Abstract: The current invention is generally directed to apparatuses and methods for controlling tension and tension disturbances in a web being continuously unwound from a roll of spirally wound web material. In accordance with the present disclosure, a rotary dancer mechanism is used for applying active and variable forces to a moving web in response to irregularities, such as variations in tension. In one aspect, the apparatus and method of the present disclosure may be used to attenuate undesired disturbances in the web as the web is being fed into a process.

Abstract: The current invention is generally directed to apparatuses and methods for controlling tension and tension disturbances in a web being continuously unwound from a roll of spirally wound web material. In accordance with the present disclosure, a rotary dancer mechanism is used for applying active and variable forces to a moving web in response to irregularities, such as variations in tension. In one aspect, the apparatus and method of the present disclosure may be used to attenuate undesired disturbances in the web as the web is being fed into a process.

Abstract: A through-air dryer system that diverts the airflow within the through-air dryer during warm up and cool down from the normal airflow during the drying of paper in the papermaking process. During warm up and cool down, a majority of the airflow is supplied to one of the dryer's heads and extracted through the opposite head to reduce thermal stresses. If needed to further reduce thermal stresses, a minority of the airflow is supplied through the dryer's shell.

Abstract: A system and process for producing tissue webs is disclosed. The tissue webs are formed from an aqueous suspension of fibers and dried using a through-air dryer. During formation of the web, the web is transferred from a transfer fabric to a throughdrying fabric and then conveyed around a drying cylinder of a through-air dryer. In accordance with the present invention, a pressurized roll emits a gaseous stream through a pressurized zone that pushes and transfers a wet web from a transfer fabric to the throughdrying fabric. The amount of pressure used during the transfer can vary depending upon the particular application and may be used to control the bulk of the web. By using a pressurized transfer roll, the amount the throughdrying fabric is wrapped around the drying cylinder of the through-air dryer can be maximized for increasing the efficiency of the system and the process.

Abstract: A through-air dryer is disclosed. The through-air dryer includes a cylindrical deck made from a plurality of deck plates that support a throughdrying fabric. The deck plates are supported by opposing hubs. Each of the hubs is in communication with a bearing that is mounted to a stationary shaft for allowing the cylindrical deck and the hubs to rotate. The bearings are positioned so as to create a through-air dryer structure that remains stable during operation and allows for easy calculation of loads on the dryer.

Abstract: A system and process for producing tissue webs is disclosed. The tissue webs are formed from an aqueous suspension of fibers and dried using a through-air dryer. During formation of the web, the web is transferred from a transfer fabric to a throughdrying fabric and then conveyed around a drying cylinder of a through-air dryer. In accordance with the present invention, a pressurized roll emits a gaseous stream through a pressurized zone that pushes and transfers a wet web from a transfer fabric to the throughdrying fabric. The amount of pressure used during the transfer can vary depending upon the particular application and may be used to control the bulk of the web. By using a pressurized transfer roll, the amount the throughdrying fabric is wrapped around the drying cylinder of the through-air dryer can be maximized for increasing the efficiency of the system and the process.

Abstract: A system and process for producing tissue webs is disclosed. The tissue webs are formed from an aqueous suspension of fibers and dried using a through-air dryer. During formation of the web, the web is transferred from a transfer fabric to a throughdrying fabric and then conveyed around a drying cylinder of a through-air dryer. In accordance with the present invention, a pressurized roll emits a gaseous stream through a pressurized zone that pushes and transfers a wet web from a transfer fabric to the throughdrying fabric. The amount of pressure used during the transfer can vary depending upon the particular application and may be used to control the bulk of the web. By using a pressurized transfer roll, the amount the throughdrying fabric is wrapped around the drying cylinder of the through-air dryer can be maximized for increasing the efficiency of the system and the process.

Abstract: A system and process for packaging groups of products, such as spirally wound paper products are disclosed. During the packaging of groups, a continuous supply of a wrapping material is unwound and cut periodically in the edge regions. Optionally, a perforation line may also be formed into the wrapping material in between the two cut edges. The cut edges form flaps that are then wrapped around the product groups and sealed. The wrapping material is then broken along the perforation lines in order to form individual packages. Finally, the ends of the packages are folded and sealed.

Abstract: A through-air dryer is disclosed. The through-air dryer includes a cylindrical deck made from a plurality of deck plates that support a throughdrying fabric. The deck plates are supported by opposing hubs. Each of the hubs is in communication with a bearing that is mounted to a stationary shaft for allowing the cylindrical deck and the hubs to rotate. The bearings are positioned so as to create a through-air dryer structure that remains stable during operation and allows for easy calculation of loads on the dryer.

Abstract: A through-air drying apparatus is disclosed. The through-air drying apparatus includes a rotating drying cylinder over which a tissue web is carried and dried. A hood surrounds the drying cylinder leaving an open free end. In accordance with the present invention, an external baffle is positioned adjacent to the open free end of the drying cylinder to prevent external air from leaking in or infiltrating the drying cylinder.

Abstract: A through-air dryer is disclosed. The through-air dryer includes a cylindrical deck made from a plurality of deck plates that support a throughdrying fabric. The deck plates are supported by opposing hubs. Each of the hubs is in communication with the bearing that is mounted to a stationary shaft for allowing the cylindrical deck and the hubs to rotate. The bearings are positioned so as to create a through-air dryer structure that remains stable during operation and allows for easy calculation of loads on the dryer.

Abstract: A process for increasing the tactile properties of a base web without adversely affecting the strength of the web is disclosed. In general, the process includes the steps of placing a base web in between a first moving conveyor and a second moving conveyor. The conveyors are then wrapped around a shear inducing roll which creates shear forces that act upon the base web. The shear inducing roll typically has a relatively small diameter. In some applications, more than one shear inducing roll may be incorporated into the system. In other applications, the shear inducing roll can also be a nip roll for decreasing the caliper of the base web. The shear inducing roll may be stationary, as in the form of a stationary shoe with a convex edge, or may rotate. In one embodiment, the shear inducing roll can rotate on an air bearing.

Abstract: An apparatus for slitting a sheet material web as it is wound onto a roll including at least one winding drum supporting the web, a moveably reel spool positioned in a parallel and spaced apart relationship with the winding drum, a slitting device and a control system. The slitting device includes a track member and a slitting member moveably mounted on the track member. The slitting member continuously slits the sheet material web longitudinally along its length as it is wound onto the roll. The control system controls the position of the slitting member on the track so as to maintain a predetermined penetration of the slitting member within the roll as the roll increases in size.

Abstract: A process for increasing the tactile properties of a base web without adversely affecting the strength of the web is disclosed. In general, the process includes the steps of placing a base web in between a first moving conveyor and a second moving conveyor. The conveyors are then wrapped around a shear inducing roll which creates shear forces that act upon the base web. The shear inducing roll typically has a relatively small diameter. In some applications, more than one shear inducing roll may be incorporated into the system. In other applications, the shear inducing roll can also be a nip roll for decreasing the caliper of the base web. The shear inducing roll may be stationary, as in the form of a stationary shoe with a convex edge, or may rotate. In one embodiment, the shear inducing roll can rotate on an air bearing.

Abstract: A pressurized box is positioned opposite a vacuum box. The pressurized box has a leading cross machine direction baffle with a ceramic shoe which engages a forming fabric, and a trailing cross machine direction baffle of similar construction. Two end deckles complete the pressurized box. The leading cross machine direction baffle presses against a resilient seal which causes a web contained between upper and lower forming fabrics to wrap about the baffle shoe a few degrees forming an effective end seal which does not allow air to bypass the baffle. The trailing cross machine direction baffle is positioned over a vacuum box which prevents air from leaking around the trailing baffle. A vacuum box draws air through the forming fabrics and the web, from the pressurized box increasing the total pressure gradient across the web to 20 to 30 psi or more. The pressure box and opposed vacuum box form an air press. The pressure box is positioned and held against the forming fabrics by opposing air tubes.

Abstract: An apparatus for penetrating a sheet material web being carried on a fabric. The apparatus including a penetrating device and an air flow that separates a portion of the sheet material web from the fabric adjacent the penetrating device so as to bring the web into contact with the penetrating device. In one embodiment, a vacuum lifts a portion of the sheet material web into contact with a slitting member such that it continuously slits the sheet material web longitudinally along its length as the fabric carries the sheet material web beneath it. In an alternative embodiment, a pressurized air stream is directed to a bottom portion of the sheet material web so as to separate the web from the fabric.

Abstract: An apparatus for penetrating a sheet material web being carried on a fabric. The apparatus including a penetrating device and an air flow that separates a portion of the sheet material web from the fabric adjacent the penetrating device so as to bring the web into contact with the penetrating device. In one embodiment, a vacuum lifts a portion of the sheet material web into contact with a slitting member such that it continuously slits the sheet material web longitudinally along its length as the fabric carries the sheet material web beneath it. In an alternative embodiment, a pressurized air stream is directed to a bottom portion of the sheet material web so as to separate the web from the fabric.

Abstract: An apparatus for slitting a sheet material web as it is wound onto a roll including at least one winding drum supporting the web, a moveably reel spool positioned in a parallel and spaced apart relationship with the winding drum, a slitting device and a control system. The slitting device includes a track member and a slitting member moveably mounted on the track member. The slitting member continuously slits the sheet material web longitudinally along its length as it is wound onto the roll. The control system controls the position of the slitting member on the track so as to maintain a predetermined penetration of the slitting member within the roll as the roll increases in size.

Abstract: An apparatus for penetrating a sheet material web being carried on a fabric. The apparatus including a penetrating device and an air flow that separates a portion of the sheet material web from the fabric adjacent the penetrating device so as to bring the web into contact with the penetrating device. In one embodiment, a vacuum lifts a portion of the sheet material web into contact with a slitting member such that it continuously slits the sheet material web longitudinally along its length as the fabric carries the sheet material web beneath it. In an alternative embodiment, a pressurized air stream is directed to a bottom portion of the sheet material web so as to separate the web from the fabric.