U.S. patent application number 12/273746 was filed with the patent office on 2009-06-25 for absorbent paper product having complementary use components.
Invention is credited to Heather Sabrina Cummings, Noel Mathey Geoffroy, Kathryn Christian Kien, William Travis Lonigan, Paul Francis O'Connor, Connie Marie Roetker, Rachael Eden Walther.
Application Number | 20090159225 12/273746 |
Document ID | / |
Family ID | 40756067 |
Filed Date | 2009-06-25 |
United States Patent
Application |
20090159225 |
Kind Code |
A1 |
Geoffroy; Noel Mathey ; et
al. |
June 25, 2009 |
ABSORBENT PAPER PRODUCT HAVING COMPLEMENTARY USE COMPONENTS
Abstract
A sheet of paper product having two or more complementary
function components. One of the complementary function components
is a pocket.
Inventors: |
Geoffroy; Noel Mathey;
(Cincinnati, OH) ; Walther; Rachael Eden; (Union,
KY) ; Roetker; Connie Marie; (Fairfield, OH) ;
O'Connor; Paul Francis; (Portland, OR) ; Lonigan;
William Travis; (Beaverton, OR) ; Cummings; Heather
Sabrina; (Portland, OR) ; Kien; Kathryn
Christian; (Cincinnati, 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: |
40756067 |
Appl. No.: |
12/273746 |
Filed: |
November 19, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60992732 |
Dec 6, 2007 |
|
|
|
Current U.S.
Class: |
162/114 ;
162/158; 162/164.1; 162/231 |
Current CPC
Class: |
A47K 10/16 20130101;
D21H 27/002 20130101; A47L 13/17 20130101 |
Class at
Publication: |
162/114 ;
162/231; 162/158; 162/164.1 |
International
Class: |
D21H 27/00 20060101
D21H027/00; D21H 21/00 20060101 D21H021/00 |
Claims
1. A sheet of paper product comprising two or more complementary
function components, wherein one of the one or more complementary
function components is a pocket.
2. A sheet of paper product according to claim 1 wherein the one of
the one or more complementary functions occupies from about 2% to
about 30% of the surface area of one side of the web.
3. A sheet of paper product according to claim 2 wherein the one of
the one or more complementary functions occupies from about 3% to
about 10% of the surface area of one side of the web.
4. A sheet of paper product according to claim 1 wherein the pocket
is a triangle.
5. A sheet of paper product according to claim 4 wherein the pocket
has a width of from about 1'' to about 4''.
6. A sheet of paper product according to claim 4 wherein the pocket
has a height of from about 1'' to about 3''
7. A sheet of paper product according to claim 1 wherein the pocket
comprises a first side.
8. A sheet of paper product according to claim 7 wherein the pocket
further comprises a second side.
9. A sheet of paper product according to claim 1 wherein the web
further comprises a second complementary function component wherein
the second complementary function component is an abrasive
zone.
10. A sheet of paper product according to claim 9 wherein the
abrasive zone is juxtaposed on the opposite face, but in the same
MD and CD location as the pocket.
11. A continuous web of paper product comprising a plurality of
perforations; wherein the perforations provide a plurality of
sheets, each sheet comprising two or more complementary function
components; wherein one of the one or more complementary function
components is a pocket; and wherein the plurality of sheets may be
separated at the perforations.
12. The web of paper product according to claim 11 wherein the
sheets have approximately the same dimensions.
13. A web of paper product according to claim 12 wherein the
perforations are from about 1/16'' to about 1/4'' from the
pocket.
14. A sheet of paper product according to claim 11 wherein the web
is wound about a core.
15. A sheet of paper product comprising one or more complementary
function components, wherein one of the one or more complementary
function components is a non-standard material.
16. The sheet of paper product according claim 15 wherein the
non-standard material may be selected from the group consisting of:
cloth, sponge, fabric, polymer, and combinations thereof.
17. A roll paper product comprising a plurality of sheets, wherein
each sheet is separated by a line of perforations; wherein each
sheet comprises one or more complementary function components;
wherein one of the one or more complementary function components is
a non-standard material; and wherein at least one of the one or
more complementary function components are registered to about the
same position on each sheet.
Description
CROSS-REFERENCE TO RELATION APPLICATION
[0001] This application claims the benefit of provisional U.S.
application Ser. No. 60/992,732, filed Dec. 6, 2007.
FIELD OF THE INVENTION
[0002] This invention pertains to an absorbent paper product having
a complementary use component.
BACKGROUND OF THE INVENTION
[0003] Absorbent paper products are a staple of everyday life.
Absorbent paper products may be 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
functionality beyond conventional uses.
[0004] Some consumers prefer cellulosic fibrous structures that can
be easily used on multiple surfaces, or which can perform multiple
tasks. It is known to provide a product that has different surface
on either side (i.e., an abrasive face and a soft face); however,
not all consumers prefer a product wherein the different
functionalities occupy equal areas of the product.
[0005] For example, a consumer may prefer to have a small area on
the surface of the product, such as a small abrasive zone, where
the consumer may concentrate a great deal of force to the one area
to aggressively abrade an area, but then have the remainder of the
product to be smooth so that a post-abrading wipe may be easily
performed without the consumer having to reverse the product. While
it may be possible to keep multiple products that perform different
functions (i.e., one product that performs a wiping task and
another product that performs an abrading task), consumers often
prefer to minimize the number of products that they must purchase
and use.
[0006] Thus, there is the need for a paper towel product comprising
one or more zones of complementary functionality to the body of the
paper towel product. Accordingly, the present invention addresses
the above considerations by providing a paper towel product with
one or more zones of complementary functionality to the body of the
paper towel product.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] While the specification concludes with claims that
particularly point out and distinctly claim the present invention,
it is believed that the present invention will be understood better
from the following description of embodiments, taken in conjunction
with the accompanying drawings, in which like reference numerals
identify identical elements.
[0008] FIG. 1 shows a schematic view of a representative apparatus
that can incorporate the present invention;
[0009] FIG. 2A shows a perspective view of an exemplary component
that can be incorporated into the present invention;
[0010] FIG. 2B shows a perspective view of an exemplary component
that can be incorporated into the present invention;
[0011] FIG. 3 shows a perspective view of an exemplary product
according to the present invention;
[0012] FIG. 4A shows a perspective view of an exemplary product
according to the present invention;
[0013] FIG. 4B shows a cross-sectional view of the exemplary
product of FIG. 4A taken along the line 4B-4B.
[0014] FIG. 5 shows a perspective view of an exemplary product
according to the present invention in roll form.
[0015] FIG. 6 shows a perspective view of an exemplary product
according to the present invention.
[0016] FIG. 7 shows a perspective view of an exemplary product
according to the present invention in roll form.
SUMMARY OF THE INVENTION
[0017] In one embodiment, the present invention is directed to a
sheet of paper product comprising two or more complementary
function components, wherein one of the one or more complementary
function components is a pocket.
[0018] In another embodiment, the present invention is directed to
a continuous web of paper product comprising a plurality of sheets,
wherein each sheet comprises two or more complementary function
components, wherein one of the one or more complementary function
components is a pocket.
[0019] In yet another embodiment, the present invention is directed
to a sheet of paper product comprising one or more complementary
function components, wherein one of the one or more complementary
function components is a non-standard material.
[0020] In still another embodiment, the present invention is
directed to a roll paper product comprising a plurality of sheets,
wherein each sheet is separated by a line of perforations; wherein
each sheet comprises one or more complementary function components;
wherein one of the one or more complementary function components is
a non-standard material; and wherein at least one of the one or
more complementary function components are registered to about the
same position on each sheet.
DETAILED DESCRIPTION OF THE INVENTION
[0021] "Paper product", as used herein, refers to any formed,
fibrous structure products, traditionally, but not necessarily,
comprising cellulose fibers. A paper product may be described in
terms of a continuous web, or in terms of individual sheets. In one
embodiment, the paper products of the present invention include
paper towel products.
[0022] "Cellulosic fibrous structure product", as used herein,
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.
[0023] "Ply" or "Plies", as used herein, means an individual
fibrous structure or sheet of fibrous structure, optionally to be
disposed in a substantially contiguous, face-to-face relationship
with other plies, forming a multi-ply fibrous structure. It is also
contemplated that a single fibrous structure can effectively form
two "plies" or multiple "plies", for example, by being folded on
itself. In one embodiment, the ply has an end use as a tissue-towel
paper product. A ply may comprise one or more wet-laid layers,
air-laid layers, and/or combinations thereof. If more than one
layer is used, it is not necessary for each layer to be made from
the same fibrous structure. Further, the layers may or may not be
homogenous within a layer. The actual makeup of a fibrous structure
product ply is generally determined by the desired benefits of the
final tissue-towel paper product, as would be known to one of skill
in the art. The fibrous structure may comprise one or more plies of
non-woven materials in addition to the wet-laid and/or air-laid
plies.
[0024] "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. 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.
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.
[0025] "Complementary function" or "complementary functionality",
as used herein, means a function, utility or purpose that is
different, but which may accompany or supplement a different
function. Some exemplary, nonlimiting examples of pairs of
complementary functions include: scrubbing and wiping, abrading and
polishing, and polishing wiping. Those of skill in the art will
appreciate that there may be more than one function that
complements (i.e., complementary function) for a particular
function.
[0026] "Non-standard material", as used herein, means a material
that is not a fibrous structure product or paper web. Nonlimiting
examples of non-standard materials include the group consisting of:
cloth, sponge, fabric, polymer, and combinations thereof.
[0027] "Basis Weight", as used herein, is the weight per unit area
of a sample reported in lbs/3000 ft.sup.2 or g/m.sup.2.
[0028] "Machine Direction" or "MD", as used herein, means the
direction parallel to the flow of the fibrous structure through the
papermaking machine and/or product manufacturing equipment.
[0029] "Cross Machine Direction" or "CD", as used herein, means the
direction perpendicular to the machine direction in the same plane
of the fibrous structure and/or fibrous structure product
comprising the fibrous structure.
Base Structure
[0030] The present invention is equally applicable to all types of
consumer paper products such as paper towels, toilet tissue, facial
tissue, napkins, and the like. In one embodiment, the present
invention product may be made using a papermaking machine, such as
one exemplified in U.S. Pat. Nos. 4,528,239 or 7,229,528.
[0031] 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, as well as mechanical pulps including,
groundwood, thermomechanical pulp, chemically modified, and the
like. Chemical pulps may be used 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 there from. 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.
Additionally, fibers derived from wood pulp such as cotton linters,
bagesse, and the like, can be used. Additionally, fibers derived
from recycled paper, which may contain any of all of the categories
as well as other non-fibrous materials such as fillers and
adhesives used to manufacture the original fibrous structure
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, 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 counteract any
advantage presented by the instant invention.
[0032] In one embodiment the present invention may comprise a
co-formed fibrous structure. A co-formed fibrous structure
comprises a mixture of at least two different materials wherein at
least one of the materials comprises a non-naturally occurring
fiber, such as a polypropylene fiber, and at least one other
material, different from the first material, comprises a solid
additive, such as another fiber and/or a particulate. In one
example, a co-formed fibrous structure comprises solid additives,
such as naturally occurring fibers, such as wood pulp fibers, and
non-naturally occurring fibers, such as polypropylene fibers.
[0033] Synthetic fibers useful herein include any material, such
as, but not limited to, those selected from the group consisting of
polyesters, polypropylenes, polyethylenes, polyethers, polyamides,
polyhydroxyalkanoates, polysaccharides, and combinations thereof.
The synthetic fiber may comprise a polymer. The polymer may be any
material, such as, but not limited to, those materials selected
from the group consisting of polyesters, polyamides,
polyhydroxyalkanoates, polysaccharides and combinations thereof.
More specifically, the material of the polymer segment may be
selected from the group consisting of poly(ethylene terephthalate),
poly(butylene terephthalate), poly(1,4-cyclohexylenedimethylene
terephthalate), isophthalic acid copolymers (e.g., terephthalate
cyclohexylene-dimethylene isophthalate copolymer), ethylene glycol
copolymers (e.g., ethylene terephthalate cyclohexylene-dimethylene
copolymer), polycaprolactone, poly(hydroxyl ether ester),
poly(hydroxyl ether amide), polyesteramide, poly(lactic acid),
polyhydroxybutyrate, and combinations thereof.
[0034] Further, the synthetic fibers can be a single component
(i.e., single synthetic material or mixture makes up entire fiber),
bi-component (i.e., the fiber is divided into regions, the regions
including two or more different synthetic materials or mixtures
thereof and may include co-extruded fibers) and combinations
thereof. It is also possible to use bicomponent fibers, or simply
bicomponent or sheath polymers. Nonlimiting examples suitable
bicomponent fibers are fibers made of copolymers of polyester
(polyethylene terephthalate)/polyester (polyethylene terephthalate)
(otherwise known as "CoPET/PET" fibers), which are commercially
available from Fiber Innovation Technology, Inc., Johnson City,
Tenn.
[0035] These bicomponent fibers can be used as a component fiber of
the structure, and/or they may be present to act as a binder for
the other fibers present. Any or all of the synthetic fibers may be
treated before, during, or after the process of the present
invention to change any desired properties of the fibers. For
example, in certain embodiments, it may be desirable to treat the
synthetic fibers before or during the papermaking process to make
them more hydrophilic, more wettable, etc.
[0036] These multicomponent and/or synthetic fibers are further
described in U.S. Pat. Nos. 6,746,766, 6,946,506, and 6,890,872;
U.S. Publication Nos. 2003/0077444A1, 2003/0168912A1,
2003/0092343A1, 2002/0168518A1, 2005/0079785A1, 2005/0026529A1,
2004/0154768A1, 2004/0154767, 2004/0154769A1, 2004/0157524A1, and
2005/0201965A1.
[0037] The fibrous structure 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; EP 677612; and U.S. Patent
App. No. 2004/0192136A1.
[0038] The fibrous structure substrates may be manufactured via a
wet-laid making process where the resulting web may be comprised of
fibrous structure selected from the group consisting of:
through-air-dried fibrous structure plies, differential density
fibrous structure plies, wet laid fibrous structure plies, air laid
fibrous structure plies, conventional fibrous structure plies, and
combinations thereof.
[0039] Optionally, the fibrous structure substrate may be
foreshortened by creping or by wet microcontraction. 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.
[0040] Conventionally pressed tissue paper and methods for making
such paper are known in the art. For example, U.S. Pat. No.
6,547,928. One suitable tissue paper is pattern densified tissue
paper which is characterized by having a relatively high-bulk field
of relatively low fiber density and an array of densified zones of
relatively high fiber density. The high-bulk field is alternatively
characterized as a field of pillow regions. The densified zones are
alternatively referred to as knuckle regions. The densified zones
may be discretely spaced within the high-bulk field or may be
interconnected, either fully or partially, within the high-bulk
field. Processes for making pattern densified tissue webs are
disclosed in U.S. Pat. Nos. 3,301,746, 3,974,025, 4,191,609,
4,637,859, 3,301,746, 3,821,068, 3,974,025, 3,573,164, 3,473,576,
4,239,065, and 4,528,239.
[0041] Uncompacted, non pattern-densified fibrous structures are
also contemplated within the scope of the present invention and are
described in U.S. Pat. Nos. 3,812,000 and 4,208,459. Uncreped
tissue paper as defined in the art is also contemplated. The
techniques to produce uncreped tissue in this manner are taught in
the prior art. For example, European Pat. App. Nos. 0677 612A2,
0617 164 A1, and 5,656,132.
[0042] The substrate which comprises the fibrous structure of the
present invention may be cellulosic, non-cellulosic, or a
combination of both. The substrate may be conventionally dried
using one or more press felts or through-air dried. If the
substrate which comprises the paper according to the present
invention is conventionally dried, it may be conventionally dried
using a felt which applies a pattern to the paper as taught by
commonly assigned U.S. Pat. No. 5,556,509 and PCT Application WO
96/00812. The substrate which comprises the paper according to the
present invention may also be through air dried. A suitable through
air dried substrate may be made according to commonly assigned U.S.
Pat. No. 4,191,609.
Making Products With One or More Zones of Complementary
Function/Components
[0043] The present invention comprises one or more zones of
complementary functionality. In one embodiment, one or more
separate components may be adhesively attached to a portion of the
surface of an absorbent paper product to provide the present
invention product. Exemplary methods and apparatus for attaching
individual components to a moving web are described in U.S. Pat.
Nos. 6,589,149, 6,074,333 and 6,527,902, and U.S. Pat. Pub. No.
2003/0079330.
[0044] FIG. 1 shows an exemplary apparatus 10 that may be used to
attach individual components 20 to a continuous moving web 24. In
the exemplary embodiment, two or more transfer arms 42 rotate about
an axis A that is parallel with the CD direction. The transfer arms
may receive individual components 20 from a suitable web supply 90.
In one embodiment, adhesive may be applied to the individual
components 20 from an adhesive application roll 50 and the transfer
arms 42 may deposit the component 20 onto the moving web 24 where
the component 20 may be married to the moving web 24 by a component
marrying roll 30 to provide the web 24 with discrete, individual
components. In one embodiment, the transfer arms 42 may use a
vacuum to stabilize the component 20 as the component 20 is moved
from the web supply 90 to the moving web 24.
[0045] In one embodiment, an individual component occupies from
about 2% to about 30% of the surface area of one side of the web 24
(or individual sheet of product, if the product has been separated
into individual sheets). In another embodiment, an individual
component occupies from about 3% to about 10% of the surface area
of one side of the web or sheet. One of skill in the art may
appreciate that it may be possible to provide a plurality of
perforations along the surface of the continuous web 24 so that a
consumer may separate the web 24 into individual sheets.
[0046] In one embodiment, the web 24 is provided in roll form. In
another embodiment, the web 24 is provided in roll form about a
core.
Components: Pocket
[0047] One of skill in the art will appreciate that any individual
component can be used to perform a complementary function with the
base web structure. In one embodiment, the individual component is
a pocket or slot. The pocket or slot may be any shape that is
suitable for the intended purpose. In one embodiment, the shape of
the pocket or slot may be selected from the group consisting of:
triangle, square, round, oblong, rectangular, quadrilateral,
parallelogram, and combinations thereof.
[0048] An exemplary embodiment of a pocket 20a according to the
present invention is shown in FIG. 2A. In one embodiment, the
pocket 20a comprises a top side 202 and a bottom side 204 and has a
width W of from about 1'' to about 4''. In one embodiment, the
pocket 20a has a length L of from about 1'' to about 4''. An
alternative exemplary embodiment of a pocket 20a is shown in FIG.
2B. In the exemplary embodiment of FIG. 2B, the pocket 20a is
triangular and has a width W of from about 1'' to about 4'' and a
height H of from about 1'' to about 3''. Those of skill in the art
may appreciate that a pocket may or may not have a first side 202
and a second side 204. In one embodiment, a pocket comprises only a
first side 202 and the edges 202a around the perimeter of the
pocket may be adhesively attached to the web 24.
[0049] An exemplary embodiment of a web 24 comprising a plurality
of components 20, such as pockets 20a is shown in FIG. 3. In the
exemplary embodiment, the web 24 further comprises perforations 57
so that the web 24 may be separated into individual sheets 59.
[0050] Without wishing to be limited by theory, it is thought that
a pocket or slot may facilitate the use of the present invention
paper product by providing consumers with a means for securing one
or more consumer's fingers in the product during use.
Components: Abrasive Zone
[0051] In one embodiment, the complementary function may be
abrasiveness/abrading. Abrasive surfaces for use with a paper towel
or scrub-pad-type products are described in U.S. Pat. Nos.
6,993,805 and Canadian Pat. No CA 2129244. Abrasive zones may be
applied to the surface of the web as described supra or using any
means known in the art. Registration of Multiple Component Zones or
Component with Perforations In some embodiments, a first component
zone may be registered with a second component zone (i.e., a pocket
may be registered with an abrasive zone) wherein the first
component zone occupies a particular MD and CD position on the web
(or on an individual sheet) and wherein the second component zone
occupies the same MD and CD position on the web, but on the reverse
side. Similarly, it may be necessary to register the one or more
components with other features, such as perforations, for the
product to be salable to consumers. Registration of multiple
components or zones is well known in the art. Exemplary methods and
apparatus for registering two or more features on a rolled product
are described in U.S. Pat. Nos. 7,089,854, 6,929,838, and
6,928,929. The components may be the same or different sizes.
Exemplary Resultant Paper Product
[0052] The web 24 described in FIG. 1 may be perforated or
separated by any means known in the art. An exemplary embodiment is
shown in FIG. 3. In some embodiments, the sheets have approximately
the same dimensions in the MD and CD. In the exemplary embodiment
of FIG. 3, the web 24 comprises perforations 57 that are a
perforation distance D.sub.perf of from about 1/16'' to about 1/4''
in the machine direction from the individual components 20. Without
wishing to be limited by theory, it is thought that by providing a
space between the individual components (in the example of FIG. 3,
pockets 20a) and the perforations 57, when a consumer separates one
sheet 59 from another, the individual pockets 20a will not
interfere/be affected by the separation.
[0053] FIG. 4A shows an alternative embodiment of a sheet 59 of an
absorbent paper product having a first complementary use component
20aa and a second complementary use component 20bb (FIG. 4B). In
the embodiment shown, the first complementary use component 20aa
and second complementary use component 20bb are on opposite faces,
but in the same position (in terms of machine direction/cross
machine direction positioning). In one embodiment, the first
complementary use component 20a is a pocket and the second
complementary use component 20b is an abrasive zone. FIG. 4b shows
a cross-sectional view of the sheet 59 of FIG. 4A taken along the
line 4B-4B.
[0054] Without wishing to be limited by theory, it is thought that
the embodiment described in FIGS. 4A-4B provides consumers with the
unexpected advantage of providing a normal use paper towel or
absorbent paper product with a means for securing one or more of
the consumer's fingers and an abrasive zone juxtaposed on the
opposite face of the pocket wherein the consumer may then focus
more strength to the abrasive zone to aggressively remove unwanted
material or debris from a surface, but while being able to use the
remaining portions of the paper towel product as she normally
would, without having to use multiple products or reverse the paper
towel as she would have to do with many of the prior art two-sided
products.
[0055] FIG. 5 shows an exemplary embodiment of the present
invention web 24 comprising a plurality of perforations 57 and
components 20 wherein the web 24 is rolled about a core 240.
[0056] FIG. 6 shows an exemplary embodiment of the present
invention web 24 comprising a component 20 wherein the component is
a non-standard material. The non-standard material may be affixed
to any portion of the web 24 that is suitable for its intended use.
In one embodiment, the component 20 made from non-standard material
may be affixed to the approximately the same area of each sheet 59
in the web 24--in other words, the non-standard material may be
registered to the same part of each sheet 59. In a roll product,
this means that the non-standard material may be the same relative
distances away from the MD edges and/or the perforations (CD) in
the product. In the exemplary embodiment shown in FIG. 6, the
non-standard material is centered in the sheet. Thus, for a roll
product, the non-standard material is centered in each sheet
relative to the MD edges and the perforations 57 (shown in FIG.
7).
Foldability
[0057] In some embodiments, the sheet of paper product may be
folded for packaging, consumer presentation, and the like. An
exemplary method of making a folded fibrous structure can be
achieved by the following. A supply roll of fibrous material is
unwound by driving the circumferential surface, end face surfaces,
core, or any combination thereof. The unwinding speed is controlled
to achieve a target web speed, relative speed to downstream
operations, or web tension. The web is then converted or otherwise
provided with a complimentary function zone as described above. The
web is then separated into at least two longitudinal web strips by
linear or non-linear shear slitting, linear or non-linear score
slitting, linear or non-linear die cutting, linear or non-linear
water jet cutting, linear or non-linear laser cutting, or any other
suitable means known in the art. The web strips are then folded
using folding boards, turn bars, or any other devices known in the
art, to create a "C" or "Z" fold configuration in which at least
one portion of at least one web strip is deformed in the transverse
direction to produce at least one flap which overlies the remaining
portion of the web strip. Flaps which include non-linear edges may
be oriented such that they form a complementary pattern once the
edges are positioned in a proximate configuration. The folded web
strips are then passed over a turn bar known to one of skill in the
art and redirected to flow in a direction generally perpendicular
to the original direction of web travel. Turn bars for each web
strip may be positioned in different machine direction locations to
reorient the web strips such that, after being redirected, they may
be juxtaposed to one another for more efficient winding. Transverse
zones of weakness may then be imparted to the folded web strips to
enable easier dispensing by the user. Said embossing, indicia
addition, slitting, folding, and imparting of transverse zones of
weakness transformations may be phased to one another in the
machine direction or the cross machine direction or both. The web
strips are then rewound into a rolled product, either on a core or
in a coreless configuration. The winding operation may control the
rotational velocity of the core, the surface speed of the winding
product's circumferential surface, or any combination thereof. The
wound rolls are then transferred to other operations for wrapping,
packing, and the like. Alternative transformation sequences and/or
manufacturing methods known to one skilled in the art may also be
used.
[0058] All documents cited in the Detailed Description of the
Invention are, in relevant part, incorporated herein by reference;
the citation of any document is not to be construed as an admission
that it is prior art with respect to the present invention. Terms
or phrases defined herein are controlling even if such terms or
phrases are defined differently in the incorporated herein by
reference documents.
[0059] 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.
[0060] 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".
* * * * *