CA2290494C - Cellulosic web, method and apparatus for making the same using papermaking belt having angled cross-sectional structure, and method of making the belt - Google Patents

Abstract

A papermaking through-air drying belt (10) and a method of making the same, as well as a paper web produced on the belt and the process of making the web are disclosed. The belt (10) comprises a resinous framework (20) having a web side surface (21) defining an X-Y plane, a backside surface (22) opposite the web-side surface, a Z-direction perpendicular to the X-Y plane, and a plurality of discrete deflection conduits (30) extending between the web-side surface and the backside surface. Each of the discrete conduits (30) has an axis (33) and walls (35).
The axes (33) of at least some of the discrete conduits (30) and the Z-direction form acute angles (Q) therebetween.

Description

Mar-04-Ob 04:~tpm From-SIkBAS LTD 416595 1306 T-1t8 P:006/02T F-1~4 I
CELLUL~SIC WEB, METHI:?I~ AND AFPAItATUS FOR MAK.IhTG THE SAIVIE
USING PAPERMAICIN .t"~r BEL.T HAV1NG ANGLED CROSS-SECTiCNAL
. STRUCTURE, ~,ND METHOD OF MAKING THE BELT ~ .
FIEI~D OP TIC INVENTION
The present invention is related to processes for malting stroxlg, soft, absorbent cellulo5ie webs.. ' Ii~!'ore particatlarly, this inveritioa is concerned v~rith strttetured cellalosic webs having low density regions.aad high.deztsity regions, and with papermaking belts utilised for making such paper webs. - . . .
HACK!GItO~Ut3D DF TIC IN~VENITCrN
Paper prd~ucts are used for s variety of psupasss.. Paper towels, facial tissues;
toilet tissues, and.the lika are iru const~uat use.'s~ modrran indu~ialized societies. The large demand for~~eh paper products has created a deznand.far improved versions of the preduci5. lfthe paper products such as paper towe3s, foetal tissues, toilet tissues, and the like arc t~ perforaz their i»tayded tasla and to iind wide aceeptattce, they _ - ~ ~ must possess cotts,in phy~cal oharacceristics. Among the..morc important .of these characteristics arc ~rtr.~~31, softne~ and absosbauy.
Stretsgth is the abt~ity of a paper wed to retain 'rts physical irwt~egrity daring use.
Sofiitess is the pleasing tactile sensation consurna-s percdve when they use the paper for its intendetl-pctrpos~s. . . ~ . .
- Absorbency is the eharactuistia of the paper that allows the paper tc~ take up' - , . snd retain fluids, particularly water and aqueous solutiosts sttd suspensions.
lmpot't$ut not co~llr is the absal~tc quantity .of #luid a givar $mount of paper ~I hold, but also the rate at which ttte pspcr will absorb the fltud_ Through-air dryuig papexmaldn$ belts comprising g reinforcing structure sad a -resinous frame~~ ~ otlt are descra'bed in commonly assigned U.S. Patatt' 4,514,345 .
issued t4 Johnson d al. on A.pr_ 30, 1985; U.S. Paten't 4,528,239 issued to Trokh~an on July 9, t5~85; U.S. Patent 4,529,~8tJ issued to T~alcharx on July 16, 1985;
~U.S_ Palest 4.437,859 issncd to Troldtan on loll. 2Q, 1989; U.S. pster~t 5,334,2$9 issued to 'frokhan et a1 on Aug. 2, 1994.
The paper produced on the belts disclosed in these patents is charaatezised by having two physically distinct regions: a continuous netr~rark region having a Mar-D4-04 04:2Bpm from-SIMBAS LTD 416595 7306 T-178 P.007/027 F-124

2 relatively high density and a re;~ion comprised of a plurality of domes dispersed throughout the whole of the network region. The domes are of relatively low density xnd relatively iaw.intrinsic strength compared to the network regions.
Such belts have been used to produce commercially successful products such as Hounty paper towels and Charmin Ultra toilet tissue, both produced and sold by the instant assignee.
U'.S. Patents 5,245,Q2S issued to Trokhan c;t al. on Sep. 14, 1993; and 5,527,4.28 issued to Trokhan et al. on June 18, 1996, disclose a cellulosic fibrous structure comprising a plurality of regions: an essentially continuous first region of a relatively high basis weight; a second region of a relatively low or zero basis weight and circumscribed by and adjacent the first region; and a third region of an intermediate basis weight and juxtaposed with the second region. A forming belt for producing such a paper comprises a patterned array of discrete protuberances joined to a reinforcing scrueture. Annuluses between adjacent protuberances provide space into which papermaking fibers may he deflected to form the first region. >rn addition, each individual protuberance may have an aperture therein. The apertures in the individual protuberances also provide space into which the papermalfing fibers may deflect to form the third region.
Still. a search foe improved products has continue.
It may be dcsirai7le in some :astanc~s~ to produce >~ellulosic webs having "angled" cross-sectional pancrns, i~.c., the webs which » where viewed in the cross-section ~ have the domes extending from an essentially continuous network region such that the domes ,are not generally perpendicular, but instead are xcu~tcly angled, rtlative to the plane of the netrwarl: region. Particularly, such "angled"
dames may irnprovr the web's softness due to increased collapsibility of the angles domes, compared to the prrpendieularly upstanding domes. In addition, it is believed that such angled suucttu~s will. possess an ability tc~ direct absorbed fluids in a desired (and prcdcterminexl) direction, based on the specific (and a3so predetermined) orientation of the domes in the web. Such propcrtie~ may be very bariefeial in a variety of disposable products.
Therefore, it is an object of an aspect of the present iztventiozt to provide a ceilulosic web having at least two regions: an essentially continuous regiozt and a region comprising a patterned array of discrete domes or knucldes extending from the essentially continuous region such that the axes of the domes or knuckles and the general plane of the essentially continuous region form acute angles therebetween.
Zt is another object of an aspect of the present inventiozt to provide a process.of making such cellulosic webs.

ldar-04-04 04:26pm From-SII~BAS LTD 416595 T306 T-1T8 P.006/D2T F-124 a It is still another object of an aspect of the present invention to provide a paperrnalting belt for producing such cellulosic webs.
Zt is a further object of an aspect of the present invention to provide a process ofmaking suchpapermaking belt.
SUMMARY CIF THE IN~I~NTIaN
A macroscopically rnonoplanar papermaking belt of the present invention may be used in a papermalcir3g machine as a forming belt andlor as a through-air drying belt.
The through-air drying belt comprises a resinous framework having a we'b-side surface which defines an 3~-Y plane, a backside surface opposite the web-side surface, a Z-direction perpendicular to the 3~-Y plane, and a plurality of discrete deflection conduits extending between the web-side surface and the 'backside surface. Preferably, the plurality of conduits comprises a non-random repeating patterned array. &ieh of the discrete conduits has art axis and walls. The axes of at least same of the discrete conduits and the Z-direction farnra, acute angles therebetween. Preferably, the throu,gla-air drying belt farther comprises an air-permeable reinforcing structure positioned between the web-side surface and the backside surface of the resinous framework. The reinforcing structure has a web-facing side and a machine-facing side apposite the web-facing side.
In the through-air drying belt, the web=side surface of the framework has an essentially continuovss web-side network formed thereia. and the backside surface of the framework has a backside network formed therein. The web-side network defines web-side openings, and the backside network defines backside openings of the discrtta .conduits. The web-side openings are off set relative . to the corrcsporrding bacirsid~e operrixtgs within the X-Y plane in at least one direction perpendicular to the Z-direction. The tliscrefe conduits may be tapered, preferably negatively tapered, relative to their, respective axes in at least one direction perF.:.oiicular to the Z-direction, The forming i5elt of the present invention comprises an air-permeable reinforcing structure and a resinous framework joined to the reinforcing s:~.~cture.
The reinforcing structure has a web~facing side def n'sng an X-Y plane, a machine-facing side apposite the web-facing side, and a Z-direcuort perpendicular to the 7C-Y
plane. The resinous framework is comptis~ed of a plurality of discrete protuberances joined to arid extcziding from the reinforcing structure. Each of the protuberances has an axis, a top surface, a t~ase~surf"ace opposite the top surface, and wails spacing apart and intcrconneeting'the tap surface and the base surface. Preferably, the i~ar-04-04 04:29pm From-SIaBAS LTD 416595 T306 T-1t6 P.009/02T F-124 discrete protuberances are circumscribed by and adjacent to an area of essentially continuous deflection conduits. A plurality of the tap surfaces defines a web-side surface, and a pluzality of the base surfaces defines a backside surface of the resinous frarz~ework.
In the forming belt of the present invention, the axes of at least some of the protuberances and the Z-direction form an acute angles therebetween. The top surfaces of at least some of the protuberances are off-set relative to the corresponding base surfaces of the same protuberances within the ?~-'Y plane in at least one direction perpendicular to the Z-direction. The web-facing side of the reinforcing structure has preferably an essentially continuous web-facing network ~ormod therein" which web-facing network is defined by the area of essentially continuous de#lectian conduits- The walls of at least some of the protuberances may be tapered relative the axes of these protuberances- Frefernbly, the plurality of protuberances comprises a non-random repeatitxg patterned array in the X-Y plane. Xn one embodiment, the plurality of discrete protuberances has a plurality of discrete deflection conduits extending from the web-side surface to the back surface of the resinous fi~xowork. Preferably, each of the plurality of discrete pzbtuberamees has at least one discrete deflection conduit therein.
In both the through-air drying bolt and the forming belt, the backside surface Fnay optionally be textured.
According to an aspect ofthe presexlt invention, there is provided a macroscopically monoplanar papermaking belt far use in a papermaking machine, the papennaking belt comprising a resinous framework homing a web-side surface defining an ~~-'f' plane, a backside surface opposite the web-side surface, a Z-direction perpendicular to the X-Y plane, and a plurality of discrete deflection conduits extending between the web-side surface and the backside surface, each of the discrete conduits having an axis and walls, the axes of at least same ofthe discrete conduits and the Z-direction forming acute angles therebetween.
A method of making the belt of the present invention comprises the steps of {a) providing an apparatus for generatixrg curing radiation in a first direction;
{b) proVidin~; a liquid photosensitive resin;
(c) providing a forming unit having a working surface and capable of receiving the liquid photosensitive resin;

Mar-04-04 04:29pm From-SIMBAS LTD 416695 T306 T-1T6 P.O10/02T F-124 (d) providing an air-permeable reinforcing structure to be joined to the cured phatnsensitive resin, the reinforcing structure having a web-facing side and a machine-faein,g side opposite said web-facing side;
(e) disposing said reinforcing structure in said forming unit;
(f) disposing flue liquid photosensitive resin in said forming unit thereby Forming a coating of the liquid photosensitive resin, the coating having a first surface and a second surface opposite the first surface, and a prc-selected t>faiclaoess defined by these first and second surfaces;
(g) disposing the forming unit containing the coating of liquid photosensitive resin in the ~at~di~etic::-.>-uay~: ~l~sat-+~e-fr ~t-s~.Ge~f tlte~,caa~g-and-that direct:r::
Form an acute angie therebetween;
(h) providing a mask having opaque regions and transparent regions defining a pre-selected pattern;
(i) positioning the mask between the first surface of tire ce~ating and the apparatus for generating curing radiation such that the mask is in adjacent relation with the first strtface, the opaque regions of the mask shielding a portion of the coating from the curing radiation of the apparatus, and the transparent regions leaving other portions of the coating unshielded for the curing radiation of the apparatus;
(j) curing said unshielded portions of the coating, and leaving the shielded portions of the coating uncured by exposing the coating to radiation having an activating wavelength from t'he apparatus for generating curing radiation through the mask to form a partially formed belt;
(k) removing substantially all uncured liquid photosensitive resin from the partially-formed belt to leave a hardened resixious structure which forms a framework having 3 Wpb-5lde 511T1~1Ce formed by the first surface being cured and a backside surface formed by the second surface being cured, Depending an a particular predetersnined design of the desired framework (continuous framework for the through-ai~r drying belt, or the iiamework comprising the plurality of protuberances for the forming belt), the belt will have either a plurality of discrete conduits in the re;ions which were shieided from tire curing radiation by the opaque regions of the mask, or a plurality of discrete protuberances extending from the reinforcing struct~e in the regions which were not shielded and therefore became cured.

Mar-D4-04 04:29pm From-SIMBAS LTD 416595 t3D6 T-1t8 P.011/02t F-124 Sa The steps (d) and (e) are the necessary sups for mixing the farmitag belt, and the highly preferred steps for making the through-air drying belt.
According to another aspect of the present invenrion, there is provided a method of making a macroscopically monoplartar papermaking belt, the method comprising the steps of:
providing an apparatus for generating curing radiation in a first direction;
providing a liquid photosensitive resin;
providing a forming unit having a vrorking surface and capable of receiving the liquid photosensitive resin;
disposing the liquid photosensitive resin in the forming unit thereby forming a coating of the liquid photosensitive resin, the coating having a first surface and a second surface opposite the first surface, the coating having a pre-selected thickaness;
disposing the forming unit containing the coating of liquid photosensitive resin therein in the frst direction, such that the first surface of the caatin,g and the first direction form an acute angle therebetween;
providing a mask having opaque regions and transparent regioxis, the regions defining a pre-selected pattern;
positioning the mask between the first surface of the coating and the apparatus far generating curutg radiation such that the mask is in adjacent relation with the first Surface, the opaque regions of the mask shielding a portion of the coating from the curing radiation of the apparatus, and the transparent regions leaving other portions of the coating unshielded for the curing radiation of the apparzttus;
curing the unshielded portions of the coating, and leaving the shielded portions of the coating uncuredby exposing the coating radiation having an activating wavelength from the apparatus for generating curing radi atian through the mask to form a partially-formed belt; and .
removing substantially all uncured liquid photosensitive resin from the partially-formed belt to leave a hardened resinous structure which forms a framework having a v~.eb-side surface formed by the first surface being cured, a backside surface formed by the second surface being cured, a Z-direction ~dar-04-04 04:30pm From-SII~AS LTD 416595 T306 T-lT8 P.012/02T F-124 5b perpendicular to the web-side surface, and a plurality of discrete conduits in the regions which were shielded from the curing radiation by the opaque regions of the mask, the conduits extending lxtween the web-side surface and the backside surface, each ofthe conduits having an axis and walls, the axes of at least same of the conduits and the Z-direction forming acute angles therebetween.
A cellulosie web made by using the through-air drying belt having an essentially continuous framework will have at least two regions disposed in a non-random and repeating pattern: a macroscopically manoplanar, patterned, and essentially continuous network r.;gion forming a network plane and preferably having relatively high density, and a domes region preferably having relatively law density. The domes region connprises discrete dames extending from the network plane in at least one direction Such that this at least one direction and the network plane form an acute angle therebetween.
According to another aspect of the present invention, there is provided a macroscopically moncrplanar papezm,aking belt for use in a papermaking machine, flee papermaking belt comprising:
an air-p~nn~able reinforcing structure having a web-facing side defining an X-Y plane, a maehW e-facing side opposite the web-Facing side, and a Z-direction perpendicular to the h-Y plane; and a resinous frarnework comprised of a plurality of discrete protuberances joined to and extending from the reinforcing structure, eacb of the protuberances having an axis, a top stwface, a base surface opposite the tap surface, and walls spacing apart and irxtercannecting the top surface and the base surface, the axes of at least some of the protuberances and the 2-direction forming acute angles therebetween, a plurality of the top surfaces defining a web-side surface of the resinous framework, and a plurality of the base surfaces defining a backsi de surface of the resinous framework.
According to a further aspect of the present invention, there is provided a method of making a macroscopically monoplanar papermaking belt, the znetbod comprising the steps of;
providing an apparatus for generating curing radiation in a first direction;
providing a liquid photosensitive resin;

Mar-04-04 04:30pm From-SIMBAS LTD 416696 T306 T-118 P.013/02T F-124 Sc providing a forming unit having a warkiug surface and capable of receiving the liquid photosensitive resin;
providing an air..permeable reinforcing structure having a web-facing side defining an ~-~,'' plane, a machine-faciztg side opposite the web-facing side, and a Z-direction perpendicular to the X-Y plane;
bringing at least a portion of the machine-facing side of the reinforcing structure into contact with the working surface of the Forming unit;
applying a coating of the liquid photosensitive resin to at least one side of the reinforcing structure so that the coating farms a first surface and a second surface opposite the first surface, the coating haviztg a pre-selected thiclmess;
disposing tl7e forming unit containing the coating of liquid photosensitive resin therein in the first direction such that the first surface of the coating and the first direction forax an acute angle therebetween;
providing a mask having opaque regions and transparent regions, the regions defining a pre-selected pattern;
positioning the mask between the first surface of the coating and the apparatus for generating curing radiation such that the mask is in adjacent relation with the first surface, the opaque regions of the rnaslc shielding a portion of the coating from the curing radiation of the apparatus, and the transparent regions leaving other portions of the coating unshielded far the curing radiation of the apparatus;
curing the unshielded portions of the coating, and leaving the shielded portions of the coating uncured by exposing the coating to radiation having an activating wavelength froxrt the apparatus for generating curing radiation through the mask to Corm a partially-fonnc;d belt; and removing substantially all uncured liquid photosensitive resin from the partially-formed belt to leave a hardened resinous structure which forms a framework having a web-side surface formed by the first surface being cured, a backside surface formed by the second surface being cured, a 2-direction perpendicular to the web-side surface, the framework being comprised of a plurality of discrete protuberances joined to and extending from the reinforcing structure, each of the protuberances having an axis, a base surface, a top surface, and walls spacin,~ apart and interconnecting the base Mar-04-04 04:30pm From-SIMBAS LTD 416595 2306 T-1TB P.014/027 F-124 5d surface and the tap surface, the axes of at least same of the protuberances and the Z-direction forming acute angles therebetween, a plurality of the top surfaces defining the web-side surface of ik~e resinous framework, and a plurality of the base surfaces defining the backside surface of the resinous framework.
The cellulosic web farmed on the forming belt having the framework comprised of the plurality of discrete protuberances will have at Least two regions disposed in a non-random and repeating gatxe~: a macroscopically planar and patterned first region defining an X-Y plane and preferably having a relatively high basis weight, and a second region preferably having a relatively Low basis weight and circumscribed by and adjacent to the first region. The first region comprises an essentially continuous network farmed over the area of essentially continuous conduits of the forming belt's framework. ',fhe second region is comprised of a plurality of discrete knuckles formed over the discrete protuberances of the forming belt's framework. The protuberances extend fram the first region in at least one "angled" direction such that this at least one direction and the X-Y plane form an acute angle therebetween. The web formed on the forming belt having the discrete deflection conduits through the protuberances may also have a third region having an intermediate basis weight relative to the basis weight of the first region and the basis weight of the second region, the third region being juxtaposed with the second region.
In its through-air drying aspect, a process for producing a cellulosic fibrous web comprises the steps of:
(a) providing a plurality of cellulosic papermaking fibers suspended in a liquid carrier;
(b) providing a forming belt;
(c) depositing the plurality of cellulosic papermaking fibers suspended in a liquid carrier on the forming belt;
(d) draining the liquid carrier through the forming belt thereby forming an embryonic web of the papermaking fibers on the forming belt;
(e) providing a macroscopically monoplanar through-air drying belt comprising a resinous framework having a web-side surface defining an X-Y plane, a backside surface opposite the web-side surface, a Z-direction perpendicular to the X-Y
plane, and a plurality of discrete deflection conduits extending between the web-side surface and the backside surface, each of the conduits having an axis and walls, the axes of at least some of the conduits and the Z-direction forming an acute angles therebetween;
(~ depositing the embryonic web to the web-side surface of the resinous framework of the through-air drying belt;
(g) applying a fluid pressure differential to the embryonic web to deflect at least a portion of the papermaking fibers into the discrete deflection conduits and to remove water from the embryonic web into the discrete deflection conduits thereby forming an intermediate web which comprises a macroscopically monoplanar, patterned, and essentially continuous network region, and a domes region comprising a plurality of discrete domes protruding from, circumscribed by, and adjacent to the network region, each of the domes having an axis, the axes of at least some of the domes and the Z-direction forming acute angles therebetween.
A process for producing the embryonic cellulosic fibrous web on the forming belt of the present invention comprises the steps of:
(a) providing a plurality of cellulosic fibers suspended in a liquid earner;

(b) providing a macroscopically monoplanar forming belt comprising an air-permeable reinforcing structure having a web-facing side defining an X-Y
plane, a machine-facing side opposite said web-facing side, and a Z-direction perpendicular to said X-Y plane, the forming belt further comprising a resinous framework comprised of a plurality of discrete protuberances joined to and extending from the reinforcing structure, each of the protuberances having a base surface, a top surface, walls spacing apart and interconnecting the base surface and the top surface, and an axis, the axes of at least some of the protuberances and the Z-direction forming acute angles therebetween, a plurality of the top surfaces defining a web-side surface of the resinous framework, and a plurality of the base surfaces defining a backside surface of the resinous framework;
(c) depositing the cellulosic fibers and the carrier onto the forming belt;
(d} draining the liquid carrier through the forming belt, thereby forming a macroscopically planar and patterned first region disposed in the X-Y plane, the first region comprising an essentially continuous network and preferably having a relatively high basis weight; and a second region comprised of a plurality of discrete knuckles circumscribed by and adjacent to the first region and preferably having a relatively low basis weight, the knuckles extending from the first region in at least one direction, this at least one direction and the Z-direction forming an acute angle therebetween.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic top plan view of a papermaking belt of the present invention having an essentially continuous web-side network and discrete deflection conduits.
FIG. lA is a schematic fragmentary cross-sectional view of the papermaking belt taken along lines IA-lA of FIG. 1, and showing the discrete deflection conduits which are angled relative to the Z-direction.
FIG. 1 B is a schematic fragmentary cross-sectional view of the papermaking belt taken along lines 1B-1B of FIG. 1.
FIG. 1 C is a schematic fragmentary cross-sectional view of the papermaking belt of the present invention having angled and negatively tapered conduits.
FIG. 2 is a schematic top plan view of the papermaking belt of the present invention comprising a resinous framework formed by discrete protuberances encompassed by an essentially continuous area of deflection conduits.

FIG. 2A is a schematic fragmentary cross-sectional view of the papermaking belt taken along lines 2A-2A of FIG. 2, and showing the discrete protuberances which are angled relative to the Z-direction and positively tapered.
FIG. 3 is a schematic top plan view of a papermaking belt similar to that shown in FIG. 2, and comprising a resinous framework formed by a plurality of discrete protuberances having a plurality of discrete deflection conduits therein.
FIG. 3A is a schematic fragmentary cross-sectional view of the papermaking belt taken along lines 3A-3A of FIG. 3, and showing positively tapered protuberances having negatively tapered discrete conduits therein.
FIG. 4 is a schematic top plan view of a paper web produced on the papermaking belt of the present invention shown in FIGS. 1-1C, the paper web having three zones of knuckles, the knuckles of each zone having a specific orientation different from the orientations of the knuckles of the other two zones.
FIG. 4A is a schematic fragmentary cross-sectional view of the paper web taken along lines 4A-4A of FIG. 4.
FIG. 4B is a schematic fragmentary cross-sectional view of the paper web taken along lines 4B-4B of FIG. 4.
FIG. 4C is a schematic fragmentary cross-sectional view of the paper web taken along lines 4C-4C of FIG. 4.
FIG. 4D is a schematic fragmentary cross-sectional view of a prophetic web produced on the papermaking belt of the present invention shown in FIGS. 3 and 3A.
FIG. 5 is a schematic perspective view of an apparatus for generating curing radiation which can be utilized for curing a photosensitive resin to form a resinous framework comprising the papermaking belt of the present invention.
FIG. SA is a schematic cross-sectional view of the apparatus shown in FIG.
5.
FIG. 5B is a schematic cross-sectional view of the apparatus of controlled radiation directing curing radiation in more than one pre-determined radiating direction.
FIG. SC is a schematic cross-sectional view of another embodiment of the apparatus of controlled radiation.
FIG. 6 is a schematic side elevational view of one embodiment of a continuous papermaking process utilized in the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 6, the preferred embodiment of the papermaking belt I O of the present invention is an endless belt. However, the papermaking belt 10 of the present invention may be incorporated into numerous other forms that include, for example, stationary plates for use in making handsheets or other batch processes, or rotating drums for use with other continuous processes. As used herein, the term "papermaking belt 10," or simply "belt 10" is a generic term which includes both a forming belt l0a and a through-air drying belt lOb, both shown in FIG. 6. The forming belt l0a travels in the direction indicated by a directional arrow "A," and the through-air drying belt i0b travels in the direction indicated by a directional arrow "B." Because both the forming belt I Oa and the through-air drying belt l Ob possess certain common characteristics, it is convenient in relevant parts of the Specification to refer to both the forming belt l0a and the through-air drying belt IOb as simply "the belt 10." However, when distinguishing between the forming belt l0a and the through-air drying belt 10b is necessary or helpful for understanding the present invention, the reference will be made to "the forming belt 10a," or to "the through-air drying belt lOb." Regardless of the physical form of the papermaking belt 10 and its function in the papermaking process, the belt 10 of the present invention has the characteristics described below.
As shown in FIGS. 1-4C and 6, the belt 10 of the present invention has a web-contacting side 11 and a backside 12 opposite the web-contacting side 11. As should be clear from the definition, the web-contacting side 11 contacts and thereby supports a web 60 on the belt 10. The backside 12 contacts the machinery employed in the papermaking process, such as a vacuum pick-up shoe 17a and a multislot vacuum box 17b and various rolls, etc. For clarity, as used herein, the web 60 is referenced by the same reference numeral 60, regardless of a particular stage of its processing. The distinction between the various stages of the web's processing, although significant, does not require the use of different reference numerals for the purposes of describing the present invention. An adjective immediately preceding the term "web" will clearly and definitely indicate a particular stage of the web's processing, for example: "embryonic web 60," "intermediate web 60," "imprinted web 60," "predried web 60," "dried web 60," and a final product -- "paper web 60."
FIGs. 1-3C show various embodiments of the belt 10 of the present invention.
FIGs. 1-1C illustrate the papermaking belt 10 which may preferably be utilized as the through-air drying belt lOb; and FIGs. 2-3A show embodiments of the belt which can preferably be utilized as the forming belt 10a. The belt 10 comprises a resinous framework 20 and a reinforcing structure 50 joined to the resinous framework 20. It should be pointed out that the reinforcing structure 50 is necessary for the forming belt l0a and highly preferred for the through-air drying belt l Ob.

The resinous framework, or simply framework, 20 has a web-side surface 21, a backside surface 2? opposite the web-side surface 21, and a plurality of deflection conduits 30 extending between the web-side surface 21 and the backside surface If desired, the backside surface 22 may be textured according to the commonly assigned U.S. Patents: 5,275,700 issued Jan.4, 1994 to Trokhan; 5,334,289 issued Aug. 2, 1994 to Trokahan et al.; 5,364,504 issued Nov. 15, 994 to Smurkoski , et al. The reinforcing structure 50 is preferably positioned, between the web-side surface 21 and the backside surface 22 of the framework 20. The reinforcing structure 50 is substantially liquid-pervious, and may comprise a foraminous element, such as a woven screen or other apertured structures. The reinforcing. structure 50 has a web-facing side 51 and a .machine-facing side 52 opposite to the web-facing side 51. The web-facing side ~ 1 of the reinforcing structure 50 corresponds to the web-side surface 21 of the framework 20, and the rna~:hine-facing side 52 of the reinforcing structure 50 corresponds to the ~' backside surface 22 of the framework 20.
Ln the .embodiment shown in FIGS. 1-1C, the framework 24 comprises an_ cssenti.ally cot-;tinuous pattern, and the plurality ~of deflection conduits 30 comprises a plurality of discrete orifices, or holes, extending from the web-side surface 21 to the backside surface 22 -of the frarr~ework 2U. .Prefezably, the discrete conduits 30 are afir'anged in' a pre-selected patteriin the'frarnework 20. More preferably, the pattern of the arrangement of the conduits 30 is non-random and repeating. The papenmaking belt 10 having a continuous framework 2Q and discrete deflection conduits 30 may preferably be utilized as the through-air drying belt lOb. The par~ermaking belt 10 having a continuous framewoFk 20 and discrete deflection conduits 30 is primarily disclosed in the commonly assigned U.S: Patents 4,528,239 issued Jul. 9, 1985 to Trokhan; 4,529,480 issued Jul. 16, 1985 to Trokhan;
4,637,859 issued Jan. 20, 1987 to Trokhan; 5,098,522 issued Mar. 24,-1992 to Trokhan et al.;
5,275,700 issued Jan. 4, 1994 to Trokhan; 5,334,289 issued Aug. 2, 1994 to Trokhan;
and 5,364,504 issued Nov. 15, 1985 to Smurkoski et al.
In another embodiment of the belt 10 shown in FIGs. 2-3C, the framework 20 comprises a plurality of discrete protuberances 40 extending from the reinforcing structure 50 and adjacent to an area of essentially continuous deflection conduits 70.
The discrete protuberances 40 are preferably circumscribed by the area of essentially continuous deflection conduits 70. In the embodiments shown in FIGS. 2-3C, the region of essentially continuous deflection conduits 70 preferably defines an Ilar-04-04 04:31pm From-SiwBAS LTD 416595 T306 T-1Z8 P.016/02T F-124 II
essentially continuous web-facing network 51 * formed in the web-facing side 51 of the reinforcing structure SQ_ The term "essentially continuous" indicates that interruptions in absolute gean~etrical continuity may be tolerable, while ,are not preferred, as long as these intetTUptions do not adversely affect the performance of the belt i0 of the present invention. It should also be carefully noted that embodiments (not shown) are possible in which interruptions in the absolute continuity of t~lte framework 20 (in the through-air drying belt 1 Ob) ~ ar interruptions irt the absolute continuity of the conduits 70 (in the forming belt IOa) are intended as a part of the overall design of the belt 10. 7"hese embodiments are trot illustrated but can easily be visualized by combining the framervor6:'s pattern of the ~ through-2,ir drying belt I Ob -with the framework's pattern of the forming belt I Oa in such a way that some of the areas of the "combined" belt comprise the pattern of the ti~rough-air crying belt 14b, while the other parts o.f the same "combined" belt campri,;e the~~ttern, Qf the forming .belt 1 aa. . ~ - . .
As ahoy.-~ is 1=1Gs_ 3-3C, the individual, protuberances 40 may also have the discrete deflection conduits 30 disposed therein and extending Fr~osn the web-side surface 21 to the backside surface 22 of the framework 20. The papermaking belt 3 0 having the frrainpc~wo~lC '~0 ~eornprising the discrete pratubemnces 40 rs'lay preferably >, ;; . ;.. : , be utitiz~cd as the fo:rr.,:zig belt j~7a. The pap~rmaking, belt t 4 hav;ng the framework 20 comprising the dixrete pmtuberartees 41~ is primarily disclosed in the comt=ronly assigned U.S. Patent 4,245,05 issued 9ep. 14, 1993 to Trakhan et al. and U.S.
Patent 5,527,428 issued yun. 18, 199=6 to Trokhan et al. Also, the papermaking belt 10 having the discrete protuberances raised above the plane of the fabric may be made according to the European Patent Application 95105513.6, Publication l~To.: 0 6'77 di2 A2, filed 12.04.95, inventor Wendt et al.
The belt 10 is preferably air-pezmeable and liquid-pervious in at least one direction, particularly the direction from the web-contacting side 11 to the backside x2.
As used herein, the term "liquid-pervious" refers to the condition where a liquid carrier of a fibroa~ slurry may be transmitted thrQUgh the belt 10 without significant obstruction. It is not, however, necessary, ar even desired, that the entire surface area oftl~e be2t IO be liquid-pervious. It is only necessary that the liquid carrier be easily removed from the slurry leaving on the web-contaatirig side 1 I of the belt 10 an embryonic web of the paparmakizig fibers.
The web-sida surface 21 of the frarniewark 20 defuses the web-cozitacting side of she papermaacing belt 10; and the machine-facing surface 22 of the frarileWOrk 20 de~ir~es the backside t2 of the papermaking belt 1 O. Therefore, it also could be said that the discrete deflection conduits 30 and the essentially continuous deflection conduits 70 extend intermediate the web-contacting side 11 of the belt 10 and the backside 12 of the belt 10. The discrete deflection conduits 30 (or simply "conduits 30") and the essentially continuous conduits 70 (or simply "conduits 70") channel water from the web b0 which rests on the web-side surface 21 of the framework to the backside surface 22 of the framework 20 and provide areas into which the fibers of the web 60 can be deflected and rearranged to form dome areas --comprising either discrete domes 65 (FIG. 4) or "continuous domes" forming a first region 64* (FIG. 4D) in the web 60. As used herein, the term "domes" indicates elements of the web 60 formed by the fibers deflected into the deflection conduits 30, 70. The domes 65 generally correspond in geometry and -- during the papermaking process -- in position to the deflection conduits 30, 70 during the papermaking process. By conforming to the deflection conduits 30, 70 during the papermaking process, the regions of the web 60 comprising the domes 65 are deflected such that the domes 65 protrude outwardly and extend from the general plan of the web 60, thereby increasing a thickness, or caliper, of the web 60 in a Z-direction. As used herein, the Z-direction is orthogonal to the general plane of the web 60 and the belt 20, as illustrated in several Figures of the present Application.
Of course, if the papermaking belt 10 having an area of essentially continuous conduits 70 is used, the domes 65 of the paper web 60 will comprise an essentially continuous dome region 65.
Now referring to FIGs. 1-1 C, the web-side surface 21 of the essentially continuous resinous framework 20 defines the general plane of the belt 10, or an X-Y plane. Because the web-facing side 51 of the reinforcing structure 50 is generally parallel to the web-side surface 21, the web-facing side S1 may also be viewed as defining the X-Y plane. The Z-direction defined hereinabove is therefore the direction perpendicular to the X-Y plane. The web-side surface 21 of the framework 20 has a web-side network 21 * formed therein. Likewise, the backside surface 22 of the framework 20 has a backside network 22* formed therein. Because the discrete conduits 30 extend between the web-side surface 21 and the backside surface 22 of the framework 20, each of the discrete conduits 30 has a pair of openings: a web-side opening 31 and a backside opening 32. The web-side network 21 * formed in the web-side surface 21 defines the web-side openings 31 of the conduits 30;
and the backside network 22* formed in the backside surface 22 defines the backside openings of the conduits 30.
Each discrete conduit 30 has walls 35 extending between the web-side surface 21 (or the web-side network 21 *) and the backside surface 22 (or the backside 7 _ .. _ _ . _. _ _ . ._v .______ __.

network 22*). As will be shown below, the walls 35 of the same conduit 30 may form different angles relative to the Z-direction. Each discrete conduit 30 has an axis 33. As used herein, the "axis 33" of the conduit 30 is an imaginary straight line connecting the center C 1 of the web-side opening 31 and the center C2 of the backside opening 32. The center C I of the web-side opening 31 is a center of an X-Y area of the opening 31, i.e., a point of an X-Y plane of the opening 31, which point coincides with the center of mass of a thin uniform distribution of matter over this X-Y plane of the opening 31. Analogously, the center C2 of the backside opening 32 is the center of an X-Y area of the opening 32. One skilled in the art will readily recognize that if the opening 31 comprises a figure that is bilaterally symmetrical relative to an axis parallel to at least one of the X-Y
directions, then in a Z-directional (i.e., vertical) cross-section perpendicular to that at least one of the X-Y directions, the center C 1 of the web-side opening 31 will be positioned in the middle of a web-side cross-sectional dimension "d" of the web-side opening 31 (FIGs. 1 A and 1 C). Likewise, if the opening 32 comprises a figure that is bilaterally symmetrical relative to an axis parallel to at least one of the X-Y
directions, then in a Z-directional cross-section perpendicular to that at least one of the X-Y
directions, the center C2 of the backside opening 32 will be positioned in the middle of a backside cross-sectional dimension "e" of the backside opening 32 (FIGS. 1 A
and 1C). For example, in the embodiment shown in FIGs. l-1B, the web-side opening 31 of the conduit 30 comprises a diamond-shape figure bilaterally symmetrical relative to an axis "md" parallel to the machine direction MD. In the Z-directional cross-section perpendicular to MD (or, in other words, in the "vertical CD
cross-section") the center C1 of the web-side opening 3I is positioned in the middle of the web-side CD cross-sectional dimension "d," as best shown in FIG. 1 A. The backside opening 32 also comprises a diamond-like figure bilaterally symmetrical relative to an axis {not shown) parallel to MD. In the Z-directional cross-section perpendicular to MD (or, in the "vertical CD cross-section"), the center C2 of the backside opening 32 is positioned in the middle of the backside CD cross-sectional dimension "e," as best shown in FIG. 1 B. The diamond-like openings 31 and 32 of the conduits shown in FIGs. 1-1C are also bilaterally symmetrical relative to an axes "cd" parallel to the cross-machine direction CD. Therefore, analogously to the "d"
and "e" discussed hereabove, in the Z-directional cross-section perpendicular to CD
{or in the "vertical MD cross-section"), the centers C 1 and C2 of the openings 31 and 32, respectively, are positioned in the middle of their respective MD
cross-sectional dimensions "dl" and "el", as illustrated in FIG. IB. It should be carefully noted that the web-side openings 31 need not be identical to the corresponding _ _-___ backside openings 32, nor the web-side openings 31 need have the same general shape (for example, circle, or diamond-like shape) as the backside opening 32.
According to the present invention, the web-side openings 31 are off set relative to the backside openings 32 within the X-Y plane and in at least one direction which is perpendicular to the Z-direction. One skilled in the art will readily recognize that there are infinite directions perpendicular to the Z-direction (or "X-Y directions"), all of which are included in the scope of the present invention.
However, for clarity and convenience of illustrating the present invention, the present invention is discussed primarily in the context of the mutually perpendicular machine direction MD and cross-machine direction CD.
In papermaking, the machine direction MD indicates that direction which is parallel to the flow of the web 60 (and therefore the belt 10) through the papermaking equipment. The cross-machine direction CD is perpendicular to the machine direction MD and parallel to the general plane of the belt 10. Both the machine direction MD and the cross-machine direction CD can be viewed as parallel to the X-Y plane. Consequently, the Z-direction is perpendicular to both the MD
and the CD.
FIGs. 1 A and 1 C show that the web-side openings 3 I are off set relative to the corresponding backside openings 32 in the cross-machine direction CD. In FIGs.
1 A and I C a dimension of an off set is indicated by the symbol "T." As used herein, the "off set" in the context of the conduit 30 or a protuberance means the distance between the center C I of the web-side opening 31 and the center C2 of the backside opening 32 measured in, or geometrically projected to, the X-Y plane. If the web-side opening 31 is off set relative to the backside opening 32 in a direction other than either the MD or the CD, it still may be convenient to define the off set in the MD and the CD, as mutually perpendicular projections of a real dimension of the off set to the corresponding MD cross-section and CD cross-section, respectively.
Therefore, as used herein, the "MD off set" indicates a projection of the actual off set to the MD. Likewise, the "CD aff set" indicates a projection of the actual off set to the CD.
FIGs. 1-1 B and 1 C schematically show various embodiments of the papermaking belt 10 of the present invention, comprising the framework 20 which has the discrete conduits 30 therein. In FIGs. 1-1B, the web-side openings 31 are off set relative to the backside openings 32 in the cross-machine direction CD
(FIGs.
1 and lA). The dimension T and an angle Q formed between the axis 33 and the Z-direction define the CD off set of the web-side opening 31 relative to the backside opening 32 of the conduit 30.

If the web-side cross-sectional dimension "d" is equal to the backside cross-sectional dimension "e" in a Z-directional (vertical) cross-section parallel to one of the X-Y directions, the opposing walls 35 of the conduit 30 are mutually parallel in that X-Y direction, and the conduit 30 is said to be non-tapered in that X-Y
direction. Conversely, if the web-side cross-sectional dimension "d" is not equal to the backside cross-sectional dimension "e" in a Z-directional cross-section parallel to one of the X-Y directions, the opposing walls 35 are not mutually parallel in that X-Y direction, and the conduit 30 is said to be tapered relative to the axis 33 in that X-Y direction. If the web-side cross-sectional dimension "d" is greater than the backside cross-sectional dimension "e" in a Z-directional cross-section parallel to one of the X-Y directions, the conduit 30 is negatively tapered in that X-Y
direction.
Conversely, if the backside cross-sectional dimension "e" is greater than the web-side cross-sectional dimension "d" in a Z-directional cross-section parallel to one of the X-Y directions, the conduit 30 is positively tapered in that X-Y
direction: For example, assuming that in FIG. lA, the web-side CD cross-sectional dimension "d"
is greater than the backside CD cross-sectional dimension "e," the conduit 30 shown in FIG. 1 A is negatively tapered in CD. Analogously, the same conduit 30 shown in FIG. 1B is negatively tapered in the MD if dl>d2.
While it is not necessary, it is preferred that the discrete conduits 30 be negatively tapered in both the machine direction MD and the cross-machine direction CD. It should be carefully noted that while the embodiment illustrated in FIGS. 1-1 C comprises the framework 20 having the discrete conduits 30 which are tapered in both the mutually perpendicular MD and CD, an embodiment is possible, in which the discrete conduits 30 are tapered only in one of the MD or CD.
This embodiment can easily be visualized by one skilled in the art by assuming that the dimensions "d" and "e" in FIG. lA are equal, and the dimensions "dl" and "el"
in FIG. 1 B are not equal (i. e., d=e, and d 1 >e 1 ). Then, the discrete conduits 30 will be tapered in the MD (FIG. 1B) and non-tapered in the CD (FIG. lA). An embodiment (not shown) is also possible, while not preferred, in which the conduits 30 are negatively tapered in one of the X-Y directions, and are positively tapered in the other of the X-Y directions.
Another way of defining the tapered conduits 30 is illustrated in FIG. 1 C. In FIG. 1 C, the Z-direction and the axis 33 of the conduit 30 form the angle Q
therebetween. The web-side CD cross-sectional dimension "d" is greater than the backside CD cross-sectional dimension "e." Therefore, an angle Q 1 formed in the CD cross-section between the Z-direction and a wall 35a of the conduit 30 is greater than an angle Q2 formed in the CD cross-section between the Z-direction and a wall 35b of the conduit 30, opposite to the wail 35a in the cross-section.
FIGS. 2-3C illustrate other embodiments of the papermaking belt 10 of the present invention. In the embodiments shown in FIGS. 2-3C, the resinous framework 20 of the belt 10 comprises a plurality of discrete protuberances 40, preferably forming a patterned array. The plurality of protuberances 40 is joined to the reinforcing structure 50 and preferably comprises individual protuberances joined to and extending outwardly from the web-facing side 51 of the reinforcing structure 50. In the embodiments illustrated in FIGS. 2-3C, the web-facing side 51 of the reinforcing structure defines the X-Y plane. Each protuberance 40 has a top surface 41, a base surface 42 opposite the top surface 41, and walls 45 spacing apart and interconnecting the top surface 4I and the base surface 42. The plurality of the top surfaces 41 define the web-side surface 21 of the framework 20; and the plurality of the base surfaces 42 define the backside surface 22 of the framework 20.
As illustrated in FIGs. 2 and 2A, the plurality of protuberances 40 are arranged such thatthe protuberances 40 are preferably encompassed by and adjacent to the area of essentially continuous conduits 70 which extends from the top surfaces 41 of the protuberances 40 to the web-facing side 51 of the reinforcing structure 50. As used herein, the "area of essentially continuous conduits 70" defines an area between the adjacent protuberances 40 into which the fibers of the web 60 can deflect during the papermaking process according to the present invention. The area of essentially continuous conduits 70 has a defined flow resistance which is dependent primarily upon the pattern, size, and spacing of the individual protuberances and of the reinforcing structure S0. In the preferred embodiment, each protuberance 40 is substantially equally spaced from the adjacent protuberance 40, providing an essentially continuous conduit 70 preferably having substantially uniform flow resistance characteristics. If desired, the protuberances 40 may be clustered together so that one or more protuberances 40 is unequally spaced from an adjacent protuberance 40.
The web-facing side 51 of the reinforcing structure 50 has an essentially continuous web-facing network 51 * formed therein and defined by the area of essentially continuous conduits 70. Preferably, the protuberances 40 are distributed in a non-random repeating pattern so that the fibers deposited onto the essentially continuous web-facing network 51 * around and between the protuberances 40 are distributed more uniformly throughout the web-facing network 51 *. More preferably, the protuberances 40 are bilaterally staggered in an array.

The belt 10 of the present invention is essentially macroscopically monoplanar. As used herein, the requirement that the belt IO is "essentially _ macroscopically monoplanar" refers to the overall geometry of the belt 10 when it is placed in a two-dimensional configuration and has, as a whole, only minor and tolerable deviations from the absolute planarity, which deviations do not adversely affect the belt's performance. The possible pre-determined differences in height among the protuberances 40 are considered minor relative to the overall dimensions of the belt 10 and do not affect the belt 10 being macroscopically monoplanar.
Each protuberance 40 has an axis 43. Analogously to the axis 33 of the discrete conduit 30 defined in great detail above, the axis 43 of the individual protuberance 40 is an imaginary straight line connecting a center P1 of the top surface 4I and a center P2 of the base surface 42 (FIG. 2A). The center PI of the top surface 41 is a center of the top surface 41, i.e., a point of the top surface 41, which point would coincide with the center of mass of a thin uniform distribution of matter over this top surface 41. Analogously, the center P2 of the base surface 42 is a center of the base surface 42. By analogy with the discrete conduits 30, if the top surface 41 comprises a figure that is bilaterally symmetrical relative to an axis (not shown) parallel to at least one of the X-Y directions, then in a Z-directional (i.e., vertical) cross-section perpendicular to that X-Y direction, the top surface center P 1 will be positioned in the middle of a cross-sectional dimension "f' of the area of the top surface 41, as shown in FIG. 2. Likewise, if the base surface 42 comprises a figure that is bilateralIy symmetrical relative to an axis (not shown) parallel to at least one of the X-Y directions, in a Z-directional cross-section perpendicular to that X-Y direction, the base surface center P2 will be positioned in the middle of a cross-sectional dimension "g" of the area of the base surface 42.
In accordance with the present invention, the Z-direction and the axes 43 of at least some of the protuberances 40 form an acute angle S therebetween, as shown in FIG 2A. The top surfaces 4I of at least some of the protuberances are off set relative to the corresponding base surfaces 42 of the same protuberances within the X-Y plane and in at least one direction which is perpendicular to the Z-direction.
In FIGs. 2 and 2A, the top surfaces 41 are off set relative to the base surfaces 42 in the cross-machine direction CD. An X-Y distance "V" between the top surface center P 1 and the base surface center P2, and an angle S formed between the axis 43 and the Z-direction define the off set of the top surface 41 relative to the base surface 42.
If the top surface cross-sectional dimension "f' is equal to the base surface cross-sectional dimension "g" in a Z-directional (vertical) cross-section parallel to one of the X-Y directions, the opposing walls 45 are mutually parallel, and the protuberance 40 is non-tapered in that X-Y direction. Conversely, if the top surface cross-sectional dimension "f' is not equal to the base surface cross-sectional dimension "g" in a Z-directional cross-section parallel to one of the X-Y
directions, the opposing walls 45 are not mutually parallel in that X-Y direction, and the protuberance 40 is tapered relative to the axis 43 in that X-Y direction. If the top surface cross-sectional dimension "f' is smaller than the base surface cross-sectional dimension "g" in a Z-directional cross-section parallel to one of the X-Y
directions, the protuberance 40 is positively tapered in that X-Y direction. If the top surface cross-sectional dimension "f' is greater than the base surface cross-sectional dimension "g" in a Z-directional cross-section parallel to one of the X-Y
directions, the protuberance 40 is negatively tapered in that X-Y direction. For example, assuming that in FIG. 2A, the top surface cross-sectional CD dimension "f' is smaller than the base surface cross-sectional CD dimension "g," the protuberances 40 shown in FIG. 2A are positively tapered in CD.
While it is not necessary, it is preferred that if the framework 20 comprising the tapered discrete protuberances 40 is to be utilized, the discrete protuberances 40 be positively tapered in both the machine direction MD and the cross-machine direction CD. However, the embodiment is possible, in which the discrete protuberances 40 are tapered only in one of the MD and CD.
Referring now to FIGS. 3 and 3A, the plurality of discrete protuberances 40 may have a plurality of discrete deflection conduits 30 therein. The discrete deflection conduits 30 extend from the web-side surface 21 to the backside surface 22 of the framework 20, or, in other words, from the top surfaces 41 to the base surfaces 42 of the protuberances 40, because, as has been explained hereinabove, the plurality of top surfaces 41 form the web-side surface 21 of the resinous framework 20, and the plurality of base surfaces 42 form the backside surface 22 of the framework 20. Preferably, each individual protuberance 40 has one discrete conduit 30 extending from the top surface 41 to the base surface 42.
As has been described hereinabove, each discrete conduit 30 has the web-side opening 31 and the backside opening 32. The web-side openings 31 are preferably off set relative to the corresponding backside openings 32 in one of the X-Y
direction. In the belt 10 of the present invention, having the framework 20 comprising the discrete protuberances 40 which have the discrete conduits 30 therein, the off sets of the protuberances 40 are preferably, while not necessarily, coincidental with the off sets of the conduits 30 disposed in the corresponding protuberances 40. As shown in FIG. 3A, the axes 33 of the discrete conduits 30 are preferably coincidental with the axes 43 of the protuberances 40, and the angles Q
formed by the axes 33 and the Z-direction are preferably equal to the corresponding angles S formed by the axes 43 and the Z-direction. In FIG. 3A, the protuberances 40 are positively tapered, and the discrete conduits 30 disposed in the protuberances 40 are negatively tapered.
An embodiment (not shown) is possible, although not preferred, in which the axis 33 of the discrete conduit 30 is not coincidental with the axis 43 of the protuberance 40, and the angle Q formed by the axis 33 and the Z-direction is not equal to the angle S formed by the axis 43 and the Z-direction. The respective off sets of the protuberance 40 and the discrete conduit 30 may not be equal in the latter case.
The flow resistance of the discrete conduits 30 through the protuberance 40 is different from, and typically greater than, the flow resistance of the essentially continuous conduits 70 between adjacent protuberances 40. Therefore, when the belt 10 having both the discrete conduits 30 and the essentially continuous conduits 70 is utilized as a forming belt 10a, typically more of the liquid carrier will drain through the continuous conduits 70 than through the discrete conduits 30, and consequently, relatively more fibers will be deposited onto the areas of the reinforcing structure 50 which are subjacent to the continuous conduits 70 (i.e., the web-facing network 51 *) than onto the areas of the reinforcing structure 50 which are subjacent to the discrete conduits 30.
The essentially continuous conduits 70 and the discrete conduits 30, respectively, define high flow rate and low flow rate zones in the belt 10.
The initial mass flow rate of the liquid carrier through the continuous conduits 70 is preferably greater than the initial mass flow rate of the liquid carrier through the discrete conduits 30.
It should be recognized that no liquid carrier will flow through the protuberances 40, because the protuberances 40 are impervious to the liquid carrier.
However, depending upon the elevation of the top surface 41 of the protuberances 40 relative to the web-facing side 51 of the reinforcing structure 50 and the length of the cellulosic fibers, cellulosic fibers may be deposited on the top surfaces 41 of the protuberances 40.
As used herein, the "initial mass flow rate" refers to the flow rate of the liquid carrier when the liquid carrier is first introduced to and deposited upon the forming belt 10a. Of course, it will be recognized that both flow rate zones will decrease in mass flow rate as a function of time as the discrete conduits 30 or the essentially continuous conduits 70 become obturated with cellulosic fibers suspended in the Mar-04-04 04:31pm From-511~BAS LTD 416595 1306 T-1t3 P.01T/02T F-124 zo liquid carrier attd retained by the belt 10a. The difference in flow resistance between the discrete conduits 30 and the continuous conduits ?0 pro~rides a nxeans ~'or retaining differem basis weights of cellulosic fibers in a pattern in the different zones of the belt 1 Oa. .
This difference in flow rates through the zones is referred to as "staged draining," in reco~ition that a step discontinuity exists between the initial flow rate of'the liquid carrier through the high flow rate zones and the law flow rate zones.
The more detailed description of the staged draining arid its benefits tnsy:be found in ' the commonly assigned T1.S. Patent 5,245,023 referenced above. .
Tlre .papermaicing belt 10 of the present inventi4rx maybe made according to the method comprising the following Steps. , First, an apparatus fur generating curing radiation should bc-provided. One emt~odi.rrzt of the apparatus for generatircg.curing radiation is art apparatus 80 for ~
ge»erating curing radiation R in at least a first radi:~t~r.,g direction U1.
The agparacus 80 schernatifiatly shown in FIG. 5 comprises two primary elements_ an elongate . reflector 82 and ~an~ elonga:z soeuee of radiation 8S. Several embodiments of the .
' apparatus 80 far generating curing radiation R are disclosed ~n the commonly assigned co-pending Application entitled "Apparatus far Gexaerating ~onaralied , ' ' Radiation for Curing Photosensitive I~.esin" Bled in the name of Trokhan on the sane date as the present application.
'Then, a liquid photosensitive resin should be provided. The suitable photosensitive resin is disclosed in the commonly assigned'1J.S. patent 5,514,523, issued ozt Dec. 20, 1993 to P.D. Trakhan et al:
The next step is prnviding a farming unit 87 having a working surface. 88.
The forming wnit 87 should be capable of receiving the liquid photosensitive resin.
The next step is providing the air-permeable reinforcing structure 50 described hereinabove, If the preferred papermaking belt 10 is to be manufactured in the form of endless belt, the reinforcing structure 50 should also be an endless belt.
It should be noted that the step afpraviding the reinforcing structure 50 is necessary for the belt 1 O having the framework 2Q which is comprised of the plurality of discrete protuberances 40. In the case of manufacturing the belt 1fJ comprising the essentially continuous $amework 20, the reinforcing structure 50 is not necessary, although highly preferred.

Mar-04-04 D4:32pm From-SI~BAS LTD 416696 T306 T-1T8 P.O16/02t F-124 If the reinforcing structure 50 is to be utilized, the next steps are bringing at least a portion of the machine-facing side 5? of the reinforcing structure SD
into contact with the working surface 88 of the forming unit $0, and applying a coating of t'Se liquid photosensitive resin to at least the web-facing side 51 of the reinforcing structure 50. The Coating has a pre-selected thickness, and after the costing is applied to the reinforcing structure 50, the coating farms a >;;rst swface~25 and a second surface 27 opposite the first surface 25. After the process of eurirtg is complete, the first surface 25 will farm the web-side surface 21 afthe framework 20.
and the second surface 37 will form the backside surface 22 of the framework 20.
The steps of bridging a 'portion of the machine-facing side 52 of the reinforcing structure 30 into contact with the working surface 88 and applying a coating ~of the resin to the web~facing side 51 of the reinforcing Structure 50 are described in greater detail in the above-mentioned patent 5,514,523.
... . If the,r~einfarcing structure 50 i5 no~ tv br ~L~ilized, tlae liquid photosensitive resin may simply be disposed in the forming unit A f thereby forming~a coating, of the resin of a pr::-selected thickness, the coating having the .first surface ZS
and the second surface 27 opposite the first surface 25_ After the. c oating of the liquid photosensitive resin has been formed (with ar without the reinfoa;:irrg structure 50), the next step is disposing the forming unit 87 codtaiaing the co~~ti-:g of the liciuid photps~rtsitive resin, ixs the first r2w;toting direction U 1 such that the first surface 25 of the coating anc! the first radiating direction U 1 form an acute angle W therebetween. This step rnay be accomplished by positioning the coating of the rrsin as schemasicalty shown in FIG. 5A. If desired., the angle of incidence of the curing radiation rnay be parallri to the axis thmugh the cotlitnator 90 (1~IGs. 5 and SA), T'he c,~ Kcal point is that the resin coating is rrtaintained in acute angular ' relationship with the direction of the radiation during the curing process.
The angular relationship may be accomplished by adjusting either the~position of the resin or the sklrection of the radiation, so that perpendicularity is avoided and 3n acute angle ootained.
Alternatively or additionally, this step may be accomplished by utilizing ata apparatus of controlled radiation HO* schematically shown in FfG. SB.
The apparatus of controlled radiation 80* schEmatically shown In FIG_ 5i3 comprises three sections 82: 82a, 8x17, 82c. The section 82b is movably connected to the section 82a, and the section 82c is movably connected to the section 82b. Each section 82 {82a, 82b, 82c) comprises a plurality of reflective facets 83 {83a, 83b, 83c, respectively). Each individual reflective facet 83 is independently adjustable in the cross-section. The source of radiation 85 is movable in the cross-section.
The combination of independent adjustability of the individual reflective facets 83 and the independent adjustability of the individual sections 82 combined with the movability of the source of radiation 85 allows to direct the curing radiation generated by the apparatus 80* in at least one pre-determined radiating direction in the cross-section. In FIG. SB, the apparatus 80* directs the curing radiation in the first radiating direction U1, a second radiating direction U2, and a third radiating direction U3.
FIG. SC shows another embodiment of the apparatus of controlled radiation 80*. The apparatus 89 shown in FIG. SC comprises several sources of radiation, preferably bulbs, 85. Each bulb 85 has its longitudinal direction essentially perpendicular to the machine direction MD. Each bulb 85 has its own collimating element 90 disposed between the bulb 85 and the photosensitive resin being cured.
The collimating elements 90 are disposed such that the curing radiation emitted by each bulb has its own predetermined direction (U1, U2, U3, as schematically shown in FIG. SC). Subtractive walls 89 are preferably provided to restrict the mutual interference between the portions of the curing radiation having different directions U1, U2, U3.
The embodiments of the apparatus 80* shown in FIGs. SB and SC
prophetically produce the belts 10 having sophisticated three-dimensional designs of the resinous framework 20. In FIGS. SB and SC, for example, the resin being cured by the apparatus 80* will form the framework 20 having three zones H1, H2, and distinguished by relative "angled" orientations of the discrete conduits 30 (or the discrete protuberances 40 in the case of the forming belt 1 Oa).
The next step is providing a mask 96 having opaque regions 96a and transparent regions 96b. The purpose of the mask is to shield certain areas of the liquid photosensitive resin from exposure to the curing radiation R so that these shielded areas will not be cured, i.e., will remain fluid, and will be removed after curing is completed. The unshielded areas of the liquid photosensitive resin will be exposed to the curing radiation R to form the hardened framework 20. The opaque regions 96a and the transparent regions 96b define a pre-selected pattern corresponding to a specific desired design of the resinous framework 20. If, for example, the belt 10 having a substantially continuous resinous framework 20 is to be produced, the transparent regions 96b must form a continuous area generally corresponding to the X-Y plane of the desired web-side network 21 * of the framework 20.
The next step is positioning the mask 96 between the first surface 25 of the resin coating and the apparatus 80 such that the mask 96 is preferably in adjacent relation with the first surface 25. The opaque regions 96a of the mask shield a portion of the coating from the curing radiation R, and the transparent regions 96b leave the other portions of the coating unshielded for the curing radiation R.
The next step is curing of the unshielded portions of the coating by exposing the coating to the curing radiation R having an activating wavelength from the apparatus 80 through the mask 96 to form a partially-formed belt, and leaving the shielded portions of the coating uncured.
The final step is removing substantially all uncured liquid photosensitive resin from the partially-formed belt to leave a hardened resinous structure. This hardened resinous structure forms a framework 20 having a web-side surface 21 formed by the first surface 25 being cured, and a backside surface 22 formed by the second surface 27 being cured.
In the case of the belt 10 comprising a continuous framework 20, the framework 20 has a plurality of discrete conduits 30 in the regions which were shielded from the curing radiation R by the opaque regions 96a of the mask 96.
The discrete conduits 30 extend between the web-side surface 22 (or the cured first surface 25) and the backside surface 27 (or the cured second surface 27), each of the conduits 30 having the axis 33 and the walls 35, the axes of at least some of the conduits and the Z-direction forming an acute angles therebetween, as has been described in greater detail above.
In the case of the belt 10 having the framework 20 comprising the plurality of discrete protuberances 40, the plurality of discrete protuberances 40 extends from the reinforcing structure 50, each of the protuberances having the axis 43, the base surface 42, the top surface 41, and the walls 45 spacing apart and interconnecting the base surface 41 and the top surface 42. The plurality of the top surfaces 41 define the web-side surface 21 of the resinous framework 20, and the plurality of base surfaces 42 define the backside surface 22 of the resinous framework 20. The axes 43 of at least some of the protuberances 40 and the Z-direction form acute angles therebetween, as has been described in greater detail above.
The papermaking process which utilizes the papermaking belt 10 of the present invention is described below, although it is contemplated that other processes utilizing the belt 10 may also be used. By way of background it should be ~lar-04-04 04:32pm Frvm-SII~AS LTD 416596 2306 T-1t6 P.018/02T F-124 appreciated that the belt 10 comprising the resinous framework 20 which is substantially Cdntinuous is primarily utilized as a through-air drying belt i Ob, while the bett~ 10 comprising the framework 20 in the form of the plurality of discrete protube~.rtces 40 ~ is primarily utilised as a fotttxing wire 1 Via, as schematically illustrated in FICr_ b_ It cls~es real exclude, however, the alternative uses.
i. e., that the belt 10 comprising the substantially continuous resinous framework 20 maybe used as a forming belt I Qa, and the belt 10 comprising the resinous framework ?0 in the form of the plurality of discrete protuberances 40 may be used as a through-air drying belt t Ob.
The overall papetmaking process which uses the papermaking belt 10 of the present invention comprises a number of steps or operations which occur in the general sequence as noted below. It is to !ae understood, however, that the steps described below are intended to assist a reader in understanding the process of the present inverAtion, and that the invention is nc~x irmite~ to processes with o:xly a c~errain number or ~:~rrangemtnt of steps. In ibis regard, it is noted that it is possible to combine at least sortie of the following steps so that they are performed cortcturently. Likewise, it is possible to separate at least ststrte of the following steps -into xwo or more step, without departing from the scope of this inventit~n.
FIG. 6 is a simplifit~d, schematic repcesentatio~n of one embodiment of a continuous paper~r~aking ~machitte useful in the practice of the pap~:rcnaking process of the present invention. As has been defined above, the papermaking belt I 4 of the present invention includes the forming belt l0a and the tluoetgh-air drying belt 10b, bout shown in the preferred form of endless belts in FIG. 6.
The first step i$ to provide a plurality of cellulosie fibers entrained ~in a liquid carrier, or, in other words, an aqt~us dispersion of papermaking Ethers. The .
ceilulosic fibexs a:z not dissolved in the Iicluid earner, but merely suspended therein.
The equipment for preparing the aqueous dispersion of papermaking fibers is well-known in the pxpetrnakittg art and is therefore not shown in FIG. 6_ The aqueous dispersion of paFertnalciieg fibers is provided to s headbox IS. A single tteadbox is shown in FIG. 6. However, it is to be tutderstaad that there may be multiple headbaxes in alternative arrangements of the paperm-airing process of the present invention. The headlvox(es) and the equipment for preparing the aqueous dispersion of papermaking, fibers are preferably of the type disclosed in U.S. Patent No.

3,9t34,77I, issued to Morgan and Rich on November 30, 1976. The preparation of the aqueous dispersion and the characteristics of the aqueous dispersion are described in greater detail in 'U.S. patent tlar-04-04 04:33pm From-SIkBAS LTD 416696 T306 T-1TB P.020/02t F-124

4.,529,480 issued to Trokham on July 1~, 1985:
The adueous dispersion of papermakiizg fibers supplied by the headbox I S is delivered to a forming belt. such as the ~osming belrs ' as of the,Rresent invention. for carrying out't~e second step bf tlxe prapermaking process. The forming belt i Oa is supported by a bireast roll 1$a and a plurality of return rolls designated as I 8b and t 8c. The forming wire I Oa is propelled in the direction indicated by the directional arrow A by a conventional drive means v.~ell known to one skilled in the art and therefore not shown in FIG 6. , There may also be associated with ~ the papermaking machine shown in FhL"s. 6 optional auxiliary units and, devices which one commonly associated with papermaking machines and with forming t5elts, including:
fornting boards, hydrofoils, vacuum boxes, tension roils, support rolls, wire cleaning showers, and the like, which are conventional and welt-known in the papermaking art . and therefore also not shown in FhG. 6.
The preferred s Earn. ing belt l0a is the macroscopically manoplanar belt ;r. , comprising the air-pernxeable reinforcing structure SQ and the resinous framework ~r~ joined to the reinforcing structutr 50. ~ As has. been described above, the .,;,.
reinforcing structure 50 has the web-facing side S t and the mx:c>°Line-facing side SZ
opposite the machine-fuemg_sidc 51. .T'te web-facing side 51 defines rye X-Y
plane of the far._~.iing belt l0: this X-Y pfanc being_perpendicuiar to the ~-cli~ection. The framework 20 is comprised of the plurality of ~discr~ete protuberances 40 joined to and extending from the reinforcing structure 50. F~ch of the protuberances 40 has the top. surface 41, the base surface 42, the walls 45 sparing apart and intereonnertittg the top surface 41 and the base surface 42, and the axis 43 connecting the center of the top surface 4 i and the center of the base surface 42_ The plwrality~ of top surfaces 42 define the web-side ,surface 3',, and the plurality of base surfaces 4~ define the ldackside stufacc 22 of the framework 20. Ln accordance with the present invention, the axes 43 of at least some of the protuberances 40 ~ and the Z-direction,form acute angles S theri~betweett.
If the fcirning belt 10a has the area of essentially cony;taous conduits 70 and the phuality of discs~t~e deflection condu~ets 30 disposed in the protuberances 40, the belt l0a has high flow rate liquid pervious zones and low flow rate liquid pervious zones respectively defined by the cssetttially continuous deflection conduits 70 and the discrete conduits ~0_ The liquid carrier and entrained cellulosic fibers are deposited onto the forming belt 10a illustrated in f=igure 6. The liguid carrier is drained through the fotTrsing belt tOa in two simultaneous stages, a high flow rate stage and a low ~1aw rata stage. In the high flow rate stage, the Iiguid carrier drains h~lar-04-04 04:33pm From-SII~BAS LTD 416896 T306 T-1T8 P:021/62T F-124 through the liquid pervious high flow rate zones at a given initial flow rate until vbturation occurs (or the liquid carrier is na longer introduced to this portion of the forrning~belt 10). In the low flow rate. stage, the liquid carrier drains through low flow rate zones of the forming tae.lt I Oa at a given initial fl4w ~.te which is less than the initial flow rate through the high flaw rate zones.
As has been noted above, the high flow rate liquid pervious zones and the low flow rate liquid pervious zones in the belt l0a decrease as a function of time, due to expected obturatian of moth ztmes. It is believed that the low flow rate zones may obtuxrate before the high flow rate zones obturate.
Without being bound by theory, the Applic2~nt believes that the first occurring zane obturation rnay be due to the lesser hydraulic radius and greater flow resistance of such zones, based upon factors such as the flow area, wetted perimeter, shape and distribution of the low flow rate zotlts, or may be due to a greater flow rate through such zone accompanied by a greater depiction of fbers. The Ivw fla~N ratf z.~nes may, for example. comprise discrete conduits 30 through the, protuber~artces 40, w-hictt discrete Conduits 30 have a greater flow resistance than the essentially eontihuous conduits 7p between adjacent protuberances 40. It is important than tote ratio of the flow. rrsistances between the discrete conduits 30 and the essentially continuous condu:~s 70 be properly prapottioned. 'Ihe flow resistance of the discrete cQreduits 30 and the essentially ca~trtiriiuous conduits.70 rna~y be determined by using the hydraulic radius, as described in the eomrxaonly assigned U.S. Patent

5,527,428 referenced above.
"Ilte next steps are depositing the plurality of cellulosic papermaking fibers suspended in a liquid carrier on the forming belt t0a and draining the liquid carrier through the farming belt thereby forming an embryonic web 60 of the paperznalcing fibers on the foaming belt l0a_ As used herein. the "embryonic web" is the web of fibers which is subjected to rearrangement on the forming belt, and.
preferably the forming belt 10a of the present invention, dtuing the course of the paperntaking proccs.,s. The characte.~'.stics of the ea~t~tyonie web 60 and the various possible techniques .for forming the embryonic web 6U are described in the cortemonly assigned U'.S. Pat~~nt 4,~2~,480. In the process shown in FIG. 6, the embryonic web 60 is formed from the cellulosic ftbexs suspended in s. liquid carrier between breast roll 18a and return roll 18b by depositing the cellulosic fibers suspended in a Iiqtud carrier onto the forming wire l0a and removing a portion of the liquid earner through the belt 10a. ~orxveztt~ioxia! vacuttrn boxes, forming boards, hydx'ofoils, and tb.e lil~e which are not shown in FIG. 6 are useful in effecting the removal of liquid~carrier.

The embryonic web 60 formed on the forming belt l0a of the present invention and shown in FIG. 4D has a first side 61 * and a second side 62*
opposite the first side 61 *. The first side 61 * is that side which is associated with the web-contacting surface 11 of the belt 10a. When the belt 10 of the present invention is utilized as the forming belt 10a, the embryonic web 60 shown in FIG. 4D
comprises a macroscopically planar and patterned first region 64* (corresponding to the area of essentially continuous conduits 70) preferably having a relatively high basis weight, and a second region 65* (corresponding to the area of discrete protuberances 40) preferably having a relatively low basis weight. The first region 64*
comprises an essentially continuous network; and the second region 65* comprises a plurality of discrete "angled" knuckles 65* extending from the first region 64* in at least one direction. This at least one direction (defined by an imaginary axis 63* of a knuckle of the second region 65) and the Z-direction form an acute angle L
therebetween (corresponding to the acute angles S formed between the Z-direction and the axes 43 of the conduits 40). The second region 65* is circumscribed by and adjacent to the first region 64*. The second region 65* comprising the discrete angled knuckles having a low basis weight preferably occur in a non-random repeating pattern corresponding to the pattern of the plurality of discrete protuberances 40 of the forming belt 10a.
If the forming belt l0a has the essentially continuous conduits 70 and the discrete conduits 30, the embryonic web 60 may comprise a third region 66*
preferably having an intermediate basis weight relative to the basis weight of the first region 64* and the basis weight of the second region 65*. The third region 66*
occurs in a preferred non-random repeating pattern substantially corresponding to the low flow rate zones, i. e., the zones of the discrete conduits 30. The third region 66* is juxtaposed with, and preferably circumscribed by, the second region 65*.
After the embryonic web 60 is formed, the embryonic web 60 travels with the forming wire l0a in the direction indicated by the directional arrow A
(FIG. 6) to be brought into the proximity of the through-air drying belt lOb. The preferred through-air belt lOb is described in great detail hereinabove. The through-air belt lOb is a macroscopically monoplanar papermaking belt comprising the resinous framework 20 having the web-side surface 21 defining the X-Y plane, the backside surface 22 opposite the web-side surface 21, the Z-direction perpendicular to the X-Y plane, and the plurality of discrete deflection conduits 30 extending between the web-side surface 21 and the backside surface 22. Each of the conduits 30 has the axis 33 and the walls 35. In accordance with the present invention, the axes 33 of at least some of the conduits 30 and the Z-direction form the acute angles Q
therebetween.
The next steps are depositing the embryonic web 60 to the web-side surface 21 of the resinous framework 20 of the through-air drying belt l Ob and applying a fluid pressure differential to the embryonic web 60 to deflect at least a portion of the papermaking fibers into the discrete deflection conduits 30 and to remove water from the embryonic web 60 into the discrete deflection conduits 30 thereby forming an intermediate web 60.
In the embodiment illustrated in FIG. 6, the through-air drying belt lob of the present invention travels in the direction indicated by directional arrow B.
The belt l Ob passes around the return rolls 19c, 19d, impression nip roll 19e, return rolls 19a, and 19b. An emulsion distributing roll 19f distributes an emulsion onto the through-air drying belt lOb from an emulsion bath. The loop around which the through-air drying belt l Ob of the present invention travels also includes a means for applying a fluid pressure differential to the web 60, which means in the preferred embodiment of the present invention comprises vacuum pick-up shoe 17a and a vacuum box 17b.
The loop may also include a pre-dryer (not shown). In addition, water showers (not shown) may preferably be utilized in the papermaking process of the present invention to clean the through-air drying belt l Ob of any paper fibers, adhesives, and the like, which may remain attached to the through-air drying belt lOb after it has traveled through the final step of the papermaking process. Associated with the through-air drying belt lOb of the present invention, and also not shown in FIG. 6, are various additional support rolls, return rolls, cleaning means, drive means, and the like commonly used in papermaking machines and all well known to those skilled in the art.
When the through-air drying belt lOb of the present invention is utilized in the papermaking process, the intermediate web 60 shown in FIGs. 4-4C comprises a macroscopically monoplanar, patterned, and essentially continuous network region 64 preferably having relatively high density and a domes region 65 preferably having relatively low density. The domes region 65 comprises a plurality of discrete domes 65, or 65a, 65b, 65c, protruding from, circumscribed by, and adjacent to the network region 63. Each of the domes 65 has an axis 63. The axes 63 of at least some of the domes 65 and the Z-direction form acute angles K (FIG. 4B) and acute angles M1 and M3 (FIG. 4C) therebetween.
The papermaking process of the present invention may also include an optional step of pre-drying the intermediate web 60 to form a pre-dried web 60. Any convenient means conventionally known in the papermaking art can be used to dry _...__._ _~ _ _ __ __ .

the intermediate web 60. For example, flow-through dryers, non-thermal, capillary dewatering devices, and Yankee dryers, alone and in combination, are satisfactory.
The next step in the papermaking process is impressing the web-side network 21 * of the resinous framework 20 into the pre-dried web 60 by interposing the predried web 60 between the belt 10 and an impression surface to form an imprinted web 60 of papermaking fibers. If the intermediate web 60 is not subjected to the optional pre-drying step, this step is performed on the intermediate web 60.
The step of impressing is carried out in the machine illustrated in FIG. 6 when the pre-dried (or intermediate) web 60 passes through the nip formed between the impression nip roll 19e and the Yankee drier drum 14. As the predried web 60 passes through this nip, the network pattern formed on the web-side network 21 * of the framework 20 is impressed into the pre-dried web 60 to form an imprinted web 60.
The next step in the papermaking process is drying the imprinted web 60. As the imprinted web 60 separates from the belt 10, it is adhered to the surface of Yankee dryer drum 14 where it is dried to a consistency of at least about 95%
to form a dried web 60.
The next step in the papermaking process is an optional, and highly preferred, step of foreshortening the dried web 60. As used herein, foreshortening refers to the reduction in length of a dry paper web 60 which occurs when energy is applied to the dry web 60 in such a way that the length of the web 60 is reduced and the fibers in the web 60 are rearranged with an accompanying disruption of fiber-fiber bonds.
Foreshortening can be accomplished in any of several well-known ways. The most common, and preferred, method is creping schematically shown in FIG. 6. In the creping operation, the dried web 60 is adhered to a surface and then removed from that surface with a doctor blade. As shown in FIG. 6, the surface to which the web 60 is usually adhered also functions as a drying surface, typically the surface of the Yankee dryer drum 14. Generally, only the non-deflected portions of the web 60 which have been associated with web-side network 21 * on the web-contacting side 11 of the papermaking belt 10 are directly adhered to the surface of Yankee dryer drum 14. The pattern of the web-side network 21 * and its orientation relative to the doctor blade will in major part dictate the extent and the character of the creping imparted to the web. If desired, the dried web 60 may not be creped.
The general physical characteristics of the paper web 60 which is made by the process of the present invention utilizing the through-air drying belt l0a having an essentially continuous framework 20 are described in the aforementioned U.S.

liar-D4-04 D4:33pm From-SIIr~AS LTD 416686 1306 T-1T8 P.022/02T F-124 Patent 4,529,480 entitled "''Tissue Paper", which issued to ~'rokhan an 3~u13~
I6, 1.9$5:
'fhe plurality of domes 65 in the paper web 60 of the present invention, however, will prophetically fatztt an "angled" pattern, due to the "angled"
positicm of thG conduits 30 of the through-air drying belt 10 of the present invention. 1t should be understood that the steps of imprinting, drying, and - especially --ereping may interfere with the "angled" position of the domes 65. That is to say, the processing of the web 60 after it is separated fmm the through-air drying belt I Ob ~.~ay affect the overall configuration of the. domes 55 as well as the acute angles K (FI~'~_ 4B) anii~
M 1. M3 (F1.f~r. 4C) formed between the Z-direction and the aces of the domes 55 in such a way tlsat throe acute angles may not be ~t~al to the corresponding angles Q
between the Z-direction and the axes 33 of the conduits 30. It is believed, however, that the paper vveb 50 according to the present invention will have the crass-sectional " ~ngled° Gatterrt of the domes ~5 generally following the cross-sectional angled pattern of the conduits 30 of the resinous framewor': ~~.
!=1Gs_ 4-.~C show one orophetie embodiment of the paper web b0 according tv thr prrsen' ~avention_ Pmt~rabty, the domes 65 are disposed in a non-s~rcdom and repeating pattern which corresponds to the pattern of the diserett conduits 30 of the resinous framework ~0 of the btlt 10. While r:~t being inte~:~..a .to be bound by theory. the~Applicar.' 1=;.lieves that tat paper 60 having the acutely angled dorrrcs 65 is softer than the comparable paper ktaving domes generally perpendicular relative to ,thr plane of the network region 64, because the acutely angled domes 65 are believed to be more easily collapsible i3tart the generally perpendicularly upstanding domes. Moreover. it is believed that the angled domes G5 having a speeiftc pre-determined direetiona) orientation rnay provide a benefit of facilitating a distribution of liquids is a desired dir~eetion. This property may provt to be very beneficial if the paper b0 is ustd in such disposable products as diapers, sanitary napkins, wipes, and the like.
For example, the paper web 6~ r~_~wn in 1~IG:~. 4 and 4C has three zones of relative orientation: a first zone H1, the seGand zotve H~, and a third zone H3_ As best shov..t in FIGS. 4 and 4~, the first wne HI has the domes 65a oriented in a first direction hl, the second zone H2 has the dames 65b oriented in a second direction h~'. and the third gone H3 has the domes 55c oriented iut a third direction h3_ Viewed in plane, the first direction hl and the second direction h2 are directed towards each other, and the third direction h3 is perpendicular to the first and second directions hl, h2.

Claims (15)

WHAT IS CLAIMED IS:

1. A macroscopically monoplanar papermaking belt for use in a papermaking machine, said papermaking belt comprising a resinous framework having a web-side surface defining an X-Y plane, a backside surface opposite said web-side surface, a Z-direction perpendicular to said X-Y plane, and a plurality of discrete deflection conduits extending between said web-side surface and said backside surface, each of said discrete conduits having an axis and walls, the axes of at least some of said discrete conduits and said Z-direction forming acute angles therebetween.

2. The papermaking belt of Claim 1, further comprising an air-permeable reinforcing structure positioned between said web-side surface and said backside surface of said resinous framework, said reinforcing structure having a web-facing side and a machine-facing side opposite said web-facing side.

3. The papermaking belt of Claim 1 or 2, wherein said web-side surface of said framework has an essentially continuous web-side network formed therein and said backside surface of said framework has a backside network formed therein, said web-side network defining web-side openings of said conduits, and said backside network defining backside openings of said conduits.

4. The papermaking belt according to any one of Claims 1 to 3, wherein said web-side openings are off set relative to said corresponding backside openings within said X-Y plane in at least one direction perpendicular to said Z-direction.

5. The papermaking belt according to any one of Claims 1 to 4, wherein at least some of said discrete conduits are tapered relative to said axes in at least one direction perpendicular to said Z-direction.

6. The papermaking belt according to Claim 5 wherein at least some of the discrete conduits are negatively tapered.

7. A method of making a macroscopically monoplanar papermaking belt, said method comprising the steps of:
providing an apparatus for generating curing radiation in a first direction;
providing a liquid photosensitive resin;
providing a forming unit having a working surface and capable of receiving said liquid photosensitive resin;
disposing said liquid photosensitive resin in said forming unit thereby forming a coating of said liquid photosensitive resin, said coating having a first surface and a second surface opposite said first surface, said coating having a pre-selected thickness;
disposing said forming unit containing said coating of liquid photosensitive resin therein in said first direction such that said first surface of said coating and said first direction form an acute angle therebetween;
providing a mask having opaque regions and transparent regions, said regions defining a pre-selected pattern;
positioning said mask between said first surface of said coating and said apparatus for generating curing radiation such that said mask is in adjacent relation with said first surface, said opaque regions of said mask shielding a portion of said coating from the curing radiation of said apparatus, and said transparent regions leaving other portions of said coating unshielded for the curing radiation of said apparatus;
curing said unshielded portions of said coating, and leaving said shielded portions of said coating uncured by exposing said coating radiation having an activating wavelength from said apparatus for generating curing radiation through said mask to form a partially-formed belt; and removing substantially all uncured liquid photosensitive resin from said partially-formed belt to leave a hardened resinous structure which forms a framework having a web-side surface formed by said first surface being cured, a backside surface formed by said second surface being cured, a Z-direction perpendicular to said web-side surface, and a plurality of discrete conduits in the regions which were shielded from said curing radiation by said opaque regions of said mask, said conduits extending between said web-side surface and said backside surface, each of said conduits having an axis and walls, said axes of at least some of said conduits and the Z-direction forming acute angles therebetween.

8. The method according to Claim 7, further comprising the steps of:
providing a reinforcing structure to be joined to the cured photosensitive resin, said reinforcing structure having a web-facing side and a machine-facing side opposite said web-facing side; and disposing said reinforcing structure in said forming unit with said liquid photosensitive resin.

9. A macroscopically monoplanar papermaking belt for use in a papermaking machine, said papermaking belt comprising:
an air-permeable reinforcing structure having a web-facing side defining an X-Y plane, a machine-facing side opposite said web-facing side, and a Z-direction perpendicular to said X-Y plane; and a resinous framework comprised of a plurality of discrete protuberances joined to and extending from said reinforcing structure, each of said protuberances having an axis, a top surface, a base surface opposite said top surface, and walls spacing apart and interconnecting said top surface and said base surface, the axes of at least some of said protuberances and said Z-direction forming acute angles therebetween, a plurality of said top surfaces defining a web-side surface of said resinous framework, and a plurality of said base surfaces defining a backside surface of said resinous framework.

10. The papermaking belt according to Claim 9, wherein said web-facing side of said reinforcing structure has an essentially continuous web-facing network formed therein, said web-facing network being defined by an area of essentially continuous deflection conduits, said area of essentially continuous deflection conduits circumscribing and being adjacent to said discrete protuberances.

11. The papermaking belt according to Claim 9 or 10, wherein said top surfaces of at least some of said protuberances are off set relative to said corresponding base surfaces of said at least some of said protuberances within said X-Y plane in at least one direction perpendicular to said Z-direction.

12. The papermaking bell according to any one of Claims 9 to 11, wherein said walls of at least some of said protuberances are tapered relative to said axes of said at least some of said protuberances.

13. The papermaking belt according to any one of Claims 9 to 12, wherein said plurality of discrete protuberances has a plurality of discrete deflection conduits therein, said discrete deflection conduits extending from said web-side surface to said back surface of said resinous framework.

14. A method of making a macroscopically monoplanar papermaking belt, said method comprising the steps of:
providing an apparatus for generating curing radiation in a first direction;
providing a liquid photosensitive resin;
providing a forming unit having a working surface and capable of receiving said liquid photosensitive resin;
providing an air-permeable reinforcing structure having a web-facing side defining an X-Y plane, a machine-facing side opposite said web-facing side, and a Z-direction perpendicular to said X-Y plane;
bringing at least a portion of said machine-facing side of said reinforcing structure into contact with said working surface of said forming unit;
applying a coating of said liquid photosensitive resin to at least one side of said reinforcing structure so that said coating forms a first surface and a second surface opposite said first surface, said coating having a pre-selected thickness;
disposing said forming unit containing said coating of liquid photosensitive resin therein in said first direction such that said first surface of said coating and said first direction form an acute angle therebetween;
providing a mask having opaque regions and transparent regions, said regions defining a pre-selected pattern;
positioning said mask between said first surface of said coating and said apparatus for generating curing radiation such that said mask is in adjacent relation with said first surface, said opaque regions of said mask shielding a portion of said coating from the curing radiation of said apparatus, and said transparent regions leaving other portions of said coating unshielded for the curing radiation of said apparatus;
curing said unshielded portions of said coating, and leaving said shielded portions of said coating uncured by exposing said coating to radiation having an activating wavelength from said apparatus for generating curing radiation through said mask to form a partially-formed belt; and removing substantially all uncured liquid photosensitive resin from said partially-formed belt to leave a hardened resinous structure which forms a framework having a web-side surface formed by said first surface being cured, a backside surface formed by said second surface being cured, a Z-direction perpendicular to said web-side surface, said framework being comprised of a plurality of discrete protuberances joined to and extending from said reinforcing structure, each of said protuberances having an axis, a base surface, a top surface, and walls spacing apart and interconnecting said base surface and said top surface, said axes of at least some of said protuberances and said Z-direction forming acute angles therebetween, a plurality of said top surfaces defining said web-side surface of said resinous framework, and a plurality of said base surfaces defining said backside surface of said resinous framework.

15. The method according to Claim 14, wherein said plurality of discrete protuberances further has a plurality of discrete deflection conduits therein, said discrete deflection conduits extending from said web-side surface to said backside surface.