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WO2025111356A1 - Dispositif d'alimentation en matériau particulaire pour formation de mousse - Google Patents

Dispositif d'alimentation en matériau particulaire pour formation de mousse Download PDF

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Publication number
WO2025111356A1
WO2025111356A1 PCT/US2024/056706 US2024056706W WO2025111356A1 WO 2025111356 A1 WO2025111356 A1 WO 2025111356A1 US 2024056706 W US2024056706 W US 2024056706W WO 2025111356 A1 WO2025111356 A1 WO 2025111356A1
Authority
WO
WIPO (PCT)
Prior art keywords
supply hopper
foam
valve
airlock
supply
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/US2024/056706
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English (en)
Inventor
Greg J. DeGrave
Stephen A. Marrano
Kyle KRAUTKRAMER
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Kimberly Clark Worldwide Inc
Kimberly Clark Corp
Original Assignee
Kimberly Clark Worldwide Inc
Kimberly Clark Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Kimberly Clark Worldwide Inc, Kimberly Clark Corp filed Critical Kimberly Clark Worldwide Inc
Publication of WO2025111356A1 publication Critical patent/WO2025111356A1/fr
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21F—PAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
    • D21F9/00—Complete machines for making continuous webs of paper

Definitions

  • tissue products such as facial tissue, bath tissue, paper towels, industrial wipers, and the like, are produced according to a wet laid process.
  • Wet laid webs are made by depositing an aqueous suspension of pulp fibers onto a forming fabric and then removing water from the newly- formed web.
  • foam forming process In order to improve various characteristics of tissue webs, webs have also been formed according to a foam forming process.
  • foam forming process a foamed suspension of fibers is created and spread onto a moving porous conveyor for producing an embryonic web.
  • Foam formed webs can demonstrate improvements in bulk, stretch, caliper, and/or absorbency.
  • foam forming can be used to make all different types of webs and products. For example, relatively long fibers and synthetic fibers can be incorporated into webs using a foam forming process. Thus, foam forming processes can be more versatile than many wet laid processes.
  • superabsorbent material is added to the foam prior to the headbox.
  • Adding superabsorbent material to the foam can be challenging. For instance, air can be entrained into the foam in addition to the superabsorbent material, which can negatively affect performance of the foam in the headbox.
  • a system for improved introduction of superabsorbent material into foam would be useful.
  • the present disclosure is directed to an improved process and system for adding particulate material, such as superabsorbent material, to a flow of foam to a headbox.
  • a pump such as an eductor, may draw the particulate material into the flow of foam to the headbox.
  • a particulate material feeder assembly positioned upstream of the headbox on a flow path for the foam to the headbox includes an rotary airlock valve between a first supply hopper and a second supply hopper. Particulate material within the first supply hopper chamber may flow from the first supply hopper into the second supply hopper during operation of the rotary airlock valve.
  • the rotary airlock valve may also block airflow between the first supply hopper and the second supply hopper.
  • the rotary airlock valve may supply particulate material while also limiting available air in the second supply hopper for entrainment into the foam.
  • a pressure supply line separate from the pump, may also be coupled to the rotary airlock valve.
  • the pressure supply line may draw air from and/or supply air to the rotary airlock valve.
  • the pressure supply line may evacuate air from the rotary airlock valve in order to limit the air that flows from the first supply hopper with the particulate material into the second supply hopper when the rotary airlock valve operates to transfer the particulate material from the first supply hopper to the second supply hopper.
  • the above-described particulate material feeder assembly may advantageously allow for continuous operation of the foam forming process at the headbox by refilling the supply hopper with particulate material, e.g., without introducing significant volumes of air into foam.
  • a foam forming system includes a headbox and a superabsorbent material feeder assembly positioned upstream of the headbox on a flow path for foam to the headbox.
  • the superabsorbent material feeder assembly is configured for adding superabsorbent material to the foam.
  • the superabsorbent material feeder assembly includes a first supply hopper, a second supply hopper spaced from the first supply hopper, and a rotary airlock valve disposed between the first and second supply hoppers.
  • the rotary airlock valve is configured for transferring the superabsorbent material from the first supply hopper to the second supply hopper.
  • a pressure supply line coupled to the rotary airlock valve and configured for flowing air into and/or from the rotary airlock valve.
  • a particulate material feeder for a foam forming system includes a first supply hopper, a second supply hopper spaced from the first supply hopper, and a rotary airlock valve disposed between the first and second supply hoppers.
  • the rotary airlock valve is configured for transferring particulate material from the first supply hopper to the second supply hopper.
  • a pressure supply line coupled to the rotary airlock valve and configured for flowing air into and/or from the rotary airlock valve.
  • a method for feeding particulate material within a foam forming process includes flowing particulate material from a first supply hopper into a rotary airlock valve, drawing air out of the particulate material in the rotary airlock valve, transferring the particulate material within the rotary airlock valve to a second supply hopper, and metering the particulate material into a flow of foam to a headbox.
  • FIG. 1 is a schematic view of a system and process according to an example embodiment of the present disclosure for forming webs from a foamed suspension of materials;
  • FIG. 2 is a schematic view of a system and process according to an example embodiment of the present disclosure for depositing a foamed suspension of materials onto a forming surface in accordance with the present disclosure
  • FIG. 3 is a schematic view of a system and process according to an example embodiment of the present disclosure for feeding superabsorbent material during foam forming of a non-woven web;
  • FIG. 4 is a schematic view of a superabsorbent material feeder assembly of the example system and process of FIG. 3;
  • FIG. 5 is a schematic view of a superabsorbent material feeder assembly according to another example embodiment of the present disclosure.
  • FIG. 6 is a flow diagram of a process according to an example embodiment of the present disclosure for feeding superabsorbent material during foam forming of a non-woven web.
  • the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of the elements.
  • the terms “includes” and “including” are intended to be inclusive in a manner similar to the term “comprising.”
  • the term “or” is generally intended to be inclusive (i.e. , “A or B” is intended to mean “A or B or both”). Approximating language, as used herein throughout the specification and claims, is applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related.
  • a value modified by a term or terms, such as “about,” “approximately,” and “substantially,” are not to be limited to the precise value specified.
  • the approximating language may correspond to the precision of an instrument for measuring the value.
  • the approximating language may refer to being within a ten percent (10%) margin.
  • the term “foam formed product” means a product formed from a suspension including a mixture of a solid, a liquid, and dispersed gas bubbles.
  • the term “foam forming process” means a process for manufacturing a product involving a suspension including a mixture of a solid, a liquid, and dispersed gas bubbles.
  • foaming fluid means any one or more known fluids compatible with the other components in the foam forming process. Suitable foaming fluids include, but are not limited to, water.
  • foam half life means the time elapsed until the half of the initial foam mass reverts to liquid water.
  • the term “layer” refers to a structure that provides an area of a substrate in a height direction of the substrate that is comprised of similar components and structure.
  • nonwoven web means a web having a structure of individual fibers or threads which are interlaid, but not in an identifiable manner as in a knitted web.
  • percent As used herein, unless expressly indicated otherwise, when used in relation to material compositions the terms "percent”, “%”, “weight percent”, or “percent by weight” each refer to the quantity by weight of a component as a percentage of the total except as whether expressly noted otherwise.
  • personal care absorbent article refers herein to an article intended and/or adapted to be placed against or in proximity to the body (i.e., contiguous with the body) of the wearer to absorb and contain various liquid, solid, and semi-solid exudates discharged from the body. Examples include, but are not limited to, diapers, diaper pants, training pants, youth pants, swim pants, feminine hygiene products, including, but not limited to, menstrual pads or pants, incontinence products, medical garments, surgical pads and bandages, and so forth.
  • superabsorbent material refers to water-swellable, water-insoluble organic or inorganic materials including superabsorbent polymers and superabsorbent polymer compositions capable, under the most favorable conditions, of absorbing at least about ten times (1 OX) their weight, or at least about fifteen times (15X) their weight, or at least about twenty-five times (25X) their weight in an aqueous solution containing nine-tenths (0.9) weight percent sodium chloride.
  • machine direction refers to the direction of travel of the forming surface onto which fibers are deposited during formation of a nonwoven web.
  • cross-machine direction refers to the direction which is perpendicular to the machine direction defined above.
  • Pulp refers to fibers from natural sources such as woody and non- woody plants.
  • Woody plants include, for example, deciduous and coniferous trees.
  • Non-woody plants include, for example, cotton, flax, esparto grass, milkweed, straw, jute, hemp, and bagasse.
  • Pulp fibers may include hardwood fibers, softwood fibers, and mixtures thereof.
  • average fiber length refers to an average length of fibers, fiber bundles and/or fiber-like materials determined by measurement utilizing microscopic techniques.
  • a sample of at least 20 randomly selected fibers is separated from a liquid suspension of fibers.
  • the fibers are set up on a microscope slide prepared to suspend the fibers in water.
  • a tinting dye is added to the suspended fibers to color cellulose-contain ing fibers so they may be distinguished or separated from synthetic fibers.
  • the slide is placed under a Fisher Stereomaster II Microscope-S19642/S19643 Series. Measurements of 20 fibers in the sample are made at 20X linear magnification utilizing a 0-20 mils scale and an average length, minimum and maximum length, and a deviation or coefficient of variation are calculated.
  • the average fiber length will be calculated as a weighted average length of fibers (e.g., fibers, fiber bundles, fiber-like materials) determined by equipment such as, for example, a Kajaani fiber analyzer Model No. FS-200, available from Kajaani Oy Electronics, Kajaani, Finland.
  • a sample is treated with a macerating liquid to ensure that no fiber bundles or shives are present.
  • Each sample is disintegrated into hot water and diluted to an approximately 0.001% suspension.
  • Individual test samples are drawn in approximately 50 to 100 ml portions from the dilute suspension when tested using the standard Kajaani fiber analysis test procedure.
  • the average length data measured by the Kajaani fiber analyzer is that it does not discriminate between different types of fibers.
  • the average length represents an average based on lengths of all different types, if any, of fibers in the sample.
  • staple fibers means discontinuous fibers made from synthetic polymers such as polypropylene, polyester, post consumer recycle (PCR) fibers, polyester, nylon, and the like, and those not hydrophilic may be treated to be hydrophilic. Staple fibers may be cut fibers or the like. Staple fibers can have cross-sections that are round, bicomponent, multicomponent, shaped, hollow, or the like.
  • the metering device may be disposed within a sealed casing, e.g., such that an interior of the metering device containing the superabsorbent material is pressurized to differ from atmospheric pressure, e.g., by a pump, such as an edcutor, that injects the superabsorbent material from the metering device into the flow of foam to the headbox.
  • An interior of the second supply hopper may also be pressurized to differ from atmospheric pressure, and air may be flowed into and/or from the superabsorbent material fed to the second supply hopper in order to limit entrainment of air from the second supply hopper into the flow of foam to the headbox.
  • a rotary airlock valve may be positioned between a first supply hopper and the second supply hopper.
  • the rotary airlock valve can supply superabsorbent material from the first supply hopper to the second supply hopper during operation of the rotary airlock valve, and the airlock valve can also block airflow from the first supply hopper into the second supply hopper.
  • the rotary airlock valve may be connected to a pressure supply line, separate from the pump, that flows air into and/or out of the superabsorbent material in the rotary airlock valve prior to flowing the superabsorbent material from the rotary airlock valve into the second supply hopper.
  • a first pressure sensor may measure an air pressure in the rotary airlock valve
  • a second pressure sensor may measure an air pressure in the second supply hopper.
  • a controller may be configured for adjusting the air pressure within the rotary airlock valve based on measurements from the first and second sensors. For instance, the controller may adjust a valve to increase or decrease the flow rate of air out of the rotary airlock valve through the pressure supply line. As another example, the controller may adjust a valve to increase or decrease a flow rate of motive fluid through a Venturi pump in order to change the air pressure within the rotary airlock valve.
  • the controller may be configured for adjusting the air pressure within the rotary airlock valve such that a difference between the air pressures within the rotary airlock valve and the second supply hopper is less than a threshold value.
  • a threshold value e.g., at least a portion of the rotary airlock valve and the second supply hopper may be pressurized to substantially the same magnitude prior to the superabsorbent material entering the second supply hopper.
  • removing air from the superabsorbent material in the rotary airlock valve may advantageously limit entrainment of air from the second supply hopper into the flow of foam to the headbox.
  • the headbox may be continuously fed with superabsorbent material without undesired entrainment of air into the flow of foam to the headbox.
  • stability of the foam may be maintained while continuously feeding superabsorbent material into the flow of foam to the headbox.
  • FIGS. 1 and 2 an example embodiment of a system and process in accordance with aspects of the present disclosure is shown.
  • solid material such as fibers and/or superabsorbent particles, water, and a foam forming agent are added to a tank and mixed until the desired air content, bubble size/foam stability, and solid dispersion are achieved, such as a fiber dispersion.
  • the fiber-containing foam may then optionally be diluted during the process, especially when a recycle stream is present.
  • the air content of the foamed suspension is between about thirty percent (30%) and about sixty-five percent (65%).
  • example aspects of the process and system of the present disclosure are directed to separating foam from free air and managing foam, e.g., during foam forming of a nonwoven web.
  • FIG. 1 illustrates a system and process for producing a foamed suspension of fibers and for forming webs from the foamed suspension of fibers.
  • the system may include a mixing tank 12 configured to form the foamed suspension of fibers.
  • the foamed suspension of fibers may then be fed to a headbox or web forming system 10 that deposits the foamed suspension of fibers onto a porous forming surface 26 for forming a web 14.
  • the mixing tank 12 may be in communication with a water supply 22 for feeding water to the tank and a foaming agent or surfactant supply 24 for feeding a surfactant to the tank 12.
  • a fiber furnish may also be fed to the tank 12 and combined with the water and surfactant.
  • the aqueous solution formed by combining the surfactant and water may be agitated and formed into a foam for forming a foamed suspension of fibers.
  • various other materials may be combined in the tank 12. Such other materials, for instance, may include superabsorbent particles or the like.
  • the surfactant or foaming agent for instance, may include any suitable surfactant.
  • the foaming agent may include sodium lauryl sulfate, which is also known as sodium laureth sulfate or sodium lauryl ether sulfate.
  • Other foaming agents include sodium dodecyl sulfate or ammonium lauryl sulfate.
  • the foaming agent may include any suitable cationic and/or amphoteric surfactant.
  • other foaming agents include fatty acid amines, amides, amine oxides, fatty acid quaternary compounds, and the like.
  • a nonionic surfactant is used.
  • the nonionic surfactant may include an alkyl polyglycoside.
  • the surfactant may be a C8 alkyl polyglycoside, a C10 alkyl polyglycoside, or a mixture of C8 and C10 alkyl polyglycosides.
  • the foaming agent may be combined with water generally in an amount greater than about one-tenth of a percent (0.1 %) by weight, such as in an amount greater than about half of a percent (0.5%) by weight, such as in an amount greater than about seven-tenths of a percent (0.7%) by weight.
  • One or more foaming agents may generally be present in an amount of from about one- hundredth of a percent (0.01 %) by weight to about five percent (5%) by weight, such as in an amount up to about two percent (2%) by weight.
  • a foam generally refers is an aggregate of hollow cells or bubbles.
  • the foam density can vary depending upon the particular application and various factors including the fiber furnish used.
  • the foam density of the foam may be greater than about two hundred grams per liter (200 g/L), such as greater than about two hundred and fifty grams per liter (250 g/L), such as greater than about three hundred grams per liter (300 g/L).
  • the foam density is generally less than about six hundred grams per liter (600 g/L), such as less than about five hundred grams per liter (500 g/L), such as less than about four hundred grams per liter (400 g/L), such as less than about three hundred and fifty grams per liter (350 g/L).
  • a lower density foam having a foam density of generally less than about three hundred and fifty grams per liter (350 g/L), such as less than about three hundred and forty grams per liter (340 g/L), such as less than about three hundred and thirty grams per liter (330 g/L).
  • the foam may generally have an air content of greater than about forty percent (40%), such as greater than about fifty percent (50%), such as greater than about sixty percent (60%), e.g. , at standard temperature and pressure (STP).
  • STP standard temperature and pressure
  • the air content is generally less than about seventy-five percent (75%) by volume, such as less than about seventy percent (70%) by volume, such as less than about sixty-five percent (65%) by volume.
  • the foam may be formed in the presence of a fiber furnish or, alternatively, the foam may first be formed and then combined with a fiber furnish.
  • any fibers capable of making a basesheet such as a tissue web or other similar type of nonwoven, may be used.
  • Fibers suitable for making webs include any natural or synthetic cellulosic fibers including, but not limited to: nonwoody fibers, such as cotton, abaca, kenaf, sabai grass, flax, esparto grass, straw, jute hemp, bagasse, milkweed floss fibers, and pineapple leaf fibers; and woody or pulp fibers, such as those obtained from deciduous and coniferous trees, including softwood fibers, such as northern and southern softwood kraft fibers; hardwood fibers, such as eucalyptus, maple, birch, and aspen.
  • nonwoody fibers such as cotton, abaca, kenaf, sabai grass, flax, esparto grass, straw, jute hemp, bagasse, milkweed floss fibers, and pineapple leaf fibers
  • woody or pulp fibers such as those obtained from deciduous and coniferous trees, including softwood fibers, such as northern and southern softwood kraft fibers; hardwood fibers, such as
  • Pulp fibers may be prepared in high-yield or low-yield forms and may be pulped in any known method, including kraft, sulfite, high-yield pulping methods and other known pulping methods. Fibers prepared from organosolv pulping methods may also be used.
  • a portion of the fibers may be synthetic fibers, such as rayon, polyolefin fibers, polyester fibers, bicomponent sheath-core fibers, multi-component binder fibers, and the like.
  • the fibers may be virgin fibers or recycled fibers.
  • the fibers may be staple fibers and may have an average length of from about three millimeters (3 mm) to about one hundred and fifty millimeters (150 mm).
  • An exemplary polyethylene fiber is Fybrel®, available from Minifibers, Inc. (Jackson City, Tenn.). When containing synthetic polymer fibers, the web may be thermally bonded where the fibers intersect.
  • Synthetic cellulose fiber types include rayon in all its varieties and other fibers derived from viscose or chemically-modified cellulose.
  • Chemically treated natural cellulosic fibers may be used, such as mercerized pulps, chemically stiffened or crosslinked fibers, or sulfonated fibers.
  • mercerized pulps For good mechanical properties in using papermaking fibers, it may be desirable that the fibers be relatively undamaged and largely unrefined or only lightly refined. While recycled fibers may be used, virgin fibers are generally useful for their mechanical properties and lack of contaminants.
  • Mercerized fibers, regenerated cellulosic fibers, cellulose produced by microbes, rayon, and other cellulosic material or cellulosic derivatives may be used.
  • Suitable papermaking fibers may also include recycled fibers, virgin fibers, or mixes thereof.
  • the fibers may have a Canadian Standard Freeness of at least two hundred (200), more specifically at least three hundred (300), more specifically still at least four hundred (400), and most specifically at least five hundred (500).
  • Papermaking fibers that may be used include paper broke or recycled fibers and high yield fibers.
  • High yield pulp fibers are those papermaking fibers produced by pulping processes providing a yield of about sixty-five percent (65%) or greater, more specifically about seventy-five percent (75%) or greater, and still more specifically about seventy-five percent (75%) to about ninety- five percent (95%). Yield is the resulting amount of processed fibers expressed as a percentage of the initial wood mass.
  • Such pulping processes include bleached chemithermomechanical pulp (BCTMP), chemithermomechanical pulp (CTMP), pressure/pressure thermomechanical pulp (PTMP), thermomechanical pulp (TMP), thermomechanical chemical pulp (TMCP), high yield sulfite pulps, and high yield Kraft pulps, all of which leave the resulting fibers with high levels of lignin.
  • High yield fibers are well known for their stiffness in both dry and wet states relative to typical chemically pulped fibers.
  • the web may also be formed without a substantial amount of inner fi ber-to-fi ber bond strength.
  • the fiber furnish used to form the base web may be treated with a chemical debonding agent.
  • the debonding agent may be added to the foamed fiber slurry during the pulping process or may be added directly to the headbox.
  • Suitable debonding agents include cationic debonding agents, such as fatty dialkyl quaternary amine salts, mono fatty alkyl tertiary amine salts, primary amine salts, imidazoline quaternary salts, silicone quaternary salt and unsaturated fatty alkyl amine salts.
  • Other suitable debonding agents are disclosed in U.S. Pat. No. 5,529,665 to Kaun, the entirety of which is incorporated herein by reference. In particular, Kaun discloses the use of cationic silicone compositions as debonding agents.
  • the debonding agent used in the process of the present disclosure may be an organic quaternary ammonium chloride and, particularly, a silicone-based amine salt of a quaternary ammonium chloride.
  • the debonding agent may be PROSOFT.RTM. TQ1003, marketed by the Hercules Corporation.
  • the debonding agent may be added to the fiber slurry in an amount of from about one kilogram per metric ton (1 kg/tonne) to about ten kilograms per metric ton (10 kg/tonne) of fibers present within the slurry.
  • the debonding agent may be an imidazoline-based agent.
  • the imidazoline-based debonding agent may be obtained, for instance, from the Witco Corporation.
  • the imidazoline-based debonding agent may be added in an amount of between two kilograms per metric ton (2.0 kg/tonne) to about fifteen kilograms per metric ton (15 kg/tonne).
  • odor control agents such as odor absorbents, activated carbon fibers and particles, baby powder, baking soda, chelating agents, zeolites, perfumes or other odor-masking agents, cyclodextrin compounds, oxidizers, and the like.
  • Superabsorbent particles may also be employed. Additional options include cationic dyes, optical brighteners, humectants, emollients, and the like.
  • the foamed suspension of fibers may be fed to the web forming system 10.
  • the web forming system 10 may include includes one or more forming zones. In the example embodiment of FIG. 2, three forming zones are shown, including first forming zone 50, second forming zone 52, and third forming zone 54. The forming zones 50, 52, and 54 are positioned along the porous forming surface 26. In one example embodiment, as shown in FIG.
  • the porous forming surface 26 may be at an incline with respect to horizontal
  • the porous forming surface 26 may be oriented at an angle with the horizontal of greater than about ten degrees (10°), such as greater than about twenty degrees (20°), such as greater than about thirty degrees (30°), and generally less than about sixty degrees (60°), such as less than about fifty degrees (50°).
  • Each forming zone 50, 52, and 54 may be configured to receive a separate and independent flow of the foamed suspension of fibers for depositing the foamed suspension of fibers onto the forming surface 26.
  • the first forming zone 50 may deposit a foamed suspension of fibers directly onto the forming surface 26.
  • the second forming zone 52 may be configured to deposit a second flow rate of the foamed suspension of fibers on top of the fibers deposited by the first forming zone 50.
  • the third forming zone 54 may deposit a flow of the aqueous suspension of fibers on top of the fibers deposited by the first forming zone 50 and the second forming zone 52. In this manner, a multilayered web may be formed. It should be understood, however, that the system and process of the present disclosure may include only a single forming zone for forming single layered webs.
  • each forming zone 50, 52, and 54 may be in fluid communication with a separate and independent foamed fibrous supply line.
  • first forming zone 50 may be in communication with a first foamed fibrous supply line 56
  • the second forming zone 52 may be in fluid communication with a second foamed fibrous supply line 58
  • the third forming zone 54 may be in fluid communication with a third foamed fibrous supply line 60.
  • the first, second, and third supply lines 56, 58, and 60 may be configured to feed a foamed suspension of fibers to each of the respective forming zones 50, 52, and 54 at a determined and selected flow characteristic, which may be, for instance, flow rate, such as volumetric flow rate, pressure, air content, and/or density.
  • each of the supply lines 56, 58, and 60 may be in fluid communication with the mixing tank 12 as shown in FIG. 1 .
  • the first supply line 56 may include a first injection line 62 that is connected to the mixing tank 12.
  • the second supply line 58 may include a second injection line 64
  • the third supply line 60 may be in communication with a third injection line 66.
  • the injections lines 62, 64, and 66 may all be in communication with the mixing tank 12 for feeding the foamed suspension of fibers to each of the forming zones 50, 52, and 54.
  • the system 10 may include separate mixing tanks, and each of the first, second, and third injection lines 62, 64, and 66 may be connected to a different, respective mixing tank for feeding the foamed suspension of fibers to the web forming system 10.
  • each of the foamed fibrous supply lines 56, 58, and 60 may include a pumping device, a flow meter, such as a volumetric flow meter, a pressure monitoring device, and/or a temperature monitoring device.
  • Each foamed fibrous supply line 56, 58, and 60 may also be in communication with a density monitoring device.
  • the density monitoring device for instance, may be part of one of the other devices, such as part of the flow meter.
  • the density of the foamed suspension of fibers may be calculated using information received from the other instruments.
  • the first foamed fibrous supply line may include a first pumping device 68, a first flow meter 74, a first pressure monitoring device 80, and a first temperature monitoring device 81 ;
  • the second foamed fibrous supply line 58 may include a second pumping device 70, a second flow meter 76, a second pressure monitoring device 82, and a second temperature monitoring device 83;
  • the third foamed fibrous supply line 60 may include a third pumping device 72, a third flow meter 78, a third pressure monitoring device 84 and a third temperature monitoring device 85.
  • the pumping devices 68, 70, and 72 may be adjustable such that the foamed suspension of fibers may be independently fed to each forming zone 50, 52, and 54 at a desired, selected flow rate and/or pressure.
  • the flow meters 74, 76, and 78, the pressure monitoring devices 80, 82, and 84 (e.g., volumetric flow rate), and the temperature monitoring devices 81 , 83 and 85 may monitor flow rates, pressures, and temperatures upstream from the forming surface for calculating at least one characteristic of the flow of the foamed suspension of fibers at the forming surface.
  • the flow meters 74, 76, and 78, the pressure monitoring devices 80, 82, and 84, the temperature monitoring devices 81 , 83 and 85 may be placed in communication with one or more controllers.
  • the controllers may include microprocessors or any suitable programmable device.
  • the pumping devices 68, 70, and 72 may also be placed in communication with the one or more controllers.
  • the controllers may be configured to adjust the pumping devices 68, 70, and 72 based upon information received from the flow meters 74, 76, and 78, from the pressure monitoring devices 80, 82, and 84, and/or from the temperature monitoring devices 81 , 83 and 85. In this manner, the foamed suspension of fibers may be fed to each forming zone 50, 52, and 54 at a flow rate within desired set points and/or at a pressure within desired set points for optimizing formation of a web on the forming surface 26.
  • Information received from the flow meters 74, 76, and 78, from the pressure monitoring devices 80, 82, and 84, and/or from the temperature monitoring devices 81 , 83, and 85 may be used to determine the characteristics of the foamed suspension of fibers at the location of the measurements.
  • the density of the foamed suspension of fibers may be measured or calculated from the information received from the various instruments.
  • This information may be sent to the controllers for then calculating at least one characteristic of the foamed suspension of fibers at the forming surface.
  • the controller may be programmed to correct the determined volumetric flow rate at the forming surface based upon changes in density, pressure, and temperature.
  • the foamed suspension can experience a pressure drop when being emitted from the supply line onto the forming surface that changes the density of the foamed suspension.
  • One method for calculating downstream values of the foamed suspension, for instance, is disclosed in U.S. Patent No. 4,764,253, which is incorporated herein by reference.
  • first drain device 86 in fluid communication with a first drain line 92.
  • second drain device 88 in fluid communication with a second drain line 94.
  • third drain device 90 in communication with a third drain line 96.
  • the first, second, and third forming zones 50, 52, and 54 may be adjacent to one another along the forming surface 26 and may be positioned on one side of the forming surface 26.
  • the drain devices 86, 88, and 90 may also be adjacent to one another and may be positioned on the opposite side of the forming surface 26 in alignment with the forming zones 50, 52, and 54.
  • the drain devices may be any suitable static or dynamic drain device capable of draining fluids from the web or from the forming surfaces.
  • the drain device may be a static suction or vacuum box.
  • the drain device may be a drum, such as a rotating drum that applies suction.
  • each drain line 92, 94, and 96 may include a corresponding flow control device, flow meter, temperature monitoring device, and pressure monitoring device.
  • the first drain line 92 may include a first flow control device 98, a first flow meter 104, a first temperature monitoring device 105, and a first pressure monitoring device 110;
  • the second drain line 94 may include a second flow control device 100, a second flow meter 106, a second temperature monitoring device 107, and a second pressure monitoring device 112;
  • the third drain line 96 may include a third flow control device 102, a third flow meter 108, a third temperature monitoring device 109, and a third pressure monitoring device 114.
  • the flow control devices 98, 100, and 102 may be any suitable device for controlling flow through the line and may be, an adjustable valve or a pump. Pumps, for instance, may be used to apply suction to the forming surface. Alternatively, draining can occur through gravity. In still another example embodiment, each flow control device 98, 100, and 102 may be a combination of a pump and an adjustable valve.
  • the system 10 may further include one or more controllers 116.
  • the controllers 116 may include microprocessors or any suitable programmable devices. As shown in FIG. 2, each flow control device 98, 100, and 102, each flow meter 104, 106, and 108, each temperature monitoring device 105, 107, and 109, each density monitoring device, and/or each pressure monitoring device 110, 112, and 114 may be in communication with the controller 116.
  • the controller 116 may receive information from the flow meters 104, 106, and 108, the temperature monitoring devices 105, 107, and 109, the optional density monitoring devices, and/or the pressure monitoring devices 110, 112, and 114 for making adjustments to the flow control devices 98, 100, and 102 for controlling the flow rate in which fluids are drained from each of the drain devices 86, 88, and 90.
  • the combination of receiving information from the flow control devices 98, 100, and 102 which may be volumetric flow meters, from the pressure monitoring devices 110, 112, and 114, from the temperature monitoring devices 105, 107, and 109, and/or from optional density monitoring devices may be used to quantify the fluid discharge flows containing both gases and liquids.
  • the controller 116 may use the above information to calculate a flow rate, such as a volumetric flow rate, at the forming surface and control the volumetric flow rate based upon at least one characteristic of the foamed suspension being fed to the forming surface. The controller 116 may then control the flow control devices 98, 100, and 102 to achieve a calculated discharge flow rate through each drain device and drain line.
  • the process and system of the present disclosure may further include a sealing zone 120 positioned along the forming fabric 26 and in fluid communication with a sealing fluid supply line 122. As shown in FIG. 2, the sealing fluid supply line 122 may include a pumping device 124, a flow meter 126, a pressure monitoring device 128, and a temperature monitoring device 129.
  • the sealing fluid supply line 122 is for feeding a fluid, particularly a liquid, to the sealing zone 120.
  • Sealing fluid may be any suitable liquid.
  • the sealing fluid may be water, a water and surfactant solution, or the like.
  • the sealing fluid may be non-fibrous.
  • a sealing fluid may be fed to the sealing fluid zone 120 at a flow rate and/or at a pressure such that sealing fluid deposited onto the forming surface 26 forms a fluid seal that prevents air flow in an upstream longitudinal direction.
  • Information received from the flow meter 126, the pressure monitoring device 128, the temperature monitoring device 129, and optionally a density monitoring device may be used to calculate volumetric flow rates of the foam at the forming surface.
  • the sealing zone 120 may be positioned upstream from and adjacent to the plurality of forming zones.
  • the sealing zone 120 may also be placed opposite a sealing drain device 130 connected to a sealing drain line 132.
  • the sealing drain line 132 may include a flow control device 134, a flow meter 136, a temperature monitoring device 137, and a pressure sensing device 138 that may all be in communication with the controller 116.
  • the flow rate of drainage of the sealing fluid may be controlled based upon the flow rate or pressure at which the sealing fluid enters or exits the sealing zone 120.
  • the web forming system 10 as shown in FIG. 2 may also include a suction zone 140 adjacent to the plurality of formation zones and positioned downstream from the formation zones.
  • the suction zone 140 may be in fluid communication with a drain line 142 which may include a pressure monitoring device 144.
  • the suction zone 140 is for drawing fluids through the embryonic web 14 after the web has been formed.
  • the suction zone 140 is for removing excess fluids, particularly liquids, from the web 14.
  • the drainage flow rate of the foamed suspension of fibers being drained through the one or more drain devices may be controlled such that excess fluid from the one or more forming zones enters the suction zone 140.
  • the suction zone 140 facilitates draining fluids from the web 14 without causing any detrimental effects.
  • the separator tank 150 may be configured to separate free gases from foam.
  • the separator tank 150 may include a gas outlet 152 that may be connected to a vacuum source and a liquid outlet 154.
  • the liquid collected in the separator tank 150 may include a water and surfactant mixture.
  • a pumping device 156 may be used to pump liquids from the separator tank 150 to a liquid tank 158 which may also be placed in communication with a water source 160.
  • the liquid tank 158 may be used to recycle the water and surfactant mixture back into the process through the supply lines 56, 58, 60, and 122.
  • FIG. 1 merely represents one example embodiment of a process for drying the web 14 after being formed. As shown, the web 14 is formed on the forming surface 26 and conveyed downstream.
  • the endless traveling forming fabric 26, for instance, may be supported and driven by rolls 28.
  • the formed web 14 may have a consistency of less than about fifty percent (50%), such as less than about twenty percent (20%), such as less than about ten percent (10%), such as less than about five percent (5%).
  • the forming consistency may be less than about two percent (2%), such as less than about one and eight-tenths percent (1 .8%), such as less than about one and a half percent (1 .5%).
  • the forming consistency is generally greater than about a half percent (0.5%), such as greater than about eight-tenths percent (0.8%).
  • the web 14 is conveyed downstream and optionally further dewatered.
  • the process may optionally include a plurality of vacuum devices 16, such as vacuum and vacuum rolls.
  • the vacuum boxes assist in removing moisture from the newly formed web 14.
  • the forming fabric 26 may also be placed in communication with a steambox 18 positioned above a pair of vacuum rolls 20.
  • the steambox 18, for instance, may increase dryness and reduce cross-directional moisture variance.
  • the applied steam from the steambox 18 heats the moisture in the wet web 14 causing the water in the web to drain more readily, especially in conjunction with the vacuum rolls 20.
  • the newly formed web 14 is conveyed downstream and dried.
  • the web 14 may be dried using any suitable drying device.
  • the web 14 may be through-air dried or placed on a heated drying drum and creped or left uncreped.
  • the formed web 14 is placed in contact with two heated drying drums 38 and 40.
  • the web 14 may be fed to a through-air dryer prior to being wound into a roll.
  • the embodiment in FIG. 2 is for forming multilayer webs.
  • the process of the present disclosure may be used to create single layer webs from a foamed suspension of materials.
  • system 200 for feeding superabsorbent material, or other solid particles, into a foam forming system according to an example embodiment of the present disclosure is shown. It will be understood that system 200 may be utilized in or with any foam forming system or process for forming webs from a foamed suspension of fibers. For example, system 200 may be used in or with the example systems and processes shown in FIGS. 1 and 2 and described above.
  • system 200 may be used in or with other systems and processes for forming webs from a foamed suspension of fibers in alternative example embodiments.
  • system 200 includes a headbox 210 and a superabsorbent material feeder assembly 220.
  • the headbox 210 may be configured for forming a web from one or more foamed suspension of fibers.
  • a foamed suspension of fibers 214 may be pumped from a tank 212 towards a headbox 210.
  • the foamed suspension of fibers 214 may be deposited on a formation surface to for an embryonic web, e.g., as described above for the web forming system 10.
  • the superabsorbent material feeder assembly 220 may add superabsorbent material 202 to the foamed suspension of fibers 214 upstream of the headbox 210.
  • the foamed suspension of fibers 214 flowing into the headbox 210 may include superabsorbent material 202.
  • the superabsorbent material feeder assembly 220 may be positioned upstream of the headbox 210 along the flow of foamed suspension of fibers 214 to the headbox 210.
  • the superabsorbent material feeder assembly 220 may be configured for adding superabsorbent material to foam, such as the flow of foamed suspension of fibers 214.
  • the superabsorbent material feeder assembly 220 may include a first supply hopper 230, a second supply hopper 240, and a rotary airlock valve 250.
  • the first supply hopper 230 may be fillable with superabsorbent material 202.
  • the superabsorbent material 202 may flow from a supply tank 234 to the first supply hopper 230, and the superabsorbent material 202 may be contained within an interior 232 of the first supply hopper 230.
  • a control valve 236 may regulate the flow of superabsorbent material 202 from the supply tank 234 to the first supply hopper 230.
  • the superabsorbent material 202 may be manually or otherwise added to the first supply hopper 230.
  • the rotary airlock valve 250 is disposed between the first supply hopper 230 and the second supply hopper 240.
  • the rotary airlock valve 250 is configured for regulating a flow of superabsorbent material 202 from the first supply hopper 230 to the second supply hopper 240.
  • the superabsorbent material 202 in the interior 232 of the first supply hopper 230 may be transferred by the rotary airlock valve 250 into an interior 242 of the second supply hopper 240.
  • the second supply hopper 240 may be positioned below the first supply hopper 230 such that the superabsorbent material 202 is gravity-fed into the rotary airlock valve 250 from the first supply hopper 230 and from the rotary airlock valve 250 into the second supply hopper 240 when the rotary airlock valve 250 is operating. Conversely, when the rotary airlock valve 250 is not operating, the rotary airlock valve 250 may block the superabsorbent material 202 in the interior 232 of the first supply hopper 230 from flowing into the interior 242 of the second supply hopper 240 from the rotary airlock valve 250.
  • the rotary airlock valve 250 may also be configured for regulating airflow between the first supply hopper 230 and the second supply hopper 240.
  • the rotary airlock valve 250 may block airflow between the interior 232 of the first supply hopper 230 and the interior 242 of the second supply hopper 240 through the rotary airlock valve 250.
  • the interior 232 of the first supply hopper 230 may be contiguous with ambient atmosphere, e.g., such that the interior 232 of the first supply hopper 230 is at atmospheric pressure and is not pressurized (e.g., positively or negatively) relative to ambient pressure.
  • the interior 242 of the second supply hopper 240 may be pressurized, e.g., at less than atmospheric pressure.
  • the rotary airlock valve 250 may block air flow both when the rotary airlock valve 250 is operating and not operating to limit or prevent air flow between the interior 232 of the first supply hopper 230 and the interior 242 of the second supply hopper 240 through the rotary airlock valve 250, e.g., due to the pressure differential between the first and second supply hoppers 230, 240.
  • the superabsorbent material 202 may include air therein.
  • the superabsorbent material feeder assembly 220 may include features for removing the air from the superabsorbent material 202 in the rotary airlock valve 250 before the superabsorbent material 202 enters the second supply hopper 240.
  • a pressure supply line 260 may be coupled to the rotary airlock valve 250.
  • the pressure supply line 260 may be configured for flowing air into and/or from the rotary airlock valve 250.
  • the pressure supply line 260 may be connected to a vacuum source 262, and the vacuum source 262 may generate negative pressure for drawing air out of the rotary airlock valve 250.
  • air may be removed from the superabsorbent material 202 in the rotary airlock valve 250 via the vacuum supply line 260.
  • the air may be removed from the superabsorbent material 202 in the rotary airlock valve 250 via the vacuum supply line 260 before the superabsorbent material 202 enters the second supply hopper 240.
  • the vacuum source 262 may be any suitable device for generating negative pressure relative to ambient atmosphere.
  • the vacuum source 262 may include one or more of a Venturi pump or a rotary vane pump.
  • the pressure supply line 260 may be connected to a positive pressure source, such as a pump, compressor, etc., that may generate positive pressure for flowing air into the rotary airlock valve 250.
  • the pressure level in the rotary airlock valve 250 may be controlled by a backpressure regulator receiving a pressure signal from the rotary airlock valve 250 or pump 280.
  • the pressure level in the rotary airlock valve 250 may be controlled by a control valve 264 coupled to the pressure supply line 260, and the control valve 264 may be configured for regulating the flow of air into and/or from the rotary airlock valve 250, e.g., based on a pressure signal from the rotary airlock valve 250.
  • the vacuum level in the rotary airlock valve 250 may be controlled by a venturi pump supplied by compressed air, and the flow rate/pressure of the air may be controlled to adjust the vacuum level, e.g., based on a pressure signal from the rotary airlock valve 250.
  • the rotary airlock valve 250 may include an airlock casing 300, a rotor 310, and a motor 320.
  • the rotor 310 may be disposed within the airlock casing 300.
  • the airlock casing 300 may form a vacuum casing for the rotor 310.
  • ambient air flow into and out of the rotary airlock valve 250 may be blocked or limited by the airlock casing 300, e.g., except from the first supply hopper 230 and/or an ambient atmospheric port.
  • the airlock casing 300 may be mounted to the first and second supply hoppers 230, 240.
  • the airlock casing 300 may be mounted to the first supply hopper 230 at an outlet 231 of the first supply hopper 230, and the airlock casing 300 may be mounted to the second supply hopper 240 at an inlet 241 of the second supply hopper 240.
  • the superabsorbent material 202 from the first supply hopper 230 may enter the airlock casing 300 at the outlet 231 of the first supply hopper 230, and the superabsorbent material 202 from the airlock casing 300 may enter the second supply hopper 240 at the inlet 241 of the second supply hopper 240.
  • the motor 320 may be coupled to the rotor 310 such that the rotor 310 is rotatable within the airlock casing 300.
  • the rotor 310 may transfer the superabsorbent material 202 within the airlock casing 300 from the outlet 231 of the first supply hopper 230 to the inlet 241 of the second supply hopper 240.
  • the rotor 310 may be arranged for rotating about a substantial horizontal axis (FIG. 4), a substantially vertical axis (FIG. 3), or other orientations depending on the desired arrangement.
  • the rotor 310 may define a plurality of airlock chambers 252 (FIG. 3).
  • the chambers 252 may include two, three, four, or more chambers 252 depending upon the desired arrangement.
  • the rotor 310 may include a first chamber 312, a second chamber 314, a third chamber 316, and a fourth chamber 318.
  • Each of the airlock chambers 252 may sequentially align with the outlet 231 of the first supply hopper 230 and the inlet 241 of the second supply hopper 240 as the motor 320 rotates the rotor 310 within the airlock casing 300.
  • the airlock chambers 252 may receive the superabsorbent material 202 from the outlet 231 of the first supply hopper 230 and transfer the superabsorbent material 202 within the airlock casing 300 to the inlet 241 of the second supply hopper 240.
  • the airlock casing 300 may also include an evacuation port 302 and an ambient atmospheric port 304.
  • the evacuation port 302 may be in fluid communication with the pressure supply line 260.
  • the pressure supply line 260 may flow air into and/or out of the airlock casing 300 via the evacuation port 302.
  • each of the airlock chambers 252 may sequentially align with the evacuation port 302, and the pressure supply line 260 may flow air into and/or out of the aligned airlock chambers 252 via the evacuation port 302 as the rotor 310 rotates within the airlock casing 300.
  • the ambient atmospheric port 304 may be in fluid communication with ambient air around the airlock casing 300. Thus, ambient air may enter the airlock casing 300 via the ambient atmospheric port 304, e.g., to limit or prevent rapid pressure equilibration between the airlock chambers 252 and the interior 232 of the first supply hopper 230.
  • each of the airlock chambers 252 may sequentially align with the ambient atmospheric port 304, and ambient air may enter each of the airlock chambers 252 via the ambient atmospheric port 304 prior to aligning with the outlet 231 of the first supply hopper 230 as the rotor 310 rotates within the airlock casing 300.
  • each of the first, second, third, and fourth airlock chambers 312, 314, 316, 2318 may be contiguous with a respective one of the outlet 231 of the first supply hopper 230, the evacuation port 302, the inlet 241 of the second supply hopper 240, and the ambient atmospheric port 304 as the motor 320 rotates the rotor 310 within the airlock casing 300.
  • the superabsorbent material feeder assembly 220 may include an equilibration valve 254 (FIG. 3).
  • the equilibration valve 254 may be disposed on an equilibration line between the rotary airlock valve 250 (e.g., on the airlock casing 300 at or adjacent the ambient atmospheric port 304). Opening the equilibration valve 254 may advantageously equilibrate pressure differences between the airlock chambers 252 and the first supply hopper 230 at a controlled rate, e.g., prior to aligning the airlock chambers 252 with the outlet 231 of the first supply hopper 230.
  • the second supply hopper 240 is configured for receiving the superabsorbent material 202 from the first supply hopper 230 to the second supply hopper 240 via the rotary airlock valve 250.
  • the interior 242 of the second supply hopper 240 may be filled with the superabsorbent material 202 from the interior 232 of the first supply hopper 230 when the rotary airlock valve 250 is operating.
  • the second supply hopper 240 may be configured for feeding the superabsorbent material 202 into the foamed suspension of fibers 214.
  • a metering device 270 may be positioned to receive superabsorbent material 202 from the interior 242 of the second supply hopper 240.
  • the metering device 270 may be positioned at or proximate a bottom portion of the second supply hopper 240 such that the superabsorbent material 202 is gravity-fed from the interior 242 of the second supply hopper 240 to the metering device 270.
  • the metering device 270 may be configured for feeding the superabsorbent material 202 into the foamed suspension of fibers 214 at a selected rate.
  • the metering device 270 may supply the superabsorbent material 202 to a pump 280, such as an eductor, and the pump 280 may draw the superabsorbent material 202 into the foamed suspension of fibers 214 due to a motive fluid (e.g., the foamed suspension of fibers 214) generating a pressure reduction via the Venturi effect.
  • the metering device 270 may be any suitable device for feeding the superabsorbent material 202.
  • the metering device 270 may include one or more of a Christy feeder, a vibrating hopper, a screw feeder, etc. In the example embodiment shown in FIG.
  • the metering device 270 includes a hopper 272 that directs the superabsorbent material 202 to the pump 280, and the metering device 270 is disposed within a vacuum box 274 to block or limit introduction of ambient air into the foamed suspension of fibers 214 via the pump 280.
  • the pump 280 may also draw air into the foamed suspension of fibers 214.
  • the superabsorbent material feeder assembly 220 may include features for limiting the volume of air entering the foamed suspension of fibers 214.
  • the superabsorbent material feeder assembly 220 may advantageously add the superabsorbent material 202 to the foamed suspension of fibers 214 without negatively affecting the stability of the foamed suspension of fibers 214 by introducing excess air into the foamed suspension of fibers 214.
  • the pump 280 may draw air from the second supply hopper 240 into the foamed suspension of fibers 214 in addition to the superabsorbent material 202.
  • the rotary airlock valve 250 may also block airflow between the first supply hopper 230 and the second supply hopper 240.
  • the rotary airlock valve 250 may limit or prevent air from the first supply hopper 230 from flowing into the second supply hopper 240 as the pump 280 draws superabsorbent material 202 into the foamed suspension of fibers 214.
  • the pressure supply line 260 may draw air out of the rotary airlock valve 250 while the rotary airlock valve 250 is operating to transfer the superabsorbent material 202 to the second supply hopper 240, e.g., in order to limit the volume of air transferred into the second supply hopper 240 from the superabsorbent material 202 in the rotary airlock valve 250.
  • various components of the superabsorbent material feeder assembly 220 may cooperate to limit the volume of air entering the foamed suspension of fibers 214, e.g., via the pump 280, while the superabsorbent material feeder assembly 220 feeds the superabsorbent material 202 into the foamed suspension of fibers 214.
  • the metering device 270, the second supply hopper 240, and other components of superabsorbent material feeder assembly 220 may be sealed relative to ambient air in order to limit or prevent introduction of the ambient air into the foamed suspension of fibers 214 via the pump 280.
  • superabsorbent material feeder assembly 220 may be configured to allow a limited bleed of air or other gases into the superabsorbent material feeder assembly 220 in order to facilitate the feeding of the superabsorbent material 202 into the foamed suspension of fibers 214
  • the bleed of air or other gases is limited in order to avoid negatively affecting the stability of the foamed suspension of fibers 214.
  • system 200 may also include or be in operative communication with a processing device or a controller 290 that may be generally configured to facilitate operation of at least a portion of system 200.
  • control valve 236, rotary airlock valve 250, control valve 264, metering device 270, various sensors, and other components of system 200 may be in communication with controller 290.
  • the controller 290 may receive inputs from the sensors and may adjust operation of the components of system 200, such as the rotary airlock valve 250, based at least in part on the inputs from the sensors.
  • control valve 236, rotary airlock valve 250, control valve 264, metering device 270, the various sensors, and other components of system 200 may be in communication with controller 290 via, for example, one or more signal lines or shared communication busses. In this manner, Input/Output (“I/O”) signals may be routed between controller 290 and various operational components of system 200.
  • I/O Input/Output
  • processing device may generally refer to any suitable processing device, such as a general or special purpose microprocessor, a microcontroller, an integrated circuit, an application specific integrated circuit (ASIC), a digital signal processor (DSP), a field-programmable gate array (FPGA), a logic device, one or more central processing units (CPUs), a graphics processing units (GPUs), processing units performing other specialized calculations, semiconductor devices, etc
  • ASIC application specific integrated circuit
  • DSP digital signal processor
  • FPGA field-programmable gate array
  • CPUs central processing units
  • GPUs graphics processing units
  • processing units performing other specialized calculations, semiconductor devices, etc
  • these “controllers” are not necessarily restricted to a single element but may include any suitable number, type, and configuration of processing devices integrated in any suitable manner to facilitate appliance operation.
  • controller 290 may be constructed without using a microprocessor, e.g., using a combination of discrete analog and/or digital logic circuitry (such as switches, amplifiers, integrators, comparators, flip-flops, AND/OR gates, and the like) to perform control functionality instead of relying upon software.
  • Controller 290 may include, or be associated with, one or more memory elements or non- transitory computer-readable storage mediums, such as RAM, ROM, EEPROM, EPROM, flash memory devices, magnetic disks, or other suitable memory devices (including combinations thereof). These memory devices may be a separate component from the processor or may be included onboard within the processor.
  • these memory devices may store information and/or data accessible by the one or more processors, including instructions that may be executed by the one or more processors. It should be appreciated that the instructions may be software written in any suitable programming language or may be implemented in hardware. Additionally, or alternatively, the instructions may be executed logically and/or virtually using separate threads on one or more processors.
  • controller 290 may be operable to execute programming instructions or microcontrol code associated with an operating cycle of system 200.
  • the instructions may be software or any set of instructions that when executed by the processing device, cause the processing device to perform operations, such as running one or more software applications, adjusting the operating parameters of rotary airlock valve 250, etc.
  • controller 290 as disclosed herein is capable of and may be operable to perform any methods, method steps, or portions of methods as disclosed herein.
  • methods disclosed herein may be embodied in programming instructions stored in the memory and executed by controller 290.
  • the memory devices may also store data that may be retrieved, manipulated, created, or stored by the one or more processors or portions of controller 290.
  • the data may include, for instance, data to facilitate performance of methods described herein.
  • the data may be stored locally (e.g . , on controller 290) in one or more databases and/or may be split up so that the data is stored in multiple locations.
  • the one or more database(s) may be connected to controller 290 through any suitable network(s), such as through a high bandwidth local area network (LAN) or wide area network (WAN).
  • LAN local area network
  • WAN wide area network
  • controller 290 may further include a communication module or interface that may be used to communicate with one or more other component(s) of system 200, controller 290, or any other suitable device, e.g., via any suitable communication lines or network(s) and using any suitable communication protocol.
  • the communication interface may include any suitable components for interfacing with one or more network(s), including for example, transmitters, receivers, ports, controllers, antennas, or other suitable components.
  • the controller 290 may be configured for controlling operation of the control valve 236, the rotary airlock valve 250, the control valve 264, the metering device 270, and other components of system 200 based at least in part on inputs from various sensors, such as an airlock pressure sensor 292 and a second supply hopper pressure sensor 294.
  • the airlock pressure sensor 292 may be configured for measuring an air pressure within the rotary airlock valve 250 (e.g., at the evacuation port 302 in the airlock casing 300).
  • the airlock pressure sensor 292 may be any suitable pressure sensor for measuring the pressure within the rotary airlock valve 250.
  • the second supply hopper pressure sensor 294 may be configured for measuring an air pressure within the second supply hopper 240.
  • the second supply hopper pressure sensor 294 may be any suitable pressure sensor for measuring the pressure within the interior 242 of the second supply hopper 240.
  • the controller 290 may control components of system 200 in order to feed the superabsorbent material 202 into the foamed suspension of fibers 214.
  • the controller 290 may activate the metering device 270 such that the metering device 270 feeds the superabsorbent material 202 from the second supply hopper 240 to the pump 280, which draws the superabsorbent material 202 into the foamed suspension of fibers 214.
  • the controller 290 may operate various components of the superabsorbent material feeder assembly 220 to add superabsorbent material 202 to the second supply hopper 240 without negatively affecting the stability of the foamed suspension of fibers 214 by introducing excess air into the foamed suspension of fibers 214.
  • the controller 290 may open the control valve 236 such that superabsorbent material 202 from the supply tank 234 flows to the first supply hopper 230.
  • the controller 290 may close the control valve 236 in order to stop the flow of superabsorbent material 202 into the first supply hopper 230.
  • the controller 290 may also open the control valve 264 to remove air from the rotary airlock valve 250 via the pressure supply line 260.
  • air may also be removed from the superabsorbent material 202 in the rotary airlock valve 250 via the pressure supply line 260.
  • superabsorbent material 202 may be added to the second supply hopper 240 via an airlock approach, in which discrete volumes of superabsorbent material 202 are added to the rotary airlock valve 250.
  • the air in the rotary airlock valve 250 is evacuated by the pressure supply line 260, which is separate from the pump 280, e.g., until the pressure pressure in the rotary airlock valve 250 is about equal to the pressure of the second supply hopper 240.
  • the rotary airlock valve 250 may allow the superabsorbent material 202 to be continuously added to the second supply hopper 240.
  • FIG. 6 illustrates a method 400 for foam forming according to an example embodiment of the present subject matter.
  • method 400 may be used in or with system 200 (FIG. 3) to assist with feeding superabsorbent material into a flow of foam to a headbox.
  • the controller 290 of system 200 may be programmed or configured to implement method 400. While method 400 is described in greater detail below in the context of system 200, it will be understood that method 400 may be used in or within any suitable system or process in alternative example embodiments
  • superabsorbent material flows from a first supply hopper to a rotary airlock valve.
  • superabsorbent material 202 may flow from the first supply hopper 230 to the rotary airlock valve 250 at 410.
  • the controller 290 may activate the rotary airlock valve 250 such that the superabsorbent material 202 flows from the first supply hopper 230 to the rotary airlock valve 250.
  • the superabsorbent material 202 may be manually added to the first supply hopper 230.
  • method 400 may include measuring an air pressure within the rotary airlock valve at 420.
  • the airlock pressure sensor 292 may measure the air pressure within the rotary airlock valve 250 (e.g., at the evacuation port 302 in the airlock casing 300).
  • method 400 may further include adjusting the pressure for flowing air into and/or from the rotary airlock valve based on the measured air pressure in the rotary airlock valve.
  • the controller 290 may adjust a backpressure regulator on the pressure supply line 260 based at least in part on the measured air pressure within the rotary airlock valve 250 from the airlock pressure sensor 292.
  • the controller 290 may adjust a flow of motive fluid through a Venturi pump configured as the pressure source 262 based at least in part on the measured air pressure within the rotary airlock valve 250 from the airlock pressure sensor 292.
  • the pressure applied to the rotary airlock valve 250 at 420 may be controlled, e.g., to about match the pressure within the second supply hopper 240.
  • air may be added to the rotary airlock valve.
  • the pressure supply line 260 may supply air into the rotary airlock valve 250 at 420.
  • the superabsorbent material within the rotary airlock valve may be transferred to the second supply hopper.
  • the rotary airlock valve 250 may be operated at 430 such that the superabsorbent material 202 in the rotary airlock valve 250 flows into the interior 242 of the second supply hopper 240.
  • the superabsorbent material is metered into a flow of foam to a headbox.
  • the metering device 270 fed the superabsorbent material 202 from the second supply hopper 240 into the foamed suspension of fibers 214 at a selected rate at 440.
  • the controller 290 may activate the metering device 270.
  • Method 400 may also include drawing the superabsorbent material into the flow of foam to the headbox via a pump, such as an eductor.
  • the metering device 270 may supply the superabsorbent material 202 to the pump 280, and the pump 280 may draw the superabsorbent material 202 into the foamed suspension of fibers 214.
  • the pump may also draw air from the second supply hopper into the foam.
  • the pump 280 may draw air from the second supply hopper 240 into the foamed suspension of fibers 214 in addition to the superabsorbent material 202.
  • the rotary airlock valve 250 may also block airflow between the first supply hopper 230 and the second supply hopper 240.
  • the rotary airlock valve 250 may limit or prevent air from the first supply hopper 230 from flowing into the second supply hopper 240 as the pump 280 draws superabsorbent material 202 into the foamed suspension of fibers 214.
  • FIG. 6 depicts steps performed in a particular order for purposes of illustration and discussion Those of ordinary skill in the art, using the disclosures provided herein, will understand that the steps of any of the methods discussed herein may be adapted, rearranged, expanded, omitted, or modified in various ways without deviating from the scope of the present disclosure.
  • a foam forming system comprising: a headbox; a superabsorbent material feeder assembly positioned upstream of the headbox on a flow path for foam to the headbox, the superabsorbent material feeder assembly configured for adding superabsorbent material to the foam, the superabsorbent material feeder assembly comprising a first supply hopper, a second supply hopper spaced from the first supply hopper, a rotary airlock valve disposed between the first and second supply hoppers, the rotary airlock valve configured for transferring the superabsorbent material from the first supply hopper to the second supply hopper, and pressure supply line coupled to the rotary airlock valve and configured for flowing air into and/or from the rotary airlock valve.
  • Second example embodiment The foam forming system of the first example embodiment, wherein the first supply hopper is configured such that air within the first supply hopper is at ambient atmospheric pressure, and the second supply hopper is configured such that air within the second supply hopper is at a vacuum pressure relative to the ambient atmospheric pressure.
  • the superabsorbent material feeder assembly further comprises a pump positioned on the flow path for foam to the headbox, and the pump is configured for drawing the superabsorbent material into the foam.
  • Fourth example embodiment The foam forming system of any one of first through third example embodiments, wherein the pump is configured for drawing air from the second supply hopper into the foam, and the rotary airlock valve blocks airflow between the first and second supply hoppers.
  • the foam forming system of any one of the first through sixth example embodiments wherein the rotor defines a plurality of airlock chambers that each align with an outlet of the first supply hopper and an outlet of the second supply hopper as the motor rotates the rotor within the airlock casing.
  • the plurality of airlock chambers comprises no less than a first airlock chamber, a second airlock chamber, a third airlock chamber, and a fourth airlock chamber.
  • the airlock casing comprises an evacuation port and an ambient atmospheric port; the evacuation port in fluid communication with the pressure supply line; and each of the first, second, third, and fourth airlock chambers is contiguous with a respective one of the outlet of the first supply hopper, the evacuation port, the outlet of the second supply hopper, and the ambient atmospheric port as the motor rotates the rotor within the airlock casing.
  • Tenth example embodiment The foam forming system of any one of the first through nineth example embodiments, wherein the first supply hopper is disposed above the rotary airlock valve, and the second supply hopper is disposed below the rotary airlock valve.
  • Eleventh example embodiment The foam forming system of any one of the first through tenth example embodiments, further comprising a metering valve configured for regulating a flow of the superabsorbent material from the second supply hopper into the flow path for foam to the headbox.
  • a particulate material feeder for a foam forming system comprising: a first supply hopper; a second supply hopper spaced from the first supply hopper; a rotary airlock valve disposed between the first and second supply hoppers, the rotary airlock valve configured for transferring particulate material from the first supply hopper to the second supply hopper; and a pressure supply line coupled to the rotary airlock valve and configured for flowing air into and/or from the rotary airlock valve.
  • a method for feeding particulate material within a foam forming process comprising: flowing particulate material from a first supply hopper into a rotary airlock valve; drawing air out of the particulate material in the rotary airlock valve; transferring the particulate material within the rotary airlock valve to a second supply hopper; and metering the particulate material into a flow of foam to a headbox.
  • Fourteenth example embodiment The method of the thirteenth example embodiment, wherein air within the first supply hopper is at ambient atmospheric pressure, and air within the second supply hopper is at a vacuum pressure relative to the ambient atmospheric pressure.
  • Fifteenth example embodiment The method of either the thirteenth or the fourteenth example embodiments, wherein metering the particulate material comprises drawing the particulate material into the flow of foam via a pump.
  • Sixteenth example embodiment The method of any one of the thirteenth through fifteenth example embodiments, wherein the pump also draws air from the second supply hopper into the foam, and the rotary airlock valve blocks airflow between the first and second supply hoppers.
  • Eighteenth example embodiment The method of any one of the thirteenth through seventeenth example embodiments, wherein metering the particulate material comprises metering the particulate material into the flow of foam via a metering valve.

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Abstract

L'invention concerne un procédé et un système pour ajouter un matériau particulaire à un flux de mousse vers une bâche d'alimentation. Un dispositif d'alimentation en matériau particulaire comprend une première trémie d'alimentation pouvant être remplie d'un matériau particulaire, une seconde trémie d'alimentation et une vanne rotative à sas située entre les première et seconde trémies d'alimentation. La vanne rotative à sas est conçue pour transférer le matériau superabsorbant de la première trémie d'alimentation à la seconde trémie d'alimentation. Une conduite d'alimentation en pression est couplée à la vanne rotative à sas et conçue pour faire circuler de l'air dans et/ou depuis la vanne rotative à sas.
PCT/US2024/056706 2023-11-21 2024-11-20 Dispositif d'alimentation en matériau particulaire pour formation de mousse Pending WO2025111356A1 (fr)

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US63/601,386 2023-11-21

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US20230212800A1 (en) * 2020-05-29 2023-07-06 Kimberly-Clark Worldwide, Inc. Apparatus for forming a substrate

Citations (3)

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Publication number Priority date Publication date Assignee Title
US6033199A (en) * 1993-10-19 2000-03-07 The Procter & Gamble Company Apparatus for forming an intermittent stream of particles for application to a fibrous web
US20030192659A1 (en) * 2001-10-30 2003-10-16 Yancey Michael J. Dried singulated crosslinked cellulose pulp fibers
US20190232606A1 (en) * 2018-01-30 2019-08-01 Seiko Epson Corporation Sheet manufacturing apparatus and sheet manufacturing method

Patent Citations (3)

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Publication number Priority date Publication date Assignee Title
US6033199A (en) * 1993-10-19 2000-03-07 The Procter & Gamble Company Apparatus for forming an intermittent stream of particles for application to a fibrous web
US20030192659A1 (en) * 2001-10-30 2003-10-16 Yancey Michael J. Dried singulated crosslinked cellulose pulp fibers
US20190232606A1 (en) * 2018-01-30 2019-08-01 Seiko Epson Corporation Sheet manufacturing apparatus and sheet manufacturing method

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20230212800A1 (en) * 2020-05-29 2023-07-06 Kimberly-Clark Worldwide, Inc. Apparatus for forming a substrate
US20240279856A1 (en) * 2020-05-29 2024-08-22 Kimberly-Clark Worldwide, Inc. Apparatus for forming a substrate

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