Absorbent sheet made by fabric crepe process

• US 7,588,661 B2
• Filed: 06/05/2008
• Issued: 09/15/2009
• Est. Priority Date: 10/07/2002
• Status: Expired due to Term

• Current Assignee: GPCP IP Holdings LLC
• Original Assignee: Georgia-Pacific Consumer Products LP (KOCH Industries Incorporated)
• Inventors: Super, Guy H., McCullough, Stephen J., Edwards, Steven L., Eggen, Richard W., Krueger, Jeffrey E., Lomax, David W., Duggan, David P., Baumgartner, Dean J., Jones, Colin A.
• Primary Examiner(s): FORTUNA, JOSE A
• Application Number:
  US12/156,820
• Publication Number:
  US 20080236772A1
• Time in Patent Office: 467 Days
• Field of Search: 162/109, 162111-113, 162115-117, 162123-133, 162/193, 162/197, 162204-207, 162/141, 162/147, 162/164.1, 428152-153, 428/156, 428/172
• US Class Current: 162/109
• 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 11/145 including a through-drying process
• CPC Class Codes: D21H 21/20 Wet strength agents
• CPC Class Codes: D21H 25/005 Mechanical treatment D21H25/08, D21H25/18 take precedence
• 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 428/24446 Wrinkled, creased, crinkled or creped
• CPC Class Codes: Y10T 428/24455 Paper
• CPC Class Codes: Y10T 428/24479 including variation in thickness

Abstract

A process for making absorbent cellulosic paper products such as sheet for towel, tissue and the like, includes compactively dewatering a nascent web followed by wet belt creping the web at an intermediate consistency of anywhere from about 30 to about 60 percent under conditions operative to redistribute the fiber on the belt, which is preferably a fabric. In preferred embodiments, the web is thereafter adhesively applied to a Yankee dryer using a creping adhesive operative to enable high speed transfer of the web of intermediate consistency such as a poly(vinyl alcohol)/polyamide adhesive. An absorbent sheet so prepared from a papermaking furnish exhibits an absorbency of at least about 5 g/g, a CD stretch of at least about 4 percent, and an MD/CD tensile ratio of less than about 1.1, and also exhibits a maximum CD modulus at a CD strain of less than 1 percent and sustains a CD modulus of at least 50 percent of its maximum CD modulus to a CD strain of at least about 4 percent. Products of the invention may also exhibit an MD modulus at break 1.5 to 2 times their initial MD modulus.

Claims

1. A web of cellulosic fibers comprising:

(i) a plurality of pileated fiber enriched regions of relatively high local basis weight interconnected by way of (ii) a plurality of lower local basis weight linking regions whose fiber orientation is biased along the direction between pileated regions interconnected thereby;

the web exhibiting an absorbency of at least about 5 g/g, a CD stretch of at least about 4 percent, and an MD/CD tensile ratio of less than about 1.1, wherein the sheet exhibits a maximum CD modulus at a CD strain of less than 1 percent and sustains a CD modulus of at least 50 percent of its maximum CD modulus to a CD strain of at least about 4 percent.

2. The web of cellulosic fibers according to claim 1, further including a plurality of integument regions of fiber spanning the pileated regions of the web and the linking regions of the web such that the web has substantially continuous surfaces.

3. The web of cellulosic fibers according to claim 1, wherein the absorbent web sustains a CD modulus of at least 75 percent of its peak CD modulus to a CD strain of 2 percent.

4. The web of cellulosic fibers according to claim 1, wherein the web has an absorbency of from about 5 g/g to about 12 g/g.

5. The web of cellulosic fibers according to claim 1, wherein the web defines an open mesh structure.

6. The web according to claim 5, impregnated with a polymeric resin.

7. The web according to claim 6, wherein the resin is a cured polymeric resin.

8. An absorbent sheet prepared from a papermaking furnish, said absorbent sheet exhibiting an absorbency of at least about 5 g/g, a CD stretch of at least about 4 percent, and an MD/CD tensile ratio of less than about 1.1, wherein the sheet exhibits a maximum CD modulus at a CD strain of less than 1 percent and sustains a CD modulus of at least 50 percent of its maximum CD modulus to a CD strain of at least about 4 percent.

9. The absorbent sheet according to claim 8, wherein the absorbent sheet sustains a CD modulus of at least 75 percent of its peak CD modulus to a CD strain of 2 percent.

10. The absorbent sheet according to claim 8, wherein the sheet has an absorbency of from about 5 g/g to about 12 g/g.

11. The absorbent sheet according to claim 8, wherein the absorbency of the sheet (g/g) is at least about 0.7 times the specific volume of the web (cc/g).

12. The absorbent sheet according to claim 8, wherein the absorbency of the sheet (g/g) is from about 0.75 to about 0.9 times the specific volume of the web cc/g).

13. The absorbent sheet according to claim 8, wherein the sheet has a CD stretch of from about 5 percent to about 20 percent.

14. The absorbent sheet according to claim 8, wherein the sheet has a CD stretch of from about 5 percent to about 10 percent.

15. The absorbent sheet according to claim 8, wherein the sheet has a CD stretch of from about 6 percent to about 8 percent.

16. The absorbent sheet according to claim 8, wherein the sheet has an MD stretch of at least about 40 percent.

17. The absorbent sheet according to claim 8, wherein the sheet has an MD stretch of at least about 50 percent.

18. The absorbent sheet according to claim 8, wherein the sheet has an MD stretch of at least about 70 percent.

19. The absorbent sheet according to claim 8, wherein the sheet exhibits an MD/CD dry tensile ratio of from about 0.5 to about 0.9.

20. The absorbent sheet according to claim 8, wherein the sheet exhibits an MD/CD dry tensile ratio of from about 0.6 to about 0.8.

21. An absorbent sheet prepared from a papermaking furnish, said absorbent sheet exhibiting an absorbency of at least about 5 g/g, a CD stretch of at least about 4 percent, an MD stretch of at least about 15 percent and an MD/CD tensile ratio of less than about 1.1.