Paper machine fabrics having controlled release

This invention is directed to paper machine fabrics having controlled release of chemicals. More particularly, this invention is directed to a method for achieving controlled release of chemicals and a method of modifying a felt for a papermaking machine which comprises the steps of: PA0 (a) preparing a foam comprising resin and a chemical such as a detergent, surfactant, or other chemical modifier; PA0 (b) applying said foam from step (a) to the surface of said fabric; and PA0 (c) permitting said foam mixture to dry and cure.

FIELD OF THE INVENTION 
This invention is directed to paper machine fabrics having controlled 
release of chemicals. More specifically, this invention is directed to a 
method for achieving controlled release of chemicals from paper machine 
fabrics by coating the fabrics with foamed resins. 
BACKGROUND OF THE INVENTION 
The modern papermaking machine is in essence a device for removing water 
from the paper furnish. The water is removed sequentially in three stages 
or sections of the machine. In the first or forming section, the furnish 
is deposited on a moving forming wire, and water is drained through the 
wire to leave a paper sheet or web having a solids content of from about 
14 to 30 percent by weight. The formed web is carried into a press section 
and passed through one or more press nips on a moving press fabric to 
remove sufficient water to form a sheet having a solids content of from 
about 36 to 50 percent by weight. This sheet is transferred to the dryer 
section of the papermaking machine where drying fabrics press the paper 
sheet to hot steam heated cylinders to obtain a final paper sheet dryness 
of from about 92 to 96 percent solids content. 
On papermaking machines, endless belts are employed in the various sections 
to carry the sheet or web of paper. There are a wide variety of forms of 
the endless belts, some fabricated from metal and others from textile 
material such as cotton, glass, or wool, or synthetic fibrous or 
filamentous material such as polyamide or polyester. The selection of a 
given material is dependent to some degree upon the use to which the 
fabric will be put, i.e., as a forming fabric, press fabric, drying 
fabric, etc. 
One form of belt which has been used extensively as a forming medium in the 
forming section of the papermaking machine is one fabricated from an open 
weave of synthetic, polymeric resin monofilaments. Such fabrics generally 
perform well in the forming section although there are certain 
limitations. For example, these monofilaments have an affinity for 
accumulating a build-up of pitch, tars, and other contaminants during use. 
This shortens the overall life of the forming fabric and can require 
frequent halts of the papermaking machine for mechanical cleaning and 
application of chemicals. Such shut-down cleaning may be required as 
frequently as on a weekly basis. 
Those skilled in the art have long appreciated that the efficiency of water 
removal in the press section of the papermaking machine is critical to 
overall efficiency in the papermaking process. There are two reasons for 
this: 
First, a large amount of water must be removed from the sheet at the 
presses to realize a good drying economy. And second, greater efficiency 
in water removal creates a drier and hence stronger sheet less susceptible 
to breaking. 
A large variety of clothing constructions have been proposed as 
papermakers' press fabrics advantageously employed in the press section of 
a papermaking machine. In fact, there has been a continual evolution of 
clothing constructions, corresponding to improvements in the papermaking 
machine itself. This evolution began with the early woven felt, woven of 
spun yarn and then mechanically felted or fulled. A later development was 
found in the "Batt-on-Base" construction consisting of a woven fabric base 
and a batt surface attached by needling. The needled Batt-on-Mesh fabrics 
of multifilaments and monofilaments are widely used today and have been 
said to be the "standard of the industry." However, a wide variety of 
other constructions are available, including non-woven press fabrics and 
composite laminates which comprise two or more separate base fabrics. See, 
for example, U.S. Pat. Nos. 2,567,097, 3,059,312, and 3,617,442, all of 
which are incorporated herein by reference. 
The fabrics for us in the drying section of the papermaking machine have 
historically been called dryer felts. In recent years, one form of fabric 
commonly employed in the dryer section of a papermaking machine is 
referred to as a "screen" and is fabricated by weaving synthetic 
monofilaments or twisted multifilaments together in an open weave. These 
screen fabrics have also become known as "drying fabrics". These drying 
fabrics are generally woven flat, and the ends are thereafter joined to 
form an endless fabric. The weave selected may be a one, two, or three 
layer weave of synthetic yarns such as multifilament, spun, or, most 
commonly, monofilament yarns. 
In carrying the paper web through the dryer section of the papermaking 
machine, the fabric aids in sheet drying, controls shrinkage of the paper 
web, and prevents cockles. The fabric must possess strength, dimensional 
stability, and resistance to abrasion and have a functional permeability. 
In recent years all monofilament structured fabrics have been developed to 
meet the above-described needs of a drying fabric. However, drying fabrics 
fabricated from all monofilament fabrics, similarly to forming wires, 
accumulate deposits of pitch, tar, and other contaminants such as paper 
fines and fillers. Shut-down cleaning may be required as frequently as 
every 2 to 3 weeks, and cleaning over a long period of time may become 
less effective as filling of the fabric voids continues. This, of course, 
would most undesirably result in a high percentage of unsatisfactory paper 
product. 
In general, the papermakers' forming fabrics, press fabrics, and drying 
fabrics require periodic mechanical and/or chemical cleaning to remove 
debris or contaminants which accumulate during use. Certain chemical 
additives are also advantageously used during initial break-in periods. 
For example, it is common to use small amounts of a detergent applied 
through a full width shower on press fabrics during the running life of 
the fabrics. The use of such a detergent shower is intended for 
conditioning a press fabric to be more able to accept water from the sheet 
and thus aid a fabric in keeping clean and draining properly. It is also 
known from prior art that the use of free detergent dissolved in the stock 
water aids in pressing water from the sheet of paper being produced. 
According to U.S. Pat. No. 4,569,883, paper machine fabrics are treated 
with chemicals which are dispensed or released while the fabric is in 
motion. However, it would be advantageous to have chemicals released more 
slowly than they are according to this patent. 
Dispensing of small quantities of surfactant throughout the life of the 
press fabric is beneficial. However, since difficulty in pressing water 
from paper is mostly experienced in the initial few days and during the 
compaction of the fabric to its equilibrium caliper (thickness), the 
addition of surfactant during this break-in period is most beneficial. 
During break-in it is also important to keep the fabric clean so that paper 
stock particles are not trapped within the press fabric, thus impeding 
uniform sheet water drainage. The surfactant would act as a cleaning agent 
as well. It is also possible to minimize cost and foam buildup since this 
method reduces the amount needed, if applied via a shower, because 
dispensing of the surfactant is controlled and at the fabric/paper 
interface. 
With the structured fabrics of the present invention, many of the 
above-described shortcomings of the prior art are removed. Drying fabrics 
constructed according to the invention may be fabricated from an all 
monofilament fabric which provides for extended periods of time an 
exceptionally smooth surface to contact the paper sheet. As a result, 
relatively mark free paper product is obtained, while all of the desired 
advantages of an all monofilament drying fabric are retained. 
Press fabrics are broken-in more rapidly and require less frequent 
shut-down cleaning, thereby improving the efficiency of the papermaker's 
machine for a longer period of time. The overall operating life of the 
forming fabrics and press fabrics can be significantly increased over 
prior art. 
OBJECTS OF THE INVENTION 
It is an object of the invention to provide papermaking fabrics having 
controlled release of chemicals. 
It is also an object of the invention to provide a method for controlling 
the release of chemicals from papermaking fabrics. 
It is a further object of the invention to provide a method for achieving 
controlled release of chemicals from papermaking machine fabrics by 
coating the fabrics with foamed resins which entrap detergent. 
These and other objects of the invention will become more apparent from the 
discussion below.

DETAILED DESCRIPTION OF THE INVENTION 
Applicant has developed an improved fabric useful in papermaking machines. 
The invention comprises a fabric treated with detergent derived from a 
foam coating that has been applied, and said fabric is a significant 
improvement over known treated press fabrics. Papermaking fabrics coated 
according to the invention have the following advantages: 
(1) Enhanced fabric cleanability; 
(2) Increased resistance to filling; 
(3) Increased and/or more uniform sheet/fabric dewatering for improved 
papermaking machine efficiency; 
(4) Faster break-in; and 
(5) Enhanced wet up/wettability. 
The fabrics to be treated include those fabrics known in the art. Typical 
fabrics are described in, for example, U.S. Pat. Nos. 2,354,435, 3,158,984 
3,425,392, 3,657,068, 4,382,987, and British Patent No. 980,288, all of 
which are incorporated herein by reference. 
Useful resin compositions include synthetic, flexible, polymeric resin 
foams such as polyurethane. Also useful are foams based upon polyether, 
polyester, polyisocyanate foams, polyolefins, and the like, or a 
combination of two or more such polymeric resins. Typical of useful resin 
compositions are Emulsion 26172 (an acrylic Emulsion available from B.F. 
Goodrich), Permuthane HD2004 (a water-based polyurethane emulsion 
available from C.L. Hauthaway), and Aridall 1080 (a super absorbent 
acrylic polymer available from Chemdal Corp.). 
Any of many known detergent and/or surfactant systems can be used according 
to the invention, including known anionic, cationic, or zwitterionic 
surfactant compositions. Examples of useful detergents include Triton X114 
and Triton X200, each of which is available from Rohm & Haas Co. 
The resin foam composition can be prepared by admixing the various 
components and then foaming or frothing the resulting mixture. In a 
preferred embodiment of the invention, water and detergent are mixed with 
a polymer to form a gel. The gel is then finely divided into 
microcapsules, and the microcapsules are dispersed into a polymeric 
emulsion. This emulsion is then frothed. 
According to the invention this foam is applied to a surface, or surfaces, 
of a fabric, allowed to dry, and then cured. Drying and curing can each be 
effected by air drying at room temperature for a sufficient length of time 
or at elevated temperatures for from about 1 minute to 5 hours. The 
temperature and time for drying or curing will be dependent upon the foam 
employed, manufacturing conditions, and the like. 
The drying and curing could be performed in separate steps or 
simultaneously. In some cases it may be desirable to calender the fabric 
after drying and before the curing step. 
The foam could be applied by an number of known procedures which include, 
for example, blade coating techniques which can be on roll, off roll, or 
table; squeeze coating; transfer coating, spraying; kiss or applicator 
roll; slot applicator; and brush application. A single layer can be 
applied or multiple layers of the same or different foam formulations can 
be applied to obtain a given final result. 
The resultant foam may reside entirely upon the surface of the fabric to 
the extent of 90% or more extending above the fiber surface plane, or it 
may be partially embedded into the surface to the extent of about 50%, 
leaving 50% above the surface. Otherwise the foam may lie primarily 
embedded in the fabric, penetrating partially or wholly into the fabric. 
The thus modified fabric will have therein microcapsules containing 
chemical, which chemical will be released over time. 
The following examples are intended to illustrate the invention and should 
not be construed as limiting the invention thereto. The examples employ 
detergents; however, other materials might be considered for slow release 
that would substantially alter surface or other fabric characteristics 
such as oleophobic, oleophilic, hydrophobic, hydrophilic, cationic, 
anionic, etc. 
EXAMPLES 
Example 1 
A 50:50 by weight mixture of Emulsion 26172 and Permuthane HD2004 was 
prepared, and 10% by weight, based upon the weight of that mixture, of 
Triton X114 was added. The resultant mixture was stirred at room 
temperature in a bench top mixer until it foamed. The foam was applied to 
a sample of DURAGROOVE.TM. fabric (available from Albany International 
Corp.), and a Gardner knife set at zero gap (scrape coating) was used to 
remove unabsorbed foam. 
The coated fabric sample was dried in an oven and cured at 300.degree. F. 
for 10 minutes, after which the coated fabric sample and an uncoated 
fabric sample were tested for air permeability. The original, uncoated 
fabric sample had an air permeability of 145 cfm, and the coated fabric 
had an air permeability of 49 cfm, as measured on the Frazier Air 
Permeability Tester. (Units are expressed as cubic feet of air passing 
through a square foot of fabric in one minute.) 
Even though the coated fabric was partially filled with foam, it initially 
absorbed water at a rate about twice the original, as measured by a 
standard textile drop spread test. 
Example 2 
A solution of 50% by weight water and 50% by weight Triton X114 detergent 
was admixed into a super absorbent acrylic polymer (Aridall 1080) until a 
stiff gel was formed. The gel was finely divided in a blender and then 
dispersed into a urethane emulsion. The resultant mixture was frothed to a 
21:1 blow ratio in a laboratory mixer at room temperature. 
A sample from a trim strip of a DURAVENT.TM. fabric (available from Albany 
International Corp.) was coated in the same manner as in Example 1. The 
treated sample was dried in an oven and then cured at 300.degree. F. for 
10 minutes. 
When the coated sample was subsequently washed, the detergent did not 
diffuse out of the fabric rapidly, as is normally the case, apparently due 
to entrapment by the gel. Also, the coated fabric wet up much faster than 
an uncoated fabric, which tends to be hydrophobic. Repeated washings and 
dryings did not reduce the rate of wetting up. 
Example 3 
A series of samples were prepared using the procedure outlined in Example 
2. The foam mixture was coated onto the fabric samples at zero gap, 20 
mils, and 50 mils. The fabric sample was from the same source as in 
Example 2. 
Wettability was observed for the samples prepared in Example 3 using the 
"Beaker" test and the standard textile drop spread test. In the "Beaker" 
test, the sample, a one inch fabric disk, is placed face down on the 
surface of water, and the times are noted for wet through. The time to 
sink and the time for the first wet spot to appear on the disk are also 
noted. 
In the drop spread test the time for a single drop to spread to its maximum 
limit on the fabric surface is measured. The uniformity of the drop spread 
differs from sample to sample. In some cases the drop spreads radially 
from the center and in others fingers travel randomly. 
The data obtained on the samples is set forth in the following table: 
TABLE I 
______________________________________ 
Time to 
First Time to Time to Drop 
Sample Wet Spot 100% Wet Submerge Spread 
______________________________________ 
Control 
&gt;&gt;5 Hrs. &gt;&gt;&gt;5 Hrs. &gt;&gt;&gt;5 Hrs. 
Drop did 
not pene- 
trate fabric 
0 Gap 2 Sec. 1.3 Min. 3.7 Min. 1.0 Sec. - 
uniform 
20 mil 8 Sec. 2.5 Min. 3.2 Min. 1.5 Sec. - 
uniform 
50 mil 20 Sec 3.0 Min. 8.6 Min. 2.0 Sec. - 
uniform 
______________________________________ 
It can be seen from Table I that the coated samples wet much more rapidly 
than the control and that the rate of wet up could be controlled by 
changing the thickness of the coating. 
Example 4 
Polyurethane water-based emulsion was loaded with 10% by weight of Triton 
X200 detergent and frothed into a stable low density foam. Due to the low 
density, several layers of froth could be squeegeed onto the fabric, which 
in this case was DURAGROOVE.TM. or DURAVENT.TM.. Non-uniformity of the 
coating was minimized by using several layers of low density foam, which 
tended to average out the non-uniformities of each individual layer. 
Uncoated and coated fabric samples were tested for air permeability. The 
results were as follows: 
TABLE II 
______________________________________ 
Air Permeability 
Sample Fabric (cfm/sq.ft.) 
______________________________________ 
A* Uncoated DURAGROOVE .TM. 
66 
B* Coated DURAGROOVE .TM. 
63 
C* Uncoated DURAVENT .TM. 
22 
D Coated DURAVENT .TM. 
20 
______________________________________ 
*Control 
After the urethane coated samples were cured, they were washed, vacuumed, 
and dried for several cycles. The fabric surfaces still released detergent 
even after these washing and drying cycles. 
Example 5 
A froth wherein a detergent is encapsulated in urethane emulsion was 
prepared as described in Example 2. The froth was low density and very 
stable. This froth was applied to a DURAVENT.TM. fabric sample, and the 
sample was then passed over a vacuum slot on a dryer to draw the foam into 
the fabric The fabric was then dried and the urethane cured at 300.degree. 
F. 
After 12 repeated washings and dryings, the coated fabric sample continued 
to wet up more rapidly than the uncoated fabric sample. 
The preceding specific embodiments are illustrative of the practice of the 
invention. It is to be understood, however, that other expedients known to 
those skilled in the art or disclosed herein, may be employed without 
departing from the spirit of the invention or the scope of the appended 
claims.