FIELD

[0001] The present teachings relate to a system including a fabric steam shower (or box) and a fabric vacuum system located on a paper machine that assists in manufacturing paper with predetermined characteristics.

BACKGROUND

[0002] Typically, paper machines include a wet end with a wire that moves in a machine direction. The wire has a width (i.e., cross-machine direction) and stock is applied substantially along the entire width of the wire. A plurality of blades or other devices are located under the wire to assist in removing water from the stock on the wire. The paper is passed to a second section having a different wire or a fabric where further dewatering occurs and then to a third section where the paper is heated to remove the remaining water from the sheet of paper. Typically, changes to the paper machine are made by a user adjusting machine characteristics such as a slice opening or machine speed based upon dry end test results. The paper may have a moisture profile in a cross-machine direction and a machine direction. An operator may attempt to control or adjust a moisture profile of the sheet; however, despite these attempts a speed of the paper machine may be limited based upon an amount of water removal from the sheet.

[0003] Examples of paper machines may be disclosed in U.S. Patent Nos. 5,397,437; 7,887,673; 8,216,427; 8,414,741 ; and 9,273,429; PCT Patent Application Publication No. WO1 997/016593; and European Patent No. EP2647759 all of which are expressly incorporated herein by reference for all purposes. Thus, there is a need for moisture control so that a paper machine speed or throughput may be increased. What is needed is device that increases a bulk of the paper. What is needed is steam showers, vacuum box, or both that embosses the sheet. What is needed is a water removal device located between the dryer and press section or fabric section.

SUMMARY

[0004] The present teachings provide: a fabric steam shower comprising: (a) one or more steam discharges that provide steam to a predetermined location; (b) one or more barriers that disturb the steam being applied so that the steam extends into the sheet; and wherein the fabric steam shower is configured to apply the steam to a fabric and a sheet at a location along a paper machine before a dryer and after a transfer box.

[0005] The present teachings provide: a system comprising: (a) a fabric steam shower and (b) a fabric vacuum system located opposite the fabric steam shower and configured to have a fabric of a paper machine and a sheet of paper being carried on the fabric pass therebetween so that moisture is removed from the fabric and the sheet.

[0006] The present teachings provide: a method comprising: (a) transferring a sheet of paper from a forming section to a fabric section; (b) applying steam to the sheet of paper in the fabric section; and (c) applying vacuum to the sheet of paper in the fabric section; wherein the amount of vacuum applied is sufficiently large to pull the sheet into the fabric so that the sheet is embossed by the fabric before the sheet moves to the dryer.

[0007] The present teachings provide moisture control so that a paper machine speed or throughput may be increased. The present teachings provide a device that increases a bulk of the paper. The present teachings provide steam showers, vacuum box, or both that embosses the sheet. The present teachings provide is a water removal device located between the dryer and press section or fabric section.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] FIG. 1 is a perspective view of a paper machine;

[0009] FIG. 2 is a side view of a paper machine; and

[0010] FIG. 3A is a close-up view of a fabric steam shower and fabric vacuum system in the circle III of FIG. 2.

[0011] FIG. 3B is a close-up view of a fabric steam shower and fabric vacuum system.

[0012] FIG. 3C is a close-up view of a fabric steam shower and fabric vacuum system.

[0013] FIG. 3D is a close-up view of a fabric steam shower and fabric vacuum system.

[0014] FIG. 4A illustrates orifice sizes in the steam shower or the fabric vacuum system.

[0015] FIG. 4B illustrates orifice sizes in the steam shower or the fabric vacuum system.

[0016] FIG. 4C illustrates orifice sizes in the steam shower or the fabric vacuum system.

[0017] FIG. 4D illustrates orifice sizes in the steam shower or the fabric vacuum system.

DETAILED DESCRIPTION

[0018] The explanations and illustrations presented herein are intended to acquaint others skilled in the art with the invention, its principles, and its practical application. Those skilled in the art may adapt and apply the invention in its numerous forms, as may be best suited to the requirements of a particular use. Accordingly, the specific embodiments of the present invention as set forth are not intended as being exhaustive or limiting of the teachings. The scope of the teachings should, therefore, be determined not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. Other combinations are also possible as will be gleaned from the following claims, which are also hereby incorporated by reference into this written description.

[0019] The present teachings are predicated upon providing an improved system, control system, inspection system, method of controlling, or a combination thereof for a steam showers, a vacuum system, or both of a paper machine. The paper machine may be a fourdrinier paper machine. The paper machine may be a twin wire paper machine, top wire former, gap former, tissue machine, cylinder mould machine, counter flow vat, Saint Ann’s former, or a combination thereof. The paper machine may be any paper machine where stock or paper travels in a machine direction and may be monitored, controlled, dried, or a combination thereof. The paper machine taught herein may be any paper machine that functions to create paper. The paper machine may be any style and/or type that forms paper. The paper machine may have a frame. The paper machine may have opposing frames. One frame may extend along a tending side and one frame may extend along a back side. The tending side of a paper machine may be a side where an operator or machine tender primarily works from. The back side of a paper machine may be a side of the paper machine opposite the tending side where the gears, motors, and equipment may be located, thus, accessibility of the paper machine may be limited. The paper machine may have one frame that extends in a cross-machine direction to connect the back side (machine side) to the tending side. The paper machine may have multiple frames that extend in the machine direction. The paper machine includes a headbox that applies stock in a wet end or a forming section.

[0020] The forming section functions to form one or more sheets. The forming section may have multiple headboxes and multiple wire sections so that multiple sheets may be formed and then combined in the fabric section. The forming section may include one or more wires. The forming section may form a sheet out of a plurality of fibers. A forming section may include a breast roll and a couch roll. The forming section may be located upstream of a couch roll or may terminate at a couch roll. The forming section may function to assist in receiving stock from the slice opening and to assist in configuring the stock so that fibers in the stock are oriented in a desired orienting (e.g., machine direction, cross machine direction, random). The forming section may include one or more foils, one or more forming boards, or both. The first foil of all of the foil sections may be a forming board. The forming section may be free of a forming board. The forming board may be static. The forming board may be movable in the machine direction. The forming board may move so that the distance between the forming board and the headbox is increased or decreased. The forming board may be height adjustable. The forming board may be angle adjustable. The forming board may be moved to increase or decrease the amount of water removed from the stock jet.

[0021] The headbox functions to apply stock to a wire or between wires. The headbox may apply stock to a wire, a forming board, or both. The headbox may be gravity fed, pressurized, or both. The headbox may apply stock at a speed slower, faster, or at a same speed as a speed of one or more wires in the wet end. The headbox may function to apply stock to a wet end, above a breast roll, on foils, or a combination thereof. The headbox may function to apply stock to a wire while the wire passes over a forming board or over a forming section. The headbox may apply stock to the wire at a location proximate to a breast roll and a forming board. The headbox may have a top portion that is movable up and down or forwards and backwards toward or away from a wire. For example, a static head of fluid may be adjusted by moving a top of the headbox (or a fluid within the headbox) up or down, or the amount of stock applied to the wire may be adjusted by moving a top of the headbox up or down (e.g., adjusting a slice opening). The headbox may include one or more slice openings.

[0022] The slice opening may function to guide stock from the headbox onto the wire or between wires. The slice opening may vary a velocity of stock traveling onto a wire, a volume of stock onto a wire, an angle of stock approaching a wire, or a combination thereof. The slice opening may be adjusted. The slice opening may have a top portion or a bottom portion that are movable. The top portion may increase a height or decrease a height of a slice opening. The top portion may pivot so as to change an angle of the stock jet while increasing a distance between the top portion and the bottom portion. The bottom portion may be movable in the machine direction, into a nip between two wires, or both. The bottom portion may change a distance between the headbox and the forming board, breast roll, wire, or a combination thereof. The bottom portion, the top portion, or both may change an angle of the stock jet relative to the wire, the forming board, or both. The top portion, the bottom portion, or both may move in the machine direction (e.g., forward and backward); up and down (e.g., towards and away from the wire); pivot a portion towards or away from the wire; or a combination thereof. The slice opening may affect a contact location, contact angle, stock velocity, or a combination thereof of the stock jet relative to the wire, breast roll, forming board, forming section, nip between wires, or a combination thereof.

[0023] The stock jet functions to place stock on a wire while beginning to impart certain characteristics into the fibers in the stock. For example, if a stock jet is moving slower than a wire (e.g., drag) the fibers may tend to be aligned in the machine direction. In another example, if the stock jet is moving at a same speed as the wire the fibers may tend to be more randomly oriented than when the stock jet is in rush or drag.

[0024] The one or more wires function to allow a fluid to pass therethrough while retaining solids on the wire. The one or more wires may assist in dewatering stock. The one or more wires may be two or more wires. The two or more wires may converge. The two or more wires may form a nip therebetween. The two or more wires may be separated by stock, a sheet, paper, or a combination thereof. The wire may be a porous continuous belt that travels along a forming section, a top former, a bottom former, or a combination thereof. The wire may be flexible enough to be moved and changed by foils, rolls, vacuum boxes, steam showers, or a combination thereof within the various sections, opposite the wires, or both. The wire may be metal, plastic, a polymer, woven, non-woven, or a combination thereof. The wire may be a fabric material. The wire may include pores or be porous so that water may be removed from the stock but solids retained. The wire may support stock until the stock is sufficiently strong to become a self-supporting sheet. The wet end may have a wire that travels in a machine direction with stock or travels in the machine direction for at least a portion of the travel of the wire and the stock is dewatered as the wire moves in the machine direction. Preferably, the wet end includes an endless wire that travels in a machine direction. The width of the wire may extend in the cross-machine direction. The wet end may have opposing edges that may have stock that runs along a cross-machine direction and falls off the wire. The wet end may end with a couch roll (i.e., couch roll end) that functions to wrap the wire and guide the wire in a direction opposite the machine direction so that an endless wire is formed. One or more return rolls may be located after the couch roll to assist in returning the wire. The one or more return rolls may be free of contact with the paper. The couch roll may be the last roll in the wet end to come into contact with the paper. The couch roll may be located between the wet end or forming section and the fabric section.

[0025] The couch roll may function to dewater. The couch roll may include suction. The couch roll may be a vacuum roll. The couch roll may end the wet end. The couch roll may assist in guiding a sheet from the wet end into a press section. The stock may be sufficiently dry when the stock reaches the couch roll that the stock has paper like qualities and is self-supporting. The couch roll may assist in dewatering the stock so that the stock is sufficiently strong to exit the wet end or forming section of the paper machine. The stock may be sufficiently self-supporting once the sheet passes over the couch roll so that the sheet may be transferred to another section. One or more steam showers may be located proximate to the couch roll to dewater the stock so that the stock is sufficiently strong to move from the wet end to a press section.

[0026] Stock as discussed herein is a slurry of fibers mixed in water and optional paper chemicals to enhance certain final paper characteristics. Stock may include fiber, fines, filers, chemicals, virgin fibers, recycled fibers, synthetic fibers, mineral fibers, glass fibers, polymer fibers, or a combination thereof. The stock preferably is at 90 percent or more, 95 percent or more, or even 99 percent or more water at the headbox (e.g., has a consistency of about 1 percent or less stock and 99 percent or more water by weight). As the stock travels in the machine direction the stock is dewatered (e.g., (i.e. , a direction of movement from a wet end to a dry end) the foils or blades and groups of foils (e.g., foil sections) or groups of blades (e.g., blade sections) remove the water and consistency (i.e., percentage of water in the stock) decreases). Water may continually be removed from the stock as the stock travels toward the dryer or dryers. The stock at some point will go from being a primarily liquid state to being a primarily solid state typically at a sheet consistency of between about 8 percent to about 10 percent.

[0027] The breast roll may be the first roll of the wet end (i.e., at the headbox end), may assist in formation, may remove water from the stock, or a combination thereof. The breast roll may be the lead roll in a wet end. The breast roll may be located proximate to the headbox, the slice opening, or both. The breast roll may be located on an opposite end of the wet end as the couch roll in the machine direction (i.e., downstream). The breast roll and couch roll may be located within a same plane. The wet end may function to receive stock and dewater stock. One or more forming boards, forming sections, or both may be located between the breast roll and the foil sections. The breast roll, the couch roll, or both may be a vacuum roll.

[0028] The vacuum rolls may function to remove water from stock, paper, a forming sheet of paper, or a combination thereof. The vacuum rolls may be a couch roll. The vacuum roll may be a passive vacuum roll (i.e., have holes that receive and remove fluid). The vacuum roll may be an active vacuum roll (i.e., have suction that draws fluid into the roll). The vacuum roll may be located in a wet end. The vacuum roll may be located in a press section. The vacuum roll may be located proximate to a dryer. A uhle box or non-rotating vacuum device may be in a place of a vacuum roll. The vacuum roll may be located proximate to a Yankee dryer, within a wet end, within a fabric section, within a forming section, or a combination thereof.

[0029] The wet end may be a portion of the paper machine where the paper has a consistency of about 15 percent or less or about 10 percent or less (i.e., 10 percent solids and 90 percent water). The wet end may be a portion of the paper machine that is located upstream of a press section. The wet end may receive stock that is primarily water and remove the water until a sheet is formed. The wet end may have one or more and preferably a plurality of foil sections (or blade sections) or a plurality of water removal devices. For example, the wet end may have a first section, second section, third section, fourth section, or more. The wet end may remove water from stock. The wet end may be the forming section if the paper machine is a tissue paper machine. The wet end may impart activity into the stock so that formation of the stock is controlled, formation of a sheet of paper is controlled, the fibers are oriented or reoriented, the fibers remain suspended within water. The wet end may lock the orientation of the fibers substantially as the fibers and/or stock exit the slice opening of the headbox or within 5 m or less, 4 m or less, or 3 m or less from the headbox.

[0030] Blades and foils as discussed herein may be used interchangeably. If a foil section is present, the foil sections may each include one or more foils and preferably a plurality of foils. The foil section may be a singular foil in contact with the wire proximate to the headbox. The foils may be height adjustable, angle adjustable, fixed, or a combination thereof. The foil sections may include one or more forming boards. The forming section may be free of a forming board. The forming boards may be part of a forming board section. The forming board section may include height adjustable foils, angle adjustable foils, fixed foils, static foils, or a combination thereof. The wet end includes edges in a cross-machine direction (i.e., a direction that is perpendicular to a machine direction). The plurality of foils may be broken into one or more groups of foils and preferably a plurality of groups of foils that extend in the machine direction. The groups of foils may be all height adjustable, all angle adjustable, all static, or a combination thereof. The groups of foils may include both height adjustable foils and angle adjustable foils; both static and height adjustable, both static and angle adjustable; height adjustable foils, angle adjustable foils, and static adjustable foils; or a combination thereof. The types of blades may be alternating (e.g., static blades and height adjustable blades; static and angle adjustable blades; height adjustable blades and angle adjustable blades; or a combination thereof). The static blades may be located at a beginning and an end and angle adjustable or height adjustable blades may be located therebetween. The paper machine may include two or more groups of foils, three or more groups of foils, four or more groups of foils, or five or more groups of foils. Each group of foils may include two or more foils, four or more foils, six or more foils, or even ten or more foils. A first set of foils may include a forming board and then a set of foils. There may not be a forming board and there may only be foils. The types of foils (e.g., static, angle adjustable, height adjustable) may be grouped in any order. For example, the group of foils may include two angle adjustable foils then one static foil and the three height adjustable foils. Each foil may be a different type in an alternating fashion. The blades may be adjusted based upon one or more monitored conditions of a monitoring system. Preferably, a monitoring system monitors the stock at one or more locations between the headbox and the dryer. The monitoring system may monitor a steam showers, vacuum box, or both.

[0031] The one or more steam showers (or steam boxes, which are used interchangeably herein) function to remove water, dry the paper, add water, add steam, level a cross-machine moisture profile, reduce variation of a moisture profile in a cross-machine direction (e.g., reduce the variation in moisture to ±5 percent or less, ± 3 percent or less, or even ±1 percent or less), or a combination thereof. The steam showers may be located in the forming section, steam fabric section or both. A steam shower in the forming section is a wire steam shower. The steam shower in the fabric section may be a fabric steam shower or a wet moulding box steam shower. The wire steam shower and the fabric steam shower may be identical. The wire steam shower and the fabric steam shower may be different. The steam showers may remove water from the sheet.

[0032] The steam showers may change an amount of moisture in a sheet by about 1 percent or more, about 2 percent or more, about 4 percent or more, or about 5 percent or more (e.g., if the moisture is 20 percent before the steam showers the moisture will be 23 percent ±1 after the steam showers). The steam showers may change an amount of moisture in a sheet by about 15 percent or less, about 10 percent or less, or about 5 percent or less (±2 percent). The one or more steam showers may be located in the wet end.

[0033] The steam shower may apply steam at a pressure of about 10 KPa or more, 25 KPa or more, about 50 KPa or more, or about 75 KPa or more. The steam shower may apply steam at a pressure of about 300 KPa or less, about 200 KPa or less, about 150 KPa or less, or about 100 KPa or less. Preferably, the steam may be applied at a pressure from about 25 KPa and about 125 KPa, more preferably from about 40 KPa and about 75 KPa, and most preferably about 45 KPa and about 60 KPa. The steam shower may be in a location where the sheet of paper has a solids content of between about 15 and 30 percent and preferably between about 20 and 25 percent. The steam showers may increase the temperature of the sheet. The steam showers may increase the temperature of the sheet a sufficient amount that the paper machine may have an increase in speed and the paper dryness maintained substantially constant.

[0034] The sheet may increase temperature by about 30 °C or more, about 50 °C or more, about 65 °C or more, about 75 °C or more, about 90 °C or more, or even about 100 °C or more. The sheet may increase temperature by about 200 °C or less, about 175 °C or less, about 150 °C or less, about 125 °C or less, or about 1 10 °C or less. The steam showers may apply a sufficient amount of steam at a sufficient pressure to assist in plastically deforming the sheet, increase bulk of the sheet, allow for an increase in speed of the paper machine, or a combination thereof. The steam showers and vacuum boxes in conjunction may plastically deform the sheet. The steam shower may soften the fibers so that the fibers of the sheet may plastically deform, deform to a shape of the fabric, or both. The steam showers may temporarily rewet the paper so that the paper deforms (e.g., embosses) into the fabric and then the vacuum removes the water so that the sheet resets in a shape of the fabric. The steam showers may be located in the press section. The steam showers may be located proximate to a dryer. The one or more steam showers may be located proximate to a wire, a fabric, or both. The one or more steam showers may be located between a wire and a dryer. One or more steam showers may be located in the wet end. For example, one steam showers may be located proximate to a foil section and one steam showers may be located proximate to a vacuum roll or vacuum box. The one or more steam showers may be located above a vacuum. A wire or fabric may be located between the steam showers and the paper or a sheet. Preferably, a steam showers may be directly located above paper or a sheet of paper being created. The steam showers may mirror a shape of the paper at a location that the steam showers are located. For example, if the paper is between a roll and a foil the steam showers will be flat and if the paper is wrapping a roll then the steam showers may have a curved shape. The one or more steam showers may include a housing that protects internal components, directs steam towards a sheet of paper, maintains the steam showers in a location, or a combination thereof.

[0035] The one or more steam showers may include a plurality of steam showers. The one or more steam showers may include a primary steam shower and a secondary steam shower. The primary steam shower and the secondary steam shower may apply a same amount of steam or different amounts of steam. The amount of steam applied at the amount of pressure discussed herein. The primary steam shower and the secondary steam shower may provide a different amount of steam, steam at different pressures, steam at different temperatures, stream at different pounds, or a combination thereof. The primary steam shower may apply a higher- pressure steam, a steam at a higher level of superheating (e.g., higher amount of pounds) than the secondary steam shower. The primary steam shower may apply steam over a larger area than the secondary steam shower. The primary steam shower may be located opposite a primary vacuum box. The secondary steam shower may be located opposite a secondary vacuum box. The primary steam shower may be in a primary location or opposite a high-pressure steam box. The secondary shower may be in a secondary location or opposite a lower pressure steam shower. The one or more steam showers may be only a primary steam shower. The one or more steam showers may be only a secondary steam shower. The one or more steam showers may include both a primary steam shower and a secondary steam shower. The one or more steam showers may be one or more discrete primary steam showers, one or more discrete secondary steam showers, or both. The one or more steam showers may be a single steam shower that is divided into a primary steam shower and a secondary steam shower. The primary steam shower and the secondary steam shower may be located in a single housing.

[0036] The housing may function to support the steam showers at a predetermined location. The housing may direct steam in a predetermined direction or to a predetermined location. The housing may be an external shell that holds diffusers, valves, steam headers, connects to support arms, connects to linear actuators, connects to rotary actuators, has pivot points, has zone feed pipes, has guides, has slides, or a combination thereof. The housing may assist in directing steam through steam dischargers. The housing may contain diffusers that direct the steam to the steam dischargers. The housing may contain all of the elements of the steam showers discussed herein and the housing may be moved and the components of the steam showers may be moved with the housing. The housing may prevent contact between surroundings and the components within the housing. The housing may have a geometric shape. The housing may have a cross-sectional shape that is square, triangle, trapezoid, rhombus, oval, pentagon, or a combination thereof. The shape may be non-geometric. The housing may be made of metal or plastic. Preferably, the housing is made of stainless steel. More preferably, the housing is made of 316 stainless steel or a corrosion resistant alloy. The housing may be substantially closed at locations where steam is not desired so that steam is directed towards one or more diffusers or steam dischargers.

[0037] The steam discharges function to direct steam to one or more locations along a crossmachine direction of a sheet of paper. The steam dischargers may be varied along the crossmachine direction so that drying, a moisture profile, or both may be controlled. Two or more steam discharges may be located in parallel in a machine direction of the sheet. The steam dischargers may be holes, perforations, gaps between pieces of material, nozzles, jets, or a combination thereof. The steam discharges may be passive parts of the housing. For example, the steam may be directed through the steam discharges and the amount of steam directed though may be controlled by diffusers or valves. The steam discharge may be located proximate to one or more barriers. The steam discharge may be one or more orifices that are located downstream of a barrier, upstream of a barrier, between barriers, or a combination thereof.

[0038] The one or more orifices may part of a steam shower, located within a face of a steam shower, or both. The one or more orifices may be symmetrical, asymmetrical, circular, oval, square, diamond, geometric, non-geometric, equally spaced apart, unequally spaced apart, randomly spaced apart, all similar sized, sized differently, a slot, or a combination thereof. The one or more orifices may extend partially across the face or entirely across the face. The one or more orifices may be located in one or more rows, two or more rows, or three or more rows. Each of the plurality of rows may have orifices that are identical. Row to row may have orifices that are different sized, shaped, or both. Inside of a row the orifices may be all a same size and shape. Inside of a row may have orifices of varying size and shape. The orifices may have a variable size or shape. The orifices may be changed to change an amount of steam applied to a sheet. The orifices may be varied based upon an amount of vacuum applied. The orifices may be increased in size based upon an increase or decrease in size of a port of the vacuum, an amount of vacuum applied, or both. The steam discharge may be a line and be free of any orifices. The orifices may be decreased in size based upon an increase or decrease in size of a port of the vacuum, an amount of vacuum applied, or both. The orifices may be tapered such that a first end of the orifice has a smaller opening than a second end of the orifice. The orifices may be a same size and shape as a port discussed herein. The teachings of the ports may apply to the teachings of the orifices and vice versa. The ports and orifices may be substantially a same size and shape and be located across from one another. The orifices may be located proximate to a barrier.

[0039] The barrier may function to assist the steam to penetrate into and through the sheet, dry the sheet, or both. The barrier may function to create turbulence, an eddy, or both. The barrier may create a low-pressure area. The barrier may assist in driving the steam through the sheet. The barrier may have a peak that extends outward towards the sheet with a back side (e.g., trough) (downstream) that is located away from the sheet relative to the peak. The barrier may be part of the housing. The barrier may include one or more peaks, one or more troughs, or both. The barrier may prevent steam from discharging into some areas while directing the steam to other areas. The barrier may be a step, a wing shape, or both. There may be one or more barriers, two or more barriers, three or more barriers, or four or more barriers on each steam shower, the barriers may extend in the cross-machine direction and be parallel to one another. The barrier may direct the steam to locations proximate to the vacuum system so that the vacuum system assists in moving the steam into and/or through the sheet.

[0040] The fabric vacuum system (e.g., a vacuum system) functions to remove steam, moisture, water, move air through a sheet, or a combination thereof. The vacuum system may function to dry a fabric or wire. The vacuum system may be or include a wire vacuum box, a fabric vacuum box, or both. The wire vacuum box and the fabric vacuum box may be identical. The wire vacuum box and the fabric vacuum box may be different. The vacuum system may assist in drawing water from a sheet into a fabric or wire. The vacuum system may function to prevent re- watering of the sheet due to the steam shower. The vacuum system may apply a sufficient amount of vacuum to remove the steam from the paper, the fabric, or both. The vacuum system may apply a sufficient amount of vacuum to prevent the steam from condensing in the paper, the fabric, or both. The vacuum system may apply a vacuum of about 100 mmHg or more, about 200 mmHg or more, about 300 mmHg or more, about 400 mmHg or more, about 500 mmHg or more, or even about 600 mmHg or more. The vacuum system may apply a vacuum of about 1000 mmHg or less, about 900 mmHg or less, about 800 mmHg or less, about 700 mmHg or less, or about 650 mmHg or less.

[0041] The one or more vacuum boxes function to be located proximate to or in contact with a sheet of paper or a fabric and to remove moisture, steam, fluid, or a combination thereof from the sheet or the fabric. The vacuum box may be in contact with a fabric to remove fluid, steam, water, or a combination thereof. The vacuum box may be in direct contact with the fabric and may pull the fabric into the vacuum box, at least temporarily, so that the felt deforms as the felt passes over the vacuum box. For example, the vacuum may deform the sheet such that that vacuum box may be a moulding box. The vacuum box may include one or more and preferably a plurality of ports and one or more fluid legs. The one or more vacuum boxes may be a plurality of vacuum boxes. The vacuum boxes may include a primary vacuum box, a secondary vacuum box, or both. [0042] The primary vacuum box may function to apply a first amount of vacuum. The primary vacuum box may apply vacuum. The primary vacuum box may apply vacuum of about 16 KPa or more, 32 KPa or more, 50 KPa or more, or 67 KPa or more. The primary vacuum may apply vacuum of about 150 KPa or less, 125 KPa or less, 100 KPa or less, or about 75 KPa or less (e.g., ± 5 KPa). The primary vacuum box may be a moulding box. For example, the primary vacuum box may pull a large amount of vacuum (e.g., between about 50 and 75 KPa) such that the sheet and felt are pulled tight so that the shape of the felt is embossed into the sheet. The primary vacuum box may be located opposite a steam box or a steam shower. The primary vacuum box may be located upstream of a secondary vacuum box.

[0043] The secondary vacuum box functions to remove water, steam, condensation, or both from a felt, a sheet, or both. The secondary vacuum box may apply a lower amount of vacuum than the primary vacuum box. The secondary vacuum box may apply a same amount of vacuum as the primary vacuum box. The primary vacuum box and the secondary vacuum box may apply a ratio of vacuum. The ratio of primary vacuum to secondary vacuum may be about 1 :1 or more, about 1 .2:1 or more, 1 .5:1 or more, about 2:1 or more, about 3:1 or more, or about 4:1 or more. The ratio of primary vacuum to secondary vacuum may be about 10:1 or less, about 7:1 or less, or about 5:1 or less. The secondary vacuum may be applied after the primary vacuum. The secondary vacuum box may be located opposite a steam shower, a primary steam shower, or a secondary steam shower. The secondary vacuum box may be located directly opposite a secondary steam shower. The secondary vacuum box and the primary vacuum box may be spaced apart. The secondary vacuum box may be connected to the primary vacuum box. The secondary vacuum box and the primary vacuum box may be located within a same housing and located apart by a divider.

[0044] The divider functions to separate a primary vacuum box and secondary vacuum box; two secondary vacuum boxes; two primary vacuum boxes; or a combination thereof. The divider may isolate the vacuum boxes so that each of the vacuum boxes may be separately connected to a different vacuum system, water extending into one vacuum box will not affect another vacuum box, or both. The divider may isolate the vacuum boxes. The divider may be a wall. The divider may be a seal. The divider may be an internal wall within a housing so that multiple vacuum boxes are located within a single housing. The divider may separate a housing into multiple different zones. The divider may split a single vacuum source into being applied at multiple different zones or regions. The divider may separate one group of ports from a second group of ports so that the ports are fluidly separate.

[0045] The ports function to allow fluid, steam, water, or a combination thereof to enter into the vacuum box. The ports may be through holes in a wall of the vacuum box. The ports may have a constant shape. The ports may have a smallest opening proximate to a sheet or fabric and then increase in size as the port extends through a wall of the vacuum box. The ports may taper. The ports may taper so that suction or vacuum at a contact location between the vacuum box and the felt or sheet is not minimized due to fluid losses. The ports may allow the sheet to be pulled therein. The ports may be rows of parallel openings. The ports may extend in the crossmachine direction. The vacuum box may include one or more, two or more, three or more, four or more, or five or more ports extending parallel to one another along the machine direction. The ports may be 10 or less or 8 or less openings in the vacuum box. The number of ports may be selected to achieve a desired amount of water removal. The size and shape of the ports may be substantially uniform. The size and shape of the ports may vary as water is removed. For example, the first ports may have a larger opening than the last ports or vice versa as the sheet extends in the machine direction so that pressure on the sheet may be varied. The shape of the ports may vary. Some ports may have a uniform shape along a thickness of the port (e.g., in a direction of a thickness of the vacuum box). The ports may be shaped to pull steam into the vacuum box and then create a pressure drop so that the steam condenses within the vacuum box. The ports may be sized and shaped so that fluid may be moved into the vacuum box. [0046] The ports function to receive fluid, water, or both. The ports may be identical in size and shape as to the orifices discussed herein. The teachings for the orifices may apply to the ports. The ports may be round, circular, oval, square, tapered from front to back, geometric, nongeometric, symmetrical, a slot, or a combination thereof. The ports may be symmetrical relative to one another. The ports may be asymmetrical relative to one another. The ports may extend completely or partially across a face. The ports may be in rows. Each row may have ports that are identical. Each row of ports may be different from another row of ports. The ports within a row may be different sized and shaped. The rows of ports may be one or more rows, two or more rows, or three or more rows. The rows of ports may alternate in size, shape, or both. The ports in the rows may be randomly spaced, equally spaced, or both. The ports may lead into a fluid leg and condensation may condense in the fluid leg.

[0047] The fluid leg functions to remove condensate, water, or both. The fluid leg prevents fluid from moving back into contact with the sheet, the fabric, the felt, the wire, or a combination thereof. The fluid leg may drain the fluid to a location that is separate from the vacuum applying apparatus. The fluid leg may prevent fluid from exiting the vacuum box and moving to the motor that supplies the vacuum. The fluid leg may assist in heating the sheet, removing water from the sheet, or both before the sheet moves to the dryer.

[0048] The dryer function to remove water from the sheet. The dryer may function to dry the sheet so that the sheet is dry (0% moisture) or substantially free of moisture (e.g., about 5 percent or less or about 3 percent or less). The dryer may dry through direct contact. The dryer may dry by directly contacting the sheet with a metal dryer. The dryer may dry with thermal energy (e.g., indirect drying). The dryer may dry with heated air. The dryer may be a Yankee dryer. Preferably, the dryer is a through air dryer (TAD). The paper machine may include both a TAD and a Yankee dryer. Preferably, the dryer only includes a TAD.

[0049] The Yankee dryer, TAD, or both may function to remove water from paper. Preferably, the Yankee dryer, TAD, or both removes water from tissue, tissue paper, paper toweling, toilet paper, or a combination there. The Yankee dryer, TAD, or both may be free of direct contact with a steam showers. The Yankee dryer, TAD, or both may be located after a steam shower (e.g., directly after a steam show with no intervening heating or drying devices). The steam showers may introduce fluid to the paper so that once dried by the Yankee dryer, the TAD, or both the moisture profile of the paper may be consistent in the cross-machine direction (e.g., a fluctuation of about 5 percent or less, or about 3 percent or less in moisture content). The dryers may be controlled by a monitoring system so that a moisture, a moisture profile, or both may be controlled. [0050] The monitoring system may monitor the forming section, the fabric section, machine cleanliness, steam showers cleanliness, moisture before a steam shower, moisture after a steam shower, or a combination thereof. Preferably, the monitoring system taught herein monitors the steam showers. More preferably, the monitoring system monitors temperature, moisture, bulk, or a combination thereof of a sheet entering, exiting, or both the steam showers. The monitoring system may visually inspect a steam showers, monitor pressure of the steam showers, monitor back pressure of a steam showers, monitor application regions, monitor application consistency, or a combination thereof. The monitoring system may include one or more static sensors, one or more movable sensors, or both. The monitoring may have one type of sensor that continuously operates and one type of sensor that intermittently operates.

[0051] The one or more sensors function to monitor pressure, cleanliness, debris, steam exiting a diffuser, sheet moisture, a moisture profile, or a combination thereof. The one or more sensors may function to send signals to a control system so that the control system controls a cleaning system, the steam showers, valves, machine speed, vacuum, or a combination thereof. The one or more sensors may be located along a side of the paper machine, the steam showers, before a steam shower, after a steam shower, or a combination thereof. The one or more sensors may be located normal to a steam showers, vacuum system, or both. The one or more sensors may be located at an angle relative to the steam showers, vacuum system, or both. The one or more sensors may view an entire length of a steam showers, vacuum system, or both (e.g., a length of the steam showers or vacuum box extending in the cross-machine direction). The one or more sensors may monitor a portion of a length of a steam showers, vacuum system, or both. Multiple sensors may be used to monitor an entire length of a steam shower, a vacuum box, or both. Only a portion of a steam shower, vacuum box, or both may be monitored and a remainder of the steam shower, vacuum box, or both may be extrapolated based upon the monitored portion. For example, if a steam shower, vacuum box, or both are 10 m long, then 2 m may be monitored and 8 m of the steam showers that is not monitored may be extrapolated based upon the sensing of the 2 m. A combination of sensor types may be used. Some sensors may monitor moisture, temperature, or both. Some sensors may visually monitor. The sensors may use ultrasound, infrared, CMOS sensor, charge-coupled device, matrix camera, area scan camera, line scan camera, microwave, a temperature sensor, nuclear, capacitance, pressure, vacuum, distance, suspension height, pressure, back pressure, moisture sensor, or a combination thereof. The one or more sensors may be a plurality of sensors or a multitude of sensors. All of the sensors may be the same type of sensor. Different types of sensors may be used together. For example, one sensor may be an infrared sensor and another sensor may be a CMOS sensor. The one or more sensors may be a color sensor, he one or more sensors may be monochrome sensor. The one or more sensors may be one or more sensors, two or more sensors, four or more sensors, six or more sensors, or even ten or more sensors. Each of the sensors may produce images that have a plurality of pixels or be converted to an image with a plurality of pixels. Each of the sensors may produce pixels that may be categorized. The one or more sensors may include an air purge. The one or more sensors may include a cleaning mechanism. The one or more sensors may include a self-cleaning lens. The one or more sensors may include a wipeable lens. The one or more sensors may remove vapor, fluids, steam, debris, stock, or a combination thereof.

[0052] The method may include applying steam, applying vacuum, or both. The method may heat the sheet with steam. The method may apply steam directly before a dryer and preferably before a through air dryer. The fabric steam shower and fabric vacuum system may be directly opposed.

[0053] Figure 1 illustrates a perspective view of the paper machine 2 having a tending side 16 and a bas side 18. The paper machine includes a slice opening 4 and headbox 6 between a wire 8 and a wire 8’. The wire 8 is part of the top former 20 and the wire 8’ is part of the bottom former 22. The bottom former 22 includes a pair of wire vacuum boxes 12 and a wire steam shower 10 located opposite across from one of wire vacuum boxes 12. The wire 8’ of the bottom former 22 extends around a breast roll 24 and a couch roll 26. The paper travels from the headbox 6 in the machine direction 14 from the bottom former 22 to the fabric section 40. The fabric section 40 includes a fabric 42 and a transfer box 44 that assists in transferring the sheet from the wire 8’ to the fabric 42. A fabric steam shower 50 and a fabric vacuum system 60 are located after the transfer box 44 to remove water from the fabric 42 and the paper. After the fabric steam shower 50 and the fabric vacuum system 60 is a dryer 80 that continues to dry the paper as the paper moves in the machine direction 14.

[0054] Figure 2 is a side view of the paper machine 2. The paper machine 2 has a forming section 3 and a fabric section 40. The forming section 3 includes a top former 20 having a wire 8 and a bottom former 22 having a wire 8’. The fabric section 40 includes a fabric 42 and a dryer 80.

[0055] Figure 3A is a close-up view of the fabric steam shower 50 and the fabric vacuum system 60 in the circle III of Figure 2. The fabric steam shower 50 includes a housing 56 with steam discharges 52 located proximate to barriers 54 that assist in moving fluid though a sheet of paper 30 and fabric 42 and into the fabric vacuum system 60. The fabric vacuum system 60 includes a fabric vacuum box 60 having a plurality of ports 64 that draw fluid into the fabric vacuum box 62 and fluid leg 66 where fluids are collected and are removed. [0056] Figure 3B is a close-up view of a fabric vacuum system 60 including a fabric vacuum boxes 62 (e.g., a moulding box). The fabric vacuum boxes 62 include a primary vacuum box 70 (or moulding box) and a secondary vacuum box 72 (or moulding box). The primary vacuum box 70 includes ports 64 that pull a higher amount of vacuum than the ports 64 in the secondary vacuum box 72. A steam shower 50 is located opposite the secondary vacuum box 72 with a sheet 30 and fabric 42 extending therebetween so that steam extends from the steam shower 50 through the sheet 30 and the fabric 42 and into the secondary vacuum box 72.

[0057] Figure 3C is a close-up view of a fabric vacuum system 60 including a fabric vacuum boxes 62 (e.g., a moulding box). The fabric vacuum boxes 62 include a primary vacuum box 70 (or moulding box) and a secondary vacuum box 72 (or moulding box). The primary vacuum box 70 and the secondary vacuum box 72 are located within a single housing and separated by a divider 74. The primary vacuum box 70 includes ports 64 that pull a higher amount of vacuum than the ports 64 in the secondary vacuum box 72. A steam shower 50 is located opposite the secondary vacuum box 72 with a sheet 30 and fabric 42 extending therebetween so that steam extends from the steam shower 50 through the sheet 30 and the fabric 42 and into the secondary vacuum box 72.

[0058] Figure 3D is a close-up view of a fabric vacuum system 60 including a fabric vacuum boxes 62 (e.g., a moulding box). The fabric vacuum boxes 62 include a primary vacuum box 70 (or moulding box) and a secondary vacuum box 72 (or moulding box). The primary vacuum box 70 and the secondary vacuum box 72 are two discrete vacuum boxes. The primary vacuum box 70 includes ports 64 that pull a higher amount of vacuum than the ports 64 in the secondary vacuum box 72. Steam showers 50 are located opposite the fabric vacuum boxes 62 with a sheet 30 and fabric 42 extending therebetween so that steam extends from the steam shower 50 through the sheet 30 and the fabric 42 and into the vacuum boxes 62. The vacuum boxes 62 include a primary vacuum box 70 and a secondary vacuum box 72. The steam showers 50 include a primary steam shower 76 and a secondary steam shower 78.

[0059] Figure 4A illustrates a face of a steam shower 50 and/or a vacuum box 62. The steam showers 50, the vacuum box 62, or both include orifices 58 or ports 64, respectively. As shown, all of the orifices 58 or ports 64 are substantially a same size and are all equally spaced apart.

[0060] Figure 4B illustrates a face of a steam shower 50 and/or a vacuum box 62. The steam showers 50, the vacuum box 62, or both include orifices 58 or ports 64, respectively. As shown, all of the orifices 58 or ports 64 in a first row 90 have a first size and all of the orifices 58’ or ports 64’ in a second row 92 have a second size that is different from the first row 90. [0061] Figure 4C illustrates a face of a steam shower 50 and/or a vacuum box 62. The steam showers 50, the vacuum box 62, or both include orifices 58 or ports 64, respectively. As shown, a first row 90 has orifices 58 or ports 62 of a first size and orifices 58’ or ports 64’ of a second size. The second row 92 has orifices 58 or ports 62 of a first size and orifices 58’ or ports 64’ of a second size in an alternating manner from the first row 90.

[0062] Figure 4D a face of a steam shower 50 and/or a vacuum box 62. The steam showers 50, the vacuum box 62, or both include orifices 58 or ports 64, respectively. A second row 92 includes orifices 58, 58’ or ports 64, 64’ of two different sizes. A first row has orifices 58” or ports 64” of a third size that are different than the orifices 58, 58’ or ports 64, 64’. The orifices 58” or ports 64” are oval and the orifices 58, 58’ or ports 64, 64’ are substantially circular in shape.

[0063] Variation 1 may comprise a fabric steam shower comprising: (a) one or more steam discharges that provide steam to a predetermined location; (b) one or more barriers that disturb the steam being applied to a sheet extending adjacent to the predetermined location so that the steam extends into the sheet; and wherein the fabric steam shower is configured to apply the steam to a fabric and the sheet at a location along a paper machine before a dryer and after a transfer box.

[0064] Variation 2 may comprise the fabric steam shower of variation 1 , wherein the one or more steam discharges are a plurality of steam discharges.

[0065] Variation 3 may comprise the fabric steam shower of variation 1 or 2, wherein each of the plurality of steam discharges are an orifice having a same size and shape.

[0066] Variation 4 may comprise the fabric steam shower of variation 1 or any of the preceding variations, wherein the plurality of steam discharges are perforations within the fabric steam shower.

[0067] Variation 5 may comprise the fabric steam shower of variation 1 or any of the preceding variations, wherein the one or more steam discharges are located up stream of the one or more barriers.

[0068] Variation 6 may comprise the fabric steam shower of variation 1 or any of the preceding variations, wherein a face of the fabric steam shower is curved, flat, has flat regions, or a combination thereof.

[0069] Variation 7 may comprise a system comprising: (1 ) a fabric steam shower and may comprise a steam shower of any of variations 1 through 6 and (2) a fabric vacuum system located opposite the fabric steam shower and configured to have a fabric of a paper machine and a sheet of paper being carried on the fabric pass therebetween so that moisture is removed from the fabric and the sheet. [0070] Variation 8 may comprise the system of variation 7, wherein the fabric vacuum system includes a primary vacuum box and a secondary vacuum box and the fabric steam shower is located across from the secondary vacuum box.

[0071] Variation 9 may comprise the system of variation 8 or any of the preceding variations, wherein the primary vacuum box and the secondary vacuum box are located within a same housing and spaced apart by a divider.

[0072] Variation 10 may comprise the system of variation 9 or any of the preceding variations, wherein the fabric vacuum system includes a plurality of ports.

[0073] Variation 11 may comprise the system of variation 10 or any of the preceding variations, wherein each of the plurality of ports are identical.

[0074] Variation 12 may comprise the system of variation 10 or any of the preceding variations, wherein each of the plurality of ports are different.

[0075] Variation 13 may comprise the system of variation 10 or any of the preceding variations, wherein the plurality of ports are tapered.

[0076] Variation 14 may comprise a paper machine comprising the system of variation 7 or any of the preceding variations, wherein the system is located between a forming section and a dryer of the paper machine.

[0077] Variation 15 may comprise the paper machine of variation 14 or any of the preceding variations, wherein the paper machine is a tissue machine.

[0078] Variation 16 may comprise the paper machine of variation 14 or any of the preceding variations, wherein the dryer is a through air dryer (TAD).

[0079] Variation 17 may comprise a method comprising: (1 ) transferring a sheet of paper from a forming section to a fabric section; (2) applying steam to the sheet of paper in the fabric section; and (3) applying vacuum to the sheet of paper in the fabric section; wherein an amount of the vacuum applied is sufficiently large to pull the sheet into the fabric so that the sheet is embossed by the fabric before the sheet moves to a dryer.

[0080] Variation 18 may comprise the method of variation 17 or the system, method, or paper machine of any of the preceding variations, wherein the steam heats the sheet of paper about 2 °C or more, about 3 °C or more, or about 5°C or more.

[0081] Variation 19 may comprise the method of variation 17 or the system, method, or paper machine of any of the preceding variations, wherein the vacuum is applied at about 200 mmHg or more, about 400 mmHg or more; about 600 mmHg or more.

[0082] Variation 20 may comprise the method of variation 17 or the system, method, or paper machine of any of the preceding variations, wherein the dryer is a through air dryer. [0083] Variation 21 may comprise the method of variation 17 or the system, method, or paper machine of any of the preceding variations, wherein a fabric steam shower applies the steam.

[0084] Variation 22 may comprise the method of variation 21 or the system, method, or paper machine of any of the preceding variations, wherein the fabric steam shower is a wet moulding box steam shower.

[0085] Variation 23 may comprise the method of variation 21 or the system, method, or paper machine of any of the preceding variations, wherein the vacuum is applied by a fabric vacuum system.

[0086] Any numerical values recited herein include all values from the lower value to the upper value in increments of one unit provided that there is a separation of at least 2 units between any lower value and any higher value. As an example, if it is stated that the amount of a component or a value of a process variable such as, for example, temperature, pressure, time and the like is, for example, from 1 to 90, preferably from 20 to 80, more preferably from 30 to 70, it is intended that values such as 15 to 85, 22 to 68, 43 to 51 , 30 to 32 etc. are expressly enumerated in this specification. For values which are less than one, one unit is considered to be 0.0001 , 0.001 , 0.01 or 0.1 as appropriate. These are only examples of what is specifically intended and all possible combinations of numerical values between the lowest value and the highest value enumerated are to be considered to be expressly stated in this application in a similar manner.

[0087] Unless otherwise stated, all ranges include both endpoints and all numbers between the endpoints. The use of "about" or "approximately" in connection with a range applies to both ends of the range. Thus, "about 20 to 30" is intended to cover "about 20 to about 30", inclusive of at least the specified endpoints.

[0088] The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. The term "consisting essentially of" to describe a combination shall include the elements, ingredients, components or steps identified, and such other elements ingredients, components or steps that do not materially affect the basic and novel characteristics of the combination. The use of the terms "comprising" or "including" to describe combinations of elements, ingredients, components or steps herein also contemplates embodiments that consist essentially of or even consists of the elements, ingredients, components or steps.

[0089] Plural elements, ingredients, components or steps can be provided by a single integrated element, ingredient, component or step. Alternatively, a single integrated element, ingredient, component or step might be divided into separate plural elements, ingredients, components or steps. The disclosure of "a" or "one" to describe an element, ingredient, component or step is not intended to foreclose additional elements, ingredients, components or steps.

[0090] It is understood that the above description is intended to be illustrative and not restrictive. Many embodiments as well as many applications besides the examples provided will be apparent to those of skill in the art upon reading the above description. The scope of the invention should, therefore, be determined not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. The omission in the following claims of any aspect of subject matter that is disclosed herein is not a disclaimer of such subject matter, nor should it be regarded that the inventors did not consider such subject matter to be part of the disclosed inventive subject matter.

[0091] 2 Paper Machine

[0092] 3 Forming Section

[0093] 4 Slice Opening

[0094] 6 Headbox

[0095] 8 Wire

[0096] 8’ Wire

[0097] 10 Wire steam Shower

[0098] 12 Wire Vacuum Box

[0099] 14 Machine Direction

[00100] 16 Tending Side

[00101] 18 Back side

[00102] 20 Top Former

[00103] 22 Bottom Former

[00104] 24 Breast Roll

[00105] 26 Couch Roll

[00106] 30 Sheet

[00107] 40 Fabric Section

[00108] 42 Fabric

[00109] 44 T ransfer Box

[00110] 50 Wet Molding Box Steam Shower

[00111] 52 Steam Discharge

[00112] 54 Barrier [00113] 56 Housing

[00114] 58 Orifice

[00115] 60 Fabric Vacuum System

[00116] 62 Fabric Vacuum Box (Moulding Box)

[00117] 64 Ports

[00118] 66 Fluid Leg

[00119] 70 Primary Vacuum Box or Moulding Box

[00120] 72 Secondary Vacuum Box or Moulding Box

[00121] 74 Divider

[00122] 76 Primary Steam Shower

[00123] 78 Secondary Steam Shower

[00124] 80 Dryer

[00125] 90 First Row

[00126] 92 Second Row