Note: Descriptions are shown in the official language in which they were submitted.
~ 20~6~12
MF.T~IOD 7~ND ~PPI~ TU_FOR Tlll~ L'l~ODUCTION
OF MULTIPLY C~LT ULOSIC E30ARD
7~NI) I'RODUCT 013T7~INED 'I'IIE:REBY
This invention relates to multiply cellulosic,
e.g. paper, board which is particularly suitable for use in
the manufacture of containers for liquid food products, and
more particularly for disposable mil]c cartons, and to meth-
ods and appara~us ~or the manuFacture of such board.
Disposable containers for liquid food productshave long been manufactured from celluIosic board that is
formed using conventional fourdrinier papcrmakin~ machines.
Such board is most usually sinqle ply ancl of a basls wcight
in excess of about 150 lb./~000 ft2. 01 recent there has
been eonsiderable e~fort exerted toward produciny multip]y
board for use ln such disposab]e containers in ~n cf~ort to
reduce the overall eost of the board, while maintaining
those board properties that arc essential for its successful
use in disposabIe liquid food containers. Systems such as
those shown in U.S. Pakent Nos. 3,6~1,193, 3,~91,501,
4,00~,968 and ~,~72,2~ have been su~ested for use in
makinq multiply paper board. In these patents the apparatus
and methods disclosed for the manufacture of multiply board,
i.e. three or more plies, require complica~ed and expensive
equipment and in most, there is duplication of equipment for
developing each of the plies. It is desired therefore that
there be a method for producing multiply board of at least
three~layers whieh requires less extensive, hence less
expensive, modification of existin~ papermaking equipment
and which provides a multiply board havin~J cl lessor quantity
of fibers in the board, but which provides properties equal
or superior to sin~lc ply boarcl.
::
206~812
In accordance witll the metllod of tlle present
invention, ~irst and second streams of cellulosic pulps are
deposited substantial].y si.mu].taneously onto a ~orwardly
moving foraminous papermaking fabric, e.g. a fourdrinier
wire, to develop Ei.rst and second layers of a mul-tiply web.
These overlaid layers are dewatered to a consistency of
between about 1.~% and about 3.5%, by weight, and thereupon
are mechanically int~grat:ed ~t their interface and thcir
formatlon enhanced. Such mechanical intec3ration ~urther
conditions the upper sur~ace oE the second layer ~or the
receipt of a third layer of pulp. Such thircl layer is
developed by depos.iting a stream of ccllulosic pulp onto the
upper surface o~ the second layer at a location just down-
stream of the wet line o~ the bilayered web on the wire.
].5 Substantlally immecliately followiny tllC dePOSitiOn Of SUCh
third layer, the three layers are captured bctwccn the
initial forming fabric and a further form~minous ~orming
fabric that is ovcrlaid on-to the top surfacc of tlle third
.
layer. Thereafter, the multilayered web is dewatered up-
20~ wardly through the several layers of the web to hydraul.ical-
ly integrate the second and thlrd layers alld enhancc the
integration of the first and second layers. Thereafter, the
~:
web is further dewatered, dried and collected. In a pre-
erred embodiment, the web is dried and fed through a size
press prior to final drying to develop a surface size on
opposite surfaces of the web, and then calendered. Still
~: .
further, in the preferred embodi.ment, the composition of the
second layer o~ fibers includes less expensive fibrous
matter, such as a larger percentage of hardwood fibers, and
the total quant.ity of fibers dcposited as the secolld layer
preferably is between ahout 0% and about 300% greater than
20g6812
-the quantity oE tl~e ~ibers IcE)osited in ~ormincJ eithcr tl~e
~irst or third out~r layers. Ill tili~ m~nncr, thc apparell~
bulk of th~ secorld (inner) ]aycr prc~er~hly is ~Jrc~t~r tll.ln
th~t of either o~ t~le first or tl~.ird layel.~, but t~ ov~r~ll
S caliper of the board product is m~intained at about th~ s~me
caliper as single ply boar-l made ~rom t11e same total wcight
of fi~ers. The multiply bo.lrd of the pres~nt illVCl-tiOn
exhibits pertinent: propertie~ t:h~t ar e equal to or s~lperior
to the same properties of sincJle ply ~o~rd. Especially, the
present board exhibits the modu1~s, stiffness, bulqe resist-
ancc, and other propcrties oi a s.inr~lc pl.y boarcl, ~nd docs
SO Witll t~le pres~rl~ board collt~.inill~ betwcen about ~ and
11% ]css ~ih~r COIltCIlt, I:)y wei-~lt.
~urther objcctivos alld advallt~cJes, ~s well as
understandinc3 o~ the prcsent invelltionr will bc proviclccl
from the followin~ description, incl~l-lill(J thc fi~ures, i
Wll i. C ll:
Fic~ure 1 is a sc~lem~lt.ic r~prcscntati.oll o~ onc
embocliment o~ an apparatus ~or us~ in carryi:llc~ out the
method oE the pres~nt invention;
Fic~ure 2 :is a schcmc~tic r~r?r~s~nt~ion oE ~ m~lti-
ply board in accord~ncc with thc prcsent inv~ntion a~
:
d~pictin~3 variDus ~eatures tl~er~of, and
Figure 3 shows a turned-up corner portion of a web
roduced in accordance with an embodiment o~ the ~resent
invention.
With speci~ic re~crerlce to l~i-Jure 1, ther~ is
depicted a preferred embodi.ment oE apr?aratus ~or carryillq
out the met}~od of the present invention anc~ compri.ses a
; continuous lool1 ~ourdrinicr wire lO which is traincd ~bout
a breast roll 12, a couch ro]l 1~, nnd one or more idler
rolls 16 and 1~. 'rhe wire inclucles an upper run 20 whicll i5
supported as by c~ plurality of suction devices 22 ~ncl/or
foi]s 2~, all as are well knowll in tlle art. The wire is
moved in a ~orwarcl clir~ction, by dr;ve meall3 not SllC)WIl, as
~l
2~812
indicated by arrow 26. ~djacent the breast roll 12, there
is provided a headbox 2~ which in the preferxed embodiment
comprises two flow channels 30 and 32, cach of whicll is in
fluid communication with its respective source of cellulosic
pulp (not shown). Pulp streams from the respective channels
30 and 32 are maintained as separate streams until substan-
tially the moment of their discharge from a dual slice 34.
These two streams are deposited substantlally simultaneously
as separate layers of pulp onto the wire 12 as it i5 moving
forwardly to form a bilayered web 35 on the wire, such web
comprising first and second layers, 31 and 33, respectively.
In FIGU~E l, the thickness of the layers Oll the wirc 10 arc
exaggerated for purposes of illustra-tion. Onc suitable
headbox is a Strataflo unit manufactured by Beloit Corpora-
tion of Beloit, Wisconsin. As the bilayered web on the wireis move forwardly, it is partially dewatered as by the
suction devices 22 arld the foils 2~. ~t that point aloncJ
the length o~ the upper run 20 o~ the wire 12 at whic~l tlle
consistency of the fibers in thc web has reached a value of
between about 1.~% and about 3.5%, the bilayered weh is
contacted by a dandy roll 36. Such roll 36 prefcrably
comprises an open mesh formed into a cylindrical cJeometry
and positioned with its len-Jtll transverscly of the clirection
o~ forward movement of the web. The roll 36 is preferably
driven at a tan~ential speed that is subs-tantially cquiva-
lent to the forward lineal speed of the wire, e.~., 100~ ~
5%. ~urther, the roll 36 i5 mounted so that it can be forced
into pressurized contact with the upper surface of the web
35, such that between about 2 to 4 inches of the circumfer-
ential dimension of the roll is in contact with the wcb asthe ~eb moves forwardly. This 2 to ~ inch "footprint" of
..... ~
2~6812
the roll 36 extends across the full width of the web ~5.
The open mesh character Oe tl~e roll 36 serves to mechanical-
ly enga~e the fibers of the web and enhance the integration
Oe the first and sccond layers Oe the web at their int~rface
as well as enhancing the overall formation of the web.
Further, the open mesh smooths and conditions the top sur-
face of the second layer 33 for receivin~ a further layer of
pulp thereon. One suitable dandy roll is formed of phospllor
bronæe wire having a mesh count of 15 x 13 cm, an opell area
of about 39.5%, a warp yarn diameter Oe 0.2G mm, and a weft
yarn diameter of 0.25 mm.
Followin~ inte~ration of the first and second
layers of the web, and at a location substant1ally immedi-
ately downstream of the wet line of the bilayered web on the
wîre, a ~urther, i.e. third, layer oL pulp is deposited
onto the upper surface Oe tlle web as ~rom a second~ry he~d-
box ~3. This headbox may be of conventional sin~le-slice
desi~n. The pulp deposited onto the we~ erOm the secondary
headbox preferably is subst.antially equivalcnt in composi-
tion and quantity as the pulp deposited onto the wire from
~; the channel 32 of the headbox 2~, thereby causing the first
and third layers of the web to be substantially identical in
a preferred embodiment. Substantially immediately after the
third layer of pulp has been deposited onto the web 35, the
trilayered web 1s captured between a further foraminouspapermaking fabric ~0 which is trainecl about a plurality of
rolls 42, 4~, 46 and 48. In a preferred embodiment, such
fabric 40 is a part of a device known in the art as a Bel
Bond unit, manufactured by 13eloit Corporation of Beloit,
Wisconsin. The Bel Bond unit includes one or more suction
devices 50 disposed on that sicle of the wire ~0 oppositc the
web 35 and adapted to withclraw water erOm the web in an
. ,.. ,_,~, .
.. . . . . . .
2~6~12
~pward direction. lrhis action serves to hyd~a~llically
inte~rate the second ancl third layers of the web, as well as
to further dewater the web.
The partially dewatered web is withdrawn from tlle
wire 12 at the couch roll 1~ and directed tl-rou~ll a wct
press 62. In the depicted wet press section G2, the web 35
is first cc)ntacted by a suction pic~c up roll 66 about wilicl
there is trained a fir~t feit 6~. Tlle web is next capturcd
between the first felt 6~ and a second felt 70 and clirccted
throuc3h a first press nip 72 betwcen a groovcd roll 7~ and a
suction roll 76. Thereafter, the web, while still on the
first felt 6~ and trained about the suction roll 76, is
passed through a second press nip 78 developed between a
suction roll 76 and a hard-sur~aced roll ~0. ~ollowinc3 the
s~cond press nip 7a, the wcb is arJaill c~L>tured b~twccn th~
irst felt 63 and a third felt ~2 and conveyecl throur3ll a
third press nip 8~ established between a further c3rooved
roll ~6 and a smooth roll ~. Pressurc loads in thc press
nlps of 200, 300, and 600 p.l.i., respectively, have been
found suitable. Other wet press desic3ns known in tlle art
would also suffice.
The web exiting tlle wet press section is conveyed
through a dryer section 6~ within which the web is passed~
over a series of heated rolls 90 and dried. After the
lnitial drying, a water solution or slurry of sizinc3
material may be depositecl on the surEace of the shect in a
size press 60. Surrace siæing further strengthens the shect
sur~ace layer and can include materials that promote a
hydrophobic nature of the sheet surfacc. In thc depicted
size press 60, the web 35 is ~ccl ovcr a roll G1, tllc
through the nip 71 betwcen a pair oE rolls 63 and 65.
. 2~66gl2
Siziny solution is fe~ into ~le nip 71 from one or ~Ot~l o~
sources 67 and 69 of sizincJ solution, dcpendin~ upon whether
one or hoth surfaces oE the weh are to receive sizin~. From
thc nip 71, the size~ wch i5 fed thro-lcJ}l a second drycr 6~'
which includes heated rolls ~0'. The dried web may be
passed through one or more nips (calendered) to i1nprove
surPace smoothness. The dry web is collected in a roll 92.
/ ~ turned-up corner portion 9~ of a web 35 produced
in accordance witll the presellt method is depic~ed in Fi~ure
3. The depicted w~b compriscs a first (~ottom) layer 31, a
second ~inner) layer 32 and a third ~top) layer 33. In the
depicted web portion, the several layers are delineated for
purposes of illustration, but it is to be rccoqni7.ed that
the inter~aces between laycrs are not so pronounced in the
actual web.
Thus, ~hc pre~errccl cmbo~liment o the me~ho(l of
the present invention comprises the stcps of preparill~
first, second, ancl thi].d .slurries oF ce].lulosic fibers i.n
an aqueous medium, dcpositin~ a stream oE the first slurry
onto a forwardly movin~ papermaking Pabric at a irst veloc-
ity sufficient to form a Pirst layer of fibers on said
fabric, substantially simultaneously depositing a stream of
the second slurry onto the upper surface of the first layer
of fibers at a velocity sufficicnt to dcposit onto said
25 first laycr betwc¢n about 0% and 300% ~reater quantity oP
fibers from the second slurry than the quantity of fibers
deposited from the first slurry, commencing dewaterin~ of
the bilayered web and when it has achieved a consistency of
between about l.B% and about 3.5~, mechanically integrating
the first and socond layers at their intcrf~ce, depositin[J a
stream o~ the third slurry onto the upper surface of the
inteyrated bilayered weh at a location .immediately down-
U
2 ~ 2
stream of the wet line of the web on the formin~ fabric,substantially .immediately after depos.ition of the third
layer, capturing -the ~eb be~ween the Eirst form.in~ fabric
and a further foraminous fabric, and withdrawing water from
the trilayered web throu~h the further fabric to hydrauli~
cally integrate the second and third layers of the web. ~s
desired a surface size may be deposited on the opposite flat
surfaces of the web, and the web therea~ter dried and/or
calendered.
The pulp slurries employed in the present inven-
tion are selected to develop ~irst and tllird outer layers of
the present board that c~pture therebetwcen a secolld, i.e.
inner, layer which exhib.its an apparent bullc that is sub-
stantially qreater than the apparent bulk of the outer
layers. In th.is mann~r, the overall caliper of the boar~l is
developed with less fibrous content of the board tllan for
sinyle ply board forme~ from li.ke ~ibers. In the preferred
embod.iment, the pulp used for thc firs~ ancl third layers is
of the same composition, namely about 75% sol`twood ancl 25%
hc~rdwood flbers, at a consistency o~ about 0.8~ by wei~ht,
based on oven dried f1bers and a C.S.F. of about 500. The
:~ preferred composition of the inner layer is about ~.5% soft-
; wood and 75% hardwood fibers, at a consistency of about 0.~%
: :
~ : : and a C.S.~. of about G10. The greater percentage o~ soft-
~:25 wood fibers in the pulp for the outer layers provides ~or
the development oE stren~Jth in these layers, ~ood surface
.~smoothness of the board product, and other properties. ~s
noted above, the quanti.ty of fibers for the inner layer
deposited on the wire is between about 0% and 300% greater
than the quantity of fihers c~eposited in the formation of
each of the outer layers. l3y this means, the inner layer
`:~
2~66~12
develops an apparent hulki.ness which aids in il~partinc3 to
the boarcl product a final caliper that i.5 equiv~lent to the
caliper o a si.ngle ply boarcl, but whose total fiber con-
tent is about 9% to 1.1% less than the fiber content of A
single ply board. In this manner, the present invention
provides the means for produciny more board product with
less fibers, and doincJ so without loss of -the desired
properties of the board. ~s the relative volume o the pulp
for forming the inner ply varies bclow about 0~ or above
about 300% there is a nc~ti.ceable dccrease in the desircd
properties of the board.
~ key proper-ty for judgincJ strenc3th of three-ply
versus si.n~le ply board is stiffness. In tlle present dis-
closure, stiffness refers to the ~eometric mean value of
1.5 stiffness (square root of thc product of machine dircction
[M. D. ] and cross direction [C.D.] sti~ne~;s). ~ti~fness .is
related to basis weight by the equation:
stiffness = stifness constant x ~q. l
(caliper)l 6 x
: ~ 20 basi.s weicJht
or
: stiffness = (stiffness constant x ~q. 2
: : basis weight2 6)/apparent
density
::
;~:25 Yield improvement ~is calculated also using these equations,
;i.e. percent reduction in basis weight that ~ives equal
stiffness. The followincJ Table I shows the avera~e apparent
density, average stiffncss constant anc~ calculated yield
improvement of various boards madc in accordance with the
pr~sent method:
. 2a66s12
rr~r3r,li` I
~vera~e ~vera~e Improved
13Oard ~pparent Stiffness Yield
Samples Density constant %
~s-made
single ply 9.63 0.00~8 1~.9
three ply 9.~7 0.0065
Surface sized/
uncalendered
single plylO.lO 0.0066 9.0
three ply 9.~ O.OOnl
Surface sized/
calendered
sinyle plyll.23 0.0061 ~.7
three ply lO.93 0.007~
Vario~s of the softwoods and/or hardwoods may be
employed ln the pulps employed in the present inve1ltion.
International Pine softwood fibers and ~0-2 llardwood pulps
hclve been found most suitable, are re-1dily available and
simi].ar to pulps produced in khe souther1l United Stat~s. In
the formation of the pulps, there may be added thereto the
usual wet-end chcmicals to improve dry strcn~th, improve wet
stren~th, improve retentio1l, alter p11, etc., such as Kymene,
Acco-stren~th ~6, c~ustic for pll adjustment, etc., as de-
sired. Further, tests have shown that the additio1l of lO~
or more of brolce to the pulp has no detectable deleterious
effect upon the desired properties of the board product.
~ Whereas the consistency of the pulp may be the same for cach
i~ layer, pre~erably from about 0.5 to about 0.~, the consist-
ency of pu1p for each layer may be selected to be of a
specific value for that layer. The average consistency of
the pulps used for formation of the first and second layers
(total amount of so1ids/total flow from both the channels 30
and 32 of the headbox 2~) may ran~Je from between about 0.6~
to about l.1%, dependinq upon the desired basis wei~ht of
'
11
. 2~6812
the board produet. The pulp consistellcy employed to obtain
a particular basis weight of product is also a function of
the wire speed. Table II presents the data from a series of
~sts ~mployiny the present method to produce bo~rd ~roduct
of various basis weights.
T~BLE II
~asisWire Speed Primary Primary
Wei~ht (fpm) ~low 1Consistency2
(lb~3000 (l/min.) (%~
t~) _
160 129~ ~9~9 .~o
~ o .92
200 1030 ~9~9 .76
220 93~ ~7~ 3
250 ~o~ ~765 .75
2~2 725 ~552 .~
2~2 705 ~91 .~7
2~2 77~ ~30~ .9~
282 B53 ~552 1.02
1 qlotal flow from lleadbox 2~
:
2 Total amount of solids/primary flow
Board product use~ul in the manufacture of con-
tainers for liquid food products preferably contain a starch
size on the opposite outer surfaces o the board. ~ccord-
incJly, it is preferred in the present method to pass theformed web throu~h a size press containin3 a conventional
starch size to thereby deposit between about 1 and nbout 3
lb (based on 3000 ft2) o sizinc~ onto each of the opposite
i, ~:~ :
surfaces of the web. In a typical mill run, about 35 lb of
~starch per ton of fibers, produces a suitable sizing of the
~ web. Other sizes, combinations of sizes, and/or quantities
;~ of slzes may be employed to obtain specifie results.
;~ Tlle sized web may be cal~ndered as desirecl.
i : :
. .
,
,
12
..
2~68~2
EX~MPLF I
Multiple test rulls us:in~ the present method werc
made to produce both sin~le ply and multiply boarcl suitable
for use in disposable containers for liquid food products.
In the several runs, the composition of the pulps employed
for the several layers of the multiply product and the wire
speed were selected to procluce different wei~hts of board.
All runs were made Oll apparatus as shown in the Fi~ures and
described herein, except that the dandy roll ancl secondary
headbox were eliminated when making the single ply board.
The pulp employed in thc sin~le ply board was a 50/50 pine
to hardwood blend at 610 C.S.F. and 0.~% consistency. Other
variables were sct as noted in the tables presented hcrein-
after and in Table II above.
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Paper board manufactured in accordance with the
present invention was converted to quart-size and half-
qallon-size milk cartons and tcsted. Prior to its conver-
sion, boards havinc3 a basls wei~ht oE l~0, 200 and 220
lb/3000 ft2 were passed through an extruder and coated wi-th
about 16.7 lb of matte po]yetllylcne on the outer sur~ace of
the third layer of the boards and about 10.7 lb. of gloss
polyethylene on the outer surEace oE the first (wire) layer
of the boards. Boards havinq a basis weicJht oE 250 and 2~0
lb/3000 ft2 were coated with 18.9 lb. of matte PE on their
third layer surfaces and 11.1 lb of ~loss ~E on their wire
sides. The results of teStincJ of converted milk cartons are
given in Tables VII and VIII. These clata show that the
cartons made from the multiply board of the present inven-
lS tion compared favorably to li~e cartons macle from sinc~le ply
board.
22
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