Patent Publication Number: US-2012024487-A1

Title: Fibrous web formed on a structured fabric

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This is a continuation-in-part of U.S. patent application Ser. No. 12/847,519, entitled “STRUCTURED FABRIC”, filed Jul. 30, 2010, which is incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates generally to papermaking, and relates more specifically to a fibrous web formed on a structured fabric employed in papermaking. 
     2. Description of the Related Art 
     In a conventional papermaking process, a water slurry, or suspension, of cellulosic fibers (known as the paper “stock”) is fed into a gap between two endless woven wires that travels between two or more rolls. At least one of the wires are often referred to as a “structured fabric” that provides a papermaking surface on the upper surface of its upper run which operates as a filter to separate the cellulosic fibers of the paper stock from the aqueous medium, thereby forming a wet paper web. The aqueous medium drains through mesh openings of the structured fabric, known as drainage holes, by gravity or vacuum located on the lower surface of the upper run (i.e., the “machine side”) of the fabric. 
     After leaving the forming section, the paper web is transferred to a press section of the paper machine, where it is passed through the nips of one or more pairs of pressure rollers covered with another fabric, typically referred to as a “press felt.” Pressure from the rollers removes additional moisture from the web; the moisture removal is often enhanced by the presence of a “batt” layer of the press felt. The paper is then transferred to a dryer section for further moisture removal. After drying, the paper is ready for secondary processing and packaging. 
     Typically, papermakers&#39; fabrics are manufactured as endless belts by one of two basic weaving techniques. In the first of these techniques, fabrics are flat woven by a flat weaving process, with their ends being joined to form an endless belt by any one of a number of well-known joining methods, such as dismantling and reweaving the ends together (commonly known as splicing), or sewing on a pin-seamable flap or a special foldback on each end, then reweaving these into pin-seamable loops. A number of auto-joining machines are available, which for certain fabrics may be used to automate at least part of the joining process. In a flat woven papermakers&#39; fabric, the warp yarns extend in the machine direction and the filling yarns extend in the cross machine direction. 
     In the second basic weaving technique, fabrics are woven directly in the form of a continuous belt with an endless weaving process. In the endless weaving process, the warp yarns extend in the cross machine direction and the filling yarns extend in the machine direction. Both weaving methods described hereinabove are well known in the art, and the term “endless belt” as used herein refers to belts made by either method. 
     Effective sheet and fiber support are important considerations in papermaking, especially for the forming section of the papermaking machine, where the wet web is initially formed. Additionally, the structured fabrics should exhibit good stability when they are run at high speeds on the papermaking machines, and preferably are highly permeable to reduce the amount of water retained in the web when it is transferred to the press section of the paper machine. In both tissue and fine paper applications (i.e., paper for use in quality printing, carbonizing, cigarettes, electrical condensers, and the like) the papermaking surface comprises a very finely woven or fine wire mesh structure. 
     In a conventional tissue forming machine, the sheet is formed flat. At the press section, 100% of the sheet is pressed and compacted to reach the necessary dryness and the sheet is further dried on a Yankee and hood section. The sheet is then creped and wound-up, thereby producing a flat sheet. 
     In an ATMOS™ system, a sheet is formed on a structured or molding fabric and the sheet is further sandwiched between the structured or molding fabric and a dewatering fabric. The sheet is dewatered through the dewatering fabric and opposite the molding fabric. The dewatering takes place with airflow and mechanical pressure. The mechanical pressure is created by a permeable belt and the direction of air flow is from the permeable belt to the dewatering fabric. This can occur when the sandwich passes through an extended pressure nip formed by a vacuum roll and the permeable belt. The sheet is then transferred to a Yankee by a press nip. Only about 25% of the sheet is slightly pressed by the Yankee while approximately 75% of the sheet remains unpressed for quality. The sheet is dried by a Yankee/Hood dryer arrangement and then dry creped. In the ATMOS™ system, one and the same structured fabric is used to carry the sheet from the headbox to the Yankee dryer. Using the ATMOS™ system, the sheet reaches between about 35 to 38% dryness after the ATMOS™ roll, which is almost the same dryness as a conventional press section. However, this advantageously occurs with almost 40 times lower nip pressure and without compacting and destroying sheet quality. Furthermore, a big advantage of the ATMOS™ system is that it utilizes a permeable belt which is highly tensioned, e.g., about 60 kN/m. This belt enhances the contact points and intimacy for maximum vacuum dewatering. Additionally, the belt nip is more than 20 times longer than a conventional press and utilizes airflow through the nip, which is not the case on a conventional press system. 
     Actual results from trials using an ATMOS™ system have shown that the caliper and bulk of the sheet is 30% higher than the conventional through-air drying (TAD) formed towel fabrics. Absorbency capacity is also 30% higher than with conventional TAD formed towel fabrics. The results are the same whether one uses 100% virgin pulp up to 100% recycled pulp. Sheets can be produced with basis weight ratios of between 14 to 40 g/m 2 . The ATMOS™ system also provides excellent sheet transfer to the Yankee working at 33 to 37% dryness. A key aspect of the ATMOS™ system is that it forms the sheet on the molding fabric and the same molding fabric carries the sheet from the headbox to the Yankee dryer. This produces a sheet with a uniform and defined pore size for maximum absorbency capacity. 
     U.S. patent application Ser. No. 11/753,435 filed on May 24, 2007, the disclosure of which is hereby expressly incorporated by reference in its entirety, discloses a structured fabric for an ATMOS™ system. The fabric utilizes an at least three float warp and weft structure which, like the prior art fabrics, is symmetrical in form. 
     U.S. Pat. No. 5,429,686 to CHIU et al., the disclosure of which is hereby expressly incorporated by reference in its entirety, discloses structured forming fabrics which utilize a load-bearing layer and a sculptured layer. The fabrics utilize impression knuckles to imprint the sheet and increase its surface contour. This document, however, does not create pillows in the sheet for effective dewatering of TAD applications, nor does it teach using the disclosed fabrics on an ATMOS™ system and/or forming the pillows in the sheet while the sheet is relatively wet and utilizing a hi-tension press nip. 
     U.S. Pat. No. 6,237,644 to HAY et al., the disclosure of which is hereby expressly incorporated by reference in its entirety, discloses structured forming fabrics which utilize a lattice weave pattern of at least three yarns oriented in both warp and weft directions. The fabric essentially produces shallow craters in distinct patterns. This document, however, does not teach using the disclosed fabrics on an ATMOS™ system. 
     What is needed in the art is an efficient effective single layer fabric weave pattern to be used in a papermaking machine. 
     SUMMARY OF THE INVENTION 
     In one aspect, the invention provides a fibrous web including a fibrous construct having at least one formed surface feature. The surface feature including a topographical pattern reflective of a weave pattern in a fabric used in a papermaking machine having a through-air drying system. The fabric including a single layer of yarns arranged in a repeating weave pattern, each weave pattern including a plurality of warp yarns substantially oriented in a machine direction (MD) defining MD yarns; and a plurality of weft yarns substantially oriented in a cross machine direction (CD) defining CD yarns. The MD yarns each having at least one long float within the weave pattern. Each long float being adjacent to at least one other long float of an MD yarn. The weave pattern being a plain weave apart from the long floats. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein: 
         FIG. 1  shows a repeating weave pattern having a square shape of a top side or paper facing side of an embodiment of a structured fabric of the present invention, each ‘X’ indicating a location where a warp MD yarn passes over a weft CD yarn; 
         FIG. 2  shows the weave pattern of the structured fabric of  FIG. 1 ; 
         FIG. 3  shows a repeating weave pattern having a square shape of a top side or paper facing side of another embodiment of a structured fabric of the present invention, each ‘X’ indicating a location where a warp MD yarn passes over a weft CD yarn; 
         FIG. 4  shows the weave pattern of the structured fabric of  FIG. 3 ; 
         FIG. 5  shows a repeating weave pattern having a square shape of a top side or paper facing side of yet another embodiment of a structured fabric of the present invention, each ‘X’ indicating a location where a warp MD yarn passes over a weft CD yarn; 
         FIG. 6  shows the weave pattern of the structured fabric of  FIG. 5 ; 
         FIG. 7  shows a repeating weave pattern having a square shape of a top side or paper facing side of yet another embodiment of a structured fabric of the present invention, each ‘X’ indicating a location where a warp MD yarn passes over a weft CD yarn; 
         FIG. 8  shows the weave pattern of the structured fabric of  FIG. 7 ; 
         FIG. 9  shows a repeating weave pattern having a square shape of a top side or paper facing side of yet another embodiment of a structured fabric of the present invention, each ‘X’ indicating a location where a warp MD yarn passes over a weft CD yarn; 
         FIG. 10  shows the weave pattern of the structured fabric of  FIG. 9 ; 
         FIG. 11  shows a repeating weave pattern having a square shape of a top side or paper facing side of yet another embodiment of a structured fabric of the present invention, each ‘X’ indicating a location where a warp MD yarn passes over a weft CD yarn; 
         FIG. 12  shows the weave pattern of the structured fabric of  FIG. 11 ; 
         FIG. 13  shows a repeating weave pattern having a square shape of a top side or paper facing side of yet another embodiment of a structured fabric of the present invention, each ‘X’indicating a location where a warp MD yarn passes over a weft CD yarn; 
         FIG. 14  shows the weave pattern of the structured fabric of  FIG. 13 ; 
         FIG. 15  shows a repeating weave pattern having a square shape of a top side or paper facing side of yet another embodiment of a structured fabric of the present invention, each ‘X’ indicating a location where a warp MD yarn passes over a weft CD yarn; 
         FIG. 16  shows the weave pattern of the structured fabric of  FIG. 15 ; 
         FIG. 17  shows a repeating weave pattern having a square shape of a top side or paper facing side of yet another embodiment of a structured fabric of the present invention, each ‘X’ indicating a location where a warp MD yarn passes over a weft CD yarn; 
         FIG. 18  shows the weave pattern of the structured fabric of  FIG. 17 ; 
         FIG. 19  shows a repeating weave pattern having a square shape of a top side or paper facing side of yet another embodiment of a structured fabric of the present invention, each ‘X’ indicating a location where a warp MD yarn passes over a weft CD yarn; 
         FIG. 20  shows the weave pattern of the structured fabric of  FIG. 19 ; 
         FIG. 21  shows a repeating weave pattern having a square shape of a top side or paper facing side of yet another embodiment of a structured fabric of the present invention, each ‘X’ indicating a location where a warp MD yarn passes over a weft CD yarn; 
         FIG. 22  shows the weave pattern of the structured fabric of  FIG. 21 ; 
         FIG. 23  shows a repeating weave pattern having a square shape of a top side or paper facing side of yet another embodiment of a structured fabric of the present invention, each ‘X’ indicating a location where a warp MD yarn passes over a weft CD yarn; 
         FIG. 24  shows the weave pattern of the structured fabric of  FIG. 23 ; 
         FIG. 25  shows a repeating weave pattern having a square shape of a top side or paper facing side of yet another embodiment of a structured fabric of the present invention, each ‘X’ indicating a location where a warp MD yarn passes over a weft CD yarn; 
         FIG. 26  shows the weave pattern of the structured fabric of  FIG. 25 ; 
         FIG. 27  shows a repeating weave pattern having a square shape of a top side or paper facing side of yet another embodiment of a structured fabric of the present invention, each ‘X’ indicating a location where a warp MD yarn passes over a weft CD yarn; 
         FIG. 28  shows the weave pattern of the structured fabric of  FIG. 27 ; 
         FIG. 29  illustrates a schematic cross-sectional view of an embodiment of an ATMOS™ papermaking machine; 
         FIG. 30  illustrates a schematic cross-sectional view of another embodiment of an ATMOS™ papermaking machine; 
         FIG. 31  illustrates a schematic cross-sectional view of another embodiment of an ATMOS™ papermaking machine; 
         FIG. 32  illustrates a schematic cross-sectional view of another embodiment of an ATMOS™ papermaking machine; 
         FIG. 33  illustrates a schematic cross-sectional view of another embodiment of an ATMOS™ papermaking machine; 
         FIG. 34  illustrates a schematic cross-sectional view of another embodiment of an ATMOS™ papermaking machine; 
         FIG. 35  illustrates a schematic cross-sectional view of another embodiment of an ATMOS™ papermaking machine; 
         FIG. 36  illustrates a schematic cross-sectional view of another embodiment of an ATMOS™ papermaking machine; and 
         FIG. 37  is a schematic process flow diagram of a throughdrying process in accordance with this invention, illustrating an uncreped throughdrying process with only one throughdryer; 
         FIG. 38  is a schematic process flow diagram of a throughdrying process in accordance with this invention, illustrating an uncreped throughdrying process having two throughdryers in series; and 
         FIG. 39  shows another schematic view of an apparatus for practicing the present invention product and process. 
     
    
    
     Corresponding reference characters indicate corresponding parts throughout the several views. The exemplification set out herein illustrates one embodiment of the invention, in one form, and such exemplification is not to be construed as limiting the scope of the invention in any manner. 
     DETAILED DESCRIPTION OF THE INVENTION 
     The particulars shown herein are by way of example and for purposes of illustrative discussion of the embodiments of the present invention only and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the present invention. In this regard, no attempt is made to show structural details of the present invention in more detail than is necessary for the fundamental understanding of the present invention, and the description is taken with the drawings making apparent to those skilled in the art how the forms of the present invention may be embodied in practice. 
     The present invention relates to a structured fabric for a papermaking machine, a former for manufacturing a paper web, and also to a former which utilizes the structured fabric, and in some embodiments a belt press, in a papermaking machine. 
     The present invention also relates to a twin wire former ATMOS™ system which utilizes the structured fabric which has good resistance to pressure and excessive tensile strain forces, and which can withstand wear/hydrolysis effects that are experienced in an ATMOS™ system. The system may also include a permeable belt for use in a high tension extended nip around a rotating roll or a stationary shoe and a dewatering fabric for the manufacture of premium tissue or towel grades. The fabric has key parameters which include permeability, weight, caliper, and certain compressibility. 
     The structured fabric of the present invention is illustrated in  FIGS. 1-28 .  FIG. 1  depicts a weave pattern  10  from a top pattern view of the web facing side of the fabric (i.e., a view of the papermaking surface). The numbers 1-20 shown on the bottom of the pattern identify the warp, machine direction (MD) yarns while the right side numbers 1-20 show the weft, cross-direction (CD) yarns. The symbol X illustrates a location where a warp yarn passes over a weft yarn and an empty box illustrates a location where a warp yarn passes under a weft yarn. As shown in  FIG. 1 , the areas that are shaded indicate long float warp yarns, which float over at least two weft yarns. The shaded areas form a MD float pattern, while the non-shaded areas represent a plain weave pattern. In a like manner the weave patterns of  FIGS. 3 ,  5 ,  7 ,  9 ,  11 ,  13 ,  15 ,  17 ,  19 ,  21 ,  23 ,  25 , and  27  illustrate other embodiments of the present invention. 
       FIG. 2  illustrates the weave pattern of the MD yarns relative to the CD yarns with the CD yarns being represented in each line as the numbers, with the line being the pattern of the MD yarn. Each line representing the MD yarn identified along the left side of the Fig. In a like manner  FIG. 4  corresponds to  FIG. 3  and so on with the even numbered figures through  FIG. 28 , corresponding to the odd numbered figure that is numerically one less than the even numbered Fig. 
     The embodiments shown in  FIGS. 1-28  are illustrative of the invention and the invention is not limited to the weave patterns shown therein. 
     The fabric of  FIGS. 1-28  illustrates a repeating weave pattern square of the fabric that encompasses twenty MD warp yarns (yarns 1-20 numbered along the bottom of each pattern) and twenty weft yarns (yarns 1-20 that are numbered along the right side of each pattern). There are long floats of the MD warp yarns over the weft yarns, with the long float being over at least two weft yarns, and in most patterns over at least three weft yarns. Although in some patterns the MD warp yarn float is over at least four or even over at least five weft yarns. 
     Where the MD warp yarns have there long float they are always adjacent to at least one other MD warp yarn that is also undergoing a long float. The float beginning and ending are offset in the MD by one weft yarn position. The contiguous adjacent MD warp yarns form an MD yarn float pattern, with at least one being present in each weave pattern  10 . The MD yarn float patterns are replicated in weave pattern  10 , and includes minor-image or reflected MD yarn float patterns. The MD yarn float patterns can be symmetrical or asymmetrical. For example, in  FIG. 1  there is one MD yarn float pattern having a float over five weft yarns that is only four MD yarns wide and there is another MD yarn float pattern having a float over five weft yarns that is five MD yarns wide. So, while the patterns are similar and are a reflection of each other, they are also asymmetrical. 
     Looking at  FIG. 3 , there are MD yarn float patterns that are mirror-images and are symmetrical. The MD yarns float over three weft yarns and are three MD yarns wide. In each case apart from the MD yarn float patterns the weave of the single layer fabric is a simple weave pattern. In many cases the plain weave pattern surrounds the MD yarn float patterns. In some weave patterns, such as those of  FIGS. 17 and 19 , the simple weave patterns appear surrounded by MD yarn float patterns. 
     The parameters of the structured fabric shown in  FIGS. 1-28  can have a mesh (number of warp yarns per inch) and a count (number of weft yarns per inch) of any amount. The single-layered fabric should have a high permeability value due to the nature of a single layer fabric and the way it is woven. Regarding yarn dimensions, the particular size of the yarns is typically governed by the mesh of the papermaking surface and the yarn size can be selected based upon the intended use. Fabrics employing these yarn sizes may be implemented with polyester yarns or with a combination of polyester and nylon yarns. 
     The structured fabric can also be treated and/or coated with an additional polymeric material that is applied by, e.g., deposition. The material can be added cross-linked during processing in order to enhance fabric stability, contamination resistance, drainage, wearability, improve heat and/or hydrolysis resistance and in order to reduce fabric surface tension. This aids in sheet release and/or reduced drive loads. The treatment/coating can be applied to impart/improve one or several of these properties of the fabric. As indicated previously, the topographical pattern in the paper web can be changed and manipulated by use of different single-layer weaves. Further enhancement of the pattern can be attained by adjustments to the specific fabric weave by changes to the yarn diameter, yarn counts, yarn types, yarn shapes, permeability, caliper and the addition of a treatment or coating etc. In addition, a printed design, such as a screen-printed design, of polymeric material can be applied to the fabric to enhance its ability to impart an aesthetic pattern into the web or to enhance the quality of the web. Finally, one or more surfaces of the fabric or molding belt can be subjected to sanding and/or abrading in order to enhance surface characteristics. 
     The characteristics of the individual yarns utilized in the fabric of the present invention can vary depending upon the desired properties of the final papermakers&#39; fabric. For example, the materials comprising yarns employed in the fabric of the present invention may be those commonly used in papermakers&#39; fabric. As such, the yarns may be formed of polypropylene, polyester, nylon, or the like. The skilled artisan should select a yarn material according to the particular application of the final fabric. 
     By way of non-limiting example, the structured fabric is a single-layered woven fabric which can withstand high pressures, heat, moisture concentrations, and which can achieve a high level of water removal and also mold or emboss the paper web. These characteristics provide a structured fabric appropriate for the Voith ATMOS™ papermaking process. The fabric preferably has a width stability and a suitable high permeability and preferably utilizes hydrolysis and/or temperature resistant materials, as discussed above. The fabric is preferably a woven fabric that can be installed on an ATMOS™ machine as a pre-joined and/or seamed continuous and/or endless belt. Alternatively, the structured fabric can be joined in the ATMOS™ machine using, e.g., a pin-seam arrangement or can otherwise be seamed on the machine. 
     The invention also provides for utilizing the structured fabric disclosed herein on a machine for making a fibrous web, e.g., tissue or hygiene paper web, etc., which can be, e.g., a twin wire+a permeable belt ATMOS™ system. Referring again to the drawings, and more particularly to  FIGS. 29-35 , there is a fibrous web machine including a headbox  22  that discharges a fibrous slurry between a forming fabric  26  and a structured fabric  28  having a weave pattern  10 . It should be understood that structured fabric  28  is an embodiment of the structured fabric discussed above in connection with  FIGS. 1-28 . Rollers  30  and  32  direct fabric  26  in such a manner that tension is applied thereto, against slurry  24  and structured fabric  28 . Structured fabric  28  is supported by forming roll  34  which rotates with a surface speed that matches the speed of structured fabric  28  and forming fabric  26 . Structured fabric  28  has peaks and valleys as defined by weave pattern  10 , which give a corresponding structure to web  38  formed thereon. Structured fabric  28  travels in a web direction, and as moisture is driven from the fibrous slurry, structured fibrous web  38  takes form. The moisture that leaves the slurry travels through forming fabric  26 . 
     The fibrous slurry is formed into a web  38  with a structure that matches the shape of structured fabric  28 . Forming fabric  26  is porous and allows moisture to escape during forming. Further, water is removed through dewatering fabric  82 . The removal of moisture through fabric  82  does not cause compression of web  38  traveling on structured fabric  28 . 
     Due to the formation of the web  38  with the structured fabric  28  the pockets of the fabric  28  are fully filled with fibers. Therefore, at the Yankee surface  52  the web  38  has a much higher contact area, up to approximately 100%, as compared to the prior art because the web  38  on the side contacting the Yankee surface  52  is almost flat. 
     Referring to  FIG. 29 , there is shown an embodiment of the process where a structured fibrous web  38  is formed. Structured fabric  28  carries a three dimensional structured fibrous web  38  to an advanced dewatering system  50 , past vacuum box  67  and then to a position where the web is transferred to Yankee dryer  52  and hood section  54  for additional drying and creping before winding up on a reel (not shown). 
     A shoe press  56  is placed adjacent to structured fabric  28 , holding fabric  28  in a position proximate Yankee dryer  52 . Structured fibrous web  38  comes into contact with Yankee dryer  52  and transfers to a surface thereof, for further drying and subsequent creping. 
     A vacuum box  58  is placed adjacent to structured fabric  28  to achieve improved solids levels. Web  38 , which is carried by structured fabric  28 , contacts dewatering fabric  82  and proceeds toward vacuum roll  60 . Vacuum roll  60  operates at a vacuum level of −0.2 to −0.8 bar with a preferred operating level of at least −0.4 bar. Hot air hood  62  is optionally fit over vacuum roll  60  to improve dewatering. 
     Optionally a steam box can be installed instead of the hood  62  supplying steam to the web  38 . The steam box preferably has a sectionalized design to influence the moisture re-dryness cross profile of the web  38 . The length of the vacuum zone inside the vacuum roll  60  can be from 200 mm to 2,500 mm, with a preferable length of 300 mm to 1,200 mm and an even more preferable length of between 400 mm to 800 mm. The solids level of web  38  leaving suction roll  60  is 25% to 55% depending on installed options. A vacuum box  67  and hot air supply  65  can be used to increase web  38  solids after vacuum roll  60  and prior to Yankee dryer  52 . Wire turning roll  69  can also be a suction roll with a hot air supply hood. As discussed above, roll  56  includes a shoe press with a shoe width of 80 mm or higher, preferably 120 mm or higher, with a maximum peak pressure of less than 2.5 MPa. To create an even longer nip to facilitate the transfer of web  38  to Yankee dryer  52 , web  38  carried on structured fabric  28  can be brought into contact with the surface of Yankee dryer  52  prior to the press nip associated with shoe press  56 . Further, the contact can be maintained after structured fabric  28  travels beyond press  56 . 
     Now, additionally referring to  FIG. 30 , there is shown yet another embodiment of the present invention, which is substantially similar to the invention illustrated in  FIG. 29 , except that instead of hot air hood  62 , there is a belt press  64 . Belt press  64  includes a permeable belt  66  capable of applying pressure to the machine side of structured fabric  28  that carries web  38  around vacuum roll  60 . Fabric  66  of belt press  64  is also known as an extended nip press belt or a link fabric, which can run at 60 KN/m fabric tension with a pressing length that is longer than the suction zone of roll  60 . 
     Preferred embodiments of the fabric  66  and the required operation conditions are also described in PCT/EP2004/053688 and PCT/EP2005/050198 which are herewith incorporated by reference. 
     The above mentioned references are also fully applicable for dewatering fabrics  82  and press fabrics  66  described in the further embodiments. 
     Belt  66  is a specially designed extended nip press belt  66 , made of, for example reinforced polyurethane and/or a spiral link fabric. Belt  66  also can have a woven construction. Such a woven construction is disclosed, e.g., in EP 1837439. Belt  66  is permeable thereby allowing air to flow there through to enhance the moisture removing capability of belt press  64 . Moisture is drawn from web  38  through dewatering fabric  82  and into vacuum roll  60 . 
     Referring to  FIG. 31 , there is shown another embodiment of the present invention which is substantially similar to the embodiment shown in  FIG. 30  with the addition of hot air hood  68  placed inside of belt press  64  to enhance the dewatering capability of belt press  64  in conjunction with vacuum roll  60 . 
     Referring to  FIG. 32 , there is shown yet another embodiment of the present invention, which is substantially similar to the embodiment shown in  FIG. 30 , but including a boost dryer  70  which encounters structured fabric  28 . Web  38  is subjected to a hot surface of boost dryer  70 , and structured web  38  rides around boost dryer  70  with another woven fabric  72  riding on top of structured fabric  28 . On top of woven fabric  72  is a thermally conductive fabric  74 , which is in contact with both woven fabric  72  and a cooling jacket  76  that applies cooling and pressure to all fabrics and web  38 . The pressing process does not negatively impact web quality. The drying rate of boost dryer  70  is above 400 kg/hr m 2  and preferably above 500 kg/hr m 2 . The concept of boost dryer  70  is to provide sufficient pressure to hold web  38  against the hot surface of the dryer thus preventing blistering. Steam that is formed at the knuckle points of fabric  28  passes through fabric  28  and is condensed on fabric  72 . Fabric  72  is cooled by fabric  74  that is in contact with cooling jacket  76 , which reduces its temperature to well below that of the steam. Thus the steam is condensed to avoid a pressure build up to thereby avoid blistering of web  38 . The condensed water is captured in woven fabric  72 , which is dewatered by dewatering device  75 . It has been shown that depending on the size of boost dryer  70 , the need for vacuum roll  60  can be eliminated. Further, depending on the size of boost dryer  70 , web  38  may be creped on the surface of boost dryer  70 , thereby eliminating the need for Yankee dryer  52 . 
     Referring to  FIG. 33 , there is shown yet another embodiment of the present invention substantially similar to the invention disclosed in  FIG. 30  but with an addition of an air press  78 , which is a four roll cluster press that is used with high temperature air and is referred to as a High Pressure Through Air Dryer (HPTAD) for additional web drying prior to the transfer of web  38  to Yankee dryer  52 . Four-roll cluster press  78  includes a main roll, a vented roll, and two cap rolls. The purpose of this cluster press is to provide a sealed chamber that is capable of being pressurized. The pressure chamber contains high temperature air, for example, 150° C. or higher and is at a significantly higher pressure than conventional TAD technology, for example, greater than 1.5 psi resulting in a much higher drying rate than a conventional TAD. The high-pressure hot air passes through an optional air dispersion fabric, through web  38  and fabric structured  28  into a vent roll. The air dispersion fabric may prevent web  38  from following one of the cap rolls. The air dispersion fabric is very open, having a permeability that equals or exceeds that of fabric structured  28 . The drying rate of the HPTAD depends on the solids content of web  38  as it enters the HPTAD. The preferred drying rate is at least 500 kg/hr m 2 , which is a rate of at least twice that of conventional TAD machines. 
     Advantages of the HPTAD process are in the areas of improved sheet dewatering without a significant loss in sheet quality and compactness in size and energy efficiency. Additionally, it enables higher pre-Yankee solids, which increase the speed potential of the invention. Further, the compact size of the HPTAD allows for easy retrofitting to an existing machine. The compact size of the HPTAD and the fact that it is a closed system means that it can be easily insulated and optimized as a unit to increase energy efficiency. 
     Referring to  FIG. 34 , there is shown another embodiment of the present invention. This is significantly similar to the embodiments shown in  FIGS. 30 and 33  except for the addition of a two-pass HPTAD  80 . In this case, two vented rolls are used to double the dwell time of structured web  38  relative to the design shown in  FIG. 33 . An optional coarse mesh fabric may be used as in the previous embodiment. Hot pressurized air passes through web  38  carried on structured fabric  28  and onto the two vent rolls. It has been shown that depending on the configuration and size of the HPTAD, more than one HPTAD can be placed in series, which can eliminate the need for roll  60 . 
     Referring to  FIG. 35 , a conventional twin wire former  90  may be used to replace the crescent former shown in previous examples. The forming roll can be either a solid or open roll. If an open roll is used, care must be taken to prevent significant dewatering through the structured fabric to avoid losing basis weight in the pillow areas. The outer forming fabric  93  can be either a standard forming fabric or one such as that disclosed in U.S. Pat. No. 6,237,644. The inner fabric  91  should be a structured fabric that is much coarser than the outer forming fabric  90 . For example, inner fabric  91  may be similar to structured fabric  28 . A vacuum roll  92  may be needed to ensure that the web stays with structured fabric  91  and does not go with outer wire  90 . Web  38  is transferred to structured fabric  28  using a vacuum device. The transfer can be a stationary vacuum shoe or a vacuum assisted rotating pick-up roll  94 . The second structured fabric  28  is at least the same coarseness and preferably coarser than first structured fabric  91 . The process from this point is the same as the process previously discussed in conjunction with  FIG. 30 . The registration of the web from the first structured fabric to the second structured fabric is not perfect, and as such some pillows will lose some basis weight during the expansion process, thereby losing some of the benefit of the present invention. However, this process option allows for running a differential speed transfer, which has been shown to improve some sheet properties. Any of the arrangements for removing water discussed above as may be used with the twin wire former arrangement and a conventional TAD. 
     Referring to  FIG. 36  there is illustrated another ATMOS™ system having many elements as discussed above. The ATMOS™ system of  FIG. 36 , is further described in WO 2010/069695 having a priority date of Dec. 19, 2008. Belt press  64  constitutes a first pressing zone where web  38  is pressed. Web  38  proceeds to a second pressing zone  65  where web  38  is pressed again. 
       FIGS. 37-39  illustrate types of TAD systems, specifically those described in the patent record of Kimberly-Clark (See WO 2005/073461 A1) and Procter &amp; Gamble (See WO 2009/069046 A1).  FIG. 37  illustrates one of many papermaking processes to which the invention is applicable. Shown is an uncreped throughdried tissue process in which a twin wire former having a layered papermaking headbox  205  injects or deposits a stream of an aqueous suspension of papermaking fibers between two forming fabrics  206  and  207 . Forming fabric  207  being the same as structured fabric  28 , discussed above. Forming fabric  207  serves to support and carry the newly-formed wet web  208  downstream in the process as the web is partially dewatered to an appropriate consistency, such as about 10% dry weight percent. As shown in this example, profiling of the web in accordance with this invention takes place at the point in the process where the exhaust gas recovery plenum  211  and the vacuum box(es)  210  are positioned. Additional dewatering of the wet web can be carried out, such as by vacuum suction, using one or more steam boxes in conjunction with one or more vacuum suction boxes (not shown) while the wet web is supported by the forming fabric  207 . 
     The wet web  208  is then transferred from the forming fabric  207  to a transfer fabric  213  traveling at a slower speed than the forming fabric  207  in order to impart increased MD stretch into the web. The transfer is carried out to avoid compression of the wet web, preferably with the assistance of a vacuum shoe  214 . Although not shown, it is within the scope of this invention for the profiling to take place at any point while the web is supported by the transfer fabric as well as the forming fabric  207 . 
     The web is then transferred from the transfer fabric  213  to the throughdrying fabric  220  with the aid of a vacuum transfer roll  215  or a vacuum transfer shoe. Transfer is preferably carried out with vacuum assistance to ensure deformation of the sheet to conform to the throughdrying fabric, thus yielding desired bulk, flexibility, CD stretch and appearance. 
     The vacuum shoe (negative pressure) can be supplemented or replaced by the use of positive pressure from the opposite side of the web to blow the web onto the next fabric in addition to or as a replacement for sucking it onto the next fabric with vacuum. Also, a vacuum roll or rolls can be used to replace the vacuum shoe(s). 
     While supported by the throughdrying fabric  220 , the web is dried to a final consistency, typically about 94 percent or greater, by the throughdryer  225  and thereafter transferred to a carrier fabric  230 . The dried basesheet  227  is transported to the reel  235  using carrier fabric  230  and an optional carrier fabric  231 . An optional pressurized turning roll  233  can be used to facilitate transfer of the web from carrier fabric  230  to fabric  231 . Although not shown, reel calendering or subsequent off-line calendering can be used to improve the smoothness and softness of the basesheet. 
     The hot air used to dry the web while passing over the throughdryer is provided by a burner  240  and distributed over the surface of the throughdrying drum using a hood  241 . The air is drawn through the web into the interior of the throughdrying drum via fan  243  which serves to circulate the air back to the burner. In order to avoid moisture build-up in the system, a portion of the spent air is vented  245 , while a proportionate amount of fresh make-up air  247  is fed to the burner. The exhaust gas recycle stream  250  provides exhaust gas to the exhaust gas recovery plenum  211  operatively positioned in the vicinity of one or more vacuum suction boxes  210 , such that exhaust gas fed to the exhaust gas recovery plenum is drawn through the web, through the papermaking fabric and into the vacuum box(es) in order to control the consistency profile the web. The humidity of the recycled exhaust gas can be about 0.15 pounds of water vapor or greater per pound of air, more specifically about 0.20 pounds of water vapor or greater per pound of air, and still more specifically about 0.25 pounds of water vapor or greater per pound of air. 
       FIG. 38  is a schematic process flow diagram of another throughdrying process in accordance with this invention, similar to that illustrated in  FIG. 37 , but in which two throughdryers are used in series to dry the web. The components of the second throughdryer are given the same reference numbers used for the first throughdryer, but distinguished with a “prime”. When two throughdryers are used as shown, the exhaust gas from the first (primary) throughdryer is recycled to the exhaust gas recovery plenum  211  because of its relatively greater heat value. As previously noted, if the throughdryers are operated in such a fashion that the relative heat value of the second throughdryer is greater than the first for the given application, the exhaust gas from the second throughdryer can be used for the recycle stream to the exhaust gas recovery plenum  211 . 
     Optionally, exhaust gas from the second throughdryer can be used to heat and/or profile the dewatered web by providing an exhaust gas recycle stream  255  which, as shown, is directed to exhaust gas recovery plenum  256  opposite vacuum roll or shoe  257 . Any of the web-contacting or sheet-contacting rolls in the vicinity of vacuum roll or shoe  257  are also suitable locations for introducing the exhaust gas for purposes of profiling in accordance with this invention should these rolls be equipped with vacuum. As an alternative (not shown), a vacuum box can be placed within the loop of fabric  213  and the plenum  256  can be placed operatively opposite this vacuum box to profile the web. 
     As described supra, one fibrous structure useful in achieving the fibrous structure paper product of the present invention is the through-air-dried (TAD), differential density structure described in U.S. Pat. No. 4,528,239. Such a structure may be formed according to the nonlimiting embodiment of the apparatus exemplified in  FIG. 39 . The apparatus  300  includes a head box  310 , a Fourdrinier section  320  comprising a Fourdrinier wire  322 , a press section  330  comprising a TAD carrier fabric  332 , which is the same as structured fabric  28  discussed above and a Yankee Dryer  340 . 
     In one embodiment, it is possible to operate the papermaking machine such that there is a differential velocity between the TAD carrier fabric  332  and the Fourdrinier wire  322  to provide increased fibers in the pillow regions of the fibrous web. The Fourdrinier wire  322  may even run at a higher speed than the TAD carrier fabric  332 . 
     As described supra, it is found that some consumers prefer a relatively bulky product as compared to a relatively cushiony product. It is surprisingly found that in addition to the process/additive changes described supra, in some embodiments during the transfer of the slurry from the Fourdrinier wire to the TAD carrier fabric, if the speed of the Fourdrinier wire and the speed of the TAD carrier fabric are approximately equal, or if the Fourdrinier wire is operating at a relatively slower speed than the TAD carrier fabric, then a relatively high amount of fibers are distributed in the walls of the formed features compared to the formed features of the prior art and a relatively bulky product may be achieved. In other embodiments, the speed of the Fourdrinier wire is from about 0% to about −6% of the TAD carrier fabric (wire-to-press draw of from about 0% to about −6%). One of skill in the art will appreciate that a resin coated belt may be used instead of a TAD carrier fabric. 
     While this invention has been described with respect to at least one embodiment, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.