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Patent 2461063 Summary

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(12) Patent: (11) CA 2461063
(54) English Title: CELLULOSIC WEB, METHOD AND APPARATUS FOR MAKING THE SAME USING PAPERMAKING BELT HAVING ANGLED CROSS-SECTIONAL STRUCTURE, AND METHOD OF MAKING THE BELT
(54) French Title: BANDE CELLULOSIQUE, PROCEDE ET APPAREIL PERMETTANT DE PRODUIRE LADITE BANDE A L'AIDE D'UNE COURROIE A STRUCTURE TRANSVERSALE ANGULAIRE, ET PROCEDE DE FABRICATION DE COURROIE
Status: Expired
Bibliographic Data
(51) International Patent Classification (IPC):
  • D21H 27/02 (2006.01)
  • D21F 11/00 (2006.01)
(72) Inventors :
  • HUSTON, LARRY L. (United States of America)
(73) Owners :
  • THE PROCTER & GAMBLE COMPANY (United States of America)
(71) Applicants :
  • THE PROCTER & GAMBLE COMPANY (United States of America)
(74) Agent: WILSON LUE LLP
(74) Associate agent:
(45) Issued: 2005-07-26
(22) Filed Date: 1998-05-18
(41) Open to Public Inspection: 1998-11-26
Examination requested: 2004-04-06
Availability of licence: N/A
(25) Language of filing: English

Patent Cooperation Treaty (PCT): No

(30) Application Priority Data:
Application No. Country/Territory Date
08/858,661 United States of America 1997-05-19
08/858,662 United States of America 1997-05-19

Abstracts

English Abstract

A papermaking through-air drying belt (10) and a method of making the same, as well as a paper web produced on the belt and the process of making the web are disclosed. The belt (10) comprises a resinous framework (20) having a web side surface (21) defining an X-Y plane, a backside surface (22) opposite the web- side surface, a Z-direction perpendicular to the X-Y plane, and a plurality of discrete deflection conduits (30) extending between the web-side surface and the backside surface. Each of the discrete conduits (30) has an axis (33) and walls (35). The axes (33) of at least some of the discrete conduits (30) and the Z-direction form acute angles (Q) therebetween.


French Abstract

Une courroie de fabrication du papier par séchage d'air (10) et un procédé de fabrication de celle-ci, ainsi qu'une bande de papier produite sur la courroie et le procédé de fabrication de la bande sont décrits. La courroie (10) comprend un cadre résineux (20) ayant une surface côté bande (21) définissant un plan X-Y, une surface arrière (22) opposée à la surface côté bande, une direction Z perpendiculaire au plan X-Y et une pluralité de conduits de déflexion discrets (30) qui s'étendent entre la surface côté bande et la surface arrière. Chacun des conduits discrets (30) a un axe (33) et des parois (35). Les axes (33) d'au moins certains des conduits discrets (30) et la direction Z forment des angles aigus (Q) entre eux.

Claims

Note: Claims are shown in the official language in which they were submitted.



-31-

WE CLAIM:

1. A paper web having at least two regions disposed in a non-random and
repeating pattern, said web comprising:
a macroscopically monoplanar, patterned, and essentially continuous network
region forming a network plane and having a relatively high density, and
a domes region having a relatively low density, said domes region comprising
discrete domes extending from said network plane in at least one direction
such that
said at least one direction and said network plane form an acute angle
therebetween.

2. A paper web having at least two regions disposed in a non-random and
repeating pattern, said web comprising:
a macroscopically monoplanar, patterned, and essentially continuous network
region forming a network plane, and
a domes region comprising discrete domes extending from said network plane
in at least one direction such that said at least one direction and said
network plane
form an acute angle therebetween.

3. A process for producing a cellulosic fibrous web having at least two
regions
disposed in a non-random repeating pattern, the process comprising the steps
of:
providing a plurality of cellulosic papermaking fibers suspended in a liquid
carrier;
providing a forming belt;
depositing said plurality of cellulosic papermaking fibers suspended in said
liquid carrier on said forming belt;
draining said liquid carrier through said forming belt thereby forming an
embryonic web of said papermaking fibers on said forming belt;



-32-

providing a macroscopically monoplanar through-air drying belt comprising a
resinous framework having a web-side surface defining an X-Y plane, a backside
surface opposite said web-side surface, a Z-direction perpendicular to said X-
Y plane,
and a plurality of discrete deflection conduits extending between said webside
surface
and said backside surface, each of said conduits having an axis and walls,
said axes of
at least some of said conduits and said Z-direction forming acute angles
therebetween:
depositing said embryonic web to said web-side surface of said resinous
framework of said papermaking belt;
applying a fluid pressure differential to said embryonic web to deflect at
least
a portion of said papermaking fibers into said discrete deflection conduits
and to
remove water from said embryonic web into said discrete deflection conduits
thereby
forming an intermediate web, said intermediate web comprising a
macroscopically
monoplanar, patterned, and essentially continuous network region, and a domes
region comprising a plurality of discrete domes protruding from, circumscribed
by,
and adjacent to said network region, each of said domes having an axis, the
axes of at
least some of said domes and said Z-direction forming acute angles
therebetween.

4. A fibrous web having at least two regions disposed in a non-random and
repeating pattern, said web comprising:
a macroscopically planar and patterned first region comprising an essentially
continuous network forming a network plane, said first region having a
relatively high
basis weight; and
a second region having a relatively low basis weight and comprised of a
plurality of discrete knuckles circumscribed by and adjacent to said first
region, said
knuckles extending from said first region in at least one direction, said at
least one
direction and said network plane forming an acute angle therebetween.

5. The fibrous web according to Claim 4, further comprising a third region
having an intermediate basis weight relative to the basis weight of said first
region
and the basis weight of said second region, said third region being juxtaposed
with
said second region.



-33-

6. A process for producing a cellulosic fibrous web having at least two
regions
disposed in a non-random repeating pattern, the process comprising the steps
of
providing a plurality of cellulosic fibers suspended in a liquid carrier;
providing a macroscopically monoplanar papermaking belt comprising an air
permeable reinforcing structure having a web-facing side defining an X-Y
plane, a
machine-facing side opposite said web-facing side, and a Z-direction
perpendicular to
said X-Y plane, said papermaking belt further comprising a resinous framework
comprised of a plurality of discrete protuberances joined to and extending
from said
reinforcing structure, each of said protuberances having an axis, a base
surface, a top
surface, and walls spacing apart and interconnecting said base surface and
said top
surface, said axes of at least some of said protuberances and said Z-direction
forming
acute angles therebetween, a plurality of said top surfaces defining a webside
surface
of said resinous framework, and a plurality of base surfaces defining a
backside
surface of said resinous framework;
depositing said cellulosic fibers and said carrier onto the papermaking belt;
draining said liquid carrier through said papermaking belt, thereby forming a
macroscopically planar and patterned first region disposed in said X-Y plane
and
comprising an essentially continuous network, and a second region comprised of
a
plurality of discrete knuckles, said knuckles being circumscribed by, adjacent
to and
extending from said first region in at least one direction, said at least one
direction and
said Z-axis forming an acute angle therebetween.


Description

Note: Descriptions are shown in the official language in which they were submitted.


CA 02461063 2004-04-06
CELLULOS1C WEB, METHOD AND APPARATUS FOR MAKING THE SAME
USING PAPERMAICING BELT HAVING ANGLED CROSS-SECTIONAL
STRUCTURE, AND METHOD OF MAKING THE BELT
FIELD OF THE INVENTION
The present invention is related to processes for making strong, soft,
absorbent cellulosic webs. More particularly, this invention is concerned with
structured cellulosic webs having low density regions.and high density
regions, and
with papeimaking belts utilized for making such paper webs.
BACKGROUND OF THE INVENTION
Paper pre~ucts are used for a variety of p~:.rpoaes. Paper towels, facial
tissues;
toilet tissues, and the like are in constant use iri modra~n industrialized
societies. The
large demand for such paper products has created a demand for improved
versions of
the products. If the paper products such as paper towEas, facial tissues,
toilet tissues,
and the like are t~ perform their intended tasks and to find wide acceptance,
they
must possess certain hh;':9cal charactensncs. Among the more important .of
these
characteristics are stra~o.~i, softness, and absorbency.
Strength is the ability of a papa web to retain its physical integrity during
use.
Softness is the pleasing tactile xnsation consumers percave when they ux the
papa for its intended pwposes.
Absorbency is the characteristic of the paper that aDows the papa to take up
and retain fluids, particularly wata and aqueous solutions and suspensions.
Important not c~n~yr is the absolute quantity of fluid a g'rvcn amount of papa
will hold,
but also the rate at which the papa will absorb the fluid.
?hrough-air drying papaTnaking belts comprising a reinforcing structure and a
resinous frames :.irk are dacnbed in commonly assigned U.S. Patent 4,514,345 .
issued to Johnson ct al. on Apr. 30, 1985; U.S. Patent 4,528,239 issued to
?rokhan
on July 9, 1985; U.S. Patent 4,529,480 issued to T~~~chan on July 16, 1985; ~
U.S.
Patent 4,637,859 issued to Trokhan on Jan. 20, 1987; U.S. Patent 5,334,289
issued
to Trokhan et al on Aug. 2, 1994.
The paper produced on the belts disclosed in these patents is characterized by
having two physically distinct regions: a continuous network region having a

CA 02461063 2004-04-06
7
relatively high density and a region comprised of a plurality of domes
dispersed
throughout the whole of the network region. The domes are of relatively low
density and relatively low intrinsic strength compared to the network regions.
Such
belts have been used to produce commercially successful products such as
Bounty
paper towels and Charmin Ultra toilet tissue, both produced and sold by the
instant
assignee.
U.S. Patents 5,245,025 issued to Trokhan et al. on Sep. 14, 1993; and
5,527,428 issued to Trokhan et al. on June 18, 1996, disclose a cellulosic
fibrous
structure comprising a plurality of regions: an essentially continuous first
region of a
relatively high basis weight; a second region of a relatively low or zero
basis weight
and circumscribed by and adjacent the first region; and a third region of an
intermediate basis weight and juxtaposed with the second region. A forming
belt for
producing such a paper comprises a patterned array of discrete protuberances
joined
to a reinforcing structure. Annuluses between adjacent protuberances provide
space
into which papermaking fibers may be deflected to form the first region. In
addition,
each individual protuberance may have an aperture therein. The apertures in
the
individual protuberances also provide space into which the papermaking fibers
may
deflect to form the third region.
Still, a search for improved produce ha~ continued.
tt may be desirable in some instar~~ to produce ._ellulosic webs having
"angled" cross-sectional patterns, l.c., the webs which -- when viewed in the
cross-
section -- have the domes extending from an essentially continuous network
region
such that the domes are not generally perpendicular, but instead are acutely
angled,
relative to the plane of the network region. Particularly, such "angled" domes
may
improve the web's softness due to increased collapsibility of the angles
domes,
compared to the perpendicularly upstanding domes. In addition, it is believed
that
such angled structures will. possess an ability to direct absorbed fluids in a
desired
(and predetermined) direction, based on the specific (and also predetermined)
orientation of the domes in the web. Such properties may bE very beneficial in
a __
variety of disposable products.
Therefore, it is an object of an aspect of the present invention to provide a
cellulosic web having at least two regions: an essentially continuous region
and a
region comprising a patterned array of discrete domes or knuckles extending
from
the essentially continuous region such that the axes of the domes or knuckles
and the
general plane of the essentially continuous region form acute angles
therebetween.
It is another object of an aspect of the present invention to provide a
process of
making such cellulosic webs.

CA 02461063 2004-04-06
J
It is still another object of an aspect of the present invention to provide a
papermaking belt for producing such cellulosic webs.
It is a further object of an aspect of the present invention to provide a
process
of making such papermaking belt.
SUMMARY OF THE INVENTION
A macroscopically monoplanar papermaking belt of the present invention
may be used in a pa f,ermaking machine as a forming belt and/or as a through-
air
drvirQ belt.
The through-air drying belt comprises a resinous framework having a web-
side surface which defines an X-Y plane, a backside surface opposite the web-
side
surface, a Z-direction perpendicular to the X-Y plane, and a plurality of
discrete
deflection conduits extending between the web-side surface and the backside
surface. Preferably, the plurality of conduits comprises a non-random
repeating
patterned array. Each of the discrete conduits has an axis and walls. The axes
of at
least some of the discrete conduits and the Z-direction form acute angles
therebetween. Preferably, the through-air drying belt further comprises an air-

permeable reinforcing structure positioned between the web-side surface and
the
backside surface of the resinous framework. The reinforcing structure has a
web-
facing side and a machine-facing side opposite the web-facing side.
In the through-air dn~ing belt, the web-side surface of the framework has an
essentially continuous web-side network formed therein, and the backside
surface of
the framework has a backside network formed therein. The web-side network
defines web-side openings, and the backside network defines backside openings
of
the discrete conduits. The web-side openings are off set relative to the
corresponding backside openings within the X-Y plane in at least one direction
perpendicular to the Z-direction. 'I?te discrete conduits may be tapered,
preferably
negatively tapered, relative to their respective axes in at least one
direction
perF_.tdicular to the Z-direction.
The forming belt of the present invention comprises an air-permeable
reinforcing structure and a resinous framework joined to the reinforcing
s:rscture.
The reinforcing structure has a web-facing side defining an X-Y plane, a
machine-
facing side opposite the web-facing side, and a Z-direction perpendicular to
the X-Y
plane. The resinous framework is comprised of a plurality of discrete
protuberances
joined to and extending from the reinforcing structure. Each of the
protuberances
has an axis, a top surface, a base surface opposite the top surface, and walls
spacing
apart and interconnecting the top surface and the base surface. Preferably,
the

CA 02461063 2004-04-06
4
discrete protuberances are circumscribed by and adjacent to an area of
essentially
continuous deflection conduits. A plurality of the top surfaces defines a web-
side
surface, and a plurality of the base surfaces defines a backside surface of
the
resinous framework.
In the forming belt of the present invention, the axes of at least some of the
protuberances and the Z-direction form an acute angles therebetween. The top
surfaces of at least some of the protuberances are off set relative to the
corresponding base surfaces of the same protuberances within the X-Y plane in
at
least one direction perpendicular to the Z-direction. The web-facing side of
the
reinforcing structure has preferably an essentially continuous web-facing
network
formed therein, which web-facing network is defined by the area of essentially
continuous deflection conduits. The walls of at least some of the
protuberances may
be tapered relative the axes of these protuberances. Preferably, the plurality
of
protuberances comprises a non-random repeating patterned array in the X-Y
plane.
In one embodiment, the plurality of discrete protuberances has a plurality of
discrete
deflection conduits extending from the web-side surface to the back surface of
the
resinous framework. Preferably, each of the plurality of discrete
protuberances has
at least one discrete deflection conduit therein. In both the through-air
drying belt
and the forming belt, the backside surface may optionally be textured.
A method of making the belt of the present invention comprises the steps of:
(a) providing an apparatus for generating curing radiation in a first
direction;
(b) providing a liquid photosensitive resin;
(c) providing a forming unit having a working surface and capable of
receiving the liquid photosensitive resin;
(d) providing an air-permeable reinforcing structure to be joined to the cured
photosensitive resin, the reinforcing structure having a web-facing side and a
machine-facing side opposite said web-facing side;
(e) disposing said reinforcing structure in said forming unit;
(f) disposing the liquid photosensitive resin in said forming unit thereby
forming a coating of the liquid photosensitive resin, the coating having a
first
surface and a second surface opposite the first surface, and a pre-selected
thickness
defined by these first and second surfaces;
(g) disposing the forming unit containing the coating of liquid photosensitive

CA 02461063 2004-04-06
resin in the first direction such that the first surface of the coating and
the first
direction form an acute angle therebetween;
(h) providing a mask having opaque regions and transparent regions defining
a pre-selected pattern;
(i) positioning the mask between the first surface of the coating and the
apparatus for generating curing radiation such that the mask is in adjacent
relation
with the first surface, the opaque regions of the mask shielding a portion of
the
coating from the curing radiation of the apparatus, and the transparent
regions
leaving other portions of the coating unshielded for the curing radiation of
the
apparatus;
(j) curing said unshielded portions of the coating, and leaving the shielded
portions of the coating uncured by exposing the coating to radiation having an
activating wavelength from the apparatus for generating curing radiation
through the
mask to form a partially-formed belt;
(k) removing substantially all uncured liquid photosensitive resin from the
partially-formed belt to leave a hardened resinous structure which forms a
framework having a web-side surface formed by the first surface being cured
and a
backside surface formed by the second surface being cured. Depending on a
particular predetermined design of the desired framework (continuous framework
for the through-air drying belt, or the framework comprising the plurality of
protuberances for the forming belt), the belt will have either a plurality of
discrete
conduits in the regions which were shielded from the curing radiation by the
opaque
regions of the mask, or a plurality of discrete protuberances extending from
the
reinforcing structure in the regions which were not shielded and therefore
became
cured.
The steps (d) and (e) are the necessary steps for making the forming belt, and
the highly preferred steps for making the through-air drying belt.
According to an aspect of the present invention, there is provided a paper
web having at least two regions disposed in a non-random and repeating
pattern, the
web comprising:
a macroscopically rnonoplanar, patterned, and essentially continuous
network region forming a network plane and having a relatively high density,
and
a domes region having a relatively low density, the domes region

CA 02461063 2004-04-06
Sa
comprising discrete domes extending from the network plane in at least one
direction such that the at least one direction and the network plane form an
acute
angle therebetween.
According to another aspect of the present invention, there is provided a
paper web having at least two regions disposed in a non-random and repeating
pattern, the web comprising:
a macroscopically monoplanar, patterned, and essentially continuous
network region forming a network plane, and
a domes region comprising discrete domes extending from the network plane
in at least one direction such that the at least one direction and the network
plane
form an acute angle therebetween.
According to another aspect of the present invention, there is provided a
process for producing a cellulosic fibrous web having at least two regions
disposed
in a non-random repeating pattern, the process comprising the steps of:
providing a plurality of cellulosic papermaking fibers suspended in a liquid
carver,
providing a forming belt;
depositing the plurality of cellulosic papermaking fibers suspended in a
liquid Garner on the forming belt;
draining the liquid carrier through the forming belt thereby forming an
embryonic web of the papermaking fibers on the forming belt;
providing a macroscopically monoplanar through-air drying belt comprising
a resinous framework having a web-side surface defining an X-Y plane, a
backside
surface opposite the web-side surface, a Z-direction perpendicular to the X-Y
plane,
and a plurality of discrete deflection conduits extending between the web-side
surface and the backside surface, each of the conduits having an axis and
walls, the
axes of at least some of the conduits and the Z-direction forming an acute
angles
therebetween;
depositing the embryonic web to the web-side surface of the resinous
framework of the papermaking belt;
applying a fluid pressure differential to the embryonic web to deflect at
least
a portion of the papermaking fibers into the discrete deflection conduits and
to
remove water from the embryonic web into the discrete deflection conduits

CA 02461063 2004-04-06
Sb
thereby forming an intermediate web, the intermediate web comprising a
macroscopically monoplanar, patterned, and essentially continuous network
region,
and a domes region comprising a plurality of discrete domes protruding from,
circumscribed by, and adjacent to the network region, each of the domes having
an
axis, the axes of at least some of the domes and the Z-direction forming acute
angles
therebetween.
According to another aspect of the present invention, there is provided a
fibrous web having at least two regions disposed in a non-random and repeating
pattern, the web comprising:
a macroscopically planar and patterned first region comprising an essentially
continuous network forming a network plane, the first region having a
relatively
high basis weight; and
a second region having a relatively low basis weight and comprised of a
plurality of discrete knuckles circumscribed by and adjacent to the first
region, the
knuckles extending from the first region in at least one direction, the at
least one
direction and the network plane forming an acute angle therebetween.
According to another aspect of the present invention, there is provided a
process for
producing a cellulosic fibrous web having at least two regions disposed in a
non-
random repeating pattern, the process comprising the steps of:
providing a plurality of cellulosic fibers suspended in a liquid carrier;
providing a macroscopically monoplanar papermaking belt comprising an air
permeable reinforcing structure having a web-facing side defining an X-Y
plane, a
machine-facing side opposite the web-facing side, and a Z-direction
perpendicular to
the X-Y plane, the papermaking belt further comprising a resinous framework
comprised of a plurality of discrete protuberances joined to and extending
from the
reinforcing structure, each of the protuberances having an axis, a base
surface, a top
surface, and walls spacing apart and interconnecting the base surface and the
top
surface, the axes of at least some of the protuberances and the Z-direction
forming
acute angles therebetween, a plurality of the top surfaces defining a web-side
surface
of the resinous framework, and a plurality of base surfaces defining a
backside
surface of the resinous framework;
depositing the cellulosic fibers and the carrier onto the papermaking belt;
draining the liquid carrier through the papermaking belt, thereby forming a

CA 02461063 2004-04-06
C
macroscopically planar and patterned first region disposed in the X-Y plane
and
comprising an essentially continuous network, and a second region comprised of
a
plurality of discrete knuckles, the knuckles being circumscribed by, adjacent
to and
extending from the first region in at least one direction, the at least one
direction and
the Z-axis forming an acute angle therebetween.
A cellulosic web made by using the through-air drying belt having an
essentially continuous framework will have at least two regions disposed in a
non-
random and repeating pattern: a macroscopically monoplanar, patterned, and
essentially continuous network region forming a network plane and preferably
having relatively high density, and a domes region preferably having
relatively low
density. The domes region comprises discrete domes extending from the network
plane in at least one direction such that this at least one direction and the
network
plane form an acute angle therebetween.
The cellulosic web formed on the forming belt having the framework
comprised of the plurality of discrete protuberances will have at least two
regions
disposed in a non-random and repeating pattern: a macroscopically planar and
patterned first region defining an X-Y plane and preferably having a
relatively high
basis weight, and a second region preferably having a relatively low basis
weight
and circumscribed by and adjacent to the first region. The first region
comprises an
essentially continuous network formed over the area of essentially continuous
conduits of the forming belt's framework. The second region is comprised of a

CA 02461063 2004-04-06
6
plurality of discrete knuckles formed over the discrete protuberances of the
forming
belt's framework. The protuberances extend from the first region in at least
one
"angled" direction such that this at least one direction and the X-Y plane
form an
acute angle therebetween. The av;:b formed on the forming belt having the
discrete
deflection conduits through the protuberances may also have a third region
having
an intermediate basis weight relative to the basis weight of the first region
and the
basis weight of the second region, the third region being juxtaposed with the
second
region.
In its through-air drying aspect, a process for producing a cellulosic fibrous
web comprises the steps of:
(a) providing a plurality of cellulosic papermaking fibers suspended in ~a
liquid
carver;
(b) providing a forming belt;
(c) depositing the plurality of cellulosic papermaking fibers suspender: ii, a
liquid
carriers o:~ the forming belt;
(d) draining the liquid carrier through the forming belt thereby forming an
embryonic web of the papcrmaking fibers on the forming belt;
(e) providing a macroscopically monopiana.~ though-air drying belt comprising
a
resi: ~~.5 IaWllewG~w having a web-side surface jea'ning an X-Y plane, a
backside
surface opposite the web-side surface, a Z-directs.,.. perpendicular to the X-
Y plane,
and a plurality of discrete deflection conduits extending between the web-side
surface and the backside surface, each of the conduits having an axis and
walls, the
axes of at least some of the conduits and the Z-direction forming an acute
angles
thercbetween;
(f) depositing the embryonic web to the web-side surface of the resinous
framework
of the through-air drying belt;
(g) applying a fluid pressiue differential to the embryonic web to deflect at
least a
portion of the papenmaking fibers into the discrete deflection conduits and to
remove
water fro~n the embryonic web into the d~ ~:.-ete deflection conduits thereby
forming
an intermediate web which comprises a macroscopically monoplanar, patterned,
and
essentially continuous network region, and a domes region comprising a
plurah;~ of
discrete domes protruding from, circumscribed by, and adjacent to the network
region, each of the domes having an axis, the axes of at least some of the
domes and
the Z-direction forming acute angles thcrebetween.
A process for producing the embryonic cellulosic fibrous web on the forming
belt of the present invention comprises the steps of-.
(a) providing a plurality of cellulosic fibers suspended in a liquid carrier;

CA 02461063 2004-04-06
7
(b) providing a macroscopically monoplanar forming belt comprising an air-
permeable reinforcing structure having a web-facing side defining an X-Y
plane, a
machine-facing side opposite said web-facing side, and a Z-direction
perpendicular
to said X-Y plane, the forming beU further comprising a resinous frar,~ework
comprised of a plurality of discrete protuberances joined to and extending
from the
reinforcing structure, each of the protuberances having a base surface, a top
surface,
walls spacing apart and interconnecting the base surface and the top surface,
and an
axis, the axes of at least some of the protuberances and the Z-directiu~
forming acute
angles therebetween, a plurality of the tog surfaces defining a web-side
surface of
the resinous framework, and a plurality of the base surfaces defining a
backside
surface of the resinous framework;
(c) depositing the celiulosic fibers and the carrier onto the forming belt;
(d) draining the liquid carrier through the forming belt, thereby forming a
-racro~:~opically planar and patterned first region disposed in the X-Y plane,
the first
egioi. .;omprising an essentially continuous r.~twork and preferably having a
relatively high basis weight; and a second region comprised of a plurality of
discrete
knuckle, circumscribed 1.~ and adjacent to the first region and preferably
having a
relatively low basis weight, the knuckles extending from the first region in
at least
one direction, this at least one direction and th,: 4-direction cn~-_.ing an
acute angle
therebetween.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. I is a schematic top plan view of a papenmaking belt of the present
invention having an essentially continuous web-side network and discrete
deflection
conduits.
FIG. 1 A is a schematic fragmentary cross-sectional view of the papermaking
belt taken along lines 1 A-1 A of FIG. 1, and showing the discrete deflection
conduits
which are angled relative to the Z-direction.
FIG. 1 B is a schematic fragmentary cross-se:~ional view of the papermaking
belt taken along lines 1 B-1 B of FIG. t .
r.IG. 1C is a schematic fragmentary cross-sectional view of the papermaking
bctt of the present invention having angled and negatively tapered conduits.
F1G. 2 is a schematic top plan view of the papcrmaking belt of the present
invention comprising a resinous framework formed by discrete protuberances
encompassed by an essentially continuous area of deflection conduits.

CA 02461063 2004-04-06
FIG. 2A is a schematic fragmentary cross-sectional view of the papermaking
belt taken along lines 2A-2A of FIG. 2, and showing the discrete protuberances
which are angled relative to the Z-direction and positively tapered.
FIG. 3 is a schematic top plan view of a papc:rraaking belt similar to that
shown in FIG. ~, and comprising a resinous framework formed by a plurality of
discrete protuberances having a plwality of discrete deflection conduits
therein.
FIG. 3A is a schematic fragmentary cross-sectional view of the papermaking
belt taken along lines 3A-3A of FIG. 3, and showing positively tapered
protuberances having negatively tapered discrete conduits therein.
FIG. 4 is a schematic top plan view of a paper web produced on the
papermaking belt of the present invention shown in FIGs. 1-1C, the paper web
having three zones of knuckles, the knuckles of each zone having a specific
orientation different from the orientations of the knuckles of the other two
canes.
FIG. 4A is a xhematic fragmentary cross-sectional view' of the paper web
taken along lines 4A-4A of FI(,~. 4.
FIG. 4B is a schematic fragmentary cross-sectional view of the paper web
taken along lines 4B-48 of FIG. 4.
FIG. 4C is a schematic fragmentary cross-sectional view c.r .he paper web
taken along lincs 4C-4C of ~'ly. ~.
FIG. ~~,~ is a schematic fragmentary cross-sectional view of a pt~raetic web
produccd on the papcrmaking belt of the present invention shown in FIGS. 3 and
3A.
FIG. 5 is a xhcmatic perspective view of an apparatus for generating curing
radiation which can be utilized for curing a photosensitive resin to form a
resinous
framcwork comprising the papermaking belt of the present invention.
FIG. 5A is a xhematic cross-sectional vices of the apparatus shown in FIG.
5.
FIG. 5B is a xhetnatic cross-sectional view of the apparatus of controlled
radiation directing curing radiation in more than one pre-determined radiating
direction.
FIG. SC is a xhematic cross-scctional view of another embodiment of the
apparatus of controlled radiation.
FIG. 6 is a xhcmatic side elevational view of one embodiment of a
continuous papermaking proccss utilized in the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 6, the preferred embodiment of the papermaking belt 10 of
the present invention is an endless belt. However, the papermaking belt 10 of
the

CA 02461063 2004-04-06
9
present invention may be incorporated into numerous other forms that include,
for
example, stationary plates for use in making handsheets or other batch
processes, or
rotating drums for use with other continuous processes. As used herein, the
term
"papermaking belt 10," or simply "belt 10" is a generic term which includes
both a
forming belt 10a and a through-air drying belt 10b, both shown in FIG. 6. The
forming belt IOa travels in the direction indicated by a directional arrow
"A," and the
through-air drying belt lOb travels in the direction indicated by a
directional arrow
"B." Because both the forming belt 10a and the through-air drying belt l Ob
possess
certain common characteristics, it is convenient in relevant parts of the
Specification
to rrfer to both the forming belt 10a and the through-air drying belt lOb as
simply
"the belt 10." However, when distinguishing between the forming belt 10a and
the
through-air drying belt lOb is necessary or helpful for understanding the
present
invention, the reference will be made to "the forming belt 10a," or to "the
through-
air dying belt l Ob.". ~°.garrl~.ss of the physical form of the
papetmaking belt 10 and
its function in the pnperma:::ag process, the belt 10 of the present invewion
has the
characteristics described below.
As shown in FIGs. 1-.4l a.ld 6, the belt : ~~ of the present invention has a
web-
.- contacting side 11 and a backside 12 opposite the web-contacting side 11.
As
should be clear from the definition, the web-contacting side 11 cont;.:.~~,
ar,d therel~~~
uppons a web 60 on the belt 10. The >;acl.side 12 contacts the machinery
employed
in the pape:rmaking process. such as a vacuum pick-up shoe 17a and a multislot
vacuum box 17b and various rolls, etc. For clarity, as used herein, the web 60
is
refrrrnced by the same reference numeral 60, regardless of a particular stage
of its
processing. The distinction between the various stages of the web's
processing,
although significant, does not require the use of different reference numerals
for the
purposes of describing the present invention. An adjective immediately
preceding
the term "web" will clearly and definitely indicate a particular stage of the
web's
processing, for example: "embryonic web 60," "intermediate web 60," "imprinted
web 60," "predried web 60," "dried web 60." and a final product -- "paper ;veb
60."
FIGS. 1-3C show various embodiments of the belt 10 ~f the present invention.
FIGs. 1-lC illustrate the pa~~rmaking belt 10 which may preferably be utilized
as
the through-air drying belt 10b; and FIGs. 2-3A show embodiments of the belt
10
which can preferably be utilized as the forming belt 10a. The belt 10
comprises a
resinous framework 20 and a reinforcing swcture SO joined to the resinous
framework 20. It should be pointed out that the reinforcing structure 50 is
necessary
for the forming belt 1 Oa and highly preferred for the through-air drying belt
l Ob.

CA 02461063 2004-04-06
10
The resinous framework, or simply framework, 20 has a web-side surface 21, a
backside surface 22 opposite the web-side surface 21, and a plurality of
deflection
conduits 30 extending between the web-side surface 21 and the backside surface
22.
If desired, the backside surface 22 may be textured according to the commonly
assigned and incorporated herein by reference U.S. Patents: 5,275,700 issued
Jan. 4,
1994 to Trokhan; 5.334,289 issued Aug. 2, 1994 to Trokhan et al.; 5,364,504
issued
Nov. 15, 1994 to Smurkoski et al. The reinforcing structure 50 is preferably,
positioned between the web-side surface 21 and the backside surface 22 of the
framework 20. The reinforcing svucture 50 is substantially liquid-pervious,
and
may comprise a for~aminous element, such as a woven screen or other apertured
structures. The reinforcing structure 50 has a web-facing side 5'1 and a
machine-
facing side 52 opposite to the web-Facing side 51. The web-facing side 51 of
the
reinforcing structure 50 corresponds to the web-side surface 21 of the
framework 20,
anti the rna~:hine-facing side 52 of the reinforcing structure 50 corresponds
to the
backside surface 22 of the framework 20.
In the embodiment shown in FIGS. 1-1 C, the framework 20 comprises an,
essentially a~rtinuous paper.., and the plurality of deflection conduits 30
comprises
a plurality of discrete orifices, or holes, extending from the web-side
surface 21 to
the backside surface 22 of the framework 20. Prefeaably, the ;iisc;ete
conduits 30
are arranged in' a prr-selected paneri: in the fryamework 20. More preferably,
the
pattern of the arrangement of the conduits 30 is non-random and repeating. The
papermaking belt 10 having a continuous framework 24 and discrete deflection
conduits 30 may preferably be utilized as the through-air drying belt 10b. The
panermaking belt 10 having a continuous framework 20 and discrete deflection
conduits 30 is primarily disclosed in the commonly assigned U.S. Patents
4,528,239
issued Jul. 9, 1985 to Trokhan; 4,529,480 issued Jul. 16, 1985 to Trokhan;
4,637,859
issued Jan. 20, 1987 to Trokhan; 5,098,522 issued Mar. 24, 1992 to Trokhan et
al.;
5,275,700 issued Jan. 4, 1994 to Trokhan; 5,334,289 issued Aug. 2, 1994 to
Trokhan;
and 5,364,504 issued Nov. 15, 1985 to Smurkoski et al.
In another embodiment of the belt 10 shown in FIGS. 2-3C, the framework 20
comprises a plurality of discrete protuberances 40 extending from the
reinforcing
structure 50 and adjacent to an area of essentially continuous deflection
conduits 70.
The discrete protuberances 40 are preferably circumscribed by the area of
essentially
continuous deflection conduits 70. In the embodiments shown in FIGS. 2-3C, the
region of essentially continuous deflection conduits 70 preferably defines an

CA 02461063 2004-04-06
essentially continuous web-facing network 51 * formed in the web-facing side
51 of
the reinforcing swcture ~0.
The term "essentially continuous" indicates that interruptions in absolute
gec:n~etrical continuity may be tolerable, while ~r~e -not preferred, as long
as these
interruptions do not adversely affect the performance of the belt 10 of the
present
invention. It should also be carefully noted that embodiments (not shown) are
possible in which interruptions in the absolute continuity of the framework 20
(in the
through-air drying belt 10b) or interruptions in the absolute continuity of
the
conduits 70 (in the forming belt 10a) are intended as a part of the overall
design of
the belt 10. These embodiments are not illustrated but can easily be
visualized by
combining the framework's pattern of the through-air drying belt lOb with the
framework's pattern of the forming belt 10a in such a way that some of the
areas of
the "combined" belt comprise the pattern of the through-air drying belt 10b,
while
the other pats of the same "combined" belt comprae the~attern of the forming
belt
10a. ~ '
As show- ~ in FIGs. 3-3C, the individual protuberances 40 may also have the
discrete deflection conduits 30 disposed therein anal extending fron< :he web-
side
surface 21 to th-° t-.ackside swface 22 of the framework 20. The
papermaking belt 10
having the frayeworic ?0 comprising the discrete protuberances 40 may
preferably
be' utilized as the,fo~mifig belt 10a. The papermaking belt 10 hav;rtg the
framework
20 comprising the discrete protuberances 40 is primarily disclosed in the
commonly
assigned U.S. Patent 4,245,025 issued Sep. 14, 1993 to Trokhan et al. and U.S.
Patent
5,527,428 issued Jun. 18, 1996 to Trokhan et al. Also, the papermaking belt 10
having
the discrete protuberances raised above the plane of the fabric may be made
according
to the European Patent Application 95105513.6, Publication No.: 0 677 612 A2,
filed
12.04.95, inventor Wendt et al.
The belt 10 is preferably air-permeable and liquid-pervious in at least one
direction, particularly the direction from the web-contacting side 11 to the
backside 12.
As used herein, the term "liquid-pervious" refers to the condition where a
liquid earner
of a fibrous slurry may be transmitted through the belt 10 without significant
obstruction. It is not, however, necessary, or even desired, that the entire
surface area
of the belt 10 be liquid-pervious. It is only necessary that the liquid
carrier be easily
removed from the slurry leaving on the web-contacting side 11 of the belt 10
an
embryonic web of the papermaking fibers.
The web-side surface 21 of the framework 20 defines the web-contacting side 11
of the papermaking belt 10; and the machine-facing surface 22 of the framework
20
defines the backside 12 of the papermaking belt 10. Therefore, it also could
be

CA 02461063 2004-04-06
12
said that the discrete deflection conduits 30 and the essentially continuous
deflection
conduits 70 extend intermediate the web-contacting side 11 of the belt 10 and
the
backside 12 of the belt 10. The discrete deflection conduits 30 (or simply
"conduits
30") and the essentially continuous conduits 70 (or simply "conduits 70")
channel
water from the web 60 which rests on the web-side surface 21 of the framework
20
to the backside surface 22 of the framework 20 and provide areas into which
the
fibers of the web 60 can be deflected and rearranged to form dome areas --
comprising either discrete domes 65 (FIG. 4) or "continuous domes" forming a
first
region 64* (FIG. 4D) in the web 60. As used herein, the term "domes" indicates
elements of the web 60 formed by the fibers deflected into the deflection
conduits
30, 70. The domes 65 generally correspond in geometry and -- during the
papermaking process -- in position to the deflection conduits 30, 70 during
the
papermaking process. By conforming to the deflection conduits 30, 70 during
the
papermaking process, the regions of the web 60 comprising the domes 65 are 1
deflected such that the domes 65 protrude outwardly and extend from the
general
plan of the web 60, thereby increasing a thickness. or caliper, of the web 60
in a Z-
direction. As used herein, the Z-~diection is orthogonal to the general plane
of the
web 60 and the belt 10, as illustrated in several Figures of the present
Application.
C ' ,bourse, if the papetmaking belt 10 having an~ rea of essentially cc'
nt:nuous
c~,lauits 70 is used, the domes 65 ofwthe Fw~ r web 60 wii: comprise an
essentially
continuous dome region 65.
Now referring to FIGS. 1-IC, the web-side surface 21 of the essentially
continuous resinous framework 20 defines the general plane of the belt 10, or
an X-
Y plane. Because the web-facing side 51 of the reinforcing swcture 50 is
generally
parallel to the web-side surface 21, the web-facing side S 1 may also be
viewed as
defining the X-Y plane. The Z-direction defined hereinabovc is therefore the
direction perpendicular to the X-Y plane. The web-side surface 21 .of the
framework
20 has a web-side network 21' formed therein. Likewise, the backside surface
22 of
the framework 20 has a backside network 22* formed therein Because the
ciscretc
conduits 30 extend between the web-side surface 21 and the backside surface 22
of
the framework 20, each of the ,:~screte conduits 30 has a pair of openings: a
web-
sidc opening 31 and a backside opening 32. The web-side network 21 * formed in
the web-side surface 21 defines the web-side openings 3'1 of the conduits 30;
and the
backside network 22~ formed in the backside surface 22 defines the backside
openings of the conduits 30.
Each discrete conduit 30 has walls 35 extending between the web-side surface
1 (or the web-side network 21 *) and the backside surface 22 (or the backside

CA 02461063 2004-04-06
13
network 22*). As will be shown below, the walls 35 of the same conduit 30 may
form different angles relative to the Z-direction. Each discrete conduit 30
has an
axis 33. As used herein, the "axis 33" of the conduit 30 is an imaginary
straight line
connecting the center C 1 of the web-side opening 31 and the center C2 of the
backside op~rrng 32. The center C 1 of the web-side opening 3I is a center of
an X-
Y area of the opening 31, i.e., a point of an X-Y plane of the opening 3I,
which
point coincides with the center of mass of a thin uniform distribution of
matter over
this X-Y plane o.' 'he opening 31. Analogously, the center C2 of the backside
opening 32 is the center of an X-Y area of the opening 32. One skilled in the
art will
readily recognize that if the opening 31 comprises a figure that is
bilaterally
symmetrical relative to an axis parallel to at least one of the X-Y
directions, then in a
Z-directional (i.e., vertical) cross-section perpendicular to that at least
one of the X-
Y directions, the center C 1 of the web-side opening 31 will be positioned in
the
middle of a web-side cross-sectiora..l dimension "d" of the web-ssde r~:ning
31
~GIGs. I A and I C). Likewise, if the opening 32 comprises a figure ai~at i::
'~ilaterally
5j mmetrical relative to an axis parall ~~ to at least one of the X-Y
directions, then in a
Z-directional cross-section perpendicular to that at least one of the X-Y
d:e:~tions,
the center C2 of the backside opening 32 will be positioned in the middle of a
,. ackside cross-~,eciional dimension "e" of .'.:P backside opening 32 (FIGS.
1 A and
1 C ). For example, in the embodiment she u~~n in FIGs. I -1 B, the web-side
opening
31 of the conduit 30 comprises a diamond-shape figure bilaterally symmetrical
relative to an axis "md" parallel to the machine direction MD. In the Z-
directional
cross-section perpendicular to MD (or, in other words, in the "vertical CD
cross-
scction" ) the center C 1 of the web-side opening 31 is positioned in the
middle of the
web-side CD cross-sectional dimension "d," as best shown in FIG. l A. The
backside opening 32 also comprise a diamond-like figure bilaterally
symmetrical
relative to an axis (not shown) parallel to MD. In the Z-directional cross-
section
perpendicular to MD (or, in the "vertical CD cross-section"), the center C2 of
the
barksidc opening 32 is positioned i,l chc middle of the backside CD cross-
sectional
dimension "e," as t:.st shown in FI(;. l B. The diamond-like openings 3 i and
32 of
the conduits shown in FIGs. I-IC are also bilaterally symmetrical relative ,,~
an axes
"cd" parallel to the cross-machine direction CD. Therefore, analogously to the
"d"
and "e" discussed hercabove, in the Z-directional cross-section perpendicular
to CD
(or in the "vertical MD cross-section"), the centers C 1 and C2 of the
openings 31
and 32, respectively, are positioned in the middle of their respective MD
cross-
sectional dimensions "d I " and "e 1 ", as illustrated in FIG. I B. h should
be carefully
noted that the web-side openings 31 need not be identical to the corresponding

CA 02461063 2004-04-06
14
backside openings 32, nor the web-side openings 3I need have the same general
shape (for example, circle, or diamond-like shape) as the backside opening 32.
According to the present invention, the web-side openings 31 are off set
relative lo the backside openings 32 within the X-Y plane and in at least one
direction which is perpendicular to the Z-direction. One skilled in the art
will
readily recognize that there are infinite directions perpendicular to the Z-
direction
(or "X-Y directions"), all of which are included in the scope of the present
invention.
However, for clarity and convenience of illustrating the present invention,
the
present invention is discussed primarily in the context of the mutually
perpendicular
machine direction MD and cross-machine direction CD.
In papermaking, the machine direction MD indicates that direction which is
parallel to the flow of the web 60 (and therefore the belt 10) through the
papermaking equipment. The cross-machine direction CD is perpendicular to the
machine direction MD and parallel to the geoeratl p~ar~e of the belt 10. Both
the ~
machine direction MD and the cross-machine direction CD can be viewed as
parallel
to the X-Y plane. Consequently, the Z-direction is perpendicular to both the
MD
and the CD.
FIGS. 1 A and '. C show that the web-side openings 3I are off set relative to
the
corresponding backside r~renings 32 in the cross-machine direction CD. In
FIGS.
1 A and 1 C a dimension ,.~ an off set is indicated by the symi~ol " . " As
used herr:;n,
the "off set" in the context of the conduit 30 or a protuberance means the
distance
between the center C 1 of the web-side opening 31 and the center C2 of the
backside
opening 32 measured in, or geometrically projected to, the X-Y plane. If the
web-
side opening 31 is off set relative to the backside opening 32 in a direction
other
than either the MD or the CD, it still may be convenient to define the off set
in the
MD and the CL',~as mutually perpendicular projections of a real dimension of
the
off set to the corresponding MD cross-section and CD cross-section,
respectively.
Therefore, as used herein, the "MD off set" indicates a projection of the
actual off
yet to the MD. I.i~-wise, the "CD off set" indicates a projection of the
actual off set
to the C D.
FIGs. 1-1 B and 1 C schematically show v,:.ious embodiments of the
papermaking belt 10 of the present invention, comprising the framework 20
which
has the discrete conduits 30 therein. 1n FIGS. 1-IB, the web-side openings 31
are
off set relative to the backside openings 32 in the cross-machine direction CD
(FIGs.
1 and IA). The dimension T and an angle Q formed between the axis 33 and the
Z-direction define the CD off set of the web-side opening 31 relative to the
backside
opening 32 of the conduit 30.

CA 02461063 2004-04-06
IS
if the web-side cross-sectional dimension "d" is equal to the backside cross-
sectional dimension "e" in a Z-directional (vertical) cross-section parallel
to one of
the X-Y directions, the opposing wails 35 of the conduit 30 are mutually
parallel in
that X-Y direction, and the conduit 30 is sai<: to be non-tapered in that X-Y
direction. Conversely, if the web-side cross-sectional dimension "d" is not
equal to
the backside cross-sectional dimension "e" in a Z-directional cross-section
parallel to
one of the X-Y directions, the opposing walls 35 are not mutually parallel in
that X-
Y direction, and the conduit 30 is said to ~ tapered relative to the axis 33
in that X-
Y direction. If the web-side cross-sectional dimension "d" is greater than the
backside cross-sectional dimension "e" in a Z-directional cross-section
parallel to
one of the X-Y directions, the conduit 30 is negatively tapered in that X-Y-
direction.
Conversely, if the backside cross-sectional dimension "e" is greater than the
web-
side cross-sectional dimension "d" in a Z-directional cross-section parallel
to one of
the X-Y directions, the conduit 30 is positively tapered in shat X-Y
direction. For
example, assuming tha~ v~ FIG. IA, the web-side CD cross-sectional dimension
"d"
is greater than the backside CD cross-sectional dimension "e,' the conduit 34
shown
an FIG. IA is negatively tapered in CD. Analogously, the same conduit 30 shown
in
FIG. I B is negatively tapered in the MD if dl>d2.
While it is nc, necessary, y ~s preferred that the discrete. .conduits 30 be
nrgativP~y tapered in both the machine direction MD and t ~~ cross-machine
direction CD. It should be carefully noted that while the embodiment
illustrated in
FIGS. 1-1 C comprises the framework 20 having the discrete conduits 30 which
are
tapered in both the mutually perpendicular MD.and CD, an embodiment is
possible,
in which the discrete conduits 30 arc tapered only in one of the MD or CD.
This
embodiment can easily be visualized by one skilled in the art by assuming that
the
dimensions "d" and "c" in FIG. 1 A are equal, and the dim ~usions "d 1 " and
"e 1 " in
FIG. l B are not equal (l. e., d=e, and d 1 >e 1 ). Then, the discrete
conduits 30 will be
tapered in the MD (FIG. 1 B) and non-tapered in the CD (FIG. 1 A). An
embodiment
(not shown) is also pos.~~ble, while not preferred, in wt»h the conduits 30
are
negatively .,:pored in one of the X-Y directions, and are ~;rsitively tapered
in the
other of the X-Y directions.
Another way of defining the tapered conduits 30 is illustrated in FIG. 1 C. In
FIG. 1 C, the Z-direction and the axis 33 of the conduit 30 form the angle Q
therebetween. The web-side CD cmss-sectional dimension "d" is greater than the
backside CD cross-sectional dimension "e." Therefore, an angle Q1 formed in
the
CD cross-section between the Z-direction and a wall 35a of the conduit 30 is
greater

CA 02461063 2004-04-06
16
than an angle Q2 formed in the CD cross-section between the Z-direction and a
wall
35b of the conduit 30, opposite to the wall 35a in the cross-section.
FIGS. ?-3C illustrate other embodiments of the papermaking belt 10 of the
present invention. In the c~~bodiments shown in FIGs. 2-3C, the resinous
framework 20 of the belt 10 comprises a plurality of discrete protuberances
40,
preferably forming a patterned array. The plurality of protuberances 40 is
joined to
the reinforcing structure 50 and preferably comprises individual protuberances
40
joined to and extending outwardly from the web-facing side 51 of the
reinforcing
structure 50. In the embodiments illustrated in FIGs. 2-3C, the Web-facing
side 51
of the reinforcing structure defines the X-Y plane. Each protuberance 40 has a
top
surface 41, a base surface 42 opposite the top surface 41, and walls 45
spacing apart
and interconnecting the top surface 41 and the base surface 42. The plurality
of the
top surfaces 41 define the web-side surface 2 l of the framework 20; and the
plurality
of the base surfaces 42 define the backsitie surface 22 of the framework 1~.~.
.~~ s illustrated in FIGS. ? and 2A, the t lurality of protuberances 40 are
arranged
such that the protuberances 40 are preferably encompassed by and adjacent to
the
area of essentially continuous conduits 70 which extends from the top surfaces
~,' of
the protuberances a~ to the wcb-facing side ~ l of the reinforcing structure
S0. As
use ; '~etein, the ' yea of essentially continuous ~ :~r: suits 70" defines an
area between
the adjacent protuberances 40 into which the fibers of the web 60 can deflect
during
the psprrmaking process according to the present invention. The area of
essentially
continuous conduits 70 has a defined flow resistance which is dependent
primarily
upon the pattern, size. and spacing of the individual protuberances and of the
reinforcing sttvcttue 50. In the preferred embodiment. each protuberance 40 is
substantially equally spaced from the adjacent protuberance 40, providing an
rsscntially continuous conduit 70 prel;.rably having substantially uniform
flow
rcsistancc characteristics. If desired, the protuberances 40 may be clustered
together
so that one or more protuberances 40 is unequally spaced from an adjacent
protub ~~ance 40.
The web-facing side 51 of the reinforcing structure 50 has an essentially
continuous web-facing network 51' formed therein and defined by the ama of
essentially continuous conduits 70. Preferably, the protuberances 40 are
distributed
in a non-random rcpcating pattern so that the fibers deposited onto the
essentially
continuous web-facing network 51 * around and between the protuberances 40 are
distributed more uniformly throughout the web-facing network 51'. More
preferably, the protuberances 40 are bilaterally staggered in an array.

CA 02461063 2004-04-06
17
The belt 10 of the present invention is essentially macroscopically
monoplanar. As used herein, the requirement that the belt 10 is "essentially
macroscopically monoplanar" refers to the overall geometry of the belt 10 when
it is
placed in a two-dimensional configuration and has, as a whole, only...~inor
and
tolerable deviations from the absolute planarity, which deviations do not
adversely
affect the belt's performance. The possible pre-determined differences in
height
among the protuberances 40 are considered minor relative to the overall
dimensions
of the belt 10 and do not affect the belt 10 being macroscopically
.nvnoplanar.
Each protuberance 40 has an axis 43. Analogously to the axis 33 of the
discrete conduit 30 defined in great detail above, the axis 43 of the
individual
protuberance 40 is an imaginary straight line connecting a center PI of the
top
surface 41 and a center P2 of the base surface 42 (FIG. 2A). The center P1 of
the
top surface 41 is a center of the top surface 41, i.e., a point of the top
surface 41,
whi~~ point would coincide with the center of mass of a thin uniform
distribution c~i
ma:w.:r over this top surface 41. Analogously, t!~~ center P2 of the base
surface 42 is
a center of the base surface 42. By analogy wiui the discrete conduits 30, if
the toh
surface -'-I comprises t figure that is bilaterally symmetrical relative to an
axis (not
shogun) parallel to at least one of the X-Y directions, then in a Z-
directional (i.e.,
vertical) cross-section perpendicular to that '':-'direction. ~t;a top surface
center P1
will be pc~sition:v:d ~n the middle of a cross-sectional dimension "f' of the
area of the
top surface 41, as shown in FIG. 2. Likewise, if the base surface 42 comprises
a
figure that is bilatecally symmetrical relative to an axis (not shown)
parallel to at
least one of the X-Y directions. in a Z-directional cross-section
perpendicular to that
X-Y direction, the base surface center P2 will be positioned in the middle of
a cross-
sectional dimension "g" of the arrea of the base surface 42.
In accordance with the present invention, the Z-direction and the axes 43 of .
i
least some of the protuberances 40 form an acute angle S therebetween, as
shown in
FIG 2A. The top surfaces 41 of at least some of the protuberances are off set
relative to the corresponding base surfaces 42 of ~he same protuberances
within th°-
X-Y plane and in at (east one direct:-~n which is perpendicular to th;, Z-
direction.
in FIGs. 2 and 2A, the top surfaces 41 arc off set relative to the base
surfaces
42 in the cross-machine direction CD. An X-Y distance "V" between the top
surface
center P I and the base surface center P2, and an angle S formed between the
axis 43
and the Z-direction define the off set of the top surface 41 relative to the
base
surface 42.
If the top surface cross-sectional dimension "f" is equal to the base surface
cross-sectional dimension "g" in a Z-directional (vertical) cross-section
parallel to

CA 02461063 2004-04-06
18
one of the X-Y directions, the opposing walls 45 are mutually parallel, and
the
protuberance 40 is non-capered in that X-Y direction. Conversely, if the top
surface
cross-sectional dimension "f' is not equal to the base surface cross-sectional
dimension "g" in a Z-directional cross-section parallel r~ one of the X-Y
directions,
the opposing walls 4~ are not mutually parallel in that X-Y direction. and the
protuberance 40 is tapered relative to the axis 43 in that X-Y direction. If
the top
surface cross-sectional dimension "f' is smaller than the base surface cross-
sectional
dimension "g" in a Z-directional cross-section parallel to one of the X-Y
directions,
the protuberance 40 is positively tapered in that X-Y direction. If the top
surface
cross-sectional dimension "f is greater than the base surface cross-sectional
dimension "g" in a Z-directional cross-section parallel to one of the X-Y
directions,
the protuberance 40 is negatively tapered in that X-Y direction. For example,
assuming that in FIG. ''A, the top surface cross-sectional CD dimension "f is
smaller than the base surface cross-sectional CD dimension "g,' the
protuberances
-i0 shown in F1G. 2A are positively tapered in CD.
While it is not necessary, it is preferred that if the framework '?0
comprising
the tapered discrete protuberances 40 is to be utilized the discrete
protuberances 40
be positively tapered in both the machine direction MD and t~.: cross-machine
direction CD. Howeve- he embou..~ent is possible, in which l'... ' discrete
protubcrancr~ 40 arc tapered only in one of the MD and CD.
Referring now to Fits. 3 and 3A, the plurality of discrete protuberances 40
may have a plurality of discrete deflection conduits 30 therein. The discrete
deflection conduits 30 extend firom the web-side surface 2 l to the backside
surface
~~ of the framework 20, or, in other words, from the top surfaces 41 to the
base
surfaces 42 of the protuberances 40, because, as has been explained
hereinabove,
the plurality of top surfaces 41 form the web-side surface ~1 of the resinous
framework 20, and the plurality of base surfaces 42 form the backside surface
22 of
the framework 20. Preferably, each individual protuberance 40 has one discrete
conduit 30 exter.~'ng from the t~~p surface 41 to the base surface ~~'.
As has been described hereinabove, each discrete conduit 30 has the web-side
opening 31 and the backside opening 32. The web-side openings 31 are
preferably
off set relative to the corresponding backside openings 32 in one of the X-Y
direction. In the belt 10 of the present invention, having the framework 20
comprising the discrete protuberances 40 which have the discrete conduits 30
therein, the off sets of the protuberances 40 are preferably, while not
necessarily,
coincidental with the off sets of the conduits 30 disposed in the
corresponding
protuberances 44. As shown in FIG. 3A, the axes 33 of the discrete conduits 30
are

CA 02461063 2004-04-06
19
preferably coincidental with the axes 43 of the protuberances 40, and the
angles Q
formed by the axes 33 and the Z-direction are preferably equal to the
corresponding
angles. S formed by the axes 43 and the Z-direction. In FIG. 3A, the
protuberances
40 are positively tapered, and the discrete conduits 30 disposed in the
protuberances
40 are negatively tapered.
An embodiment (not shown) is possible. although not preferred, in which the
axis 33 of the discrete conduit 30 is not coincidental with the axis 43 of the
protuberance 40, and the angle Q formed by the axis 33 and the Z-direction is
not
equal to the angle S formed by the axis 43 and the Z-direction. The respective
off
sets of the protuberance 40 and the discrete conduit 30 may not be equal in
the latter
case.
The flow resistance of the discrete conduits 30 through the protuberance 40 is
different from, and typically greater than, the flow resistance of the
essentially
continuous conduits 7th berri-°en adjacent protuberances 40. Therefore,
when the
belt 10 having both tl~e dis~:;ete conduits 30 and the essentially
contim::.~:~s conduits
70 is utilized as a forming belt 10a, typically more of the liquid carrier
will drain
through the continuous conou~ s 70 than ttu~vgh the discrete conduits 30, and
consequently. relatively more fibers will be deposited onto the areas of the
-einforcing structure 50 which arc subjacent to the continuous cond~.itw 70
(i.e.. tl~~
web-facing network 51 * ) than onto the .~i :as of the re;:~forcing structure
SO which
are subjacent to the discrete conduits 30.
The essentially continuous conduits 70 and the discrete conduits 30,
respectively, define high flow rate and low flow rate zones in the belt 10.
The initial
mass flow rate of the liquid carrier through the continuous conduits 70 is
preferably
greater than the initial mass flow rate of the liquid carrier through the
discrete
conduits 30.
It should be recognized that no liquid carrier will flow through the
protuberances 40, because the protuberances 40 are impervious to the liquid
carrier.
However, depending upon the elevation of the top surface 41 of the pre:
tberances
40 relative to the web-facing side S l of the reinforcing struc:ure 50 and the
length of
the cellulosic fibers, cellulostc fibers may be deposited on the top surfaces
41 of the
protuberances 40.
As used herein, the "initial mass flow rate" refers to the flow rate of the
liquid
carrier when the liquid carrier is first introduced to and deposited upon the
forming
belt 10a. Of course, it will be recognized that both flow rate zones will
decrease in
mass flow rate as a function of time as the discrete conduits 30 or the
essentially
continuous conduits 70 become obturated with cellulosic fibers suspended in
the

CA 02461063 2004-04-06
liquid carrier and retained by the belt 10a. The difference in flow resistance
between
the discrete conduits 30 and the continuous conduits 70 provides a means for
retaining different basis weights of cellulosic fibers in a pattern in the
different zones
of the belt 1 Oa.
This difference in flow rates through the zones is referred to as "staged
draining," in recognition that a step discontinuity exists between the initial
flow rate
of'the liquid carrier through the high flow rate zones and the low flow rate
zones.
The more detailed description of the staged draining and its benefits may be
found in
the commonly assigned U.S. Patent 5,245,025 referenced above.
The papermaking belt 10 of the present invention maybe made according to
the method comprising the following steps.
First, an apparatus for generating curing radiation should be.provided. One
err~t;odi.rc~nt of the apparatus for generating curing radiation is an
apparatus 80 for
generating curing Tadiation R in at least a first radi:,tlr.g direction U 1.
The apparatus
80 schematically shown in FIG. 5 comprises two primary elements: an elongate
reflector g? and an elonga:e source of radiation 85. Several embodiments of
the
apparatus 80 for generating curing radiation R are disclosed sn the commonly
assigned co-pending Application entitled "Apparatus for Generating Controlled
Radiation for Curing Photosensitive Resin" filed in the name of Trokhan on the
same date as the present application.
Then, a liquid photosensitive resin should be provided. The suitable
photosensitive resin is disclosed in the commonly assigned U.S. Patent
5,514,523,
issued on Dec. 20, 1993 to P.D. Trokhan et al.
The next step is providing a forming unit 87 having a working surface 88.
The forming unit 87 should be capable of receiving the liquid photosensitive
resin.
The next step is providing the air-permeable reinforcing structure 50
described
hereinabove. If the preferred papermaking belt 10 is to be manufactured in the
form
of endless belt, the reinforcing structure 50 should also be an endless belt.
It should
be noted that the step of providing the reinforcing structure 50 is necessary
for the belt
10 having the framework 20 which is comprised of the plurality of discrete
protuberances 40. In the case of manufacturing the belt 10 comprising the
essentially
continuous framework 20, the reinforcing structure 50 is not necessary,
although highly
preferred.

CA 02461063 2004-04-06
21
if the reinforcing structure 50 is to be utilized, the next steps are bringing
at
least a portion of the machine-facing side 52 of the reinforcing structure 50
into
contact with the working surface 88 of the forming unit 80, and applying a
coating
o' i'te liquid photosensitive resin to at least the web-facing side 51 of the
reinforcing
structure 50. The coating has a pre-selected thickness, and after the coating
is
applied to the reinforcing structure 50, the coating forms a first surface ~
25 and a
second surface 27 opposite the first surface' 25. After the process of curing
is
complete, the first surface 25 will form the web-side surface 21 of the
framework 20,
and the second surface ?7 will form the backside surface 22 of the framework
20.
The steps of bringing a ponion of the machine-facing side 52 of the
reinforcing
structure 50 into contact with the working surface 88 and applying a coating
of the
resin to the web-facing side 51 of the reinforcing structure 50 are described
in
greater detail in the above-mentioned patent 5,514,523.
if the.reinforcing swcture 50 is nr;; to be i:~ilized, the liquid
photosensitive
resin may simply be disposed in the forming unit o I thereby forming a coating
of the
resin of a pr,-selected thickness, the coating having the first surface 25 and
the
second surface 27 opposite the first surface 25.
After th~~ r oaring of the liquid photosensitive resin has been formed (with
or
without the reinfor;:ir:g structwe 50), the next step is disposing the forming
unit .87
containing the co,~ti-:g of the liquid photosensitive resin. in the first
r~~.,'iating
direction U 1 such that the first surface 25 of the coating and the first
radiating
direction U 1 form an acute angle W therebetween. This step may be
accomplished
by positioning the coating of the resin as schematically shown in FIG. 5A. If
desired, the angle of incidence of the curing radiation may be parallel to the
axis
through the collimator 90 (FIGs. 5 and SA).
The c:~:ical point is that the resin coating is maintained in acute angular
relationship with the direction of the radiation during the curing process.
The
angular relationship may be accomplished by adjusting either the position of
the
resin or the ~firection of the radiation, so that perpendicularity is avoided
and arr
acute angle ootained.
Alternatively or additionally, this step may be accomplished by utilizing an
apparatus of controlled radiation 80* schematically shown in FIG. 5B.
The apparatus of controlled radiation 80* schematically shown in FIG. 5B
comprises
three sections 82: 82a, 82b, 82c. The section 82b is movably

CA 02461063 2004-04-06
77
connected to the section 82a, and the section 82c is movably connected to the
section 82b. Each section 82 (82a, 82b, 82c) comprises a plurality of
reflective
facets ~ 83 (83a, 83b, 83c, respectively). Each individual reflective facet 83
is
independently adjustable in the cross-section. The source of radiation 85 is
movable
in the cross-section.
The combination of independent adjustability of the individual reflective
facets
83 and the independent adjustability of the individual sections 82 combined
with the
movability of the source of radiation 85 allows to direct the curing radiation
generated by the apparatus 80* in at least one pre-determined radiating
direction in
the cross-section. In FIG. 5B, the apparatus 80* directs the curing radiation
in the
first radiating direction Ul, a second radiating direction U2, and a third
radiating
direction U3.
F1G. SC shows another embodiment of the apparatus of controlled radiation
8U*. The apparatus 89 snow;: xn FIG. SC comprises several sources of
radiation,
preferably bulbs, 85. Each bulb 85 has its longitudinal direction ~s: entially
perpendicular to the machine direction MD. Each bulb 85 has its own
collimating
element 90 disposed between thu ~,rlb 85 and the photosensitive resin being
cured.
The collimating elements 90 are disposed such that the curing radiation
emitted by
ev::;: bulb has its own predetermined direction (U1, U2, U3, as schemat:wa~iy
shown
inn r 1G. SC). Subtractive walls 89 arc p.-°F~~.rably ~provien d to
restrict the mutual
interference between the portions of the curing radiation having different
directions
U1. U'_. U~.
The embodiments of the apparatus 80* shown in FIGS. 5B and SC
prophetically produce the belts 10 having sophisticated three-dimensional
designs of
the resinous framework 20. In FIGS. 5B and SC, for example, the resin being
cured
by the apparatus 80* will form the framework 20 having three zones H 1, H2,
and H3
distinguished by relative "angled" orientations of the discrete conduits 30
(or the
discrete protuberances 40 in the case of the forming belt 10a).
The next sttp is providing a mask 96 having opa;,:~e regions 'mesa and
transparent regions 96b. The purpose of the mask is to shield certain areas of
the
liquid photosensitive resin fro~:~ exposure to the curing radiation R so that
these
shielded areas will not be cured, i.e., will remain fluid, and will be removed
after
curing is completed. The unshielded areas of the liquid photosensitive resin
will be
exposed to the curing radiation R to form the hardened framework 20. The
opaque
regions 96a and the transparent regions 96b define a pre-selected pattern
corresponding to a specific desired design of the resinous framework 20. If,
for
example, the belt 10 having a substantially continuous resinous framework 20
is to

CA 02461063 2004-04-06
23
be produced, the transparent regions 96b must form a continuous area generally
corresponding to the X-Y plane of the desired web-side network 21 * of the
framework 20.
The next step is positioning the mask 96 between the first surface 25 of the
resin coating and the apparatus 80 such that the mask 96 is preferably in
adjacent
relation with the first surface 25. The opaque regions 96a of the mask shield
a
portion of the coating from the curing radiation R, and the transparent
regions 96b
leave the other port»ns of the coating unshielded for the curing radiation R.
The next step is curing of the unshielded portions of the coating by exposing
the coating to the curing radiation R having an activating wavelength from the
apparatus 80 through the mask 96 to form a partially-formed belt, and leaving
the
shielded portions of the coating uncured.
The final step is removing substantially all uncured liquid photosensitive
resin
from the partially-formed belt to leave a hardened resinous structurF . This '-
.3rdened
r~: ~s nous structure forms a framework 20 having a web-side surface . l
fon:.~d by the
first surface 25 being cured. and a bac=aide surface 22 formed by the second
surface
'_'7 being cured.
In the case of the belt 10 comprising a continuous framework 20, the
n unework ~_~1 '-as a plurality of discrete r.,,.~duits 30 in the regions
which were
shielded from the curing radiation R by the ~sr°~.lue regions 96a of
the mask 96. The
discrete conduits 30 extend between the web-side surface 22 (or the cured
first
surface '_'S) and the backside surface 27 (or the cured second surface 27),
each of the
conduits 30 having the axis 33 and the walls 35, the axes of at least some of
the
conduits and the Z-direction forming an acute angles therebetween, as has been
described in gt-eater detail above.
!n the case of the belt 10 hay il~g the framework 20 comprising the plurality
of discrete protuberances 40, the plurality of discrete protuberances 40
extends from
the reinforcing structure 50, each of the protuberances having the axis 43,
the base
sur~':ece 42, the top surface 41, and thr ~ galls 45 spacing apart and
interconnecting the
base surface 41 and .he top surface ~:::. The plurality of the top surfaces 41
define
the web-side surface 21 of the resinous framework 20, and the pluralit a of
base
surfaces 42 define the backside surface 22 of the resinous framework 20. The
axes
43 of at least some of the protuberances 40 and the Z-direction fotTrt acute
angles
therebetwecn, as has been described in greater detail above.
The papetmaking process which utilizes the papermaking belt 10 of the
present invention is dexribed below, although it is contemplated that other
processes utilizing the belt 10 may also be used. By way of background it
should be

CA 02461063 2004-04-06
24
appreciated that the belt 10 comprising the resinous framework 20 which is
substantially continuous is primarily utilized as a through-air drying bell l
Ob, while
the belt 10 comprising the framework 20 in the form of the plurality of
discrete
protube.Ances 40 is primarily utilized as a forming wire 10a, as schematically
illustrated in FIG. 6. It does not exclude, however, the alternative uses, i.
e., that the
belt 10 comprising the substantially continuous resinous framework 20 may be
used
as a forming belt 10a, and the belt 10 comprising the resinous framework 20 in
the
term of the plurality of discrete protuberances 40 may be used as a through-
air
drying belt l Ob. '
The overall papermaking process which uses the papermaking belt 10 of the
present invention comprises a number of steps or operations which occur in the
general sequence as noted below. It is to be understood, however, that the
steps
described below are intended to assist a reader in understanding the process
of the
present invention, and that the invention is not imiied to processes with only
a
certain number or u-rangement of steps. In This regard, it is noted that it is
possible
to combine at least some of the following steps so that they are performed
concurrently. Likewise, it is possible to separate at least some of the
following steps
-into two or more steh~ without departing from the scope of this invention.
,
FIG. 6 is a simpiifla.~d. schematic representation of one embodiment of a
continuous papermaking machine useful in the practice of the pap~Trraaking
proeess
of the present invention. As has been defined above, the papermaking belt 10
of the
present invention includes the forming belt 10a and the through-air drying
belt 10b,
both shown in the preferred form of endless belts in FIG. 6.
The first step is to provide a plurality of cellulosic fibers entrained in a
liquid
carrier, or, in other words, an aqueous dispersion of papermaking fibers. The
cellulosic fibers azc not dissolved in the liquid carrier, but merely
suspended therein.
The equipment for preparing the aqueous dispersion of papermaking fibers is
well-
known in the papermaking art and is therefore not shown in FIG. 6. The aqueous
d'~spersioa of pap~nnaking fibers is provided to a headbox 15. A single
headbox is
shown in FIG. 6. However, it is to be understood that there may be multiple
hcadboxes in alternative arrangements of the papermaicing process of the
present ,
invention. The headbox(es) and the equipment for preparing the aqueous
dispersion
of papermaking fibers arc preferably of the type disclosed in U.S. Patent No.
3,994,771, issued to Morgan and Rich on November 30, 1976. The preparation of
the
aqueous dispersion and the characteristics of the aqueous dispersion are
described in
greater detail in U.S. Patent

CA 02461063 2004-04-06
4,529,480 issued to Trokhan on July 16, 1985.
The aqueous dispersion of papermaking fibers supplied by the headbox 15 is
delivered to a forming belt. such as the forming belt '.0a of the;gresent
invention, for
carrying out i:fie second step of the papermaking process. The forming belt
IOa is
supponed by a breast roll 18a and a plurality of return rolls designated as
18b and
18c. The forming wire 10a is propelled in the direction indicated by the
directional
arrow A by a conventional drive means v~ell known to one skilled in the art
and
therefore not shown in FIG 6. There may also be associated with the
papermaking
machine shown in FIG. 6 optional auxiliary units and.devices which are
commonly
associated with papetmaking machines and with forming belts, including:
forming
boards, hydrofoils, vacuum boxes, tension rolls, support rolls, wire cleaning
showers, and the like, which are conventional and well-known in the
papermaking
art . and therefore also not shown in F1G. 6.
--T; ~ ;
The preferred forn-~_ng belt 10a is the macroscopically monoplanar belt
comprising the air-permeable reinforcing structure 50 and the resinous
Cramework
~~ joined to the reinforcing structure 50. As has been described above, the
,,,
reinforcing sweture 50 has the web-facing side 51 and the ma~civ.ine-facing
side 53
opposite the machine-fac~.~g side S 1. T !;e web-facing side 51 def nes he X-Y
plane
of the for~-ring belt 10, this X-Y plane being _perpendicular to the Z -
d:;ection. The
framework 20 is comprised of the plurality of discrete protuberances 40 joined
to
and extending from the reinforcing structure 50. Each of the protuberances 40
has
the top surface 41, the base surface 42, the walls 45 spacing apart and
interconnecting the top surface 41 and the base surface 42, and the axis 43
connecting the center of the top surface 41 and the center of the base surface
42.
The plurality of top surfaces 42 define the web-side surface ?'., and the
plurality of
base surfaces 42 define the backside surface 22 of the framework 20. In
accordance
with the present invention, the axes 43 of at least some of the protuberances
40 and
the Z-direction form acute angles S therebetween.
If the fuming belt 10a has the area of essentially contt~~~ous conduits 70 and
the plurality of discrete deflection conduits 30 disposed in the protuberances
40, the
belt 10a has high flow rate liquid pervious zones and low flow rate liquid
pervious
zones respectively defined by the essentially continuous deflection conduits
70 and
the discrete conduits 30. The liquid carrier and entrained cellulosic fibers
are
deposited onto the forming belt 10a illustrated in Figure 6. The liquid
carrier is
drained through the forming belt 10a in two simultaneous stages, a high flow
rate
stage and a low flow rate stage. 1n the high flow rate stage, the liquid
carrier drains

CA 02461063 2004-04-06
26
through the liquid pervious high flow rate zones at a given initial flow rate
until
obturation occurs (or the, liquid carrier is no longer introduced to this
portion of the
forming-belt 10). In the low flow rate stage, the liquid carrier drains
through low
flow rate zones of the forming b~.lt l0a at a given initial flow rate which is
less than
the initial flow rate through the high flow rate zones.
As has been noted above, the high flow rate liquid pervious zones and the low
flow rate liquid pervious zones in the belt l0a decrease as a function of
time, due to
expected obturation of uoth zones. It is believed that the low flow rate zones
may
obturate before the high flow rate zones obturate.
Without being bound by theory, the Applicant believes that the first occurring
zone obturation may be due to the lesser hydraulic radius and greater flow
resistance
of such zones, based upon factors such as the flow area, wetted perimeter,
shape and
distribution of the tow flow rate zones, or may be due to a greater flow rate
through
such zone accompanied by a greater depiction of fibers. The low fl~ ~ N ratf
z. ones
may, t~~r example, comprise discrete conduits 30 through the protuberances 40,
which discrete conduits 30 have a greater flow resistance than the essentially
continuous conduits 70 between adjacent protuberances 40. It is important tha'
the
ratio of the flow resistances between the ;'iscrete conduits 30 and the
essentially
continuous conduits 70 be properly proportioned. The flow resistance of the
discrete
conduits 30 and the essentially continuous cond~iis~70 may be determined by
using
the hydraulic radius, as described in the commonly assigned U.S. Patent
5,527,428
referenced above.
The next steps arc depositing the plurality of cellulosic papemnaking fibers
suspended in a liquid carrier on the fomling belt l0a and draining the liquid
carrier
through the forming belt thereby forming an embryonic web 60 of the
papermaking
fibers on the forming belt 10a. As used herein, the "embryonic web" is the web
of
fibers which is subjected to rearrangement on the forming belt, and,
preferably the
forming heft l0a of the present invention, during the course of the
papermaking
proccs;_ The charactc~stics of the en,t,~yonic web 60 and the various possible
_
techniques for forming the embryonic web 60 are described in the commonly
assigned U.S. Patent 4,529,480. In the process shown in FIG. 6, the embryonic
web 60
is formed from the cellulosic fibers suspended in a liquid earner between
breast roll
18a and return roll 18b by depositing the cellulosic fibers suspended in a
liquid carrier
onto the forming wire 1 Oa and removing a portion of the liquid carrier
through the belt
10a. Conventional vacuum boxes, forming boards, hydrofoils, and the like which
are
not shown in FIG. 6 are useful in effecting the removal of liquid carrier.

CA 02461063 2004-04-06
27
The embryonic web 60 formed on the forming belt l0a of the present
invention and shown in FIG. 4D has a first side 61 * and a second side 62*
opposite
the first side 61 *. The first side 61 * is that side which is associated with
the web-
contacting surface I 1 of the belt 10a. When the belt 10 of the present it
~~:ntion is
utilized as the forming belt 10a, the embryonic web 60 shown in FIG. 4D
comprises
a macroscopically planar and patterned first region 64* (corresponding to the
area of
essentially continuous conduits 70) preferably having a relatively high basis
weight,
and a second region 65* (corresponding to the area of discrete ~rotuber~artces
40)
preferably having a relatively low basis weight. The first region 64*
comprises an~
essentially continuous network; and the second region 65* comprises a
plurality of
discrete "angled" knuckles 65* extending from the first region 64* in at least
one
direction. This at least one direction (defined by an imaginary axis 63* of a
knuckle
of the second region 65) and the Z-direction form an acute angle L
therebetween
~corr:~t~onding to the acute angles S formed between the Z-direction and the
axes 4"
of t~:_ conduits 40). The second region 65* is ~i-cumscribed by and adjacent
to the
first region 64*. The second region 65* compnsing the discrete angled knuckles
having. a low basis w a ght preferably occur in a non-random repeating pattern
corresponding to the pattern of the plurality of discrete protuberances 40 of
the
forming belt 10a.
1 f the fo~ ~~: ig belt I Oa has the essentially continuous conduits 70 and
the
~iiscrrtr conduits 30, the embryonic web 60 may comprise a third region 66*
pret~rably having an intermediate basis weight relative to the basis weight of
the
first region 64* and the basis weight of the second region 65*. The third
region 66*
cx:curs in a preferred non-random repeating pattern substantially
corresponding to
the low flow rate cones, i. e., the zones of the discrete conduits 30. The
third region
66* is juxtaposed with, and preferably circumscribed by, the second region
65*.
After the embryonic web 60 is formed, the embryonic web 60 travels with
the foaming wire l0a in the direction indicated by the directional arrow A
(FIG. 6) to
be brought into the proximity of the through-air drying belt lOb. The
preferred
through-air belt lOb is described in great detail hercinabove. Tht through-air
belt
IOb as a macroscopically monoplanar papermaking belt comprising the resinous
framework 20 having the web-side surface 21 defining the X-Y plane, the
backside
surface 22 opposite the web-side surface 21, the Z-direction perpendicular to
the X-
Y plane, and the plurality of discrete deflection conduits 30 extending
between the
web-side surface 21 and the backside surface 22. Each of the conduits 30 has
the
axis 33 and the walls 35. In accordance with the present invention, the axes
33 of at

CA 02461063 2004-04-06
70
least some of the conduits 30 and the Z-direction form the acute angles Q
therebetween.
The next steps are depositing the embryonic web 60 to the web-side surface 21
of the resinous framework 20 of the through-air dryin~ tell l Ob and applying
a fluid
pressure differential to the embryonic web 60 to deflect at least a portion of
the
papermaking fibers into the discrete deflection conduits 30 and to remove
water
from the embryonic web 60 into the discrete deflection conduits 30 thereby
forming
an intermediate web 60.
In the embodiment illustrated in F1G. 6, the through-air drying belt l Ob of
the
present invention travels in the direction indicated by. directional arrow B.
The belt
l Ob passes around the return rolls 19c, 19d, impression nip roll 19e, return
rolls 19a,
and 19b. An emulsion distributing roll 19f distributes an emulsion onto the
through-
air drying belt lOb from an emulsion bath. The loop around which the through-
air
drying belt l Ob of the present invention travels also includes a means for
applying a
fluid pressure differential to ti:e web 60. which means in the preferred
embodiment
of the present invention comprises vacuum pick-up shoe 17a and n vacuum box
17b.
The :.pop may also include a pre-dryer (not shown). In addition, water showers
(not
shown) may preferably be utilized in the papermaking process of the present
invention to clean the thrc ~y~;-ar dryinb ' -it l Ob of any paper fibers, a
t.n. lives, and
,he like, wh'th may remain attached to the through-air drying belt 1 G: ..rter
it has
fravcled through the final step of the papermaking process. Associated with
the
through-air drying belt lOb of the present invention, and also not shown in
FIG. 6,
are various additional support rolls, return rolls, cleaning means. drive
means, and
the like commonly used in papcrmaking machines and all well known to those
skilled in the art.
When the through-air drying belt lOb of the present invention is utilized in
the papcrmaking process, the intermediate web 60 shown in FIGs. 4-4C comprises
a
macroscopically monoplanar, patterned, and essentially continuous network
region
64 preferably h~~~ing rclativ~.i ~ high density and a domes n.a;:on 65
preferably
having relatively low density. The domes region 65 comprises a plurality of
discrete
domes 65, or 65a, 65b, 65c, protruding from, circumscribed by, and adjacent to
the
network region 63. Each of the domes 65 has an axis 63. The axes 63 of at
least
some of the domes 65 and the Z-direction form acute angles K (FIG. 4B) and
acute
angles M 1 and M3 (FIG. 4C) therebetween.
The papermaking process of the present invention may also include an
optional step of pre-drying the intermediate web 60 to form a pre-dried web
60. Any
convenient means conventionally known in the papermaking art can be used to
dry

CA 02461063 2004-04-06
29
the intermediate web 60. For example, flow-through dryers, non-thermal,
capillary
dewatering devices, and Yankee dryers, alone and in combination, are
satisfactory.
The next step in the papertnaking process is impressing the web-side network
1 * of the resinous framework 20 into the pre-dried web 60 by interposing the
predried web 60 between the belt 10 and an impression surface to form an
imprinted
web 60 of papermaking fibers. If the intermediate web 60 is not subjected to
the
optional pre-drying step, this step is performed on the intermediate web 60.
The step of impressing is carried out in the machine illustrated in FIG. 6
when
the pre-dried (or intermediate) web 60 passes through the nip formed between
the
impression nip roll 19e and the Yankee drier drum 14. As the predried web 60
passes through this nip, the network pattern formed on the web-side network 21
* of
the framework 20 is impressed into the pre-dried web 60 to form an imprinted
web
60.
The next step n~ u'ie prparmaking process is drying the imprinted web 60. As
the imprinted web 6U separates from the belt 10, it is adhered to tf:~ surface
of
~'anl:ee dryer drum 14 where it is dried to a consistency of at least about
95% to
form a dried web 60.
The next step in the papermaking process is an optional, and highly preferred,
. tep of foreshortening the dried web 60. As used herein, foreshorten; ng
;eaars to t1
.;.duction in length of a dry paper web 60 which occur.: when energy is
applied to
the dry web 60 in such a way that the length of the web 60 is reduced and the
fibers
in the web 60 are rearranged with an accompanying disruption of fiber-fiber
bonds.
Foreshortening can be accomplished in any of several well-known ways. The most
common, and preferred, method is creping schematically shown in F1G. 6. In the
crcping operation, the dried web 60 is adhered to a surface and then removed
from
that surface with a doctor blade. As shown in FIG. 6, the surface to which the
web
60 is usually adhered also functions as a drying surface, typically the
surface of the
Yankee dryer drum 14. Generally, only the non-deflected portions of the web 60
which have been associated with web-side network 21 * on the web-contwvting
side
11 of the paperrnaking belt 10 are directly adhered to the surface of Yankee
dryer
drum 14. The pattern of the ~~ eb-side network 21 * and its orientation
relative to the
doctor blade will in major part dictate the extent and the character of the
creping
imparted to the web. If desired, the dried web 60 may not be creped.
The general physical characteristics of the paper web 60 which is made. by the
process of the prrsent invention utilizing the through-air drying belt 10a
having an
essentially continuous framework 20 are described in the aforementioned U.S.

CA 02461063 2004-04-06
Patent 4,529,480 entitled "Tissue Paper", which issued to Trokhan on July 16,
1985.
The plurality of domes 65 in the paper web 60 of the present invention,
however, will prophetically form an "angled" pattern, due to the "angled"
posi~il~n of
the conduits 30 of the through-air drying belt 10 of the present invention. It
should
be understood that the steps of imprinting, drying, and -- especially --
creping may
interfere with the "angled" position of the domes 65. That is to say, the
processing
of the web 60 after it is separated from the through-air drying belt l Ob
~.~ay affect the
overall configuration of the domes 65 as well as the acute angles K (FIG. 4B)
and
M1, M3 (F1G. 4C) formed between the Z-direction and the axes of the domes 65
in
such a way that these acute angles may not be equal to the corresponding
angles Q
betv~-een the Z-direction and the axes 33 of the conduits 30. It is believed,
however,
that the paper web 60 according to the present invention will have the cross-
sectional
" jnc~ led" a astern of the domes 65 generally following the cross-sectional
angled
pattern of the conduits 30 of the resinous framewor'.; ~.%Ø
FIGS. 4aC show one prophetic embodiment of the paper web 60 according to
the presen' v. mention. Pret~rably, the domes 65 are disposed in a non-random
and
repeating pattern which corresponds to the pattern of the discrete conduits 30
of the
resinous framework ?0 of the belt 10. While r:~t ae:ng intes:~.:,,d to be
bound by
theory, the AFplicar.' ~--:lieves that tn_ paper 60 having the acutely angled
domes 65
is softer than the comparable paprr having domes generally perpendicular
relative to
thr plane of the network region 64, because the acutely angled domes 65 are
believed to be more easily collapsible than the generally perpendicularly
upstanding
domes. Moreover, it is believed that the angled domes 65 having a specific pre-

determined directional orientation may provide a benefit of facilitating a
distribution
of liquids in a desired direction. This property may prove to be very
beneficial if the
paper 60 is used in such disposable products as diapers, sanitary napkins,
wipes, and
the like.
For example, the paper web 60 r:.~wn in F1G~~. 4 and 4C has three Zones of
relative orientation: a first zone H 1, the second zone H2, and a third zone
H3. As
best shoH.r in FIGS. 4 and 4C, the first zone H1 has the domes 65a oriented in
a first
direction hl, the second zone H2 has the domes 65b oriented in a second
direction
h~, and the third zone H3 has the domes 65c oriented in a third direction h3.
V iewed in plane, the first direction h 1 and the second direction h2 are
directed
towards each other, and the third direction h3 is perpendicular to the first
and second
directions h 1, h2.

Representative Drawing
A single figure which represents the drawing illustrating the invention.
Administrative Status

For a clearer understanding of the status of the application/patent presented on this page, the site Disclaimer , as well as the definitions for Patent , Administrative Status , Maintenance Fee  and Payment History  should be consulted.

Administrative Status

Title Date
Forecasted Issue Date 2005-07-26
(22) Filed 1998-05-18
(41) Open to Public Inspection 1998-11-26
Examination Requested 2004-04-06
(45) Issued 2005-07-26
Expired 2018-05-18

Abandonment History

There is no abandonment history.

Payment History

Fee Type Anniversary Year Due Date Amount Paid Paid Date
Request for Examination $800.00 2004-04-06
Registration of a document - section 124 $100.00 2004-04-06
Registration of a document - section 124 $100.00 2004-04-06
Application Fee $400.00 2004-04-06
Maintenance Fee - Application - New Act 2 2000-05-18 $100.00 2004-04-06
Maintenance Fee - Application - New Act 3 2001-05-18 $100.00 2004-04-06
Maintenance Fee - Application - New Act 4 2002-05-21 $100.00 2004-04-06
Maintenance Fee - Application - New Act 5 2003-05-20 $200.00 2004-04-06
Maintenance Fee - Application - New Act 6 2004-05-18 $200.00 2004-04-06
Maintenance Fee - Application - New Act 7 2005-05-18 $200.00 2005-04-01
Final Fee $300.00 2005-05-13
Maintenance Fee - Patent - New Act 8 2006-05-18 $200.00 2006-04-05
Maintenance Fee - Patent - New Act 9 2007-05-18 $200.00 2007-04-10
Maintenance Fee - Patent - New Act 10 2008-05-19 $250.00 2008-04-07
Maintenance Fee - Patent - New Act 11 2009-05-18 $250.00 2009-04-07
Maintenance Fee - Patent - New Act 12 2010-05-18 $250.00 2010-04-07
Maintenance Fee - Patent - New Act 13 2011-05-18 $250.00 2011-04-18
Maintenance Fee - Patent - New Act 14 2012-05-18 $250.00 2012-04-16
Maintenance Fee - Patent - New Act 15 2013-05-21 $450.00 2013-04-15
Maintenance Fee - Patent - New Act 16 2014-05-20 $450.00 2014-04-15
Maintenance Fee - Patent - New Act 17 2015-05-19 $450.00 2015-04-13
Maintenance Fee - Patent - New Act 18 2016-05-18 $450.00 2016-04-12
Maintenance Fee - Patent - New Act 19 2017-05-18 $450.00 2017-04-26
Owners on Record

Note: Records showing the ownership history in alphabetical order.

Current Owners on Record
THE PROCTER & GAMBLE COMPANY
Past Owners on Record
HUSTON, LARRY L.
Past Owners that do not appear in the "Owners on Record" listing will appear in other documentation within the application.
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Document
Description 
Date
(yyyy-mm-dd) 
Number of pages   Size of Image (KB) 
Abstract 2004-04-06 1 17
Description 2004-04-06 33 1,906
Claims 2004-04-06 3 124
Drawings 2004-04-06 9 249
Cover Page 2004-05-20 1 49
Representative Drawing 2004-05-20 1 15
Claims 2005-02-18 3 133
Claims 2004-10-15 3 127
Representative Drawing 2005-07-20 1 14
Cover Page 2005-07-20 1 48
Correspondence 2004-04-20 1 44
Assignment 2004-04-06 3 121
Correspondence 2004-05-19 1 17
Prosecution-Amendment 2004-05-20 2 49
Correspondence 2004-09-22 19 734
Correspondence 2004-10-21 1 13
Correspondence 2004-10-22 1 16
Prosecution-Amendment 2005-02-18 4 146
Prosecution-Amendment 2004-10-15 6 265
Prosecution-Amendment 2004-12-24 2 41
Correspondence 2005-05-13 1 38
Office Letter 2017-01-05 2 86
Office Letter 2017-01-05 2 88
Correspondence 2016-11-03 3 133
Correspondence 2016-12-01 3 130
Correspondence 2016-11-28 138 7,757