SANITARY TISSUE PRODUCTS COMPRISING A SURFACE PATTERN AND METHODS FOR MAKING SAME

Abstract

Sanitary tissue products having a surface containing a surface pattern having a filamentary pattern and a complementary line pattern.

Description

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. Design application No. 29/350,577, filed Nov. 19, 2009.

FIELD OF THE INVENTION

The present invention relates to sanitary tissue products comprising a surface comprising a surface pattern and more particularly to sanitary tissue products comprising a surface comprising a surface pattern containing a filamentary pattern and a complementary line pattern.

BACKGROUND OF THE INVENTION

Sanitary tissue products comprising surfaces comprising surface patterns are known in the art. For example, embossed and/or wet-molded sanitary tissue products that comprise a surface comprising a surface pattern are known in the art. Surface patterns have been used for aesthetic reasons and for providing consumers with a perception about a characteristic or property of the sanitary tissue products.

Known surface patterns for sanitary tissue products include surface patterns that comprise a wavy line pattern and dot patterns as shown in FIG. 1. Other known surface patterns comprise entirely dots and/or dashes and still others comprise entirely lines. None of such known surface patterns comprise a filamentary pattern and a complementary line pattern.

Consumers of sanitary tissue products, such as bath tissue, paper towels and/or facial tissue, continue to desire surface patterns on their sanitary tissue products that provide or are perceived by consumers to provide improved cleaning and/or strength over known surface patterns on sanitary tissue products.

Accordingly, there is a need for a sanitary tissue product comprising a novel surface pattern, for example a surface pattern that provides consumers with a perception of improved cleaning and/or strength compared to known sanitary tissue product surface patterns.

SUMMARY OF THE INVENTION

The present invention fulfills the needs described above by providing a sanitary tissue product comprising a novel surface pattern, for example a surface pattern that comprises a filamentary pattern and a complementary line pattern.

In one example of the present invention, a sanitary tissue product having a surface that comprises a surface pattern comprising a filamentary pattern and a complementary line pattern, is provided

In another example of the present invention, a method for making a sanitary tissue product according to the present invention is provided.

The present invention provides sanitary tissue products comprising a novel surface pattern and methods for making such sanitary tissue products.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top plan view of a prior art surface pattern for a sanitary tissue product;

FIG. 2A is a schematic representation of an example of a filamentary pattern according to the present invention;

FIG. 2B is a schematic representation of another example of a filamentary pattern according to the present invention;

FIG. 2C is a schematic representation of another example of a filamentary pattern according to the present invention;

FIG. 3A is a schematic representation of an example of a filamentary line pattern according to the present invention;

FIG. 3B is a schematic representation of another example of a filamentary line pattern according to the present invention;

FIG. 3C is a schematic representation of another example of a filamentary line pattern according to the present invention;

FIG. 4A is a schematic representation of an example of a line according to the present invention;

FIG. 4B is a schematic representation of another example of a line according to the present invention;

FIG. 4C is a schematic representation of another example of a line according to the present invention;

FIG. 5 is a top plan view of an example of a sanitary tissue product comprising a surface pattern comprising a filamentary pattern and a complementary line pattern according to the present invention;

FIG. 6 is a top plan view of another example of a sanitary tissue product comprising a surface pattern comprising a filamentary pattern and a complementary line pattern according to the present invention;

FIG. 7 is a top plan view of another example of a sanitary tissue product comprising a surface pattern comprising a filamentary pattern and a complementary line pattern according to the present invention;

FIG. 8 is a top plan view of another example of a sanitary tissue product comprising a surface pattern comprising a filamentary pattern and a complementary line pattern according to the present invention;

FIG. 9 is a top plan view of another example of a sanitary tissue product comprising a surface pattern comprising a filamentary pattern and a complementary line pattern according to the present invention;

FIG. 10 is a top plan view of another example of a sanitary tissue product comprising a surface pattern comprising a filamentary pattern and a complementary line pattern according to the present invention;

FIG. 11 is a top plan view of another example of a sanitary tissue product comprising a surface pattern comprising a filamentary pattern and a complementary line pattern according to the present invention;

FIG. 12 is a top plan view of another example of a sanitary tissue product comprising a surface pattern comprising a filamentary pattern and a complementary line pattern according to the present invention;

FIG. 13 is a top plan view of another example of a sanitary tissue product comprising a surface pattern comprising a filamentary pattern and a complementary line pattern according to the present invention;

FIG. 14 is a top plan view of another example of a sanitary tissue product comprising a surface pattern comprising a filamentary pattern and a complementary line pattern according to the present invention; and

FIG. 15 is a top plan view of another example of a sanitary tissue product comprising a surface pattern comprising a filamentary pattern and a complementary line pattern according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Definitions

“Sanitary tissue product” as used herein means a soft, low density (i.e. <about 0.15 g/cm³ measured at 95 g/in²) sanitary tissue product useful as a wiping implement for post-urinary and post-bowel movement cleaning (toilet tissue), for otorhinolaryngological discharges (facial tissue), multi-functional absorbent and cleaning uses (absorbent towels) and wet and dry wipes. The sanitary tissue product may be convolutedly wound upon itself about a core or without a core to form a sanitary tissue product roll. Alternatively, the sanitary tissue product may be in the form of discrete sheets.

The sanitary tissue products and/or fibrous structures of the present invention may exhibit a basis weight of greater than 15 g/m² to about 120 g/m² and/or from about 15 g/m² to about 110 g/m² and/or from about 20 g/m² to about 100 g/m² and/or from about 30 to 90 g/m². In addition, the sanitary tissue products and/or fibrous structures of the present invention may exhibit a basis weight between about 40 g/m² to about 120 g/m² and/or from about 50 g/m² to about 110 g/m² and/or from about 55 g/m² to about 105 g/m² and/or from about 60 to 100 g/m².

The sanitary tissue products of the present invention may exhibit a density (measured at 95 g/in²) of less than about 0.60 g/cm³ and/or less than about 0.30 g/cm³ and/or less than about 0.20 g/cm³ and/or less than about 0.10 g/cm³ and/or less than about 0.07 g/cm³ and/or less than about 0.05 g/cm³ and/or from about 0.01 g/cm³ to about 0.20 g/cm³ and/or from about 0.02 g/cm³ to about 0.10 g/cm³.

The sanitary tissue products of the present invention may be in the form of sanitary tissue product rolls. Such sanitary tissue product rolls may comprise a plurality of connected, but perforated sheets of fibrous structure, that are separably dispensable from adjacent sheets.

The sanitary tissue products of the present invention may comprise additives such as softening agents such as silicones and quaternary ammonium compounds, temporary wet strength agents, permanent wet strength agents, bulk softening agents, lotions, silicones, wetting agents, latexes, especially surface-pattern-applied latexes, dry strength agents such as carboxymethylcellulose and starch, and other types of additives suitable for inclusion in and/or on sanitary tissue products.

“Fibrous structure” as used herein means a structure that comprises one or more filaments and/or fibers. In one example, a fibrous structure according to the present invention means an orderly arrangement of filaments and/or fibers within a structure in order to perform a function. Non-limiting examples of fibrous structures of the present invention include paper, fabrics (including woven, knitted, and non-woven), and absorbent pads (for example for diapers or feminine hygiene products).

Non-limiting examples of processes for making fibrous structures include known wet-laid papermaking processes, which includes rush transfer and/or fabric creping and/or wet-micro contraction and/or wet pressing papermaking processes and air-laid papermaking processes. Such processes typically include steps of preparing a fiber composition in the form of a suspension in a medium, either wet, more specifically aqueous medium, or dry, more specifically gaseous, i.e. with air as medium. The aqueous medium used for wet-laid processes is oftentimes referred to as a fiber slurry. The fibrous slurry is then used to deposit a plurality of fibers onto a forming wire or belt such that an embryonic fibrous structure is formed, after which drying and/or bonding the fibers together results in a fibrous structure. Further processing the fibrous structure may be carried out such that a finished fibrous structure is formed. For example, in typical papermaking processes, the finished fibrous structure is the fibrous structure that is wound on the reel at the end of papermaking, and may subsequently be converted into a finished product, e.g. a sanitary tissue product.

The fibrous structures of the present invention may be homogeneous or may be layered. If layered, the fibrous structures may comprise at least two and/or at least three and/or at least four and/or at least five layers.

The fibrous structures of the present invention may be co-formed fibrous structures.

“Co-formed fibrous structure” as used herein means that the fibrous structure comprises a mixture of at least two different materials wherein at least one of the materials comprises a filament, such as a polypropylene filament, and at least one other material, different from the first material, comprises a solid additive, such as a fiber and/or a particulate. In one example, a co-formed fibrous structure comprises solid additives, such as fibers, such as wood pulp fibers, and filaments, such as polypropylene filaments.

“Solid additive” as used herein means a fiber and/or a particulate.

“Particulate” as used herein means a granular substance or powder.

“Fiber” and/or “Filament” as used herein means an elongate particulate having an apparent length greatly exceeding its apparent width, i.e. a length to diameter ratio of at least about 10. In one example, a “fiber” is an elongate particulate as described above that exhibits a length of less than 5.08 cm (2 in.) and a “filament” is an elongate particulate as described above that exhibits a length of greater than or equal to 5.08 cm (2 in.).

Fibers are typically considered discontinuous in nature. Non-limiting examples of fibers include wood pulp fibers and synthetic staple fibers such as polyester fibers.

Filaments are typically considered continuous or substantially continuous in nature. Filaments are relatively longer than fibers. Non-limiting examples of filaments include meltblown and/or spunbond filaments. Non-limiting examples of materials that can be spun into filaments include natural polymers, such as starch, starch derivatives, cellulose and cellulose derivatives, hemicellulose, hemicellulose derivatives, and synthetic polymers including, but not limited to polyvinyl alcohol filaments and/or polyvinyl alcohol derivative filaments, and thermoplastic polymer filaments, such as polyesters, nylons, polyolefins such as polypropylene filaments, polyethylene filaments, and biodegradable or compostable thermoplastic fibers such as polylactic acid filaments, polyhydroxyalkanoate filaments and polycaprolactone filaments. The filaments may be monocomponent or multicomponent, such as bicomponent filaments.

In one example of the present invention, “fiber” refers to papermaking fibers. Papermaking 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, for example, groundwood, thermomechanical pulp and chemically modified thermomechanical pulp. Chemical pulps, however, may be preferred since they impart a superior tactile sense of softness to tissue sheets made therefrom. Pulps derived from both deciduous trees (hereinafter, also referred to as “hardwood”) and coniferous trees (hereinafter, also referred to as “softwood”) may be utilized. The hardwood and softwood fibers can be blended, or alternatively, can be deposited in layers to provide a stratified web. U.S. Pat. No. 4,300,981 and U.S. Pat. No. 3,994,771 are incorporated herein by reference for the purpose of disclosing layering of hardwood and softwood fibers. Also applicable to the present invention are fibers derived from recycled paper, which may contain any or all of the above categories as well as other non-fibrous materials such as fillers and adhesives used to facilitate the original papermaking. Non-limiting examples of suitable hardwood pulp fibers include eucalyptus and acacia. Non-limiting examples of suitable softwood pulp fibers include Southern Softwood Kraft (SSK) and Northern Softwood Kraft (NSK).

In addition to the various wood pulp fibers, other cellulosic fibers such as cotton linters, rayon, lyocell and bagasse can be used in this invention. Other sources of cellulose in the form of fibers or capable of being spun into fibers include grasses and grain sources.

In addition, trichomes such as from “lamb's ear” plants and seed hairs can also be utilized in the fibrous structures of the present invention.

“Weight average molecular weight” as used herein means the weight average molecular weight as determined using gel permeation chromatography according to the protocol found in Colloids and Surfaces A. Physico Chemical & Engineering Aspects, Vol. 162, 2000, pg. 107-121.

“Basis Weight” as used herein is the weight per unit area of a sample reported in lbs/3000 ft² or g/m² and is measured according to the Basis Weight Test Method described herein.

“Caliper” as used herein means the macroscopic thickness of a fibrous structure. Caliper is measured according to the Caliper Test Method described herein.

“Bulk” as used herein is calculated as the quotient of the Caliper, expressed in microns, divided by the Basis Weight, expressed in grams per square meter. The resulting Bulk is expressed as cubic centimeters per gram. In one example, the sanitary tissue products of the present invention, exhibit Bulks of greater than about 3 cm³/g and/or greater than about 6 cm³/g and/or greater than about 9 cm³/g and/or greater than about 10.5 cm³/g up to about 30 cm³/g and/or up to about 20 cm³/g. These examples of sanitary tissue products of the present invention derive the Bulks referred to above from their corresponding basesheets, which are the sheets produced by the papermaking machine without post treatments such as embossing. Nevertheless, the basesheets of this invention can be embossed to produce even greater bulk or aesthetics, if desired, or they can remain unembossed. In addition, the basesheets of this invention can be calendered to improve smoothness or decrease the Bulk if desired or necessary to meet existing product specifications.

“Density” as used herein is calculated as the quotient of the Basis Weight expressed in grams per square meter divided by the Caliper expressed in microns.

“Machine Direction” or “MD” as used herein means the direction parallel to the flow of the fibrous structure through the fibrous structure making machine and/or sanitary tissue product manufacturing equipment.

“Cross Machine Direction” or “CD” as used herein means the direction parallel to the width of the fibrous structure making machine and/or sanitary tissue product manufacturing equipment and perpendicular to the machine direction.

“Ply” as used herein means an individual, integral fibrous structure.

“Plies” as used herein means two or more individual, integral fibrous structures disposed in a substantially contiguous, face-to-face relationship with one another, forming a multi-ply sanitary tissue product. It is also contemplated that an individual, integral fibrous structure can effectively form a multi-ply sanitary tissue product, for example, by being folded on itself.

“Surface pattern” with respect to a sanitary tissue product in accordance with the present invention means herein a pattern that is present on at least one surface of the sanitary tissue product. The surface pattern may be a textured surface pattern such that the surface of the sanitary tissue product comprises protrusions and/or depressions as part of the surface pattern. For example, the surface pattern may comprise embossments. The surface pattern may be a non-textured surface pattern such that the surface of the sanitary tissue product does not comprise protrusions and/or depressions as part of the surface pattern. For example, the surface pattern may be printed on a surface of the sanitary tissue product.

“Filamentary pattern” as used herein means a filamentary line pattern that comprises at least one motif “Motif” as used herein means a distinctive and oftentimes recurring shape. The motif may be any shape and/or size. Non-limiting examples of suitable shapes include circles, ovals, rectangles, squares, triangles, portions of any of such shapes and derivatives of any such shapes. In one example, a filamentary pattern is the area between two parallel or substantially parallel lines that includes at least one shape. FIG. 2A shows an example of a filamentary pattern 10, which is a filamentary line pattern 12 formed from two continuous lines 14, wherein the filamentary line pattern 12 comprises a motif 16, according to the present invention. FIG. 2B shows an example of a filamentary pattern 10, which is a filamentary line pattern 12 formed from a continuous line 14 and a broken line 18, wherein the filamentary line pattern 12 comprises a motif 16, according to the present invention. FIG. 2C shows an example of a filamentary pattern 10, which is a filamentary line pattern 12 formed from two broken lines 18, wherein the filamentary line pattern 12 comprises a motif 16, according to the present invention. Two or more filamentary patterns within the surface pattern may exhibit one or more common dimensions and/or one or more different dimensions.

“Filamentary line pattern” as used herein means an image and/or actual area of a midline of a strip under a homeomorphism of the strip onto itself. In one example, a filamentary line pattern is the area between two parallel or substantially parallel lines. FIG. 3A shows an example of a filamentary line pattern 12 formed from two continuous lines 14 according to the present invention. FIG. 3B illustrates an example of a filamentary line pattern 12 formed from a continuous line 14 and a broken line 18 according to the present invention. FIG. 3C shows an example of a filamentary line pattern 12 formed from two broken lines 18 according to the present invention. Two or more filamentary line patterns within the surface pattern may exhibit one or more common dimensions and/or one or more different dimensions.

“Line” as used herein means a series of points, which may be connected to one another along the length defined by the series of points. FIG. 4A shows an example of a line 20 comprising a series of points that are not connected together forming a line. FIG. 4B shows an example of a line 20 comprising a series of points (the points are not visible as discrete points) that are connected forming a line. FIG. 4C shows an example of a line 20 comprising a series of points where a portion of the points are connected and a portion of the points are not connected forming a line.

“Complementary line pattern” as used herein means a line that complements, such as by running along side one or more filamentary patterns of the present invention. In one example, the complementary line pattern may be a broken line pattern where the series of points are not connected to one another along its length. In another example, the complementary line pattern may be a continuous line pattern where the series of points are connected to one another along its length. Two or more complementary line patterns within the surface pattern may exhibit one or more common dimensions and/or one or more different dimensions.

“Spaced apart from one another center-to-center” as used herein means the distance between two objects from one objects symmetry axis to the other objects symmetry axis.

“Minimum width” as used herein with respect to a filamentary pattern and/or complementary line pattern means the minimum width of the pattern as measured perpendicular to the patterns' symmetry axis from one continuous line or broken line segment to the other continuous line or broken line segment of the filamentary pattern and/or complementary line pattern.

“Embossed” as used herein with respect to a sanitary tissue product means a sanitary tissue product that has been subjected to a process which converts a smooth surfaced fibrous structure to a decorative surface by replicating a design on one or more emboss rolls, which form a nip through which the fibrous structure passes. Embossed does not include creping, microcreping, printing or other processes that may impart a texture and/or decorative pattern to a fibrous structure.

“Line embossment” as used herein means an embossment that comprises a continuous line that has an aspect ratio of greater than 1.5:1 and/or greater than 1.75:1 and/or greater than 2:1 and/or greater than 5:1. In one example, the line embossment exhibits a length of at least 2 mm and/or at least 4 mm and/or at least 6 mm and/or at least 1 cm to about 10.16 cm and/or to about 8 cm and/or to about 6 cm and/or to about 4 cm.

The continuous lines and/or broken lines of the filamentary pattern and/or filamentary line pattern of the present invention may be formed by a line embossment or line embossments. In one example, the continuous lines and/or broken lines of the filamentary pattern and/or filamentary line pattern of the present invention may be formed by lines that are formed by wet molding and/or a through-air-drying fabric and/or an imprinted through-air-drying fabric.

“Dot embossment” as used herein means an embossment that exhibits an aspect ratio of about 1:1. Non-limiting examples of dot embossments are embossments that are shaped like circles, squares, rectangles (dashes) and/or triangles. A plurality of dot embossments may form a broken line of a filamentary pattern and/or filamentary line pattern.

“Water-resistant” as it refers to a surface pattern or part thereof means that a pattern retains its structure and/or integrity after being saturated by water and the pattern is still visible to a consumer. In one example, the continuous lines and/or broken lines of the filamentary pattern and/or filamentary line pattern may be water-resistant.

Fibrous Structure

As shown in FIGS. 5 to 15, an example of a fibrous structure 22 of the present invention comprises a surface 24 exhibiting a machine direction and a cross machine direction. The surface 24 having a surface pattern comprising a filamentary pattern 10 and a complementary line pattern 26. As shown in FIGS. 5, to 15 two or more, for example a plurality of filamentary patterns 10 may form part of the surface pattern on the fibrous structure 22. As shown in FIGS. 5 to 15, two or more, for example a plurality of complementary line patterns 26 may form part of the surface pattern on the fibrous structure 22.

As shown in FIGS. 5 to 15, the filamentary pattern 10 may comprise a motif 28 comprising one or more dots 30. The motif 28 may comprise a plurality of dots 30. The plurality of dots 30 may create a dot pattern. As shown in FIGS. 5 to 15, two or more motifs 28 may be spaced apart from one another center-to-center by at least 0.25 cm and/or at least 0.5 cm and/or at least 0.75 cm and/or at least 1.0 cm and/or at least 1.25 cm and/or at least 1.5 cm and/or at least 1.75 cm and/or at least 2 cm and/or at least 2.25 cm and/or at least 2.5 cm and/or at least 3 cm and/or at least 5 cm as shown by R₁.

When the surface pattern comprises two or more filamentary patterns 10 as shown in FIGS. 5 to 15, at least one of the two or more filamentary patterns 10 may comprise a motif 28 comprising one or more dots 30.

In one example, the surface pattern comprises two or more filamentary patterns 10 wherein at least two of the two or more filamentary patterns 10 are spaced apart from one another center-to-center by at least 1 cm and/or at least 1.5 cm and/or at least 2 cm and/or at least 2.25 cm and/or at least 2.5 cm and/or at least 3 cm and/or at least 5 cm as shown by F₁ in FIGS. 5 to 15.

One or more filamentary patterns and/or complementary line patterns of the present invention may exhibit a minimum width of at least 40 mils and/or at least 50 mils and/or at least 60 mils and/or to about 220 mils and/or to about 200 mils and/or to about 170 and/or to about 150 mils and/or to about 100 mils.

When the surface pattern comprises two or more complementary line patterns 26 as shown in FIGS. 5 to 15, at least two of the two or more complementary line patterns 26 are spaced apart from one another center-to-center by at least 2 mm and/or at least 3 mm and/or at least 4 mm and/or at least 5 mm and/or at least 7 mm as shown by R₂.

In one example, one or more continuous lines and/or broken line segments forming a filamentary pattern and/or complementary line pattern may exhibit a minimum width of at least 10 mils and/or at least 20 mils and/or at least 30 mils and/or to about 100 mils and/or to about 80 mils and/or to about 60 mils.

In addition to the filamentary pattern and complementary line pattern, the surface pattern may further comprise discrete elements, such as discrete motifs 32 as shown in FIG. 9. The discrete motifs 32 may comprise one or more dots 30.

The surface pattern may be an emboss pattern, imparted by passing a fibrous structure through an embossing nip comprising at least one patterned embossing roll patterned to impart a surface pattern according to the present invention, and/or a water-resistant pattern (i.e., wet-molded pattern), such as a patterned through-air-drying belt that is patterned to impart a surface pattern according to the present invention, and/or a rush transfer or fabric creped or wet pressed imparted surface pattern or portions thereof, which imparts texture to the sanitary tissue product typically during the sanitary tissue product-making process.

In yet another example of the present invention. the sanitary tissue product may comprise a patterned sanitary tissue product comprising a surface having a surface pattern, wherein the surface pattern comprises a first region comprising a plurality of parallel or substantially parallel straight line segments spaced apart from one another by at least 0.5 mm and/or at least 0.7 mm and/or at least 1 mm and a second region exhibiting a surface area of greater than 50 mm², wherein the surface area is void of the straight line segments. The straight line segments are spaced apart from one another center-to-center by at least 1 mm and/or at least 2 mm and/or at least 3 mm and/or less than 40 mm and/or less than 30 mm and/or less than 20 mm and/or less than 10 mm.

The surface pattern may be present on the surface of the sanitary tissue product in any orientation with respect to the machine direction (MD). For example, the surface pattern and/or filamentary pattern and complementary line pattern may be at an angle of from about 10° to about 80° and/or from about 30° to about 60° and/or from about 40° to about 55° to the machine direction.

The sanitary tissue products comprising a surface pattern of the present invention may be perceived by consumers of sanitary tissue products as being able to provide better cleaning of soil compared to sanitary tissue products comprising surface patterns not within the scope of the present invention and improved strength compared to sanitary tissue products comprising surface patterns not within the scope of the present invention.

Methods for Making Sanitary Tissue Products

The sanitary tissue products of the present invention may be made by any suitable process known in the art. The method may be a sanitary tissue product making process that uses a cylindrical dryer such as a Yankee (a Yankee-process) or it may be a Yankeeless process as is used to make substantially uniform density and/or uncreped sanitary tissue products.

The sanitary tissue product of the present invention may be made using a molding member. A “molding member” is a structural element that can be used as a support for an embryonic web comprising a plurality of cellulosic fibers and a plurality of synthetic fibers, as well as a forming unit to form, or “mold,” a desired microscopical geometry of the sanitary tissue product of the present invention. The molding member may comprise any element that has fluid-permeable areas and the ability to impart a microscopical three-dimensional pattern to the structure being produced thereon, and includes, without limitation, single-layer and multi-layer structures comprising a stationary plate, a belt, a woven fabric (including Jacquard-type and the like woven patterns), a band, and a roll. In one example, the molding member is a deflection member. The molding member may comprise a surface pattern according to the present invention that is imparted to the sanitary tissue product during the sanitary tissue product making process.

A “reinforcing element” is a desirable (but not necessary) element in some embodiments of the molding member, serving primarily to provide or facilitate integrity, stability, and durability of the molding member comprising, for example, a resinous material. The reinforcing element can be fluid-permeable or partially fluid-permeable, may have a variety of embodiments and weave patterns, and may comprise a variety of materials, such as, for example, a plurality of interwoven yarns (including Jacquard-type and the like woven patterns), a felt, a plastic, other suitable synthetic material, or any combination thereof.

In one example of a method for making a sanitary tissue product of the present invention, the method comprises the step of contacting an embryonic fibrous web with a deflection member (molding member) such that at least one portion of the embryonic fibrous web is deflected out-of-plane of another portion of the embryonic fibrous web. The phrase “out-of-plane” as used herein means that the sanitary tissue product comprises a protuberance, such as a dome, or a cavity that extends away from the plane of the sanitary tissue product. The molding member may comprise a through-air-drying fabric having its filaments arranged to produce linear elements within the sanitary tissue products of the present invention and/or the through-air-drying fabric or equivalent may comprise a resinous framework that defines deflection conduits that allow portions of the sanitary tissue product to deflect into the conduits thus forming linear elements within the sanitary tissue products of the present invention. In addition, a forming wire, such as a foraminous member may be arranged such that linear elements within the sanitary tissue products of the present invention are formed and/or like the through-air-drying fabric, the foraminous member may comprise a resinous framework that defines deflection conduits that allow portions of the sanitary tissue product to deflect into the conduits thus forming linear elements within the sanitary tissue products of the present invention.

In another example of a method for making a sanitary tissue product of the present invention, the method comprises the steps of:

• • (a) providing a fibrous furnish comprising fibers;
  • (b) depositing the fibrous furnish onto a foraminous member to form an embryonic fibrous web;
  • (c) associating the embryonic fibrous web with a deflection member comprising a surface pattern; and
  • (d) drying said embryonic fibrous web such that that the surface pattern is imparted to the dried sanitary tissue product.

In another example of a method for making a sanitary tissue product of the present invention, the method comprises the steps of:

• • (a) providing a fibrous structure; and
  • (b) imparting a surface pattern to the fibrous structure to produce the sanitary tissue product.

In another example, the step of imparting a surface pattern to a sanitary tissue product comprises contacting a molding member comprising a surface pattern with a sanitary tissue product such that the pattern is imparted to the sanitary tissue product. The molding member may be a patterned belt that comprises a surface pattern.

In another example, the step of imparting a surface pattern to a sanitary tissue product comprises passing a sanitary tissue product through an embossing nip formed by at least one embossing roll comprising a surface pattern such that the surface pattern is imparted to the sanitary tissue product.

NON-LIMITING EXAMPLES

Non-Limiting Example

Non-limiting examples of fibrous structures of the present invention, for example paper towels, can be produced utilizing a cellulose pulp furnish consisting of a Northern Softwood Kraft (NSK) and Eucalyptus Hardwood (EUC) at a ratio of approximately 70/30. The NSK is refined as needed to maintain target wet burst at the reel. Any furnish preparation and refining methodology common to the papermaking industry can be utilized.

A 3% active solution Kymene 1142 (available from Ashland Inc.) is added to the refined NSK line prior to an in-line static mixer and 1% active solution of Advantage DF285, an ethoxylated fatty alcohol defoamer available from Ashland Inc. is added to the EUC furnish. The addition levels are 21 and 1 lbs active/ton of paper, respectively.

The NSK and EUC thick stocks are then blended into a single thick stock line followed by addition of 1% active carboxymethylcellulose (CMC) solution at 7 and 1 lbs active/ton of paper towel, and optionally, a softening agent may be added.

The thick stock is then diluted with white water at the inlet of a fan pump to a consistency of about 0.15% based on total weight of NSK and EUC fiber. The diluted fiber slurry is directed to a non layered configuration headbox such that the wet web formed onto a Fourdrinier wire (foraminous wire).

Dewatering occurs through the Fourdrinier wire and is assisted by deflector and vacuum boxes. The Fourdrinier wire is of a 5-shed, satin weave configuration having 87 machine-direction and 76 cross-direction monofilaments per inch, respectively. The speed of the Fourdrinier wire is about 750 fpm (feet per minute).

The embryonic wet web is transferred from the Fourdrinier wire at a fiber consistency of about 24% at the point of transfer, to a patterned belt through-air-drying resin carrying fabric that is used to impart the surface pattern to the fibrous structure. To provide fibrous structure products of the present invention, the speed of the patterned through-air-drying fabric is approximately the same as the speed of the Fourdrinier wire. In another example, the embryonic wet web may be transferred to a patterned belt and/or fabric that is traveling slower, for example about 20% slower than the speed of the Fourdrinier wire (for example a wet molding process).

Further de-watering is accomplished by vacuum assisted drainage until the web has a fiber consistency of about 30%.

While remaining in contact with the patterned drying fabric, the web is pre-dried by air blow-through pre-dryers to a fiber consistency of about 65% by weight.

After the pre-dryers, the semi-dry web is transferred to a Yankee dryer and adhered to the surface of the Yankee dryer with a sprayed creping adhesive. The creping adhesive is an aqueous dispersion with the actives consisting of about 22% polyvinyl alcohol, about 11% CREPETROL® A3025, and about 67% CREPETROL® R6390. CREPETROL® A3025 and CREPETROL® R6390 are commercially available from Ashland Inc. (formerly Hercules Inc.). The creping adhesive is delivered to the Yankee surface at a rate of about 0.15% adhesive solids based on the dry weight of the web. The fiber consistency is increased to about 97% before the web is dry creped from the Yankee with a doctor blade.

The doctor blade has a bevel angle of about 25° and is positioned with respect to the Yankee dryer to provide an impact angle of about 81°. The Yankee dryer is operated at a temperature of about 177° C. and a speed of about 800 fpm. The fibrous structure is wound in a roll using a surface driven reel drum having a surface speed of about 656 feet per minute. In another example, the doctor blade may have a bevel angle of about 45° and is positioned with respect to the Yankee dryer to provide an impact angle of about 101° and the reel may be run at a speed that is about 15% faster than the speed of the Yankee.

The fibrous structure may be subsequently converted into a two-ply paper towel product having a basis weight of about 45-55 g/m².

Test Methods:

Unless otherwise specified, all tests described herein including those described under the Definitions section and the following test methods are conducted on samples that have been conditioned in a conditioned room at a temperature of 23° C.±1.0 (confirmed ° C.) and a relative humidity of 50%±2% (confirmed) for a minimum of 2 hours (confirmed) prior to the test. All tests are conducted in such conditioned room. Do not test samples that have defects such as wrinkles, tears, holes, and like. Samples are referred to as usable units. “Usable units” as used herein means sheets (single or multi-ply), flats from roll stock, and preconverted flats. All instruments are calibrated according to manufacturers specifications.

Basis Weight Test Method

Basis weight of a fibrous structure and/or sanitary tissue product sample is measured by selecting twelve (12) usable units of the fibrous structure and making two stacks of six (6) usable units each. If perforations or folds are present, keep them aligned on the same side when stacking the usable units. A precision cutter is used to cut each stack into exactly 3.500 in.×3.500 in. squares + or −0.0035 in tolerance in each dimension. The two stacks of cut squares are combined to make a basis weight stack of twelve (12) squares thick. The stack is then weighed on a top loading balance with a minimum resolution of 0.001 g. The top loading balance must be protected from air drafts and other disturbances using a draft shield. Weights are recorded when the readings on the top loading balance become constant. The Basis Weight is calculated as follows:

$\mathrm{Basis}\mathrm{Weight}\left(\mathrm{lbs}\text{/}3000{\mathrm{ft}}^2\right)=\frac{\mathrm{Weight}\mathrm{of}\mathrm{basis}\mathrm{weight}\mathrm{stack}\left(g\right)\times 3000{\mathrm{ft}}^2}{\begin{array}{c}453.6g\text{/}\mathrm{lbs}\times 12\left(\mathrm{usable}\mathrm{units}\right)\times \\ \left[12.25{\mathrm{in}}^2\left(\mathrm{Area}\mathrm{of}\mathrm{basis}\mathrm{weight}\mathrm{stack}\right)/144{\mathrm{in}}^2\right]\end{array}}$ $\mathrm{Basis}\mathrm{Weight}\left(g\text{/}m^2\right)=\frac{\mathrm{Weight}\mathrm{of}\mathrm{basis}\mathrm{weight}\mathrm{stack}\left(g\right)\times 10,000{\mathrm{cm}}^2\text{/}m^2}{79.0321{\mathrm{cm}}^2\left(\mathrm{Area}\mathrm{of}\mathrm{basis}\mathrm{weight}\mathrm{stack}\right)\times 12\left(\mathrm{usable}\mathrm{units}\right)}$

Report result to the nearest 0.1 (lbs/3000 ft² or g/m²) Sample dimensions can be changed or varied using a similar precision cutter as mentioned above, so as at least 100 square inches of sample area in stack (Brant to edit this as he finalizes these changes)

Caliper Test Method

Caliper of a fibrous structure and/or sanitary tissue product is measured using a Progage Thickness Tester available from Thwing-Albert Instrument Company, West Berlin, N.J. Samples are prepared by cutting four (4) usable units such that each cut sample is at least 2.5 inches length in MD and CD dimensions, avoiding creases, folds, and obvious defects. The stainless steel pressure foot has a circular surface area of 3.14 in² (2 inch diameter). Each sample is individually confined between a horizontal flat surface (anvil) and the pressure foot loading surface, both made of smooth stainless steel. Place the specimen (individual usable unit) on the anvil in such a position that its edges extend at least 0.25 inches beyond the outside perimeter of the contacting pressure foot. The pressure foot lowers at a speed of 0.03 in/sec, with a dwell time of 3 seconds and a confining pressure of 95 g/in² The caliper is calculated as the average caliper of the four samples. The result is reported in mils (0.001 in) to the nearest 0.1 mils

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.”

Every document cited herein, including any cross referenced or related patent or application, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.

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.

Claims

1. A sanitary tissue product having a surface, wherein the surface comprises a surface pattern comprising a filamentary pattern and a complementary line pattern.

2. The sanitary tissue product according to claim 1 wherein the filamentary pattern comprises a motif comprising a dot.

3. The sanitary tissue product according to claim 2 wherein the motif comprises a plurality of dots.

4. The sanitary tissue product according to claim 3 wherein the plurality of dots create a dot pattern.

5. The sanitary tissue product according to claim 1 wherein the filamentary pattern comprises two or more motifs that are spaced apart from one another center-to-center by at least 1.5 cm.

6. The sanitary tissue product according to claim 1 wherein the surface pattern comprises two or more filamentary patterns.

7. The sanitary tissue product according to claim 6 wherein at least one of the two or more filamentary patterns comprises a motif comprising a dot.

8. The sanitary tissue product according to claim 6 wherein at least two of the two or more filamentary patterns are spaced apart from one another center-to-center by at least 1 cm.

9. The sanitary tissue product according to claim 1 wherein the filamentary pattern is formed by two continuous lines.

10. The sanitary tissue product according to claim 9 wherein at least one of the two continuous lines exhibits a minimum width of at least 10 mils.

11. The sanitary tissue product according to claim 1 wherein the filamentary pattern is formed by at least one broken line.

12. The sanitary tissue product according to claim 1 wherein the filamentary pattern exhibits a minimum width of at least 40 mils.

13. The sanitary tissue product according to claim 1 wherein the surface pattern comprises two or more complementary line patterns.

14. The sanitary tissue product according to claim 13 wherein at least two of the two or more complementary line patterns are spaced apart from one another center-to-center by at least 2 mm.

15. The sanitary tissue product according to claim 1 wherein the complementary line pattern is formed by two continuous lines.

16. The sanitary tissue product according to claim 15 wherein at least one of the two continuous lines exhibits a minimum width of at least 10 mils.

17. The sanitary tissue product according to claim 1 wherein the complementary line pattern is formed by at least one broken line.

18. The sanitary tissue product according to claim 1 wherein the complementary line pattern exhibits a minimum width of at least 40 mils.

19. A method for making a sanitary tissue product according to claim 1, the method comprises the steps of:

(a) providing a fibrous furnish comprising fibers;

(b) depositing the fibrous furnish onto a foraminous member to form an embryonic fibrous web;

(c) associating the embryonic fibrous web with a deflection member comprising a surface pattern; and

(d) drying said embryonic fibrous web such that that the surface pattern is imparted to the dried sanitary tissue product.

20. A method for making a sanitary tissue product according to claim 1, the method comprises the steps of:

(a) providing a fibrous structure; and

(b) imparting a surface pattern to the fibrous structure to produce the sanitary tissue product.