Multi-ply absorbent sheet of cellulosic fibers

• US 8,911,592 B2
• Filed: 02/22/2012
• Issued: 12/16/2014
• Est. Priority Date: 10/07/2002
• Status: Active Grant

• Current Assignee: GPCP IP Holdings LLC
• Original Assignee: Georgia-Pacific Consumer Products LP (KOCH Industries Incorporated)
• Inventors: Edwards, Steven L., Super, Guy H., McCullough, Stephen J., Reeb, Ronald R., Chou, Hung Liang, Yeh, Kang Chang, Dwiggins, John H., Harper, Frank D.
• Primary Examiner(s): FORTUNA, JOSE A
• Application Number:
  US13/402,011
• Publication Number:
  US 20120164407A1
• Time in Patent Office: 1,028 Days
• Field of Search: 162/109, 162111-113, 162115-117, 162123-133, 162/135, 162/158, 162/172, 156/183, 428152-153, 428/156, 428/212, 428/172, 264282-283
• US Class Current: 162/123
• CPC Class Codes: D21H 27/005 relating to physical or mechanical properties, e.g. tensile strength, stretch, softness
• CPC Class Codes: D21H 27/007 relating to absorbency, e.g. amount or rate of water absorption, optionally in combination with other parameters relating to physical or mechanical properties
• CPC Class Codes: D21H 27/30 Multi-ply for surface covering D21H27/18; making on paper-making machines D21F9/00, D21F11/00
• CPC Class Codes: Y10T 428/24455 Paper
• CPC Class Codes: Y10T 428/24479 including variation in thickness
• CPC Class Codes: Y10T 428/24851 Intermediate layer is discontinuous or differential

Abstract

A multi-ply absorbent sheet of cellulosic fiber includes continuous outer surfaces, and an absorbent core between the outer surfaces. The absorbent core includes a non-woven fiber network comprising a plurality of pileated fiber enriched regions of a relatively high local basis weight interconnected by way of a plurality of lower local basis weight linking regions whose fiber orientation is biased along the direction between pileated fiber enriched regions, interconnected thereby, and a plurality of fiber-deprived cellules between the fiber enriched regions and the linking regions, also being characterized by a local basis weight lower than that of the fiber enriched regions.

Claims

1. A multi-ply absorbent sheet of cellulosic fiber, the sheet comprising:

(a) continuous outer surfaces; and

(b) an absorbent core between the outer surfaces, the absorbent core including a non-woven fiber network comprising;

(i) a plurality of pileated fiber enriched regions having a 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 the pileated fiber enriched regions interconnected thereby, and (iii) a plurality of fiber-deprived cellules between the pileated fiber enriched regions and the linking regions, the fiber-deprived cellules having a local basis weight that is lower than that of the pileated fiber enriched regions,

wherein the non-woven network of the absorbent core is an open mesh structure, such that the plurality of fiber-deprived cellules have regions devoid of fiber.

2. The multi-ply absorbent sheet according to claim 1, wherein the sheet is a two-ply sheet.

3. The multi-ply absorbent sheet according to claim 1, wherein the sheet is a three-ply sheet.

4. The multi-ply absorbent sheet according to claim 1, wherein the regions devoid of fiber have an average span of from about 10 to about 2500 microns.

5. The multi-ply absorbent sheet according to claim 1, wherein regions devoid of fiber have an average span of from about 50 to about 500 microns.

6. The multi-ply absorbent sheet according to claim 1, wherein the fiber-deprived cellules have an average span of from about 50 to about 2500 microns.

7. The multi-ply absorbent sheet according to claim 1, wherein the fiber-deprived cellules have an average span of from about 100 to about 500 microns.

8. The multi-ply absorbent sheet according to claim 1, wherein the fiber-deprived cellules comprise a plurality of integuments of fiber connecting (i) pileated to adjacent pileated regions and (ii) linking to adjacent linking regions.

9. The multi-ply absorbent sheet according to claim 1, wherein the sheet has a bulk of at least about 6 cc/g.

10. The multi-ply absorbent sheet according to claim 1, wherein the sheet has a bulk of at least about 7.5 cc/g.

11. The multi-ply absorbent sheet according to claim 1, wherein the sheet has a bulk of at least about 10 cc/g.

12. The multi-ply absorbent sheet according to claim 1, wherein the sheet has a bulk of at least about 15 cc/g.

13. The multi-ply absorbent sheet according to claim 1, wherein the sheet has an absorbency of at least 5 g/g.

14. The multi-ply absorbent sheet according to claim 1, wherein the sheet has an absorbency of at least about 7 g/g.

15. The multi-ply absorbent sheet according to claim 1, wherein the sheet has an absorbency of at least about 9 g/g.

16. The multi-ply absorbent sheet according to claim 1, wherein the sheet has an absorbency of at least about 11 g/g.

17. The multi-ply absorbent sheet according to claim 1, wherein the sheet has an absorbency of at least about 13 gig.

18. The multi-ply absorbent sheet according to claim 1, wherein the sheet has a void volume fraction of from about 0.75 to about 0.85.

19. The multi-ply absorbent sheet according to claim 1, wherein the sheet has a Wet Springback Ratio of at least about 0.65.

20. The multi-ply absorbent sheet according to claim 1, wherein the sheet has a Wet Springback Ratio of from about 0.6 to about 0.8.

21. A two-ply absorbent sheet of cellulosic fiber, the sheet comprising:

(a) a first ply having a substantially continuous first surface and a second surface with local variations in basis weight, the first ply comprising (i) a plurality of pileated fiber enriched regions having a 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 the pileated fiber enriched regions interconnected thereby, and (iii) a plurality of fiber-deprived cellules between the pileated fiber enriched regions and the linking regions, the fiber-deprived cellules having a local basis weight that is lower than that of the pileated fiber enriched regions; and

(b) a second ply having a substantially continuos third surface and a fourth surface with a local variation in basis weight, the second ply comprising (i) a plurality of pileated fiber enriched regions having a 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 the pileated fiber enriched regions interconnected thereby, and (iii) a plurality of fiber-deprived cellules between the pileated fiber enriched regions and the linking regions, the fiber-deprived cellules having a local basis weight that is lower than that of the pileated fiber enriched regions,

wherein the plurality of fiber-deprived cellules of both the first ply and the second ply have regions devoid of fiber, and

wherein the plies are secured to each other such that the second surface of the first ply is in contact with the fourth surface of the second ply to form the core of the sheet and the first surface of the first ply and the third surface of the second ply are outer surfaces of the sheet.

22. A three-ply absorbent sheet comprising:

(a) a first outer ply of cellulosic sheet having a substantially continuous surface;

(b) a second outer ply of cellulosic sheet having a substantially continuous surface; and

(c) an absorbent core ply sandwiched between the first outer ply and the second outer ply, and consisting essentially of a non-woven fiber network of cellulosic fiber comprising (i) a plurality of pileated fiber enriched regions having a 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 the pileated fiber enriched regions interconnected thereby, and (iii) a plurality of fiber-deprived cellules between the pileated fiber enriched regions and the linking regions, the fiber-deprived cellules having a local basis weight that is lower than that of the fiber enriched regions,

wherein the non-woven network of the absorbent core ply is an open mesh structure, such that the plurality of fiber-deprived cellules have regions devoid of fiber.

23. A multi-ply absorbent sheet of cellulosic fiber, the sheet comprising:

(a) outer continuous surfaces; and

(b) an absorbent core between the outer surfaces, the absorbent core including a non-woven fiber network comprising (i) a plurality of pileated fiber enriched regions having a 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 the pileated fiber enriched regions interconnected thereby, and (iii) a plurality of fiber-deprived cellules between the pileated fiber enriched regions and the linking regions, the fiber-deprived cellules having a local basis weight that is lower than that of the fiber enriched regions,

wherein the non-woven network of the absorbent core is an open mesh structure, such that the plurality of fiber-deprived cellules have regions devoid of fiber, and

wherein at least one of the outer surfaces of the sheet is provided with a fused wax composition in intimate contact with the fibers in the web, the fused wax composition including a wax and an emulsifier fused in situ with the sheet and being disposed in the sheet so that the open interstitial microstructure between fibers in the web is substantially preserved, and the sheet has a laterally hydrophobic outer surface that exhibits a moisture penetration delay of at least about 2 seconds.

24. The multi-ply absorbent sheet according to claim 23, wherein the laterally hydrophobic outer surface of the sheet exhibits a moisture penetration delay of from about 3 seconds to about 40 seconds.

25. The multi-ply absorbent sheet according to claim 23, wherein the laterally hydrophobic outer surface of the sheet exhibits a moisture penetration delay of at least about 5 seconds.

26. The multi-ply absorbent sheet according to claim 23, wherein the laterally hydrophobic outer surface of the sheet exhibits a moisture penetration delay of at least about 10 seconds.