Method for manufacturing a uniform deflection element

Abstract

Method for manufacturing a uniform deflection element (10) comprising at least one reinforcing element (14) and a plurality of regularly spaced projections (18) extending from said reinforcing element (14), wherein the reinforcing element (14) comprises MD-oriented elements and CD-oriented elements in a multi-layered configuration, wherein at least two of the projections (18) are similar in size and shape, each projection (18) comprising a transition section (24) with a transition section width (TW) and a forming section (26) with a forming section width (FW), and wherein the transition section width (TW) is less than the forming section width (FW), wherein the projections (18) are uniform with the reinforcing element (14) such that, in cross-section, the projections (18) and the reinforcing element (14) are formed as a single unit and not from separate parts.the procedure comprises the following steps: , a. Providing a manufacturing device for additive manufacturing; b. Providing at least one material for the uniform deflection element (10), wherein the material to be used is compatible with the additive manufacturing device; c. Generating a three-dimensional digital image of objects in a repeating element of the uniform deflection element (10), wherein the objects include the at least one reinforcement element (14) and the projections (18) of the uniform deflection element (10), and wherein the objects further include the transition sections (24) and the forming sections (26) on the projections (18); d. Compiling the objects into a digitized file containing the projections (18) located on the reinforcement element (14); e. Importing the digitized file to generate a numerical control file for the additive manufacturing device; and f. Applying the material using the additive manufacturing device to produce the uniform deflection element.

Description

AREA OF INVENTION

[0001] The present invention relates to deflection elements for the production of strong, soft, absorbent fibrous webs, such as paper webs. In particular, this invention relates to structured fiber webs, devices used for the production of such structured fiber webs, and methods for doing so. BACKGROUND OF THE INVENTION

[0002] Products made from fibrous webs are used for a wide variety of purposes. For example, paper towels, facial tissues, toilet paper, napkins, and the like are in constant use in modern industrial societies. The high demand for such paper products has led to a demand for improved versions. If paper products like paper towels, facial tissues, napkins, toilet paper, mop heads, and the like are to fulfill their intended functions and gain widespread acceptance, they must possess certain physical properties.

[0003] Among the most important of these characteristics are strength, softness, absorbency, and cleanability. Strength is the ability of a paper web to maintain its physical integrity during use. Softness is the pleasant tactile feel that consumers perceive when using the paper for its intended purposes. Absorbency is the property of the paper that allows it to absorb and retain liquids, especially water and aqueous solutions and suspensions. Important is not only the absolute amount of liquid a given amount of paper can hold, but also the rate at which the paper absorbs the liquid. Cleanability refers to the ability of a fibrous structure to remove and / or retain soil, dirt, or bodily fluids from a surface, such as a kitchen counter, or from a body part, such as a user's face or hands.

[0004] Air-drying papermaking tapes comprising a reinforcing element and a resin backing, and / or fiber webs produced using these tapes, are known and described, for example, in the following jointly granted U.S. patent US 4,528,239 A, granted to Trokhan on July 9, 1985. Trokhan teaches a web in which the resinous backing is bonded to the fluid-permeable reinforcing element (such as a woven structure or felt). The resin backing may be continuous, semi-continuous, comprise multiple individual protrusions, or any combination thereof. The resin backing extends outward from the reinforcing element to form a web side of the tape (i.e., the surface on which the web is positioned during a papermaking process), a back side facing the web side, and deflections extending between them.The deflection elements create spaces into which paper fibers are redirected by applying a pressure differential during the papermaking process. Because of this function, such papermaking belts are also known in technical fields as "deflection elements." The terms "papermaking belt" and "deflection element" can be used interchangeably here.

[0005] Papers produced on deflection elements disclosed in Trokhan are generally characterized by having at least two physically distinct regions: a region with a first rise and typically with a relatively high density, and a region extending from the first region to a second rise and typically with a relatively low density. The first region is typically formed from the fibers that have not been deflected into the deflections, and the second region is typically formed from the fibers that are deflected into the deflections of the deflection element.The papers produced using tapes that have a continuous resin backbone and a multitude of individual deflections distributed throughout them comprise a continuous high-density network region and a multitude of individual low-density cushions (or domes) distributed through, separated from, and extending from the network region. The continuous high-density network region is primarily designed to provide strength, while the majority of the low-density cushions are mainly intended to provide softness and absorbency. Such tapes have been used to produce commercially successful products, such as BOUNTY® paper towels and CHARMIN® toilet paper, all manufactured and sold by the present applicant.

[0006] Typically, certain aspects of a fiber structure's absorbency depend strongly on its surface area. This means that for a given fiber web (including fiber composition, basis weight, etc.), the web's surface area increases with its absorbency and, for certain structured webs, its cleanability. In structured webs, the low-density cushions distributed throughout the web increase its surface area, thereby enhancing its absorbency. The three-dimensionality of the structured web can improve its cleanability by providing a larger scrubbing area. Increasing the web's surface area by expanding the area encompassing the relatively low-density cushions would reduce the web area comprising the relatively high-density network, which provides strength.This means that increasing the ratio of the area encompassed by the cushions to the area encompassed by the network would negatively affect the paper's strength, as the cushions have relatively low inherent strength compared to the network areas. Therefore, it would be highly desirable to minimize the need for a compromise between the high-density network area, which primarily provides strength, and the low-density surface area, which primarily provides softness and absorbency.

[0007] An improvement to the deflection element, intended for use as papermaking belts to produce paper with an increased surface area, is disclosed in jointly granted U.S. patent US 6,660,129 B1, issued to Cabell et al. on December 9, 2003. The disclosure by Cabell et al. teaches a deflection element that increases the surface area by creating a fibrous structure, wherein the second region has fiber domes and fibrous cantilever sections extending laterally from the domes. The fibrous cantilever sections increase the surface area of ​​the second region and, in some embodiments, form pockets that essentially have voids between the fibrous cantilever sections and the first region. These pockets are capable of absorbing additional quantities of liquid, thus further increasing the absorbency of the fiber structure.

[0008] Cabell et al. teaches processes for fabricating such deflection elements through a modification of the process taught by Trokhan. In one aspect, the deflection element comprises a multilayer framework formed by at least two UV-cured layers bonded together in an opposing orientation, and the framework is connected to a reinforcing element. Each of the layers has a deflection section. The deflection section of one layer is fluid-permeable and positioned such that sections of this layer correspond to the deflection elements of the other layer, thus encompassing a multitude of suspended sections. Cabell et al. teaches the fabrication of a deflection by curing a coating of a curable material through a mask with opaque and transparent regions and a three-dimensional topography.

[0009] However, the deflection element and the method of Cabell et al. have the disadvantage that it is not possible to obtain uniform patterns of cantilevered sections. That is, the shape, size, and distribution of individual domes with cantilevered sections are determined randomly. This is because the use of a mask and UV-curable resins imposes certain inherent limitations on the topography of the frame that can be connected to a reinforcement element, including the shape, size, and distribution of individual domes. In particular, the topography of the deflection frame is dictated by the mask (or masks in a two-layer version), and therefore the choice of topographies for the deflection element is limited to those for which a suitable mask can be manufactured.

[0010] Efforts to improve the masks to offer broader options for UV curing and to connect the frame for the reinforcing element are ongoing and include, for example, the technological approach described in the concurrently pending provisional US application 62 / 076,036 entitled "Mask and Papermaking Belt Made Therefrom," filed by Seger et al. on November 6, 2014. Seger et al. teaches a three-dimensional mask that allows for certain improvements in mask design to enable greater design freedom for non-random individual domes for producing paper structures with an enlarged surface area. The surface is generated in redirections that are not achieved randomly; that is, the mask is designed to achieve a pattern of non-random shapes, sizes, and distributions of domes on the redirecting element.

[0011] The deflection element by Seger et al. is not intended to produce fiber structures that are described as self-supporting sections in Cabell et al. That is, while Seger et al. can generate new structures for domes that are not random in terms of shape, size, and distribution, these new structures do not appear to produce self-supporting structures that are useful for increasing the absorption and purification capacity of the fiber structures produced on them.

[0012] Accordingly, there is an unmet need for a deflection element with a three-dimensional topography that cannot be achieved by a technology based on UV curing of a framework to be connected with a reinforcement element.

[0013] Furthermore, there is an unmet need for fibrous structures such as hygiene paper products with a three-dimensional structure that cannot be achieved with redirections that have a topography produced using a technology based on a UV-curing framework and that are to be connected with a reinforcing element.

[0014] In addition, there is an unmet need for a method for manufacturing a deflection element with a three-dimensional topography that cannot be achieved by a technology based on UV curing of a framework to be connected with a reinforcement element.

[0015] Additionally, there is an unmet need for a uniform deflection element with a structure similar to those produced by UV curing of a framework to be connected with a reinforcing element.

[0016] Additionally, there is an unmet need for a deflection element with a pattern of regularly aligned and dimensioned deflection elements that feature domes with cantilevered structures.

[0017] Additionally, there is an unmet need for a deflection element with domes featuring cantilevered structures, wherein the domes of each deflection are manufactured according to a predetermined design in terms of shape, size, and distribution.

[0018] US 2015 / 0102526 A1 describes a method for producing a fabric, comprising the steps of: developing a three-dimensional model of a fabric; and using the three-dimensional model in an additive manufacturing process to produce a fabric. In one example, a substrate produced by an additive manufacturing process resembles a papermaking fabric, with respective sections instead of top MD yarns and CMD yarns.

[0019] US 2006 / 0061016 A1 describes a three-dimensionally designed mold for the production of flexible structures. In one example, the mold comprises a pattern with a multitude of discrete protrusions, wherein the mold comprises a resin microstructure bonded to a reinforcing element.

[0020] US 6,576,091 B1 describes a deflection element with a framework. The framework comprises a multilayered structure consisting of at least two layers connected planarly. The deflection element may include a reinforcing element positioned between the fabric side and at least a portion of the back side of the framework. Each of the layers may comprise a substantially continuous network, a semi-continuous network, or a plurality of discrete protrusions. A method for fabricating the deflection element includes the steps of forming each of the layers and subsequently joining the layers in a planar relationship such that portions of one layer correspond to the deflection conduit portion of the other layer. In an example, a deflection element comprises a framework and a reinforcing element.The framework has a first layer and a second layer, and the second layer has a multitude of projections. SUMMARY OF THE INVENTION

[0021] The invention is specified in claim 1 and the dependent claims. Further embodiments are specified in the subclaims. A unitary deflection element and a method for manufacturing a unitary deflection element are disclosed.The method may include the following steps: providing an additive manufacturing device; providing a material for the uniform deflection element, wherein the material is to be compatible for use in the additive manufacturing device; generating a three-dimensional digital image of objects in a repeating element of the uniform deflection element, wherein the objects comprise at least one reinforcement element and at least one projection of the uniform deflection element; assembling the objects in a digitized file that includes at least one projection located on the reinforcement element; importing the digitized file to generate a numerical control file; and depositing the material using the additive manufacturing device to produce the uniform deflection element. BRIEF DESCRIPTION OF THE DRAWINGS Fig. Figure 1 is a computer-generated image showing a perspective view of the structure of an embodiment of a unitary deflection element of the present invention; Fig. Figure 2 is a computer-generated image showing a perspective view of the structure of an embodiment of a unitary deflection element of the present invention; Fig. Figure 3 is a cross-sectional view of the uniform deflection element, which is in Fig. 1 is shown, along line 3-3 from Fig. 1. Fig. Figure 4 is a cross-sectional view of the uniform deflection element, which is shown in Fig. 2 is shown, along line 4-4 from Fig. 2; Fig. Figure 5 is a computer-generated image showing a perspective view of the structure of an embodiment of a unitary deflection element of the present invention; Fig. Figure 6 is a cross-sectional view of the uniform deflection element, which is shown in Fig. 2 is shown, along line 6-6 from Fig. 5. Fig. Figure 7 is a schematic representation of a cross-sectional view of a section of a uniform deflection element. Fig. Figure 8 is a schematic representation of a cross-sectional view of a section of a uniform deflection element. Fig. Figure 9 is a schematic representation of a cross-sectional view of a section of a uniform deflection element. Fig. Figure 10 is a schematic representation of a cross-sectional view of a section of a uniform deflection element. Fig. Figure 11 is a photographic perspective view of a unitary deflection element of the present invention, which is manufactured according to the present invention. Fig. 12 is a top view of the in Fig. 11 represented a uniform deflection element. Fig. Figure 13 is a schematic cross-sectional view of a representative diversion on which fibers of a fiber structure are deposited. Fig. Figure 14 is a schematic cross-sectional view of a representative rerouting where fibers of a fiber structure are removed. Fig. Figure 15 is a schematic side elevation view of the method for producing a fiber structure according to an embodiment of the present invention. Fig. Figure 16 is a photograph of a fiber structure produced according to the present invention. Fig. Figure 17 is a micrograph of a cross-section of the fiber structure, shown in Fig. 16. DETAILED DESCRIPTION OF THE INVENTION Uniform deflection element

[0022] The deflection element of the present invention can be a single structure produced by additive manufacturing processes, including what is commonly described as “3D printing.” As such, the single deflection element is not achieved by using a mask and a UV-curable resin, as taught in the aforementioned U.S. Patent 4,528,239, in which a resin and a reinforcing element are provided as separate parts and joined as separate components in a non-single-unit manner. However, because structurally the single deflection element resembles deflection elements in which a resinous framework is UV-cured to bond a reinforcing element and is used in a papermaking process, it is described using these terms.That is to say, one section of the unified deflection element of the present invention is described as a "reinforcing element" or "reinforcing element section," and another section is described as a "patterned frame" or "frame section." The term "deflection element," as used herein, refers to a structure useful for the production of fiber webs such as absorbent paper products, but which has domes defining deflections that are not formed by an underlying woven or grid structure. To clarify: woven papermaking fabrics or papermaking fabrics based on a woven pattern, and papermaking fabrics that do not have features present in a woven pattern, are not deflection elements as used in the present disclosure.

[0023] The term "unified," as used here, means that the deflection element is not a unit comprising previously separate components joined together. Unified can mean that all sections described herein are formed as a single unit, rather than as separate parts joined together. Deflection elements as described herein can be produced in an additive manufacturing process to be unified, in contrast to processes that produce deflection elements that join separate components together or modify them in some other way. A unified deflection element may incorporate different features and different materials for the various features, such as the patterned frame and a reinforcing element, as described below.

[0024] As in the Fig. As shown in Figures 1-6, a unified deflection element 10 of the present invention can comprise two identifiable sections: a patterned frame 12 and a reinforcing element 14. The unified deflection elements shown in the Fig. 1, Fig. 3 and Fig. Figure 5 shows digitally generated images of non-restrictive embodiments of uniform deflection elements. These digital images are used in the method for manufacturing a uniform deflection element 10, as described in more detail below. Due to the precision associated with additive manufacturing technology, the uniform deflection element 10 has a substantially identical structure to that shown in the digital images, so the digital images are used to describe the various features of the uniform deflection element 10.

[0025] The reinforcing element is porous, with an open area sufficient to allow water to pass through during drying processes, but preventing fibers from being pulled through during dewatering processes, including pressing and vacuum processes. When fibers are formed into the deflecting element during the production of fiber substrates, the reinforcing element acts as a "backstop" to prevent or minimize fiber loss through the uniform deflecting element.

[0026] The patterned framework 12 has one or more deflections 16, which represent the cavities between the domes 18. These domes are uniform structures in the Z-direction and are primarily used to form corresponding fibrous structures that are formed on the deflection element 10. The reinforcing element 14 ensures fluid-permeable structural stability of the deflection element 10. The uniform deflection element 10 can be made from a variety of materials or a combination of materials, limited only by the additive manufacturing technology used to form the deflection element and its desired structural properties, such as strength and flexibility. In one embodiment, the uniform deflection element 10 can be made of metal, metal-impregnated resin, plastic, or a combination thereof.In one embodiment, the uniform deflection element is sufficiently strong and / or flexible to be used as a papermaking belt or a section thereof in a batch process or in commercial papermaking equipment.

[0027] The uniform deflecting element 10 has a back side 20 and a web side 22. In a fiber manufacturing process, the web side is the side of the deflecting element onto which fibers, such as papermaking fibers, are applied / deposited. As defined herein, the back side 20 of the deflecting element 10 forms an XY plane, where X and Y may generally correspond to CD and MD, respectively, when paper is produced in a commercial papermaking process in connection with the use of the deflecting element 10. A person skilled in the art will recognize that the symbols “X”, “Y”, and “Z” denote a system of Cartesian coordinates, wherein the mutually perpendicular “X” and “Y” define a reference plane formed by the back side 20 of the uniform deflecting element 10 when arranged on a flat surface, and “Z” defines a direction orthogonal to the XY plane.The person skilled in the art will recognize that the use of the term "plane" does not require absolute flatness or smoothness of any section or feature described as planar. In fact, the back side 20 of the deflecting element 10 may have a texture, including a so-called "back side structure," which is helpful when the deflecting element is used as a papermaking belt on vacuum rollers in a papermaking process, as described in Trokhan or Cabell et al.

[0028] As used herein, the term “Z-direction” denotes any direction perpendicular to the XY plane. Analogously, the expression “Z-dimension” means a dimension, distance, or parameter measured parallel to the Z-direction and can be used to refer to dimensions such as the height of domes or the thickness or strength of the uniform deflection element. It should be carefully noted, however, that an element that “extends” in the Z-direction need not itself be oriented strictly parallel to the Z-direction; the expression “extends in the Z-direction” in this context merely indicates that the element extends in a direction that is not parallel to the XY plane.Similarly, an element that extends in a direction parallel to the XY plane need not be entirely parallel to the XY plane; such an element can be oriented in a direction that is not parallel to the Z direction.

[0029] The person skilled in the art will also recognize that the uniform deflection element 10 need not have a planar configuration over its entire length (and in some embodiments it may not), particularly when it is used in a commercial process for producing a fiber structure 500 of the present invention and in the form of a flexible element or band running through the device in a machine direction (MD) indicated by a directional arrow “B”, ( Fig. 15) is used. The concept of the uniform deflection element 10, which is arranged on a flat surface and has the macroscopic “XY” plane, is conventionally used here to describe the relative geometry of several elements of the uniform deflection element 10, which can generally be flexible. A person skilled in the art will recognize that if the uniform deflection element 10 curves or otherwise deforms / deviates from its planar shape, the XY plane follows the configuration of the uniform deflection element 10.

[0030] As used herein, the term “macroscopic” refers to the overall geometry of a structure under consideration when it is brought into a two-dimensional configuration. In contrast, “microscopic” refers to relatively small details of the structure under consideration, without regard to its overall geometry. For example, the expression “macroscopically planar” in the context of the uniform deflection element 10 means that, when placed in a two-dimensional configuration, the uniform deflection element 10 exhibits only minor deviations from absolute planarity overall, and these deviations do not adversely affect the performance of the uniform deflection element. At the same time, the patterned frame 12 of the uniform deflection element 10 may exhibit a microscopic three-dimensional pattern of deflections and hanging sections, as described below.

[0031] As in the Fig. 1, Fig. 3 and Fig. 5 and in more detail in the cross-sectional views Fig. 2, Fig. 4 and Fig. As shown in Figure 6, the patterned frame 12 comprises a plurality of domes 18. Each dome 18 extends in the Z-direction on the track side 22 of the deflection element. Each of the plurality of domes 18 can be uniform with the reinforcing element 14 and extends from there in the Z-direction at a transition section 24. The transition section 24 is the area where the uniform structure deviates from the reinforcing element 14 in the Z-direction, and the projection transitions from a proximal end at the reinforcing element 14, via a transition region height TH in the Z-direction, to a distal end with the projection-forming shaping section 26. The key distinction for a uniform deflection element, as described, is that there is no connection of individual sections, e.g., between the reinforcing element 14 and the transition section 24, and between the transition section 24 and the dome 18, at the transition sections 32. B.curable resin on a woven filament backing. The reinforcing element, transition sections, and domes can be made of a single material, with a continuous material transition occurring between any two sections. Sections of the reinforcing element, transition sections, and domes may differ in material content, but in the uniform deflection elements described here, the material transition is due to different materials used in an additive manufacturing process, rather than to individual materials adhering, curing, or otherwise bonding.

[0032] The transition section 24 can essentially be a plane with a low to non-z-dimensional height TH, as can be seen from the in Fig. 4 and Fig. The uniform structure shown in the 6 cross-sections can be understood as a cross-sectional view of the structure shown in the Fig. 2 and Fig. The structure shown in Figure 5 is similar. Similarly, the transition section 24 can have a Z-dimension height TH of approximately 0.1 mm to approximately 5 mm, which essentially allows the forming of the dome 18's shaping section 26 from the reinforcing element, as can be seen from the uniform structure of the cross-section in Figure 5. Fig. Figure 3 clearly shows which is a cross-sectional view of the in Fig. The structure shown in 1 is shown.

[0033] The transition section 24 can have a transition section width TW, which is the smallest dimension of the cross-section of the transition section parallel to the XY plane. If the transition section 24 is essentially cylindrical, the TW can thus be the diameter of the circular cross-section. If the transition section 24 is essentially elongated or linear in the MD, as in Fig. 1, the TW is the width of the transition section 24 in the CD, as shown in Fig. 3. If the dome 18 is “donut” shaped with a transition height TH of essentially zero, as in Fig. As shown in Figure 6, the TW can be the smallest dimension across the donut shape parallel to the XY along the circumference of the donut shape in the transition section. The person skilled in the art will recognize from the present disclosure that the possible shapes for transition sections and forming sections are practically unlimited, but in each shape the dimensions of the transition sections and the forming sections can be determined according to the principles disclosed herein.

[0034] The forming sections 26 can extend outwards in at least one direction from a distal end of the transition section 24 parallel to the X-Y plane, such that the forming sections 26 have at least one dimension FW measured parallel to the X-Y plane that is greater than the transition section width TW. The space between the multiple domes 18 forms diversions 16 that extend in the Z-direction from the web side 22 to the rear side 20 of the diverting element 10 and provide spaces into which a variety of fibers can be deposited during a papermaking process to form so-called fibrous "cushions" 510 adjacent to and possibly surrounded by so-called "knuckles" 520 of the fiber structure 500 (as in the Fig. 13 and Fig. 14 (shown in more detail). In a fluid-permeable uniform deflection element 10, the diversions extend from the track side 22 to the rear side 20 through the entire thickness of the structured frame 12.

[0035] In general, the diversions can be 16 semi-continuous (as in Fig. 1 shown), continuously (as in Fig. 2 shown) or discontinuously, i.e. individually (as in Fig. 5 shown). Accordingly, the domes can be semi-continuous (as in Fig. 1 shown), continuously (as in Fig. 5 shown) or discontinuously, i.e. individually (as in Fig. 3 shown). As can be understood from the description of the structured frame of the deflection element 10, fiber structures produced on the deflection element can form semi-continuous knuckles and cushions (when placed on a deflection element with the structure of Fig. 1 are manufactured), or continuous cushions and discontinuous, i.e. single knuckles (when manufactured on a deflection element with the structure of ABB, 2) or discontinuous, i.e. single cushions and continuous knuckles (when manufactured on a deflection element with the structure of ABB, 5).

[0036] The term “continuous” refers to a section of the structured frame 12 that has “continuity” in all directions parallel to the XY plane and in which any two points on or within this section can be connected by an unbroken line that lies completely on or within this section over the entire length of the line.

[0037] The term “semi-continuous scaffold” refers to a layer of the patterned scaffold 12 which has “continuity” in all but at least one direction parallel to the X-Y plane and in which no two points on or within this layer can be connected by an unbroken line that runs completely on or within this layer over the entire length of the line.

[0038] The term "individual" in relation to diversions or domes on the patterned framework 12 refers to areas that are isolated and discontinuous in all directions parallel to the XY plane. A patterned framework 12 that has a plurality of individual domes is in Fig. 2 shown. In a patterned frame, 12 individual domes, 18, the diversion is continuous.

[0039] To distinguish the different types of deflection elements used in the Fig. 1 to Fig. To summarize, as described in section 6, the patterned frame of a deflection element, as described in Fig. Figure 1 shows an example of a deflection element with a semi-continuous frame of domes and diverters. The patterned frame of a deflection element, as shown in Fig. Figure 2 shows an example of a deflection element with a continuous diversion and individual domes. The patterned frame of a deflection element, as shown in Fig. Figure 5 shows an example of a deflection element which features individual diversions and continuous couplings.

[0040] There is practically an infinite number of shapes, sizes, spacings, and orientations that can be selected for the transition sections 24 and the forming sections 26, and correspondingly for the resulting domes 18 and deflectors 16. The actual shapes, sizes, orientations, and spacings can be specified and produced by additive manufacturing processes based on a desired design of the final product, such as a fiber structure with a regular pattern of substantially identical "bulging" cushions, as detailed below. The improvement of the present invention is that the shapes, sizes, spacings, and orientations of the domes 18, including domes with transition sections 24 and forming sections 26, are not limited by the constraints imposed on the deflectors previously produced by UV curing of a resin through a patterned mask.This means that the size and shape of the reinforcing elements 14, the domes 18, and, if present, the transition sections 24 and forming sections 26 are not limited to the shapes achievable by essentially “visible” light transmission curing from above, i.e., by light directed from the web side 22 onto the deflecting element. For example, such line-of-sight light transmission curing of a curable resin prevents effective curing of the forming section 26 with a larger XY dimension than the transition section 24.

[0041] In contrast to the “hanging sections” taught in US 6,660,129, which extend from the plurality of domes in at least one direction, the forming sections 26 of the present invention can be uniform and can be consistent in size and shape over two or more or all of the plurality of domes. That is to say, instead of being randomly distributed in a pattern that cannot be predetermined due to the limitations of the mask design and placement, the domes 18 of the present invention can be uniformly produced over the entire deflection element. In one embodiment, at least two domes 18 on the uniform deflection element 10 can be substantially identical in size and shape."Substantially identical" means that the design intent is for two or more domes to be identical in size and shape, but minor differences may exist due to manufacturing limitations or irregularities. Two domes that have the same shape and a total cross-sectional deviation of less than 5% (as in the [reference]) are considered to be of the same type. Fig. 3 and Fig. 4), are considered to be essentially identical. In one embodiment, at least two domes 18 on the uniform deflection element 10 can be similar in size and shape. "Similar" means that the intention of the design is for the two or more domes to have the same shape or size, but some variations in the patterned frame may be present. Two domes that have the same shape and a deviation of less than 15% in the overall cross-section (as shown in the Fig. 3 and Fig. 4 shown), are considered similar in size and shape.

[0042] As in the Fig. As shown in Figure 1, a uniform deflection element 10 can be described as comprising two identifiable sections: a structured frame 12 and a reinforcement element 14. The reinforcement element can be fluid-permeable and can generally be described as a net-like pattern or grid material. The reinforcement element 14 can be structurally a woven pattern and generally functionally equivalent to the woven filament reinforcement elements used in the method by Trokhan or Cabell et al. discussed above. The reinforcement element 14 can be multilayered, i.e., in addition to a CD element, as shown in Figure 1. Fig. 6 shown as element 14A, the reinforcement element can have MD-oriented elements, as in Fig. Figure 6 shows element 14B, oriented in a different Z-direction relative to the CD element. Naturally, any multi-stage, multi-layer structure can be used for the reinforcing element, with elements oriented in any direction, as long as it is sufficiently strong, flexible, and fluid-permeable to be used in a batch or commercial papermaking process. A fluid-permeable reinforcing element can have a defined percentage open area, ranging from approximately 1% to approximately 99%, or from approximately 10% to approximately 80%, or from approximately 20% to approximately 60%, or from approximately 1% to approximately 50%, or from approximately 1% to approximately 30%, or from approximately 1% to approximately 20%.In the present invention, the reinforcing element 14 can be designed and built in virtually infinite sizes and shapes, which, compared to previous reinforcing elements made of woven filament, provides greater design freedom with regard to size, shape and percentage open area.

[0043] The patterned frame 12 of the domes 18 defines the diverts 16 used to form a corresponding fiber structure formed at the diverting element 10. The patterned frame 12 can comprise at least two domes 18, each similar or substantially identical in size and shape. The domes 18 have transition sections 24 and form forming sections 26. In one embodiment, the patterned frame 12 comprises a plurality of domes 18, all of which are similar or substantially identical in size and shape. In one embodiment, the patterned frame 12 comprises a plurality of spaced domes 18, all of which have substantially identical shaped and dimensioned transition sections 24 and forming sections 26, and the domes 18 can be arranged in a regular, spaced configuration of parallel linear segments of the X-Y plane, either in the MD (as in Fig. (1 shown) or CD or diagonally arranged at some angle to MD and CD, and the domes accordingly define substantially identically shaped and dimensioned diversions 16 between each adjacent domes 18. In common, non-restrictive language, the domes 18 can be described as lines or ribs of domes, the lines being straight or curvilinear but remaining substantially parallel, and the width FW of the forming section being greater than the width of the transition section TW to give a 'bulging' impression in cross-section. Thus, in cross-section, the lines of the domes may be, for example, keyhole-shaped (1), mushroom-shaped, circular, oval, inverted triangular, T-shaped, inverted L-shaped, or pebble-shaped, or combinations of these shapes, where the width PW of the forming section is greater than the width of the transition section TW in each individual dome.

[0044] As in the Fig. As shown in Figure 2, a uniform deflection element 10 can be described as comprising two identifiable sections: a structured frame 12 and a reinforcing element 14. The reinforcing element may be fluid-permeable. The patterned frame 12 defines the deflections 16 used to form a corresponding structure in paper produced on the deflection element 10, and the reinforcing element 14 provides structural stability. The patterned frame 12 comprises at least two domes 18, each similar or substantially identical in size and shape. In one embodiment, the structured frame 12 comprises a plurality of individual domes 18, all having substantially identical shaped and dimensioned transition sections 24 and forming forming sections 26.In one embodiment, the patterned frame 12 comprises a plurality of domes 18, all having substantially identical shaped and dimensioned transition sections 24 and forming areas 26, and the domes 18 are arranged in a regular, spaced configuration of individual units in the XY plane, distributed at regular intervals in both the MD and the CD. The domes can accordingly define a continuous diversion 16, which is defined by the cavity section between the domes 18.

[0045] In common, non-restrictive language, the domes 18 can be described as individual, spaced-apart domes, each dome having a shape that is egg- or pebble-shaped ( Fig. 2) or donut-shaped (as in Fig. 5) may be mushroom-shaped or any other shape or combination of shapes where the width PW of the forming section is greater than the width of the transition section TW in each individual dome.

[0046] As in the Fig. As shown in Figure 5, a uniform deflection element 10 can be described as comprising two identifiable sections: a structured frame 12 and a reinforcing element 14. The reinforcing element can be fluid-permeable. As shown in Fig. Figure 6 shows a cross-sectional view of diversion 10. Fig. 5, the reinforcing element 14 can have CD-oriented strands 14A and MD-oriented strands 14B in a two-layer stacked configuration. However, the strands of the reinforcing element can be a simple grid, or it can mimic a woven pattern, or it can be any other pattern that makes it fluid-permeable while maintaining structural stability. The patterned frame 12 defines the diverts 16 that are used to form a corresponding structure in paper, which is produced at the diverting element 10, and the reinforcing element 14 provides structural stability. The patterned frame 12 made of Fig. Figure 5 shows a continuous dome 18. That is, while the occurrence of individual ring-shaped domes is maintained, the dome 18 is made of Fig. 5 continuous, i.e. all Z-direction elements are connected in a “continuous joint” version of a deflection element, and the continuous joint forms individual diverts 16 that give individual cushions in a fiber structure fabricated on it.

[0047] The invention has previously been described as a deflection element with domes having a forming section width FW that is greater than the transition section width TW, in order to exhibit a "bulging" appearance in cross-section, but the deflection element need not have this feature. That is, the invention can be a single deflection element having a back side defining an XY plane and a plurality of domes, each dome having a three-dimensional shape such that each cross-sectional area of ​​the dome parallel to the XY plane has an equal or larger area than each cross-sectional area of ​​the dome located at a greater distance from the XY plane in the Z direction.

[0048] Thus, show Fig. Figures 7-10 are a non-restrictive example of cross-sectional shapes of domes that do not exhibit a bulging impression or otherwise have a width FW of the forming section that is greater than a width TW of the transition section. The images of Fig. Figures 7-10 show cross-sections of representative dome shapes in height, analogous to those in the Fig. 3, Fig. 4 and Fig. The 6 cross-sectional shapes shown. The exemplary shapes shown in the Fig. 7, Fig. 8, Fig. 9 to Fig. Figure 10 is intended to be representative of a virtually unlimited number of shapes and sizes, all of which have in common that the deflection element is a single unit. In one embodiment, the single reinforcing element and the domes are manufactured using an additive manufacturing process to be of a single structure, rather than being produced by assembling separate components to form a deflection element.

[0049] As in Fig. Figure 7, which shows a representative dome 18, shows that the dome 18 can have a generally smooth, rounded shape. The reinforcing element 14 can be, or appear to be, a grid, a weave, or any other open, perforated structure in which the domes are arranged in a pattern. It should be noted that the reinforcing element 14 can be multilayered, as shown above in relation to Fig. 6 described. It should also be noted that the in Fig. The cross-section shown in Figure 7 depicts a single dome, but it can represent a multitude of closely spaced domes with the same cross-section. Furthermore, the cross-section can be that of a dome shaped like part of a sphere, such as a hemisphere, or it can be a dome of an elongated, linear shape in a semi-continuous pattern similar to that of the dome shown in Figure 7. Fig. Be 1.

[0050] As in Fig. As shown in Figure 8, the dome 18 can have a generally pointed, ribbed, or pyramidal shape. The reinforcing element 14 can be a grid, a woven structure, or any other open, perforated structure in which the domes are arranged in a pattern. It should be noted that the reinforcing element 14 can be multilayered, as shown above in relation to Fig. 6 described. It is also understood that the in Fig. The cross-section shown in Figure 8 depicts a single dome, but there may be a multitude of closely spaced domes in the cross-section shown. Furthermore, the cross-section may also be of a dome that takes the form of a linear, ribbed element in a semi-continuous pattern similar to that shown in Figure 8. Fig. The dome shown in Figure 1 can have a pyramidal shape, such as a three- or four-sided pyramid. Furthermore, it can be the cross-section of a dome that has the shape of a cone.

[0051] As in Fig. As shown in Figure 9, the dome 18 can have a generally pointed, ribbed, or pyramidal shape. The reinforcing element 14 can be a grid, a woven structure, or any other open, perforated structure in which the domes are arranged in a pattern. It should be noted that the reinforcing element 14 can be multilayered, as shown above in relation to Fig. 6 described. It is also understood that the in Fig. The cross-section shown in Figure 9 depicts a single dome, but there may be a multitude of closely spaced domes in the cross-section shown. Furthermore, the cross-section of a dome may be the shape of a linear, flat, cranked element in a semi-continuous pattern similar to that shown in Figure 9. Fig. The dome shown in Figure 1 can have a truncated pyramid shape, such as a flat, three- or four-sided pyramid. Furthermore, it can have a cross-section of a dome shaped like a truncated cone.

[0052] As in Fig. As shown in Figure 10, the dome 18 can have a multi-tiered form. Two levels are shown, one generally flat and the other generally curved in a representative shape. The reinforcing element 14 can be a grid, a woven structure, or any other open, perforated structure in which the domes are arranged in a pattern. It should be noted that the reinforcing element 14 can be multi-layered, as shown above in relation to Fig. 6 described. It is also understood that the in Fig. The cross-section shown in Figure 10 depicts a single dome, but there may be a multitude of closely spaced domes in the cross-section shown. Furthermore, the cross-section may also be of a dome that takes the form of a linear, flat, cranked element in a semi-continuous pattern similar to that shown in Figure 18. Fig. 1 shown, may have, or it may be a dome that features a series of two or more generally concentric multi-level shapes, such as concentric circular shapes.

[0053] Here too, the ones in the Fig. The forms shown in Figures 7-10 are representative and not limiting. In general, the invention is a unified deflection element, wherein the deflection element has a section, identified as a reinforcing element and at least one dome, extending from the reinforcing element. The deflection element as shown in the Fig. As shown in Figures 7-10, a uniform deflection element may have a transition section 32 where the deflection element transitions from the reinforcing element to the dome. The key distinguishing feature of a uniform deflection element is that there is no joining of separate sections, such as a curable resin on a woven filament backing, in the transition section. The reinforcing element and the domes may consist of one or more materials, but with a continuous transition mixture between one and the other. Sections of the reinforcing element and the domes may differ in material content, but in uniform deflection elements, the material transition is due to different materials used in an additive manufacturing process, rather than to materials or sections that adhere, cure, or are otherwise joined.The domes of the deflection element define diversions within which a fiber structure can be formed. The porous nature of the reinforcement structure allows water to be removed from an unfinished fiber fabric, as described in more detail below. Method for manufacturing a uniform deflection element

[0054] A uniform deflection element can be produced using a 3D printer as a manufacturing device for additive manufacturing. Uniform deflection elements of the invention were produced using a MakerBot Replicator 2, available from MakerBot Industries, Brooklyn, NY, USA. Other alternative additive manufacturing processes include, for example, selective laser sintering (SLS), stereolithography (SLA), direct metal laser sintering, or fused deposition modeling (FDM, as distributed by Stratasys Corp., Eden Prairie, MN), also known as fused filament fabrication (FFF).

[0055] The material used for the uniform deflection element of the invention is polylactic acid (PLA), which is supplied in a 1.75 mm diameter filament in various colors, for example, TruWhite and TruRed. Other alternative materials can be liquid photopolymer, high-melting-point filament (50 °C to 120 °C above the Yankee temperature), flexible filament (e.g., NinjaFlex PLA, available from Fenner Drives, Manheim, PA, USA), wood composite filament, metal / composite filament, nylon powder, metal powder, or fast-setting epoxy. In general, any material suitable for 3D printing can be used, with the material selection being determined by desired properties regarding strength and flexibility, which in turn can be determined, for example, by operating conditions in a paper manufacturing process.In the present invention, the method for producing fiber substrates with relatively stiff deflection elements can be achieved.

[0056] A 2D image of a repeating element of a desired uniform deflection element, created, for example, in AutoCAD, DraftSight, or Illustrator, can be exported to a 3D file, such as a drawing file in SolidWorks 3D CAD or other NX software. The repeating element contains the dimensional parameters for the wall angles, dome shape, and other features of the deflection element. Optionally, you can create a file directly in the 3D modeling program, such as Google SketchUp or other solid modeling programs that can generate an STL (Standard Tessellation Language) file. The STL file for a repeating element and repeating element dimensions for the present invention were exported to and imported by the MakerWare software used by the MakerBot printer. Optionally, Slicr3D software can be used for this step.

[0057] The next step involves assembling objects for the various features of a deflection element, such as the reinforcement element, transition sections, and domes, assigning Z-direction dimensions to each. Once all objects are assembled, they are imported and used to create an x3g print file. An x3g file is a binary file read by the MakerWare machine that contains all the instructions for printing. The output x3g file can be saved to an SD card or, optionally, connected directly to a computer via a USB cable. The SD card containing the x3g file can then be inserted into the MakerBot 3D printer's slot. Generally, any numerical control file, such as G-code files, as commonly known in the field, can be used to import a print file into the additive manufacturing device.

[0058] Before printing, the build platform of the MakerBot 3D printer can be prepared. If the build plate is not heated, it can be prepared with 3M Scotch-Blue Painter Tape #2090, available from 3M, Minneapolis, MN, USA. For a heated build plate, the plate is prepared using Kapton tape, manufactured by DuPont, Wilmington, DE, USA, and water-soluble glue stick adhesive, or hairspray, with a barrier film. The build platform should be clean and free of oil, dust, lint, or other particles.

[0059] The print nozzle of the MakerBot 3D printer used to manufacture the invention was heated to 230 °C.

[0060] The printing process is initiated to print the deflector, after which the device and deflector are allowed to cool. Once the deflector has cooled sufficiently, it can be removed from the build plate using a flat spatula, putty knife, or other suitable tool or device. The deflector can then be used in a process for fabricating a fiber structure, as described below.

[0061] Fig. 11 and Fig. Figure 12 shows a uniform deflection element manufactured according to the above procedure. The uniform deflection element has essentially the same shape profile as the digital image of Fig. 5, whose image file was used in the production of the uniform deflection element. The uniform deflection element, which is in the Fig. 11 and Fig. Figure 12 was produced using a MakerBot 3D printer, as described above, as a single unit with a pattern of solid ring-shaped or donut shapes, the donut shapes defining thirty-four individual diverts per square inch inside.

[0062] The uniform deflection element 10 may have a specific resulting open area R. As used here, the term “specific resulting open area” (R) means a ratio of a cumulative projected open area (ΣR) of all deflections of a given unit of the surface area (A) of the uniform deflection element to that given area (A) of that unit, i.e., R = ΣR / A, where the projected open area of ​​each individual deflection is formed by a smallest projected open area of ​​such deflection as measured in a plane parallel to the XY plane. The specific open area may be expressed as a fraction or as a percentage.For example, if a hypothetical layer has two thousand individual diversions distributed over a unit area (A) of thirty thousand square millimeters, and each diversion has a projected open area of ​​five square millimeters, the cumulative projected open area (ΣR) of all two thousand diversions is ten thousand square millimeters (5 mm x 2,000 = 10,000 mm). 2 ), and the specific resulting open area of ​​such a hypothetical layer is R = ⅓, or 33.33% (ten thousand square millimeters divided by thirty thousand square millimeters).

[0063] The cumulative projected open area of ​​each individual conduit is measured based on its smallest projected open area parallel to the XY plane, since some conduits may be non-uniform along their length or the thickness of the deflecting element. For example, some conduits may be tapered, as described in jointly granted U.S. Patents 5,900,122 and 5,948,210. In other embodiments, the smallest open area of ​​each conduit may be located between the upper surface and the lower surface of the uniform deflecting element.

[0064] The specific resulting open area of ​​the unitary deflection element can be at least 1 / 5 (or 20%), more precisely, at least 1 / 8 (or 40%), and even more precisely, at least 2 / 6 (or 60%). According to the present invention, the first specific resulting open area R1 can be larger than, substantially equal to, or smaller than the second resulting open area R2.

[0065] The deflection element, which is in the Fig. 11 and Fig. Figure 12 shows that the deflection element was produced in a generally flat configuration, built up by additive manufacturing from a back surface 20 to a web surface 22. When these are produced from sufficiently large dimensions, such deflection elements can be folded into a continuous strip, as is currently done in the field of woven papermaking strips. However, the deflection element of the present invention can also be achieved in a seamless strip configuration, as shown in Figure 12. Fig. 13. That is, the deflection element can be constructed in the form of a seamless band, with the back side 20 representing the inner surface of the band and the web side 22 representing the outer surface of the band.

[0066] The seamless belt deflection element, which is in Fig. Figure 13 is generally represented in the form of a cylinder, but the shape need not be cylindrical. As shown, a first circumferential edge 34 of the deflection element 10 forms one end of the cylindrical shape and can be the base in contact with the build plate of the additive manufacturing device, such as the MakerBot 3D printer, which is used to produce the seamless ribbon deflection element 10 shown in Figure 13. Fig. Figure 13 shows how to manufacture it using the process described above. Similarly, the additive manufacturing process builds the deflection element in the direction of arrow W. Fig. 13 upwards, which means that the final dimension in this direction can be considered the width of the strip thus formed. Once formed, the seamless strip deflection element 10 can be mounted on a cylinder (such as a vacuum cylinder) of the same dimensions or supported by rollers in a non-cylindrical configuration and used as a deflection element to form a fiber structure.

[0067] The seamless belt deflection element 10 can have domes 18 and diverters 16 as described herein, where it is understood that the X, Y and Z dimensions are as shown in Fig. 13. That is, the X and Y coordinates can be considered as being in the plane of a localized section of the seamless tape deflection element 10, and the Z direction can be considered as extending radially outwards from the back side 20 to the track side 22. Fiber structure

[0068] One purpose of the deflecting element 10 is to provide a forming surface on which fibrous structures, including hygiene wipe products such as paper towels, toilet paper, facial tissues, wipes, dry or wet wipe covers, and the like, can be formed. When the deflecting element 10 is used in a papermaking process, it can be employed at the "wet end" of a papermaking process, as described in more detail below, in which fibers from a fibrous slurry are deposited on the web side 22 of the deflecting element 10. As discussed below, some of the fibers can be deflected into the diversions 16 of the uniform deflecting element 10, causing some of the deflected fibers, or portions thereof, to be arranged within the cavities, i.e., in the diversions formed by the domes 18 of the uniform deflecting element 10.

[0069] As is clear from the above description, and as in Fig. 14 and Fig. As shown in Figure 15, the fiber structure 500 can be shaped to the general form of the deflection element 10, including the diverters 16, such that the shape and size of the knuckles and cushion features of the fiber structure closely approximate the size and shape of the domes 18 and the diverters 16. A cross-section of a representative deflection element 10 is shown in the Fig. 14 and Fig. 15 shown. Note that the one in the Fig. 13 and Fig. The cross-section shown in Figure 14 may be of a deflection element with semi-continuous domes and diversions, such as the one in Fig. 1 shown, or it can also be a deflection element with individual domes 18, each of which has a substantially cylindrical transition section 24 and a substantially spherical forming section 26, similar to a ‘golf ball on a T’, as in Fig. Figure 2 shows a cross-section, or it could also be a deflection element with a continuous dome and individual diversions. The cross-section shown is therefore not intended to be restrictive, but rather representative, in order to explain the formation of fiber structures.

[0070] As in Fig. 14 Fibers with a constant base weight can be pressed or otherwise introduced over the domes and into the diversions 16 to form low-density cushions 510 in the finished fiber structure. Similarly, fibers arranged on the forming section 26 of the domes 18 can generally form high-density knuckles 520. However, it is important that when it / they are dried and removed from the diversion, for example by peeling in the direction of arrow P in Fig. 15, the fiber structure can maintain the general shape of cushions and ankles, which closely resemble the domes 18 and the deflections of the deflecting element 10. Thus, as in Fig. As shown in Figure 15, the cushions 510 can have a cushion transition section 512 with a cushion transition width PTW corresponding to the minimum distance dimension parallel to the XY plane between adjacent forming sections 12 of adjacent domes 18. Similarly, the cushions 510 can have a cushion top 514 with a cushion top width PW, which is the minimum dimension measured between adjacent transition sections 24 of the domes 18. The cushions 510 can have a cushion height PH that is closest to the height TH of the transition section 24 and a cushion transition height that is closest to the height FH of the forming section 26.

[0071] In general, the deflection element 10 of the present invention therefore allows the production of a fiber structure with a plurality of regularly spaced cushions of relatively low density extending from knuckles of relatively high density, wherein at least two of the cushions are similar in size and shape, the cushion having a cushion transition section extending from a proximal end of a knuckle of relatively high density, the cushion transition section having a cushion transition section width PTW; and a cushion top extending from a distal end of the cushion transition section, the cushion top having a cushion top width PW.

[0072] The deflecting element 10 of the present invention facilitates the production of a fiber structure in which the cushion transition section width PTW can be smaller than the cushion transition width PW. Therefore, the fibrous cushions 510 of the paper produced on the deflecting element 10 can have a density lower than the density of the rest of the fibrous structure 500, thus enhancing the absorbency and softness of the fibrous structure 500 as a whole. The cushions 510 also contribute to increasing the total surface area of ​​the fiber structure 500, further promoting its absorbency and softness.

[0073] As with the deflecting element 10 discussed above, there is a virtually unlimited number of shapes, sizes, spacings, and orientations that can be selected for the shapes and sizes of the cushions 510. The actual shapes, sizes, orientations, and spacings of the cushions are determined by the design of the deflecting element and can be specified based on a desired fiber structure. The improvement of the present invention is that the shapes, sizes, spacings, and orientations of the cushions 510 are not limited by the constraints of deflecting elements previously produced by UV curing of a resin through a patterned mask. That is, the size, shape, and uniformity of the cushions 510 can be predetermined and achieved in a manner that is not possible by using deflecting elements produced essentially by line-of-sight UV curing.As discussed above, such line-of-sight light transmission prevents effective curing of the forming section 26, which has a larger XY dimension than the transmission section, especially in a uniform manner for most or all domes.

[0074] In contrast to the “fibrous cantilevered sections” taught in US 6,660,129, which extend “laterally from the fibrous domes” at a second height, two or more of the cushions 510 of the present invention can be uniform in size and shape and can be repeated in a uniform pattern over a fibrous structure. That is, instead of having an arbitrarily distributed pattern of cushions that are not substantially identical or similar due to the limitations of the mask design and placement, the cushions 510 of the present invention can be uniformly formed over the deflecting element. In one embodiment, at least two cushions 510 on the fibrous structure can be substantially identical in size and shape."Substantially identical" means that the design intent is for two or more cushions to be identical in size and shape, but minor differences may exist due to manufacturing limitations or irregularities. Two cushions of the same shape that differ from each other in the difference between cushion top width PW and cushion transition width PTW by less than 5% are considered substantially identical. Due to the fibrous nature of the cushions, PW and PTW for a cushion of interest can be considered identical to the minimum dimension measured between adjacent transition sections 24 of the domes 18 and the minimum dimension measured parallel to the XY plane between adjacent forming sections 12 of adjacent domes 18.This means that, due to the forming properties of the deflecting element 10, the dimensions of the fiber structure produced on it can have dimensions corresponding to the cavity dimensions of the deflecting element. In one embodiment, at least two cushions 510 of similar size and shape are located on the fiber structure 500. By "similar" is meant that the intention of the design is that the two or more cushions have the same shape or size, but some variations may be present in the patterned frame. Method for producing a fibrous structure

[0075] With reference to Fig. 16 An exemplary embodiment of the method for producing the fiber structure 500 of the present invention comprises the following steps. First, a plurality of fibers 501 are provided and deposited on a forming wire of a papermaking machine, as is known in the art.

[0076] The present invention provides for the use of a variety of fibers, such as cellulose fibers, synthetic fibers, or other suitable fibers, and any combination thereof. Papermaking fibers suitable for the present invention include cellulose fibers, which are generally known as wood pulp fibers. Fibers obtained from softwoods (gymnosperms or conifers) and hardwoods (angiosperms or deciduous trees) are considered for use in this invention. The specific species of tree from which the fibers are obtained is unimportant. The hardwood and softwood fibers may be mixed or, alternatively, applied in layers to provide a laminated web. U.S. Patents No. 4,300,981, granted on November 17, 1981, to Carstens, and U.S. Patent No. 3,994,771, granted on November 30, 1976, to Morgan et al. are included herein by reference for the purpose of disclosing the layering of hardwood and softwood fibers.

[0077] The pulp fibers can be produced from the native wood by any suitable pulping process. Chemical processes such as sulfite, sulfate (including Kraft), and soda processes are suitable. Mechanical processes such as thermomechanical (or Asplund) processes are also suitable. In addition, various semi-chemical and chemi-mechanical processes can be used. Both bleached and unbleached fibers are considered for use. If the fibrous web of this invention is intended for use in absorbent products such as paper towels, bleached northern softwood Kraft pulp fibers can be used. Pulps useful herein include chemical pulps such as Kraft, sulfite, and sulfate pulps, as well as mechanical pulps, including, for example, milled wood, thermomechanical pulps, and chemi-thermo-mechanical (CTMP) pulp.Pulp obtained from both deciduous and coniferous trees can be used.

[0078] In addition to various cellulose fibers, other cellulose fibers, such as cotton linters, rayon, and bagasse, can be used in this invention. Synthetic fibers, such as polymer fibers, can also be used. Elastomeric polymers, polypropylene, polyethylene, polyester, polyolefin, and nylon can be used. The polymer fibers can be produced by spunbond processes, meltblown processes, and other suitable processes known in the field. It is assumed that thin, long, and continuous fibers produced by spunbond and meltblown processes can be advantageously used in the fiber structure of the present invention, since these fibers are assumed to be easily deposited into the pockets of the uniform deflection element of the present invention.

[0079] The paper raw material can include a variety of additives, including, but not limited to, fiber binders such as wet-strength binders, dry-strength binders, and chemical plasticizer compositions. Suitable wet-strength binders include, but are not limited to, materials such as polyamide epichlorohydrin resins sold under the trade name KYMENE™ 557H by Hercules Inc., Wilmington, Del. Suitable temporary wet-strength binders include, but are not limited to, synthetic polyacrylates. One suitable temporary wet-strength binder is PAREZ™ 750, distributed by American Cyanamid of Stanford, Connecticut. Suitable dry-strength binders include materials such as carboxymethylcellulose and cationic polymers, such as ACCO™ 711. The CYPRO / ACCO family of dry-strength materials is available from CYTEC of Kalamazoo, Michigan.

[0080] The paper stock can include a release agent to prevent the formation of some fiber-to-fiber bonds when the web is dried. The release agent, in combination with the energy supplied to the web by the dry creping process, causes a portion of the web to compact. In one embodiment, the release agent can be applied to fibers forming an intermediate fiber layer positioned between two or more layers. The intermediate layer acts as a release layer between the outer fiber layers. The creping energy can therefore compact a section of the web along the release layer. Suitable release agents include chemical plasticizer compositions such as those disclosed in U.S. Patent A-5,279,767, granted on January 18, 1994, to Phan et al., the disclosure of which is incorporated herein by reference. Suitable biodegradable chemical plasticizer compositions are disclosed in U.S. Patents No.5,312,522, granted on May 17, 1994, to Phan et al., which discloses U.S. Patents Nos. 5,279,767 and 5,312,522, the disclosures of which are incorporated herein by reference. Such chemical plasticizer compositions can be used as separating agents to inhibit fiber-to-fiber bonding in one or more layers of the fibers forming the web. A suitable plasticizer for separating the fibers in one or more layers of the fibers forming the web 20 is a papermaking additive containing DiEster Di (Touch Hardened) tallow dimethylammonium chloride. A suitable plasticizer is ADOGEN® brand papermaking additive, available from Witco Company of Greenwich, Conn.

[0081] The unfinished web can typically be produced from an aqueous dispersion of papermaking fibers, although dispersions in liquids other than water can be used. The fibers are dispersed in the carrier liquid to achieve a consistency of about 0.1 to about 0.3 percent. Alternatively, and without being theoretically limited, the present invention is considered applicable to wet forming processes in which the fibers are dispersed in a carrier liquid to achieve a consistency of less than about 50 percent. In yet another alternative embodiment, and without being theoretically limited, the present invention is considered applicable to airlaid structures, including airlaid webs comprising cellulose fibers, synthetic fibers, and mixtures thereof.

[0082] Conventional papermaking fibers can be used, and the aqueous dispersion can be formed in the conventional manner. Conventional papermaking equipment and processes can be used to form the unfinished web on the Fourdrinier wire. Joining the unfinished web to the uniform deflector can be achieved by simply transferring the web between two moving endless belts, assisted by differential fluid pressure. The fibers can be deflected into the uniform deflector 10 by applying a differential fluid pressure induced by an applied vacuum. Any technique, such as the use of a Yankee drum dryer, can be used to dry the interweb. Shortening can be achieved by any conventional technique, such as creping.

[0083] The multitude of fibers can also be supplied in the form of a moistened fiber web (not shown), which should preferably be in a state in which sections of the web can be effectively deflected into the diversions of the uniform deflection element and the cavities formed between the suspended sections and the XY plane.

[0084] In Fig. 16 The unfinished web, comprising fibers 501, is transferred from a forming wire 23 to a belt 21 on which a uniform deflection element 10 with a surface area of ​​approximately 52 to 77 square centimeters (8 to 12 square inches) is arranged by placing it on the belt 21 upstream of a vacuum receiving shoe 48a. Alternatively or additionally, several fibers or a fibrous slurry can be applied directly from a headbox or by other means, including in a batch process, to the uniform deflection element 10 (not shown). The paper-making belt, comprising a uniform deflection element 10 held between the unfinished web and the belt 21, runs past optional dryer / vacuum devices 48b and rollers 19a, 19b, 19k, 19c, 19d, 19e and 19f in the direction schematically indicated by arrow “B”.

[0085] A portion of the fibers 501 is deposited into the deflection section of the uniform deflection element 10 to cause some of the deposited fibers or sections to be arranged within the cavities formed by the domes 18 of the uniform deflection element 10. Depending on the process, a mechanical and fluid pressure differential, alone or in combination, can be used to deposit a portion of the fibers 501 into the deflections of the uniform deflection element 10. For example, in a through-air drying process, a vacuum device 48c can apply a fluid pressure differential to the unfinished web arranged on the uniform deflection element 10, thereby depositing fibers into the deflections of the uniform deflection element 10.The separation process can optionally be continued with additional vacuum pressure to further separate the fibers into the diversions of the uniform deflection element 10.

[0086] Finally, a partially formed fibrous structure associated with the uniform deflection element 10 can be separated from the uniform deflection element on the roller 19k during transfer to a Yankee dryer 128. In this way, the uniform deflection element 10 with the fibers located on it is pressed against a pressure surface, such as the surface of a Yankee drying drum 128, thereby generally compacting high-density knuckles 520, as in the Fig. 14 and Fig. Figure 15 shows that in some cases these fibers, which are arranged within the diversions, can also be at least partially compacted.

[0087] After creping by the Yankee dryer, a fiber structure 500 of the present invention is created and can be further processed or converted as desired. Example

[0088] A uniform deflection element 10 of the present invention from the one in Fig. The type shown in section 5 is in the Fig. 11 and Fig. 12 shown. Fig. Figure 11 is a perspective view of a uniform deflection element and Fig. Figure 12 is a top view of the same uniform deflection element.

[0089] How to get into the Fig. 11 and Fig. As can be seen in Figure 12, the uniform deflection element has essentially the same shape as the digital image of Fig. 5. In the example shown, the uniform diverter element was manufactured using a MakerBot 3D printer, as described above, as a single unit having a pattern of a solid ring shape or “donut” shape, with the donut shapes inside defining thirty-four individual diverters per square inch.

[0090] The cumulative projected open area (ΣR) of the diversions was 3.65 square centimeters (0.565 square inches). The specific resulting open areas R1 and R2 (i.e., the ratios of the cumulative projected open area of ​​a given section, i.e., the reinforcement element section and the domes, to a given surface area) were calculated: R = 57%. The domes 18 have a forming element height FH of approximately 0.08 cm (approximately 0.03 inches) and a forming element width FW (in this case, the width of the annular section of the donut mold) of approximately 0.08 cm (approximately 0.03 inches). The domes 18 have a transition width of approximately 0.0185 cm (approximately 0.0073 inches), and the outside of the donut in plan view has a diameter of approximately 0.04330 cm (approximately 0.01705 inches). The deflection element 10 has a deflection element height DMH of approximately 0.197 cm (approximately 0.0775 inches).The domes 18 are located on a 21 × 21 grid reinforcement element 14, thus simultaneously forming a single deflection element. The reinforcement element comprises a layer of spaced MD-oriented rectangular cross-section elements, upon which a layer of spaced CD-oriented rectangular cross-section elements is arranged (to form the 21 × 21 grid), each rectangular cross-section element being 0.0368 centimeters (0.0145 inches) wide (MD or CD) and 0.0559 centimeters (0.0220 inches) high (Z-direction). The domes extend from the top of the CD-oriented elements.

[0091] Paper was manufactured using the uniform deflection element 10, as described in the Fig. 11 and Fig. 12 shown, on a paper machine, as with reference to Fig. 16. The paper consisted of 40% NSK (Northern Softwood Kraft), 10% SSK (Southern Softwood Kraft), 35% Fibria Eucalyptus (Hardwood Kraft), and 15% Broke. Each pulp was crushed using a conventional rotor. The NSK (Northern Softwood Kraft) and SSK (Southern Softwood Kraft) pulps were combined and crushed for 8 minutes to approximately 3.0 wt% fiber, then transferred to feed hopper "D". The Fibria Eucalyptus (Hardwood Kraft) was crushed for 3 minutes to approximately 3.0 wt% fiber and then transferred to feed hopper "B". The Broke was crushed for 8 minutes to approximately 3.0 wt% fiber and then transferred to feed hopper "A". The combined and homogeneous slurry of NSK and SSK pulp is passed through a refiner and refined to a Canadian Standard Freeness (CSF) of approximately 300 to 500. Then, to impart wet strength, a reinforcing additive (e.g.,Kymene® 5221) is added to the combined NSK / SSK fiber blend stock pipe at a rate of approximately 10.5 kg per tonne (about 21.0 lbs per tonne) of fiber. All fiber slurries are combined together, then blended in series as a homogeneous slurry, and then passed through a thick stock pipe. Finnfix / CMC® is added to the homogeneous thick slurry before it enters the blower pump, where it is diluted to about 0.15 wt% to about 0.2 wt% fiber to provide additional dry strength. At dilution, the homogeneous slurry is then directed to the headbox of a Fourdrinier paper machine forming section moving at 271 meters per minute (888 feet per minute).The unfinished web is transferred from the forming wire (Microtex J76 Design, Albany International) to the uniform deflection element 10, which moves at a speed of about 244 meters per minute (about 800 feet per minute), by means of a vacuum grinder set to about 42.0 kPa (about 12.4 inches Hg).

[0092] The web was formed directly on the uniform deflection element 10 of the present invention, vacuumed, and dried. After drying, the sheet was separated from the uniform deflection element 10. The uncreped web yielded a conditioned basis weight of approximately 22.6 g / m². 2 (approximately 13.9 pounds per 3000 feet squared) (at 21 °C (70 °F) and 50% RH over 2 hours).

[0093] The formed path is in the Fig. 17 and Fig. 18 shown. Fig. Figure 17 is a photograph of a surface of the fiber structure 500, showing the topography imparted to the fiber structure by the uniform deflection element. Fig. 18 is a micrograph of a cross-section of the in Fig. Figure 17 shows the fiber structure 500 and shows dimensions of an ankle / cushion 510 section of the fiber structure 500.

Claims

[1] Method for manufacturing a uniform deflection element (10) comprising at least one reinforcing element (14) and a plurality of regularly spaced projections (18) extending from said reinforcing element (14), wherein the reinforcing element (14) comprises MD-oriented elements and CD-oriented elements in a multi-layered configuration, wherein at least two of the projections (18) are similar in size and shape, each projection (18) comprising a transition section (24) with a transition section width (TW) and a forming section (26) with a forming section width (FW), wherein the transition section width (TW) is less than the forming section width (FW), wherein the projections (18) are uniform with the reinforcing element (14) such that, in cross-section, the projections (18) and the reinforcing element (14) are formed as a single unit and not from separate parts,the procedure comprises the following steps: a. Providing a manufacturing device for additive manufacturing; b. Providing at least one material for the uniform deflection element (10), wherein the material to be used is compatible with the additive manufacturing device; c. Generating a three-dimensional digital image of objects in a repeating element of the uniform deflection element (10), wherein the objects include the at least one reinforcement element (14) and the projections (18) of the uniform deflection element (10), and wherein the objects further include the transition sections (24) and the forming sections (26) on the projections (18); d. Compiling the objects into a digitized file containing the projections (18) located on the reinforcement element (14); e. Importing the digitized file to generate a numerical control file for the additive manufacturing device; and f. Applying the material using the additive manufacturing device to produce the uniform deflection element. [2] The method for producing a uniform deflection element according to claim 1, further characterized in that the manufacturing device for additive manufacturing is a 3D printer. [3] The method for producing a uniform deflection element according to one of claims 1 or 2, further characterized in that the digitized file describes the reinforcement element (14) which defines an XY plane and the plurality of regularly spaced projections (18), wherein each projection (18) has a three-dimensional shape such that each cross-sectional area of ​​the projection (18) parallel to the XY plane has the same or a smaller area than each cross-sectional area of ​​the projection (18) at a greater distance from the XY plane in the Z direction. [4] The method for producing a uniform deflection element according to one of claims 1 to 3, further characterized in that the plurality of regularly spaced projections (18) represent individual units which are arranged in a regular, spaced configuration in both the MD and the CD, wherein each individual unit has a cross-section, wherein the cross-sectional shape is selected from keyhole-shaped, mushroom-shaped, circular, oval, inverted triangles, T-shaped, inverted L-shaped, egg-shaped or pebble-shaped shapes and combinations thereof. [5] Method for manufacturing a uniform deflection element (10) comprising at least one reinforcing element (14) and a plurality of regularly spaced projections (18) extending from said reinforcing element (14), wherein the reinforcing element (14) comprises MD-oriented elements and CD-oriented elements in a multi-layered configuration, wherein at least two of the projections (18) are similar in size and shape, each projection (18) comprising a transition section (24) with a transition section width (TW) and a forming section (26) with a forming section width (FW), wherein the transition section width (TW) is less than the forming section width (FW), wherein the projections (18) are uniform with the reinforcing element (14) such that, in cross-section, the projections (18) and the reinforcing element (14) are formed as a single unit and not from separate parts.the procedure comprises the following steps: a. Providing a manufacturing device for additive manufacturing; b. Providing at least one material for the uniform deflection element (10), wherein the material to be used is compatible with the additive manufacturing device; c. Generating a three-dimensional digital image of objects in an element of the unified deflection element (10), wherein the objects include the at least one reinforcement element (14) and the projections (18) of the unified deflection element (10), and wherein the objects further include the transition sections (24) and the forming sections (26) on the projections (18); d. Compiling the objects into a digitized file containing the projections (18) located on the reinforcement element (10); e. Importing the digitized file to generate a numerical control file for the additive manufacturing device; and f. Applying the material using the additive manufacturing device to produce the uniform deflection element (10). [6] The method for manufacturing a uniform deflection element according to claim 5, further characterized by , that the digitized file describes the uniform deflection element (10) in which at least two of the projections (18) are adjacent to each other and are separated by a cavity that defines a deflection. [7] The method for producing a uniform deflection element according to one of claims 5 or 6, further characterized in that the digitized file describes the reinforcement element (14) which defines an XY plane and the plurality of regularly spaced projections (18), wherein each projection (18) has a three-dimensional shape such that each cross-sectional area of ​​the projection (18) parallel to the XY plane has the same or a smaller area than each cross-sectional area of ​​the projection (18) at a greater distance from the XY plane in the Z direction. [8] The method for producing a uniform deflection element according to one of claims 5 to 7, further characterized in that the plurality of regularly spaced projections (18) represent individual units which are arranged in a regular, spaced configuration in both the MD and the CD, wherein each individual unit has a cross-section, wherein the cross-sectional shape is selected from keyhole-shaped, mushroom-shaped, circular, oval, inverted triangles, T-shaped, inverted L-shaped, egg-shaped or pebble-shaped forms and combinations thereof. [9] Method for manufacturing a uniform deflection element (10) comprising at least one reinforcing element (14) and a plurality of regularly spaced projections (18) extending from said reinforcing element (14), wherein the reinforcing element (14) comprises MD-oriented elements and CD-oriented elements in a multi-layered configuration, wherein at least two of the projections (18) are similar in size and shape, each projection (18) comprising a transition section (24) with a transition section width (TW) and a forming section (26) with a forming section width (FW), wherein the transition section width (TW) is less than the forming section width (FW), wherein the projections (18) are uniform with the reinforcing element (14) such that, in cross-section, the projections (18) and the reinforcing element (14) are formed as a single unit and not from separate parts.the procedure comprises the following steps: a. Provision of a 3D printer for additive manufacturing; b. Providing at least one material for the uniform deflection element (10), wherein the material to be used is compatible with the 3D printing device; c. Generating a three-dimensional digital image of objects in an element of the unified deflection element (10), wherein the objects comprise the at least one reinforcement element (14) and the projections (18) with the transition sections (24) and the forming sections (26); d. Compiling the objects into a digitized file containing the projections (18) located on the reinforcement element (14); e. Importing the digitized file to generate a numerical control file for the 3D printer; and f. Applying the material using the 3D printer to produce the uniform deflection element (10). [10] The method for manufacturing a uniform deflection element according to claim 9, further characterized by , that the digitized file describes the uniform deflection element (10) in which at least two of the projections (18) are adjacent to each other and are separated by a cavity that defines a deflection. [11] The method for producing a uniform deflection element according to one of claims 9 or 10, further characterized in that the digitized file describes the reinforcement element (10) which defines an XY plane and the plurality of regularly spaced projections (18), wherein each projection (18) has a three-dimensional shape such that each cross-sectional area of ​​the projection (18) parallel to the XY plane has the same or a smaller area than each cross-sectional area of ​​the projection (18) at a greater distance from the XY plane in the Z direction. [12] The method for producing a uniform deflection element according to one of claims 9 to 11, further characterized in that the plurality of regularly spaced projections (18) represent individual units which are arranged in a regular, spaced configuration in both the MD and the CD, wherein each individual unit has a cross-section, wherein the cross-sectional shape is selected from keyhole-shaped, mushroom-shaped, circular, oval, inverted triangles, T-shaped, inverted L-shaped, egg-shaped or pebble-shaped shapes and combinations thereof.

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