Towel with quality wet scrubbing properties at relatively low basis weight and an apparatus and method for producing same

Patent metadata

Field	Value
Publication number	US-2016160448-A1
Application number	US-201414561802-A
Country	US
Kind code	A1
Filing date	Dec 5, 2014
Priority date	Dec 5, 2014
Publication date	Jun 9, 2016
Grant date	—

Abstract

A multi-ply absorbent product having a wet scrubbing resistance greater than 120 revolutions and a basis weight of between 30 and 50 grams per square meter. A heated adhesive is applied between two single plies/webs, the multiple plies are embossed according to particular parameters, and the embossed webs are compressed with a marrying roll. The adhesive is heated to a temperature of between approximately 32 degrees C. to 66 degrees C. for application between the multiple plies. For each ply, the embossed area generally occupies between approximately 5 to 15% of the total surface area of a surface of the ply, the depth of embossment of the surface is generally between approximately 0.28 and 0.43 centimeters deep, and the embossment of the surface is generally between approximately 0.04 to 0.08 square centimeters in size.

First claim

What is claimed is:

1 . An absorbent product comprising:
a laminate of at least two plies, wherein each of the at least two plies is embossed and the at least two plies are adhered together, the absorbent product having a wet scrubbing resistance greater than 120 revolutions and a basis weight of between 30 and 50 grams per square meter.

2 . The absorbent product of claim 1 , wherein at least one of the at least two plies comprises cellulosic-based fibers.

3 . The absorbent product of claim 2 , wherein the cellulosic-based fibers are comprised of one or more of wood pulp, cannabis , cotton, regenerated or spun cellulose, jute, flax, ramie, bagasse, or kenaf fibers.

4 . The absorbent product of claim 2 , wherein at least one of the at least two plies comprises synthetic fibers.

5 . The absorbent product of claim 1 , wherein at least one of the at least two plies comprises synthetic fibers.

6 . The absorbent product of claim 5 , wherein the synthetic fibers are comprised of one or more of a polyolefin, polyester and polylactic acid.

7 . The absorbent product of claim 1 , wherein at least one of the at least two plies is produced using an air-laid process.

8 . The absorbent product of claim 1 , wherein at least one of the at least two plies is produced using a wet-laid process.

9 . The absorbent product of claim 1 , wherein the at least two plies are adhered together with a water soluble adhesive mixture comprised of polyvinyl alcohol, polyvinyl acetate, starch based resins or mixtures thereof,
wherein the water soluble adhesive is applied to at least one ply of the at least two plies at a temperature of between approximately 32 degrees C. to 66 degrees C.

10 . The absorbent product of claim 9 , wherein the water soluble adhesive mixture further comprises a water soluble cationic resin selected from the group consisting of polyamide-epichlorohydrin resins, glyoxalated polyacrylamide resins, polyethyleneimine resins, polyethylenimine resins, or mixtures thereof.

11 . The absorbent product of claim 1 , wherein each of the at least two plies comprises an embossed area, wherein the embossed area occupies between approximately 5 to 15% of the total surface area of a surface of the ply.

12 . The absorbent product of claim 1 , wherein each of the at least two plies comprises an embossed area having a surface, wherein a depth of embossment of the surface is between approximately 0.28 and 0.43 centimeters.

13 . The absorbent product of claim 1 , wherein each of the at least two plies comprises an embossed area having a surface, wherein each embossment of the surface is between approximately 0.04 and 0.08 square centimeters in size.

14 . The absorbent product of claim 1 , wherein the absorbent product is one of a paper towel, a disposable towel or wipe, a bath or facial tissue, or a nonwoven product.

15 . A method for laminating at least two plies together to form a multi-ply absorbent product, the method comprising:
(a) embossing at least two plies; (b) applying a heated adhesive to an interior side of at least one of the at least two plies to adhere the at least two plies together, wherein the interior side is a side of a ply that comes into a face-to-face relationship with another ply for lamination and wherein the adhesive is heated prior to being applied; and (c) marrying the at least two plies that have been embossed after the heated adhesive has been applied; whereby a laminate of the at least two plies is obtained, and the laminate has a wet scrubbing resistance greater than 120 revolutions and a basis weight of between 30 and 50 grams per square meter.

16 . The laminating method of claim 15 , wherein the step of embossing is performed using embossing rolls, the embossing rolls having a plurality of embossing knobs with crests thereon, and wherein the heated adhesive is applied with an adhesive applicator roll to the absorbent product at the crests of the embossing knobs.

17 . The laminating method of claim 15 , wherein the applied adhesive comprises a water soluble adhesive mixture comprised of
(a) between approximately 1% to 10% by weight of polyvinyl alcohol, polyvinyl acetate, starch based resins or mixtures thereof, and (b) between 80% to 99% by weight of water;
wherein the water soluble adhesive mixture applied to at least one ply of the at least two plies of absorbent product at a temperature of between approximately 32 degrees C. to 66 degrees C.

18 . The laminating method of claim 15 , wherein the water soluble adhesive mixture further comprises up to 10% by weight of a water soluble cationic resin selected from the group consisting of polyamide-epichlorohydrin resins, glyoxalated polyacrylamide resins, polyethyleneimine resins, polyethylenimine resins, or mixtures thereof.

19 . The laminating method of claim 15 , wherein, before being applied, the heated adhesive is maintained at a temperature of between approximately 32 degrees C. to 66 degrees C. in an insulated tank.

20 . The laminating method of claim 15 , wherein each of the at least two plies comprises an embossed area, wherein the embossed area occupies between approximately 5 to 15% of the total surface area of a surface of the ply.

21 . The laminating method of claim 15 , wherein each of the at least two plies comprises an embossed area having a surface, wherein a depth of embossment of the surface is between approximately 0.28 and 0.43 centimeters.

22 . The laminating method of claim 15 , wherein each of the at least two plies comprises an embossed area having a surface, wherein each embossment of the surface is between approximately 0.04 and 0.08 square centimeters in size.

23 . The laminating method of claim 15 , further comprising the step of agitating the heated adhesive prior to application.

24 . An absorbent product made according to the method of claim 15 , wherein the absorbent product is one of a paper towel, a disposable towel or wipe, a bath or facial tissue, or a nonwoven product.

25 . The laminating method of claim 15 , wherein at least one of the at least two plies comprises cellulosic-based fibers.

26 . The laminating method of claim 25 , wherein the cellulosic-based fibers are comprised of one or more of wood pulp, cannabis , cotton, regenerated or spun cellulose, jute, flax, ramie, bagasse, or kenaf fibers.

27 . The laminating method of claim 15 , wherein at least one of the at least two plies comprises synthetic fibers.

28 . The laminating method of claim 27 , wherein the synthetic fibers are comprised of one or more of a polyolefin, polyester or polylactic acid.

29 . The laminating method of claim 15 , wherein at least one of the at least two plies comprises synthetic fibers and at least a second of the at least two plies comprises cellulosic based fibers.

30 . The laminating method of claim 15 , wherein at least one of the at least two plies is produced using an air-laid process.

31 . The laminating method of claim 15 , wherein at least one of the at least two plies is produced using a wet-laid process.

32 . An apparatus for laminating at least two plies together to form a multi-ply absorbent product, the apparatus comprising:
(a) a plurality of embossing rolls that emboss the at least two plies with a plurality of embossing ro

Assignees

• First Quality Tissue Llc

Inventors

• Miller Iv Byrd Tyler
• Pence Justin S
• Ramaratnam Karthik
• Sealey James E
• Kessling Courtney E
• Anklam Chris B
• Gahan Shannon
• Andrukh Taras Z

Classifications

• D21H21/20

  Wet strength agents · CPC title

• D21H27/38 Primary

  at least one of the sheets having a fibrous composition differing from that of other sheets · CPC title

• D21H27/007

  relating to absorbency, e.g. amount or rate of water absorption, optionally in combination with other parameters relating to physical or mechanical properties · CPC title

• D21H27/02 Primary

  Patterned paper (patterned coatings D21H19/66; embossing B31F1/07; prepared on the paper-making machines D21F11/00) · CPC title

• D21H19/10

  Coatings without pigments (D21H19/66 takes precedence) · CPC title