Classifications

• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/407—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties containing absorbing substances, e.g. activated carbon
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
  • D04H1/425—Cellulose series
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
  • D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
  • D04H1/43835—Mixed fibres, e.g. at least two chemically different fibres or fibre blends
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
  • D04H1/56—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving in association with fibre formation, e.g. immediately following extrusion of staple fibres
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
  • D04H1/72—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
  • D04H1/72—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
  • D04H1/736—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged characterised by the apparatus for arranging fibres
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
  • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
  • D04H3/14—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
  • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
  • D04H3/16—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion

Definitions

• the present invention relates to coforming processes for commingling two or more materials, for example solid additives, for example fibers and/or particulates, and filaments, and equipment; namely, forming boxes, useful in such coforming processes and more particularly to coforming processes for commingling filaments with one or more fibers, such as pulp fibers, and forming boxes useful therein.
• Forming boxes have been used in the past to facilitate the commingling ("coforming") of two or more materials such as filaments and fibers during a fibrous structure making process.
• the known forming boxes were designed to have one material, for example pulp fibers, being injected into another material, for example filaments, in a perpendicular fashion (90° to one another) as shown in Prior Art Fig. 1.
• the prior art forming box (coform box) 10 shown in Fig. 1 has a first material inlet 12 and a second material inlet 14. Filaments 16 from a filament source 18, such as a die, enter the coform box 10 through the first material inlet 12.
• the pulp fibers 20 contact the filaments 16 inside the coform box 10 in a perpendicular fashion, in other words at an angle ⁇ of 90° from one side ("single-sided injection").
• a known coforming process commingles filaments 16 from a filament source 18, such as a die, with pulp fibers 20, from a fiber source 22, such as a picker roll, by injecting a single stream of the pulp fibers 20 into the intersection of two streams of filaments 16 in an open, non-enclosed, non-controlled environment (i.e., not within a forming box).
• the current invention discloses the addition of air at greater than the natural ability of the jet to entrain, as well as the introduction of liquid water, both of which result in more rapid removal of heat from the jet.
• Prior Art Fig. 3 shows an example of another known coforming process that commingles filaments 16 with pulp fibers 20 by injecting a single stream of pulp fibers 20, from a fiber source 22, such as a picker roll, into one side ("single-sided injection") of a single stream of filaments 16 from a filament source 18, such as a die, at a angle of 90° in an open, non-enclosed, non- controlled environment (i.e., not within a forming box).
• a fiber source 22 such as a picker roll
• the problems with this coforming process are 1) it relies more heavily on the natural entrainment from room air to quench the polymer forming the filaments, for example polypropylene; 2) the 90° introduction of pulp to the melt results in jet instability and CD control issues, especially at higher JARS; and 3) heat transfer issues associated with the natural entrainment limitation and lack of liquid water.
• a problem with existing coforming processes is that the formation of a fibrous structure made from the coforming process, even when a known forming box is used in the process, needs improved due to multiple (and sometimes contradictory) requirements on what must occur in the coform box in order to meet consumer desires. These requirements include, but are not limited to:
• the present invention fulfills the need described above by providing a coforming process and/or a forming box that commingles two or more separate materials at a non-90° angle, for example at an angle of less than 90°.
• One solution to the problem identified above with respect to known coforming processes and known forming boxes is to increase the stability of the coforming process by utilizing a forming box within which two or more separate materials, such as filaments and pulp fibers, are commingled in a non-perpendicular fashion, for example in a non-90° angle, such as an angle of less than 90° and/or less than 85° and/or less than 75° and/or less than 45° and/or less than 30° and/or to about 0° and/or to about 10° and/or to about 25°.
• the present invention has unexpectedly addressed one or more of the multiple (and sometimes contradictory) requirements identified above that must occur in the forming box (coform box) in order to meet consumer desires; namely,
• the coform box should be designed such that the length of Lc is appropriate to the ratio of mass flow rates and length of dimension Lp, such that a flow separation does not occur in the lower box while also not overly constricting the flow exiting the box, which would cause needlessly high static pressures in the system and effect other components in aerodynamic communication with the coform box.
• coform boxes to date have not been intentionally designed to maximize the heat transfer (either into or out of a jet), while at the same time minimizing the amount of mass used in that heat transfer and maximizing the stability of the jet undergoing the transfer.
• the coform box of the present invention addresses this dichotomy by increasing heat transfer and jet instability at a constant mass flow rate and velocity of stream A as ⁇ and/or ⁇ 2 goes to 90°, increasing heat transfer and jet instability at a constant mass flow rate and angle as the velocity of stream A increases (by decreasing dimension Lp).
• improved heat removal from the coform box of the present invention can be achieved by the introduction of liquid water into the coform box, utilizing the sensible and latent heat of a liquid to remove heat extremely rapidly from the jet.
• the addition of the liquid to the coform box could impart additional functionality to the substrate either through the addition of a dissolved solid which could precipitate upon liquid evaporation, or through the addition of a functional liquid.
• a forming box comprising one or more filament inlets, for example polymer filament inlets, and one or more solid additive inlets, wherein at least one of the filament inlets is in fluid communication with a filament source for example a polymer filament source, such as a die, and at least one of the solid additive inlets is in fluid communication with an additive source, for example a solid additive source, such that during operation of the forming box one or more filaments enter the forming box through the at least one filament inlet and one or more solid additives enter the forming box through the at least one solid additive inlet such that the one or more filaments and the one or more solid additives contact each other at a non-90° angle, for example at an angle of less than 90°, is provided.
• a filament source for example a polymer filament source, such as a die
• an additive source for example a solid additive source
• a forming box comprising one or more filament inlets and one or more additive inlets such that at least one of the one or more filament inlets is at an angle of less than 90° to at least one of the additive inlets, is provided.
• a forming box comprising one or more filament inlets and one or more solid additive inlets wherein at least one of the one or more filament inlets and at least one of the one or more solid additive inlets are positioned in the forming box at a non-90° angle, for example at an angle of less than 90°, relative one another, is provided.
• a forming box comprising one or more filament inlets and one or more solid additive inlets wherein at least one of the one or more filament inlets and at least one of the one or more solid additive inlets are positioned in the forming box such that filaments entering the forming box through at least one of the filament inlets and solid additives entering the forming box through at least one of the solid additive inlets contact each other inside the forming box at a non-90° angle, for example at an angle of less than 90°, relative to one another, is provided.
• a forming box comprising one or more filament inlets and one or more solid additive inlets such that filaments entering the forming box through at least one of the filament inlets and solid additives entering the forming box through at least one of the solid additive inlets contact each other at a non-90° angle, for example at an angle of less than 90°, relative to one another, is provided.
• a forming box comprising one or more filament inlets and two or more solid additive inlets such that filaments entering the forming box through at least one of the filament inlets and solid additives entering the forming box through at least two of the solid additive inlets contact each inside the forming box, is provided.
• a forming box comprising two or more filament inlets and two or more solid additive inlets such that filaments entering the forming box through at least one of the filament inlets and solid additives entering the forming box through at least one of the solid additive inlets contact each other inside the forming box, is provided.
• a process for making a fibrous structure comprising the steps of:
• a process for making a fibrous structure comprising the steps of:
• angles associated with the forming box and/or inlets of the forming box for example that impact the angle at which a first material, for example filaments, is contacted by a second material, for example a solid additive, is controllable and/or adjustable, for example during operation.
• the present invention provides coforming processes and forming boxes useful therein.
• Fig. 1 is an example of a prior art coforming process that utilizes a forming box
• Fig. 2 is an example of a prior art coforming process that does not utilize a forming box
• Fig. 3 is an another example of a prior art coforming process that does not utilize a forming box
• Fig. 4A is a cross-sectional, schematic view of an example of a forming box in accordance with the present invention used in a coforming process of the present invention
• Fig. 4B is a cross-sectional, schematic view of another example of a forming box in accordance with the present invention.
• Fig. 5 is another example of a forming box in accordance with the present invention.
• Fig. 6A is an example of a fibrous structure making process in accordance with the present invention.
• Fig. 6B is another example of a fibrous structure making process in accordance with the present invention.
• Fig. 6C is another example of a fibrous structure making process in accordance with the present invention.
• Fig. 6D is another example of a fibrous structure making process in accordance with the present invention.
• Fig. 6E is another example of a fibrous structure making process in accordance with the present invention
• Fig. 7 is an example of a die useful in the coforming processes of the present invention
• Fig. 8 is a partial, expanded view of the die shown in Fig. 7;
• Fig. 9A is a diagram of a support rack utilized in the HFS Test Method described herein;
• Fig. 9B is a cross-sectional view of Fig. 9A;
• Fig. 1 OA is a diagram of a support rack cover utilized in the VFS Test Method described herein;
• Fig. 10B is a cross-sectional view of Fig. 10A.
• Fig. 11 is a schematic representation of an apparatus used in the Sled Surface Drying Test Method.
• Coforming and/or “coforming process” as used herein means a process by which two or more separate materials are commingled.
• coforming comprises a process by which one or more and/or two or more first materials, for example filaments, such as polymer filaments, are commingled with one or more and/or two or more second materials, for example solid additives, such as fibers, for example pulp fibers.
• first materials for example filaments, such as polymer filaments
• second materials for example solid additives, such as fibers, for example pulp fibers.
• two or more separate materials are commingled together to form a mixture of the two or more materials.
• filaments can be commingled with fibers to form a mixture of filaments and fibers that can be collected to form a fibrous structure according to the present invention.
• JAR as used herein means the mass ratio of air between one of the side streams of air and the center stream of air, or Mp/Mj as shown in the Fig. 4B.
• Measureum is a vector quantity, defined as mass times the velocity vector.
• Housing as used herein means an enclosed or partially-enclosed volume formed by one or more walls through which one or more materials pass.
• Forming box as used herein means a portion of a housing's volume within which commingling of two or more separate materials occurs.
• the forming box is a portion of the housing within which one or more and/or two or more first materials, for example filaments, such as polymer filaments, are commingled with one or more and/or two or more second materials, for example solid additives, such as fibers, for example pulp fibers.
• the forming box comprises two or more inlets for receiving two or more separate materials to be commingled.
• the forming box further comprises at least one outlet for evacuating the mixture of materials from the forming box.
• the forming box' s at least one outlet opens to a collection device, for example a fabric and/or belt, such as a patterned belt, for receiving the mixture of materials, for example filaments and fibers, resulting in a fibrous structure.
• a collection device for example a fabric and/or belt, such as a patterned belt
• the receipt by the collection device of the mixture of materials may be aided by a vacuum box.
• the forming box may be a stand alone, separate, discrete, modular device that can be inserted into a machine, such as a fibrous structure making machine, and/or it may be a fully integrated component of a larger machine, such as a fibrous structure making machine so long as at least one first material and at least one second material, are capable of entering the forming box and commingling with one another according to the present invention.
• First material as used herein means a material that is separate from at least one other material, for example a second material.
• the first material comprises filaments, such as polymer filaments.
• Solid material as used herein means a material that is separate from the first material.
• the second material comprises solid additives, such as fibers, for example pulp fibers.
• Stream(s) of solid additives as used herein means a plurality of solid additives, for example a plurality of fibers, that are moving generally in the same direction.
• a stream of solid additives is a plurality of solid additives that enter a forming box of the present invention through the same solid additive inlet at the same time or substantially the same time.
• Stream(s) of filaments as used herein means a plurality of filaments that are moving generally in the same direction.
• a stream of filaments is a plurality of filaments that enter a forming box of the present invention through the same filament inlet at the same time or substantially the same time.
• the stream of filaments may be a stream of meltblown filaments and/or a stream of spunbond filaments.
• Stream(s) of fibers as used herein means a plurality of fibers that are moving generally in the same direction.
• a stream of fibers is a plurality of fibers that enter a forming box of the present invention through the same fiber inlet at the same time or substantially the same time.
• the stream of fibers may be a stream of pulp fibers.
• Fiber inlet as used herein means an entrance to the forming box through which one or more filaments enter.
• Solid additive inlet as used herein means an entrance to the forming box through which one or more solid additives enter.
• a “fiber inlet” is an example of a solid additive inlet wherein the fiber inlet means an entrance to the forming box through which one or more fibers enter.
• Fibrous structure as used herein means a structure that comprises one or more filaments and/or one or more fibers, which are considered solid additives for the present invention.
• a fibrous structure according to the present invention means an orderly arrangement of filaments and solid additives within a structure in order to perform a function.
• Non-limiting examples of fibrous structures of the present invention include paper, fabrics (including woven, knitted, and non-woven), and absorbent pads (for example for diapers or feminine hygiene products).
• the fibrous structure is wound on a roll, for example in a plurality of perforated sheets, and/or cut into discrete sheets.
• the fibrous structures of the present invention may be homogeneous or may be layered.
• the fibrous structures may comprise at least two and/or at least three and/or at least four and/or at least five layers.
• the fibrous structures of the present invention are co-formed fibrous structures.
• Co-formed fibrous structure as used herein means that the fibrous structure comprises a mixture of at least two different materials wherein at least one of the materials comprises a filament, such as a polypropylene filament, and at least one other material, different from the first material, comprises a solid additive, such as a fiber and/or a particulate.
• a co- formed fibrous structure comprises solid additives, such as fibers, such as wood pulp fibers, and filaments, such as polypropylene filaments.
• Solid additive as used herein means a fiber and/or a particulate.
• Porate as used herein means a granular substance, powder and/or particle, such as an absorbent gel material particle.
• Fiber and/or “Filament” as used herein means an elongate particulate having an apparent length greatly exceeding its apparent width, i.e. a length to diameter ratio of at least about 10.
• a "fiber” is an elongate particulate as described above that exhibits a length of less than 5.08 cm (2 in.) and a “filament” is an elongate particulate as described above that exhibits a length of greater than or equal to 5.08 cm (2 in.).
• Fibers are typically considered discontinuous in nature.
• fibers include wood pulp fibers and synthetic staple fibers such as polyester fibers.
• Filaments are typically considered continuous or substantially continuous in nature.
• Filaments are relatively longer than fibers.
• Non-limiting examples of filaments include meltblown and/or spunbond filaments.
• Non-limiting examples of materials that can be spun into filaments include natural polymers, such as starch, starch derivatives, cellulose and cellulose derivatives, hemicellulose, hemicellulose derivatives, and synthetic polymers including, but not limited to polyvinyl alcohol filaments and/or polyvinyl alcohol derivative filaments, and thermoplastic polymer filaments, such as polyesters, nylons, polyolefins such as polypropylene filaments, polyethylene filaments, and biodegradable or compostable thermoplastic fibers such as polylactic acid filaments, polyhydroxyalkanoate filaments and polycaprolactone filaments.
• the filaments may be monocomponent or multicomponent, such as bicomponent filaments.
• the polymer filaments of the present invention comprise a thermoplastic polymer, for example a thermoplastic polymer selected from the group consisting of: polyeolefins, such as polypropylene and/or polyethylene, polyesters, polyvinyl alcohol, nylons, polylactic acid, polyhydroxyalkanoate, polycaprolactone, and mixtures thereof.
• the thermoplastic polymer comprises a polyolefin, for example polypropylene and/or polyethylene.
• the thermoplastic polymer comprises polypropylene.
• fiber refers to papermaking fibers.
• Papermaking fibers useful in the present invention include cellulosic fibers commonly known as wood pulp fibers.
• Applicable wood pulps include chemical pulps, such as Kraft, sulfite, and sulfate pulps, as well as mechanical pulps including, for example, groundwood, thermomechanical pulp and chemically modified thermomechanical pulp.
• Chemical pulps may be preferred since they impart a superior tactile sense of softness to tissue sheets made therefrom. Pulps derived from both deciduous trees (hereinafter, also referred to as "hardwood”) and coniferous trees (hereinafter, also referred to as "softwood”) may be utilized.
• the hardwood and softwood fibers can be blended, or alternatively, can be deposited in layers to provide a stratified web.
• U.S. Pat. No. 4,300,981 and U.S. Pat. No. 3,994,771 are incorporated herein by reference for the purpose of disclosing layering of hardwood and softwood fibers.
• fibers derived from recycled paper which may contain any or all of the above categories as well as other non-fibrous materials such as fillers and adhesives used to facilitate the original papermaking.
• cellulosic fibers such as cotton linters, rayon, lyocell and bagasse can be used in this invention.
• Other sources of cellulose in the form of fibers or capable of being spun into fibers include grasses and grain sources.
• “Sanitary tissue product” as used herein means a soft, low density (i.e. ⁇ about 0.15 g/cm3) web useful as a wiping implement for post-urinary and post-bowel movement cleaning (toilet tissue), for otorhinolaryngological discharges (facial tissue), and multi-functional absorbent and cleaning uses (absorbent towels).
• the sanitary tissue product may be convolutedly wound upon itself about a core or without a core to form a sanitary tissue product roll.
• the sanitary tissue product of the present invention comprises a fibrous structure according to the present invention.
• the sanitary tissue products of the present invention may exhibit a basis weight between about 10 g/m 2 to about 120 g/m 2 and/or from about 15 g/m 2 to about 110 g/m 2 and/or from about 20 g/m 2 to about 100 g/m 2 and/or from about 30 to 90 g/m 2 .
• the sanitary tissue product of the present invention may exhibit a basis weight between about 40 g/m 2 to about 120 g/m 2 and/or from about 50 g/m 2 to about 110 g/m 2 and/or from about 55 g/m 2 to about 105 g/m 2 and/or from about 60 to 100 g/m 2 .
• the sanitary tissue products of the present invention may exhibit a total dry tensile strength of greater than about 59 g/cm (150 g/in) and/or from about 78 g/cm (200 g/in) to about 394 g/cm (1000 g/in) and/or from about 98 g/cm (250 g/in) to about 335 g/cm (850 g/in).
• the sanitary tissue product of the present invention may exhibit a total dry tensile strength of greater than about 196 g/cm (500 g/in) and/or from about 196 g/cm (500 g/in) to about 394 g/cm (1000 g/in) and/or from about 216 g/cm (550 g/in) to about 335 g/cm (850 g/in) and/or from about 236 g/cm (600 g/in) to about 315 g/cm (800 g/in).
• the sanitary tissue product exhibits a total dry tensile strength of less than about 394 g/cm (1000 g/in) and/or less than about 335 g/cm (850 g/in).
• the sanitary tissue products of the present invention may exhibit a total dry tensile strength of greater than about 196 g/cm (500 g/in) and/or greater than about 236 g/cm (600 g/in) and/or greater than about 276 g/cm (700 g/in) and/or greater than about 315 g/cm (800 g/in) and/or greater than about 354 g/cm (900 g/in) and/or greater than about 394 g/cm (1000 g/in) and/or from about 315 g/cm (800 g/in) to about 1968 g/cm (5000 g/in) and/or from about 354 g/cm (900 g/in) to about 1181 g/cm (3000 g/in) and/or from about 354 g/cm (900 g/in) to about 984 g/cm (2500 g/in) and/or from about 394 g
• the sanitary tissue products of the present invention may exhibit an initial total wet tensile strength of less than about 78 g/cm (200 g/in) and/or less than about 59 g/cm (150 g/in) and/or less than about 39 g/cm (100 g/in) and/or less than about 29 g/cm (75 g/in).
• the sanitary tissue products of the present invention may exhibit an initial total wet tensile strength of greater than about 118 g/cm (300 g/in) and/or greater than about 157 g/cm (400 g/in) and/or greater than about 196 g/cm (500 g/in) and/or greater than about 236 g/cm (600 g/in) and/or greater than about 276 g/cm (700 g/in) and/or greater than about 315 g/cm (800 g/in) and/or greater than about 354 g/cm (900 g/in) and/or greater than about 394 g/cm (1000 g/in) and/or from about 118 g/cm (300 g/in) to about 1968 g/cm (5000 g/in) and/or from about 157 g/cm (400 g/in) to about 1181 g/cm (3000 g/in) and/or from about
• the sanitary tissue products of the present invention may exhibit a density (measured at 95 g/in 2 ) of less than about 0.60 g/cm 3 and/or less than about 0.30 g/cm 3 and/or less than about 0.20 g/cm 3 and/or less than about 0.10 g/cm 3 and/or less than about 0.07 g/cm 3 and/or less than about 0.05 g/cm 3 and/or from about 0.01 g/cm 3 to about 0.20 g/cm 3 and/or from about 0.02 g/cm 3 to about 0.10 g/cm 3 .
• the sanitary tissue products of the present invention may exhibit a total absorptive capacity of according to the Horizontal Full Sheet (HFS) Test Method described herein of greater than about 10 g/g and/or greater than about 12 g/g and/or greater than about 15 g/g and/or from about 15 g/g to about 50 g/g and/or to about 40 g/g and/or to about 30 g/g.
• HFS Horizontal Full Sheet
• the sanitary tissue products of the present invention may exhibit a Vertical Full Sheet (VFS) value as determined by the Vertical Full Sheet (VFS) Test Method described herein of greater than about 5 g/g and/or greater than about 7 g/g and/or greater than about 9 g/g and/or from about 9 g/g to about 30 g/g and/or to about 25 g/g and/or to about 20 g/g and/or to about 17 g/g.
• VFS Vertical Full Sheet
• the sanitary tissue products of the present invention may be in the form of sanitary tissue product rolls.
• Such sanitary tissue product rolls may comprise a plurality of connected, but perforated sheets of fibrous structure, that are separably dispensable from adjacent sheets.
• one or more ends of the roll of sanitary tissue product may comprise an adhesive and/or dry strength agent to mitigate the loss of fibers, especially wood pulp fibers from the ends of the roll of sanitary tissue product.
• the sanitary tissue products of the present invention may comprises additives such as softening agents, temporary wet strength agents, permanent wet strength agents, bulk softening agents, lotions, silicones, wetting agents, latexes, especially surface-pattern- applied latexes, dry strength agents such as carboxymethylcellulose and starch, and other types of additives suitable for inclusion in and/or on sanitary tissue products.
• additives such as softening agents, temporary wet strength agents, permanent wet strength agents, bulk softening agents, lotions, silicones, wetting agents, latexes, especially surface-pattern- applied latexes, dry strength agents such as carboxymethylcellulose and starch, and other types of additives suitable for inclusion in and/or on sanitary tissue products.
• Basis Weight as used herein is the weight per unit area of a sample reported in lbs/3000 ft 2 or g/m 2 .
• Machine Direction or “MD” as used herein means the direction parallel to the flow of the fibrous structure through the fibrous structure making machine and/or sanitary tissue product manufacturing equipment.
• Cross Machine Direction or “CD” as used herein means the direction parallel to the width of the fibrous structure making machine and/or sanitary tissue product manufacturing equipment and perpendicular to the machine direction.
• Ply as used herein means an individual, integral fibrous structure.
• Plies as used herein means two or more individual, integral fibrous structures disposed in a substantially contiguous, face-to-face relationship with one another, forming a multi-ply fibrous structure and/or multi-ply sanitary tissue product. It is also contemplated that an individual, integral fibrous structure can effectively form a multi-ply fibrous structure, for example, by being folded on itself.
• Total Pore Volume as used herein means the sum of the fluid holding void volume in each pore range from ⁇ to ⁇ radii as measured according to the Pore Volume Test Method described herein.
• Pore Volume Distribution as used herein means the distribution of fluid holding void volume as a function of pore radius. The Pore Volume Distribution of a fibrous structure is measured according to the Pore Volume Test Method described herein.
• additives as used herein means the additives solid additives, liquid additives, gas additives, plasma additives, and mixtures thereof. Even though the examples exemplified herein are directed to solid additives, other additives may be utilized with the forming boxes of the present invention.
• the additive is a solid additive, such as pulp, for example wood pulp fibers.
• the additive may comprise a liquid additive, for example a liquid additive comprising a dissolved solid additive that precipitates in the forming box during operation.
• Figs. 4A and 4B show examples of forming boxes 30 of the present invention.
• the forming boxes 30 are defined by a housing 32.
• the housing 32 may be made from any suitable material such as metal, polycarbonate, or glass.
• the housing 32 encloses and/or defines the forming boxes' volume 34 where at least a first material, for example one or more filaments 36, for example polymer filaments such as polyolefin filaments (e.g., polypropylene filaments), which enters the forming box 30 through one or more first material inlets, for example filament inlets 38, and at least a second material, for example one or more solid additives 40, such as fibers, for example pulp fibers (e.g., wood pulp fibers), which enters the forming box 30 through one or more second material inlets, for example solid additive inlets 42, commingle.
• a first material for example one or more filaments 36, for example polymer filaments such as polyolefin filaments (e.g.,
• the first material, for example filaments 36 commingle with the second material, for example fibers 40, inside the forming box's volume 34 defined by the housing 32 as a result of the second material, for example fibers 40, contacting the first material, for example filaments 34, at an angle ⁇ and/or ⁇ 2, at least one of which is not 90° (a non-90° angle), for example at an angle of less than 90° and/or less than 85° and/or less than 75° and/or less than 45° and/or less than 30° and/or to about 0° and/or to about 10° and/or to about 25°.
• At least one of the first material inlets is positioned within the housing 32 at a non-90° angle, for example at an angle of less than 90° and/or less than 85° and/or less than 75° and/or less than 45° and/or less than 30° and/or to about 0° and/or to about 10° and/or to about 25° with respect to at least one of the second material inlets, for example solid additive inlets 42.
• This non-90° angle can be achieved by various ways, for example by fixed designs of the first material inlets and/or second material inlets and/or by controllable and/or adjustable designs of the first material inlets and/or second material inlets.
• one or more first material inlets may be in fluid communication with a first material source, such as a filament source for example a polymer filament source comprising a spinnerette, such as a die 44, that supplies filaments 24 to at least one of the filament inlets 38.
• a first material source such as a filament source for example a polymer filament source comprising a spinnerette, such as a die 44, that supplies filaments 24 to at least one of the filament inlets 38.
• one or more second material inlets for example solid additive inlets
• an additive source for example a solid additive source, such as a fiber source 46, such as a fiber spreader and/or a hammermill and/or a forming head and/or eductor, that supplies fibers 40 to at least one of the solid additive inlets 42.
• a forming box for example coform box, according to the present invention may exhibit the following dimensions and/or ratios of the dimensions.
• dimension Lj may be greater than 0.03 and/or greater than 0.05 and/or greater than 0.075 and/or greater than 0.1 and/or greater than 0.125 and/or less than 10 and/or less than 7 and/or less than 5 and/or less than 3 inches.
• dimension Lj is from about 0.125 to about 3 inches.
• dimension Lp may be greater than 0.1 and/or greater than 0.25 and/or greater than 0.5 and/or greater than 0.75 and/or greater than 1 and/or less than 15 and/or less than 12 and/or less than 10 and/or less than 8 and/or less than 6 inches.
• dimension Lp is from about 1 to about 6 inches.
• dimension Lc may be greater than 0.5 and/or greater than 0.75 and/or greater than 1 and/or greater than 1.25 and/or greater than 1.5 and/or greater than 2 and/or less than 30 and/or less than 25 and/or less than 20 and/or less than 15 and/or less than 12 inches.
• dimension Lc is from about 2 to about 12 inches.
• dimension Ls may be greater than 0.1 and/or greater than 0.25 and/or greater than 0.5 and/or greater than 0.75 and/or greater than 1 and/or less than 30 and/or less than 25 and/or less than 20 and/or less than 15 and/or less than 12 inches.
• dimension Ls is from about 1 to about 12 inches.
• the forming box of the present invention exhibits dimension ratios of Lc:Ls of less than 12:1 and/or less than 12:7 and/or less than 7:7 and/or less than 3:7.
• the forming box of the present invention exhibits dimension ratios of Lc:Lp of less than 12:1 and/or less than 11:4 and/or less than 7:4 and/or less than 3 :4.
• a coforming process that utilizes a forming box of the present invention exhibits a JAR during operation of at least 0.5 and/or at least 1 and/or at least 1.5 and/or at least 2 and/or at least 2.5 and/or at least 3.0 and/or at least 3.5 and/or at least 4.0 and/or less than 15 and/or less than 12 and/or less than 10 and/or less than 8.
• a fibrous structure made from a coforming process of the present invention for example that uses a forming box in accordance with the present invention, for example as shown in Figs. 4A or 4B, exhibits a MD Basis Weight Coefficient of Variation (COV) of less than 11% and/or less than 10% and/or less than 8% and/or less than 6% and/or about 0% and/or greater than 0.5% as measured according to the MD Basis Weight Test Method described herein.
• COV MD Basis Weight Coefficient of Variation
• a fibrous structure made from a coforming process of the present invention for example that uses a forming box in accordance with the present invention, for example as shown in Figs. 4 A or 4B, wherein the coforming process exhibits a JAR during operation of at least 0.5 and/or at least 1 and/or at least 1.5 and/or at least 2 and/or at least 2.5 and/or at least 3.0 and/or at least 3.5 and/or at least 4.0 and/or less than 15 and/or less than 12 and/or less than 10 and/or less than 8 exhibits a MD Basis Weight Coefficient of Variation (COV) of less than 11% and/or less than 10% and/or less than 8% and/or less than 6% and/or about 0% and/or greater than 0.5% as measured according to the MD Basis Weight Test Method described herein.
• COV MD Basis Weight Coefficient of Variation
• MD Basis Weight COV data for fibrous structures (Inventive A-D) of the present invention made according to the present invention and/or using the coforming processes of the present invention and the forming boxes of the present invention are shown in Table 1 below along with examples of known fibrous structures (1-4) that were made without using the processes and/or forming boxes of the present invention.
• a forming box comprises one or more filament inlets and one or more solid additive inlets, wherein at least one of the filament inlets is in fluid communication with a filament source and at least one of the solid additive inlets is in fluid communication with an additive source, for example a solid additive source, such that during operation of the forming box one or more filaments enter the forming box through the at least one filament inlet and one or more solid additives enter the forming box through the at least one solid additive inlet such that the one or more filaments and the one or more solid additives contact each other at a non-90° angle, for example at an angle of less than 90°.
• an additive source for example a solid additive source
• a forming box comprises one or more filament inlets and one or more solid additive inlets wherein at least one of the one or more filament inlets and at least one of the one or more solid additive inlets are positioned in the housing at a non-90° angle, for example at an angle of less than 90° and/or less than 85° and/or less than 75° and/or less than 45° and/or less than 30° and/or to about 0° and/or to about 10° and/or to about 25° relative to one another.
• This non-90° angle can be achieved by various ways, for example by fixed orientation of the filament inlets and/or solid additive inlets within the housing and/or by controllable and/or adjustable orientations of the filament inlets and/or solid additive inlets within the housing.
• a forming box comprises one or more filament inlets and one or more solid additive inlets wherein at least one of the one or more filament inlets and at least one of the one or more solid additive inlets are positioned in the housing such that filaments entering the forming box through at least one of the filament inlets and solid additives entering the forming box through at least one of the solid additive inlets contact each other inside the forming box at a non-90° angle, for example at an angle of less than 90°, relative to one another.
• a forming box comprises one or more filament inlets and one or more solid additive inlets such that filaments entering the forming box through at least one of the filament inlets and solid additives entering the forming box through at least one of the solid additive inlets contact each other at a non-90° angle, for example at an angle of less than 90°, relative to one another.
• a forming box comprises one or more filament inlets and two or more solid additive inlets such that filaments entering the forming box through at least one of the filament inlets and solid additives entering the forming box through at least two of the solid additive inlets contact each inside the forming box.
• a forming box comprises two or more filament inlets and two or more solid additive inlets such that filaments entering the forming box through at least one of the filament inlets and solid additives entering the forming box through at least one of the solid additive inlets contact each other inside the forming box.
• the housing is designed to inhibit and/or prevent and/or mitigate buildup and/or deposition of materials, such as filaments and/or solid additive on the walls of the housing.
• the housing is subjected to heat prior to, during, and/or after the coforming process.
• the forming box may comprise, in addition to the first material inlets and the second material inlets, a plurality of other material inlets, such as an inlet for steam and/or moisture.
• a plurality of other material inlets such as an inlet for steam and/or moisture.
• the orientation of these other material inlets may be the same or different as described above with respect to the first and second material inlets, for example regarding angles relating to the positioning of the other material inlets within the housing defining the volume of the forming box.
• the forming box (coform box) of the present invention is geometrically symmetric with respect to the forming box's cross machine-direction axis.
• the forming box (coform box) of the present invention exhibits symmetric momentum with respect to the forming box's cross machine-direction axis.
• the forming box (coform box) of the present invention exhibits symmetric horizontal momentum with respect to the forming box's cross machine-direction axis.
• the inlets are independently controllable during operation, for example independently controllable with respect to concentration, type of additive, composition, aspect ratio of additive, and mixtures thereof.
• the filament inlets for example at least two of the polymer filament inlets are independently controllable during operation, for example independently controllable with respect to concentration, type of polymer, composition, and mixtures thereof.
• a coforming process comprises the steps of:
• a. providing a forming box 30 defined by a housing 32, wherein the forming box 30 comprises one or more first discrete material inlets, for example one or more filament inlets 38 and one or more second material inlets, for example one or more solid additive inlets 42; and b.
• FIGs. 4A and 4B Another example of a coforming process according to the present invention is also shown in Figs. 4A and 4B.
• This coforming process comprises the steps of:
• a. providing a forming box 30 defined by a housing 32, wherein the forming box 30 comprises one or more first discrete material inlets, for example one or more filament inlets 38 and one or more second material inlets, for example one or more solid additive inlets 42, wherein at least one of the one or more filament inlets 38 is positioned in the housing 32 at a non-90° angle, for example at an angle of less than 90° and/or less than 85° and/or less than 75° and/or less than 45° and/or less than 30° and/or to about 0° and/or to about 10° and/or to about 25°, relative to at least one of the one or more solid additive inlets; and
• This coforming process example may or may not include the use of a forming box 30.
• the coforming process does include the use of a forming box 30 wherein the single stream of filaments 24 and the two or more streams of solid additives 40, such as a fibers, commingle by the two or more streams of solid additives 40 contacting the single stream of filaments 24 inside the volume 34 defined by the housing 32 at a non-90° angle, for example at an angle of less than 90° and/or less than 85° and/or less than 75° and/or less than 45° and/or less than 30° and/or to about 0° and/or to about 10° and/or to about 25°, relative to one another.
• a forming box 30 wherein the single stream of filaments 24 and the two or more streams of solid additives 40, such as a fibers, commingle by the two or more streams of solid additives 40 contacting the single stream of filaments 24 inside the volume 34 defined by the housing 32 at a non-90° angle, for example at an angle of less than 90° and/or less than 85° and/or less than 75
• This coforming process example may or may not include the use of a forming box 30.
• the coforming process does include the use of a forming box 30 wherein the two or more streams of filaments 24 and the two or more streams of solid additives 40, such as a fibers, commingle by the two or more streams of solid additives 40 contacting the two or more streams of filaments 24 inside the volume 34 defined by the housing 32 at a non-90° angle (angled ⁇ 3, ⁇ 4, 85 , and ⁇ 6 ) for example at an angle of less than 90° and/or less than 85° and/or less than 75° and/or less than 45° and/or less than 30° and/or to about 0° and/or to about 10° and/or to about 25°, relative to one another.
• a non-90° angle angled ⁇ 3, ⁇ 4, 85 , and ⁇ 6
• a non- limiting example of a process for making a fibrous structure according to the present invention comprises the steps of:
• a filament source 44 comprising a die 48 (as shown in Figs. 7 and 8), for example a multi-row capillary die, comprising one or more filament-forming holes 50, wherein one or more fluid-releasing holes 52 are associated with one filament-forming hole 50 such that a fluid, such as air, exiting the fluid-releasing hole 52 is parallel or substantially parallel (less than 45° and/or less than 30° and/or less than 20° and/or less than 15° and/or less than 10° and/or less than 5° and/or less than 3° and/or about 0° to an exterior surface of a filament exiting the filament-forming hole 50;
• a plurality of filaments 24 comprising the first polymer from the die 48; d. combining the filaments 24 with solid additives 40 delivered from a solid additive source 46, such as a hammermill and/or solid additive spreader and/or airlaying equipment such as a forming head, for example a forming head from Dan- Web Machinery A/S, and/or an eductor, inside a forming box 30 defined by a housing 32 that defines a forming box's volume 34 such that the filaments 24 and solid additives 40 contact each other at a non-90° angle, for example at an angle of less than 90° and/or less than 85° and/or less than 75° and/or less than 45° and/or less than 30° and/or to about 0° and/or to about 10° and/or to about 25°, relative to each other to form a mixture; and
• a solid additive source 46 such as a hammermill and/or solid additive spreader and/or airlaying equipment
• a forming head for example
• a collection device 56 such as a fabric and/or belt, for example a patterned belt that imparts a pattern, for example a non-random, repeating pattern to a fibrous structure, with or without the aid of a vacuum box 58, to produce a fibrous structure 60.
• the forming box 30 may comprise one or more first material inlets, for example one or more filament inlets 38 through which one or more filaments 24, for example meltblown filaments, are introduced into the forming box 30, and one or more second material inlets, for example one or more solid additive inlets 42 through which one or more solid additives 40, such as fibers, are introduced into the forming box 30 such that one or more filaments 24 contact the one or more solid additives 40, for example fibers, inside the volume 34 of the forming box 30.
• first material inlets for example one or more filament inlets 38 through which one or more filaments 24, for example meltblown filaments, are introduced into the forming box 30, and one or more second material inlets, for example one or more solid additive inlets 42 through which one or more solid additives 40, such as fibers, are introduced into the forming box 30 such that one or more filaments 24 contact the one or more solid additives 40, for example fibers, inside the volume 34 of the forming box 30.
• a fibrous structure making process comprises the steps of:
• a filament source 44 for example a die, such as a spunbond die or a meltblow die 48 as shown in Figs. 7 and 8, which illustrates an example of a multi-row capillary die comprising one or more filament-forming holes 50, wherein one or more fluid-releasing holes 52 are associated with one filament-forming hole 50 such that a fluid, such as air, exiting the fluid-releasing hole 52 is parallel or substantially parallel (less than 45° and/or less than 30° and/or less than 20° and/or less than 15° and/or less than 10° and/or less than 5° and/or less than 3° and/or about 0° to an exterior surface of a filament exiting the filament- forming hole 50;
• a solid additive source such as a hammermill and/or solid additive spreader and/or airlaying equipment such as a forming head, for example a forming head from Dan-Web Machinery A/S, and/or an eductor, inside a forming box 30 defined by a housing 32 that defines a forming box's volume 34 such that the filaments 24 and solid additives 40 contact each other at a 90° angle and/or at a non-90° angle, for example at an angle of less than 90° and/or less than 85° and/or less than 75° and/or less than 45° and/or less than 30° and/or to about 0° and/or to about 10° and/or to about 25°, relative to each other to form a mixture; and
• a solid additive source not shown
• a hammermill and/or solid additive spreader and/or airlaying equipment such as a forming head, for example a forming head from Dan-Web Machinery A/S, and/or an eductor
• a collection device 56 such as a fabric and/or belt, for example a patterned belt that imparts a pattern, for example a non-random, repeating pattern to a fibrous structure, with or without the aid of a vacuum box 58, to produce a fibrous structure 60.
• the fibrous structure making process as shown in Figs. 6A to 6E may further comprise one or more air sources 62, such as cooling air, quenching air, and/or drying air.
• one or more air sources 62 such as cooling air, quenching air, and/or drying air.
• the components of the fibrous structure making process for example the one or more filament sources 44, the one or more air sources 62, the forming box 30 along with its inlets 38 and 42 may all be connected to one another by housing 32.
• the fibrous structure making process may further comprise a venturi attenuation zone 64.
• the venturi attenuation zone 64 comprises one or more high velocity air sources 66 that delivers high velocity air to the filaments 24 prior to the forming box 30 (as shown in Fig. 6B) and/or to the mixture 54 of filaments 24 and solid additives 40 after the forming box 30 (as shown in Figs. 6A, 6C, 6D, and 6E).
• the filament source 44 receives molten polymer, for example a polyolefin, such as polypropylene, under pressure. This molten polymer is then spun via pressure from the filament source 44 (for example a die) to form filaments 24.
• the filaments 24 are subjected to cooling air, from one or more air sources 62, which serves to lower the molten polymer to below its freezing temperature.
• the filaments 24 continue traveling toward the collection device 56 and are aided in attenuation by the venturi attenuation zone 64. Subsequent to the venturi attenuation zone 64, one or more solid additives 40 - laden flow is then introduced into the filaments 24 in the forming box 30.
• the filaments 24 are aided in attenuation by the venturi attenuation zone 64.
• the mixture 54 is then collected on the collection device 56, with or without the aid of the vacuum box 58, to form the fibrous structure 60.
• the fibrous structure 60 may then be subjected to further post processing operations such as thermal bonding, embossing, tuft-generating operations, slitting, cutting, perforating, and other converting operations.
• the filament source 44 receives molten polymer, for example a polyolefin, such as polypropylene, under pressure.
• This molten polymer is then spun via pressure from the filament source 44 (for example a die) to form filaments 24.
• the filaments 24 are subjected to cooling air, from one or more air sources 62, which serves to lower the molten polymer to below its freezing temperature.
• the filaments 24 continue traveling toward the collection device 56.
• One or more solid additives 40 - laden flow is then introduced into the filaments 24 in the forming box 30.
• the filaments 24 are aided in attenuation by the venturi attenuation zone 64.
• the mixture 54 is then collected on the collection device 56, with or without the aid of the vacuum box 58, to form the fibrous structure 60.
• the fibrous structure 60 may then be subjected to further post processing operations such as thermal bonding, embossing, tuft-generating operations, slitting, cutting, perforating, and other converting operations.
• the forming box 30 (coform box), as shown in Fig. 6E, comprises one or more filament inlets 38, one or more cooling air inlets 63 through which cooling air enters the housing 32 from one or more air sources 62, one or more solid additive inlets 42, and one or more venturi attenuation zones 64, which aid in attenuation filaments 24 passing through the forming box 30 and/or the housing 32 defining the forming box 30.
• the forming box 30 may comprise one or more first material inlets, for example one or more filament inlets 38 through which one or more filaments 24, for example spunbond filaments, are introduced into the forming box 30, and one or more second material inlets, for example one or more solid additive inlets 42 through which one or more solid additives 40, such as fibers, are introduced into the forming box 30 such that one or more filaments 24 contact the one or more solid additives 40, for example fibers, inside the volume 34 of the forming box 30.
• first material inlets for example one or more filament inlets 38 through which one or more filaments 24, for example spunbond filaments, are introduced into the forming box 30, and one or more second material inlets, for example one or more solid additive inlets 42 through which one or more solid additives 40, such as fibers, are introduced into the forming box 30 such that one or more filaments 24 contact the one or more solid additives 40, for example fibers, inside the volume 34 of the forming box 30.
• a fibrous structure making process of the present invention comprises the step of commingling a plurality of solid additives 40 with a plurality of filaments 24.
• the solid additives 40 are wood pulp fibers, such as SSK fibers and/or Eucalytpus fibers, and the filaments 24 are polypropylene filaments.
• the solid additives 40 may be combined with the filaments 24, such as by being delivered to a stream of filaments 24 from a solid additive source 46 such as a hammermill via a solid additive spreader and/or forming head and/or eductor to form a mixture 54 of filaments 24 and solid additives 40.
• an apparatus for separating the solid additives 40 as described in US Patent Application Publication No. 20110303373 may be used to facilitate delivery of the solid additives 40.
• the solid additives 40 may be delivered to the stream of filaments 24 from two or more sides of the stream of filaments 24.
• the filaments 24 may be created by meltblowing from a meltblow die, for example a die 48 of Figs. 7 and 8.
• the mixture 54 of solid additives 40 and filaments 24 are collected on a collection device 56, such as a belt to form a fibrous structure 60.
• the collection device 54 may be a patterned and/or molded belt that results in the fibrous structure 60 exhibiting a surface pattern, such as a non-random, repeating pattern of microregions.
• the molded belt may have a three-dimensional pattern on it that gets imparted to the fibrous structure 60 during the process.
• the patterned belt may comprise a reinforcing structure, such as a fabric upon which a polymer resin is applied in a pattern.
• the pattern may comprise a continuous or semi-continuous network of the polymer resin within which one or more discrete conduits are arranged.
• the fibrous structure 60 is made using a die 48 (Figs. 7 and 8) comprising at least one and/or 2 or more and/or 3 or more rows of filament- forming holes 50 from which filaments 24 are spun. At least one row contains 2 or more and/or 3 or more and/or 10 or more filament-forming holes 50.
• the die 48 comprises fluid-releasing holes 52, such as gas-releasing holes, in one example air-releasing holes, that provide attenuation to the filaments 24 formed from the filament-forming holes 50.
• One or more fluid-releasing holes 52 may be associated with a filament-forming hole 50 such that the fluid exiting the fluid-releasing hole 52 is parallel or substantially parallel (rather than angled like a knife-edge die) to an exterior surface of a filament 24 exiting the filament-forming hole 50.
• the fluid exiting the fluid-releasing hole 52 contacts the exterior surface of a filament 24 formed from a filament-forming hole 50 at an angle of less than 30° and/or less than 20° and/or less than 10° and/or less than 5° and/or about 0°.
• One or more fluid releasing holes 52 may be arranged around a filament-forming hole 50.
• one or more fluid-releasing holes 52 are associated with a single filament-forming hole 50 such that the fluid exiting the one or more fluid releasing holes 52 contacts the exterior surface of a single filament 24 formed from the single filament-forming hole 50.
• the fluid-releasing hole 52 permits a fluid, such as a gas, for example air, to contact the exterior surface of a filament 24 formed from a filament-forming hole 50 rather than contacting an inner surface of a filament 24, such as what happens when a hollow filament is formed.
• the die 48 comprises a filament-forming hole 50 positioned within a fluid-releasing hole 52.
• the fluid-releasing hole 52 may be concentrically or substantially concentrically positioned around a filament-forming hole 50 such as is shown in Figs. 7 and 8.
• the fibrous structure 60 may be subjected to post-processing operations such as embossing, thermal bonding, tuft-generating operations, moisture-imparting operations, slitting, folding, lotioning, surface treating, and combining with other fibrous structure plies operations (not shown) to form a finished fibrous structure or sanitary tissue product.
• post-processing operations such as embossing, thermal bonding, tuft-generating operations, moisture-imparting operations, slitting, folding, lotioning, surface treating, and combining with other fibrous structure plies operations (not shown) to form a finished fibrous structure or sanitary tissue product.
• a surface treating operation that the fibrous structure may be subjected to is the surface application of an elastomeric binder, such as ethylene vinyl acetate (EVA), latexes, and other elastomeric binders.
• EVA ethylene vinyl acetate
• latexes latexes
• other elastomeric binders such as ethylene vinyl
• the fibrous structure 60 may be calendered, for example, while the fibrous structure 60 is still on the collection device 56.
• the fibrous structure 60 may be densified, for example with a non- random repeating pattern.
• the fibrous structure 60 may be carried on a porous belt and/or fabric, through a nip, for example a nip formed by a heated steel roll and a rubber roll such that the fibrous structure 60 is deflected into one or more of the pores of the porous belt resulting in localized regions of densification.
• suitable porous belts and/or fabrics are commercially available from Albany International under the trade names VeloStat, ElectroTech, and MicroStat.
• the nip applies a pressure of at least 5 pounds per lineal inch (pli) and/or at least 10 pli and/or at least 20 pli and/or at least 50 pli and/or at least 80 pli.
• the process for making fibrous structure 60 may be close coupled (where the fibrous structure is convolutedly wound into a roll prior to proceeding to a converting operation) or directly coupled (where the fibrous structure is not convolutedly wound into a roll prior to proceeding to a converting operation) with a converting operation to emboss, print, deform, surface treat, or other post- forming operation known to those in the art.
• direct coupling means that the fibrous structure 60 can proceed directly into a converting operation rather than, for example, being convolutedly wound into a roll and then unwound to proceed through a converting operation.
• the process of the present invention may include preparing individual rolls of fibrous structure and/or sanitary tissue product comprising such fibrous structure(s) that are suitable for consumer use.
• the fibrous structure may be contacted by a bonding agent (such as an adhesive and/or dry strength agent), such that the ends of a roll of sanitary tissue product according to the present invention comprise such adhesive and/or dry strength agent.
• the process may further comprise contacting an end edge of a roll of fibrous structure with a material that is chemically different from the filaments and fibers, to create bond regions that bond the fibers present at the end edge and reduce lint production during use.
• the material may be applied by any suitable process known in the art.
• suitable processes for applying the material include non-contact applications, such as spraying, and contact applications, such as gravure roll printing, extruding, surface transferring.
• the application of the material may occur by transfer from contact of a log saw and/or perforating blade containing the material since, for example, the perforating operation, an edge of the fibrous structure that may produce lint upon dispensing a fibrous structure sheet from an adjacent fibrous structure sheet may be created.
• the process of the present invention may include preparing individual rolls of fibrous structure and/or sanitary tissue product comprising such fibrous structure(s) that are suitable for consumer use.
• the melt blend is heated to 475°F through a melt extruder.
• nozzles per cross-direction inch of the 192 nozzles have a 0.018" inside diameter while the remaining nozzles are unused for PP delivery
• Approximately 0.19 grams per hole per minute (ghm) of the melt blend is extruded from the open nozzles to form meltblown filaments from the melt blend.
• Approximately 420 SCFM of compressed air is heated such that the air exhibits a temperature of 395°F at the spinnerette.
• Approximately 500 grams / minute of Koch 4825 semi-treated SSK pulp is defibrillated through a hammermill to form SSK wood pulp fibers (solid additive).
• Approximately 1600 SCFM of air at 80°F and 80% relative humidity (RH) is drawn into the hammermill and carries the pulp fibers to a solid additive spreader.
• the solid additive spreader turns the pulp fibers and distributes the pulp fibers in the cross-direction such that the pulp fibers are injected into the meltblown filaments at a non-90° angle (a non-perpendicular fashion) for example at an angle of less than 90° as described herein through a 4" x 15" cross-direction (CD) slot.
• a forming box surrounds the area where the meltblown filaments and pulp fibers are commingled.
• This forming box is designed to reduce the amount of air allowed to enter or escape from this commingling area
• a forming vacuum pulls air through a forming fabric thus collecting the commingled meltblown filaments and pulp fibers to form a fibrous structure.
• the forming vacuum is adjusted until an additional 400 SCFM of room air is drawn into the slot in the forming box.
• the fibrous structure formed by this process comprises about 75% by dry fibrous structure weight of pulp and about 25% by dry fibrous structure weight of meltblown filaments.
• meltblown layer of the meltblown filaments can be added to one or both sides of the above formed fibrous structure.
• This addition of the meltblown layer can help reduce the lint created from the fibrous structure during use by consumers and is preferably performed prior to any thermal bonding operation of the fibrous structure.
• the meltblown filaments for the exterior layers can be the same or different than the meltblown filaments used on the opposite layer or in the center layer(s).
• the fibrous structure may be convolutedly wound to form a roll of fibrous structure.
• the end edges of the roll of fibrous structure may be contacted with a material to create bond regions.
• a 20%:27.5%47.5%:5% blend of Lyondell-Basell PH835 polypropylene : Lyondell- Basell Metocene MF650W polypropylene : Exxon-Mobil PP3546 polypropylene : Polyvel S- 1416 wetting agent is dry blended, to form a melt blend.
• the melt blend is heated to 400°F through a melt extruder.
• the solid additive spreaders turn the pulp fibers and distribute the pulp fibers in the cross-direction such that the pulp fibers are injected into the meltblown filaments at a non-90° angle (a non-perpendicular fashion) for example at an angle of less than 90° as described herein through a 4 inch x 15 inch cross- direction (CD) slot.
• the two solid additive spreaders are on opposite sides of the meltblown filaments facing one another.
• a forming box surrounds the area where the meltblown filaments and pulp fibers are commingled. This forming box is designed to reduce the amount of air allowed to enter or escape from this commingling area.
• the fibrous structure formed by this process comprises about 75% by dry fibrous structure weight of pulp and about 25% by dry fibrous structure weight of meltblown filaments.
• a meltblown layer of the meltblown filaments can be added to one or both sides of the above formed fibrous structure.
• This addition of the meltblown layer can help reduce the lint created from the fibrous structure during use by consumers and is preferably performed prior to any thermal bonding operation of the fibrous structure.
• the meltblown filaments for the exterior layers can be the same or different than the meltblown filaments used on the opposite layer or in the center layer(s).
• the fibrous structure, while on a patterned belt e.g. Velostat 170PC 740 by Albany International
• Velostat 170PC 740 by Albany International
• the steel roll having an internal temperature of 300 F as supplied by an oil heater.
• the fibrous structure can be adhered to a metal roll, or creping drum, using sprayed, printed, slot extruded (or other known methodology) creping adhesive solution.
• the fibrous structure is then creped from the creping drum and foreshortened.
• the fibrous structure may be subjected to mechanical treatments such as ring rolling, gear rolling, embossing, rush transfer, tuft-generating operations, and other similar fibrous structure deformation operations.
• two or more plies of the fibrous structure can be embossed and/or laminated and/or thermally bonded together to form a multi-ply fibrous structure.
• the fibrous structure may be convolutedly wound to form a roll of fibrous structure.
• the end edges of the roll of fibrous structure may be contacted with a material to create bond regions.
• the fibrous structures of the present invention exhibit a pore volume distribution unlike pore volume distributions of other known fibrous structures, for example other known structured and/or textured fibrous structures.
• references to fibrous structures of the present invention are also applicable to sanitary issue products comprising one or more fibrous structures of the present invention.
• the fibrous structures of the present invention have surprisingly been found to exhibit improved absorbent capacity and surface drying.
• the fibrous structures comprise a plurality of filaments and a plurality of solid additives, for example fibers.
• the fibrous structures of the present invention comprise a plurality of filaments and optionally, a plurality of solid additives, such as fibers.
• the fibrous structures of the present invention may comprise any suitable amount of filaments and any suitable amount of solid additives.
• the fibrous structures may comprise from about 10% to about 70% and/or from about 20% to about 60% and/or from about 30% to about 50% by dry weight of the fibrous structure of filaments and from about 90% to about 30% and/or from about 80% to about 40% and/or from about 70% to about 50% by dry weight of the fibrous structure of solid additives, such as wood pulp fibers.
• the filaments and solid additives of the present invention may be present in fibrous structures according to the present invention at weight ratios of filaments to solid additives of from at least about 1:1 and/or at least about 1:1.5 and/or at least about 1:2 and/or at least about 1:2.5 and/or at least about 1:3 and/or at least about 1:4 and/or at least about 1:5 and/or at least about 1 :7 and/or at least about 1: 10.
• the solid additives for example wood pulp fibers, may be selected from the group consisting of softwood kraft pulp fibers, hardwood pulp fibers, and mixtures thereof.
• hardwood pulp fibers include fibers derived from a fiber source selected from the group consisting of: Acacia, Eucalyptus, Maple, Oak, Aspen, Birch, Cottonwood, Alder, Ash, Cherry, Elm, Hickory, Poplar, Gum, Walnut, Locust, Sycamore, Beech, Catalpa, Sassafras, Gmelina, Albizia, Anthocephalus, and Magnolia.
• Non-limiting examples of softwood pulp fibers include fibers derived from a fiber source selected from the group consisting of: Pine, Spruce, Fir, Tamarack, Hemlock, Cypress, and Cedar.
• the hardwood pulp fibers comprise tropical hardwood pulp fibers.
• suitable tropical hardwood pulp fibers include Eucalyptus pulp fibers, Acacia pulp fibers, and mixtures thereof.
• the hardwood pulp fibers exhibit a Kajaani fiber cell wall thickness of less than 5.98 ⁇ and/or less than 5.96 ⁇ and/or less than 5.94 ⁇ .
• the hardwood pulp fibers exhibit a Kajaani fiber width of less than 14.15 ⁇ and/or less than 14.10 ⁇ and/or less than 14.05 ⁇ and/or less than 14.00 ⁇ and/or less than 13.95 ⁇ and/or less than 13.90 ⁇ .
• the hardwood pulp fibers exhibit a Kajaani millions of fibers/gram of greater than 24 millions of fibers/gram and/or greater than 20.5 millions of fibers/gram and/or greater than 21 millions of fibers/gram and/or greater than 21.5 millions of fibers/gram and/or greater than 22 millions of fibers/gram and/or greater than 22.5 millions of fibers/gram and/or greater than 23 millions of fibers/gram and/or greater than 23.5 millions of fibers/gram and/or greater than 24 millions of fibers/gram and/or greater than 24.5 millions of fibers/gram and/or greater than 25 millions of fibers/gram.
• the hardwood pulp fibers exhibit a Kajaani fiber cell wall thickness of less than 6.15 ⁇ and/or less than 6.10 ⁇ and/or less than 6.05 ⁇ and/or less than 6.00 ⁇ and/or less than 5.98 ⁇ and/or less than 5.96 ⁇ and/or less than 5.94 ⁇ .
• the hardwood pulp fibers exhibit a ratio of Kajaani fiber length ( ⁇ ) to Kajaani fiber width ( ⁇ ) of less than 45 and/or less than 43 and/or less than 41.
• the hardwood pulp fibers exhibit a ratio of Kajaani fiber coarseness of less than 0.074 mg/m and/or less than 0.0735 mg/m
• the wood pulp fibers comprise softwood pulp fibers derived from the kraft process and originating from southern climates, such as Southern Softwood Kraft (SSK) pulp fibers.
• the wood pulp fibers comprise softwood pulp fibers derived from the kraft process and originating from northern climates, such as Northern Softwood Kraft (NSK) pulp fibers.
• the wood pulp fibers present in the fibrous structure may be present at a weight ratio of softwood pulp fibers to hardwood pulp fibers of from 100:0 and/or from 90: 10 and/or from 86: 14 and/or from 80:20 and/or from 75:25 and/or from 70:30 and/or from 60:40 and/or about 50:50 and/or to 0: 100 and/or to 10:90 and/or to 14:86 and/or to 20:80 and/or to 25:75 and/or to 30:70 and/or to 40:60.
• the weight ratio of softwood pulp fibers to hardwood pulp fibers is from 86: 14 to 70:30.
• the fibrous structures of the present invention comprise one or more trichomes.
• suitable sources for obtaining trichomes, especially trichome fibers are plants in the Labiatae (Lamiaceae) family commonly referred to as the mint family.
• suitable species in the Labiatae family include Stachys byzantina, also known as Stachys lanata commonly referred to as lamb's ear, woolly betony, or woundwort.
• Stachys byzantina as used herein also includes cultivars Stachys byzantina 'Primrose Heron' , Stachys byzantina 'Helene von Stein' (sometimes referred to as Stachys byzantina 'Big Ears'), Stachys byzantina 'Cotton Boll' , Stachys byzantina 'Variegated' (sometimes referred to as Stachys byzantina 'Striped Phantom'), and Stachys byzantina 'Silver Carpet' .
• the fibrous structures of the present invention exhibit a pore volume distribution such that greater than 8% and/or at least 10% and/or at least 14% and/or at least 18% and/or at least 20% and/or at least 22% and/or at least 25% and/or at least 29% and/or at least 34% and/or at least 40% and/or at least 50% of the total pore volume present in the fibrous structures exists in pores of radii of from 2.5 ⁇ to 50 ⁇ as measured by the Pore Volume Distribution Test Method described herein.
• the fibrous structures of the present invention exhibit a sled surface drying time of less than 50 seconds and/or less than 45 seconds and/or less than 40 seconds and/or less than 35 seconds and/or 30 seconds and/or 25 seconds and/or 20 seconds as measured by the Sled Surface Drying Test Method described herein.
• the fibrous structures of the present invention exhibit a pore volume distribution such that at least 2% and/or at least 9% and/or at least 10% and/or at least 12% and/or at least 17% and/or at least 18% and/or at least 28% and/or at least 32% and/or at least 43% of the total pore volume present in the fibrous structure exists in pores of radii of from 91 ⁇ to 140 ⁇ as measured by the Pore Volume Distribution Test Method described herein.
• the fibrous structures of the present invention exhibit a pore volume distribution such that at least 2% and/or at least 9% and/or at least 10% and/or at least 12% and/or at least 17% and/or at least 18% and/or at least 20% and/or at least 28% and/or at least 32% and/or at least 43% of the total pore volume present in the fibrous structure exists in pores of radii of from 91 ⁇ to 120 ⁇ and/or exhibit a pore volume distribution such that less than 50% and/or less than 45% and/or less than 40% and/or less than 38% and/or less than 35% and/or less than 30% of the total pore volume present in the fibrous structure exists in pores of radii of from ⁇ to 200 ⁇ as measured by the Pore Volume Distribution Test Method described herein.
• the fibrous structures of the present invention exhibit a pore volume distribution such that at least 20% and/or at least 28% and/or at least 32% and/or at least 43% of the total pore volume present in the fibrous structure exists in pores of radii of from 91 ⁇ to 120 ⁇ and exhibit a pore volume distribution such that less than 40% and/or less than 38% and/or less than 35% and/or less than 30% of the total pore volume present in the fibrous structure exists in pores of radii of from 10 ⁇ to 200 ⁇ as measured by the Pore Volume Distribution Test Method described herein.
• the fibrous structures of the present invention exhibit a pore volume distribution such that at least 2% and/or at least 9% and/or at least 10% and/or at least 12% and/or at least 17% and/or at least 18% and/or at least 20% and/or at least 28% and/or at least 32% and/or at least 43% of the total pore volume present in the fibrous structure exists in pores of radii of from 91 ⁇ to 140 ⁇ and/or exhibit a pore volume distribution such that less than 50% and/or less than 45% and/or less than 40% and/or less than 38% and/or less than 35% and/or less than 30% of the total pore volume present in the fibrous structure exists in pores of radii of from ⁇ to 200 ⁇ and/or exhibit a pore volume distribution such that less than 50% and/or less than 45% and/or less than 40% and/or less than 38% and/or less than 35% and/or less than 30% of the total pore volume present in the fibrous structure exists in pores of radii of from
• the fibrous structures of the present invention exhibit a pore volume distribution such that at least 43% of the total pore volume present in the fibrous structure exists in pores of radii of from 91 ⁇ to 140 ⁇ and exhibit a pore volume distribution less than 40% and/or less than 38% and/or less than 35% and/or less than 30% of the total pore volume present in the fibrous structure exists in pores of radii of from 101 ⁇ to 200 ⁇ and exhibit a pore volume distribution less than 40% and/or less than 38% and/or less than 35% and/or less than 30% of the total pore volume present in the fibrous structure exists in pores of radii of from 12 ⁇ to 200 ⁇ as measured by the Pore Volume Distribution Test Method described herein.
• the fibrous structures of the present invention exhibit a pore volume distribution such that at least 2% and/or at least 9% and/or at least 10% and/or at least 12% and/or at least 17% and/or at least 18% and/or at least 20% and/or at least 28% and/or at least 32% and/or at least 43% of the total pore volume present in the fibrous structure exists in pores of radii of from 91 ⁇ to 140 ⁇ and/or exhibit a pore volume distribution such that less than 50% and/or less than 45% and/or less than 40% and/or less than 38% and/or less than 35% and/or less than 30% of the total pore volume present in the fibrous structure exists in pores of radii of from ⁇ to 200 ⁇ as measured by the Pore Volume Distribution Test Method described herein.
• the fibrous structures of the present invention exhibit a pore volume distribution such that at least 43% of the total pore volume present in the fibrous structure exists in pores of radii of from 91 ⁇ to 140 ⁇ and exhibit a pore volume distribution less than 40% and/or less than 38% and/or less than 35% and/or less than 30% of the total pore volume present in the fibrous structure exists in pores of radii of from 10 ⁇ to 200 ⁇ as measured by the Pore Volume Distribution Test Method described herein.
• the fibrous structure of the present invention exhibits at least a bi-modal pore volume distribution (i.e., the pore volume distribution exhibits at least two modes).
• a fibrous structure according to the present invention exhibiting a bi-modal pore volume distribution provides beneficial absorbent capacity and absorbent rate as a result of the larger radii pores and beneficial surface drying as a result of the smaller radii pores.
• the fibrous structures of the present invention exhibit a VFS of greater than 5 g/g and/or greater than 6 g/g and/or greater than 8 g/g and/or greater than 10 g/g and/or greater than 11 g/g as measured by the VFS Test Method described herein.
• the fibrous structures of the present invention exhibit a HFS of greater than 5 g/g and/or greater than 6 g/g and/or greater than 8 g/g and/or greater than 10 g/g and/or greater than 11 g/g as measured by the HFS Test Method described herein.
• the fibrous structure of the present invention alone or as a ply of fibrous structure in a multi-ply fibrous structure, comprises at least one surface (interior or exterior surface in the case of a ply within a multi-ply fibrous structure) that consists of a layer of filaments.
• the fibrous structure of the present invention alone or as a ply of fibrous structure in a multi-ply fibrous structure, comprises a scrim material.
• the fibrous structure of the present invention alone or as a ply of fibrous structure in a multi-ply fibrous structure, comprises a creped fibrous structure.
• the creped fibrous structure may comprise a fabric creped fibrous structure, a belt creped fibrous structure, and/or a cylinder creped, such as a cylindrical dryer creped fibrous structure.
• the fibrous structure may comprise undulations and/or a surface comprising undulations.
• the fibrous structure of the present invention alone or as a ply of fibrous structure in a multi-ply fibrous structure, comprises an uncreped fibrous structure.
• the fibrous structure of the present invention alone or as a ply of fibrous structure in a multi-ply fibrous structure, comprises a foreshortened fibrous structure.
• the fibrous structures of the present invention and/or any sanitary tissue products comprising such fibrous structures may be subjected to any post-processing operations such as embossing operations, printing operations, tuft-generating operations, thermal bonding operations, ultrasonic bonding operations, perforating operations, surface treatment operations such as application of lotions, silicones and/or other materials and mixtures thereof.
• Non-limiting examples of suitable polypropylenes for making the filaments of the present invention are commercially available from Lyondell-Basell and Exxon-Mobil.
• Any hydrophobic or non-hydrophilic materials within the fibrous structure, such as polypropylene filaments, may be surface treated and/or melt treated with a hydrophilic modifier.
• surface treating hydrophilic modifiers include surfactants, such as Triton X-100.
• melt treating hydrophilic modifiers that are added to the melt, such as the polypropylene melt, prior to spinning filaments include hydrophilic modifying melt additives such as VW351 and/or S-1416 commercially available from Polyvel, Inc. and Irgasurf commercially available from Ciba.
• the hydrophilic modifier may be associated with the hydrophobic or non-hydrophilic material at any suitable level known in the art.
• the hydrophilic modifier is associated with the hydrophobic or non-hydrophilic material at a level of less than about 20% and/or less than about 15% and/or less than about 10% and/or less than about 5% and/or less than about 3% to about 0% by dry weight of the hydrophobic or non- hydrophilic material.
• the fibrous structures of the present invention may include optional additives, each, when present, at individual levels of from about 0% and/or from about 0.01% and/or from about 0.1% and/or from about 1% and/or from about 2% to about 95% and/or to about 80% and/or to about 50% and/or to about 30% and/or to about 20% by dry weight of the fibrous structure.
• Non- limiting examples of optional additives include permanent wet strength agents, temporary wet strength agents, dry strength agents such as carboxymethylcellulose and/or starch, softening agents, lint reducing agents, opacity increasing agents, wetting agents, odor absorbing agents, perfumes, temperature indicating agents, color agents, dyes, osmotic materials, microbial growth detection agents, antibacterial agents and mixtures thereof.
• the fibrous structure of the present invention may itself be a sanitary tissue product. It may be convolutedly wound about a core to form a roll. It may be combined with one or more other fibrous structures as a ply to form a multi-ply sanitary tissue product. In one example, a co- formed fibrous structure of the present invention may be convolutedly wound about a core to form a roll of co-formed sanitary tissue product. The rolls of sanitary tissue products may also be coreless. TEST METHODS
• Pore Volume Distribution measurements are made on a TRI/Autoporosimeter
• the TRI/Autoporosimeter is an automated computer-controlled instrument for measuring pore volume distributions in porous materials (e.g., the volumes of different size pores within the range from 1 to 1000 ⁇ effective pore radii).
• Complimentary Automated Instrument Software, Release 2000.1, and Data Treatment Software, Release 2000.1 is used to capture, analyze and output the data. More information on the TRI/Autoporosimeter, its operation and data treatments can be found in The Journal of Colloid and Interface Science 162 (1994), pgs 163-170, incorporated here by reference.
• determining Pore Volume Distribution involves recording the increment of liquid that enters a porous material as the surrounding air pressure changes.
• a sample in the test chamber is exposed to precisely controlled changes in air pressure.
• the size (radius) of the largest pore able to hold liquid is a function of the air pressure.
• different size pore groups drain (absorb) liquid.
• the pore volume of each group is equal to this amount of liquid, as measured by the instrument at the corresponding pressure.
• the effective radius of a pore is related to the pressure differential by the following relationship.
• pores are thought of in terms such as voids, holes or conduits in a porous material. It is important to note that this method uses the above equation to calculate effective pore radii based on the constants and equipment controlled pressures. The above equation assumes uniform cylindrical pores. Usually, the pores in natural and manufactured porous materials are not perfectly cylindrical, nor all uniform. Therefore, the effective radii reported here may not equate exactly to measurements of void dimensions obtained by other methods such as microscopy. However, these measurements do provide an accepted means to characterize relative differences in void structure between materials.
• the equipment operates by changing the test chamber air pressure in user- specified increments, either by decreasing pressure (increasing pore size) to absorb liquid, or increasing pressure (decreasing pore size) to drain liquid.
• the liquid volume absorbed at each pressure increment is the cumulative volume for the group of all pores between the preceding pressure setting and the current setting.
• the liquid is a 0.2 weight % solution of octylphenoxy polyethoxy ethanol (Triton X-100 from Union Carbide Chemical and Plastics Co. of Danbury, CT.) in distilled water.
• a 1.2 ⁇ Millipore Glass Filter (Millipore Corporation of Bedford, MA; Catalog # GSWP09025) is employed on the test chamber' s porous plate.
• a plexiglass plate weighing about 24 g (supplied with the instrument) is placed on the sample to ensure the sample rests flat on the Millipore Filter. No additional weight is placed on the sample.
• pressures for this application is as follows (effective pore radius in ⁇ ): 1, 2.5, 5, 10, 15, 20, 30, 40, 50, 60, 70, 80, 90, 100, 120, 140, 160, 180, 200, 225, 250, 275, 300, 350, 400, 500, 600,
• a blank condition (no sample between plexiglass plate and Millipore Filter) is run to account for any surface and/or edge effects within the chamber. Any pore volume measured for this blank run is subtracted from the applicable pore grouping of the test sample. This data treatment can be accomplished manually or with the available
• Percent (% ) Total Pore Volume is a percentage calculated by taking the volume of fluid in the specific pore radii range divided by the Total Pore Volume.
• the TRI/Autoporosimeter outputs the volume of fluid within a range of pore radii.
• the first data obtained is for the "2.5 micron" pore radii which includes fluid absorbed between the pore sizes of 1 to 2.5 micron radius.
• the next data obtained is for "5 micron" pore radii, which includes fluid absorbed between the 2.5micron and 5 micron radii, and so on.
• % Total Pore Volume 91-140 micron pore radii (volume of fluid between 91-140 micron pore radii) / Total Pore Volume.
• Basis weight of a fibrous structure sample is measured by selecting twelve (12) individual fibrous structure samples and making two stacks of six individual samples each. If the individual samples are connected to one another vie perforation lines, the perforation lines must be aligned on the same side when stacking the individual samples.
• a precision cutter is used to cut each stack into exactly 3.5 in. x 3.5 in. squares. The two stacks of cut squares are combined to make a basis weight pad of twelve squares thick.
• the basis weight pad is then weighed on a top loading balance with a minimum resolution of 0.01 g.
• the top loading balance must be protected from air drafts and other disturbances using a draft shield. Weights are recorded when the readings on the top loading balance become constant.
• Basis Weight Weight of basis weight pad (g) x 10,000 cm 2 /m 2
• the level of filaments present in a fibrous structure having an initial basis weight can be determined by measuring the filament basis weight of a fibrous structure by using the Basis Weight Test Method after separating all non-filament materials from a fibrous structure. Different approaches may be used to achieve this separation. For example, non-filament material may be dissolved in an appropriate dissolution agent, such as sulfuric acid or Cadoxen, leaving the filaments intact with their mass essentially unchanged. The filaments are then weighed. The weight percentage of filaments present in the fibrous structure is then determined by the equation:
• % wt. Filaments 100 * (Filament Mass/Initial Basis Weight of Fibrous Structure) The % wt. Solid Additives present in the fibrous structure can then be determined by subtracting the % wt. Filaments from 100% to arrive at the % wt. Solid Additives.
• the machine direction (MD) Basis Weight of a fibrous structure sample is measured by using a precision cutter to cut thirty-five single ply 100mm x 50mm rectangle samples. Each sample should be weighed individually. Each 100mm x 50mm rectangle sample are to be oriented so that the 100mm axis is in the cross-direction (CD), from the same CD position, and be located in the MD as close as possible to each other, so that the intent of capturing the immediate MD basis weight variation at any CD location is achieved. The weight of the rectangle samples are then weighed on a top loading balance with a minimum resolution of 0.01 g. The top loading balance must be protected from air drafts and other disturbances using a draft shield. The weights of the rectangle samples are recorded when the readings on the top loading balance become constant.
• the Basis Weight (BW) of the fibrous structure is calculated as follows:
• BW Weight of basis weight sample (g) x 10,000 cm 2 /m 2
• MD Basis Weight Variation or "MD Basis Weight COV"
• MD Basis Weight Variation is defined as the standard deviation of basis weights divided by the average basis weights as measured according to the MD Basis Weight Test Method described above for thirty-five 50mm (MD) x 100mm (CD) fibrous structure samples as measured according to the MD Basis Weight Test Method described above.
• the Horizontal Full Sheet (HFS) test method determines the amount of distilled water absorbed and retained by a fibrous structure of the present invention. This method is performed by first weighing a sample of the fibrous structure to be tested (referred to herein as the "dry weight of the sample”), then thoroughly wetting the sample, draining the wetted sample in a horizontal position and then reweighing (referred to herein as "wet weight of the sample”). The absorptive capacity of the sample is then computed as the amount of water retained in units of grams of water absorbed by the sample. When evaluating different fibrous structure samples, the same size of fibrous structure is used for all samples tested.
• the apparatus for determining the HFS capacity of fibrous structures comprises the following:
• An electronic balance with a sensitivity of at least ⁇ 0.01 grams and a minimum capacity of 1200 grams.
• the balance should be positioned on a balance table and slab to minimize the vibration effects of floor/benchtop weighing.
• the balance should also have a special balance pan to be able to handle the size of the sample tested (i.e.; a fibrous structure sample of about 11 in. (27.9 cm) by 11 in. (27.9 cm)).
• the balance pan can be made out of a variety of materials. Plexiglass is a common material used.
• a sample support rack (Figs. 9A and 9B) and sample support rack cover (Figs. 10A and 10B) is also required.
• Both the rack and cover are comprised of a lightweight metal frame, strung with 0.012 in. (0.305 cm) diameter monofilament so as to form a grid as shown in Fig. 9A.
• the size of the support rack and cover is such that the sample size can be conveniently placed between the two.
• the HFS test is performed in an environment maintained at 23+ 1°C and 50+ 2% relative humidity.
• a water reservoir or tub is filled with distilled water at 23+ 1°C to a depth of 3 inches (7.6 cm).
• the balance is then zeroed (tared).
• One sample is carefully placed on the sample support rack.
• the support rack cover is placed on top of the support rack.
• the sample (now sandwiched between the rack and cover) is submerged in the water reservoir. After the sample is submerged for 60 seconds, the sample support rack and cover are gently raised out of the reservoir.
• the sample, support rack and cover are allowed to drain horizontally for 120+5 seconds, taking care not to excessively shake or vibrate the sample. While the sample is draining, the rack cover is carefully removed and all excess water is wiped from the support rack. The wet sample and the support rack are weighed on the previously tared balance. The weight is recorded to the nearest O.Olg. This is the wet weight of the sample.
• the gram per fibrous structure sample absorptive capacity of the sample is defined as
• absorbent capacity (wet weight of the sample - dry weight of the sample) / (dry weight of the sample) and has a unit of gram/gram.
• the Vertical Full Sheet (VFS) test method determines the amount of distilled water absorbed and retained by a fibrous structure of the present invention. This method is performed by first weighing a sample of the fibrous structure to be tested (referred to herein as the "dry weight of the sample”), then thoroughly wetting the sample, draining the wetted sample in a vertical position and then reweighing (referred to herein as "wet weight of the sample”). The absorptive capacity of the sample is then computed as the amount of water retained in units of grams of water absorbed by the sample. When evaluating different fibrous structure samples, the same size of fibrous structure is used for all samples tested.
• the apparatus for determining the VFS capacity of fibrous structures comprises the following: 1) An electronic balance with a sensitivity of at least ⁇ 0.01 grams and a minimum capacity of 1200 grams.
• the balance should be positioned on a balance table and slab to minimize the vibration effects of floor/benchtop weighing.
• the balance should also have a special balance pan to be able to handle the size of the sample tested (i.e.; a fibrous structure sample of about 11 in. by 11 in.).
• the balance pan can be made out of a variety of materials. Plexiglass is a common material used.
• a sample support rack (Figs. 9A and 9B) and sample support rack cover (Figs. 10A and 10B) is also required. Both the rack and cover are comprised of a lightweight metal frame, strung with 0.012 in. diameter monofilament so as to form a grid as shown in Fig. 9 A. The size of the support rack and cover is such that the sample size can be conveniently placed between the two.
• the VFS test is performed in an environment maintained at 23+ 1°C and 50+ 2% relative humidity.
• a water reservoir or tub is filled with distilled water at 23+ 1°C to a depth of 3 inches.
• the sample, support rack and cover are allowed to drain vertically (at angle greater than 60° but less than 90° from horizontal) for 60+5 seconds, taking care not to excessively shake or vibrate the sample. While the sample is draining, the rack cover is removed and excess water is wiped from the support rack. The wet sample and the support rack are weighed on the previously tared balance. The weight is recorded to the nearest O.Olg. This is the wet weight of the sample.
• the procedure is repeated for with another sample of the fibrous structure, however, the sample is positioned on the support rack such that the sample is rotated 90° in plane compared to the position of the first sample on the support rack.
• the gram per fibrous structure sample absorptive capacity of the sample is defined as
• VFS (wet weight of the sample - dry weight of the sample).
• the sled surface drying test is performed using constant rate of extension tensile tester with computer interface (a suitable instrument is the MTS Alliance using Testworks 4 Software, as available from MTS Systems Corp., Eden Prairie, MN) using a load cell for which the forces measured are within 10% to 90% of the limit of the cell.
• the instrument is fitted with a coefficient of friction fixture and sled as depicted in ASTM D 1894-01 figure lc. (a suitable fixture is the Coefficient of Friction Fixture and Sled available as #769-3000 from Thwing- Albert, West Berlin, NJ).
• the movable (upper) pneumatic jaw is fitted with rubber faced grips, suitable to securely clamp the sled's lead wire.
• the target surface is a black Formica ® brand laminate #909-58 which has a contact angle (water) of 66 + 5 degrees. All testing is performed in a conditioned room maintained at 23 °C + 2 C° and 50 % + 2 % relative humidity. The test area is substantially free from air drafts from doors, ventilation systems, or lab traffic. The target surface at the observation zone is illuminated at 7.5 lumens + 0.2 lumens.
• the lower fixture 502 consist of a stage 505, 40 in long by 6 in wide by 0.25 in thick, mounted via a shaft 507 designed to fit the lower mount of tensile tester.
• a locking collar 508 is used to stabilize the platform and maintain horizontal alignment.
• the stage is covered with the Formica target 506 which is 38 in long by 6 in wide by 0.128 in thick.
• a pulley 509 is attached to the stage 505 which directs the wire lead 504 from the sled 503 into the grip faces of the upper fixture 500. Time is measured using a lab timer capable of measuring to the nearest 0.1 sec. and certified traceable to NIST.
• the observer should monitor a 1 in wide observation zone 511, located between 28 to 29 inches from the distal edge of the target 506, while at an observation angle of approximately 45 degrees from the horizontal plane of the platform 505. The timer is stopped when all signs of the water have disappeared. Record the Sled Surface Drying Time to the nearest 0.1 sec.
• Testing is repeated for a total of 20 replicates for each sample. Clean the surface every five specimen or when a new sample is to be tested. The data set can be evaluated using the Grub's T test (Tcrit ⁇ 90%) for outliers, but no more than 3 replicates can be discarded. If more than 3 outliers exist, a second set of 20 replicates should be tested. Average the replicate samples and report the Sled Surface Drying Time to the nearest 0.1 sec.

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