Note: Descriptions are shown in the official language in which they were submitted.
CA 02463892 2004-04-16
WO 03/040470 PCT/US02/33074
FABRIC COMPRISING NONWOVEN ELEMENTS FOR USE IN THE MANUFACTURE OF TISSUE
PRODUCTS HAVING VISUALLY DISCERNABLE BACKGROUND TEXTURE REGIONS BORDERED
CURVILINEAR DECORATIVE ELEMENTS AND METHOD OF MANUFACTURE OF TISSUE PRODUCTS
BACKGROUND
The present invention relates to the field of paper manufacturing. More
particularly, the present invention relates to the manufacture of absorbent
tissue
products such as bath tissue, facial tissue, napkins, towels, wipers, and the
like.
Specifically, the present invention relates to improved fabrics used to
manufacture
absorbent tissue products having visually discernible background texture
regions
bordered by curvilinear decorative elements, methods of tissue manufacture,
methods of fabric manufacture, and the actual tissue products produced.
In the manufacture of tissue products, particularly absorbent tissue
products, there is a continuing need to improve the physical properties and
final
product appearance. It is generally known in the manufacture of tissue
products
that there is an opportunity to mold a partially dewatered cellulosic web on a
papermaking fabric specifically designed to enhance the finished paper
product's
physical properties. Such molding can be applied by fabrics in an uncreped
through air dried process as disclosed in U.S. Patent No. 5,672,248 issued on
September 30, 1997 to Wendt et al., or in a wet pressed tissue manufacturing
process as disclosed U.S. Patent No. 4,637,859 issued on January 20, 1987 to
Trokhan. Wet molding typically imparts desirable physical properties
independent
of whether the tissue web is subsequently creped, or an uncreped tissue
product is
produced.
However, absorbent tissue products are frequently embossed in a
subsequent operation after their manufacture on the paper machine, while the
dried tissue web has a low moisture content, to impart consumer preferred
visually
1
CA 02463892 2004-04-16
WO 03/040470 PCT/US02/33074
appealing textures or decorative lines. Thus, absorbent tissue products having
both desirable physical properties and pleasing visual appearances often
require
two manufacturing steps on two separate machines. Hence, there is a need to
combine the generation of visually discernable background texture regions
bordered by curvilinear decorative elements with the paper manufacturing
process
to reduce manufacturing costs. There is also a need to develop a paper
manufacturing process that not only imparts visually discernable background
texture regions bordered by curvilinear decorative elements to the sheet, but
also
maximizes desirable physical properties of the absorbent tissue products
without
deleteriously affecting other desirable physical properties.
Previous attempts to combine the above needs, such as those disclosed in
U.S. Patent No. 4,967,805 issued on November 6, 1990 to Chiu, U.S. Patent No.
5,328,565 issued on July 12, 1994 to Rasch et al., and in U.S. Patent No.
5,820,730 issued on October 13, 1998 to Phan et al., have manipulated the
papermaking fabric's drainage in different localized regions to produce a
pattern in
the wet tissue web in the forming section of the paper machine. Thus, the
texture
results from more fiber accumulation in areas of the fabric having high
drainage
and fewer fibers in areas of the fabric having low drainage. Such a method can
produce a dried tissue web having a non-uniform basis weight in the localized
areas or regions arranged in a systematic manner to form the texture. While
such
a method can produce textures, the sacrifice in the uniformity of the dried
tissue
web's physical properties such as tear, burst, absorbency, and density can
degrade the dried tissue web's performance while in use.
For the foregoing reasons, there is a need to generate aesthetically pleasing
combinations of background texture regions and curvilinear decorative elements
in
the dried or partially dried tissue web, while being manufactured on the paper
machine, using a method that produces a substantially uniform density dried
tissue
web which has improved performance while in use.
Numerous woven fabric designs are known in papermaking. Examples are
provided by Sabut Adanur in Paper Machine Clothing, Lancaster, Pennsylvania:
2
CA 02463892 2004-04-16
WO 03/040470 PCT/US02/33074
Technomic Publishing, 1997, pp. 33 - 113, 139 - 148,159 - 168, and 211 - 229.
Another example is provided in Patent Application WO 00/63489, entitled "Paper
Machine Clothing and Tissue Paper Produced with Same," by H.J. Lamb,
published on October 26, 2000.
SUMMARY
The present invention comprises paper manufacturing processes that may
satisfy one or more of the foregoing needs. For example, a paper manufacturing
fabric of the present invention, when used as a throughdrying fabric in an
uncreped
tissue making process , produces an absorbent tissue product having a
substantially uniform density as well as possessing visually discernable
background texture regions bordered by curvilinear decorative elements. The
present invention is also directed towards fabrics for manufacturing the
absorbent
tissue product, processes of making the absorbent tissue product, processes of
making the fabric, and the absorbent tissue products themselves.
Therefore in one aspect, the present invention relates to a fabric for
producing an absorbent tissue product with visually discernible background
texture
regions bordered by curvilinear decorative elements comprising: a woven fabric
having background texture regions formed by MD warp floats alternating with MD
warp sinkers woven into a support structure (i.e., at least a single layer of
CD
shutes) below the MD floats; the warps and shutes at the borders of the
background texture regions are arrayed to form transition regions comprising
the
curvilinear decorative elements.
In another aspect, the present invention relates to a method for
manufacturing an absorbent tissue product with visually discernable background
texture regions bordered by curvilinear decorative elements comprising:
forming
the wet tissue web, partially dewatering the wet tissue web, rush transferring
the
wet tissue web, wet molding the wet tissue web into a fabric having visually
discernible background texture regions bordered by curvilinear decorative
elements, and throughdrying the web.
3
CA 02463892 2004-04-16
WO 03/040470 PCT/US02/33074
In an additional aspect, the present invention relates to a tissue product
with
background texture regions bordered by curvilinear decorative elements that
form
aesthetically pleasing repeating patterns comprising: visually discernable
background texture regions of MD ripples, ridges, or the like, corresponding
to a
image of the background texture regions of the fabric, bordered by curvilinear
decorative elements, corresponding to an image of the curvilinear transition
regions of the fabric, where the curvilinear decorative elements in the tissue
web
are visually distinct from the background texture regions in the tissue.
Unlike U.S. Patent No. 5,672,248 issued on September 30, 1997 to Wendt
et al., where the warp knuckles are closely spaced or contacting and arranged
into
patterns, the present invention produces the curvilinear decorative elements
in the
absorbent tissue product at a substantially continuous transition region which
forms borders between background texture regions. The curvilinear decorative
elements comprise geometric configurations with the leading end of one or more
raised MD floats adjacent to or in proximity to the trailing end of another
raised MD
float. The decorative pattern consists of the visually discernable background
texture regions, such as corrugations, lines, ripples, ridges, and the like,
and the
curvilinear decorative elements which form transition regions between the
background texture regions. It is the arrangement of the transition regions in
the
present invention that provide the decorative pattern. Because the curvilinear
decorative elements are produced at the transition region (rather than from a
decorative pattern resulting from shoulder to shoulder or side by side
positioning of
warp knuckles of other fabrics) the raised MD floats can be purposely
distributed
more uniformly across the sheet side surface of the fabric to improve the
uniformity
and CD stretch properties of the tissue web with respect to physical
properties
while still imparting a distinctive texture highlighted by curvilinear
decorative
elements as a decorative pattern to the tissue web. In addition, because the
curvilinear decorative elements producing the distinctive pattern occurs at
the
relatively small transition area, it is possible to weave the fabric with more
intricate
patterns than possible in the fabrics disclosed in U.S. Patent No. 5,672,248.
4
CA 02463892 2004-04-16
WO 03/040470 PCT/US02/33074
The background texture regions are designed to impart preferred finished
product properties when used as an UCTAD throughdrying fabric, including roll
bulk, stack bulk, CD stretch, drape, and durability. The curvilinear
decorative
elements may provide additional hinge points to enhance finished product
drape.
The background texture regions in the finished product contrast visually with
the
curvilinear transition regions, providing the decorative effect.
In one aspect of the present invention, the curvilinear decorative elements
form woven transition regions which allow the warps to alternate function
between
MD warp float and MD warp sinker. When finished so the warps are parallel to
the
MD, the background texture regions across each transition region are out of
phase
with each other, with the highest parts of one background texture region
corresponding to the lowest part of the other. This out of phase alternation
results
in improved anti-nesting behavior, significantly improving the roll firmness -
roll bulk
relationship at a given one-sheet caliper.
In some embodiments, all of the floats (or elevated regions) in a background
region are surrounded by sinkers (or depressed regions), with the possible
exception of floats adjacent to a transition region or fabric edge, and all of
the
sinkers (or depressed regions) in a background region are surrounded by floats
(or
elevated regions), with the possible exception of sinkers adjacent to a
transition
region or fabric edge.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features, aspects., and advantages of the present invention
will be better understood with regard to the following description, appended
claims,
and accompanying drawings where:
5
CA 02463892 2004-04-16
WO 03/040470 PCT/US02/33074
FIGURE 1A is a schematic diagram of one embodiment of the fabric of the
present
invention.
FIGURE 1 B is a schematic diagram of one embodiment of the fabric of the
present
invention.
FIGURE 2 is a schematic diagram of one embodiment of the fabric of the present
invention.
FIGURE 3 is a cross-sectional view of one embodiment of the fabric of the
present
invention.
FIGURE 4 is a cross-sectional view of one embodiment of the fabric of the
present
invention.
FIGURE 5 is a cross-sectional view of one embodiment of the fabric of the
present
invention.
FIGURE 6 is a cross-sectional view of one embodiment of the fabric of the
present
invention.
FIGURE 7 is a schematic diagram of a surface profile and corresponding
material
lines of one embodiment of the fabric of the present invention.
FIGURE 8 is a cross-sectional view of one embodiment of the fabric of the
present
invention.
FIGURE 9 is a schematic diagram of one embodiment of the fabric of the present
invention.
FIGURE 10 is a CADEYES display screen shot of a putty impression of one
embodiment of the fabric of the present invention.
6
CA 02463892 2004-04-16
WO 03/040470 PCT/US02/33074
FIGURE 11 is a CADEYES display screen shot of dried tissue molded on one
embodiment of the fabric of the present invention.
FIGURE 12 is a CADEYES display screen shot of dried tissue molded on one
embodiment of the fabric of the present invention.
FIGURE 13 is a CADEYES display screen shot of dried tissue molded on one
embodiment of the fabric of the present invention.
FIGURE 14 is a CADEYES display screen shot of dried tissue molded on one
embodiment of the fabric of the present invention.
FIGURE 15 is a CADEYES display screen shot of dried tissue molded on one
embodiment of the fabric of the present invention.
FIGURE 16 is a CADEYES display screen shot of a putty impression of one
embodiment of the fabric of the present invention.
FIGURE 17 is a CADEYES display screen shot of a putty impression of one
embodiment of the fabric of the present invention.
FIGURE 18 is a schematic diagram of one embodiment of the fabric of the
present
invention.
FIGURE 19 is a schematic diagram of one embodiment of the fabric of the
present
invention.
FIGURE 20 is a schematic diagram of one embodiment of the fabric of the
present
invention.
FIGURE 21 is a schematic diagram of one embodiment of the fabric of the
present
invention.
7
CA 02463892 2004-04-16
WO 03/040470 PCT/US02/33074
FIGURE 22 is a schematic diagram of one embodiment of the fabric of the
present
invention.
FIGURE 23 is a CADEYES display screen shot of a putty impression of one
embodiment of the fabric of the present invention.
FIGURE 24 is a CADEYES display screen shot of a putty impression of one
embodiment of the fabric of the present invention.
FIGURE 25 is a schematic diagram of one embodiment of the fabric of the
present
invention.
FIGURE 26A is a schematic diagram of one embodiment of the fabric of the
present invention.
FIGURE 26B is a schematic diagram of one embodiment of the fabric of the
present invention.
FIGURE 26C is a schematic diagram of one embodiment of the fabric of the
present invention.
FIGURE 26D is a schematic diagram of one embodiment of the fabric of the
present invention.
FIGURE 26E is a schematic diagram of one embodiment of the fabric of the
present invention.
FIGURE 27 is a schematic diagram for making an uncreped dried tissue web in
accordance with an embodiment of the present invention.
FIGURE 28 is a photograph of one embodiment of the fabric of the present
invention.
8
CA 02463892 2004-04-16
WO 03/040470 PCT/US02/33074
FIGURE 29 is a photograph of the air side of a dried tissue web made using one
embodiment of the fabric of the present invention.
FIGURE 30 is a photograph of the fabric side of a dried tissue web made using
one embodiment of the fabric of the present invention.
DEFINITIONS
As used herein, "curvilinear decorative element" refers to any line or
visible pattern that contains either straight sections, curved sections, or
both that
are substantially connected visually. Thus, a decorative pattern of
interlocking
circles may be formed from many curvilinear decorative elements shaped into
circles. Similarly, a pattern of squares may be formed from many curvilinear
decorative elements shaped into individual squares. It is understood that
curvilinear decorative elements also may appear as undulating lines,
substantially
connected visually, forming signatures or patterns as well as multiple warp
mixed
with single warp to generate textures of more complicated patterns.
Also, as used herein "decorative pattern" refers to any non-random
repeating design, figure, or motif. It is not necessary that the curvilinear
decorative
elements form recognizable shapes, and a repeating design of the curvilinear
decorative elements is considered to constitute a decorative pattern.
As used herein, the term "float" means an unwoven or non-interlocking
portion of a warp emerging from the topmost layer of shutes that spans at
least two
consecutive shutes of the topmost layer of shutes.
As used herein, a "sinker" means a span of a warp that is generally
depressed relative to adjacent floats, further having two end regions both of
which
pass under one or more consecutive shutes.
As used herein, "machine-direction" or "MD" refers to the direction of travel
of the fabric, the fabric's individual strands, or the paper web while moving
through
9
CA 02463892 2009-09-09
the paper machine. Thus, the MD test data for the tissue refers to the
tissue's
physical properties in a sample cut lengthwise in the machine-direction.
Similarly,
"cross-machine direction" or "CD" refers to a direction orthogonal to the
machine-direction extending across the width of the paper machine. Thus, the
CD
test data for the tissue refers to the tissue's physical properties in a
sample cut
lengthwise in the cross-machine direction. In addition, the strands may be
arranged at acute angles to the MD and CD directions. One such arrangement is
described in "Rolls of Tissue Sheets Having Improved Properties", Burazin et
al.,
EP 1 109 969 Al which published on June 27, 2001.
As used herein, "plane difference" refers to the z-direction height difference
between an elevated region and the highest immediately adjacent depressed
region. Specifically, in a woven fabric, the plane difference is the z-
direction height
difference between a float and the highest immediately adjacent sinker or
shute.
Z-direction refers to the axis mutually orthogonal to the machine direction
and
cross-machine direction.
As used herein, "transfer fabric" is a fabric that is positioned between the
forming section and the drying section of the web manufacturing process.
As used herein, "transition region" is defined as the intersection of three or
more floats on three or more consecutive MD strands. The transition regions
are
formed by deliberate interruptions in the textured background regions, which
may
result from a variety of arrangements of intersections of the floats. The
floats may
be arranged in an overlapping intersection or in a non-overlapping
intersection.
As used herein, a "filled" transition region is defined as a transition region
where the space between the floats in the transition region is partially or
completely filled with material, raising the height in the transition area.
The filling
material may be porous. The filling material may be any of the materials
discussed
hereinafter for use in the construction of fabrics. The filling material may
be
CA 02463892 2004-04-16
WO 03/040470 PCT/US02/33074
substantially deformable, as measured by High Pressure Compressive Compliance
(defined hereinafter).
As used herein, the term "warp" can be understood as a strand
substantially oriented in the machine direction, and "shute" can be understood
to
refer to the strands substantially oriented in the cross-machine direction of
the
fabric as used on a papermachine. The warps and shutes may be interwoven via
any known fabric method of manufacture. In the production of endless fabrics,
the
normal orientation of warps and shutes, according to common weaving
terminology, is reversed, but as used herein, the structure of the fabric and
not its
method of manufacture determine which strands are classified as warps and
which
are shutes.
As used herein "strand" refers a substantially continuous filament suitable
for weaving sculptured fabrics of the present invention. Strands may include
any
known in the prior art. Strands may comprise monofilament, cabled
monofilament,
staple fiber twisted together to form yarns, cabled yarns, or combinations
thereof.
Strand cross-sections, filament cross sections, or stable fiber cross sections
may
be circular, elliptical, flattened, rectangular, oval, semi-oval, trapezoidal,
parallelogram, polygonal, solid, hollow, sharp edged, rounded edged, bi-lobal,
multi-lobal, or can have capillary channels. Strand diameter or strand cross
sectional shape may vary along its length.
As used herein "multi-strand" refers to two or more strands arranged side
by side or twisted together. It is not necessary for each side-by-side strand
in a
multi-strand group to be woven identically. For example, individual strands of
a
multi-strand warp may independently enter and exit the topmost layer of shutes
in
sinker regions or transition regions. As a further example, a single multi-
strand
group need not remain a single multi-strand group throughout the length of the
strands in the fabric, but it is possible for one or more strands in a multi-
strand
group to depart from the remaining strand(s) over a specific distance and
serve, for
example, as a float or sinker independently of the remaining strand(s).
11
CA 02463892 2009-09-09
As used herein, "Frazier air permeability" refers to the measured value of
a well-known test with the Frazier Air Permeability Tester in which the
permeability
of a fabric is measured as standard cubic feet of air flow per square foot of
material
per minute with an air pressure differential of 0.5 inches (12.7 mm) of water
under
standard conditions. The fabrics of the present invention can have any
suitable
Frazier air permeability. For example, thoughdrying fabrics can have a
permeability from about 55 standard cubic feet per square foot per minute
(about
16 standard cubic meters per square meter per minute) or higher, more
specifically
from about 100 standard cubic feet per square foot per minute (about 30
standard
cubic meters per square meter per minute) to about 1,700 standard cubic feet
per
square foot per minute (about 520 standard cubic meters per square meter per
minute), and most specifically from about 200 standard cubic feet per square
foot
per minute (about 60 standard cubic meters per square meter per minute) to
about
1,500 standard cubic feet per square foot per minute (about 460 standard cubic
meters per square meter per minute).
DETAILED DESCRIPTION
The Process
Referring to FIGURE 27, a process of carrying out the present invention will
be described in greater detail. The process shown depicts an uncreped through
dried process, but it will be recognized that any known papermaking method or
tissue making method can be used in conjunction with the fabrics of the
present
invention. Related uncreped through air dried tissue processes are described
in
U.S. Patent No. 5,656,132 issued on August 12, 1997 to Farrington et al. and
in
U.S. Patent No. 6,017,417 issued on January 25, 2000 to Wendt et al.
In addition, fabrics having a sculpture layer and a load bearing layer useful
for
making uncreped through air dried tissue products are disclosed in U.S. Patent
No. 5,429,686 issued on July 4, 1995 to Chiu et al.
12
CA 02463892 2009-09-09
Exemplary methods for the production of creped tissue and other paper products
are disclosed in U.S. Patent No. 5,855,739, issued on January 5, 1999 to
Ampulski
et al.; U.S. Patent No. 5,897,745, issued on April 27, 1999 to Ampulski et
al.; U.S.
Patent No. 5,893,965, issued on April 13, 1999 to Trokhan et al.; U.S. Patent
No.
5,972,813 issued on October 26, 1999 to Polat et al.; U.S. Patent No.
5,503,715,
issued on April 2, 1996 to Trokhan et al.; U.S. Patent No. 5,935,381, issued
on
August 10, 1999 to Trokhan et al.; U.S. Patent No. 4,529,480, issued on July
16,
1985 to Trokhan; U.S. Patent No. 4,514,345, issued on April 30, 1985 to
Johnson
et al.; U.S. Patent No. 4,528,239, issued on July 9, 1985 to Trokhan; U.S.
Patent
No. 5,098,522, issued on March 24, 1992 to Smurkoski et al.; U.S. Patent No.
5,260,171, issued on November 9, 1993 to Smurkoski et al.; U.S. Patent No.
5,275,700, issued on January 4, 1994 to Trokhan; U.S. Patent No. 5,328,565,
issued on July 12, 1994 to Rasch et al.; U.S. Patent No. 5,334,289, issued on
August 2, 1994 to Trokhan et al. ; U.S. Patent No. 5,431,786, issued on July
11,
1995 to Rasch et al.; U.S. Patent No. 5,496,624, issued on March 5, 1996 to
Stelljes, Jr. et al.; U.S. Patent No. 5,500,277, issued on March 19, 1996 to
Trokhan et al.; U.S. Patent No. 5,514,523, issued on May 7, 1996 to Trokhan et
al.; U.S. Patent No. 5,554,467, issued on September 10, 1996, to Trokhan et
al.;
U.S. Patent No. 5,566,724, issued on October 22, 1996 to Trokhan et al.; U.S.
Patent No. 5,624,790, issued on April 29, 1997 to Trokhan et al.; U.S. Patent
No.
6,010,598, issued on January 4, 2000 to Boutiller et al.; and, U.S. Patent No.
5,628,876, issued on May 13, 1997 to Ayers et al.
In Figure 27, a twin wire former 8 having a papermaking headbox 10 injects
or deposits a stream 11 of an aqueous suspension of papermaking fibers onto a
plurality of forming fabrics, such as the outer forming fabric 12 and the
inner
forming fabric 13, thereby forming a wet tissue web 15. The forming process of
the
present invention may be any conventional forming process known in the
papermaking industry. Such formation processes include, but are not limited
to,
13
CA 02463892 2004-04-16
WO 03/040470 PCT/US02/33074
Fourdriniers, roof formers such as suction breast roll formers, and gap
formers
such as twin wire formers and crescent formers.
The wet tissue web 15 forms on the inner forming fabric 13 as the inner
forming fabric 13 revolves about a forming roll 14. The inner forming fabric
13
serves to support and carry the newly-formed wet tissue web 15 downstream in
the
process as the wet tissue web 15 is partially dewatered to a consistency of
about
percent based on the dry weight of the fibers. Additional dewatering of the
wet
tissue web 15 may be carried out by known paper making techniques, such as
10 vacuum suction boxes, while the inner forming fabric 13 supports the wet
tissue
web 15. The wet tissue web 15 may be additionally dewatered to a consistency
of
at least about 20%, more specifically between about 20% to about 40%, and more
specifically about 20% to about 30%. The wet tissue web 15 is then transferred
from the inner forming fabric 13 to a transfer fabric 17 traveling preferably
at a
slower speed than the inner forming fabric 13 in order to impart increased MD
stretch into the wet tissue web 15.
The wet tissue web 15 is then transferred from the transfer fabric 17 to a
throughdrying fabric 19 whereby the wet tissue web 15 preferentially is
macroscopically rearranged to conform to the surface of the throughdrying
fabric
19 with the aid of a vacuum transfer roll 20 or a vacuum transfer shoe like
the
vacuum shoe 18. If desired, the throughdrying fabric 19 can be run at a speed
slower than the speed of the transfer fabric 17 to further enhance MD stretch
of the
resulting absorbent tissue product 27. The transfer is preferably carried out
with
vacuum assistance to ensure conformation of the wet tissue web 15 to the
topography of the throughdrying fabric 19. This yields a dried tissue web 23
having the desired bulk, flexibility, CD stretch, and enhances the visual
contrast
between the background texture regions 38 and 50 and the curvilinear
decorative
elements which border the background texture regions 38 and 50.
In one embodiment, the throughdrying fabric 19 is woven in accordance with
the present invention, and it imparts the curvilinear decorative elements and
background texture regions 38 and 50, such as substantially broken-line like
14
CA 02463892 2004-04-16
WO 03/040470 PCT/US02/33074
corduroy, to the wet tissue web 15. It is possible, however, to weave the
transfer
fabric 17 in accordance with the present invention to achieve similar results.
Furthermore, it is also possible to eliminate the transfer fabric 17, and
transfer the
wet tissue web 15 directly to the throughdrying fabric 19 of the present
invention.
Both alternative papermaking processes are within the scope of the present
invention, and will produce a decorative absorbent tissue product 27.
While supported by the throughdrying fabric 19, the wet tissue web 15 is
dried to a final consistency of about 94 percent or greater by a throughdryer
21 and
is thereafter transferred to a carrier fabric 22. Alternatively, the drying
process can
be any noncompressive drying method that tends to preserve the bulk of the wet
tissue web 15.
In another aspect of the present invention, the wet tissue web 15 is pressed
against a Yankee dryer by a pressure roll while supported by a woven sculpted
fabric 30 comprising visually discernable background texture regions 38 and 50
bordered by curvilinear decorative elements. Such a process, without the use
of
the sculpted fabrics 30 of the present invention, is shown in U.S. Patent No.
5,820,730 issued on October 13, 1998 to Phan et al. The compacting action of a
pressure roll will tend to densify a resulting absorbent tissue product 27 in
the
localized regions corresponding to the highest portions of the sculpted fabric
30.
The dried tissue web 23 is transported to a reel 24 using a carrier fabric 22
and an optional carrier fabric 25. An optional pressurized turning roll 26 can
be
used to facilitate transfer of the dried tissue web 23 from the carrier fabric
22 to the
carrier fabric 25. If desired, the dried tissue web 23 may additionally be
embossed
to produce a combination of embossments and the background texture regions
and curvilinear decorative elements on the absorbent tissue product 27
produced
using the throughdrying fabric 19 and a subsequent embossing stage.
Once the wet tissue web 15 has been non-compressively dried, thereby
forming the dried tissue web 23, it is possible to crepe the dried tissue web
23 by
transferring the dried tissue web 23 to a Yankee dryer prior to reeling, or
using
CA 02463892 2009-09-09
alternative foreshortening methods such as microcreping as disclosed in U.S.
Patent No. 4,919,877 issued on April, 24, 1990 to Parsons et al.
In an alternative embodiment not shown, the wet tissue web 15 may be
transferred directly from the inner forming fabric 13 to the throughdrying
fabric 19
and the transfer fabric 17 eliminated. The throughdrying fabric 19 Is
constructed
with raised MD floats 60, and illustrative embodiments are shown in FIGURES
1A,
1 B, 2, 9, and 28. The throughdrying fabric 19 may be traveling at a speed
less
than the inner forming fabric 13 such that the wet tissue web 15 is rush
transferred,
or, in the alternative, the throughdrying fabric 19 may be traveling at
substantially
the same speed as the inner forming fabric 13. If the throughdrying fabric 19
is
traveling at a slower speed than the speed of the inner forming fabric 13, an
uncreped absorbent tissue product 27 is produced. Additional foreshortening
after
the drying stage may be employed to improve the MD stretch of the absorbent
tissue product 27. Methods of foreshortening the absorbent tissue product 27
include, by way of illustration and without limitation, conventional Yankee
dryer
creping, microcreping, or any other method known in the art.
Differential velocity transfer from one fabric to another can follow the
principles taught in any one of the following patents: U.S. Patent
No. 5,667,636, issued on September 16, 1997 to Engel et al.; U.S. Patent No.
5,830,321, issued on November 3, 1998 to Lindsay et al.; U.S. Patent No.
4,440,597, issued on April 3, 1984 to Wells et al.; U.S. Patent No. 4,551,199,
issued on November 5, 1985 to Weldon; and, U.S. Patent No. 4,849,054, issued
on July 18, 1989 to Klowak.
In yet another alternative embodiment of the present invention, the inner
forming fabric 13, the transfer fabric 17, and the throughdrying fabric 19 can
all be
traveling at substantially the same speed. Foreshortening may be employed to
improve MD stretch of the absorbent tissue product 27. Such methods include,
by
way of illustration without limitation, conventional Yankee dryer creping or
microcreping.
16
CA 02463892 2009-09-09
Any known papermaking or tissue manufacturing method may be used to
create a three-dimensional web 23 using the fabrics 30 of the present
invention as
a substrate for imparting texture to the wet tissue web 15 or the dried tissue
web
16. Though the fabrics 30 of the present invention are especially useful as
through
drying fabrics and can be used with any known tissue making process that
employs throughdrying, the fabrics 30 of the present invention can also be
used in
the formation of paper webs as forming fabrics, transfer fabrics, carrier
fabrics,
drying fabrics, imprinting fabrics, and the like in any known papermaking or
tissue
making process. Such methods can include variations comprising any one or
more of the following steps in any feasible combination:
= web formation in a wet end in the form of a classical Fourdrinier, a gap
former,
a twin-wire former, a crescent former, or any other known former comprising
any known headbox, including a stratified headbox for bringing layers of two
or
more furnishes together into a single web, or a plurality of headboxes for
forming a multilayered web, using known wires and fabrics or fabrics of the
present invention;
= web formation or web dewatering by foam-based processes, such as
processes wherein the fibers are entrained or suspended in a foam prior to
dewatering, or wherein foam is applied to an embryonic web prior to dewatering
or drying, including the methods disclosed in U.S. Patent 5,178,729, issued on
January 12, 1993 to Janda, and U.S. Patent No. 6,103,060, issued on August
15, 2000 to Munerelle et al.
= differential basis weight formation by draining a slurry through a forming
fabric
having high and low permeability regions, including fabrics of the present
invention or any known forming fabric;
= rush transfer of a wet web from a first fabric to a second fabric moving at
a
slower velocity than the first fabric, wherein the first fabric can be a
forming
fabric, a transfer fabric, or a throughdrying fabric, and wherein the second
fabric
can be a transfer fabric, a throughdrying fabric, a second throughdrying
fabric,
or a carrier fabric disposed after a throughdrying fabric (one exemplary rush
17
CA 02463892 2009-09-09
transfer process is disclosed in U.S. Patent No. 4,440,597 to Wells et al,
wherein
the aforementioned fabrics can be selected from any known suitable fabric
including fabrics of the present invention;
= application of differential air pressure across the web to mold it into one
or more
of the fabrics on which the web rests, such as using a high vacuum pressure in
a vacuum transfer roll or transfer shoe to mold a wet web into a throughdrying
fabric as it is transferred from a forming fabric or intermediate carrier
fabric,
wherein the carrier fabric, throughdrying fabric, or other fabrics can be
selected
from the fabrics of the present invention or other known fabrics;
= use of an air press or other gaseous dewatering methods to increase the
dryness of a web and/or to impart molding to the web, as disclosed in U.S.
Patent No. 6096169, issued on August 1, 2000 to Hermans et al.; U.S. Patent
No. 6,197,154, issued on March 6, 2001 to Chen et al.; and, U.S. Patent No.
6,143,135, issued on November 7, 2000 to Hada et al.;
= drying the web by any compressive or noncompressive drying process, such as
throughdrying, drum drying, infrared drying, microwave drying, wet pressing,
impulse drying (e.g., the methods disclosed in U.S. Patent No. 5,353,521,
issued on October 11, 1994 to Orloff and U.S. Patent No. 5,598,642, issued on
February 4, 1997 to Orloff et al.), high intensity nip dewatering,
displacement
dewatering (see J.D. Lindsay, "Displacement Dewatering To Maintain Bulk,"
Paperi Ja Puu, vol. 74, No. 3, 1992, pp. 232-242), capillary dewatering (see
any
of U.S. Patent Nos. 5,598,643; 5,701,682; and 5,699,626, all of which issued
to Chuang et al.), steam drying, etc.
= printing, coating, spraying, or otherwise transferring a chemical agent or
compound on one or more sides of the web uniformly or heterogeneously, as in
a pattern, wherein any known agent or compound useful for a web-based
product can be used (e.g., a softness agent such as a quaternary ammonium
compound, a silicone agent, an emollient, a skin wellness agent such as aloe
vera extract, an antimicrobial agent such as citric acid, an odor-control
agent, a
pH control agent, a sizing agent; a polysaccharide derivative, a wet strength
agent, a dye, a fragrance, and the like), including the methods of U.S. Patent
18
CA 02463892 2009-09-09
No. 5,871,763, issued on February 16, 1999 to Luu et al.; U.S. Patent No.
5,716,692, issued on February 10, 1998 to Warner et al.; U.S. Patent No.
5,573,637, issued on November 12, 1996 to Ampulski et al.; U.S. Patent No.
5,607,980, issued on March 4, 1997 to McAtee et al.; U.S. Patent No.
5,614,293, issued on March 25, 1997 to Krzysik et al.; U.S. Patent No.
5,643,588, issued on July 1, 1997 to Roe et al.; U.S. Patent No. 5,650,218,
issued on July 22, 1997 to Krzysik et al.; U.S. Patent No. 5,990,377, issued
on
November 23, 1999 to Chen et al.; and, U.S. Patent No. 5,227,242, issued on
July 13, 1993 to Walter et al.)
= imprinting the web on a Yankee dryer or other solid surface, wherein the web
resides on a fabric that can have deflection-conduits (openings) and elevated
regions (including the fabrics of the present invention), and the fabric is
pressed
against a surface such as the surface of a Yankee dryer to transfer the web
from the fabric to the surface, thereby imparting densification to portions of
the
web that were in contact with the elevated regions of the fabric, whereafter
the
selectively densified web can be creped from or otherwise removed from the
surface;
= creping the web from a drum dryer, optionally after application of a
strength
agent such as latex to one or more sides of the web, as exemplified by the
methods disclosed in U.S. Patent No. 3,879,257, issued on April 22, 1975 to
Gentile et al.; U.S. Patent No. 5,885,418, issued on March 23, 1999 to
Anderson et al.; U.S. Patent No. 6,149,768, issued on November 21, 2000 to
Hepfordj
= creping with serrated crepe blades (e.g., see U.S. Patent No. 5,885,416,
issued
on March 23, 1999 to Marinack et al.) or any other known creping or
foreshortening method; and,
= converting the web with known operations such as calendering, embossing,
slitting, printing, forming a multiply structure having two, three, four, or
more
plies, putting on a roll or in a box or adapting for other dispensing means,
packaging in any known form, and the like.
19
CA 02463892 2004-04-16
WO 03/040470 PCT/US02/33074
The fabrics 30 of the present invention can also be used to impart texture to
airlaid webs, either serving as a substrate for forming a web, for embossing
or
imprinting an airlaid web, or for thermal molding of a web.
Fabric Structure
Figure 1A is a schematic showing the relative placement of the floats 60 on
the paper-contacting side of the woven sculpted fabric 30 according to the
present
invention. The floats 60 consist of the elevated portions of the warps 44
(strands
substantially oriented in the machine direction). Not shown for clarity are
the
shutes (strands substantially oriented in the cross-machine direction) and
depressed portions of the warps 44 interwoven with the shutes, but it is
understood
that the warps 44 can be continuous in the machine direction, periodically
rising to
serve as a float 60 and then descending as one moves horizontally in the
portion of
the woven sculpted fabric 30 schematically shown in Figure 1A.
In a first background region 38 of the woven sculpted fabric 30, the floats 60
define a first elevated region 40 comprising first elevated strands 41.
Between
each pair of neighboring first elevated strands 41 in the first background
region 38
is a first depressed region 42. The depressed warps 44 in the first depressed
region 42 are not shown for clarity. The combination of machine-direction
oriented,
alternating elevated and depressed regions forms a first background texture
39.
In a second background region 50 of the woven sculpted fabric 30, there are
second elevated strands 53 defining a second elevated region 52. Between each
pair of the neighboring second elevated strands 53 in the second background
region 50 is a second depressed region 54. The depressed warps 44 in the
second depressed region 54 are not shown for clarity. The combination of
machine-direction oriented, alternating second elevated and depressed regions
52
and 54 forms a second background texture 51.
Between the first background region 38 and the second background region
50 is a transition zone 62 where the floats 44 from either the first
background
CA 02463892 2004-04-16
WO 03/040470 PCT/US02/33074
region 38 or the second background region 50 descend to become sinkers (not
shown) or depressed regions 54 and 42 in the second background region 50 or
first background region 38, respectively. In the transition region 62, ends or
beginning sections of the floats 60 from different background texture regions
38
and 50 overlap, creating a texture comprising adjacent floats 60 rather than
the
first or second background textures 39 and 51 which have alternating floats 60
and
first or second depressed regions 42 and 54, respectively. Thus, the
transition
region 62 provides a visually distinctive interruption to the first and second
background textures 39 and 51 of the first and second background regions 38
and
50, respectively, and form a substantially continuous transition region to
provide a
macroscopic, visually distinctive curvilinear decorative element that extends
in
directions other than solely the machine direction orientation of the floats
60. In
Figure 1A, the transition region 62 forms a curved diamond pattern.
The overall visual effect created by a repeating unit cell comprising the
curvilinear transition region 62 of Figure 1A is shown in Figure 1 B, which
depicts
several continuous transition regions 62 forming a repeating wedding ring
pattern
of curvilinear decorative elements.
Figure 2 depicts a portion of a woven sculpted fabric 30 made according to
the present invention. In this portion, the three shutes 45a, 45b, and 45c are
interwoven with the six warps 44a - 44f. A transition region 62 separates a
first
background region 38 from a second background region 50. The first background
region 38 has first elevated strands 41 a, 41 b, and 41 c which define the
first
elevated regions 40a, 40b, and 40c, and the first depressed strands 43a, 43b,
and
43c which define the first depressed regions 42 (only one of which is
labeled). The
alternation between the first elevated regions 40a, 40b, and 40c and the first
depressed regions 42 creates a first background texture 39 in the first
background
region 38.
Likewise, the second background region 50 has second elevated strands
53a, 53b, and 53c which define the second elevated regions 52a, 52b, and 52c,
21
CA 02463892 2004-04-16
WO 03/040470 PCT/US02/33074
and the second depressed strands 55a, 55b, and 55c which define the second
depressed regions 54 (only one of which is labeled).
The alternation of second elevated regions 52a, 52b, and 52c with the
second depressed regions 54 creates a second background texture 51 in the
second background region 50. The warps 44a, 44b, and 44c forming the first
elevated regions 40a, 40b, and 40c in the first background region 38 become
the
second depressed regions 54 (second depressed strands 55a, 55b, and 55c) in
the second background region 50, and visa versa.
In general, the warps 44 in either of the first and second background region
38 and 50 alternate in the cross-machine direction between being floats 60 and
sinkers 61, providing a background texture 39 or 51 dominated by machine
direction elongated features which become inverted (floats 60 become sinkers
61
and visa versa) after passing through the transition zone 62.
Three crossover zones 65a, 65b, and 65c occur in the transition region 62
where a first elevated strand 41 a, 41 b, or 41 c descends below a shute 45a,
45b,
or 45c in the vicinity where a second elevated strand 53a, 53b, or 53c also
descends below a shute 45a, 45b, or 45c. In the crossover zone 65a, the warps
44a and 44d both descend from their status as floats 60 in the first and
second
background regions 38 and 50, respectively, to become sinkers 61, with the
descent occurring between the shutes 45b and 45c.
The crossover zone 65c differs from the crossover zones 65a and 65b in
that the two adjacent warps 44c and 44f descend on opposite sides of a single
shute 45a. The tension in the warps 44c and 44f can act in the crossover zone
65c to bend the shute 45a downward more than normally encountered in the first
and second background regions 38 and 50, resulting in a depression in the
woven
sculpted fabric 30 that can result in increased depth of molding in the
vicinity of the
crossover zone 65c. Overall, the various crossover zones 65a, 65b, and 65c in
the transition region 62 provide increased molding depth in the woven sculpted
fabric 30 that can impart visually distinctive curvilinear decorative elements
to an
22
CA 02463892 2004-04-16
WO 03/040470 PCT/US02/33074
absorbent tissue product 27 molded thereon, with the visually distinct nature
of the
curvilinear decorative elements being achieved by means of the interruption in
the
texture dominated by the MD-oriented floats 60 between two adjacent background
regions 38 and 50 and optionally by the increased molding depth in the
transition
region 62 due to pockets or depressions in the woven sculpted fabric 30
created by
the crossover zones 65a, 65b, and 65c.
The first and second depressed strands 43 and 55 can be classified as
sinkers 61, while the first and second elevated strands 41 and 53 can be
classified
as floats 60.
The shutes 45 depicted in Figure 2 represent the topmost layer of CD shutes 33
of
the woven sculpted fabric 30, which can be part of a base layer 31 of the
woven
sculpted fabric 30. A base layer 31 can be a load-bearing layer. The base
layer 31
can also comprise multiple groups of interwoven warps 44 and shutes 45 or
nonwoven layers (not shown), metallic elements or bands, foam elements,
extruded polymeric elements, photocured resin elements, sintered particles,
and
the like.
Figure 3 is a cross-sectional view of a portion of a woven sculpted fabric 30
showing a crossover region 65 similar to that of crossover region 65c in
Figure 2.
Five consecutive shutes 45a - 45e and two adjacent warps 44a and 44b are
shown. The two warps 44a and 44b -serve as a first elevated strand 41 and
second elevated strand 53, respectively, in a first background region 38 and a
second background region 50, respectively, where the warps 44a and 44b are
floats 60 defining a first elevated region 40 and a second elevated region 52,
respectively. After passing through the transition region 62 and crossing over
the
shute 45c in a crossover region 65, the two warps 44a and 44b each become
sinkers 61 as the two warps 44a and 44b extend into the second background
region 50 and the first background region 38, respectively.
- In the crossover zone 65, the two adjacent warps 44a and 44b descend on
opposite sides of a single shute 45c. The tension in the warps 44c and 44f can
act
in the crossover zone 65 to bend the shute 45c downward relative to the
23
CA 02463892 2004-04-16
WO 03/040470 PCT/US02/33074
neighboring shutes 45a, 45b, 45d, and 45e, and particularly relative to the
adjacent shutes 45b and 45d, resulting in a depression in the woven sculpted
fabric 30 having a depression depth D relative to the maximum plane difference
of
the float 60 portions of the warps 44a and 44b in the adjacent first and
second
background regions 38 and 50, respectively, that can result in increased depth
of
molding in the vicinity of the crossover zone 65.
The maximum plane difference of the floats 60 may be at least about 30%
of the width of at least one of the floats 60. In other embodiments, the
maximum
plane difference of the floats 60 may be at least about 70%, more specifically
at
least about 90%. The maximum plane difference of the floats 60 may be at least
about 0.12 millimeter (mm). In other embodiments, the maximum plane difference
of the floats 60 may be at least about 0.25 mm, more specifically at least
about
0.37 mm, and more specifically at least about 0.63 mm.
Figure 4 depicts another cross-sectional view of a portion of a woven
sculpted fabric 30 showing a crossover region 65. Seven consecutive shutes 45a
-
45g and two adjacent warps 44a and 44b are shown.
The two warps 44a and 44b serve as a first elevated strand 41 and second
elevated strand 53, respectively, in a first background region 38 and second
background region 50, respectively, where the warps 44a and 44b are floats 60
defining a first elevated region 40 and second elevated region 52,
respectively.
The transition region 62 spans three shutes 45c, 45d and 45e. Proceeding from
right to left, the first elevated strand 41 enters the transition region 62
between the
shutes 45f and 45e, descending from its status as a float 60 in first
background
region 38 as it passes beneath the float 45e. It then passes over the shute
45d
and then descends below the shute 45c, continuing on into the second
background
region 50 where it becomes a sinker 61. The second elevated strand 53 is a
mirror
image of the first elevated strand 41 (reflected about an imaginary vertical
axis, not
shown, passing through the center of the shute 45d) in the portion of the
woven
sculpted fabric 30 depicted in Figure 4. Thus, the second elevated strand 53
enters the transition region 62 between the shutes 45b and 45c, passes over
the
24
CA 02463892 2004-04-16
WO 03/040470 PCT/US02/33074
shute 45d, and then descends beneath the shute 45e to become a sinker 61 in
the
first background region 38. The first elevated strand 41 and the second
elevated
strand 53 cross over each other in a crossover region 65 above the shute 45d,
which may be deflected downward by tension in the warps 44a and 44b.
Also depicted is the topmost layer of CD shutes 33 of the woven sculpted
fabric 30, which can define an upper plane 32 of the topmost layer of CD
shutes 33
when the fabric 30 is resting on a substantially flat surface. Not all shutes
45 in the
topmost layer of CD shutes 33 sit at the same height; the uppermost shutes 45
of
the topmost layer of CD shutes 33 determine the elevation of the upper plane
32 of
the topmost layer of CD shutes 33. The difference in elevation between the
upper
plane 32 of the topmost layer of CD shutes 33 and the highest portion of a
float 60
is the "Upper Plane Difference," as used herein, which can be 30% or greater
of
the diameter of the float 60, or can be about 0.1 mm or greater; about 0.2 mm
or
greater; or, about 0.3 mm or greater.
Figure 5 depicts another cross-sectional view of a portion of a woven
sculpted fabric 30 showing a transition region 62 with a crossover region 65,
the
transition region 62 being between a first background region 38 and a second
background region 50. Eleven consecutive shutes 45a - 45k and two adjacent
warps 44a and 44b are shown. The configuration is similar to that of Figure 4
except that the warp 44a which forms the first elevated strand 41 is shifted
to the
right by about twice the typical shute spacing S such that the warp 44a no
longer
passes over the same shute (45e in Figure 5, analogous to 45d in Figure 4 ) as
the warp 44b that forms the second elevated strand 53 before descending to
become a sinker 61. Rather, the warp 44a is shifted such that the warp 44a
passes over the shute 45g before descending to become a sinker 61. Both the
warps 44a and 44b pass below the shute Of in the crossover region 65.
Figure 6 depicts yet another cross-sectional view of a portion of a woven
sculpted fabric 30 showing a transition region 62 with a crossover region 65.
Seven consecutive shutes 45a - 45g and two adjacent warps 44a and 44b are
shown. The crossover region 65 is similar to the crossover regions 65a and 65b
of
CA 02463892 2004-04-16
WO 03/040470 PCT/US02/33074
Figure 2. Both warps 44a and 44b descend below a common shute 45d in the
transition region 62, becoming the sinkers 61.
Figure 7 will be discussed hereinafter with respect to the analysis of the
profile lines.
Figure 8 is a cross-sectional view depicting another embodiment of a
woven sculpted fabric 30. Here the two adjacent warps 44a and 44b are shown
interwoven with the five consecutive shutes 45a - 45e. As the warp 44a enters
the
transition region 62 from the first background region 38 where the warp 44a is
a
float 60, the warp 44a descends below the shute 45c in the transition region
62
and then rises again as it leaves the transition region 62 to become a float
60 in
the second background region 50. Likewise, the warp 44b is a sinker 61 in the
second background region 50, rises in the transition region 62 to pass above
the
shute 45c, then descends near the end of the transition region 62 to become a
sinker 61 in the first background region 38. In the transition region 62,
there are
two crossover regions 65 for the two adjacent warps 44a and 44b. One can
recognize that the first and second background textures 39 and 51 (not shown)
formed by successive pairs of warps 44 (e.g., adjacent floats 60 and sinkers
61,
such as the warp 44a and the warp 44b) would be interrupted at the transition
region 62, and if multiple transition regions 62 were positioned to form a
substantially continuous transition region 62 across a plurality of adjacent
warps 44
(e.g., 8 or more adjacent warps 44), a curvilinear decorative element could be
formed from the interruption in the background textures 39 and 51 of the
background regions 38 and 50, respectively, imparting a visually distinctive
texture
to the wet tissue web 15 of an absorbent tissue product 27 molded on the woven
sculpted fabric 30.
The sheets of the absorbent tissue products 27 (shown in Figures 29 and
30) of the present invention have two or more distinct textures. There may be
at
least one background texture 39 or 51 (also referred to as local texture)
created by
elevated warps 44, shutes 45, or other elevated elements in a woven sculpted
fabric 30. For example, a first background region 38 of such a woven sculpted
26
CA 02463892 2004-04-16
WO 03/040470 PCT/US02/33074
fabric 30 may have a first background texture 39 corresponding to a series of
elevated and depressed regions 40 and 42 having a characteristic depth. The
characteristic depth can be the elevation difference between the elevated and
depressed strands 41 and 43 that define the first background texture 39, or
the
elevation difference between raised elements, such as the elevated warps 44
and
shutes 45, and the upper plane 32 which sits on the topmost layer of CD shutes
33
of the woven sculpted fabric 30 (shown in Figure 4). The shutes 45 can be part
of
a base layer 31 of the woven sculpted fabric 30, which can be a load-bearing
base
layer 31 (the base layer in the woven sculpted fabric 30 of Figure 2 is
depicted as
the layer 31 of the shutes 45, but can comprise additional woven or interwoven
layers, or can comprise nonwoven layers or composite materials).
Figure 9 is a computer generated graphic of a woven sculpted fabric 30
according to the present invention depicting the shutes 45 and only the
relatively
elevated portions of the warps 44 on a black background for clarity. The most
elevated portions of the warps 44, namely, the floats 60 that pass over two or
more
of the shutes 45, are depicted in white. Short intermediate knuckles 59, which
are
portions of the warps 44 that pass over a single shute 45, are more tightly
pulled
into the woven sculpted fabric 30 and protrude relatively less. To indicate
the
relatively lesser height of the intermediate knuckles 59, the intermediate
knuckles
59 are depicted in gray, as are the shutes 45. In the center of the graphic
lies a
first background region 38 having first elevated regions 40 (machine direction
floats 60) separated from one another by the first depressed regions 41
comprising
intermediate knuckles 59, shutes 45, and sinkers 61 (not shown). As a warp 44
having a first elevated region 40 passes through the transition region 62a and
enters the second background region 50, it descends into the woven sculpted
fabric 30 and at least part of the warp 44 in the second background region 50
becomes a second depressed region 53. Likewise, the warps 44 that form a
second elevated region 52 in the second background region 50 become depressed
after passing through the transition region 62a such that at least part of
such warps
44 now form the first depressed regions 41.
27
CA 02463892 2004-04-16
WO 03/040470 PCT/US02/33074
A second transition region 62b is shown in Figure 9, although in this case it
is part of repeating elements substantially identical to portions of the first
transition
region 62a. In other embodiments, the woven sculpted fabric 30 can have a
complex pattern such that a basic repeating unit has a plurality of background
regions (e.g., three or more distinct regions) and a plurality of transition
regions 62.
Tissue Description
A second background region 50 of the woven sculpted fabric 30 may have a
second background texture 51 with a similar or different characteristic depth
compared to the first background texture 39 of the first background region 38.
The
first and second background regions 38 and 50 are separated by a transition
region 62 which forms a visually noticeable border 63 between the first and
second
background regions 38 and 50 and which provides a surface structure molding
the
wet tissue web 15 to a different depth or pattern than is possible in the
first and
second background regions 38 and 50. The transition region 62 created is
preferably oriented at an angle to the warp or shute directions. Thus, a wet
tissue
web 15 molded against the woven sculpted fabric 62 is provided with a
distinctive
texture corresponding to the first and/or second background textures 39 and/or
51
. and substantially continuous curvilinear decorative elements corresponding
to the
transition region 62, which can stand out from the surrounding first and
second
background texture regions 39 and 51 of the first and second background
regions
38 and 50 of the wet tissue web 15 by virtue of having a different elevation
(higher
or lower as well as equal) or a visually distinctive area of interruption
between the
first and second background texture regions 39 and 51 of the first and second
background regions 38 and 50, respectively.
In one embodiment, the transition region 62 provides a surface structure
wherein the wet tissue web 15 is molded to a greater depth than is possible in
the
first and second background regions 38 and 50. Thus, a wet tissue web 15
molded against the woven sculpted fabric 30 is provided with greater
indentation
(higher surface depth) in the transition region 62 than in the first and
second
background regions 38 and 50.
28
CA 02463892 2004-04-16
WO 03/040470 PCT/US02/33074
In other embodiments, the transition region 62 can have a surface depth
that is substantially the same as the surface depth of either the first or
second
background regions 38 and 50, or that is between the surface depths of the
first
and second background regions 38 and 50 (an intermediate surface depth), or
that
is within plus or minus 50% of the average surface depth of the first and
second
background regions 38 and 50, or more specifically within plus or minus 20% of
the
average surface depth of the first and second background regions 38 and 50.
When the surface depth of the transition region 62 is not greater than that of
the first and second background regions 38 and 50, the curvilinear decorative
elements corresponding to the transition region 62 imparted to the wet tissue
web
by molding against the transition region 62 is at least partially due to the
interruption in the curvilinear decorative elements provided by the first and
second
15 background regions 38 and 50 which creates a visible border 63 or marking
extending along the transition region 62. The curvilinear decorative elements
imparted to the wet tissue web 15 in the transition region 62 may simply be
the
result of a distinctive texture interrupting the first and second background
regions
38 and 50.
In one embodiment of the present invention, the first and second
background regions 38 and 50 both have substantially parallel woven first and
second elevated strands 41 and 53, respectively, with a dominant direction
(e.g.,
machine direction, cross-machine direction, or an angle therebetween), wherein
first background texture 39 in the first background region 38 is offset from
the
second background texture 51 in the second background region 50 such that as
one moves horizontally (parallel to the plane of the woven sculpted fabric 30)
along
a woven first elevated strand 41 in the first background region 38 toward the
transition region 62 and continues in a straight line into the second
background
region 50, a second depressed region 54 rather than a second elevated strand
58
is encountered in the second background region 50.
29
CA 02463892 2004-04-16
WO 03/040470 PCT/US02/33074
Likewise, a first depressed region 42 that approaches the transition region
62 in the first background region 38 becomes a second elevated strand 53 in
the
second background region 50. When the woven sculpted fabric 30 is comprised of
woven warps 44 (machine direction strands) and shutes 45 (cross-machine
direction strands), the first and second elevated regions 40 and 52 are floats
60
rising above the topmost layer of CD shutes 33 of the woven sculpted fabric 30
and crossing over a plurality of roughly orthogonal strands before descending
into
the topmost layer of CD shutes 33 of the woven sculpted fabric 30 again.
For example, a warp 44 rising above the topmost layer of CD shutes 33 of
the woven sculpted fabric 30 can pass over 4 or more shutes 45 before
descending into the woven sculpted fabric 30 again, such as at least any of
the
following number of shutes 45: 5, 6, 7, 8, 9, 10, 15, 20, and 30. While the
warp 44
in question is above the topmost layer of CD shutes 33, the immediately
adjacent
warps 44 are generally lower, passing into the topmost layer of CD shutes 33.
As
the warp 44 in question then sinks into the topmost layer of CD shutes 33, the
adjacent warps 44 rise and extend over a plurality of shutes 45. Generally,
over
much of the woven sculpted fabric 30, four adjacent warps 44 arbitrarily
numbered
in order 1, 2, 3, and 4, can have warps 44 1 and 3 rise above the topmost
layer of
CD shutes 33 to descend below the topmost layer of CD shutes 33 after a
distance, at which point warps 44 2 and 4 are initially primarily below the
surface of
the warps 44 in the topmost layer of CD shutes 33 but rise in the region where
warps 44 1 and 3 descend.
In another embodiment of the present invention, the first and second
background regions 38 and 50 both have substantially parallel woven first and
second elevated strands 41 and 53 with a dominant direction (e.g., machine
direction, cross-machine direction, or an angle therebetween), wherein first
background texture 39 in the first background region 38 is offset from the
second
background texture 51 in the second background region 50 such that as one
moves horizontally (parallel to the plane of the woven sculpted fabric 30)
along a
woven first elevated strand 41 in the first background region 38 toward the
transition region 62 and continues in a straight line into the second
background
CA 02463892 2004-04-16
WO 03/040470 PCT/US02/33074
region 50, a woven second elevated strand 53 rather than a second depressed
region 54 is encountered in the second background region 50. Likewise, a first
depressed region 42 that approaches the transition region 62 in the first
background region 38 becomes a second depressed region 54 in the second
background region 50.
In another embodiment of the present invention, the woven sculpted fabric
30 is a woven fabric having a tissue contacting surface including at least two
groups of strands, a first group of strands 46 extending in a first direction,
and a
second group of strands 58 extending in a second direction which can be
substantially orthogonal to the first direction, wherein the first group of
strands 46
provides elevated floats 60 defining a three-dimensional fabric surface
comprising:
a) a first background region 38 comprising a plurality of substantially
parallel first elevated strands 41 separated by substantially parallel first
depressed strands 43, wherein each first depressed strand 43 is
surrounded by an adjacent first elevated strand 41 on each side, and
each first elevated strand 41 is surrounded by an adjacent first
depressed strand 43 on each side;
b) a second background region 50 comprising a plurality of substantially
parallel second elevated strands 53 separated by substantially parallel
second depressed strands 55, wherein each second depressed strand
55 is surrounded by an adjacent second elevated strand 53 on each
side, and each second elevated strand 53 is surrounded by an adjacent
second depressed strand 55 on each side; and,
c) a transition region 62 between the first and second background regions
38 and 50, wherein the first and second elevated strands 41 and 53 of
both the first and second background regions 38 and 50 descend to
become, respectively, the first and second depressed strands 43 and 55
of the second and first background regions 38 and 50.
In the transition region 62, the first group of strands 46 may overlap with a
number
of strands in the second group of strands 58, such as any of the following: 1,
2, 3,
4, 5, 10, two or more, two or less, and three or less.
31
CA 02463892 2004-04-16
WO 03/040470 PCT/US02/33074
Each pair of first elevated floats 41 is separated by a distance of at least
about 0.3 mm. In other embodiments, each pair of first elevated floats 41 is
separated by a distance ranging between about 0.3 mm to about 25 mm, more
specifically between about 0.3 mm to about 8 mm, more specifically between
about
0.3 mm to about 3 mm, more specifically between about 0.3 mm to about 1 mm,
more specifically between about 0.8 mm to about 1 mm. Each pair of second
elevated floats 53 is separated by a distance of at least about 0.3 mm. In
other
embodiments, each pair of second elevated floats 53 is separated by a distance
ranging between about 0.3 mm to about 25 mm, more specifically between about
0.3 mm to about 8 mm, more specifically between about 0.3 mm to about 3 mm,
more specifically between about 0.3 mm to about 1 mm, more specifically
between
about 0.8 mm to about 1 mm.
The resulting surface topography of the dried tissue web 23 may comprise a
primary pattern 64 having a regular repeating unit cell that can be a
parallelogram
with sides between 2 and 180 mm in length. For wetlaid materials, these three-
dimensional basesheet structures can be created by molding the wet tissue web
15 against the woven sculpted fabrics 30 of the present invention, typically
with a
pneumatic pressure differential, followed by drying. In this manner, the three-
dimensional structure of the dried tissue web 23 is more likely to be retained
upon
wetting of the dried tissue web 23, helping to provide high wet resiliency.
In addition to the regular geometrical patterns (resulting from the first and
second background texture regions 39 and 51, and the curvilinear decorative
elements of the primary pattern 64, imparted by the woven sculpted fabrics 30
and
other typical fabrics used in creating a dried tissue web 23, additional fine
structure, with an in-plane length scale less than about 1 mm, can be present
in
the dried tissue web 23. Such a fine structure may stem from microfolds
created
during differential velocity transfer of the wet tissue web 15 from one fabric
or wire
to another fabric or wire prior to drying. Some of the absorbent tissue
products 27
of the present invention, for example, appear to have a fine structure with a
fine
surface depth of 0.1 mm or greater, and sometimes 0.2 mm or greater, when
height profiles are measured using a commercial moire interferometer system.
32
CA 02463892 2004-04-16
WO 03/040470 PCT/US02/33074
These fine peaks have a typical half-width less than 1 mm. The fine structure
from
differential velocity transfer and other treatments may be useful in providing
additional softness, flexibility, and bulk. Measurement of the fine surface
structures and the geometrical patterns is described below.
CADEYES MEASUREMENTS
One measure of the degree of molding created in a wet tissue web 15 using
the woven sculpted fabrics 30 of the present invention involves the concept of
optically measured surface depth. As used herein, "surface depth" refers to
the
characteristic height of peaks relative to surrounding valleys in a portion of
a
structure such as a wet tissue web 15 or putty impression of a woven sculpted
fabric 30. In many embodiments of the present invention, topographical
measurements along a particular line will reveal many valleys having a
relatively
uniform elevation, with peaks of different heights corresponding to the first
and
second background texture regions 39 and 51 and a more prominent primary
pattern 64. The characteristic elevation relative to a baseline defined by
surrounding valleys is the surface depth of a particular portion of the
structure
being measured. For example, the surface depth of a first or second background
texture regions 39 or 51 of a wet tissue web 15 may be 0.4 mm or less, while
the
surface depth of the primary pattern 66 may be 0.5 mm or greater, allowing the
primary pattern 64 to stand out from the first or second background texture
regions
39 or 51.
The wet tissue webs 15 created in the present invention possess three-
dimensional structures and can have a Surface Depth for the first or second
background texture regions 39 or 51 and/or primary pattern 64 of about 0.15
mm.
or greater, more specifically about 0.3 mm. or greater, still more
specifically about
0.4 mm. or greater, still more specifically about 0.5 mm. or greater, and most
specifically from about 0.4 to about 0.8 mm. The primary pattern 64 may have a
surface depth that is greater than the surface depth of the first or second
background texture regions 39 or 51 by at least about 10%, more specifically
at
least about 25%, more specifically still at least about 50%, and most
specifically at
33
CA 02463892 2009-09-09
least about 80%, with an exemplary range of from about 30% to about 100%.
Obviously, elevated molded structures on one side of a wet tissue web 15 can
correspond to depressed molded structures on the opposite of the wet tissue
web
15. The side of the wet tissue web 15 giving the highest Surface Depth for the
primary pattern 64 generally is the side that should be measured.
A suitable method for measurement of Surface Depth is moire
interferometry, which permits accurate measurement without deformation of the
surface of the wet tissue webs 15. For reference to the wet tissue webs 15 of
the
present invention, the surface topography of the wet tissue webs 15 should be
measured using a computer-controlled white-light field-shifted moire
interferometer
with about a 38 mm field of view. The principles of a useful implementation of
such
a system are described in Bieman et al. (L. Bieman, K. Harding, and A.
Boehnlein,
"Absolute Measurement Using Field-Shifted Moire," SPIE Optical Conference
Proceedings, Vol. 1614, pp. 259-264, 1991). A suitable commercial instrument
for
moire interferometry is the CADEYES interferometer produced by Integral
Vision
(Farmington Hills, Michigan), constructed for a 38-mm field-of-view (a field
of view
within the range of 37 to 39.5 mm is adequate). The CADEYES system uses
white light which is projected through a grid to project fine black lines onto
the
sample surface. The surface is viewed through a similar grid, creating moire
fringes that are viewed by a CCD camera. Suitable lenses and a stepper motor
adjust the optical configuration for field shifting (a technique described
below). A
video processor sends captured fringe images to a PC computer for processing,
allowing details of surface height to be back-calculated from the fringe
patterns
viewed by the video camera.
In the CADEYES moire interferometry system, each pixel in the CCD video
image is said to belong to a moire fringe that is associated with a particular
height
range. The method of field-shifting, as described by Bieman et al. (L. Bieman,
K.
Harding, and A. Boehnlein, "Absolute Measurement Using Field-Shifted Moire,"
SPIE Optical Conference Proceedings, Vol. 1614, pp. 259-264, 1991) and as
originally patented by Boehnlein (U.S. Patent No. 5,069,548), is used to
identify
the fringe number for each point in the video
34
CA 02463892 2004-04-16
WO 03/040470 PCT/US02/33074
image (indicating which fringe a point belongs). The fringe number is needed
to
determine the absolute height at the measurement point relative to a reference
plane. A field-shifting technique (sometimes termed phase-shifting in the art)
is
also used for sub-fringe analysis (accurate determination of the height of the
measurement point within the height range occupied by its fringe). These field-
shifting methods coupled with a camera-based interferometry approach allows
accurate and rapid absolute height measurement, permitting measurement to be
made in spite of possible height discontinuities in the surface. The technique
allows absolute height of each of the roughly 250,000 discrete points (pixels)
on
the sample surface to be obtained, if suitable optics, video hardware, data
acquisition equipment, and software are used that incorporates the principles
of
moire interferometry with field-shifting. Each point measured has a resolution
of
approximately 1.5 microns in its height measurement.
The computerized interferometer system is used to acquire topographical
data and then to generate a grayscale image of the topographical data, said
image
to be hereinafter called "the height map". The height map is displayed on a
computer monitor, typically in 256 shades of gray and is quantitatively based
on
the topographical data obtained for the sample being measured. The resulting
height map for the 38-mm square measurement area should contain approximately
250,000 data points corresponding to approximately 500 pixels in both the
horizontal and vertical directions of the displayed height map. The pixel
dimensions of the height map are based on a 512 x 512 CCD camera which
provides images of moire patterns on the sample which can be analyzed by
computer software. Each pixel in the height map represents a height
measurement at the corresponding x- and y-location on the sample. In the
recommended system, each pixel has a width of approximately 70 microns, i.e.
represents a region on the sample surface about 70 microns long in both
orthogonal in-plane directions). This level of resolution prevents single
fibers
projecting above the surface from having a significant effect on the surface
height
measurement. The z-direction height measurement must have a nominal accuracy
of less than 2 microns and a z-direction range of at least 1.5 mm. (For
further
background on the measurement method, see the CADEYES Product Guide,
CA 02463892 2004-04-16
WO 03/040470 PCT/US02/33074
Integral Vision, Farmington Hills, MI, 1994, or other CADEYES manuals and
publications of Integral Vision, formerly known as Medar, Inc.).
The CADEYES system can measure up to 8 moire fringes, with each fringe
being divided into 256 depth counts (sub-fringe height increments, the
smallest
resolvable height difference). There will be 2048 height counts over the
measurement range. This determines the total z-direction range, which is
approximately 3 mm in the 38-mm field-of-view instrument. If the height
variation
in the field of view covers more than eight fringes, a wrap-around effect
occurs, in
which the ninth fringe is labeled as if it were the first fringe and the tenth
fringe is
labeled as the second, etc. In other words, the measured height will be
shifted by
2048 depth counts. Accurate measurement is limited to the main field of 8
fringes.
The moire interferometer system, once installed and factory calibrated to
provide the accuracy and z-direction range stated above, can provide accurate
topographical data for materials such as paper towels. (Those skilled in the
art
may confirm the accuracy of factory calibration by performing measurements on
surfaces with known dimensions). Tests are performed in a room under Tappi
conditions (23 C, 50% relative humidity). The sample must be placed flat on a
surface lying aligned or nearly aligned with the measurement plane of the
instrument and should be at such a height that both the lowest and highest
regions
of interest are within the measurement region of the instrument.
Once properly placed, data acquisition is initiated using Integral Visions's
PC software and a height map of 250,000 data points is acquired and displayed,
typically within 30 seconds from the time data acquisition was initiated.
(Using the
CADEYES system, the "contrast threshold level" for noise rejection is set to
1,
providing some noise rejection without excessive rejection of data points).
Data
reduction and display are achieved using CADEYES software for PCs, which
incorporates a customizable interface based on Microsoft Visual Basic
Professional for Windows (version 3.0). The Visual Basic interface allows
users to
add custom analysis tools.
36
CA 02463892 2004-04-16
WO 03/040470 PCT/US02/33074
The height map of the topographical data can then be used by those skilled
in the art to identify characteristic unit cell structures (in the case of
structures
created by fabric patterns; these are typically parallelograms arranged like
tiles to
cover a larger two-dimensional area) and to measure the typical peak to valley
depth of such structures. A simple method of doing this is to extract two-
dimensional height profiles from lines drawn on the topographical height map
which pass through the highest and lowest areas of the unit cells. These
height
profiles can then be analyzed for the peak to valley distance, if the profiles
are
taken from a sheet or portion of the sheet that was lying relatively flat when
measured. To eliminate the effect of occasional optical noise and possible
outliers,
the highest 10% and the lowest 10% of the profile should be excluded, and the
height range of the remaining points is taken as the surface depth.
Technically,
the procedure requires calculating the variable which we term "P10," defined
at the
height difference between the 10% and 90% material lines, with the concept of
material lines being well known in the art, as explained by L. Mummery, in
Surface
Texture Analysis: The Handbook, Hommelwerke GmbH, Muhlhausen, Germany,
1990. In this approach, which will be illustrated with respect to FIGURE 7,
the
surface 70 is viewed as a transition from air 71 to material 72. For a given
profile
73, taken from a flat-lying sheet, the greatest height at which the surface
begins -
the height of the highest peak - is the elevation of the "0% reference line"
74 or the
"0% material line," meaning that 0% of the length of the horizontal line at
that
height is occupied by material 72. Along the horizontal line passing through
the
lowest point of the profile 73, 100% of the line is occupied by material 72,
making
that line the 100% material line" 75. In between the 0% and 100% material
lines
74 and 75 (between the maximum and minimum points of the profile), the
fraction
of horizontal line length occupied by material 72 will increase monotonically
as the
line elevation is decreased. The material ratio curve 76 gives the
relationship
between material fraction along a horizontal line passing through the profile
73 and
the height of the line. The material ratio curve 76 is also the cumulative
height
distribution of a profile 73. (A more accurate term might be "material
fraction
curve").
37
CA 02463892 2004-04-16
WO 03/040470 PCT/US02/33074
Once the material ratio curve 76 is established, one can use it to define a
characteristic peak height of the profile 73. The P10 "typical peak-to-valley
height"
parameter is defined as the difference 77 between the heights of the 10%
material
line 78 and the 90% material line 79. This parameter is relatively robust in
that
outliers or unusual excursions from the typical profile structure have little
influence
on the P10 height. The units of P10 are mm. The Overall Surface Depth of a
material 72 is reported as the P10 surface depth value for profile lines
encompassing the height extremes of the typical unit cell of that surface 70.
"Fine
surface depth" is the P10 value for a profile 73 taken along a plateau region
of the
surface 70 which is relatively uniform in height relative to profiles 73
encompassing
a maxima and minima of the unit cells. Unless otherwise specified,
measurements
are reported for the surface 70 that is the most textured side of the wet
tissue webs
of the present invention, which is typically the side that was in contact with
the
through-drying fabric 19 when air flow is toward the throughdryer 21.
Detailed Description of Figures
FIGURE 10 shows a screen shot 66 of the CADEYES software main
window containing a height map 80 of a putty impression of the woven sculpted
fabric 30 made in accordance with the present invention. The height map 80 was
created with a 35-mm field of view optical head with the CADEYES moire
interferometry system. The putty impression was made using 65 grams of coral-
colored Dow Corning 3179 Dilatant Compound (believed to be the original "Silly
Putty " material) in a conditioned room at 23 C and 50% relative humidity. The
Dilatant Compound was rendered more opaque for better results with moire
interferometry by the addition of 0.8 g of white solids applied by painting
white
Pentel (Torrance, CA) Correction Pen fluid (purchased 1997) on portions of
the
putty, allowing the fluid to dry, and then blending the painted portions to
uniformly
disperse the white solids (believed to be primarily titanium dioxide)
throughout the
putty. This action was repeated approximately a dozen times until a mass
increase of 0.8 grams was obtained. The putty was rolled into a flat, smooth 9-
cm
wide disk, about 0.7 cm thick, which was placed over the woven sculpted fabric
30.
A stiff, clear plastic block with dimensions 22 cm x 9 cm x 1.3 cm, having a
mass of
38
CA 02463892 2004-04-16
WO 03/040470 PCT/US02/33074
408 g, was centered over the putty disk and a 3.73 kg brass cylinder of 6.3-cm
diameter was placed on the plastic block, also centered over the putty disk,
and
allowed to reside on the block for 8 seconds to drive the putty into the woven
sculpted fabric 30. After 8 seconds, the brass cylinder and plastic block were
removed, and the putty was gently lifted from the woven sculpted fabric 30.
The
molded side of the putty was turned face up and placed under a 35-mm field-of-
view optical head of the CADEYES device for measurement.
In the height map 80 in FIGURE 10, the horizontal bands of dark and light
areas correspond to elevated and depressed regions. In a first background
region
38', there are first elevated regions 40' and first depressed regions 42'
created by
molding against the first depressed regions 42 and the first elevated regions
40,
respectively, in a first background region 38 of a woven sculpted fabric 30
(not
shown). In a second background region 50', there are second elevated regions
52'
and second depressed regions 54' corresponding to the second depressed regions
52 and the second elevated regions 54 in a second background region 50 of a
woven sculpted fabric 30 (not shown). Between the first background region 38'
and the second background region 50' is a transition region 62' which is
elevated,
corresponding to a depressed transition region 62 of a woven sculpted fabric
30
(not shown). The elevated curvilinear decorative elements forming a transition
region 62' on the molded surface define a repeating elevated primary pattern
64 in
which the repeating unit can be described as a diamond with concave sides. The
junctions of the opposing MD strands in the transition region 62 of a woven
sculpted fabric 30 (not shown) form pockets or segments of different plane
height
which visually connect to form curvilinear decorative elements making
aesthetically
pleasing design highlights in materials molded thereon.
The height map 80 contains some optical noise distorting the image along
the left border of the height map 80, and occasional spikes from optical noise
in
other portions of the image. Nevertheless, the structure of the putty
impression is
clearly discernible. The profile display 81 below the height map 80 shows the
topography in the form of a profile 82 taken along a vertical profile line 87.
The
topographical features of the profile 82 include peaks and valleys
corresponding to
39
CA 02463892 2004-04-16
WO 03/040470 PCT/US02/33074
first and second elevated regions 40' and 52' (the peaks) and first and second
depressed regions 42' and 54' (the valleys), respectively, and the elevated
transition regions 62' that form the repeating curvilinear primary pattern 64.
FIGURE 11 shows a screen shot 66 of the CADEYES software main
window containing a height map 80 of a dried tissue web 23 molded on a woven
sculpted fabric 30, using a process substantially the same as the one
described in
the Example. The height map 80 is for a zoomed-in region covering a single
unit
cell of the curvilinear primary pattern 64. The face-up side of the dried
tissue web
23 - i.e., the surface being measured - is the side that was remote from the
woven
sculpted fabric 30 during through air drying, termed the "air side" of the
dried tissue
web 23, as opposed to the opposing "fabric side" (not shown) that was in
contact
with the woven sculpted fabric 30 during through drying. Here, through drying
on
the woven sculpted fabric 30 imparted a molded texture that resembles the
inverse
of the texture in FIGURE 10. Thus, in the first background region 38', there
are
first elevated regions 40' and first depressed regions 42' created by molding
of the
fabric side of the tissue against first elevated regions 40 and first
depressed
regions 42, respectively, in a first background region 38 of a woven sculpted
fabric
30 (not shown). In the second background region 50', there are second elevated
regions 52' and second depressed regions 54' corresponding to second elevated
regions 52 and second depressed regions 54 in a second background region 50 of
a woven sculpted fabric 30 (not shown). Between the first background region
38'
and the second background region 50' is a transition region 62' which is
depressed
on the side of the dried tissue web 23 measured (the air side), but elevated
on the
opposing side (the fabric side), corresponding to a depressed transition
region 62
of a woven sculpted fabric 30 (not shown). The depressed curvilinear
decorative
elements forming the transition region 62' on the molded surface of the dried
tissue
web 23 define a repeating elevated primary pattern 64 in which the repeating
unit
can be described as a diamond with concave sides. The junctions of the
opposing
MD strands in the transition region 62 of a woven sculpted fabric 30 (not
shown)
form pockets or segments of different plane height which visually connect to
form
curvilinear decorative elements making aesthetically pleasing design
highlights in
CA 02463892 2004-04-16
WO 03/040470 PCT/US02/33074
materials molded thereon. Thus, the depressed transition regions 62' form a
repeating curvilinear primary pattern 64.
The profile 82 along a vertical profile line 87 on the height map 80 is shown
in the profile display 81 below the height map 80, in which two depressed
transition
regions 62' can be seen in the midst of the otherwise regular peaks and
valleys,
wherein the peaks correspond to first and second elevated regions 40' and 52',
respectively, and the valleys correspond to first and second depressed regions
42'
and 54', respectively.
FIGURE 12 depicts a section of the height map 80 of FIGURE 10 further
displaying a profile 82 along a vertical profile line 87 on the height map 80.
The
profile 82 shown in a vertically oriented profile display 81 comprises peaks
and
valleys, wherein the peaks correspond to first and second elevated regions 40'
and
52', respectively, and the valleys correspond to first and second depressed
regions
42' and 54', respectively, with transition regions 62' also visible as
relatively
elevated features. A characteristic height of the peaks away from the
transition
regions 62' is about 0.54 mm, while the transition regions 62' display higher
and
broader peaks, with heights of about 0.75 mm.
FIGURE 13 shows a section of a height map 80 for the dried tissue web 23
throughdried on the woven sculpted fabric 30 used in FIGURE 10, but with the
sculpted fabric face up of the dried tissue web 23 (the side that was in
contact with
the woven sculpted fabric 30 during through drying). The profile display 81
shows
a profile 82 measured along the vertical profile line 87 drawn across the
height
map 80 corresponding to the cross-machine direction of the tissue web 23. The
profile 82 has peaks corresponding to first and second elevated regions 40'
and
52', respectively, and the valleys corresponding to first and second depressed
regions 42' and 54', respectively, with transition regions 62' also visible as
relatively elevated features. The profile 82 shows that the broad peaks in the
transition region 62' have a greater height than the peaks away from the
transition
region 62'. Relative to the valleys (the first depressed regions 42') in the
first
background region 38, the peaks of the transition region 62' show a height of
about
41
CA 02463892 2004-04-16
WO 03/040470 PCT/US02/33074
0.55 mm. In the first background region 38', the peaks (the first elevated
regions
40') have about half the height of the transition region 62' (e.g., a height
of about
0.25 mm).
FIGURE 14 shows a portion of the height map 80 of FIGURE 11 with an
accompanying profile display 81 showing a profile 82 taken along the
horizontal
(machine direction) profile line 87 drawn on the height map 80. The profile 82
extends along the second elevated regions 52' outside of the first background
region 38' and along the first depressed region 42' within the first
background
region 38'. A height difference Z of about 0.5 mm is spanned from the higher
portion of the second elevated region 52' to the depressed transition region
62'.
FIGURE 15 is similar to FIGURE 14 except that a different profile line 87 is
used, resulting in a different displayed profile 82 in the profile display 81.
The
profile line 87 runs substantially in the machine direction, passing along a
first
depressed region 42' in the first background region 38', then passing through
a
transition region 62' and then along a second elevated region 52' in the
second
background region 50'. A vertical height difference Z of about 0.42 mm is
spanned
from the second elevated region 52' to the first depressed region 42'. The
transition region 62 is about 0.2 mm lower than the first depressed region 42'
on
this view of the fabric side of a molded dried tissue web 23 that has been
throughdried on a woven sculpted fabric 30 according to the present invention.
FIGURE 16 shows a height map 80 of a putty impression of another woven
sculpted fabric 30 made in accordance to the present invention, with a profile
display 81 showing a profile 82 measured along a profile line 87 that spans a
first
background region 38 and a second background region 50' with a transition
region
62' therebetween. Based on the profile 82, the transition region 62' differs
from the
first elevated region 40' by over than 0.4 mm, and differs from the second
depressed region 54' by over 0.8 mm (the height Z). Here the transition region
62'
forms a curvilinear decorative element with arcuate sides that entirely bound
a
closed area, though a portion of the closed area is not shown . Such closed
areas
can have a maximum diameter (maximum length of a line that can fit within the
42
CA 02463892 2004-04-16
WO 03/040470 PCT/US02/33074
closed boundary while in the plane of the woven sculpted fabric 30) of any of
the
following: 5 mm or greater; 10 mm or greater; 25 mm or greater; 50 mm or
greater; and, 180 mm or greater, with an exemplary range of from about 8 mm to
about 75 mm.
FIGURE 17 shows a height map 80 of a putty impression of yet another
woven sculpted fabric 30 made in accordance to the present invention, wherein
the
transition regions 62' form parallel lines at an angle relative to the
substantially
unidirectional warps 44 of the woven sculpted fabric 30. In the profile
display 81, a
profile 82 is shown corresponding to the surface height along the profile line
87 is
substantially oriented in the cross-machine direction. The profile line 87
passes
over second elevated regions 52' and second depressed regions 54' in the
second
background region 50', then passes across a transition region 62' and then
over
first elevated regions 40' and second depressed regions 42'. Here each
transition
region 62' is substantially straight and forms a long line parallel to other
transition
regions 62'. In general, when a transition region 62' defines a line, the line
can be
at any angle to the machine direction (direction of the warps 44), such as an
absolute angle of 20 degrees or more, more specifically from about 20 degrees
to
less than 90 degrees, most specifically from about 30 degree to about 65
degrees.
The height difference Z between the most elevated portion of the transition
region
62' along the profile 82 and the first depressed region of the first
background
region 38 is about 0.6 mm.
FIGURE 18 shows a schematic of a composite sculpted fabric 100
comprising a base 102 with nonwoven raised elements 108 attached thereon.
Together, the base 102 and the raised elements 108 form an upper porous
member 105 in the composite sculpted fabric 100 which can comprise additional
layers (not shown) beneath the base 102. As discussed hereafter, the sculpted
fabric 100 need not be composite, but can be formed from a single material,
though composite materials such as nonwoven elements joined to a woven fabric
can be useful in providing strength or other properties in some embodiments.
When used as a throughdrying fabric, the sculpted fabric 100 (like other
fabrics of
the present invention intended for use in throughdrying) generally should be
43
CA 02463892 2004-04-16
WO 03/040470 PCT/US02/33074
permeable enough to permit through drying under a gas pressure differential.
For
example, the porous upper member 105 or the entire sculpted fabric 100 can
have
a Frazier air permeability of about 250 standard cubic feet per square foot
per
minute (about 76 standard cubic meters per square meter per minute) or higher.
When used as an imprinting fabric or other non-throughdrying fabric, the
sculpted
fabric 100 can, in some embodiments, have a lower permeability, such as a
Frazier
air permeability of about 150 standard cubic feet per square foot per minute
(about
46 standard cubic meters per square meter per minute) or less.
The raised elements 108 as shown are aligned substantially in the machine
direction 120 (orthogonal to the cross-machine direction 118) in the portion
of the
composite sculpted fabric 100 shown, though the raised elements 108 could be
oriented in any direction and could be oriented in a plurality of directions.
All
embodiments shown herein for raised elements 108 oriented primarily in the
machine direction can be adapted equally well to raised elements 108 oriented
in
the cross-machine direction, for example, or for multiple textured regions
having
raised elements 108 oriented in a variety of directions. The raised elements
108
as depicted have a height H (relative to the base 102), a length L, and a
width W.
The height H can be greater than about 0.1 mm, such as from about 0.2 mm to
about 5 mm, more specifically from about 0.3 mm to about 1.5 mm, and most
specifically from about 0.3 mm to about 0.7 mm. The length L can be greater
than
2 mm, such as about 3 mm or greater, or from about 4 mm to about 25 mm. The
width W can be greater than about 0.1 mm such as from about 0.2 mm to about 2
mm, more specifically from about 0.3 mm to about 1 mm.
In a first background region 38, the machine-direction oriented, elongated
raised elements 108 act as floats 60 that serve as first elevated regions 40,
with
first depressed regions 42 therebetween that reside substantially on the
underlying
base 102, which can be a woven fabric. In a second background region 50, the
raised elements 108 act as floats 60 that serve as second elevated regions 52,
with second depressed regions 54 therebetween that reside substantially on the
underlying base 102.
44
CA 02463892 2004-04-16
WO 03/040470 PCT/US02/33074
A transition region 62 is formed when a first elevated region 40 from a first
background region 38 of the composite sculpted fabric 100 has an end 122 in
the
vicinity of the beginning 124 of two adjacent second elevated regions 52 in a
second background region 50 of the composite sculpted fabric 100, with the end
122 disposed in the cross-machine direction 118 at a position intermediate to
the
respective cross-machine direction locations of the two adjacent second
elevated
regions 52, wherein the end 122 of raised elements 108 (either a first
elevated
region 40 or second elevated region 52) refers to the termination of the
raised
element 108 encountered while moving along the composite sculpted fabric 100
in
the machine direction 120, and the beginning 124 of a raised element 108
refers to
the initial portion of the raised element 108 encountered while moving along
the
composite sculpted fabric 100 in the same direction. Were the raised elements
108 oriented in another direction, the direction of orientation for each
raised
element 108 is the direction one moves along in identifying ends 122 and
beginnings 124 of raised elements 108 in order to identify their relationship
in a
consistent manner. Generally, features of the raised elements 108 can be
successfully identified when either of the two possible directions (forward
and
reverse, for example) along the raised element 108 is defined as the positive
direction for travel.
The transition region 62 separates the first and second background regions
38 and 50. The shifting of the cross-machine directional locations of the
raised
elements 108 in the transition region 62 creates a break in the patterns of
the first
and second background regions 38 and 50, contributing to the visual
distinctiveness of the portion of the wet tissue web 15 molded against the
transition
region 62 of the composite sculpted fabric 100 relative to the portion of the
wet
tissue web 15 molded against the surrounding first and second background
regions 38 and 50. In the embodiment shown in FIGURE 18, the transition region
62 is also characterized by a gap width G which is the distance in the machine
direction 120 (or, more generally, whatever direction the raised elements 108
are
predominantly oriented in) between an end 122 of a raised element 108 in the
first
background region 38 and the nearest beginning 124 of a raised element 108 in
the second background region 50. The gap width G can vary in the transition
CA 02463892 2004-04-16
WO 03/040470 PCT/US02/33074
region 62 or can be substantially constant. For positive gap widths G such as
is
shown in FIGURE 18, G can vary, by way of example, from about 0 to about 20
mm, such as from about 0.5 mm to about 8 mm, or from about 1 mm to about 3
mm.
A base 102 can be a woven or nonwoven fabric, or a composite of woven
and nonwoven elements or layers. The base 102 generally serves to hold the
raised elements 108 in place, and can provide strength and integrity to the
entire
composite sculpted fabric 100, which can comprise additional layers (not
shown)
such as load-bearing layers beneath the base 102. The base 102 can also be
made from the same material as the raised elements 108, and may be unitary
with
the raised elements 108, providing a unitary upper porous member 105, in
contrast
to the integral composite upper porous member 105 shown in Figure 18, where
raised elements 108 have been attached to a separate base 102 rather than
being
formed therewith or therefrom.
In the case of a unitary upper porous member 105, the upper porous
member 105 can be entirely nonwoven, as can be the entire sculpted fabric 100.
For example, the upper porous member 105 can be formed from a single, unitary
porous web such as a fibrous nonwoven layer of a polymeric material formed by
any known process, including materials such as an airlaid web, a spunbond
fabric,
a meltblown fabric, a bonded carded web, an electrospun fabric, or
combinations
thereof. The porous web can be sculpted according to the principles of the
present
invention to impart raised elements 108 above a base 102. Methods of sculpting
can include embossing to densify selected regions to form a base 108 serving
as a
depressed layer unitary with raised elements 108. A variety of operations can
transform an initially substantially uniform porous web into a sculpted upper
porous
member 105 (or sculpted fabric 100) according to the present invention. Such
operations can leave the porous web with substantially the same basis weight
distribution (i.e., no mass is added or subtracted from the porous web during
treatment), as is commonly the case for embossing, stamping, thermal molding,
and the like, or the operation can modify the basis weight of the porous web.
Operations that modify the basis weight of the porous web include mechanical
46
CA 02463892 2004-04-16
WO 03/040470 PCT/US02/33074
drilling, laser drilling, adding molten resin that is subsequently cured to
from raised
elements 108 (the resin can be substantially the same material as the base 102
and if properly bonded, can become substantially unitary with the base 102),
and
the like. A porous web can be molded by any means (cast molding, thermal
molding, etc.) initially or after initial formation into a unitary sculpted
upper porous
member 105.
The embodiment of the base 102 depicted in Figure 18 is a woven base
fabric, with the shutes 45 extending in the cross-machine direction 118 and
the
warps 44 in the machine direction 120. The base 102 can be woven according to
any pattern known in the art and can comprise any materials known in the art.
As
with any woven strands for any fabrics of the present invention, the strands
need
not be circular in cross-section but can be elliptical, flattened,
rectangular, cabled,
oval, semi-oval, rectangular with rounded edges, trapezoidal, parallelograms,
bi-
lobal, multi-lobal, or can have capillary channels. The cross sectional shapes
may
vary along a raised element 108; multiple raised elements with differing cross
sectional shapes may be used on the composite sculpted fabric 100 as desired.
Hollow filaments can also be used.
The raised elements 108 can be integral with the base 102. For example, a
composite sculpted fabric 100 can be formed by photocuring of elevated
resinous
elements which encompass portions of the warps 44 and shutes 45 of the base
102. Photocuring methods can include UV curing, visible light curing, electron
beam curing, gamma radiation curing, radiofrequency curing, microwave curing,
infrared curing, or other known curing methods involving application of
radiation to
cure a resin. Curing can also occur via chemical reaction without the need for
added radiation as in the curing of an epoxy resin, extrusion of an autocuring
polymer such as polyurethane mixture, thermal curing, solidifying of an
applied
hotmelt or molten thermoplastic, sintering of a powder in place on a fabric,
and
application of material to the base 102 in a pattern by known rapid
prototyping
methods or methods of sculpting a fabric. Photocured resin and other polymeric
forms of the raised elements 108 can be attached to a base 102 according to
the
methods in any of the following patents: U.S. Patent No. 5,679,222, issued on
47
CA 02463892 2009-09-09
October 21, 1997 to Rasch et al.; U.S. Patent No. 4,514,345, issued on April
30,
1985 to Johnson et al.; U.S. Patent No. 5,334,289, issued on August 2, 1994 to
Trokhan et al.; U.S. Patent No. 4,528,239, issued on July 9, 1985 to Trokhan;
U.S. Patent No. 4,637,859, issued on January 20, 1987 to Trokhan; commonly
owned U.S. Patent No. 6,120,642, issued on September 19, 2000 to Lindsay and
Burazin.
The raised elements 108 can also be extruded or applied as a foam material to
be
joined to the base 102. Sintering, adhesive bonding, thermal fusing, or other
known methods can be used to attach the raised elements 108 to the base 102,
especially in the formation of a composite sculpted fabric 30 having nonwoven
elements on the tissue contacting side.
U.S. Patent No. 6,120,642, issued on September 19, 2000 to Lindsay and
Burazin, discloses methods of producing sculpted nonwoven throughdrying
fabrics,
and such methods can be applied in general to create composite sculpted
fabrics
100 of the present invention. In one embodiment, such composite sculpted
fabrics
100 comprise an upper porous nonwoven member and an underlying porous
member supporting the upper porous member, wherein the upper porous
nonwoven member comprises a nonwoven material (e.g., a fibrous nonwoven, an
extruded polymeric network, or a foam-based material) that is substantially
deformable. More specifically, the can have a High Pressure Compressive
Compliance (hereinafter defined) greater than 0.05, more specifically greater
than
0.1, and wherein the permeability of the wet molding substrate is sufficient
to
permit an air pressure differential across the wet molding substrate to
effectively
mold said web onto said upper porous nonwoven member to impart a three-
dimensional structure to said web.
As used herein, "High Pressure Compressive Compliance" is a measure of
the deformability of a substantially planar sample of the material having a
basis
weight above 50 gsm compressed by a weighted platen of 3-inches in diameter to
impart mechanical loads of 0.2 psi and then 2.0 psi, measuring the thickness
of the
48
CA 02463892 2009-09-09
sample while under such compressive loads. Subtracting the ratio of thickness
at
2.0 psi to thickness at 0.2 psi from I yields the High Pressure Compressive
Compliance. In other word, High Pressure Compressive Compliance = I -
(thickness at 2.0 psi/thickness at 0.2 psi). The High Pressure Compressive
Compliance can be greater than about 0.05, specifically greater than about
0.15,
more specifically greater than about 0.25, still more specifically greater
than about
0.35, and most specifically between about 0.1 and about 0.5. In another
embodiment, the High Pressure Compressive Compliance can be less than about
0.05, in cases where a less deformable composite sculpted fabric 100 is
desired.
10.
Other known methods can be used to created the composite sculpted
fabrics 100 of the present invention, including laser drilling of a polymeric
web to
impart elevated and depressed regions, ablation, extrusion molding or other
molding operations to impart a three-dimensional structure to a nonwoven
material,
stamping, and the like.
FIGURE 19 depicts another embodiment of a composite sculpted fabric 100
comprising a base 102 with raised elements 108 attached thereon, similar to
that
of FIGURE 18 but with raised elements 108 that taper to a low height H2
relative to
the minimum height H, of the raised element 108. H, can be from about 0.1 mm
to
about 6 mm, ,such as from about 0.2 mm to about 5 mm, more specifically from
about 0.25 mm to about 3 mm, and most specifically from about 0.5 mm to about
1.5 mm. The ratio of H2 to H, can be from about 0.01 to about 0.99, such as
from
about 0.1 to about 0.9, more specifically from about 0.2 to about 0.8, more
specifically still from about 0.3 to about 0.7, and most specifically from
about 0.3 to
about 0.5. The ratio of H2 to H, can also be less than about 0.7, about 0.5,
about
0.4, or about 0.3. Further, the gap width G, the distance between the
beginning
124 and ends 122 of nearby raised elements 108 from adjacent first and second
background regions 38 and 50, is now negative, meaning that the end 122 of one
raised element 108 (a first elevated region 40) in the first background region
38
extends in machine direction 120 past the beginning 124 of the nearest raised
49
CA 02463892 2004-04-16
WO 03/040470 PCT/US02/33074
element 108 (a second elevated region 52) in the second background region 50
such that raised elements 108 overlap in the transition region 62. Two gap
widths
G are shown: G1 and G2 at differing locations in the composite sculpted fabric
100.
Here the gap width G has nonpositive values, such as from about 0 to about -10
mm, or from about -0.5 mm to about -4 mm, or from about -0.5 mm to about -2
mm. However, a given composite sculpted fabric 100 may have portions of the
transition region 62 that have both nonnegative and nonpositive (or positive
and
negative) values of G.
It is recognized that other topographical elements may be present on the
surface of the composite sculpted fabric 100 as long as the ability of the
raised
elements 108 and the transition region 62 to create a visually distinctive
molded
wet tissue web 15 is not compromised. For example, the composite sculpted
fabric 100 could further comprise a plurality of minor raised elements (not
shown)
such as ovals or lines having a height less than, for example, about 50% of
the
minimum height H1 of the raised elements 108.
FIGURES 20 - 22 are schematic diagram views of the raised elements 108
in a composite sculpted fabric 100 depicting alternate forms of the raised
elements
108 according to the present invention. In each case, a set of first raised
elements
108' in a first background region 38 interacts with a set of second raised
elements
108" in a second background region 128 to define a transition region 62
between
the first and second background regions 38 and 50, wherein both the
discontinuity
or shift in the pattern across the transition region 62 as well as an optional
change
in surface topography along the transition region 62 contribute to a
distinctive
visual appearance in the wet tissue web 15 molded against the composite
sculpted
fabric 100, wherein the loci of transition regions 62 define a visible pattern
in the
molded wet tissue web 15 (not shown). In FIGURE 20, the first and second
raised
elements 108' and 108" overlap slightly and define a nonlinear transition
region 62
(i.e., there is a slight curve to it as depicted). Further, parallel, adjacent
raised
elements 108 in either a first or second background region 38 or 50, are
spaced
apart in the cross-machine direction 118 by a distance S slightly greater than
the
width W of a first or second raised element 108' or 108" (e.g., the cross-
machine
CA 02463892 2004-04-16
WO 03/040470 PCT/US02/33074
direction spacing from centerline to centerline of the first and second raised
elements 108' and 108" divided by the width W of the first and second raised
elements 108' and 108" can be greater than about 1, such as from about 1.2 to
about 5, or from about 1.3 to about 4, or from about 1.5 to about 3. In FIGURE
21,
the spacing S is nearly the same as the width W (e.g., the ratio S/W can be
less
than about 1.2, such as about 1.1 or less or about 1.05 or less). Further, the
overlapping first and second raised elements 108' and 108" in the transition
region
62 results in a gap width of about -2W or less (meaning that the ends 122 and
beginnings 124 of the first and second raised elements 108' and 108" overlap
by a
distance of about twice or more the width W of the first and second raised
elements 108' and 108"). In FIGURE 22, the tapered raised elements 108 are
depicted which are otherwise similar to the raised elements 108 as shown in
FIGURE 20.
It will be recognized that the shapes and dimensions of the raised elements
108 need not be similar throughout the composite sculpted fabric 100, but can
differ from any of the first and second background region 38 or 50 to another
or
even within a first or second background region 38 or 50. Thus, there may be a
first background region 38 comprising cured resin first raised elements 108'
having
a shape and dimensions (W, L, H, and S, for example) different from those of
the
second raised elements 108" of the second background region 50.
The raised elements 108 need not be straight, as generally depicted in the
previous figures, but may be curvilinear.
In Figures 23 and 24, a portion of the CADEYES height map 80 referred to
in Figure 17 was used to identify the approximate contour of elevated portions
of
the transition region 62'. The original portion of the height map 80 is shown
in
Figure 23. The modified version is shown in Figure 24. The modified version
was
created by importing the original into the PhotoPlus 7 graphics program for
the
PC by Serif, Inc. (Hudson, New Hampshire). The image was treated with the
"Stretch" command to distribute the color histogram levels more fully across
the
spectrum. Then the most elevated portion of the transition region 62' in the
lower
51
CA 02463892 2004-04-16
WO 03/040470 PCT/US02/33074
half of the image was selected by clicking with the color selection tool set
to a
tolerance value of 12. The selected region of the transition region 62' was
then
filled with white. The same procedure was applied to the transition region 62'
in
the upper left hand corner of the image. The white portions of the transition
region
62' in effect show the shape of the contour encompassing the highest portions
of
the surface, and correspond roughly to the upper contours that could be
imparted
to a dried tissue web 23. The elevated contours have a generally sinuous
shape,
with depresses islands corresponding to the floats 60 or knuckles of the woven
sculpted fabric 30.
Figure 25 depicts a portion of a dried tissue web 23 having a continuous
background texture 146 depicted as a rectilinear grid, though any pattern or
texture
could be used. The dried tissue web 23 further comprises a raised transition
region 62' which has a visually distinctive primary pattern 145. In a local
region
148 of the dried tissue web 23 that spans both sides of a portion of the
transition
region 62', two portions the background texture 146 define, at a local level,
a first
background region 38' and a second background region 50' separated by a
transition region 62' in the dried tissue web 23. Thus, the first background
region
38' and the second background region 50', though separated by the transition
region 62', are nevertheless contiguous outside the local region 148 of the
dried
tissue web 23. In other embodiments, the transition region 62' can define
enclosed first and second background regions 38' and 50', respectively, that
are
contiguous outside of a local region 148 or fully separated first and second
background regions 38' and 50', respectively, that are not contiguous.
Figures 26a - 26e show other embodiments for the arrangement of the
warps 44 in the first background region 38 of a woven sculpted fabric 30
(though
the embodiment shown could equally well be applied to a second background
region 50), taken in cross-sectional views looking into the machine direction.
Figure 26a shows an embodiment related to those of Figures 1a, 1b, and 2,
wherein each single float 60 is separated from the next single float 60 by a
single
sinker 61. However, single strands are not the only way to form the first
elevated
regions 40 (which could equally well be depicted as second elevated regions
52) or
52
CA 02463892 2004-04-16
WO 03/040470 PCT/US02/33074
the first depressed regions 42 (which could equally well be depicted as second
depressed regions 54). Rather, Figures 26b - 26e show embodiments in which at
least one of the first elevated regions 40 or first depressed regions 42
comprises
more than one warp 44. Figure 26b shows single spaced apart single strand
floats 60 forming the first elevated regions 40, interspaced (with respect to
a view
from above the shute 45) by double-strand sinkers 61 (or, equivalently, pairs
of
adjacent single-strand sinkers 61) which define first depressed regions 42
between
each first elevated region 40. In Figure 26c, the first elevated regions 40
each
comprise pairs of warps 44, while the interspaced first depressed regions 42
likewise comprise pairs of warps 44 forming double-strand sinkers 61. In
Figure
26d, double-strand first elevated regions 40 are interspaced by triple-strand
first
depressed regions 42. In Figure 26e, the single-, double-, and triple-strand
groups
form both the first elevated regions 40 and the first depressed regions 42.
Many
other combinations are possible within the scope of the present invention.
Thus,
any machine-direction oriented elevated or depressed region in a woven
sculpted
fabric 30 can comprise a group of any practical number of warps 44, such as
any
number from 1 to 10, and more specifically from 1 to 5. Such groups can
comprise
parallel monofilament strands or multifilament strands such as cabled
filaments.
The Product
FIGURE 28 is a photograph of a woven sculpted fabric 30 embodiment of
the present invention. The decorative pattern repeats in a rectangular unit
cell
which is about 33 mm MD by 38 mm CD in size. The width of the floats 60 is
about
0.70 mm. The adjacent elevated floats 60 are separated by a distance which
averages about 0.89 mm.
In the woven sculpted fabric 30 shown in FIGURE 28, the plane difference
varies in the MD and CD throughout the fabric unit cell. For a given float 60,
the
plane difference tends to be minimal near transition regions 62 and maximal
half
way between two transition regions 62 in the MD. In general, plane difference
is
larger for a long sinker 61 between two long floats 60 than a short sinker 61
53
CA 02463892 2004-04-16
WO 03/040470 PCT/US02/33074
between two short floats 60. This variation in plane difference contributes to
the
aesthetics of the overall decorative pattern.
In the woven sculpted fabric 30 shown in FIGURE 28, the separation
distance between adjacent elevated floats 60 varies in the MD and CD
throughout
the fabric unit cell. This variation in separation distance between adjacent
elevated
floats 60 contributes to the aesthetics of the overall decorative pattern.
FIGURES 29 and 30 shows the air side and the fabric side an absorbent
tissue product 27 made in accordance with the present invention as described
herein in the Example, depicting an interlocking circular primary pattern 64
made
from the distinctive background textures 39 and 51 and curvilinear decorative
elements on the dried tissue web 23 by a plurality of transition areas 62 of
throughdrying fabric 19. The distinctive background textures 39 and 51 and
curvilinear decorative elements, in addition to providing valuable consumer
preferred aesthetics, also unexpectedly improve physical attributes of the
absorbent tissue product 27. The distinctive background textures 39 and 51 and
curvilinear decorative elements in the dried tissue web 23 produced by the
transition areas 62 form multi-axial hinges improving drape and flexibility of
the
finished absorbent tissue product 27. In addition, the distinctive background
textures 39 and 51 and curvilinear decorative elements are resistant to tear
propagation improving tensile strength and machine runnability of the dried
tissue
web 23.
In yet another advantage, the increased uniformity in spacing of the raised
MD floats 60 possible with the present invention, while still producing
distinctive
background textures 39 and 51 and curvilinear line primary patterns 64,
maintains
higher levels of caliper and CD stretch compared to decorative webs produced
by
the fabrics disclosed in U.S. Patent No. 5,429,686. The possibility of
optimizing
the uniformity and spacing of the raised MD floats 60 in the CD direction,
without
regard to spacing considerations in order to form the distinctive background
textures 39 and 51 and curvilinear decorative elements in the dried tissue web
23,
is a significant advantage within the art of papermaking. The present
invention
54
CA 02463892 2004-04-16
WO 03/040470 PCT/US02/33074
allows for improved uniformity of the raised MD floats 60 in the CD direction,
and
the flexibility to form a multitude of complex distinctive background textures
39 and
51 and curvilinear decorative elements in the dried tissue web 23 within a
single
processing step.
EXAMPLE
In order to further illustrate the absorbent tissue products of the present
invention, an uncreped throughdried tissue product was produced using the
method substantially as illustrated in FIGURE 27. More specifically, a blended
single-ply towel basesheet was made in which the fiber furnish comprised about
53% bleached recycled fiber (100% post consumer content), about 31 % bleached
northern softwood Kraft fiber, and about 16% bleached southern softwood Kraft
fiber.
The fiber was pulped for 30 minutes at about 4-5 percent consistency and
diluted to about 2.7 percent consistency after pulping. Kymene 557LX
(commercially available from Hercules in Wilmington, DE) was added to the
fiber at
about 9 kilograms per tonne of pulp.
The headbox net slice opening was about 23 millimeters. The consistency
of the stock fed to the headbox was about 0.26 weight percent.
The resulting wet tissue web 15 (shown in FIGURE 27) was formed on a c-
wrap twin-wire, suction form roll, former with outer forming fabric 12 and
inner
forming fabric 13 being Voith Fabrics 2164-A33 fabrics (commercially available
from Voith Fabrics in Raleigh, NC). The speed of the forming fabrics was about
6.9 meters per second. The newly-formed wet tissue web 15 was then dewatered
to a consistency of about 22-24 percent using vacuum suction from below inner
forming fabric 13 before being transferred to transfer fabric 17, which was
traveling
at about 6.3 meters per second (10 percent rush transfer). The transfer fabric
17
was a Voith Fabrics 2164-A33 fabric. Vacuum shoe 18 pulling about 420
millimeters of mercury vacuum was used to transfer the wet tissue web 15 to
the
transfer fabric 17.
CA 02463892 2004-04-16
WO 03/040470 PCT/US02/33074
The wet tissue web 15 was then transferred to a throughdrying fabric 19
(Voith Fabrics t4803-7, substantially as shown in FIGURE 28). The
throughdrying
fabric 19 was traveling at a speed of about 6.3 meters per second. The wet
tissue
web 15 was carried over a pair of Honeycomb throughdryers (like the
throughdryer
21 and commercially available from Valmet, Inc. (Honeycomb Div.) in Biddeford,
ME) operating at a temperature of about 195 degrees C and dried to final
dryness
of at least about 97 percent consistency. The resulting uncreped dried tissue
web
23 was then tested for physical properties without conditioning.
The fabric side of the resulting towel basesheet may appear substantially as
shown in FIGURE 29. The air side of the resulting towel basesheet may appear
substantially as shown in FIGURE 30.
The resulting dried tissue web 23 had the following properties: Basis
Weight, 42 grams per square meter; CD Stretch, 5.5 percent; CD Tensile
Strength,
1524 grams per 25.4 millimeters of sample width; Single Sheet Caliper, 0.55
millimeters; MD Stretch, 8.0 percent; MD Tensile Strength, 1765 grams per 25.4
millimeters of sample width; and, an wedding ring pattern as shown in FIGURES
29 and 30.
It will be appreciated that the foregoing examples and description, given for
purposes of illustration, are not to be construed as limiting the scope of
this
invention, which is defined by the following claims and all equivalents
thereto.
56
