U.S. patent number 3,673,052 [Application Number 04/760,600] was granted by the patent office on 1972-06-27 for method of manufacturing a disposable product.
This patent grant is currently assigned to Paper Converting Machine Company, Inc.. Invention is credited to John J. Bradley, Charles J. Sanders, Howard J. Slawny, Rudolph E. Small.
United States Patent |
3,673,052 |
Small , et al. |
June 27, 1972 |
**Please see images for:
( Certificate of Correction ) ** |
METHOD OF MANUFACTURING A DISPOSABLE PRODUCT
Abstract
A disposable product such as paper toweling made up of united
sheets, at least one of which is of cellulose material, the
adhesive joining the sheets being provided on areas which outstand
from one of the sheets by virtue of being provided therein by a
plate cylinder in a press arrangement.
Inventors: |
Small; Rudolph E. (Green Bay,
WI), Bradley; John J. (Green Bay, WI), Sanders; Charles
J. (De Pere, WI), Slawny; Howard J. (Green Bay, WI) |
Assignee: |
Paper Converting Machine Company,
Inc. (Green Bay, WI)
|
Family
ID: |
25059594 |
Appl.
No.: |
04/760,600 |
Filed: |
September 18, 1968 |
Current U.S.
Class: |
156/164; 156/209;
156/229; 156/277; 156/291; 156/292; 162/132 |
Current CPC
Class: |
B32B
37/20 (20130101); A47K 10/16 (20130101); B32B
38/06 (20130101); B32B 29/005 (20130101); B31F
1/07 (20130101); B32B 2555/02 (20130101); Y10T
156/1023 (20150115); B31F 2201/0733 (20130101); B31F
2201/0756 (20130101); B31F 2201/0787 (20130101); B31F
2201/0797 (20130101); B31F 2201/0761 (20130101); B31F
2201/0738 (20130101); B31F 2201/0728 (20130101); B31F
2201/073 (20130101) |
Current International
Class: |
A47K
10/00 (20060101); B31F 1/07 (20060101); B31F
1/00 (20060101); A47K 10/16 (20060101); B31f
001/18 (); B32b 007/14 () |
Field of
Search: |
;162/124,132,123,116,197,362,117
;156/290,291,206,209,199,164,277,292 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Quarforth; Carl D.
Assistant Examiner: Lehmann; E. E.
Claims
We claim:
1. In a process for manufacturing a multi-ply absorptive paper
product, the steps comprising: continuously embossing a pair of
webs of cellulosic material to form a plurality of closely spaced
embossments, continuously printing an adhesive on selected minor
portions of one of said webs by passing said one web through a nip
including a patterned roll having corresponding selected minor
portions raised thereon and a back-up roll which carries said
adhesive to thereby apply adhesive to said web in the area of said
nip where said raised portions bear against said back-up roll and
on the side of said web opposite that contacted by said raised
portions, the remainder of said web being substantially free of
adhesive, said minor raised portions being arranged in an open
pattern leaving large areas relative to the size of the embossments
free of adhesive, continuously traveling said other web towards
said one web for engagement with the adhesive printed thereon and
selectively uniting said webs in the areas carrying adhesive.
2. A process in accordance with claim 1 wherein the selective
uniting of said webs is effected by passing said webs through a
pressing nip having an upstanding pattern which is similar to and
in register with said printed adhesive pattern for pressing said
webs together at the adhesive printed minor portions thereof while
maintaining other areas free of compression thereby avoiding
subjecting other portions of said web to compressive forces which
would crush said united web between the adhesive printed
portions.
3. A process in accordance with claim 1 including the further steps
of longitudinally tensioning one of said webs relative to the other
prior to uniting said webs and relieving said tensioned web of
tension thereafter whereby the united webs have a generally quilted
configuration.
4. In a process for manufacturing a multi-ply absorptive paper
product, the steps comprising: continuously embossing a pair of
webs of cellulosic material to form a plurality of closely spaced
embossments, continuously printing an adhesive on selected minor
portions of one of said webs by passing said one web through a nip
including a patterned roll having corresponding selected minor
portions raised thereon and a back-up roll carrying adhesive to
thereby apply adhesive to said web in the area of said nip where
said raised portions bear against said back-up roll, the remainder
of said web being substantially free of adhesive, said minor raised
portions being arranged in an open pattern leaving large areas
relative to the size of the embossments free of adhesive,
continuously traveling said other web towards said one web for
engagement with the adhesive printed thereon, then passing said
webs through a pressing nip having an upstanding pattern which is
similar to and in register with said printed adhesive pattern for
pressing said webs together at the adhesive printed minor portions
thereof while maintaining other areas free of compression thereby
avoiding subjecting other portions of said web to compressive
forces which would crush said united web between the adhesive
printed portions and longitudinally tensioning one of said webs
relative to the other prior to uniting said webs and relieving said
tensioned web of tension thereafter whereby the united webs have a
generally quilted configuration.
Description
BACKGROUND AND SUMMARY OF INVENTION
Heretofore paper toweling has been provided utilizing two sheets
which have been adhered together. One form of this product makes
use of "peg-to-peg" embossing so as to develop a "pillow" type
construction. The areas between opposed embossments are relatively
small and therefore do not provide the most efficient structure as
well as appearance for home use. Also because of the type of
embossing, the speed of production is seriously limited, also
limited is the use of various adhesives. It will be appreciated
that the adhesive between the male-embossed sheets must set prior
to the time the contacted sheets leave the nip of the embossing
rolls. Thus, limitations of speed and adhesive are present.
According to the present invention, at least one of the sheets is
caused to travel with and partially wrapped on a plate cylinder,
and with the adhesive being provided on the surface of the sheet
remote from the cylinder. The cylinder advantageously is equipped
with an outstanding pattern of an open perimetric configuration,
i.e., diamonds, squares, etc. Further, we find that such a sheet
can be embossed so as to achieve the advantages of the previously
known toweling without the disadvantages and limitations heretofore
pointed out. The adhesive-equipped sheet is thereafter integrated
or united in the adhesive-equipped areas with a second sheet or
web. In the instance where toweling is desired, the second web is
paper, i.e., of fibrous or cellulose construction. Where the
disposable product is to be a placemat or similar product, the
second web may be plastic, i.e., polyethylene. Still further, in
some instances three or more plies may be employed.
We further have found that the second sheet may be embossed but
that an extremely advantageous product such as toweling resulting
from the two embossed sheets can be achieved without having the
embossments aligned, i.e., in register, as was the case with
preceding products.
Still further, we find it extremely advantageous to tension one of
the webs, preferably the "unprinted" web (with adhesive) during the
time it is integrated with the other web or webs. This then results
in a product wherein the previously tensioned web "puckers" or
contracts when relieved of tensioning stress so as to develop an
extremely desirable quality in the resultant product both from the
standpoint of appearance and structure. The product has an
essentially "quilted" appearance which not only is attractive but
also provides pockets for the take up of the moisture -- important
where, for example, the product is used as toweling.
The invention is described in conjunction with the accompanying
drawing, in which
FIG. 1 is a schematic, essentially elevational, view of apparatus
employed in the production of the disposable product according to
the teachings of this invention; FIG. 2 is an enlarged fragmentary
sectional view taken along the sight line 2--2 applied to FIG.
1;
FIG. 3 is an enlarged fragmentary perspective view, partially in
section, of the product resulting from the use of the apparatus of
FIG. 1; and
FIG. 4 is another schematic, essentially elevational, view of
apparatus for practicing the invention so as to develop a three-ply
sheet as contrasted to the two-ply sheet resulting from the
apparatus of FIG. 1.
In the illustration given, and with particular reference to FIG. 1,
the numeral 10 designates generally a fibrous web which is seen to
pass between embossing rolls 11 and 12. The embossing rolls may be
engraved steel rolls with patterns of embossments provided therein.
For example, the pattern may be a repeat type having from 10 to 200
projections or protuberances per square inch, each raised to a
height of from about 0.01 to about 0.05 inch whereby the sheet 10,
when subjected to such action results in having an embossed surface
of from 10 to 75 percent of its total area. The web 10 then passes
over an idler roll 13 and about a plate cylinder generally
designated 14. The plate cylinder 14, as can be seen in FIG. 2,
includes a rubber covering 14a which overlies the steel interior
roll 14b. The web 14 is seen to be in partial wrapping engagement
for travel with the roll 14 and, in the course of so traveling,
picks up a layer of adhesive 15. This occurs on the portions of the
web which are in contact with the raised portions 16 provided on
the rubber covering 14a of the plate cylinder 14. The adhesive is
derived from a glue bath 17 (see the extreme left-hand portion of
FIG. 1) and is picked up therefrom by means of a rubber covered
roller 18. The roller 18 (which constitutes a fountain roll)
transfers the adhesive from the bath 17 to a transfer roll 19 from
which it is applied to selected portions of web 10.
The web 10, now equipped with adhesive in preselected portions
(based upon the configuration of the rubber printing plate portions
16), is integrated with a second web 20. The web is seen to have
passed between embossing rolls 21 and 22 which are optional though
advantageous depending upon end usage. Whether surfaced for
embossment or not, the rolls 21 and 22 are run at a slower speed
than succeeding rolls engaging the web 20 so that the web 20 is
tensioned. The webs 10 and 20 are integrated in the nip defined by
the cylinders 14 and 23. The united webs after traveling a portion
of the arcuate length of the roll 23 are caused to pass between a
nip 24 defined by rolls 23 and 25. Thereafter the multi-ply web 26
is directed to other structure (not shown) for reeling,
perforation, etc. In some instances we structure the roll 25 with a
plate identical to that of 14a and registered to contact the webs
only where glue has been applied by 14a. This insures a good glue
bond without crushing of the embossing where glue has not been
applied.
A number of distinct advantages arise from the manner of glue
application just described. For one thing, the glue does not come
in contact with the plate cylinder 14 so there is no problem of
cleaning. Further, in previous arrangements, glue had been applied
to the so-called "plate" cylinder and tended to attack the
"sticky-back" which was employed to adhere the plate 14a to the
steel roll 14b. For example, sticky-back is used here at the inner
face designated 14c in FIG. 2 (between the plate 14a and the
cylinder 14b).
The product can be seen by reference to FIG. 3 wherein there is a
distinct puffiness or quilted appearance in the resulted multi-ply
sheet 26. In FIG. 3, it will be seen that the upper ply or web 10
is caused to puff or quilt by virtue of the contracted nature of
the under ply 20. Further, it is seen that the web 20 has fewer
fibers per unit area in contact with the adhesive as at 15 than the
web 10, this resulting from the fact that the web 20 was stretched
at the time the bond (via the adhesive) was made between the sheets
10 and 20.
A modified form of the invention is seen and can be practiced by
the showing in FIG. 4. In FIG. 4 two webs are embossed and united
to a third unembossed or plain web. Thus, the showing in FIG. 4 is
essentially a duplication of portions of the showing in FIG. 1. In
FIG. 4, the numeral 110 designates a first embossed web (as by the
rolls 111 and 112). This web is passed around a plate cylinder 114.
Simultaneously with all the foregoing, a second web 110' is
embossed by virtue of having passed between embossing rolls 111'
and 112' and adhesive equipped by virtue of being in partial
wrapping engagement with a plate cylinder 114'. The plate cylinders
114 and 114' may be be substantially identical to the plate
cylinder 14 of FIG. 1. The web 120 which ultimately is interposed
between the webs 110 and 110' in the resultant product 128 is seen
to have been tensioned by being fed into the nip provided by the
rolls 114 and 114' at a slower speed than the webs 110 and
110'.
As pointed out previously, the inventive arrangement avoids speed
limitation characteristic of prior embossed toweling and similar
products. Additionally, there are substantial savings in
operational costs and there is a distinct simplicity in design and
layout. There is no longer the requirement of the accuracy of
aligned embossments and the practice of the invention permits a
variety of product options. In the case of toweling, the typical
paper webbing may have a basis weight of from ten to 50 pounds per
ream, i.e., per 3,000 square feet. Also other webs such as film,
foil, etc. may be employed.
While in the foregoing specification a detailed description of the
invention has been set down for the purpose of explanation, many
variations of the details hereingiven may be made by those skilled
in the art without departing from the spirit and scope of the
invention.
* * * * *