BRPI0609219A2 - Method and apparatus for making a sheet having an applied pattern of filler material - Google Patents

Abstract

METHOD AND APPARATUS FOR MANUFACTURING A SHEET THAT HAS AN APPLIED STANDARD OF ADDITIONAL MATERIAL. The present invention relates to a high speed apparatus (2) for applying a cigarette paper material during manufacture utilizing at least two independently operable movable hole devices (10, 10 '), each positioned to deposit horizontal strips of material on a sheet of paper (22) at the dry end of a Fourdrinier screen (6). The resulting sheet may be cut into multiple sheets, each sheet having a width corresponding to the effective width of a movable orifice device. The apparatus can simultaneously produce both banded and stripped paper for wrapping tobacco during cigarette manufacture.

Description

Report of the Invention Patent for "METHOD AND APPARATUS FOR APPLYING MATERIAL ON A WIDE HIGH SPEED NETWORK"

BACKGROUND OF THE INVENTION

The present invention relates to a method and apparatus for applying a predetermined pattern of filler material to a base network, preferably in the form of strips, and more specifically to a high speed method and apparatus for producing cigarette papers which It has regions with bands of additional material.

SUMMARY

A method and apparatus are described for the high speed production of a sheet having regions with strips of filler material, more specifically a cigarette paper having strips of additional cellulosic material added thereto. The method includes the steps of: preparing a first slurry of fibrous material and a liquid and providing such slurry to a movable web of a papermaking machine, and draining the liquid from the first slurry to form an advancing fibrous sheet. at a first nominal linear speed. A second slurry of filler material is prepared and supplied in at least one of a plurality of dispensing devices, each having a movable belt with one or more holes. The belt moves so that its velocity component in the direction of movement of the sheet is substantially the same as the nominal linear speed of the sheet. The second slurry is deposited as transverse strips on the sheet through the hole (s), with the length of each strip corresponding to the width of the associated dispensing device projected over the transverse dimension of the sheet. After drying, the sheet may be split or split into two or more narrow sheets for subsequent use. The dry sheet transverse strips can be optically inspected to evaluate the width and spacing characteristics so that the operation of the dispensing devices can be dynamically adjusted to provide uniform width and spacing of the transverse strips over the sheet. includes at least two applicators for applying a filler pattern to the sheet produced by a papermaking machine. Each applicator is positioned at an angle to the direction of movement of the sheet so that each applicator covers a corresponding portion of the sheet width. Each applicator additionally includes a continuous continuous belt to regulate communication between a reservoir for the filler material and the top of the sheet. The applicator continuous belt is operable so that the component of its velocity parallel to the sheet surface in the direction of sheet movement corresponds to the linear velocity of sheet movement and each hole deposits a transverse strip over the sheet. The apparatus further includes a means for selectively operating each of the applicators so that the strip pattern can be applied to the entire width of the sheet or to a portion of the width.

BRIEF DESCRIPTION OF DRAWINGS

Figure 1 is a schematic view of a papermaking machine constructed according to a preferred embodiment;

Figure 2 is a perspective view of a paper constructed according to the methodologies and apparatus of the preferred embodiment;

Figure 3 is a perspective view of a cigarette constructed with the paper of Figure 2;

Figure 4 is a side view of the movable orifice applicator constructed according to a preferred embodiment;

Figure 5 is a broken perspective view of the applicator of Figure 4;

Figure 6 is a top plan view of the applicator tracking control system as viewed in the direction of the double-ended arrow B-B in Figure 5;

Figure 7 is a cross-sectional view of the camera housing taken on line VII-VII in Figure 4;

Figure 8 is a detail perspective view of the applicator endless belt shown in Figure 4; Figure 9 is a partial sectional view, in detail, of an alternative embodiment of the applicator chamber housing of Figure 4.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Existing paper machine installations do not have identical proportions, sizes, operating speeds, and the like. In order to use such banded cigarette paper making machines, the band application apparatus must fit within the existing physical arrangement to avoid significant additional capital investments. Moreover, there are occasions where papermaking machines are needed to produce not only banner paper but also banner paper. When a mobile orifice device applies the filler material to a mesh, the applicator travel angle becomes small for larger machines, which requires the applicator to operate at speeds that may be multiple of the nominal screen speed of the machine. paper making machine. When the paper machine operates at speeds of 7.5 m / s (1500 ft / min) and above, the need for speed for the applicator may cause non-uniformity of band and non-uniformity of band spacing. Moreover, current paper inspection techniques for banner paper commonly occur after the papermaking operation has been completed.

Referring to Figure 1, a preferred embodiment comprises a cigarette papermaking machine 2 which is operable to manufacture a paper with strips 3 (see figure 2) having uniformly spaced strips 5 apart. Such banded paper 3 may be used in cigarette manufacture (see Figure 3) where the lanes 5 comprise regions designated for self-extinguishing the cigarette. Papermaking machine 2 (FIG. 1) preferably includes a head box 4 operatively located at one end of a Fourdrinier screen 6, a feedstock slurry is prepared and supplied to a slurry of feedstock. feedstock such as a race tank 8 in communication with headstock 4. Machine 2 also includes at least two dispensing devices, such as movable hole applicators 10, 10 ', in operative communication with a source of added slurry prepared such as a daily tank 12.

The head box 4 may typically be used in the papermaking industry to deposit the cellulosic pulp onto the Fourdrinier 6 screen. In the usual context, the head box 4 communicates with the race tank 8 via a plurality of Preferably, the feedstock of the race tank 8 constitutes a refined cellulosic pulp such as a flax or wood pulp as is common practice in the cigarette paper industry. Pulp is usually a mixture of water, fiber, and additives that include fillers such as chalk.

Fourdrinier's screen 6 moves in a longitudinal direction, has a width transverse to that longitudinal direction, and operates at a generally constant nominal linear speed. The first slurry from race tank 8 is supplied through the head box 4 to the movable Fourdrinier 6 screen.

Fourdrinier screen 6 carries the pulp deposited from headstock 4 along a path in the general direction of arrow 16 in figure 1. As screen 6 advances, liquid water drains from the pulp through screen 6 under influence of gravity to form a fibrous sheet. Vacuum boxes may be provided at some locations along the Fourdrinier 6 screen to aid in the removal of water from the pulp, as is the practice established in the cigarette papermaking technique. At some point along the Fourdrinier 6 screen, sufficient water has drained and / or been removed from the base sheet pulp to establish what is commonly referred to as a dry line 20. In dry line 20, the texture of the slurry transforms from a watery, shiny appearance on a surface appearance that most closely resembles that of the finished base sheet (but in a wet condition). Approximately at dry line 20, the moisture content of the pulp material is approximately 85 to 90%, which may vary depending on operating conditions and the like. The surface of the sheet 22 is generally flat and is supported by the display screen 6.

Downstream of the dry line 20, the base sheet 22 separates from the Fourdrinier screen 6 in a suction press 24. From there, the Fourdrinier screen 6 continues in the loop back of its endless path. In addition to the suction press 24, the base sheet 22 continues through the remainder of the papermaking system which includes drying section 27 which further dries and presses the base sheet 22 and conditions it on the surface to a paper content. desired final moisture and texture. Such a drying apparatus is well known in the papermaking art and may include drying felts 26 and the like.

Just at the end of the papermaking machine, a suitable conventional winding machine 28, 29 is provided for collecting paper on reels for further processing and / or use. Such a winding apparatus 28, 29 is well known in the papermaking technique.

During the papermaking process, it is sometimes desirable to apply a pattern to the sheet before the sheet is dried so that the pattern becomes part of the paper sheet itself rather than a surface treatment such as, for example. print. A preferred pattern comprises a plurality of transverse bands evenly spaced over the base sheet. The strips may, for example, comprise a filler material useful in affecting the combustibility of the resulting paper sheet. The materials used to perform self-extinguishing cigarettes are candidates for such standards.

The papermaking devices currently used to make cigarette paper differ in many ways. Papermaking machines vary in terms of the Fourdrinier 6 web width, the Fourdrinier 6 web speed, the longitudinal spacing between the head box 4 and the suction press 24, and the longitudinal line spacing. dry 20 and suction press 24 to give only a few. For example, papermakers may have screen widths ranging from less than 3 meters to more than 5 meters. Similarly, machines can have the Fourdrinier display operating at a linear speed of less than 120 m / s (400 ft / s) to greater than 450 m / s (1500 ft / s). For the purposes of this description, widths greater than 3 meters are considered wide and linear speeds exceeding 150 m / s (500 ft / miss) are considered high speeds.

The methods and apparatus for applying filler patterns to a mesh at the wet end of a papermaking machine are preferably adaptable to accommodate the idiosyncrasies of existing machine installations. To apply a filler to large, high-speed papermaking machines, a plurality of dispensing devices are used that apply a zone pattern across a base sheet. Each dispensing device may incorporate the characteristics of a movable filler applicator that is described in commonly assigned US Patent No. 5,997,691, issued December 7, 1999 to Gautam et al. hereby incorporated herein by reference to it.

Referring to Figure 1, two or more applicators, such as movable hole applicators 10, 10 ', are provided between dry line 20 and suction press 24 to apply separate patterns of filler to sheet 22. Each applicator It is operable to apply the pattern to a corresponding portion of the width of the sheet. Applicators 10, 10 'may be parallel to each other and offset as shown. The applicators 10, 10 'may also be offset relative to each other longitudinally along the Fourdrinier web 6 as necessary to accommodate the obstructions in place for the papermaking machine. Applicators 10, 10 'may be positioned at the same or different angles to the longitudinal direction of the machine if desired.

As the required length of such a movable hole applicator 10, 10 'is a function of (i) the width of the sheet, (ii) the longitudinal speed of the papermaking machine, and (iii) the angle between the applicator and the direction. In a longitudinal direction in which the sheet advances along the Fourdriier mesh, the use of multiple applicators reduces the physical length required along the Fourdrinier mesh by reciprocal number of applicators used. Thus, multiple applicators may be used to prevent limitations that might otherwise be imposed by the above noted physical characteristics of papermaking machines.

An applicator travel angle can be defined as the acute angle between the longitudinal direction of movement of the Fourdrinier web and the inclined direction of movement of the movable orifice device. Alternatively the applicator travel angle can be defined as the complement of the acute angle between the longitudinal direction of the machine and the plane within which the edge of the movable orifice belt operates. For low applicator travel angle values, the linear velocity of the movable orifice belt becomes a multiple of the nominal linear velocity of the Fourdrinier screen. For example, at an applicator travel angle of 30 °, the belt speed is twice the linear screen speed; For an applicator travel angle of approximately 19.5 °, the belt speed is three times the nominal linear screen speed; and for an applicator angle of approximately 14.5 °, the belt speed is four times the nominal linear screen speed. High-speed papermaking facilities operate at nominal linear speeds from 420 m / s to 450 m / s (1400 ft / s to 1500 ft / s). At the range speeds required for the low travel angles, the fluid mechanical characteristics of the filler material and the physical limitations of applicator operation may combine to cause splashing and / or insufficient uniformity in the deposited pattern. Multiple applicators 10, 10 "may be employed which allow the applicator travel angle for each applicator to be increased thereby reducing belt speed to acceptable levels so that splashing is avoided and the deposited pattern is uniform.

Moreover, where applicators 10, 10 'are selectively operable, that is, they can be used simultaneously, separately, or turned off, and the papermaking operation can produce a banded pattern across the sheet, a pattern with strips over just a portion of the sheet, or a paper without strips across the sheet. For example, where both banner paper and banner paper are required simultaneously for cigarette making, papermaking machine 2 may be operated with one of the applicators 10, 10 'operating and the other applicator on hold. Thus, half of the resulting cigarette wrapping product may be banded and the other half bandless.

The details of movable orifice applicator 10 will now be described. It will be understood by those skilled in the art that the details of each additional movable hole applicator 10 'are substantially the same, with the possible exception of length. Referring now to both figures 1 and 4, a daily tank addition slurry 12 is provided for the movable orifice applicator 10. Preferably, the movable orifice applicator 10 comprises an elongated chamber housing 30 for establishing a reservoir reservoir. adding slurry in an oblique relationship through Fourdrinier 6 fabric path 16. The reservoir receives the adding slurry from the daily tank 12. The movable orifice applicator 10 also includes a continuous perforated steel belt 32 , whose travel is directed around a drive wheel 34 at the downstream end of the applicator, a guide wheel 36 at the apex of the movable hole applicator 10, and a follower wheel 38 at the upstream end of the camera housing 30, i.e. opposite to the drive wheel 34. Upstream and downstream are seen to be relative to the movement of the Fourdrinier 6 and sheet 22 fabric.

Endless belt 32 moves through a lower portion of chamber 30 and as it leaves chamber 30, belt moves through a cleaning box 42. Then belt 30 32 moves towards the drive wheel 34 and continues throughout the remainder of its circumference.

The belt 32 (see figure 8) preferably has a plurality of evenly spaced holes along its length. As each perforation or hole 44 (Figure 8) of the belt 32 passes through the lower portion of the chamber housing 30, the hole 44 communicates with the addition slurry reservoir established within the chamber housing 30. At such time, a flow 40 (FIG. 4) of addition slurry discharges from hole 44 as hole 44 runs through the length of the chamber housing 30. Discharge flow 40 pushes over the base sheet 22 passing under movable hole applicator 10 to provide or create a transverse band of additional (addition) material on the base sheet 22. The operating speed of belt 32 varies from one arrangement to another, but as an example, belt 32 is driven at approximately 5, 55 meters per second (1111 feet per minute) when the Fourdrinier display moves at approximately 2.5 meters per second (500 feet per minute) and camera housing 30 is oriented with a 27 ° displacement angle relative to the direction of the screen. The spacing of the holes 44 along the belt 32 and the operating speed of the belt 32 are selected such that a plurality of streams 40, 40 'simultaneously emanate from under the chamber housing 30 during operation of the movable hole applicator. Due to the oblique orientation of the movable hole applicator with respect to the base sheet path 16 and the relative velocities of the Fourdrinier screen 6 and the endless belt 32, each stream of addition material 40 will create a strip of addition material over base sheet 22, wherein the strip has a length corresponding to the operating length of the movable orifice applicator 10. The operating length is the length in the transverse direction of the web 6 through which orifice 44 may deposit the filler material. At the speeds and angle above, the movable orifice applicator 10 will repeatedly generate or deposit the transverse bands of filler material that are oriented normal to a longitudinal edge of the base sheet 22 and evenly spaced from each other along the sheet 22. In combination, the multiple applicators 10, 10 'are operable to deposit the aligned or offset bands substantially across the entire width of the Fourdrinier 6 screen. If desired, the angle and / or relative velocities may be altered to produce bands which are obliquely inclined to the edge of the base sheet 22.

After the belt 32 exits the camera housing 30, the portions of the belt 32 adjacent each hole 44 are cleaned of added slurry in the cleaning station 42. The belt 32 and each associated hole then proceeds along the belt circuit. without end 32 to reenter chamber 30 to repeat an application of a strip over base sheet 22.

Referring specifically to Figure 1, the mobile orifice applicator 10 is preferably obliquely situated across the Fourdri-nier mesh 6 at a location downstream of the dry line 20 where the condition of the base sheet 22 is such that it can accept The addition material without the addition material dispersing very finely through the entire local mass of the base sheet slurry. The applicator 10 is evenly spaced above the sheet 22 so that the flow 40, 40 'of measuring material emanating from the holes 44 falls through the same distance between the applicator 10 and the flat upper surface of the sheet 22. At that location From the applicator 10, the base sheet 22 retains a sufficient moisture content (approximately 85 to 90%) that the slurry is allowed to penetrate (or establish a hydrogen bond) to a degree sufficient to bond and integrate the filler material. on the base sheet 22.

Preferably, a vacuum box 19 located under the chamber housing 30 of the movable orifice applicator 10 extends coextensively with the applicator providing a local support for the Fourdrinier screen 6 as well as facilitating the attachment / integration of the slurry. with base sheet 22. Vacuum box 19 is constructed in accordance with designs commonly used in the papermaking industry (such as those of vacuum boxes 18). Vacuum housing 19 operates at a relatively modest vacuum level, preferably in approximately 1524 millimeters (60 inches) of water or less. Optionally, additional vacuum boxes 18 'may be located downstream of the movable orifice applicator 10 to remove the additional quantum of water that the slurry may contribute. Much of the removal of water from the filler material has been found to occur in the suction press 24 where a vacuum is applied from approximately 560 mm to 640 mm (22 to 25 in.) Of mercury.

The movable hole applicator 10 is supported in its position on the Fourdrinier fabric 6 in a suitable conventional manner so that the movable hole applicator 10 can be lowered consistently to a desired location above the Fourdrinier fabric 6, preferably preferably. that the bottom of the chamber housing 30 releases the base sheet 22 onto the Fourdrinier 6 screen from approximately 25.4 to 50.8 mm (one to two inches), preferably less than 40 mm (1.5 in.). .

Preferably, the chamber housing 30 has a selected length such that the chamber housing 30 covers a portion of the width of the sheet 22, measured transverse to the papermaking machine. The multiple applicators 10, 10 'are arranged so that the adjacent ends of their respective chamber housings 30 are above a common longitudinal line on the sheet 22 so that the transverse bands of adjacent applicators 10, 10' are not overlap. The applicators 10, 10 'are also arranged so that the outermost edge of the applicator adjacent the corresponding sheet edge extends beyond the edge of the base sheet 22. When there are three or more applicators, the edges of the outermost applicators have an overlap relationship with the edges of the sheet. The ends of the inner applicators may overlap or not overlap in the transverse direction through the base sheet. The overextension of chamber housings 30 at the sheet edges ensures that any fluid discontinuities that exist or appear at the end portions of chamber housings 30 do not affect discharge streams 40 as streams 40 deposit the filler through In such an arrangement, any errant jet emanating from the ends of the chamber housing 30 occurs over the edge portions of the base sheet 22 which are trimmed at or about the suction press 24. Likewise, the overlap Whether or not the strips overlap through the base sheet may be trimmed to provide continuous coils of evenly stripe paper.

The vertical support structure for the movable hole applicators 10, 10 'may be hinged over one another to adjust the applicator travel angle for the applicators 10, 10' relative to the Fourdrinier 6 screen. Preferred practice involves securing the vertical support structure and only adjusting the speed of the endless belt 32 in response to changes in the operating conditions of the papermaking machine 2.

Chamber housing 30 receives tanker slurry 12 at spaced locations along chamber housing 30. Chamber housing reservoir 30 may also include a plurality of linearly disposed compartments through which the endless belt 32 passes through . Uniform pressure is preferably maintained along the length of chamber 30 by the interaction of a flow distribution system 60, a pressure monitoring system 62 and a programmable logic controller 64 such that the pumping action of belt 32 and other flow disturbances along the length of chamber 30 are locally and continuously compensated to achieve the desired pressure uniformity across the entire length of chamber 30. A main circulation pump 15 provides the daily tank addition slurry. 12 for flow distribution system 60.

Details of how the controller initiates and maintains uniform pressure throughout chamber 30 is known, see, for example, commonly assigned U.S. Patent No. 5,997,691.

A selectable speed motor drives the drive wheel.

34 and is operatively connected therewith by a suitable conventional drive belt. Preferably, the motor is supported by the movable orifice applicator structure 10, and both the motor and drive belt are contained within a housing to trap any foreign material (such as pieces of paste) that may find their way. and are otherwise thrown from the drive system to the drive wheel 34. The drive wheel 34 is advantageously positioned at the downstream end of the chamber housing 30 along the path of belt 32 so that belt 32 is pulled through A significant degree of directional stability is achieved by the tight fitting between the belt 32 and the elongated camera housing 30 across the entire length of the housing 30. However, precise tracking control for the belt 32 through around its travel circuit is effected by placing an infrared proximity sensor 54 in a location adjacent to the guide wheel 36. Infrared proximity proximity device 54 comprises a transmitter 56 and a sensor 58 which are mutually aligned with respect to one of the edges of the belt 32 so that if the belt floats laterally from its intended course, a sensor signal is affected by an increase or relative decrease in edge interference with the emitter beam. A controller 59 communicates with sensor 58, interprets changes in sensor 58 signal, and adjusts the guide wheel offset 36 about a vertical geometry axis to return belt edge 32 to its appropriate, predetermined position. relative to the beam of the emitter 56.

Referring now also to FIG. 6, the guide wheel 36 rotates about a horizontally disposed axis 36a, which itself is pivoted about a vertical geometry axis in a pivot connection 57 by the controlled actuation of a pneumatic actuator 61. The actuator 61 is operably connected to a free end portion 36b of axis 36a and responds to signals received from controller 59. Preferably, both pivot connection 57 and actuator 61 are fixed relative to the overall structure of applicator 10 during operation. from applicator 10; and a connection 54a is provided between sensor 54 and free end 36b of shaft 36a such that sensor 54 rotates as the offset of guide wheel 36 is adjusted. Connection 54a ensures that sensor 54 remains near the edge of belt 32 as guide wheel 36 is adjusted.

Preferably, actuator 61 and hinged connection 57 are affixed to a plate 39a which is vertically displaceable along fixed vertical guides 39b and 39c. Preferably, a vertical, releasable tensioning is applied to the plate 39a in order to force the guide wheel 36 into its operative position and to provide a tension on the endless belt 32.

Along the return path of the endless belt 32, the drive wheel 34 over the guide wheel 36 and back to the guide wheel 38, the belt 32 is contained by a plurality of housings, including the outer housings 68 68 'and a central housing 70 which also contains the infrared proximity sensor 54 and tracking system controller 59. The housing 68, 68' and housing 70 prevent the wandering of slurry onto the base sheet. 22 as the belt 32 passes through the return portion of its circuit.

Referring specifically to Figure 4, the housings 70 and various other applicator components 10 (such as wheels 34, 36 and 38; the chamber housing 30; the cleaning housing 42; and the motor 52) are supported by and / or a flat frame member 72. The flat frame member 72 itself is secured at retention points 73, 73 'to a transverse member (a T-beam, box beam or the like), whose transverse member is supported by the support frame. vertical. In an alternative, a beam member I or a box beam member may be used as a surrogate for frame member 72, with chamber housing 30 and other devices being supported from the beam member.

Referring to Figure 5, in any support arrangement, the camera housing 30 is preferably suspended from the support member with two or more spaced adjustable risers 77a, 77b allowing vertical and lateral adjustment (along arrows yex in Figure 5 respectively) of each end of the chamber housing 30 so that the chamber housing 30 can be precisely leveled and precisely inclined with respect to the Fourdrinier fabric and so that the chamber housing 30 can be precisely aligned with the belt 32 to minimize scrubbing.

Referring now to Figure 7, the camera housing 30 includes in its

bottom portion 76 is a slotted base plate 78 as well as a first and second wear strips 79 and 80 which cooperate with base plate 78 to define a pair of opposed, elongated slots 81 and 82 which slide the edge portions Preferably, elongated slits 81 and 82 are formed along a central lower portion of the base plate 78, but alternatively, could be formed at least partially or fully on the wear strips 79 and 80.

The central slot 84 in the base plate 78 terminates within the confines of the chamber housing 30 adjacent the end portions 50, 50 'of the chamber housing 30. Preferably, each end of the central slot 84 is cut out to prevent buildup. of slurry solids at these locations. The width of the central slot 84 is selected to minimize fluid exposure within the chamber housing 30 to the pumping action of the belt 32. In the preferred embodiment, the slot is approximately 10 mm (3/8 in.) Wide, while the diameter of the holes 44 in the endless belt 32 is preferably approximately 2.4 mm (3/32 in.).

Each wear strip 79, 80 extends along a corresponding opposite side of the lower portion 76 of the slurry box 30, co-extensively with the base plate 78. An elongate shim 86 and a plurality of spaced fasteners 88 ( (preferably screws) attach the wear strips 79, 80 to the adjacent, overlapping portion of the base plate 78. However, the holes 44 may have any desired configuration such as symmetrical or asymmetrical non-circular apertures.

Tolerances between the respective edge portions of the belt 32 and the slots 81, 82 should be minimized to seal the lower portion 76 of the camera housing 30. However, the fit between the belt 32 and the slots 81, 82 should not be so tight as to provide for the grip of the endless belt 32 within the slots 81, 82. In the preferred embodiment, these compensating considerations are met when the slots 81, 82 are configured to have a total tolerance of 1.6. mm (1/16 in.) full tolerance in one direction of width across non-end belt 32. In normal belt direction the belt preferably has a thickness of 0.508 mm (0.020 in) while slots 81, 82 are 0.58 mm (0.023 in.) deep. These ratios achieve the desired balance of proper sealing and the need for easy passage of the belt 32 through the lower portion 76 of the chamber housing 30.

Preferably, the wear strips 79, 80 are constructed of ultra high molecular weight polypropylene or Dalron.

Included within the confines of the chamber housing 30 are the chamfered inserts 89, 90 which extend along and fill the defined corners between the base plate 78 and each of the vertical walls 91, 92 of the housing housing 30. Preferably the inserts have a 45 degree inclination of the vertical walls 91, 92 towards the central slit 84 of the base plate 78. This arrangement prevents fluid stagnation within the confines of the chamber housing 30, which otherwise would tend to accumulate the solid content of the slurry and possibly clog the chamber housing 30 and the holes 44 of the endless belt 32.

Near lower portion 76 of chamber housing 30, a plurality of spaced pressure ports 94 communicate pressure monitoring system 62 with the interior of slurry box 30.

Along the upper portion of the chamber housing 30, a plurality of spaced feed ports 96 are located along the vertical wall 91. The feed ports 96 communicate flow distribution system 60 with the interior of the slurry box 30 Preferably, the feed ports 96 are located near the lid plate 31 of the chamber housing 30. Flow distribution system 60 has been noted with reference to Figure 1.

The feed ports 96 are vertically spaced by a distance h above the location where the endless belt 32 runs through the lower portion 76 of the camera housing 30. The feed ports 96 feed the slurry into the camera housing 30 in a substantially direction horizontal. The vertical placement and horizontal orientation of the ports 96 dampen the vertical velocity components in the fluidone or around the region of the endless belt 32 in the lower portion 76 of the chamber housing 30. The arrangement also decouples the discharge streams 40 through the holes. 44 of the input streams at the power ports 96.

The height h in the preferred embodiment is approximately 203.2 mm (8 in.) Or more; however, the vertical distance h between the feed ports 96 and the endless belt 32 may be as small as 152.4 mm (6 in.). With greater distances to h, there are fewer disturbances and interactions between fluid adjacent to the endless belt 32 and fluid conditions at the feed ports 96.

In the preferred embodiment, twelve feeder ports 96 are used, but the applicator is functional with as few as six input power ports 96. Although not preferred, the applicator is expected to operate with as few as four input power ports 96. The number of feed ports 96 depends on the portion of the sheet width that the specific applicator should cover. Preferred spacing between feed ports 96 is approximately 304.8 mm (twelve in.) And preferably no greater than approximately 0.6 m (twenty four inches), although it is possible to operate with even greater separation. .

Referring now to Figure 8, each hole 44 along the endless belt 32 includes a chamfered portion 45 adjacent the side of the endless belt 32 facing into the chamber housing 30. With such an arrangement, the solids content of the slurry It is not permitted to accumulate in or around holes 44 during applicator operation 1.0. More specifically, the slurry fiber is not allowed to accumulate around the hole and deflect the slurry jets being discharged. Consequently, the beveled portions 45 of the holes 44 promote consistent delivery of applicator fluid paste 10 and reduce defects and maintenance.

Referring now to Figure 9, in an alternative embodiment of the camera housing 30 ', the vertical walls 91', 92 ', together with the base plate 78' and the inclined bevel elements 89 ', 90' cooperate with a retractable armature 100, which supports an elongated wear strip 102 at its operative end portion. The elongated wear strip 102 extends the length of the chamber housing 30 'and is supported at spaced locations along each side of the chamber 30' by a plurality of retractable reinforcements 100 and 101. In this embodiment, the wear strips 79 'and 80' are mounted on and retractable with the armatures 100 and 101 respectively. In Figure 9, the armatures 100 along one side of the chamber housing 30 'are shown in a recessed position, while the armatures 101 along the opposite side of the chamber housing 30' are shown in a coupled position, where the respective wear strip 90 'is tensioned against the base plate 78'. In actual operation, the armatures 100 and 101 are hinged between the recessed and coupled positions simultaneously.

Each retractable armature 100, 101 is pivotably mounted on one or a pair of vertical flanges 106, which preferably provides support for an actuator mechanism 107 for moving the retractable armature 100, 101 from a operable coupling position where the wear strips 89 ', 90' are forced against the base plate 78 'to an indented position where the wear strips 89', 90 'are spaced from the base plate 78'.

The actuator mechanism 107 is preferably an air cylinder 108 which is operatively connected to the pivot arms 109, 110 of the armatures 100 and 101, respectively. Other mechanical devices could be selected to articulate the retractable armor 100 and 101, as would readily be apparent to one skilled in the art when reading this description.

An elastomeric seal 104 is provided between the lower portions of the chamber housing walls 91 ', 92' and the base plate 78 'to create a fluid tight seal around the entire periphery of the base plate 78'.

In operation, all reinforcements 100, 101 along both sides of the chamber housing 30 'are hinged simultaneously so that the wear strips 79', 80 'are moved as units to and from their operative and coupled positions. Retractable armatures 100, 101 facilitate quick and fast maintenance, repair and / or replacement of the 32 'endless belt, wear strips 79', 80 'and baseplate 78'.

As discussed above, after sheet 22 leaves suction press 24 (see Figure 1), the sheet advances through drying section 27 where additional moisture is removed and the cellulosic fiber sheet is dried to the moisture content level. wanted. As the sheet 22 leaves drying section 27, it passes through an optical inspection means 120 which examines the transverse bands of filler material and assesses bandwidth uniformity and spacing uniformity between adjacent bands or lines. To perform this optical inspection, the optical inspection system may include a plurality of suitable conventional cameras distributed in a linear arrangement above the sheet 22 and directed downwardly on the upper surface of the sheet within a housing 122. The cameras may be evenly spaced apart. others so that the position of the chamber is indicative of the lateral location on the sheet, i.e. a longitudinal zone of the sheet. In addition, the field of view for adjacent cameras may overlap slightly to ensure that the entire width of the sheet is subject to optical inspection. As an example, 16 cameras may be distributed in the array.

Optical inspection system 120 communicates its inspection signals via conventional wiring 124 suitable for applicator programmable controllers 64, 64 '. The longitudinal zones of the sheet monitored by the cameras of the optical inspection system 120 correspond to regions of the applicators 10, 10 'fed by the feed ports 96. Thus, if a lack of line width uniformity is detected in a portion of a line, programmable controllers use the feedback signal from inspection system 120 to appropriately adjust the supply material supplied to feed port 96 which corresponds to the longitudinal zone of the sheet where lack of bandwidth uniformity has been detected. This adjustment in feed port 96 occurs dynamically, that is, while paper is being produced thereby preventing the production of large quantities of defective paper that must be discarded or reprocessed. In addition, dynamic return adjustment and control can avoid the need for post-paper inspection.

If a lack of band spacing uniformity is detected by the optical inspection system 120, then the feedback signals are employed to properly adjust the linear speed of the movable orifice belt 32 of the appropriate applicator 10, 10 '. In this way, the band spacing of the transverse bands on the sheet can be dynamically adjusted to remain within design tolerances for band to band spacing. Again, the dynamic return adjustment and control for the strip spacing provided by the optical inspection system can be used to avoid post fabrication inspection of the fabricated paper.

After passing through the optical inspection system 120, the sheet enters a divider 125 to divide the sheet 22 into two or more longitudinal portions 130, 132. The divider 125 may, for example, include an appropriate number of cutting discs 126 laterally positioned over the sheet 22 to cut the sheet into the desired longitudinal portions 130, 132. Cutting discs 126 may couple a stop roll 128 so that disc 126 and roll 128 cooperate to cut the sheet in position of disc 126 as the sheet passes between disc 126 and stop 128.

Although a single cutting disc 126 is shown, this arrangement would be suitable for an installation using two movable hole applicators 10, 10 '. Where, for example, three applicators are used, it may be desired to divide the sheet 22 into three longitudinal portions. In this case, two cutting discs 126 would be used with the same stop roll 128, the discs being spaced apart to provide desired width portions of the sheet.

Downstream of divider 125, the individual sheet portions 130, 132 are collected by the corresponding winding apparatus 28, 29. Here again, although only two winding apparatuses are shown, one could be provided for each longitudinal sheet portion in applications where the original sheet 22 is divided into more than two portions.

In manufacturing scenarios where both banner and stripped papers are required, the papermaking machine can be operated with one of the applicators 10, 10 'being idle. As a result, one longitudinal portion 132 of the sheet may be banded and collected while the other longitudinal portion 130 of the sheet is stripped and collected simultaneously. This capability increases the manufacturing flexibility of the papermaking apparatus.

The general standard papermaking method according to the description has been described in conjunction with the above description of the apparatus. Furthermore, the operation of the cigarette paper making machine and the preferred embodiment method typically utilizes a linen raw material. However, the apparatus and associated methodologies are readily usable with other raw materials such as hardwood pulps and softwood pulps, eucalyptus pulps and other types of pulps used in the papermaking industry. Alternative pulps may have different line characteristics, such as differences in average fiber length, which may require adjustment of the degree of refinement in the preparation of the base sheet slurry with some pulps. Regardless of what type of pulp is used, the slurry should be sufficiently processed to prevent fiber buildup in or around belt holes 44, which in turn avoids jet deflections in holes 44.

As the flow of fluid stream 40 emanating from each orifice 44 as orifice 44 passes along the lower portion of chamber 30 is proportional to the pressure differential across orifice 44, it is desirable for fluid pressure to be established and then maintained as evenly as possible along the entire path of each hole RPI (6.1) 1644 of 7/9/2002 along the lower portion 76 of the camera housing 30. A new high speed method and apparatus for applying a material on a network have been described in this specification. It will be apparent to those skilled in the art that numerous modifications, variations, substitutions, and equivalents exist for various aspects of the inventions set forth in the appended claims. Accordingly, all such variations, modifications, variations, substitutions, and equivalents that fall within the spirit and scope of the invention as set forth in the appended claims are intended to be encompassed by the appended claims.

Claims (17)

1. Method of manufacturing a sheet having an applied filler pattern, the method comprising the steps of: preparing a first fluid paste of fibrous material and a liquid; providing the first fluid paste to a movable screen having a direction. longitudinal, a web width transverse to that longitudinal direction, and a nominal linear velocity; drain the liquid from the first slurry through the movable web to form a fibrous sheet; prepare a second slurry of filler material; operate at least one of a plurality of dispensing devices, each device having a continuous belt with a plurality of holes spaced therethrough, a reservoir, a main length, and inclined with respect to the longitudinal direction such that each dispensing device covers a corresponding portion of the width of the provide the addition slurry to the reservoir of at least one device distribution site; move the continuous belt with a rated belt speed that has a speed component in the longitudinal direction substantially the same as the nominal linear speed; and placing transverse strips of the addition slurry over the fibrous sheet through the holes, where the length of each transverse strip is not greater than the portion of screen width corresponding to the dispensing device. A manufacturing method according to claim 1, comprising: providing the addition fluid paste to the reservoir of each dispensing device; and placing transverse strips of addition slurry into a plurality of longitudinally extending zones which are parallel to each other and together extend substantially across the width of the screen. A method of manufacture according to claim 1, further including the step of dividing the sheet into at least two narrower sheets, each narrowest sheet having a width corresponding to the dispensing device which has deposited the transverse strips thereon. . A manufacturing method according to claim 3, which includes the additional step of independently winding each of the narrowest sheets for subsequent use. A manufacturing method according to claim 1, further including the steps of: optically inspecting the transverse strips on the sheet to determine width and spacing characteristics; and dynamically adjust the operation of at least one of the dispensing devices in response to the optical inspection step to provide uniform width and spacing of the transverse strips over the sheet. A manufacturing method according to claim 1, further comprising the steps of: supplying the addition slurry to a plurality of compartments linearly disposed within the reservoir; and advancing the at least one hole sequentially through the plurality of linearly disposed compartments. A manufacturing method according to claim 6, further including the steps of: optically inspecting the transverse strips on the sheet to determine width and spacing characteristics as a function of lateral location on the sheet; and dynamically adjust the pressure within each switchgear compartment in response to the optical inspection step to provide uniform width and spacing of the transverse strips over the sheet. A method of manufacture according to claim 1, wherein the first slurry and the addition material are cigarette paper ingredients. A manufacturing method according to claim 1, wherein the screen has a width greater than three meters and the linear speed is greater than 2.5 meters per second (500 feet per minute). Apparatus for making a sheet having an applied pattern of filler material comprising: a Fourdrinier mesh operable for preparing a continuous sheet of fibrous material which moves in a longitudinal direction at a nominal linear speed, has a width transverse to that of the longitudinal direction, and a generally flat surface, at least two dispensing devices each operable to deposit a stream of addition material onto the generally flat surface of the sheet, each having a sump reservoir, a length and a continuous belt operable to move between the reservoir and the flat surface at a belt velocity including at least one orifice, so that when the orifice aligns with the reservoir a flow of addition material is deposited on the surface generally flat, each distribution device being inclined with respect to the longitudinal direction so that each dispensing device covers a corresponding portion of the sheet width, the belt speed having a longitudinal component generally parallel to the longitudinal direction and a transverse component generally perpendicular to the longitudinal direction, the longitudinal component being substantially equal to the nominal linear speed. ; It is a control system that selectively operates each of the distribution devices. Apparatus according to claim 10, wherein: each dispensing device covers a portion of the width of the sheet; Each dispensing device deposits a plurality of generally parallel bands of filler material onto the surface of the sheet. Apparatus according to claim 10, further including a cutting device for longitudinally cutting the sheet into parallel narrower sheets, each narrower sheet having a width corresponding to a stripped region formed by the respective dispensing device. Apparatus according to claim 10, further including: an operable drying system for drying the sheet positioned downstream of the dispensing devices, an optical inspection system operable for determining the width of the filler strips positioned at downstream of the drying system, operatively connected with the distribution devices; A control system that responds to the optical inspection system to adjust the supply of filler material to the dispensing devices to provide bands of uniform width and / or thickness. Apparatus according to claim 10, further comprising: an operable drying system for drying the sheet positioned downstream of the dispensing devices, an optical inspection system operable for determining the spacing between the strips of filler positioned downstream of the drying system operatively connected with the dispensing devices; It is a control system that responds to the optical inspection system to adjust the timing device belt speed operation to provide uniformly spaced ranges. Apparatus according to claim 10, further including: an operable drying system for drying the sheet positioned downstream of the dispensing devices, an optical inspection system operable to determine the uniformity and spacing of the filler strips , positioned downstream of the drying system, operatively connected with the dispensing devices; A control system that responds to the optical inspection system to adjust the operation of the dispensing devices to provide bands of uniform width and / or thickness. Apparatus according to claim 10, wherein the dispensing devices are parallel to one another and laterally displaced. 17. Apparatus which is a cigarette paper making machine.