Manufacturing system

Abstract

According to an example aspect, there is provided a manufacturing system (100a, 100b), comprising a primary unit for generation of a foamed fibrous furnish, a secondary unit for generation of an aqueous furnish or a foamed fibrous furnish, a primary web forming device (101) for the foamed fibrous furnish, a secondary web forming device (102) for the aqueous 5 furnish or the foamed fibrous furnish, and a shared wire (103).

Description

MANUFACTURING SYSTEMFIELD

[0001] The present invention relates to a manufacturing system. Particularly, the present invention relates to a manufacturing system for a foamed fibrous web and a wet web.BACKGROUND

[0002] Typically, in the foam-laid method a fibre web is formed from a dispersion of fibres in a foamed liquid. A pulp or fibre furnish is first prepared in a pulper, followed by dewatering and mixing with a foam or foamable liquid comprising a surfactant and water. The fibres are dispersed in the foam and the formed fibre-foam is deposited on a wire and the main portion of the liquid, which is essentially in the form of foam, is removed.

[0003] Building a new manufacturing line only for the foam formed products is expensive. However, wet-laying lines, which are used in large scale for the manufacture of paper and cardboard products, are not be suitable for manufacturing novel foam formed products as such. In addition, two parallel lines may not reach full load capacity.

[0004] An object of the present invention is to mitigate at least some of the above- mentioned problems. An object of the present invention is to provide a manufacturing line for both wet laid and foam formed products.SUMMARY

[0005] According to a first aspect of the present disclosure, there is provided a manufacturing system, comprising:- a primary unit for generation of a foamed fibrous furnish,- a secondary unit for generation of an aqueous furnish or a foamed fibrous furnish,- a primary web forming device for the foamed fibrous furnish,- a secondary web forming device for the aqueous furnish or the foamed fibrous furnish, and- a shared wire, wherein:- in a first configuration of the manufacturing system, the primary web forming device is arranged to feed the generated foamed fibrous furnish from the primary unit onto the shared wire to obtain a fibrous web,- in a second configuration of the manufacturing system, the secondary web forming device is arranged to feed the generated aqueous furnish from the secondary unit onto the shared wire to obtain a wet web, or the generated foamed fibrous furnish from the primary unit onto the shared wire to obtain a fibrous web,- in an optional third configuration of the manufacturing system the primary web forming device and the secondary web forming device are arranged to simultaneously feed the generated foamed fibrous furnish onto the shared wire to obtain a multi-layer fibrous web, or feed the generated foamed fibrous furnish and the generated aqueous furnish, respectively, onto the shared wire to obtain a multi-layer web.

[0006] Significant benefits are gained with aid of the present manufacturing system. It enables connecting a foam forming line to an existing manufacturing line, such as to a wet laid line. Thus, it enables producing foam formed products and other products with the same manufacturing line. Switching from one product to another is quick and the parts of the different forming lines do not interfere with each other's operation. The present manufacturing system is more cost effective and sustainable than two separate lines for different products. It enables the use of breaks in the production of the other products to produce products by foam forming.

[0007] One or more embodiments may comprise one or more features from the following itemized list:- the manufacturing system comprises a further wire- the primary web forming device is arranged to feed the generated foamed fibrous furnish from the primary unit onto the further wire to obtain a fibrous web- the further wire is arranged to feed the obtained fibrous web onto the shared wire- the further wire is arranged above the shared wire- the manufacturing system comprises one or more than one dewatering device below the shared wire- the manufacturing system comprises one or more than one dewatering device below the further wire, when in use- the dewatering device(s) is / are configured to dewater the obtained fibrous web- the dewatering device(s) comprise(s) one or more than one suction box- the manufacturing system comprises a wire pit- the manufacturing system comprises a means for guiding the foam, which is connected to the wire pit for receiving water and foam from the dewatering device(s) and guiding the foam to the wire pit- the means for guiding the foam comprises a lock water tank or an air separation container- the manufacturing system comprises one or more than one binder applicator- the binder applicator(s) is / are arranged to apply a binder composition, additives and / or other functional components onto the obtained fibrous web- the binder applicator(s) is / are on the shared wire- the binder applicator(s) is / are on the further wire- the binder applicator(s) is / are after the shared wire- the manufacturing system comprises a pre-dyer after the binder applicator(s)- the primary web forming device is configured to add the binder composition, additives and / or other functional components onto the foamed fibrous furnish- the secondary web forming device is configured to add the binder composition, additives and / or other functional components onto the foamed fibrous furnish- the web forming device is a headbox, such as an inclined headbox, a gap former headbox, a vertical headbox or a hydraulic headbox- the manufacturing system comprises one or more than one manifold for spreading the foamed fibrous furnish to the primary web forming device- the manufacturing system comprises one or more than one manifold for spreading the foamed fibrous furnish to the secondary web forming device- the manufacturing system comprises a drying section arranged to receive the dewatered web from the shared wire and to dry the dewatered web- the manufacturing system comprises a non-contact dryer arranged to receive the dewatered fibrous web from the shared wire and to dry the dewatered fibrous web- the manufacturing system comprises a size press- the manufacturing system comprises a calander- the primary unit comprises or is connected to a means for increasing consistency of fibres of the foamed fibrous furnish, before the primary web forming device or the secondary web forming device- the means for increasing the consistency of fibres comprises a screw press or a belt press- the consistency is configured to be adjusted to 10-50 %, such as to 20-40 %, by the means for increasing consistency- the primary unit comprises or is connected to a foam mixing tank for mixing foam and the fibres received from the means for increasing consistency of the fibres, to produce the foamed fibrous furnish- the secondary unit comprises or is connected to a foam mixing tank for mixing foam and the fibres received from the means for increasing consistency of the fibres, to produce the foamed fibrous furnish- the primary unit comprises or is connected to a means for screening the fibres of the foamed fibrous furnish to remove fibre conglomerations from the foamed fibrous furnish, before feeding the foamed fibrous furnish to the primary web forming device or the secondary web forming device- the secondary unit comprises or is connected to a means for screening the fibres of the foamed fibrous furnish to remove fibre conglomerations from the foamed fibrous furnish, before feeding the foamed fibrous furnish to the primary web forming device or the secondary web forming device- the means for screening the fibres comprises a screen

[0008] According to a second aspect of the present disclosure, there is provided use of the manufacturing system for producing a fibrous web for a paper, fabric, felt or porous material.

[0009] One or more embodiments may comprise one or more features from the following itemized list:- the fibrous web comprises natural or synthetic fibres having fibre lengths of 0.5-500 mm, for example 1-400 mm, such as 1.8-200 mm- the fibrous web has a grammage of 10-1000 g / m2, for example 20-100 g / m2, such as 25-45 g / m2- the fibrous web has a fibre content of 40-100 weight-%, for example 80-100 weight- %, such as 94-100 weight-%BRIEF DESCRIPTION OF THE DRAWINGS

[0010] FIGURE 1 illustrates a manufacturing system in accordance with at least some embodiments;

[0011] FIGURE 2 illustrates a manufacturing system comprising a further wire in accordance with at least some embodiments;

[0012] FIGURE 3 illustrates an inclined headbox in accordance with at least some embodiments;

[0013] FIGURE 4 illustrates a gap former in accordance with at least some embodiments;

[0014] FIGURE 5A and 5B illustrate a vertical headbox in accordance with at least some embodiments;

[0015] FIGURE 6 illustrates a hydraulic headbox in accordance with at least some embodiments;

[0016] FIGURE 7 illustrates a manufacturing system comprising binder applicators and pre-dryer in accordance with at least some embodiments;

[0017] FIGURE 8 illustrates a manufacturing system comprising binder applicators and pre-dryer after a press section in accordance with at least some embodiments;

[0018] FIGURE 9 illustrates a manufacturing system comprising a further wire, and binder applicators and pre-dryer after a press section in accordance with at least some embodiments; and

[0019] FIGURE 10 illustrates a primary unit for generation of a foamed fibrous furnish, a wire pit and a means for guiding the foam in accordance with at least some embodiments.EMBODIMENTS

[0020] In the present context, the term “fibrous furnish” refers to a furnish, which can comprise plant-based, i.e. natural fibres, synthetic fibres, and mixtures and combinations thereof.

[0021] In the present context, the term “aqueous furnish” refers to a non-foamed fibrous furnish, for example an aqueous slurry or a gypsum slurry.

[0022] In the present context, the term “web forming device” refers to a device, which is configured to form a web. The device can be for example, a headbox.

[0023] In the present context, the term “fibrous web” refers to a web, which can comprise plant-based, i.e. natural fibres, synthetic fibres, and mixtures and combinations thereof.

[0024] In the present context, the term “multilayer fibrous web” refers to a web that is formed by at least two overlapping layers of fibres. There can be a plurality of such overlapping layers, typically 2 to 10, in particular 2 or 3. A structure of the layers may vary depending on, for example, a fibre type, quantity or ratios of the fibres, or a binder content. The layer may comprise functional additives.

[0025] According to an aspect, there is provided a manufacturing system 100a, 100b, comprising:- a primary unit for generation of a foamed fibrous furnish,- a secondary unit for generation of an aqueous furnish or a foamed fibrous furnish,- a primary web forming device 101 for the foamed fibrous furnish,- a secondary web forming device 102 for the aqueous furnish or the foamed fibrous furnish, and- a shared wire 103, wherein:- in a first configuration of the manufacturing system 100a, 100b, the primary web forming device 101 is arranged to feed the generated foamed fibrous furnish from the primary unit onto the shared wire 103 to obtain a fibrous web,- in a second configuration of the manufacturing system 100a, 100b, the secondary web forming device 102 is arranged to feed the generated aqueous furnish from the secondary unit onto the shared wire 103 to obtain a wet web, or the generated foamed fibrous furnish from the primary unit onto the shared wire 103 to obtain a fibrous web,- in an optional third configuration of the manufacturing system 100a, 100b, the primary web forming device 101 and the secondary web forming device 102 arearranged to simultaneously feed the generated foamed fibrous furnish onto the shared wire 103 to obtain a multi-layer fibrous web, or feed the generated foamed fibrous furnish and the generated aqueous furnish, respectively, onto the shared wire 103 to obtain a multi-layer web.

[0026] Significant benefits are gained with aid of the present manufacturing system 100a, 100b. It enables connecting a foam forming line to an existing manufacturing line, such as to a wet laid line. Thus, it enables producing foam formed products and other products with the same manufacturing line. Switching from one product to another is quick and the parts of the different forming lines do not interfere with each other's operation. The present manufacturing system is more cost effective and sustainable than two separate lines for different products. It enables the use of breaks in the production of the other products to produce products by foam forming.

[0027] The primary web forming device 101 can be arranged to feed the foamed fibrous furnish from the primary unit.

[0028] The secondary web forming device 102 can be arranged to feed the aqueous furnish or the foamed fibrous furnish from the secondary unit, or the foamed fibrous furnish from the primary unit.

[0029] In the first configuration, the manufacturing system 100a, 100b is configured to produce the fibrous web. The secondary unit for generation of the aqueous furnish and the secondary web forming device 102 may not be used.

[0030] In the second configuration, the manufacturing system 100a, 100b is configured to produce the wet web or the fibrous web. The secondary web forming device 102 is configured to feed the generated aqueous furnish or the generated foamed fibrous furnish onto the shared wire 103. The primary web forming device 101 may not be used. This enables using the secondary web forming device 102, which can be for example, the web forming device of the existing wet forming manufacturing system, also for obtaining the fibrous web.

[0031] In the third configuration, the primary web forming device 101 and the secondary web forming device 102 are used simultaneously to feed the generated foamed fibrous furnish on the shared wire 103. The primary web forming device 101 can feed a first layer on the shared wire 103 and the secondary web forming device 102 can feed a secondlayer on the shared wire 103 above the first layer, or vice versa. The primary web forming device 101 can be arranged to feed the foamed fibrous furnish from the primary unit. The secondary web forming device 102 can be arranged to feed the foamed fibrous furnish from the secondary unit. Thus, a multi-layer fibrous web comprising fibrous layers can be obtained.

[0032] Alternatively, in the third configuration, the primary web forming device 101 is configured to feed the generated foamed fibrous furnish and the secondary web forming device 102 is configured to feed the generated aqueous furnish on the shared wire 103. The primary web forming device 101 can feed a first layer on the shared wire 103 and the secondary web forming device 102 can feed a second layer on the shared wire 103 above the first layer, or vice versa. Thus, a multi-layer fibrous web comprising a fibrous layer and a wet formed layer can be obtained.

[0033] FIGURE 1 illustrates a manufacturing system 100a in accordance with at least some embodiments. The manufacturing system 100a comprises a primary web forming device 101, a secondary web forming device 102 and a shared wire 103. The primary web forming device 101 and / or the secondary web forming device can feed a web on the shared wire 103. Thus, the primary web forming device 101 and the secondary web forming device 102 can be interchangeable or used at the same time.

[0034] The primary unit or the secondary unit can comprise or be connected to one or more pressure screen 127 for filtering out impurities and separating fibres in a fibre stock preparation. For example, the primary unit or the secondary unit can comprise a pressure screen for synthetic fibres and a pressure screen for natural fibres.

[0035] The fibrous furnish can comprise plant-based, i.e. natural fibres, synthetic fibres, and mixtures and combinations thereof. Natural fibres can be cellulose or lignocellulose fibres. In particular, the fibres are sourced from cellulose or lignocellulose raw materials, for example, by using chemical or semi-chemical pulping or defibering. The fibres can also be mechanical pulp fibres or recycled fibres. Natural fibres can be plant fibres sourced from, for example, cereal crop straws, wheat straw, reed canary grass, reed, flax, hemp, kenaf, jute, ramie, sisal, abaca, seeds, coir, bamboo, bagasse, cotton kapok, milkweed, pineapple, cotton, rice, cane, esparto grass, Phalaris arundinacea, and combinations thereof. The synthetic fibres can be thermoplastic polymer fibres, such as polylactide, glycolic acidpolymer, polyolefin, polyethylene terephthalate, polyester, polyamide, polyvinyl alcohol or bicomponent (bico) fibres.

[0036] The plant-based fibres can be micro- or nanofibres.

[0037] The average fibre length of the fibres can be 0.5-500 mm, for example 1-400 mm, such as 1.8-200 mm.

[0038] The primary unit or the secondary unit can further comprise or be connected to a fibre mixing tank 128 for mixing the fibres, and optionally broke, after processing the fibres by the pressure screen(s) 127.

[0039] The primary unit or the secondary unit can further comprise or be connected to a pre-thickener 129, which can comprise a bow screen. The pre-thickener 129 can be placed after the fibre mixing tank 128. The pre thickener 129 enables increasing a consistency of fibres.

[0040] The primary unit or the secondary unit can further comprise or be connected to a means for increasing a consistency of fibres 120 of the foamed fibrous furnish, such as a screw press or a belt press, before the primary web forming device 101 or secondary web forming device 102. The purpose of the means for increasing the consistency of the fibres 120 is to dewater the fibre mass and thus prevent excess water from entering the foam process. Excessive water causes an increase in the amount of wastewater and unnecessary consumption of the foaming chemical.

[0041] The consistency of the fibres can be adjusted to 10-50 %, preferably 20-40 % by the means for increasing consistency of the fibres 120.

[0042] The primary unit or the secondary unit can further comprise or be connected to a filtrate tank 126, which can be placed after the pre-thickener 129 and / or the means for increasing a consistency of fibres 120.

[0043] The primary unit or the secondary unit can further comprise or be connected to a foam mixing tank 121 for mixing foam and the fibres received from the means for increasing the consistency of the fibres 120, to produce the foamed fibrous furnish generated in the primary unit or the secondary unit, respectively. In the foam mixing tank 121, a mixing element mixes a foam or foamable liquid of water, one or more foaming agent and the fibres into a uniform mass.

[0044] The foaming agents for producing foams are selected from surface active agents, which enable the formation of a foam. Thus, typically, the foaming agent is selected from water-soluble foaming polymeric agent and water dispersible foaming polymeric agents and combinations thereof The foaming agent can be selected from water soluble glycans, water dispersible glycans, water soluble hydrophilic polymers and water dispersible hydrophilic polymers and combinations thereof. The foaming agent can be a non-ionic agent, such as alkyl polyglucoside (APG), an anionic agent, such as sodium dodecyl sulfate (SDS), a cationic agent, such as cetrimonium bromide (CT AB), or a zwitterionic agent, such as lauryldimethylamine oxide (LDAO). The water soluble glycans and water dispersible glycans can be selected from polysaccharides and derivatives thereof. The water soluble hydrophilic polymers and water dispersible hydrophilic polymers can also be selected from poly( vinyl alcohol)s and poly( vinyl acetate)s and copolymers thereof.

[0045] The fibres can be dispersed directly into the foam or foamable liquid, or by first treating the fibres in a separate dispersing process, together with, for example, wetting or dispersing agents. Examples of dispersing and wetting agents include anionic surfactants and modified siloxanes.

[0046] A consistency of the foamed fibrous furnish can be 0.5-5 %, for example 0.5- 5 %.

[0047] The primary unit or the secondary unit can further comprise a means for screening the fibres 123 of the foamed fibrous furnish, such as a screen, to remove fibre conglomerations from the foamed fibrous furnish, before feeding the foamed fibrous furnish generated in the primary unit to the primary web forming device 101 or the foamed fibrous furnish generated in the secondary unit to the secondary web forming device 102. This enables improving quality of the foamed fibrous furnish.

[0048] The manufacturing system 100a, 100b can further comprise one or more than one manifold(s) for spreading the foamed fibrous furnish to primary web forming device 101 or the secondary web forming device 102, to form one or more than one foamed fibrous furnish layer. For producing the multi-layer fibrous product or the multi-layer web, the manufacturing system 100a, 100b can comprise more than one manifold to form more than one foamed fibrous furnish layer. Thus, a separate manifold can be used for each layer.

[0049] The primary web forming device 101 for the foamed fibrous furnish can be placed above the secondary web forming device 102 for the aqueous furnish or the foamed fibrous furnish.

[0050] A consistency of the foamed fibrous furnish can be 0.1-4 %, such as 0.1-2 %, in the primary web forming device 101.

[0051] FIGURE 10 illustrates a primary unit for generation of a foamed fibrous furnish in accordance with at least some embodiments. The primary unit comprises two pressure screens 127 for filtering out impurities and separating fibres in a fibre stock preparation. The pressure screens 127 are connected to a fibre mixing tank 128. The primary unit further comprises a pre-thickener 129 and a means for increasing a consistency of fibres 120. A filtrate tank 126 is connected to the pre-thickener 129 and the means for increasing a consistency of fibres 120. A foamed fibrous furnish is prepared in a foam mixing tank 121. A means for screening the fibres 123 of the foamed fibrous furnish is used to remove fibre conglomerations from the foamed fibrous furnish before feeding the foamed fibrous furnish to a web forming device.

[0052] The manufacturing system 100b can comprise a further wire 104, wherein in the first configuration: the primary web forming device 101 is arranged to feed the generated foamed fibrous furnish from the primary unit onto the further wire 104, to obtain a fibrous web, and the further wire 104 is arranged to feed the obtained fibrous web onto the shared wire 103. This enables using the further wire 104 for generation of the fibrous web, but also the shared wire 103 for guiding the fibrous web to units of the existing manufacturing system for finishing the web. In addition, this enables producing a multi-layer fibrous product, because a first fibrous web can be generated on the further wire 104, a secondary fibrous web can be generated on the shared wire 103 and the webs can be combined on the shared wire 103 to form the multi-layer fibrous web.

[0053] The further wire 104 can be arranged above the shared wire 103. The further wire 104 can be arranged on a forming section of the existing line. The further wire 104 can be placed so that it does not have effect on the function of the shared wire. Optionally, the further wire 104 can be arranged so that it can be mechanically lifted upwards, when only shared wire is in use.

[0054] FIGURE 2 illustrates a manufacturing system 100b comprising a further wire104 in accordance with at least some embodiments. Fibrous web formation takes place in a primary web forming device 101. The fibrous web is formed onto a further wire 104. The further wire 104 is arranged above the shared wire 103. The fibrous web is transferred along a shared wire 103. Wet web formation can take place in a secondary web forming device 102. The wet web is formed onto the shared wire 103. The primary web forming device 101 and the secondary web forming device 102 can be interchangeable or used at the same time.

[0055] The manufacturing system 100a, 100b can further comprise one or more than one dewatering device 105 below the shared wire 103 or below the further wire 104, when in use, which dewatering device(s) 105 is / are configured to dewater the obtained fibrous web.

[0056] The further wire 104 can form an upper wire unit above the shared wire 103.The primary web forming device 101 for the foamed fibrous furnish and the dewatering device 105 for the foamed web can be placed on an upper part of the upper wire unit.

[0057] The dewatering device(s) 105 can comprise one or more than one suction box.

[0058] FIGURE 1 further illustrates a dewatering device 105 in accordance with at least some embodiments. Fibrous web formation takes place in the primary web forming device 101. The fibrous web is formed onto the shared wire 103 and foam exits through the shared wire 103 to the dewatering device 105 of the shared wire 103. The dewatering device105 of the fibrous web can comprise suction boxes, which are placed between foils of the dewatering device 105 of the shared wire 103 and foam is removed by vacuum to the wire pit.

[0059] FIGURE 2 further illustrates a dewatering device 105 in accordance with at least some embodiments. The fibrous web is formed onto the further wire 104 and foam exits through the further wire 104 to the dewatering device 105. The wet web is formed onto the shared wire 103 and water can exit through the shared wire 103 to the dewatering device 105 of the shared wire 103.

[0060] The web forming device 101, 102 can be a headbox, such as an inclined headbox, a gap former headbox, a vertical headbox or a hydraulic headbox. FIGURES 3 to 7 illustrate examples of the headboxes.

[0061] FIGURE 3 illustrates an inclined headbox in accordance with at least some embodiments. A web is formed onto a shared wire 103, which is slightly slanted upwards. An arrow illustrates a moving direction of the shared wire 103. A cover 107 is placed on the shared wire 103 to enhance removing of a foam. A dewatering device 105 is under the shared wire 103. A discharge opening 108 is on an upper end of the cover 107. A manifold 106 is placed before the inclined head box.

[0062] FIGURE 4 illustrates a gap former headbox in accordance with at least some embodiments. A web is fed between a gap 109 formed by two wires, i.e. a bottom wire 118 and a top wire 119. An arrow illustrates a moving direction of the bottom wire 118. A dewatering device 105 is under a bottom wire 118. A manifold 106 is placed before the gap former head box. The bottom wire 118 is configured to feed the web onto the shared wire 103 for further processing.

[0063] FIGURES 5A and 5B illustrate a vertical headbox in accordance with at least some embodiments. A web is fed between a gap 109 formed between two wires, i.e. a bottom wire 118 and a top wire 119, which gap can extend downwards, as illustrated in FIGURE 5 A, or upwards, as illustrated in FIGURE 5B. Arrows on the bottom wires 118 illustrate moving directions of the bottom wires 118. Dewatering devices are 105 placed on the both sides of the gap 109. The bottom wire 118 is configured to feed the web onto the shared wire 103 for further processing.

[0064] FIGURE 6 illustrates a hydraulic headbox in accordance with at least some embodiments. A web is fed onto an open wire section comprising a shared wire 103. The web is dewatered by a dewatering device 105 comprising foils and suction boxes.

[0065] The manufacturing system 100a, 100b can further comprise a wire pit 124. The wire pit 124 serves as a collection tank for a fibreless foam. The fibreless foam is returned to the wire pit 124 from dewatering of the primary web forming device 101 or the secondary web forming device 102. The foam is used to dilute the fibre foam mass to an appropriate level into the primary web forming device 101 or the secondary web forming device 102.

[0066] The manufacturing system 100a, 100b can optionally comprise a means for guiding the foam 125, such as a lock water tank or an air separation container. The means for guiding the foam 125 can be connected to the wire pit 124 for receiving water and foam from the suction means or box(es) and guiding the foam to the wire pit 124. It may notalways be possible to place the wire pit 124 to the optimal place into a basement of the existing manufacturing line, such as a basement of a paper or carboard machine. Then, the means for guiding the foam 125, such as the lock water tank or the air separation container, can be provided for collecting water and foam from the suction means or box(es) and guiding the foam to the wire pit 124.

[0067] A lock water tank can be a shallow tank to which drain ducts are connected from the dewatering device 105. The air separation container can be a container which upper part is under-pressurized to more efficiently remove the foam from the dewatering device 105. The air separation container can also be used on paper or cardboard machines, wherein a basement cannot be used and or does not exist.

[0068] FIGURE 10 illustrates a wire pit 124 and a means for guiding the foam 125.The means for guiding the foam 125, such as a lock water tank or an air separation container, are connected to the wire pit 124 for receiving water and foam from the suction means or box(es) and guiding the foam to the wire pit 124. After that, the foam can be guided to the foam mixing tank 121 to dilute the fibre foam mass to an appropriate level.

[0069] The manufacturing system 100a, 100b can further comprise one or more than one binder applicator 110, which is / are arranged to apply a binder composition, additives and / or other functional components onto the obtained fibrous web.

[0070] The binder applicator(s) 110 can be arranged on the shared wire 103 or the further wire 104. Then, the binder composition, additives and / or other functional components can be applied on the fibrous web already on a forming section 116.

[0071] Alternatively, the binder applicator(s) 110 can be arranged after the shared wire 103. The manufacturing system can further comprise a forming section 116 after the shared wire 103 and the binder applicator(s) 110 can be arranged after the forming section 116. Then, the binder composition, additives and / or other functional components can be applied on the fibrous web after the forming section 116 and the press section 117.

[0072] The binder composition, additives and / or other functional components can be applied onto the obtained fibrous web at one or at several points. Thus, it is possible arrange two to five sequential coating points in order to apply the binder composition, additives and / or other functional components onto the obtained fibrous web. The fibrous web can be dried between the application runs.

[0073] The binder applicator(s) can be selected from a water dispersion coating unit, a foam coating unit and a spray coating unit and any combination thereof.

[0074] The binder composition, additives and / or other functional components can be applied in the form of an aqueous solution or an aqueous dispersion. By using water as a carrier for the binder composition, additives and / or other functional components, it is possible to improve the penetration of the binder composition, additives and / or other functional components into the fibre matrix to be generated, in between the fibres, especially the natural fibres.

[0075] Typically, the fibrous web is planar and it is comprised of two opposite planar surfaces, in which case the binder composition, additives and / or other functional components can be applied onto at least one of its planar surfaces. However, it is also possible to apply the binder composition, additives and / or other functional components to both sides, or, if there are several sequential application points, the binder composition, additives and / or other functional components can be brought at one point only to one surface and at another application point to both sides of the fibrous web.

[0076] It is also possible to facilitate the penetration of the binder composition, additives and / or other functional components into the fibrous web, during the application or immediately thereafter, by directing a suction to the binder composition, additives and / or other functional components from the opposite side of the fibrous web.

[0077] Examples of the binders are natural binders and biopolymers, such as starch and starch modificates and derivatives, chitosans, alginates, and synthetic binders, for example latexes, such as vinyl acetate and acrylate latex and polyurethanes and SB latexes and mixtures thereof, and various copolymers, especially copolymers of synthetic binder polymers. Also, polyvinyl alcohol and polyvinyl acetate can be used.

[0078] The binder can be brought to the surface of the fibre layer in the form of binder foam.

[0079] Into the binder composition it is possible to add substances which are capable of modifying the properties of the fibrous web, such as synthetic fibres or plasticisers, such as sorbitol or glycerol, or similar polyols, or fine material, such as cellulose-based fine material or nano-cellulose.

[0080] The additives can be brought to the fibrous web by means of or together with the binder composition, with which additives it is possible to improve the mechanical and thermal properties of the fibrous web, such as heat-sealability, stretchability, air permeability, printability, thermal conductivity, water vapour permeability, absorption characteristics and friction.

[0081] By means of or together with the binder composition, it is also possible to bring other functional components, such as pigments and fillers, and hydrophobic sizes, such as ASA (alkyl succinic anhydride) or AKD (alkyl ketene dimer), and other typical additives used in papermaking.

[0082] The manufacturing system 100a, 100b can further comprise a pre-dyer 114 after the binder applicator(s). Due to the pre-dryer 114, the binder does not foul felts of the press section or the rollers of the drying section, because an excess moisture can be removed.

[0083] The pre-dryer 114 can be can be selected from an infrared (IR) dryer, a dryer wire 115, a radiant heater or a hot air blower, or any combination thereof.

[0084] Alternatively, the binder composition, additives and / or other functional components can be mixes to the foamed fibrous furnish in the primary unit. Thus, the binder applicator(s) can be omitted.

[0085] Alternatively, the primary web forming device 101 or the secondary web forming device 102 can be configured to add the binder composition, additives and / or other functional components onto the foamed fibrous furnish. The foamed fibrous furnish can be generated in the primary unit or the secondary unit. The primary web forming device 101 can be configured to add the binder composition, additives and / or other functional components onto the foamed fibrous furnish generated in the primary unit. The secondary web forming device 102 can be configured to add the binder composition, additives and / or other functional components onto the foamed fibrous furnish generated in the secondary unit. The binder composition, additives and / or other functional components can be fed as their own layer onto the primary web forming device 101 or the secondary web forming device 102. Thus, the binder applicator(s) can be omitted.

[0086] FIGURE 7 illustrates a manufacturing system 100b comprising binder applicators 110 and a pre-dryer 114 in accordance with at least some embodiments. The manufacturing system comprises a manifold 106 and a primary web forming device 101.The binder applicators 110 include a water dispersion coating unit 111, a foam coating unit 112 and a spray coating unit 113. However, any other combination of the binder applicators 110 can be used. A pre-dry er 114 is arranged after the binder applicators 110. The web is transferred by a dryer wire 115 to the pre-dry er 114.

[0087] FIGURE 8 illustrates a manufacturing system 100a comprising binder applicators 110 and pre-dry er 114 after a press section 117 in accordance with at least some embodiments. The manufacturing system 100a comprises a primary web forming device 101, a secondary web forming device 102 and a shared wire 103 on a forming section 116. The primary web forming device 101 and / or the secondary web forming device can feed a web on the shared wire 103. A press section 117 is arranged after the forming section 116. The manufacturing system has a binder applicator 110 after the press section 117 and a predryer 114, for example an infrared (IR) dryer, after the binder applicator 110 and before an optional drying section (not illustrated).

[0088] FIGURE 9 illustrates a manufacturing system 100b comprising a further wire 104, and binder applicators 110 and pre-dryer 114 after a press section 117 in accordance with at least some embodiments. The manufacturing system 100b further comprises a primary web forming device 101, a secondary web forming device 102 and a shared wire 103 on a forming section 116. The further wire 104 is arranged above the shared wire 103. A press section 117 is arranged after the forming section 116. The manufacturing system comprises a binder applicator 110 after the press section 117 and a pre-dryer 114, for example an infrared (IR) dryer, after the binder applicator 110 and before an optional drying section.

[0089] The manufacturing system 100a, 100b can further comprise a drying section arranged to receive the dewatered web from the shared wire 103 and to dry the dewatered web, or a non-contact dryer arranged to receive the dewatered fibrous web from the shared wire 103 and to dry the dewatered fibrous web. If the manufacturing system 100a, 100b comprises a binder applicator 110 after the press section 117 and a pre-dryer 114 after the binder applicator 110, as described above, the drying section can be arranged after the pre- dryer 114.

[0090] The drying section can comprise for example, a cylinder dryer.

[0091] The non-contact dryer can be for example, an IR dryer, a vacuum dryer, a hot air dryer, a through-air-dryer, or combinations thereof.

[0092] Drying is typically carried out until a final moisture content of less than 20 % by weight, typically less than 15 % by weight, in particular less than 10 % by weight is reach.

[0093] The manufacturing system 100a, 100b can further comprise a size press and / or a calander.

[0094] The manufacturing system 100a, 100b can be used to produce a fibrous web for a paper, fabric, felt or porous material.

[0095] The fibrous web can comprise natural or synthetic fibres having fibre lengths of 0.5-500 mm, for example 1-400 mm, such as 1.8-200 mm, and wherein the fibrous web has a grammage of 10-1000 g / m2, for example 20-100 g / m2, such as 25-45 g / m2and a fibre content of 40-100 weight-%, for example 80-100 weight-%, such as 94-100 weight-%.

[0096] It is to be understood that the embodiments of the invention disclosed are not limited to the particular structures, process steps, or materials disclosed herein, but are extended to equivalents thereof as would be recognized by those ordinarily skilled in the relevant arts. It should also be understood that terminology employed herein is used for the purpose of describing particular embodiments only and is not intended to be limiting.

[0097] Furthermore, the described features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. In the description, numerous specific details are provided, such as examples of lengths, widths, shapes, etc., to provide a thorough understanding of embodiments of the invention.

[0098] The verbs “to comprise” and “to include” are used in this document as open limitations that neither exclude nor require the existence of also un-recited features. The features recited in depending claims are mutually freely combinable unless otherwise explicitly stated. Furthermore, it is to be understood that the use of "a" or "an", i.e. a singular form, throughout this document does not exclude a plurality.REFERENCE SIGNS LIST100a, 100b manufacturing system101 primary web forming devicesecondary web forming device shared wire further wire dewatering device manifold cover discharge opening gap binder applicator water dispersion coating unit foam coating unit spray coating unit pre-dry er dryer wire forming section press section bottom wire top wire means for increasing consistency of fibres foam mixing tank means for screening fibres wire pit means for guiding foam filtrate tank pressure screen fibre mixing tank pre-thickener

Claims

CLAIMS:

1. A manufacturing system (100a, 100b), comprising:- a primary unit for generation of a foamed fibrous furnish,- a secondary unit for generation of an aqueous furnish or a foamed fibrous furnish,- a primary web forming device (101) for the foamed fibrous furnish,- a secondary web forming device (102) for the aqueous furnish or the foamed fibrous furnish, and- a shared wire (103), wherein:- in a first configuration of the manufacturing system (100a, 100b), the primary web forming device (101) is arranged to feed the generated foamed fibrous furnish from the primary unit onto the shared wire (103) to obtain a fibrous web,- in a second configuration of the manufacturing system (100a, 100b), the secondary web forming device (102) is arranged to feed the generated aqueous furnish from the secondary unit onto the shared wire (103) to obtain a wet web, or the generated foamed fibrous furnish from the primary unit onto the shared wire (103) to obtain a fibrous web,- in an optional third configuration of the manufacturing system (100a, 100b) the primary web forming device (101) and the secondary web forming device (102) are arranged to simultaneously feed the generated foamed fibrous furnish onto the shared wire (103) to obtain a multi-layer fibrous web, or feed the generated foamed fibrous furnish and the generated aqueous furnish, respectively, onto the shared wire (103) to obtain a multi-layer web.

2. The manufacturing system (100b) according to claim 1, further comprising a further wire (104), wherein in the first configuration: the primary web forming device (101) is arranged to feed the generated foamed fibrous furnish from the primary unit onto the further wire (104), to obtain a fibrous web, and the further wire (104) is arranged to feed the obtained fibrous web onto the shared wire (103).

3. The manufacturing system (100b) according to claim 2, wherein the further wire (104) is arranged above the shared wire (103).

4. The manufacturing system (100a, 100b) according to claim 2 or 3, further comprising one or more than one dewatering device (105) below the shared wire (103) or below the further wire (104), when in use, which dewatering device(s) (105) is / are configured to dewater the obtained fibrous web.

5. The manufacturing system (100a, 100b) according to claim 4, wherein the dewatering device(s) (105) comprise(s) one or more than one suction box.

6. The manufacturing system (100a, 100b) according to claim 4 or 5, further comprising:- a wire pit (124), and- optionally, a means for guiding the foam (125), such as a lock water tank or an air separation container, which means for guiding the foam (125) is connected to the wire pit for receiving water and foam from the dewatering device(s) (105) and guiding the foam to the wire pit (124).

7. The manufacturing system (100a, 100b) according to any one of the preceding claims, further comprising one or more than one binder applicator (110), which binder applicator(s) (110) is / are arranged to apply a binder composition, additives and / or other functional components onto the obtained fibrous web.

8. The manufacturing line (100a, 100b) according to claim 7, wherein the binder applicator(s) (110) is / are on the shared wire (103) or the further wire (104), or after the shared wire (103).

9. The manufacturing system (100a, 100b) according to claim 7 or 8, further comprising a pre-dyer (113) after the binder applicator(s) (110).

10. The manufacturing system (100a, 100b) according to any one of the preceding claims 1 to 6, wherein the primary web forming device (101) or the secondary web forming device (102) is configured to add a binder composition, additives and / or other functionalcomponents onto the foamed fibrous furnish generated in the primary unit or the secondary unit.

11. The manufacturing system (100a, 100b) according to any one of the preceding claims, wherein the web forming device (101, 102) is a headbox, such as an inclined headbox, a gap former headbox, a vertical headbox or a hydraulic headbox.

12. The manufacturing system (100a, 100b) according to any one of the preceding claims 4 to 11 , further comprising a drying section arranged to receive the dewatered web from the shared wire (103) and to dry the dewatered web, or a non-contact dryer arranged to receive the dewatered fibrous web from the shared wire (103) and to dry the dewatered fibrous web.

13. The manufacturing system (100a, 100b) according to any one of the preceding claims, wherein the primary unit comprises or is connected to a means for increasing consistency of fibres (120) of the foamed fibrous furnish, such as a screw press or a belt press, before the primary web forming device (101) or secondary web forming device (102).

14. The manufacturing system (100a, 100b) according to claim 13, wherein the primary unit or the secondary unit comprises or is connected to a foam mixing tank (121) for mixing foam and the fibres received from the means for increasing consistency of the fibres (120), to produce the foamed fibrous furnish generated in the primary unit or the secondary unit.

15. The manufacturing system (100a, 100b) according to claim 14, wherein the primary unit or the secondary unit comprises or is connected to a means for screening the fibres (123) of the foamed fibrous furnish, such as a screen, to remove fibre conglomerations from the foamed fibrous furnish, before feeding the foamed fibrous furnish generated in the primary unit to the primary web forming device (101) or the foamed fibrous furnish generated in the secondary unit to the secondary web forming device (102).

16. The manufacturing system (100a, 100b) according to any one of the preceding claims, wherein in the first configuration, the secondary unit for generation of the aqueous furnish and the secondary web forming device (102) are not used.

17. The manufacturing system (100a, 100b) according to any one of the preceding claims, wherein in the second configuration, the primary web forming device (101) is not used.

18. The manufacturing system (100a, 100b) according to any one of the preceding claims, wherein in the optional third configuration, the primary web forming device (101) is arranged to feed the foamed fibrous furnish from the primary unit and the secondary web forming device (102) is arranged to feed the foamed fibrous furnish from the secondary unit onto the shared wire (103) to obtain the multi-layer fibrous web.

19. The manufacturing system (100a, 100b) according to any one of the preceding claims 1 to 17, wherein in the optional third configuration, the primary web forming device (101) is configured to feed the generated foamed fibrous furnish and the secondary web forming device (102) is configured to feed the generated aqueous furnish on the shared wire (103) to obtain the multi-layer web.

20. Use of the manufacturing system 100a, 100b of any one of the preceding claims for producing a fibrous web for a paper, fabric, felt or porous material.

21. The use according to claim 20, wherein the fibrous web comprises natural or synthetic fibres having fibre lengths of 0.5-500 mm, for example 1-400 mm, such as 1.8-200 mm, and wherein the fibrous web has a grammage of 10-1000 g / m2, for example 20-100 g / m2, such as 25-45 g / m2and a fibre content of 40-100 weight-%, for example 80-100 weight-%, such as 94-100 weight-%.

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