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 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 paper web drying apparatus and process is provided in which the heated air drying medium is replaced with between 10 percent to 100 percent of live steam. The addition of a steam component to the drying medium provides for a higher drying temperature to be supplied to the wet moving web. The introduction of live pressurized steam contributes to the load of force of the drying medium, thereby decreasing the energy requirements of blower motors. The introduction of pressurized live steam also lowers the free atmospheric oxygen content of the drying medium which reduces the burning or scorch hazard associated with high temperature drying of a cellulose web.

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 paper web drying apparatus and process is provided in which the heated air drying medium is replaced with between 10 percent to 100 percent of live steam. The addition of a steam component to the drying medium provides for a higher drying temperature to be supplied to the wet moving web. The introduction of live pressurized steam contributes to the load of force of the drying medium, thereby decreasing the energy requirements of blower motors. The introduction of pressurized live steam also lowers the free atmospheric oxygen content of the drying medium which reduces the burning or scorch hazard associated with high temperature drying of a cellulose web.

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 method for making uncreped throughdried tissues is disclosed in which the dried tissue sheet is fully supported by a fabric up to the reel. This method eliminates the open draw between the throughdryer and the reel and thereby eliminates sheet breaks normally associated with such open draws. In addition, the machine direction strength of the sheet can be reduced since the added strength is not needed to traverse the open draw normally present in current processes. Reducing the MD strength in turn enables the production of more square, less stiff sheet, which improves the tactile properties of the product.

Abstract: A method for making uncreped throughdried tissues is disclosed in which the dried tissue sheet is fully supported by a fabric up to the reel. This method eliminates the open draw between the throughdryer and the reel and thereby eliminates sheet breaks normally associated with such open draws. In addition, the machine direction strength of the sheet can be reduced since the added strength is not needed to traverse the open draw normally present in current processes. Reducing the MD strength in turn enables the production of more square, less stiff sheet, which improves the tactile properties of the product.