CN1112476C - Paper structure having at least three regions including decorative indicia comprising low basis weight region - Google Patents

Abstract

A paper web and method of making the paper web are disclosed. The paper web includes at least three regions disposed in a non random, repeating pattern. The three regions are distinguishable from each other by at least one property selected from the group consisting of basis weight, density, and fiber composition. The paper web has a relatively high basis weight background portion (100) and decorative indicia (200). The decorative indicia (200) comprises one or more relatively low basis weight regions (220).

Description

Paper structure having at least three zones including decorative indicia with low basis weight zones

field of invention

This invention relates to cellulosic fibrous structures having at least three regions of distinct density. More specifically, the invention relates to paper having relatively low basis weight decorative indicia and methods of producing the same.

Background of the invention

Cellulosic fibrous structures, such as paper, are known in the prior art. It is often desirable to have regions of different basis weight within the same cellulosic fiber product. The two areas serve different purposes. The high basis weight regions impart tensile strength to the fibrous structure. The low basis weight zone saves raw material, especially fibrous raw material used in the papermaking process, and imparts absorbency to the fibrous structure. In the case of deterioration, the low basis weight regions may be small pores in the fibrous structure. However, it is not necessary that the low quantitation region be a small hole.

Absorbency and strength, as well as softness, will be very important when the fibrous structure is used for its intended purpose. In particular, the fibrous structures described herein are useful in facial tissue, toilet tissue, paper towels, bibs, and napkins, each of which is frequently used on a daily basis. If these products are to perform their intended tasks and be widely used, the fibrous structure must possess and maximize the above-mentioned physical properties. Wet tensile strength and dry tensile strength are measures of how a fibrous structure retains its physical integrity during use. Absorbency is the property of a fibrous structure in contact with liquids. When evaluating the aforementioned consumer products, not only must the absolute amount of the liquid absorbed by the fibrous structure have to be considered, but also the rate at which the fibrous structure absorbs the liquid must be considered. Additionally, the paper products have been used in disposable absorbent articles such as feminine hygiene napkins and diapers.

Attempts have been made in the prior art to provide paper with two different basis weights, or to rearrange the fibers. Examples include: US795,719 (issued to Motz on July 25, 1905); US3,025,585 (issued to Griswold on March 20, 1962); US3,034,180 (issued to Greiner et al. on May 15, 1962) ; US 3,159,530 (issued December 1, 1964 to Heller et al); US 3,549,742 (issued December 22, 1970 to Benz); and US 3,322,617 (issued March 30, 1967 to Osborne).

Additionally, it would be desirable to provide tissue paper products that possess both bulk and flexibility. Improved bulk and flexibility can be provided by interleaving pressed or unpressed zones, as shown in US 4,191,609, issued March 4, 1980 to Trokhan, which is incorporated herein by reference.

There have been several attempts to provide improved porous elements for the manufacture of such cellulosic fibrous structures, the most important of which is described in US 4,514,345 (issued April 30, 1985 to Johnson et al), incorporated herein by This patent is incorporated by reference. Johnson et al. teach mounting hexagonal elements on a frame in a batch liquid coating process.

Another method of making tissue papers that are preferred by consumers is to dry the paper structure in order to impart greater bulk, tensile strength, and burst strength to the tissue paper product. Examples of paper structures made by this method are disclosed in US 4,637,859, issued January 20, 1987 to Trokhan, which is incorporated herein by reference. US 4,637,859, which is hereby incorporated by reference, shows discrete dome-shaped protrusions dispersed throughout a continuous network. The continuous network provides strength properties, while the relatively thick domes provide softness and absorbency.

A disadvantage of the papermaking process disclosed in US 4,637,859 is that drying the paper web is energy intensive and expensive and often requires the use of through drying equipment. Furthermore, the papermaking process disclosed in US 4,637,859 limits the speed at which the paper web is subjected to final drying in the Yankee dryer. This limitation is believed to be due (at least in part): to the pattern imparted to the web prior to delivery onto the Yankee dryer. In particular, the discontinuous domes described in US 4,637,859 cannot be dried as well on the Yankee surface as the continuous network described in US 4,637,859. Therefore, for a given concentration and basis weight, there is a limit to the speed at which the Yankee can be run.

Conventional tissue paper produced by pressing a web in a nip with one or more press felts can run at relatively high speeds. Conventionally pressed paper, once dry, is embossed to pattern the web and increase the macroscopic thickness of the web. For example, an embossed pattern is typically formed in a tissue product after the tissue product is dried.

However, embossing methods generally impart a specific aesthetic appearance to the paper structure at the expense of other properties of the paper structure. In particular, embossing a dry web breaks the bonds between the fibers in the cellulosic structure. Since these bonds are said to be formed and fixed as the embryonic fiber pulp dries, breakage of the bonds will occur during dry embossing. After the paper structure has dried, the mobilized fibers perpendicular to the plane of the paper structure by embossing will break the fiber-to-fiber bonds. The breaking of bonds will reduce the tensile strength of the dry web. In addition, embossing is usually carried out after drying the web on the drying cylinder and creping it. Embossing after creping destroys the creping pattern imparted to the web. Embossing will remove the creping pattern in certain portions of the web, for example by compacting or stretching the creping pattern. Such a result is undesirable since the creping pattern will improve the softness and flexibility of the dried web.

One problem with paper made according to the prior art is that excess low basis weight regions will reduce the strength of the paper.

It is therefore an object of the present invention to overcome the problems described, in particular for single-ply paper. In particular, it is an object of the present invention to provide a paper web having decorative indicia formed through relatively low basis weight regions without the need for a comprehensive balance of web strength, absorbency, and softness.

Another object of the present invention is to provide a paper and a method of making a multi-zone paper web, wherein the paper web has a predetermined pattern of relatively high density regions and relatively low density regions, and can utilize relatively low energy and Expenses for drying.

Another object of the present invention is to provide a method for the production of multi-region paper with relatively low basis weight decorative indicia that can be formed on existing paper machines (conventional or with throughdrying) without the need for The paper machine was greatly improved.

Another object of the present invention is to provide a paper web and a method of making the paper web, wherein, to provide aesthetic benefits, the paper web has decorative indicia comprising low basis weight areas, and increased bulk, bulk, and absorbency, thereby providing not only desired bulk but also desired softness to consumers of paper products.

Summary of the invention

The present invention provides a paper web having two back-to-back surfaces and at least three zones. The three zones are arranged in a non-random, repeating pattern and are differentiated from each other by at least one property selected from the group consisting of basis weight, density, and fiber composition. The web contains decorative indicia comprising one or more regions having a basis weight that is lower than that of at least a portion of the surrounding base portion of the paper web.

The term "decorative indicia" as used in the present invention refers to a recognizable shape imparted to a paper web, preferably during initial formation of the paper web. The shapes include, but are not limited to: flower shapes, animal shapes, geometric figures, and the like. The decorative indicia preferably comprises less than about 30% of the surface area of the web, thereby enhancing the differentiation of the decorative indicia from the base portion of the web.

The base portion of the web is selectively densified to provide a continuous web of relatively high density and regions of relatively low density dispersed throughout the web. The relatively high density continuous web provides strength, while the relatively low density regions provide bulk and absorbency.

In addition to relatively low basis weight regions, decorative indicia may also include relatively high basis weight regions. The relatively low basis weight region of the decorative indicia may enclose one or more intervals whose basis weight is substantially equal to the basis portion basis weight, alternatively the intervals have a different basis weight than the base portion basis weight. These relatively high quantitative intervals may be surrounded by relatively low quantitative regions. These relatively high-weight regions are selectively densified to provide relatively high-density regions and relatively low-density regions within the decorative indicia.

In one embodiment, the web comprises from about 5 to about 5000 decorative indicia per square meter of the web. The relatively high basis weight portion of the web comprises a relatively high density continuous wire region and at least about 10,000 relatively low density regions per square meter of the web dispersed throughout the continuous wire region. The base portion has a smoothness value of less than about 900 on at least one of the back-to-back surfaces of the web to provide a surface that feels smooth and soft.

The decorative indicium may comprise relatively low basis weight regions having a basis weight of about 25% to about 75% of the basis weight of the surrounding decorative indicium. The decorative indicium may comprise a relatively low basis weight region having a basis weight that is less than about 75% of the basis weight of the base portion surrounding the decorative indicia. In one embodiment, the decorative indicium may comprise a relatively low basis weight region having a basis weight less than about 60% of the basis weight comprising the base portion surrounding the decorative indicium.

An advantage of the present invention is that the decorative indicia provides aesthetic appeal to the consumer and the web retains the strength and absorbency of multidensity paper. In addition, the webs of the present invention can have relatively smooth surfaces despite the decorative indicia and multi-density regions. The smooth surface provides consumers with a preferred softness and also aids in visual differentiation of decorative indicia. Additionally, the smooth surface surrounding the low basis weight decorative indicia emphasizes the distinctiveness of the relatively low basis weight decorative indicia, thereby enhancing the aesthetic appearance of the paper web.

Additionally, the present invention provides paper structures comprising a multilayer web having two back-to-back surfaces and at least three zones.

Additionally, the present invention provides a process for preparing a paper web having three zones arranged in a non-random, repeating pattern and differing from one another in at least one property selected from the group consisting of basis weight, density, and fiber components. The method comprises the steps of: providing a plurality of cellulosic fibers suspended in a liquid carrier; providing a fiber retaining forming member having a liquid permeable region; depositing the cellulosic fibers and the liquid carrier on the forming member; Under the condition, liquid carrier is expelled through forming element, so that form the paper web of at least one relatively high basis weight area and and decorative indicium, described decoration mark comprises one or more relatively low basis weight areas; Provide the paper web with paper web patterning surface supporting means; feeding a web from a forming element to a web patterning surface of a web supporting means; selectively densifying at least a portion of the relatively high basis weight region to provide a relatively high density region and a relatively low basis weight region within the relatively high basis weight region A nonrandom, repeating pattern of density regions.

Figure overview

While the invention concludes with claims particularly pointing out and expressly claiming the scope of the invention, it is believed that the invention will be better understood from the following description of the invention when taken in conjunction with the accompanying drawings in which, likewise Components are denoted by the same reference numbers:

Figure 1A is a plan view of a paper web made in accordance with the present invention showing three decorative indicia.

FIG. 1B is an enlarged plan view of a single decorative indicia shown in FIG. 1A and illustrating different frequencies of creping.

Figure 2 is a cross-sectional view of the web shown in Figure IB, taken along line 2-2 in Figure IB.

Figure 3 is a photograph of a portion of a web made in accordance with the present invention showing a decorative indicia.

Figure 4 is a schematic diagram of a paper machine used to make a paper web according to the invention showing a paper web formed on forming elements and selectively densified on a web support device.

Figure 5 is a photograph of the sheet side of a forming element comprising a liquid permeable structure formed from textile filaments and a liquid impermeable photopolymer resin layer attached to the textile filaments used to make the web of the present invention , so as to form a flow restricting part corresponding to the decorative marking.

Figure 6 is a partial plan view of the shaped element shown in Figure 5, the shaped element of Figure 6 comprising four flow restricting members.

Figure 7 is a cross-sectional view showing the web supported on the forming element of Figure 6 .

Figure 8 is a photograph showing the sheet side surface of a web support in the form of an embossed fabric comprising a felt layer and a patterned photopolymer layer attached to the felt layer to provide a continuous web press printed surface.

FIG. 9 is a plan view of the sheet-side portion of the web support device shown in FIG. 8. FIG.

Figure 10 is a cross-sectional view showing the web being transferred to the web support apparatus shown in Figure 9 to provide a web having a first surface conforming to the apparatus and a second surface that is substantially smooth.

Figure 11 is a schematic diagram showing the transfer of the web to the Yankee dryer.

Figure 12 is a plan view of a paper web made in accordance with another embodiment of the present invention, the paper web comprising: discrete decorative indicia, and a relatively high basis weight base portion comprising continuous web regions interspersed within the web regions Discontinuous relatively low-density areas in the interior, and discontinuous relatively high-density areas scattered in each relatively low-density area.

Figure 13 is a cross-sectional view of the web of Figure 12 taken along line 13-13 of Figure 12 .

Figure 14 is a plan view of an apparatus for preparing the web shown in Figure 12, the apparatus comprising a web patterning layer attached to a porous element made of textile filaments.

Figure 15 is a cross-sectional view of the device of Figure 14 .

Figure 16 is an illustration of a paper machine for making a paper web using the apparatus of Figures 14 and 15 .

Figure 17 is a diagram showing a web being transferred to the apparatus shown in Figure 15 to form a web having a first surface conforming to the apparatus and a second surface that is substantially smooth.

Figure 18 is an illustration of the web on the apparatus shown in Figure 15 being carried between press rolls and Yankee dryers to impart a pattern to a first surface of the web and to adhere a second surface of the web Attached to Yankee dryer.

Detailed description of the invention

Figures 1A, B and 2 illustrate a paper web 20 made in accordance with the present invention, and Figure 3 is a photograph of the paper structure illustrated in Figures 1A, B and 2 . The web is wetlaid and therefore substantially free of dry embossing.

Referring to Figures 1A, B and 2, a paper web 20 has back-to-back first and second surfaces 22 and 24, respectively. Web 20 comprises at least three regions arranged in a non-random, repeating pattern. These three regions differ from each other by at least one property selected from basis weight, density, and fiber component.

Figure 2 is a cross-sectional view of the portion of the web shown in Figures 1A and 1B. In FIG. 2, the line densities through the web thickness are used to briefly illustrate the respective basis weights of the different webs. The portion of the web represented by five lines through the web thickness represents a region of relatively high basis weight, while the portion of the web represented by three lines represents a region of relatively low basis weight.

The web 20 includes a relatively high basis weight base portion 100 . Additionally the web includes discrete, visually distinguishable decorative indicia 200 dispersed throughout the base portion 100 in a non-random, repeating pattern. As will be described in more detail below, decorative indicia 200 can be imparted to a web by selectively removing water from the web during web formation. The decorative indicium includes one or more relatively low weight regions 220 . The basis weight of the zone 220 is lower than that of the surrounding base portion 100 of the web.

The relatively high basis weight base portion 100 is selectively densified to have at least one high density region and at least one low density region. In the embodiment shown in FIGS. 1A, 1B and 2, the base portion 100 is selectively densified so as to have a relatively high density, continuous web region 110 and a plurality of Discontinuous, relatively low density region 130 . Region 130 is thicker than region 110 .

The relatively low basis weight region 220 may have the shape of a closed loop defining a number of adjacent relatively high basis quantity intervals 240 . The quantification everywhere within the interval 240 is higher than that of the relatively low quantification area 220 surrounding that particular interval 240 . Each zone 240 has a perimeter formed by a closed loop of relatively low basis weight region 220 .

In a preferred embodiment, each segment 240 is bordered by an adjacent segment 240 on no more than half of its perimeter. Preferably, at least some of the intervals 240 are characterized by having a perimeter such that any straight line drawn through the interval 240 has no more than three intersection points with the perimeter of the interval. Without being bound by theory, it is believed that, without unduly reducing the strength of the web 20, the geometry of the zones allows the decorative indicium 200 to be discerned by the naked eye and to have a pleasing aesthetic.

The relatively high-quantity region 240 may be optionally densified to provide relatively high-density regions and relatively low-density regions. In FIGS. 1A and 1B , the relatively high basis weight interval 240 includes a relatively high density continuous web 260 and discrete, relatively low density regions 280 dispersed throughout the continuous web 260 .

In one embodiment, the paper web 20 comprises from about 5 to about 5000 decorative indicia 200 per square meter of the web, most preferably from about 25 to about 1000 decorative indicia 200 per square meter of the web to increase the base portion The difference between 100 and 200 in decorative marks. The relatively high basis weight base portion 100 of the web comprises at least about 10,000 relatively low density regions 130 per square meter of the web, the relatively thicker low density regions being dispersed throughout the continuous web region 110 to enhance the absorbency of the web and bulkiness.

The base portion 100 has a smoothness value of less than about 900 on at least one of the back-to-back surfaces of the web. In FIG. 2 , the smoothness value of surface 24 is lower than the smoothness value of surface 22 . The smoothness value of surface 24 is preferably less than about 900. In particular, the surface smoothness ratio of the web 20 is greater than about 1.15, more preferably greater than about 1.20, even more preferably greater than 1.25, more preferably greater than about 1.30, and most preferably greater than about 1.40, wherein said surface The smoothness ratio is the value obtained by dividing the surface smoothness of surface 22 by the surface 24 smoothness value.

In one embodiment, the surface 24 of the web 20 has a surface smoothness value of less than about 900, more preferably less than about 850. The reverse side 22 has a surface smoothness value of at least about 900, more preferably at least about 1000.

The method of measuring the surface smoothness value is described in "Surface Smoothness" below. The Surface Smoothness value of a surface increases as the surface becomes more structured and less smooth. Therefore, a relatively low surface smoothness value indicates a relatively smooth surface.

The basis weight of the region 220 is about 75% lower than the basis weight of the surrounding base portion 100 . The basis weight of the relatively low basis weight region 220 is about 25% to about 75% of the basis weight of the base portion 100 .

In one embodiment, the basis weight of the region 220 is less than about 60% of the basis weight of the surrounding base portion 100 . The basis weight of the base portion 100 may be between about 10 grams and about 70 grams per square meter. The basis weight of the relatively low basis weight region 220 is between about 5 grams per square meter and about 35 grams per square meter.

The decorative indicium includes one or more relatively low weight regions 220 . The basis weight of relatively low basis weight zone 220 is preferably less than about 20 grams per square meter, more preferably less than about 15 grams per square meter. In one embodiment, base portion 100 may have a basis weight of between about 10 grams per square meter and about 30 grams per square meter, and relatively low basis weight region 220 may have a basis weight of between about 5 grams per square meter and about 15 grams per square meter. The basis weight of the region 240 may be approximately equal to the basis weight of the base portion 100 .

The web of the present invention has the advantage that the decorative indicia provides aesthetic appeal to the consumer, yet the web retains the strength and absorbency of multidensity paper. In addition, the webs of the present invention have decorative indicia and multiple density regions, and also have a relatively smooth surface. The smooth surface provides a preferred softness to the consumer. In addition, the smooth surface surrounding the low basis weight decorative indicia will emphasize the distinctiveness of the relatively low basis weight decorative indicia, thereby enhancing the aesthetic appearance of the paper web.

The continuous web regions 110 and the discontinuous regions 130 can be shortened, such as by crimping. In FIG. 1B , the corrugated ridges of the continuous web region 110 are indicated by numeral 115 and extend generally in the transverse direction. Likewise, the discrete, relatively low density and relatively thick regions 130 can also be shortened to have corrugated ridges 135 .

The continuous mesh region 110 may be a relatively high density, macroscopically uniplanar continuous mesh region as disclosed in US 4,637,859. The relatively low density and relatively thick regions 130 may be interleaved, as described in US 4,637,859. However, region 130 is not a dome as shown in US 4,637,859. The zone 130 is in the continuous web zone 110 as described in US 08/748,871 ("A paper web having relatively thinner continuous web zones and discontinuous relatively thicker zones in the continuous web zone", November 1996 14 application, applicant Phan,), which is hereby incorporated by reference.

A paper web 20 having a relatively smooth surface 24 can be used to make a multiply tissue paper having an outwardly facing smooth surface. For example, two or more layers of paper web 20 may be joined to form a ply tissue such that the two outwardly facing surfaces of the ply tissue include surface 24 of web 20 and the surface of the outer ply 22 faces inward. Additionally, by combining the web 20 of the present invention with a conventionally formed and dried web, two-ply paper structures can be produced. Paper web 20 may be bonded to a conventional paper web such that surface 24 faces outward.

The basis weight of the web 20 can be from about 10 grams per square meter to about 70 grams per square meter. The web 20 has a macroscopic caliper of at least about 0.1 mm, more preferably at least about 0.2 mm, and a bulk density of less than about 0.12 g/cc (quantity divided by macroscopic caliper, multiplied by an appropriate conversion factor if units are inconsistent). The basis weight, macroscopic thickness, and bulk density of the paper web are measured as follows.

The web 20 shown in Figures 1-2 can also have an absorbent capacity of at least about 15 grams per gram. The measuring method of the absorbing capacity is as follows. Thus, the web 20 exhibits the absorption benefits of a high bulk web, along with the benefits of a relatively smooth surface typically associated with conventional felt press tissue paper.

Figure 3 is a photograph of the surface 22 of a paper web 20 made in accordance with the present invention showing the decorative indicia 200 of the base portion 100, the continuous web 110 and the discontinuous regions 130 of relatively low density.

Paper structures comprising such webs can also be made from paper webs comprising multiple layers having two surfaces back to back and at least three zones.

Description of paper making method

The paper structure 20 according to the present invention can be produced using the papermaking apparatus shown in FIG. 4 . The paper of the invention is initiated by providing a plurality of fibers to be suspended in a liquid carrier, such as an aqueous dispersion of papermaking fibers in the form of a suspension; and depositing the papermaking fiber suspension from the headbox 1500 onto the fiber retention forming element 1600 Preparation method of structure 20. In Figure 4, the forming element 1600 is in the form of a continuous strip. A suspension of papermaking fibers is deposited onto the forming element 1600 and dewatered from the suspension by the forming element 1600 to form a web of papermaking fibers supported on the forming element 1600 . The papermaking fiber suspension may include relatively long fibers having an average fiber length greater than or equal to 2.0 mm, and relatively short fibers having an average fiber length less than 2.0 mm. For example, the relatively long fibers may comprise softwood fibers and the relatively short fibers may comprise hardwood fibers. Softwood and hardwood fibers are described in more detail below.

Figure 5 is a photograph of the web-facing side of a forming element 1600 suitable for making a web 20 of the present invention. Figure 6 is a simplified illustration of the web-facing side of forming element 1600. Figure 7 is an illustration of a cross-section of the forming element 1600 showing the embryonic paper 543 deposited on the web-facing side of the forming element 1600.

The forming element 1600 comprises: a liquid permeable textile substrate 1610 and a flow restricting member 1650 deposited on the textile substrate 1610 . Textile substrate 1610 includes longitudinal filaments 1612 and transverse filaments 1614 . The shape of the flow restricting member 1650 corresponds to the decorative indicia formed on the paper web 20 . Textile substrate 1610 provides a first dewatering zone corresponding to the portion of textile substrate 1610 not covered by flow restricting member 1650 . The first dehydration zone has a first dehydration rate. The portion of the forming element 1600 on which the flow restricting member 1650 is disposed provides a second dewatering zone having a second dewatering rate that is lower than the first dewatering rate.

The liquid carrier (eg, water) is removed from the forming element 1600 in two states corresponding to the first and second dehydration zones. Thus, fibers in aqueous suspension tend to flow out of the second dewatering and accumulate in the first dewatering zone, whereby a relatively low basis weight zone aligned with the flow restricting member 1650 is formed. Relatively short fibers tend to accumulate in the first zone. At least some of the relatively long fibers can bridge the width of the flow restricting member. Thus, in the relatively low basis weight region of the decorative mark, the average fiber length of the papermaking fibers is greater than the average fiber length of the papermaking fibers in the surrounding portion of the paper web.

Flow restricting member 1650 may be formed on textile substrate 1610 by selectively curing a photopolymerizable resin on textile substrate 1610 . The flow restricting member 1650 is generally liquid impermeable, therefore, the second dehydration rate of the second dehydration zone is substantially zero. Photopolymerizable resins as generally disclosed in US5,503,715 (published April 2, 1996 in the name of Trokhan et al.) and US 5,534,326 (published July 9, 1996 in the name of Trokhan et al.) may be used, A suitable fiber retention forming element 1600 is formed, both of which are hereby incorporated by reference.

The flow restricting element 1650 may be formed from a combination of linear and/or curvilinear segments 1660 that together form a closed region 1670 . The segment 1660 has a width W (FIG. 6), which is generally measured perpendicular to the length of the portion. If the web is made from one type of fiber, then the width W is preferably less than about half the average fiber length, more preferably less than about one quarter the average fiber length. If the web is made from a homogeneous mixture of different types of fibers including hardwood and softwood fibers, the width W of the segment 1660 is preferably less than about half the average fiber length of the hardwood fibers forming the web, most preferably less than about a quarter. On the other hand, if the web comprises two or more layers, then the width W should be less than about 1/2, more preferably less than about 1/4, the average fiber length of the hardwood fibers in the layers adjacent to the forming element 1600.

For example, for making a furnish of 100% eucalyptus fibers, the width W should be less than about 0.5 mm based on an average fiber length of about 1.0 mm. Alternatively, if the furnish is made from 100% northern softwood kraft fibers having an average fiber length of about 3.0 mm, then the width W should be less than about 1.5 mm.

The resulting decorative indicia may each comprise a relatively low basis weight region having the shape of a closed loop completely surrounding at least one relatively high basis weight interval 240 . The width of the region of relatively low basis weight (equivalent to width W) measured anywhere along the closed loop shape is between about 0.2 millimeters and about 2 millimeters.

The flow restricting member 1650 may have any suitable decorative shape, including but not limited to: flower shapes, animal shapes, geometric shapes such as circles, squares, and triangles. Preferably, the segments 1660 of the flow restricting member 1650 are positioned on the shaping element 1600 such that at least some of the segments 1660, preferably most of the segments 1660 form an angle A (FIG. 6) of at least 15 degrees to the transverse direction (CD in FIG. 6). . Such positioning provides the advantage that the relatively low basis weight region 220 is advantageously oriented with respect to the cross direction of the web. When the web is creped on the dryer cylinder, the blades are substantially parallel to the transverse direction of the web. Thus, the impact of the blade will have little adverse effect on the appearance and structure of the relatively low basis weight region 220 if the segment 1660 is angled from the transverse direction. In particular, if the relatively low basis weight regions are oriented substantially parallel to the cross direction, it is believed that the doctor blade will "digg out" the relatively low basis weight regions 220, thereby adversely affecting the decorative appearance of the web.

It is contemplated that all types of wood pulp will generally constitute the papermaking fibers used in the present invention. However, other cellulosic fiber pulps, such as linters, bagasse, rayon, etc., can also be used without disqualification. Wood pulps useful in the present invention include chemical pulps, such as kraft, kraft and sulfite pulps, and mechanical pulps, including, for example, groundwood, thermomechanical pulp and chemithermomechanical pulp (CTMP). Pulps from coniferous and deciduous trees can be used. Additionally, non-cellulosic fibers, such as synthetic fibers, may also be used.

Both hardwood and softwood pulps can be used alone or in combination. Hardwood fibers and softwood fibers may be mixed and additionally deposited in layers to provide a layered web. US 4,300,981 (Carstens, issued November 17, 1981) and US 3,994,771 (Morgan et al., issued November 30, 1976) are incorporated by reference for the disclosure of layered structures of hardwood fibers and softwood fibers.

Papermaking furnishes may contain a variety of additives including, but not limited to, fibrous bonding materials such as wet strength bonding materials, dry strength bonding materials, and chemical softening components. Suitable wet strength binders include, but are not limited to, polyamide-epichlorohydrin resins such as those sold under the tradename KYMENE(R) 557H by Hercules Inc. (Wilmington, Delaware). Suitable temporary wet strength binders include, but are not limited to, synthetic polyacrylates. A suitable temporary wet strength binder is PAREZ(R) 750 sold by American Cyanamid (Stanford, CT).

Suitable dry strength binders include materials such as carboxymethyl cellulose, cationic polymers such as ACCO(R) 711. CYRPO/ACCO-like dry strength materials are available from CYTEC (Kalamazoo, MI).

The papermaking furnish deposited on the forming element 1600 may contain a debonding agent to inhibit the formation of certain fiber-fiber bonds as the web dries. The debonding agent and the energy provided by the dry creping process will re-open a portion of the web. In one embodiment, a debonding agent is applied to fibers forming an intermediate fiber layer disposed between two or more fiber layers. The middle layer acts as a debonding layer between the fiber outer layers. Thus, the creping energy can partially re-open the web along the detachment layer.

Accordingly, a paper web having a relatively smooth surface that is effectively dried on a heated drying surface, such as that of a Yankee dryer, can be formed. Furthermore, the dry web may also have regions of different densities due to re-opening at the creping blades, including: continuous relatively high-density web regions, and discontinuous relatively low-density regions produced by the creping process .

Suitable debonding agents include: chemical softening compositions as disclosed in US 5,279,767 (issued January 18, 1994 to Phan et al). Suitable biodegradable chemical softening compositions are disclosed in US 5,312,522 (issued May 17, 1994 to Phan et al.). US 5,279,767 and US 5,312,522 are hereby incorporated by reference. The chemical softening composition is useful as a debonding agent for inhibiting fiber-fiber bonding in one or more layers of fibers from which a paper web is made.

One suitable softening agent for detaching the fibers in one or more layers of fibers forming the web 20 is a papermaking additive comprising diester di(contact curable) tallow dimethyl ammonium chloride. A suitable softener is: ADOGEN(R) paper additives available from Witco Corporation, Greenwich, CT.

The paper web 543 is preferably prepared from an aqueous dispersion of papermaking fibers, although dispersions in liquids other than water may be used. The fibers are dispersed in the carrier fluid to a concentration of from about 0.1% to about 0.3%. The percent concentration of a dispersion, suspension, web or other system is defined as: 100 multiplied by the weight of dry fibers in the system under consideration divided by the total weight of the system. Fiber weights are always expressed on a dry fiber basis.

The paper blank 543 can be formed by a continuous papermaking process as shown in FIG. 4, or a batch process, such as a handsheet papermaking process, can be used. After the dispersion of papermaking fibers is deposited onto the forming element 1600, a portion of the aqueous dispersion medium is passed through the forming element 1600 to form the web 543 by processes known to those skilled in the art. To form the web 543, water can be removed from the aqueous dispersion of papermaking fibers using a vacuum box, forming board, dewatering board, or the like.

FIG. 7 shows a blank formed on the forming element 1600 . The portion of the web supported on the flow restricting member 1650 is indicated at 543A, and the portion of the web supported on the textile substrate 1610 is indicated at 543B. Portion 543A corresponds to relatively low quantitative region 220 in FIGS. 1A and 1B , and portion 543B corresponds to relatively high quantitative base portion 100 and interval 240 in FIGS. 1A and 1B .

Preferably, the height difference D between the flow restricting member 1650 and the top surface of the textile substrate 1610 is less than about 6 mils (0.006 inches; 0.152 millimeters) in order to provide a substantially smooth first and second surfaces 547 and 549. The paper blank 543 is usually a single plane. More preferably, the height difference D is less than about 3 mils (0.076 mm). Preferably, the height difference D is less than about 1/6 of the average length of the fibers in the web, most preferably less than about 1/6 of the average length of the hardwood fibers in the web. The web 543 travels with the forming element 1600 running around the turning roll 1502 and into the vicinity of the web support device 2200 .

Referring to Figures 4, 8, 9, and 10, the next step in preparing the web 20 includes transferring the web 543 from the forming element 1600 to the web support device 2200 and supporting it on the first side 2202 of the device 2200 The transferred web (indicated at 545 in Figure 4). Preferably, at the point of transfer to the web support apparatus 2200, the web has a consistency of between about 5% and about 20%.

Referring to FIGS. 8-10 , the web support apparatus 2200 includes a dewatering felt layer 2220 and a web patterning layer 2250 . To dry and pattern the web on the machine, the web support device 2200 may be in the form of a continuous belt. The web support device 2200 has a first facing paper web surface 2202 and a second opposite surface 2204 . In FIGS. 8 and 9 , the web support device 2200 is viewed with the first facing paper web 2202 facing the observer. The first facing web 2202 includes: a first web-contacting surface and a second web-contacting surface.

In FIGS. 8 and 9 , the first web-contacting side is the first felt side 2230 of the felt layer 2220 . The first carpet surface 2230 is arranged at a first height 2231 . The first felt side 2230 is the felt surface that the web contacts. The felt layer 2220 also has a reverse second felt surface 2232 .

In FIGS. 8 and 9 , the second web contacting surface is provided by a web patterning layer 2250 . The web patterning layer 2250 joined to the felt layer 2220 has a web contacting top surface 2260 disposed at a second level 2261. The difference between the first height 2231 and the second height 2261 is less than the thickness of the web being transferred onto the web support device 2200 . Surfaces 2260 and 2230 may be arranged at the same height, and as a result, heights 2231 and 2261 are the same. Additionally, surface 2260 may be slightly higher than surface 2230 , or surface 2230 may be slightly higher than surface 2260 .

The height difference is greater than or equal to 0.0 mil (0.0 mm) and less than about 8.0 mil (0.203 mm). In one embodiment, the height difference is less than about 6.0 mils (0.15 mm), more preferably less than about 4.0 mils (0.10 mm), and most preferably less than about 2.0 mils (0.05 mm) in order to maintain a relatively smooth surface 24.

The dewatering felt layer 2220 is water permeable and capable of receiving and containing water expressed from the wet web of papermaking fibers. The web patterning layer 220 is impermeable to water and does not receive or contain water expressed from the web of papermaking fibers. The web patterning layer 2250 may have a continuous web contacting top surface 2260, as shown in FIGS. 8 and 9 . In addition, the web patterning layer may also be discontinuous or semi-continuous.

Preferably, the web patterning layer 2250 comprises a photosensitive resin that may first be disposed on the first surface 2250 in liquid form and then cured by irradiation to cause a portion of the web patterning layer 2250 to penetrate and Thereby a firm bond is made to the first felt surface 2230 . Preferably, the web patterning layer 2250 does not extend through the entire thickness of the felt layer 2220, but extends through less than about half the thickness of the felt layer 2220 to maintain the flexibility and compressibility of the web support device 2200, particularly the felt layer. 2220 for flexibility and compressibility.

A suitable dewatering felt layer 2220 comprises a nonwoven batt mat 2240 of natural or synthetic fibers attached to a support structure formed of textile filaments 2244, such as by needling. Suitable materials from which the nonwoven batting is made include, but are not limited to, natural fibers such as wool, and synthetic fibers such as polyester and nylon. The fibers forming the batt 2240 may have a denier of about 3 to about 20 grams per 9000 meters of filament length.

The felt layer 2220 may have a layered structure and may contain a mixture of various fibers and sizes. The felt layer 2220 is formed to facilitate transport of moisture received in the web away from the first felt surface 2230 and to transport the moisture towards the second surface 2232 . The carpet layer 2220 may have fine and relatively dense fill fibers disposed adjacent the first carpet surface 2230 . When compared with the density and pore size of the felt layer 2220 adjacent to the second felt surface 2232, the felt layer 2220 adjacent to the first felt surface 2230 preferably has a relatively high density and a relatively small pore size, and as a result, access to the first felt surface The moisture of 2230 will be carried away from the first surface 2230 .

The thickness of the dewatered felt layer 2220 is greater than about 2 millimeters. In one embodiment, the dewatered felt layer 2220 has a thickness between about 2 millimeters and about 5 millimeters.

The following documents are incorporated by reference for the purpose of disclosing the application of photosensitive resins to dewatering felts and for the disclosure of suitable dewatering felts: PCT Publications WO 96/00812 (published January 11, 1996), WO 96/25555 (August 1996 Published on August 22), WO96/25547 (published on August 22, 1996), all of which are filed in the name of Trokhan et al; filed August 22, 1996); US08/640,452 "High Absorption/Low Reflectance Blanket with Patterned Layer" (applied April 30, 1996); and US08/672,293 "Preparation of wet-laminated Page Method" (filed June 28, 1996).

The dewatering felt 2220 may have an air permeability of less than about 200 standard cubic feet per minute (scfm) (about 5.6 cubic meters per minute), expressed in scfm at a pressure differential across the thickness of the dewatering felt of about 0.5 inches of water , a measure of the number of cubic feet of air passing through one square foot of blanket layer per minute. In one embodiment, the air permeability of the dewatered felt layer 2220 is between about 5 and about 200 scfm (about 0.14 and about 5.6 cubic meters per minute), more preferably less than about 100 scfm (2.8 cubic meters per minute).

The dewatered felt layer 2220 has a basis weight of between about 800 g/ ^m2 and about 2000 g/ ^m2 and an average density (basis weight divided by thickness) of between about 0.35 g/ ^cm3 and about 0.45 g/ ^cm3 . The air permeability of the web support device 2200 is lower than or equal to the air permeability of the felt layer 2220 .

One suitable felt layer 2220 is an Amflex 2 press felt manufactured by Appleton Mills Company (Appleton, Wisconsin). The felt layer 2220 has a thickness of about 3 mm, a basis weight of about 1400 g/ ^m2 , an air permeability of about 30 scfm (0.84 cubic meters per minute), and has three ply multifilament top and bottom warp threads and four ply multitwisted monofilament weft threads. double support structure. The batt 2240 may comprise polyester fibers of about 3 denier at the first surface 2230 and about 10-15 denier in a batt base below the first surface 2230 .

The web support device 2200 shown in FIG. 9 has a web patterning layer 2250 having a continuous web-like web contacting top surface 2260 in which there are a number of discrete openings 2270 . Suitable opening 2270 shapes include, but are not limited to, circular, oval elongated in the machine direction (MD in FIG. 9 ), polygonal, irregular, or combinations thereof. As shown in FIG. 9, the projected surface area of the continuous webbed top surface 2260 may be between about 5% and about 75% of the projected area of the web support device 2200, preferably between about 25% and about 50% of the projected area of the device 2200. %between.

The continuous mesh top surface 2260 can have at least about 10,000, more preferably at least about 50,000 discrete openings 2270 per square meter of projected area of the device 2200, as shown in FIG. The device 2200 has at least about 15,000 discrete openings 2270 . In one embodiment, the continuous reticulated top surface 2260 has at least about 100,000 discrete openings 2270 per square meter.

The discrete openings 2270 may be interleaved in the machine direction (MD) and cross direction (CD) as described in US 4,637,859 (issued January 20, 1987), incorporated herein by reference. Additionally, other photopolymer patterns may be used in order to provide different densified patterns to the web.

conveying the web onto the web support device 2200 such that the first side 547 of the conveyed web is supported on and coincident with the surface 2202 of the device 2200, wherein a portion of the web 545 is supported on the surface 2260, A portion rests on the felt surface 2230 . The second side 549 of the web remains substantially smooth and has a macroscopically uniplanar configuration. Referring to Figure 10, the height difference between the surface 2260 and the surface 2230 of the web support device 2200 should be small enough so that, as the web is conveyed onto the device 2200, the second side of the web remains substantially smooth and macroscopically uniplanar . In particular, the height difference between the surface 2260 and the surface 2230 should be smaller than the thickness of the paper blank at the paper delivery position.

The step of transferring the web 543 to the apparatus 2200 is provided at least in part by applying a hydraulic differential to the web 543 . Referring to FIG. 4, the web 543 may be vacuum transferred from the forming element 1600 to the apparatus 2200 by a vacuum source 600 such as a vacuum shoe or vacuum roll shown in FIG. Downstream of the web threading location, one or more additional vacuum sources 620 may also be provided for further dewatering.

The web 545 carried on the apparatus 2200 is fed in the machine direction (MD of FIG. 4 ) into the nip 800 provided between the vacuum press roll 900 and the hard surface 875 of the heated Yankee dryer 880 . Referring to FIG. 11 , a steam hood 2800 may be positioned just upstream of the nip 800 . Steam may be applied directly to the surface 549 of the web 545 using a steam hood as the surface 547 of the web 545 is passed on the vacuum press roll 900 .

The steam cover 2800 is installed corresponding to the vacuum pressure supply part 920 of the vacuum pressure roller. A vacuum section 920 is provided to introduce steam into the web 545 and felt layer 2220. The steam provided by the steam hood 2800 heats the water in the web 545 and the felt layer 2220, thereby reducing the viscosity of the water in the web and felt layer 2220. Therefore, the water in the web and felt layer 2220 can be more easily removed by the vacuum provided by the roll 900.

At pressures below about 15 psi (1.02 atmospheres), the steam hood 2800 can provide about 0.3 pounds of saturated steam per pound of dry fiber (0.3 grams of saturated steam per gram of dry fiber). At surface 2204, vapor portion 920 is provided to provide a vacuum of about 1 to about 15 inches (about 25.4 millimeters to about 381 millimeters) of mercury, preferably between about 3 and about 12 inches (about 76.2 millimeters to about 304.8 millimeters) of mercury .

A suitable vacuum press roll 900 is: a vacuum press roll manufactured by Winchester Roll Products. A suitable steam hood 2800 is: Model D5A manufactured by Measurex-Devron Corporation (North Vancouver, British Columbia, Canada).

The vacuum providing section 920 is connected to a vacuum source (not shown). The vacuum providing portion 920 is stationary with respect to the rotating surface 910 of the roller 900 . Surface 910 may be an apertured or grooved surface through which vacuum is applied to surface 2204 . The direction of rotation of surface 910 is shown in FIG. 11 . The vacuum providing portion 920 provides a vacuum at the surface 2204 of the web support device 2200 as the web and device 2200 pass through the vapor hood 2800 and through the nip 800 . Although only one vacuum providing section 920 is shown, in other embodiments it may be desirable to provide separate vacuum providing sections, each providing a different vacuum at the surface 2204 as the device 2200 travels along the roll 900. vacuum.

A Yankee dryer usually consists of a steam-heated steel or iron cylinder. Referring to FIG. 11 , the web support is fed into the nip 800 on apparatus 2200 so that the second, substantially smooth side 549 of the web is conveyed onto the surface 875 . Upstream of the nip, nozzles 890 apply adhesive to the surface 875 at a point before the web is delivered to the surface 875 .

The adhesive may be a polyvinyl alcohol based adhesive. Alternatively, the adhesive may be: CREPREOL(R) adhesive manufactured by Hercules Corporation, Wilmington Delaware. For those embodiments where the web is introduced onto the Yankee dryer 880 at a consistency greater than about 45%, a polyvinyl alcohol based creping adhesive is typically used. At consistency below about 40%, a binder such as CREPREOL(R) binder is used.

The adhesive can be applied to the web directly or indirectly (eg, onto the Yankee surface 875) in a number of ways. For example, the adhesive is sprayed onto the web, for example in the form of droplets, or onto the Yankee surface 875 . Alternatively, adhesive may be applied to surface 875 by a transfer roller or brush. In another embodiment, the creping binder may be added to the papermaking furnish at the wet end of the paper machine, such as adding the binder to the papermaking furnish of the headbox 500 . For each ton of papermaking fibers dried on the Yankee dryer 880, about 2 pounds to about 4 pounds (about 908 grams to about 1816 grams) of binder may be added.

The vacuum providing portion 920 of the roll 900 provides a vacuum at the surface 2204 of the web support device 2200 as the web passes through the nip 800 on the device 2200 . In addition, the web patterning layer 2250 of the web support apparatus 2200 will impart the first surface 547 of the web 545 with Surface 2260 conforms to the pattern. Because the second surface 549 is a substantially smooth and macroscopically uniplanar surface, the second surface 549 is substantially snug and adheres to the drying surface 875 as the web passes through the nip 800 . Second surface 549 rests on smooth surface 875 to maintain a substantially smooth and macroscopically uniplanar configuration as the web passes through the nip. Thus, a predetermined pattern can be imparted to the first surface 547 of the paper web 545 while the second surface 549 remains substantially smooth. When the web 545 is transferred onto the surface 875 and imparts the pattern of the surface 2260 to the web to selectively densify the web, it is preferred that the consistency of the web 545 is between about 20% and about 60%. The pattern of surface 2260 is imparted to the paper web so as to provide continuous web regions 110 and discontinuous regions of relatively low density 130 as shown in Figures 1A and IB.

Without being bound by theory, it is believed that since substantially all of the second surface 549 rests on the Yankee surface 875, as the web 545 dries on the Yankee, its The drying efficiency will be higher than the drying efficiency of the web when only a selected portion of the second surface is applied to the Yankee dryer.

In particular, it is believed that drying from a relatively low consistency to a relatively high consistency on a relatively high rotational speed Yankee dryer allows the web to 545 has a basis weight of at least about 8 lbs/3000 ^ft2 (13 g/ ^m2 ), more preferably at least about 10 lbs/3000 ^ft2 (16.3 g/ ^m2 ). Additionally, it is believed that a web 545 having the basis weight described above can be obtained from a consistency of less than about 30%, more preferably from a consistency of less than 25% (as the web is passed onto the dryer cylinder 880) at relatively high web travel speeds. ) to a consistency of at least about 90%, more preferably to a consistency of about 95% (as the web exits the dryer cylinder through creping), which enables economical production of the web 20.

In comparison, it is believed that for the same drying conditions and dryer design, a Yankee dryer pair having a continuous wire and discontinuous dome as disclosed in US 4,637,859 and a basis weight of at least about 10 lbs. The drying speed of a 3000 ^ft2 (16.8 g/ ^m2 ) web will be limited because the domes cannot be dried as fast as a continuous wire.

The final step in forming paper structure 20 includes creping paper web 545 from surface 875 with doctor blade 1000, as shown in FIG. Without being bound by theory, it is believed that the energy imparted to the web 545 by the doctor blade 1000 will cause at least some portions of the web, especially those portions not imprinted by the web patterning surface 2260, such as relatively low density areas 130 and 280 become bulked or dedensified. Thus, the creping step of the web from the surface 875 with the doctor blade 1000 provides a web having a first compacted relatively thinner region and a second relatively thicker region, wherein the relatively thinner The regions correspond to the pattern imparted to the first surface of the web. In one embodiment, the blades are angled at about 25 degrees and positioned relative to the Yankee dryer to provide an impingement angle of about 81 degrees.

The paper structure 20 shown in FIGS. 1B and 3 is shortened due to creping of relatively high density continuous web regions 110 and relatively low density discontinuous regions 130 . The creping frequency in region 110 may be different than the creping frequency in region 130 . Generally, the frequency of creping in region 130 is lower than the frequency of creping in continuous web region 110 . This difference in corrugation frequency is illustrated in FIG. 1B , where corrugation ridges 115 are more closely spaced (higher frequency) than corrugation ridges 135 .

Thus, web 20 provides the decorative aesthetics provided by decorative indicia 200 without embossing. Additionally, web 20 has flexibility provided by creping of the high and low density regions, bulk and absorbency provided by low density regions 130 and 280, and softness provided by relatively smooth surface 24.

In another embodiment of the present invention, the web support apparatus 2200 may include a resin layer disposed on a porous base member comprising a fabric of textile filaments. Referring to FIGS. 14-18 , the device 2200 may include a resin layer 2250 disposed on the fabric 1220 . As shown in FIG. 14, resinous layer 2250 has a continuous web of web contacting surface 2260 that defines discrete openings 2270. As shown in FIG. Fabric 1220 includes longitudinal filaments 1242 and transverse filaments 1241 . Device 2200 has a first side 2202 and a second side 2204 . The first side 2202 includes a first web-contacting surface and a second web-contacting surface.

In FIGS. 14 and 15 , the first web contacting surface at a first level 1231 is provided by a discontinuous nip surface 1230 at the intersection of the filaments 1241 and 1242 . The top surfaces of filaments 1241 and 1242 may be sanded or otherwise abraded to provide relatively flat, generally oval knuckle surface 1230 . A second web contacting surface is provided by the web patterning layer 2250 . The web patterning layer 2250 attached to the fabric 1220 has a web contacting top surface 2260 at a second height 2261.

The difference between the first height 1231 and the second height 2261 is less than the thickness of the web as it is transferred onto the web support device 2200 . Continuous surface 2260 and discontinuous surface 1230 may be provided at the same height such that heights 1231 and 2261 are the same. Additionally, surface 2260 may be slightly higher than surface 1230 , or surface 1230 may be slightly higher than surface 2260 .

The height difference is greater than or equal to 0.0 mil (0 mm) and less than about 5.0 mil (0.127 mm). In one embodiment, the height difference is less than about 4.0 mil (0.10 mm), more preferably less than about 2.0 mil (0.05 mm), and most preferably less than about 1.0 mil (0.025 mm), so that the dryer sheet The web maintains a relatively smooth surface 24.

The web shown in Figures 12 and 13 may be formed using the web support apparatus 2200 shown in Figures 14 and 15 . Figure 12 is a plan view of a paper web 20 according to an alternative embodiment of the present invention. Figure 13 is a cross-sectional view of the web shown in Figure 12 .

Referring to Figures 12 and 13, a paper web has a base portion 100 and decorative indicia 200 forming relatively low basis weight regions 220. The base portion 100 comprises a relatively high density continuous web 110 , and discontinuous relatively low density regions 130 dispersed throughout the continuous web region 110 . One or more discrete relatively high density regions 135 are interspersed within each relatively low density region 130 .

The relatively low basis weight region 220 may have the shape of a closed loop defining a number of adjacent relatively high basis weight intervals 240 (seven intervals 240 in FIG. 12). The quantification everywhere within the interval 240 is higher than that of the relatively low quantification area 220 surrounding that particular interval 240 . Each zone 240 has a perimeter formed by a closed loop of relatively low basis weight region 220 . Zone 240 may be selectively densified to contain a relatively high density, continuous web 260 , and discrete regions 280 of relatively low density interspersed within web 260 . Each discrete region of relatively low density 280 surrounds a number of discrete regions of relatively higher density 285 .

The continuous wires 110 and 260 conform to the surface 2260 of the web support device 2200 shown in FIG. 14 . Discontinuous regions of relatively high density 135 and 285 coincide with surface 1230 shown in FIG. 14 . Relatively low density regions 130 and 280 of the web in FIG. 12 coincide with those portions of the web that are not aligned with either surface 2260 or surface 1230 .

Figure 13 is a cross-sectional view of the portion of the web shown in Figure 12 . The line densities of the web thicknesses in Figure 13 are used to briefly illustrate the relative weights of the different web portions. Portions of the web represented by five lines across the web represent areas of relatively high basis weight, while portions of the web represented by three lines represent regions of relatively low basis weight.

16-18 illustrate the use of a web support apparatus 2200 to form the web 20 shown in FIG. 12 . 4-7 above, a paper blank 543 having a first smooth surface and a second smooth surface is formed on the forming element 1600 so as to have a relatively low basis weight decorative indicia and a relatively high basis basis portion. The web is then vacuumed onto the apparatus 2200 to provide the web 545 supported on the first side 2202 of the apparatus 2200 . As shown in FIG. 17, first surface 547 coincides with surface 2260 and surface 1230, and second surface 549 remains a substantially smooth and macroscopically uniplanar surface.

Next, the web 545 and web support apparatus 2200 are passed through a throughdrying apparatus 650 ( FIG. 16 ) in which heated air is passed directly through the web 545 as it is supported on the apparatus 2200 . The heated air enters the surface 549 and passes through the web 545 before passing through the apparatus 2200.

Throughdrying apparatus 650 may be used to dry web 545 from about 30% consistency to about 70% consistency. US 3,303,576 (to Sisson) and US 5,274,930 and 5,584,126 (to Ensign et al.) are incorporated by reference for purposes of illustrating suitable through-dryers for use in the present invention. Alternatively, the web may be dewatered according to US 4,556,450, issued December 3, 1985 to Chuang et al., which is incorporated herein by reference.

The partially dried web 545 is passed through the nip 800 between the press roll 900 and the Yankee 880 in registration with the apparatus 220 . The continuous web surface 2260 and the discontinuous surface 1230 are pressed into the surface 547 of the paper web 545 as the web passes through the nip 800 . Adhesive provided through nozzle 890 is used to bond substantially all of substantially smooth surface 549 to surface 875 of heated Yankee dryer 880 .

Although one forming element 1600 is shown in Figures 4 and 16, it should be understood that other forming wire configurations can also be used in combination with one or more headboxes, each capable of providing one layer or Multiple layers of fiber furnish to provide multiple layers of paper web. US3,994,771 (issued to Morgan et al.) and US4,300,981 (issued to Carstens et al.) and commonly assigned US patent application (filed on October 24, 1996 in the name of Phan and Trokhan, entitled "Having improved functional Permanent layered tissue paper") discloses a wet-laid process, which is hereby incorporated by reference. Various forming wire configurations can be used, including twin wire formers. Additionally, various headbox configurations may be employed to provide a web having one or more fibrous layers.

In another embodiment, the paper supported on the web support 2200 can be made dehydration. In the nip, the web is sandwiched between the web support device 2200 and a layer of dewatering felt. To illustrate the dewatering of the web by pressing the web, the following patent documents are hereby incorporated by reference:

PCT publications WO96/00812 (published January 11, 1996), WO96/25555 (published August 22, 1996), WO96/25547 (published August 22, 1996), all of which are based on Trokhan et al. Nominal applications; US08/701,600 "Method for applying resins to substrates for papermaking" (filed August 22, 1996); US08/640,452 "High absorption/low reflectivity felt with patterned layers" (1996 April 30, 1996); and US08/672,293 "Method for preparing wet-pressed tissue paper using selectively permeable felt" (June 28, 1996); and US5,580,423 (authorized December 3, 1996 in Ampulski et al).

Example:

The following examples illustrate the practice of the invention, but are not meant to limit the invention.

Example 1

First, a 3% by weight aqueous suspension of northern softwood kraft (NSK) fibers was prepared using a conventional pulper. A 2% solution of a temporary wet strength resin (ie, PAREZ ⁽ R) 750 sold by American Cyanamid Company, Stanford, CT) at a rate of 0.2% by dry fiber weight was added to the NSK stock tube. The NSK slurry was diluted to a concentration of about 0.2% at the mixing pump. Next, a 3% by weight aqueous suspension of the eucalyptus fibers was obtained using a conventional pulper. A 2% solution of debonding agent (ie, Adogen ⁽ R) SDMC sold by Witco Corporation, Dublin, OH) was added to a tube of eucalyptus pulp at a rate of 0.1% by weight of the fiber. The eucalyptus slurry was diluted to a consistency of about 0.2% at the mix pump.

The treated furnish streams are mixed in the headbox and deposited onto forming elements 1600 shown in Figure 16 to form a uniform web. Forming element 1600 includes a Fourdrinier forming wire having flow restricting features 1650 formed by curing a photopolymer layer on the forming wire. Dewatering is carried out by passing through a fourdrinier wire with the help of a water deflector and a vacuum suction box. The Fourdrinier has a three-layer square structure with 90 longitudinal monofilaments and 72 transverse monofilaments per inch. The diameter of the monofilament is about 0.15-0.20mm. The air permeability of the forming fabric was about 1050 scfm (29.4 cubic meters). Flow through the forming screen is prevented by flower-shaped photopolymer flow restriction members 1650 as shown in FIG. 5 . The composite flow restricting member 1650 has a projected area equal to approximately 10% of the projected area of the shaped element. The height difference D (FIG. 7) is approximately 0.003 inches (0.076 mm).

The wet web is transferred from the forming element 1600 to a web support device 2200 having a dewatering felt layer 2220 and a photosensitive resin web patterning layer 2250; the fiber concentration at the transfer position is about 10%. The dewatering felt 2220 is an Amflex 2 press felt. Blanket 2220 comprises polyester fiber batting. The surface denier of the batt is 3, and the base denier is 10-15. The felt layer 2220 has a basis weight of 1436 g/ ^m2 , a thickness of about 3 mm, and an air permeability of about 30 to about 40 scfm (about 0.84 cubic meters to about 1.12 cubic meters). The web patterning layer 2250 comprises a continuous web-like web contacting surface 2260 defining a plurality of discrete openings 2270 extending in the machine direction (MD) as shown in FIG. 9 . The web patterning layer 2250 has a projected area approximately equal to 35% of the projected area of the web support device 2200 . The height difference 2261 between the web contacting surface 2260 and the first felt surface 2230 is about 0.005 inches (0.127 millimeters).

The web is passed onto a web support apparatus 2200 to provide a generally single planar web 545 . Threading and flexing was performed at a vacuum threading position with a differential pressure of approximately 20 inches (508 mm) Hg. Further dewatering was accomplished by vacuum assisted dewatering until the web had a fiber consistency of about 25%. The web 545 is then sent to the nip 800 . The vacuum roll 900 has a pressing surface 910 with a hardness of about 60 P&J. The web 545 is compressed against the compacted surface of the Yankee dryer 880 by pressing the web 545 and the web support device 2200 between the press surface 910 and the surface of the Yankee dryer 880 with a compressive force of about 200 psi. Surface 875. The compacted web was bonded to the Yankee dryer with a polyvinyl alcohol based creping adhesive. The consistency of the fibers is increased to at least about 90% prior to dry creping the web with a doctor blade. The scraper has a bevel angle of about 20 degrees and is positioned relative to the Yankee dryer to provide an impingement angle of about 76 degrees; the Yankee dryer operates at about 800 fpm (feet per minute) (about 244 meters per minute) . The dry web was formed into a web at a speed of 650 fpm (200 meters per minute).

Convert the paper web into two-ply bath tissue. The two-ply toilet paper has a basis weight of about 25 lbs/3000 square ^feet (42.04 grams per square meter) and contains about 0.2% temporary wet strength resin and about 0.1% debonding agent. The resulting tissue paper is bulky, soft, absorbent, and aesthetically pleasing, and can be used as bath tissue.

Example 2

First, a 3% by weight aqueous suspension of northern softwood kraft (NSK) fibers was prepared using a conventional pulper. A 2% solution of a temporary wet strength resin (ie, PAREZ ⁽ R) 750 sold by American Cyanamid Company, Stanford, CT) at a rate of 0.2% by dry fiber weight was added to the NSK stock tube. The NSK slurry was diluted to a concentration of about 0.2% at the mixing pump. Next, a 3% by weight aqueous suspension of eucalyptus fibers was prepared using a conventional pulper. A 2% solution of debonding agent (ie, Adogen ⁽ R) SDMC sold by Witco Corporation, Dublin, OH) was added to a tube of eucalyptus pulp at a rate of 0.5% by weight of the fiber. The eucalyptus slurry was diluted to a consistency of about 0.2% at the mix pump. Furthermore, a 3% by weight aqueous suspension of eucalyptus fibers was obtained using a conventional pulper. A 2% solution of debonding agent (i.e., ^Adogen® SDMC sold by Witco Corporation (Dublin, OH)) and a 2% solution of dry strength binder (i.e., available from National Starch and Chemical Company ( New York), ^Redibond® 5320 sold in New York) was added to the eucalyptus pulp tube. The eucalyptus slurry was diluted to a consistency of about 0.2% at the mix pump.

Individually processed furnish streams (stream 1 = 100% NSK / stream 2 = 100% dissociated eucalyptus pulp / stream 3 = 100% eucalyptus pulp) were separated in the headbox and deposited onto the graph On the forming element 1600 shown in Fig. 6, a 3-layer paper web is formed. The forming element 1600 comprises: a forming wire. Dewatering takes place through the forming wire with the help of water baffles and suction boxes. The forming wire, manufactured by Appleton Wire (Appleton, Wisconsin), was a three-layer square weave configuration with 90 longitudinal filaments per inch and 72 transverse filaments per inch. The diameter of the monofilament is about 0.15-0.20mm. The air permeability of the forming fabric was about 1050 scfm (29.4 cubic meters). Flow through the forming screen is prevented by flower-shaped photopolymer flow restriction members 1650 as shown in FIG. 6 . The composite flow restricting member 1650 has a projected area equal to approximately 10% of the projected area of the shaped element. The height difference D (FIG. 7) is approximately 0.003 inches (0.076 mm).

The wet web is transferred from the forming element 1600 to a web support device 2200 having a dewatering felt layer 2220 and a photosensitive resin web patterning layer 2250; the fiber concentration at the transfer position is about 10%. The dewatering felt 2220 is an Amflex 2 press felt. Blanket 2220 comprises polyester fiber batting. The surface denier of the batt is 3, and the base denier is 10-15. The felt layer 2220 has a basis weight of 1436 g/ ^m2 , a thickness of about 3 mm, and an air permeability of about 30 to about 40 scfm (about 0.84 cubic meters to about 1.12 cubic meters). The web patterning layer 2250 comprises a continuous web-like web contacting surface 2260 that defines a plurality of discrete openings 2270, as shown in FIG. The web patterning layer 2250 has a projected area approximately equal to 35% of the projected area of the web support device 2200 . The height difference 2261 between the web contacting surface 2260 and the first felt surface 2230 is about 0.010 inches (0.254 millimeters).

The web is passed onto a web support apparatus 2200 to provide a generally single planar web 545 . Threading and flexing was performed at a vacuum threading position with a differential pressure of approximately 20 inches (508 mm) Hg. Further dewatering was accomplished by vacuum assisted dewatering until the web had a fiber consistency of about 25%. The web 545 is then sent to the nip 800 . The vacuum roll 900 has a pressing surface 910 with a hardness of about 60 P&J. The web 545 is compressed against the compacted surface of the Yankee dryer 880 by pressing the web 545 and the web support device 2200 between the press surface 910 and the surface of the Yankee dryer 880 with a compressive force of about 200 psi. Surface 875. The compacted web was bonded to the Yankee dryer with a polyvinyl alcohol based creping adhesive. The consistency of the fibers is increased to at least about 90% prior to dry creping the web with a doctor blade. The scraper has a bevel angle of about 20 degrees and is positioned relative to the Yankee dryer to provide an impingement angle of about 76 degrees; the Yankee dryer operates at about 800 fpm (feet per minute) (about 244 meters per minute) . The dry web was formed into a web at a speed of 650 fpm (200 meters per minute).

Convert the paper web into two-ply bath tissue. The two-ply bath tissue has a basis weight of about 25 lbs/3000 square ^feet , (42.04 grams per square meter) and contains about 0.2% temporary wet strength resin and about 0.1% debonding agent. The resulting tissue paper is bulky, soft, absorbent, and aesthetically pleasing, and can be used as bath tissue.

Example 3

First, a 3% by weight aqueous suspension of northern softwood kraft (NSK) fibers was prepared using a conventional pulper. A 1% solution of a permanent wet strength resin (ie, Kymene ⁽ R) 557H sold by Hercules Incorporated (Wilmington, DE)) was added to the furnish tube at a rate of 0.25% by total dry fiber weight of the sheet. A 0.25% solution of dry strength resin (ie, CMC from Hercules Incorporated (Wilmington, DE)) was added to the furnish stock pipe prior to the mix pump at a rate of 0.05% by total sheet dry fiber weight. Next, a 3% by weight aqueous suspension of eucalyptus fibers was prepared using a conventional pulper. A 2% solution of debonding agent (ie, Adogen ⁽ R) SDMC sold by Witco Corporation, Dublin, OH) was added to a tube of eucalyptus pulp at a rate of 0.1% by weight of the fiber. The eucalyptus slurry was diluted to a consistency of about 0.2% at the mix pump.

Individually processed furnish streams (stream 1 = 100% NSK / stream 2 = 100% eucalyptus pulp) are separated in the headbox and deposited onto the forming element 1600 shown in Figure 6 to form a layered paper width. The forming element 1600 comprises a forming wire. Dewatering takes place through the forming wire with the help of water baffles and suction boxes. The forming wire, manufactured by Appleton Wire (Appleton, Wisconsin), was a three-layer square weave configuration with 90 longitudinal filaments per inch and 72 transverse filaments per inch. The diameter of the monofilament is about 0.15-0.20mm. The air permeability of the forming fabric was about 1050 scfm (29.4 cubic meters). Flow through the forming screen is prevented by flower-shaped photopolymer flow restriction members 1650 as shown in FIG. 6 . The composite flow restricting member 1650 has a projected area equal to approximately 10% of the projected area of the shaped element. The height difference D (FIG. 7) is approximately 0.003 inches (0.076 mm).

The wet web is transferred from the photopolymer resin forming wire to the web support 2200 having a dewatering felt layer 2220 and a photosensitive resin web patterning layer 2250; the fiber concentration at the transfer position is about 10%. The dewatering felt 2220 is an Amflex 2 press felt. Blanket 2220 comprises polyester fiber batting. The surface denier of the batt is 3, and the base denier is 10-15. The felt layer 2220 has a basis weight of 1436 g/ ^m2 , a thickness of about 3 mm, and an air permeability of about 30 to about 40 scfm (about 0.84 cubic meters to about 1.12 cubic meters). The web patterning layer 2250 comprises a continuous web-like web contacting surface 2260 that defines a plurality of discrete openings 2270, as shown in FIG. The web patterning layer 2250 has a projected area approximately equal to 35% of the projected area of the web support device 2200 . The height difference 2261 between the web contacting surface 2260 and the first felt surface 2230 is about 0.010 inches (0.254 millimeters).

The web is transferred onto the web support device 2200. Threading and flexing was performed at a vacuum threading position with a differential pressure of approximately 20 inches of Hg. Further dewatering is accomplished by vacuum assisted dewatering, and optionally pressing of the web between the web opening device and a separate dewatering felt. After pressing, the web 545 is sent to the nip 800 . The vacuum roll 900 has a pressing surface 910 with a hardness of about 60 P&J. The web 545 is compressed against the compacted surface of the Yankee dryer 880 by pressing the web 545 and the web support device 2200 between the press surface 910 and the surface of the Yankee dryer 880 with a compressive force of about 200 psi. Surface 875. The compacted web was bonded to the Yankee dryer with a polyvinyl alcohol based creping adhesive. The consistency of the fibers is increased to at least about 90% prior to dry creping the web with a doctor blade. The scraper has a bevel angle of about 25 degrees and is positioned relative to the Yankee dryer to provide an impingement angle of about 81 degrees; the Yankee dryer runs at about 800 fpm (feet per minute) (about 244 meters per minute) . The dry web was formed into a web at a speed of 650 fpm (200 meters per minute).

Converts a decorated paper web into a two-ply facial tissue. This two-ply facial tissue has a basis weight of approximately 18 lbs/3000 ^ft2 (30.27 g/m2) and contains approximately 1% permanent wet strength resin, approximately 0.2% dry strength binder and approximately 0.1% dissociated agent. The resulting two-ply tissue paper is bulky, soft, absorbent, and aesthetically pleasing, and can be used as facial tissue.

other examples

The following prophetic other examples serve to illustrate the practice of the invention without limitation.

Example 4

First, a 3% by weight aqueous suspension of northern softwood kraft (NSK) fibers was prepared using a conventional pulper. A 2% solution of a temporary wet strength resin (ie, PAREZ ⁽ R) 750 sold by American Cyanamid Company, Stanford, CT) at a rate of 0.2% by dry fiber weight was added to the NSK stock tube. The NSK slurry was diluted to a concentration of about 0.2% at the mixing pump. Next, a 3% by weight aqueous suspension of eucalyptus fibers was prepared using a conventional pulper. A 2% solution of debonding agent (ie, Adogen ⁽ R) SDMC sold by Witco Corporation, Dublin, OH) was added to a tube of eucalyptus pulp at a rate of 0.1% by weight of the fiber. The eucalyptus slurry was diluted to a consistency of about 0.2% at the mix pump.

The treated furnish streams are mixed in the headbox and deposited onto forming elements 1600 shown in Figure 6 to form a uniform web. Forming element 1600 includes a Fourdrinier forming wire having flow restricting features 1650 formed by curing a photopolymer layer on the forming wire. Dewatering is carried out by passing through a fourdrinier wire with the help of a water deflector and a vacuum suction box. The Fourdrinier has a three-layer square structure with 90 longitudinal monofilaments and 72 transverse monofilaments per inch. The diameter of the monofilament is about 0.15-0.20mm. The air permeability of the forming fabric was about 1050 scfm (29.4 cubic meters). Flow through the forming screen is prevented by flower-shaped photopolymer flow restriction members 1650 as shown in FIG. 6 . The composite flow restricting member 1650 has a projected area equal to approximately 10% of the projected area of the shaped element. The height difference D (FIG. 7) is approximately 0.003 inches (0.076 mm).

The wet web is transferred from the forming element 1600 to the web support device 2200 shown in Figures 14-15 made according to US 4,528,239 (Trokhan, published on July 9, 1985); the fiber concentration at the transfer position is about 10%, which patent is hereby incorporated by reference. The height difference (FIG. 15) between heights 2261 and 1231 is approximately 0.015 inches (0.38 mm). Further dewatering was accomplished by vacuum assisted dewatering until the web had a fiber consistency of about 28%. The patterned paper web was then predried to a fiber consistency of about 65% by weight by air drying. The web was then bonded to the surface of the Yankee dryer with a spray creping adhesive comprising 0.25% polyvinyl alcohol (PVA) in water.

The consistency of the fibers is increased to at least about 90% prior to dry creping the web with a doctor blade. The scraper has a bevel angle of about 25 degrees and is positioned relative to the Yankee dryer to provide an impingement angle of about 81 degrees; the Yankee dryer runs at about 800 fpm (feet per minute) (about 244 meters per minute) . The dry web was formed into a web at a speed of 650 fpm (200 meters per minute).

Converts embellished paper webs into two-ply bath tissue. The two-ply toilet paper has a basis weight of about 25 lbs/3000 square ^feet (42.04 grams per square meter) and contains about 0.2% temporary wet strength resin and about 0.1% debonding agent. The resulting two-ply tissue paper is bulky, soft, absorbent, and aesthetically pleasing, and can be used as a bath towel.

Example 5

First, a 3% by weight aqueous suspension of northern softwood kraft (NSK) fibers was prepared using a conventional pulper. A 2% solution of a temporary wet strength resin (ie, PAREZ ⁽ R) 750 sold by American Cyanamid Company, Stanford, CT) at a rate of 0.2% by dry fiber weight was added to the NSK stock tube. The NSK slurry was diluted to a concentration of about 0.2% at the mixing pump. Next, a 3% by weight aqueous suspension of eucalyptus fibers was prepared using a conventional pulper. A 2% solution of debonding agent (ie, Adogen ⁽ R) SDMC sold by Witco Corporation, Dublin, OH) was added to a tube of eucalyptus pulp at a rate of 0.1% by weight of the fiber. The eucalyptus slurry was diluted to a consistency of about 0.2% at the mix pump.

Separately processed furnish streams (stream 1 = 100% eucalyptus pulp / stream 2 = 100% NSK / stream 3 = 100% eucalyptus pulp) were separated in the headbox and deposited into the On forming element 1600, a 3-ply web is formed. The forming element 1600 comprises a forming wire. Dewatering takes place through the forming wire with the help of water baffles and suction boxes. The forming wire, manufactured by Appleton Wire (Appleton, Wisconsin), was a three-layer square weave configuration with 90 longitudinal filaments per inch and 72 transverse filaments per inch. The diameter of the monofilament is about 0.15-0.20mm. The air permeability of the forming fabric was about 1050 scfm (29.4 cubic meters). Flow through the forming screen is prevented by flower-shaped photopolymer flow restriction members 1650 as shown in FIG. 6 . The composite flow restricting member 1650 has a projected area equal to approximately 10% of the projected area of the shaped element. The height difference D (FIG. 7) is approximately 0.003 inches (0.076 mm).

The wet web is transferred from the forming element 1600 onto a 44 x 33 drying/imprinting fabric as shown in US 4,191,609 (issued to Trokhan on March 4, 1980) with a fiber consistency of about 10% at the threading position , which is incorporated herein by reference. Further dewatering was accomplished by vacuum assisted dewatering until the web had a fiber consistency of about 28%. The patterned paper web was then predried to a fiber consistency of about 65% by weight by air drying. The web was then bonded to the surface of the Yankee dryer with a spray creping adhesive comprising 0.25% polyvinyl alcohol (PVA) in water.

The consistency of the fibers is increased to at least about 90% prior to dry creping the web with a doctor blade. The scraper has a bevel angle of about 25 degrees and is positioned relative to the Yankee dryer to provide an impingement angle of about 81 degrees; the Yankee dryer runs at about 800 fpm (feet per minute) (about 244 meters per minute) . The dry web was formed into a web at a speed of 650 fpm (200 meters per minute).

Converts a decorated paper web into single ply bath tissue. The single ply toilet paper has a basis weight of about 18 lbs/3000 square ^feet (30.27 grams per square meter) and contains about 0.3% temporary wet strength resin and about 0.1% debonding agent. The resulting single ply tissue paper is bulky, soft, absorbent, and aesthetically pleasing, and can be used as a bath towel.

Example 6

First, a 3% by weight aqueous suspension of northern softwood kraft (NSK) fibers was prepared using a conventional pulper. A 2% solution of a temporary wet strength resin (ie, PAREZ ⁽ R) 750 sold by American Cyanamid Company, Stanford, CT) at a rate of 0.2% by dry fiber weight was added to the NSK stock tube. The NSK slurry was diluted to a concentration of about 0.2% at the mixing pump. Next, a 3% by weight aqueous suspension of eucalyptus fibers was prepared using a conventional pulper. A 2% solution of debonding agent (ie, Adogen ⁽ R) SDMC sold by Witco Corporation, Dublin, OH) was added to a tube of eucalyptus pulp at a rate of 0.1% by weight of the fiber. The eucalyptus slurry was diluted to a consistency of about 0.2% at the mix pump.

Separately processed furnish streams (stream 1 = 100% eucalyptus pulp / stream 2 = 100% NSK / stream 3 = 100% eucalyptus pulp) were separated in the headbox and deposited into the On forming element 1600, a 3-ply web is formed. The forming element 1600 comprises a forming wire. Dewatering takes place through the forming wire with the help of water baffles and suction boxes. The forming wire, manufactured by Appleton Wire (Appleton, Wisconsin), was a three-layer square weave configuration with 90 longitudinal filaments per inch and 72 transverse filaments per inch. The diameter of the monofilament is about 0.15-0.20mm. The air permeability of the forming fabric was about 1050 scfm (29.4 cubic meters). Flow through the forming screen is prevented by flower-shaped photopolymer flow restriction members 1650 as shown in FIG. 6 . The composite flow restricting member 1650 has a projected area equal to approximately 10% of the projected area of the shaped element. The height difference D (FIG. 7) is approximately 0.003 inches (0.076 mm).

The wet web is transferred from the forming element 1600 to a web support device 2200 comprising a layer of photopolymer cast onto a textile reinforcement according to US 4,528,239 (issued to Trokhan on July 9, 1985), cited in The fiber consistency of the paper position is about 10%. The textile reinforcement has about 59 filaments extending in the longitudinal direction and about 44 filaments extending in the transverse direction and may be prepared according to US 4,191,609 (issued to Trokhan on March 4, 1980).

The height difference between 2261 and 1231 (Figure 15) is approximately 0.03 inches (0.076 mm). Further dewatering was accomplished by vacuum assisted dewatering until the web had a fiber consistency of about 28%. The patterned paper web was then predried to a fiber consistency of about 65% by weight by air drying. The web was then bonded to the surface of the Yankee dryer with a spray creping adhesive comprising 0.25% polyvinyl alcohol (PVA) in water.

The consistency of the fibers is increased to at least about 90% prior to dry creping the web with a doctor blade. The scraper has a bevel angle of about 20 degrees and is positioned relative to the Yankee dryer to provide an impingement angle of about 76 degrees; the Yankee dryer operates at about 800 fpm (feet per minute) (about 244 meters per minute) . The dry web was formed into a web at a speed of 650 fpm (200 meters per minute).

Converts a decorated paper web into single ply bath tissue. The single ply toilet paper has a basis weight of about 18 lbs/3000 square ^feet (30.27 grams per square meter) and contains about 0.3% temporary wet strength resin and about 0.1% debonding agent. The resulting single ply tissue paper is bulky, soft, absorbent, and aesthetically pleasing, and can be used as a bath towel.

Test Methods:

Surface smoothness

The surface smoothness of the sides of the paper web is measured based on the Physiological Surface Smoothness (PSS) measurement method listed in the 1991 International Symposium on Paper Physics, TAPPI Book 1, page 19, entitled "Tissue Machinery Methods for Measuring Performance" by Ampulski et al., which is hereby incorporated by reference. The PSS measurement method used here is the point-by-point sum of the amplitude values as described in the above article. The measurement procedures outlined in this article are also generally described in US 4,959,125 (to Spendel) and US 5,059,282 (to Ampulski et al), which are hereby incorporated by reference.

In order to test the paper sample of the present invention, the PSS measurement method in the above-mentioned article is used to measure the surface smoothness, wherein the following improved steps are arranged:

Instead of entering the digitized data pairs (amplitude and time) into SAS software for 10 samples as described in the above article, using LABVIEW software from National Instruments (Austin, Texas), Sample collection, digitization, and static processing of data for surface smoothness measurements. Use the "Amplitude and PhaseSpectrum.vi" module in the LABVIEW software package to generate each amplitude spectrum, where "Amp Spectrum Mag Vrms" is selected as the output spectrum. The resulting output spectra were used for each of the 10 samples.

Each output spectrum was smoothed using the following weighting factors in LABVIEW: 0.000246, 0.000485, 0.00756, 0.062997. These weighting factors were chosen to mimic the smoothing provided by the factors 0.0039, 0.0077, 0.120, 1.0 indicated in the above article for the SAS program.

After smoothing, each spectrum was filtered using the frequency filter indicated in the above article. PSS values (microns) were then calculated for each individual filter spectrum as described in the above article. The surface smoothness of the web side is the average of 10 PSS values measured on 10 samples of the same web side. Likewise, the surface smoothness of the reverse side of the web can also be measured. The smoothness ratio is obtained by dividing the higher surface smoothness value (corresponding to the more organized side of the web) by the lower surface smoothness value (corresponding to the smoother side of the web).

Quantitative:

The basis weight (macro basis weight) of the paper web is measured using the following procedure.

The paper to be measured was conditioned for a minimum of 2 hours at 71-75°F and 48-52% relative humidity. The conditioned paper was cut to provide twelve 3.5 x 3.5 inch (8.89 cm x 8.89 cm) test pieces. Using a suitable platen cutter, such as a Thwing-Albert Alfa Hydraulic Pressure Sample Cutter, Model 240-10, cut these samples six at a time. Two stacks of six samples each were then combined into a 12-ply stack and conditioned for a minimum of 15 minutes at 71-75°F and 48-52% relative humidity.

The stack of 12 layers was then weighed on a calibrated analytical balance. The balance is kept in the same room where the samples are conditioned. A suitable balance is manufactured by the company Sartorius Instrument, model A200S. The weighed weight is the weight (in grams) of a stack of 12 layers, each layer having an area of 12.25 square inches (79.01 square meters).

Calculate the basis weight (weight of a single layer per unit area) of the web in pounds per 3000 square feet using the following formula:

Or simply: Quantitative (lbs/3000 ^ft2 ) = weight of 12-layer stack (grams) x 6.48

Quantification of the basic part:

The basis weight of the web was measured using the following procedure. Using the paper web, a sample of the base portion (the sample does not include the decorative indicia or a portion of the decorative indicia) is cut. Cut the specimen as large as possible without including decorative markings. Measure the area of each sample and weigh the sample. The basis weight was calculated by dividing the weight of the sample by the area of the sample. At least three samples were measured and the data averaged in order to obtain a quantification of the basis.

Quantification of relatively low quantitation regions:

Quantitation in relatively low quantitation regions was measured using the following procedure.

A computer, scanner, and an image analysis software program are used to determine the surface area of relatively low quantitation regions. A suitable computer is an Apple Macintosh Model 7200/90. A suitable scanner is: AGFA ArcusII scanner from AGFA-Gevaert N.V. (Belgium) with a resolution of 600 dpi. A suitable image analysis software is: NIH IMAGE, version 1.59, available from the National Institute (Health).

Use the following procedure to scan the sample and measure the surface area of relatively low quantitative regions in the sample. Samples were cut from the paper web, each sample including a decorative indicia surrounded by a base portion. Each sample is weighed to obtain the total weight of the sample, TW.

Each sample was mounted on a piece of black paper to provide a black background when scanned. Scan the mounted sample with the AGFAArcus II scanner. Images were scanned into a computer using Adobe Photoshop version 3.0.5 software. The Adobe software was incrementally utilized with the FotoLook P.S. 2.07.2 plug-in module from AGFA-Gevaert. Set the scan settings to: automatic, 600dpi resolution, grayscale (no color). The mounted specimen is scanned along the scale to provide geometric calibration.

Then open the scanned image of each sample with NIH IMAGE software, and use the ruler image for calibration. The calibration factor is approximately 235.2 pixels/mm. Use the image analysis software to measure the total area of the specimen based on the specimen perimeter.

Then, the image is smoothed twice with a 3×3 kernel before determining the trim mark outline. The image is then densified into highlighted pixels with grayscale values between 64 and 254. The "magic wand tool" was then used to define the outline of the decorative mark, including all relatively low quantitation areas within the mark. The part of the image other than the decorative mark is discarded, and the image of the decorative mark is pasted on the new document. The magic wand is then used to inscribe the relatively high-quantity areas (intervals) with the decorative indicia, leaving only the portion of the image corresponding to the relatively low-quantity areas. The image of relatively low quantitation regions is then sliced for density to select those pixels with grayscale values 64-254. The software then calculates the area of the selected pixels to provide the surface area of relatively low-quantity areas within the decorative indicia.

After using the image analysis software to measure the surface area of the relatively low quantification area, the quantification of the relatively low quantification area is determined by calculating BW1 in the following formula:

TW＝(BW1)×(AREA1)+(BW2)×(AREA2)

In the formula, TW is the total weight of the sample with decorative marks, BW1 is the quantification of the relatively low quantitative area, AREA1 is the area of the relatively low quantitative area measured by the image analysis software, and BW2 is the quantitative of the basic part, which can be calculated according to The sample is cut from the base part as mentioned above to measure, and AREA2 is equal to the area obtained by subtracting the area of AREA1 from the total area of the sample (calculated based on the circumference of the sample). Therefore, the above formula can be used to find the value of BW1. At least three samples were measured and the results averaged to determine the quantitation of areas of relatively low quantitation.

Macro Thickness or Dry Thickness:

Macroscopic or dry caliper was measured using the dry caliper measurement procedure disclosed in US 4,469,735, issued September 4, 1984 to Trokhan, which is incorporated herein by reference.

Bulk density:

Bulk density is equal to the basis weight of the web divided by the macroscopic thickness of the web and is expressed in units of weight per unit volume. If basis weight and thickness are measured in different units, appropriate conversion factors may be used.

Absorbency:

The absorbency of the paper web was measured using the Absorbency Test Method in the Cross Direction as disclosed in the aforementioned reference US 4,469,735.

Measurement of the height of the web support device:

The following steps are used to measure the height difference between the height 231 of the first felt surface and the height 261 of the web contacting surface 260 . Support the web support unit on a flat horizontal surface with the patterned side of the web facing up. A needle with a circular contact surface was mounted on a Federal Products two-dimensional gauge (model 432B-81 amplifier modified with an EMD-4320 W1 breakaway probe), manufactured by Federal Products (Providence, Rhode Island) . The instrument is calibrated by measuring: the differential pressure between two precision shims of known thickness providing a known height difference. The instrument is zeroed slightly below the first felt surface 230 to ensure free running of the probe. At the measurement position, the probe exerts a pressure of about 0.24 g/ ^mm2 . Take at least three measurements at each height. The measurements at each height are averaged. Calculates the difference between the altitude means to provide the altitude difference. Use the same procedure to measure the height difference between heights 1231 and 2261.

Claims (43)

1. paper web that back-to-back two surfaces and at least three districts are arranged, described three districts are with arranged in patterns nonrandom, that repeat, and distinguish each other by being selected from least one performance in the following performance, that is: quantitatively, density and fibre fractionation, it is characterized in that, this paper web comprises and has first quantitative high quantitatively base area and the decorative indicia, and this decorative indicia comprises one or more low quantitatively zones, and it quantitatively is lower than base area first quantitative around the small part of paper web.

2. paper web as claimed in claim 1 is characterized in that, described decorative indicia drains moisture by selectivity from paper web and gives paper web.

3. paper web as claimed in claim 1 is characterized in that, described decorative indicia comprise quantitatively be lower than 15 the gram/square metre low quantification area.

4. paper web as claimed in claim 3 is characterized in that, comprises a plurality of discontinuous, decorative indicias of being separated from each other, and described base area with discontinuous decorative indicia separately.

5. paper web as claimed in claim 4 is characterized in that, every square metre of paper surface has 5 to 5000 discontinuous decorative indicias.

6. paper web as claimed in claim 5, it is characterized in that, described base area comprises that at least one high-density region and at least one density are lower than the density regions of described high-density region, the low quantitatively zone that quantitatively is higher than described decorative indicia of high-density region and density regions quantitatively.

7. paper web as claimed in claim 6 is characterized in that, base area comprises that highdensity continuous net-shaped zone and a plurality of discontinuous density are lower than the density regions of described high-density region, and density regions is dispersed in the highdensity continuous net-shaped zone.

8. paper web as claimed in claim 7 is characterized in that, highdensity continuous net-shaped zone has different wrinkling frequencies with discontinuous density regions.

9. paper web as claimed in claim 8 is characterized in that, every square metre of paper surface, base area comprises at least 10,000 discontinuous density regions.

10. paper web as claimed in claim 4, it is characterized in that, each decorative indicia comprises the low quantitatively zone with the closed-loop path shape of surrounding at least one high quantitatively zone fully, and the low quantitatively width of measuring at any point along the closed-loop path in zone is that 0.2mm is to 2mm.

11. paper web as claimed in claim 10, it is characterized in that, described low quantitative zone has the closed-loop path shape that forms between a plurality of adjacent high density areas, in each interval arbitrary place quantitatively be higher than described low quantitatively zone quantitatively, each interval girth is formed by the low quantitatively part closed-loop path in zone.

12. paper web as claimed in claim 11 is characterized in that, the total girth in each interval and adjacent arbitrary interval does not pass half of self full girth.

13. paper web as claimed in claim 1 is characterized in that, the bulk density of described paper web is less than 0.12 gram/cubic centimetre.

14. paper web as claimed in claim 1 is characterized in that, the base area surface flatness of at least one is less than 900 in the back-to-back surface of paper web.

15. paper structure that comprises the paper web of multilayer claim 1.

16. paper web as claimed in claim 1 is characterized in that, comprises long paper fibre and the short paper fibre shorter than long paper fibre,, in the average fiber length in the low quantitatively zone of described decorative indicia greater than the average length of paper web paper fibre partly on every side.

17. the wet lapped paper web with back-to-back two surfaces, this paper web is characterised in that:

Every square metre of paper surface has 5 to 5000 discontinuous decorative indicias, and each decorative indicia comprises one or more low quantitatively zones; With

High quantitatively base area, it separates decorative indicia, quantitatively is higher than low quantitatively zone, and base area comprises the zone with the different densities of the arranged in patterns of nonrandom, repetition.

18. paper web as claimed in claim 17, it is characterized in that, high quantitatively base area comprises that highdensity continuous net-shaped zone and a plurality of discontinuous density are lower than the density regions of described high-density region, and density regions is dispersed in the highdensity continuous net-shaped zone.

19. paper web as claimed in claim 17 is characterized in that, the quantitative base area of described height comprises discontinuous high-density region.

20. paper web as claimed in claim 17 is characterized in that, the low quantification area of described decorative indicia quantitatively be lower than 15 the gram/square metre.

21. paper web as claimed in claim 20 is characterized in that, the base area surface flatness of at least one is less than 900 in the back-to-back surface of paper web.

22. paper web as claimed in claim 20 is characterized in that, bulk density is less than at least 0.12 gram/cubic centimetre.

23. paper web as claimed in claim 20 is characterized in that, described decorative indicia drains moisture by selectivity from paper web and gives paper web.

24. paper web as claimed in claim 23 is characterized in that, described base area comprises the zone of different densities, and paper web is given in these zones after giving paper web with decorative indicia.

25. paper structure that comprises the paper web of multilayer claim 17.

26. the wet lapped paper web with back-to-back two surfaces, this paper web is characterised in that:

Every square metre of paper surface has 5 to 5000 discontinuous decorative indicias, and each decorative indicia comprises one or more 15 gram/rice that quantitatively are lower than ²Low quantitatively zone; With

High quantitatively base area, it separates decorative indicia, quantitatively be higher than low quantitatively zone, base area comprises highdensity continuous net-shaped zone and at least 10000 discontinuous density regions of every square metre of paper web, the density of density regions is lower than high-density region, and is dispersed in the whole continuous mesh-like area, wherein, on at least one face on back-to-back two surfaces of paper web, the surface smoothness value of base area is lower than 900.

27. the wet lapped paper web with back-to-back two surfaces, this paper web is characterised in that:

Every square metre of paper surface has 5 to 5000 discontinuous decorative indicias, and each decorative indicia comprises one or more quantitative 15 gram/rice ²Low quantitatively zone; With

The high quantitatively base area of separating decorative indicia, the different densities district that base area is provided with nonrandom repeat patterns, every square metre of paper web of base area comprises at least 50000 discontinuous density regions, wherein, on at least one face on back-to-back two surfaces of paper web, the surface smoothness value of base area is lower than 900.

28. the wet lapped paper web with back-to-back two surfaces, this paper web is characterised in that:

Every square metre of paper surface has 5 to 5000 discontinuous decorative indicias, and each decorative indicia comprises one or more quantitative 15 gram/rice ²Low quantitatively zone; With

The high quantitatively base area of separating decorative indicia, base area comprises highdensity continuous net-shaped zone, many density that are dispersed in the whole continuous net-shaped zone are lower than density regions and many discontinuous high-density regions that is dispersed in each density regions of continuous netted high-density region.

29. the production method of a paper web, described paper web have three zones of arranging with nonrandom, repeat patterns and described zone at least by being selected from by quantitatively, at least one performance in the group that density and fibre fractionation are formed and difference to some extent each other; The method is characterized in that and comprise the steps:

The many fibers that are suspended in the liquid-carrier are provided;

Provide and have the fiber retention forming element that liquid can see through the district;

Fiber and liquid-carrier are deposited on the forming element;

In two synchronous steps, liquid-carrier is got rid of by forming element, so that form a paper web, described paper web has a high relatively quantitative zone at least and comprises one or more relative low quantitatively decorative indicias in zone;

The paper web bracing or strutting arrangement on band Web patterning surface is provided;

Be passed to paper web on the Web patterning surface of paper web bracing or strutting arrangement from forming element;

Optionally make to the high relatively quantitative zone of small part and carry out densification, so that nonrandom, the repeat patterns of first densified area and second densified area to be provided, in high relatively quantitative zone, the density of second densified area is higher than first densified area.

30. method as claimed in claim 29, it is characterized in that, provide the step of many fibers to comprise the fiber that many different lengths are provided, comprise many fiber and many fibers with second fibre length with first fibre length, the fiber with second fibre length is shorter than the fiber with first fibre length.

31. method as claimed in claim 30 is characterized in that, fiber laydown is included in deposition leaf wood and needle-leaved wood fibre on the forming element in the step on the forming element.

32. method as claimed in claim 30 is characterized in that, fiber laydown is included in stacked leaf wood and needle-leaved wood fibre on the forming element in the step on the forming element.

33. method as claimed in claim 32 is characterized in that, the step of fiber laydown on forming element comprised deposition needle-leaved wood fibre layer and directly contacting with forming element.

34. method as claimed in claim 29 is characterized in that, the step that removes liquid-carrier by forming element comprises that every square metre of paper surface of formation has the paper embryo of 5 to 5000 discontinuous decorative indicias.

35. method as claimed in claim 29, it is characterized in that, described paper web bracing or strutting arrangement comprises continuous net-shaped Web patterning layer, described patterned layer limits many second continuous paper web contact surfaces with the first discontinuous first paper web contact surface of highly arranging and second height, wherein optionally make to the step of the high quantitative regional densification of small part and comprise: paper web is attached on the paper web bracing or strutting arrangement, form many discontinuous first densified area to cause, the corresponding many discontinuous first paper web contact surfaces of discontinuous first densified area.

36. method as claimed in claim 35 is characterized in that, the surface that optionally makes the step of carrying out densification to the high relatively quantitative zone of small part be included in every square metre of paper web provides at least 10000 discontinuous first densified area.

37. method as claimed in claim 36 is characterized in that, the step that removes liquid-carrier by forming element comprises that every square metre of paper surface of formation has the paper embryo of 5 to 5000 discontinuous decorative indicias.

38. method as claimed in claim 29 is characterized in that, the step of carrying out densification to the high relatively quantitative zone of small part is comprised form discontinuous second densified area that is dispersed in the whole high relatively quantitative zone.

39. method as claimed in claim 29 is characterized in that, web transfers also is being included in the step of squeezing paper web between woollen blanket layer and the paper web bracing or strutting arrangement to the paper web bracing or strutting arrangement.

40. method as claimed in claim 29 is characterized in that, also comprises introducing when paper web is supported on the paper web bracing or strutting arrangement adding the step of hot-air by paper web.

41. the production method of a paper web, described paper web have three zones of arranging with nonrandom, repeat patterns and described zone at least by being selected from by quantitatively, at least one performance in the group that density and fibre fractionation are formed and difference to some extent each other; The method is characterized in that and comprise the steps:

Many cellulose fibres that are suspended in the liquid-carrier are provided;

Provide carrying liqs can see through the fiber retention forming element in district;

Cellulose fiber peacekeeping liquid-carrier is deposited on the forming element;

In two synchronous steps, liquid-carrier is got rid of by forming element, so that form a paper web, described paper web has a high relatively quantitative zone at least and comprises one or more relative low quantitatively decorative indicias in zone, wherein said paper web has first surface, second surface, and a thickness;

The paper web bracing or strutting arrangement that has in the face of the side of paper web is provided, comprises the first paper web contact surface and the second paper web contact surface, wherein, the difference in height between the first paper web contact surface and the second paper web contact surface is less than the thickness of paper web;

Paper web is passed on the paper web bracing or strutting arrangement from forming element, and wherein, the first surface of paper web is supported on the first and second paper web contact surfaces of paper web bracing or strutting arrangement;

After the transfer step, optionally make to the high relatively quantitative zone of small part and carry out densification, so that nonrandom, the repeat patterns of first densified area and second densified area to be provided, in high relatively quantitative zone, the density of second densified area is higher than first densified area.

42. method as claimed in claim 41, it is characterized in that, optionally make the step of carrying out densification to the high relatively quantitative zone of small part be included in the first surface pattern of giving paper web under the situation of smooth basically, the macroscopical monoplane of the second surface configuration that keeps paper web.

43. method as claimed in claim 42 is characterized in that, may further comprise the steps:

The heat drying surface is provided;

The second surface of smooth basically, the macroscopical monoplane of paper web configuration is pressed close to the heat drying surface;

At heat drying dry tack free paper web;

Make paper web wrinkling on the heat drying surface.

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