Method of making a clothlike pattern densified web

• US 20060124261A1
• Filed: 11/09/2005
• Published: 06/15/2006
• Est. Priority Date: 09/02/2003
• Status: Active Grant

• Current Assignee: Kimberly-Clark Worldwide Incorporated (Kimberly-Clark Corporation)
• Original Assignee: Jeffrey Dean Lindsay, Jeffrey Janne Johnson, Mark John Hassman, Maurizio Tirimacco, Michael Alan Hermans, Mike Thomas Goulet, Rebecca Catherine Mohr
• Inventors: Hermans, Michael Alan, Lindsay, Jeffrey Dean, Tirimacco, Maurizio, Hassman, Mark John, Goulet, Mike Thomas, Mohr, Rebecca Catherine, Johnson, Jeffrey Janne
• Granted Patent: US 7,435,312 B2
• Time in Patent Office: Days
• US Class Current: 162/117
• CPC Class Codes: B32B 2317/18 Cellulose, modified cellulose or cellulose derivatives, e.g. viscose B32B2317/10, B32B2317/12, B32B2317/16 take precedence
• CPC Class Codes: B32B 29/00 Layered products comprising a layer of paper or cardboard
• CPC Class Codes: B32B 3/28 characterised by a layer comprising a deformed thin sheet , i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled B32B29/08 takes precedence
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: D21H 19/74 the substrate having an uneven surface, e.g. crêped or corrugated paper
• CPC Class Codes: D21H 21/18 Reinforcing agents
• CPC Class Codes: D21H 27/02 Patterned paper patterned coatings D21H19/66; embossing B31F1/07; prepared on the paper-making machines D21F11/00
• CPC Class Codes: D21H 27/30 Multi-ply for surface covering D21H27/18; making on paper-making machines D21F9/00, D21F11/00

Abstract

An improved paper and the process of making an improved paper web are disclosed. The improved paper is characterized as having two regions; one is a network (or open grid) region and the other is a plurality of domes. At least a portion of either region of the paper web contains a bonding material that penetrates at least partially through the paper'"'"'s thickness.

Claims

1. A process for making a paper web comprising the steps of:

forming an embryonic paper from paper making fibers contacting the embryonic web with a deflection member having an embryonic web contracting surface comprising a macroscopically monoplanar, patterned, continuous network surface defining within the deflection member a plurality of discrete, isolated, nonconnecting deflection conduits; and

the deflection member having a second surface;

deflecting at least a portion of the embryonic web into the deflection conduits intermediate the embryonic web contacting surface and the second surface and rearranging the papermaking fibers to form an intermediate web of the papermaking fibers;

predrying the intermediate web in association with the deflection member to a consistency of from about 25% to about 98% to form a pre-dried web of paper making fibers;

impressing the network surface into the pre-dried web by interposing the pre-dried web between the deflection member and an impression surface to form an imprinted web of papermaking fibers;

drying the imprinted web;

applying a bonding material to either the imprinted web or to the pre-dried web of paper making fibers to form a bond material penetrated paper web.

2. The process of claim 1 wherein the embryonic web is formed from an aqueous dispersion of papermaking fibers.

3. The process of claim 1 wherein the embryonic web is an air laid web of papermaking fibers.

4. The process of claim 2 further comprising hydrating the air laid embryonic web with water prior to deflecting the embryonic web into the deflection conduits.

5. The process of claim 1 further comprising foreshortening the bond material penetrated paper web.

6. The process of claim 1 further comprising foreshortening the bond material penetrated paper web and then curing the bond material.

7. The process of claim 1 wherein the bond material is applied in an online operation on a paper machine prior to drying the imprinted web.

8. The process of claim 1 wherein the bond material is applied in an offline process after drying the imprinted web on a paper machine.

9. The process of claim 1 wherein the impressing comprises interposing the pre-dried web and the deflection member between an impression nip roll and a Yankee dryer.

10. The process of claim 1 wherein the impressing comprises interposing the pre-dried web and the deflection member between an anvil roll and a transfer roll.

11. The process of claim 10 wherein the impressing further comprises interposing the pre-dried web and the deflection member between an anvil roll and a transfer roll.

12. The process of claim 1 further comprising applying a vacuum to a vacuum anvil roll.

13. The process of claim 12 further comprising wrapping the deflection member and pre-dried web at least partially around a circumference of the vacuum anvil roll.