US3905863A - Process for forming absorbent paper by imprinting a semi-twill fabric knuckle pattern thereon prior to final drying and paper thereof - Google Patents

Process for forming absorbent paper by imprinting a semi-twill fabric knuckle pattern thereon prior to final drying and paper thereof Download PDF

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US3905863A
US3905863A US457043A US45704374A US3905863A US 3905863 A US3905863 A US 3905863A US 457043 A US457043 A US 457043A US 45704374 A US45704374 A US 45704374A US 3905863 A US3905863 A US 3905863A
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Prior art keywords
fabric
paper
percent
imprinting
semi
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US457043A
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English (en)
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Peter G Ayers
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Procter and Gamble Co
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Procter and Gamble Co
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Priority to US457043A priority Critical patent/US3905863A/en
Priority to CA201,613A priority patent/CA1007911A/en
Priority to DK303474AA priority patent/DK137248B/da
Priority to AU69861/74A priority patent/AU6986174A/en
Priority to CH771274A priority patent/CH592209A5/xx
Priority to DE19742427291 priority patent/DE2427291A1/de
Priority to NO742069A priority patent/NO141904C/no
Priority to FI1753/74A priority patent/FI175374A/fi
Priority to SE7407532A priority patent/SE412262B/xx
Priority to IT23743/74A priority patent/IT1014871B/it
Priority to IE1204/74A priority patent/IE40284B1/en
Priority to FR7419847A priority patent/FR2241642B1/fr
Priority to NL7407635A priority patent/NL7407635A/xx
Priority to JP49065508A priority patent/JPS5742760B2/ja
Priority to GB2558974A priority patent/GB1436067A/en
Priority to US05/588,580 priority patent/US3974025A/en
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    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21F—PAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
    • D21F11/00—Processes for making continuous lengths of paper, or of cardboard, or of wet web for fibre board production, on paper-making machines
    • D21F11/006—Making patterned paper
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21F—PAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
    • D21F11/00—Processes for making continuous lengths of paper, or of cardboard, or of wet web for fibre board production, on paper-making machines
    • D21F11/14—Making cellulose wadding, filter or blotting paper

Definitions

  • ABSTRACT A low-density, soft, bulky and absorbent paper sheet exhibiting a diamond-shaped pattern in its surface after creping, said paper being characterized by having a cross-directional stretch of from about 3.5 percent to about 6 percent, as well as improved softness, surface feel and drape, said paper sheet being particularly suitable for use in tissue, toweling and sanitary products.
  • the aforesaid paper sheets are produced by impressing a dobdash knuck1e pattern, wherein the long axis of the dash impressions is aligned parallel to the machine direction of papermaking, using the back side of a monofilament, polymeric fiber, semi-twill fabric of selected coarseness, the knuckle imprint area of which constitutes between about 20 percent and about 50 percent of the total fabric surface area, as measured in the plane of the knuckles, on an uncompacted paper web at selected fiber consistencies, induced by thermal predrying, prior to final drying and creping.
  • This invention relates to improvements in papermaking and non-woven web manufacturing operations and particularly to the provision of a low-density, soft, bulky and absorbent paper sheet characterized by having significantly greater cross-directional stretch, as well as improved softness, surface feel and drape when compared to paper sheets produced by prior art papermaking and non-woven web manufacturing methods.
  • the present invention consists of a monofilament, polymeric fiber, semi-twill fabric which when used to imprint an uncompacted paper web at selected fiber consistencies, induced by thermal pre-drying, will produce a dotdash pattern wherein the long axis of the dash impressions is aligned parallel to the machine direction of paper-making and the long axis of the dot impressions is aligned parallel to the cross-machine direction.
  • the aforesaid imprinting fabric is especially suitable for use in papermaking and non-woven web manufacturing operations, such as the papermaking operation disclosed in U.S. Pat. No. 3,301,746, issued to Sanford et al. on Jan. 31, 1967, said patent being incorporated herein by reference, wherein the surface characteristics of such fabrics are of operational and product characteristic importance.
  • the present invention consists of a monofilament, polymeric fiber, semi-twill fabric of the type normally used for transporting a moist web through the forming, pressing and drying sections of a papermaking machine, which monofilament, polymeric fiber, semi-twill fabric is woven and thereafter shrunk by heat treatment to result in a dimensionally heat stable fabric having uniform knuckle heights in conjunction with minimum free or interstitial area on the surface of the fabric which will contact the uncompacted paper web, said fabric having been further improved by abrading its web contacting sur face with a fine abrasive medium to increase its knuckle imprint area.
  • a Fourdrinier paper machine paper stock is fed onto a traveling endless belt that is supported and driven by rolls associated with the machine and which serves to the papermaking surface of the machine.
  • Foundrinier belts are commonly formed from a length of woven Fourdrinier fabric with its ends joined together in a seam to provide an endless belt.
  • Fourdrinier fabrics of this type generally comprise a plurality of spaced longitudinal warp filaments and a plurality of spaced transverse woof or weft filaments which have been woven together on a suitable loom.
  • warp filaments of the fabric are, for purposes of this specification, defined as those which run parallel to the machine direction of papermaking and non-woven web manufacturing machines to form a continuous carrier belt; woof or weft filaments are, for purposes of this specification, defined as those which run in the cross-machine direction.
  • the imprinting fabric suggested for use in U.S. Pat. 3,301,746, to which the present invention has particular relevance, may be of square or diagonal weave, and can be of any specific construction including, for example, plain or semi-twill weave.
  • a preferred imprinting fabric, according to the teachings of the aforesaid Sanford et a1. patent, has about 20 to about 60 meshes per inch and is formed from filaments having a diameter of from about 0.008 to about 0.02 inches.
  • Paper sheets produced in accordance with the teachings of U.S. Pat. No. 3,301,746 utilizing a monofilament, polymeric fiber, semi-twill imprinting fabric exhibit properties similar in most respects to paper sheets produced utilizing a plain weave imprinting fabric having filaments of approximately the same diameter when the semi-twill fabric is installed so that its conventional face side is used to imprint the uncompacted paper web.
  • the conventional face side of the semi-twill fabric assuming the fabric has uniform knuckle heights on its web contacting side, will produce a dot-dash pattern wherein the long axis of the dash impressions is aligned parallel to the crossmachine direction and the long axis of the dot impressions is aligned parallel to the machine direction.
  • the dash impressions result from each weft filament passing in a repeated pattern under one: warp filament and then over the next two warp filaments, while the dot impressions result from each warp filament passing in a repeated pattern over one weft filament and then under the next two weft filaments on the conventional face side of the fabric.
  • paper sheets imprinted by the conventional face side of a semi-twill fabric are doctored from the drying drum, the dot-dash knuckle impressions are aligned essentially between the creping folds. The resulting creping folds are, therefore, substantially uninterrupted across the sheets surface.
  • paper sheets produced utilizing the conventional face side of a semi-twill imprinting fabric exhibit properties substantially similar to paper sheets produced utilizing a plain weave imprinting fabric, i.e., a low-density, soft, bulky and absorbent paper sheet characterized by having .uniforrncreping folds which extend substantially uninterrupted across the width of the sheet.
  • the dash impressions result from each warp filament passing in a repeated pattern under one weft filament and then over the next two weft filaments, while the dot impressions result from each weft filament passing in a repeated pattern over one'warp filament and then under the next two warp filaments on the back side of the fabric.
  • Paper sheets imprinted with the back side of a conventional semi-twill, monofilament, polymeric fiber fabric unlike paper sheets imprinted with either a plain weave fabric or the conventional face side of a semitwill fabric, exhibit a diamond-shaped pattern after creping.
  • a means of preparing a dimensionally heat stable, plain weave, monofilament, polymeric fiber fabric having uniform knuckle heights and minimum free area on each side of the fabric is disclosed in U.S. Pat. No. 3,473,576 issued to Amneus on Oct. 21, 1969, said patent being incorporated herein by reference.
  • a plain weave fabric is prepared by selecting polymeric warp monofilaments having a relatively high heat-induced shrinkage potential and further selecting an initial warp monofilament spacing in the loom according to a mathematical equation disclosed in the aforementioned Amneus patent.
  • Polymeric woof monofilaments are then selected which have a relatively low heat induced shrinkage potential, and these woof monofilaments are woven and beaten in the weaving process into a plain weave fabric having an initial caliper calculated according to yet another mathematical equation disclosed in the aforementioned Amneus patent.
  • the fabric knuckles are brought to uniform on both sides of the fabric and the minimum free area of the fabric is set by a heat shrinkage treatment which maintains the fabric in warp tension while allowing it to shrink in the woof direction.
  • the initial warp filament spacing and caliper of a semi-twill fabric necessary to produce minimum free area and uniform knuckle heights on the back side of the fabric after heat treatment are determined experimentally by trial and error.
  • Another object of the present invention in a preferred embodiment, is to provide a monofilament, polymeric fiber, semi-twill fabric for use in papermaking and non-woven web manufacturing operations, the back surface of which fabric has a total knuckle imprint area of from about percent to about 50 percent of the total fabric surface area, as measured in the plane of the knuckles, and which knuckle imprint area has a surface finish at least equal in smoothness to the surface finish induced by abrasion with an abrasive medium having an effective abrasive grain size-of less than about 300 mesh.
  • a low density, soft, bulky and absorbent paper sheet is provided, said paper sheet exhibiting a diamond 6 shaped pattern in its surface after creping, said paper sheet being characterized by having a cross-directional stretch of from about 2 percent to about 6 percent, as well as improved softness, surface feel and drape, said paper sheet being particularly suitable for use in tissue, toweling, and sanitary products.
  • the soft, bulky and absorbent paper sheets of the present invention are produced, in a preferred embodi ment, generally in accordance with the teachings of U.S. Pat. No. 3,301,746 by forming an uncompacted paper web, supporting said uncompacted paper web on the back side of a monofilament, polymeric fiber, semitwill imprinting fabric having about 20 to about 60 meshes per inch, said imprinting fabric having been formed from filaments having a diameter of from about 0.008 inches to about 0.025 inches, the back side of said fabric having had its knuckle imprint area increased in accordance with the teachings of U.S. Pat. No.
  • the back side of the monofilament, polymeric fiber, semi-twill imprinting fabric is prepared in accordance with the teachings of U.S. Pat. No. 3,573,164 by abrading the knuckle surfaces to increase the knuckle imprint area to between about 20 percent and about 50 percent of the total fabric surface area, as measured in the plane of the knuckles, as well as to polish the knuckle surfaces.
  • the monofilament, polymeric fiber, semitwill fabric is woven and heat treated so as to produce a dimensionally heat stable fabric having uniform knuckle heights and minimum free area on its back side prior to abrading the knuckle surfaces on the back side of the fabric.
  • FIG. 1 is a plan view of an enlarged portion of a conventional right-hand semi-twill, monofilament, polymeric fiber fabric as viewed from the back side, i.e., that side of the fabric which according to the teachings of the prior art does not normally contact the web.
  • the monofilament, polymeric fiber, semi-twill fabric is shown prior to any abrasion treatment and prior to use as an endless or continuous fabric belt in papermaking or non-woven web manufacturing operations.
  • FIG. 2 is an enlarged cross-sectional view of the semitwill fabric illustrated in FIG. 1, taken looking in the cross-machine direction (CD) along line 2-2 in FIG. 1, which crosssectional view illustrates the higher relative elevation and the smooth knuckle surfaces of the warp filaments on each side of the fabric.
  • CD cross-machine direction
  • FIG. 3 is an enlarged cross-sectional view of the semitwill fabricjillustrated in FIGS. 1 and 2, taken looking in themachine direction (MD) along line 3-3 in FIG. 1, which cross-sectional view illustrates the lower relative elevation and the smooth knuckle surfaces of the woof or weft filaments.
  • FIG. 4 is a simplified illustration of an'enlarged partial plan view of an uncreped paper sheet which has been imprinted utilizing the conventional face side of a semi-twill fabric such as is shown in FIGS. 1 through 3.
  • the long axis of the dot impressions formed by the warp filaments is aligned parallel to the machine direction.
  • FIG. 5 is a simplified illustration of an enlarged partial plan view of an uncreped paper sheet which has been imprinted utilizing the back side of a semi-twill fabric such as is shown in FIG. 1 through 3.
  • the long axis of the dash impressions formed by the warp filaments is aligned parallel to the machine direction.
  • FIG. 6 is an enlarged cross-sectional view of a monofilament, polymeric fiber, semi-twill fabric such as is illustrated in FIGS. 1 through 3, taken looking in the cross-machine direction at a point corresponding to line 22 in FIG. 1, after the fabric has been subjected to a heat treatment process sufficient to produce uniform knuckle heights on the conventional face side of the fabric.
  • FIG. 7 is an enlarged cross-sectional view of the semitwill fabric illustrated in FIG. 6, taken looking in the machine direction at a point corresponding to line 33 in FIG. 1.
  • FIG. 8 is a simplified illustration of an enlarged partial plan view of an uncreped paper sheet which has been imprinted utilizing the conventional face side of a monofilament, polymeric fiber, semi-twill fabric such as is illustrated in FIGS. 6 and 7.
  • the long axis of the dash impressions formed by the woof or weft filaments is aligned parallel to the cross-machine direction, while the long axis of the dot impressions formed by the warp filaments is aligned parallel to the machine direction.
  • FIG. 9 is a simplified illustration of an enlarged partial plan view of an uncreped paper sheet which has been imprinted utilizing the back side of a semi-twill fabric such as is illustrated in FIGS. 6 and 7.
  • the long axis of the dash impressions formed by the warp filaments is aligned parallel to the machine direction.
  • FIG. 10 is an enlarged cross-sectional view of a monofilament, polymeric fiber, semi-twill fabric such as is illustrated in FIGS. 1 through 3 and 6 and 7, taken looking in the cross-machine direction at a point corresponding to line 22 in FIG. 1, after the fabric has been subjected to a heat treatment process sufficient to produce uniform knuckle heights and minimum free area on the back side of the fabric. It should be noted that at this point, the knuckle heights on the conventional face side of the fabric are no longer uniform.
  • FIG. 11 is an enlarged cross-sectional view of the semi-twill fabric illustrated in FIG. 10, taken looking in the machine direction at a point corresponding to line 3-3 in FIG. 1.
  • FIG. 12 is a simplified illustration of an enlarged partial plan view of an uncreped paper sheet which has been imprinted utilizing the conventional face side of a semi-twill fabric such as is illustrated in FIGS. 10 and 1 l.
  • the long axis of the dash impressions formed by the woof or weft filaments is aligned parallel to the crossmachine direction.
  • FIG. 13 is a simplified illustration of an enlarged partial plan view of an uncreped paper sheet which has been imprinted utilizing the back side of a semi-twill fabric such as is illustrated in FIGS. 10 and 11.
  • the long axis of the dash impressions formed by the warp filaments is aligned parallel to the machine direction, while the long axis of the dot impressions formed by the woof or weft filaments is aligned parallel to the crossmachine direction.
  • the dot impressions are present at this stage due to the fact that the knuckles 'on the back side of the fabric are of uniform height.
  • FIG. 14 is an enlarged cross-sectional view of a monofilament, polymeric fiber, semi-twill fabric such as is illustrated in FIGS. 10 and 11, taken looking in the cross-machine direction at a point corresponding to line 22 in FIG. 1, after the back side of the fabric has been abraded to increase its knuckle imprint area.
  • FIG. 15 is an enlarged cross-sectional view of the semi-twill fabric illustrated in FIG. 14, taken looking in the machine direction at a point corresponding to line 33 in FIG. 1.
  • FIG. 16 is a plan view of an enlarged portion of the monofilament, polymeric fiber, semi-twill fabric illustrated in FIGS. 14 and 15, as viewed from the back side of the fabric.
  • FIG. 17 is a plan view photograph, enlarged about 12 times actual size, of an uncreped paper sheet which has been imprinted utilizing the back side of a semi-twill fabric such as is shown in FIGS. 14, 15, and 16.
  • the pattern produced is similar to that shown in FIG. 13, but the dot-dash impressions constitute a greater percentage of the surface area of the paper due to the increased knuckle imprint area of the fabric.
  • FIG. 18 is an illustration of an enlarged cross-sectional view of the uncreped paper sheet of FIG. 17, taken looking in the cross-machine direction along line 18-18 in FIG. 17.
  • FIG. l9 is a plan view photograph, enlarged about 6 times actual size, of a paper sheet such as is shown in FIGS. 17 and 18 after creping.
  • the long axis of the impressions visible after creping is oriented generally in the cross-machine direction, while the overall surface of the paper exhibits a diamond-shaped pattern characteristic of paper sheets made in accordance with the present invention.
  • FIG. 20 is an illustration of an enlarged cross-section view of the creped paper sheet of FIG. 19, taken looking in the cross-machine direction along line 2020 in FIG. 19.
  • the long axis of the dash impressions 9, where present, is aligned parallel to the crossmachine direction, while the long axis of the dot impressions 3, where present, is aligned parallel to the machine direction.
  • the back side of the semi-twill fabrics referred to herein shall be defined as that side which would not normally contact the paper web according to the teachings of the prior art, i.e., the side of the semi-twill fabric which would, depending upon its particular condition, produce one of the imprint patterns illustrated in FIGS. 5, 9, 13, or 17 (assuming it is a right-hand semi-twill fabric).
  • the long axis of the dash impressions 8 is aligned parallel to the machine direction, while the long axis of the dot impressions 10, where present, is aligned parallel to the cross-machine direction.
  • FIG. 1 represents an enlarged plan view of aportion of a conventional right-hand, monofilament, polymeric fiber, semi-twill fabric as viewed from the back side.
  • the semi-twill fabric illustrated in FIG. 1 has not been used on a paper machine nor has it been accorded any special abrading treatment.
  • the warp monofilaments l are aligned parallel to the machine direction, while the woof or weft monofilaments 2 are aligned parallel to the cross-machine direction.
  • the imprinting fabric illustrated in FIG. 1 has about 20 to about 60 meshes per inch and is formed from monofilament polymeric fibers having diameters ranging from about 0.008 inches to about 0.025 inches.
  • FIGS. 2 and 3 are cross-sectional views of the semi-twill fabric illustrated in FIG. 1, taken looking respectively in the cross-machine and machine directions.
  • the knuckles formed at the cross-over points of the warp filaments 1 and the woof filaments 2 are not coplanar on either the face or the back side of the fabric.
  • the warp filaments l are at a higher relative elevation than the woof filaments 2 on both sides of the fabric. This is termed, for purposes of this specification, a warp-high condition of the fabric.
  • FIG. 4 is a simplified illustration of the knuckle imprint pattern which would result if a semitwill fabric such as is illustrated in FIGS. 1 through 3 were installed so that the conventional face side of the fabric were utilized to imprint an uncreped paper web produced in accordance with the teachings of U.S. Pat. No. 3,301,746 issued to Sanford et al. on Jan. 31, 1967, said patent being incorporated herein by reference.
  • the dot impressions 3 visible on the surface of such an uncreped paper sheet after imprinting form a pattern corresponding to the knuckles 4 of the warp filaments 1 on the conventional face side of the fabric.
  • the dot impressions 3 are formed by the warp filaments l, the long axis of the dot impressions is aligned parallel to the machine direction.
  • the knuckles 7 formed by the woof filaments 2 on the conventional face side of the fabric do not form a corresponding impression in the uncompacted paper web due to the fact that they are at a lower relative elevation than the warp filament knuckles 4.
  • FIG. illustrates the knuckle imprint pattern which would result if an uncompacted paper web produced in accordance with the teachings of U.S. Pat. No.
  • 3,301,746 were imprinted utilizing the back side of an imprinting fabric such as is illustrated in FIGS. 1 through 3. Because the warp filaments 1 are at a higher relative elevation than the woof filaments 2 on the back side of the fabric, only the peaks of the knuckles 5 formed by the warp filaments are impressed into the paper web during the imprinting process. Since the warp filaments 1 run in the machine direction, the resulting pattern consists of a series of relatively long dash impressions 8, wherein the long axis of the impressions is aligned parallel to the machine direction.
  • the imprint pattern illustrated in FIG. 5 differs from the imprint pattern illustrated in FIG. 4 in two important respects.
  • the fabric In order for the knuck- 1 1 les 5 and 6 on the back side of the fabric to reach uniform heights, the fabric must be subjected to further heat treatment; The additional heat treatment in turn causes the heights of the knuckles 4 and 7 on the conventional face side of the semi-twill fabric to again become non-uniform.
  • the initial warp filament spacing and caliper of a semi-twill fabric necessary to produce minimum free area and uniform knuckle heights on the back side of the fabric after heat treatment is determined experimentally by trial and error.
  • a monofilament, polymeric fiber, semi-twill fabric is prepared'by selecting warp monofilaments having a relatively high heat-induced shrinkage potential in the range of about 10 percent to about 30 percent, preferably about'l6 percent. After selecting and spacing the warp monofilaments, polymeric woof monofilaments are selected which have a relatively low heat-induced shrinkage potential in the range of about 2 percent to about 8 percent, preferably about 4 percent.
  • the heat shrinkage treatment takes advantage of the aforementioned shrinkage characteristics of the warp and woof monofilaments.
  • the heat shrinkage treatment comprises subjecting the initially woven fabric to a series of heat applications as it is stretched and secured at its ends in the lengthwise or warp direction, while it is free to shrink in the woof direction.
  • the heat shrinkage treatment is conveniently applied to the initially woven semi twill fabric while the fabric is mounted as an endless belt on a finishing table such as those conventionally used in finishing metal Fourdrinier wires.
  • a conventional wire finishing table consists of two adjustable rolls for supporting, tensioning and driving the wire or fabric to be finished as an endless belt.
  • the heat shrinkage can be induced conveniently by an infrared source mounted as a bank above and across the initially woven fabric. The infrared source heats areas of the initially woven fabric as the fabric slowly revolves on the rolls of the wire finishing table. Heat is applied to the fabric in successive treatments of about 5 seconds to about 40 seconds, preferably about seconds, per treatment. The fabric temperatures during the successive applications of heat approach gradually the softening point of the selected monofilament polymeric fibers.
  • a semi-twill fabric which has been subjected to the aforementioned heat treatment process, although not locked-up as in the case of a plain weave fabric subjected to such a heat treatment process, is dimensionally heat stable at the temperatures encountered in the web imprinting process disclosed in U.S. Pat. No. 3,301,746. 3,301,746.
  • the temperature of the fibers in the successive heat treating passes is increased to a maximum temperature immediately below the softening point of the selected fibers.
  • the heat treating temperature used with Treviera fibers is about 360 to about 400F, preferably about 375F.
  • a sufficient number of successive heating treatments or passes are employed to insure that the monofilament polymeric fibers making up the fabric structure have been at the highest heat treating temperature for a total time of about 15 to about seconds.
  • an initial warp filament spacing in the loom and an initial caliper of the semi-twill fabric are determined experimentally by trial and error to take into account the heat-induced shrinkage which occurs during the above described dimensional heat stabilization process.
  • FIGS. 6 and 7 are enlarged cross-sectional views of a monofilament, polymeric fiber, semi-twill fabric such as is illustrated in FIGS. 1 through 3 after a heat treat ment process such as that described above has been initiated.
  • FIG. 6 is taken looking in the cross-machine direction at a point corresponding to line 2-2 in FIG. I, while FIG. 7 is taken looking in the machine direction at a point corresponding to line 33 in FIG. 1.
  • FIGS. 6 and 7 represent an intermediate condition of the fabric which occurs during the heat treatment process, prior to achieving uniform knuckle heights and minimum free area on the back side of the fabric.
  • FIG. 6 represents the condition which results when the warp filaments I tend to draw themselves closer to a straight line due to the heat induced shrinkage.
  • FIG. 8 is a simplified illustration of an enlarged partial plan view of an uncreped paper sheet produced in accordance with the teachings of US. Pat. No. 3,301,746, which uncreped paper sheet has been imprinted utilizing the conventional face side of a monofilament, polymeric fiber, semi-twill fabric such as is illustrated in FIGS. 6 and 7.
  • the knuckle imprint pattern is similar to that shown in FIG. 4 wherein the dot impressions 3 formed by the knuckles 4 of the warp monofilaments 1 on the conventional face side of the fabric are illustrated, but the dash impressions 9 formed by the knuckles 7 of the woof monofilaments 2 are also present. Because the woof monofilaments 2 are aligned parallel to the cross-machine direction, the long axis of the dash impressions 9 is also aligned paral- 13 lel to the cross-machine direction.
  • FIG. 9 is a simplified illustration of an enlarged partial plan view of an uncreped paper sheet produced in accordance with the teachings of US Pat. No. 3,301,746, which uncreped paper sheet has been imprinted utilizing the back side of a semi-twill fabric such as is illustrated in FIGS. 6 and 7.
  • the long axis of the dash impressions 8 formed by the knuckles of the warp monofilaments l is aligned parallel to the machine direction.
  • paper sheets utilizing the imprinting pattern illustrated in FIG. 8 exhibit a basic regularity of creping wherein the crepe ridges extend substantially uninterrupted across the entire width of the sheet. Addition of the dash impressions 9 to the imprinting pattern does not alter the fact that the imprinted paper sheet is adhered to the dryer drum only at interrupted intervals corresponding to the spacing, in the machine direction, of the dot impressions 3. Paper sheets imprinted with the pattern illustrated in FIG. 9, on the other hand, exhibit a diamond-shaped pattern characteristic of paper sheets made in accordance with the present invention when doctored from the dryer drum.
  • FIG. 10 is taken looking in the cross-machine direction at a point corresponding to line 2-2 in FIG. 1, while FIG. 11 is taken looking in the machine direction at a point corresponding to line 3-3 in FIG. 1.
  • Heat-induced shrinkage of the warp monofilaments l as shown in FIG.
  • the woof monofilaments 2 which, unlike the warp monofilaments l, are not subjected to tension tend to wrap themselves more completely about the warp monofilaments 1 located on the conventional face side of the fabric. Simultaneously, the woof monofilaments 2 tend to belly" or gradually wrap themselves about the two adjacent warp monofilaments 1 located on the back side of the fabric.
  • the heights of the warp monofilament knuckles 5 on the back side of the fabric and the woof monofilament knuckles 6 on the back side of the fabric become uniform, while the heights of the woof monofilament knuckles 7 on the conventional face side of the fabric and the warp monofilament knuckles 4 on the conventional face side of the fabric become nonuniform.
  • the condition illustrated in FIGS. 10 and 1] should result, i.e., a dimensionally heat stabilized semitwill fabric having uniform knuckle heights as well as minimum free area on its back side.
  • FIG. 12 is a simplified illustration of an enlarged partial plan view of an uncreped paper sheet made in accordance with the teachings of US. Pat. No. 3,301 ,746, which uncreped paper sheet has been imprinted utilizing the conventional face side of a semitwill fabric such as is illustrated in FIGS. 10 and 11.
  • the imprinting pattern is basically similar to that shown in FIG. 8, but the dot impressions 3 formed by the warp monofilament knuckles 4 on the conventional face side of the fabric are no longer present due to the fact that the warp monofilament knuckles 4 are at a lower relative elevation than the woof monofilament knuckles 7 on the conventional face side of the fabric.
  • Paper sheets imprinted with the pattern illustrated in FIG. 12 exhibit properties substantially similar to sheets imprinted with the patterns shown in FIGS. 4 and 8 after creping.
  • FIG. 13 is a simplified illustration of an enlarged partial plan view of an uncreped paper sheet produced in accordance with the teachings of US. Pat. No. 3,301,746, which uncreped paper sheet has been imprinted utilizing the back side of a semi-twill fabric such as is illustrated in FIGS. 10 and 11.
  • the dash impressions 8 formed by the warp filament knuckles 5 on the back side of the fabric are essentially the same as those illustrated in FIG. 8, but the dot impressions 10 formed by the woof monofilament knuckles 6 on the back side of the fabric are also present due to the fact that the warp filament knuckles 5 and the woof filament knuckles 6 on the back side of the fabric areof uniform height.
  • Paper sheets produced utilizing the back side of a semitwill fabric such as is illustrated in FIGS. 10 and ll.for imprinting purposes exhibit a diamond-shaped surface appearance aftercreping, which surface appearance is characteristic of papersheets made in accordance with applicants invention.
  • the diamond-shaped pattern becomes more pronounced.
  • the back side of a monofilament, polymeric fiber, semi-twill imprinting fabric in a preferred embodiment of the present invention, is subjected to a treatment wherein the knuckle surfaces of the fabric are abraded using either a wet or dry sandpaper having an effective abrasive grain size of about 300 mesh to about 500 mesh as an abrasive medium.
  • the abrasive media can be mounted on drums for rotative application to the fabric knuckle surfaces.
  • the abrading process can be performed while continuously showering the fabric with water or other cleansing and lubricating fluid, for example light oil, to remove abraded particles and facilitate the polishing operation.
  • the above described abrading operation can be conducted in several stages.
  • the initial abrasion can be carried out with an abrasive medium having an effective abrasive grain size of about 300 mesh, and this initial abrading operation can be followed by an abrasive polishing treatment using a water lubricated wet sandpaper having an effective abrasive grain size of about 500 mesh.
  • Polishing abrasives such as talc, rouge and crocus cloth can also be used to further polish the knuckle surfaces.
  • FIGS. 14 and are enlarged cross-sectional views of a monofilament, polymeric fiber, semitwill fabric such as is illustrated in FIGS. 10 and 11 after the back side of the fabric has been abraded to increase its knuckle imprint area to between about percent and about 50 percent of the total fabric surface area, as measured in the plane of the knuckles.
  • FIG. 16 is a plan view of an enlarged portion of the fabric illustrated in FIGS. 14 and 15, as viewed from the back side of the fabric.
  • the fabric illustrated in FIGS. 14 through 16 represents a preferred embodiment of the present invention
  • FIGS. 14 and 15 taken looking in the cross-machine and machine directions respectively, illustrate the fabric profile which is presented to an uncompacted paper web when the fabric is utilized for imprinting purposes in accordance with the teachings of US. Pat. No. 3,301,746.
  • the warp filament knuckles 5 and the woof filament knuckles 6 as shown in FIGS. 10 and 11 have been abraded to form the plateau-like warp filament knuckles 5 and Woof filament knuckles 6 illustrated in FIGS. 14 and 15.
  • the plateau-like knuckle surfaces 5' and 6' impress an uncompacted paper web to a uniform depth, thus producing a more distinct imprint pattern.
  • the moist paper web carried on an imprinting fabric of the present invention can be thermally pre-dryed by means of passing hot gases, for example air, through the moist paper web and the imprinting fabric.
  • hot gases for example air
  • One suitable apparatus for pre-drying the moist paper web is disclosed in US. Pat. No. 3,303,576 issued to Sisson on Feb. 14, I967, which patent is incorporated herein by reference.
  • the means by which thermal predrying is accomplished is not critical, it is critical that the relationship of the moist web to the imprinting fabric be maintained once established.
  • thermal pre-drying is used to effect a fiber consistency in the moist paper web from about 30 percent to about percent, preferably about 40 percent to about 80 percent.
  • the aforementioned Sanford et al. patent further teaches that at fiber consistencies less than about 30 percent, the desirably balanced sheet characteristics of softness, bulk and absorbency suffer because the sheet and the fibers thereof are two moist, and yielding occures during the imprinting step.
  • the aforementioned Sanford et al. patent also teaches that pre-drying to fiber consistencies above about 80 percent precludes the development of effective tensile strengths in the imprinted paper sheet.
  • Imprinting the fabric knuckle pattern in the moist web by pressing the pre-dryed web against a relatively non-yielding surface, for example, an unheated steel roll or a Yankee dryer surface, while the pre-dryed web is yet carried on the imprinting fabric results in a paper sheet having impressed in its surface, to a depth of at least 30 percent of its machine glazed caliper the knuckle pattern of the imprinting fabric.
  • Machine glazed claiper refers to the caliper of the paper sheet taken directly from the Yankee dryer, before creping.
  • the knuckle surfaces and 6' illustrated in FIGS. 14 through 16 in a preferred embodiment of the present invention, are impressed to a uniform depth of at least 30 percent of the machine glazed caliper of the uncreped paper sheet.
  • the pressure required for the imprinting of the imprinting fabric pattern can be provided, in a preferred embodiment of the present invention, by one or more pressure rolls operating on the imprinting fabric to force the knuckles of the fabric into the surface of the pre-dryed web and to force the pre-dryed web surface under the knuckles against a Yankee dryer surface.
  • the imprinting step described above be the first substantial overall mechanical compaction step which the paper web has received during formation and pre-drying.
  • FIG. 17 is a photograph of an enlarged partial plan view of an uncreped paper sheet made in accordance with the teachings of US. Pat. No. 3,301,746, utilizing the back side of a semi-twill fabric such as is illustrated in FIGS. 14 through 16 to imprint the uncompacted paper web.
  • the resulting knuckle imprint pattern is basically similar to that shown in FIG. 13.
  • the dash impressions 8 formed by the warp filament knuckles 5' and the dot impressions formed by the woof filament knuckles 6' constitute a greater percentage of the sheets surface area due to the increase in the size of the fabric knuckles.
  • the impressions 8 and 10 are more distinct due to the fact that they are of substantially uniform depth, having been produced by the plateau-like surfaces of the knuckles 5 and 6'.
  • FIG. 18 is an illustration of an enlarged cross-sectional view of the uncreped paper sheet of FIG. 17, taken looking in the cross-machine direction along line 18-48 in FIG. 17.
  • FIG. 19 is a photograph of an enlarged partial plan view of a creped paper sheet made in accordance with the teachings of US. Pat. No. 3,301,746, utilizing the back side of a semi-twill fabric such as is illustrated in FIGS. 14 through 16 to imprint the uncompacted paper web prior to creping.
  • the long axis of the impressions 11 visible after creping appears to be oriented generally in the cross-machine direction.
  • FIG. 20 is an illustration of an enlarged cross-sectional view of the paper sheet of FIG. 19, taken looking in the cross-machinc direction along line 2020 in FIG. 19.
  • a finished paper sheet such as is illustrated in FIGS. 19 and 20, produced in accordance with the present invention exhibits improvements in cross-directional stretch, softness, surface feel and drape which are not achievable by the paper manufacturing process disclosed in US. Pat. No. 3,301,746 when a similarly precharacteristics, does not produce the improvements in cross-directional stretch, softness, surface feel and drape which are realized by increasing the knuckle imprint area on the back side of a semi-twill imprinting fabric.
  • creped paper sheets exhibiting a diamond-shaped surface appearance composed substantially of cellulosic fibers, having basic weights of from about 5 to about 40 pounds per 3000 square feet, and exhibiting a repeating pattern of discrete impressed areas are produced.
  • Furnish comprised of a 50 percent softwood kraft and a 50 percent hardwood sulfite stock was utilized throughout the entire series of tests.
  • An adhesive coat was applied to the Yankee dryer surface by utilizing a wire glue roll of approximately 40 mesh turning at a lineal speed of approximately 9 feet per minute at its periphery in an open glue pot and then spraying the glue picked up on the wire mesh glue roll onto the surface of the Yankee dryer drum by means of a series of air jets located interiorly of the glue roll and operating continuously at an air pressure of p.s.i.g.
  • the glue utilized was purchased under the specification Peter Cooper IX from the Peter Cooper Corporation of Gowanda, New York.
  • the mixture, as applied, contained 1 part glue and 99 parts water.
  • the pre-dryed and imprinted web was caused to part from the imprinting fabric at the pressure nip exit and adhere to the Yankee dryer surface by means of the adhesive coat described above.
  • the dry creped sheet was removed from the Yankee dryer by means of a conventional doctor blade so that the finished product had 12 percent stretch as crepe folds.
  • the fabrics were both 31 (machine direction) by 28 (crossmachine direction) mesh utilizing warp and woof 19 monofilaments having a diameter of 0.45 mm. (about 0.018 inches).
  • One of the fabrics was woven so as to present its back side as a web contacting surface and the other was woven so as to present its conventional face side as a web contacting surface. Both of the fabrics, as received, were in a configuration similar to that illustrated in FIGS.
  • the fabric woven so as to present its back side as a web contacting surface was found to have an initial knuckle imprint area of about 21.2 percent in the asreceived condition, while the fabric woven so as to present its conventional face side as a web contacting surface was found to have a knuckle imprint area of about 23.4 percent in the as-received condition.
  • Example I Data taken from paper samples made utilizing the imprinting fabric having its back side in contact with the uncompacted paper web is reported hereinbelow under Example I. Data taken from paper samples made utilizing the imprinting fabric having its conventional face side in contact with the uncompacted paper web is reported hereinbelow under Example II. With the exception of the imprinting fabrics, the paper machine conditions were unchanged between Examples I and II.
  • each fabric was abraded in accordance with the teachings of US. Pat. No. 3,573,164.
  • the knuckle imprint area on the fabric utilizing its back side as a web contacting surface was increased from approximately 21.2 percent to approximately 28.4 percent, while the knuckle imprint area of the fabric utilizing its conventional face side as a web contacting surface was increased from approximately 23.4 percent to approximately 34.1 percent.
  • the tests were repeated keeping all paper machine conditions, other than the increased knuckle imprint area of the fabrics, unchanged. The results of tests performed on sample paper sheets taken during each run are tabulated hereinbelow under Examples Ill and IV.
  • Example III The data set forth in Example III is taken from sample sheets made utilizing the semi-twill imprinting fabric which presented its back side to the uncompacted paper web, while the data set forth in Example IV is taken from sample sheets made utilizing the semi-twill fabric which presented its conventional face side to the uncompacted paper web.
  • Example V Data set forth in Example V is taken from paper sheets made utilizing the semi-twill fabric which presented its back side to the uncompacted paper web, while data set forth in Example VI is taken from paper sheets made utilizing the semi-twill fabric which presented its conventional face side to the uncompacted paper web.
  • the caliper of a paper sheet at grams per square inch is the thickness of that sheet when subjected to a compressive load of 80 grams per square inch.
  • the tensile strengths in the machine direction (MD) and cross-machine direction (CD), as tabulated in the Examples hereinbelow, are reported as the force in grams that a 1 inch wide sample with a 4 inch span between the tensile tester clamps, cut in the MD or CD direction, can withstand before breaking, as measured on a standard Thwing-Albert Tensile Tester such as is available from the Thwing-Albert Instrument Company of Philadelphia, Pennsylvania.
  • a Thwing-Albert I-Iandle-O-Meter catalogue num-. ber 21 1-3, such as is available from the Thwing-Albert Instrument Company of Philadelphia, Pennsylvania, was used to measure a combination of stiffness and sliding friction of the paper samples.
  • a high Handle-O- Meter or I-I-O-M reading indicates a lack of softness and is, therefore, undesirable.
  • a lower I-I-O-M reading indicates a softer sheet.
  • Two 4 /2 inch by 4 /2 inch paper samples were placed side by side over the 0.25 inch wide Handle-O-Meter slot located beneath the blade of the unit.
  • the Shirley Stiffness Tester is described in ASTM Standard Method No. 1388.
  • the horizontal platform of the instrument is supported by two side pieces made of plastic. These side pieces have engraved on them index lines at the standard angle of deflection of 41 /2.
  • 21 tached to the instrument is a mirror which enables the operator to view both index lines from a convenient position.
  • the scale of the instrument is graduated in centimeters. The scale may be used as a template for cutting the specimens to size.
  • a rectangular strip ofpaper 6 inches by 1 inch, is cut to the same size as the scale and then both scale and specimen are transferred to the platform with the specimen underneath.- Both are slowly pushed forward.
  • the strip of paper will commence to droop over the edge of the platform as the scale and specimen are advanced. Movement of the scale and the specimen is continued until the tip of the specimen viewed in the mirror cuts both of the index lines.
  • the amount of overhang, I can immediately be read off from the scale mark opposite a zero line engraved on the side of the platform.
  • the bending length 0, for purposes of these tests, shall be defined as the length of paper that will bend under its own weight to a definite extent. it is a measure of the stiffness that determines draping quality. The calculation is as follows: i
  • Flexural rigidity, G is a measure of stiffness associated with handle.
  • the calculation of flexural rigidity, G, in the present instance is as follows:
  • the bending modulus, q as reported in the Examples hereinbelow, is independent of the dimensions of the strip tested and may be regarded as .the intrinsic stiffness of the material. Therefore, this value may be used to compare the stiffness of materials having different 10 thicknesses. For its calculation, the thickness or caliper of the paper sample must be measured at a pressure of 1 pound per square inch.
  • the bending modulus, q is; then given by:
  • G is the flexural rigidity of the particular paper sample as determined above, expressed in mg. cm.
  • g is the thickness or caliper of the particular paper sample, expressed in mils, when subjected to a pressure of 1 pound per square inch.
  • the knuckle imprint areas referred to in the Examples hereinbelow were determined by making an impression with pressure sensitive paper in each of four areas on the web contacting surface of the imprinting 3O fabric utilized in the particular Example. Enlarged photographs were taken of each of the four impressions, and a unit-cell of knuckles, i.e., one repeating pattern of knuckles, was enclosed in each photograph. The total area of each enclosed unit-cell and the total area of the knuckles inside each such unit-cell'we re then 40
  • the Examples below compare the finished sheet properties of paper samples produced in accordance with the present invention with the sheet properties of paper samples produced utilizing the conventional face side of a similar imprinting fabric at various stages of fabric treatment.
  • EXAMPLE 1 Back side of imprinting fabric contacting web Cal Basis Sample no. ipcr at Knuckle weight Bending (for indentigm/ imprint pounds] Tensile Tensile Handle Handle- Stretch Stretch Modulus fication pursq.in., area, 3,000 MD,gm./ CD,gm./ O-Meter O-Meter MD. CD. q",kg./ poses only) inches percent sq.ft. in. in. MD CD "/1 71 sq.cm.
  • EXAMPLE 11 Conventional face side of imprinting fabric contacting web Cal- Basis Sample no.' iper at Knuckle weight Bending (for indenti- 80 gm/ imprint pounds/ Tensile Tensile Handle- Handle- Stretch Stretch Modulus fication pursq.in., area, 3,000 MD,gm./ CD,gm./ O-Meter O-Meter MD, CD, q,kg./ poses only) inches percent sq.ft. in. in. MD CD sq.cm.
  • EXAMPLE 111 Back side of imprinting fabric contacting web Cal- Basis Sample no. iper at Knuckle weight Bending (for indenti- 80 gm/ imprint pounds/ Tensile Tensile Handle- Handle- Stretch Stretch Modulus fication pursq.in.. area, 3,000 MD,gm./ CD,gm./ O-Meter OMeter MD. CD, q,kg./ poses only). inches percent sq.ft. in. in. MD CD 7: sq.cm.
  • EXAMPLE lV Conventional face side of imprinting fabric contacting web Cal- Basis Sample no. iper at Knuckle weight Bending 1 (for indenti- 80 gm/ imprint pounds/ Tensile Tensile Handle Handle- Stretch Stretch Modulus fication pursq.in., area, 3,000 MD,gm./ CD,gm./ O-Meter O-Meter MD, CD. q".kg./ poses only) inches percent sq.ft. in. in. MD CD sq.cm.
  • EXAMPLE V Back side of imprinting fabric contacting web Cal- Basis Sample no. iper at Knuckle weight Bending (for indenti- 80 gm/ imprint pounds/ Tensile Tensile Handle- Handle- Stretch Stretch Modulus fication pursq.in., area. 3,000 MD,gm./ CD.gm./ O Metcr O-Meter MD, CD, q",kg./ poses only) inches percent sq.ft. in. in. MD CD "/1 7r sq cm.
  • EXAMPLE V1 Conventional face side of imprinting fabric contacting weh Cal- 7 Basis Sample no. iper at Knuckle weight Bending (for indenti- 80 gm/ imprint pounds/ Tensile Tensile Handle- Handle- Stretch Stretch Modulus fication pursq.in., area. 3,000 MD.gm./ CD.gm./ O-Mcter O-Mctcr MD, CD. q",kg./ poses only) inches percent sq.ft. in. in. MD CD /1 sq.cm.
  • EXAMPLE Vl Continued Conventional face side of imprinting fabric contacting web Cal- Basis Sample no. iper at Knuckle weight Bending (for indenti- 80 gm/ imprint pounds ⁇ Tensile Tensile Handle- Handle- Stretch Stretch Modulus fication pursq.in., area, 3,000 MD,gm./ CD,gm./ O-Meter O-Meter MD. CD, q",kg./ poses only) inches percent sq.ft. in. in. MD CD sq.cm.
  • a process for the manufacture of a soft, bulky and absorbent paper sheet which comprises the steps of:
  • said imprinting fabric being formed from filaments having a diameter of about 0.008 to about 0.025 inches,
  • step (a) is molded to conform to the pattern of the imprinting fabric prior to thermally pre-drying the uncompacted paper web in step (c).
  • a process for the manufacture of a soft, bulky and absorbent paper sheet which comprises the steps of: a. forming an uncompacted paper web having a uniform basis weight of about 9 to about 25 pounds per 3000 square feet,
  • step (a) is molded to conform to the pattern of the imprinting fabric prior to thermally pre-drying the uncompacted web in step (c).
US457043A 1973-06-08 1974-04-01 Process for forming absorbent paper by imprinting a semi-twill fabric knuckle pattern thereon prior to final drying and paper thereof Expired - Lifetime US3905863A (en)

Priority Applications (16)

Application Number Priority Date Filing Date Title
US457043A US3905863A (en) 1973-06-08 1974-04-01 Process for forming absorbent paper by imprinting a semi-twill fabric knuckle pattern thereon prior to final drying and paper thereof
CA201,613A CA1007911A (en) 1973-06-08 1974-06-04 Process for forming absorbent paper by imprinting a semi-twill fabric knuckle pattern thereon prior to final drying and paper thereof
AU69861/74A AU6986174A (en) 1973-06-08 1974-06-06 Absorbent paper
CH771274A CH592209A5 (xx) 1973-06-08 1974-06-06
DE19742427291 DE2427291A1 (de) 1973-06-08 1974-06-06 Verfahren zur herstellung von weichem, dickgriffigem, saugfaehigem papier
DK303474AA DK137248B (da) 1973-06-08 1974-06-06 Fremgangsmåde til fremstilling af et blødt, fyldigt og absorberende papirsark.
IT23743/74A IT1014871B (it) 1973-06-08 1974-06-07 Processo per formare carta assor rente mediante impressione di un disegno a nodi di tessuto semidia gonale su di essa prima dell asciu gamento finale e carta cosi otte nuta
SE7407532A SE412262B (sv) 1973-06-08 1974-06-07 Forfarande for framstellning av ett mjukt, voluminost och absorberande pappersark
NO742069A NO141904C (no) 1973-06-08 1974-06-07 Fremgangsmaate for fremstilling av absorberende papir
IE1204/74A IE40284B1 (en) 1973-06-08 1974-06-07 Paper sheets and processes for their manufacture
FR7419847A FR2241642B1 (xx) 1973-06-08 1974-06-07
NL7407635A NL7407635A (xx) 1973-06-08 1974-06-07
FI1753/74A FI175374A (xx) 1973-06-08 1974-06-07
JP49065508A JPS5742760B2 (xx) 1973-06-08 1974-06-08
GB2558974A GB1436067A (en) 1973-06-08 1974-06-10 Paper sheets and processes for their manufacture
US05/588,580 US3974025A (en) 1974-04-01 1975-06-19 Absorbent paper having imprinted thereon a semi-twill, fabric knuckle pattern prior to final drying

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US36844073A 1973-06-08 1973-06-08
US457043A US3905863A (en) 1973-06-08 1974-04-01 Process for forming absorbent paper by imprinting a semi-twill fabric knuckle pattern thereon prior to final drying and paper thereof

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JP (1) JPS5742760B2 (xx)
AU (1) AU6986174A (xx)
CA (1) CA1007911A (xx)
CH (1) CH592209A5 (xx)
DE (1) DE2427291A1 (xx)
DK (1) DK137248B (xx)
FI (1) FI175374A (xx)
FR (1) FR2241642B1 (xx)
GB (1) GB1436067A (xx)
IE (1) IE40284B1 (xx)
IT (1) IT1014871B (xx)
NL (1) NL7407635A (xx)
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