Abstract: A method for the production of a fibrous web having textile length fibers wherein a fiber furnish is formed by dispersion of the fibers in an unfoamed carrier medium of water and an associative thickener of ethylene oxide base urethane block copolymers or hydroxyethylcellulose ethers having a C.sub.10 to C.sub.24 alkyl side chain in an amount within the range of from about 1 to about 150 pounds of thickener per ton of dry fiber and including an anionic viscosity modifier in the range of 10 to 500 ppm. The furnish having a consistency in the range of 0.05 to 0.2 weight percent fibers is supplied to a high speed papermaking machine for forming a fibrous web. The textile length fibers may be polyester fibers being 1.5 denier and 3/4 inches. The high speed papermaking machine may be a twin-wire papermaking machine or a suction breast roll papermaking machine or a crescent former papermaking machine.

Abstract: A product press formed from a paperboard and a method for forming the same is provided, wherein the product includes a press formed three-dimensional curvilinear region having a desired shape and containing a formation improvement structure for facilitating the press formation and maintenance of the desired product shape and for preventing the machine directionality of the paperboard from distorting the product from its desired shape. The press formed paperboard product of the preferred embodiment comprises a planar wall having a periphery which is at least partially curvilinear and a peripheral wall angularly oriented with respect to the planar wall. The peripheral wall extends along at least a portion of the curvilinear periphery of the planar wall and the closest portion of the peripheral wall is spaced a substantial radial distance from the periphery of the planar wall.

Abstract: Novel multi-layer paper and tissue products are provided, which possess strength, softness and absorbency. The products comprise either at least two foam deposited paper layers, wherein the foams have different air contents therein, or foam and water deposited layers. The layers can be deposited at about identical feed pressures from a single headbox while still possessing differing tensile strength ratios. Novel processes for forming such products are also provided.

Abstract: A grease and oil resistant container useful for baking foods contained therein at elevated temperatures which includes a bottom wall and an upturned side wall extending the periphery of the bottom wall having an inner layer of parchment paper and an outer layer of ovenable paperboard. Preferably, the side wall includes a rim that extends outwardly from the side wall in an arcuate path. The rim may include a peripheral lip which extends downwardly from the rim. The container is formed by deep drawing a flat, circular blank. The blank includes an ovenable paperboard base layer and an inner, food compatible parchment layer. In addition, prior to press forming the blank, a plurality of radially extending pleats are formed circumferentially about the outer area of circular blank which will aid in the formation of a substantially rigid side wall.

Abstract: A method of foam forming of paper includes the steps of metering a controlled feed of fiber dispersed in an aqueous liquid into a dewatering device, wherein the consistency of the fiber dispersed in the aqueous liquid input to the dewatering device is between about 0.5 and about 7% by weight. A uniform continuous strand of semi-moist pulp is obtained wherein the consistency of the semi-moist pulp leaving the dewatering device is between about 8 and 30% by weight. A stream of a foamed aqueous admixture is obtained and introduced into a dispersing mixer having shearing action extending substantially throughout a zone substantially athwart the flow path of the uniform continuous strand and the foamed aqueous stream and forming a stream of dispersed fiber bearing aqueous foam. The dispersed fiber bearing aqueous stream is conducted to the inlet of a positive displacement pump.

Abstract: A blank cutting technique in a process for manufacturing containers such as paperboard cups, canisters and cartons provides a flaired edge which, in one embodiment, forms a precurl to facilitate the formation of a completed brim curl and in another embodiment, is used to provide a flaired edge on a lid flap of a carton. In the latter case, the flaired edge which is created assists in insertion of the lid flap into the carton opening and creates an improved seal. In the blank cutting technique, stock material is positioned on a die cutting bed across a stepped portion. The stock material is cut along a cutting line offset from and substantially parallel to the stepped portion and against a lower surface of the die cutting bed defined by the stepped portion during the cutting operation, whereby the flaired edge is formed.

Abstract: A thermoformable, rigid or semi-rigid polypropylene foam sheet having a smooth surface and a uniform cell structure and a density of at least 2.5 lbs/ft.sup.3 is prepared by extruding a mixture of a nucleating agent, a physical blowing agent and a polypropylene resin having a high melt strength and high melt elasticity.

Abstract: A foam-formed nonlaminated stratified paper tissue and method of making the same includes a first zone of foam-formed paper tissue formed from a furnish of hardwood fiber. A second zone of foam-formed paper tissue is formed from a furnish of softwood fiber. The second zone is formed unitary and entangled with the first zone to form a nonlaminated stratified paper tissue. A high softness integument is defined adjacent to an outer surface of the first zone and a substratum is defined adjacent to a surface of the second zone spaced away from the integument. The integument on the outer surface of the first zone includes an enriched region having a substantial purity of hardwood fiber and the substratum on the surface of the second zone includes an enriched region having a substantial purity of softwood fiber. The enriched region of substantially pure hardwood fiber provides an extremely soft and smooth surface detectable by human somatic sensibility.

Abstract: A tear strip is formed in a paperboard container blank by scoring a line of weakness on each of the opposite surfaces. The lines are offset from each other to form between them an area where the piles are easily separated. One or both lines are formed by impressing the blank with a diamond pattern knurling tool.

Abstract: A foam-formed nonlaminated stratified paper tissue includes a first layer of bulky anfractuous fiber blend and a second layer of fiber blend having enhanced softness and caliper as compared to a conventional tissue of equivalent basis weight and strength. In a preferred embodiment, the first layer is a fiber blend of a bulky anfractuous fiber and a chemithermomechanical pulp. A method of forming a foam-formed nonlaminated stratified web of paper tissue material includes supplying a first furnish of a bulky anfractuous fiber blend directly to a foraminous support member. A second furnish of fiber blend is supplied onto the first furnish disposed on the foraminous support member. The furnishes may also be supplied in reverse order depending upon the forming configuration of the machine used. The first and second furnishes form a web of paper tissue material which is dried in a drying device to a predetermined dryness.

Abstract: A security paper includes at least two layers of paper each having inner and outer surfaces and predetermined mechanical properties, color and optical density. Authentication indicia is printed on the inner surface of at least one layer. The indicia is formed of a chemically, mechanically and thermally stable medium having a predetermined color, color intensity and optical density. A chemically, mechanically and thermally stable adhesive permanently adheres the inner surfaces of the layers together. The adhesive has a predetermined color and optical density. The color and optical density of the layers, the color, color intensity and optical density of the medium and the color and optical density of the adhesive combine to render the authentication indicia detectable in transmitted light and substantially imperceptible in reflected light.

Abstract: An apparatus for emboss bonding two or more lightweight cellulosic webs to form a multi-ply article, the apparatus including a first cylindrical roll having a metal surface and being disposed for rotation about a cross machine rotation axis, an etched area of the surface of the first roll defining a pattern having pedetermined dimensions for forming proximate the perimeter of the article an emboss bond, the etched area comprising a plurality of truncated right rectangular pyramidal cavities in the roll surface disposed in adjacent relationship in the machine direction and the cross machine direction, and a second cylindrical roll disposed to cooperatively rotate with the first roll and to define therewith a nip for engaging the webs, the second roll having an impressionable surface capable of conforming under pressure to the etched area or having an etched area defining a complementary pattern for meshing engagement with the etched area on the first roll.

Abstract: A thermoformable, rigid or semi-rigid polypropylene foam sheet having a smooth surface and a uniform cell structure and a density of at least 2.5 lbs/ft.sup.3 is prepared by extruding a mixture of a nucleating agent, a physical blowing agent and a polypropylene resin having a high melt strength and high melt elasticity.

Abstract: A disposable cup lid has intersecting straw insertion slits and rip-stop end cuts located transversely to and spaced from the ends of the straw insertion slits. In a preferred embodiment, the rip-stop end cuts are stamped lines of weakness or perforations, located perpendicularly to, and between about 1/32 and 1/16 inch beyond, the ends of the straw insertion slits. In another preferred embodiment, the end cuts are portions of the arc of a circle with a diameter slightly larger than the length of the straw insertion slits. The rip-stop end cuts, together with the straw insertion slits, define frangible reinforcing webs connecting wedge-shaped lid portions defined by the straw insertion slits. The webs strengthen the cup during shipment, during mounting on the cup, and during transportation of the filled cup prior to insertion of the straw. The webs are broken by insertion of the straw, resulting in a structure that effectively prevents the force of straw insertion from tearing the top surface of the lid.

Abstract: A disposable, cloth-like towel of superior wet strength and absorbency comprises a scrim coated with a superabsorbent material, with one or more nonwoven fibrous webs bonded to the coated scrim. The superabsorbent coating preferably is formed by wetting the scrim with water or an aqueous adhesive, applying a solid hydrophilic polymer to the scrim, then applying a nonwoven absorbent cellulosic web to the coated scrim and drying the resulting composite laminate. Bonding of the scrim to the nonwoven fibrous web can be achieved by applying an adhesive to the side of the cellulosic web which is brought into contact with the coated scrim.

Abstract: A method and apparatus for separating surfactant depleted liquid from an at least partially stable foamed aqueous admixture of water, surfactant and air includes introducing the at least partially stable foamed admixture to a channel of preselected height, length, width and inclination at such a flow rate as the foamed admixture passes through the channel. A substantially translational motion of the foamed admixture is maintained through the bulk of the channel. As the foamed admixture translates through the channel, surfactant depleted liquid drains from the interstices thereof. The air content of the foamed admixture does not increase above the air content at which substantial overdrying begins to occur in the foamed admixture. Tranquil interface flow conditions are maintained in the flow of surfactant depleted liquid drained from the foamed admixture for so long as it is in contact with the admixture.

Abstract: An improved heaterboard, and method and apparatus for producing same is disclosed herein. A foil layer is bonded to a paperboard substrate and a circuit path is cut in the foil layer to define a heating circuit. In a preferred method, the circuit is defined by cut scores and short-circuiting across the cut scores is prevented by a reverse scoring operation in which the circuit pattern is scored in the surface of the heaterboard opposite the surface having the foil heating layer thereon. Various heaterboard circuit patterns and an apparatus for forming heaterboards are also disclosed.

Abstract: A method for simultaneously drying a moist fibrous web and imprinting a pattern in each side thereof by passing the web through the nip between a patterned heated roll and a pressing roll, on a carrier having a nonplanar imprinting surface.

Abstract: Microwave interactive coating compositions are disclosed which comprise finely divided carbon, a powdered inert solid and a binder. A preferred composition comprises finely divided carbon, finely divided microwave reactive metal, powdered inert material and a dielectric binder, preferably an acrylic latex. These compositions are capable of producing microwave reactive heaters comparable to those produced by vapor deposition of metals on a carrier film.

Abstract: A thermoformable, rigid or semi-rigid polypropylene foam sheet having a smooth surface and a uniform cell structure and a density of at least 2.5 lbs/ft.sup.3 is prepared by extruding a mixture of a nucleating agent, a physical blowing agent and a polypropylene resin having a high melt strength and high melt elasticity.