U.S. patent application number 11/726561 was filed with the patent office on 2008-09-25 for papermaking belt having a three dimensional surface pattern.
Invention is credited to Ward William Ostendorf, Rebecca Howland Spitzer, Grant Edward Tompkins.
Application Number | 20080230200 11/726561 |
Document ID | / |
Family ID | 39590547 |
Filed Date | 2008-09-25 |
United States Patent
Application |
20080230200 |
Kind Code |
A1 |
Tompkins; Grant Edward ; et
al. |
September 25, 2008 |
Papermaking belt having a three dimensional surface pattern
Abstract
A papermaking belt for making a fibrous structure product that
has a machine direction, a cross machine direction orthogonal and
co-planar with the machine direction, and a Z-direction mutually
orthogonal to both the machine and cross machine directions. The
papermaking belt also has a framework having a structure formed by
a first layer wherein the first layer comprises a plurality of
deflection conduits that correspond to a resultant image and extend
in the Z-direction, where the resultant image being the product of
at least one image modification algorithm. Further, at least one of
the image modification algorithms is a beta image modification
algorithm such that the beta image modification algorithm is a
three dimensional image modification algorithm. The papermaking
belt also has a reinforcing element.
Inventors: |
Tompkins; Grant Edward;
(Fairfield, OH) ; Spitzer; Rebecca Howland;
(Cincinnati, OH) ; Ostendorf; Ward William; (West
Chester, OH) |
Correspondence
Address: |
THE PROCTER & GAMBLE COMPANY;Global Legal Department - IP
Sycamore Building - 4th Floor, 299 East Sixth Street
CINCINNATI
OH
45202
US
|
Family ID: |
39590547 |
Appl. No.: |
11/726561 |
Filed: |
March 22, 2007 |
Current U.S.
Class: |
162/289 |
Current CPC
Class: |
D21F 11/006
20130101 |
Class at
Publication: |
162/362 |
International
Class: |
D21G 9/00 20060101
D21G009/00 |
Claims
1. A papermaking belt for making a fibrous structure product having
a machine direction, a cross machine direction orthogonal and
co-planar thereto, and a Z-direction mutually orthogonal to both
the machine and cross machine directions comprising: a framework,
the framework comprising: a structure formed by a first layer
wherein the first layer comprises a plurality of deflection
conduits that correspond to a resultant image and extend in the
Z-direction, the resultant image being the product of at least one
image modification algorithm; wherein at least one of the image
modification algorithms is a beta image modification algorithm, the
beta image modification algorithm being a three dimensional image
modification algorithm; and a reinforcing element.
2. The papermaking belt according to claim 1 wherein the resultant
image is the product of at least two image modification algorithms,
a first image modification algorithm being an alpha image
modification algorithm and a second image modification algorithm
being a beta image modification algorithm.
3. The papermaking belt according to claim 2 wherein an alpha image
modification algorithm is performed prior to the beta image
modification algorithm.
4. The papermaking belt according to claim 3 wherein the alpha
image modification algorithm is a two dimensional image
modification algorithm.
5. The papermaking belt according to claim 2 wherein the resultant
image is the product of a plurality of alpha image modification
algorithms.
6. The papermaking belt according to claim 5 wherein the beta image
modification algorithm is performed after all alpha image
modification algorithms.
7. The papermaking belt according to claim 1 wherein the resultant
image is vectorized.
8. The papermaking belt according to claim 7 wherein the resultant
image is vectorized after all of the at least one image
modification algorithms have been applied.
9. The papermaking belt according to claim 1 wherein the first
layer further comprises a photosensitive resin.
10. The papermaking belt according to claim 9 wherein the
photosensitive resin comprises a solid polymeric material which has
been rendered solid by actinic radiation.
11. The papermaking belt according to claim 1 wherein the fibrous
structure product is an absorbent paper product.
12. A framework for a papermaking belt, the framework comprising a
photosensitive resin that has been exposed to actinic radiation
through a mask comprising an image, the image being the product of
at least one image modification algorithm, wherein one of the at
least one image modification algorithm is a beta image modification
algorithm and wherein the beta image modification algorithm is a
three dimensional image modification algorithm.
13. The framework according to claim 12 wherein the image is the
product of at least two image modification algorithms.
14. The framework according to claim 13 wherein one of the at least
two image modification algorithms is an alpha image modification
algorithm, the alpha image modification algorithm being performed
prior to the beta image modification algorithm.
15. The framework according to claim 14 wherein the alpha image
modification algorithm is a two dimensional image modification
algorithm.
16. The papermaking belt according to claim 14 wherein the beta
image modification algorithm is performed after all alpha image
modification algorithms.
17. The papermaking belt according to claim 14 comprising a
plurality of alpha image modification algorithms.
18. The papermaking belt according to claim 12 wherein the
resultant image is vectorized.
19. The papermaking belt according to claim 18 wherein the
resultant image is vectorized after all of the one or more image
modification algorithms have been applied.
20. A process for making an image for a papermaking belt wherein
the image is the product of: (a) providing an image; and (b)
performing at least one image modification algorithm thereon, one
of the at least one image modification algorithms being a beta
image modification algorithm and the beta image modification
algorithm being a three-dimensional image modification algorithm to
provide a resultant image.
21. The process according to claim 20 further comprising the step:
(c) modifying the image with a second image modification algorithm,
the image modification algorithm being an alpha image modification
algorithm.
22. The process according to claim 21 wherein step (c) is performed
before step (b).
23. The process according to claim 22 wherein the alpha image
modification algorithm is a two dimensional image modification
algorithm.
24. The process according to claim 21 further comprising the step:
(d) modifying the image with a plurality of alpha image
modification algorithms.
25. The process according to step 24 wherein step (d) is performed
before step (b).
26. The process according to claim 20 further comprising the step:
(e) vectorizing the resultant image.
27. The process according to claim 26 wherein step (e) is performed
after step (b).
28. The process according to claim 20 further comprising the step:
(f) converting the resultant image to an industrially usable
format.
29. A process for making a papermaking belt comprising the steps
of: (a) providing an image; (b) performing at least one image
modification algorithm on the image, one of the at least one image
modification algorithms being a beta image modification algorithm
and the beta image modification algorithm being a three-dimensional
image modification algorithm to provide a resultant image; (c)
using the resultant image as a template to form a mask; (d)
radiating a photosensitive resin that is disposed on the surface of
a reinforcing element through the mask; and (e) removing the
uncured photosensitive resin.
30. The process according to claim 29 further comprising the step:
(f) modifying the image with a second image modification algorithm,
the image modification algorithm being an alpha image modification
algorithm.
31. The process according to claim 21 wherein step (f) is performed
before step (b).
32. The process according to claim 31 wherein the alpha image
modification algorithm is a two dimensional image modification
algorithm.
33. The process according to claim 30 further comprising the step:
(g) modifying the image with a plurality of alpha image
modification algorithms.
34. The process according to step 33 wherein step (g) is performed
before step (b).
35. The process according to claim 29 further comprising the step:
(h) vectorizing the resultant image.
36. The process according to claim 35 wherein step (h) is performed
after step (b).
37. The process according to claim 29 further comprising the step:
(i) converting the resultant image to an industrially usable
format.
38. The process according to claim 37 wherein step (i) further
comprises the step: (i)(1): printing the industrially usable format
onto a transparent surface to form a mask.
39. The process according to claim 29 wherein the papermaking belt
further comprises a negative-tone image of the resultant image.
Description
FIELD OF THE INVENTION
[0001] This invention pertains to the apparatus for producing
images disposed upon a products, particularly papermaking belts
that make a product which has a three an image disposed thereon
that presents a three dimensional effect to the observer.
BACKGROUND OF THE INVENTION
[0002] Absorbent paper products are a staple of everyday life.
Absorbent paper products are used as consumer products for paper
towels, toilet tissue, facial tissue, napkins, and the like. The
large demand for such paper products has created a demand for
improved aesthetics and functional benefits in absorbent paper
products, and as a result, has driven the need for novel methods
for providing these visual effects and benefits to absorbent paper
products.
[0003] Visual effects may be provided on an absorbent paper product
by a number of techniques. For example, a pattern may be embossed
onto the surface of a paper web as it is being converted.
Alternatively, a pattern may be molded directly onto the surface of
a paper web using a patterned papermaking belt. Patterns provided
onto the surface of paper products not only provide the consumer
with a positive visual appearance both at the time of purchase and
during use, but may also provide a number of functional advantages.
For example, a highly textured surface as can be provided by
embossing or by the use of textured belts may increase the
softness, absorbency, or caliper of a paper product.
[0004] With the advent and growth of the computer imaging industry
there has been a rapid saturation of consumers with three
dimensional computer graphics, images, and effects. Without being
limited by theory, it is thought that consumers perceive the use of
such three dimensional effects as denoting a product or good that
is technologically advanced, in addition to providing an
interesting visual experience to the consumer. As a result, many
consumers prefer goods that provide such a three dimensional
effect.
[0005] Accordingly, there exists the need to provide a means for
providing an absorbent paper product having an aesthetically
pleasing surface pattern having a three dimensional effect.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is an exemplary flow diagram illustrating a method of
creating surface patterns for cellulosic fibrous structure
products.
[0007] FIG. 2 is a top plan view of an exemplary image. The image
being a "checkerboard."
[0008] FIG. 3 is a top plan view of an exemplary resultant image of
FIG. 2 after a "triangular tile" image modification algorithm has
been applied.
[0009] FIG. 4 is a top plan view of an exemplary resultant image of
FIG. 3 after a "bulge" image modification algorithm has been
applied.
[0010] FIG. 5 is an expanded top plan view of the image of FIG. 4
by the region labeled 5.
[0011] FIG. 6 is a top plan view of an exemplary resultant image of
FIG. 5 after vectorization.
[0012] FIG. 7A is a fragmentary top plan view of an exemplary
embodiment of a papermaking belt.
[0013] FIG. 7B is a cross sectional view of the papermaking belt of
FIG. 7A taken along line 7B-7B.
SUMMARY OF THE INVENTION
[0014] The present invention relates to a papermaking belt for
making a fibrous structure product. The papermaking belt has a
machine direction, a cross machine direction orthogonal and
co-planar with the machine direction, and a Z-direction mutually
orthogonal to both the machine and cross machine directions. The
papermaking belt comprises a framework and a reinforcing element.
The framework has a structure formed by a first layer wherein the
first layer comprises a plurality of deflection conduits that
correspond to a resultant image and extend in the Z-direction,
where the resultant image being the product of at least one image
modification algorithm. Further, at least one of the image
modification algorithms is a beta image modification algorithm such
that the beta image modification algorithm is a three dimensional
image modification algorithm.
[0015] In another embodiment, the present invention relates to a
framework for a papermaking belt. The framework has a
photosensitive resin that has been exposed to actinic radiation
through a mask comprising an image. The image is the product of at
least one image modification algorithm. The at least one image
modification algorithm is a beta image modification algorithm. The
beta image modification algorithm is a three dimensional image
modification algorithm.
DETAILED DESCRIPTION OF THE INVENTION
Definitions
[0016] As used herein, "paper product" refers to any formed,
fibrous structure products, traditionally, but not necessarily,
comprising cellulose fibers. In one embodiment, the paper products
of the present invention include tissue-towel paper products.
[0017] As used herein, "fibrous structure" or "fibrous structure
product" refers to products comprising paper tissue or paper towel
technology in general, including, but not limited to, conventional
felt-pressed or conventional wet-pressed fibrous structure product,
pattern densified fibrous structure product, starch substrates, and
high bulk, uncompacted fibrous structure product. Non-limiting
examples of tissue-towel paper products include disposable or
reusable, toweling, facial tissue, bath tissue, table napkins,
placemats, wipes, and the like.
[0018] As used herein, "image" refers to any figure, drawing, or
other visual representation in any coordinate system. In one
embodiment, an image can be a simple geometric figure which may be
selected from, but not limited to: rectangles, squares, circles,
triangles, ovals, polygons, quadrilaterals, and combinations
thereof. In another embodiment, an image can be a random
non-geometric shape.
[0019] As used herein, "resultant image" refers to the consequent
image after an image modification algorithm has been applied to an
image.
[0020] As used herein, "image modification algorithm," also known
to those of skill in the art as a "filter", refers to an algorithm
that performs one or more mathematical operations on the
mathematical expression of the image. The modified (operated on)
image is referred to as a resultant image. Exemplary mathematical
operations that may be used as image modification algorithms
include, but are not limited to, rotations, reflections and
translations. For instance, a transformation performed in a two
dimensional (sometimes referred to by those of skill in the art as
"Euclidean") plane can move every point of the image by a fixed
distance in the same direction or even shift the origin of the
coordinate system to a new point. For example, if v is a fixed
vector, then the translation T.sub.v(p) about another vector p can
be described mathematically as:
T.sub.v(p)=p+v
An image modification algorithm may have one or more adjustable
parameters or variables that affect the extent to which the
mathematical operation may affect the resultant image (such as p in
the above example). As a result, one image modification algorithm
may be adjusted to provide different resultant images by changing
the parameters, such as p, selected for each image modification
algorithm.
[0021] As used herein, "resolution" refers the measure of sharpness
of an image expressed as the total number of pixels, or points of
color, per unit area (i.e. the number density of pixels) in the
image.
[0022] As used herein, "raster image" also known to those of skill
in the art as a "bitmap" refers to a data file or structure
representing a grid of pixels in an image. Without wishing to be
limited by theory, it is thought that the quality of a raster image
is limited by the resolution and the type of information in each
pixel (so called "color depth"). For example, an image sampled at
640.times.480 pixels (therefore containing 307,200 pixels) may not
appear as clear as an image sampled at 1280.times.1024 (1,310,720
pixels) in the same area.
[0023] As used herein, "vector image" refers to images that may be
comprised of one or more individual, scalable geometric objects,
such as curves and polygons, which may be defined by a mathematical
function. A non-limiting example of a vector image which can be
described by a geometric object is a circle. One embodiment of a
circle that may be defined by a geometric object may be expressed
by the function:
f(r)=[(x-h).sup.2+(y-k).sup.2].sup.1/2
where h and k are the x- and y-coordinates of the center of the
circle in a Euclidian plane and r is the radius of the circle.
Thus, a circle with radius of 5 units around the origin (x- and
y-coordinates of 0) may be described as:
5=[x.sup.2+y.sup.2].sup.1/2
Without wishing to be bound by theory, because a vector image may
be defined mathematically, it is thought that it is possible to
freely change any number of parameters without causing a loss of
resolution as the image is modified or scaled to a larger size. For
example, the circle with a radius of 5 units as described above can
be scaled to a circle of radius 10 units by simply altering the
radius (a parameter):
10=[x.sup.2+y.sup.2].sup.1/2
Alternatively, the circle may be scaled and translated so that it
has a radius of 6 units and is no longer centered about the origin,
but centered about the x-coordinate -2 and the y-coordinate +3:
6=[(x+2).sup.2+(y-3).sup.2].sup.1/2
A vector image may be distinguished from a raster image in that
vector images represent an image through the use of geometric
objects such as curves and polygons while raster images are
represented using pixels.
[0024] As used herein, "vectorize" or "vectorizing" refers to the
process of converting any raster image to a vector image. It is
known in the art that raster images which have been vectorized can
be rescaled without quality loss. A nonlimiting example of a method
for converting a raster image to a vector image is to replace the
pixels in a raster image with geometric objects to form a vector
image. This conversion can be done manually or using a software
package such as Adobe Illustrator.TM., CorelDRAW!.TM., and Adobe
Streamline.TM.. Without being limited by theory, many software
packages trace lines around a raster image and assign geometric
objects to the traced outline of the raster image. An example of a
method for converting a raster image to a vector image is disclosed
in U.S. Pat. No. 5,715,331.
[0025] As used herein, "industrially usable format" refers to any
file type that can be used as a template for the creation of any
article of manufacture. Nonlimiting examples of articles of
manufacture include, but are not limited to: a patterned belt,
emboss roll, or print roll. Examples of industrially usable formats
include, but are not limited to: Computer Aided Design or CAD
(*.dwg or *.dxf) format and Adobe Illustrator.TM. (*.ai)
format.
[0026] As used herein, "fibrous structure" as used herein means an
arrangement of fibers produced in any papermaking machine known in
the art to create a ply of paper. "Fiber" means an elongate
particulate having an apparent length greatly exceeding its
apparent width. More specifically, and as used herein, fiber refers
to such fibers suitable for a papermaking process. The present
invention contemplates the use of a variety of paper making fibers,
such as, natural fibers, synthetic fibers, as well as any other
suitable fibers, starches, and combinations thereof. Paper making
fibers useful in the present invention include cellulosic fibers
commonly known as wood pulp fibers. Applicable wood pulps include
chemical pulps, such as Kraft, sulfite and sulfate pulps;
mechanical pulps including groundwood, thermomechanical pulp;
chemithermomechanical pulp; chemically modified pulps, and the
like. Chemical pulps, however, may be preferred in tissue towel
embodiments since they are known to those of skill in the art to
impart a superior tactical sense of softness to tissue sheets made
therefrom.
[0027] Pulps derived from deciduous trees (hardwood) and/or
coniferous trees (softwood) can be utilized herein. Such hardwood
and softwood fibers can be blended or deposited in layers to
provide a stratified web. Exemplary layering embodiments and
processes of layering are disclosed in U.S. Pat. Nos. 3,994,771 and
4,300,981.
[0028] Additionally, fibers derived from non-wood pulp such as
cotton linters, bagesse, and the like, can be used. Additionally,
fibers derived from recycled paper, which may contain any or all of
the pulp categories listed above, as well as other non-fibrous
materials such as fillers and adhesives used to manufacture the
original paper product may be used in the present web. In addition,
fibers and/or filaments made from polymers, specifically hydroxyl
polymers, may be used in the present invention. Non-limiting
examples of suitable hydroxyl polymers include polyvinyl alcohol,
starch, starch derivatives, chitosan, chitosan derivatives,
cellulose derivatives, gums, arabinans, galactans, and combinations
thereof. Additionally, other synthetic fibers such as rayon,
lyocel, polyester, polyethylene, and polypropylene fibers can be
used within the scope of the present invention. Further, such
fibers may be latex bonded. Other materials are also intended to be
within the scope of the present invention as long as they do not
interfere or counter act any advantage presented by the instant
invention.
[0029] As used herein, "Machine Direction" or "MD" means the
direction parallel to the flow of the fibrous structure through a
papermaking machine and/or product manufacturing equipment.
[0030] As used herein, "Cross Machine Direction" or "CD" means the
direction perpendicular to, and coplanar with, the machine
direction of the fibrous structure and/or fibrous structure product
comprising the fibrous structure.
[0031] As used herein, "Z-direction" means the direction normal to
a plane formed by machine direction and cross machine
directions.
Process for Producing a 3-D Image
[0032] FIG. 1 is a flow chart illustrating the steps of one
embodiment of the present method for developing three dimensional
surface patterns for fibrous structure products. Referring to FIG.
1, a first image 10 is provided by the user. This first image 10
may be provided by any means known in the art. In an exemplary
embodiment, the first image may be created using a software program
that will be performing the image modification algorithm(s), by
hand (outside of a computer), or by using a computer software
program that can be different from the one that will be applying
the image modification algorithm to the first image 10. In one
embodiment, a first image 10 may be drawn by hand outside of the
computer. If the first image 10 is drawn by hand, then one of skill
in the art may appreciate that an optical scanner may be used to
scan such a hand-drawn image into an image file format. The
software can then apply the image modification algorithms to the
resulting image file. If the first image 10 is drawn using a
different software program than what will be used to perform image
modification algorithms, then that image could be saved in an image
file format that will be usable by the software that will perform
the image modification algorithms. Nonlimiting examples of image
files are jpeg (.jpg) or tiff (.tiff) files.
[0033] The first image 10 may then be modified using an alpha image
modification algorithm 20. By convention herein, an alpha image
modification algorithm 20 may be a two dimensional image
modification algorithm. An alpha image modification algorithm 20
can be repeated any number of times with any combination or
sequence of image modification algorithms to create a variety of
resultant images. An alpha image modification 20 may be performed
using any suitable software package. Nonlimiting examples of
suitable software packages for performing two dimensional image
modifications include: Adobe Photoshop.TM., Adobe Illustrator.TM.,
Adobe After Effects.TM., Cinema 4D.TM., Maya.TM., 3D Studio
Max.TM., Lightwave 3D.TM., the like, and combinations thereof.
Examples of two dimensional image modification algorithms include,
but are not limited to: tile (which replicates a single object any
number of times), kaleidoscope (which divides an image into smaller
parts, replicates the smaller parts and then rotates the replicated
parts), blur (which diffuses the pixels which comprise a raster
image), the like and combinations thereof. The terms given as
examples are those from the Apple Motion.TM. software package. It
should be understood by those of skill in the art that the terms
used to describe two dimensional image modification algorithms can
be purely arbitrary when compared to the actual mathematical
operation(s) that are used because similar image modification
algorithms may have different names in different software
packages.
[0034] The image that results from the first image 10 modification
algorithm 20 may be further modified by applying a beta image
modification algorithm 30. Alternatively, in one embodiment, the
first image 10 may be modified by applying a beta image
modification algorithm 30 without having been modified by an alpha
image modification algorithm 20. By convention, a beta image
modification algorithm 30 is a three dimensional image modification
algorithm. It is believed that the image that results from an alpha
image modification algorithm 20 may be modified by any number of
additional alpha image modification algorithms 20 before being
modified by a beta image modification algorithm 30. Without being
limited by theory, it is thought that a beta image modification
algorithm 30 can be visually differentiated from two-dimensional
image modification algorithms because three-dimensional image
modification algorithms create an apparent difference in scale or
sense of depth. Further, in one embodiment, a beta image
modification algorithm 30 applied to an image causes the resultant
image have a "falloff effect" at the edges of the resultant image.
A falloff effect may be described as having the appearance of the
edges gradually dropping off in the z-direction. Examples of three
dimensional imaging software packages include, but are not limited
to: Cinema 4D.TM., Maya.TM., Apple Motion.TM., 3D Studio Max.TM.,
the like, and combinations thereof. Within Apple Motion.TM.,
examples of three dimensional image modification algorithms
include, but are not limited to: black hole (which creates a hole
in the image having a falloff effect at the resultant edges of the
image around the circle), bulge (which creates a circle in the
image and maps the pixels within the circle from a Cartesian
coordinate system onto a polar coordinate system), disc warp (which
chooses a section of an image, rotates that section, and then
creates a falloff effect at the edges of that section), the like
and combinations thereof.
[0035] Once the beta image modification algorithm 30 is applied,
the resultant image may be converted from a raster image to a
vector image 40 using any means known in the art. The vector image
40 may be converted to an industrially usable format 50. The
industrially usable format 50 may then be used as a template to
make a papermaking belt 52, embossing roll 55, or pattern for a
print roll 58 as described infra. The process describing the
construction of a papermaking belt is described in the "Papermaking
Belt" section below. The resultant image can then be provided to a
fibrous structure product 60.
[0036] FIG. 2 is an exemplary embodiment of a first image 10. In
the exemplary embodiment the first image 10 is a checkerboard
having squares 9 with a solid color fill that are arranged
diagonally from one another. The first image 10 may be created by
hand drawing or by using any software drawing applications as
discussed supra. In the exemplary embodiment, the checkerboard is
created using the "checkerboard" function in the Apple Motion.TM.
software program.
[0037] FIG. 3 is an exemplary embodiment of the image first image
10 of FIG. 2 after an alpha image modification algorithm 20 has
been applied to the first image 10. In this exemplary embodiment
the alpha image modification algorithm 20 is a "triangular tile"
algorithm used in the Apple Motion.TM. software package. In the
exemplary embodiment, the alpha image modification algorithm 20
divides the checkerboard pattern into smaller pieces and rotates
those pieces to form a first resultant image 300.
[0038] FIG. 4 is an exemplary embodiment of the first resultant
image 300 of FIG. 3 after a beta image modification algorithm 30 is
applied. In this exemplary embodiment the beta image modification
algorithm is a three dimensional image modification algorithm.
Specifically, the image modification algorithm is a "bulge"
algorithm used in the Apple Motion.TM. software package. In the
exemplary embodiment, the beta image modification algorithm 30
identified a circular area within the first resultant image 300 and
mapped the points from a Cartesian coordinate system within the
circular area onto a polar coordinate system within the circular
area to yield a second resultant image 400.
[0039] FIG. 5 is a magnified view of FIG. 5 taken within the area
defined as 5. As can be seen in FIG. 5, the border lines 510 that
define the shapes of the pattern appear to be grainy and are not
crisp due to any scaling or rotation from the image modification
algorithms only operating on pixels and not on geometric
objects.
[0040] FIG. 6 is a view of FIG. 5 once the image of FIG. 5 has been
converted from a raster image to a vector image 40 using the
automatic vectorization feature in the Apple Motion.TM. software
package. As can be seen in FIG. 6, once vectorized, the border
lines 510 that define the shapes of the pattern are crisp because
the image modification algorithm was able to operate on a geometric
object rather than operating on pixels. As discussed supra,
vectorizing an image defines that image in terms of mathematical
functions that can be scaled and manipulated without a loss of
image data.
Papermaking Belt Having a Three Dimensional Image Thereon
[0041] The images produced according to the process of the present
invention may be applied to the surface of the fibrous structure
product by any means known in the art. For example, the rasterized
and/or vectorized images as produced by the process described
herein can be applied via the application of ink to the surface of
a fibrous structure product. Suitable processes for applying ink to
a roll and then from the roll to the fibrous structure product by
printing include, but are not limited to lithography, letter press,
gravure, screen printing, intaglio, and flexography. The method for
transferring an image of the present invention to a print roll or
other printing mechanism may be done using any method that is known
in the art. An exemplary embodiment of using ink to create surface
patterns on fibrous structure products is disclosed in U.S. Pat.
No. 7,037,575.
[0042] Alternatively, the images may be imparted to a fibrous
structure product by embossing. The present invention images may be
transferred to an embossing roll using any means known in the art.
Knob to knob embossing is well known in the art as illustrated by
commonly assigned U.S. Pat. No. 3,414,459. The images may also be
imparted to the fibrous structure product by nested embossing as
illustrated by U.S. Pat. No. 4,320,162. In addition, the images may
be imparted to the fibrous structure product by dual ply lamination
embossing as illustrated by U.S. Pat. No. 5,468,323.
Patterned Belt
[0043] Patterned belts can also be used to apply images to fibrous
structure products. Processes for using patterned belts to make
fibrous structure products that have images disposed thereon
include, but are not limited to those processes disclosed in U.S.
Pat. No. 3,301,746, U.S. Pat. No. 3,974,025, U.S. Pat. No.
4,239,065, U.S. Pat. No. 4,528,239, and U.S. Pat. Application No.
60/855576.
[0044] FIG. 7A is an exemplary embodiment of a portion of a
papermaking belt 100 produced according to the present invention.
The papermaking belt 100 may be used as a through air drying belt,
a forming wire, a backing wire for a twin wire former, a transfer
belt, or, with appropriate batting, as a press felt, etc. Except as
noted, the following discussion is directed to through air drying
belt although the foregoing executions are contemplated to be
within the scope of the invention.
[0045] The papermaking belt 100 has a machine direction, a cross
machine direction, and a thickness extending in a Z-direction
perpendicular to the plane formed by the machine and cross machine
directions that may receive a slurry of fibers that form the
fibrous structure product. Without being limited by theory, it is
thought that deflection conduits within the framework mold the
slurry of fibers as the fibrous structure product is formed. As a
result, the arrangement of the deflection conduits within the
framework may be used to impart an image as described herein onto
the surface of the fibrous structure product. The papermaking belt
100 comprises two primary components: a framework 120 and a
reinforcing element 130. The framework 120 may comprise any
suitable material, including, without limitation, a resinous
material (such as a photosensitive resin), a plastic, a metal,
metal-impregnated polymers, a molded or extruded thermoplastic or
pseudo-thermoplastic material, and in one embodiment comprises a
cured polymeric photosensitive resin.
[0046] FIG. 7B is a cross-sectional view of FIG. 7A taken along
lines 7B-7B showing the relationship of the belt 100, framework
120, and reinforcing element 130 in the machine direction and the
Z-direction.
[0047] The reinforcing element 130 may comprise a woven fabric as
is known in the art. The reinforcing element 130 may be
fluid-permeable, fluid-impermeable, or partially fluid-permeable
(meaning that some portions of the reinforcing element may be
fluid-permeable while other portions thereof may not be). Examples
of the reinforcing element include, but are not limited to, a woven
element, a felt, a mesh wire, or combinations thereof.
Exemplary Method of Making a Patterned Belt
[0048] The papermaking belt 100 according to the present invention
may be made by curing a photosensitive resin through a mask. A mask
may be made using any means known in the art. Nonlimiting examples
of methods for making masks for photoradiation purposes are
described in U.S. Pat. Nos. 3,877,810, 4,374,911, 6,783,898 and
U.S. Pat. App. No. 2004/0126710 A1. In one embodiment, an image
produced according to the present invention that is in an
industrially usable format 50 may be used as a template to form the
mask. In one embodiment, the industrially usable format 50 may be
saved as an Encapsulated Postscript (or *.eps) file format and then
opened using a software printing program such as, but not limited
to, Wasatch SoftRIP.TM., that may take the resultant image from the
*.eps file and repeat the resultant image over a user-specified
length and width. The software printing program will then print the
image onto a transparent surface to form a mask having first
regions which are transparent to actinic radiation and second
regions which are opaque to the actinic radiation. In one
embodiment, the printing can be done in one step by transferring
the ink to a transparent film using a printer such as, but not
limited to a Hewlett Packard.TM. Design Jet 5000.
[0049] The regions in the mask which are transparent to the actinic
radiation will form like regions in the photosensitive resin which
cure and become the framework 130 of the papermaking belt 100.
Conversely, the regions of the mask which are opaque to the actinic
radiation will cause the resin in the corresponding positions to
remain uncured. Uncured resin may be removed during the beltmaking
process and does not form part of the papermaking belt 100. Because
the mask will determine what the surface of the belt will look
like, the mask may be patterned according to any image that may be
created as discussed supra.
[0050] The belt of the present invention may be formed by a process
comprising the following steps: First, providing a coating of a
liquid curable material. In one embodiment, the liquid curable
material comprises a first layer. In one embodiment the liquid
curable material is a photosensitive resin. The coating can be
applied by any means known in the art. In one embodiment the coat
is provided by dispensing liquid curable material through a nozzle.
The thickness of the coating can be controlled by, for example, a
roll, a bar, a knife, or any other suitable means known in the art.
In one embodiment the coating of liquid curable material is
supported by a forming surface, the coating having a first
thickness. Second, providing a source of actinic radiation to cure
the liquid curable material. In one embodiment, the source of
actinic radiation may be a lamp having a bulb capable of providing
light at the appropriate wavelength to cure the liquid curable
material. Third, providing a mask having a pre-selected pattern of
transparent regions and opaque regions that correspond to an image
produced according to the present invention therein and positioning
the first mask between the coating of the curable material and the
source of curing radiation so that the opaque regions of the first
mask shield areas of the coating from the curing radiation while
the transparent regions of the first mask cause other areas of the
coating to be unshielded. Fourth, curing the unshielded areas of
the coating by exposing the coating to the actinic radiation
through the mask having an image thereon. The shielded areas of the
coating uncured. Fifth, removing substantially all uncured liquid
curable material from the partly-formed first layer to leave a
hardened or semi-hardened material structure. Sixth, removing
substantially all uncured liquid curable material from the cured
layer to leave a hardened material or semi-hardened material
structure that corresponds to the negative tone of the image
described infra.
[0051] In one embodiment, a backing film may be provided and
positioned between the forming surface and the coating of a liquid
photosensitive resin, to protect the forming surface from being
contaminated by the liquid resin. If the papermaking belt having a
reinforcing element is desired, the process may further include
steps of providing a suitable reinforcing element supported by the
forming surface, the reinforcing element having a paper facing side
and a machine facing side, and depositing a coating of a liquid
photosensitive resin to the paper facing side of the reinforcing
element.
Products
[0052] The fibrous structure product may comprise a tissue-towel
paper product known in the industry. Embodiment of these substrates
may be made according U.S. Pat. Nos. 4,191,609, 4,300,981,
4,191,609, 4,514,345, 4,528,239, 4,529,480, 4,637,859, 5,245,025,
5,275,700, 5,328,565, 5,334,289, 5,364,504, 5,527,428, 5,556,509,
5,628,876, 5,629,052, 5,637,194, and 5,411,636; European Patent
677,612; U.S. Patent App. No. 2004/0192136A1 and U.S. Provisional
Patent No. 60/855499.
[0053] In one embodiment, the fibrous structure product may be
manufactured via a wet-laid paper making process. In other
embodiments, the fibrous structure product may be manufactured via
a through-air-dried paper making process or foreshortened by
creping or by wet microcontraction. In some embodiments, the
resultant plies of fibrous structure may be differential density
fibrous structure plies, wet laid fibrous structure plies, air laid
fibrous structure pliles, conventional fibrous structure plies, and
combinations thereof. Creping and/or wet microcontraction are
disclosed in U.S. Pat. Nos. 6,048,938, 5,942,085, 5,865,950,
4,440,597, 4,191,756, and 6,187,138.
[0054] In one embodiment, the fibrous structure product may be a
paper towel product or a toilet tissue product having an image as
produced by the process of the present invention disposed thereon.
Paper towel products and toilet tissue products having images
disposed thereon are described in U.S. Provisional Patent No.
60/855499.
EXAMPLE
Making a Three Dimensional Image
[0055] One embodiment of creating an image in an industrially
usable format that could be used for making a paper product with a
three dimensional surface pattern according to the present
invention includes the following components: An Apple Mac.TM.
computer with the Apple Motion.TM. and Adobe Illustrator.TM.
software packages installed.
[0056] The steps used to create a paper product with a three
dimensional surface pattern the following steps are:
Creating the Three Dimensional Pattern
[0057] 1. Launch the Apple Motion.TM. software package. Using the
"library" tab, choose the "generators" option. From that option
choose the "checkerboard" and drag it onto the stage. [0058] 2.
From the "library" tab choose the "Triangular Tile" effect located
in the "Image Units" sub folder with the base image selected.
Adjust the "angle" and "width" parameters to produce the desired
effect. [0059] 3. From the "library" tab choose the "bulge" effect
in the Distortion sub folder with the base image selected. Adjust
the "amount" and "scale" parameters to produce the desired effect.
[0060] 4. Go to the "file" tab and choose "export." [0061] 5.
Change the export time from "movie" to "single frame" and export
the frame as an image format (*.jpg/JPEG). [0062] 6. Close Apple
Motion.TM. and launch Adobe Illustrator.TM. [0063] 7. Import the
exported 2D pattern into Adobe Illustrator by dragging the exported
file onto the canvas from the file browser. [0064] 8. Select the
image and in the upper toolbar, choose "live trace." Adjust the
parameters for Live Trace. Leave all parameters at the default
levels except disable the "stroke" parameter, choose "only" option
in the "fill" parameter, and adjust the "edge tolerance" parameter
to produce the desired effect. [0065] 9. Click on the image to
select it and choose "expand" from the top toolbar. [0066] 10. From
the file tab choose "export." When asked what kind of file to
export, choose the AutoCad format (*.dwg). [0067] 11. With the CAD
file in hand, a patterned belt as described above can be made using
any means known in the art for making a mask.
[0068] All publications, patent applications, and issued patents
mentioned herein are hereby incorporated in their entirety by
reference. Citation of any reference is not an admission regarding
any determination as to its availability as prior art to the
claimed invention.
[0069] 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 dimension or value and a
functionally equivalent range surrounding that dimension or value.
For example, a dimension disclosed as "40 mm" is intended to mean
"about 40 mm".
[0070] 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.
* * * * *