US1883144A - Art of making paper and felted sheet materials - Google Patents

Description

M. R. WARE ART OF AKING PAPER AND FELTED SHEET MATERIALS 2 Sheets-.Sheet Filed 001;. 14. 1929 INVEN'TOR y BY '%:h` l l n 1 AT ORNEY Oct. 18,1932. M. R. WARE 1,883,144

'ART OF MAKING PAPER AND FELTED SHEET MATERIALS y FiledfOct. 14, 1929 2 Sheets-Sheet 2 INVENTOR Patented Oct. 18, 15932 UNITED STATES PATENT ol-*FlcE nELvrN a. WARE, or BALTIMORE, MARYLAND, AsaIGNoE ro .ronNs-mNvrLLE conroaarroN, or NEW Yonx, N. y., a coEroEarIoN or NEW Yom:

EET or MAKING PAPER AND EELTED snEE'r MA'rEEuLs Applioatfon med October 14, 1929. Serial No. 399,658.

This invention relates to the art of making paper and felted sheet materials-of a porous nature which may be readily dried and are adapted tobe easilyl impregnated with saturating materials.- This application is a conj tinuation in part and improvement on Patent No. 1,732,176, granted October 15, 1929. The important value of this method of manufactureJ lies in the fact that with any given` grade of paper stock thatmay be used, a sheet can be ormed which is much less compacted than sheets formed by machines or methods now and heretofore employed.

Heretofore, generally speaking, paper and sheet materials made from pulp or water stock fibrous materials -have been' manufactured by forming a web upon'a carrierl by either gravity( flow or gravity and suction means and then transferring or couching to a feltcarrierand drawing the water therefrom by mechanical pressure means used alone or in combination with suitable suction means, thereby necessitating a more orfless complex arrangement and structure for producing a web suitably drained for transferring tothe lusual drying machine. It has been noted that with. machines of the' above type and others of diiferent types now being used the webs, due to numerous mechanical operations, are compacted while being drained, thereby producing a more or less dense sheet which not only retards the drying-thereof but'also retards the saturating thereof-with any treating solutlon or impregnating compound.

' n its general aspects this invention involves the depositing of a fibrous watered stock upon a travelling perforated or reticulated, endless carrier to rformy a web, from which the Water is drained by means of suitablyvarran ed suction'means without subjectstretching action of the sheet, thereby'causing shrinkage crosswiseand comp/acting the sheet.

ing-,the we to any mechanical operating or In the preferred form, the watered stock is drawn on to the traveling carrier by means of a controllable variable suction means in a web-forming cylinder over which the endless carrier passes.

This method of manufacture is articu ,larly adapted to form matted webs o a loose whilebeing formed and drained are not only subjected to fewer 'mechanical operations ythan heretofore used, but also special care .l

has been taken to eliminate the application of all mechanical pressures and operations which have a 4'tendency to compact, until the web or sheet is sufficiently drained so that the application of any mechanical pressure thereon Will not materiallychange the physical characterA thereof. The sheets produced the travel of the carrier,the fibres are not only drawn upon themselves, but are also crisscrossed in all directions, thereby produclng a wet web' which, when drained 'and treated 'as hereinabove stated, produces a more loosely textured sheet having an unusual fluiy and matted nature which is tear-resisting in all directions and easily dried 'and saturated with impregnating compounds.

This invention may be best understood vby 'reference to the accompanying drawings, 'in

which Figure l is a side elevation of the machine constituting the invention with parts broken away,showin the arrangement of vacuum boxes in the fa ricating drum and also shows .ing the internal arrangement of the stock to the endless conveyor belt.

Fig. 2 is a plan view of the machine.

Fi 3. is a' section on the line 3 3 of Fig. 1, loo ing in the direction of thearrows and vat and the relation of endless belt deckels `textured nature, forl the reason that the webs open forward end so that illustrating the arrangement of the vacuum boxes in the fabricating drum.

This invention ispdescribed with reference to the accompanying drawings in order to facilitate an understanding thereof.

Referring to the drawings in detail, the same reference characters designatin the various parts throughout all figures of te drawings, designates a base, preferably of cast iron or such usual materials as are employed for this purpose, upon which the framework 11 of the machine 1s mounted, which framework may be cast integral therewith as shown in the drawings. At one end of the machine, as shown in Flgure 1, is a vat 12 made in two parts 12a and 412b hinged together at 120, the latter part lying adjacent the fabricating drum and having extensions or side boards 12d extending over the drumq and extending a certain distance beyond the drum along the carrying endless belt to be described. The purpose ofthe hingedv construction is to permit the portion o f the vat, 12b and the sideboards 12d to be lifted off of the drum and folded back on the portion 12a or suspended from a suitable `support in case it is desired to remove the belt or for any other P purpose. The vat or tank 12 is provided with the usual tortuous passageway around a plus rality of baflles, two of which are illustrated at 13 and 14, extending from the top and the bottom of the vat respectively so that the stock may be delivered to the portion of the vat 12b, thoroughly agitated and of uniform mixture. The vat may be arranged with an the stock will flow onto a fabricating drum, to be described, from the side, as shownsin Figure 1. The fabricating drum or roll 15 is ysuitably mounted for rotation by means of hollow trunnions 16 and 17 in journal boxes 16a and 17a respectively secured to the frame 11. The drum is of openwork construction preferably having slats extending lon itudinally of the drum and spaced apart a out its periphery.

Mounted on the opposite end of the frame is a plurality of rolls 27, 27a'l and 28 which cooperate with the drum 15 to support an endless carrying belt .or apron 29 of reticulate material and preferably consisting .of a

strip of closely woven wire cloth, either woven endless or spliced as may be desired, which endless belt` is trained about the drum and is of sufiicient length topass around rolls 27 and 28 over rolls 30 and 31 and un- Ader the tensioning roll 32 lying between rolls 30 and 31. The roll 32 is journaled in brackyets 32a at the'ends of screws 32?) which are provided one on each side of the machine mounted in ears 320 extendin from the sides ofthe frame. Encircling tiesel screws are compression s rino's 32d having their ends respectively a uttmg against ears 32o and nuts 32e. Adjacent .the -rolls 27, 27a and 28 is provideda roll 33 mounted upon arms 34a ofthe levers 34. The levers 34 are pivoted to the frame 11 intermediate of their ends at 35 and may be adjusted to position roll 33 relative to rolls 27 and 27a so that the desired pressure may be exerted'on the fibrous web between said rolls,'by means of shafts 41- journaled to the frame 11 and having' threaded connection with the ends of arms 34?) of the leversv 34; shafts 41 being operated by means of hand wheel 36 and Worms 38 on shaft 37 meshing with worm wheels 40 on shafts 41. The roll 33 may be covered with a woolen jacket 42 to prevent slippinor of the fibre web, which jacket is preferably shrunk thereon and made fast at the ends. ,The roll 33 is of larger diameter than the rolls 27 and 28 and is designed to rest on the upper surface of the belt between said rolls. Roll 33 is rovided with trunnions 45 which are rotata ly mounted in journal boxes 44 slidably mountedon the lever arms 34a, the journalv boxes 44 being adjustablyheld on the said arms by means of screw bolts 46 rotatably connected with the j ournal boxes and having threaded connection with lugs 47 projecting from the lever arms. T he urpose of this roll 33 is to cooperate with the rolls 27, 27a and 28 in order to exert pressure on the web of felt'fibres resting on the upper surfacev of the belt 29, and to couchthe sheet or web to a drying carrier 29a; and in order that the pressure exerted may be yaried the outer ends of the lever arms 34a are connected, by rods 51 having turn buckles 52 thereon, with levers 48 pivoted to the frame at 49 and having weights 50 slidably adjusted along their arms 48a. By the above arrangement, all mechanical pressures are remote tothe place of formation of the wet web, and as they are applied to the web on a non-stretchable carrier, the original formation of the web or sheet is subthe fibres into a parallel relation.

The side walls 12e of the portion 12b of the vat 12 adjacent the drum 15 are spaced apart a distance equal to the. width of the endless belt 29 and the side boards 12d are attached thereto. Secured to the lower edge of the side boards are aprons in the form of strips of cloth or. flexible material 12g, the lower edges of. which are slightly spaced from the `endless belt. The urpose of these aprons is to break the joint tween the side board and the deckel. The rolls 56 lie below the bottom' of the tank in order to cause the rubber deckel to contact with the endless belt 29 ahead of the point where the stock is fed thereto and in order to revent stock and water from spilling out of) the vat under the -stantially maintained without drawing'of drum an'apron 12h is secured along the edge ,l

outside surface thereof] are rolls 53, 54, 55-

and 56v about which are trained rubber belts oraprons 57 which act as deckels, the lower surfacesof which are adapted to conform at the sides thereof` with the belt 29 as it vpasses around the upper surface of the drum 15 and to press against the edge of the fibre de osited on said belt 29. These rubber dec els are extended forwardly of the drum 15 to the forward edge ofthe side boards, as will be seen by reference to Fig, 1, for their move-` ment about the rolls 53, 54, 55 and 56 uponl t eliminating dead pockets which tend to slow up the flow of the stock., and cause whirls or eddies in Which slimes and fibres collect and lfinally break away, and flow over the sheet producing slime spots, lumps and uneven formations. Also, the stock will require less water for suspension when handled in the above type of head box or vat, as the vacuum formation causes a more rapid flow, thereby doing away with the deadened flows as commonly used in gravity formation in the thereupon.

Fourdrinier or cylinder type of machines.

Doctors for cleaning theI various rolls which contact with 4the surface of the fibrous web or with the side of the belt with which said web has contacted are provided in connection with said rolls. A doctor 58 having a Wooden doctor blade 58a contacting with the surface of` the roll 33 is provided, which is supported by a suitable frame 59 and connected therewith by adjustment screws 60, the frame 59 being supported by journal boxes 44. This blade may be supplemented in its cleaning action by a shower pipe 61 extending transversely of the machine adjacent the roll 33 and adapted to sprinkle Water In connection with rolls 30 and 31 are provided doctors 62 and 63 which carry rubber doctor blades for scraping any fibre from said rolls which may have been deposited thereon by the belt 29. For assisting in cleaning the belt 29l andsalvagng the fibre adhering thereto after the web has been taken off, a shower ipe 64 is extended transversely of the machine above the lower reach of the belt adjacent the roll 27, which shower pipe is adapte-d to sprinkle water on the belt as it passes that point, washing any adherng.

libre oif into collecting receptacles of well-l lnown character, not shown.

Mounted within the drum`15 and arranged for angular adjustment relative theretois a Vvacuum box 19 having walls 19d and a plurality of compartments 19a, 195 and 19o separated by partitions 20a and 205, said vacuumbox being supported at one end by means of the trunnion 21 rotatably mounted in a journal box 22 formed integral with the supporting structure 23 which may be attached to the journal box 16a in which the trunnion 16 is mounted byany suitable means, as by screw bolts 24. At the opposite end of the vacuum box is provided a hollow shaft 25 which is journaled in the bracket 26 secured i to' the frame 11. The partitions 20a and 205 extend into fand partition this hollow shaft 25` whereby each compartment ofthe vacuum box may be connectedseparately with -a vacuum pump as hereinafter de-` scribed. The walls 19d are provided'at the edges with anges 19e of suflicient width to connect with slats adj acentthe said walls 19d when` the said walls happen to fall between said slats and to prevent suction being exerted except through the cylindrical surface of said drum.

, Connected with the compartments 19a, 195

and 19e through the extensions thereof in the 1 hollow shaft .25, are a plurality of suction pipes 65, 66 and 67 which connect thr `ugh a manifold 68 and pipe 69 with a suct on device, as a vacuum pump 70, of any desired construction, the suctionhthrough the pipes 65, 66 and 67 being controlled by valves 71, 72v

and 73. The respective compartment exten-V sions have short lengths of pipe 65a, 66a and 67a extending therefrom which connect with pipes 65, 66 and 67 by means of a length offlexible hose 75, 76, and 77, which construction permits of the angular adjustment of the vacuum box described above. The purose of the vacuum box 19 is to suck the water '1n the vat 12 through a mesh of the endless By using the vacuum-formation in combinatlon with the stock vat it is unnecessary to use any mechanism for the purpose of crossing fibres in the manufacture of a sheet of paper on this type machine, as the natural suspension of the 'libres in the watered stock as ordinarily used is just about the desired formation'2 provided they can be drawn onto the sheet 1n the same condition as they are when suspended in water, which is made possible by vacuum formation. With this arrangement, the stock on flowing to the vat will'V become attached and bound together by the action of the vacuum, and, due to the vacuum action-being quicker than the action of the cylinder turnin against the stock, will cause the fibres tobe ormed into a sheet in a crisscross relation before the revolving action of the roll has any disturbing effect on the nat-' ural form of suspension, Whereas with the gravity fiow in the present type cylinder machines, the current 1s so dead that the action f the cylinder without the vacuum means has a tendency to drag the fibers, causing them to lie lon itudinal with the sheet, forming a denser s eet which does not permit of rapid saturati on. Other vacuum boxes along the course of travel of the forming belt are provided for further drying the web, as, for example, at 7 8, 78a, 786 and 79, the boxes 78, 78a and 786 being connected by pipes 80, 80a and 806 to a suction device 7 0a, and the box 79 to a suction device 706 by pipe 81. All the above pipes have valves therein for the purpose of regulating the suction pressures in the l respective boxes. In the preferred Y method of operation, the valves are regulated s0 that the suction increases from the webforming cylinder to the couching roll, so that the web is gradually drained without subjecting the forming or carrier belt to undue binding stress against the faces of the boxes, particularly where there lis a considerable amount of water therein, as at the head end of the machine. By use of the above suction arrangement, the web may be drained to any degree desired before it reaches the couchin g roll, thereby effecting a substantial or any desired drying before being contacted by any mechanical pressure means.

A supporting or guide roll 83 may be provided on the frame at any suitable point for sup orting the weight of the upper strand of the lt 29 and guiding it as it passes from the drum 15 laden with the fibre web to the rolls 27 and 28.

Inasmuch as belts of wire cloth, such as belt 29, are very heavy and difficult to place upon the drum and rolls,- provision is made for removing the rolls 27, 27a and 28 with their integral supporting structure 89 which is so connected with the base of the frame 10 that it may be detached therefrom by sliding it sldewlse on tracks 90. The supports 91 and 93 of roll 83 and drum 15, respectively, on one side of the machine are removable, leaving the drum and roll suspended in place, said supports 91 and 93 being slidable transversely of the machine on tracks 92 and 94, respectively. The tension roll 32 is likewfse detachable by removing the sha'ft 95 on which it is mounted from its bearings 96.

The various rotatable parts of the machine are power-driven through a motor 97 or any other suitable means connected with the shaft 98 on which the roll 27 is secured for rotation therewith, the roll 28 being driven from said shaft 98 through cross belt 99 trained over cone pulleys 100 and 101, the latter being sev cured to a stub shaft 102 journaled in a suitable bearing 103 onthe frame of the machine, thepposite end of said stub shaft being prov1 with a gear 104 meshing with a gear i -having a gear 112 secured thereon and meshing with a similar gear 113 on the end of the cylinder l5.

The-operation of the machine is as follows The fibrous pulp after being screened in the usual manner travels through suitable pipes, not shown and not part ofthis invention, to the vat 12 being agitated and brought to a uniform mixture by passing around baffles 13 and 14, arriving finally in the compart` ment adjacent the drum 15. The pulp will deposit on the belt 29 partially by gravity, the water passing through the mesh thereof, and

partially by suction exerted thereon through the vacuum compartments 19a, 196, 19e suitablyV adjusted to the inner surface of the drum. The vacuum pressure in said conipartments is regulated individually by their respective valves 71, 72 and 73. As the belt 29 passes upwardly over the drum 15, the rubber deckel belts -57 will eliminate the rough edges, giving the desired deckcled edge to the web of pulp fibre.

As thepulp is carried rearwardly by the belt 29. it passes over vacuum boxes 78, 78a

and 786, which extract additional water therefrom, `thence over the roll 28, which may be called the vacuum roll having a vacuum box 79, thereby' draining and driving the web. The belt then passes between rolls 28, 27a and 27 on the under surface thereof and the acketed roll 33 on the upper surface, the latter being adjusted to the pressure and location relative to said rolls 27', 27a and 28 necessary to produce any desired pressure on the web of fibre pulp. After passing between these rolls, the web may be guided ofi' of theroll 27, which may be known as the drive roll, and may go direct to dryers or be passed between a series of presses or the like. In the preferred form the draining suction devices are disposed below the web, however, the same may be disposed above the web. Also the blowing or forcing of heated vair against the web towards the suction means greatly expedites the draining and drying of the web.

The endless belt 29 of course continues around the driving roll 27 and under the shower at 611, where the belt is almost coinpletely cleaned of any fibre adhering thereto. From thence the belt passes over and under the guide rolls 30, 32 and 31. rlfhe cleaning of the belt is further effected by means of the rubber doctor blades 62 and 03 adjacent the respective rolls 30 and 31. The White water containing the fibre scraped 0r washed from the belt 29 is caught in the usual manner and directed fo a salvaging plant.

In passing o ff of the vacuum-roll 28 it will .eoftopro'uce a homo eneoussheet.

, With the'above combination, it is possible,I

by suitable adjustment of theweb forming vacuum box and pro er manipulation of the suction valves relate thereto, along with the controllable suction boxes and the jacketed roll, to readily manufacture various grades and textures of papers' and sheet materials. Because of the more rapid dryin due to the vacuum suction boxes 1t is possile to carry out the 'rocess with a shorter carrying belt for-the bre web and at a greater speed than in machines now in use, and the ressing which ma be applied with controlla levariation to the web between rolls 33 and 27, 27a and 28 eliminates the necessity of an further pressin before the usual final rying of the web. urther,. the sheets made by this method are more uniformlymatted in all directions and retain their original formation and elasticity better than sheets heretofore made, for the reason that the webs are formed by vacuum means/on a non-stretchable carrier which, with its associated draining .and treating means, renders the webs in suitable condition to pass directly to the usual dryers, omitting numerous drawsand felt drying or draining belts with their usual pressure rollers, which have a tendency to stretch the carrier belts and draw the fibresv into a parallel compact relation. The sheets by this method of manufacture are delivered substantially in the condition they p are formed, not being subjected to any stretching and cross wise shrinkage, thereby producing sheets having a high degree of elas- -ticity and which are much stronger crosswise than., those' heretofore produced.

' The above described method has been .found to be connection wit the manufacture of asbestos webs or sheetswhich may be readily impregnated or saturated with asphalt lforV roofing purposes. Heretofore, in view of the slow shedding characteristic of asbestos, sheets or 4Webs of asbestos have been built up by multiple cylinder machines in plies or laminations,fs-which do not thoroug 1y mat tovether Asbestos sheetsv made by the atter method and others now and heretofore used compact the fibres, making a dense sheet which notonly reta-rds the drying thereof, but also retards the saturation or impregnation thereof. l

lto-produce a sheet" suitable for roofing purpaper and pa er board 1n plies, w ich does articularly advantageous in- By the method used in this invention, the asbestos stock is drawn onto the web-forming carrier in one homogeneous layer with the fibres arranged in a criss-cross loosely matted relation, which is readily drained by the suction means and substantially maintained in the original formation for the reason that there are no mechanical pressure applications until the web is moreor less dried. The web made by the above method is more or le'ss loosely textured and porous, depending u on the water content of the web, which is rea ily controllable by regulating the series of suction means before the web reaches the pressure rollers at vthe tail end of the machine. rlhis loose textured web is thoroughly' matted together, and has a somewhat fluffy nature, and 1s readily. saturated and treated with asphalt` poses. 4 It has also been found that with this vacuum formation and the combination used in connection therewith, longer 'fibres may be used, thereby enabling the usel of asbestos fibres as they are produced at the mines with substantially no treating orI refining.

Proper regulation of the/vacuum boxin the web-forming cylinder also eliminates the necessity of manufacturin `certain rades of awa with aws, s litting, ragged edges, crus ing checking, dckel-troubles, overloading of the cylinders: stopping up'of stuff gates, variation of. eight and Waste. The' rapidity-of production possible with this machine prevents thevwater in the vat from becoming frothy and slimy, and consequently avoids production of slime spots on the paper and avoids thin and 'thick streaks.

What I claim is 1. In apaper machine of the class described, characterized by anendless belt running over a web-formin suction cylinder, the combination with said elt and cylinder of a couch roll operating on the formed web at a point in the belt path of movement remote from the cylinder, said couch roll constituting theu first factor of mechanical pressure-application to be encountered by the paper web, and means, operating between the cylinder anfll) couch roll, for draining water from the we 2. In a paper machine of the class described, characterized by an endless wire belt runnin-g over a web-formin 'suction cylinder, 120. the combination with said elt and cylinder of a couch roll operating on the formed web at apoint in the belt path of movement remote from the cylinder, said couch roll con-A stituting the first factor of mechanical pres- 1255 sure-application to be encountered by the aper we ,and suction means, operating etween the cylinder and couch roll, for drainingwater from the web. 1 i

3. In a paper machine o f the Aclass described, characterizedby an endless perforated belt running over a web-forming suction cylinder, the combination with said belt and cylinder of a couch roll operating on the formed web at a point in the belt path of movement remote.` from the cylinder, said couch roll constituting the first factor of me# chanical pressure-application to be encountered by the paper web, and a series of suction boxes, operating between the cylinder and couch roll, for draining water from the web, and means for drying the web.'

4. In a paper machine of the class described, characterized by an endless wire belt running over a web-forming suction cylinder, the combination with said belt and cylinder of a couch roll operating on the formed web at a oint in thebelt path of movement remote rom the cylinder, said couch roll constituting the' first factor of mechanical pressureapplication to be encountered by the paper. web, and suction means, operating between.-

the cylinder and couch roll, for draining water from the web, said suction means being variable and controllable.

"5. In a paper machine of the class described, characterized by an endless wire belt running over a web-forming suction cylinder,

the combination with said belt and cylinder of a couch roll operating on the formed web at a point in the belt path of movement remote fromthe cylinder, said couch roll constituting the rst factor of mechanical pressureapplication to be encountered by the paper web, and suction means, operating between the'cylinder and couch roll, for draining water from the web, said suction increasing from the head to the tail end of the machine.

6. In a paper machine of the class described, characterized by an endless belt running over a web-forming cylinder, the combination `with said belt and cylinder of a couch roll operating on the formed web at a point in the belt path of movement remote from the cylinder, said' couch roll constituting the first factor of mechanical pressure-application to be encountered by the paper. web,

and means, operating between the cylinder and couch roll, for draining water from the web, said cylinder having a controllable variable vacuum suction box for drawing the fibres thereon.

7. A method of making paper, which cornprises forming a wet web of fibrous material upon a conveyor by suction means, and drawing water from the web without subjecting it to compacting pressure until the water! content is so far reduced as to render any subsequently applied mechanical pressure ineffective to compact the web, and then drying the web, thereby producing a loose-textured bibu- A lous sheet. A 8. A method of making a'loose textured asbestos sheet material, which comprises forming a wet web of fibrous asbestos material 9. A method of making porous asbestosv sheet material, which comprises drawing' a wetf web of fibrous asbestos material upon a conveyor at a speed faster than the travel of the conveyor to form a criss-cross loose textured mat, and then draining the water from the web without subjecting it to compacting pressure until the water content is so far reduced as to render the subsequently applied mechanical pressure inefiective to compact the web.

`l0. A method of making a loose textured slicet material and the like, which comprises drawing a wet web of fibrous material upon a carrier, draining the water from the web without stretching and crosswise shrinkage of the web and then subjecting it to rolling pressure on the same carrier, the water content of the web being sufliciently reduced so that the rolling pressure is ineffective to produce any substantial compacting of the web.

11. A method of making a bibulous sheet material and the like, which comprises drawing a wet' web of fibrous material upon a carrier. at a speed greater than the travel of the carrier ythereby causing the fibers to be arranged in a criss-cross loosely matted relation, draining the water from the web and then subjecting it to rolling pressure on the forming carrier. the water content of the web being sufficiently,l reduced so that the pressure is ineffective to produce any substantial compacting of the web.

12. A method of making a fluffy asbestos sheet material and the like, which comprises drawing a wet web of fibrous asbestos material upon a carrier at a speed greater than the travel of the carrier, draining the water from the web by suction means, and then subjecting it to rolling pressure on the forming carrier and then drying the web, the water content of the web being sufficiently reduced ,so that therolling pressure is ineffective to

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