Methods for forming a fluted composite

• US 20060005934A1
• Filed: 02/28/2005
• Published: 01/12/2006
• Est. Priority Date: 03/19/1998
• Status: Active Grant

• Current Assignee: Charles E. Miller, Clifford R. Bolstad, Daniel T. Bunker, Fred B. Howard, Peter A. Graef
• Original Assignee: Charles E. Miller, Clifford R. Bolstad, Daniel T. Bunker, Fred B. Howard, Peter A. Graef
• Inventors: Graef, Peter A., Howard, Fred B., Bunker, Daniel T., Bolstad, Clifford R., Miller, Charles E.
• Granted Patent: US 7,166,190 B2
• Time in Patent Office: Days
• US Class Current: 162/146
• CPC Class Codes: A61F 13/15617 Making absorbent pads from fibres or pulverulent material with or without treatment of the fibres
• CPC Class Codes: A61F 13/15658 Forming continuous, e.g. composite, fibrous webs, e.g. involving the application of pulverulent material on parts thereof
• CPC Class Codes: A61F 13/15699 Forming webs by bringing together several webs, e.g. by laminating or folding several webs, with or without additional treatment of the webs
• CPC Class Codes: A61F 13/534 having an inhomogeneous composition through the thickness of the pad A61F13/538, A61F13/539 take precedence; homogeneous cores with tissue wrapping A61F13/53
• CPC Class Codes: A61F 13/536 having discontinuous areas of compression
• CPC Class Codes: A61F 2013/1539 being expandable
• CPC Class Codes: A61F 2013/4581 with absorbent core in separated pieces
• CPC Class Codes: A61F 2013/530386 with pulp and polymeric
• CPC Class Codes: A61F 2013/530481 having superabsorbent materials, i.e. highly absorbent polymer gel materials
• CPC Class Codes: D21C 9/002 by chemical means; preparation of dewatered pulp, e.g. in sheet or bulk form, containing special additives
• CPC Class Codes: D21F 11/002 by using a foamed suspension
• CPC Class Codes: D21F 11/006 Making patterned paper
• CPC Class Codes: D21F 11/04 paper or board consisting on two or more layers
• CPC Class Codes: D21F 11/14 Making cellulose wadding, filter or blotting paper
• CPC Class Codes: D21F 9/006 paper or board consisting of two or more layers
• CPC Class Codes: D21H 11/20 Chemically or biochemically modified fibres

Abstract

Methods for forming an absorbent fibrous composite containing absorbent material dispersed in bands through the composite and along the composite'"'"'s length are disclosed. The methods generally include depositing a fibrous slurry on a foraminous support to form a web and depositing or injecting absorbent material into the web across its width to provide a web having absorbent material in bands along the composite'"'"'s length. Drying the web provides a fluted absorbent composite. In one embodiment, the method is a wetlaid method and in another embodiment, the method is a foam-forming method. Preferably, the methods are twin-wire forming methods.

Claims

1. A method for making a fibrous layer, comprising:

refining cellulosic fibers to provide refined fibers, wherein the cellulosic fibers comprise crosslinked cellulosic fibers;

combining the refined fibers with a dispersion medium to provide a fibrous slurry;

depositing the fibrous slurry on a foraminous support to provide a wet composite;

introducing an adsorbent material into said wet composite at a plurality of points, said absorbent material having an absorbent capacity greater than the refined cellulosic fibers; and

drying the wet composite to provide a fibrous layer.

2. The method of claim 1, wherein the cellulosic fibers comprise a blend of crosslinked cellulosic fibers and noncrosslinked cellulosic fibers.

3. The method of claim 2, wherein the noncrosslinked fibers are at least one of softwood fibers or hardwood fibers.

4. The method of claim 2, wherein the noncrosslinked fibers comprise southern pine fibers.

5. The method of claim 1, wherein the cellulosic fibers comprise a blend of crosslinked cellulosic fibers and southern pine fibers.

6. The method of claim 1, wherein the cellulosic fibers comprise a refined blend of said crosslinked cellulosic fibers and southern pine fibers.

7. The method of claim 1, wherein the cellulosic fibers comprise a blend of crosslinked cellulosic fibers and refined southern pine fibers.

8. The method of claim 1, wherein the cellulosic fibers comprise a refined blend of crosslinked cellulosic fibers and refined southern pine fibers.

9. The method of claim 1, wherein the method is carried out on at least one of a Fourdrinier or a twin-wire papermaking machine.

10. The method of claim 1, wherein the method is at least one of a wetlaid method and a foam-forming method.

11. A method for making a fibrous layer, comprising:

refining cellulosic fibers to provide refined fibers, wherein the cellulosic fibers comprise

combining the refined fibers with a dispersion medium to provide a fibrous slurry;

moving a first foraminous element in a first path;

moving a second foraminous element in a second path;

passing a first portion of the fibrous slurry into contact with the first foraminous element;

passing a second portion of the fibrous slurry into contact with the second foraminous element;

forming a fibrous web from the slurry by withdrawing liquid from the slurry through the first and second foraminous elements;

introducing and absorbent material into said fibrous web at a plurality of points, said absorbent material having an absorbant capacity greater than the refined cellulosic fibers; and

drying the web provide a fibrous layer.

12. The method of claim 11, wherein the cellulosic fibers comprise a blend of crosslinked cellulosic fibers and noncrosslinked cellulosic fibers.

13. The method of claim 12, wherein the noncrosslinked fibers are at least one of softwood fibers or hardwood fibers.

14. The method of claim 12, wherein the noncrosslinked fibers comprise southern pine fibers.

15. The method of claim 11, wherein the cellulosic fibers comprise a blend of crosslinked cellulosic fibers and southern pine fibers.

16. The method of claim 11, wherein the cellulosic fibers comprise a refined blend of said crosslinked cellulosic fibers and southern pine fibers.

17. The method of claim 11, wherein the cellulosic fibers comprise a blend of crosslinked cellulosic fibers and refined southern pine fibers.

18. The method of claim 11, wherein the cellulosic fibers comprise a refined blend of crosslinked cellulosic fibers and refined southern pine fibers.

19. The method of claim 11, wherein the method is at least one of a wetlaid method or a foam-forming method.