechanically eliminating many of the unwanted fiber-to-fiber bonds (fiber bundles) that can be contained in the blade to produce fluff paste of consistent quality and uniform. The slurry slurry is deposited in a movement at the bottom of the wire formation to form a network reserve. The slurry of slurry is placed in contact with an apex of wire formation in motion. The network reserve is subjected to greater or lesser dehydration creating layers formed separately to reduce the fiber-to-fiber bond. The network reserve can be subjected to strong pulsating shear forces when it is being advanced along the wire formation bottom to break most of the fiber bundles contained in the network. The slurry slurry can be deposited on the wire forming bottom using an inlet box with dilution control to selectively adjust the slurry slurry concentration. A shoe press can be used to dehydrate the net after it is subjected to pulsating shear force. The net can be dried using (...).
    公开号:BR112014020087B1
    申请号:R112014020087-4
    申请日:2013-01-25
    公开日:2021-01-12
    发明作者:Jyriki T. Jaakkola；James E. Sealey
    申请人:International Paper Company；
    IPC主号:
    专利说明:

    Background of the invention
    [0001] This invention relates generally to the wet forming processes for preparing soft pulp from soft wood pulp and, more particularly, to the improved processes for preparing soft pulp blades that eliminate many fiber bundles- unwanted fiber (fiber bundles) that can be contained in the blade to produce consistent and uniform soft pulp quality. These improved processes also allow the manufacturer to control stock consistency being formed by localized dilution to achieve a directional weight base transverse to the machine allowing the manufacturer to produce high quality soft pulp while using low consistency inbox. The soft pulp produced by the processes of the present invention is soft, flexible, and has less knot content or hard points. The processes of the present invention are capable of producing soft pulp sheets having low variability in weight, moisture, Mullen resistance and other attributes of physical sheets. Consequently, a soft pulp blade made in accordance with the present invention must have low fragment energy while having high fragment quality which results in significantly reduced fibrillation energy when the blade is finally processed. The invention is especially useful for the production of soft pulp intended for use as the absorbent layer in disposable diapers, sanitary napkins, absorbent hygienic products and air laid products.
    [0002] Absorbent products employing fibrillation wood pulp have been available for many years. This basic wood pulp used in such products is usually called "soft pulp". In the United States, soft pulp is most typically made from a completely bleached Kraft pine pulp process produced in a relatively heavy compass, blades on a high weight basis. The product is rewound into continuous rolls for loading to the buyer. Since the roll product is later intended to be reprocessed within the individual fibers, low strength sheet is desirable and typically little or no refinement is used prior to roll manufacture. The requirements for surface uniformity and formation are similarly moderate.
    [0003] At the manufacturer's plant, the rolls are continuously fed into a device, such as a hammer mill, to be reduced as much as reasonably possible for individual fibers. Defibrillation is the process of releasing the fibers from each other before the soft pulp between the product forming machinery. The fibrillated product is generally called a "soft" cellulose. For example, the soft pulp can then be continuously extended to air inside cushions for inclusion in the desired product. The most demanding application of soft pulps is in the production of “air laid” products, used, for example, in household utensils and various applications of towels in homes, industry and hospitals. As mentioned above, the soft pulp blades for “air laid” products are usually defibrillated in a hammer mill. Soft pulp blades, however, can contain significant numbers of fiber bundles that are bonded together during lamination processes. These unwanted fiber bundles, often referred to as knots, eggs ("nits"), bones and flakes in the industry, present a problem during defibrillation. Hammer mills used for soft production are very energy consuming and bundles of fibers present in the soft pulp blades will increase the amount of energy spent during defibrillation. Furthermore, while vigorous defibrillation can reduce the knot content, and is in the expense of considerable fiber breakage and a resulting high content of very fine dust material. To compensate for this problem, the pulp mill may require the chemical addition of detachers before sheet formation. Therefore, the important parameters that are considered for defibrillation drying are shredding energy, that is, the amount of energy required to chop the blade and the knot content, that is, the amount of agglomeration of the fibers bound in each one. In heavy manufacturing operations, the reduction in energy consumption will ultimately lead to less expensive products. In addition, many manufacturers require high quality soft pulp to be used in their products due to consumer demands. Consequently, manufacturers of soft pulp blades are interested in creating blades having low fragmentation energy while still providing high quality soft. Bottom grade soft pulp blades cannot be used in certain applications and as such are often discounted for use in the manufacture of bottom quality products.
    [0004] The softness of wood pulp can be expressed in terms of properties such as Mullen resistance (the strength of the pulp or a pulp product, measured in Kilopascals (kPa)), and Kamas energy (the energy required to convert a quantity determined pulp or pulp product for a soft material, measured in Watt hours per kilogram (Wh / kg)). Mullen resistance can be defined as the energy required to blow a hole in the blade. Some in the industry refer to this energy as "burning energy". Mullen resistance is a good indication (but does not fully prove) the energy required to cut the blade (cutting energy). Typically, the bottom Mullen resistance, the facility is to cut the soft pulp blade. The background values of Mullen resistance and Kamas energy also correlate with softness, increasing the pulp take-off. Although it is desirable for manufacturers to decrease Mullen resistance, it should not be done at the expense of the quality of the fragment.
    [0005] In the state of the art of preparing fine paper, the stock is usually ejected from a device known in the industry as an input box in order to gently discharge over the movement of the fabric handle, known as the yarn former, which moves at a speed typically between about 3% of the wire speed, called precipitation and drag (“rush-drag”), respectively. In the manufacture of soft pulp, the equipment is usually run in about + 10% of precipitation ("rush"). The excessive j / w ratio assists Mullen resistance. The drain of water from the stock during wire formation so that a network is formed on the wire former. Excessive precipitation or drag can further induce the orientation of the network fibers towards the machine and may result in different and some unwanted physical properties on the machine and cross directions. Manufacturers, therefore, are interested in the orientation of the fiber and, consequently, have control of the orientation of the fibers being deposited on the formation of the yarn in order to achieve the desired physical properties.
    [0006] As mentioned above, wood fibers have a tendency to attract one another, forming a lump, the effect being called flocculation. Flocculation is decreased by background consistency and either by stirring the incoming sludge or in the inbox. However, deflocculation becomes very difficult at consistency well above 0.5%. Minimizing the degree of flocculation is important for the physical properties of thin paper or soft pulp.
    [0007] Usually, the stock is supplied in extremely high pressure to the inbox through pumping equipment and the stock is ejected from the inbox through a device known as a "cutting lip". Consequently, it is essential that the flow rate of stock in a dispensing tube disposed on the side of the inbox is the same as the flow rate of stock moving through a dispensing tube disposed on the opposite side of the inbox. The stock flow rate is usually defined as the number of cubic feet of stock passing a particular point every minute. The stock flow rate must remain constant or as constant as possible during the inbox. The amount of fiber per unit area (weight basis) of the network formed should ideally be constant across the width of the machine and along the direction of the machine. If the stock has been perfectly mixed and if the slice edge opening is the same across the entire cross directional width of the inbox machine, then the weight of the fibers within the stock per inch of width across of the stock range ejected through the cutting edge (“slice lip”) must be substantially constant. The resulting net should then have a uniform basis weight in a transverse direction of the machine. However, in practice, it is often difficult to maintain constant pressure on the supply stock and a consistent uniform on the stock. Consequently, maintaining the same fiber distribution within the stock presents problems when the effort to maintain a uniform base weight across the width of a formed network.
    [0008] Soft pulp manufacturers also face the problem of maintaining a transverse directional base weight of the machine controlled from the formed net. Manufacturers must control a base weight of the formed net to improve the quality of the final product. Consequently, the manufacturer of the soft pulp must control the base weight without compromising the fiber orientation profile. In addition, the manufacturer must also be careful with the need to simultaneously minimize the degree of flocculation in order to retain the desired physical properties of the soft pulp.
    [0009] Consequently, it would be desirable to provide processes for forming soft pulp sheets having improved volume, softness and reduced inter-fiber bond without sacrificing the absorbent properties of the pulp. In addition, there is a need for processes for producing high quality soft pulp blades that have significantly lower Mullen resistance (firing energy) without loss of fragment quality. There is also a need to achieve a more uniform base weight profile without compromising the fiber orientation profile. An improved base weight and a more uniform transverse direction can promote a more stable operation in the hammer mill and a uniform end product for the user. The new processes of the present invention fulfill these and other needs. Summary of the invention
    [0010] The present invention provides new processes for the manufacture of soft pulp sheets having a reduced number of fiber-to-fiber bonds (fiber bundles) and low variability in weight, moisture, Mullen resistance and other physical blade attributes. The soft pulp blades made in accordance with the present invention will have low fragment energy while retaining high fragment quality. The present invention also uses processes and equipment having dilution control associated with an input box to achieve a very uniform cross-directional weight base across the width of the machine to thereby improve the quality of the final product and run the equipment paper formation with less consistency in the inbox. The use of dilution control with the headbox improves the base weight profile to produce more stable operations in the hammer mill and a more uniform end product.
    [0011] In a particular aspect of the present invention, a pulp slurry made of soft pulp fibers in an aqueous solution is deposited on the bottom wire (also known as a "forming wire") of a papermaking machine to create a stock network (also referred to as a "link" in the industry). Due to its nature, pulp sludge includes both individual fibers and clumped fibers together in fiber-to-fiber bonds forming “fiber bundles”. The presence of these fiber bundles is undesirable in the formation of the soft pulp sheet, since these fiber bundles will dry and remain on the finished sheet as unwanted clumps of fibers. The additional energy is usually necessary to be spent by the product manufacturer when the soft pulp blade is being defibrillated due to the presence of these unwanted clumps. In addition, these fiber bundles reduce the quality of soft to be produced. In one aspect of the present invention, the mesh is placed on a moving bottom wire and is subjected to high pulsating shear forces that act on the fiber bundles contained in the mesh to break most of them down into the individual fibers or size bundles minors. The net is later dehydrated and dried to produce a soft pulp sheet having a reduced number of unwanted fiber bundles.
    [0012] In one aspect of the present invention, the net is advanced by the bottom wire and brought into contact with the top forming wire that cooperates with the bottom wire to press some of the liquids from the network. The top forming yarn and the bottom yarn can be, for example, the components of a paper forming machine known as an "apex forming" machine or a "twin yarn" machine. In this aspect of the present invention, the mesh is placed between two wires and is subjected to an up and down dehydration reducing the tendency of the fiber to bind. The use of an apex and a bottom and top wire allows the net to be dehydrated from both sides, instead of one side, which helps to decrease the size of the fiber bundles. The use of the bottom and top wire also retains the net within a somewhat confined space to allow the net to be subjected to pulsating high shear forces that act to break the fiber bundles that have been formed in the net. The top forming yarn promotes better fiber distribution and reduces the localized area of the flake which creates irregular resistance characteristics for the soft pulp.
    [0013] In one aspect of the present invention, the pulsating shear force can be applied to the mesh in an area where the top forming wire is in contact with the mesh. The pulsating forces act on the fiber bundles contained in the formed network and are large enough in amplitude to break most of these unwanted fiber bundles. Pulsing forces can be applied, for example, to the network in an area where the top forming wire makes contact with the network. The pulsating forces act on the fiber bundles contained in the formed network and are large enough in amplitude to break a majority of these unwanted fiber bundles. The network is then fed into a press machine which contacts the network to press the additional liquid solution from the network. In a particular aspect of the invention, the pressing machine can be a paper forming machine known as a "shoe press". A shoe press can be used since the press provides a larger "jaw" area that removes liquid from the mesh under a background pressure that of the conventional press roll known in the art. The shoe press provides a larger jaw area that allows a reduced pressure force to be applied to the soft pulp stock network when it molds through the press machine. Since the soft pulp stock network is thicker than conventional thin paper stock, the shoe press allows for reduced forces that help prevent compression of the pulp fibers while still providing substantial dehydration capacity. A single shoe press or multiple shoe presses pressing in series could be implemented for dehydration purposes. The shoe press could be combined with other pressure machines, such as roller presses, to progressively dehydrate the net. Finally, after the net has been dehydrated by the respective press machine, heat can be applied to the net (via dryers) to evaporate the additional liquid from the net.
    [0014] In another aspect of the present invention, a vacuum can be applied to the network when pulsating shear forces are being applied to the network. The vacuum can be applied at the same location where pulsating shear blades are being applied to the network to increase the shearing action transmitted on the fiber bundles contained in the network. This increased shear force created by the vacuum assists in breaking the fiber-to-fiber connections found in the formed network.
    [0015] In another aspect of the present invention, the pulp slurry can be deposited on the bottom wire using an inbox that has dilution control. In this particular aspect of the invention, a liquid, such as water, could be selectively added to the pulp slurry to adjust the consistency of the sludge being deposited on the bottom wire to allow the manufacturer to adjust the transverse directional base weight of the mesh being formed. In this sense, a transverse directional base weight on the machine can be connected without compromising the fiber orientation.
    [0016] In other aspects of the invention, more than one type of pulp sludge could be used to create a soft pulp blade having multiple layers. Additives, such as a dye, could be added to the sludge in other aspects of the invention. A multiple inlet box with or without dilution control could be used to deposit the stock sludge on the bottom wire.
    [0017] Alternatively, multiple inboxes with or without dilution control could be used to create the multi-layered soft pulp blade with additives. After the net has been subjected to pulsating shear forces, it can be further dehydrated in the pressure equipment such as a shoe press or a series of shoe presses. In another aspect of the invention, additional press equipment such as roller presses could be used with the shoe press to further dehydrate the mesh.
    [0018] Other features and advantages of the present invention will become apparent from the following detailed description of the invention, when taken in conjunction with the exemplary drawings accompanying the process. Brief description of the drawings
    [0019] Figure 1 illustrates a schematic view of a process for forming a continuous soft pulp blade according to the present invention.
    [0020] Figure 2 illustrates a schematic view showing an enlarged image of the apex former or twin spinning machine depicted in figure 1, which can be used to apply pulsating shear forces on the stock network when it is being advanced to the dewatering machines downstream.
    [0021] Figure 3 illustrates a schematic view that represents top and bottom blades of the apex forming figure 2 in greater detail.
    [0022] Figure 4 illustrates a flow chart representing the processes and machinery that can be used in the formation of soft pulp sheets according to the present invention.
    [0023] Figure 5 is a flow chart representing the alternative processes and machinery that can be used in the formation of soft pulp sheets according to the present invention.
    [0024] Figure 6 illustrates a flow chart representing alternative processes and machinery that can be used in the formation of soft pulp sheets according to the present invention.
    [0025] Figure 7 illustrates a schematic view showing the multi-layered soft pulp blades that can be formed using the processes of the present invention.
    [0026] Figure 8 illustrates a schematic view showing alternate multilayer soft pulp blades with additives that can be formed using the processes of the present invention. Detailed description of preferred embodiments
    [0027] Figures 1-3 represent schematic views of a particular process according to the present invention for forming soft pulp sheets. According to the process shown in figure 1, a pulp sludge 10 is released from the stock container 12 to an inlet box 14. The stock container 12 retains the processed pulp sludge after being prepared using techniques known from the state of the art. technical. As noted above, pulp sludge 12, also referred to as a “pulp stock”, can typically include cellulose fibers such as chemically digested wood pulp fibers when their main component is suspended in water or a liquid solution based on Water. The slurry may also include as a minor component, mechanical and synthetic wood pulp or other non-cellulosic fibers, chemical surfactants and other elements known in the papermaking known in the art. Preferably, but optionally, the pulp blade has gone through a bleaching process to create white soft pulp stock. The pulp sludge leaves the inlet box 14 through an adjustable height opening called the slip 16 and is carefully deposited so that it gently discharges over a moving fabric handle, here referred to as the bottom forming wire 18 that can be observed on conventional Fourdrinier machines or a “tip forming machine” or “twin wire” machine that may include a second wire that contacts the network (discussed in more detail below).
    [0028] The term “yarn” is well known in the art and generally referred to as a specially woven plastic or fabric mesh conveyor that is used to create a continuous paper web that transforms the source of the wood pulp into a sheet of paper. It would be appreciated that many different types of yarns could be used according to the processes of the present invention.
    [0029] It should be appreciated that the bottom forming wire 18 is shown schematically since any of a number of paper forming equipment could be implemented in accordance with the present invention. The pulp blade is deposited at a speed typically about 10% of precipitation ("rush"). The higher percentage of precipitation assists production and an appropriate Mullen resistance in the soft pulp. The water drains from the stock during wire formation so that a network 20 is formed on the bottom forming wire. Excessive precipitation and dragging induces more orientation of the fibers of the mesh 20 towards the machine and typically creates poorer contacts between the fibers that could produce in different thin papermaking and sometimes unwanted physical properties in the machine and transverse direction of the thin paper, but with the soft pulp will reduce the shredding energy and fiber for fiber binding. Manufacturers, therefore, are interested in the orientation of the fiber and, consequently, have control over the orientation of the fibers being deposited on the formation of the yarn in order to achieve the desired physical properties.
    [0030] To achieve a directional base weight, the process of the present invention uses the inlet box 14 can include the dilution control (not shown) that allows the operator to dilute the consistency of the slurry slurry when it leaves the inbox 14 and is deposited on the bottom wire 18. Consequently, the inlet box 14 would include the dilution lines (not shown) or other liquid supply equipment to control the dilution of the pulp sludge flowing through the inlet box in order to check the base weight in the transverse direction of the net 20 being produced. The use of dilution control associated with the inlet box 14 achieves a weight based on the very uniform transverse direction across the width of the machine, thereby improving the quality of the final product and allowing the manufacturer to run the equipment with less consistency in inbox. This part of the process allows the slurry of the fiber pulp to be filtered over the continuous bottom forming yarn 18 to form a wet fiber network having a specific basis weight. In this way, the present invention is able to control the base weight of the formed net to improve the quality of the final product. This aspect of the present invention thus controls the base weight without compromising the orientation profile of the fiber.
    [0031] The stock network 20 that is initially deposited on the bottom wire 18 is almost soft and moist due to the presence of a high amount of the liquid making the pulp sludge. Consequently, as is known in the papermaking technique, the liquid must be drained from the mesh 20 (referred to as "dehydration") in order to finally produce a dry soft pulp blade. In this sense, the drainage units 22 can be located under the base where the mesh 20 is initially deposited on the bottom wire 18 to allow the liquid to be drained through smaller openings formed in the bottom wire 18. However, these drainage units 22, which may include a vacuum or suction device to drain the liquid, are not able to completely drain the net 20. The additional drying equipment must be used to progressively dehydrate the stock net 20. The net 20 moves together with the bottom wire in the direction represented by the arrow 24. The net 20 is fed into a former 26 which includes a second top forming wire 28 which contacts the apex to the net 20 and, together with the bottom 18, assists in pressing the additional liquid from the wet web 20. The web 20 entering the wire former 26 typically has a drying time of about 2-4%.
    [0032] As can be better seen in figure 2, the apex of yarn 28 converges with the bottom yarn 18 along the length of the former 26 to allow sufficient pressure forces to be connected to press some of the liquids from the net 20 In addition, forming apex 26 has dewatering chambers 30 that include vacuum sources (not shown) that drain liquid from the network 20 passing over the vacuum within the individual storage container 32A-32C. The vacuum (represented by the arrows in figures 2 and 3) for the first container 32A can be run at a bottom rate that of the last containers 32B and 32C. For example, the vacuum associated with container 32A could run at about 5-10 kPa. The vacuum associated with the second container 32B could run at about 5-20 kPa. Finally, the vacuum associated with the third vessel 32C could be run at about 10-25 kPa. It should be appreciated that the number of containers and the voids associated with each container can vary depending on the base weight of the soft pulp blade being created. Additionally, one or more suction boxes 34 could be placed below bottom wire 18 to drain the liquid from the network 20 as well. Typically, mesh 20 could lead to forming apex 26 in about 8-14% solids.
    [0033] The apex of the yarn 28 of the trainer 26 and the fiber and bottom 18 converge together through the use of a set of top blades 36 located under the dehydration chambers 30 together with a preferred set of bottom loaded blades 38 located directly under the bottom wire 18. These blades 36 and 38 can be made from materials such as ceramics. These loadable blades 38 (the load element) are designed to move the bottom wire 18 upwards so that the top wire 28 contacts the top blades 36. This and the vacuum between the blades 36 result in a tight effect that induce some of the liquids being squeezed from the mesh 20 and forming a fiber layer against the top thread 40 which is separated from the layer formed at the bottom 42. These separately formed layers have a lower tendency for the fiber to become connect the fiber. As can be seen better in figure 3, the top blades 36 are generally stationary while the bottom blades 38 are mobile. The displacement of the bottom blade 38 between the adjacent top blades 36 induces the top and bottom wires to move in an acute up and down movement, which creates a strong pulsating shear force that is successively transferred to the network 20 when it passes through the wire former 26. These strong pulsating shear forces are designed to break many of the fiber bundles present in the wet network. Since the mesh 20 has a high humidity state when entering the wire former 26, any fiber bundle contained in the mesh will be very susceptible to the shear forces that can break fiber-to-fiber bonds. An appropriate device that uses the top and bottom blades for loading the top and bottom wires of a wire former which is described in U.S. Patent No. 5,695,613, which is incorporated herein in its entirety.
    [0034] It should be appreciated that in the state of the art of thin paper stocking technique, a very low charge is normally applied through the bottom blades 38 during the pressure or dehydration process since the medium or the shear forces pulsing could damage the thickness of the stock network being formed over the peak of the formation. However, as discussed in greater detail below, high pulsating shear forces are desired in the processes of the present invention since the slurry slurry forming the network 20 contains many fiber-to-fiber bonds. The pulp slurry contains numerous fibers in the pulp which cannot possibly be free of fiber-to-fiber bonds when the sludge leaves the inlet box 14. Dilution of the pulp slurry can lead to some of the fiber bundles being broken when the mud comes out of the inbox. However, there may still be many fiber-to-fiber packages that will be dispersed within the stock network. In addition, it is known from the paper machine technique that fibers have a tendency to create fiber-to-fiber bundles in stock. For this reason, the number of fiber bundles remaining in the stock 20 network is of greatest interest to soft pulp manufacturers. Consequently, some manufacturers suggest mechanical steps or chemical treatment to be employed during the time that the slurry slurry is being processed first, to reduce the number of fiber bundles entering the inbox. For example, in US patent 6,059,924, a process is described in which the pulp slurry is moderately refined prior to the blade forming step. Said process requires additional equipment to be used to refine the slurry of slurry before it enters the inbox. Other methods to address the problem of unwanted fiber bundles require chemical additives to be added to the slurry slurry. However, these processes can lead to additional costs in the manufacture of the soft pulp blade.
    [0035] The processes of the present invention use high pulsating shear forces that break the fiber bundles once the mesh 20 has been deposited on the bottom wire 18. In this sense, the blades 36 and 38 of the top trainer, provide a type of appropriate mechanism that is capable of producing pulsating and cyclic shear forces, which act on the net 20 when it passes over the blades. The pulsating shear force is usually non-uniform which induces the network 20 to pass extreme fluctuations of shear forces to assist in the breaking of any type of fiber-to-fiber link that is dispersed in the network. The application time of these pulsating high shear forces occurs when the net 20 is still very wet (only about 2-4% dry) since the connection in the wet mud is easier to break with the applied pulsating forces.
    [0036] As can be seen in figure 3, the bottom blade 38 is pushed up closer between the two top blades 36 to put considerable force on the net 20 when it passes over this region of the top former. This creates an acute up and down movement that produces the pulsating shear force that is applied to the mesh 20. As can be seen further in figure 3, the mesh 20 has a finely dry top surface 40 and the bottom surface 42 with a medium portion 44 that remains substantially in a fluid state when the network passes along blades 36 and 38. The combination and vacuum (represented by the arrows in figure 3) in the dehydration chambers 30 match the pulsating shear forces produced by the top and bottom blades 36 and 38 to create shear forces that are strong enough to break most, if not all, of the fiber bundle present within the thin top and bottom surfaces 40 and 42, along with the portion median fluid 44. However, the integrity of the soft pulp blade will not be affected by the crushing received during this part of the process, as the placement of the top yarn 28 and the bottom yarn 18 helps to maintain the net 20 intact when it moves through and eventually leaves the top former 26. When the net 20 proceeds to the next dehydration equipment, a significant amount of the solution was removed from the net 20, but more importantly, a significant amount of the fiber-to-fiber packages has been broken, which will result in a more uniform soft pulp blade. After the drying of the net top former 20 is high enough, to prevent the fibers from moving freely in relation to each other, preventing new floc formation.
    [0037] Dehydration in the dehydration chambers 30 will form the fiber layer 40 against the top yarn which is separated from the layer formed in the bottom yarn 42 with the drainage units 22. As these layers are formed separately, the fibers will not are wound together due to the medium portion of the fluid 44, the fiber-to-fiber bond is reduced compared to the traditional lamina that has only one direction of dehydration during formation. Two additional layered formations will reduce the size and number of fiber bundles as well as the effect of shear with load elements. These effects will reduce the energy required to break the network into individual fibers in the hammer mill or similar equipment.
    [0038] After the net 20 leaves the top trainer 26, it still has considerable moisture and needs to be dehydrated by additional dehydration machines. As can be seen in figure 1, the net 20 initially enters a roll press 50, illustrated in this case as two sets of calender rolls covered with felt 52, 54, each defining a respective jaw through which the net 20 passes . After leaving the first roller press 50, the net 20 enters a shoe press 56 which is schematically shown to include a pair of rollers 60 and a movable shoe 58 which places a load force on the net 20. The shoe press includes cylinders 62-68 which are used to advance a felt mat 70. The shoe press is particularly useful in the dehydration process since shoe 58 can be designed to have a larger contact area (jaw) than the press conventional roll. Consequently, the larger jaw on the shoe press allows more contact surface, longer residence time on the jaw, with the net 20 resulting in greater drainage of the liquid from the net. In addition, due to the greater surface area of the shoe press, a lower peak pressure during the jaw is required to be applied by the shoe. Since the net thickness can be quite large, pulp manufacturers might prefer not to compress the net too much, as the combined fiber can become compressed during the dehydration process. The shoe press 56 thus helps to prevent unwanted compression of the mesh. The net 20 then leaves the shoe press 56 and can enter another press machine, such as another roller press 72, again illustrated as two sets of calender rolls 74, 76, each defining a respective jaw through the which network 20 passes through.
    [0039] From the dehydration section, the net enters a drying section 80 of the soft pulp manufacturing line. In a conventional soft pulp blade manufacturing line, drying section 80 may include multiple cylinders or drum dryers with net 20 after a serpentine route around the respective dryers and emerge as a dry blade or tarp 82 from the entrance to the drying section. The alternating sides of the wet net 20 will be exposed to hot surfaces when the net 20 passes from cylinder to cylinder. In many cases, the soft pulp net 20 is held close to the surface of the dryers by a fabric having carefully controlled permeability for steam and air. The heat is transferred from the hot cylinder to the still moist network, allowing any remaining liquid to be evaporated. Other alternative drying equipment, alone or in addition to the drum dryer or drum dryer, can be included in the drying process. Typically, the dry pulp blade 82 emerges from the dryer section having an average maximum moisture content of no more than about 5% by weight of the fibers, more preferably, no more than about 6% to 10% in weight and more often about 7%.
    [0040] In the embodiment of figure 1, the dry blade 82 is taken on a roll 84 for transportation in a soft pulp processing equipment where the blade can be defibrillated for use in the manufacture of the soft pulp absorbent products. Alternatively, the dry blade 82 can be harvested in a wrapping apparatus 86 from which the bales 88 of the individual soft pulp blades are created and packaged together.
    [0041] With reference now to figure 4, a flow chart shows the sequence of steps that can be performed in the formation of a soft pulp sheet according to the processes of the present invention. Initially, the pulp sludge can be prepared using a traditional single stocking technique which is well known in the art. Stock preparation could optionally include bleaching wood pulp using known bleaching methods, including, for example, and without limitation those described in U.S. Patent No. 6,893,473. Then, the pulp slurry is released into an inlet box that may or may not include dilution control to dilute the slurry concentration when it is being released over the bottom wire. The bottom yarn and yarn apex may be part of a yarn forming machine well known in the art. The top forming can be adjusted to apply a high pulsating shear force on the network stock. The net formed on the bottom wire can then be advanced on a number of different machines and combinations of machines to assist in dehydrating the net. For example, a single shoe press can be used to dehydrate the net. Another alternative is to use multiple shoe presses in series to progressively dehydrate the net. Another alternative is to use one or more presses on rollers with a single shoe press. The dehydration process could use a single roller press or multiple presses, and the shoe press to progressively dehydrate the mesh. Any of the presses can be a single or double felt. Consequently, there are several ways associated with the processes of the present invention in effectively dehydrating the formed network. Finally, the net could leave the dehydration machine to advance the net within a drying section. As mentioned above, the drying section can be created using a number of different drying equipment well known in the state of the art, such as cylinder dryers, which help to promote better separation of the fibers and to reduce the binding of the resulting fibers in a bottom Mullen resistance.
    [0042] With reference now to figure 5, another flowchart shows the sequence of steps that can be carried out in the formation of soft pulp sheets according to the processes of the present invention. Initially, the multi-slurry sludge is prepared using the multi-layer stock preparation. Said techniques are well known in the art. Stock preparation could optionally include bleaching wood pulps using known bleaching methods, including, for example, and without limitation, those described in U.S. Patent No. US 6,893,473. Then, the slurry from the pulp is released into an inlet box that may or may not include dilution control. If dilution controls are available, the concentration of the sludge can be diluted as the wort is being deposited on the bottom wire. Alternatively, the pulp slurry could be released to multiple inlet boxes with or without dilution. An individual inbox could be used to deposit a particular sludge on a bottom wire. A wire forming machine could be used as described in greater detail above to break many of the fiber bundles dispersed in the network stock. The multiple sludge contained in the multiple inboxes could be deposited on multiple top formers and Fourdriniers. The resulting nets formed by both these processes can then be dehydrated using, for example, a single shoe press or multiple shoe presses in series. Multiple roll presses could be used as well. Any of the presses can be single or double felt. The net could then leave the dehydration machine and be advanced through a drying section as described above.
    [0043] Figure 7 shows a schematic view representing a multi-layered soft pulp blade 90 that includes a top section 92, a middle section 94 and a bottom section 96. The top and bottom sections 92 and 96 they can be made, for example, from the same soft material while the center section could be made from a different soft material. All layers could be made from different stock as well. The soft pulp blade can be made with any number of layers. Consequently, it should be appreciated that there may be a number of different layer combinations and the composition of layers that can be created using the processes described here.
    [0044] With respect to figure 6, another flowchart shows that the sequence of steps can be performed in the formation of soft pulp sheets made with additives. Initially, the multi-slurry sludge is prepared with additives, such as dyes, detachments, odor control, static and gender control, using stock preparation techniques in multiple layers of additives well known in the prior art. The pulp slurry is then released into a multi-layered inlet box that may or may not include dilution control to dilute the slurry concentration when they are being released over the bottom wire. The sludge can then be deposited on the bottom wire and a top forming machine. The resulting net could then be dehydrated using the dehydration equipment described in the previous graphs. For example, a single shoe press or multiple shoe presses in series could be used to dehydrate the net. Alternatively, multiple roller presses and a single shoe press or multiple shoe presses could be used to dewater the mesh. Finally, the net could come out of the dehydration machine and be advanced into a drying section. It is clear that such additives mentioned above could optionally be applied to the net in addition to, alternatively, at any stage, embodiment, or purpose of the process of preparing the soft pulp blade described here below or above, including without limitation applications in including without limitation spraying, coating, or the type of surface applications.
    [0045] Figure 8 shows a schematic view representing a multi-layer additive soft pulp blade 100 that includes a top section 102, a middle section 104 and a bottom section 106. The bottom and top sections 102 and 106 can be made from the same soft material and the same additives while the central section 104 could be made from the same or a different soft material. The additives in this central section 104 could be different from those used in the top and bottom sections. The soft pulp blade can be made of any number of layers, each layer having different or similar additives. Consequently, it should be appreciated that there may be a number of different combinations of layers and additives added to a particular layer using the processes described here.
    [0046] The various equipment that can be implemented to achieve the various processes described here are generally commercially available. For example, a simple inbox that can be used can be a Valley model manufactured by Voith Paper. An appropriate inbox with dilution control includes the SymFlo model manufactured by Metso Paper and the Valley model manufactured by Voith Paper. An appropriate multilayer inbox includes the SymFlo model manufactured by Metso Paper. The top trainer used to apply the pulsating force and the vacuum to the formed network includes the MB model, manufactured by Metso and the PFI model manufactured by Johnson Foils. The appropriate shoe press includes the OptiPress model manufactured by Metso Paper and the NipcoFlex model manufactured by Voith Paper. Roll presses that can be used include the Combi Press model manufactured by Beloit. The drying equipment includes appropriate equipment such as the SymDry model manufactured by Metso Paper and the Airborn model manufactured by Andriz.
    [0047] Generally, any soft pulp or soft pulp fiber is suitable for use in the present invention, and the selection thereof is within the known technical area of the soft pulp and the soft pulp fibers of the art. The type of soft pulp or the soft pulp fiber suitable for use here is not intended to be limiting. The soft pulp typically includes cellulose fiber. The type of cellulose fiber is not critical, and any of said fibers known or suitable for use in soft pulp paper can be used. For example, soft pulp can be made from pulp fibers derived from hardwood trees, softwood trees, or a combination of hardwood trees and softwood trees. Soft pulp fibers can be prepared by one or more known operations or proper digestion, refinement, and / or bleaching operations such as, for example, known mechanics, thermomechanical, chemical and / or semi-chemical pulp and / or others well-known pulping processes. The term "hardwood pulps" as used here includes fibrous pulp derived from the woody substance of deciduous trees (angiosperms) such as birch, oak, beech, maple, and eucalyptus. The term "softwood pulp" as used herein includes fibrous pulps derived from the woody substance of coniferous trees (gymnosperms) such as spruce varieties, and pine such as Loblolly pine, cut pine, Colorado spruce, balsam spruce , and Douglas fir. In some embodiments, at least a portion of the pulp fibers may be provided from non-woody herbaceous plants including, but not limited to, Indian Kenaf plant, hemp, jute, flax, sisal or Philippine banana, despite the legal restrictions and other considerations may make use of hemp and other sources of fiber impractical or impossible. Both bleaching and unbleached soft pulp fiber can be used. The recycled soft pulp fibers are also suitable for use. When bleached, any bleaching method is appropriate, including, for example, and without limitation to those described in U.S. Patent No. US 6,893,473. The soft pulp and soft pulp fibers can be treated or untreated, and they can optionally contain in one or more of the additives, or a combination thereof, which are known in the art. Given the teachings here, the level of treatment, if desired, and the amount of additives can be easily determined by a person skilled in the art in the soft pulp and the soft pulp fibers of the prior art.
    [0048] In a broad aspect of the present invention, it is also contemplated that the pulp can be treated with bond-inhibiting chemicals, detachers as they are commonly called, chemical softeners, or other chemical additives, during the preparation of the soft pulp blade , to alter the processing or aesthetic characteristics of the finished soft pulp or the finished soft pulp and absorbent products made from said soft pulp. The addition of said chemical is usually effected by adding the chemical to the pulp before the formation of the slide in multiple or single layers or by spraying the pulp after the formation of the non-woven net and sometimes during the initial mechanical dehydration. Included within these materials are fatty acid soaps, aria or alkyl sulfonates, compounds of quaternary ammonium and the like. Usually, said materials could be used in an amount below 0.5% by weight and, frequently, below about 0.1% by weight of the dry pulp.
    [0049] As discussed here, if desired, additives such as pH adjusting agent, bleach, dye, odor control, pigment, optical brightening agent, wetting agent, binder, bleaching agent, trivalent cationic metal, sulfate aluminum, other additives, or a combination thereof can be used. Said compounds are known in the art and, otherwise, commercially available. Given the teachings here, a technician in the subject of soft pulp and paper making with soft pulp of the technique would be able to select and use these when appropriate. If present, the amount of the additive is not particularly limited. Of course, said additives mentioned above could optionally be applied to the network t at any stage, embodiment, or purpose of the soft pulp blade preparation process described here below or above, including, without limitation, surface applications including without spray limitation, coating, or the kind of surface applications.
    [0050] The dry blade of the soft pulp fibers typically has a thickness of about 20 to 80 mils, a base weight of 200 to 900 g / m.sup.2, a burning index of 0.5 to 3, 0 kPa.multiple points.m.sup.2 / g. The dry pulp blade generally has a density of about 0.3 to about 1.0 g / cm.
    [0051] In one embodiment, the additive can be present in amounts ranging from about 0.005 to about 50 weight percent based on the weight of the soft pulp blade. This variation includes all values and sub-ranges between them, including about 0.005, 0.006; 0.007; 0.008; 0.009; 0.01; 0.02; 0.03; 0.04; 0.05; 0.06; 0.07; 0.08; 0.09; 0.1; 0.2; 0.3; 0.4; 0.5; 0.6; 0.7; 0.8; 0.9; 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, and 50 weight percent, or any combination thereof, based on weight of the finished soft pulp blade.
    [0052] In one embodiment, the soft pulp blade may have a basis weight ranging from 100 to 1100 grams. This variation includes all values and sub-ranges here, for example, 100, 125, 150, 175, 200, 225, 250, 275, 300, 400, 500, 600, 700, 800, 900, 1000, 1100, or any combination of the same or tracks between them.
    [0053] The soft pulp blade made in accordance with the present invention can be made in a number of different products. These products include, but are not limited to, absorbent products, paper products, personal care products, medical products, insulation products, construction products, structural material, cement, food products, veterinary products, packaging products, diapers, absorbent tampon, sanitary wipes, incontinence pads, absorbent towels, gauze, bandage, flame retardant, and combinations thereof.
    [0054] Numerous modifications and variations in the present invention are possible in light of the above teachings. It should, therefore, be understood that within the scope of protection of the claims accompanying the application, the invention may be practiced in a manner other than that specifically described herein.
    权利要求:
    Claims (24)
    [0001]
    1. Process to prepare a soft pulp blade, CHARACTERIZED by the fact that it comprises: - creating a pulp sludge that includes soft pulp fibers suspended in a liquid, the pulp sludge containing multiple bundles of fibers formed from fibers of soft pulp that are joined together and dispersed within the pulp slurry; - applying a quantity of the pulp sludge over a moving bottom forming wire to form a network thereof, the pulp sludge being dispensed by an input box; - applying a top forming wire to the net and dehydrating the net through the top forming wire; - applying high pulsating shear forces over the net large enough to break some of the soft pulp fiber bundles using a stationary blade top and a movable blade bottom set, the top blade set having a vacuum between the blades and being adapted to contact the top forming wire and the bottom set of blades being adapted to contact the bottom forming wire, the movement of the bottom blades inducing the net to move sharply up and down, wherein the bottom blades move the bottom forming wire upwardly inducing the top forming wire to come into contact with the top blade assembly; and - to control the base in crossed weight in the net, by varying the concentration of the pulp sludge being deposited from the input box on the bottom formation wire.
    [0002]
    2. Process, according to claim 1, CHARACTERIZED by the fact that it also includes still dehydrating the net liquid after the net has been subjected to pulsating shear forces.
    [0003]
    3. Process, according to claim 1, CHARACTERIZED by the fact that it also includes: applying heat to the network.
    [0004]
    4. Process according to claim 1, CHARACTERIZED by the fact that the liquid is added to the slurry slurry leaving the inlet box to adjust the slurry slurry concentration before being deposited on the bottom forming wire.
    [0005]
    5. Process according to claim 1, CHARACTERIZED by the fact that the top forming wire contacts the network and the pulsating shear forces are applied in a region where the top forming wire and the forming wire of bottom contacts the network.
    [0006]
    6. Process according to claim 1, CHARACTERIZED by the fact that the portion of the pulsating shear forces applied to the network is created by subjecting the network to a vacuum source.
    [0007]
    7. Process for preparing a soft pulp blade, CHARACTERIZED by the fact that it comprises: - creating a pulp sludge that includes soft pulp fibers suspended in a liquid, the pulp sludge containing multiple bundles of fibers formed from the fibers of the soft pulp that are joined together and dispersed within the slurry of the pulp; - apply the slurry slurry over a moving bottom forming wire that moves the slurry slurry deposited in a forward direction to form a network, the slurry slurry being dispensed through an inbox; - applying pulsating shear forces of sufficient magnitude on the network to break some of the fiber bundles contained in the network through the use of a top blade set and a bottom blade set, at least one of the top and bottom sets of blades being movable, the top blade set adapted to contact the top forming wire and the bottom blade set adapted to contact the bottom forming wire, and the bottom blades move the bottom forming wire to top inducing the top forming wire to contact the top set of blades; - contact the network with a dewatering machine downstream from the application of pulsating shear forces, in which the dewatering machine comprises a shoe press; and - adjusting the cross-weight base in the slurry slurry by diluting at least a portion of the slurry slurry concentration when it is being deposited from the headbox on the bottom forming wire.
    [0008]
    8. Process, according to claim 7, CHARACTERIZED by the fact that it also includes: applying a top forming wire over the network and dehydrating the network through the top forming wire.
    [0009]
    9. Process for preparing a soft pulp blade, CHARACTERIZED by the fact that it comprises: - creating a pulp sludge that includes soft pulp fibers suspended in a liquid, the pulp sludge containing multiple fiber bundles formed from the fibers of soft pulp that are joined together and dispersed within the pulp slurry; - place the pulp sludge in an inbox with dilution control that allows the concentration of the pulp sludge to be diluted when the pulp sludge leaves the inbox; - apply the pulp sludge to a moving bottom forming wire that moves the sludge deposited in a forward direction to form the net; - contacting the network with a top forming wire cooperating with the bottom forming wire to dehydrate the network liquid using a top set of blades and a set of bottom blades, at least one of the top and bottom sets of blades being movable, the top blade set adapted to contact the top forming wire and the bottom blade set adapted to contact the bottom forming wire, wherein the bottom blade set moves the forming wire bottom up and induces the top forming wire to come into contact with the top set of blades; - contact the net with a dewatering machine downstream from the contact of the net with a top forming wire, in which the dewatering machine comprises a jaw shoe press comprising a roller, a shoe and a mat, in which the jaw shoe press contacts the net to remove some liquid from the net; and - applying heat to the network to evaporate additional liquid from the network.
    [0010]
    10. Process according to claim 9, CHARACTERIZED by the fact that it also includes: applying a second pulp slurry to the first pulp sludge mentioned to form a multilayer network.
    [0011]
    11. Process according to claim 10, CHARACTERIZED by the fact that the first mentioned slurry slurry and the second slurry slurry are deposited on the bottom forming wire using a multi-layered inlet box.
    [0012]
    12. Process, according to claim 10, CHARACTERIZED by the fact that the second pulp slurry is deposited on the bottom forming wire from a second inlet box.
    [0013]
    13. Process to prepare a soft pulp blade, CHARACTERIZED by the fact that it comprises: - creating a first pulp sludge that includes the soft pulp fibers suspended in a liquid, the pulp sludge containing multiple fiber bundles formed from the soft pulp fibers that are bonded together and dispersed within the first pulp slurry; - creating a second pulp slurry that includes the soft pulp fibers suspended in a liquid, the pulp sludge containing multiple fiber bundles formed from the soft pulp fibers that are bonded together and dispersed within the second pulp slurry; - apply the first pulp slurry and the second pulp sludge over a bottom forming wire that moves the sludge sludge deposited in a forward direction to form a multilayered network; - contacting the multilayer network with a top forming wire that cooperates with the bottom forming wire using a top blade set and a bottom blade set to dehydrate some of the liquid from the multilayer network forming a layer of fiber against the top and bottom forming thread, at least one of the top and bottom blade assemblies being movable, the top blade assembly adapted to contact the top forming wire and the bottom blade assembly adapted to contact the bottom forming wire, wherein the bottom blade assembly moves the bottom forming wire upwards and induces the top forming wire to contact the top blade assembly; - contacting the multilayer network with a dewatering machine downstream from the multilayer contact with a top forming wire, wherein the dewatering machine comprises a jaw shoe press comprising a roller, a shoe and a mat , in which the clamping shoe press extracts the additional liquid from the multilayer mesh; and - applying heat to the multilayer mesh to evaporate the additional liquid from the multilayer mesh.
    [0014]
    14. Process according to claim 13, CHARACTERIZED by the fact that the first pulp slurry and the second pulp sludge are deposited on the bottom forming wire using a multi-layered inlet box.
    [0015]
    15. Process, according to claim 14, CHARACTERIZED by the fact that the second pulp slurry is deposited on the bottom forming wire from a second inlet box.
    [0016]
    16. Process, according to claim 1, CHARACTERIZED by the fact that the pulsating shear forces have variable energy.
    [0017]
    17. Process, according to claim 1, CHARACTERIZED by the fact that it also includes: contacting the network with another dehydration machine after the network has been partially dehydrated through the top forming wire and the bottom forming wire.
    [0018]
    18. Process according to claim 17, CHARACTERIZED by the fact that the dehydration machine is a shoe press.
    [0019]
    19. Process, according to claim 1, CHARACTERIZED by the fact that a bottom blade is positioned on one side of the net and located between the adjacent top blades on an opposite side of the net and moves upwards, closer between the adjacent top blades in order to induce the net to move in an acute up and down movement.
    [0020]
    20. Process according to claim 19, CHARACTERIZED by the fact that a first vacuum source closer to the inlet box than a second vacuum source generates less vacuum than the second vacuum source.
    [0021]
    21. Process according to claim 7, CHARACTERIZED by the fact that a portion of the pulsating shear forces applied to the network is created by subjecting the network to the first and second vacuum sources, so that a first vacuum source more near the inlet box than a second vacuum source generates less vacuum than the second vacuum source.
    [0022]
    22. Process according to claim 9, CHARACTERIZED by the fact that a portion of the pulsating shear forces applied to the network is created by subjecting the network to the first and second vacuum sources, so that a first vacuum source more near the inlet box than a second vacuum source generates less vacuum than the second vacuum source.
    [0023]
    23. Process according to claim 9, CHARACTERIZED by the fact that a bottom blade is positioned on one side of the net and located between the adjacent top blades on an opposite side of the net and moves upwards, closest between adjacent top blades in order to induce the net to move in a sharp up and down movement.
    [0024]
    24. Process according to claim 13, CHARACTERIZED by the fact that a portion of the pulsating shear forces applied to the network is created by subjecting the network to the first and second vacuum sources, so that a first more vacuum source near the inlet box than a second vacuum source generates less vacuum than the second vacuum source.
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    同族专利:
    公开号 | 公开日
    EP2817450B1|2017-08-30|
    US20170081802A1|2017-03-23|
    CA2915297A1|2013-08-22|
    CL2014002179A1|2015-04-10|
    RU2014134914A|2016-03-20|
    US20130213594A1|2013-08-22|
    CA2864704C|2016-12-13|
    CN105568776A|2016-05-11|
    US20150013926A1|2015-01-15|
    US9347182B2|2016-05-24|
    CN105544308A|2016-05-04|
    NZ715295A|2016-10-28|
    NZ628539A|2016-04-29|
    US8871059B2|2014-10-28|
    CN104220669B|2016-01-13|
    EP2817450A1|2014-12-31|
    CA2864704A1|2013-08-22|
    WO2013122731A1|2013-08-22|
    US20160237623A1|2016-08-18|
    IN2014DN07338A|2015-04-24|
    CN105544308B|2017-12-12|
    CA2915297C|2018-07-17|
    RU2598284C2|2016-09-20|
    CN104220669A|2014-12-17|
    CN105568776B|2017-11-03|
    EP3279395A1|2018-02-07|
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    法律状态:
    2018-03-27| B06F| Objections, documents and/or translations needed after an examination request according art. 34 industrial property law|
    2019-09-03| B06U| Preliminary requirement: requests with searches performed by other patent offices: suspension of the patent application procedure|
    2020-12-15| B09A| Decision: intention to grant|
    2021-01-12| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 25/01/2013, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    US13/398,144|US8871059B2|2012-02-16|2012-02-16|Methods and apparatus for forming fluff pulp sheets|
    US13/398,144|2012-02-16|
    PCT/US2013/023062|WO2013122731A1|2012-02-16|2013-01-25|Methods for forming fluff pulp sheets|
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