Process for increasing the basis weight of sheet materials
View Patent ↗Sheet-like products are disclosed containing an additive composition. In accordance with the present disclosure, the additive composition is applied to a creping surface. A base sheet is then pressed against the creping surface for contact with the additive composition. The base sheet is then creped from the creping surface causing the additive composition to transfer to the base sheet. In particular, the additive composition is transferred to the base sheet in amounts greater than about 1% by weight, such as from about 2% to about 50% by weight. The additive composition can comprise, for instance, a thermoplastic polymer resin containing an aqueous dispersion, a lotion, a debonder, a softener, or mixtures thereof.
1. A process for producing a sheet product comprising:
applying an additive composition to a moving creping surface, the additive composition comprising a lotion, a debonder, a softener, aloe, vitamin E, an oxidized polyethylene or mixtures thereof;
pressing a base sheet against the creping surface after the additive composition has been applied, the additive composition adhering the base sheet to the creping surface; and
removing the base sheet from the creping surface, wherein the additive composition transfers to the base sheet such that the additive composition comprises at least about 1% of the basis weight of the sheet product.
2. A process as defined in claim 1 , wherein the additive composition comprises from about 2% to about 50% of the basis weight of the sheet product.
3. A process as defined in claim 1 , wherein the base sheet is creped from the creping surface.
4. A process as defined in claim 1 , wherein the base sheet comprises an air formed web.
5. A process as defined in claim 1 , wherein the base web comprises a spunbond web or a meltblown web.
6. A process as defined in claim 1 , wherein the base sheet comprises a hydroentangled web, the base sheet containing synthetic fibers and cellulosic fibers.
7. A process as defined in claim 1 , wherein the base sheet comprises a co-formed web, the web containing synthetic fibers and cellulosic fibers.
8. A process as defined in claim 1 , wherein the creping surface is heated to a temperature from about 20° C. to about 150° C.
9. A process as defined in claim 1 , wherein the base sheet is on the creping surface for a period of time from about 120 milliseconds to about 2,000 milliseconds prior to being removed from the creping surface.
10. A process as defined in claim 1 , wherein the creping surface comprises a surface of a rotating cylinder.
11. A process as defined in claim 1 , wherein the additive composition comprises the lotion.
12. A process as defined in claim 11 , wherein the lotion comprises a wax and an oil.
13. A process as defined in claim 1 , wherein the additive composition comprises from about 2% to about 30% of the basis weight of the sheet product.
14. A process as defined in claim 1 , wherein the additive composition comprises from about 2% to about 15% of the basis weight of the sheet product.
15. A process as defined in claim 1 , wherein the base sheet comprises a woven or knitted fabric.
16. A process as defined in claim 15 , wherein the base sheet contains polyester fibers.
17. A process as defined in claim 15 , wherein the base sheet contains nylon fibers, wool fibers, cotton fibers, or mixtures thereof.
18. A process as defined in claim 1 , wherein the base sheet comprises a bonded carded web.
19. A process as defined in claim 1 , wherein the additive composition comprises an adhesive combined with a lotion.
20. A process as defined in claim 1 , wherein the additive composition comprises a latex polymer combined with a lotion.
21. A process as defined in claim 19 , wherein the adhesive comprises a vinyl acetate-ethylene polymer.
22. A process as defined in claim 19 , wherein the adhesive comprises a vinyl acetate, an ethylene carbon monoxide polymer, a polyacrylate, a styrene butadiene, a polyurethane, a starch, or mixtures thereof.
23. A process as defined in claim 1 , wherein the additive composition comprises the debonder.
24. A process as defined in claim 1 , wherein the additive composition comprises the softener.
25. A process as defined in claim 1 , wherein the additive composition comprises aloe, vitamin E, an oxidized polyethylene, or mixtures thereof.