Note: Descriptions are shown in the official language in which they were submitted.
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STACKABLE AND STACKED ABSORBENT PAPER PRODUCT
FIELD OF THE INVENTION
The disclosure relates to absorbent paper products, such as bath tissue,
facial tissue, and
paper towels and to methods for making and marketing such paper products.
BACKGROUND OF THE INVENTION
Absorbent paper products, such as bath tissue, facial tissue, and paper towels
are well
known. Such products are commonly used in households, businesses, restaurants,
shops, and the
like. Most often absorbent paper products are supplied on a roll for
dispensing. For example,
paper towels typically are marketed on a cardboard roll from which an end user
can tear off one
sheet at a time.
While rolled absorbent paper products in the form of bath tissue and paper
towels are
virtually ubiquitous, there are some shortcomings to such rolled
configurations. First, for paper
towels, for example, one-handed dispensing can be difficult. That is, the user
often must hold the
roll still with one hand while tearing off a single sheet with the other hand.
Two-handed
dispensing avoids the problem of inadvertently pulling off many sheets when
only one sheet was
intended. Often the reason one wishes to use paper towels is because his or
her hands are wet,
and two-handed dispensing can result in one hand, i.e., the "holding" hand
getting portions of the
roll of paper towels wet.
Secondly, when supplied in roll format, much of the volume of the product is
empty air
space. That is, the open core, typically in the form of a cardboard tube, is
empty space that takes
up volume but delivers no product to the consumer. This empty space must be
packaged and
shipped, and the cardboard tube is typically discarded as trash. Thus, current
configurations have
built-in costs not related to the actual benefit delivered to the consumer in
the form of absorbent
products.
Yet a third drawback of absorbent paper products in roll format is that they
require
another device, i.e., a roll holder, for operation. That is, paper towels, for
example, are intended
to be used with a horizontally- or vertically-disposed bar that holds the roll
in place for
dispensing. If such a device is not already present in the location a user
desires to use the
product, the user must purchase and/or mount the device prior to use of the
absorbent paper
product roll.
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Circular, cone-shaped, stacked paper products are known. For example, US
7,954,665,
issued to Abbosh, et al., on June 7, 2011, describes wipes being formed into
non-planar form and
stacked in a cone shape. However, the flat, round, disc-shaped wipes disclosed
in Abbosh et al.,
result in waste when cut out of a web of paper because of the nature of
circular shapes, which do
not tessellate, i.e., the shape cannot be "tiled" in a two-dimensional plane
with no overlaps and
no gaps. Further, it is believed the circular shaped wipes and/or the cone-
shaped stack of
Abbosh et al., each or both can be perceived negatively by consumers. When
utilized in a
kitchen or bathroom, for example, a different shape of tissue/wipe or a
different configuration of
stacked tissues/wipes can provide for more pleasing aesthetics as well as
other technical benefits
related to dispensing and use.
Accordingly, it would be desirable to have an absorbent paper product
manufactured and
delivered in a form that facilitates easier one-handed dispensing.
Additionally, it would be desirable to have an absorbent paper product
manufactured and
delivered in a form not having a cardboard tube and the resulting non-paper
filled volume and
requirement for a second mounting device.
Further, it would be desirable to have a stacked paper product suitable for
one-handed
dispensing, but which lessens, minimizes, or avoids the problem of waste
associated with
circular-shaped wipes.
SUMMARY OF THE INVENTION
An absorbent paper product is disclosed. The absorbent paper product can be in
a non-
circular shape when unfolded and flattened, and folded in a stackable, non-
planar form for
dispensing. The absorbent paper product can be non-circular in shape when
unfolded and
flattened, and can be a tessellating shape or a non-tessellating shape.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a prior art pattern for absorbent paper products.
FIG. 2 is an exemplary pattern of two-dimensional tessellating shapes useful
for
absorbent paper products.
FIG. 3 is an example of a non-circular, non-tessellating shape of an absorbent
paper
product.
FIG. 4 is an example of a folded, cone-shaped absorbent paper product.
FIG. 5 is an example of a two-dimensional shape before folding into a non-
planar form.
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FIG. 6 is an example of a stackable, non-planar form of the non-circular two-
dimensional
shape shown in FIG. 5.
FIG. 7 is an example of a stackable, non-planar form of the non-circular two-
dimensional
shape shown in FIG. 5.
FIG. 8 is an example of a stack of non-planar absorbent paper products.
FIG. 9 is cross-sectional view of Section 9-9 in FIG. 8.
FIG. 10 is an example of a pattern of non-circular, non-tessellating shaped
absorbent
paper products.
FIG. 11 is an example of a pattern of non-circular, tessellating shaped
absorbent paper
products.
FIG. 12 is an example of a pattern of non-circular, tessellating shaped
absorbent paper
products.
FIG. 13 is an example of a pattern of non-circular, tessellating shaped
absorbent paper
products.
FIG. 14 is an example of a fold pattern and method of folding an absorbent
paper product
from a two-dimensional planar form to a stackable non-planar form.
FIG. 15 is an example of a fold pattern and method of folding an absorbent
paper product
from a two-dimensional planar form to a stackable non-planar form.
FIG. 16 is a perspective view of the absorbent paper product shown in FIG. 15
showing
an exemplary folding pattern from the bottom.
FIG. 17 is a plan view of a stack of stackable, non-planar absorbent paper
products shown
in FIGS. 15 and 16.
FIG. 18 is an example of a fold pattern and method of folding an absorbent
paper product
from a two-dimensional planar form to a stackable non-planar form.
FIG. 19A is a top view of an absorbent paper product folded into a stackable
non-planar
form.
FIG. 19B is a side view of an absorbent paper product folded into a stackable
non-planar
form.
FIG. 20 is a perspective view of an absorbent paper product folded into a
stackable non-
planar form.
FIG. 21 is an example of a non-circular two-dimensional shape of an absorbent
paper
product prior to folding into a non-planar form.
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FIG. 22 is a perspective view of the absorbent paper product shown in FIG. 21
showing
an exemplary folding pattern from the top.
FIG. 23 is a perspective view of the absorbent paper product shown in FIG. 21
showing
an exemplary folding pattern from the bottom.
FIG. 24 is a plan view of a stack of stackable, non-planar absorbent paper
products.
FIG. 25 is a perspective view of a stack of stackable, non-planar absorbent
paper
products.
FIG. 26 is a perspective view of a stack of stackable, non-planar absorbent
paper products
showing a flap for dispensing.
FIG. 27 is a perspective view of a stack of stackable, non-planar absorbent
paper
products.
FIG. 28 is a perspective view of a stack of stackable, non-planar absorbent
paper
products.
FIG. 29 is a perspective view of a package suitable for containing a stack of
stackable,
non-planar absorbent paper products.
DETAILED DESCRIPTION OF THE INVENTION
In an embodiment, the present invention is an absorbent paper product having
at least one
ply and manufactured and marketed such that each absorbent paper product is in
a form
characterized by being in a non-planar, three-dimensional configuration. In
some embodiments
each absorbent paper product is non-circular when in a flattened and unfolded
state. In some
embodiments each absorbent paper product has a shape which tessellates, that
is, the shape can
be repeated in a tiled configuration in two-dimensions without overlap and
without gaps. At
least some non-planar absorbent paper product can be folded in one or more
creased folds to
form the non-planar configuration. Each non-planar absorbent paper product can
be stacked with
other like products to form a stack of a plurality of absorbent paper
products. The absorbent
paper product can be a facial tissue, bath tissue, paper towel, napkin, or the
like, and it is believed
that the most utility for such a product is likely to be when the paper is
designed for absorbency,
that is, the paper is intended to absorb relatively high amounts of fluids
such as water in cleaning
and wiping tasks. Such absorbent paper products are currently provided in roll
form, such as
those marketed as BOUNTY paper towels, for example.
The absorbent paper of the absorbent paper product can be any of known
absorbent paper
known for use as facial tissue, bath tissue, paper towel, napkin, or the like,
and will not be
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described in detail herein. As used herein, the term "absorbent paper" is
meant to include paper
products, including paper products made with cellulosic fibers, having as a
primary intended use
absorbing liquids and/or cleaning. Absorbent paper products such as paper
towels are intended
to absorb liquids, but also function to clean or scrub, and can be combined
with cleaners to have
5 a primary intended use of cleaning. In an embodiment, the absorbent paper
products of the
present invention may exhibit a CRT absorbent capacity of from about 0.1 grams
per square inch
to about 1.5 grams per square inch, from about 0.2 grams per square inch to
about 1.2 grams per
square inch, when tested according to the Test Methods herein. Thus,
substrates such as films,
polymer films, foils, non-absorbent wipes, filter paper, paper utilized for
paper cups, and other
forms of substrates that do not have a primary intended purpose of absorbency
are not considered
absorbent paper as used herein. In general, any absorbent paper product made
by known
papermaking methods, including wet laying and through air drying, and which
can be embossed,
can be utilized in the present invention. Therefore, the description below is
non-limiting with
respect to the particular absorbent paper product to be used, the particular
manufacturing method,
or the particular format. The absorbent paper product can be embossed, creped
and/or printed.
An example of a known shape for wipes that can be folded and stacked in a non-
planar
form is shown in FIG. 1. As shown, a portion of a web 10 can have cut out of
it one or more
circular shaped wipes 12 which regardless of how configured in a pattern on
web 10, necessarily
leave waste paper in the regions between the circular shapes, for example, the
regions denoted as
14 in FIG. 1. This waste, which at minimum is about 21.4% of the starting
sheet of absorbent
paper, adds to the cost of the finished wipe product; even if it is recycled,
the process of recycling
itself adds cost to a finished product. The prior art circular-shaped product
is known to be folded
into a non-planar, conical-shaped stacked configuration, as disclosed in the
aforementioned US
7,954,665.
The current invention provides an improvement in non-planar, stacked forms of
absorbent
paper products. The absorbent paper products can be folded into non-planar
forms for
dispensing, and can be non-circular when unfolded and flattened. As disclosed
in more detail
below, the absorbent paper product of the invention can be further described
in at least three
distinct ways: (1) stackable, non-planar, absorbent paper products being in a
non-circular shape
when flattened and unfolded, and wherein the non-circular shape is a non-
tessellating shape; (2)
stackable, non-planar, absorbent paper products being in a non-circular shape
when flattened and
unfolded, and wherein the non-circular shape is a tessellating shape; and, (3)
absorbent paper
products having a first shape when flattened and unfolded, which when folded
into a stackable,
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non-planar form has a first portion defining a base having a second shape and
a second portion
defining a peak. The second shape can be different from the first shape.
By "tessellating shape" as used herein is meant a shape for an individual
absorbent paper
product, e.g., a sheet of paper towel, which in identical, two-dimensional,
planar forms can be
repeated in a tiled pattern with no overlaps and no gaps. A simple example of
a web 20 from
which can be cut a plurality of absorbent paper products 22 being in a non-
circular shape when
flattened and unfolded, and wherein the non-circular shape is a tessellating
shape, is shown in
FIG. 2, which shows a repeating pattern 42 of square-shaped absorbent paper
products 22.
By "stacked" or "stackable" as used herein is meant the property of folded,
non-planar
forms of absorbent paper products to be nested one to another to form a
relatively compact stack
from which one or more absorbent paper products can be independently removed.
That is, the
absorbent paper products are not connected, such as by perforated lines, but
are each discrete and
dispensable in a stacked, non-planar form, individually. Once dispensed, the
absorbent paper
product can be manipulated for use, including by being pressed back into a
generally two-
dimensional, planar form for wiping up spills, for example.
A simple example of a non-circular, non-tessellating shaped absorbent paper
product 24
is shown in FIG. 3. For simplicity, only one absorbent paper product 24 is
shown in its flattened,
unfolded form and how it appears when cut from a larger web 20 of paper.
Typically shaped
absorbent paper products are cut, for example by die cutting, from a larger
flat web 20 of paper.
The web 20 can be made in a known paper-making process in which the web has an
essentially
endless length in the machine direction MD, which is the direction the web
runs as it is reeled
onto finished rolls. Likewise, the web has a cross-direction, CD, which is the
direction
associated with the width of web 20 during processing. As can be understood, a
plurality of
absorbent paper products 24 can be cut out of a given web 20, with the number
being limited
only by the size of the absorbent paper products 24 and the size of the web
20.
Of course, virtually any non-circular shape can be envisioned; the shape shown
in FIG. 3
is exemplary only. As shown, rather than have a circular shape, the rounded
overall shape of the
absorbent paper product has a scalloped edge 36. The edge 36 could likewise be
modified such
that the edge 36 exhibits an overall impression of "flower-petal shaped" or
"zig-zag shaped" or
"star-burst shaped," with the common physical characteristic being that the
edge 36 of the shape
is not uniformly smooth and circular. Likewise, the overall shape need not
approximate a circle,
but could be oval, ellipsoid, diamond, square, and other geometric shapes that
can be folded into
non-planar forms for stacking as described herein.
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The benefit to having a non-circular, non-tessellating shape as shown in FIG.
3 is not
necessarily scrap reduction; this design, if repeated over a web and die cut
could result in scrap
generation. However, having an edge profile other than smooth and circular
provides for
additional gripping portions, i.e., tabs, which can aid in removing a single
absorbent paper
product from a stack of such products. For example, as shown in FIG. 4, a
folded, cone-shaped
absorbent paper product 26 having a non-circular, non-tessellating shape, can
have downwardly
extending tabs 28 formed by the non-circularity of the shape's edge 36. As
such, each tab can
function to provide a liftable portion of the product, such that a finger
and/or thumb can more
easily grasp the product for removable.
The non-circular, non-tessellating shaped absorbent paper product 24 can be
folded to
form a non-planar absorbent paper product 26 having a base portion 33 and a
peak 37. As shown
in FIG. 4, in a simple form, the non-circular, non-tessellating shaped
absorbent paper product 24
can have two folds, a first fold 30 and a second fold 32 which form a single
flap 38. Upon
making the first fold and the second fold, each originating from a common
interior portion 34 of
the non-circular, non-tessellating shaped absorbent paper product 24 and
extending to an edge
36, the non-circular, non-tessellating shaped absorbent paper product 24 is
forced into a non-
planar form having a base 33 and a peak 37, which is suitable for stacking
with like-folded
products. In general, the common interior portion 34 of the non-planar form
will coincide with
the peak 37, which in the embodiment illustrated in FIG. 4 can be considered
to be a pointed tip.
By "pointed tip" is not meant necessarily a tip having a geometric point, but
a tip generally
having the appearance of a point based on the geometries of the folding
pattern.
The non-circular shaped absorbent paper products, whether tessellating, 22, or
non-
tessellating 24, can be folded to be stackable in non-planar forms for
dispensing. In general, any
two or more folds that force an absorbent paper product into a non-planar form
can be utilized in
the present invention. However, for commercial purposes it is believed that
certain fold patterns
and aesthetic properties are beneficial. That is, when stacked, the stack of
non-circular wipes can
have a certain organization, consistency, or symmetry of products such that it
appears to the end
user in a pleasant, appealing manner, and as well presents a pleat (or flap)
for grasping in an
organized, consistent manner to ease in dispensing.
In general, for all the non-circular shapes disclosed herein, they can be
folded with at
least two folds to form at least one folded, flattened pleat, or flap 38, as
shown in FIG. 4, and in
more detail in FIGS. 5-7. In its simplest form, for a non-circular shape
having a peripheral edge
36, a first fold 30 and a second fold 32 can each originate from the interior
portion 34, and can
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originate from a center point 35 of the non-circular, non-tessellating shaped
absorbent paper
product 24, which coincides with the peak 37 of the non-planar form. Each fold
can extend to
the edge 36, and the second fold 32 can be folded in, or "tucked" under the
first fold, which can
be folded over to form a flap 38. The flap 38 can be used to grasp the topmost
absorbent paper
product of the stack for dispensing. In the illustrated embodiment, the angle
subtended between
the two folds determines the size of the flap 38 and, as well, the extent of
non-planarity of the
final, non-planar product. One way of characterizing non-planarity is to
consider a height, H, of
a single stackable, non-planar absorbent paper product, the height being
measured from the base
33 to the peak 37. If the angle is relatively small, the flap width at the
peripheral edge 36, W,
will be relatively small, and the height, H, will be relatively low, as shown
in FIG. 6. Likewise,
if the angle is relatively large, the flap width at the perimeter, W, will be
relatively large, and the
height, H, will be relatively high, as shown in FIG. 7. For each shape of
interest, the non-
circular, non-tessellating shaped absorbent paper product 24 can then be
forced into a non-planar
form 40, which is suitable for stacking with like-folded products, as shown in
FIG. 8.
As shown in FIG. 8, each of the folded, non-planar absorbent paper products 40
can be
nested with other folded, non-planar absorbent paper products 40 to for a
stack 42 of folded, non-
planar absorbent paper products. In FIG. 8, there are four non-planar
absorbent paper products
40 stacked. The lower-most absorbent paper product forms a stack base 44,
which can rest on a
counter top, for example, or in a dispensing device, and the stack can rest in
a generally vertical
orientation with a vertical axis V being generally orthogonal to a dispensing
surface, such as a
kitchen counter top. Depending on the shape of the absorbent paper products
before folding, the
fold pattern, and the stack configuration, the full perimeter 36 of the
lowermost non-planar
absorbent paper products 40 may not contact the dispensing surface. The top-
most absorbent
paper product is available for dispensing by, for example, pulling up on the
exposed flap 38. As
can be appreciated from the description herein, the stacked, nested absorbent
paper products can
form a cylindrical, or pyramidal, structure that eliminates a central void, as
is present in current
products rolled onto cores, such as rolled paper towels and toilet paper. The
elimination of the
central void permits better shipping, storage, and countertop efficiency. In
essence, more paper
per volume is produced, shipped, stored, and utilized by a consumer.
Importantly, and in accordance with an embodiment of the invention, the stack
42 need
not be conical in shape. That is, the perimeter 36 of the lower-most absorbent
paper product 44
that serves as the base need not form a circular shape. This is true even if
the absorbent paper
products are circular in their flattened, unfolded state. As shown in the
cross-section of FIG. 9,
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the shape of the stack 42 can be flattened, so to speak, or altered from a
conical shape that has a
generally circular shape cross section, into a shape having an aspect ratio
between a major
dimension D1 and a minor dimension D2 which is less than dimension Dl. That
is, the aspect
ratio AR, of D1/D2 can be greater than 1. AR can be between 1.1 and 10, or
between 2 and 10,
or between 3 and 5. In this manner, a stack 42 of absorbent paper product 44
can have a very
different aesthetic look, and can have a lower "profile" in one dimension,
such that it can sit
closer to a wall on a kitchen counter, for example. As discussed above,
depending on the shape
of the absorbent paper products before folding, the fold pattern, and the
stack configuration, the
full perimeter 36 of the lowermost non-planar absorbent paper products 40 may
not contact the
dispensing surface. Therefore, the "shape" of the perimeter 36 of the
lowermost non-planar
absorbent paper product 40, i.e., shape of the base claimed as the second
shape herein, can be
considered to be the shape projected in cross-section and viewed from below,
as shown in FIG. 9,
and the aspect ratio need not be precisely determined, but in cases of general
interest where a
significant non-circular base shape is desired, can be considered greater than
1 based on a visual
inspection of the relative, visually-ascertained dimensions D1 and D2.
Thus, in one embodiment, the invention can be described as a non-conical stack
of
absorbent paper products (which paper products can have a planar, two-
dimensional shape that is
circular, non-circular, tessellating or non-tessellating), each absorbent
paper product being in a
folded, non-planar form, the non-conical stack having a base portion in a
shape having an aspect
ratio greater than 1.
Virtually any other non-circular geometric shape, such as ovals and rhomboids
(not
shown), could be folded into a non-planar, stackable shape having a base
portion and a peak. In
an embodiment, the non-circular shape can be a polygonal shape approaching
circular, thereby
reducing the scrap generated when circular shapes are cut out of a web. For
example, as shown
in FIG. 10, a pattern 40 of non-circular, non-tessellating shaped absorbent
paper products 24 in
the shape of dodecagons can be arranged such that the area of the web not used
for absorbent
paper products, i.e., scraps areas 14, is less than that associated with
circular shapes. As shown
in the example of FIG. 10, for example, the triangular gaps between the
dodecagons is scrap, but
the area of scrap web can be significantly lessened, with the overall
impression to a user of the
absorbent paper product being that it is circular.
Accordingly, in an embodiment, the present invention can be described as an
absorbent
paper product being in a polygonal shape when flattened and unfolded, and
being folded in a
stackable, non-planar form for dispensing, the non-planar form having a first
portion defining a
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base and a second portion defining a peak. Further, the non-circular shape can
be a non-
tessellating shape.
A simple example of a non-circular, tessellating pattern 42 of shaped
absorbent paper
products 22, shown in FIG. 2, is referred to again. Such shapes permit
"tiling" of the shaped
5 absorbent paper products 22 such that once cut, such as by die cutting,
for example, from web 20,
there is minimal scrap generated. In such patterns, the edges of one absorbent
paper product 22
can be each coterminous with the edges of adjacent absorbent paper products
22.
FIG. 11 shows another exemplary pattern 42 of non-circular, tessellating
shaped
absorbent paper products 22 in the shape of triangles. The pattern can be cut
from a web 20 of
10 paper, such as by die cutting to form individual triangle-shaped
absorbent paper products 22.
FIG. 12 shows another exemplary pattern 42 of non-circular, tessellating
shaped
absorbent paper products 22 in the shape of hexagons. The pattern can be cut
from a web 20 of
paper, such as by die cutting to form individual hexagon-shaped absorbent
paper products 22.
FIG. 13 shows another exemplary pattern 42 of non-circular, tessellating
shaped
absorbent paper products 22 in the shape of irregular pentagons. The pattern
can be cut from a
web 20 of paper, such as by die cutting to form individual pentagon-shaped
absorbent paper
products 22.
An example of a stackable, non-planar absorbent paper product 40 suitable for
stacked
dispensing and made from a paper product in the shape of a hexagon is shown in
FIG. 14. As
shown in the sequence A-E of FIG. 14, a plurality of absorbent paper products
22 cut into a
hexagon shape are shown in FIG. 14A. Cutting can be by die cutting as is known
in the art, or
other suitable cutting methods. As shown, waste between shapes is minimized
and limited only
to the edge regions of web 20. One such absorbent paper product 22 cut from
web 20 is shown
in FIG. 14B, and a representative fold pattern is shown in FIG. 14C. Once
folded as shown in
FIG. 14C, a non-planar absorbent paper product 40 is formed, the absorbent
paper product 40
which in this case forms a pointed tip and which can be described as four-
sided pyramid having a
base 33, which in this case forms a square shape, and a peak 37. Also formed
is a single flap 38
which can be grasped to dispense the topmost absorbent paper product 40 when a
plurality of
absorbent paper products 40 so formed are stacked for dispensing as shown in
FIG. 14E. While
the absorbent paper product 40 is shown having a base in the shape of a
square, the shape can be
modified such that the base shape is rhombus- or diamond-shaped. In either a
square-shaped
base or a rhombus-shaped base, the shape of the absorbent paper product when
flattened and
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unfolded, i.e., hexagonal, is different from the shape of the base of the
folded, non-planar form,
i.e., square or rhombus.
FIGS. 15 and 16 show another exemplary absorbent paper product being in a non-
circular
shape when flattened and unfolded (FIG. 15A), and being folded in a stackable,
non-planar form
for dispensing, the non-planar form having a first portion defining a base 33
and a second portion
defining a peak 37 (FIG. 16). In the example shown in FIGS. 15-16, the non-
circular shape is a
rectangle, which can be a square, and the non-planar form is a four-sided
pyramidal shape. To
obtain the four-sided pyramidal shape shown in FIG. 16, a generally square-
shaped absorbent
paper product can be folded as shown in FIG. 15 A-F. One difference between
the four-sided
pyramidal shape shown in FIG. 16, and the four-sided pyramidal shape shown in
FIG. 14D is that
the four-sided pyramidal shape shown in FIG. 16 has two flaps 38 for grasping
by a user
dispensing a topmost absorbent paper product 40 when a plurality of absorbent
paper products 40
so formed are stacked for dispensing, as shown in FIG. 17. The presence of two
flaps 38
provides the benefit of ensuring that at least one corner of the pyramidal
shape having a flap is
likely to be presented to a user desiring to grasp a flap for dispensing.
Thus, a stack 42 of non-
planar absorbent paper products folded as shown in FIGS. 15 and 16 can rest in
virtually any
orientation on a countertop, for example, while increasing the probability
that for any given
orientation a conveniently flap is presented for grasping.
Another example of an absorbent paper product being in a non-circular shape
when
flattened and unfolded, and being folded in a stackable, non-planar form for
dispensing, the non-
planar form having a first portion defining a base 33 and a second portion
defining a peak 37 is
shown in FIGS. 18-20. In the example shown in FIGS. 18-20, the non-circular
shape of the
absorbent paper product is a square, as shown in FIG. 18, and the non-planar
form 40 of the
absorbent paper product is a three-sided pyramidal shape having one flap 38,
as shown in FIGS.
19A-B and FIG. 20.
To obtain the three-sided pyramidal shape shown in FIG. 20, a generally square-
shaped
absorbent paper product 22 can be folded along the fold lines 52 and 53
indicated as dashed lines
in FIG. 18. To start, each corner 54 of absorbent paper product 22 can be
folded along fold lines
52 to essentially meet at the common interior portion 34, i.e., folded down
and under when in the
orientation viewed in FIG. 18. When corners 54 are folded to meet essentially
in the center, e.g.,
at portion 34, the shape is again a square, with the sides represented by fold
lines 52, and having
corners 54A. The shape as folded can be creased with folds along lines 53 for
further
manipulation, which includes bringing any two adjacent corners 54A together,
such that an
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additional fold can be made at 55, which can form a tab or flap, which, when
folded down forms
flap 38 as shown in FIGS. 19A and B and FIG. 20. The resulting non-planar
absorbent paper
product is a stackable three-sided pyramidal shape having one flap 38, a base
33 and a peak 37,
the peak being in the shape of generally pointed tip.
In general, the non-circular, tessellating shaped absorbent paper products 22
of the
present invention can have any tessellating shape. For commercial purposes it
is believed best if
the shape lends itself to household tasks such as wiping up spills, cleaning
counters and other
household surfaces, including reaching into crevices, cracks, and other hard
to clean areas. In
general, therefore, the shape can be a polygon and can have a minimal cross
sectional area of at
least about 10 square inches to about 100 square inches.
Another representative example of a product of the present invention is
described with
reference to FIGS. 21 ¨ 26. The example is described with respect to an
absorbent paper product
that is again square in its planar, two-dimensional shape, but the
description, basic structure of
the stack, and user benefits provided when folded, is the same for other
shapes as well, including
circular, and non-circular polygonal shapes, including tessellating and non-
tessellating shapes.
The folding and stacking described herein can be achieved by hand, or by
machine.
As shown in FIG. 21, a square (when in a planar, unfolded, two-dimensional
state)
absorbent paper product 22, which can be a cellulosic substrate useful as a
paper towel, can be
folded with two diagonal folds 50 that cross at a common interior portion 34
which can be the
center. The two diagonal folds 50 can each extend from opposite corners 54.
For shapes other
than square, two folds that cross at generally right angles to generally
divide the absorbent paper
product into quadrants can be used to achieve the same fold pattern as
described herein. In
general, it is not important that the folds be exactly from corner to corner,
or be exactly
orthogonal to one another. The basic fold pattern illustrated can be achieved
with satisfactory
finished product features when folds are inexact, but closely approximate the
folds as described.
To form the absorbent paper product 22 into a stackable, non-planar form,
another fold,
indicated at 60 in FIG. 21 can be folded inwardly as indicated in FIG. 22,
which in one
configuration can be considered the top of the non-planar form. Corners 54 can
be brought
together in the direction indicated by arrows 62 in FIG. 22 and, in this
manner, the two portions,
or faces, 56 are folded adjacent one another and the two portions, or faces,
58 are folded adjacent
one another. Once folded, the flaps formed by the faces 56 and 58 and their
respective fold 60
can be moved to one side of the form, as indicated by arrows 64 in FIG. 23,
which in this
example, can be considered the bottom of the non-planar form.
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A plan view, i.e., a top view in one embodiment, of a stackable, non-planar
form of an
absorbent paper product folded as described above, is shown in FIG. 24. As
shown, perimeter 36
at the base of the product exhibits a non-circular shape, or footprint, which
in this case is a
diamond shape produced by additional folds 68, which are optional. In a
simpler form, the
perimeter 36 can form a footprint having a generally oval shape or a prolate
spheroid shape with
generally pointed ends where flap comers 54 meet. As shown, the shape has an
aspect ratio AR
of D1/D2 greater than 1. Although the representation in FIG. 24 is non-
limiting with respect to
dimensions, the approximate aspect ratio AR of 2 is representative of a
commercial embodiment
of a stack of non-planar absorbent products.
A stack 42 of non-planar absorbent paper products 26 is shown in FIG. 25. As
shown, the
non-planar form allows for each absorbent paper product 26 to nest with
adjacent absorbent
paper products to form a relatively compact stack that can used as is, or
supplied and used with a
dispenser 72, which can be a paper or plastic holding device that helps
stabilize the stack during
use. Some starting, two-dimensional shapes, such as a circle and the square
described above,
once formed into a non-planar shape having a non-circular perimeter shape, can
result in a non-
planar footprint, i.e., the perimeter of the lowermost product does not lie in
a plane, which can
result in stack instability due to a potential rocking (in the case of a
generally circular shape) or
tipping (in the case of a generally square shape) tendency, for example. The
dispenser 72 can be
formed as necessary to have a flat lower surface 74 for stable use on kitchen
countertops, for
example.
One advantage of the invention when folded as described herein is illustrated
in FIG. 26.
At least two flaps 70 are formed by the fold, the flaps being generally easily
graspable by a user
(in contrast to the single flap formed by the fold shown in FIGS. 8 and 9, for
example). Flaps 70,
also shown in FIG. 23, are formed by one of the sides 66 and one each of
portions 56 and 58.
Flaps can be formed by the pressure of folding and stacking to lie generally
flat for stacking, but
are easily separated for lifting and removal of the topmost product, as shown
in FIG. 26. The
presence of two or more flaps facilitates more flexible orientation of the
stack so that a flap is
more likely to be presented to a user without the user having to turn the
stack to find a flap.
When an absorbent paper product 22 having a first shape that is square when
flat and then
folded as shown in FIGS. 21-23 into its non-planar form for stacking and
dispensing, the
peripheral edge 36 can be in a "football" shape, and the long edges tend to be
arched into a curve
between flap corners 54. That is, when folded as shown in FIGS. 21-23, the
peripheral edge 36
forms a second shape that does not necessarily lie in a plane, and the folded
paper product does
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not necessarily sit flat on a surface with substantially all of peripheral
edge 36 in contact with the
surface.
Another example of an absorbent paper product being in a non-circular shape
when
flattened and unfolded, and being folded in a stackable, non-planar form for
dispensing, the non-
planar form having a first portion defining a base 33 and a second portion
defining a peak 37 is
shown in FIGS. 27-29. In the example shown in FIGS. 27-29, the non-circular
shape of the
absorbent paper product is a rectangle which can be folded, such as C-folded,
as shown in FIG.
27, and the non-planar form 40 of the absorbent paper product is an inverted V-
shape as shown in
FIG. 28. While the embodiment illustrated is in the form of a C-fold, the
particular fold selected
is not to be limiting. The absorbent paper product can be folded in any manner
desired according
to the desired finished product, including in MD and/or CD C-folds, I-folds, W-
folds, or even
unfolded. Additionally, the V-shaped absorbent paper towels can be stacked by
sequentially
stacking individual sheets, or by stacking in clips of sheets, as is known in
the art, and then
sequentially stacking the clips to form a stack of a desired height.
In the embodiment shown, in FIGS. 27 and 28, the peak 37 is not a pointed tip,
but rather
a ridge line. By ridge line it is not intended to mean a straight line, or a
particular level of
pointedness, but the ridge is distinguished over, for example, a U-shaped
stack of facial tissues.
The absorbent paper product, having a generally V-shaped fold can be stacked
into a stack 42 for
dispensing. In the embodiment of a non-planar form 40 of an absorbent paper
product in an
inverted V-shape, the base of the non-planar form can be considered to have
the shape projected
to the surface as the "footprint" of the stack. As such, the base of the non-
planar form 40
illustrated in FIG. 27 can be considered to be rectangular, or square. A
rectangular or square
footprint of a package of stacked folded absorbent paper products, such as
that shown in FIG. 28,
offers a benefit of space efficiency in packaging and shipping. That is, being
basically square, a
plurality of packaged stacks 42 can be palletized side by side with minimal
space between them,
resulting in higher pallet density of packaged product. Closely spaced stacks,
being in side to
side contact can also offer more vertical stability for higher palletized
stack heights. Once
shipped to a retail customer, a plurality of packaged stacks 42 can be stacked
on store shelves
with similar stack density, thereby better utilizing retail shelf space.
In use, a user can grasp a flap formed by one of the C-folds and lift off the
topmost
absorbent paper product. A package base 80 can aid in keeping the stack in the
desired V-shape.
The base can be made of paper, plastic, or other suitably stiff material
capable of holding the
shape of the stack of absorbent paper products. The stack 42 can be housed for
shipping and
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dispensing in a container 82, with the stack fitting snugly inside container
82, and extending at
least partially above the top 84 of container 82. Further, the container 82
can have on at least one
side a notch or opening 86 that exposes stacked absorbent products further
down the stack, and
permits a user to access such absorbent products more easily. In addition to
permitting easier
5 access to the stacked absorbent products, the notch 86 permits the user
to reach in from the side
and grab a plurality of stacked absorbent products in one grab. This "dosing"
feature is a benefit
of many embodiments of stacked absorbent products disclosed herein.
Again, the embodiments disclosed herein are exemplary only. The starting two-
dimensional starting shapes could be circular or non-circular, polygonal,
tessellating, and non-
10 tessellating. Non-circular shapes provide distinct advantages such as
providing for more
aesthetically pleasing shapes as well as providing perimeter features such as
the tabs 28 that can
provide for easy grasping and lifting of the topmost product. Non-circular,
tessellating shapes
offer the distinct advantage of reducing or eliminate waste during production,
as the shapes
utilize the entirety of the starting web of material. Further, a stack having
a non-circular stack
15 cross-section, i.e., a non-circular footprint offers the distinct
advantage of presenting a smaller
dimension in at least one orientation such that the stack can be set on a
kitchen counter closer to a
wall or comer, to be out of the way.
Test Methods
Unless otherwise specified, all tests described herein including those
described under the
Definitions section and the following test methods are conducted on samples
that have been
conditioned in a conditioned room at a temperature of 23 C 1.0 C and a
relative humidity of
50% 2% for a minimum of 24 hours prior to the test. All plastic and paper
board packaging
articles of manufacture, if any, must be carefully removed from the samples
prior to testing. The
samples tested are "usable units." "Usable units" as used herein means sheets,
flats from roll
stock, pre-converted flats, fibrous structure, and/or single or multi-ply
products. Except where
noted all tests are conducted in such conditioned room, all tests are
conducted under the same
environmental conditions and in such conditioned room. Discard any damaged
product. Do not
test samples that have defects such as wrinkles, tears, holes, and like. All
instruments are
calibrated according to manufacturer's specifications.
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Basis Weight Test Method
Basis weight of a fibrous structure is measured on stacks of twelve usable
units using a
top loading analytical balance with a resolution of 0.001 g. The balance is
protected from air
drafts and other disturbances using a draft shield. A precision cutting die,
measuring 8.890 cm
0.00889 cm by 8.890 cm 0.00889 cm is used to prepare all samples.
With a precision cutting die, cut the samples into squares. Combine the cut
squares to
form a stack twelve samples thick. Measure the mass of the sample stack and
record the result
to the nearest 0.001 g.
The Basis Weight is calculated in g/m2 as follows:
Basis Weight = (Mass of stack) / [(Area of 1 square in stack) x (No. of
squares in stack)]
Basis Weight (g/m2) = Mass of stack (g) / 1179.032 (cm2) / 10,000 (cm2/m2) x
121
Report result to the nearest 0.1 g/m2. Sample dimensions can be changed or
varied using
a similar precision cutter as mentioned above, so as at least 645 square
centimeters of sample
area is in the stack.
CRT Absorbency
This test incorporates the following CRT equipment absorbency calculation
methods
The Slope of the Square Root of Time (SST 2-15) Test Method.
The Time Integrated CRTMax (TIR.005) Test Method
CRT Capacity Test Method
The SST method and CRTMax TIR method both measure rate over a wide spectrum of
time to capture a view of the product pick-up rate over the useful lifetime.
In particular, the SST
method measures the absorbency rate via the slope of the mass versus the
square root of time
from 2-15 seconds. The CRTMAX TIR measures time integrated absorbency rate
using a
0.005g/sec threshold stop criteria.
Overview
The absorption (wicking) of water by a fibrous sample is measured over time. A
sample
is placed horizontally in the instrument and is supported by an open weave net
structure that rests
on a balance. The test is initiated when a tube connected to a water reservoir
is raised and the
meniscus makes contact with the center of the sample from beneath, at a small
negative pressure.
Absorption is controlled by the ability of the sample to pull the water from
the instrument for
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approximately 20 seconds. Rate is determined as the slope of the regression
line of the outputted
weight vs. sqrt (time) from 2 to 15 seconds.
Apparatus
Conditioned Room - Temperature is controlled from 73 F + 2 F (23 C + 1 C).
Relative
Humidity is controlled from 50% + 2%
Sample Preparation ¨ Product samples are cut using hydraulic/pneumatic
precision cutter
into 3.375 inch diameter circles for SST, CRT Max and 3 inch diameter circles
for CRT capacity.
Capacity Rate Tester (CRT) - The CRT is an absorbency tester capable of
measuring
capacity and rate. The CRT consists of a balance (0.001g), on which rests on a
woven grid (using
nylon monofilament line having a 0.014" diameter) placed over a small
reservoir with a delivery
tube in the center. This reservoir is filled by the action of solenoid valves,
which help to connect
the sample supply reservoir to an intermediate reservoir, the water level of
which is monitored by
an optical sensor.
The CRT is run with a -2mm water column, controlled by adjusting the
height of water in the supply reservoir.
Software - Lab View based custom software specific to CRT Version 4.2 or
later.
Water - Distilled water with conductivity < 10 uS/cm (target <5 uS/cm) @ 25 C
Sample Preparation
For this method, a usable unit is described as one finished product unit
regardless of the
number of plies. Condition all samples with packaging materials removed for a
minimum of 2
hours prior to testing. Discard at least the first ten usable units from the
roll. Remove two usable
units and cut one 3.375-inch (SST, CRTMax) or 3.0 inch (CRT Capacity) circular
sample from
the center of each usable unit for a total of 2 replicates for each test
result. Do not test samples
with defects such as wrinkles, tears, holes, etc. Replace with another usable
unit which is free of
such defects
Sample Testing
Pre-test set-up
1. The water height in the reservoir tank is set -2.0 mm below the top of the
support rack
(where the towel sample will be placed).
2. The supply tube (8mm I.D.) is centered with respect to the support net.
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3. Test samples are cut into circles of 3-3/8" SST, CRTMax) or 3" (CRT
Capacity) diameter
and equilibrated at Tappi environment conditions for a minimum of 2 hours.
Test Description
1. After pressing the start button on the software application, the supply
tube moves to 0.33
mm below the water height in the reserve tank. This creates a small meniscus
of water
above the supply tube to ensure test initiation. A valve between the tank and
the supply
tube closes, and the scale is zeroed.
2. The software prompts you to "load a sample". A sample is placed on the
support net,
centering it over the supply tube, and with the side facing the outside of the
roll placed
downward.
3. Close the balance windows, and press the "OK" button -- the software
records the dry
weight of the circle.
4. The software prompts you to "place cover on sample". The plastic cover is
placed on top
of the sample, on top of the support net. The plastic cover has a center pin
(which is flush
with the outside rim) to ensure that the sample is in the proper position to
establish
hydraulic connection. Four other pins, 1 mm shorter in depth, are positioned
1.25-1.5
inches radially away from the center pin to ensure the sample is flat during
the test. The
sample cover rim should not contact the sheet. Close the top balance window
and click
"OK".
5. The software re-zeroes the scale and then moves the supply tube towards the
sample.
When the supply tube reaches its destination, which is 0.33 mm below the
support net, the
valve opens (i.e., the valve between the reserve tank and the supply tube),
and hydraulic
connection is established between the supply tube and the sample. Data
acquisition
occurs at a rate of 5 Hz, and is started about 0.4 seconds before water
contacts the sample.
6. The test runs for at least 20 seconds. For CRTMax test is stopped when rate
of increase
of water absorbed falls below 0.005g/s otherwise test stops at 300 seconds.
For CRT
Capacity the test is stopped when rate of increase of water absorbed falls
below 0.0015
g/s otherwise test stops at 300 secs. After this, the supply tube pulls away
from the sample
to break the hydraulic connection.
7. The wet sample is removed from the support net. Residual water on the
support net and
cover are dried with a paper towel.
8. Repeat until all samples are tested.
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9. After each test is run, a *.txt file is created (typically stored in the
CRT/data/rate
directory) with a file name as typed at the start of the test. The file
contains all the test
set-up parameters, dry sample weight, and cumulative water absorbed (g) vs.
time (sec)
data collected from the test.
Calculating CRT Capacity g/sq inch
Capacity (g/sq in) = 0.14147x Final Weight (g water absorbed)
Where 0.14147 is the inverse of the area of the 3 inch circle and this
multiplier converts
values to a per square inch basis
Calculation of Rate of Uptake
Take the raw data file that includes time and weight data.
First, create a new time column that subtracts 0.4 seconds from the raw time
data to adjust
the raw time data to correspond to when initiation actually occurs (about 0.4
seconds after data
collection begins).
Second, create a column of data that converts the adjusted time data to square
root of time
data (e.g., using a formula such as SQRT() within Excel).
Third, calculate the slope of the weight data vs the square root of time data
(e.g., using the
SLOPE() function within Excel, using the weight data as the y-data and the
sqrt(time) data as the
x-data, etc.). The slope should be calculated for the data points from 2 to 15
seconds, inclusive
(or 1.41 to 3.87 in the sqrt(time) data column).
Calculation of Slope of the Square Root of Time (SST 2-15)
The start time of water contact with the sample is estimated to be 0.4 seconds
after the
start of hydraulic connection is established between the supply tube and the
sample (CRT Time).
This is because data acquisition begins while the tube is still moving towards
the sample, and
incorporates the small delay in scale response. Thus, "time zero" is actually
at 0.4 seconds in
CRT Time as recorded in the *.txt file.
The slope of the square root of time (SST) from 2-15 seconds is calculated
from the slope
of a linear regression line from the square root of time between (and
including) 2 to 15 seconds
(x-axis) versus the cumulative grams of water absorbed. The units are g/sec
5.
Reporting Results
Report the average slope to the nearest 0.01 g/s 5.
Calculation of Time Integrated Rate with 0.005g/s threshold (CRTMax TIR 0.005)
CRTMax TIRØ005, aka "time integrated rate using a 0.005 g/sec threshold", is
calculated by integrating the area under the rate (g/sec, y-axis) vs. time
(sec, x-axis) curve,
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starting at "CRT time" = 0.4, until the "Time Average Rate" is 0.005 g/sec or
less (referencing
"Time Average Rate" beginning at CRT Time =1.4 sec).
CRT Max TIRØ005 = 1 RCA(i) ¨ CA(i-1)) * IR(i)1 +
RCA(i) ¨CA(i-1)) * (IR(i-1) ¨ IR(i)) * 0.5)1
5
Where:
i = CRT Time increment, starting at 0.4 sec, until the "CRT Time" when Time
Average
Rate (at 1.4 seconds and after), is equal to or below 0.005 g/sec.
CA = cumulative water absorbed (g)
10 IR = instantaneous rate (g/sec)
Elongation/Tensile Strength/TEA/Tangent Modulus Test Method
Elongation (Stretch), Tensile Strength, TEA and Tangent Modulus are measured
on a
constant rate of extension tensile tester with computer interface (a suitable
instrument is the EJA
15 Vantage from the Thwing-Albert Instrument Co. Wet Berlin, NJ) using a
load cell for which the
forces measured are within 10% to 90% of the limit of the load cell. Both the
movable (upper)
and stationary (lower) pneumatic jaws are fitted with smooth stainless steel
faced grips, with a
design suitable for testing 1 inch wide sheet material (Thwing-Albert item
#733GC). An air
pressure of about 60 psi is supplied to the jaws.
20 Eight usable units of fibrous structures are divided into two stacks
of four usable units
each. The usable units in each stack are consistently oriented with respect to
machine direction
(MD) and cross direction (CD). One of the stacks is designated for testing in
the MD and the
other for CD. Using a one inch precision cutter (Thwing-Albert JDC-1-10, or
similar) take a CD
stack and cut one, 1.00 in 0.01 in wide by 3 - 4 in long stack of strips
(long dimension in CD).
In like fashion cut the remaining stack in the MD (strip's long dimension in
MD), to give a total
of 8 specimens, four CD and four MD strips. Each strip to be tested is one
usable unit thick, and
will be treated as a unitary specimen for testing.
Program the tensile tester to perform an extension test, collecting force and
extension data
at an acquisition rate of 20 Hz as the crosshead raises at a rate of 2.00
in/min (5.08 cm/min) until
the specimen breaks. The break sensitivity is set to 80%, i.e., the test is
terminated when the
measured force drops to 20% of the maximum peak force, after which the
crosshead is returned
to its original position.
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Set the gage length to 1.00 inch. Zero the crosshead and load cell. Insert the
specimen
into the upper and lower open grips such that at least 0.5 inches of specimen
length is contained
in each grip. Align specimen vertically within the upper and lower jaws, then
close the upper
grip. Verify specimen is aligned, then close lower grip. The specimen should
be fairly straight
between grips, with no more than 5.0 g of force on the load cell. Add a pre-
tension force of 3g
This tension is applied to the specimen to define the adjusted gauge length,
and, by definition is
the zero strain point. Start the tensile tester and data collection. Repeat
testing in like fashion for
all four CD and four MD specimens. Program the software to calculate the
following from the
constructed force (g) versus extension (in) curve.
Eight samples are run on the Tensile Tester (four to the MD and four to the
CD) and
average of the respective dry total tensile, dry Fail TEA and dry Fail Stretch
is reported as the
Dry Total Tensile, Dry Fail TEA and Dry Fail Stretch. Fail TEA is defined as
tensile energy
absorbed (area under the load vs. strain tensile curve) from zero strain to
fail force point, with
units of g/in. Dry Fail Stretch is defined as the percentage strain measured
after the web is
strained past its peak load point, where the force drops to exactly 50% of its
peak load force.
The dry Fail TEA is then divided by the basis weight of the strip from which
it was tested
to arrive at the TEA of the present invention, and is calculated as follows:
TEA = Fail TEA/ Basis Weight of Strip (g/m2)
The MD and CD dry tensile strengths are determined using the above equipment
and
calculations in the following manner.
Tensile Strength in general is the maximum peak force (g) divided by the
specimen width
(1 in), and reported as g/M to the nearest 1 g/M.
Average Tensile Strength=sum of tensile loads measures (MD)/(Number of tensile
stripes
tested (MD)*Number of useable units or plys per tensile stripe)
This calculation is repeated for cross direction testing.
Dry Total Tensile = Average MD tensile strength + Average CD tensile strength
The Dry Tensile value is then normalized for the basis weight of the strip
from which it
was tested. The normalized basis weight used is 24 g/m2, and is calculated as
follows:
Normalized DTT1 = DTT1 * 24 (g/m2) / Basis Weight of Strip (g/m2)
The various values are calculated for the four CD specimens and the four MD
specimens.
Calculate an average for each parameter separately for the CD and MD
specimens.
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In the interests of brevity and conciseness, any ranges of values set forth in
this
specification are to be construed as written description support for claims
reciting any sub-ranges
having endpoints which are whole number values within the specified range in
question. By way
of a hypothetical illustrative example, a disclosure in this specification of
a range of 1-5 shall be
considered to support claims to any of the following sub-ranges: 1-4; 1-3; 1-
2; 2-5; 2-4; 2-3; 3-5;
3-4; and 4-5.
The dimensions and values disclosed herein are not to be understood as being
strictly
limited to the exact numerical values recited. Instead, unless otherwise
specified, each such
dimension is intended to mean both the recited value and a functionally
equivalent range
surrounding that value. For example, a dimension disclosed as "40 mm" is
intended to mean
"about 40 mm."
Every document cited herein, including any cross referenced or related patent
or
application, is hereby incorporated herein by reference in its entirety unless
expressly excluded
or otherwise limited. The citation of any document is not an admission that it
is prior art with
respect to any invention disclosed or claimed herein or that it alone, or in
any combination with
any other reference or references, teaches, suggests or discloses any such
invention. Further, to
the extent that any meaning or definition of a term in this document conflicts
with any meaning
or definition of the same term in a document incorporated by reference, the
meaning or definition
assigned to that term in this document shall govern.
While particular embodiments of the present invention have been illustrated
and
described, it would be obvious to those skilled in the art that various other
changes and
modifications can be made without departing from the spirit and scope of the
invention. It is
therefore intended to cover in the appended claims all such changes and
modifications that are
within the scope of this invention.
