KR100356001B1 - Paper structures having at least three regions including decorative indicia comprising low basis weight regions - Google Patents

Abstract

A paper web and method of making the paper web are disclosed. The paper web includes at least three regions disposed in a non random, repeating pattern. The three regions are distinguishable from each other by at least one property selected from the group consisting of basis weight, density, and fiber composition. The paper web has a relatively high basis weight background portion (100) and decorative indicia (200). The decorative indicia (200) comprises one or more relatively low basis weight regions (220).

Description

PAPER STRUCTURES HAVING AT LEAST THREE REGIONS INCLUDING DECORATIVE INDICIA COMPRISING LOW BASIS WEIGHT REGIONS

Cellulose fiber structures such as paper are known in the art. Often, it is necessary to have areas with different basis weights in the same cellulose fiber product. The two areas serve different purposes. Higher basis weight areas impart tensile strength to the fiber structure. Lower basis weight areas can be used to economically utilize raw materials, in particular fibers used in papermaking processes, and to impart absorbency to the fiber structure. In the case of deterioration, low basis weight areas may represent perforations or holes in the fiber structure. However, areas of low basis weight need not be drilled.

The properties of absorbency and strength, and furthermore the properties of ductility, are important when the fiber structure is used for its intended purpose. In particular, the fiber structures described herein can be used as cosmetic tissues, toilet tissues, paper towels, bibs and napkins, which are frequently used today. In order for these products to perform their intended tasks and to be widely accepted, the fiber structures must exhibit the above mentioned physical properties and maximize them. Wet and Dry Tensile strengths are one of the capabilities of a fiber structure to maintain its physical integrity during use. Absorbency is a property of the fiber structure that holds the fluid in contact. The absolute amount of fluid and the rate at which the fibrous structure absorbs this fluid should both be taken into account when evaluating one of the consumer products described above. Moreover, such paper products are used in disposable absorbent articles such as sanitary napkins and diapers.

Attempts have been made in the art to provide paper having two different basis weights or to rearrange the fibers otherwise. For example, US Pat. No. 795,719, filed July 25, 1905 to Motz; US Patent No. 3,025,585, issued March 20, 1962 to Griswold; US Patent No. 3,034,180, issued May 15, 1962 to Greiner et al .; US Patent No. 3,159,530, issued to Heller et al. On December 1, 1964; US Patent No. 3,549,742 to Benz, dated Dec. 22, 1970; US Patent No. 3,322,617, issued to Osborn on May 30, 1967.

Individually, it is desirable to provide a tissue product with both bulk and flexibility. Improved volume and flexibility can be provided through bilaterally compressed and uncompressed zones as shown in US Pat. No. 4,191,609 to Trokhan, issued March 4, 1980, which is incorporated herein by reference. Is incorporated herein by reference.

Several attempts to provide improved porous members for making such cellulose fiber structures are known and one of the most important is disclosed in US Pat. No. 4,514,345 to Johnson et al. On April 30, 1985. And the U.S. patent is incorporated herein by reference. U.S. Patent No. 4,514,345 discloses a hexagonal element attached to a skeleton in a batch liquid coating process.

Another method of making a consumer desired tissue product is to dry the paper structure to impart greater volume, tensile strength and burst strength to the tissue product. An example of a paper structure made in this manner is disclosed in US Pat. No. 4,637,859 to Trokhan, issued January 20, 1987, which is incorporated herein by reference. U. S. Patent No. 4,637, 859 shows discrete domed protrusions distributed over a continuous network, which is incorporated herein by reference. Continuous network provides strength, while relatively thick domes provide softness and absorbency.

One disadvantage of the papermaking method disclosed in US Pat. No. 4,637,859 is that drying such webs is relatively energy intensive and expensive, and typically requires the use of an air drying apparatus. In addition, the papermaking method disclosed in US Pat. No. 4,637,859 can be limited to the rate at which the web can be finally dried on a Yankee dryer drum. This limitation is considered, at least in part, due to the pattern imparted to the web before the web is transferred to the Yankee drum. In particular, individual domes disclosed in US Pat. No. 4,637,859 may not be dried efficiently on Yankee surfaces, such as the continuous network disclosed in US Pat. No. 4,637,859. Thus, for a given concentration level and basis weight, the speed at which the Yankee drum can be operated is limited.

Conventional tissue paper made by pressing a web in a press nip with one or more press felts can be made at a relatively high speed. Conventional pressurized paper, once dried, can be embossed to pattern the web and to increase the macro-caliper of the web. For example, the embossed pattern is usually formed in the tissue paper product after the tissue paper product is dried.

However, the embossing process typically imparts a particular aesthetic appearance to the paper structure while sacrificing other properties of the structure. In particular, embossing the dried paper web breaks the bond between the fibers in the cellulose structure. This rupture occurs because the adhesive portion is formed and set upon drying of the unformed fiber slurry. After drying the paper structure, the fibers moving at right angles to the plane of the paper structure by embossing break the fiber-to-fiber bond. Broken bonds reduce the tensile strength of the dried paper web. Embossing is also usually carried out after creping the paper web dried from the drying drum. Embossing after creping can break the creping pattern imparted to the web. For example, embossing can remove the creping pattern on a portion of the web by compressing or stretching the creping pattern. This result is undesirable because the creping pattern improves the ductility and flexibility of the dried web.

One problem with paper made in accordance with the teachings of the prior art is that excessive amounts of low basis weight areas can reduce the strength of the paper.

It is therefore an object of the present invention to overcome this problem, and in particular to overcome this problem with a single layer of paper. In particular, it is an object of the present invention to provide a paper web having a decorative display formed by areas of relatively low basis weight without compromising the strength, absorbency, and ductility characteristics of the paper web.

Another object of the present invention is to provide a multi-zone paper web and a method for producing the same, wherein the web has a predetermined pattern of relatively high density regions and relatively low density regions, but can be dried at relatively lower energy and cost.

Another object of the present invention is a method of producing a multi-zone paper having a relatively low basis weight decorative display which can be formed in a conventional paper machine (conventional or through air drying performance) without substantially modifying the paper machine. To provide.

Another object of the present invention is to have a decorative display comprising a low basis weight area for the web to provide an aesthetic advantage in combination with improved volume caliper, bulk density and absorbent performance, thereby providing a It is to provide a paper web and a method of making the same that provides both volume and ductility.

Summary of the Invention

The present invention provides a paper web having opposing surfaces and at least three regions. The three regions are arranged in a regularly repeating pattern and are distinguishable from each other by at least one property selected from the group consisting of basis weight, density and fiber composition. The paper web includes a decorative indicia, the decorative indicia comprising one or more regions having a basis weight lower than the basis weight of at least a portion of the surrounding background portion of the web.

The term "decorative indicia" as used herein refers to a recognizable shape or shapes that are imparted to a web, preferably imparted to the web during initial forming of the web. Such shapes include, but are not limited to, flower shapes, animal shapes, geometric shapes, and the like. Preferably, the decorative indicia occupies about 30% or less of the surface area of the web, thereby improving the distinction between the background and the decorative indicia of the web.

The background portion of the web is selectively densified to provide a continuous network of relatively high density and a relatively low density area dispersed throughout the network. Relatively high density continuous networks provide strength, while relatively low density areas provide volume and absorbency.

In addition to the areas of relatively low basis weight, the decorative display may include areas of relatively high basis weight. The relatively low basis weight area of the decorative indicia may surround one or more cells having a basis weight substantially equal to the basis weight of the background portion, or optionally different from the basis weight of the background portion. These relatively high basis weight cells may be surrounded by regions of relatively low basis weight. These relatively high basis weight cells can be selectively densified to provide a relatively high basis weight area and a relatively low basis weight area within the decorative display.

In one embodiment, the paper web includes about 5 to about 5000 decorative indicia per square meter of the web. The relatively high basis weight background of the web comprises a relatively dense continuous network area and at least about 10,000 relatively low density areas per square meter of the web, the relatively low density area being dispersed through the continuous network area. The background has a smoothness value of at most about 900 microns on at least one of the opposed surfaces of the web, providing a smooth and smooth surface upon contact.

The decorative indicia may comprise a relatively low basis weight region having a basis weight of about 25% to about 75% of the basis weight of the background portion surrounding the decorative indicia. The decorative indicia may comprise a relatively low basis weight region having a basis weight less than about 75% of the basis weight of the surrounding background. In one embodiment, the decorative indicia may comprise a relatively low basis weight region having a basis weight less than about 60% of the basis weight of the surrounding background portion.

The paper web of the present invention has the advantage that the decorative web provides the aesthetics desired by the consumer while the paper web retains the strength and absorbency of the multi-density paper. Moreover, the paper web of the present invention has a decorative display portion and a multi-density region, but has a relatively smooth surface. The smooth surface provides the softness desired by the consumer and helps to visually distinguish the decorative markings. In addition, the smooth surface surrounding the low basis weight decorative markings highlights the distinctiveness of the relatively low basis weight decorative markings, thereby improving the aesthetic appearance of the web.

The present invention also provides a method of making paper webs having three regions arranged in a regularly repeating pattern and distinguishable from each other due to at least one property selected from the group consisting of basis weight, density and fiber composition. . The method includes providing a plurality of cellulose fibers suspended in a liquid carrier; Providing a fiber retaining molding element having a liquid permeable zone; Attaching the cellulose fiber and the liquid carrier onto the molding element; Discharging said liquid carrier through said forming element in two simultaneous steps to form a web having a decorative indicia comprising at least one relatively high basis weight region and at least one relatively low basis weight region; Providing a web support device having a web patterned surface; Transferring the web from the forming element to a web patterned surface of the web support device; Selectively densifying at least a portion of the relatively high basis weight region to provide a regularly repeating pattern of relatively high density regions and relatively low density regions within the relatively high basis weight region.

FIELD OF THE INVENTION The present invention relates to a cellulose fiber structure having at least three regions distinguished by intensive properties, and more particularly to decorative indicia of relatively low basis weight. It relates to a paper having and a method of producing the paper.

Although this specification ends with the claims particularly pointed out and specifically clarified the subject matter of the present invention, the present invention is better understood from the following description taken in conjunction with the accompanying drawings, in which like elements use substantially the same reference numerals. Can be.

1A is a plan view showing three decorative markings as part of a paper web made in accordance with the present invention;

FIG. 1B is an enlarged plan view showing one decorative display unit shown in FIG. 1A and showing different crepe frequencies; FIG.

FIG. 2 is a schematic cross-sectional view taken along line 2-2 of FIG. 1B as a paper web of the type shown in FIG. 1B;

3 is a photograph showing one decorative marking as part of a paper web made in accordance with the present invention;

4 is a schematic view of a paper machine, which can be used to make the paper web of the present invention, in which the paper machine is shown shaped on a forming element and optionally densified in a web support device, FIG.

5 is a photograph showing a sheet side of a forming element that can be used to make a paper web of the present invention, the forming element being coupled to the woven filament and a liquid permeable structure formed of a woven filament to correspond to a decorative display. Comprising a patterned liquid impermeable photopolymer resin layer forming a flow inhibiting member,

6 is a part of a forming element of the type shown in FIG. 5, wherein the forming element has four flow inhibiting members;

FIG. 7 is a schematic cross-sectional view showing an unformed web supported on a forming element of the type shown in FIG. 6;

FIG. 8 is a photograph showing a sheet side surface of a web support device in the form of a printed fabric comprising a felt layer and a patterned photopolymer layer bonded to the felt layer to provide a continuous reticulated web printing surface;

9 is a plan view of a portion of the seat side of the web support device of the type shown in FIG. 8;

FIG. 10 is a schematic cross-sectional view showing a paper web conveyed to a web support device of the type shown in FIG. 9 to provide a paper web having a first surface corresponding to the device and a second surface that is substantially smooth;

11 is a schematic diagram showing a paper web transferred to a Yankee dryer;

12 is manufactured in accordance with another embodiment of the present invention, comprising a separate decorative display, a relatively high basis weight background comprising continuous reticulated areas, a separate relatively low density area dispersed throughout the reticulated tissue, A plan view of a paper web having separate relatively high density regions dispersed over each relatively low density region,

FIG. 13 is a cross sectional view of the paper web of FIG. 12 taken along line 13-13 of FIG. 12;

FIG. 14 is a plan view of an apparatus for use in making a paper web of the type shown in FIG. 12, comprising a web patterning layer bonded to a perforated element formed of woven filaments, FIG.

15 is a cross-sectional view of the device of FIG. 14;

FIG. 16 is a schematic representation of a paper machine for producing paper webs with the apparatus of FIGS. 14 and 15;

FIG. 17 is a schematic diagram illustrating the formation of a paper web having a second surface substantially smooth with a first surface conforming to the device shown in FIG. 15;

FIG. 18 shows the paper web on the device shown in FIG. 15 being transferred between the press roll and the Yankee drying drum to impart a pattern to the first surface of the paper web and attach the second surface of the paper web to the Yankee drum;

1A, 1B and 2 show a paper web 20 made according to one embodiment of the invention, and FIG. 3 is a photograph of a paper structure of the type shown in FIGS. 1A, 1B and 2. . Paper webs are wet and substantially free of dry relief.

1A, 1B and 2, the paper web 20 has opposed first and second surfaces 22, 24, respectively. The paper web 20 includes at least three regions arranged in a regularly repeating pattern. The three regions can be distinguished from each other by at least one property selected from the group consisting of basis weight, density and fiber composition.

2 is a cross-sectional view of a portion of a paper web of the type shown in FIGS. 1A and 1B. In Figure 2 the line density over the web thickness is used to schematically show the relative basis weights of different parts of the web. The portions of the web shown by the five lines throughout the web thickness represent regions of relatively high basis weight, and the portions depicted by the three lines represent regions of relatively low basis weight.

The paper web 20 has a relatively high basis weight background 100. In addition, the paper web has visually distinct discrete decorative displays 200 distributed over the background 100 in a regularly repeating pattern. The decorative indicia 200 can be imparted to the web by selectively dehydrating it from the web during shaping of the web, as described in more detail below. The decorative indicia includes one or more relatively low basis weight regions 220. The basis weight of region 220 is lower than the basis weight of peripheral background 100 of the paper web.

The relatively high basis weight background 100 is selectively densified to have at least one high density region and at least one low density region. In the embodiment shown in FIGS. 1A, 1B, and 2, the background portion 100 is a relatively dense continuous network region 110 and a number of separate dispersed over the continuous network region 110. It is selectively densified to have a relatively low density region 130. Region 130 is relatively thicker than region 110.

The relatively low basis weight region 220 may have a closed path shape that outlines a number of adjacent relatively high basis weight cells 240. The basis weight everywhere in each cell 240 is higher than the basis weight of the relatively low basis weight region 220 surrounding the particular cell 240. Each cell 240 has a boundary formed by the closed loop portion of the region 220 of relatively low basis weight.

In one preferred embodiment, each cell 240 has only one half of the boundary of any one adjacent cell 240. Preferably, at least some of the cells 240 are characterized by having a border, and characterized in that any straight line drawn through the cell 240 has a border so as to intersect the border of the cell at three or less locations. . Although not theoretically limited, the geometry of these cells allows the decorative indicia 200 to be visually distinct and aesthetically pleasing without significantly reducing the strength of the web 20.

The relatively high basis weight cell 240 is selectively densified to provide a relatively high density region and a relatively low density region. 1A and 1B, a relatively high basis weight cell 240 includes a relatively high density of continuous network 260 and separate relatively low density regions 280 distributed over the network 260.

In one embodiment, to improve the contrast between the background portion 100 and the decorative markings 200, the paper web 20 uses about 5 to about 5000 decorative markings 200 per square meter of the web, Most preferably, from about 25 to about 1000 decorative indicators 200 per square meter of the web. The relatively high basis weight background 100 of the web may include at least about 10,000 relatively low density regions 130 per square meter of the web, wherein the relatively thicker density regions are dispersed through the continuous reticular regions 110 to form the web. Improves its absorbency and volume.

Background 100 has a smoothness value of about 900 microns or less on at least one of the opposed surfaces of the web. In FIG. 2, the smoothness value of surface 24 is less than the smoothness value of surface 22. Preferably, the smoothness value of the surface 24 is about 900 microns or less. In particular, the paper web 20 may have a surface smoothness ratio of about 1.15 or greater, more preferably about 1.20 or greater, even more preferably about 1.25 or greater, even more preferably about 1.30 or greater, most preferably about 1.40 or greater, Here, the surface smoothness ratio is a value obtained by dividing the surface smoothness value of the surface 22 by the surface smoothness value of the surface 24.

In one embodiment, the surface 24 of the web 20 may have a surface smoothness of about 900 microns or less, more preferably about 850 microns or less. The opposed surface 22 may have a surface smoothness value of at least about 900 μ, more preferably at least about 1000 μ.

The method of measuring the value of the surface smoothness of a surface is demonstrated in the "surface smoothness" part below. The value of surface smoothness for a surface increases if the surface is more textured and less smooth. Thus, relatively low surface smoothness indicates a relatively smooth surface.

The basis weight of region 220 may be less than about 75% of the basis weight of peripheral background 100. The relatively low basis weight region 220 may have a basis weight between about 25% and about 75% of the basis weight of the background portion 100.

In one embodiment, the basis weight of region 220 may be less than about 60% of the basis weight of peripheral background 100. The basis weight of the background portion 100 may be about 10 g / m 2 to about 70 g / m 2. The basis weight of the relatively low basis weight region 220 may be from about 5 g / m 2 to about 35 g / m 2.

The basis weight of the relatively low basis weight region 220 is preferably about 20 g / m 2 or less, and more preferably about 15 g / m 2 or less. In one embodiment, the basis weight of the background portion 100 may be about 10 g / m 2 to about 30 g / m 2, and the basis weight of the relatively low basis weight area 220 may be about 5 g / m 2 to about 15 g / m 2. . The basis weight of the area 240 may be about the same as the basis weight of the background part 100.

The paper web of the present invention has the advantage that the decorative display provides the aesthetics desired by the consumer while the paper web maintains the strength and absorbency of the multi-density paper. Moreover, the paper web of the present invention has a decorative display and a multi-density region, but has a relatively smooth surface. The smooth surface provides the ductility desired by the consumer. In addition, the smooth surface surrounding the low basis weight decorative markings highlights the contrast of the relatively low basis weight decorative markings, thereby improving the aesthetic appearance of the web.

The continuous network region 110 and the separate region 130 can both be reduced by creping. In FIG. 1B, the crepe ridges of the continuous reticular regions 110 are indicated by reference numeral 115 and generally extend in the cross-machine direction. Similarly, separate relatively low density and relatively thicker regions 130 can also be reduced to have crepe edges 135.

The continuous network region 110 may be a relatively high density, macroscopic, single plane continuous network region of the type disclosed in US Pat. No. 4,637,859. The relatively low density and relatively thicker region 130 can be staggered on both sides as disclosed in US Pat. No. 4,637,859. However, region 130 is not domed like the type shown in US Pat. No. 4,637,859. Region 130 is a paper web having a relatively thin continuous network region and a separate relatively thick region in the plane of the continuous network region, filed in the name of Phan, dated Nov. 14, 1996. A Relatively Thinner Continuous Network Region Discrete Relatively Thicker Regions In the Plane of the Continuous Network Region), as disclosed in US patent application Ser. No. 08 / 748,871, disposed in the plane of the continuous reticular region 110 And the patent application is incorporated herein by reference.

Paper web 20 having a relatively smooth surface 24 may be useful for making multiple ply tissues with outwardly smooth surfaces. For example, two or more webs 20 can be combined to form multiple ply tissue, with two surfaces facing outward of the multiple ply tissue comprising a surface 24 of the web 20, the outer ply Surface 22 will face inward. Alternatively, two ply paper structures can be produced by combining the web 20 of the present invention with conventionally formed and dried paper webs. Web 20 may be coupled to a conventional paper web such that surface 24 faces outward.

The basis weight of the paper web 20 may be from about 10 g / m 2 to about 70 g / m 2. The paper web 20 has a macro-caliper of at least about 0.1 mm, more preferably at least about 0.2 mm, and a bulk density of about 0.12 g / cm 3 or less (basis weight divided into macro-calipers, If they do not match, they can be multiplied by an appropriate conversion factor. Methods for measuring basis weight, macro-caliper and bulk density of webs are described below.

Paper web 20 of the type shown in FIGS. 1A and 1B may have an absorption capacity of at least about 15 g per gram. The method for measuring the absorption capacity is described later. Thus, the paper web 20 exhibits the benefits of absorbing high volume paper web when combined with the advantages of a relatively smooth surface commonly associated with conventional felt press tissue paper.

3 is a photograph of the surface 22 of a paper web 20 made in accordance with the present invention, wherein the decorative display 200, the continuous network 110, and the separate relatively low density of the background 100 are separate. The area 130 is shown.

The paper structure 20 according to the present invention can be manufactured with the papermaking device shown in FIG. The method of making the paper structure 20 of the present invention provides a plurality of fibers suspended in a liquid carrier, such as an aqueous dispersant in the form of slurry papermaking, and retains the slurry of papermaking fibers from the headbox 1500. By attaching on the forming element 1600, the disclosure is initiated. The forming element 1600 is in the form of a continuous belt in FIG. 4. The slurry of papermaking fibers adheres to the forming element 1600, through which the water of the slurry is dehydrated to form an unformed web of papermaking fibers 543 supported by the forming element 1600. The slurry of papermaking fibers may comprise relatively long fibers having an average fiber length of 2.0 mm or larger, and relatively short fibers having an average fiber length of 2.0 mm or smaller. For example, relatively long fibers may comprise softwood fibers and relatively short fibers may comprise hardwood fibers. Hardwood and softwood are described in detail later.

5 is a photograph of a side facing a web of forming element 1600 suitable for making paper web 20 according to the present invention. 6 is a schematic view of a side facing a web of forming element 1600. FIG. 7 is a cross-sectional view of forming element 160 showing unformed web 543 attached on the side facing web of forming element 1600.

The forming element 1600 includes a liquid permeable woven base 1610 and a flow inhibiting member 1650 disposed on the woven base 1610. Woven base 1610 includes a machine direction filament 1612 and a transverse machine direction filament 1614. The flow inhibiting member 1650 has a shape corresponding to the decorative display portion formed on the web 20. Woven base 1610 provides a first dewatering zone corresponding to the portion not covered by flow inhibiting member 1650. The first dehydration zone has a first dehydration rate. The portion of the forming element 1600 in which the flow inhibiting member 1650 is disposed provides a second dewatering zone having a second dewatering rate lower than the first dewatering rate.

The liquid carrier (ie, water) is discharged through the shaping element 1600 in two simultaneous stages corresponding to the first and second dehydration zones. Thus, fibers in the aqueous slurry tend to flow out of the second dehydration zone and accumulate in the first dehydration zone, thereby aligning with the flow inhibiting member 1650 to form a relatively low basis weight region. Relatively short fibers tend to accumulate in the first zone. At least a portion of the relatively longer fibers may connect the width of the flow inhibiting member. As a result, the average fiber length of the papermaking fibers in the relatively low basis weight area of the decorative indicia is greater than the average fiber length of the papermaking fibers in the peripheral portion of the web.

Flow inhibiting member 1650 may be formed on the woven base by selectively curing the photopolymer resin on woven base 1610. This flow inhibiting member 1650 is generally liquid impermeable, such that the second dehydration zone has a second dehydration rate that is substantially zero. Suitable fiber bearing molding elements 1600 are described in US Pat. No. 5,503,715 to Trokhan et al. On April 2, 1996, and US Patent No. 5 to Trokhan et al. On July 9, 1996. It may be formed from a photopolymer resin as disclosed in US Pat. No. 5,534,326, which is incorporated herein by reference.

Flow inhibiting member 1650 may be formed from a combination of linear and / or curved segments 1660, which together form a closed cell 1670. Segment 1660 has a width W (FIG. 6) measured generally perpendicular to the segment length. If the web is formed into a single form of fiber, the width W is preferably about ½ or less, more preferably about ¼ or less of the average fiber length of the fiber. If the web is formed as a homogeneous mixture of different fiber types including hardwood fibers and softwood fibers, the width W of the segment 1660 is preferably about ½ or less of the average fiber length of the hardwood fibers forming the web. More preferably, it is about 1/4 or less. On the other hand, if the web comprises two or more layers, the width W should be about ½ or less, more preferably about ¼ or less of the average fiber length of the hardwood fibers in the layer adjacent to the forming element 1600.

For example, for molding stock made from 100% Eucalyptus fibers, the width W should be less than about 0.5 mm based on an average fiber length of about 1.0 mm. Optionally, when the molding stock is made of 100% Northern Softwood Kraft fibers with an average fiber length of about 3.0 mm, the width W should be less than about 1.5 mm.

The resulting decorative indicia may each comprise a relatively low basis weight region having a closed path shape completely surrounding at least one relatively high basis weight cell 240. The width (corresponding to the width W) of the region of relatively low basis weight as measured at any point along the closed path shape is between about 0.2 mm and about 2 mm.

The flow inhibiting member 1650 may have any suitable ornamental shape including, but not limited to, a flower shape, an animal shape, or geometric shapes such as circles, squares, triangles, and the like. Preferably, at least a portion of the segment 1660, preferably the majority of the segments 1660, form a containment angle A (FIG. 6) of at least about 15 ° with respect to the transverse machining direction (CD in FIG. 6). Segment 1660 of member 1650 is oriented on forming element 1600. This orientation provides the advantage that the relatively low basis weight region 220 is advantageously oriented relative to the transverse machining direction of the paper web. When paper is creped from the dryer drum, the doctor blade is substantially parallel to the transverse machining direction of the paper web. As a result, if the segment 1660 is angled with respect to the transverse machining direction, the doctor blade impact will less adversely affect the appearance and structure of the relatively low basis weight region 220. In particular, if the relatively low basis weight area is oriented substantially parallel to the transverse machining direction, the doctor blade may stand out a portion of the relatively low basis weight area 220, thereby adversely affecting the decorative appearance of the web. I think it's crazy.

It is anticipated that various wood pulp will normally comprise the papermaking fibers used in the present invention. However, other cellulosic fibrous pulp such as cotton liners, Bagasse, rayon, and the like can be used, which is also a subject of the present invention. Useful wood pulp include chemical pulp such as Kraft and sulfide and sulfate pulp, as well as mechanical pulp such as natural wood, thermomechanical pulp and chemical-thermomechanical pulp (CTMP). Pulps extracted from deciduous and coniferous trees can be used. Optionally, other non-cellulosic fibers such as synthetic fibers can also be used.

Both hardwood pulp and softwood pulp may be used separately or together. Hardwood and softwood may be mixed or, optionally, attached in layers to provide a layered web. US Patent No. 4,300,981 to Carstens on November 17, 1981, and US Patent No. 3,994,771 to Morgan et al. On November 30, 1976 include hardwood fibers and softwood fibers. Is disclosed in layers, which are incorporated herein by reference.

The paper molding stock may include, but is not limited to, various additives including fiber binder materials such as wet reinforcing binder materials, dry reinforcing binder materials, and chemical soft compositions. Suitable wet reinforcing binders include materials such as polyamide-epichlorohydrin resins manufactured by Hercules Inc., Wilmington, Delaware, and sold under KYMENE® 557H. It is not limited to this. Suitable instant wet reinforcing binders include, but are not limited to, synthetic polyacrylates. A suitable instant wet reinforcing binder is PAREZ® 750, sold by American Cyanamid, Stanford, Connecticut.

Suitable dry reinforcing binders include materials such as catacylmethyl cellulose and cationic polymers such as ACCO® 711. The CYPRO / ACCO family of dry reinforcing materials is available from CYTEC, Calama, Mich.

The paper molding stock adhered onto the molding element 1600 may include a release agent that inhibits some fibers from adhering to the fibers as the web dries. Leaving agents, combined with the energy provided to the web by a dry creping process, cause a portion of the web to be debulked. In one embodiment, the leaving agent may be applied to the fibers forming an intermediate fibrous layer located between two or more layers. The intermediate layer acts as a release layer between the outer layers of the fibers. Thus, the creping energy may cause a portion of the web to debulking along the release layer.

As a result, the web can be formed to have a relatively smooth surface for efficient drying on a heated dry surface, such as a heated dry surface of a Yankee drying drum. However, due to rebulking in the creping blades, the dried web has areas of different density, including relatively high density areas of continuous network and separate relatively low density areas creped by the creping process. Can be.

Suitable leaving agents include chemically soft compositions such as those disclosed in US Pat. No. 5,279,767, issued January 18, 1994 to Phan et al. Suitable biodegradable chemical soft compositions are disclosed in US Pat. No. 5,311,522, issued May 17, 1994 to Phan et al. U.S. Patent Nos. 5,279,767 and 5,311,522 are incorporated herein by reference. Such chemically soft compositions can be used as a leaving agent to inhibit the fibers in one or more layers of the fibers that make up the web from adhering to the fibers.

One emollient suitable for detaching the fibers from one or more layers of the fibers when forming the web 20 includes DiEster Di (Touch Hardened) Tallow Dimethyl Ammonium Chloride. Paper additive. Suitable softeners are ADOGEN® papermaking additives available from the Witco Company, Greenwich, Connecticut.

Unformed web 543 is preferably made from an aqueous dispersant of papermaking fibers, but dispersants in liquids other than water may be used. The fibers are dispersed in the carrier liquid and have a concentration of about 0.1% to 0.3%. The percent concentration of the dispersant, slurry, web or other system is defined as 100 times the index determined by dividing the weight of dry fibers in the system under consideration by the total weight of the system. Fiber weight is always displayed based on dry fibers.

Unformed web 543 may be formed by the continuous papermaking process shown in FIG. 4, or alternatively, a batch process, such as a handsheet manufacturing process, may be used. After the dispersant of the paper fiber is attached onto the forming element 1600, the unformed web 543 removes a portion of the aqueous dispersion medium through the forming element 1600 by techniques known to those skilled in the art. It is formed by. Vacuum boxes, forming boards, hydrofoils, and the like are used to perform the removal of water from the aqueous dispersant of the papermaking fiber to form the unformed web 543.

7 illustrates an unformed web formed on the forming element 1600. The portion of the unformed web supported on the flow inhibiting member 1650 is indicated by reference 543A, and the portion of the unformed web supported on the woven base 1610 is indicated by reference 543B. have. Portion 543A corresponds to the relatively low basis weight region 220 of FIGS. 1A and 1B, and portion 543B corresponds to the relatively high basis weight background 100 and the cell 240 of FIGS. 1A and 1B. do.

The difference in height D between the top surface of the flow inhibiting member 1650 and the woven base 1610 is a substantially single planar unformed web 543 having substantially smooth first and second surfaces 547, 549. Preferably less than about 6 mils (0.006 inches; 0.152 mm). More preferably, the difference in height D is about 3 mils or less. Preferably, the height D is about 1/6 or less of the average fiber length of the fibers in the web, most preferably about 1/6 or less of the average fiber length of the hardwood fibers in the web. The unformed web 543 is moved with the forming element 1600 about the return roll 1502 and moved near the web support device 2200.

4 and 8-10, the next step in manufacturing the paper web 20 is to transfer the unformed web 543 from the forming element 1600 to the web support device 2200, and the device ( Supporting the transferred web (indicated by reference numeral 545 in FIG. 4) on the first side 2202 of 2200. Preferably, the concentration of unformed web is about 5% to 20% at the time of transfer to the web support device 2200.

8 to 10, the web support device 2200 includes a dewatering felt layer 2220 and a web patterning layer 2250. Web support device 2200 may be in the form of a continuous belt to dry and impart a paper web on a paper machine. The web support device 2200 has a first side 2202 facing the web and an opposite second side 2204. The web support device 2200 is viewed with the first side 2202 facing the web towards the viewer in FIGS. 8 and 9. The first side 2202 facing the web includes a first web contact surface and a second web contact surface.

8 and 9, the first web contact surface is the first felt surface 2230 of the felt layer 2220. First felt surface 2230 is located at first height 2231. First felt surface 2230 is a web contact felt surface. The felt layer 2220 also has an opposite second felt surface 2232.

8 and 9, the second web contact surface is provided by web patterned layer 2250. Web patterned layer 2250 bonded to felt layer 2220 has web contact upper surface 2260 at a second height 2221. The difference between the first height 2231 and the second height 2221 is less than the thickness of the paper web when the paper web is conveyed to the web support device 2200. Surfaces 2260 and 2230 may be disposed at the same height such that heights 2231 and 2261 are the same. Optionally, surface 2260 may be slightly above surface 2230, or surface 2230 may be slightly above surface 2260.

The difference in height is 0.0 mil or larger and less than about 8.0 mil. In one embodiment, the difference in height is less than about 6.0 mils (0.15 mm), more preferably less than about 4.0 mils (0.10 mm), most preferably to maintain a relatively smooth surface 24 Is less than about 2.0 mils (0.05 mm).

The dewatering felt layer 2220 is water permeable and can receive and retain water compressed from the wet web of papermaking fibers. Web patterning layer 2250 is water impermeable and does not receive or retain water compressed from a web of papermaking fibers. Web patterned layer 2250 may have a continuous web contact top surface 2260 as shown in FIGS. 8 and 9. Optionally, the web patterned layer can be discontinuous or semicontinuous.

Preferably, web patterning layer 2250 comprises a photosensitive resin, which photoresist is deposited as a liquid on first surface 2230, and then a portion of web patterning layer 2250 is first felt surface 2230. ) And is cured by spinning to securely adhere to the first felt surface 2230. The web patterned layer 2250 does not extend through the entire thickness of the felt layer 2220, but extends through about ½ or less of the thickness of the felt layer 2220, thereby providing flexibility and compressibility of the web support device 2200. In particular, the flexibility and compressibility of the felt layer 2220 is maintained.

Suitable dewatering felt layer 2220 includes nonwoven cotton 2240 of natural or synthetic fibers bonded by, for example, needling, to a support structure formed from woven filaments 2244. Suitable materials from which the nonwoven cotton can be made include, but are not limited to, natural fibers such as wool and synthetic fibers such as polyester and nylon. The fibers forming the cotton 2240 have deniers of about 3 g to about 20 g per 9,000 meters of filament length.

The felt layer 2220 may be a layered structure and may include a mixture of fiber shapes and sizes. Felt layer 2220 is formed to promote transfer of water received from the web from first felt surface 2230 toward second felt surface 2232. Felt layer 2220 may have finer, relatively densely packed fibers disposed adjacent to first felt surface 2230. Preferably, the felt layer 2220 is adjacent to the first felt surface 2230 and has a relatively high density and relatively small pore size when compared to the density and hole size of the felt layer 2220 adjacent the second felt surface 2232. In this way, water entering the first surface 2230 is carried from the first surface 2230.

The dewatering felt layer 2220 may have a thickness greater than about 2 mm. In one embodiment, the dewatering felt layer 2220 may have a thickness between about 2 mm and about 5 mm.

International Publication No. WO 96/00812, published January 11, 1996, all filed in the name of Trokhan, and International Application Publication No. WO 96/25555, published 22 August 1996. And International Application Publication No. WO 96/25547, published August 22, 1996; US Patent Application No. 08 / 701,600, entitled "Method for Applying a Resin to a Substrate for Use in Papermaking," filed August 22, 1996; US Patent Application No. 08 / 640,452, entitled "High Absorbence / Low Reflectance Felts with a Patter Layer," filed April 30, 1996; US patent application Ser. No. 08 / 672,293, filed June 28, 1996, entitled "Method of Making Wet Pressed Tissue Paper with Felts Having Selected Permeabilities" It is incorporated herein by reference to describe the application of the photosensitive resin to the dewatering felt and to disclose a suitable dewatering felt.

Dewatering felt layer 2220 is about 200 standard ft ³ / min (standard cubic feet per minute: scfm) can have an air permeability less than the air permeability of the standard ft ³ / min here is the dehydration of about 0.5 inches of water This is a measure of the number of ft ³ of air per minute passing through the ft ² area of the felt layer at the pressure difference across the felt thickness. In one embodiment, the dewatering felt layer 2220 has an air permeability of about 5 standard ft ³ / min to about 200 standard ft ³ / min, more preferably about 100 standard ft ³ / min. .

The dewatering felt layer 2220 may have a basis weight of about 800 g / m 2 to about 2000 g / m 2 and an average density (a basis weight divided by thickness) of about 0.35 g / cm 3 to 0.45 g / cm 3. The air permeability of the web support device 2200 is less than or equal to the permeability of the felt layer 2220.

One suitable felt layer 2220 is Amflex 2 Press Felt, manufactured by Appleton Mills Company, Apelton, Wisconsin. The felt layer 2220 may have a thickness of about 3 mm, a basis weight of about 1400 g / m 2, and air permeability of about 30 standard ft ³ / min, three ply multifilament top and bottom wraps, and four ply cabled It has a bilayer support structure having a monofilament transverse machining fabric. The cotton 2240 may include polyester fibers having about 3 denier at the first surface 2230 and about 10 denier to 15 denier at the cotton substrate underlying the first surface 2230.

The web support device 2200 shown in FIG. 9 has a web patterned layer 2250 having a continuous reticulated web contact top surface 2260 having a plurality of individual openings 270 therein. Suitable shapes for openings 2270 include, but are not limited to, circular, elongated ovals, polygons, irregular shapes, or mixtures thereof in the machining direction (MD in FIG. 9). The protruding surface area of the continuous mesh top surface 2260 can be from about 5% to about 75% of the protruding area of the web support device 2200, as can be seen in FIG. 9, and preferably the device 2200. From about 25% to about 50% of the projected area of.

The continuous mesh top surface 2260 may have at least about 10,000, more preferably at least about 50,000 individual openings 2270 per square meter of the projected area of the device 2200, most preferably shown in FIG. 9. As may have at least about 15,000 individual openings 2270 per square meter of device 2200.

Individual openings 2270 may be staggered bilaterally in the machining direction (MD) and transverse machining direction (CD), as disclosed in US Patent No. 4,637,859, issued January 20, 1987, which is incorporated herein by reference. Cited herein.

The web is conveyed to the web support device 2200, and the first face 547 of the conveyed web 545 is supported on and conforms to the side 2202 of the device 2200, and the web 545 A portion of) is supported on surface 2260, and a portion of web is supported on felt surface 2230. The second face 549 of the web remains substantially smooth and macroplanar in planar shape. Referring to FIG. 10, the height difference between the surface 2260 and the surface 2230 of the web support device 2200 is small enough so that the second side of the web is substantially smooth when the web is transferred to the device 220. It remains macroplanar macroscopically. In particular, the difference in height between surface 2260 and surface 2230 should be less than the thickness of the unformed web at the time of transfer.

Transferring the unformed web 543 to the apparatus 2200 may be at least partially provided by applying different fluid pressure to the unformed web 543. Referring to FIG. 4, the unformed web 543 is vacuumed from the forming element 1600 to the apparatus 2200 by the vacuum source 600 shown in FIG. 4, such as a vacuum shoe or vacuum roll. In addition, one or more vacuum sources 620 may be provided downstream of the unformed web transfer point to further effect dehydration.

The web 545 is conveyed in the machining direction (MD in FIG. 4) on the device 2200 with a nip 800 provided between the vacuum press roll 900 and the hard surface 875 of the heated Yankee dryer drum 880. do. Referring to FIG. 11, the vapor hood 2800 may be located immediately upstream of the nip 800. The vapor hood may be used to direct vapor onto the surface 549 of the web 545 when the surface 547 of the web 545 is transported onto the vacuum press roll 900.

The vapor hood 2800 is mounted opposite the portion of the vacuum providing portion 920 of the vacuum press roll. The vacuum provider 920 sucks vapor into the web 545 and the felt layer 2200. The vapor provided by the vapor hood 2800 heats the water in the paper web 545 and felt layer 2220, thereby reducing the viscosity of the web and felt layer 2220. Thus, the water in the web and felt layer 2220 can be more easily removed by the vacuum provided by the roll 900.

The vapor hood 2800 may provide about 0.3 pounds of saturated steam per pound of dry fiber at a pressure less than about 15 psi. The vacuum provider 920 provides a vacuum of about 1 inch to 15 inches of mercury, preferably at about 2 inches to 12 inches of mercury at the surface 2204. Suitable vacuum press roll 900 is a suction press roll made by Winchester Roll Products. Suitable steam hood 2800 is Model D5A manufactured by Measurex-Devron Company, North Vancouver, British Columbia, Canada.

The vacuum providing unit 920 is in communication with a vacuum source (not shown). The vacuum provider 920 is fixed relative to the rotating surface 910 of the roll 900. Surface 910 may be a drilled or grooved surface through which a vacuum is applied to surface 2204. Surface 910 rotates in the direction shown in FIG. 11. The vacuum provider 920 provides a vacuum at the surface 2204 of the web support device 2200 when the web and device 2200 are transported through the vapor hood 2800 and through the nip 800.

Although only one vacuum provider 920 is shown, in other embodiments a separate vacuum provider may be provided, each vacuum providing a surface 2204 as the device 2200 rotates around the roll 900. Different vacuum).

Yankee dryers typically include steam heated steel or iron drums. Referring to FIG. 11, the web 545 is conveyed into a nip 800 supported on the device 2200 such that the substantially smooth second side 549 of the web can be transferred to the surface 875. Prior to the point at which the web is transferred to the surface 875 upstream of the nip, the nozzle 890 applies adhesive to the surface 875.

The adhesive may be a polyvinyl alcohol based adhesive. Optionally, the adhesive may be a CREPTOL® adhesive manufactured by Hercules Company, Wilmington, Delaware. In addition, other adhesives may be used. Generally, in embodiments where the web is transferred to the Yankee drum 880 at a concentration of at least about 45%, a polyvinyl alcohol-based creping adhesive may be used. At concentrations up to about 40%, adhesives such as CREPTOL® adhesives can be used.

The adhesive can be applied to the web in many ways, either directly or indirectly (such as applying to Yankee surface 875). For example, the adhesive may be sprayed in the form of droplets on the web or on the Yankee surface 875. Optionally, the adhesive may also be applied to the surface 875 by a transfer roller or brush. In another embodiment, the creping adhesive may be added to the paper molding stock at the wet end of the paper machine, such as adding the adhesive to the paper molding stock in the headbox 500. An adhesive of about 2 to 4 pounds per tonne of paper fiber dried on the Yankee drum 880 may be applied.

When the web is transported on the device 2200 through the nip 800, the vacuum provider 920 of the roll 900 provides a vacuum at the surface 2204 of the web support device 2200. In addition, when the web is transported on the apparatus 2200 between the vacuum press roll 900 and the dryer surface 800 through the nip 800, the web patterned layer 2250 of the web support apparatus 2200 has a surface 2260. ) Is applied to the first surface 547 of the web 545. Since the second face 549 is a substantially smooth and macroscopically planar face, substantially all of the second surface 549 is positioned relative to the dryer surface 875 when the web is transported through the nip 800, It is attached to the surface. When the web is transported through the nip, the second face 549 is supported against the smooth surface 875 to maintain a substantially flat and macroscopic cross-sectional shape. Thus, while a predetermined pattern can be imparted to the first side 547 of the web 545, the second side 549 remains substantially smooth. Preferably, the web 545 has a concentration of about 20% to about 60% when the web 545 is transferred to the surface 875 and the pattern of the surface 2260 is applied to the web to selectively densify the web. A pattern of surface 2260 is imparted to the web to provide the continuous reticular region 110 and the separate relatively low density region 130 shown in FIGS. 1A and 1B.

Although not theoretically limited, as a result of substantially all of the second side 549 being positioned relative to the Yankee surface 875, drying of the web 545 on the Yankee has only an optional portion of the second side relative to the Yankee. It is believed to be more efficient than could have been achieved in the positioned web.

In particular, a web having a basis weight of at least about 8 lb / 3000 ft ² (13 g / m 2), more preferably at least about 10 lb / 3000 ft ² (16.3 g / m 2) when substantially all of the second side 549 is positioned relative to the Yankee It is contemplated that 545 can be dried from a relatively low concentration to a relatively high concentration at a relatively high Yankee speed. Moreover, such webs 545 having the basis weight characteristics described above, at relatively high web speeds that enable economic production of paper webs 20, preferably less than about 30% and more preferably 25% (webgauge drum 880). It is contemplated that it may be dried from a concentration of [when transferred to] to a concentration of at least about 90% or less, more preferably 95% or less (when the web is removed by creping from the drum).

As a comparative example, for the same drying conditions and dryer design, Yankee dryer speed for drying paper with a continuous network and a separate dome and a basis weight of at least about 10 lb / 3000 ft ² , as disclosed in US Pat. No. 4,637,859. Is thought to be limited due to the tendency of the dome not to dry rapidly, such as a continuous network.

The final step in forming the paper structure 20 is to creep the web 545 from the surface 875 with the doctor blade 1000 as shown in FIG. Although not theoretically limited, the energy imparted to the web 545 by the doctor blade 1000 bulks or unmills at least a portion of the web, particularly web patterned surfaces such as relatively low density regions 130, 128. The portion of the web not printed by 2260 is bulked or non-milled. Thus, creping the web from the surface 875 to the doctor blade 1000 has a compact, relatively thin first region corresponding to the pattern imparted to the first face of the web, and a relatively thicker second region. Provide a web. In one embodiment, the doctor blade has an oblique angle of about 25 ° and is positioned relative to the Yankee dryer to provide an impact angle of about 81 °.

The paper structure 20 shown in FIGS. 1B and 3 is shortened due to creping in a relatively dense continuous network region 110 and in a separate relatively low density region 130. The creping frequency in the region 110 may be different from the creping frequency in the region 130. In general, the creping frequency in region 130 is lower than the creping frequency in continuous network 110. This difference in crepe frequency is shown in FIG. 1B, and the crepe ridge 115 is more closely spaced from each other than in the case of the crepe ridge 135 (high frequency).

Thus, the paper web 20 provides a decorative aesthetic imparted by the decorative display 200 without the need for embossing. Moreover, the web 20 is flexible by creping in both high and low density regions, the volume and absorbency provided by the low density regions 130 and 280, and the ductility provided by the relatively smooth surface 24. Indicates.

In another alternative embodiment of the invention, the web support device 2200 may include a resin layer disposed on a porous background element comprised of a fabric of woven filaments. Referring to FIGS. 14-18, the device 2200 may include a resin layer 2250 disposed on the woven fabric 1220. The resin layer 2250 has a continuous network web contact surface 2260 that defines a separate opening 2270 as shown in FIG. 14. Woven fabric 1220 includes machining direction filaments 1242 and transverse machining direction filaments 1241. The device 2200 has a first side 2202 and a second side 2204. First side 2202 has first and second web contact surfaces.

In FIGS. 14 and 15, the first web contact surface at first height 1231 is provided by individual knuckle surfaces 1230 located at the bifurcation of filaments 1241, 1242. The top surfaces of the filaments 1241 and 1242 may be sanded or otherwise polished to provide a relatively flat and generally elliptical knuckle surface 1230. The second web contact surface is provided by web patterned layer 2250. Web patterned layer 2250 bonded to woven fabric 1220 has web contact top surface 2260 at a second height 2221.

The difference between the first height 1231 and the second height 2221 is less than the thickness of the paper web when the paper web is conveyed to the web support device 2200. Continuous surfaces 2260 and individual surfaces 1230 may be disposed at the same height such that heights 1231 and 2261 are the same. Optionally, surface 2260 may be slightly higher than surface 1230, or surface 1230 may be slightly higher than surface 2260.

The height difference is 0.0 mil or larger and less than about 5.0 mil. In one embodiment, the height difference is about 4.0 mils (0.10 mm) or less, more preferably about 2.0 mils (0.05 mm), most preferably about 1.0 mils (to maintain the relatively smooth surface 24 of the dried web). 0.025 mm).

The web support device 2200 shown in FIGS. 14 and 15 can be used to form the paper webs shown in FIGS. 12 and 13. 12 is a plan view of a paper web 20 according to another embodiment of the present invention. FIG. 13 is a cross-sectional view of a paper web of the type shown in FIG. 12.

12 and 13, the paper web 20 has a background portion 100 and a decorative display portion 200 including a region 220 of relatively low basis weight. Background 100 includes a relatively dense continuous network region 110 and a separate relatively low density region 130 dispersed over the network region 110. One or more discrete regions 135 of relatively high density are distributed over each of the relatively low density regions 130.

The relatively low basis weight region 220 may have a closed path shape indicating a number of adjacent and relatively high basis weight cells 240 (seven cells 240 in FIG. 12). The basis weight everywhere in each cell 240 is higher than the basis weight of the area 220 surrounding the particular cell 240. Each cell 240 has a boundary formed by the closed loop portion of the region 220 of relatively low basis weight. Cell 240 may optionally be densified to include a relatively high density of continuous network 260 and a relatively separate low density area 280 distributed over the continuous network 260. Each separate relatively low density area 280 surrounds a plurality of separate relatively high density areas 285.

The continuous network 110, 260 corresponds to the surface 2260 of the web support device 2200 shown in FIG. 14. Separate relatively high density regions 135, 285 correspond to surface 1230 shown in FIG. 14. The relatively low density regions 130, 280 of the web shown in FIG. 12 correspond to the surface 2260 or portions of the web that are not aligned with the surface 1230.

13 is a cross-sectional view of a portion of a paper web of the type shown in FIG. 12. Line density through the web thickness in FIG. 13 is used to schematically show the relative basis weights of different portions of the web. The portions of the web shown by the five lines throughout the web thickness represent regions of relatively high basis weight, and the portions depicted by the three lines represent regions of relatively low basis weight.

16-18 illustrate the formation of a web 20 of the type shown in FIG. 12 using a web support device 2200. As described above with respect to FIGS. 4-7, the unformed web 543 having the first and second smooth surfaces is formed on the forming element 1600 to have a relatively low basis weight decorative display and a relatively high basis weight background. Is formed. The web is then vacuum conveyed to the device 2200 to provide a web 545 supported on the first side 2202 of the device 2200. As shown in FIG. 17, the first surface 547 coincides with the surface 2260 and the surface 1230, and the second surface 549 remains a substantially smooth and macroscopically flat surface.

Web 545 and web support device 2200 are then conveyed through through air drying device 650 (FIG. 16), where heated air is directed through web 545 while web 545 Is supported on the device 2200. The heated air enters the surface 549 and is directed to pass through the web 545 and through the apparatus 2200.

Through air drying apparatus 650 may be used to dry web 545 at a concentration of about 30% to about 70%. US Pat. Nos. 3,303,576 to Sisson and US Pat. Nos. 5,274,930 and 5,584,126 to Ensign et al. Are incorporated herein by reference to describe suitable through-air dryers for use in the practice of the present invention. . Optionally, the web can be dehydrated according to the subject matter of US Pat. No. 4,556,450, issued December 3, 1985 to Chuang et al., Which is incorporated herein by reference.

The partially dried web 545 and device 2200 are directed to pass through a nip 800 formed between the press roll 900 and the Yankee drum 880. Continuous mesh surface 2260 and individual surface 1230 are stamped into surface 547 of web 545 as the web is transported through nip 800. The adhesive supplied by the nozzle 890 is used to attach substantially the entirety of the substantially smooth surface 549 to the surface 875 of the heated Yankee drum 880.

Although only one forming element 1600 is shown in FIGS. 4 and 16, other forming wire forms can also be used in combination with one or more headboxes, each headbox being formed of a fiber molding material to provide a multilayer web. Has the ability to provide one or more layers. US Patent No. 3,994,771 to Morgan et al., US Patent No. 4,300,981 to Carstens et al., Filed Oct. 24, 1996 in the names of Phan and Trokhan, and jointly Layers are disclosed in the assigned US patent application entitled "Layered Tissue Having Improved Functional Properties", which is incorporated herein by reference. Various forms of shaped wire forms can be used, including twin wire formers. In addition, various types of headbox designs may be used to provide a web having one or more fibrous layers.

In yet another embodiment, the web supported on the web support device 2200 may be dewatered by pressing the web between the support device, such as the type shown in FIG. 9 or FIG. 14, and the dewatering felt layer in the press nip. . The web is located between the web support device 2200 and a layer of dewatering felt in the press nip.

All in the name of Trokhan et al., WO 96/00812, published January 11, 1996, and WO 96/25555, published August 22, 1996; , International Application Publication No. WO 96/25547, published August 22, 1996; US Patent Application No. 08 / 701,600, entitled "Method for Applying a Resin to a Substrate for Use in Papermaking," filed August 22, 1996; US Patent Application No. 08 / 640,452, entitled "High Absorbence / Low Reflectance Felts with a Patter Layer," filed April 30, 1996; US Patent Application No. 08 / 672,293, entitled "Method of Making Wet Pressed Tissue Paper with Felts Having Selected Permeabilities," filed June 28, 1996; ; US Patent No. 5,580,423, issued December 3, 1996, in the name of Ampulski et al., Is incorporated herein by reference to describe dewatering a web by pressurizing the web.

Example

The following examples illustrate the embodiments of the invention but do not limit the invention.

Example 1

First, an aqueous slurry of 3% by weight of Northern Softwood Kraft (NSK) fibers is prepared using a conventional repulping machine. 2% solution of instantaneous wet reinforcement resin (ie, PAREZ® 750, sold by American Cyanamid Corporation, Stanford, Connecticut) was laminated with NSK at a rate of 0.2% by weight of dry fibers. Is added to the pipe. NSK slurry is diluted to about 0.2% concentration in a fan pump. Second, an aqueous slurry of 3% by weight of Eucalyptus fibers is prepared using a conventional repulping machine. 2% solution of leaving agent (ie Adogen® SDMC sold by Witco Corporation, Dublin, Ohio) is added to one of the eucalyptus laminated pipes at a rate of 0.1% by weight of the dry fibers. do. Eucalyptus slurry is diluted to a concentration of about 0.2% in a fan pump.

The treated mold stock stream is mixed in the headbox and placed on a forming element 1600 of the type shown in FIG. The forming element 1600 includes a Fourdrinier forming wire having a flow inhibiting member 1650 formed by a photopolymer layer cured on the forming wire. Dewatering takes place through the forming wires and is assisted by deflectors and vacuum boxes. Molded wire manufactured by Appleton Wire, Appleton, WI, is a three-layer square weave with 90 filaments in each machining direction and short filaments in 72 transverse machining directions per inch. . The short filament diameter ranges from about 0.15 mm to 0.20 mm. Molding wire air permeability is about 1050 scfm. Flow through the forming wire is suppressed by the photopolymer flow inhibiting member 1650 having a petal shape as shown in FIG. 5. The combined flow inhibiting member 1650 has a raised area that is about 10% of the raised area of the forming element. The difference in height D (FIG. 7) is about 0.003 inches (0.076 mm).

The unformed wet web is transferred from the forming element 1600 to the web support device 2200 having the dewatered felt layer 2220 and the photosensitive resin web patterned layer 2250 at a fiber concentration of about 10% at the time of transfer. The dewatering felt layer 2220 is an Amflex 2 Press Felt. Felt 2220 includes a cotton of polyester fiber. The surface denier of the cotton is 3 and the substrate denier is 10-15. The felt layer 2220 has a basis weight of 1436 g / m 2, a caliper of about 3 mm, and air permeability of about 30 scfm to about 40 scfm. Web patterned layer 2250 includes a continuous mesh web contact surface 2260 that defines a number of individual openings 2270 that are elongated in the machining direction MD, as shown in FIG. 9. The web patterned layer 2250 has a raised area equal to about 35% of the raised area of the web support device 2200. The difference in height 2221 between the upper web contact surface 2260 and the first felt surface 2230 is about 0.005 inches (0.127 mm).

Unformed web is generally transferred to web support device 2200 to provide a single planar web 545. At the time of vacuum transfer, transfer and deflection are provided with a pressure difference of about 20 inches of mercury. Further dewatering is effected by the vacuum assisted dehydrator until the web has a fiber concentration of about 25%. Web 545 is conveyed to nip 800. Vacuum roll 900 has a compressive surface 910 with a hardness of about 60 PJ. Web 545 compresses surface 875 of Yankee dryer drum 880 by pressurizing web 545 and web support device 200 between compression surface 910 and Yankee dryer drum 880 at a compression pressure of about 200 psi. Is compressed for Polyvinyl alcohol-based creping adhesives are used to attach the compressed web to a Yankee dryer. Fiber concentration is increased by at least about 90% before the web is creped to the doctor blade. The doctor blade has an oblique angle of about 20 ° and is positioned relative to the Yankee dryer to provide an impact angle of about 76 °. The Yankee dryer operates at about 800 fpm (feet per minute) (about 244 m / min). The dry web is formed into a roll at a speed of 650 fpm (200 m / min).

Decorative webs are converted to 2 ply toilet tissue paper. The two ply toilet tissue paper has a basis weight of about 25 lb / 3000 ft ² and contains about 0.2% instantaneous wet reinforcement resin and about 0.1% of leaving agent. The resulting two ply tissue paper is bulky, soft, absorbent, aesthetic and suitable for use as toilet tissue.

Example 2

First, an aqueous slurry of 3% by weight of Northern Softwood Kraft (NSK) fibers is prepared using a conventional repulping machine. 2% solution of instantaneous wet reinforcement resin (ie, PAREZ® 750, sold by American Cyanamid Corporation, Stanford, Connecticut) was laminated with NSK at a rate of 0.2% by weight of dry fibers. Is added to the pipe. NSK slurry is diluted to about 0.2% concentration in a fan pump. Second, an aqueous slurry of 3% by weight of Eucalyptus fibers is prepared using a conventional repulping machine. 2% solution of leaving agent (ie Adogen® SDMC sold by Witco Corporation, Dublin, Ohio) is added to one of the eucalyptus laminated pipes at a rate of 0.5% by weight of dry fibers. do. Eucalyptus slurry is diluted to a concentration of about 0.2% in a fan pump. Third, an aqueous slurry of 3% by weight of Eucalyptus fibers is prepared using a conventional repulping machine. 2% solution of leaving agent (ie Adogen® SDMC sold by Witco Corporation, Dublin, Ohio) and 2% solution of dry reinforcing binder [New York, NY, USA] Redibond® 5320 manufactured by National Starch and Chemical Corporation is added to eucalyptus laminated pipes at a rate of 0.1% by weight of the dry fibers. Eucalyptus slurry is diluted to a concentration of about 0.2% in a fan pump.

The individually processed molding stock stream (stream 1 = 100% NSK / stream 2 = 100% off eucalyptus / stream 3 = 100% eucalyptus) is separated from the headbox and placed on the forming element 1600 of the type shown in FIG. Attached to form a three-layer web. The forming element 1600 includes a forming wire. Dewatering takes place through the forming wires and is assisted by deflectors and vacuum boxes. Molded wire manufactured by Appleton Wire, Appleton, WI, is a three-layer square weave with 90 filaments in each machining direction and short filaments in 72 transverse machining directions per inch. . The short filament diameter ranges from about 0.15 mm to 0.20 mm. Molding wire air permeability is about 1050 scfm. Flow through the forming wire is suppressed by the photopolymer flow inhibiting member 1650 having a petal shape as shown in FIG. 6. The combined flow inhibiting member 1650 has a raised area that is about 10% of the raised area of the forming element. The difference in height D (FIG. 7) is about 0.003 inches (0.076 mm).

The unformed wet web is transferred from the forming element 1600 to the web support device 2200 having the dewatered felt layer 2220 and the photosensitive resin web patterned layer 2250 at a fiber concentration of about 10% at the time of transfer. The dewatering felt layer 2220 is an Amflex 2 Press Felt. Felt 2220 includes a cotton of polyester fiber. The surface denier of the cotton is 3 and the substrate denier is 10-15. The felt layer 2220 has a basis weight of 1436 g / m 2, a caliper of about 3 mm, and air permeability of about 30 scfm to about 40 scfm. Web patterned layer 2250 includes a continuous mesh web contact surface 2260 that defines individual openings 2270 as shown in FIG. 9. The web patterned layer 2250 has a raised area equal to about 35% of the raised area of the web support device 2200. The difference in height 2221 between the upper web contact surface 2260 and the first felt surface 2230 is about 0.010 inch (0.254 mm).

Unformed web is generally transferred to web support device 2200 to provide a single planar web 545. At the time of vacuum transfer, transfer and deflection are provided with a pressure difference of about 20 inches of mercury. Further dewatering is achieved by the vacuum assisted dehydrator until the web has a fiber concentration of about 25%. Web 545 is conveyed to nip 800. Vacuum roll 900 has a compressive surface 910 with a hardness of about 60 PJ. Web 545 compresses surface 875 of Yankee dryer drum 880 by pressurizing web 545 and web support device 200 between compression surface 910 and Yankee dryer drum 880 at a compression pressure of about 200 psi. Is compressed for Polyvinyl alcohol-based creping adhesives are used to attach the compressed web to a Yankee dryer. Fiber concentration is increased by at least about 90% before the web is creped to the doctor blade. The doctor blade has an oblique angle of about 20 ° and is positioned relative to the Yankee dryer to provide an impact angle of about 76 °. The Yankee dryer operates at about 800 fpm (feet per minute) (about 244 m / min). Drying webs are formed in rolls at a speed of 650 fpm (200 m / min).

Decorative webs are converted to 2 ply toilet tissue paper. The two ply toilet tissue paper has a basis weight of about 25 lb / 3000 ft ² and contains about 0.2% instantaneous wet reinforcement resin and about 0.1% of leaving agent. The resulting two ply tissue paper is bulky, soft, absorbent, aesthetic and suitable for use as toilet tissue.

Example 3

First, an aqueous slurry of 3% by weight of Northern Softwood Kraft (NSK) fibers is prepared using a conventional repulping machine. A 1% solution of permanently wet reinforcing resin (ie, KYMENE® 557H manufactured by Hercules Inc., Wilmington, Delaware, USA), accounts for 0.25% by weight of the total sheet dry fiber. Furnace material is added to the laminated pipe. A 0.25% solution of dry reinforcement resin (ie CMC manufactured by Hercules Inc., Wilmington, DE) was molded before the fan pump at a rate of 0.05% by weight of the total sheet dry fibers. It is added to a stock laminate. Second, an aqueous slurry of 3% by weight of Eucalyptus fibers is prepared using a conventional repulping machine. 2% solution of leaving agent (ie Adogen® SDMC sold by Witco Corporation, Dublin, Ohio) is added to one of the eucalyptus laminated pipes at a rate of 0.1% by weight of the dry fibers. do. Eucalyptus slurry is diluted to a concentration of about 0.2% in a fan pump.

Individually processed mold stock streams (stream 1 = 100% NSK / stream 2 = 100% eucalyptus) are separated in the headbox and attached onto the forming element 1600 of the type shown in FIG. 6 to form a layered web. The forming element 1600 has a forming wire. Dewatering takes place through the forming wires and is assisted by deflectors and vacuum boxes. Molded wire manufactured by Appleton Wire, Appleton, Wisconsin, USA, is a three-layer square weave with filaments in 90 machining directions and short filaments in 72 transverse machining directions per inch. The short filament diameter ranges from about 0.15 mm to 0.20 mm. Molding wire air permeability is about 1050 scfm. Flow through the forming wire is suppressed by the photopolymer flow inhibiting member 1650 having a petal shape as shown in FIG. 6. The combined flow inhibiting member 1650 has a raised area that is about 10% of the raised area of the forming element 1600. The difference in height D (FIG. 7) is about 0.003 inches (0.076 mm).

The unformed wet web is transferred from the photopolymer forming wire to the web support device 2200 having the dewatered felt layer 2220 and the photosensitive resin web patterned layer 2250 at a fiber concentration of about 10% at the time of transfer. The dewatering felt layer 2220 is an Amflex 2 Press Felt. Felt 2220 includes a cotton of polyester fiber. The surface denier of the cotton is 3 and the substrate denier is 10-15. The felt layer 2220 has a basis weight of 1436 g / m 2, a caliper of about 3 mm, and air permeability of about 30 scfm to about 40 scfm. Web patterned layer 2250 includes a continuous mesh web contact surface 2260 that defines individual openings 2270 as shown in FIG. 9. The web patterned layer 2250 has a raised area equal to about 35% of the raised area of the web support device 2200. The difference in height 2221 between the upper web contact surface 2260 and the first felt surface 2230 is about 0.010 inch (0.254 mm).

Unformed web is transferred to web support device 2200. At the time of vacuum transfer, transfer and deflection are provided with a pressure difference of about 20 inches of mercury. Further dewatering is achieved by vacuum assisted dehydrator and optionally by pressurizing the web between the web support device and the individual dewatering felt. After being compressed, the web is conveyed to the nip 800. Vacuum roll 900 has a compressive surface 910 with a hardness of about 60 PJ. Web 545 compresses surface 875 of Yankee dryer drum 880 by pressurizing web 545 and web support device 200 between compression surface 910 and Yankee dryer drum 880 at a compression pressure of about 200 psi. Is compressed for Polyvinyl alcohol-based creping adhesives are used to attach the compressed web to a Yankee dryer. Fiber concentration is increased by at least about 90% before the web is creped to the doctor blade. The doctor blade has an oblique angle of about 25 ° and is positioned relative to the Yankee dryer to provide an impact angle of about 81 °. The Yankee dryer operates at about 800 fpm (feet per minute) (about 244 m / min). The dry web is formed into a roll at a speed of 650 fpm (200 m / min).

Decorative webs are converted into two ply cosmetic tissue paper. The two ply cosmetic tissue paper has a basis weight of about 18 lb / 3000 ft ² and contains about 1% permanent wet reinforcement resin, about 0.2% dry reinforcement binder and about 0.1% leaving agent. The resulting two ply tissue paper is bulky, soft, absorbent, aesthetic and suitable for use as a cosmetic tissue.

Another expected embodiment:

The following prospective examples do not limit the practice of the invention.

Example 4

First, an aqueous slurry of 3% by weight of Northern Softwood Kraft (NSK) fibers is prepared using a conventional repulping machine. 2% solution of instantaneous wet reinforcement resin (ie, PAREZ® 750, sold by American Cyanamid Corporation, Stanford, Connecticut) was laminated with NSK at a rate of 0.2% by weight of dry fibers. Is added to the pipe. NSK slurry is diluted to about 0.2% concentration in a fan pump. Second, an aqueous slurry of 3% by weight of Eucalyptus fibers is prepared using a conventional repulping machine. 2% solution of leaving agent (ie Adogen® SDMC sold by Witco Corporation, Dublin, Ohio) is added to one of the eucalyptus laminated pipes at a rate of 0.1% by weight of the dry fibers. do. Eucalyptus slurry is diluted to a concentration of about 0.2% in a fan pump.

The treated mold stock stream is mixed in a headbox and placed on a forming element 1600 of the type shown in FIG. 6 to form a homogeneous web. The forming wire has a forming wire. Dehydration takes place through the forming wires and is assisted by deflectors and vacuum boxes. Molded wire manufactured by Appleton Wire, Appleton, WI, is a three-layer square weave with 90 filaments in each machining direction and short filaments in 72 transverse machining directions per inch. . The short filament diameter ranges from about 0.15 mm to 0.20 mm. Molding wire air permeability is about 1050 scfm. Flow through the forming wire is suppressed by the photopolymer flow inhibiting member 1650 having a petal shape as shown in FIG. 6. The combined flow inhibiting member 1650 has a raised area that is about 10% of the raised area of the forming element 1600. The difference in height D (FIG. 7) is about 0.003 inches (0.076 mm).

Unformed wet webs were made in accordance with US Pat. No. 4,528,239, issued to Trokhan on July 9, 1985 from the molding element 1600 at a fiber concentration of about 10% at the time of transfer. Transferred to a web support device 2200 of the type shown in 15, which is incorporated herein by reference. The height difference between the heights 2221 and 1231 (FIG. 15) is about 0.015 inches (0.38 mm). Further dewatering is achieved by the vacuum assisted dehydrator until the web has a fiber concentration of about 28%. The patterned web is pre-dried by air blow-through to a fiber concentration of about 65% by weight. The web is then attached to the surface of the Yankee Dryer with a sprayed creping adhesive comprising 0.25% aqueous solution of polyvinyl alcohol (PVA).

Fiber concentration is increased by at least about 90% before the web is creped to the doctor blade. The doctor blade has an oblique angle of about 25 ° and is positioned relative to the Yankee dryer to provide an impact angle of about 81 °. The Yankee dryer operates at about 800 fpm (feet per minute) (about 244 m / min). The dry web is formed into a roll at a speed of 650 fpm (200 m / min).

Decorative webs are converted to 2 ply toilet tissue paper. The two ply toilet tissue paper has a basis weight of about 25 lb / 3000 ft ² and contains about 0.2% instantaneous wet reinforcement resin and about 0.1% of leaving agent. The resulting two ply tissue paper is bulky, soft, absorbent, aesthetic and suitable for use as toilet tissue.

Example 5

First, an aqueous slurry of 3% by weight of Northern Softwood Kraft (NSK) fibers is prepared using a conventional repulping machine. 2% solution of instantaneous wet reinforcement resin (ie, PAREZ® 750, sold by American Cyanamid Corporation, Stanford, Connecticut) was laminated with NSK at a rate of 0.2% by weight of dry fibers. Is added to the pipe. NSK slurry is diluted to about 0.2% concentration in a fan pump. Second, an aqueous slurry of 3% by weight of Eucalyptus fibers is prepared using a conventional repulping machine. 2% solution of leaving agent (ie Adogen® SDMC sold by Witco Corporation, Dublin, Ohio) is added to one of the eucalyptus laminated pipes at a rate of 0.1% by weight of the dry fibers. do. Eucalyptus slurry is diluted to a concentration of about 0.2% in a fan pump.

The individually processed molding stock stream (stream 1 = 100% eucalyptus / stream 2 = 100% NSK / stream 3 = 100% eucalyptus) is separated from the headbox and attached onto the forming element 1600 of the type shown in FIG. To form a three-layer web. The forming element 1600 has a forming wire. Dewatering takes place through the forming wires and is assisted by deflectors and vacuum boxes. Molded wire manufactured by Appleton Wire, Appleton, WI, is a three-layer square weave with 90 filaments in each machining direction and short filaments in 72 transverse machining directions per inch. . The short filament diameter ranges from about 0.15 mm to 0.20 mm. Molding wire air permeability is about 1050 scfm. Flow through the forming wire is suppressed by the photopolymer flow inhibiting member 1650 having a petal shape as shown in FIG. 6. The combined flow inhibiting member 1650 has a raised area that is about 10% of the raised area of the forming element. The difference in height D (FIG. 7) is about 0.003 inches (0.076 mm).

Unformed wet webs were 44 × 33 dried in the form shown in US Pat. No. 4,191,609, issued to Trokhan on March 4, 1980 from the forming element 1600 at a fiber concentration of about 10% at the time of transfer. / Printed fabric, which is incorporated herein by reference. Further dewatering is achieved by the vacuum assisted dehydrator until the web has a fiber concentration of about 28%. The patterned web is pre-dried by air through-blowing to a fiber concentration of about 65% by weight. The web is then attached to the surface of the Yankee Dryer with a sprayed creping adhesive comprising 0.25% aqueous solution of polyvinyl alcohol (PVA).

Fiber concentration is increased by at least about 90% before the web is creped to the doctor blade. The doctor blade has an oblique angle of about 25 ° and is positioned relative to the Yankee dryer to provide an impact angle of about 81 °. The Yankee dryer operates at about 800 fpm (feet per minute) (about 244 m / min). The dry web is formed into a roll at a speed of 650 fpm (200 m / min).

The decorative web is converted into a single ply toilet tissue paper. The single ply toilet tissue paper has a basis weight of about 18 lb / 3000 ft ² and contains about 0.3% instantaneous wet reinforcement resin and about 0.1% of leaving agent. The resulting single ply tissue paper is bulky, soft, absorbent, aesthetic and suitable for use as toilet tissue.

Example 6

First, an aqueous slurry of 3% by weight of Northern Softwood Kraft (NSK) fibers is prepared using a conventional repulping machine. 2% solution of instantaneous wet reinforcement resin (ie, PAREZ® 750, sold by American Cyanamid Corporation, Stanford, Connecticut) was laminated with NSK at a rate of 0.2% by weight of dry fibers. Is added to the pipe. NSK slurry is diluted to about 0.2% concentration in a fan pump. Second, an aqueous slurry of 3% by weight of Eucalyptus fibers is prepared using a conventional repulping machine. 2% solution of leaving agent (ie Adogen® SDMC sold by Witco Corporation, Dublin, Ohio) is added to one of the eucalyptus laminated pipes at a rate of 0.1% by weight of the dry fibers. do. Eucalyptus slurry is diluted to a concentration of about 0.2% in a fan pump.

The individually processed molding stock stream (stream 1 = 100% eucalyptus / stream 2 = 100% NSK / stream 3 = 100% eucalyptus) is separated from the headbox and attached onto the forming element 1600 of the type shown in FIG. To form a three-layer web. The forming element 1600 has a forming wire. Dewatering takes place through the forming wires and is assisted by deflectors and vacuum boxes. Molded wire manufactured by Appleton Wire, Appleton, Wisconsin, USA, is a three-layer rectangular fabric with filaments in 90 machining directions and short filaments in 72 transverse machining directions per inch. The short filament diameter ranges from about 0.15 mm to 0.20 mm. Molding wire air permeability is about 1050 scfm. Flow through the forming wire is suppressed by the photopolymer flow inhibiting member 1650 having a petal shape as shown in FIG. 6. The combined flow inhibiting member 1650 has a raised area that is about 10% of the raised area of the forming element. The difference in height D (FIG. 7) is about 0.003 inches (0.076 mm).

Unformed wet webs were cast on woven reinforcing members according to US Pat. No. 4,528,239, issued to Trokhan on July 9, 1985 from the forming element 1600 at a fiber concentration of about 10% at the time of transfer. Up to a web support device 2200 comprising a photopolymer layer, which is incorporated herein by reference. The woven reinforcing member has about 59 filaments extending in the machining direction and about 44 filaments extending in the transverse machining direction, and is assigned U.S. Patent No. 4,191,609 to Trokhan on March 4, 1980. It may be prepared according to the call.

The difference in heights 2221 and 1231 (FIG. 15) is about 0.003 inches (0.076 mm). Further dewatering is achieved by the vacuum assisted dehydrator until the web has a fiber concentration of about 28%. The patterned web is pre-dried by air through-blowing to a fiber concentration of about 65% by weight. The web is then attached to the surface of the Yankee Dryer with a sprayed creping adhesive comprising 0.25% aqueous solution of polyvinyl alcohol (PVA).

Fiber concentration is increased by at least about 90% before the web is creped to the doctor blade. The doctor blade has an oblique angle of about 20 ° and is positioned relative to the Yankee dryer to provide an impact angle of about 76 °. The Yankee dryer operates at about 800 fpm (feet per minute) (about 244 m / min). The dry web is formed into a roll at a speed of 650 fpm (200 m / min).

The decorative web is converted into a single ply toilet tissue paper. The single ply toilet tissue paper has a basis weight of about 18 lb / 3000 ft ² and contains about 0.3% instantaneous wet reinforcement resin and about 0.1% of leaving agent. The resulting single ply tissue paper is bulky, soft, absorbent, aesthetic and suitable for use as toilet tissue.

Test Methods :

Surface smoothness

The surface smoothness of the side of the paper web is described by Ampulski et al. In the 1991 International Paper Physics Conference, TAPPI Book 1 and described on page 19, "Method for the Measurement." of the Mechanical Properties of Tissue Paper "is measured according to the method of measuring the physiological surface smoothness (PSS) disclosed in the paper, which is incorporated herein by reference. The PSS measurement used herein is the sum of the amplitude values one by one as disclosed in the above paper. The measurement procedure disclosed in the paper is disclosed in US Pat. No. 4,959,125 to Spendel and US Pat. No. 5,059,282 to Ampulski et al., Which is incorporated herein by reference.

To test the paper sample of the present invention, the PSS measurement method in the above paper is used to measure the surface smoothness, and there are procedural variations as follows.

As disclosed in the paper, instead of putting digitalized data pairs (amplitude and time) for 10 samples into SAS software, surface smoothness measurements were obtained from National Instruments, Austin, Texas, USA. This is done by collecting, digitizing and statistically processing data for 10 samples using (registered trademark). Each amplitude spectrum is generated using the "Sixth Amplitude and Phase Spectrum." Module in the LABVIEW software package, and "Amp Spectrum Mag Vrms" is selected as the output spectrum. The output spectrum is obtained for each of 10 samples.

Each output spectrum is then smoothed using a weight factor of LABVIEW: 0.000246, 0.000485, 0.00756, 0.062997. These smoothing factors are chosen to mimic the smoothness provided by the factors defined in the paper above for SAS programs, namely 0.0039, 0.0077, 0.120, 1.0.

After smoothing, each spectrum is filtered using the frequency filter defined in the article. Next, the value of the PSS (microns) is calculated for each individual filtered spectrum as defined in the paper above. The surface smoothness of the side of the paper web is the average of 10 PSS values measured from 10 samples taken from the same side of the paper web. Similarly, the surface smoothness of opposite sides of the paper web can be measured. The smoothness ratio is obtained by dividing the value of the higher surface smoothness corresponding to the more textured side of the paper web by the value of the lower surface smoothness corresponding to the smoother side of the paper web.

Basis weight

The basis weight (macro basis weight) of the web is measured using the following procedure.

The paper to be measured is controlled at a relative humidity of 48% to 52% and a temperature of 71 ° to 75 ° F. for at least 2 hours. The conditioned paper is cut 3.5 inches by 3.5 inches to provide 12 samples to measure. Samples are cut six times at a time with a suitable pressure plate cutter such as 'Thwing-Albert Alfa Hydraulic Pressure Sample Cutter, Model 240-10'. The two six sample stacks are then combined into 12 ply stacks and adjusted for at least 15 minutes at 71 ° to 75 ° F. with a relative humidity of 48% to 52%.

The 12 ply stack is then weighed with the calibrated analytical balance. The balance is kept in the same room where the sample is adjusted. A suitable balance is the "Model A200S" manufactured by Sartorius Instrument Company. This weight is the gram weight of the twelve ply stacks of paper, with each ply having an area of 12.25 in ² .

The basis weight of the paper web (weight per unit area of a single ply) is calculated in units of lb / 3000 ft ² using the following equation.

Or simply basis weight (lb / 3000ft ² ) = weight of 12 ply laminates (g) × 6.48

Background weight

The basis weight of the background of the web is measured using the following procedure. A sample of the background portion (the sample does not comprise a decorative mark or part of a decorative mark) is cut from the paper web. The sample does not contain a decorative mark and is cut as large as possible. The area of each sample is measured and the sample is weighed. The basis weight of the background is calculated by dividing the weight of the sample by the area of the sample. At least three samples are measured and averaged to determine the basis weight of the background.

Basis weight in relatively low basis area

The basis weight of the relatively low basis weight area is measured using the following procedure.

Surface areas of relatively low basis weight areas are determined using a computer, scanner, and image analysis software program. A suitable computer is the Apple Macintosh Model 7200/90. Suitable scanners are AGFA Arcus II® scanners available from AGFA-Gevaert N.V., Belgium, with a resolution of 600 dpi. Suitable image analysis software is NIH IMAGE Version 1.59, available from the National Institute of Health.

The following procedure is used to scan the sample and to measure the surface area of the relatively low basis weight area in the sample. Samples are cut from the paper web, each sample comprising a decorative indicia surrounded by a background. Each sample is weighed to find the total weight (TW) of the sample.

Each sample is provided on a piece of black paper to provide a dark background during scanning. The mounted sample is scanned using an AGFA Arcus II scanner. The image is scanned into a computer using Adobe Photoshop Version 3.0.5 ™ software. Adobe software is available from FotoLook P.S., available from AGFA-Gevaert N.V. Augmented with 2.07.2 (TM) plug-in module. Scan settings are set to Auto, 600 dpi resolution, and grayscale (no color). The mounted sample is scanned with a ruler to provide a geometric scale.

The scanned image for each sample is then opened in NIH IMAGE software and adjusted with the ruler image. The adjustment factor is about 235.2 pixels / mm. Image analysis software is used to measure the total area of the sample based on the periphery of the sample.

The image is then smoothed twice using a 3x3 kernel before defining the outline of the decorative display. Next, the image is densely cropped into the brightest pixels with grayscale values between 64 and 254. Next, a magic wand mechanism is used to draw a decorative display including all relatively low basis weight areas contained within the display. The image portion outside the decorative display is discarded and the image of the decorative display is appended to the new file. The magic wand is then used to cut a relatively high basis weight portion (cell) in the decorative display, leaving only the portion of the image corresponding to the region of relatively low basis weight. Next, the image of the region of relatively low basis weight is carefully cut to select pixels with grayscale values of 64 to 254. The software then calculates the area of the selected pixels to provide the surface area of the relatively low basis weight area in the decorative display.

If the surface area of the relatively low basis weight area is measured using image analysis software, the basis weight of the relatively low basis weight area is determined by obtaining BW1 in the following equation.

TW = (BW1) × (AREA1) + (BW2) × (AREA2)

Where TW is the total weight of the sample with a decorative display, BW1 is the basis weight of the relatively low basis weight area, AREA1 is the area of the relatively low basis weight area measured using image analysis software, and BW2 is the background described above. The basis weight of the background area that can be measured from a sample cut from the part, and AREA2 is the area of the background part of the sample. The value of AREA2 is the total area of the sample (calculated based on the boundary of the sample) minus the value of AREA1. Thus, the above equation can be used to find the value of BW1. At least three samples are measured and the results are averaged to determine the basis weight of the relatively low basis weight region.

Macro-Caliper or Dry Caliper

Macro-calipers or dry calipers are measured using the procedure for measuring dry calipers disclosed in US Pat. No. 4,469,735 to Trokhan, issued September 4, 1984, which is incorporated herein by reference. do.

Bulk density

Bulk density is the basis weight of a web divided by a macro-caliper and is reported in weight units per unit volume. Appropriate conversion factors can be used if the basis weight and caliper are measured using different units.

Absorption capacity

Absorbent capacity of the web is measured using the horizontal absorbent capacity test described in US Pat. No. 4,469,735, referenced above.

Measurement of web support device height

The height difference between the height 231 of the first felt surface and the height 261 of the web contact surface 260 is measured using the following procedure. The web support device is supported on a flat horizontal surface and the web patterned layer faces upward. A Federal Products measurement gauge (EMD-) manufactured by Federal Products Company, Rode Providence, Iceland, has a stylus with a circular contact surface of about 1.3 mm 2 and a vertical length of about 3 mm. Mounted on a model 432B-81 amplifier modified for use with the 4320 W1 breaking probe. The instrument is adjusted by determining the voltage difference between two fine shims of known thickness providing a known height difference. The instrument is zeroed at a height slightly below the first felt surface 230 to ensure non-limiting movement of the protrusions. The protrusion is positioned above the object height and lowered to measure. The protuberance is pressurized at about 0.24 g / mm 2 at the measuring point. At least three measurements are made at each height. The measured value at each height is averaged. The difference between the mean values is calculated to give the height difference.

The same procedure is used to measure the difference between the heights 1231 and 2261.

Claims (44)

A paper web having an opposing surface and at least three regions, the three regions being arranged in a regularly repeating pattern and at least selected from the group consisting of basis weight, density, and fiber composition In the paper web, which can be distinguished from each other by one property, A high basis weight region region having a first basis weight and a decorative indicia, The decorative indicia includes one or more low basis weight regions having a basis weight lower than a first basis weight of at least a portion of the peripheral background region of the paper web. Paper web. delete Claim 1 comprising multiple plies of paper web Paper structure. In a wet paper web having opposing surfaces, 5 to 5000 separate decorative markers per square meter of the surface of the web, each decorative marker comprising at least one low basis weight region; A high basis weight background area having a basis weight higher than the low basis area that separates the decorative display, the background area comprising a region of different density arranged in a regularly repeating pattern Wet paper web. Claim 5 comprising multiple plies of the paper web Paper structure. In wet paper webs having opposed surfaces, 5 to 5000 separate decorative markings per square meter of the surface of the web, the decorative markings comprising one or more low basis weight regions each having a basis weight of 15 g / m 2 or less; A high basis weight background region having a basis weight higher than the low basis region that separates the decorative display, the background region comprising a high density continuous network region and at least 10,000 separate low density regions per square meter of the web; Wherein the low density region has a lower density than the high density region and is dispersed through the continuous network region, wherein the background region has a surface smoothness value of 900 μm or less on at least one of the opposed surfaces of the web Including the background area Wet paper web. In wet paper webs having opposed surfaces, 5 to 5000 separate decorative markings per square meter of the surface of the web, the decorative markings comprising one or more low basis weight regions each having a basis weight of 15 g / m 2 or less; A high basis weight background portion for separating the decorative display, comprising: a high density continuous network region, a plurality of low density regions dispersed through the continuous network region and having a lower density than the high density continuous network region, and the low density Comprising a high basis weight background comprising a plurality of distinct high density regions dispersed over each of the regions Wet paper web. A method of making a paper web having at least three regions distinguishable due to at least one property selected from the group consisting of a basis weight, a density and a fiber composition, arranged in a regularly repeating pattern, Providing a plurality of fibers suspended in a liquid carrier, Providing a fiber retentive forming element having a liquid permeable zone; Adhering the fibers and the liquid carrier onto the molding element; Discharging said liquid carrier through said forming element in two simultaneous steps to form a web having at least one relatively high basis weight region and a decorative indicator comprising at least one relatively low basis weight region; Providing a web support device having a web patterned surface, Transferring the web from the forming element to the web patterned surface of the web support device; Selectively densifying at least a portion of the relatively high basis weight region to provide a regularly repeating pattern of a first densified region and a second densified region having a higher density than the first densified region within the relatively high basis weight region; Containing Paper web manufacturing method. The method of claim 8, Selectively densifying at least a portion of the relatively high basis weight region includes forming separate second densified regions distributed over the relatively high basis weight region. Paper web manufacturing method. A method of making a paper web having at least three regions distinguishable due to at least one property selected from the group consisting of a basis weight, a density and a fiber composition, arranged in a regularly repeating pattern, Providing a plurality of cellulose fibers suspended in a liquid carrier, Providing a fiber retaining molding element having a liquid permeable zone; Attaching the cellulose fiber and the liquid carrier onto the molding element; Discharging the liquid carrier through the forming element in two simultaneous steps to form a web having at least one relatively high basis weight region and a decorative indicator comprising at least one relatively low basis weight region, the web being Said evacuating step having a first surface, a second surface, and a thickness, Providing a web support device having a side facing a web comprising a first web contact surface and a second web contact surface, wherein a height difference between the first web contact surface and the second web contact surface is determined by the thickness of the web. Smaller, the providing step, Conveying the web from the forming element to the web support device, wherein the first surface of the web is supported on the first and second web contact surfaces of the web support device; At least a portion of the relatively high basis weight area after the transfer step of the web to provide a regularly repeating pattern of a first densified area and a second density area having a higher density than the first densified area within the relatively high basis weight area. Selectively densifying Paper web manufacturing method. The method of claim 1, The decorative markings are provided to the web by selectively dehydrating water from the web. Paper web. The method of claim 1, The decorative display portion includes a low basis weight area having a basis weight of 15 g / m 2 or less. Paper web. The method of claim 12, A plurality of spaced apart discrete decorative indicia, the background area separating the separate decorative indicia Paper web. The method of claim 13, 5 to 5000 distinct decorative indicia per square meter of the surface of the web Paper web. The method of claim 14, The background region includes at least one high density region and at least one low density region having a lower density than the high density region, wherein the high density region and the low density region have a basis weight greater than the basis weight of the low basis region of the decorative display unit. Paper web. The method of claim 15, The background region includes a high density continuous network region and a plurality of separate low density regions dispersed through the high density continuous network region and having a lower density than the high density continuous network region. Paper web. The method of claim 16, The high density continuous network region and the separate low density region have different crepe frequencies. Paper web. The method of claim 17, The background area includes at least 10,000 separate low density areas per square meter of the web. Paper web. The method of claim 13, Each decorative display includes a low basis weight region having a closed path shape that completely encloses at least one high basis area, the width of the low basis area being measured at any point along the closed path shape. Between 0.2 mm and 2 mm Paper web. The method of claim 19, The low basis weight region has a closed path shape delineating a plurality of adjacent high basis weight cells, where the basis weight everywhere in each cell is higher than the basis weight of the low basis weight region, and each cell is of the low basis weight. With boundaries formed by closed loop portions Paper web. The method of claim 20, Each cell shares only ½ of any one adjacent cell and its boundary Paper web. The method of claim 1, The bulk density of the paper web is 0.12 g / cm 3 or less Paper web. The method of claim 1, The background region has a surface smoothness value of 900 μ or less on at least one of the opposing surfaces of the paper web. Paper web. The method of claim 1, An average fiber length of the papermaking fibers in the low basis weight region of the decorative indicia of the decorative markings, wherein the average fiber length of the papermaking fibers is longer than the average fiber length of the papermaking fibers in the peripheral portion of the paper web. Paper web. The method of claim 4, wherein The high basis weight area comprises a high density continuous network area and a plurality of separate low density areas dispersed through the high density continuous network area and having a lower density than the high density continuous network area. Wet paper web. The method of claim 4, wherein The high basis weight area comprises separate high density areas. Wet paper web. The method of claim 4, wherein The low basis weight area of the decorative display has a basis weight of 15 g / m 2 or less. Wet paper web. The method of claim 27, The background region has a surface smoothness value of 900 μ or less on at least one of the opposing surfaces of the web. Wet paper web. The method of claim 27, Having a bulk density of 0.12 g / cm 3 or less Wet paper web. The method of claim 27, The decorative indicia is provided to the web by selectively dehydrating water from the web. Wet paper web. The method of claim 30, The background portion includes regions of different densities imparted to the web after the decorative markings have been imparted to the web. Wet paper web. In wet paper webs having opposed surfaces, 5 to 5000 separate decorative markings per square meter of the surface of the web, the decorative markings comprising one or more low basis weight regions each having a basis weight of 15 g / m 2 or less; A high basis weight background portion separating said decorative indicia, said background portion comprising regions of different density arranged in a regularly repeating pattern, said background portion comprising at least 50,000 distinct high density regions per square meter of said web; Wherein the background portion comprises the high basis weight background portion having a surface smoothness value of 900 μm or less on at least one of the opposed surfaces of the web. Wet paper web. The method of claim 8, Providing the plurality of fibers includes providing fibers of different lengths having a plurality of first fibers and a plurality of second fibers, wherein the second fibers are shorter than the first fibers. Paper web manufacturing method. The method of claim 33, wherein Attaching fibers onto the forming element includes attaching a mixture of hardwood fibers and softwood fibers onto the forming element. Paper web manufacturing method. The method of claim 33, wherein Attaching fibers onto the forming element includes laminating hardwood fibers and softwood fibers on the forming element. Paper web manufacturing method. 36. The method of claim 35 wherein Attaching the fiber onto the forming element comprises attaching a layer of softwood in direct contact with the forming element. Paper web manufacturing method. The method of claim 8, Ejecting the liquid carrier through the forming element comprises forming an unformed web having 5 to 5000 distinct decorative indicia per square meter of the web. Paper web manufacturing method. The method of claim 8, The web support device includes a plurality of separate first web contact surfaces disposed at a first height and a continuous mesh web patterned layer defining a second continuous web contact surface at a second height, wherein the high basis weight area Selective densification of at least a portion of the forms a web to the web support device such that a plurality of separate first densified regions are formed, wherein the separate first densified regions contact a plurality of separate first web contacts. Corresponding to the surface Paper web manufacturing method. The method of claim 38, Selectively densifying at least a portion of the high basis area includes providing at least 10,000 separate first densified areas per square meter of the web. Paper web manufacturing method. The method of claim 39, Ejecting the liquid carrier through the forming element comprises forming an unformed web having 5 to 5000 distinct decorative indicia per square meter of the web. Paper web manufacturing method. The method of claim 8, Pressurizing the web between a felt layer and the web support device after transferring the web to the web support device. Paper web manufacturing method. The method of claim 8, Directing heated air through the web when the web is supported on the web support device; Paper web manufacturing method. The method of claim 10, Selectively densifying at least a portion of the relatively high basis weight region includes imparting a pattern to the first surface of the web while maintaining the second surface of the web in a smooth and macroplanar form. Paper web manufacturing method. The method of claim 43, Providing a heated dry surface, Positioning a smooth, macroscopically flat second surface of the web adjacent to the heated dry surface; Drying the web on the heated dry surface; Creping the web from the heated dry surface further; Paper web manufacturing method.