Fiber with release-material sheath for papermaking belts

Abstract

Fibers with release-material sheaths, methods and systems for making such fibers, papermaking belts incorporating such fibers, and papermaking processes using belts incorporating such fibers are described.

1 . A fiber for use in a papermaking belt, comprising: 
 an inner core and an outer sheath that are integrally formed, wherein the outer sheath: 
 has a thickness of at least 10 microns prior to sanding, if any, of the fiber, and  
 includes a release material with a melting temperature greater than the melting temperature of the inner core to facilitate the release of a paper web when the paper web is in contact with the fiber.  
   
   
   
       2 . A fiber for use in a papermaking belt, comprising: 
 an inner core and an outer sheath, wherein the outer sheath: 
 has a thickness of at least 10 microns prior to sanding, if any, of the fiber, and  
 includes a release material to facilitate the release of a paper web when the paper web is in contact with the fiber.  
   
   
   
       3 . The fiber of  claim 2 , wherein the core and the outer sheath are integrally formed.  
   
   
       4 . The fiber of  claim 3 , wherein the core and the outer sheath are formed by co-extrusion.  
   
   
       5 . The fiber of  claim 2 , wherein the thickness of the outer sheath is sufficient to allow sanding of the fiber without reaching the inner core.  
   
   
       6 . The fiber of  claim 2 , wherein the release material has a melting temperature greater than the melting temperature of the inner core.  
   
   
       7 . The fiber of  claim 2 , wherein the standard deviation in fiber cross-section diameter is less than 2 percent of the average fiber cross-section diameter.  
   
   
       8 . The fiber of  claim 2 , wherein the standard deviation in fiber cross-section diameter is less than 0.5 percent of the average fiber cross-section diameter.  
   
   
       9 . A method of making a fiber, comprising 
 forming a fiber core, and    forming an outer sheath around the fiber core, wherein the outer sheath: 
 has a thickness of at least 10 microns prior to sanding, if any, of the fiber, and  
 includes a release material to facilitate the release of a paper web when the paper web is in contact with the fiber.  
   
   
   
       10 . The method of  claim 9 , wherein the core and the sheath are integrally formed.  
   
   
       11 . The method of  claim 9 , wherein the core and the sheath are formed by coextrusion.  
   
   
       12 . The method of  claim 9 , wherein there is no primer between the core and the sheath.  
   
   
       13 . A paper making belt, comprising: 
 a mesh of fibers, wherein at least some of the fibers include an outer sheath integrally formed around    an inner core,    wherein the outer sheath: 
 has a thickness of at least 10 microns prior to sanding, if any, of the belt, and  
 includes a release material to facilitate the release of a fibrous web of paper when the web is in contact with the belt.  
   
   
   
       14 . The paper making belt of  claim 13 , further including a temporary release material applied to the mesh of fibers.  
   
   
       15 . A method, comprising: 
 intermeshing a plurality of fibers to form a papermaking belt, 
 wherein at least some fibers in the plurality of fibers include an outer sheath integrally formed around an inner core,  
 wherein the outer sheath: 
 has a thickness of at least 10 microns prior to sanding, if any, of the belt, and  
 includes a release material to facilitate the release of a fibrous web of paper when the web is in contact with the belt.  
 
   
   
   
       16 . The method of  claim 15 , wherein the intermeshing is done by weaving, knitting, or coiling.  
   
   
       17 . A method, comprising: 
 using a papermaking belt to carry a fibrous web in at least one part of a papermaking process, 
 wherein the belt comprises a mesh of fibers,  
 wherein at least some of the fibers include an outer sheath integrally formed around an inner core, 
 wherein the outer sheath: 
 has a thickness of at least 10 microns prior to sanding, if any, of the belt, and  
 includes a release material to facilitate the release of a fibrous web of paper when the web is in contact with the belt.