James River Corporation

James River-Norwalk, Inc.

American Can Company

James River-dixie/northern, Inc.

Bernard G Klowak

Michael P Bouchette

Gary C Grinnell

Nilo I Salmeen, Jr, Deceased

Walter L Pauls

Frederick J Vermillon, Jr

A sheet of fibrous web material having one textile-like surface and an opposite substantially smooth surface, a grain depth memory factor greater than 80, an apparent density in the range of about 4 to about 7 pound ream/caliper point in mils, a caliper (at a basis weight between about 50 and about 75 pounds/3000 square feet) greater than 0.008 inch, and a machine-direction sheet stretch of at least 5%. The invention includes a method of manufacturing the sheet comprising partially dewatering a wet fibrous web to about 30% to about 60% solids, conveying the web to a compression nip defined by a smooth-surfaced roll and a textured-surfaced fabric material, moving the fabric material at a speed of about 15% to about 35% less than the surface speed of the smooth-surfaced roll, compressing the web in the nip with a compression force between about 5 pounds/linear inch and about 100 pounds/linear inch, with an average pressure of between about 20 pounds per square inch and about 400 pounds per square inch in the compression nip, subjecting the fabric material to a tension on opposite sides of the compression nip with the tension on the fabric material entering the nip being greater than the tension on the fabric material exiting the nip, and drying the web.

Fibrous paper cover stock with textured surface pattern and method of

A sheet of fibrous web material having opposite smooth surfaces, an apparent bulk in the range of about 0.10 to about 0.20 caliper pts/lb ream and a machine direction stretch of at least 8%, wherein surface undulations on the opposite smooth surfaces of the sheet have an amplitude variance of less than 0.0002 inch. The dried web has an apparent bulk less than 0.20 caliper pts/lb ream.

Fibrous tape base material

A bulky, embossed, fibrous web material having a basis weight in the range of 5 to 50 lbs./ream and geometric means tensile strength (TS) (kg/3' width), apparent bulk (AB) (cal. pts./lb. ream), and oil holding capacity (OH) (ml/gm fiber) substantially satisfying, in absolute values, the relationships (0.27 BW-1) TS&gt;(0.17 BW-1), AB&gt;[0.7-(TS.div.20)], and OH 0.063TS.sup.2 -1.13TS+8.6. The invention includes an apparatus and a method of manufacturing the product comprising wet pressing a fibrous web to about 30% to 50% solids, conveying the web to a transfer position proximate the three-dimensional surface of an embossing fabric moving at a speed less than that of the web at the transfer position, and applying a vacuum to the web through the embossing fabric to transfer and conform the web to the three-dimensional surface of the fabric, the vacuum magnitude being in the range of 1 to 20 inches Hg.

High bulk, embossed fiber sheet material and apparatus and method of

A sheet of fibrous web material having opposite smooth surfaces, an apparent bulk in the range of about 0.10 to about 0.20 caliper pts/lb ream and a machine direction stretch of at least 8%, wherein surface undulations on the opposite smooth surfaces of the sheet have an amplitude variance of less than 0.0002 inch. The invention includes an apparatus and a method of manufacturing the product comprising partially dewatering a wet fibrous web to about 30% to 50% solids, conveying the web to a compression nip defined by a smooth-surfaced roll and a smooth-surfaced fabric material, moving the fabric material at a speed of about 10% to 20% less than the surface speed of the smooth-surfaced roll, compressing the web in the nip with a compression force of less than 15 lbs/linear inch, with an average pressure of less than about 50 psi in the compression nip, and drying the web. The dried web has an apparent bulk less than 0.20 caliper pts/lb ream.

Two or more webs (11 and 12) of highly bulked substrate are passed into a nip formed between a gravure roller (14) and an impression roller (15). The impression roller has raised areas defining an interconnected network of lines such that the webs are compressed only under the raised areas; as a result, the binding liquid applied by the gravure roller (14) to the laminate of the two webs is absorbed substantially through the webs in the compressed areas. The gravure roller (14) may have a uniform surface, such that a light coating of binding liquid is applied to the surface of the uncompressed areas in the laminate, or the gravure roller may have a pattern of etched grooves or cells which matches and registers with the pattern of raised areas on the impression roller. In the latter embodiment, binding liquid will be absorbed into the laminate only in the compressed areas. The coated laminate (21) is applied to the surface (24) of a creping cylinder (25), is dried thereon, and is creped off with a creping blade (27) to form a laminated product bound together by an interconnected network of lines of strength extending through the laminate. The areas between the lines of strength are not compressed and are not substantially coated with binding liquid, and thereby retain high bulk and absorbency. In a modified embodiment of the invention, a single impression/pressure roller and raised areas thereon is used to join and press the webs against a gravure roller and to apply the webs to a creping cylinder; and in a second modified embodiment, the web laminate is pressed and coated on one side, is substantially hot air dried without compression, is coated with binding liquid applied to the outer side, and is then applied to the creped from a creping cylinder.

Pattern bonding and creping of fibrous substrates to form laminated

A web (12) of highly bulked substrate is passed into a nip formed between a gravure roller (14) and an impression roller (15). The impression roller has raised areas defining an interconnected network of lines such that the web is compressed only under the raised areas; as a result, the binding liquid applied by the gravure roller (14) to the web is absorbed substantially through the web in the compressed areas. The gravure roller (14) may have a uniform surface, such that a light coating of binding liquid is applied to the surface of the uncompressed areas in the web, or the gravure roller may have a pattern of etched grooves or cells which matches and registers with the pattern of raised areas on the impression roller. In the latter embodiment, binding liquid will be absorbed into the web only in the compressed areas. The coated web (21) is applied to the surface (24) of a creping cylinder (25), is dried thereon, and is creped off with a creping blade (27) to form a product bound together by an interconnected network of lines of strength extending through the web. The areas between the lines of strength are not compressed and are not substantially coated with binding liquid, and thereby retain high bulk and absorbency. The once creped web may be passed through the identical process a second time such that the other side of the web receives binding liquid. The twice coated product still retains high bulk and absorbency in those areas which have not been compressed, and has lines of strength extending in a network through the product where the binding liquid has been applied. In a modified embodiment of the invention, a single impression/pressure roller with raised areas thereon is presses the web against a gravure roller and applies the web to a creping cylinder; and in a second modified embodiment, the web is pressed and coated on one side, is substantially hot air dried without compression, is coated with binding liquid applied to the other side, and is then applied to and creped from a creping cylinder.

Pattern bonding and creping of fibrous products

Paper webs are produced in a modified conventional felted wet press process in which the fiber furnish has a chemical debonding agent added thereto in high concentrations. The web (17) is formed on a conventional Fourdrinier wire (12), transferred to a moving felt (19) which presses the web against the surface of a drying cylinder (23) to reduce its water content, and is carried by the surface of the drying cylinder (23) to a creping blade (24). Liquid adhesive is applied to the surface of the creping cylinder (23) adhead of the contact with the web to provide substantial adherence of the web to the creping surface at the point of contact with the creping blade. The levels of addition of debonding agent to the pulp furnish and the amount of adhesive applied to the creping surface are selected such that the adhesion of the web to the surface at the creping blade is greater than the internal cohesion of the web. Under these conditions, a highly bulked and internally delaminated web is produced which has bulk and absorbency superior to products ordinarily produced in the conventional wet press process. The bulk and absorbency of the finished web may be further enhanced by utilizing a reverse angle creping blade (24) which meets the surface of the creping cylinder (23) at a cutting angle not more than 70.degree. and preferably between 52.degree. and 64.degree.. The reverse angle blade causes the fibers in the web to reverse direction at the line of contact with the creping blade and therefore enhances the disruption of fiber bonds to increase bulkiness.

Paper webs having high bulk and absorbency and process and apparatus for

Paper webs are produced in a modified conventional felted wet press process in which the fiber furnish has a chemical debonding agent added thereto in high concentrations. The web (17) is formed on a conventional Fourdrinier wire (12), transferred to a moving felt (19) which presses the web against the surface of a drying cylinder (23) to reduce its water content, and is carried by the surface of the drying cylinder (23) to a creping blade (24). Liquid adhesive is applied to the surface of the creping cylinder (23) adhead of the contact with the web to provide substantial adherence of the web to the creping surface at the point of contact with the creping blade. The levels of addition of debonding agent to the pulp furnish and the amount of adhesive applied to the creping surface are selected such that the adhesion of the web to the surface at the creping blade is greater than the internal cohesion of the web. Under these conditions, a highly bulked and internally delaminated web is produced which has bulk and absorbency superior to products ordinarily produced in the conventional wet press process. The bulk and absorbency of the finished web may be further enhanced by utilizing a reverse angle creping blade (24) which meets the surface of the creping cylinder (23) at a cutting angle not more than 72.degree. and preferably between 52.degree. and 64.degree.. The reverse angle blade causes the fibers in the web to reverse direction at the line of contact with the creping blade and therefore enhances the disruption of fiber bonds to increase bulkiness.

A fibrous web is uniformly adhered to the surface of a smooth creping cylinder or other creping surface without causing substantial compression of the web. A raised pattern is pressed into the web toward the creping cylinder to cause the portions of the web that are pressed to adhere more strongly to the creping surface, while the portions of the web that are not pressed remain more lightly adhered to the creping surface. The web is creped from the creping surface with a creping blade, and the resulting product has a pattern creped appearance wherein the portions of the web that are pressed are finely creped while the portions of the web that were not so pressed are coarsely creped.

Growing community of inventors

Neenah, WI, United States of America

Bernard G Klowak