WO2003004772A1

WO2003004772A1 - Multiply paper, and method and apparatus for making the same on the wet type

Info

Publication number: WO2003004772A1
Application number: PCT/KR2001/001258
Authority: WO
Inventors: Jun Soo Kim; Jeong Heon Choi
Original assignee: E-Papertec Co.,Ltd.
Priority date: 2001-07-05
Filing date: 2001-07-24
Publication date: 2003-01-16
Also published as: KR20010096675A

Abstract

The process of a multiply high performance paper is simple and excellent in operation. It is specifically desired that the multiply high performance paper is made by the multi vacuum type suction roller. The web sheets made from furnish are used as a base paper for the process. The multiply paper with special may be preferably provided by repetition of the process.

Description

MULTIPLY PAPER, AND METHOD AND APPARATUS FOR MAKING THE SAME ON THE WET TYPE

RELATED APPLICATION

The present application claims the benefit of Korean Patent Application No. 10-2001-40035 filed on July 5, 2001, under 35 U.S.C. §119, which is herein fully incorporated by reference.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates to multi-layered papers and a method and apparatus for producing the multi-layered papers and associated products.

2. Description of Related Art

Various types of multi-layered paper products and methods and apparatuses for producing the same are known in the art. Generally, a hard paper having a multi-layered structure such as pasteboard is manufactured by stacking and pasting multiple layers of paper materials. The stacking and pasting of multiple layers of paper materials increases the hardness of the pasteboard which is suitable for use as packaging boxes, binders, or file covers. Generally, a sheet or layer of paper material is manufactured by dissociating the paper material in water, beating the dissociated paper material to create joining characteristics therein, then spraying the paper material in the shape of a sheet, and then drying it to complete the process.

A conventional method and apparatus for producing multi- layered paper such as pasteboard involves the use of paper material layers of different qualities and a plurality of rollers for rolling these paper material layers. Particularly, an adhesive is applied on a surface of a first paper material layer and then a second paper material layer is pasted on top of the first paper material layer. This process is repeated until a predetermined number of paper material layers have been pasted on top of each other. Then the final product is rolled up on a cutting roller and cut appropriately to produce a multi-layered paper of desired shape and size.

However, such conventional methods and apparatuses suffer from many problems. For example, since each paper material layer must be manufactured first through a process and device separate from the process and device for pasting and layering the paper material layers, the conventional methods and apparatuses require a large scaled facility and manufacturing expense. Further, even after the paper is manufactured, the waste water generated through the process must be disposed properly, which requires a waste water disposal plant and scheme. This increases the manufacturing cost significantly.

SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to provide improved multi-layered paper products, and an improved method and apparatus for producing multi-layered paper products, which eliminate the above and other problems associated with conventional multi- layered paper products and conventional methods and apparatuses for producing the multi-layered paper products.

Other objects and further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. It should be understood, however, that the detailed description and specific examples, which indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, wherein reference numerals designate corresponding parts in the various drawings and wherein:

Fig. 1 is a diagram of an apparatus for producing a multi-layered paper product according to an embodiment of the present invention; Fig. 2 is an exploded sectional view of the apparatus of Fig. 1 according to the present invention;

Fig. 3 is a sectional view of an example of a multi-layered paper product produced according to the present invention;

Fig. 4 is a sectional view of another example of a multi-layered product produced according to the present invention; and

Fig. 5 is a diagram of an apparatus for producing a multi-layered paper product according to another embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

In the drawings, like reference numerals represent like elements.

Referring now in detail to the drawings for the purpose of illustrating preferred embodiments of the present invention, an apparatus 1 for producing a multi-layered paper or similar product according to an embodiment of the present invention as shown in Fig. 1 includes: a plurality of vats 2 (2a, 2b, 2c, 2d, 2e) containing a paper material, a paste material, or any other layer-forming material and being aligned in an assembly line fashion underneath a transport medium such as a conveyor belt; a plurality of absorbing rollers 11 (11a, l ib, l ie, l id, l ie) corresponding to the vats 2 (2a, 2b, 2c, 2d, 2e) for absorbing or adhering the paper, paste or other material contained in the corresponding vat onto the outer surface of the corresponding absorbing roller; a plurality of pressing rollers 15 (15a, 15b, 15c, 15d, 15e) operating against the corresponding absorbing rollers 11 (11a, l ib, l ie, l id, l ie); a plurality of guide rollers 4 and guide blocks 3 positioned along the assembly line for guiding the movement of the product being formed along the assembly line; a dryer 30 for drying a layered product 24 from the last pressing roller 15e to produce a final multi-layered product 25; and a cutting roller 40 for rolling the final product 25 thereon.

All the pressing rollers 15 (15a, 15b, 15c, 15d, 15e) rotate in one direction whereas all the absorbing rollers 11 (11a, l ib, l ie, l id, l ie) rotate in the opposite direction. That is, the pressing rollers 15 rotate in the clockwise direction, and the absorbing rollers 11 rotate in the counterclockwise direction. As the rollers 15 and 11 rotate, any item produced therefrom is moved along the transport medium in the transporting direction. Any existing technique or mechanism can be used to rotate selectively the rollers 15 and 11 and to move the item produced therefrom to desired locations. The apparatus 1 according to the embodiment of the present invention can be functionally divided into a base paper forming section 10 for forming a base paper layer 23, and one or more pasting sections 20 (20a, 20b, 20c, 20d) to apply additional layers 22 of paper materials to a surface of the base paper layer 23 (Fig. 2). The materials used to produce the additional layers 22 are preferably a mixture of paper materials and paste materials, such that no separate adhesive is needed to be adhere the multiple layers to each other. In this example, there are four pasting sections 20 (20a, 20b, 20c, 20d). The base paper forming section 10 includes the first pressing roller

15a, the first absorbing roller 1 la, and the first vat 2a. The first pasting section 20a includes the second pressing roller 15b, the second absorbing roller l ib and the second vat 2b. The second pasting section 20b includes the third pressing roller 15c, the third absorbing roller l ie and the third vat 2c. The third pasting section 20c includes the fourth pressing roller 15d, the fourth absorbing roller l id and the fourth vat 2d. The fourth pasting section 20d includes the fifth pressing roller 15e, the fifth absorbing roller l ie and the fifth vat 2e. Although only four pasting sections 20 (20a, 20b, 20c, 20d) are illustrated, the present invention is not limited to such and the apparatus of the present invention can include any number of pasting sections as needed.

Fig. 2 shows a detailed sectional diagram of the base paper forming section 10 and the first pasting section 20a of the apparatus 1 in Fig. 1. The rest of the pasting sections 20 (20b, 20c, 20d) operate in the same or similar manner with the same construction as the first pasting section 20a.

Referring in detail to Fig. 2, in the base paper forming section 10, the first vat 2a contains a base-paper-layer forming material 21 which is used to form the base paper layer 23. The first absorbing roller 11a includes a shell 13a in the shape of a roller or rollable item, a wire mesh cover 14a disposed on the outer surface of the shell 13a, and an absorption controller 12a disposed in the shell 13a. The absorption controller 12a can be divided into a plurality of sections A, B, C, D, E..., etc. used to control absorption or adherence of the material 21 onto the outer surface of the absorbing roller 11a as the absorbing roller 11a rotates. For example, sections A, C and D can be low-level vacuum sections, section B can be a medium-level vacuum section, and section E (optional) is a ventilation section. The vacuum sections A, B, C and D can use and/ or include any means (e.g., pump, etc.) to create a suction force for increasing or adjusting adherence of the base-paper-layer forming material 21 onto the outer surface of the first absorbing roller 1 la as the first absorbing roller 11a rotates. This allows a layer of the material 21 to form on the outer surface of the first absorbing roller 11a. The ventilation section E can use and/ or include any means to effectively circulating pressure air in the first absorbing roller 11a (e.g., from a vacuum pump of the vacuum sections to a vacuum ejector).

The first shell 13a has a plurality of slits or openings 26a that are used by the first absorption controller 12a to control adherence of the material 21 onto the outer surface of the first absorbing roller 11a. The first wire mesh cover 14a disposed on the outer surface of the shell 13a has a plurality of orifices that allow a layer of the base-paper-layer forming material 21 to form thereon. In this effort, it is better that the size of the orifices of the mesh cover 14 is much smaller than the size of the openings 26a of the first shell 13a.

The first pressing roller 15a presses against a layer of the base- paper-layer forming material 21 adhered on the outer surface of the absorbing roller 11a as the first rollers 11a and 15a are rotated in opposite directions. This produces the base paper layer 23. The base paper layer 23 is guided by the guide roller 4 and guide block 3 and delivered to the next section, the first pasting section 20a.

The first pasting section 20a and the rest of the pasting sections 20b, 20c, 20d have the same structure and configuration as the paper forming section 10 discussed above. For instance, the second absorbing roller l ib of the first pasting section 20a includes a second shell l ib in the shape of a roller or the like and having openings 26b, a second wire mesh cover 14b disposed on the outer surface of the second shell l ib, and a second absorption controller 12b having sections A, B..., etc. The second vat 2b contains a paper-paste mixture material 28 used to form an additional layer 22 on a surface of the base paper layer 23 from the base paper forming section 10.

Referring to Figs. 1 and 2, the method for producing a multi-layered paper 25 according to an embodiment of the present invention includes producing the base paper layer 23 in the base paper forming section 10, and applying an additional layer of paper material onto a surface of the base paper layer 23 in each of the pasting sections 20 (20a, 20b, 20c, 20d) to produce a layered product 24. The layered product 24 is dried by the dryer 30 to produce a final product 25 of multiple layers, and the final product 25 is rolled onto the cutting roller 40 for future use.

In the step of forming the base paper layer 23, the first vat 2a stores therein the base-paper-layer forming material 21 in somewhat liquid state or a jelly state. While the first absorbing roller 1 la rotates in the predetermined direction, the base-paper-layer forming material 21 sticks to the first wire mesh cover 14a disposed on the first shell 13a. At this time, the material 21 is not introduced into the first shell 13a due to the first wire mesh cover 14a and/ or the operation of the first absorption controller 12a, and is formed with a certain thickness on the first wire mesh cover 14a. Thereafter, this layer of the material 21 on the first wire mesh cover 14a is pressed by the first pressing roller 15a, and thereby becomes the base paper layer 23.

In one embodiment, the base-paper-layer forming material 21 supplied to the first vat 2a is a mixture of paper material particles and melting resin. The diameter of the paper material particles may equal approximately the diameter of a fiber strand. The thickness of the base paper layer 23 depends on the spacing between the first absorbing roller 11a and the first pressing roller 15a and/or the suction force controlled by the absorption controller 12a.

As the first absorbing roller 11a rotates to produce the base paper layer 23 as discussed above, the second absorbing roller l ib rotates in the second vat 2b to apply a layer 22 of a paper material or paper-paste mixture material 28 onto the base paper layer 23 when the base paper layer 23 arrives at the first pasting section 20a. As the second absorbing roller l ib rotates against the second pressing roller 15a, as shown in Fig. 2, the additional layer 22 on the second absorbing roller 1 lb is applied or pasted onto a surface of the base paper layer 23 passing through between the second pressing roller 15b and the second absorbing roller lib. Then the two-layered product is moved to the next pasting section 20b in which another layer 22 of paper/paste material is applied on a surface of the two-layered product. This process is repeated in the subsequent pasting sections 20b until the last pasting section 20d produces the layered product 24.

The layered product 24 has multiple layers composed of the base paper layer 23 and four additional layers 22 of paper/paste materials. The layered product 24 then passes through the dryer 30 and is dried to become the final product 25. Fig. 3 shows an example of the final product 25. Optionally, then the final product 25 is rolled onto the cutting roller 40. This completes the process of forming the multi- layered paper product 25 according to an embodiment of the present invention.

According to the present invention, the rotation of any one of the absorbing rollers 11 and pressing rollers 15 and the movement of any item produced from each of the sections 10 and 20 can be selectively controlled to synchronize application of the additional layer 22 onto an appropriate portion of the base paper layer 23. Fig. 4 shows another example of a multi-layered product 25' which can be produced by the apparatus of the present invention. As shown in Fig. 4, a carbon paper product 25' is composed of a base paper layer 23' and three additional layers 22' of carbon materials. The carbon paper product 25' can be used for different purposes, e.g., as a wall-paper since the carbon layers 22' have a high shelter rate against electronic waves. If a non-woven or film paper is used as the base-paper-layer forming material 21, the product 25' may be produced of a carbon fiber or carbon film. Fig. 5 illustrates an apparatus 100 for producing a multi-layered product according to another embodiment of the present invention. The apparatus 100 includes certain same elements of the apparatus 1 in Fig. 1 as indicated by the same reference numerals. However, the apparatus 100 differs from the apparatus 1 in that a drum 50 essentially replaces the pressing rollers 15 of the apparatus 1 and that the outer surface of the drum 50 defines the transporting direction of the apparatus 100.

Particularly, the apparatus 100 includes the drum 50, a base paper forming section 10', one or more pasting sections 20', one or more dryers 60, and a cutting roller 40. The base paper forming section 10' includes the first absorbing roller 11a disposed in the first vat 2a containing the base-paper-layer forming material 21. The base paper forming section 10' produces a base paper layer 23 as the rotating drum 50 mates against the first absorbing roller 11a. Each of the pasting sections 20' includes the absorbing roller l ib, l ie or l id, and a vat containing the paper/ paste material 28. Each of the absorbing rollers 11 in Fig. 5 has the same construction as the absorbing rollers 11 of the apparatus 1, such as the shells, wire mesh covers, absorption controllers, etc. As the absorbing rollers 11 rotate against the drum 50, the base paper layer 23 is formed and one or more layers 22 of paper/ paste materials are applied onto the base paper layer 23 in the same manner as in the apparatus of Fig. 1. The dryers 60 dry the product output from the last absorbing roller l id to produce the final multi-layered paper product 25, which is rolled onto the cutting roller 40 as the drum 50 and the rollers 11 rotate in opposite directions.

In the present invention, any material or substance can be supplied to the vats 2 to produce a multi-layered product of desired material(s), and the position and operation of the elements of the apparatuses of the present invention can be controlled to vary the thickness of each layer in the multi-layered product.

Moreover, although Fig. 1 shows that additional layers 22 are applied to one same side of the base paper layer 23, the apparatus 1 according to the present invention can be configured to apply the additional layers 22 to one and/ or the other side of the base paper 23, either simultaneously or selectively. For instance, the apparatus 1 can be configured such that one or more of the pasting sections 20 apply the additional layer(s) onto one side of the base paper layer 23, whereas the other pasting sections 20 apply the additional layer(s) to the other opposite side of the paper layer 23. As a result, the final product 25 would include the base paper layer 23 sandwiched between the additional layers 22. In another example, the additional layers may be applied simultaneously on both sides of the base paper layer 23. This may be accomplished by replacing the pressing roller with another absorbing roller. Obviously, other variations are possible and the present invention encompasses all such variations.

In addition, the dryers 30 and 60 can be installed optionally. The dryers 30 and 60 are attached to the apparatuses 1 and 100 to simplify the present invention. The dryers 30 and 60 can be any known dryers such as IR (infrared) dryers, Yankee dryers, etc.

Accordingly, the methods, apparatuses and products of the present invention are simple in structure, inexpensive to manufacture, durable in use, and refined in appearance. The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.

Claims

What is claimed is:

1. An apparatus for producing a multi-layered product, the apparatus comprising: a first section producing a base layer; and at least one second section producing at least one additional layer of material and applying the at least one additional layer onto the base layer to produce a multi-layered product, wherein the first section and the at least one second section are arranged in a transport direction for transporting a product from one section to another section.

2. The apparatus of claim 1, wherein the first section includes: a first storage unit supplying a base-layer forming material; a first absorbing roller rotating and thereby producing a layer of the base-layer forming material on a surface of the first absorbing roller; and a first pressing roller applying force on the layer of the base-layer forming material to produce the base layer.

3. The apparatus of claim 2, wherein the first absorbing roller includes: a first shell having first openings; and a first mesh cover having second openings smaller than the first openings and forming the layer of the base-layer forming material on a surface of the first mesh cover.

4. The apparatus of claim 3, wherein the first absorbing roller further includes: a first absorption controller disposed in the first shell and controlling adherence of the base-layer forming material on the surface of the first mesh cover.

5. The apparatus of claim 2, wherein the at least one second section includes: a second storage unit supplying an additional-layer forming material; a second absorbing roller rotating and thereby producing the additional layer from the additional-layer forming material; and a second pressing roller applying the additional layer onto the base layer.

6. The apparatus of claim 5, wherein the second absorbing roller includes: a second shell having first openings; a second mesh cover having second openings smaller than the first openings and forming the additional layer on a surface of the second mesh cover; and a second absorption controller disposed in the second shell and controlling adherence of the additional-layer forming material on the surface of the second mesh cover.

7. The apparatus of claim 2, wherein the at least one second section includes a plurality of second sections, and each of the second sections includes: a second storage unit supplying an additional-layer forming material; a second absorbing roller rotating and thereby producing the additional layer from the additional-layer forming material; and a second pressing roller applying the additional layer onto a supplied product, the supplied product being either the base layer or the base layer having at least one additional layer thereon.

8. The apparatus of claim 1, further comprising: a dryer disposed in the transport direction and drying the multi- layered product from the at least one second section; and a cutting roller rolling the dried multi-layered product thereon.

9. The apparatus of claim 1, further comprising: a drum defining the transport direction, the first and at least one second section being arranged around different parts of the drum.

10. The apparatus of claim 9, wherein the first section includes: a first storage unit supplying a base-layer forming material; and a first absorbing roller rotating against the drum, forming a layer of the base-layer forming material on a surface of the first absorbing roller, and thereby producing the base layer.

11. The apparatus of claim 10, wherein the first absorbing roller includes: a first shell having first openings; a first mesh cover having second openings smaller than the first openings and forming the layer of the base-layer forming material on a surface of the first mesh cover; and a first absorption controller disposed in the first shell and controlling adherence of the base-layer forming material on the surface of the first mesh cover.

12. The apparatus of claim 10, wherein the at least one second section includes: a second storage unit supplying an additional-layer forming material; and a second absorbing roller rotating against the drum and forming the additional layer from the additional-layer forming material, wherein the second absorbing roller includes, a second shell having first openings, a second mesh cover having second openings smaller than the first openings and forming the additional layer on a surface of the second mesh cover, and a second absorption controller disposed in the second shell and controlling adherence of the additional-layer forming material on the surface of the second mesh cover.

13. A method of producing a multi-layered product, the method comprising:

(a) producing a base layer at a first station; and (b) producing at least one additional layer at at least one second station and applying the at least one additional layer onto the base layer at the at least one second station to produce a multi-layered product, wherein the first station and the at least one second station are arranged in a transport direction for transporting a product from one station to another station.

14. The method of claim 13, wherein the producing step (a) includes: providing a base-layer forming material in a first storage unit; producing a layer of the base-layer forming material on a surface of a first absorbing roller; and applying force on the layer of the base-layer forming material to produce the base layer.

15. The method of claim 14, wherein the step of producing the layer of the base-layer forming material is performed by the first absorbing roller, wherein the first absorbing roller includes a first shell having first openings, a first mesh cover having second openings smaller than the first openings and forming the layer of the base-layer forming material on a surface of the first mesh cover, and a first absorption controller disposed in the first shell and controlling adherence of the base-layer forming material onto the surface of the first mesh cover.

16. The method of claim 13, wherein the producing step (b) includes: providing an additional-layer forming material in a second storage unit; producing the additional layer on a surface of a second absorbing roller from the additional-layer forming material; and applying the produced additional layer onto the base layer.

17. The method of claim 16, wherein the step of producing the additional layer on the surface of the second absorbing roller is performed by the second absorbing roller, wherein the second absorbing roller includes a second shell having first openings, a second mesh cover having second openings smaller than the first openings and forming the additional layer from the additional-layer forming material on a surface of the second mesh cover, and a second absorption controller disposed in the second shell and controlling adherence of the additional-layer forming material onto the surface of the second mesh cover.

18. The method of claim 13, further comprising:

(c) drying, by a dryer disposed in the transport direction, the multi-layered product produced from the producing step (b); and (d) rolling, by a cutting roller disposed in the transport direction, the dried multi-layered product thereon.

19. The method of claim 13, wherein the transport direction is defined by a drum.

20. A multi-layered product produced by the method of claim 13.