Patent Publication Number: US-11035077-B2

Title: Methods of making paper products using a molding roll

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is based on U.S. Provisional Application No. 62/292,381, filed Feb. 8, 2016, which is incorporated by reference in its entirety. 
     FIELD OF THE INVENTION 
     My invention relates to methods and apparatuses for manufacturing paper products such as paper towels and bathroom tissue. In particular, my invention relates to methods that use a molding roll to mold a paper web during the formation of the paper product. 
     BACKGROUND OF THE INVENTION 
     Generally speaking, paper products are formed by depositing a furnish comprising an aqueous slurry of papermaking fibers onto a forming section to form a paper web, and then dewatering the web to form a paper product. Various methods and machinery are used to form the paper web and to dewater the web. In papermaking processes to make tissue and towel products, for example, there are many ways to remove water in the processes, each with substantial variability. As a result, the paper products likewise have a large variability in properties. 
     One such method of dewatering a paper web is known in the art as conventional wet pressing (CWP).  FIG. 1  shows an example of a CWP papermaking machine  100 . Papermaking machine  100  has a forming section  110 , which, in this case, is referred to in the art as a crescent former. The forming section  110  includes headbox  112  that deposits an aqueous furnish between a forming fabric  114  and a papermaking felt  116 , thereby initially forming a nascent web  102 . The forming fabric  114  is supported by rolls  122 ,  124 ,  126 ,  128 . The papermaking felt  116  is supported by a forming roll  120 . The nascent web  102  is transferred by the papermaking felt  116  along a felt run  118  that extends to a press roll  132  where the nascent web  102  is deposited onto a Yankee dryer section  140  in a press nip  130 . The nascent web  102  is wet-pressed in the press nip  130  concurrently with the transfer to the Yankee dryer section  140 . As a result, the consistency of the web  102  is increased from about twenty percent solids just prior to the press nip  130  to between about thirty percent solids and about fifty percent solids just after the press nip  130 . The Yankee dryer section  140  comprises, for example, a steam filled drum  142  (“Yankee drum”) and hot air dryer hoods  144 ,  146  to further dry the web  102 . The web  102  may be removed from the Yankee drum  142  by a doctor blade  152  where it is then wound on a reel (not shown) to form a parent roll  190 . 
     A CWP papermaking machine, such as papermaking machine  100 , typically has low drying costs, and can quickly produce the parent roll  190  at speeds from about three thousand feet per minute to in excess of five thousand feet per minute. Papermaking using CWP is a mature process that provides a papermaking machine having high runability and uptime. As a result of the compaction used to dewater the web  102  at the press nip  130 , the resulting paper product typically has a low bulk with a corresponding high fiber cost. While this can result in rolled paper products, such as paper towels or toilet paper, having a high sheet count per roll, the paper products generally have a low absorbency and can feel rough to the touch. 
     As consumers often desire paper products that feel soft and have a high absorbance, other papermaking machines and methods have been developed. Through-air-drying (TAD) is one method that results in paper products with high bulk.  FIG. 2  shows an example of a TAD papermaking machine  200 . The forming section  230  of this papermaking machine  200  is shown with what is known in the art as a twin-wire forming section and it produces a sheet similar to the crescent former  110  of  FIG. 1 . As shown in  FIG. 2 , the furnish is initially supplied in the papermaking machine  200  through a headbox  202 . The furnish is directed by the headbox  202  into a nip formed between a first forming fabric  204  and a second forming fabric  206 , ahead of forming roll  208 . The first forming fabric  204  and the second forming fabric  206  move in continuous loops and diverge after passing beyond forming roll  208 . Vacuum elements such as vacuum boxes, or foil elements (not shown) can be employed in the divergent zone to both dewater the sheet and to insure that the sheet stays adhered to second forming fabric  206 . After separating from the first forming fabric  204 , the second forming fabric  206  and web  102  pass through an additional dewatering zone  212  in which suction boxes  214  remove moisture from the web  102  and second forming fabric  206 , thereby increasing the consistency of the web  102  from, for example, about ten percent solids to about twenty-eight percent solids. Hot air may also be used in dewatering zone  212  to improve dewatering. The web  102  is then transferred to a through-air drying (TAD) fabric  216  at transfer nip  218 , where a shoe  220  presses the TAD fabric  216  against the second forming fabric  206 . In some TAD papermaking machines, the shoe  220  is a vacuum shoe that applies a vacuum to assist in the transfer of the web  102  to the TAD fabric  216 . Additionally, so-called rush transfer maybe used to transfer the web  102  in transfer nip  218  as well as structure it. Rush transfer occurs when the second forming fabric  206  travels at a speed that is faster than the TAD fabric  216 . 
     The TAD fabric  216  carrying the paper web  102  next passes around through-air dryers  222 ,  224  where hot air is forced through the web to increase the consistency of the paper web  102 , from about twenty-eight percent solids to about eighty percent solids. The web  102  is then transferred to the Yankee dryer section  140 , where the web  102  is further dried. The sheet is then doctored off the Yankee drum  142  by doctor blade  152  and is taken up by a reel (not shown) to form a parent roll (not shown). As a result of the minimal compaction during the drying process, the resulting paper product has a high bulk with corresponding low fiber cost. Unfortunately, this process is costly to operate because a lot of water is removed by expensive thermal drying. In addition, the papermaking fibers in a paper product made by TAD typically are not strongly bound, resulting in a paper product that can be weak. 
     Other methods have been developed to increase the bulk and softness of the paper product as compared to CWP, while still retaining strength in the paper web and having low drying costs as compared to TAD. These methods generally involve compactively dewatering the wet web and then belt creping the web so as to redistribute the web fibers in order to achieve desired properties. This method is referred to herein as belt creping and is described in, for example, U.S. Pat. Nos. 7,399,378, 7,442,278, 7,494,563, 7,662,257, and 7,789,995 (the disclosures of which are incorporated by reference in their entirety). 
       FIG. 3  shows an example of a papermaking machine  300  used for belt creping. Similar to the CWP papermaking machine  100 , shown in  FIG. 1 , the belt creping papermaking machine  300  uses a crescent former, discussed above, as the forming section  110 . After leaving the forming section  110 , the felt run  118 , which is supported on one end by roll  108 , extends to a shoe press section  310 . Here, the web  102  is transferred from the papermaking felt  116  to a backing roll  312  in a nip formed between the backing roll  312  and a shoe press roll  314 . A shoe  316  is used to load the nip and dewater the web  102  concurrently with the transfer. 
     The web  102  is then transferred onto a creping belt  322  in a belt creping nip  320  by the action of the creping nip  320 . The creping nip  320  is defined between the backing roll  312  and the creping belt  322 , with the creping belt  322  being pressed against the backing roll  312  by a creping roll  326 . In the transfer at the creping nip  320 , the cellulosic fibers of the web  102  are repositioned and oriented. The web  102  may tend to stick to the smoother surface of the backing roll  312  relative to the creping belt  322 . Consequently, it may be desirable to apply release oils on the backing roll  312  to facilitate the transfer from the backing roll  312  to the creping belt  322 . Also, the backing roll  312  may be a steam heated roll. After the web  102  is transferred onto the creping belt  322 , a vacuum box  324  may be used to apply a vacuum to the web  102  in order to increase sheet caliper by pulling the web  102  into the creping belt  322  topography. 
     It generally is desirable to perform a rush transfer of the web  102  from the backing roll  312  to the creping belt  322  in order to facilitate transfer to creping belt  322  and to further improve sheet bulk and softness. During a rush transfer, the creping belt  322  is traveling at a slower speed than the web  102  on the backing roll  312 . Among other things, rush transferring redistributes the paper web  102  on the creping belt  322  to impart structure to the paper web  102  to increase bulk and to enhance transfer to the creping belt  322 . 
     After this creping operation, the web  102  is deposited on a Yankee drum  142  in the Yankee dryer section  140  in a low intensity press nip  328 . As with the CWP papermaking machine  100  shown in  FIG. 1 , the web  102  is then dried in the Yankee dryer section  140  and then wound on a reel (not shown). While the creping belt  322  imparts desirable bulk and structure to the web  102 , the creping belt  322  may be difficult to use. As the creping belt  322  moves through its travel, the belt bends and flexes, resulting in fatigue of the creping belt  322 . Thus, the creping belt  322  is susceptible to fatigue failure. In addition, creping belts  322  are custom designed elements with no other commercial analog. They are designed to impart a targeted structure to the paper web, and can be difficult to manufacture since they are a low volume element and little prior commercial history exists. Further, the speed of the papermaking machine  300  is slowed by the crepe ratio when the web  102  is rush transferred from the backing roll  312  to the creping belt  322 . The slower exiting web speed leads to lower production speeds compared to non-belt creped systems. Additionally, such creping belt runs require large amounts of floor space and thus increase the size and complexity of the papermaking machine  300 . Furthermore, uniform, reliable sheet transfer to the creping belt  322  may be challenging to achieve. Accordingly, there is thus a desire to develop methods and apparatuses that are able to achieve the paper qualities comparable to fabric creping without the difficulties of the creping belt. 
     SUMMARY OF THE INVENTION 
     According to one aspect, my invention relates to a method of making a fibrous sheet. The method includes forming a nascent web from an aqueous solution of papermaking fibers, dewatering the nascent web to form a dewatered web having a consistency from about ten percent solids to about seventy percent solids, moving the dewatered web on a transfer surface, and transferring the dewatered web from the transfer surface to a molding roll at a molding zone. The molding roll includes an exterior and a patterned surface on the exterior of the molding roll. Papermaking fibers of the dewatered web are redistributed on the patterned surface in order to form a molded paper web. The method also includes transferring the molded paper web to a drying section and drying the molded paper web in the drying section to form a fibrous sheet. 
     According to another aspect, my invention relates to a method of making a fibrous sheet. The method includes forming a nascent web from an aqueous solution of papermaking fibers, dewatering the nascent web to form a dewatered web having a consistency from about fifteen percent solids to about seventy percent solids, moving the dewatered web on a transfer surface, and transferring the dewatered web from the transfer surface to a first molding roll at a first molding zone. The first molding roll includes an exterior and a patterned surface on the exterior of the first molding roll. Papermaking fibers of the dewatered web are redistributed on the patterned surface of the first molding roll and a first side of the dewatered web is patterned by the patterned surface of the first molding roll, in order to form a paper web having a molded first side. The method further includes transferring the paper web from the first molding roll to a second molding roll at a second molding zone. The second molding roll includes an exterior and a patterned surface formed on the exterior of the second molding roll. Papermaking fibers of the paper web are redistributed on the patterned surface of the second molding roll and a second side of the paper web is patterned by the patterned surface of the second molding roll, in order to form a molded paper web having molded first and second sides. In addition, the method includes transferring the molded paper web to a drying section and drying the molded paper web in the drying section to form a fibrous sheet. 
     These and other aspects of my invention will become apparent from the following disclosure. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic diagram of a conventional wet press papermaking machine. 
         FIG. 2  is a schematic diagram of a through-air-drying papermaking machine. 
         FIG. 3  is a schematic diagram of a papermaking machine used with belt creping. 
         FIG. 4  is a schematic diagram of a papermaking machine configuration of a first preferred embodiment of my invention. 
         FIG. 5  is a schematic diagram of a papermaking machine configuration of the second preferred embodiment of my invention. 
         FIGS. 6A and 6B  are schematic diagrams of a portion of a papermaking machine configuration of a third preferred embodiment of my invention. 
         FIGS. 7A and 7B  are schematic diagrams of a portion of a papermaking machine configuration of a fourth preferred embodiment of my invention. 
         FIG. 8  is a schematic diagram of a portion of a papermaking machine configuration of a fifth preferred embodiment of my invention. 
         FIGS. 9A and 9B  are schematic diagrams of a portion of a papermaking machine configuration of a sixth preferred embodiment of my invention. 
         FIGS. 10A and 10B  are schematic diagrams of a portion of a papermaking machine configuration of a seventh preferred embodiment of my invention. 
         FIGS. 11A and 11B  are schematic diagrams of a portion of a papermaking machine configuration of an eighth preferred embodiment of my invention. 
         FIG. 12  is a perspective view of a molding roll of a preferred embodiment of my invention. 
         FIG. 13  is a cross-sectional view of the molding roll shown in  FIG. 12  taken along the plane  13 - 13  of  FIG. 12 . 
         FIG. 14  is a cross-sectional view of the molding roll shown in  FIG. 13  taken along line  14 - 14 . 
         FIGS. 15A, 15B, 15C, 15D, and 15E  are embodiments of a permeable shell showing detail  15  from  FIG. 14 . 
         FIG. 16  is an example of a molding layer of a preferred embodiment of my invention. 
         FIG. 17  is an example of a molding layer of a preferred embodiment of my invention. 
         FIG. 18  is a perspective view of a molding roll of a preferred embodiment of my invention. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     My invention relates to papermaking processes and apparatuses that use a molding roll to produce a paper product. I will describe embodiments of my invention in detail below with reference to the accompanying figures. Throughout the specification and accompanying drawings, the same reference numerals will be used to refer to the same or similar components or features. 
     The term “paper product,” as used herein, encompasses any product incorporating papermaking fibers. This would include, for example, products marketed as paper towels, toilet paper, facial tissues, etc. Papermaking fibers include virgin pulps or recycle (secondary) cellulosic fibers, or fiber mixes comprising at least fifty-one percent cellulosic fibers. Such cellulosic fibers may include both wood and non-wood fibers. Wood fibers include, for example, those obtained from deciduous and coniferous trees, including softwood fibers, such as northern and southern softwood kraft fibers, and hardwood fibers, such as  eucalyptus , maple, birch, aspen, or the like. Examples of fibers suitable for making the products of my invention include nonwood fibers, such as cotton fibers or cotton derivatives, abaca, kenaf, sabai grass, flax, esparto grass, straw, jute hemp, bagasse, milkweed floss fibers, and pineapple leaf fibers. Additional papermaking fibers could include non-cellulosic substances such as calcium carbonite, titanium dioxide inorganic fillers, and the like, as well as typical manmade fibers like polyester, polypropylene, and the like, which may be added intentionally to the furnish or may be incorporated when using recycled paper in the furnish. 
     “Furnishes” and like terminology refers to aqueous compositions including papermaking fibers, and, optionally, wet strength resins, debonders, and the like, for making paper products. A variety of furnishes can be used in embodiments of my invention. In some embodiments, furnishes are used according to the specifications described in U.S. Pat. No. 8,080,130 (the disclosure of which is incorporated by reference in its entirety). As used herein, the initial fiber and liquid mixture (or furnish) that is dried to a finished product in a papermaking process will be referred to as a “web,” “paper web,” a “cellulosic sheet,” and/or a “fibrous sheet.” The finished product may also be referred to as a cellulosic sheet and or a fibrous sheet. In addition, other modifiers may variously be used to describe the web at a particular point in the papermaking machine or process. For example, the web may also be referred to as a “nascent web,” a “moist nascent web,” a “molded web,” and a “dried web.” 
     When describing my invention herein, the terms “machine direction” (MD) and “cross machine direction” (CD) will be used in accordance with their well understood meaning in the art. That is, the MD of a fabric or other structure refers to the direction that the structure moves on a papermaking machine in a papermaking process, while CD refers to a direction crossing the MD of the structure. Similarly, when referencing paper products, the MD of the paper product refers to the direction on the product that the product moved on the papermaking machine in the papermaking process, and the CD of the product refers to the direction crossing the MD of the product. 
     When describing my invention herein, specific examples of operating conditions for the paper machine and converting line will be used. For example, various speeds and pressures will be used when describing paper production on the paper machine. Those skilled in the art will recognize that my invention is not limited to the specific examples of operating conditions including speeds and pressures that are disclosed herein. 
     I. First Embodiment of a Papermaking Machine 
       FIG. 4  shows a papermaking machine  400  used to create a paper web according to a first preferred embodiment of my invention. The forming section  110  of the papermaking machine  400  shown in  FIG. 4  is a crescent former similar to the forming section  110  discussed above and shown in  FIGS. 1 and 3 . An example of an alternative to the crescent forming section  110  includes a twin-wire forming section  230 , shown in  FIG. 2 . In such a configuration, downstream of the twin-wire forming section, the rest of the components of such a papermaking machine may be configured and arranged in a similar manner to that of papermaking machine  400 . An example of a papermaking machine with a twin-wire forming section can be seen in, for example, U.S. Patent Application Pub. No. 2010/0186913 (the disclosure of which is incorporated by reference in its entirety). Still further examples of alternative forming sections that can be used in a papermaking machine include a C-wrap twin wire former, an S-wrap twin wire former, or a suction breast roll former. Those skilled in the art will recognize how these, or even still further alternative forming sections, can be integrated into a papermaking machine. 
     The nascent web  102  is then transferred along a felt run  118  to a dewatering section  410 . In some applications, however, a dewatering section separate from the forming section  110  is not required, as will be discussed, for example, in the second embodiment below. The dewatering section  410  increases the solids content of the nascent web  102  to form a moist nascent web  102 . The preferable consistency of the moist nascent web  102  may vary depending upon the desired application. In this embodiment, the nascent web  102  is dewatered to form a moist nascent web  102  having a consistency preferably between about twenty percent solids and about seventy percent solids, more preferably between about thirty percent solids to about sixty percent solids, and even more preferably between about forty percent solids to about fifty-five percent solids. The nascent web  102  is dewatered concurrently with being transferred from the papermaking felt  116  to a backing roll  312 . The dewatering section  410  shown uses a shoe press roll  314  to dewater the nascent web  102  against the backing roll  312 , as described above with reference to  FIG. 3  and in, for example, U.S. Pat. No. 6,248,210 (the disclosure of which is incorporated by reference in its entirety). Those skilled in the art will recognize that the nascent web  102  may be dewatered using any suitable method known in the art including, for example, a roll press or a displacement press as described in my earlier patents, U.S. Pat. Nos. 6,161,303 and 6,416,631. As discussed further below, the nascent web  102  may also be dewatered using suction boxes and/or thermal drying. Also as discussed above with reference to  FIG. 3 , the surface of the backing roll  312  may be heated to assist with transferring the nascent web  102  to the molding roll  420 . The backing roll  312  may be heated by using any suitable means including, for example, a steam heated roll or an induction heated roll, such as the induction heated roll produced by Comaintel of Grand-Mère, Québec, Canada. The surface of the backing roll  312  is preferably heated to temperatures between about two hundred twelve degrees Fahrenheit to about two hundred twenty degrees Fahrenheit. 
     After being dewatered, the moist nascent web  102  is transferred from the surface of the backing roll  312  to a molding roll  420  in a molding zone. In this embodiment, the molding zone is a molding nip  430  formed between the backing roll  312  and the molding roll  420 . In the molding nip  430 , the papermaking fibers are redistributed by a patterned surface  422  of the molding roll  420  resulting in a paper web  102  that has variable and patterned fiber orientations and variable and patterned basis weights. In particular, the patterned surface  422  preferably includes a plurality of recesses (or “pockets”) and, in some cases, projections that produce corresponding protrusions and recesses in the molded web  102 . The molding roll  420  is rotating in a molding roll direction, which is counterclockwise in  FIG. 4 . 
     The use of the molding roll  420  imparts substantial benefits to the papermaking process. Wet molding the web  102  with the molding roll  420  improves desirable sheet properties such as bulk and absorbency over paper products produced by CWP shown in  FIG. 1  without the inefficiencies and cost of the TAD process shown in  FIG. 2 . In addition, the use of the molding roll  420  greatly reduces the complexity of the papermaking machine  400  and process as compared to processes that use belts to mold the web  102 , such as creping belt  322  shown in  FIG. 3 . Belts are difficult to manufacture and are limited in the materials that can be used to make a belt with a patterned surface. Belts require the use of multiple rolls and many different moving parts, which make belt runs complex, difficult to operate, and introduce a greater number of points of failure. Belt runs also require a large amount of volume including floor space within the paper machine and factory. As a result, such belt runs can increase the costs of an already expensive piece of capital equipment. The molding roll  420  on the other hand is relatively less complex and requires minimal volume and floor space. Existing CWP machines (see  FIG. 1 ) can be readily converted to a wet molding papermaking process by the addition of a molding roll  420  and a backing roll  312 . Because the patterned surface  422  is on or part of the molding roll  420 , it does not need to be designed to withstand bending and flexing that are required for belts. 
     In the first embodiment, the moist nascent web  102  may be transferred from the backing roll  312  to the molding roll  420  by a rush transfer. During a rush transfer, the molding roll  420  is traveling at a slower speed than the web  102  and the backing roll  312 . In this regard, the web  102  is creped by the speed differential and the degree of creping is often referred to as the creping ratio. The creping ratio in this embodiment may be calculated according to Equation (1) as:
 
Creping Ratio (%)=( S   1   /S   2 −1)×100%  Equation (1)
 
where S 1  is the speed of the backing roll  312  and S 2  is the speed of the molding roll  420 . Preferably, the web  102  is creped at a ratio of about five percent to about sixty percent. But, high degrees of crepe can be employed, approaching or even exceeding one hundred percent. The creping ratio is often proportional to the degree of bulk in the sheet, but inversely proportional to the throughput of the paper machine and thus yield of the papermaking machine  400 . In this embodiment, the velocity of the paper web  102  on the backing roll  312  may preferably be from about one thousand feet per minute to about six thousand five hundred feet per minute. More preferably velocity of the paper web  102  on the backing roll  312  is as fast as the process allows, which is typically limited by the drying section  440 . For higher bulk product where a slower paper machine speeds can be accommodated, a higher creping ratio is used.
 
     The molding nip  430  may also be loaded in order to effect sheet transfer and to control sheet properties. When rush transfer or other methods, such as vacuum transfer discussed in the third embodiment below, are used, it is possible to have little or no compression at the molding nip  430 . When molding nip  430  is loaded, the backing roll  312  preferably applies a load to the molding roll  420  from about twenty pounds per linear inch (“PLI”) to about three hundred PLI, more preferably from about forty PLI to about one hundred fifty PLI. But, for high strength, lower bulk sheets, those skilled in the art will appreciate that, in a commercial machine, the maximum pressure may be as high as possible, limited only by the particular machinery employed. Thus, pressures in excess of one hundred fifty PLI, five hundred PLI, or more may be used, if practical, and, when a rush transfer is used, provided the difference in speed between the backing roll  312  and the molding roll  420  can be maintained and sheet property requirements are met. 
     After being molded, the molded web  102  is transferred to a drying section  440  where the web  102  is further dried to a consistency of about ninety-five percent solids. The drying section  440  may principally comprise a Yankee dryer section  140 . As discussed above, the Yankee dryer section  140  includes, for example, a steam filled drum  142  (“Yankee drum”) that is used to dry the web  102 . In addition, hot air from wet end hood  144  and dry end hood  146  is directed against the web  102  to further dry the web  102  as it is conveyed on the Yankee drum  142 . The web  102  is transferred from the molding roll  420  to the Yankee drum  142  at a transfer nip  450 . Although the papermaking machine  400  of this embodiment is shown with a direct transfer from the molding roll  420  to the drying section  440 , other intervening processes may be placed between the molding roll  420  and drying section  440  without deviating from the scope of my invention. 
     In this embodiment, transfer nip  450  is also a pressure nip. Here, a load is generated between the Yankee drum  142  and the molding roll  420  preferably having a line loading of from about fifty PLI to about three hundred fifty PLI. The web  102  will then transfer from the surface of the molding roll  420  to the surface of the Yankee drum. At consistencies from about twenty-five percent to about seventy percent, it is sometimes difficult to adhere the web  102  to the surface of the Yankee drum  142  firmly enough so as to thoroughly remove the web  102  from the molding roll  420 . In order to increase the adhesion between the web  102  and the surface of the Yankee drum  142  as well as improve crepe at doctor blade  152 , an adhesive may be applied to the surface of the Yankee drum  142 . The adhesive can allow for high velocity operation of the system and high jet velocity impingement air drying, and also allow for subsequent peeling of the web  102  from the Yankee drum  142 . An example of such an adhesive is a poly(vinyl alcohol)/polyamide adhesive composition, with an example application rate of this adhesive being at a rate of less than about forty milligrams per meter squared of sheet. Those skilled in the art, however, will recognize the wide variety of alternative adhesives, and further, quantities of adhesives, that may be used to facilitate the transfer of the web  102  to the Yankee drum  142 . 
     The web  102  is removed from the Yankee drum  142  with the help of a doctor blade  152 . 
     After being removed from the Yankee dryer section  140 , is taken up by a reel (not shown) to form a parent roll  190 . Those skilled in the art will also recognize that other operations may be performed on the papermaking machine  400 , especially, downstream of the Yankee drum  142  and before the reel (not shown). These operations may include, for example, calendering and drawing. 
     With use, the patterned surface  422  of the molding roll  420  may require cleaning. Papermaking fibers and other substances may be retained on the patterned surface  422  and, in particular, the pockets. At any one time during operation, only a portion of the patterned surface  422  is contacting and molding the paper web  102 . In the arrangement of rolls shown in  FIG. 4 , about half of the circumference of the molding roll  420  is contacting the paper web  102  and the other half (hereafter free surface) is not. A cleaning section  460  may then be positioned opposite to the free surface of the molding roll  420  to clean the patterned surface  422 . Any suitable cleaning method and device known in the art may be used. The cleaning section  460  depicted in  FIG. 4  is a needle jet such as JN Spray Nozzles made by Kadant of Westford, Mass. A nozzle  462  is used to direct a cleaning medium, such as a high pressure stream of water and/or a cleaning solution, toward the patterned surface  422  in a direction that opposes the rotating direction of the molding roll  420 . The angle the cleaning medium flows is preferably between a line tangent to the patterned surface  422  at the point the cleaning medium strikes the patterned surface  422  and perpendicular to the patterned surface  422  at the same point. As a result, the cleaning medium then chisels and removes any particulate matter that has built-up on the patterned surface  422 . The nozzle  462  and stream are located in an enclosure  464  to collect the cleaning medium and particulate matter. Enclosure  464  may be under vacuum to assist in collecting the cleaning medium and particulate matter. 
     II. Second Embodiment of a Papermaking Machine 
       FIG. 5  shows a second preferred embodiment of my invention. It has been found that the lower the consistency of the moist nascent web  102  is when it is molded on the molding roll  420 , the greater affect molding has on desirable sheet properties such as bulk and absorbency. Thus in general, it is advantageous to minimally dewater the nascent web  102  to increase sheet bulk and absorbency, and in some cases, the dewatering that occurs during forming may be sufficient for molding. When the web  102  is minimally dewatered, the moist nascent web  102  preferably has a consistency between about ten percent solids to about thirty-five percent solids, more preferably between about fifteen percent solids to about thirty percent solids. With such a low consistency, more of the dewatering/drying will occur subsequent to molding. Preferably, a non-compactive drying process will be used in order to preserve as much of the structure imparted to the web  102  during molding as possible. One suitable non-compactive drying process is the use of TAD. Among the various embodiments, the moist nascent web  102  may thus be molded over a range of consistencies extending from about ten percent solids to about seventy percent solids. 
     An example papermaking machine  500  of the second embodiment using a TAD drying section  540  is shown in  FIG. 5 . Although any suitable forming section  510  may be used to form and dewater the web  102 , in this embodiment, the twin wire forming section  510  is similar to that discussed above with respect to  FIG. 2 . The web  102  is then transferred from the second forming fabric  206  to a transfer fabric  512  at transfer nip  514 , where a shoe  516  presses the transfer fabric  512  against the second forming fabric  206 . The shoe  516  may be a vacuum shoe that applies a vacuum to assist in the transfer of the web  102  to the transfer fabric  512 . The wet web  102  then encounters a molding zone. In this embodiment, the molding zone is a molding nip  530  formed by roll  532 , the transfer fabric  512 , and the molding roll  520 . In this embodiment, molding roll  520  and molding nip  530  are constructed and operated similarly to the molding roll  420  and molding nip  430  discussed above with reference to  FIG. 4 . For example, the web  102  may be rush transferred from the transfer fabric  512  to the molding roll  520  as discussed above and roll  532  maybe loaded into the molding roll  520  to control sheet transfer and sheet properties. When a speed differential is used, the creping ratio is calculated using Equation (2), which is similar to Equation (1), as follows:
 
Creping Ratio (%)=( S   3   /S   4 −1)×100%  Equation (2)
 
where S 3  is the speed of the transfer fabric  512  and S 4  is the speed of the molding roll  520 . Likewise, the molding roll  520  has a permeable patterned surface  522 , which is similar to the patterned surface  422  of the molding roll  420 , preferably having a plurality of recesses (or “pockets”) and, in some cases, projections that produce corresponding protrusions and recesses in the molded web  102 .
 
     Alternatively, the nascent web  102  may be minimally dewatered with a separate vacuum dewatering zone  212  in which suction boxes  214  remove moisture from the web  102  to achieve desirable consistencies of about ten percent solids and about thirty-five percent solids before the sheet reaches molding nip  530 . Hot air may also be used in dewatering zone  212  to improve dewatering. 
     After molding, the web  102  is then transferred from the molding roll  520  to a drying section  540  at a transfer nip  550 . As in the papermaking machine  200  discussed above with reference to  FIG. 2 , a vacuum may be applied to assist in the transfer of the web  102  from the molding roll  520  to the through-air drying fabric  216  using a vacuum shoe  552  in the transfer nip  550 . This transfer may occur with or without a speed difference between molding roll  520  and TAD fabric  216 . When a speed differential is used, the creping ratio is calculated using Equation (3), which is similar to Equation (1), as follows:
 
Creping Ratio (%)=( S   4   /S   5 −1)×100%  Equation (3)
 
where S 4  is the speed of the molding roll  520  and S 5  is the speed of the TAD fabric  216 . When rush transfer is used in both the molding nip  530  and the transfer nip  550 , the total creping ratio (calculated by adding the creping ratios in each nip) is preferably between about five percent to about sixty percent. But as with molding nip  430  (see  FIG. 4 ), high degrees of crepe can be employed, approaching or even exceeding one hundred percent.
 
     The TAD fabric  216  carrying the paper web  102  next passes around through-air dryers  222 ,  224  where hot air is forced through the web to increase the consistency of the paper web  102 , to about eighty percent solids. The web  102  is then transferred to the Yankee dryer section  140 , where the web  102  is further dried and, after being removed from the Yankee dryer section  140  by doctor blade  152 , is taken up by a reel (not shown) to form a parent roll (not shown). 
     Wet molding the moist nascent web  102  on the molding roll  520  at consistencies between about ten percent solids to about thirty-five percent solids produces a premium product with the associated costs of TAD discussed above, but still retains the other advantages of using a molding roll  520  including increased bulk and reduced fiber cost. 
     Additionally, this configuration gives a means to control so-called sidedness of the sheet. Sidedness can occur when one side of the paper web  102  has (or is perceived to have) different properties on one side of the paper web  102  and not the other. With a paper web  102  made using a CWP paper machine (see  FIG. 1 ), for example, the Yankee side of the paper web  102  may be perceived to be softer than the air side because, as the paper web  102  is pulled from the Yankee drum  142  by the doctor blade  152 , the doctor blade  152  crepes the sheet more on the Yankee side of the sheet than on the air side of the sheet. In another example, when the paper web  102  is molded on one side, the side contacting the molding surface may have an increased roughness (e.g., deeper recesses and higher protrusions) as compared to the non-molded side. In addition, the side of a molded paper web  102  contacting the Yankee drum  142  may be further smoothed when it is applied the Yankee drum  142 . 
     I have found that the molded structure imparted to the paper web  102  may not continue through the full thickness of the paper web  102 . Transfer of the wet web  102  in molding nip  530  thus predominately molds a first side  104  of the paper web  102 , and transfer in the transfer nip  550  predominately molds a second side  106  of the paper web  102 . Individually controlling the nip parameters at both the molding nip  530  and the transfer nip  550  can counteract sidedness. For example, the patterned surface  522  of the molding roll  520  may be designed with pockets and projections that impart recesses and protrusions that are deeper and higher, respectively, on the first side  104  of the paper web  102  (prior to the paper web  102  being applied to the Yankee drum  142 ) than are imparted by the TAD fabric  216  to the second side  106  of the paper web  102 . Then, when the first side  104  of the paper web  102  is applied to the Yankee drum  142 , the Yankee drum  142  will smooth the first side  104  of the paper web  102  by reducing the height of the protrusions such that, when the paper web  102  is peeled from the Yankee drum  142  by the doctor blade  152 , both the first and second sides  104 ,  106  of the paper web  102  have substantially the same properties. For example, a user may perceive that both sides have the same roughness and softness, or commonly measured paper properties are within normal control tolerances for the paper product. Counteracting sidedness is not limited to adjusting the patterned structure of the molding roll  520  and the TAD fabric  216 . Sidedness can also be counteracted by controlling other nip parameters including the creping ratio and/or the loading of each nip  530 ,  550 . 
     III. Third Embodiment of a Papermaking Machine 
       FIGS. 6A and 6B  show a third preferred embodiment of my invention. As shown in  FIG. 6A , the papermaking machine  600  of the third embodiment may have the same forming section  110 , dewatering section  410 , and drying section  440  as the papermaking machine  400  of the first embodiment shown in  FIG. 4 . Or, as shown in  FIG. 6B , the papermaking machine  602  of the third embodiment may have the same forming section  510  and drying section  540  of the second embodiment shown in  FIG. 5 . The descriptions of those sections are omitted here. As with the molding rolls  420 ,  520  of the first and second embodiments (see  FIGS. 4 and 5 , respectively), the molding roll  610  of the third embodiment has a patterned surface  612  preferably having a plurality of recesses (“pockets”). To improve sheet transfer and sheet molding, the molding roll  610  of the third embodiment uses a pressure differential to aid the transfer of the web  102  from the backing roll  312  or transfer fabric  512  to the molding roll  610 . In this embodiment, the molding roll  610  has a vacuum section (“vacuum box”)  614  located opposite to the backing roll  312  in  FIG. 6A  or roll  532  in  FIG. 6B  in a molding zone. In the embodiments shown in  FIGS. 6A and 6B , the molding zone is molding nip  620 . The patterned surface  612  is permeable such that a vacuum box  614  can be used to establish a vacuum in the molding nip  620  by drawing a fluid through the permeable patterned surface  612 . The vacuum in the molding nip  620  draws the paper web  102  onto the permeable patterned surface  612  of the molding roll  610  and, in particular, into the plurality of pockets in the permeable patterned surface  612 . The vacuum thus molds the paper web  102  and reorients the papermaking fibers in the paper web  102  to have variable and patterned fiber orientations. 
     In other wet molding processes, such as fabric creping (shown in  FIG. 3 ), a vacuum is applied subsequent to the transfer to the creping belt  322  by vacuum box  324 . In this embodiment, however, a vacuum is applied as the paper web  102  is transferred. By applying the vacuum during the transfer, both the mobility of the fibers during transfer and the pull of the vacuum increases the depth of fiber penetration into the pockets of the permeable patterned surface  612 . The increased fiber penetration results in an improved sheet molding amplitude and a greater impact of wet molding on resultant web properties, such as improved bulk. 
     The use of a vacuum transfer allows the molding nip  620  to utilize reduced or no nip loading. Vacuum transfer may thus be a less-compactive or even a non-compactive process. Compaction may be reduced or avoided between the projections of patterned surface  612  and the papermaking fibers located in the corresponding recesses formed in the web  102 . As a result, the paper web  102  may have a higher bulk than one made from a compactive process, such as fabric creping (shown in  FIG. 3 ) or CWP (shown in  FIG. 1 ). Reducing the loading at, or not loading, the molding nip  620  can also reduce the amount of wear between the backing roll  312  or transfer fabric  512  and the molding roll  610 , as compared to wear between the backing roll  312  and the creping belt  322  shown in  FIG. 3 . Reducing wear is especially important for nips that employ rush transfer because increasing crepe ratios (%) and/or increasing crepe roll loadings tend to increase wear and thus can lead to reduced runtimes. 
     Another advantage of using vacuum at the point of transfer is flexibility in the use of release agents on the backing roll  312  or transfer fabric  512 . In particular, release agents can be reduced or even eliminated. As discussed above, the paper web  102  tends to stick to the smoother of two surfaces during a transfer. Thus, release agents are preferably used in fabric creping to assist in the transfer of the paper web  102  from the backing roll  312  to the creping belt  322  (see  FIG. 3 ). Release agents require careful formulation in order to work. They also can build up on the backing roll  312  or can be retained in the paper web  102 . The use of release agents adds complexity to the papermaking process, reduces the runability of the paper machine when they are not effective, and may be deleterious to the paper web  102  properties. In this embodiment, all of these issues can thus be avoided by using vacuum at the point of transfer from the backing roll  312  or transfer fabric  512  to the molding roll  610 . 
     As discussed in the second embodiment, it is preferable for some applications to wet crepe the moist nascent web  102  when it is very wet (e.g., at consistencies from about ten percent solids to about thirty-five percent solids). Webs having these low solid contents may be difficult to transfer. I have found that these very wet webs may be effectively transferred using vacuum at the point of transfer. And, thus, still another advantage of molding roll  610  is the ability to wet crepe very wet moist nascent webs  102  using vacuum box  614 . 
     The vacuum level in the molding nip  620  is suitably large enough to draw the paper web  102  from the backing roll  312  or transfer fabric  512 . Preferably, the vacuum is from about zero inches of mercury to about twenty-five inches of mercury, and more preferably from about ten inches of mercury to about twenty-five inches of mercury. 
     Likewise, the MD length of the vacuum zone of the molding roll  610  is large enough to draw the paper web  102  from the backing roll  312  or transfer fabric  512  and into the molding surface  612 . Such MD lengths may be as small as about two inches or less. The preferable lengths may depend on the rotational speed of the molding roll  610 . The web  102  is preferably subject to vacuum for a sufficient amount of time to draw the papermaking fibers into the pockets. As a result, the MD length of the vacuum zone is preferably increased as the rotational speed of the molding roll  610  is increased. The upper limit of MD length of the vacuum box  614  is driven by the desire to reduce energy consumption and maximize the area within the molding roll  610  for other components such as a cleaning section  640 . Preferably, the MD length of the vacuum zone is from about a quarter of an inch to about five inches, more preferably from about a quarter of an inch to about two inches. 
     Those skilled in the art will recognize that the vacuum zone is not limited to a single vacuum zone, but a multi-zone vacuum box  614  may be used. For example, it may be preferable to use a two stage vacuum box  614  in which the first stage exerts a high level vacuum to draw the paper web  102  from the backing roll  312  or transfer fabric  512  and the second stage exerts a lower level vacuum to mold the paper web  102  by drawing it against the permeable patterned surface  612  and the pockets therein. In such a two stage vacuum box, the MD length and vacuum level of the first stage is preferably just large enough to effect transfer of the paper web  102 . The MD length of the first stage is preferably from about a quarter of an inch to about five inches, more preferably from about a half of an inch to about two inches. Likewise, the vacuum is preferably from about zero inches of mercury to about twenty-five inches of mercury, and more preferably from about ten inches of mercury to about twenty inches of mercury. The MD length of the second stage is preferably larger than the first. Because vacuum is applied to the paper web  102  over a longer distance, the vacuum can be reduced resulting in a paper web  102  having higher bulk. The MD length of the second stage is preferably from about a quarter of an inch to about five inches, more preferably from about a half of an inch to about two inches. Likewise, the vacuum is preferably from about ten inches of mercury to about twenty-five inches of mercury, and more preferably from about fifteen inches of mercury to about twenty-five inches of mercury. 
     By drawing a vacuum in molding nip  620 , the moist nascent web  102  may be advantageously dewatered. The vacuum draws out water from the moist nascent web  102 , as the web  102  travels on the permeable patterned surface  612  through the vacuum zone (vacuum box  614 ). Those skilled in the art will recognize that the degree of dewatering is a function of several considerations including the dwell time of the moist nascent web  102  in the vacuum zone, the strength of the vacuum, the crepe nip load, the temperature of the web, and the initial consistency of the moist nascent web  102 . 
     Those skilled in the art will recognize, however, that the molding nip  620  is not limited to this design. Instead, for example, features of the molding nip  430  of the first embodiment or molding nip  530  of the second embodiment may be incorporated with the molding roll  610  of the third embodiment. For example, it may be desirable to even further increase the bulk of the paper web  102  by combining the molding roll  610  having the vacuum box  614  with a rush transfer, which further crepes the web  102 , and the vacuum molds it at the same time. 
     The molding roll  610  of the third embodiment may also have a blow box  616  at transfer nip  630  where the web  102  is transferred from the permeable patterned surface  612  of the molding roll  610  to the surface of the Yankee drum  142  or TAD fabric  216 . Although blow box  616  provides several benefits in transfer nip  630 , the web may be transferred to the drying section  440 ,  540  without it, as discussed above with reference to transfer nip  450  (see  FIG. 4 ) or transfer nip  550  of (see  FIG. 5 ). When the drying section is a TAD drying section (see  FIG. 6B ), the web  102  may be transferred in the transfer nip  550  using the blow box  616 , the vacuum shoe  552 , or both. 
     Positive air pressure may be exerted from the blow box  616  through the permeable patterned surface  612  of the molding roll  610 . The positive air pressure facilitates the transfer of the molded web  102  at transfer nip  630  by pushing the web away from the permeable patterned surface  612  of the molding roll  610  and towards the surface of the Yankee drum  142  (or TAD fabric  216 ). The pressure in the blow box  616  is set at a level consistent with good transfer of the sheet to the drying section  440 ,  540  and is dependent on box size, and roll construction. There should be enough pressure drop across the sheet to cause it to release from the patterned surface  612 . The MD length of the blow box  616  is preferably from about a quarter of an inch to about five inches, more preferably from about a half of an inch to about two inches. 
     By using a blow box  616 , the contact pressure between the molding roll  610  and the Yankee drum  142  or TAD fabric  216  may be reduced or even eliminated, thus resulting in less compaction of the web  102  at contact points, thus higher bulk. In addition, the air pressure from the blow box  616  urges the fibers at the permeable patterned surface  612  to transfer with the rest of the web  102  to the Yankee drum  142  or TAD fabric  216 , thus reducing fiber picking. Fiber picking may cause small holes (pin holes) in the web  102 . 
     Another advantage of the blow box  616  is that it assists in maintaining and cleaning the patterned surface  612 . The positive air pressure through the roll can help to prevent the accumulation of fibers and other particulate matter on the roll. 
     As with the molding rolls  420 ,  520  of the first and second embodiments, a cleaning section  640  may be constructed opposite to the free surface of the molding roll  610  (e.g., cleaning section  460  as shown in  FIG. 4 ). Any suitable cleaning method and device known in the art may be used, including the needle jet discussed above. As an alternative to, or in combination with, a cleaning section  460  constructed opposite to the free surface, a cleaning section may be constructed inside the molding roll  610  in the section of the molding roll  610  having the free surface. An advantage of the permeable patterned surface  612  is that cleaning devices may be placed on the interior of the molding roll to clean by directing a cleaning solution or cleaning medium outward. Such a cleaning device may include a blow box (not shown) or an air knife (not shown) that forces pressurized air (as the cleaning medium) though the permeable patterned surface  612 . Another suitable cleaning device may be showers  642 ,  644  located in the molding roll  610 . The showers  642 ,  644  may spray water and/or a cleaning solution outward through the permeable patterned surface  612 . Preferably, vacuum boxes  646 ,  648  are positioned opposite to each shower  642 ,  644  on the exterior to collect the water and/or cleaning solution. Likewise, a receptacle  649 , which may be a vacuum box, encloses the showers  642 ,  644  to collect any water and/or cleaning solution that remains in the interior of the molding roll  610 . 
     IV. Fourth Embodiment of a Papermaking Machine 
       FIGS. 7A and 7B  show a fourth embodiment of my invention. As discussed above, molding may be improved by increasing the mobility of the papermaking fibers in the molding zone, which is a molding nip  710  in this embodiment. I have found that one way to increase the mobility of the papermaking fibers is to heat the moist nascent web  102 . The papermaking machines  700 ,  702  of the fourth embodiment are similar to the papermaking machines  600 ,  602  (see  FIGS. 6A and 6B , respectively) of the third embodiment, but includes features to heat the moist nascent web  102 . 
     In this embodiment, the vacuum box  720  is a dual zone vacuum box, having a first vacuum zone  722  and a second vacuum zone  724 . The first vacuum zone  722  is positioned opposite to the backing roll  312  or roll  532  and is used to transfer the moist nascent web  102  from the backing roll  312  or transfer fabric  512  to the molding roll  610 . The first vacuum zone  722  is preferably shorter and uses a greater vacuum than the second vacuum zone  724 . The first vacuum zone  722  is preferably less than about two inches and preferably draws a vacuum between about two inches of mercury and about twenty-five inches of mercury. 
     In this embodiment, the nascent web  102  is heated on the molding roll  610  using a steam shower  730 . Any suitable steam shower  730  may be used with my invention including, for example, a Lazy Steam injector manufactured by Wells Enterprises of Seattle Wash. The steam shower  730  is positioned proximate to the molding nip  710  and opposite to the second vacuum zone  724  of the vacuum box  720 . The steam shower  730  generates steam (for example saturated or superheated steam). The steam shower  730  directs the steam toward the moist nascent web  102  on the patterned surface  612  of the molding roll  610  and the second vacuum zone  724  of the vacuum box  720  uses a vacuum to draw the steam though the web  102 , thus, heating the web  102  and the papermaking fibers therein. The second vacuum zone  724  is preferably from about two inches to about twenty-eight inches and preferably draws a vacuum between about five inches of mercury and about twenty-five inches of mercury. Although, the steam shower  730  may be suitably used without a vacuum zone. The temperature of the steam is preferably from about two hundred twelve degrees Fahrenheit to about two hundred twenty degrees Fahrenheit. Any suitable heated fluid may be emitted by the steam shower, including, for example, heated air or other gas. 
     Heating the moist nascent web  102  in the molding nip  710  is not limited to a heated fluid emitted from a steam shower  730 . Instead, other techniques to heat the moist nascent web  102  may be used including, for example, heated air, a heated backing roll  312 , or heating the molding roll  420 ,  520 ,  610  itself. The molding roll  420 ,  520 ,  610 , and in particular the molding roll  420 ,  520  of the first and second embodiments, may be heated like the backing roll  312  by using any suitable means including, for example, steam or induction heating. By using air, for example, the moist nascent web  102  may be heated and dried while being molded on the molding rolls  420 ,  520  of the first and second embodiments. 
     V. Fifth Embodiment of a Papermaking Machine 
       FIG. 8  shows a fifth embodiment of my invention. The papermaking machine  800  of the fifth embodiment is similar to the papermaking machine  600  (see  FIG. 6A ) of the third embodiment, but includes a doctor blade  810  at the molding zone  820 . The doctor blade  810  is used to peel the web from the backing roll  312  and to facilitate transfer of the web  102  to the molding roll  610 . When the sheet is removed from the backing roll  312 , by the doctor blade  810 , it introduces crepe to the web, which is known to increase sheet caliper and bulk. Thus, implementation of this embodiment provides the ability to add additional bulk to the overall process. Furthermore, sheet transfer by the doctor blade  810  removes the need for contact between the backing roll  312  and the molding roll  610  because the vacuum box  614  in the molding roll  610  will effect sheet transfer to the patterned surface  612  without roll contact. By removing the need for roll to roll contact to effect sheet transfer, roll wear is reduced, especially when there are speed differences between the rolls. The doctor blade  810  may oscillate to further crepe the web  102  at the molding zone  820 . Any suitable doctor blade  810  may be used with my invention, including, for example, the doctor blade disclosed in U.S. Pat. No. 6,113,470 (the disclosure of which is incorporated by reference in its entirety). 
     VI. Sixth Embodiment of a Papermaking Machine 
       FIGS. 9A and 9B  show a sixth embodiment of my invention. The papermaking machines  900 ,  902  of the sixth embodiment are similar to the papermaking machines  600 ,  602  of the third embodiment ( FIGS. 6A and 6B , respectively). Instead of the molding roll having a patterned outer surface (e.g., permeable patterned surface  612  of the molding roll  610  in  FIGS. 6A and 6B ), a molding fabric  910  is used and the molding fabric  910  is patterned to impart structure to the moist nascent web  102  like the permeable patterned surface  612  discussed in the third, fourth, and fifth embodiments. The molding fabric  910  is supported on one end by a molding roll  920  and a support roll  930  on the other end. The molding roll  920  has a permeable shell  922  (as will be discussed further below). The permeable shell  922  allows a vacuum box  614  and a blow box  616  to be used, as discussed above in the third embodiment. 
     As with the previous embodiments, this embodiment includes a cleaning section  940 . Because of the additional space afforded by the molding fabric  910 , the cleaning section  940  may be located on the fabric run between the molding roll  920  and the support roll  930 . Any suitable cleaning device may be used. Similar to the third embodiment, a shower  942  enclosed in a receptacle  945  may be positioned on an interior of the fabric run to direct water and/or a cleaning solution outward through the molding fabric  910 . A vacuum box  944  may be located opposite to the shower  942  to collect the water and/or cleaning solution. Similar to the first and second embodiments, a needle jet may also be used in an enclosure  948  to direct water and/or a cleaning solution at an angle from a nozzle  946 . Enclosure  948  maybe under vacuum to collect the solution emitted by the spray nozzle  946 . 
     VII. Seventh Embodiment of a Papermaking Machine 
       FIGS. 10A and 10B  show a seventh embodiment of my invention. The papermaking machine  1000  shown in  FIG. 10A  is similar to the papermaking machine  400  of the first embodiment. Likewise, the papermaking machine  1002  shown in  FIG. 10B  is similar to the papermaking machine  500  of the second embodiment. In these papermaking machines  1000 ,  1002 , two molding rolls  1010 ,  1020  are used instead of one. The first molding roll  1010  is used to structure one side (a first side  104 ) of the paper web  102  using a patterned surface  1012 , and the second molding roll  1020  is used to structure the other side (a second side  106 ) using a patterned surface  1022 . Molding both surfaces of the web  102  may have several advantages; for example, it may be possible to achieve the benefits of a two-ply paper product with only a single ply, since each side of the sheet can be independently controlled by the two molding rolls  1010 ,  1020 . Also, individually molding each side of the paper web  102  may also help to reduce sidedness. In the papermaking machine  1002  shown in  FIG. 10B , having two molding rolls  1010 ,  1020  also enables the wet web  102  to be directly transferred to the first molding roll  1010  from the second forming fabric  206  and the transfer fabric  512  of  FIG. 5  to be omitted. 
     As discussed above in the second embodiment, I have found that the molded structure imparted to the paper web  102  by each molding roll  1010 ,  1020  may not continue through the full thickness of the paper web  102 . The sheet properties of each side of the paper web  102  may thus be individually controlled by the corresponding molding roll  1010 ,  1020 . For example, the patterned surfaces  1012 ,  1022  of each molding roll  1010 ,  1020  may have a different construction and/or pattern to impart a different structure to each side of the paper web  102 . Although there are advantages to constructing each molding roll  1010 ,  1020  differently, the construction is not so limited, and the molding rolls  1010 ,  1020 , particularly, the patterned surfaces  1012 ,  1022 , may be constructed the same. 
     Sidedness can be counteracted by individually controlling the structure of each side of the molded paper web  102  with the two different molding rolls  1010 ,  1020  of this embodiment. For example, the patterned surface  1012  of the first molding roll  1010  may have deeper pockets and higher projections than the patterned surface  1022  of the second molding roll  1020 . In this way, the first side  104  of the paper web  102  will have recesses and protrusions that are deeper and higher than the second side  106  of the paper web  102  prior to the paper web  102  being applied to the Yankee drum  142 . Then, when the first side  104  of the paper web  102  is applied to the Yankee drum  142 , the Yankee drum  142  will smooth the first side  104  of the paper web  102  by reducing the height of the protrusions such that, when the paper web  102  is peeled from the Yankee drum  142  by the doctor blade  152 , both the first and second sides  104 ,  106  of the paper web  102  have substantially the same properties. For example, a user may perceive that both sides have the same roughness and softness, or commonly measured paper properties are within normal control tolerances for the paper product. 
     In this embodiment, the paper web  102  is transferred from the backing roll  312  or second forming fabric  206  in a first molding zone, which is a first molding nip  1030  in this embodiment. The same considerations that apply to the features of the molding nips  430 ,  530  (see  FIGS. 4 and 5 ) in the first and second embodiments apply to the first molding nip  1030  of this embodiment. 
     After the first side  104  of the paper web  102  is molded by the first molding roll  1010 , the paper web  102  is then transferred from the first molding roll  1010  to the second molding roll  1020  in a second molding zone, which is a second molding nip  1040  in this embodiment. The paper web  102  may be transferred in both molding nips  1030 ,  1040  by, for example, rush transfer. Similar to Equations (1) and (2), the creping ratio in this embodiment for each nip  1030 ,  1040  may be calculated according to Equations (4) and (5) as:
 
Creping Ratio One (%)=( S   1   /S   6 −1)×100%  Equation (4)
 
Creping Ratio Two (%)=( S   6   /S   7 −1)×100%  Equation (5)
 
where S 1  is the speed of the backing roll  312  or second forming fabric  206 , S 6  is the speed of the first molding roll  1010  and S 7  is the speed of the second molding roll  1020 . Preferably, the web  102  is creped in each of the two molding nips  1030 ,  1040  at a ratio of about five percent to about sixty percent. But, high degrees of crepe can be employed, approaching or even exceeding one hundred percent. A unique opportunity exists with two molding nips that can be used to further modify sheet properties. Since each crepe ratio primarily affects the side of the sheet being molded the two crepe ratios can be varied relative to each other to control or vary sheet sidedness. Control systems can be used to monitor sheet properties and use these property measurements to control individual crepe ratios as well as differences between the two crepe ratios.
 
     The paper web  102  is transferred from the second molding roll  1020  to the drying section  440 ,  540  in transfer nip  1050 . As shown in  FIG. 10A , the drying section  440  includes a Yankee dryer section  140 , and the same considerations that apply to the transfer nip  450  of the first embodiment apply (see  FIG. 4 ) to the transfer nip  1050  of this embodiment. As shown in  FIG. 10B , a TAD drying section  540  is used, and the same considerations that apply to the transfer nip  550  (see  FIG. 5 ) of the second embodiment apply to the transfer nip  1050  of this embodiment. 
     VIII. Eighth Embodiment of a Papermaking Machine 
       FIGS. 11A and 11B  show an eighth embodiment of my invention. The papermaking machines  1100 ,  1102  of the eighth embodiment are similar to the papermaking machines  1000 ,  1002  of the seventh embodiment, but the two molding rolls  1110 ,  1120  of the eighth embodiment are constructed similarly to the molding roll  610  of the third embodiment (see  FIGS. 6A and 6B ) instead of the molding rolls  420 ,  520  of the first and second embodiments. The first molding roll  1110  has a permeable patterned surface  1112  and a vacuum box  1114 . The moist nascent web  102  is transferred from the backing roll  312  or second forming fabric  206  in a first molding zone, which is a first molding nip  1130  in this embodiment, using any combination of vacuum transfer using the vacuum box  1114  of the first molding roll  1110 , rush transfer (see Equation (4)) or a doctor blade  810  (see  FIG. 8 ). The first molding nip  1130  may be operated similarly to the molding nip  620  of the third embodiment. 
     After the first side  104  of the paper web  102  is molded on the first molding roll  1110 , the paper web is transferred from the first molding roll  1110  to the second molding roll  1120  in a second molding zone, which is a second molding nip  1140  in this embodiment, using any combination of a vacuum transfer using vacuum box  1124  of the second molding roll  1120 , pressure differential using blow box  1116  of the first molding roll  1110 , rush transfer (see Equation (5)). The second side  106  of the paper web  102  is then molded on the permeable patterned surface  1122  of the second molding roll  1120 . The types of transfers used individually or in combination can be varied to control sheet properties and sheet sidedness. The considerations and parameters that apply to the blow box  616  and vacuum box  614  in the third embodiment also apply to the blow box  1116  of the first molding roll  1110  and the vacuum box  1124  of the second molding roll  1120 . 
     The paper web  102  is transferred from the second molding roll  1120  to the drying section  440 ,  540  in transfer nip  1150 . As shown in  FIG. 11A , the drying section  440  includes a Yankee dryer section  140 . As shown in  FIG. 11B , a TAD drying section  540  is used. The same considerations that apply to the features of the transfer nip  630  in the third embodiment apply to the transfer nip  1150  of this embodiment, including the use of a blow box  1126  (similar to blow box  616 ) in the second molding roll  1120 . 
     IX. Adjustment of Process Parameters to Control Fibrous Sheet Properties 
     Various properties of the resultant fibrous sheet (also referred to herein as paper properties or web properties) can be measured by techniques known in the art. Some properties may be measured in real time, while the paper web  102  is being processed. For example, moisture content and basis weight of the paper web  102  may be measured by a web property scanner positioned after the Yankee drum  142  and before the parent roll  190 . Any suitable web property scanner known in the art may be used, such as an MXProLine scanner manufactured by Honeywell of Morristown, N.J., that is used to measure the moisture content with beta radiation and basis weight with gamma radiation. Other properties, for example, tensile strength (both wet and dry), caliper, and roughness, are more suitably measured offline. Such offline measurements can be conducted by taking a sample of the paper web  102  as it is produced on the paper machine and measuring the property in parallel with production or by taking a sample from the parent roll  190  and measuring the property after the parent roll  190  has been removed from the paper machine. 
     As discussed above in the first through the eighth embodiments, various process parameters can be adjusted to have an impact on the resulting fibrous sheet. These process parameters include, for example: the consistency of the moist nascent web  102  at the molding nips  430 ,  530 ,  620 ,  710 ,  1030 ,  1040 ,  1130 ,  1140  or molding zone  820 ; creping ratios; the load at the molding nips  430 ,  530 ,  620 ,  710 ,  1030 ,  1040 ,  1130 ,  1140 ; the vacuum drawn by vacuum boxes  614 ,  720 ,  1114 ,  1124 ; and the air pressure generated by blow boxes  616 ,  1116 ,  1126 . Typically, a measured value for each paper property of the resultant fibrous sheet lies within a desired range for that paper property. The desired range will vary depending upon the end product of the paper web  102 . If a measured value for a paper property falls outside the desired range, an operator can adjust the various process parameters of this invention so that, in a subsequent measurement of the paper property, the measured value is within the desired range. 
     The vacuum drawn by vacuum boxes  614 ,  720 ,  1114 ,  1124  and the air pressure generated by blow boxes  616 ,  1116 ,  1126  are process parameters that can be readily and easily adjusted while the paper machine is in operation. As a result, the papermaking processes of my invention, in particular those described in embodiments three through six and eight, may be advantageously used to make consistent fibrous sheet products by real time or near real time adjustment to the papermaking process. 
     X. Construction of the Permeable Molding Roll 
     I will now describe the construction of the permeable molding roll  610 ,  920 ,  1110 ,  1120  used with the papermaking machines of the third through sixth and eighth embodiments. For simplicity, the reference numerals used to describe the molding roll  610  ( FIGS. 6A and 6B ) of the third embodiment above will be used to describe corresponding features below.  FIG. 12  is a perspective view of the molding roll  610 , and  FIG. 13  is a cross-sectional view of the molding roll  610  shown in  FIG. 12  taken along the plane  13 - 13 . The molding roll  610  has a radial direction and a cylindrical shape with a circumferential direction C (see  FIG. 14 ) that corresponds to the MD direction of the papermaking machine  600 . The molding roll  610  also has a length direction L (see  FIG. 13 ) that corresponds to the CD direction of the papermaking machine  600 . The molding roll  610  may be driven on one end, the driven end  1210 . Any suitable method known in the art may be used to drive the driven end  1210  of the molding roll  610 . The other end of the molding roll  610 , the rotary end  1220 , is supported by and rotates about a shaft  1230 . The driven end  1210  includes a driven endplate  1212  and a shaft  1214 , which may be driven. The rotary end  1220  includes a rotary endplate  1222 . In this embodiment, the driven endplate  1212  and the rotary endplate  1222  are constructed from steel, which is a relatively inexpensive structural material. Although, those skilled in the art will recognize that the endplates  1212 ,  1222  may be constructed from any suitable structural material. The rotary plate  1222  is attached to the shaft  1230  by a bearing  1224 . A permeable shell  1310  is attached to the circumference of each of the driven endplate  1212  and the rotary endplate  1222  forming a void  1320  there between. The permeable patterned surface  612  is formed on the exterior of the permeable shell  1310 . The details of the permeable shell  1310  will be discussed further below. 
     The vacuum box  614  and the blow box  616  are located in the void  1320  and are supported by shaft  1230  and a rotary connection  1352  to driven endplate  1212  through support structure  1354 . Support structure  1354  allows both vacuum and pressurized air to be conveyed to vacuum box  614  and blow box  616 , respectively, through the shaft  1230 . Both the vacuum box  614  and the blow box  616  are stationary, and the permeable shell  1310  rotates around the stationary boxes  614 ,  616 . Although  FIG. 13  shows these boxes to be opposite to each other on the roll, it is recognized that they can be disposed at any angle around the roll circumference as needed to carry out their functions. Vacuum is drawn in vacuum box  614  through the use of a vacuum line  1332  that is part of the box support structure  1354 . A vacuum pump  1334  thus is able to apply a vacuum to the vacuum box  614  via vacuum line  1332 . Similarly, a pump or blower  1344  is used to force air through pressure line  1342  to create a positive pressure in blow box  616 . 
       FIG. 14  shows cross section of the permeable shell  1310  and vacuum box  614 , taken along line  14 - 14  in  FIG. 13 . The blow box  616  is constructed in substantially the same way as is the vacuum box  614 . As shown in  FIG. 14 , the vacuum box  614  is substantially u-shaped having a first top ends  1420  and a second top end  1430 . An open portion extends between the two top ends  1420 ,  1430  having a distance D in the circumferential (MID) direction C of the molding roll  610 . The distance D of the open portion forms the vacuum zones discussed above. In this embodiment, the vacuum box  614  is constructed from stainless steel with walls that are thick enough to accommodate the vacuum generated in the cavity  1410  and to withstand the rigors of roll operation. Those skilled in the art will recognize that any suitable structural material can be used for the vacuum box but, preferably, is one that is resistant to corrosion from moisture that may be drawn from the web by the vacuum. In this embodiment, the vacuum box  614  is depicted with one single cavity  1410  extending in the length (CD) direction L of the molding roll  610 . To draw a uniform vacuum across in the length (CD) direction L, it may be desirable to subdivide the vacuum box  614  into multiple cavities  1410 . Those skilled in the art will recognize that any number of cavities may be used. Likewise, it may be desirable to subdivide the vacuum box  614  into multiple cavities in the circumferential (MD) direction C to form, for example, the two stage vacuum box discussed above. 
     A seal is formed between each end  1420 ,  1430  of the vacuum box  614  and an inside surface of the permeable shell  1310 . In this embodiment, a tube  1422  is positioned in a cavity formed in the first top end  1420  of the vacuum box  614 . Pressure is applied to inflate the tube  1422  and to press a sealing block  1424  against the inside surface of the permeable shell  1310 . Likewise, two tubes  1432  are positioned inside cavities formed in the second top end  1430  and used to press a sealing block  1434  against the inside surface of the permeable shell  1310 . In addition, an internal roll shower  1440  may be positioned upstream of the vacuum box to apply a lubricating material, such as water, to the bottom surface of the permeable shell  1310 , thereby reducing frictional forces and wear between the sealing blocks  1424 ,  1434  and the permeable shell  1310 . Similarly, each end in the CD direction of the vacuum box  614  and blow box  616  are sealed. As may be seen in  FIG. 13 , a tube  1362  is positioned in a cavity formed in the ends of the vacuum box  614  and blow box  616  and inflated to press a sealing block  1364  against the inside surface of the permeable shell  1310 . Any suitable wear material, such as polypropylene or a polytetrafluoroethylene impregnated polymer, may be used as the sealing blocks  1364 ,  1424 , and  1434 . Any suitable inflatable material, such a rubber, may be used for the tubes  1362 ,  1422 ,  1432 . 
       FIGS. 15A through 15E  are embodiments of the permeable shell  1310  showing detail  15  in  FIG. 14 .  FIGS. 15A, 15B, and 15C  show a two layer construction of the permeable shell  1310 . The inner most layer is structural layer  1510 , and the outer layer is a molding layer  1520 . 
     The structural layer  1510  provides the permeable shell  1310  support. In this embodiment, the structural layer  1510  is made from stainless steel, but any suitable structural material may be used. The thickness of the shell is designed to withstand the forces exerted during paper production, including, for example, the forces exerted when the molding nip  620  in the third embodiment is a pressure nip. The thickness of the structural layer  1510  is designed to withstand the loads on the roll to avoid fatigue and other failure. For example, the thickness will depend on the length of the roll, the diameter of the roll, the materials used, the density of channels  1512 , and the loads applied. Finite element analysis can be used to determine practical roll design parameters and roll crown, if needed. The structural layer  1510  has a plurality of channels  1512 . The plurality of channels  1512  connects the outer layer of the permeable shell  1310  with the inside of the molding roll  610 . When a vacuum is drawn or a pressure is exerted from either of the vacuum box  614  or blow box  616 , respectively, the air is pulled or pushed through the plurality of channels  1512 . 
     The molding layer  1520  is patterned to redistribute and to orient the fibers of the web  102  as discussed above. In the third embodiment, for example, the molding layer  1520  is the permeable patterned surface  612  of the molding roll  610 . As discussed above, my invention is particularly suited for producing absorbent paper products, such as tissue and towel products. Thus, to enhance the benefits in bulk and absorbency, the molding layer  1520  is preferably patterned on a fine scale suitable to orient fibers of the web  102 . The density of each of the pockets and projections of the molding layer  1520  is preferably greater than about fifty per square inch and more preferably greater than about two hundred per square inch. 
       FIG. 16  is an example of a preferred plastic, woven fabric that may be used as the molding layer  1520 . In this embodiment, the woven fabric is shrunk around the structural layer  1510 . The fabric is mounted in the apparatus as the molding layer  1520  such that its MD knuckles  1600 ,  1602 ,  1604 ,  1606 ,  1608 ,  1610  and so forth extend along the machine direction of the papermaking machine (e.g.,  600  in  FIG. 6A ). The fabric may be a multi-layer fabric having creping pockets  1620 ,  1622 ,  1624 , and so forth, between the MD knuckles of the fabric. A plurality of CD knuckles  1630 ,  1632 ,  1634 , and so forth, is also provided, which may be preferably recessed slightly with respect to the MD knuckles  1600 ,  1602 ,  1604 ,  1606 ,  1608 ,  1610  of the creping fabric. The CD knuckles  1630 ,  1632 ,  1634  may be recessed with respect to the MD knuckles  1600 ,  1602 ,  1604 ,  1606 ,  1608 ,  1610  a distance of from about 0.1 mm to about 0.3 mm. This geometry creates a unique distribution of fiber when the web  102  is wet molded from the backing roll  312  or transfer fabric  512 , as discussed above. Without intending to be bound by theory, it is believed that the structure illustrated, with relatively large recessed “pockets” and limited knuckle length and height in the CD, redistributes the fiber upon high impact creping to produce a sheet, which is especially suitable for recycle furnish and provides surprising caliper. In the sixth embodiment, the molding layer  1520  is not attached to the structural layer  1510  and is the molding fabric  910  shown in  FIGS. 9A and 9B . 
     The molding layer  1520  is not limited, however, to woven structures. For example, the molding layer  1520  may be a layer of plastic or metal that has been patterned by knurling, laser drilling, etching, machining, embossing, and the like. The layer of plastic or metal may be suitably patterned either before or after it is applied to the structural layer  1510  of molding roll  610 . 
     Referring back to  FIG. 15A , the spacing and diameter of the plurality of channels  1512  are preferably designed to provide a relatively uniform vacuum or air pressure at the roll surface of the molding layer  1520 . To aid in applying uniform pressure, grooves  1514  that extend or radiate from the plurality of channels  1512  may be cut in the outer surface of the structural layer  1510 . Although, other suitable channel designs may be used to assist in spreading the suction or air pressure under the molding layer  1520 . For example, the top edge of the each channel  1512  may have a chamfer  1516 , as shown in  FIG. 15B . In addition, the channel  1512  geometry is not limited to right, circular cylinders. Instead, other suitable geometries may be used including, for example, a right, trapezoidal cylinder, as shown in  FIG. 15C , which may be formed when the plurality of channels  1512  is created by laser drilling. 
     The plurality of channels  1512  preferably have a construction consistent with the structural needs of the permeable shell  1310  and the ability to uniformly apply vacuum or pressure to the molding surface to effect sheet transfer and molding. In the embodiments shown in  FIGS. 15A, 15B, and 15C , the plurality of channels  1512  preferably has a mean diameter from about two hundredths of an inch to about a half of an inch, more preferably from about sixty-two thousandths of an inch to about a quarter of an inch. In calculating the mean diameter, the diameter of the grooves  1514  and chamfer  1516  may be excluded. Each channel  1512  is preferably spaced from about sixty-four thousandths of an inch to about three hundred seventy-five thousandths of an inch from the next closest channel  1512 , more preferably from about one hundred twenty-five thousandths of an inch to about a quarter of an inch. Additionally, the structural layer  1510  preferably has a density of between about fifty channels per square inch to about five hundred channels per square inch. The closer spaced channels and higher channel densities may achieve a better, more uniform distribution of air. 
     It may be difficult, however, to achieve a sufficient density of the plurality of channels  1512  to apply uniform air pressure to the molding layer  1520  and still have the structural layer provide sufficient structural support with the embodiment shown in  FIG. 15A . To alleviate this concern, an air distribution layer  1530  may be used as a middle layer, as shown in  FIG. 15D . The air distribution layer  1530  is preferably formed by a permeable material that allows the air pushed or drawn through the plurality of channels  1512  to spread under the molding layer  1520 , thus creating a generally uniform draw or pressure. Any suitable material may be used including, for example, porous sintered metals, sintered polymers, and polymer foams. Preferably, the thickness of the air distribution layer  1530  is from about one tenth of an inch to about one inch, more preferably about an eighth of an inch to about a half of an inch. When the air distribution layer  1530  is used, the density of the plurality of channels  1512  may be spread out and the diameters increased. In the embodiment shown in  FIG. 15D , the plurality of channels  1512  preferably has a diameter from about two hundredths of an inch to about five tenths of an inch, more preferably from about five hundredths of an inch to about a quarter of an inch. Each channel  1512  is preferably spaced from about five hundredths of an inch to about one inch from the next closet channel  1512 , more preferably from about on tenth of an inch to about five tenths of an inch. Additionally, the structural layer  1510  preferably has a density of between about fifty channels  1512  per square inch to about three hundred channels  1512  per square inch. 
     As shown in  FIG. 15E , a separate molding layer  1520  may not be necessary. Instead, the outer surface  1518  of the structural layer  1510  may be textured or patterned to form the permeable patterned surface  612 . In the embodiment shown in  FIG. 15E , the outer surface  1518  is patterned by knurling, but any suitable method known in the art, including, for example, laser drilling, etching, embossing, or machining, may be used to texture or to pattern the outer surface  1518 . Although  15 E shows patterning on top of a drilled shell it is also possible to apply patterning by knurling, laser drilling, etching, embossing, or machining the outer surface of the air distribution layer  1530  or molding layer  1520 , as discussed above. 
       FIG. 17  shows a top view of a knurled outer surface  1518 , and the section shown in  FIG. 15E  is taken along line  15 E- 15 E shown in  FIG. 17 . While any suitable pattern may be used, the knurled surface has a plurality projections  1710 , which in this embodiment, are pyramid shaped. The pyramid-shaped projections  1710  of this embodiment have a major axis extending in the MD direction of the molding roll  610  and a minor axis extending in the CD direction of the molding roll  610 . The major axis is longer than the minor axis, giving the base  1712  of the pyramid-shaped projections  1710  a diamond shape. The pyramid-shaped projections  1710  have four lateral sides  1714  that angle and extend downward from the pinnacle  1716  to the base  1712 . Thus, the area where four vertices of four different pyramid-shaped projections  1710  come together forms a recess or pocket  1720 . The pyramid-shaped projections  1710  and pockets  1720  of the knurled outer surface  1518  redistribute the papermaking fibers to mold and to form inverse recesses and protrusions on the paper web  102 . 
     The pyramid-shaped projections  1710  are separated by grooves  1730 . The grooves  1730  of the knurled outer surface  1518  are similar to the grooves  1514  described above with reference to  FIG. 15A . The grooves  1730  radiate outward from a channel  1512  to distribute the air being pushed or pulled through the channels  1512  across the knurled outer surface  1518  and help to evenly distribute the air across the knurled outer surface  1518 . 
     XI. Construction of the Non-Permeable Molding Roll 
     I will now describe the construction of the non-permeable molding roll  420 ,  520 ,  1010 ,  1020  used with the papermaking machines of the first, second, and seventh embodiments. For simplicity, the reference numerals used to describe the molding roll  420  of the first embodiment above will be used to describe corresponding features below.  FIG. 18  is a perspective view of the non-permeable molding roll  420 . As with the permeable molding roll  610 , described above, the non-permeable molding roll  420  has a radial direction and a cylindrical shape with a circumferential direction that corresponds to the MD direction of the papermaking machine  400 . The molding roll  420  also has a length direction that corresponds to the CD direction of the papermaking machine  400 . 
     The non-permeable molding roll  420  has a first end  1810  and a second end  1820 . Either one or both of the first or second ends  1810 ,  1820  may be driven by any suitable means known in the art. In this embodiment, both ends have shafts  1814 ,  1824  that are, respectively, connected to endplates  1812 ,  1822 . The end plates  1812 ,  1822  support each end of a shell (not shown) on which the patterned surface  422  is formed. The roll may be made from any suitable structural material known in the art including, for example, steel. The shell forms the structural support for the patterned surface  422  and may be constructed as a stainless steel cylinder, similar to the permeable shell  1310  discussed above but without the channels  1512 . The molding roll  420 , however, is not limited to this construction. Any suitable roll construction known in the art may be used to construct the non-permeable molding roll  420 . 
     The patterned surface  422  may be formed similarly to the molding layer  1520  discussed above. For example, the patterned surface  422  may be formed by a woven fabric (such as the fabric discussed above with reference to  FIG. 14 ) that is shrunk around the shell of the non-permeable molding roll. In another example, the outer surface of the shell may be textured or patterned. Any suitable method known in the art, including, for example, knurling (such as the knurling discussed above with reference to  FIG. 17 ), etching, embossing, or machining, may be used to texture or pattern the outer surface. The patterned surface  422  may also be formed by laser drilling or etching and, in such a case, is preferably formed from an elastomeric plastic, but any suitable material may be used. 
     Although this invention has been described in certain specific exemplary embodiments, many additional modifications and variations would be apparent to those skilled in the art in light of this disclosure. It is, therefore, to be understood that this invention may be practiced otherwise than as specifically described. Thus, the exemplary embodiments of the invention should be considered in all respects to be illustrative and not restrictive and the scope of the invention to be determined by any claims supportable by this application and the equivalents thereof, rather than by the foregoing description. 
     INDUSTRIAL APPLICABILITY 
     The invention can be used to produce desirable paper products, such as paper towels and bath tissue. Thus, the invention is applicable to the paper products industry.