Papermaking Belts for Making Fibrous Structures

Abstract

A papermaking belt can have a reinforcing element with a surface and a plurality of discrete knuckles extending from portions of the surface. The plurality of discrete knuckles can be arranged in a pattern of repeat units, and each of the discrete knuckles within the repeat unit can have substantially the same shape and size. At least some of the discrete knuckles can be arranged in a plurality of rows of adjacent knuckles separated by a distance, including at least a first row and a second row. The distance between at least two adjacent discrete knuckles in the first row can be different than the distance between at least two adjacent discrete knuckles in the second row.

What is claimed is: 
     
         1 . A papermaking belt, comprising:
 a reinforcing element comprising a surface;   a plurality of discrete knuckles extending from portions of the surface of the reinforcing element, wherein the plurality of discrete knuckles are arranged in a pattern of repeat units, and wherein the discrete knuckles are characterized by:   each of the discrete knuckles within the repeat unit have substantially the same shape,   each of the discrete knuckles within a repeat unit have substantially the same size; and   wherein at least some of the discrete knuckles are arranged in a plurality of rows of adjacent knuckles separated by a distance, and including at least a first row and a second row, with the distance between at least two adjacent discrete knuckles in the first row being different than the distance between at least two adjacent discrete knuckles in the second row.   
     
     
         2 . The papermaking belt of  claim 1 , wherein all of the discrete knuckles are in one of the plurality of rows. 
     
     
         3 . The papermaking belt of  claim 1 , wherein all the rows are oriented along one of either a Y-axis or an X-axis. 
     
     
         4 . The papermaking belt of  claim 1 , wherein one or more rows are oriented along a Y-axis and one or more are oriented along an X-axis. 
     
     
         5 . The papermaking belt of  claim 1 , wherein the discrete knuckles are cured resin. 
     
     
         6 . The papermaking belt of  claim 1 , wherein the discrete knuckles are polymeric deposits. 
     
     
         7 . The papermaking belt of  claim 1 , wherein the reinforcing element is a woven, porous web. 
     
     
         8 . The papermaking belt of  claim 1 , wherein the discrete knuckles define an interconnected plurality of surround areas. 
     
     
         9 . The papermaking belt of  claim 1 , wherein the discrete knuckles define a plurality of deflection conduits. 
     
     
         10 . A papermaking belt, comprising:
 a reinforcing element comprising a surface;   a plurality of discrete knuckles extending from portions of the surface of the reinforcing element, wherein the plurality of discrete knuckles are arranged in a pattern of repeat units, the repeat unit including a plurality of spaced apart rows, each row having a portion of the discrete knuckles, and wherein the discrete knuckles are characterized by:   each of the discrete knuckles within the repeat unit have substantially the same shape,   each of the discrete knuckles within a repeat unit have substantially the same size; and   wherein the discrete knuckles in each row are spaced from adjacent discrete knuckles in a non-uniform manner such that the repeat unit exhibits varying pillow widths along the row.   
     
     
         11 . The papermaking belt of  claim 10 , wherein the varying pillow widths vary from between about 0.030 inch to about 0.060 inch. 
     
     
         12 . The papermaking belt of  claim 10 , wherein the rows are non-linear. 
     
     
         13 . The papermaking belt of  claim 10 , wherein all of the discrete knuckles are in one of the plurality of spaced apart rows. 
     
     
         14 . The papermaking belt of  claim 10 , wherein all the rows are oriented along one of either a Y-axis or an X-axis. 
     
     
         15 . The papermaking belt of  claim 10 , wherein the discrete knuckles are cured resin. 
     
     
         16 . The papermaking belt of  claim 10 , wherein the discrete knuckles are polymeric deposits. 
     
     
         17 . The papermaking belt of  claim 10 , wherein the reinforcing element is a woven, porous web. 
     
     
         18 . The papermaking belt of  claim 10 , wherein the discrete knuckles define an interconnected plurality of surround areas. 
     
     
         19 . The papermaking belt of  claim 10 , wherein the discrete knuckles define a plurality of deflection conduits. 
     
     
         20 . A papermaking belt, comprising:
 a. a reinforcing element comprising a surface; and   b. a plurality of discrete knuckles arranged in a pattern of repeat units, and characterized by:   each of the discrete knuckles within the repeat unit have substantially the same shape,   each of the discrete knuckles within a repeat unit have substantially the same size; and   wherein at least some of the discrete knuckles are arranged in a plurality of rows of adjacent knuckles separated by a distance, and including at least a first row and a second row, with the distance between at least two adjacent discrete knuckles in the first row being different than the distance between at least two adjacent discrete knuckles in the second row, and wherein rows are oriented along an X-axis which is at an angle between 1 degree and 25 degrees with respect to an MD direction of the fibrous structure.