Absorbent multilayer sheet and method for making same

• US 5,840,404 A
• Filed: 04/23/1997
• Issued: 11/24/1998
• Est. Priority Date: 08/25/1995
• Status: Expired due to Term

• Current Assignee: Georgia- Pacific France (KOCH Industries Incorporated)
• Original Assignee: Fort James France
• Inventors: Graff, Pierre
• Primary Examiner(s): LONEY, DONALD J
• Application Number:
  US08/817,594
• Time in Patent Office: 580 Days
• Field of Search: 428/174, 428/154, 428/191, 428/534, 428/535, 428/178, 156/290, 156/291, 156/292, 156/209, 156/308.4, 162/109
• US Class Current: 428/154
• CPC Class Codes: B31F 1/07 Embossing , i.e. producing impressions formed by locally deep-drawing, e.g. using rolls provided with complementary profilesB31F1/128 takes precedence; corrugating B31F1/20; embossing in combination with printing B41F19/02, B41M1/24; typewriters for embossing B41J3/38; stamping in combination with deforming B41K3/36
• CPC Class Codes: B31F 2201/0733 Pattern
• CPC Class Codes: B31F 2201/0738 Cross sectional profile of the embossments
• CPC Class Codes: B31F 2201/0756 Characteristics of the incoming material, e.g. creped, embossed, corrugated
• CPC Class Codes: B31F 2201/0764 the layers being nested
• CPC Class Codes: B31F 2201/0787 Applying adhesive
• CPC Class Codes: B32B 2317/12 Paper, e.g. cardboard
• CPC Class Codes: B32B 2439/70 Food packaging
• CPC Class Codes: B32B 29/00 Layered products comprising a layer of paper or cardboard
• CPC Class Codes: B32B 29/002 as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/06; next to a bituminous or tarry layer B32B11/06; next to a water-setting substance layer B32B13/08; next to a metal layer B32B15/12; next to a glass layer B32B17/065; next to a layer formed of natural mineral fibres or particles B32B19/046; next to a wood layer B32B21/06; next to a cellulosic plastic layer B32B23/06; next to a natural or synthetic rubber layer B32B25/06; next to a synthetic resin layer B32B27/10
• 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 38/06 Embossing
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: D21H 27/40 at least one of the sheets being non-planar, e.g. crêped crêping or corrugating paper B31F
• CPC Class Codes: Y10T 156/1023 Surface deformation only [e.g., embossing]
• CPC Class Codes: Y10T 428/24463 Plural paper components
• CPC Class Codes: Y10T 428/24661 Forming, or cooperating to form cells
• CPC Class Codes: Y10T 428/31982 Wood or paper

Abstract

The invention concerns an absorbing multi-layer web (10) of at least two layers (12, 14) each including at least one embossed ply (16, 18, 20) made of a creped absorbent paper, having an outer side forming the outer side of the multi-layer web and an inner side, the inner side of the first layer (12) including first and second protrusions (22) and (24) respectively, and the inner side of the second layer (14) including third protrusions (26) nesting between the protrusions (22, 24) of the first layer, the two layers (12, 14) being bonded to each other, characterized in that the first layer (12) is a double ply including of an inner ply (16) of which the inner side includes first and second protrusions (22A) and (24A) respectively, and an outer ply (18) of which the inner side includes first protrusions (22B) and second protrusion (24B). The tops of the protrusions (22A) and (22B) are bonded to each other but not the tops of the protrusions (24A) and (24B).

Claims

1. An absorbing multi-layer web comprising at least two layers with each layer being constituted of at least one ply of absorbent paper having a specific surface weight of between 10 and 40 g/m² per ply, an outer side of one layer forming an outer side of the multi-layer web and an inner side, an inner side of a first layer of said at least two layers including first and second protrusions and an inner side of a second layer of said at least two layers including third protrusions structured to nest between said first and second protrusions of the first layer, the first layer and the second layer being bonded to each other at least a portion of tops of the first and second protrusions of the first layer and joined to the second layer between two of the third protrusions, wherein the first layer is a double ply and includes an inner ply having an inner side containing first and second protrusions, and an outer ply having an inner side containing first protrusions coinciding with the first protrusions of the inner ply and said outer ply further containing second protrusions coinciding with the second protrusions of the inner ply;

and wherein bonding between said first layer and said second layer is by adhesive present between at least a portion of tops of the first protrusions of the inner ply of the first layer and the second protrusions of the inner ply of the first layer, and wherein the tops of the first protrusions of the inner ply and the first protrusions of the outer ply are bonded adhesively.

2. Web as claimed in claim 1 wherein height (h) of the second protrusions of the outer ply is at least 50 % of height (H) of the first protrusions of the inner ply and the first protrusions of the outer ply.

3. Web as claimed in either of claims 1 or 2 wherein the first protrusions of the first layer are distributed in a spaced pattern with more than one second protrusion of the first layer being located between two consecutive first protrusions.

4. Web as claimed in claim 1 wherein adhesive-containing areas on the tops of the first protrusions of the inner ply amount to between 0.1 and 20% of one surface of the web.

5. Web as claimed in claim 4 wherein said adhesive-containing areas amount to between 1 and 5% of total surface of the web.

6. Web as claimed in claim 1 wherein adhesive-containing areas on the tops of the second protrusions of the inner ply of the first layer amount to 0.1 to 20 % of total surface of the web.

7. Web as claimed in claim 1 wherein height (H'"'"') of the third protrusions is at most equal to height (H) of the first protrusions of said first layer.

8. Web as claimed in claim 7 wherein the second layer further includes fourth protrusions of a height (h'"'"') which is at least 50% of height (H'"'"') of the third protrusions.

9. Web as claimed in either of claims 7 or 8 wherein tops of the third protrusions by means of adhesive present on at least a portion of the tops form an adhesive bond with the first layer.

10. A method for manufacturing a web as claimed in claim 1 comprising:

embossing the inner ply of the first layer to produce therein the first and second protrusions,

embossing the outer ply of the first layer to produce therein the first and second protrusions,

assembling the inner ply and the outer ply to constitute the first layer,

embossing the ply of the second layer to produce therein at least said third protrusions,

depositing adhesive on at least a portion of tops of the first and second protrusions of the inner ply of the first layer,

bringing the double ply of the first layer near the ply of the second layer in such a manner that the first protrusions and the second protrusions of the first layer nest between the third protrusions of the second layer in such a way that the tops with adhesive thereon of the first protrusions of the inner ply of the first layer adhere to tops of the first protrusions of the outer ply of the first layer and to the ply of the second layer between two third protrusions and in such a way that the tops containing adhesive of the second protrusions of the inner ply of the first layer adhere only to the ply of the second layer between two third protrusions.

11. Method as claimed in claim 10 wherein the inner ply and the outer ply of the first layer are simultaneously embossed on a first engraved cylinder which comprises a surface containing first salient elements and second salient elements, the second salient elements having a height less than that of the first salient elements, and wherein the tops of the first protrusions and the second protrusions of the inner ply of the first layer are simultaneously fitted with adhesive by a common roller applying adhesive and which cooperates with the first engraved cylinder bearing the embossed inner ply and embossed outer ply.

12. Method as claimed in claim 11 further comprising embossing the ply of the second layer on a second engraved cylinder having a surface with at least third salient elements.

13. Method as claimed in either of claim 11 or 12 wherein adhesive bonding of the first layer and the second layer to each other is by a joining roller which cooperates with the first engraved cylinder bearing nesting embossed inner ply and embossed outer ply and embossed ply of the second layer.