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Clothlike pattern densified web Number:6,991,706 from the United States Patent and Trademark Office (PTO) owispatent

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Title: Clothlike pattern densified web

Abstract: An improved paper and the process of making an improved paper web is disclosed. The improved paper is characterized as having two regions; one is a network (or open grid) region and the other is a plurality of domes. At least a portion of either region of the paper web contains a bonding material that penetrates at least partially through the paper's thickness.

Patent Number: 6,991,706 Issued on 01/31/2006 to Lindsay,   et al.

Inventors: Lindsay; Jeffrey Dean (Appleton, WI); Hermans; Michael Alan (Neenah, WI); Goulet; Mike Thomas (Neenah, WI); Hassman; Mark John (Appleton, WI); Tirimacco; Maurizio (Appleton, WI); Johnson; Jeffrey Janne (Neenah, WI); Mohr; Rebecca Catherine (Appleton, WI)
Assignee: Kimberly-Clark Worldwide, Inc. (Neenah, WI)
Appl. No.: 654219
Filed: September 2, 2003

Current U.S. Class: 162/109; 162/112; 162/113; 162/135; 162/134; 162/169; 162/123; 162/158; 162/164.1; 162/162; 156/277; 156/183; 427/391
Current Intern'l Class: D21H 21/18    (20060101); D21H 27/02    (20060101); D21H 27/30    (20060101); D21H 19/74    (20060101); B32B 29/00    (20060101)
Field of Search: 162/109,111-113,117,134-135,158,169,164.1,168.1,161,162,123,125,129 156/277,290,183,324 427/361,391 264/282,283

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Primary Examiner: Fortuna; José A.
Assistant Examiner: Murphy; B
Attorney, Agent or Firm: Baum; Scott A.
Claims


What is claimed:

1. A paper web comprising:

a macroscopically monoplanar cellulosic substrate having two elevations, a first elevation defining a first pattern comprising an essentially continuous network and a second elevation defining a second pattern comprising a plurality of discrete domes extending outward from the first elevation; the domes having a protuberance on one side and a depression on an opposing side;

a bonding material disposed on at least a portion of either elevation of the cellulosic substrate; and

wherein a majority of the bonding material is disposed on the continuous network and the bonding material penetrates at least partially through a thickness of the cellulosic substrate.

2. The paper web of claim 1 wherein the majority of the bonding material is disposed on the continuous network on a surface of the paper web opposite the protuberances.

3. The paper web of claim 1 wherein the bonding material penetrates about 60% or less through the thickness of the cellulosic substrate.

4. The paper web of claim 1 wherein the bonding material penetrates about 5% or more through the thickness of the cellulosic substrate.

5. The paper web of claim 1 wherein the bonding material penetrates about 10% to about 90% through the thickness of the cellulosic substrate.

6. The paper web of claim 1 comprising a surface area of one side of the paper web and wherein the bonding material occupies about 5% or greater of the surface area of one side of the paper web.

7. The paper web of claim 1 comprising a surface area of one side of the paper web and wherein the bonding material occupies about 60% or less of the surface area of one side of the paper web.

8. The paper web of claim 1 comprising a surface area of one side of the paper web and wherein the bonding material occupies from about 20% to about 80% of the surface area of one side of the paper web.

9. The paper web of claim 1 comprising a ratio of the bonding material mass to the fiber mass in the paper web of about 3% or greater.

10. The paper web of claim 1 comprising a ratio of the bonding material mass to the fiber mass in tile paper web of about 3% to about 60%.

11. The paper web of claim 1 comprising a melting temperature of the bonding material of about 40° C. to about 200° C.

12. The paper web of claim 1 comprising a glass transition temperature, Tg, of the bonding material from about -100° C. to about 150° C.

13. The paper web of claim 1 comprising a glass transition temperature, Tg, of the bonding material from about -40° C. to about 30° C.

14. The paper web of claim 1 comprising a glass transition temperature, Tg, of the bonding material from about -10° C. to about 10° C.

15. The paper web of claim 1 comprising a viscosity of the bonding material of about 10 poise or less.

16. The paper web of claim 1 comprising a viscosity of the bonding material of about 0.5 poise to about 5 poise.

17. The paper web of claim 1 comprising a viscosity of the bonding material of about 0.5 poise to about 50 poise.

18. The paper web of claim 1 comprising a viscosity of the bonding material of about 20 poise to about 2,000 poise.

19. The paper web of claim 1 comprising a Wet Out Time of about 3.5 seconds or greater.

20. The paper web of claim 1 comprising a CD Wet/Dry Tensile Ratio of about 45% or greater.

21. The paper web of claim 1 wherein the bonding material comprises an emulsified polymer.

22. The paper web of claim 21 wherein the emulsified polymer comprises latex.

23. The paper web of claim 21 wherein the emulsified polymer is latex free.

24. The paper web of claim 1 wherein the bonding material is cationic.

25. The paper web of claim 1 wherein the bonding material is anionic.

26. The paper web of claim 1 wherein the bonding material is nonionic.

27. The paper web of claim 1 wherein the bonding material is amphoteric.

28. The paper web of claim 1 wherein the bonding material comprises a photocured polymer.

29. The paper web of claim 1 wherein the bonding material is hydrophilic.

30. The paper web of claim 1 wherein the bonding material is hydrophobic.

31. The paper web of claim 1 wherein the cellulosic substrate is creped.

32. The paper web of claim 1 comprising a colored bonding material wherein a HunterLab Color Scale measurement of a 50 micron film of the bonding material on a white substrate yields a sum of about 10 or greater for the absolute value of the "a" value plus the absolute value of the "b" value.

33. The paper web of claim 32 wherein the sum of the absolute value of "a" plus the absolute value of "b" is about 15 or greater.

34. The paper web of claim 32 wherein the sum of the absolute value of "a" plus the absolute value of "b" is about 25 or greater.

35. The paper web of claim 1 comprising a colored bonding material wherein a HunterLab Color Scale measurement of a 50 micron film of the bonding material on a white substrate yields an "L" value of less than about 90.

36. The paper web of claim 35 wherein the "L" value is less than about 85.

37. The paper web of claim 35 wherein the "L" value is less than 80.

38. The paper web of claim 1 wherein the bonding material comprises a Gardner Color of about 4 or less.

39. A multi-ply paper web comprising:

a first ply comprising

a macroscopically monoplanar cellulosic substrate having two elevations, a first elevation defining a first pattern and a second elevation defining a second pattern; the first pattern comprising an essentially continuous network and the second pattern comprising a plurality of discrete domes extending outwardly from the first elevation; the domes having a protuberance on one side and a depression on an opposing side;

a bonding material disposed on the essentially continuous network of the first ply, and wherein the bonding material penetrates at least partially through a thickness of the cellulosic structure; and

a second ply comprising

a macroscopically monoplanar cellulosic substrate having two elevations, a first elevation defining a first pattern and a second elevation defining a second pattern; the first pattern comprising an essentially continuous network and the second pattern comprising a plurality of discrete domes extending outwardly from the first elevation; the domes having a protuberance on one side and a depression on an opposing side;

a bonding material disposed on the essentially continuous network of the second ply, and wherein the bonding material penetrates at least partially through a thickness of the cellulosic substrate web.

40. The multi-ply paper web of claim 39 wherein the domes of the first ply are orientated towards the domes of the second ply.

41. The multi-ply paper web of claim 39 wherein the network region of the first ply is orientated towards the network region of the second ply.

42. The multi-ply paper web of claim 39 wherein the domes of the first ply are orientated towards the network region of the second ply.

43. The multi-ply paper web of claim 40 wherein a majority of the bonding material on both plies is disposed on the continuous network.

44. The multi-ply paper web of claim 43 wherein the majority of the bonding material on both plies forms at least a portion of both exterior surfaces of the multi-ply paper web.

45. The multi-ply paper web of claim 44 wherein the bonding material penetrates at least about 10% or greater through the thickness of the network regions.

46. The multi-ply paper web of claim 39 wherein the first and second plies are crimped together.

47. The multi-ply paper web of claim 39 wherein the first and second plies are adhesively bonded together.

48. The paper web of claim 1 wherein the bonding material comprises a composition containing nitrogen.

49. The paper web of claim 1 wherein the bonding material comprises a thermoplastic.

50. A paper web comprising:

a macroscopically monoplanar, patterned continuous network region having a basis weight and a density;

a plurality of discrete domes having either a higher basis weight or a lower density than the network region, essentially all of the domes being dispersed throughout and encompassed by, and isolated one from another by the network region; the domes having a protuberance on one side and a depression on an opposing side;

a bonding material disposed on at least a portion of either the network region or the domes; and

wherein a majority of the bonding material is disposed on the continuous network and the bonding material penetrates at least partially through a thickness of the paper web.

51. The paper web of claim 50 wherein the domes have both a higher basis weight and a lower density than the network region.

52. The paper web of claim 50 wherein the majority of the bonding material is disposed on the continuous network on a surface of the paper web opposite the protuberances.

53. The paper web of claim 52 wherein the bonding material penetrates about 60% or less through the thickness of the cellulosic substrate.

54. The paper web of claim 52 wherein the bonding material penetrates about 5% or more through the thickness of the cellulosic substrate.

55. The paper web of claim 52 wherein the bonding material penetrates about 10% to about 90% through the thickness of the cellulosic substrate.

56. The paper web of claim 52 comprising a surface area of one side of the paper web and wherein the bonding material occupies about 5% or greater of the surface area of one side of the paper web.

57. The paper web of claim 52 comprising a surface area of one side of the paper web and wherein the bonding material occupies about 60% or less of the surface area of one side of the paper web.

58. The paper web of claim 52 comprising a surface area of one side of the paper web and wherein the bonding material occupies from about 20% to about 80% of the surface area of one side of the paper web.

59. The paper web of claim 52 comprising a ratio of the bonding material mass to the fiber mass in the paper web of about 3% or greater.

60. The paper web of claim 52 comprising a ratio of the bonding material mass to the fiber mass in the paper web of about 3% to about 60%.

61. The paper web of claim 52 comprising a melting temperature of the bonding material of about 40° C. to about 200° C.

62. The paper web of claim 52 comprising a grass transition temperature, Tg, of the bonding material from about -100° C. to about 150° C.

63. The paper web of claim 52 comprising a glass transition temperature, Tg, of the bonding material from about -40° C. to about 30° C.

64. The paper web of claim 52 comprising a glass transition temperature, Tg, of the bonding material from about -10° C. to about 10° C.

65. The paper web of claim 52 comprising a viscosity of the bonding material of about 10 poise or less.

66. The paper web of claim 52 comprising a viscosity of the bonding material of about 0.5 poise to about 5 poise.

67. The paper web of claim 52 comprising a viscosity of the bonding material of about 0.5 poise to about 50 poise.

68. The paper web of claim 52 comprising a viscosity of the bonding material of about 20 poise to about 2,000 poise.

69. The paper web of claim 52 comprising a Wet Out Time of about 3.5 seconds or greater.

70. The paper web of claim 52 comprising a CD Wet/Dry Tensile Ratio of about 45% or greater.

71. The paper web of claim 52 wherein the bonding material comprises an emulsified polymer.

72. The paper web of claim 71 wherein the emulsified polymer comprises latex.

73. The paper web of claim 71 wherein the emulsified polymer is latex free.

74. The paper web of claim 52 wherein the bonding material is cationic.

75. The paper web of claim 52 wherein the bonding material is anionic.

76. The paper web of claim 52 wherein the bonding material is nonionic.

77. The paper web of claim 52 wherein the bonding material is amphetoric.

78. The paper web of claim 52 wherein the bonding material comprises a composition containing nitrogen.

79. The paper web of claim 52 wherein the bonding material comprises a thermoplastic.

80. The paper web of claim 52 wherein the bonding material comprises a photocured polymer.

81. The paper web of claim 52 wherein the bonding material is hydrophilic.

82. The paper web of claim 52 wherein the bonding material is hydrophobic.

83. The paper web of claim 52 wherein the cellulosic substrate is creped.

84. The paper web of claim 52 comprising a colored bonding material wherein a HunterLab Color Scale measurement of a 50 micron film of the bonding material on a white substrate yields a sum of about 10 or greater for the absolute value of the "a" value plus the absolute value of the "b" value.

85. The paper web of claim 52 comprising a colored bonding material wherein a HunterLab Color Scale measurement of a 50 micron film of the bonding material on a white substrate yields an "L" value of less than about 90.

86. The paper web of claim 52 wherein the bonding material comprises a Gardner Color of about 4 or less.
Description


BACKGROUND OF THE INVENTION

The general demand for disposable paper products has created a demand for improved versions of the products and of the methods of their manufacture. Despite great strides in paper making, research and development efforts continue to be aimed at improving both the products and their processes of manufacture. Disposable products such as paper towels, facial tissues, sanitary tissues, and the like are made from one or more webs of tissue paper. If the products are to perform their intended tasks a


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