Paper webs having a watermark pattern

• US 20030102098A1
• Filed: 11/30/2001
• Published: 06/05/2003
• Est. Priority Date: 11/30/2001
• Status: Active Grant

• Current Assignee: Kimberly-Clark Worldwide Incorporated (Kimberly-Clark Corporation)
• Original Assignee: Kimberly-Clark Worldwide Incorporated (Kimberly-Clark Corporation)
• Inventors: Allen, Peter J., Burazin, Mark Alan, Tsai, Chuan-Ling, Capizzi, Joseph G.
• Granted Patent: US 7,070,678 B2
• Time in Patent Office: Days
• US Class Current: 162/203
• CPC Class Codes: D21F 11/006 Making patterned paper
• CPC Class Codes: D21F 11/14 Making cellulose wadding, filter or blotting paper
• CPC Class Codes: D21F 3/105 Covers thereof
• CPC Class Codes: Y10T 428/24273 including aperture
• CPC Class Codes: Y10T 428/24322 Composite web or sheet
• CPC Class Codes: Y10T 428/24942 including components having same physical characteristic in differing degree
• CPC Class Codes: Y10T 428/24992 Density or compression of components

Abstract

A process for producing paper webs having a pattern formed into the web is disclosed. The pattern is formed during formation of the web and is made by varying the basis weight of the web. The paper web is produced by depositing an aqueous suspension of fibers between two forming surfaces. One or both of the forming surfaces include lower permeability areas that create lower basis weight areas in the web. The lower permeability areas are contained in the forming surface according to a particular pattern. For instance, the lower permeability areas can be formed into a drainage roll sleeve contained on a drainage roll which contacts a forming surface. The drainage roll can be a forming roll or a breast roll.

Claims

1. A process for producing a paper web comprising:

forming an aqueous suspension of fibers comprising pulp fibers;

directing said aqueous suspension between a first forming surface and a second forming surface, said first and second forming surfaces being configured to allow fluids to drain from said aqueous suspension, said first forming surface located on a first drainage roll, said first drainage roll being surrounded by a first drainage roll sleeve, said first drainage roll sleeve being located between said first drainage roll and said first forming surface, said first drainage roll sleeve having a first predetermined pattern of lower permeability sections; and

forming a paper web between said first and second forming surfaces from said aqueous suspension of fibers, said paper web defining first areas having a first basis weight and second areas having a second basis weight, said first basis weight being greater than said second basis weight, said second areas forming on said first forming surface where said lower permeability sections are located on said drainage roll sleeve, said first and second areas defining a first pattern of fiber distribution gradients.

2. A process as defined in claim 1, wherein said first drainage roll is a breast roll, said breast roll defining drainage channels.

3. A process as defined in claim 1, wherein said first drainage roll is a forming roll.

4. A process as defined in claim 1, wherein said second forming surface is positioned on a second drainage roll, said second drainage roll being surrounded by a second drainage roll sleeve comprising a second predetermined pattern of lower permeability areas, said second drainage roll sleeve being located between said second drainage roll and said second forming surface, said paper web defining a second pattern of fiber distribution gradients, said second pattern of fiber distribution gradients forming on said second forming surface according to said second predetermined pattern of lower permeability areas.

5. A process as defined in claim 4, wherein said first drainage roll is a forming roll and said second drainage roll is a breast roll.

6. A process as defined in claim 4, wherein said first pattern of fiber distribution gradients and said second pattern of fiber distribution gradients form visible patterns on said paper web.

7. A paper product comprising:

a paper web containing pulp fibers comprising a first side and a second side, said first side defining first areas having a first basis weight and second areas having a second basis weight, said first and second areas located on said first side according to a first predetermined pattern, said first basis weight being at least 1.1 times greater than said second basis weight, said first side having a first pattern of fiber distribution gradients according to said first predetermined pattern.

8. A paper product as defined in claim 7, wherein said second side of said web comprises a substantially homogenous fiber distribution.

9. A paper product as defined in claim 7, wherein said second side of said web has a fiber distribution that is different than the fiber distribution of said first side.

10. A paper product as defined in claim 7, wherein said second side of said web comprises a second pattern of fiber distribution gradients according to a second predetermined pattern.

11. A paper product as defined in claim 7 wherein said second areas comprise individually discrete shapes surrounded by said first areas.

12. A paper product as defined in claim 7, wherein said pattern of fiber distribution gradients is visible.

13. A paper product as defined in claim 7, wherein said first basis weight is from about 1.1 to about 3.3 times greater than said second basis weight.

14. A paper product as defined in claim 7, wherein said paper web has a basis weight of less than about 25 lbs per ream.

15. A paper product as defined in claim 7, wherein said paper web has a basis weight of from about 25 to about 70 lbs per ream.

16. A paper product as defined in claim 7, wherein said paper web consists essentially of pulp fibers.

17. A paper product as defined in claim 7, wherein said first areas form rows surrounding said second areas.

18. A paper product as defined in claim 7, wherein said paper product has lateral edges and wherein at least certain of said rows formed by said first areas are diagonal to said lateral edges.

19. A paper product as defined in claim 11, wherein said individually discrete shapes have a greatest dimension of at least 1 mm.

20. A paper product as defined in claim 7, wherein said first areas comprise at least about 25% of the area of said paper web.

21. A paper product as defined in claim 7, wherein said paper web is a single layer.

22. A paper product as defined in claim 7, wherein said paper product comprises a tissue.

23. A paper product as defined in claim 7, wherein said paper product comprises a paper towel.

24. A paper product as defined in claim 7, wherein the pattern of second areas having a second basis weight located on the first side of the paper web substantially corresponds to a pattern of lower permeability sections on a drainage roll sleeve upon which the paper web is formed.

25. A system for producing a paper web comprising:

a head box for receiving an aqueous suspension of fibers for formation of a base web;

a first forming fabric;

a second forming fabric, said second forming fabric overlapping said first forming fabric along a determined distance, said first and second forming fabrics being configured to receive said aqueous suspension of fibers between them;

a first drainage roll positioned against said first forming fabric; and

a first drainage roll sleeve wrapped around said first drainage roll, said first drainage roll sleeve comprising first areas having a first permeability and second areas having a second permeability, said first and second areas located on said first drainage roll sleeve according to a first predetermined pattern, said first areas having a greater permeability than said second areas, said first drainage roll sleeve located between said first drainage roll and said first forming fabric.

26. The system as defined in claim 25, wherein said first drainage roll is a forming roll.

27. The system as defined in claim 26, wherein said forming roll is a vacuum roll.

28. The system as defined in claim 25, wherein said first drainage roll is a breast roll, said breast roll defining drainage channels.

29. The system as defined in claim 25, further comprising a second drainage roll positioned against said second forming fabric, said second drainage roll comprising a second drainage roll sleeve wrapped around said second drainage roll, said second drainage roll sleeve comprising third areas having a third permeability and fourth areas having a fourth permeability, said third and fourth areas located on said second drainage roll sleeve according to a second predetermined pattern, said third areas having a lower permeability than said fourth areas, said second drainage roll sleeve located between said second drainage roll and said second forming fabric.

30. The system as defined in claim 29, wherein said first drainage roll is a forming roll and said second drainage roll is a breast roll defining drainage channels.

31. The system as defined in claim 25, wherein said fluid drainage through said first forming fabric comprises from about 20% to about 90% of total fluid drainage of said system.

32. The system as defined in claim 25, wherein said fluid drainage through said first forming fabric comprises from about 40% to about 60% of total fluid drainage of said system.

33. The system as defined in claim 25, wherein said fluid flow through said first drainage roll sleeve is completely blocked off at said second areas.

34. The system as defined in claim 25, wherein said first drainage roll sleeve is a multilayer drainage roll sleeve comprising a first layer and a second layer, said first layer comprising said first and second areas, said first layer contacting said first forming fabric.

35. A drainage roll comprising:

a cylinder defining passages configured to permit the passage of fluids therethrough; and

a drainage roll sleeve wrapped around said cylinder, said drainage roll sleeve comprising first areas having a first permeability and second areas having a second permeability, said first and second areas located on said drainage roll sleeve according to a predetermined pattern, said first permeability being greater than said second permeability, said first areas comprising at least about 25% of said drainage roll sleeve.

36. A drainage roll as defined in claim 35, wherein said drainage roll is a forming roll.

37. A drainage roll as defined in claim 35, wherein said drainage roll is a breast roll.

38. A drainage roll as defined in claim 35, wherein said drainage roll sleeve is comprised of polymeric fibers.

39. A drainage roll as defined in claim 35, wherein said drainage roll sleeve is comprised of a metal.

40. A drainage roll as defined in claim 35, wherein said drainage roll sleeve further comprises a coating applied to said drainage roll sleeve according to said predetermined pattern, said coating forming said second areas.

41. A drainage roll as defined in claim 35, wherein said coating is selected from the group consisting of a glue, a paint, an epoxy, a caulk, a rubber, and a sealant.

42. A drainage roll as defined in claim 35, wherein said drainage roll sleeve further comprises a photo-sensitive resin applied to said drainage roll sleeve according to said predetermined pattern, said photo-sensitive resin forming said second areas.

43. A drainage roll as defined in claim 35, wherein said drainage roll sleeve is a multilayer drainage roll sleeve comprising a first layer and a second layer.

44. A drainage roll as defined in claim 43, wherein said first layer comprises said first areas and said second areas.

45. A drainage roll as defined in claim 35, wherein said second areas comprise a woven pattern formed into said drainage roll sleeve.

46. A drainage roll as defined in claim 35, wherein said first areas comprise a first material and said second areas comprise a second material, said second material being attached to said first material.