Abstract: A water resistant absorbent towel dispenser. The dispenser includes a container having top, bottom and side walls housing a supply of absorbent towels, and an exterior handle for facilitating transport of the dispenser. The top wall includes a finger-accessible opening through which absorbent towels may be withdrawn. In certain embodiments, the top wall is convex upwardly, but is flexible to enable it to be depressed when dispensers are stacked vertically so as to come into load bearing contact with the towel supply. In some embodiments, the top and bottom walls have interlocking configurations to add lateral stability to vertically stacked dispensers.

Abstract: A product including a web and a method of manufacturing such a product. The product may be for use as an industrial absorbent or a thermal or acoustic insulator and includes a web including scrap and/or recycled cellulose, the cellulose being selected from a source of post-industrial cellulose and/or a source of post-consumer cellulose, the cellulose being treated with a fire-retardant, the cellulose being dry before web formation, and opened, individuated bicomponent fibers mixed with the cellulose, at least some of the bicomponent fibers being thermally bonded to at least some of the cellulose. The method may include shredding the cellulose, declumping and sizing the cellulose, metering the cellulose into a spray booth, applying a fire retardant to the cellulose in the spray booth, if the fire retardant is a liquid, drying the cellulose, adding bicomponent fibers to the cellulose, forming a web, and heating the web in an oven.

Abstract: A generally cylindrical towel roll product comprises an absorbent towel roll having an upright axis, and a flexible, water resistant, protective wrapper engaging the circumferential surface of the towel roll and of sufficient strength to restrain significant diametric expansion of the towel roll when the roll is subjected to an axial load and to increase axial stiffness of the product. The wrapper includes top and bottom portions that encase the top and bottom surfaces of the roll, respectively, the top wrapper portion having an opening providing axial access to the towel roll and through which individual towels can be drawn axially from the interior of the towel roll. A removable and replaceable soil and water-resistant cover protectively covers the wrapper opening, and a rigid disc may be provided between the top surface of the towel roll and the top portion of the wrapper, the disc extending radially to the periphery of the upper surface of the roll.

Abstract: A towel product that has dual functions is provided. The towel product includes a series of stacked towels sandwiched between a first support plate and a second support plate. The first support plate, stacked towels, and second support plate are all encased in an outer wrapper. In some cases, the towel product serves as a stand-alone product. In other cases, the towel product serves as an insert to be placed inside of a towel-dispensing container. The first support plate aids in the product's insert functions when placed inside of a towel-dispensing container and the second support plate aids the product's stand-alone functions.

Abstract: An industrial absorbent and methods of manufacturing the same. In one embodiment, the industrial absorbent includes a first scrim made from at least one thermoplastic material; a second scrim made from at least one thermoplastic material; and a middle layer positioned between the first and second scrims. The middle layer includes a dry-laid web of fire-retardant treated cellulose and opened, individuated staple bicomponent fiber. At least some of the bicomponent fiber in the middle layer is thermally bonded to at least some of the cellulose in the middle layer, and the first and second scrims are thermally bonded to the middle layer.

Abstract: A water resistant absorbent towel dispenser. The dispenser includes a container having top, bottom and side walls housing a supply of absorbent towels, and an exterior handle for facilitating transport of the dispenser. The top wall includes a finger-accessible opening through which absorbent towels may be withdrawn. In certain embodiments, the top wall is convex upwardly, but is flexible to enable it to be depressed when dispensers are stacked vertically so as to come into load bearing contact with the towel supply. In some embodiments, the top and bottom walls have interlocking configurations to add lateral stability to vertically stacked dispensers.

Abstract: A generally cylindrical towel roll product comprises an absorbent towel roll having an upright axis, and a flexible, water resistant, protective wrapper engaging the circumferential surface of the towel roll and of sufficient strength to restrain significant diametric expansion of the towel roll when the roll is subjected to an axial load and to increase axial stiffness of the product. The wrapper includes top and bottom portions that encase the top and bottom surfaces of the roll, respectively, the top wrapper portion having an opening providing axial access to the towel roll and through which individual towels can be drawn axially from the interior of the towel roll. A removable and replaceable soil and water-resistant cover protectively covers the wrapper opening, and a rigid disc may be provided between the top surface of the towel roll and the top portion of the wrapper, the disc extending radially to the periphery of the upper surface of the roll.

Abstract: A filter and methods of manufacturing the same. In one embodiment, the filter includes a first scrim made from at least one thermoplastic material; a second scrim made from at least one thermoplastic material; and a middle layer positioned between the first and second scrims. The middle layer includes a dry-laid web of cellulose and opened, individuated staple bicomponent fiber. At least some of the bicomponent fiber in the middle layer is thermally bonded to at least some of the cellulose in the middle layer, and the first and second scrims are thermally bonded to the middle layer.

Abstract: Methods and machines for forming a non-woven web. In one embodiment, the machine includes one or more forming boxes. Each box has an associated fiber inlet. The forming boxes are positioned above a conveyor table. Fibrous material travels from the inlet through each forming box. A vacuum source is located underneath the conveyor table and generates an air current that pulls the fibrous material onto the conveyor table to form a web or sheet of fibrous material. In one embodiment, the fibrous sheet is formed in three layers. Vapor or steam boxes are placed adjacent to each forming box. In one embodiment, a steam box is located within the entrance of an oven. The sheet is subjected to a vapor, mist, fog, spray, or steam (generically referred to as a “suspension”) as it passes under each steam box. In one embodiment, the suspension is generated with water. Applying a water suspension to the fibrous materials provides hydrogen atoms to help create hydrogen bonding between at least some of the fibers.

Abstract: A method of forming a fibrous material includes creating a mixture of pulp, liquid, and a debonder. Drying the mixture produces pulp, which is generally mixed with binder fibers, where each binder fiber has a core and an outer layer. The core has a first melting temperature and the outer layer has a second melting temperature lower than the first melting temperature. The method includes providing the pulp and binder fibers to a dry-lay machine to form a layer of base fibrous material. In one embodiment, the layer of base fibrous material is heated to at least partially melt the binder fibers' outer layers. The method includes applying a bonding material to the layer; creping the layer; and curing the layer to form the fibrous material. Alternatively, the method includes embossing the layer of base fibrous material; and spraying a chemical bonder to the layer of base fibrous material.

Abstract: An absorbent printed paper web and methods for making the printed web, the web having a visually discernible larger pattern, which can be a logo, on at least one surface formed essentially only of a paper web and a strengthening, colored bonding material. The printed web having the larger pattern can be made using the same bonding material and process used to print the background pattern. A double recrepe process using an improved Gravure roll may be used to print both logo and background. One method includes using a Gravure roll having deep depressions for printing a geometric background pattern, which can be a cross hatch pattern defining unprinting surface areas between the repeating deep depressions. The Gravure roll can also have shallow depressions in the reverse image of a logo to be printed, where the shallow depressions can have contiguous logo areas much larger than the size of the repeating deep depressions or unprinting surface areas in the background pattern.