Ultrasonically-assisted process for making differential density cellulosic structure containing fluid-latent indigenous polymers
First Claim
1. A process for making a differential density cellulosic web comprising a first plurality of high-density micro-regions and a second plurality of low-density micro-regions, said process comprising the steps of:
- (a) providing a fibrous web comprising fluid-latent indigenous polymers and water;
(b) providing a macroscopically monoplanar molding fabric having a web-side surface and a backside surface opposite to said web-side surface;
(c) depositing said fibrous web on said web-side surface of said molding fabric;
(d) applying ultrasonic energy to at least selected portions of said fibrous web thereby contributing to softening of said fluid-latent indigenous polymers in said selected portions;
(e) impressing said web-side surface of said molding fabric into said fibrous web under pressure, thereby densifying said selected portions of said web and causing said fluid-latent indigenous polymers to flow and interconnect said cellulosic fibers which are mutually juxtaposed in said selected portions; and
(f) immobilizing said flowable fluid-latent indigenous polymers and creating bonds of said fluid-latent indigenous polymers between said cellulosic fibers which are interconnected in at least said selected portions of said fibrous web, thereby forming said first plurality of high-density micro-regions from said selected portions.
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Accused Products
Abstract
A process and an apparatus for making a differential density cellulosic web comprising a first plurality of high-density micro-regions and a second plurality of low-density micro-regions are disclosed. The process comprises the steps of providing a fibrous web containing fluid-latent indigenous polymers and water; depositing the web on a fluid-permeable molding fabric; applying ultrasonic energy to the web, thereby contributing to softening of the fluid-latent indigenous polymers in at least selected portions of the web; impressing the molding fabric into the web, thereby densifying the selected portions of the web and causing the fluid-latent indigenous polymers to flow and interconnect the fibers which are mutually juxtaposed in the selected portions; and immobilizing the fluid-latent indigenous polymers, thereby creating bonds thereof between the fibers which are interconnected in the selected portions. An apparatus comprises an ultrasonic means for applying ultrasonic energy to the web associated with the molding fabric, and a pressing means for impressing the molding fabric into the web.
24 Citations
27 Claims
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1. A process for making a differential density cellulosic web comprising a first plurality of high-density micro-regions and a second plurality of low-density micro-regions, said process comprising the steps of:
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(a) providing a fibrous web comprising fluid-latent indigenous polymers and water; (b) providing a macroscopically monoplanar molding fabric having a web-side surface and a backside surface opposite to said web-side surface; (c) depositing said fibrous web on said web-side surface of said molding fabric; (d) applying ultrasonic energy to at least selected portions of said fibrous web thereby contributing to softening of said fluid-latent indigenous polymers in said selected portions; (e) impressing said web-side surface of said molding fabric into said fibrous web under pressure, thereby densifying said selected portions of said web and causing said fluid-latent indigenous polymers to flow and interconnect said cellulosic fibers which are mutually juxtaposed in said selected portions; and (f) immobilizing said flowable fluid-latent indigenous polymers and creating bonds of said fluid-latent indigenous polymers between said cellulosic fibers which are interconnected in at least said selected portions of said fibrous web, thereby forming said first plurality of high-density micro-regions from said selected portions. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25)
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26. A process for making a differential density cellulosic web comprising a first plurality of high density micro-regions and a second plurality of low density micro-regions, said process comprising the steps of:
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(a) providing a plurality of papermaking cellulosic fibers comprising fluid-latent indigenous polymers; (b) providing a forming belt; (c) depositing said plurality of cellulosic fibers comprising fluid-latent indigenous polymers on said forming belt and forming a web of said cellulosic fibers on said forming belt; (d) providing a macroscopically monoplanar papermaking belt having a web-side surface, a backside surface opposite to said web-side surface, and deflection conduits extending between said web-side surface and said backside surface; (e) transferring said web of said cellulosic fibers to said web-side surface of said papermaking belt, said web comprising a first portion corresponding to said web-side surface, and a second portion corresponding to said deflection conduits; (f) applying ultrasonic energy to at least said first portion of said web thereby causing said fluid-latent indigenous polymers to soften in said first portion; (g) impressing said web-side surface of said papermaking belt into said web under pressure, thereby densifying said first portion of said web and causing said fluid-latent indigenous polymers to flow and interconnect said cellulosic fibers which are mutually juxtaposed in said first portion; and (h) immobilizing said flowable fluid-latent indigenous polymers thereby creating bonds of said fluid-latent indigenous polymers between said cellulosic fibers which are interconnected in said first portion.
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27. A process for making a cellulosic web, said process comprising the steps of:
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(a) providing a fibrous web comprising fluid-latent indigenous polymers and water; (b) providing a macroscopically monoplanar and fluid-permeable papermaking belt having a web-side surface defining an X-Y plane, a backside surface opposite said web-side surface, and a Z-direction perpendicular to said X-Y plane; (c) depositing said fibrous web on said web-side surface of said papermaking belt; (d) applying ultrasonic energy to said fibrous web thereby causing softening of said fluid-latent indigenous polymers in said web; (e) impressing said web-side surface of said papermaking belt into said fibrous web under pressure, thereby densifying said web and causing said fluid-latent indigenous polymers to flow and interconnect said cellulosic fibers which are mutually juxtaposed in said web under said pressure; and (f) immobilizing said flowable fluid-latent indigenous polymers thereby creating bonds of said fluid-latent indigenous polymers between said cellulosic fibers which are interconnected in said web.
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Specification