MXPA98010818A - Method for manufacturing paper tisu, pressed in hum - Google Patents

Abstract

The present invention provides a method for manufacturing a continuous wet-pressed paper. An embryonic continuous paper (120A) of papermaking fibers is formed, in a foraminous forming member (11) is transferred to a stamping member (219) to deflect a portion of the embryonic continuous papermaking fibers in the deflection conduits in the embossing member. The web (120A) and the embossing member (219) are then pressed between a first (320) and a second (360) dewatering felt at a contact point between the compression roll (300) to further deflect the fibers of making paper in the deflection conduits in the embossing member remove water from both sides of the continuous paper. The point of contact between compression rollers (300) has an extended length and may comprise compression, opposite, and concave surfaces.

Description

METHOD TO MANUFACTURE PAPER TISU, PRESSED IN HUMID FIELD OF THE INVENTION The present invention relates to the manufacture of paper, and more particularly, to a method for manufacturing a tissue paper, wet-pressed.

BACKGROUND OF THE INVENTION Disposable products such as facial tissues, sanitary napkins, paper towels and the like are typically made from one or more continuous papers. If the products are going to perform their proposed tasks, the continuous papers from which they are formed must exhibit certain physical characteristics. Among these characteristics the most important are the resistance, softness and absorbency. Resistance is the ability of a continuous paper to retain its physical integrity during use. Softness is the pleasant, pleasant sensation that the user perceives as he wrinkles the paper in his hand and puts several portions of his anatomy in contact with the continuous paper. The softness increases in general as the stiffness of the continuous paper decreases. Absorbency is the characteristic of continuous paper that allows you to take and retain fluids. Typically, the softness and / or absorbency of a continuous paper roll increases at the expense of the strength of the continuous paper. Accordingly, papermaking methods have been developed in an attempt to provide soft, absorbent, continuous paper rolls having desirable strength characteristics. A continuous paper that is thermally pre-dried with a pass-air drying system is described in US Patent No. 3,301,746 issued to Sanford et al. Then, the continuous paper portions are brought into contact with a knuckle pattern of tissue in the dryer drum. While the process of Sanford et al. Addresses the provision of improved softness and absorbency, without sacrificing tensile strength, the removal of water using the pass air driers from Sanford et al. Is very energy intensive. , and therefore, expensive. A continuous paper formed between a superior fabric and a forming mesh is described, lower in the US Patent No. 3,537,954 issued to Justus. A pattern is imparted to the continuous paper at a point of contact between rollers where the continuous paper is sandwiched between the fabric and a relatively soft and resilient papermaking felt. U.S. Patent No. 4,309,246 issued to Hulit et al. Describes the distribution of a wet, non-compacted web to an open mesh web formed from woven elements, and the pressing of continuous paper between a papermaking felt and the web. stamping fabric at a first point of contact between press rolls. The web is then transported through the stamping fabric from the first contact point between press rolls to a second contact point between press rolls in a drying drum. U.S. Patent No. 4,144,124 issued to Turunen et al. Describes a paper machine having a twin-mesh former that has a pair of endless fabrics. That can be felts. One of the endless webs transports a continuous paper to a press section. The press section may include the endless fabric conveying the continuous paper to the press section, an additional worm fabric, which may be a felt, and a mesh for printing the pattern on the continuous paper. Both Justus and Hulit and co-workers suffer from the disadvantages of pressing a wet continuous paper at a point of contact between rollers that has only one felt. During the pressing of the continuous paper, the water will come out on both sides of the continuous paper. Accordingly, the water leaving the surface of the continuous paper which is not in contact with a felt can be reintroduced to the continuous paper at the exit of the contact point between press rolls. This rewetting of continuous paper, at the outlet of the contact point between press rolls, reduces the water removal capacity of the press arrangement, breaks the fiber to fiber joints formed during pressing, and may result in the re-awakening of portions of the continuous paper that densify at the point of contact between press rolls. Turunen et al. Describe a contact point between press rollers that includes two endless fabrics, which may be felts, and a stamping mesh. However, Turunen et al. Do not transfer the continuous paper from a stamping mesh to a stamping fabric to provide initial deviation of the portions of the wet continuous paper in the stamping fabric, prior to the pressing of the continuous paper at the contact point. between press rollers. The continuous paper in Turunen, therefore, can be in general non-monoplanar at the entrance of the contact point between press rolls, resulting in a complete compaction of the continuous paper at the contact point between press rolls. The complete compaction of the continuous paper is undesirable because it limits the difference in density between different portions of continuous paper by increasing the density of portions with a relatively low density of the continuous paper. In addition, Hulit et al., And Turunen et al. Provide press arrangements, wherein the stamping fabric has discrete compaction knuckles, such as at the warp and weft crossing points of the woven filaments. The discrete, compacted sites do not provide a molded, wet sheet having a high density continuous region for transporting charges and low density discrete regions to provide absorbency. Embossing can also be used to impart volume to a continuous paper. However, the embossing of a dry continuous paper can result in the breaking of the bonds between the fibers in the continuous paper. This break occurs because the bonds are formed and then harden in the drying of the continuous paper. After the continuous paper is dried, the fibers in motion normal to the plane of the continuous paper break the bonds or bonds fiber to fiber, which in turn results in a continuous paper having less tensile strength than exists before etching relief. The following references describe embossing: European Patent Application 0499942A2; U.S. Patent Number 3,556,907, Patent P730 North American number 3,867,225, U.S. Patent Nos. 3,414,459; and U.S. Patent No. 4,759,967. As a result, paper scientists continue to look for improved paper structures that can be produced economically, and that can provide increased strength without sacrificing softness and absorbency. Accordingly, it is an object of the present invention to provide a method for dewatering or molding a continuous paper. It is another object of the present invention to provide initial deflection of a portion of a continuous paper in a stamping member, and subsequently to press the resulting non-monoplanar continuous paper and the stamping member between two deformable, water-receiving members at a point of contact between press rollers having an extended length of the contact point between rollers. Another object of the present invention is to provide a wet-pressed web that has improved strength for a given level of sheet flexibility. Another object of the present invention is to provide a continuous, non-embossed web paper having an on-line network of relatively high density, a plurality of relatively low density domes dispersed throughout the continuous network, and a region of reduced thickness transition that encloses at least partially each of the low density domes.

SUMMARY OF THE INVENTION The present invention provides a method for molding and draining a continuous paper. According to one embodiment of the present invention, an embryonic continuous paper of papermaking fibers forms into a foraminous forming member, and is transferred to a stamping member to deflect a portion of the papermaking fibers in the Embryonic continuous paper and in deflection conduits in the embossing member without densifying the embryonic continuous paper. The web and the stamping member are then pressed between a first and a second dewatering felt at a point of contact between compression rollers to further deflect the papermaking fibers in the deflection conduits in the stamping member and to Remove water from both sides of the continuous paper. The point of contact between compression rollers has an extended length of contact point between rollers, the length of contact point between rollers which is at least about 3.0 inches in the machine direction. The point of contact between compression rollers is formed between opposing compression surfaces. In a preferred embodiment, the separation of the compression rollers is formed by a press having opposite, concave and convex compression surfaces. The method of the present invention comprises the steps of: forming an embryonic continuous paper of the papermaking fibers in a foraminous forming member, the embryonic continuous paper having a first surface and a second surface; transferring the embryonic web from the foraminous forming member to a swaging member to place the second embryonic web surface adjacent a surface that contacts the web of the foraminous stamping member; diverting a portion of the papermaking fibers in the embryonic web in a portion of the bypass duct and removing the water from the embryonic web through the portion of the bypass duct to form a continuous, non-monoplane, unbalanced web , of papermaking fibers; and pressing the web into a contact point between compression rollers having a length in the machine direction of at least about 3.0 inches, wherein a first felt layer is placed adjacent to the first intermediate web surface, wherein the stamping surface of the continuous paper is placed adjacent to the second surface of the intermediate continuous paper, and wherein the diversion conduit portion is in communication for flow with the second felt layer. In one embodiment, the step of pressing the intermediate continuous paper comprises pressing the intermediate continuous paper at a point of contact between compression rollers having a length in the machine direction of between about 3.0 to about 20.0 inches, and more preferably between about 4.0 and about 10.0 inches. The step of pressing the intermediate continuous paper may comprise pressing the intermediate continuous paper into a contact point load between rollers of between about 400 pounds per linear inch of width of the contact point between rollers in the transverse direction to the machine and about 10000 per square inch of the width of the contact point between rollers in the direction transverse to the machine.

P7_0 BRIEF DESCRIPTION OF THE DRAWINGS While the specification concludes with the claims that particularly indicate and clearly claim the present invention, the invention will be better understood from the following description taken in conjunction with the accompanying drawings in which: Figure 1 is a schematic representation of an embodiment of a continuous papermaking machine, illustrating the transfer of a continuous paper from a foraminous forming member to a foraminous stamping member, which transports the continuous paper in the stamping member to a point of contact between compression rollers, and press the continuous paper conveyed in the foraminous embossing member between the first and second dewatering felts, at the point of contact between compression rollers. Figure 2 is a schematic illustration of a plan view of a foraminous embossing member having a first continuous paper contacting the surface, comprising a continuous, continuous web, patterned, patterned, macroscopically monoplanar surface , which defines within the foraminous stamping member a plurality of discrete, isolated and non-connecting deflection conduits.

P730 Figure 3 is a cross-sectional view of a portion of the foraminous embossing member shown in Figure 2, as taken along line 3-3. Figure 4 is an enlarged schematic illustration of the compression roll contact point shown in Figure 1, showing a first dewatering felt positioned adjacent to a first surface of the continuous paper, the continuous paper contacting the surface of the member of foraminous embossing placed adjacent to the second surface of the continuous paper, and a second dewatering felt positioned adjacent to the second felt that makes contact with the surface of the foraminous embossing member, wherein the point of contact between compression rolls comprises compression surfaces , convex and concave, opposite. Figure 5 is a schematic illustration of a contact point between compression rollers according to an illustrative embodiment of the invention, wherein the continuous paper is placed between a first dewatering felt and a composite embossing member, comprising a continuous foraminous paper patterning layer formed from a photopolymer bonded to the surface of a second dewatering felt, and wherein the continuous paper, the first felt and the stamping member, composite are placed between surfaces of P730 compression, convex and concave, opposite, at the point of contact between compression rollers. Figure 6 is a schematic illustration of a plan view of a molded continuous paper, formed using the foraminous embossing member, of Figures 2 and 3. Figure 7 is a cross-sectional, schematic illustration of the continuous paper of the Figure 6 taken along line 7-7 of Figure 6. Figure 8 is an enlarged view of the cross section of the continuous paper taken in Figure 7. Figure 9 is a relative embodiment of a paper machine of according to the present invention using the configuration of the contact point between compression rollers shown in Figure 5 and having a stamping member, compound comprising a foraminous, continuous paper molding layer formed from a photopolymer bonded to the surface of a layer of dewatering felt. Figure 10 is a schematic illustration of a cross section of a stamping member, composite. Figure 11 is a schematic illustration of a plan view of a foraminous embossing member having a surface that contacts the paper P730 continuous comprising a deflection conduit, with continuous design and a plurality of discrete, isolated, stamping surfaces of the continuous paper. Figure 12 is a schematic illustration of a plan view of the foraminous stamping member having a semi-continuous stamping surface of the web.DETAILED DESCRIPTION OF THE INVENTION Figure 1 illustrates one embodiment of a continuous papermaking machine that can be used in the practice of the present invention. The process of the present invention comprises a number of steps or operations that occur in sequence. While the process of the present invention is preferably carried out in a continuous manner, it will be understood that the present invention may comprise a batch operation, such as a manufacturing process for test sheets. A preferred sequence of steps will be described, with the understanding that the scope of the present invention is determined with reference to the appended claims. According to one embodiment of the present invention, an embryonic paper 120 of papermaking fibers is formed from a dispersion Aqueous P730 of papermaking fibers in a limb 11 of foraminous formation. The embryonic web 120 is then transferred to a foraminous embossing member 219 having a first surface 220 that contacts the web that comprises a continuous paper stamping surface and a diverting conduit portion. A portion of the papermaking strips in the embryonic web 120 are deflected into the diverting conduit portion of the foraminous stamping member 219 without the web becoming densified, thereby forming a continuous paper 120A. The intermediate continuous paper 120A is transported in the foraminous embossing member 219 from the foraminous forming member 11 to a contact point between the compression rollers 300. The contact point between the rollers 300 may have a length in the direction of the machine. at least about 3.5 inches. The contact point between rollers 300 has opposite compression surfaces. The opposing compression surfaces may be opposite, convex and concave compression surfaces, with the convex compression surfaces being provided by a press roll 371 and the opposite, concave compression surface that is provided by a press assembly 700. shoe. A first dewatering felt 320 is placed P730 adjacent the intermediate continuous paper 120A, and a second dewatering felt 360 is positioned adjacent the foraminous embossing member 219. The intermediate continuous paper 12A and the foraminous embossing member 219 are then pressed between the first and second dewatering felts 320 and 360. at the point of contact between compression rollers 300 to further deflect a portion of the papermaking fibers in the portion of deflection conduits of the embossing member 219; to densify a portion of the intermediate continuous paper 120A associated with the continuous paper stamping surface, and to further dewater the continuous paper by removing the water from both sides of the continuous paper, thereby forming a molded continuous paper 120B that is relatively more dry than intermediate continuous paper 120A. The molded web 120B is transported from the contact point between compression rollers 300 in the foraminous embossing member 319. The molded web 120B can be pre-dried in a pass air dryer 300 when directing heated air, to pass first through the molded web, and then through the foraminous emboss member 319, thereby further drying the molded web 120B. The continuous paper stamping surface of the foraminous stamping member 219 can then be engraved P730 in the molded web 120B such as at the roller contact point formed between a roller 209 and a dryer drum 510, thereby forming a stamped continuous paper 120C. The engraving of the stamping surface of the web in the molded web can further densify the portions of the web that are associated with the stamping surfaces of the web. The recorded continuous paper 120C can then be dried in the dryer drum 510 and crimped from the dryer drum by a doctor blade 524. Examining the process steps according to the present invention in more detail, a first step in the practice of the present invention is to provide an aqueous dispersion of papermaking fibers derived from wood pulps to form embryonic web 120. The papermaking fibers used by the present invention will normally include fibers derived from wood pulp. Other fibrous, cellulosic pulp fibers, such as cotton porridge, bagasse, etc., may be used and are proposed to be within the scope of this invention. It is also possible to use synthetic fibers, such as rayon, polyethylene and polypropylene fibers, in combination with natural cellulose fibers. A polyethylene fiber, for example that can be used in Pulpex MR, available from P730 Hercules, Inc. (Wilmington, Delaware). Applicable wood pulps include chemical pulps, such as kraft pulp, sulphite and sulfate, as well as mechanical pulps including, for example, ground wood, thermomechanical pulp and chemically modified thermomechanical pulp. Pulps derived from both deciduous trees (later, also referred to as "hardwood") and coniferous trees (later, also referred to as "softwood") can be used. Also applicable to the present invention are the thin fibers from recycled paper, which may contain any or all of the above categories as well as other non-fibrous materials as well as fillers and adhesives used to facilitate the original manufacture of paper. In addition to the papermaking fibers, other components or materials can be added to the papermaking finish. The types of additives available will depend on the particular end use of the tissue sheet contemplated. For example, in products such as toilet paper, paper towels, facial tissues and other similar products, high wet strength is a desirable attribute. In this way, it is often desirable to add chemicals known in the art as "wet strength" resins to the papermaking finish.

P730 A general description of the types of wet strength resins used in the paper technique can be found in the article TAPPI Serial No. 29, Wet Strength in Paper and Paperboard, Technical Association of the Pulp and Paper Industry (New York, 1965). The most useful wet strength resins have generally been cationic in nature. Polyamide-epichlorohydrin resins are cationic wet strength resistances that have been found to be of particular utility. Suitable types of these resins are described in U.S. Patent Nos. 3,700,623 issued October 24, 1972, and No. 3,772,076, issued November 13, 1973, both to Keim and both which are incorporated herein by reference. A commercial source of useful polyamide-epichlorohydrin resins is Hercules, Inc. of Wilmington, Delaware, which makes these resins under the trademark Kymene MR 557H. Also, polyacrylamide resins have been found to be useful as wet strength resins. These two resins are described in U.S. Patent Nos. 3,556,932, issued January 19, 1971 to Coscia et al., And 3,556,933, issued January 19, 1971 to Williams et al., Both of which are incorporated herein by reference. . A commercial source of polyacrylamide resins is P730 American Cyanamid Co. of Stanford, Connecticut, which manufactures this resin under the Parez 631 NC brand. Still other water-soluble cationic resins which find utility in this invention are urea-formaldehyde and melamine-formaldehyde resins. The most common functional groups of these polyfunctional resins are nitrogen-containing groups, such as amino groups and methylol groups attached to nitrogen. Polyethylenimine type resins may also find utility in the present invention. In addition, temporary wet strength resins such as Caldas 10 (manufactured by Japan Calit) and CoBond 1000 (manufactured by National Starch and Chemical Company) can be used in the present invention. It is to be understood that the addition of chemical compounds such as the wet strength and temporary wet strength resins discussed above to the pulp finish is optional and is not necessary for the practice of the present development. Embryonic web 120 is preferably prepared from an aqueous dispersion of papermaking fibers, although dispersions of the fibers can be used in liquids other than water. The fibers are dispersed in water to form an aqueous dispersion having a consistency of about 0.1 to about 0.3 percent. Percent consistency of a dispersion, slurry, paper P730 continuous, or another system is defined as 100 times the arithmetic quotient obtained when the weight of the dry fiber in the system under discussion is divided by the total weight of the system. The weight of fiber is always expressed as the basis of totally dry fibers. A second step in the practice of the present invention is to form the embryonic web 120 of papermaking fibers. With reference to Figure 1, an aqueous dispersion of papermaking fibers is provided in a main case 18 which can be of any convenient design. From the main box 18 the aqueous dispersion of the papermaking fibers is distributed to a foraminous forming member 11 to form an embryonic continuous paper 120. The forming member 11 may comprise a continuous Fourdrinier mesh. Alternatively, the foraminous forming member 11 may comprise a plurality of polymeric protuberances attached to a continuous reinforcing structure to provide an embryonic continuous paper 120 having two or more different base weight regions, as described in US Patent No. 5,245,025 issued September 14, 1993 to Trokhan et al., Which patent is incorporated herein by reference. While an individual training member 11 is shown in Figure 1, a P730 single or double mesh training apparatus. Other forming mesh configurations may be used, such as S or C wrap configurations. The forming member 11 is supported by an anterior roller 12 and a plurality of return rolls, of which only two return rolls 13 and 14 are shown in Figure 1. The forming member 11 is driven in the direction indicated by the arrow 81 by a driving means not shown. The embryonic web 120 is formed from the aqueous dispersion of papermaking fibers by depositing the dispersion on the foraminous forming member 11 and by removing a portion of the aqueous dispersion medium. The embryonic web 120 has a first continuous paper surface 122 that contacts the foraminous member 11 and a second continuous web surface 124 that is opposite. The embryonic web 120 can be formed in a continuous process paper process, as shown in Figure 1, or alternatively, a batch process, such as a test sheet manufacturing process, can be used. After the aqueous dispersion of papermaking fibers is deposited on a foraminous forming member 11, the embryonic continuous paper 120 is formed by the removal of a portion of the medium from P730 aqueous dispersion by techniques well known to those skilled in the art. Vacuum boxes, forming boards, similar hydrodynamic planes are useful in effecting the removal of water from the aqueous dispersion in the foraminous forming member 11. The embryonic continuous paper 120 travels with the forming member 11 around the roller. return 13 and placed in proximity of the foraminous stamping member 219. The foraminous stamping member 219 has a first surface 220 that contacts the web and a second surface 240 that contacts the felt. The surface 220 contacted with the continuous paper has a continuous paper stamping surface 222 and a portion of the bypass conduit 230, as shown in Figures 2 and 3. The portion of the bypass conduit 230 forms at least one passageway. continuous extending from the first surface 220 to the second surface 240 to transport the water through the foraminous embossing member 219. Accordingly, when the water is removed from the continuous paper of papermaking fibers and the direction of the member Foraminous embossing 219, the water can be deposited without having to contact the continuous paper of papermaking fibers again. The foraminous stamping member 219 may comprise an endless band, P730 as shown in Figure 1, and can be supported by a plurality of rollers 201-217. The foraminous stamping member 219 is driven in the direction 281 (corresponding to the machine direction) shown in Figure 1 by a driving means (not shown). The first surface 220 that contacts the web of the foraminous embossing member 219 can be sprayed with an emulsion comprising about 90 weight percent water, about 8 percent petroleum oil, about 1 percent cetyl alcohol , and about 1 percent of a surfactant such as Adogen TA-100. This emulsion facilitates the transfer of continuous paper from the embossing member 219 to the drying drum 510. Of course, it will be understood that the foraminous embossing member 219 need not comprise an endless band if it is used in the manufacture of test sheets in a batch process. In the embodiment shown in Figures 2 and 3, the first surface 220 that contacts the continuous paper of the foraminous embossing member 219 comprises a continuous, continuous, macroscopically monoplanar patterned surface 222 of continuous web. The continuous network continuous web printing surface 22 defines within the stamping member 219 P730 foraminoso a plurality of deflection conduits 230, non-connecting, isolated, discrete. The deflection conduits 230 have an opening 239 which may be of random shape and distribution, but which are preferably uniformly distributed in a preselected, repeating pattern on the first surface 220 that contacts the web. This continuous network continuous paper web 222 and the discrete bias ducts 230 are useful for forming a paper structure having a region 1083 of a network with a relatively continuous density, and a plurality of domes 1084 of a relatively low density dispersed throughout the 1083 region of a relatively high, continuous density, as shown in Figures 6 and 7. Suitable shapes for openings 239 include, but are not limited to, circles, ovals, and polygons , with hexagonal shaped openings 239 shown in Figure 2. The openings 239 can be separated in a regular and uniform manner into aligned categories and rows. Alternatively, the openings 239 can be staggered bilaterally in the machine direction (MD) and in the transverse direction to the machine (CD), as shown in Figure 2, where the address of the machine refers to that address that is parallel P730 to the flow of the continuous paper through the equipment, and the direction transversal to the machine is perpendicular to the direction of the machine. A foraminous stamping member 219 having a continuous web, continuous network stamping surface 222, and discrete, discrete deflection conduits 230 that can be manufactured in accordance with the teachings of the following North American Patents that are incorporated in the present by reference: U.S. Patent No. 4,514,345 issued April 30, 1985 to Johnson et al .; U.S. Patent No. 4,529,480 issued July 16, 1985 to Trokhan, and U.S. Patent No. 5,098,522 issued March 24, 1992 to Smurkoski et al., And U.S. Patent No. 5,514,524 issued May 7, 1996 to Trokhan et al. . With reference to Figures 2 and 3, the foraminous embossing member 219 may include a woven reinforcement member 243 for reinforcing the foraminous embossing member 219. The reinforcing member 243 may include reinforcing cords 242 in the machine direction and 241 reinforcement cords in the transverse direction to the machine, although any suitable tissue pattern can be used. The openings in the woven reinforcement element 243 formed by the interstices between the cords 241 and 242 are smaller than the size of the openings 239 P730 of the diversion conduits 230. Together, the openings in the woven reinforcement element 243 and the openings 249 of the diversion conduits 230 provide a continuous passage from the first surface 220 to the second surface 240 to convey water to the second surface 240. through the foraminous stamping member 219. The reinforcing member 243 can also provide a support surface for limiting the deflection of the fibers in the deflection conduits 230 and thereby assist in the formation of openings in the portions of the web associated with deflection conduits 230, such as domes 1084 of a relatively low density. These openings, or small holes, can be caused by water or air flow through the bypass conduits when there is a pressure difference through the continuous paper. The area of the continuous paper printing surface 222, as a percentage of the total area of the first surface 220 that contacts the web, should be between about 15 percent to about 60 percent, and more preferably between approximately 20 percent to approximately 50 percent to provide a desirable ratio of the areas of the region 1083 of a relatively high density and the domes 1084 of a P730 relatively low density shown in Figures 6 and 7. The sizes of the openings 239 of the diversion conduits 230 in the plane of the first surface 220 can be expressed in terms of the free, effective section. The effective section is defined as the area of the opening 239 in the section of the first surface 220 divided by a quarter of the perimeter of the opening 239. The effective free section should be from about 0.25 to about 3.0 times the average length of the openings. papermaking fibers used to form the embryonic web 120 and is preferably from about 0.5 to about 1.5 times the average length of the papermaking fibers. The deflection conduits 230 may have a depth 232 (Figure 3) that is between about 0.1 mm and about 1.0 mm. In an alternative embodiment, the foraminous stamping member 219 may comprise a web of tissue formed from woven filaments. The continuous paper printing surface 222 can be formed by discrete rolls formed at the crossing points of the fabric filaments. Woven filament woven webs suitable for use as the foraminous embossment member 219 are described in US Pat. Nos. 3,301,746 issued January 31, 1967 to Sanfor and P7_0 collaborators, US Patent No. 3,905,863 issued September 16, 1975 to Ayers, US Patent No. 4,191,609 issued March 4, 1980 to Trokhan and US Patent No. 4,239,065 issued December 16, 1980 to Trokhan, patents they are incorporated herein by reference. In another alternative embodiment, the foraminous embossing member may have a first surface 220 contacting continuous paper comprising a diversion conduit 230, with a continuous pattern, encompassing a plurality of embossing surfaces 222, of continuous paper, isolated, discrete. This foraminous stamping member 219 can be used to form a molded web having a network region of relatively low density, continuous, and a plurality of discrete, relatively high density regions dispersed throughout the network of a relatively low density, continuous. This foraminous stamping member is shown in Figure 11, as well as in U.S. Patent No. 4,514,345 issued April 30, 1985 to Johnson et al., Which is incorporated herein by reference. In yet another embodiment, the foraminous stamping member 219 may contain a first surface 220 that contacts the web, comprising P730 a plurality of continuous, semi-continuous paper stamping surfaces 222. As used herein, a pattern of continuous paper stamping surfaces 222 is considered to be semi-continuous if a plurality of the stamping surfaces 222 extend substantially without break along any direction on the surface 220 that contacts the stamping surface. the web, and each stamping surface is separated from the stamping surfaces 220 by a bypass conduit 230. The surface 220 that contacts the web can have stamping surfaces 222, semi-continuous, adjacent, separated by deflection conduits. semicontinuous 230. Semi-continuous patterned surfaces 222 may generally extend parallel to the machine directions or transverse to the machine, or alternatively, extend along a direction that is angled with respect to the machine and the directions transverse to the machine. This foraminous stamping member is shown in Figure 12, as well as in U.S. Patent Application Serial No. 07 / 936,954, Papermaking Belt Having Semicontinuous Pattern and Paper Made Thereon, filed August 26, 1992 in the name of Ayers et al. , applications that are incorporated herein by reference. A third step in the practice of the present invention comprises transferring the embryonic web 120 from the foraminous forming member 11 to the foraminous stamping member 219, to place the second continuous paper surface 124 on the first surface 220 contacting the continuous paper of the foraminous embossing member 219. A fourth step in the art of the present invention comprises diverting a portion of the papermaking fibers in the embryonic web 120 into the diverting conduit portion 230 of the surface 220 that contacting the continuous paper, and removing the water from the embryonic continuous paper 120 through the diverting portion portion 230 to form an intermediate continuous paper 120A of the papermaking fibers. The embryonic web 120 preferably has a consistency of between about 3 and between about 20 percent at the transfer point to facilitate the deflection of the papermaking fibers in the diverting conduit portion 230. The steps for transferring embryonic web 120 to the stamping member 219 and diverting a portion of the papermaking fibers into the web 120 in the diverting portion 230 can be provided, at least in part, by applying a P730 fluid pressure, differential to the embryonic continuous paper 120. For example, the embryonic continuous paper 120 can be transferred by vacuum from the forming member 11 to the stamping member 219, such as by a vacuum box 126 shown in Figure 1 , or alternatively, by a rotating collection vacuum roller (not shown). The pressure differential across the embryonic continuous paper 120 provided by the vacuum source (eg, vacuum box 126) biases the fibers in the diverter portion 230, and preferably removes the continuous paper water through the the portion 230 of deflection conduit for increasing the consistency of the continuous paper to between about 18 and about 30 percent. The pressure differential across embryonic web 120 can be between about 13.5 kPa and about 40.6 kPa (between about 4 and about 12 inches of mercury). The vacuum provided by the vacuum box 126 allows the transfer of the embryonic web 120 to the foraminous stamping member 219 and the deflection of the fibers in the diverting conduit portion 230 without compacting the embryonic web 120. Boxes may be included. additional vacuum to further drain the intermediate continuous paper 120A. With reference to Figure 4, the portions of the intermediate continuous paper 120A are shown offset in the deflection conduits 230 upstream of the contact point between the compression rollers 300, so that the intermediate continuous paper 120A is non-monoplanar. The intermediate continuous paper 120A is shown to have a generally uniform thickness (the distance between the first and second surfaces 122 and 124 of the continuous paper (upstream of the contact point between compression rolls 300 to indicate that a portion of the intermediate continuous paper 120A has deflected in the stamped member 219 without locally densifying or compacting the intermediate continuous paper 120A upstream of the roll gap 300. The transfer of the embryonic continuous paper 120 and the deflection of the fibers in the embryonic continuous paper in the portion 230 The deviation conduit can be achieved in an essentially simultaneous manner US Pat. No. 4,529,480 referred to above, is hereby incorporated by reference for the purpose of teaching a method for transferring an embryonic continuous paper to a foraminous member and deflecting a portion of the same. papermaking fibers in embryo paper co in the foraminous member. A fifth step in the practice of the present invention comprises pressing the intermediate continuous paper, Wet P730 120 at the point of contact between compression rollers 300 to form the molded web 120B. With reference to Figures 1 and 4, the intermediate continuous paper 120A is transported in the foraminous embossing member 219 from the foraminous forming member 11 and through the contact point between the compression rollers 300 formed between the opposing compression surface of the roller. 362 and the shoe press assembly 700. In order to describe the operation of the contact point between compression rollers 300, the stamped member 219, the dewatering felts 320 and 360, and web are enlarged by stretching relative to the roller 362 and the press assembly 700. The first dewatering felt 320 is shown to be supported at the point of contact between compression rollers adjacent the press shoe assembly 700, and urged in the direction 321 around a plurality of felt support rolls 324. The shoe press assembly 700 includes a fluid-tight pressure band 710, a pressure shoe 720, and a pressure shoe P. The pressure shoe 720 may have a concave, generally arcuate surface 722. The pressure band 710 travels a continuous path over the generally concave surface 722 and the rollers via 712. The pressure source P provides hydraulic fluid under pressure to P730 a cavity (not shown) in the pressure shoe 720. The pressurized fluid in the cavity pushes the pressure band 710 against the felt 320, and provides the loading of the contact point between compression rolls 300. The press assemblies of Shoe are generally described in the following North American Patents, which are incorporated herein by reference: U.S. Patent No. 4,559,258 to Kiuchi, U.S. Patent No. 3,974,026 to Emson et al., U.S. Patent No. 4,287,021 to Justus et al; U.S. Patent No. 4,201,624 to Mohr et al; U.S. Patent No. 4,229,253 to Cronin, U.S. Patent No. 4,561,939 to Justus; U.S. Patent No. 5,389,205 to Pajula et al; U.S. Patent No. 5,178,732 to Steiner et al., U.S. Patent No. 5,308,450 to Braun et al. The outer surface of the pressure band 710 takes a concave, generally arcuate, shape when the pressure shoe 720 passes, and provides a compression surface, concave opposite the compression surface, convex provided by the press roll 362. This portion to the outer surface of the pressure band 710 passing over the pressure shoe is designated 711 in Figure 4. The outer surface of the pressure band P730 pressure 710 can be smooth or grooved. The convex compression surface provided by the press roll 362 in combination with the opposite concave compression surface provided by the shoe press assembly 700 provides a point of contact between arcuate compression rolls having a length of machine that is at least approximately 3.0 inches. In one embodiment, the contact point between compression rollers 300 has a length in the machine direction of between about 3.0 to about 20.0 inches, and preferably from about 4.0 inches to about 10.0 inches. The second dewatering felt 360 is shown to be supported at the point of contact between compression rollers 300 adjacent the roller contact point roller 362 and urges an address 361 around a plurality of felt support rolls 364. A dewatering felt apparatus 370, which uses a vacuum box Uhle, may be associated with each of the dewatering felts 320 and 360 to remove the water transferred to the dewatering felt from the intermediate continuous paper 120A. The relatively large air permeability, the open pore structure of the second felt 360 improves P730 the ability of the dewatering apparatus 370 to remove water from the felt 360. This ensures that the felt 360 will not introduce water to the continuous paper of the entrance of the contact point between rollers 300. In addition, the open pore structure of the felt 360 also it will prevent the water pressed from the continuous paper in the felt 360 (via the diversion conduits 360) from being reintroduced and rewet the continuous paper to the felt outlet 360 from the contact point between the rollers. The press roll 362 can have a generally smooth surface. Alternatively, the roller 362 can be resumed or it can have a plurality of openings in communication for flow with a vacuum source to facilitate the removal of water in the intermediate continuous paper 120A. The roller 362 may have a rubber coating 363, such as a hard rubber cover, which may be smooth, grooved or perforated. The rubber lining 363 shown in Figure 4 provides the convex compression surface opposite the concave compression surface 711 provided by the shoe press assembly 700. The term "drainage wick" as used herein refers to a member that is absorbent, compressible and flexible so that it is deformable to allow the contour of the intermediate web 120A to not P730 monopolar in the stamping member 219, and capable of receiving and containing pressurized water from an intermediate continuous paper 120A. the dewatering felts 320 and 360 can be formed of natural materials, synthetic materials, and combinations thereof. A suitable dewatering felt comprises a nonwoven fluff of synthetic natural fibers, bonded, such as by sewing, to a support structure formed of woven filaments. Suitable materials from which the nonwoven fluff can be formed include but are not limited to, natural fibers such as wool and synthetic fibers such as polyester and nylon. The fibers from which the fluff 140 is formed can have a denier of between about 13 to about 40 grams per 9000 meters of filament length. The felt may have a layer construction, and comprise a mixture of fiber types and sizes. Dewatering felts 320 and 360 can have a thickness of between about 2 mm to about 5 mm, a basis weight of about 800 to about 2000 grams per square meter, an average density (basis weight divided by thickness) of between about 0.35 grams per cubic centimeter and approximately 0.45 grams per cubic centimeter, and an air permeability of between approximately 15 and P730 approximately 110 cubic feet per minute per square, at a pressure differential across the thickness of the dewatering felt of 0.12 kPa (0.5 inches of water). Dewatering felt 320 may have a first surface 325 having a relatively high density, a relatively small pore size and a second surface 327 having a relatively low density, a relatively large pore size. Similarly, the dewatering felt 360 may have a first surface 365 having a relatively high density, a relatively small pore size, and a second surface 367 having a relatively low density, and a relatively large pore size. Dewatering felts 322 and 360 can obtain a compressibility of between 20 and 80 percent, preferably between 30 and 70 percent, and more preferably between 40 and 60 percent. The "compressibility" as used herein is a measure of change in percentage of the thickness of the dewatering felt under a given load defined later. Dewatering felts 320 and 360 should have a compression modulus of less than 10000 psi, preferably less than 7000 psi, more preferably less than 5000 psi, and more preferably between approximately 1000 and approximately 4000 psi. The "compression module" as used in the P730 present is a measure of the speed of change of the load with change of thickness of the dewatering felt. The compressibility and the compression module are measured using the following procedure. The dewatering felt is placed on a papermaking fabric formed of woven polyester monofilament having a diameter between about 0.40 millimeters and having a square woven pattern of about 36 filaments per inch in a first direction, and about 30 filaments per inch. inch in a second direction perpendicular to the first direction. The papermaking fabric has a thickness under no compression load of approximately 0.68 millimeters (0.27 inches). This papermaking fabric is commercially available from the Appleton Wire Company of Appleton, Wisconsin. The dewatering felt is positioned so that the surface of the dewatering felt is actually in contact with the continuous paper adjacent to the papermaking fabric. The felt-fabric pair is then compressed with a constant proportion / compression tension dye tester, such as an Instron Model 4502 available from Instron Engineering Corporation of Canton, Mass. The tension tester has a circular compression foot having a Surface area of approximately 13 square centimeter (2.0 inches P730 square) attached to a crosshead that moves at a speed of 5.08 centimeters per minute (2.0 inches per minute). The thickness of the felt-woven pair is measured at loads of 0 psi, 300 psi, 450 psi, and 600 psi, when the load in the psi is calculated by dividing the load in pounds obtained from the load cell of the tester. tension by the surface area of the compression foot. Fabric thickness alone is also measured at 0 psi, 300 psi, 400 psi, and 600 psi loads. Compressibility and compression module in psi are calculated using the following equations: Comprehensibility = 100 x ((TFPO-TPO) - (TFP450-TP450) / (TFPO - TPO) Compression Module: (300 psi) x (TFP300-TP300) ) / ((TFP300-TP300) - (TFP600-TP600) where TPO, TFP300, TFP450 and TFP600 are the thickness of the felt-woven pair of loads of 0 psi, 300 psi, 450 psi and 600 psi, respectively, and TPO, TP300, TP450, and TP6700 are the thickness of the fabric only at loads of 0 psi, 300 psi, 450 psi and 600 psi, respectively. Suitable dewatering felts 320 and 360 are commercially available as SUPERFINE DURAMESH, style XY31620 from Albany International Company of Albany, New York. Alternatively, the dewatering felts 320 and P730 360 can have different constructions. For example, the felt 360 can be selected to have an air permeability of at least about 30 cubic feet per minute per square foot. The felt 320 may have an air permeability that is less than that of the felt 360. In one embodiment, the felt 360 may be an AmFlex-3S style 5615 having a wiper ratio based on 1: 1 (1 line of material of eraser for each pound of woven base reinforcement structure) and a 3-on-40 layer debris construction (3 denier fibers on 40 denier fibers, where the 3 denier fibers are adjacent to the surface 365 of the felt) This felt is available from Appleton Mills of Appleton, Wisconsin and can have an air permeability of approximately 40 cubic feet per minute per square foot. Felt 320 may be an AmSaem-2, style 2732 having the base debris ratio of 1: 1 and a debris construction of 3 over 6 layers. This felt is available from Appleton Mills of Appleton, Wisconsin and may have an air permeability of approximately 25 cubic feet per minute per square foot. The intermediate continuous paper 120A and the stamping surface 222 of the web are placed intermediate to the first and second felt layers 320 and 360 in the web.

P730 roller contact point 300. The first felt layer 320 is positioned adjacent to the first surface 122 of the intermediate continuous paper 120A. The stamping surface 222 of continuous paper is placed adjacent to the second continuous paper surface 124A 120A. The second felt layer 360 is placed at the contact point between compression rollers so that the second felt layer 360 is in flow communication with the diverting portion portion 230. With reference to Figures 1 and 4, the first surface 325 of the first dewaxing felt 320 is placed adjacent to the first surface 122 of the intermediate continuous paper 120A as the first dewaxing felt 320 is driven on the band 710. Similarly, the first surface 365 of the second felt of dewatered 360 is positioned adjacent the second surface 240 which contacts the felt of the foraminous embossing member 219 as the second dewatering felt is urged around the roll separation roller 362. Accordingly, as the intermediate continuous paper 120A is transformed through the contact point between compression rollers 300 in the foraminous embossing fabric 219, intermediate continuous 120A; the embossing fabric 219, and the first and second dewatering felts 320 and 360 are pressed together P730 between the opposing compression surfaces of the contact point between rollers 300. The intermediate continuous paper pressing 120A at the contact point between compression rollers 300 further deviates the papermaking fibers in the limb conduit portion 230 from the member of stamping 120, the majority of water of the intermediate continuous paper 120A to form the molded continuous paper 120B. The removed water and the continuous paper is received and contained in the dewatering felts 320 and 360. The water is received by the dewatering felt 360 through the deviation conduit portion 230 of the embossing member 219. The continuous paper intermediate 120A should have a consistency of between about 14 and about 80% at the entrance to the contact point between compression rollers 300. More preferably, the intermediate continuous paper 120A has a consistency of about 15 and about 35 percent in the entrance of the contact point between rollers 300. The papermaking fibers in the intermediate continuous paper 120A having this preferred consistency have relatively few fiber connections, and can be easily fixed and biased in the diversion conduit portion 230 by the first dewatering felt 320. The intermediate continuous paper 120A is pressed P730 preferably at the point of contact between compression rollers 300 at a pressure at the point of contact between rollers of at least 100 pounds per square inch (psi), more preferably at least 200 psi. In a preferred embodiment, the continuous paper 120A is pressed at the contact point between separation rollers 300 at a pressure at the point of contact between rollers greater than about 400 pounds of square inch. The length of the contact point between rollers in the machine direction can be between approximately 3.0 inches and approximately 20.0 inches. For a length of the contact point between rollers in the machine direction between 4.0 inches to 10.0 inches, the press assembly 700 is preferably operated to provide between about 400 pounds of force per linear inch of the width of the contact point between rollers in the direction transverse to the machine and approximately 10,000 pounds of force per linear inch of the width of the point of contact between rollers in the cross-machine direction. The width of the contact point between rollers in the machine's transverse direction is measured perpendicular to the plane in Figure 4. The pressure of the roller contact point in psi is calculated by dividing the force of the point of contact between the rollers.

P730 roller contact exerted on the continuous paper by the area of contact point between rollers 300. The force exerted by the contact point between rollers 300 is controlled by the pressure source P, can be calculated using several force or pressure translators familiar to those skilled in the art. The area of the contact point between rollers 300 is measured using a sheet of carbon paper and a sheet of simple white paper. The carbon paper is placed on the simple sheet of paper. The carbon paper and the single paper sheet are placed at the point of contact between compression rollers 300 with the first and second dewatering felts 320, 360 and the embossing member 219. The carbon paper is placed adjacent to the first felt of dewatered 320 and the single paper is placed adjacent to the disintegration 219. The shoe press assembly 700 is then activated to provide the desired press force, and the area of the contact point between rolls 300 at that force level is measured with the stamping that carbon paper imparts to the simple white sheet of paper. Likewise, the length of the contact point between rollers in the machine direction and the width of the contact point between rollers in the cross section to the machine can be stopped from the stamping that the carbon paper imparts to the white sheet of paper simple.

P730 The molded web 120B is preferably pressed to have a consistency of at least about 30 percent at the outlet spacing of the contact point between compression rollers 300. The pressing of the intermediate web 120A as shown in FIG. the continuous paper to provide a first region 1083 of a relatively high density, associated with the continuous paper stamping surface 222 and a second region 1084 of a relatively low density of continuous paper, associated with the portion 230 of the bypass conduit. Pressing of intermediate continuous paper 120A into the stamping fabric 219 having a continuous paper stamping surface 222, but being continuous, with macroscopically monoplanar design, as shown in Figures 2-4, provides a molded continuous paper 120B having a 1083 continuous network region, with macroscopically monoplanar design, having a relatively high density and a plurality of discrete domes 1084 and a relatively low density, dispersed throughout the network region 1083, of a relatively high density high, continuous. This continuous paper has molding 120B shown in Figures 6 and 7. This molded continuous paper has the advantage that the continuous network region 1083, of relatively high density, provides a continuous load path for P730 transport the traction loads. The molded web 120B is also characterized in that it has a third region 1084 of intermediate density extending intermediate to the first and second regions 1083 and 1084, as shown in Figure 8. The third region 1074 comprises a transition region 1073 provided adjacent to the first region 1083 of a relatively high density. The intermediate density region 1074 is formed as the first dewatering felt 320 draws the papermaking fibers in the deviation conduit portion 230, and has a tapered, generally trapezoidal, cross section. The transition region 1073 is formed by the compacting of the intermediate continuous paper 120A at the perimeter of the diversion conduit portion 230. Region 1073 encloses region 1074 of intermediate density to at least partially surround each of the domes 1084 of relatively low density. The transition region 1073 is characterized as having a thickness P that is a local minimum, and that is the thickness K of the region 1083 of a relatively high density, and a local density that is greater than the density 1083 of the density relatively high The domes of relatively low density 1074 have a thickness P which is a local maximum, and which is greater than the thickness K of the region P730 1083 continuous network, of a relatively high density. Without being limited by any theory, it is believed that the transition region 1073 acts as a joint that improves the flexibility of the continuous paper. The continuous molded paper 120B formed by the process shown in Figure 1 is characterized in that it has a relatively high draw strength and a flexibility for a given given weight level of the continuous paper and continuous paper calibrator H (Figure 8). The difference in density between the region 1083 of relatively high density and the region 1084 of relatively low density is provided, in part, by the deviation of a portion of the intermediate continuous paper 120 in the portion 230 of the deflection conduit of the stamping member. 219 to provide an intermediate, non-monoplanar continuous paper 120A upstream of the contact point between compression rollers 300. A monoplanar continuous paper transported through the contact point between compression rollers 300 will undergo some uniform compaction, thereby increasing the minimum density in the molded web 120B. the non-monoplane intermediate web portions 120A in the diverting portion 230 prevents this uniform compaction, and therefore maintains a relatively low density.

P730 The difference in density between the relatively high density region and the relatively low density region is also provided, in part, by pressing with both the first and second dewatering felts 320 and 360 to remove water from both surfaces of the paper continuous and prevent rewetting of continuous paper. water is ejected from the first and second surfaces 122 and 124 of the continuous paper as the intermediate continuous paper 120A is pressed at the point of contact between compression rolls 300. It is important that the water expelled from both surfaces of continuous paper is removed from both surfaces of continuous paper. Otherwise, the ejected water can be reintroduced to the molded continuous paper 120B at the exit of the contact point between rollers 300. For example, if the dewatering felt 360 is omitted, the water expelled from the second continuous paper surface 124 in the portion 230 of the deflection conduit can be reintroduced to the molded web 120B through the diverting portion 230 of the embossing member 219 to the contact point exit between rollers 300. The reintroduction of water into the molded web 120B is undesirable because the consistency of the molded web 120B decreases, it reduces the drying efficiency. In addition, the reintroduction of water in P730 the molded web 120B breaks the fiber bonds formed during the continuous web 120A and de-densifies the web. In particular, which returning molded web 120B will break the junctions in region 1083 of relatively high density, will reduce the speed and load carrying capacity in that region. The water is returned to the molded web 120B can also break the bonds of fibers forming the transition region 1073. The dewatering felts 320 and 360 prevent the rewetting of the continuous paper molded through both surfaces 122 and 124 of continuous paper, and thus help to maintain the region 1083 of a relatively high density and the transition region 1073. In some embodiments, it may be desirable to remove the first dewaxing felt 320 from the first surface 122 of the molded web 120B at the exit of the contact point between compression rollers 300 to prevent water from stopping in the dewaxing felt 320 to rewet the first surface 122 of the web. Similarly, it may be desirable to remove the second dewaxing felt 360 from the embossing member 219 at the exit of the roller contact point to prevent water retained in the dewatering felt 360 from being reintroduced to the continuous paper through the portion 230 P730 of diversion duct. In the embodiment shown in Figures 1 and 4, the first and second dewatering felts 320 and 360 can be supported such that they are separated from the continuous paper at the exit point of contact between rollers 300. The pressing of the continuous paper, the layers The felt and stamping member at a roller contact point having a length in the machine direction of at least about 3.0 inches can improve the dewatering of the web. For a given speed of the paper machine, the relatively long length of the contact point between rollers increases the residence time of the web and the felts at the point of contact between rollers. Therefore, water can be removed more efficiently from continuous paper, even at higher machine speeds. A sixth step in the practice of the present invention may comprise pre-drying the molded web 120B, such as with a pass-through air dryer 400 as shown in Figure 1. Molded web 120B can be pre-dried by injecting a drying gas, such as heated air, through continuous paper 120B. in one embodiment, the heated air is then directed through the molded web 120B from the first P730 continuous paper surface 122 to the second continuous paper surface 124, and subsequently through the diverting portion portion 230 of the embossing member 219 in which the molded web is transported. The air directed through the molded web 120B partially dries the molded web 120B. Furthermore, without being limited by any theory, it is believed that the air passing through the portion of the web paper associated with the diverting portion 230 can further divert the web into the diverting portion 230, reduce the density of the region 1084 of relatively low density, thereby increasing the bulk and apparent smoothness of the molded web 120B. In one embodiment, the molded web 120B may have a consistency of between about 30 and about 75 percent at the inlet of the air dryer 400, and a consistency of between about 40 and about 80 at the outlet of the air dryer 400. He passed. With reference to Figure 1, the through-air dryer 400 may comprise a hollow, rotary drum 410. The molded web 120B can be transported around the hollow drum 300 in the embossing member 219 and the heated air can be directed radially outwardly from the hollow drum 410 P730 pass through the web 120B and the embossing member 219. Alternatively, the heated air can be directed radially inwardly (not shown). Air dryers, suitable for use in the practice of the present invention are described in U.S. Patent No. 3,303,576 issued May 26, 1985 Sisson and U.S. Patent No. 5,274,930 issued January 4, 1994 to Ensign et al. collaborators, patents that are incorporated herein by reference. Alternatively, one or more pass air dryers 400 and other suitable drying devices can be loaded upstream of the roller contact point 300 to partially dry the web before pressing the web at the contact point between rolls 300. A seventh step in the practice of the present invention may comprise embossing the continuous paper stamping surface 222 of the foraminous stamping member 219 on the molded web 120B to form a stamped continuous paper 120C. stamping of the surface 222 of the continuous paper stamping surface on the molded web 120B serves to further densify the region 1083 of relatively high density of the molded web, thereby increasing the difference in density P730 between the regions 1083 and 1084. With reference to Figure 1, the molded web 120B is conveyed into the embossing member 219 and is interposed between the embossing member 219 and the printing surface at the roller contact point 490. The printing surface can comprise a surface 512 of a drying drum 510, heated and the roller contact point 490 can be formed between a roller 209 and a dryer drum 510. The continuous paper contains a stamp 120C and can be adhered afterwards. to the surface 512 of the dryer drum 510 with the aid of a pleating adhesive, and finally dried. The stamped, dry continuous paper 120C can be reduced as they are removed from the dryer drum 510, such as by pleating the stamped continuous paper 120C of the dryer drum with a doctor blade 524. The method provided by the present invention is particularly useful for making papers continuous that have a basis weight of between about 10 grams per square meter to about 65 grams per square meter. These continuous papers are suitable for use in the manufacture of paper towel products and folded, multiple, and individual handkerchiefs. In an alternative embodiment of the present invention, the air dryer of passage 400 in Figure 1 can not be omitted. The second felt 360 can be placed P730 adjacent the second surface 240 of the embossing member 219 in accordance with the molded web 120B is transported in the uncovered member 219 from the contact point between rollers 300 to the point of contact between rollers 490. The contact point between rollers 490 can be Affix between a vacuum pressure roller and a Yankee drum 510. An alternative embodiment of the present invention employs a composite stamping member 219, which is illustrated in Figures 5, 9 and 10. With reference 10, the composite stamping member 219 has a continuous paper modeling photopolymer layer 221 attached to the surface 365 of the dewaxing felt 360. The dewaxing felt 360 comprises a non-woven fluff 3610 that can be sewn to a support structure comprising woven filaments 3620. The photopolymer layer 221 has a continuous, continuous, macroscopically monoplanar continuous paper web printing surface 222. This composite stamp member 219 may comprise a photopolymer resin molded onto the surface of a dewaxing felt. The following commonly assigned US patent applications are hereby incorporated by reference for the purpose of showing the construction of this stamping member, composite.

P730 Serial Number 08 / 461,832"Web Patterning Apparatus Comprising to Felt Layer and a Photosensitive Resin Layer", filed on June 5, 1995 in the name of Trokhan et al., Which is a continuation in part of the US Patent Application Number. Series 08 / 268,154 filed on June 29, 1994; US Patent Serial Number 08 / 391,372"Method of Applying to Curable Resin to a Substrate for Use in Papermaking" filed on February 15, 1995, in the name of Trokhan et al., And "High Absorbency / Low Reflectance Felts with a Pattern Layer "presented on April 30, 1996 in the name of Ampulski et al. In Figure 9, the embryonic web 120 is transferred to the photopolymer continuous paper printing surface 222 of the composite stamping member 216. The web is crimped at the point of contact between rollers 300 between the first felt 320 and the composite stamping member 219, comprising surface 222 of continuous paper, photopolymer and second felt 360. The deviation 230 of the The photopolymer layer 221 with design is in communication for flow with the felt layer 360, as shown in Figure 10. Figure 5 is an enlarged illustration of the roller contact point 300 shown in Figure P730 9. The force provided by the shoe press assembly pushes the felt 320 against the continuous paper 120A, causing the described portions of the continuous paper 120A to be deflected in the diversion conduit 230 and compacting a continuous network portion of the continuous paper 120A, thereby forming a molded web 120B. At the contact point exit between rollers 300, the felt 320 is removed from the molded continuous paper 120, and the molded web is transported in the composite stamping member 219. The molded web 120B is transported on the stamping surface of continuous paper 222 of the continuous paper stamping member, composite to the roller contact point 490. The roller contact point 4990 in Figure 9 is formed between a roller 120B and the Yankee drum 510. The pressure roller 299 it can be a roller being a vacuum pressure roller that removes water from the continuous paper via the second felt 360. The relatively high air likelihood of the felt 360 improves this water removal. Alternatively, the pressure roller 299 may be a solid roller. With the composite stamping member 129 positioned other than the surface 224 of the molded web 120, the web is transported in the composite stamping member 219 in the web.

P730 roller separation 290 for transferring the molded web 120B to the Yankee drum 510. While embodiments have been illustrated and described particularly in the present invention, it will be obvious to those skilled in the art that various other changes and modifications can be made without that depart fthe spirit and scope of the present invention.

P730

Claims (10)

1. EIVINDICATIONS: 1. A method for forming a continuous paper, comprising the steps of: providing an aqueous dispersion of papermaking fibers; provide a member of foraminoso training; provide a first layer of dewatering felt; provide a second layer of dewatering felt; providing a contact point between compression rollers having a length in the machine direction of at least about 3.0 inches, preferably between about 3 and about 20 inches, and more preferably between about 4 and about 10 inches; providing a stamping member having a surface contacting the continuous paper comprising a continuous paper stamping surface and a portion of the bypass conduit; forming an embryonic continuous paper of papermaking fibers in the foraminous forming member, the embryonic continuous paper having a first surface and a second surface; transfer the embryonic continuous paper from P730 member foraminous to the stamping member for placing the second surface of the embryonic web adjacent to the surface that contacts the web of the foraminous stamping member; diverting a portion of the papermaking fibers in the diverting conduit portion and removing the water from the embryonic continuous paper through the diverting conduit portion to form an intermediate, non-monoplane, unwound, continuous paper of fibers paper; placing the intermediate continuous paper to the first and second felt layers at the point of contact between compression rollers, wherein the first felt layer is placed adjacent to the first continuous paper surface, wherein the continuous paper stamping surface it is placed adjacent to the second surface of the continuous paper, and wherein the portion of the bypass conduit is in communication for flow with the second felt layer; and pressing the intermediate continuous paper at the point of contact between compression rollers to form a continuous molded paper.
2. 2. The method according to claim 1, wherein the step of pressing the intermediate continuous paper comprises pressing the intermediate continuous paper into a load. P730 roller contact point between approximately 400 pounds per linear inch of the width of the roller contact point in the cross machine direction and approximately 10,000 pounds per linear inch of the width of the roller contact point in the crosswise direction machine. The method according to claim 1 or 2, further comprising the steps of: separating the first layer of dewaxed felt from the first surface of the molded web after the molded web passes through the point of contact between rollers Of compression; supporting the continuous paper molded into the stamping surface of the continuous paper after the molded continuous paper passes through the point of contact between compression rollers; provide a printing surface; etching the continuous paper stamping surface on the continuous molded paper by interposing the continuous paper molded between the continuous paper stamping surface and the printing surface to form an engraved continuous paper; and drying the recorded web 4. The method according to claims 1, 2 or 3, wherein the embossing member has a surface P730 which makes contact with the continuous paper, comprising a continuous, macroscopically monoplanar paper stamping surface. The method according to claims 1, 2 3, or 4, wherein the embossing member has a contacting surface with the continuous paper comprising a continuous, continuous network, patterned surface with macroscopically monoplanar design. defining within the foraminous stamping member a plurality of deflection conduits, not connected, isolated, discrete. The method according to claims 1, 2 3, or 4, wherein the embossing member has a continuous paper contacting surface comprising a plurality of discrete, isolated, continuous paper stamping surfaces. The method according to claims 1, 2 3, or 4, wherein the embossing member has a continuous, semi-continuous paper stamping surface. 8. The method according to claims 1, 2 3, 4, 5, 6, or 7, wherein the stamping member comprises a composite stamping member having a continuous paper stamping surface bonded to the second felt layer. 9. The method according to claims 1, 2 3, P730 4, or 5, comprising the steps of: providing a stamping member having a first contact surface with the continuous paper comprising a continuous, continuous web, continuous, macroscopically monoplane, continuous paper stamping surface, having a plurality of deflection conduits, not connected, isolated, discrete; and pressing the intermediate continuous paper at the point of contact between compression rollers to form a continuous molded paper having a continuous network region, with design, having a relatively high density and a plurality of discrete domes having a relatively low density , the domes that are dispersed throughout the network region of relatively high density, continuous, and are isolated from each other by the network region, of a relatively high density. 10. The method according to claims 1, 2 3, 4, 5, 6, 7, 8, or 9, which further includes the step of pleating the web. P730