Patent Publication Number: US-11390999-B2

Title: Method and apparatus for producing a web of extensible fibrous material

Description:
FIELD OF THE INVENTION 
     The present invention relates to a method and apparatus for producing a web of extensible fibrous material. 
     BACKGROUND OF THE INVENTION 
     Methods and apparatuses for producing webs of extensible paper are known. U.S. Pat. Nos. 2,624,245 and 3,515,633 show how to manufacture one of these webs with an apparatus comprising a heated rotating cylinder provided with a smooth side surface, and a blanket consisting of a rubber web adhered, by means of at least partially motorized return rollers, to the surface of the heated cylinder and fed at the same peripheral speed thereof. 
     In order to reduce the friction between the blanket and the smooth side surface of the heated cylinder, water or a mixture of water and silicone may be sprayed therebetween. 
     The arrangement of the blanket on the side surface of the heated cylinder and of the return rollers is such that a portion of the blanket is pressed by a roller or by a fixed return bar against the surface of the cylinder, and at that area the blanket, which before coming into contact with the cylinder had a concavity facing the opposite part of the cylinder, changes concavity and faces it. 
     The combined effect of change in concavity and removal of the web from the pressure roller, which presses it against the cylinder, determines a longitudinal compaction of the fibers of a paper web passed between the blanket and the cylinder, resulting in the transfer of good longitudinal extensibility features to the web itself, and in particular making it extensible up to about 15%. 
     However, this extensibility is only in the longitudinal direction (machine direction) but not in the transverse direction, apart from the natural extensibility which any paper sheet has. As a result, the webs obtained by means of this known process cannot be used in all those cases in which an extensible paper is also required in the transverse direction. 
     EP 824618B1 and EP 3024977A1 describe methods and apparatuses for manufacturing paper webs which are extensible in all directions. Such methods proved to be valid from the point of view of obtainable results, while however showing a certain implementation and management complexity, which limited the diffusion thereof. 
     U.S. Pat. No. 3,290,209 describes a piece of equipment for producing extensible paper by passing a fibrous web between a hard roller of metal material and an endless web of elastic material which is wound about respective return rollers. The hard roller of metal material, the surface of which is affected by incisions, rotates at a speed which is 6-15% faster than that of the web of elastic material. The function of the incisions is to eliminate the contact friction of the fibrous web with the metal roller, and in this regard, the web of elastic material shall have a hardness such as to allow the fibrous web to slide between the ridges of the incisions of the hard roller of metal material, thus avoiding the web itself from completely entering into said incisions since this would increase the contact friction. Furthermore, in this apparatus the fibrous web is fed so that the fibrous web portion upstream of the pressing area, defined by the pressure of the web of elastic material on the hard roller, is substantially rectilinear (i.e., free of concavity) and coplanar with respect to said pressing area. Last but not least, the exiting fibrous web is extensible only in the longitudinal direction (i.e., in the machine direction). 
     SUMMARY OF THE INVENTION 
     It is the object of the invention to suggest a process and/or apparatus to overcome the drawbacks of conventional solutions. 
     It is another object of the invention to suggest a process which allows to provide, in a simple form and with equipment of easy and economical construction and management, systems adapted to produce paper webs, and in general fibrous material webs, combining the advantages of a high extensibility in each direction with the merits of a low production cost. 
     It is another object of the invention to suggest a process and/or apparatus which may be implemented in a simple manner and with low costs. 
     It is another object of the invention to suggest a process and/or apparatus having an alternative and/or improved characterization, both in terms of construction and function, as compared to conventional solutions. 
     All these objects, considered individually or in any combination thereof, as well as others which will result from the following description, are achieved, according to the invention, by a method for producing webs of fibrous material extensible in all directions, and by an apparatus as described herein. 
    
    
     
       BRIEF DESCRIPTION OF THE INVENTION 
       The present invention is further clarified below in some of the preferred embodiments thereof, given merely by way of explanation and not by way of limitation, with reference to the accompanying drawings, in which: 
         FIG. 1  shows a diagrammatic side view of an apparatus to implement the method according to the invention, 
         FIG. 2  shows the apparatus according to the front view II-II in  FIG. 1 , 
         FIG. 3  shows an enlarged detail in  FIG. 2 , 
         FIG. 4  shows the same view in  FIG. 1  of the apparatus in a second embodiment, and 
         FIG. 5  shows the same view in  FIG. 1  of the apparatus in a third embodiment. 
     
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION 
     As shown in the figures, the apparatus according to the invention comprises a cylinder  2  of rigid material, preferably made of metal and/or motorized. 
     Advantageously, the metal cylinder  2  may be entirely made of metal (e.g. steel or cast iron), or possibly of metal (e.g. steel or cast iron) coated in the side surface with a layer of different material, e.g. ceramic, having different features and mechanical properties. 
     The side surface of the cylinder  2  is affected by a plurality of incisions  4 . 
     Conveniently, the incisions  4  may be in hollow or raised. Conveniently, the incisions  4  may develop in the circumferential direction or even with a different pattern, but with a circumferential component, and may be continuous or discontinuous, completely separate from one another or even intersecting one another. 
     Advantageously, the incisions  4  are such as to make the side surface of the cylinder  2  micro-scratched. 
     Conveniently, at the side surface of the cylinder  2 , the incisions  4  define along the development direction of the rotation axis of the cylinder itself (i.e. in the transverse direction) hollow portions delimited by a curved profile having a concavity facing the exterior of the cylinder  2 . 
     Conveniently, the incisions  4  are (transversely) placed side-by-side. Advantageously, between the laterally/transversely adjacent incisions  4  (i.e., in the development direction of the rotation axis of the cylinder  2 ), straight portions or curved portions are provided, having a concavity facing the interior of the cylinder  2 . 
     Conveniently, the incisions  4  may have a depth substantially from 0.01 mm to 2 mm, preferably from about 0.05 mm to 0.5 mm. 
     Conveniently, the incisions  4  may have a width substantially from 0.01 mm to 2 mm, preferably from about 0.05 mm to 0.09 mm. 
     Conveniently, the incisions  4  may have a pitch substantially from 0.01 to 10 mm. 
     Conveniently, in the case of spiral-shaped incisions  4 , the angle of inclination of the spiral may be from a minimum value, allowed by the width of the incision, to a maximum value of 45°, even if it is preferable that it is from 5° to 15°; furthermore, it may be the same over the whole axial length of the cylinder  2  or it may be opposite for the two halves of the cylinder itself. 
     The apparatus according to the invention also comprises a preferably continuous web  6 , with an outer layer of elastically compressible material. 
     Conveniently, the web  6  is mounted about at least one roller having a support and/or movement function. In particular, the web  6  is stretched between rollers  8 ,  10 ,  12 , having the function of moving the web while keeping it with a portion thereof adhering to the cylinder  2 . 
     Conveniently, the apparatus according to the invention comprises a pressing element which has the function of pressing/pushing the continuous web  6  against the cylinder  2  so as to locally reduce the thickness thereof, thus defining a pressing area  20 . Advantageously, the pressing element may be rotating, such as the roller  8  for example, or may be fixed, such as a bar, for example. 
     Conveniently, the roller  10  may be motorized and the roller  12  may be an idle return roller. Advantageously, the position of the roller  12  with respect to the pressing element  8  determines the length of the portion of web  6  wound about the cylinder  2 , i.e., the portion of web  6  which adheres to the latter. Conveniently, by varying the position of the roller  12  with respect to the pressing element  8 , or vice versa, it is possible to vary the corresponding length of the portion of web  6  which adheres to the cylinder  2 . 
     Advantageously, the web  6  consists of a rubber blanket having a thickness from 15 mm to 70 mm, preferably from 25 mm to 40 mm. 
     Advantageously, the web  6  consists of a rubber blanket having substantial longitudinal inextensibility at least on the side adhering to the return rollers  8 ,  10 ,  12 . Conveniently, this inextensibility may be obtained, for example, by applying an inextensible sheet to the rubber web  6 , or by incorporating longitudinal steel wires in the thickness of the rubber web  6 . 
     Advantageously, the web  6  has a hardness from 70 to 240 PJ, preferably from 120 to 220 PJ. 
     The web  6  with an outer layer of an elastically compressible material is kept locally pressed, preferably by means of the pressing element  8 , against the grooved side surface of the cylinder  2  at a pressing area  20 . 
     Furthermore, the cylinder  2  and the web  6  are configured and arranged so that: 
     the web  6  also adheres to the cylinder  2  over a certain portion  21  located downstream of said pressing area  20 , 
     the web  6  has a portion  21  downstream of said pressing area  20  with a concavity substantially opposite to that of a portion  22  thereof upstream of the pressing area itself, 
     in said pressing area  20  the peripheral speeds of the cylinder  2  and of the web  6  are substantially equal. 
     The operation of the apparatus described herein, which practically implements the method according to the invention, is as follows: 
     after the cylinder  2  and the web  6  are actuated, so that at the passage (i.e. at the pressing area  20 ) of the web itself between the cylinder  2  and the pressing element  8  they have the same peripheral speed, a web  14  of fibrous material is passed between them, so that it is dragged therebetween over the whole area of mutual contact thereof. 
     Conveniently, this fibrous material may consist of paper or vegetable and/or synthetic fibers, non-woven fabric, etc. Preferably, the entering fibrous material has a 40-95% degree of dryness, preferably 60-85% and even more preferably 63-75%. 
     As the web  14  of fibrous material moves between the elastically compressible material  6  and the cylinder  2 , it is subjected to different effects. 
     A first effect is due to the abrupt change in concavity of the web  6  at the upstream portion  22  of the pressing area  20 . In particular, such an abrupt change in concavity determines a longitudinal extension of the layers of the web  6  which are far from the cylinder  2 , which thus pass from a concave area to a convex area, while determining a longitudinal compaction of the layers thereof close to the cylinder  2 , passing from a convex area to a concave area. Therefore, this effect determines a longitudinal compaction of the web  14  of fibrous material, which tends to adhere to the surface of the web  6 , which in this area is compacted, and to slide instead on the cylinder  2 . 
     A second effect is due to the abrupt increase in thickness of the rubber web  6  when exiting from the passage between the pressing element  8  and the cylinder  2 , and to the consequent decrease in speed in the portion  21  downstream of the pressing/tightening area  20 . Moreover, since the magnitudes involved and the configuration of the apparatus are selected so that, in the pressing/tightening area  20 , the peripheral speed of the surface of web  6  facing the cylinder  2  is equal to the peripheral speed of the cylinder  2 , downstream of that tightening the peripheral speed of that surface of the web  6 , and therefore of the web  14  of fibrous material which adheres thereto, will clearly undergo a braking, with a further effect of longitudinal compaction of the web  14  of fibrous material. 
     A third effect is due to the presence of the incisions  4  in the surface of the cylinder  2 , which incisions, by virtue of the braking effect due to the web  6  onto the web  14  of fibrous material, in addition to determining a longitudinal compaction thereof, also cause it to accumulate inside the incisions  4 , and thus to accumulate practically in the transverse direction of the web  14  of fibrous material. 
     The combination of these three effects thus leads to obtaining a web  14  of fibrous material compacted longitudinally and with an accumulation of material in the transverse direction, and thus to a fibrous material which is practically substantially extensible in each direction. 
     Since the entity of the transverse compaction of the web  14  of fibrous material is essentially related to the features of the incisions  4 , by adjusting the shape, size and pitch thereof, it is possible to obtain a material having not only longitudinal, but also transverse extensibility, which is substantially greater than the entering web of fibrous material. 
     Advantageously, in the embodiment shown in  FIG. 4 , the return roller  12  is arranged so as to prolong the portion of web  6 —which is positioned downstream of the pressing area defined between the web itself and the pressing element—which is in contact with and adheres to the cylinder  2 , thus prolonging the longitudinal compaction effect of the web  14  due to the difference in length between the two surfaces of the web  6  in the portion in which it winds the cylinder  2 . 
     Advantageously, in the embodiment shown in  FIG. 5 , the portion of web  6  wound about the cylinder  2  is affected by a plurality of pressing elements. Preferably, the plurality of pressing elements has a graduated pressing effect, so as to obtain a change in speed of the web  6  in the winding portion, which speed change is graduated in the whole portion, instead of being concentrated on the initial portion thereof. 
     Conveniently, irrespective of the embodiment adopted, the pressing element  8  may be, as said, a roller or a non-rotating bar, of the simplest construction; in this case, the inevitable friction between this and the web  6  may be attenuated if a lubricating and/or wetting liquid, such as water or a mixture of water and silicone, for example. is sprayed therebetween. 
     From the above description, it is apparent that the method according to the invention and the apparatus for implementing it are considerably advantageous as compared to the prior art, and in particular allow obtaining fibrous materials extensible in each direction by means of a very simple apparatus with a safe and reliable operation. It may be inserted into an in-line system for the production of paper, for example, and in this case it may be fed with a layer of cellulose fiber mixture, which will form the web; or it may form a stand-alone machine, which is fed with a paper web already formed and previously subjected to wetting, so that the dry content thereof is brought to a value from 40% to 95%, preferably from 60% to 85%.