JP2006514176A - Method for producing a fiber structure comprising cellulose fibers and synthetic fibers - Google Patents

Abstract

  A fiber structure (10) and a method of making a fiber structure (10), the method comprising: providing a first plurality of fibers (101) on a forming member (13) having a groove pattern A first plurality of fibers (101) is provided such that at least a portion of the first plurality of fibers is disposed in the groove; Providing on a plurality of fibers (101) such that a second plurality of fibers (102) is disposed adjacent to the first plurality of fibers (101); And forming a single fiber structure comprising a second plurality of fibers, wherein at least the first plurality of fibers (101) or the second plurality of fibers (102) comprise synthetic fibers. .

Description

  The present invention relates to a fiber structure comprising a combination of cellulose fibers and synthetic fibers, and more specifically, having cellulose fibers distributed generally randomly and synthetic fibers distributed in a non-random pattern, or The present invention relates to a fiber structure having cellulose fibers distributed in a non-random pattern and synthetic fibers arranged almost randomly.

  Fibrous structures such as paper webs are well known in the art and are commonly used today for paper towels, toilet paper, facial tissue, napkins, wipes, and the like. Typical tissue paper is most often made of cellulosic fibers and mostly wood. Despite the wide variety of cellulosic fibers, such fibers generally have a high dry modulus and a relatively large diameter, which can result in greater bending stiffness than desired. In addition, cellulose fibers can have a relatively high stiffness when dried, which can adversely affect the flexibility of the product, and can reduce the absorbency of products obtained with a low stiffness when wet.

  To form a web, the fibers in a typical disposable paper product are bonded together by chemical interactions, and the bonds are only hydrogen bonds that occur naturally between the hydroxyl groups of the cellulose molecule. There are many. Enhancement additives can be used if greater temporary or permanent wet strength is desired. These additives usually act either by covalently reacting with cellulose or by forming a protective molecular coating around existing hydrogen bonds. However, additives can also create a relatively stiff and inelastic bond, adversely affecting the softness and absorbent properties of the product.

  By using synthetic fibers with cellulose fibers, it is possible to help overcome some of the limitations previously described. Synthetic polymers can be formed into a wide variety of fiber properties including very small fiber diameters. Furthermore, such fibers can have a lower modulus of elasticity than cellulose fibers. Thus, the fibers can be made to have very low bending stiffness, which facilitates good product flexibility. Furthermore, the functional cross-section of the synthetic fiber can be micro-engineered as desired. Synthetic fibers can also be designed to maintain a modulus of elasticity when wet, so webs made of such fibers are resistant to crunch during absorption operations. Therefore, by using heat-bonded synthetic fibers in tissue products, joined by water-resistant high-strength bonds (good for flexibility and wet strength) (good for flexibility) A strong network of highly flexible fibers results. However, synthetic fibers can be relatively expensive compared to cellulose fibers. Therefore, it is desirable to include as much synthetic fiber as is necessary to selectively place the fibers so that they are necessary or most effective to obtain the desired effect that the fibers provide.

  Accordingly, it would be advantageous to provide an improved fiber structure comprising a combination of cellulose fibers and synthetic fibers and a method for making such a fiber structure. It would also be advantageous to provide a product having synthetic fibers or cellulose fibers concentrated within a desired portion of the resulting web and a method that allows such non-random placement of such fibers.

  To address the problems associated with the prior art, we have a single fiber structure having a plurality of synthetic fibers arranged in a generally non-random pattern and a plurality of cellulose fibers arranged in a generally random manner, And invented a method of making such a structure. The method includes providing a plurality of synthetic fibers on a forming member having a groove pattern such that at least a portion of the synthetic fibers are disposed in the grooves; and a plurality of cellulose fibers on the synthetic fibers. Providing to allow the cellulose fibers to be disposed adjacent to the synthetic fibers and forming a single fiber structure comprising the synthetic fibers and the cellulose fibers.

  In an alternative embodiment, a web is provided having a plurality of cellulosic fibers arranged in a generally non-random pattern and a plurality of synthetic fibers arranged in a generally random manner. A method of making such a web includes providing a plurality of cellulose fibers on a forming member having a groove pattern so that at least a portion of the cellulose fibers are disposed in the grooves, and a plurality of syntheses. Providing the fibers on the cellulose fibers such that the synthetic fibers are positioned adjacent to the cellulose fibers and forming a single fiber structure from the synthetic fibers and the cellulose fibers. .

  As used herein, the following terms have the following meanings.

  A “single fiber structure” includes a plurality of fibers that are intertwined or otherwise joined together to form a sheet product having certain predetermined microscopic shape properties, physical properties, and aesthetic properties. It is a structure. The fibers may be cellulose and / or synthetic fibers and may be laminated or arranged differently within a single fiber structure.

  A “micro-shape” or deformation thereof is a relatively small (ie, “microscopic” shape of a structure that is not related to its overall configuration, unlike the overall (ie, “macroscopic”) shape of a fiber structure. ") Refers to details, such as surface texture. For example, in the molded member of the present invention, the combination of the fluid permeable area and the fluid impermeable area constitutes the micro shape of the molded member. The term including “macroscopic” or “macroscopic” refers to the “macro shape” or the overall shape of a structure or part thereof, when considered when placed in a two-dimensional configuration such as an XY surface Say about. For example, at a macroscopic level, a fibrous structure includes a flat sheet when it is placed on a flat surface. However, at a microscopic level, the fibrous structure is distributed over a plurality of micro-regions that form different heights, for example, a mesh region having a first height and a framework region, and the framework region. A plurality of fibers “pillows” extending outward from the surface and forming a second height can be included.

  “Basis weight” is the weight (measured in grams) of unit area (typically measured in square meters) of the fiber structure, and this unit area is taken in the plane of the fiber structure . The size and shape of the unit area in which the basis weight is measured depends on the relative and absolute size and shape of regions having different basis weights. Basis weight is measured as described in the Test Methods section below.

“Caliper” is the macroscopic thickness of a sample. The caliper should be distinguished from the heights of the different areas (which are microscopic features of those areas). Most typically, calipers are measured with a uniform load of 95 grams per square centimeter (g / cm ² ). Caliper is measured as described in the Test Methods section below.

“Density” is the ratio of the basis weight to the thickness (taken perpendicular to the plane of the fiber structure) of a region. Bulk density is the basis weight of a sample divided by a caliper that incorporates the appropriate unit conversion. Bulk density as used herein has units of grams per cubic centimeter (g / cm ³ ).

  “Machine direction” (or “MD”) is a direction parallel to the flow of the fibrous structure being made through the manufacturing apparatus. The “machine cross direction” (or “CD”) is the direction perpendicular to the machine direction.

  “X”, “Y” and “Z” denote a conventional system of Cartesian coordinates, the coordinates “X” and “Y” perpendicular to each other define a reference XY plane, and “Z” is Define what is orthogonal to the XY plane. For example, when a component such as a molded member is curved or otherwise deplanarized, the XY plane follows the shape of the component.

  A “substantially continuous” region (zone / network / framework) is any two points in its interior, with one uninterrupted line extending throughout the entire length of the line. Refers to the area where can be connected. That is, a substantially continuous region or pattern has substantial “continuity” in all directions parallel to the XY plane and is terminated only at the edge of that region. The term “substantially” refers to absolute continuity in relation to “continuous”, although slight deviations from absolute continuity are also designed and intended. It is intended to indicate that it is acceptable as long as it does not significantly affect the performance of the fiber structure or molded part.

  A “substantially semi-continuous” region (area / network / framework) may be an area having “continuity” in a direction parallel to all but at least one XY plane, Within it, one refers to an area where any set of two points cannot be connected by an uninterrupted line that extends throughout the area throughout the length of the line. Of course, slight deviations from such continuity are acceptable as long as those deviations do not significantly affect the performance of the structure or molded member.

  “Discontinuous” regions (or patterns) refer to isolated, isolated areas that are discontinuous in all directions parallel to the XY plane.

  “Redistribution” means that at least some of the plurality of fibers contained within the single fiber structure of the present invention at least partially melt, move, or move their initial in-web position, state, and / or shape, It means shrinking and / or changing in other ways.

  “Co-bonded fibers” are fused or bonded together or otherwise bonded together by melting, bonding, wrapping, chemical or mechanical bonding, at least partially while retaining their individual fiber properties. Means two or more fibers.

  The process of the present invention for making a single fiber structure generally comprises a plurality of synthetic fibers 101 arranged in a generally non-random pattern and a plurality of cellulose fibers 102 arranged in a generally random manner. It is described in terms of forming a web having (eg, as shown in FIGS. 9 and 10). However, as noted above, the method and apparatus of the present invention provides a web having a plurality of cellulosic fibers 102 arranged in a generally non-random pattern and a plurality of synthetic fibers 101 arranged in a generally random manner (eg, in FIG. 9A). As well as forming a web in which the cellulose fibers 102 and the synthetic fibers 101 are arranged in different non-random patterns. In an embodiment in which the synthetic fibers 101 are non-randomly arranged, the method provides a plurality of synthetic fibers 101 on the forming member, and the synthetic fibers 101 are arranged at least in a predetermined region or groove. Providing a plurality of cellulose fibers 102 generally randomly on a forming member including synthetic fibers 101; and including randomly arranged cellulose fibers 102 and non-randomly arranged synthetic fibers 101 Forming a single fiber structure. However, in embodiments in which the synthetic fibers 101 are arranged in a generally random manner, the method provides a plurality of cellulose fibers 102 on the forming member such that the cellulose fibers 102 are placed at least in a predetermined region or groove. Providing a plurality of synthetic fibers 101 substantially randomly on a forming member including cellulose fibers 102; randomly arranged synthetic fibers 101 and non-randomly arranged cellulose fibers 102; Forming a single fiber structure comprising:

  FIG. 1 shows one exemplary embodiment of the continuous process of the present invention, in which a water mixture or aqueous slurry 11 of cellulose fibers and synthetic fibers from a headbox 12 is deposited on a forming member 13 and initially. A web 10 is formed. In this particular embodiment, the forming member 13 is supported by rolls 13a, 13b and 13c and travels continuously in the direction of arrow A around these. In this particular embodiment, the web is formed with at least some synthetic fibers 101 arranged non-randomly. As such, the synthetic fibers 101 may be deposited directly on the forming member 13 prior to the deposition of the cellulose fibers 102. In some embodiments, more than one headbox 12 can be used and / or synthetic fibers 101 are deposited on the forming member 13 and then transferred to different forming members where the cellulose fibers 102 are then It may be deposited. Alternatively, the synthetic fiber 101 can be one of several layers deposited on the forming member 13 at about the same time as another type of fiber. In any case, in embodiments where the synthetic fibers 101 are to be non-randomly arranged, the synthetic fibers 101 are pre-determined, such as grooves 53 (eg shown in FIGS. 7 and 8) present in the forming member 13. It should be deposited in such a way that at least part of the synthetic fiber 101 faces into the region. Any of the above techniques can be used where a web having non-random arrangement of at least some of the cellulose fibers is desired.

  In one embodiment of the present invention, the synthetic fiber 101 is provided to be predominantly disposed in the groove 53 of the forming member 13. That is, when the web 10 is formed, which exceeds half of the synthetic fiber 101, it is disposed in the groove 53. In another embodiment, it is desirable for at least about 60%, about 75%, about 80%, or substantially all of the synthetic fiber 101 to be placed in the groove 53 when the web 10 is formed. In addition, the resulting web 100 desirably includes a percentage of synthetic fibers 101 disposed in one or more layers. For example, the layer formed by the fibers initially or closest to the forming member 13 may have a concentration of synthetic fibers 101 of greater than about 55%, greater than about 60%, or greater than about 75%. desirable. (A suitable method for measuring the percentage of a particular type of fiber in a web product layer is disclosed in US Pat. No. 5,178,729 (Bruce Janda, issued Jan. 12, 1993). In addition, in certain embodiments, it is desirable to provide the cellulose fibers 102 to be predominantly disposed in at least one layer adjacent to the layer formed by the synthetic fibers 101. In another embodiment, it is desirable to be disposed within at least one layer of the web 100 of at least some percent of the cellulose fibers 102, such as greater than about 55%, greater than about 60%, or greater than about 75%. At least one layer of cellulosic fibers 102 may be arranged generally randomly. In this way, the resulting web 100 can comprise a non-random pattern of synthetic fibers 101 bonded to one or more layers of cellulose fibers 102 that are generally randomly distributed (eg, FIGS. 9 and 10). ). Furthermore, it is possible to form fiber structures having micro areas with different basis weights.

  In the embodiment of the present invention in which the cellulose fibers 101 are to be non-randomly arranged, the cellulose fibers 102 can be provided to be predominantly arranged in the grooves 53 of the forming member 13. That is, more than half of the cellulose fibers 102 are placed in the grooves 53 when the web 10 is formed. In another embodiment, it is desirable for at least about 60%, about 75%, about 80%, or substantially all of the cellulose fibers 102 to be placed in the groove 53 when the web 10 is formed. In addition, the resulting web 100 desirably includes a percentage of cellulosic fibers 102 disposed in one or more layers. For example, a layer formed by fibers initially or closest to the forming member 13 may have a concentration of cellulose fibers 102 of greater than about 55%, greater than about 60%, or greater than about 75%. desirable. Further, in certain embodiments, it is desirable to provide the synthetic fibers 101 to be predominantly disposed in at least one layer adjacent to the layer formed by the cellulose fibers 102. In another embodiment, disposed in at least one layer of the web 100, such as at least some percent of the synthetic fibers 101, such as greater than about 55%, greater than about 60%, or greater than about 75%. desirable. At least one layer of the synthetic fibers 101 may be arranged generally randomly. In this way, the resulting web 100 can comprise a non-random pattern of cellulose fibers 102 bonded to one or more layers of synthetic fibers 101 that are generally randomly distributed (eg, FIG. 9A). Furthermore, as described above, fiber structures having micro areas with different basis weights can be formed.

  The forming member 13 can be any suitable structure and is typically at least partially fluid permeable. For example, the forming member 13 can have a plurality of fluid permeable areas 54 and a plurality of fluid impermeable areas 55 as shown, for example, in FIGS. The fluid permeable area or opening 54 can extend through the thickness H of the forming member 13 from the web side 51 to the back side 52. In some embodiments, some of the fluid permeable areas 54 having openings, as described in US Pat. No. 5,972,813 (issued October 26, 1999 by Polat et al.), It may be “blind”, ie “closed”. The fluid permeable zone 54, whether open or blind, forms a groove 53 into which fibers can be directed. At least one of the plurality of fluid permeable areas 54 and the plurality of fluid impermeable areas 55 typically forms a pattern throughout the molding member 50. Such patterns can include random or non-random patterns and are substantially continuous (eg, FIG. 2), substantially semi-continuous (eg, FIG. 4), separable (eg, FIG. 5), or these Any combination can be used.

  The forming member 13 may have any suitable thickness H, and indeed the thickness H can be made to vary throughout the forming member 13 as desired. Further, the groove 53 may be any shape or combination of different shapes, may have any depth D, and the depth D can vary throughout the forming member 13. The groove 53 can also have any desired volume. The depth D and volume of the groove 53 can be varied as desired to help ensure that the desired concentration of synthetic fiber 101 or cellulose fiber 102 is placed in the groove 53. In certain embodiments, it is desirable for the depth D of the groove 53 to be less than about 254 μm, or less than about 127 μm. Further, the amount of synthetic fiber 101 or cellulose fiber 102 deposited on the forming member 13 ensures that the desired ratio or percentage of synthetic fiber 101 and / or cellulose fiber 102 is within a groove 53 of a particular depth D or volume. It can be changed to be arranged in For example, in certain embodiments, it may be desirable to provide sufficient synthetic fibers 101 to substantially fill the grooves 53 so that the cellulose fibers 102 are not substantially disposed within the grooves 53 during the web manufacturing process. In this embodiment, it is desirable to provide only enough synthetic fibers 101 to fill a portion of the groove 53 so that at least some of the cellulose fibers 102 can also go into the groove 53. In another embodiment, it may be desirable to provide sufficient cellulose fibers 102 to substantially fill the groove 53 so that the synthetic fiber 101 is not substantially disposed within the groove 53 during the web manufacturing process. In an embodiment, it is desirable to provide enough cellulose fibers 102 to fill only a portion of the groove 53 so that at least a portion of the synthetic fiber 101 can also go into the groove 53.

  Some exemplary forming members 13 have a structure as shown in FIGS. 2-8 including a fluid permeable reinforcing element 70 and a pattern or framework 60 extending therefrom to form a plurality of grooves 53. be able to. In one embodiment, as shown in FIGS. 5 and 6, the forming member 13 can have a plurality of separable protrusions 61 coupled to or integral with the reinforcing element 70. The reinforcing element 70 generally serves to provide or facilitate integrity, stability, and durability. The reinforcing element 70 can be fluid permeable or partially fluid permeable, can have various embodiments and weave patterns, and various materials, such as a plurality of interwoven yarns (Jacquard type and similar). Woven patterns), felts, plastics or other synthetic materials, nets, plates with multiple holes, or any combination thereof. Examples of suitable reinforcing elements 70 are US Pat. Nos. 5,496,624 (Stelljes et al., Issued 5 March 1996), 5,500,277 (Trokhan et al., 1996). Published 19 March), and 5,566,724 (issued 22 October 1996, Trokhan et al.). Alternatively, reinforcing elements 70 including jacquard type weaving can be used. Examples of belts are US Pat. Nos. 5,429,686 (issued July 4, 1995), US Pat. No. 5,672,248 (Wendt et al., September 30, 1997). Issued), 5,746,887 (Wendt et al., Issued May 5, 1998), and 6,017,417 (Wendt et al., Issued January 25, 2000). Can be found. In addition, various designs of jacquard weave patterns can be used as the forming member 13.

  An exemplary and preferred framework element 60 and method of applying the framework 60 to the reinforcing element 70 is described, for example, in U.S. Pat. No. 4,514,345 (Johnson, issued Apr. 30, 1985), 4,528. , 239 (Trokhann, issued on July 9, 1985), 4,529,480 (Trokhann, issued on July 16, 1985), 4,637,859 (Trokhan ( Trokhann), published on January 20, 1987), 5,334,289 (Trokhann, issued on August 2, 1994), 5,500,277 (Trokhann et al., 1996) (Issued 19 March), 5,514,523 (Trokhann et al., Issued May 7, 1996), 5,628,876 (Ayers et al., 13 May 1997) Issue) No. 5,804,036 (Phan et al., Issued on September 8, 1998), No. 5,906,710 (Trokhann, issued on May 25, 1999), No. 6,039, No. 839 (Trokhann et al., Issued on March 21, 2000), No. 6,110,324 (Trokhann et al., Issued on August 29, 2000), No. 6,117,270 (Trokhan) (Trokhann), issued on September 12, 2000), 6,171,447B1 (Trokhann, issued on January 9, 2001), and 6,193,847B1 (Trokhann, 2001) Issued on Feb. 27, 2007). Further, as shown in FIG. 6, the framework 60 may include one or an opening or hole 58 that extends through the framework element 60. Such a hole 58 is different from the groove 53 and by using it helps the dewatering from the slurry or web and / or the fibers deposited on the framework 60 are fully introduced into the groove 53. Can help prevent you from moving to.

  Alternatively, the forming member 13 may include any other structure suitable for receiving fibers, including several patterns of grooves 53 into which the synthetic fibers 101 can face, including Examples include, but are not limited to, nets, composite belts, and / or felts. In any case, the pattern may be separable or substantially separable as described above, may be continuous or substantially continuous, or semi-continuous or substantially semi-continuous. It may be continuous. Certain exemplary forming members 13 that are generally suitable for use with the method of the present invention are US Pat. Nos. 5,245,025, 5,277,761, 5,443,691, 5,503,715, 5,527,428, 5,534,326, 5,614,061, and 5,654,076.

  US Pat. No. 5,580,423 (Ampulski et al., Issued December 3, 1996), No. 5,609,725 (Phan, 1997) when the forming member 13 includes a press felt. (Issued on March 11, 1997), No. 5,629,052 (issued on May 13, 1997), No. 5,637,194 (Ampulski et al., June 1997) Issued 10th), 5,674,663 (McFarland et al., Issued October 7, 1997), 5,693,187 (Ampulski et al., December 2, 1997) No. 5,709,775 (issued January 20, 1998), No. 5,776,307 (issued on July 7, 1998) , 5th No. 795,440 (Ampulski et al., Issued on August 18, 1998), No. 5,814,190 (Phan, issued on September 29, 1998), No. 5,817,377 (Trokhan et al., Issued October 6, 1998), 5,846,379 (Ampulski et al., Issued December 8, 1998), 5,855,739 (Ampleski) (Ampulski et al., Issued on Jan. 5, 1999), and 5,861,082 (Ampulski et al., Issued on Jan. 19, 1999). In an alternative embodiment, the forming member 13 can be implemented as a press felt according to the teachings of US Pat. No. 5,569,358 (Cameron, issued Oct. 29, 1996) or any other suitable structure. is there. Other structures suitable for use as the forming member 13 are described below in connection with the optional molded member 50.

  Using a vacuum device such as a vacuum device 14 disposed below the forming member 13 to apply a fluid pressure differential to the slurry disposed on the forming member 13 to promote at least partial dewatering of the initial web 10. Can do. This fluid differential pressure can also help the desired fiber, eg, synthetic fiber 101, move into the groove 53 of the forming member 13. Other known methods may be used in addition to or as an alternative to the vacuum device 14 to help dewater the web 10 and / or the fibers toward the grooves 53 of the forming member 13.

  If desired, the initial web 10 formed on the forming member 13 can be transferred from the forming member 13 to another structure such as a felt or molded member. The molded member is a structural element that can be used as a support for the initial web and as a forming unit for forming or “molding” a desired microscopic shape in the fibrous structure. The molded member may include any component having an ability to give a microscopic three-dimensional pattern to the structure generated on the upper side. The molded member may be a fixed plate, a belt, or a woven fabric such as a jacquard type. Single layer structures and multilayer structures comprising woven fabrics, bands, rolls (including patterns) are included without limitation.

  In the exemplary embodiment shown in FIG. 1, the molding member 50 is fluid permeable and is sufficient for the vacuum shoe 15 to pull the initial web 10 disposed on the forming member 13 away and adhere to the molding member 50. Apply proper vacuum pressure. 1 includes a belt that is supported by rolls 50a, 50b, 50c, and 50d and travels around these in the direction of arrow B. The molding member 50 has a side 151 that contacts the web and a back side 152 that faces the side 151 that contacts the web.

  The molded member 50 can take any suitable form and can be made of any suitable material. The molded member 50 may include any structure and may be made by any of the methods described herein in connection with the forming member 13, but the molded member 50 is limited to such structures and methods. Not. For example, the molding member 50 includes a resin frame 160 coupled to the reinforcing element 170 as shown in FIGS. 13 and 14, for example. In addition, various designs of jacquard weave patterns can be used as the molded member 50 and / or the pressure surface 210. If desired, the molded member 50 may be a press felt or include it. Suitable press felts for use with the present invention include, but are not limited to, those described herein in connection with forming member 13.

  In some embodiments, the molded member 50 can have a plurality of fluid permeable areas 154 and a plurality of fluid impermeable areas 155, for example as shown in FIGS. A fluid permeable area or opening 154 extends through the thickness H 1 of the molded member 50 from the web side 151 to the back side 152. As described above with respect to the forming member 13, the thickness 1H of the molded member can be any desired thickness. Further, the depth D1 and volume of the groove 153 can be varied as desired. Further, one or more of the fluid permeable areas 154 including the openings may be “blind” or “closed” as described above with respect to the forming member 13. At least one of the plurality of fluid permeable areas 154 and the plurality of fluid impermeable areas 155 typically forms a non-random repeating pattern throughout the molded member 50. Such patterns can include random patterns or non-random patterns, and can include substantially continuous, substantially semi-continuous, separable, or any combination thereof. The portion of the reinforcing element 170 that coincides with the opening 154 in the molded member 50 provides support for fibers that flex into the fluid permeable area of the molded member 50 during the fabrication process of the single fibrous structure 100. be able to. The reinforcing element can help prevent the fibers of the web being fabricated from passing through the molded member 50, thereby reducing the occurrence of pinholes in the resulting structure 100.

  In certain embodiments, the molded member 50 includes a plurality of suspensions extending from a plurality of base portions, as taught by US Pat. No. 6,576,090 (issued June 10, 2003). Can include parts. In such an embodiment, the suspended portion is lifted from the reinforcing element 170 to form a void between the suspended portion and the reinforcing element 170, in which the fibers of the initial web 10 are deflected and the fibrous structure 100. A cantilever portion can be formed. The molded member 50 having a suspended portion may include a multilayer structure formed of at least two layers and joined together in a face-to-face relationship. The bonded layers may be positioned such that the opening in one layer overlaps a portion of the other framework (in a direction perpendicular to the general surface of the molded member 50). Another embodiment of a molded member 50 having a plurality of suspended portions includes a process that differentially cures a layer of photosensitive resin or other curable material through a mask that includes transparent regions and opaque regions. Can be made. Opaque areas are areas having different opacity, for example areas having a relatively high opacity (not transparent) and areas having a relatively low partial opacity (somewhat transparent) including.

  When the initial web 10 is placed on the side 151 of the molding member 50 that contacts the web, the web 10 conforms at least in part to the three-dimensional pattern of the molding member 50. Further, the cellulose fibers and / or synthetic fibers of the initial web 10 are adapted to the three-dimensional pattern of the molded member 50 to become a molded web (shown as “20” in FIG. 1), or Various means can be used to encourage. (It should be understood herein that the reference numbers “10” and “20” and the terms “initial web” and “molded web” can be used interchangeably.) Applying a fluid pressure difference to the fibers. For example, as shown in FIG. 1, the vacuum devices 16 and / or 17 arranged on the back side 152 of the molding member 50 are arranged to apply a vacuum pressure to the molding member 50 and, consequently, a plurality of fibers arranged on the upper part. can do. Under the influence of the fluid pressure difference ΔP1 and / or ΔP2 caused by the vacuum pressure of each of the vacuum devices 16 and 17, a part of the initial web 10 is deflected into the groove 153 of the molding member 50 and conforms to its three-dimensional pattern. Can do.

  By deflecting a portion of the web 10 into the groove 153 of the molding member 50, the density of the resulting pillow 150 formed in the groove 153 of the molding member 50 is reduced compared to the density of the remainder of the molding web 20. Can be made. A region 168 that does not flex into the opening is later formed between the pressure surface 218 and the molded member 50, such as in a pressure nip formed between the surface 210 of the drying drum 200 and the roll 50c shown in FIG. (Example of FIG. 11) The web 20 may be embossed by being embossed. When indented, the density of region 168 may be even greater than the density of pillow 150.

  The microregions (high and low density) of the fiber structure 100 are considered to be arranged at two different heights. As used herein, the height of a region refers to its distance from the reference plane (ie, the XY plane). The reference plane can be visualized as horizontal and the height distance from the reference plane is vertical (ie, the Z direction). The height of a particular micro region of the structure 100 may be measured using any non-contact measuring device suitable for the application as is well known in the art. The fiber structure 100 according to the present invention can be placed on a reference plane with the indentation region 168 in contact with the reference plane. Pillow 150 extends vertically away from the reference plane. The plurality of pillows 150 may include symmetric pillows, asymmetrical pillows, or a combination thereof.

  Different heights of the micro regions can also be formed by the molding member 50 having a three-dimensional pattern with different depths or heights. Such three-dimensional patterns having different depths / heights can be created by sanding preselected portions of the molded member 50 and reducing their height. Alternatively, a three-dimensional mask having recesses / projections with different depths / heights can be used to form corresponding frameworks 160 with different heights. Other conventional techniques for forming surfaces with different heights can also be used for the applications described above. It should be understood that the techniques described herein for forming the molded member are also applicable to forming the forming member 13.

  Vacuum devices 16 and / or 17 and / or vacuum pick-up shoes that can push some filaments or parts thereof through the molding member 50 and thus lead to the formation of so-called pinholes in the resulting fiber structure. 15 to improve the negative effect that can result from abruptly applying a fluid pressure difference to the fiber structure being fabricated, the back side 152 of the molded member 50 should be formed with microscopic surface irregularities. Can be “non-planarized”. Such surface irregularities prevent the formation of a vacuum seal between the back side 52 of the molded member 50 and the surface of the papermaking machine (eg, the surface of a vacuum device, etc.), creating a “leak” between them. Because it helps to create, certain undesirable consequences of applying vacuum pressure in the draft drying process can be mitigated. Other methods of creating such leaks are described in US Pat. Nos. 5,718,806, 5,741,402, 5,744,007, 5,776,311, and 5,885. , 421.

  Leaks were found in U.S. Patent No. 5,624,790, U.S. Patent No. 5,554,467, U.S. Patent No. 5,529,664, U.S. Patent No. 5,514,523 and U.S. Patent No. 5,334. It can be created using a so-called “light transmission difference technique”, as described in 289. The molded member 50 applies a photosensitive resin coating to the reinforcing element having an opaque portion, and then passes the coating through the mask having transparent and opaque regions, and also through the reinforcing element, to the light of the activation wavelength. It can be made by exposure. Another method of creating backside irregularities is non-planarization as described in US Pat. No. 5,364,504, US Pat. No. 5,260,171 and US Pat. No. 5,098,522. Use of a modified forming surface or a non-planarized barrier film. The molded member 50 casts the photosensitive resin all over the reinforcing element as the reinforcing element moves over the non-planarized surface, and then activates the coating through a mask having transparent and opaque areas. It can be made by exposure to light. It should be understood that the methods and structures described in this paragraph and in the previous paragraph are applicable to the structure and formation of the forming member 13.

  The process of the present invention also covers the initial web 10 (or web 20 to be molded) with a flexible sheet of material that forms an endless band that moves with the molded member 50 so that the initial web 10 is A step of being sandwiched between the molding member 50 and the flexible material sheet for a certain period may be included. The flexible material sheet may have an air permeability that is lower than the air permeability of the molded member 50 and may be air impermeable in some embodiments. By applying a fluid pressure differential through the molding member 50 to the flexible sheet, at least a portion of the flexible sheet is deflected toward, and possibly into, the three-dimensional pattern of the molding member 50. A portion of the web 20 disposed on the molding member 50 is pushed in and closely matches the three-dimensional pattern of the molding member 50. U.S. Pat. No. 5,893,965 describes one arrangement of a process and equipment that uses a sheet of flexible material.

  In addition to or instead of the fluid pressure differential, mechanical pressure can be used to facilitate the formation of a microscopic three-dimensional pattern on the fibrous structure 100 of the present invention. Such mechanical pressure may be created by any suitable pressing surface 218 including, for example, the surface of a roll or the surface of a band. The pressing surface 218 can be smooth or can have its own three-dimensional pattern. In the latter example, the pressurizing surface 218 can be used as an embossing device, so that in conjunction with or independent of the three-dimensional pattern of the molded member 50, the fiber structure 100 being fabricated. A unique micro pattern of the convex part and / or the concave part is formed. In addition, pressure surfaces can be used to deposit various additives, such as softeners and inks, on the fiber structure being made. Various conventional techniques such as, for example, ink rolls or spray devices or showers may be used to deposit various other additives directly or indirectly onto the fiber structure being made.

  In certain embodiments, it may be desirable to shorten the fiber structure 100 of the present invention during fabrication. For example, the molding member 50 may be configured to have a linear velocity that is slower than the linear velocity of the forming member 13. Such a speed difference at the transition point from the forming member 13 to the molding member 50 can be used to achieve “microshrinkage”. A detailed example of wet microshrinkage is described in US Pat. No. 4,440,597. Such wet microshrinking can cause a web having a low fiber concentration to move from any first member (eg, a perforated forming member) to any second member (eg, an eye) that moves at a slower rate than the first member. Transfer to a rough woven fabric or the like). The speed difference between the first member and the second member can vary according to the desired final properties of the fiber structure 100. Other patents describing methods for achieving microshrinkage include, for example, US Pat. Nos. 5,830,321, 6,361,654, and 6,171,442.

  The fiber structure 100 may additionally or alternatively be shortened after it has been formed and / or after it has been substantially dried. For example, shortening can be achieved by creping the structure 100 from a rigid surface, such as the surface 210 of the drying drum 200 as shown in FIG. This and other forms of creping are known in the art. U.S. Pat. No. 4,919,756 (Sawdai, issued April 24, 1992) describes one suitable method for creping a web. Of course, a fiber structure 100 without crepes (eg, not creped) and / or otherwise shortened is considered to be a fiber structure 100 without crepes but otherwise shortened. Intended to be inside.

  In certain embodiments, it may be preferred that at least a portion of the synthetic fiber 101 is at least partially melted or softened. When the synthetic fibers 101 are at least partially melted or softened, they may be able to co-join with adjacent fibers, whether cellulose fibers 102 or other synthetic fibers 101. Fiber co-bonding can include mechanical co-bonding and chemical co-bonding. Chemical co-bonding occurs when at least two adjacent fibers are bonded together at the molecular level such that the identity of the individual co-bonded fibers is substantially lost in the co-bonded area. Fiber mechanical co-bonding occurs when one fiber simply conforms to the shape of an adjacent fiber and there is no chemical interaction between the co-bonded fibers. FIG. 12 shows one embodiment of mechanical co-bonding, where the fibers 111 are physically taken up by adjacent synthetic fibers 112. The fibers 111 can be synthetic fibers or cellulose fibers. In the example shown in FIG. 12, the synthetic fiber 112 includes a two-component structure including a core 112a and a sheath or shell, 112b, and the melting temperature of the core 112a is greater than the melting temperature of the sheath 112b, and therefore when heated. Only the sheath 112b melts while the core 112a retains its integrity. However, it should be understood that multi-component fibers containing different types of bi-component fibers and / or more than three components can be used in the present invention, as are single-component fibers. is there.

  In certain embodiments, it may be desirable to redistribute at least a portion of the synthetic fibers 101 within the web 100 after the web 100 is formed. Such redistribution can occur while the web 100 is positioned on the molding member 50 or at different times and / or locations during the process. For example, the formed web 100 is heated using a heating device 90, a drying surface 210, and / or a drying drum hood (e.g., a Yankee drying hood 80) to provide at least one of the synthetic fibers 101. Parts can be redistributed. Without being bound by theory, it is believed that the synthetic fiber 101 can move under the influence of at least one of two phenomena after being subjected to a sufficiently high temperature. . When the temperature is high enough to melt the synthetic fiber 101, the resulting liquid polymer minimizes its surface area / mass due to surface tension and is less sensitive to heat at the end of the fiber portion Tends to form a sphere-like shape. On the other hand, if the temperature is lower than the melting point, the fiber with high residual stress softens to the point where the stress is relaxed by fiber shrinkage or coiling. This is believed to occur because polymer molecules typically prefer to be in a non-linear coiled state. Fibers that are highly drawn during their manufacture and then cooled are composed of polymer molecules drawn into a metastable shape. Subsequent heating returns the fiber to a coiled state with minimal free energy.

  Redistribution may be accomplished with any number of steps. For example, the synthetic fiber 101 is blown with hot gas, for example, through a pillow portion of the web 100 while the fiber web 100 is disposed on the molding member 50, so that the synthetic fiber 101 is redistributed according to the first pattern. By doing so, the first redistribution can be received. The web 100 can then be transferred to another molding member 50 and the synthetic fibers 101 can be further redistributed according to a second pattern.

  Heating the synthetic fibers 101 in the web 100 can be accomplished by heating a plurality of micro regions corresponding to the fluid permeable areas 154 of the molded member 50. For example, hot gas from the heating device 90 can be forced through the web 100. A pre-dryer can also be used as a heat energy source. In either case, depending on the process, the direction of the hot gas flow can be reversed with respect to the direction shown in FIG. 1 so that the hot gas penetrates the web through the molding member 50. The pillow portion 150 of the web that is disposed in the fluid permeable area 154 of the molding member 50 is then primarily affected by the hot gas. The remaining part of the web 100 is shielded from the hot gas by the molding member 50. As a result, the synthetic fiber 101 is predominantly softened or melted at the pillow portion 150 of the web 10. Further, this region is a place where fiber co-joining due to melting or softening of the synthetic fiber 101 is most likely to occur.

  Although the redistribution of the synthetic fiber 101 has been described above as being affected by the passage of hot gas over at least some of the fibers 101, any suitable means for heating the fibers 101 can be used. Can be implemented. For example, thermal fluids, and microwaves, radio waves, ultrasonic energy, laser or other light energy, heating belts or rolls, heat pins, magnetic energy, or any combination of these or other known means for heating May be used. Furthermore, although the redistribution of synthetic fibers 101 is generally referred to as being affected by heating the fibers 101, the redistribution may also occur as a result of cooling a portion of the web 10. . As with heating, the cooling of the synthetic fiber 101 can cause its own redirection with respect to the shape change of the fiber 101 and / or the rest of the web. Furthermore, the synthetic fibers may be redistributed due to reaction with the redistribution material. For example, the synthetic fiber 101 may be subject to a chemical composition that softens or otherwise manipulates the synthetic fiber 101 to affect any shape, orientation, or position within the web 10. Good. Furthermore, the redistribution can be influenced by mechanical means and / or other means such as magnetic, electrostatic etc. Therefore, redistribution of synthetic fibers 101 as described herein should not be considered limited to thermal redistribution of synthetic fibers 101, but rather any portion of synthetic fibers 101 within web 10. Should be considered to encompass all known means for redistributing (eg, changing shape, orientation, or position). Further, while redistribution has been described in terms of synthetic fibers 101, cellulose fibers 102 can alternatively be redistributed by means known to affect the shape and / or orientation of cellulose fibers. You should understand that.

  Although the synthetic fibers 101 may be redistributed by the methods and means described herein, the process of producing a web is a means by which a random distribution of cellulose fibers 102 is used to redistribute the synthetic fibers 101. Can be selected so as not to have a significant impact. Thus, the resulting fiber structure 100, whether or not redistributed, is distributed in a non-random pattern with a plurality of cellulose fibers 102 randomly distributed throughout the fiber structure and throughout the fiber structure. A plurality of synthetic fibers 101. FIG. 10 schematically illustrates one embodiment of a fiber structure 100, where the cellulose fibers 102 are randomly distributed throughout the structure and the synthetic fibers 101 are distributed in a non-random repeating pattern.

  The synthetic fiber 101 can be any material selected from the group consisting of, for example, polyolefins, polyesters, polyamides, polyhydroxyalkanoates, polysaccharides, and any combination thereof. More specifically, the synthetic fiber 101 is made of polypropylene, polyethylene, poly (ethylene terephthalate), poly (butylene terephthalate), poly (1,4-cyclohexylenedimethylene terephthalate), isophthalic acid copolymers, ethylene glycol. Selected from the group consisting of copolymers, polycaprolactone, poly (hydroxyetherester), poly (hydroxyetheramide), polyesteramide, poly (lactic acid), polyhydroxybutyrate, starch, cellulose, glycogen, and any combination thereof can do. Furthermore, the synthetic fiber 101 can be a single component (ie, a single synthetic material or a mixture that assembles the entire fiber), two components (ie, the fibers are divided into regions, and the regions can be divided into two different synthetic materials or The mixture), or multi-component fibers (ie, the fibers are divided into regions, where the regions include two or more different synthetic materials or mixtures thereof), or any combination thereof. . Also, any or all of the synthetic fibers 101 may be treated before, during, or after the process of the present invention to change any desired properties of the fibers. For example, in certain embodiments, it may be desirable to treat the synthetic fiber 101 prior to or during the papermaking process to make it more hydrophilic, more wettable, and the like.

  The method of making the web 100 of the present invention may also include any other desired steps. For example, the method can include winding a web onto a roll, calendering the web, embossing the web, perforating the web, printing on the web, and / or making the web one or more other webs or materials. And a converting process such as forming a multi-ply structure. Some representative patents describing embossing include US Pat. Nos. 3,414,459, 3,556,907, 5,294,475, and 6,030,690. It is done. In addition, the method may include one or more steps that add to or enhance the properties of the web 100, such as adding softening, strengthening, and / or other treatments to the surface of the product or during web formation. . Further, the web 100 may comprise, for example, a latex as described in US Pat. No. 3,879,257, or other material or resin to provide beneficial properties to the web.

  As described above, the methods and apparatus described herein include a web 100 in which cellulose fibers 102 are distributed in a generally non-random manner and synthetic fibers 101 are distributed in a generally random manner in at least a portion of the web 100. Can also be used to form (eg, FIG. 9A). As such, it is understood that all of the variations described herein with respect to the method steps and the various equipment used in the method also apply to such alternative web embodiments. It should be understood that the alternatives and optional steps described herein apply as well.

  Various products can be produced using the fiber structure 100 of the present invention. For example, the resulting products include air, oil and water filters; vacuum cleaner filters; furnace filters; face masks; coffee filters, tea or coffee bags; insulation and sound insulation; diapers, women's pads and incontinence Non-woven fabrics for single-use hygiene products such as articles; textile fabrics for water absorption and wear flexibility such as microfibers or breathable fabrics; electrostatically charged structures for dust collection and removal Webs; stiffeners and wrapping paper, writing paper, newspaper printing paper, hard paper webs such as cardboard and paper tissue grade webs such as toilet paper, paper towels, napkins and facial tissues; surgical curtains, wounds It may find use in medical applications such as bandages, bandages and skin patches. The fiber structure 100 may also include odor absorbents, termite repellents, insecticides, rodenticides, etc. for specific applications. The resulting product can absorb water and oil and find use in oil or water spill cleaning or controlled water retention and discharge for agricultural or horticultural applications.

(Test method)
The caliper is measured by the following procedure without taking into account the small deviation from the absolute plane inherent in the multi-density tissue produced by the aforementioned incorporated patent.

  The tissue paper is preconditioned at 21-24 ° C. (71 ° -75 ° F.) and 48-52% relative humidity for at least 2 hours prior to caliper measurement. When calipers of toilet paper or other roll products are measured, first remove 15-20 sheets from the outside of the roll and discard. If facial tissue or other boxed product calipers are being measured, samples should be removed from near the center of the package. A sample is selected and then conditioned for an additional 15 minutes.

  The caliper is a low-load Swing-Albert Progage micrometer model 89- available from Thing-Albert Instrument Company, Philadelphia, Pennsylvania. Measured using 2012. The micrometer uses a 5.08 cm (2.0 inch) diameter pusher foot and a 6.35 cm (2.5 inch) diameter support anvil at a pressure of 15 grams per square centimeter. Load the sample. The micrometer has a measuring capability range of 0-0.1016 cm (0-0.0400 inch). Tissue decoration areas, perforations, edge effects, etc. should be avoided if possible.

  The basis weight is measured by the following procedure.

  Tissue samples are selected as described above and conditioned for a minimum of 2 hours at 21-24 ° C. (71 ° -75 ° F.) and 48-52% humidity. Carefully select 12 finished product sheets that are clean and free of holes, tears, wrinkles, folds, and other defects. For clarity, the finished product sheet should include the number of plies that the particular finished product being tested has. Thus, a sample set for a one-ply product includes twelve one-ply sheets, a sample set for a two-ply product includes twelve two-ply sheets, and so on. The sample set is divided into two stacks so that each contains six finished product sheets. A stack of six finished product sheets is placed on a punching die. The mold is a square measuring 8.89 cm x 8.89 cm (3.5 in x 3.5 in), flexible in the square to facilitate removal of the sample from the mold after cutting You may have a polyurethane rubber. The six finished product sheets are made using a mold and a suitable pressure plate cutter, such as the Thwing-Albert Alpha Hydraulic Pressure Sample Cutter Model 240-7A, Disconnected. A second set of six finished product sheets is also cut in the same way. Two stacks of cut finished product sheets are combined with a stack of 12 finished product sheets and conditioned at 21-24 ° C. (71 ° -75 ° F.) and 48-52% humidity for at least an additional 15 minutes. .

  The stack of 12 finished product sheets cut as described above is then weighed on a calibrated chemical balance having a sensitivity of at least 0.0001 grams. The balance is held in the same room where the sample was conditioned. A suitable balance is model A200S manufactured by Sartorius Instrument Company.

  The basis weight in pounds per 3,000 square feet for this sample is simply calculated using the following conversion formula:

この試料についての３，０００平方フィート当りポンドの単位の坪量は、次の換算式を使用して簡単に計算される：
坪量（ｌｂ／３，０００ｆｔ²）＝１２プライパッドの重量（ｇ）×６．４８
本明細書で使用される密度の単位は、立方センチメートル当りのグラム（ｇ／ｃｃ）である。ｇ／ｃｃのこれらの密度単位にとっては、坪量も平方センチメートル当りのグラムの単位で表わすのが便利であろう。この換算を行うために、次の式が使用可能である：
坪量（ｇ／ｃｍ²）＝１２プライパッドの重量（ｇ）／９４８．４

The basis weight in pounds per 3,000 square feet for this sample is simply calculated using the following conversion formula:
Basis weight (lb / 3,000 ft ² ) = 12 ply pad weight (g) × 6.48
The unit of density used herein is grams per cubic centimeter (g / cc). For these density units of g / cc, it may be convenient to express the basis weight in units of grams per square centimeter. To perform this conversion, the following equation can be used:
Basis weight (g / cm ² ) = 12 ply pad weight (g) /948.4

FIG. 3 is a side view of an embodiment of the process of the present invention. FIG. 3 is a plan view of an embodiment of a forming member having a substantially continuous framework. Sectional drawing which displays a typical formation member. FIG. 3 is a plan view of an embodiment of a forming member having a substantially semi-continuous framework. FIG. 6 is a plan view of an embodiment of a forming member having an isolated pattern framework. Sectional drawing which displays a typical formation member. Sectional drawing which shows the representative synthetic fiber distributed in the groove | channel formed in the formation member. It is sectional drawing which shows the single fiber structure of this invention, and the cellulose fiber is distributed at random on the formation member containing a synthetic fiber. It is sectional drawing of the single fiber structure of this invention, and the cellulose fiber is distributed substantially randomly, and the synthetic fiber is distributed substantially non-randomly. It is sectional drawing of the single fiber structure of this invention, and the synthetic fiber is distributed substantially randomly, and the cellulose fiber is distributed substantially non-randomly. The top view of the embodiment of the single fiber structure of the present invention. 1 is a cross-sectional view of a single fiber structure of the present invention between a pressure surface and a molded member. Sectional drawing of the bicomponent synthetic fiber co-joined with the other fiber. FIG. 3 is a plan view of an embodiment of a molded member having a substantially continuous pattern framework. FIG. 14 is a sectional view taken along line 14-14 in FIG. 13.

Claims (20)

Providing a first plurality of fibers on a forming member having a groove pattern; and wherein the first plurality of fibers are prepared such that at least a portion of the fibers are disposed within the grooves;
Providing the second plurality of fibers on the first plurality of fibers such that a second plurality of fibers is disposed adjacent to the first plurality of fibers;
Forming a single fiber structure including the first plurality of fibers and the second plurality of fibers, wherein at least the first plurality of fibers or the second plurality of fibers are synthetic fibers A method for producing a single fiber structure comprising:   The manufacturing method according to claim 1, wherein the first plurality of fibers are prepared on the forming member before the second plurality of fibers.   The manufacturing method according to claim 1, wherein at least a part of the first plurality of fibers are co-joined with each other or at least a part of the second plurality of fibers.   The manufacturing method according to any one of claims 1 to 3, wherein the first plurality of fibers are predominantly arranged in the groove during the formation of the single fiber structure.   The manufacturing method according to claim 1, wherein the first plurality of fibers form a non-random pattern in the single fiber structure.   The manufacturing method according to any one of claims 1 to 5, wherein the second plurality of fibers are distributed substantially randomly within at least one layer of the single fiber structure. The step of providing a first plurality of fibers and a second plurality of fibers includes:
Providing an aqueous slurry comprising a first plurality of fibers layered with a second plurality of fibers;
Depositing the aqueous slurry on a forming member;
The slurry is partially dewatered and at least partially distributed in the grooves on the forming member and the second plurality of fibers randomly distributed across one or more layers of the initial web. Forming the initial fiber web including the first plurality of fibers. The manufacturing method according to any one of claims 1 to 6. The forming member is moving at a first speed, and the manufacturing method includes:
Providing a second member having a second speed that is slower than the first speed;
The method according to claim 7, further comprising: transferring the initial web from the forming member to the second member so as to cause the initial web to be finely shrunk. Providing a molded member including a plurality of fluid permeable areas and a plurality of fluid impermeable areas;
Providing a drying surface to receive the single fiber structure on top;
Disposing the single fiber structure on the molded member;
Transferring the single fiber structure to the dry surface;
Heating the single fiber structure to a temperature sufficient to cause redistribution of at least a portion of the fibers in the single fiber structure. The production method according to item.   The manufacturing method of Claim 9 including the process of embossing the said some fiber between the said shaping | molding member and a pressurization surface, and densifying a part of said single fiber structure.   The step of preparing a molded member provides a molded member comprising a patterned mold selected from the group consisting of a continuous pattern, a semi-continuous pattern, an isolated pattern, or any combination thereof. The manufacturing method of Claim 10 including this.   The manufacturing method according to any one of claims 1 to 11, wherein the first plurality of fibers includes a synthetic fiber, and the second plurality of fibers includes a cellulose fiber.   Redistributing at least a portion of the synthetic fiber to form a single fiber structure in which at least a portion of the plurality of synthetic fibers are distributed in a pattern different from the pattern formed by the groove pattern. The manufacturing method of Claim 12 containing.   The manufacturing method according to claim 13, wherein the step of redistributing the synthetic fiber includes heating, cooling, mechanical manipulation, and / or chemical manipulation of at least a part of the synthetic fiber. Providing a first aqueous slurry comprising a plurality of synthetic fibers;
Providing a second aqueous slurry comprising a plurality of cellulose fibers;
Depositing the first and second aqueous slurries on a fluid permeable forming member having a groove pattern;
The deposited first and second slurries are partially dewatered, a plurality of cellulose fibers randomly distributed throughout at least one layer of a fibrous web, and at least partially non-random within the groove Forming a fibrous web comprising a plurality of synthetic fibers distributed in the
Forming the fiber web by the pattern of the grooves by applying a fluid differential pressure to the fiber web disposed on the molding member, wherein the fiber web disposed on the molding member comprises: A first plurality of micro regions corresponding to a plurality of fluid permeable areas of the molded member and a second plurality of micro regions corresponding to the plurality of fluid impermeable areas of the molded member;
By transferring the fibrous web from the molded member to the drying surface, at least some of the plurality of synthetic fibers are arranged in a predetermined pattern and the plurality of cellulose fibers are at least one of the fiber structures. Forming said single fiber structure that remains generally randomly distributed throughout the layer.   Heating the fiber web to a temperature sufficient to cause redistribution of at least a portion of the synthetic fibers within the fiber web causes a portion of the plurality of synthetic fibers to be redistributed while the plurality of 16. The production of a single fiber structure according to claim 15, comprising the step of forming the single fiber structure, wherein cellulose fibers remain generally randomly distributed throughout at least one layer of the fiber structure. Method.   The manufacturing method according to any one of claims 15 to 16, wherein the step of heating the fiber web occurs when the fiber web is disposed on the molding member and / or the drying surface.   The manufacturing method according to claim 1, wherein the single fiber structure is creped, not creped and / or embossed.   19. A method according to any one of the preceding claims, wherein the single fiber structure is combined with a separate single structure to form a multi-ply web.   The manufacturing method as described in any one of Claims 1-19 including the process of providing latex to at least one part of the at least 1 surface of the said single fiber structure.

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