U.S. patent application number 16/500318 was filed with the patent office on 2020-06-11 for production of paper that is highly stretchable in the cross direction.
The applicant listed for this patent is Billerudkorsnas AB. Invention is credited to Nils NORDLING, Fredrik NORDSTROM.
Application Number | 20200181842 16/500318 |
Document ID | / |
Family ID | 58536760 |
Filed Date | 2020-06-11 |
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United States Patent
Application |
20200181842 |
Kind Code |
A1 |
NORDLING; Nils ; et
al. |
June 11, 2020 |
PRODUCTION OF PAPER THAT IS HIGHLY STRETCHABLE IN THE CROSS
DIRECTION
Abstract
There is provided a method of producing a paper having a
grammage according to ISO 536 of 50-250 g/m2, a Gurley value
according to ISO 5636-5 of above 15 s and a stretchability
according to ISO 1924-3 in the cross direction of at least 8%, said
method comprising the steps of: a) providing a pulp, preferably
sulphate pulp; b) subjecting the pulp to refining; c) diluting the
pulp from step b) and discharging the diluted pulp at a discharge
rate to a forming wire to form a paper web, wherein the speed of
the forming wire is at least 7 m/min higher or at least 7 m/min
lower than the discharge rate; d) pressing the paper web from step
c); e) drying the paper web from step d), which drying comprises a
step of compacting the paper web in a Clupak unit.
Inventors: |
NORDLING; Nils; (Kalix,
SE) ; NORDSTROM; Fredrik; (Karlstad, SE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Billerudkorsnas AB |
Solna |
|
SE |
|
|
Family ID: |
58536760 |
Appl. No.: |
16/500318 |
Filed: |
April 5, 2018 |
PCT Filed: |
April 5, 2018 |
PCT NO: |
PCT/EP2018/058713 |
371 Date: |
October 2, 2019 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D21F 9/02 20130101; D21D
1/20 20130101; D21F 11/00 20130101; D21H 11/04 20130101; D21H
25/005 20130101; D21C 9/007 20130101; D21F 5/028 20130101; D21H
27/10 20130101; D21H 27/00 20130101 |
International
Class: |
D21F 9/02 20060101
D21F009/02; D21D 1/20 20060101 D21D001/20; D21F 5/02 20060101
D21F005/02; D21H 11/04 20060101 D21H011/04 |
Foreign Application Data
Date |
Code |
Application Number |
Apr 6, 2017 |
EP |
17165149.0 |
Claims
1. Method of producing a paper having a grammage according to ISO
536 of 50-250 g/m.sup.2, a Gurley value according to ISO 5636-5 of
above 15 s and a stretchability according to ISO 1924-3 in the
cross direction of at least 8%, said method comprising the steps
of: a) providing a pulp, preferably sulphate pulp; b) subjecting
the pulp to refining; c) diluting the pulp from step b) and
discharging the diluted pulp at a discharge rate to a forming wire
to form a paper web, wherein the speed of the forming wire is at
least 7 m/min higher or at least 7 m/min lower than the discharge
rate; d) pressing the paper web from step c); e) drying the paper
web from step d), which drying comprises a step of compacting the
paper web in a Clupak unit.
2. The method of claim 1, wherein the speed of the forming wire is
8-m/min higher or 8-25 m/min lower than the discharge rate.
3. The method of claim 1 or 2, wherein the diluted pulp is
discharged through a discharge gap of at least 40 mm, such as at
least 50 mm, such as 50-70 mm.
4. The method of any one of the preceding claims, wherein the paper
has a stretchability according to ISO 1924-3 in the cross direction
of at least 9%, such as at least 9.5%.
5. The method of any one of the preceding claims, wherein the paper
has a stretchability according to ISO 1924-3 in the machine
direction of at least 9%, such as at least 10%, such as at least
11%.
6. The method of any one of the preceding claims, wherein step b)
comprises subjecting the pulp to high consistency (HC)
refining.
7. The method of claim 6, wherein the consistency of the pulp
subjected to HC refining is at least 33%, such as at least 37%,
such as at least 38%.
8. The method of any one of the preceding claims, wherein step b)
comprises subjecting the pulp to low consistency (LC) refining.
9. The method of claim 8, wherein the energy supply in the LC
refining is 20-200 kWh per ton paper, such as 30-200 kWh per ton
paper, such as 40-200 kWh per ton paper.
10. The method of any one of the preceding claims, wherein the
paper web is compacted in the Clupak unit at a moisture content of
20-48%, such as 30-45%, such as 35-45%.
11. The method of any one of the preceding claims, wherein the line
load of the nip bar in the Clupak unit is at least 22 kN/m, such as
at least 25 kN/m, such as at least 28 kN/m.
12. The method of any one of the preceding claims, wherein the
grammage according to ISO 536 of the paper is 60-220 g/m.sup.2,
such as 80-200 g/m.sup.2.
13. The method of any one of the preceding claims, wherein the
Gurley value according to ISO 5636-5 of the paper is at least 20 s,
preferably at least 25 s, more preferably at least 35 s.
14. The method of any one of the preceding claims, wherein step e)
comprises drying the paper web from the Clupak unit in a drying
group and the speed of the paper web in the dryer group is 8-14%
lower than the speed of the paper web entering the Clupak unit.
15. The method of any one of the preceding claims, wherein the
Bendtsen roughness according to ISO 8791-2 of at least one side of
the paper is 1900 ml/min or lower, such as 1700 ml/min or lower,
such as 1500 ml/min or lower.
16. Method according to claim 1, wherein: step b comprises the
substeps of b1) subjecting the pulp to high consistency (HC)
refining at a consistency of 33-42% to the extent that the pulp
obtains a Schopper-Riegler (SR) number measured according to ISO
5267-1 of 13-19 and b2) subjecting the pulp from step b1) to low
consistency (LC) refining at a consistency of 2-6% to the extent
that the pulp obtains a Schopper-Riegler (SR) number measured
according to ISO 5267-1 of 18-40; and the speed of the forming wire
is 7-30 m/min higher or 7-30 m/min lower than the discharge rate in
step c).
Description
TECHNICAL FIELD
[0001] The invention relates to the production paper that is highly
stretchable in the cross direction.
BACKGROUND
[0002] BillerudKorsniis AB (Sweden) has marketed a highly
stretchable paper under the name FibreForm.RTM. since 2009. The
stretchability of FibreForm.RTM. in both the machine direction (MD)
and the cross direction (CD) allows it to replace plastics in many
applications. FibreForm.RTM. has been produced on paper machine
comprising an Expanda unit that compacts/creps the paper in the
machine direction to improve the stretchability.
SUMMARY
[0003] The object of the present disclosure is to provide a method
of producing a paper that is highly stretchable in the cross
direction without being a typical porous sack paper on a paper
machine comprising a Clupak unit for compacting the paper in the
machine direction.
[0004] There is thus provided a method of producing a paper having
a grammage according to ISO 536 of 50-250 g/m.sup.2, a Gurley value
according to ISO 5636-5 of above 15 s and a stretchability
according to ISO 1924-3 in the cross direction of at least 8%, said
method comprising the steps of:
[0005] a) providing a pulp, preferably sulphate pulp;
[0006] b) subjecting the pulp to refining;
[0007] c) diluting the pulp from step b) and discharging the
diluted pulp at a discharge rate to a forming wire to form a paper
web, wherein the speed of the forming wire is at least 7 m/min
higher or at least 7 m/min lower than the discharge rate;
[0008] d) pressing the paper web from step c);
[0009] e) drying the paper web from step d), which drying comprises
a step of compacting the paper web in a Clupak unit.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a schematic illustration of a Clupak unit.
[0011] FIG. 2 shows (on the y axis) the cross direction (CD)
stretchability in % of paper produced from pulp subjected to HC
refining at the consistencies 38.0%, 36.1% and 31.8%. The x axis
represents the chronological order.
[0012] FIG. 3 shows (on the y axis) the stretchability in % of lab
sheets produced from:
[0013] non-refined pulp ("non-refined, before HCR");
[0014] pulp subjected to HC refining (150 or 220 kWh/t) only
("before LCR"); and
[0015] pulp subjected to HC refining (150 or 220 kWh/t) and LC
refining ("LCR 100 kWh/t", "LCR 150 kWh/t" and "LCR 200
kWh/t").
DETAILED DESCRIPTION
[0016] The present disclosure relates to a method of producing a
paper, which is preferably uncoated. Subsequent to the method of
the present disclosure, the paper may be coated, e.g. to improve
printing properties and/or to obtain barrier properties.
[0017] The paper obtained by the method is characterized by its
stretchability, which is at least 8% in the cross direction (CD).
Preferably, the stretchability in CD is higher than 8%, such as at
least 9% or at least 9.5%. The stretchability enables formation of
three-dimensional (double curvature) shapes in the paper, e.g. by
press forming, vacuum forming or deep drawing. The formability of
the paper in such processes is further improved if the
stretchability is relatively high also in the machine direction
(MD).
[0018] Preferably, the stretchability in MD is at least 9%, such as
at least 10%, such as at least 11%. An upper limit for the
stretchability in CD may for example be 15%. An upper limit for the
stretchability in MD may for example be 20% or 25%. The
stretchability (in both MD and CD) is determined according to the
standard ISO 1924-3.
[0019] In contrast to many sack papers, which may be highly
stretchable, the paper of the present disclosure is not
particularly porous. Instead, relatively low porosity may be
preferred in the applications intended for the paper of the present
disclosure. For example, glue and some coatings have a lower
tendency to bleed through a paper of low porosity. Further, some
printing properties are improved when the porosity is reduced.
[0020] The air resistance according to Gurley, i.e. the Gurley
porosity, is a measurement of the time (s) taken for 100 ml of air
to pass through a specified area of a paper sheet. Short time means
highly porous paper. The Gurley porosity of the paper of the
present disclosure is above 15 s. The Gurley porosity is preferably
at least 20 s and more preferably 25 s, such as at least 35 s. An
upper limit for may for example be 120 s or 150 s. The Gurley
porosity (herein also referred to as the "Gurley value") is
determined according to ISO 5636-5.
[0021] The grammage of the paper of the present disclosure is
50-250 g/m.sup.2. If a stretchable material having a grammage above
250 g/m.sup.2 is desired, a laminate can be produced from a
plurality of paper layers each having a grammage in the range of
50-250 g/m.sup.2. Below 50 g/m.sup.2 the strength and rigidity is
typically insufficient. The grammage is preferably 60-220 g/m.sup.2
and more preferably 80-200 g/m.sup.2, such as 80-160 g/m.sup.2,
such as 80-130 g/m.sup.2. The standard ISO 536 is used to determine
the grammage. The Bendtsen roughness is typically lower when the
grammage is lower.
[0022] The density of the paper is typically between 700 and 1000
kg/m.sup.3. Preferred density ranges are 700-800 kg/m.sup.3 and
710-780 kg/m.sup.3. Higher density typically means reduced bending
stiffness, which is often undesired.
[0023] For aesthetic and printing purposed, the paper of the
present disclosure is preferably white. For example, its brightness
according to ISO 2470 may be at least 80%, such as at least 82%.
However, the paper may also be unbleached ("brown").
[0024] It is also desired to be able to produce a stretchable paper
with a relatively fine surface. Accordingly, the Bendtsen roughness
according to ISO 8791-2 of at least one side of the paper may be
1900 ml/min or lower, such as 1700 ml/min or lower, such as 1500
ml/min or lower. A lower limit may be 800 ml/min or 500 ml/min.
[0025] The skilled person understands that the above Bendtsen
roughness values relate to uncoated paper.
[0026] The method of the present disclosure comprises the step
of:
[0027] a) providing a pulp.
[0028] The pulp is preferably a sulphate pulp (sometimes referred
to as a "Kraft pulp"), which provides high tensile strength. For
the same reason, the starting material used for preparing the pulp
preferably comprises softwood (which has long fibers and forms a
strong paper). Accordingly, the pulp may comprise at least 50%
softwood pulp, preferably at least 75% softwood pulp and more
preferably at least 90% softwood pulp. The percentages are based of
the dry weight of the pulp.
[0029] The tensile strength is the maximum force that a paper will
withstand before breaking. In the standard test ISO 1924-3, a
stripe having a width of 15 mm and a length of 100 mm is used with
a constant rate of elongation. Tensile energy absorption (TEA) is
sometimes considered to be the paper property that best represents
the relevant strength of a paper. The tensile strength is one
parameter in the measurement of the TEA and another parameter is
stretchability. The tensile strength, the stretchability and the
TEA value are obtained in the same test. The TEA index is the TEA
value divided by the grammage. In the same manner, the tensile
index is obtained by dividing the tensile strength by the
grammage.
[0030] A dry strength agent, such as starch, may be added to
improve tensile strength. The amount of starch may for example be
1-15 kg per ton paper, preferably 1-10 or 2-8 kg per ton paper. The
starch is preferably cationic starch.
[0031] In the context of the present disclosure, "per ton paper"
refers to per ton of dried paper from the paper making process.
Such dried paper normally has a dry matter content (w/w) of
90-95%.
[0032] The TEA index of the paper obtained by the method of the
present disclosure may for example be at least 3.5 J/g (e.g.
3.5-7.5 J/g) in the MD and/or at least 2.9 J/g (e.g. 2.9-3.9 J/g)
in the CD. In one embodiment, the TEA index is above 4.5 J/g (e.g.
4.6-7.5 J/g) in MD and/or above 3.0 J/g (e.g. 3.1-3.9 J/g) in
CD.
[0033] One or more sizing agents may also be added to the pulp.
Examples of sizing agents are AKD, ASA and rosin size. When rosin
size is added, it is preferred to also add alum. Rosin size and
alum is preferably added in a weight ratio between 1:1 and 1:2.
Rosin size can for example be added in an amount of 0.5-4 kg per
ton paper, preferably 0.7-2.5 kg per ton paper.
[0034] When the paper is white, the pulp is bleached.
[0035] The method further comprises the step of:
[0036] b) subjecting the pulp to refining.
[0037] It is shown under Examples below that the CD stretchability
is increased by HC refining. By comparing the stretchability values
obtained after HC refining at 150 and 220 kWh/ton paper,
respectively, it has further been shown that a higher degree of HC
refining results in higher CD stretchability. It is also shown that
the CD stretchability is increased by LC refining. By comparing the
stretchability values obtained at 100, 150 and 200 kWh/ton paper,
respectively, it has further been shown that a higher degree of LC
refining results in higher CD stretchability.
[0038] The effect of refining on stretchability is particularly
pronounced when the refining is combined with "free drying", which
is further discussed below.
[0039] The effect LC refining, which hydrates the fibres, on CD
stretchability is particularly pronounced when the LC refining is
combined with the fibre orientation caused by the "jet/wire ratio"
discussed below.
[0040] Accordingly step b) comprises subjecting the pulp to high
consistency (HC) refining in one embodiment of the invention. In an
alternative of complementary embodiment, step b) comprises
subjecting the pulp to low consistency (LC) refining.
[0041] In a preferred embodiment, step b) comprises the substeps
of:
[0042] b1) subjecting the pulp to high consistency (HC) refining;
and
[0043] b2) subjecting the pulp from step b1) to low consistency
(LC) refining.
[0044] The consistency of the pulp subjected to HC refining is
preferably at least 33% and more preferably above 36%. In
particularly preferred embodiments, the consistency of the pulp
subjected to HC refining is at least 37%, such as at least 38% (see
FIG. 2). A typical upper limit for the consistency may be 42%.
[0045] The HC refining is typically carried out to the extent that
the pulp obtains a Schopper-Riegler (SR) number of 13-19, such as
13-18. The SR number is measured according to ISO 5267-1. To reach
the desired SR number, the energy supply in the HC refining may be
at least 100 kWh per ton paper, such as above 150 kWh per ton
paper. A typical upper limit may be 220 kWh per ton paper.
[0046] The consistency of the pulp subjected to LC refining is
typically 2-6%, preferably 3-5%. The LC refining is typically
carried out to the extent that the pulp obtains a Schopper-Riegler
(SR) number of 18-40, preferably 19-35, such as 23-35. To reach the
desired SR number, the energy supply in the LC refining may be
20-200 kWh per ton paper, such as 30-200 kWh per ton paper, such as
40-200 kWh per ton paper.
[0047] As well known to the skilled person, LC refining increases
the SR number.
[0048] In one embodiment, the method further comprises the step of
adding broke pulp to the pulp in step b) or between step b) and
step c) (step c) is discussed below). The broke pulp is preferably
obtained from the same method.
[0049] The method further comprises the step of:
[0050] c) diluting the pulp from step b) and discharging the
diluted pulp at a discharge rate to a forming wire to form a paper
web.
[0051] The diluted pulp is typically discharged as a jet stream
through a slice in the headbox. The diluted pulp is then dewatered
on the forming wire such that the paper web is formed. The diluted
pulp typically has a pH of 5-6 and a consistency of 0.2-0.5%.
[0052] In step c), the discharge rate is preferably (but not
necessarily) at least 7 m/min higher or at least 7 m/min lower than
the speed of the forming wire. Such difference in speed results in
that the proportion of fibres that are oriented in the machine
direction increases. This is in contrast to the case when the
discharge rate is the same as the speed of the forming wire, which
results in that the orientations of the fibres tend to be evenly
distributed in all directions. An increased proportion of fibres
oriented in the machine direction increases shrinkage in the cross
direction during drying, which means that the CD stretchability is
increased.
[0053] It has been shown that an increased speed difference results
in an increased CD-stretch. Impaired formation has however been
observed if the difference in speed is too high. Therefore, the
difference in speed is typically not more than 30 m/min.
[0054] In a preferred embodiment, the discharge rate is 8-25 m/min
higher or 8-25 m/min lower than the speed of the forming wire. In a
more preferred embodiment, the discharge rate is 9-23 m/min higher
or 9-23 m/min lower than the speed of the forming wire.
[0055] It is generally more preferred that the discharge rate is
higher than the speed of the forming wire. Accordingly, in a
preferred embodiment, the discharge rate is at least 7 m/min higher
than the speed of the forming wire, such as 8-m/min higher than the
speed of the forming wire, such as 9-23 m/min higher than the speed
of the forming wire.
[0056] The ratio between the discharge rate and the speed of the
forming wire is sometimes referred to as the jet/wire ratio.
[0057] In one embodiment of step c), the diluted pulp is discharged
through a discharge gap of at least 40 mm, such as at least 50 mm,
such as 50-70 mm.
[0058] By using such a relatively large gap, the CD stretchability
becomes more homogenous across the paper web. The "discharge gap"
can also be referred to the as a "discharge opening" or "slice
opening". A slice typically has a stationary lip and a regulating
lip. In such case, the discharge opening is the gap between the
stationary lip and the regulating lip.
[0059] The paper web formed in step c) typically has a dry content
of 15-25%, such as 17-23%.
[0060] The method further comprises the step of:
[0061] d) pressing the paper web from step c), e.g. to a dry
content of 30-50%, such as 36-46%.
[0062] The pressing section used for step d) typically has one, two
or three press nips. In one embodiment, a shoe press is used. In
such case, the nip of the shoe press can be the only nip of the
pressing section. A benefit of using a shoe press is improved
stiffness in the final product.
[0063] The method further comprises the step of:
[0064] e) drying the paper web from step d), which drying comprises
a step of compacting the paper web in a Clupak unit.
[0065] The step of compacting the paper web in the Clupak unit is
normally carried out at a moisture content between 20 and 48%.
Normally, step e) comprises drying of the paper web both before and
after the compacting in the Clupak unit.
[0066] The compacting in the Clupak unit increases the
stretchability of the paper, in particular in the MD, but also in
the CD. To improve surface/printing properties, the moisture
content of the paper is preferably at least 30% (e.g. 30-50%), such
as at least 35% (e.g. 35-49%), when entering the Clupak unit.
Higher moisture contents have also been shown to correlate with
higher stretchabilities in the MD.
[0067] Further, the inventors have found that the increase in
stretchability is facilitated by a relatively high nip bar line
load, i.e. at least 22 kN/m, in the Clupak unit. Preferably, the
nip bar line load is at least 25 kN/m or at least 28 kN/m. More
preferably, the nip bar line load is at least 31 kN/m. A typical
upper limit may be 38 kN/m. In the Clupak unit, the nip bar line
load is controlled by the adjustable hydraulic cylinder pressure
exerted on the nip bar. The nip bar is sometimes referred to as the
"nip roll". The relationship between nip bar line load and CD
stretchability is shown under Examples below.
[0068] In one embodiment, the rubber belt tension in the Clupak
unit is at least 5 kN/m (such as 5-9 kN/m), preferably at least 6
kN/m (such as 6-9 kN/m), such as about 7 kN/m. In the Clupak unit,
the rubber belt tension is controlled by the adjustable hydraulic
cylinder pressure exerted on the tension roll stretching the rubber
belt.
[0069] The Clupak unit typically comprises a steel cylinder. When
the paper web is compacted by the contraction/recoil of the rubber
belt in the Clupak unit, it moves relative the steel cylinder. To
reduce the friction between the paper web and the steel cylinder,
it is preferred to add a release liquid. The release liquid may be
water or water-based. The water-based release liquid may comprise a
friction-reducing agent, such as polyethylene glycol or a
silicone-based agent. In one embodiment, the release liquid is
water comprising at least 0.5%, preferably at least 1%, such as
1-4%, polyethylene glycol.
[0070] A Clupak unit is also described below with reference to FIG.
1.
[0071] After being compacted in the Clupak unit, the paper web is
normally subjected to further drying.
[0072] In one embodiment, step e) comprises drying the paper web
from the Clupak unit in a drying group and the speed of the paper
web in the dryer group is 8-14% lower than the speed of the paper
web entering the Clupak unit. A reason for lowering the speed in
this manner is to maintain the MD stretchability obtained by the
paper web in the Clupak unit.
[0073] The paper web is preferably allowed to dry freely during
part of step e), in particular after the Clupak unit. During such
"free drying", which improves the stretchability, the paper web is
not in contact with a dryer screen (often referred to as a dryer
fabric). A forced, optionally heated, air flow may be used in the
free drying, which means that the free drying may comprise fan
drying.
[0074] As shown in table 1 below, the side of the paper that
contacted the steel cylinder in the Clupak unit normally has a
finer surface than the side of the paper that contacted the rubber
belt in the Clupak unit. A chromed cylinder may be used instead of
a steel cylinder. Accordingly, it is normally preferred to print
side of the paper that contacted the steel/chromed cylinder.
[0075] Therefore, the method may further comprise the step of:
[0076] f) printing the side of the paper that contacted the
steel/chromed cylinder of the Clupak unit in step e).
[0077] FIG. 1 illustrates a Clupak unit 105, comprising an endless
rubber belt 107 (sometimes referred to as a "rubber blanket")
contacted by two blanket rolls 108, 109, a guide roll 110, a
tension roll 111 and a nip bar 112. A first hydraulic arrangement
113 exerts pressure on the tension roll 111 to stretch the rubber
belt 107. A second hydraulic arrangement 114 exerts pressure on the
nip bar 112 to press the rubber belt 107, which in turns presses
the paper web 117 against a steel cylinder 115. A release liquid
spray nozzle 116 is arranged to apply a release liquid to the steel
cylinder 115.
EXAMPLES
[0078] Full Scale Trial
[0079] A full-scale trial was carried out to produce white
stretchable paper on a paper machine normally used for producing
sack paper. The production is described below.
[0080] A bleached softwood sulphate pulp was provided. The pulp was
subjected to high consistency (HC) refining (180 kWh per ton paper)
at a consistency of about 39% and low consistency (LC) refining (65
kWh per ton paper) at a consistency of about 4.3%. Cationic starch
(7 kg per ton paper), rosin size (2.4 kg per ton paper) and alum
(3.5 kg per ton paper) were added to the pulp. In the headbox, the
pH of the pulp/furnish was about 5.8 and the consistency of the
pulp/furnish was about 0.3%. The pulp was discharged through a
discharge opening in the headbox to a forming wire to form a paper
web. The slice lip was set to form a discharge gap of 60 mm. The
speed of the forming wire was 10 m/min lower than the discharge
rate of the pulp. The dry content of the paper web leaving the wire
section was about 19%. The paper web was dewatered in a press
section having two nips to obtain a dry content of about 38%. The
dewatered paper web was then dried in a subsequent drying section
having nine dryer groups, including one Clupak unit, arranged in
series. In this context, the Clupak unit was thus considered to be
a "dryer group". The Clupak unit was arranged as dryer group seven,
which means that the paper web was dried in the drying section both
before and after being compacted in the Clupak unit. When entering
the Clupak unit, the moisture content of the paper web was 40%. The
hydraulic cylinder pressure exerted on the nip bar was set to 30
bar, resulting in a line load of 33 kN/m. The hydraulic cylinder
pressure stretching the rubber belt was set to 31 bar, resulting in
a belt tension of 7 kN/m. To reduce the friction between the paper
web and the steel cylinder in the Clupak unit, a release liquid
(1.5% polyetylene glycol) was added in an amount of 250 litre/hour.
The speed of the paper web in the dryer group directly downstream
the Clupak was 11% lower than the speed of the paper web entering
the Clupak unit.
[0081] Properties of the paper produced in the trial are presented
in table 1 below.
TABLE-US-00001 TABLE 1 Properties measured on samples obtained from
the top of the jumbo roll. Grammage (g/m.sup.2) 150 Thickness
(.mu.m) 195 Density (kg/m.sup.3) 764 Tensile strength, MD (kN/m)
12.4 Tensile strength, CD (kN/m) 6.9 Tensile index, MD (kNm/kg) 83
Tensile index, CD (kNm/kg) 46 Stretchability, MD (%) 14.4
Stretchability, CD (%) 9.9 TEA, MD (J/m.sup.2) 1010 TEA, CD T
(J/m.sup.2) 479 TEA index, MD (J/g) 6.8 TEA index, CD (J/g) 3.2
Burst strength (kPa) 775 Burst index (mN/kg) 5.2 Bending
resistance, MD (mN) 170 Bending resistance, CD (mN) 194 Bending
resistance index, MD (Nm.sup.6/kg.sup.3) 50.4 Bending resistance
index, CD (Nm.sup.6/kg.sup.3) 57.5 Gurley value (s) 38 Brightness
(%) 83 Bendtsen roughness (ml/min), SS* 1596 Bendtsen roughness
(ml/min), RS** 3246 *RS means the side of the paper contacting the
rubber belt in the Clupak unit. **SS means the side of the paper
contacting the steel cylinder in the Clupak unit.
[0082] As shown in Table 1, a paper having a Gurley value of 38 s
and a CD stretchability of 9.9% was produced. It is assumed that
the CD stretchability would have been even higher if the degree of
LC refining had been higher. The Bendtsen roughness values would
have been lower if they had been measured on a paper sample taken
from another position in the jumbo roll or after rewinding. The
Bendtsen roughness values in table 1 are thus higher than those of
the paper that is shipped to the customer.
[0083] Effect of Consistency in the HC Refining
[0084] In a full scale trial according to the above, the
consistency of the pulp subjected to HC refining was first 38% and
then lowered in two steps to 36.1% and 31.8%, respectively, by
reducing the degree to which the pulp was pressed before the HC
refining. The CD stretchability of the resulting paper was measured
three times for the 38% pulp, four times for the 36.1% pulp and
three times for the 31.8% pulp. The results are presented in FIG.
2, which indicate that the CD stretchability is generally increased
by increasing the consistency of the pulp subjected to HC refining.
A particularly positive effect on the CD stretchability is shown
for a consistency above 36%.
[0085] Effect of Nip Bar Line Load in the Clupak Unit
[0086] In a full scale trial according to the above, two different
line loads were used and the CD stretchability of the resulting
paper was measured. The results are presented in Table 2, which
shows that the average CD stretchability was increased by 6.8% by
increasing the nip bar line load from 22 to 33 kN/m.
TABLE-US-00002 TABLE 2 Nip bar line load Stretchability, CD (kN/m)
(%) Sample 1 33 9.95 Sample 2 22 9.51 Sample 3 33 9.81 Sample 4 22
9.00 Sample 5 33 10.04 Sample 6 22 9.38 Average 33 9.93 Average 22
9.30
[0087] Laboratory Trial
[0088] The correlation between refining and stretchability in the
cross direction (CD) was tested in a laboratory trial. In the
laboratory trial, non-oriented lab sheets were formed from pulps
subjected to different degrees of high consistency and low
consistency refining. The stretchability of the lab sheets, which
is considered to be representative of the CD stretchability of
paper formed on a paper machine, was then tested. The results of
the laboratory trial are presented in FIG. 3, which shows that both
HC refining and LC refining increase the stretchability. A
particularly beneficial effect is obtained when HC and LC refining
is combined. FIG. 3 further shows that there is a positive
correlation between the degree of LC refining and the
stretchability. It also shows that an increase in the degree of HC
refining increases the stretchability.
* * * * *