Technical Field The present invention relates to airlaid manufacturing and more particularly, relates to a forming wire for use in an airlaid web forming machine.

Background Absorbent structures are important in a wide range of disposable absorbent articles including baby diapers, adult incontinence products, sanitary napkins and the like. These and other absorbent structures are generally provided with an absorbent core to receive and retain body liquids. The absorbent core is usually sandwiched between a liquid pervious topsheet, whose function is to allow the passage of fluid to the core and a liquid impervious backsheet, whose function is to contain the fluid and prevent it from passing through the absorbent article to the garment of the wearer of the absorbent article.

An absorbent core for diapers and adult incontinence pads frequently includes fibrous batts or webs constructed of defiberized, loose, fluffed, hydrophilic, cellulosic fibers. The core can also include superabsorbent polymer ("SAP") particles, granules, flakes or fibers (collectively"particles").

In addition, absorbent structures can be used in a number of other applications, including nonwoven absorbent wipes, mop elements, table top and napkin materials, medical applications, such as surgical gowns and dressings, and seed mats. It will also be understood that these are only a handful of applications for nonwoven materials and many other applications exist that are within the purview of the present application.

There are a number of manufacturing processes that can be used to produce the absorbent articles. For example, one manufacturing process is an airlaid process which is used to produce an airlaid web which is typically prepared by disintegrating or defiberizing a pulp sheet or sheets typically by a hammermill to provide substantially opened fibers. The opened fibers are then air conveyed to forming heads on the airlaid web forming machine. Several manufacturers make defiberized pulp sheet airlaid web forming machines including M&J Fibretech of Denmark and Dan-Web, also of Denmark. The forming heads can include rotating or agitated drums, generally in a"race track"configuration which serve to maintain fiber separation until the fibers are pulled by vacuum onto a foraminous condensing drum or foraminous forming conveyor. Other fibers, such as a synthetic thermoplastic fiber, or superabsorbent fiber can also be introduced to the forming head through a fiber"dosing"system which includes a fiber opening, a dosing unit and an air conveyor. Non-fibrous materials, such as super-absorbent

polymer (SAP) granules can also be added to the forming head by a dosing system.

Typically, the airlaid web is transferred from the condensing drum or forming conveyor to a calender or other densification stage to densify the web, increase its strength and control web thickness. The fibers of the web are then bonded by application of a latex spray or foam addition system, followed by drying or curing. Alternatively, or additionally, any thermoplastic fiber present in the web can be softened or partially melted by application of heat to bond the fibers of the web. The bonded web can then be calendered a second time to increase strength or emboss the web with a design or pattern. If thermoplastic fibers are present, hot calendering can be employed to impart patterned bonding to the web. Water can be added to the web if necessary to maintain specified or desired moisture content, to minimize dusting and to reduce the buildup of static electricity.

While the conventional airlaid web forming machines are suitable for particular uses, these machines have a number of disadvantages that are associated therewith. For example, the basic airlay process to manufacture fibrous webs takes air-conveyed individualized fibers and deposits them onto some form of porous screen or fabric to make a mat. While this simple airlay technology may suffice for making handsheets, the technology is too simple to account for all fibrous web products made by the airlay process. In other words, the conventional parts of the airlay machinery do not permit a great deal of variability to be realized in the construction of the airlaid mat that is produced. For example, the basis weight and thickness of the airlaid web is uniform or substantially uniform throughout the entire airlaid web.

Summary What has heretofore not been available is a forming wire that is constructed so as to produce an airlaid web that has a non-uniform profile or otherwise has differing properties or characteristics. The present embodiments disclosed herein address this need and disclose a number of forming wires for use in an airlaid web forming machine. In one exemplary embodiment, the forming wire includes a feature that causes the resulting airlaid web formed therefrom to be textured and have a differential basis weight and increased surface area. More specifically, one exemplary forming wire includes a base section and a topographical feature formed integral with the base section such that the topographical feature is raised relative to the base section. Since the topographical feature is raised relative to the surrounding regions of the base section, the forming wire has a non-uniform thickness which causes the fibers to deposit in a non-uniform manner, thereby resulting in the airlaid web having regions of varying thickness and basis weight.

In one exemplary embodiment, the topographical feature is a plurality of bumps that are formed according to a predetermined pattern across a top face of the base section. The bumps can have rounded tops so that the resulting airlaid web has a plurality of dimples formed therein (which are mirror images of the bumps of the forming wire). By forming dimples in the airlaid web, the web has two distinct regions, namely, regions of low basis weight where the bumps are formed and regions of high basis weight which correspond to the areas of the web which are free of the bumps. The formation of dimples in the airlaid

web also increases the overall surface area of the web compared to a conventional flat sheet web.

In yet another embodiment, the topographical feature is in the form of raised letters (text) that are disposed across the top surface of the base section.

The raised letters are preferably displayed backwards across the top surface so that the indented letters formed in the resulting airlaid web are displayed in the correct order so that the text is readable. In this manner, the text can be the manufacturer's name, a logo, a trademark, a design or any other type of decorative indicia.

The advantages of products made by an airlaid process using the present forming wires are numerous as disclosed herein and include the ability to vary the basis weight of the airlaid web across its cross-section as well as increasing the overall surface area of the absorbent web.

Other features and advantages of the present invention will be apparent from the following detailed description when read in conjunction with the accompanying drawings.

Brief Description of the Drawing Figures The foregoing and other features of the present invention will be more readily apparent from the following detailed description and drawings figures of illustrative embodiments of the invention in which: Fig. 1 is a schematic illustration of a conventional airlaid web forming machine for producing fibrous webs from air-conveyed individualized fibers;

Fig. 2 is a perspective view of a forming wire with topographical features according to a first embodiment and formed as a part thereof; Fig. 3 is an enlarged cross-sectional view of a portion of the forming wire illustrating several topographical features ; Fig. 4 is a top plan view of a fibrous web produced using the forming wire of Fig. 2; Fig. 5 is a perspective view of a forming wire with topographical features according to a second embodiment and formed as a part thereof; Fig. 6 is a top plan view of a fibrous web produced using the forming wire of Fig. 5; Fig. 7 is a top plan view of a fibrous web according to another embodiment illustrating recessed topographical features in the form of text and dimples; and Fig. 8 is a perspective view of an exemplary topographical feature including dimensions thereof.

Detailed Description of Preferred Embodiments Fig. 1 is a schematic illustration of an exemplary airlaid web forming machine (automated line) 100 for producing fibrous webs and the like from defiberized, individualized fibers or the like. More specifically, the airlaid web forming machine 100 typically includes a device 110 for creating the fibrous starting material (stock material) that is introduced into the machine 100 to form the airlaid fibrous mat. For example, the device 110 can be in the form of a hammermill or other type of device that receives a pulp sheet (s) or the like disintegrated or defiberizes the pulp sheet (s) to provide substantially opened

fibers. The individualized fibers are then air conveyed to one or more forming heads 120 which form a part of the airlaid web forming machine 100. The forming heads 120 then deposit the individualized fibers onto a foraminous member 130 under action of a vacuum (not shown) which pulls the fibers onto the foraminous member 130.

The one or more forming heads 120 can include rotating or agitated drums, generally in a"race track"configuration which serve to maintain fiber separation until the fibers are pulled by the vacuum onto the foraminous member 130. The foraminous member 130 can be in any number of different forms, such as a foraminous condensing drum or foraminous forming conveyor, or forming wire and therefore, the foraminous member 130 can be broadly thought of as a foraminous substrate that receives the individualized fibers in a manner in which a fibrous layer (mat or stratum) is formed. For purpose of illustration only, the foraminous member 130 will be discussed hereinafter as a forming wire 130 which is generally part of a conveyor or driven assembly. Other fibers, such as a synthetic thermoplastic fiber, or superabsorbent fiber can also be introduced to the forming head through a fiber"dosing"system which includes a fiber opening, a dosing unit and an air conveyor. Non-fibrous materials, such as super-absorbent polymer (SAP) can also be added to the forming head by a dosing system. In other words, a stratum can contain, for example, cellulose fibers, SAP and other functional particles and bicomponent fibers.

As previously mentioned, several manufacturers make defiberized pulp sheet airlaid web forming machines including M&J Fibretech of Denmark and Dan-Web, also of Denmark. For example, in machines manufactured by M&J Fibretech, the forming head includes a rotary agitator above a screen. Other

fibers, such as a synthetic thermoplastic fiber, can also be introduced to the forming head through a fiber dosing system, which includes a fiber opener, a dosing unit and an air conveyor.

The fibers from the forming heads 120 are thus airlaid or delivered to the forming wire 130 under action of the vacuum so as to form thereon a deposited fibrous web (mat) or the like. The airlaid web is transferred from the forming wire 130 to a calender or other densification stage to densify the web, increase its strength and control web thickness. The fibers of the web may alternatively, or additionally, be bonded by application of a binder or foam addition system, followed by drying and curing. As a result, heat seals between the thermoplastic material and the fibers of the various strata are formed. The finished web is then rolled for future use.

As shown in Fig. 1, the machine 100 can be in the form of an airlay manufacturing line where a first material 150 is optionally unwound from a supply roll 152 and is rolled onto the forming wire 130. The first material 150 can be in the form of a carrier tissue which is used as a carrier for the other airlaid layers or in some embodiments, the tissue can be the lower stratum of the absorbent structure. However, it will be appreciated that the resulting formed web 140 does not have to include a tissue as a carrier or as the lower stratum of the absorbent structure but rather the lower stratum can be formed of fibers that pass through the forming head 120 and are deposited under vacuum on the forming wire 130.

A forming head 120 of the airlaid web forming machine distributes the desired fiber to form a lower stratum 142 of the absorbent structure (web 140).

The stratum 142 can include further fibers as previously mentioned.

It will be understood that the one or more forming heads 120 of the airlaid web forming machine 100 distribute the desired fiber for the various strata of the absorbent structure. For example, a first forming head 120 can be used to provide the first fibrous stratum 142 and in one embodiment, a particle applicator 160 is disposed downstream of the first forming head 120 for optionally or additionally applying functional particles to the lower stratum 142 deposited by the first fibrous stratum.

Optionally, the strata is compacted or densified in a nip formed by a pair of calender rolls 170. The fibers can be compressed to the desired thickness and density. The lower stratum 142 can be compacted at this point in the manufacturing process to close the pores of the web if the particles are fine and to prevent spillage on to the forming wire 130. Additional strata 144,146 can then be formed on top of the lower stratum 142 in the same manner the first stratum is formed, by use of forming heads 172,174, and optionally nips formed by calender rolls at 176,178, respectfully. Additionally, particle applicators 173,175 can be provided similar to the applicator 170. According to the illustrated embodiment, the airlaid web 140 is transferred from the forming wire 130 and is compacted or densified, for example, by use of a calendar 180 or is otherwise subjected to treatment for increasing its strength and controlling the web thickness. The web 140 is then typically subjected to further treatment including pressure, heat and/or the application of a binder. For example, a binder (such as a spray or foam binder) can be applied at binder applicators, which can be disposed after the calendar 180. A series of ovens can also be used in the present manufacturing processes, after application of the binder, for drying, curing or thermal bonding.

A further overall binder can then applied to the resulting structure. This binder

can be applied by spray, foam or mist and is applied to reduce dust-off on the surface of the structure. The airlaid structure can then be heated in additional ovens with a predetermined temperature range and it can be treated at a predetermined pressure range. The finished web can then be rolled at roll 190 for future use.

Now referring to Fig. 2-4, in accordance with one aspect of the present invention, the forming wire 130 is constructed so that the resulting web 140 is textured and has a differential basis weight and increased surface area.

More specifically, the forming wire 130 has one or more topographical features, generally indicated at 200, that are a part of the forming wire 130 which causes the airlaid fibers to deposit in a non-uniform manner, thereby resulting in the web 140 having regions of varying thickness and basis weight.

The forming wire 130 is formed from any number of different <BR> <BR> materials, such as a synthetic material (e. g. , nylon, etc. ). Preferably, the forming wire 130 is formed of a polymer material. The forming wire 130 can be constructed to have any number of different patterns and in one exemplary embodiment, the forming wire 130 is generally screen-like or mesh-like structure that has a number of openings that are defined by intersecting cords of the forming wire. In one embodiment, the openings are generally square or rectangular shaped as a result of a series of longitudinal and latitudinal cords intersecting at right angles with respect to one another. However, it will be appreciated that the cord elements can be laid down in any number of particular patterns.

Referring to Fig. 2, one exemplary forming wire 130 is illustrated and includes a screen-like (mesh) base section 132, as described above, and the one or more topographical features 200 that are formed as part of the forming wire

130. Generally speaking, the topographical features 200 are structures that are elevated relative to the base section 132 of the forming wire 130.

It will be understood that the topographical features 200 are not limited to having any particular dimensions and/or shapes so long as the one or more features 200 extend above the plane that contains the base section 132 of the forming wire 130. Most likely, the topographical features 200 are arranged according to a regular pattern, such as rows; however, the topographical features 200 can be arranged according to irregular patterns, such as a random pattern. In the illustrated embodiment, the topographical features 200 are in the form of a plurality of bumps or protrusions that are arranged according to a predetermined pattern on the base section 132 of the forming wire 130. The illustrated bumps 200 have rounded tops or can generally have conical structures. The bumps 200 are arranged in a predetermined number of rows and the bumps 200 in one row an be staggered relative to bumps 200 in the adjacent rows or the bumps 200 can be axially aligned with bumps 200 of the other rows. It will be understood that the bumps 200 can have varying heights or the bumps 200 can be all of the same height.

It will be appreciated that the bumps 200 define different regions of the forming wire 130 that behave differently, namely, regions where the bumps 200 are not present and thus the forming wire has normal air permeability in these regions and regions where the bumps 200 are present and therefore, the bumps 200 restrict the air flow through the forming wire 130 and physically blocks fiber from being deposited on the forming wire surface where the bumps 200 are present. Fibers to be deposited onto the forming wire 130 are suspended in an airstream and are deposited onto the forming wire 130 by a vacuum drawn from

below the forming wire 130. The fibers are deposited preferentially first in the regions or zones that are bump free (absence of topographical features) since these regions are of greatest airflow through the forming wire 130 and the fibers are physically excluded from the regions where the bumps 200 are present. This is generally shown in Fig. 3. The areas where the bumps 200 are present are relatively fiber free until the fiber mat is built up to the height of the bumps 200 and at that time, the fibers are no longer physically blocked and are free to be deposited randomly in all directions of the web.

Fig. 4 shows the resulting web 140 that is produced with the forming wire 130 of Figs. 2 and 3. The resulting web 140 has zones or regions 141 of high basis weight and zones or regions of low basis weight 143. The high basis weight regions 141 are formed in those regions that are bump free (e. g. zones between adjacent bumps), while the low basis weight regions are those regions of the web 140 that have recessed sections (profiled indentations) and are low basis weight because they contain less fiber owing to the action of the bump to physically block fiber from depositing in these regions. The surface area on the side of the web that is textured by the bumps 200 is increased geometrically by the shape of the bump 200 (i. e. , the web surface is the mirror image of the forming wire and therefore, the bumps become dimples (indentations) formed in the web).

The increase in surface area can easily be calculated from the dimensions and the density of the bumps 200 as described and illustrated herein.

The topographical features 200 form an integral part of the forming wire 130 and there are several processes or techniques that can be used to produce the forming wire 130 with topographical features 200 formed as a part thereof.

One exemplary process is a screen printing process in which a material, which is

preferably different from the material of the base section 132, is deposited onto and securely bonded to the base section 132 through a screen member or the like, which is commonly used in conventional screen printing processes. The screen member or the like has a predetermined pattern that permits material to pass therethrough and therefore, the openings in the screen member serve to permit the material to pass therethrough and form a complementary topographical pattern on the base section 132. In other words, if the topographical features 200 are in the form of bumps, the screen member has a series of openings that permit the material to pass therethrough to form the bumps on the base section 132.

The topographical features 200 are preferably formed of a polymer material, such as silicone or urethane. The manner of securely bonding the topographical features 200 to the base section 132 can likewise be accomplished in several different ways. For example, a mechanical coupling between the two can be provided as a result of material of the topographical features 200 capturing the cord elements of the base section 132. In other words, when the material that forms the topographical features 200 is deposited onto the base section 132, the material flows around the cord elements of the base section 132 so as to capture the cord elements when the material hardens, thereby securely bonding the feature 200 to the base section 132.

In another exemplary embodiment, the topographical features 200 are formed as part of the base section 132 by a UV curing process in which a UV curable material is deposited onto the base section 132 and then a mask is placed over the base section 132, wherein the mask has a predetermined pattern formed as a part thereof. The mask thus exposes some areas of the UV curable material layer such that when this material layer is exposed to UV light, the exposed UV

curable material is cured (hardened) while the material underneath the mask is not cured and can be simply washed away or otherwise removed when the mask itself is removed from the UV curable material. The result is that the cured UV material is securely bonded to the base section 132 and defines the topographical features 200.

In yet another embodiment, the topographical features 200 are formed by a molding process in which a moldable material is introduced into a mold and then deposited onto the base section 132 according to the predetermined pattern. The mold can be a stationary type mold in which a polymer is extruded and deposited onto the base section 132 according to the predetermined pattern, thereby forming the topographical features 200.

It will be appreciated that there are other methods, including ones that are chemical and mechanical in nature, for forming the topographical features 200 on the base section 132 in such a way that the topographical features 200 are securely bonded to the base section 132 and form an integral part thereof.

Figs. 5 and 6 illustrate a forming wire 300 according to another embodiment. In this embodiment, the forming wire 300 includes the base section 132 ; however, instead of having raised topographical features 200 in the form of bumps, the forming wire 300 has raised text 310.

In order for the corresponding recessed topographical text formed in a resulting web 400 to be readable, the raised text 310 formed on the forming wire 300 is spelled backwards. The raised text 310 is not merely limited to letters and words but rather it can be a logo or any type of ornamental or decorative indicia. For example, the raised text 310 can be a company logo, slogan, trademark, etc. For example, Fig. 5 illustrates an embodiment where text is

repeated in a pattern across the surface of the forming wire 300. The resulting web 400 that is produced from the forming wire 300 is illustrated in Fig. 6 in which a plurality of recessed topographical text 320 is formed in the web 400.

As with the other types of topographical features, the individual letters of the raised text 310 can be of the same height or the individual letters can have varying heights. In addition, an individual letter itself can have different sections of varying height.

Fig. 7 illustrates yet another fibrous web or mat 401 that includes at least two different types of recessed topographical features, namely a first recessed feature 410 and a second recessed feature 420. In one embodiment, the first recessed feature 410 is a plurality of dimples that are formed in a regular pattern, e. g., rows, or in a random pattern and the second recessed feature 420 is recessed text. The formation of the first and second recessed features 410,420 is accomplished using a forming wire constructed according to the principles disclosed herein, namely, the formation of raised topographical features as a part thereof.

The illustrated mat 400 thus includes both recessed text and recessed dimples, both of which increase the overall surface area of the mat 400 as described hereinbefore.

By placing raised topographical features 200 on the base section 132 and depositing fibers thereon, a fibrous web (mat) is produced with the mirror image of the shape of the topographical features 200. The web therefore has regions of differing basis weight and thickness as well as increased surface area.

The advantages of products made by this method of placing recessed topographical features into an airlay mat are numerous. For example, when the

product is a food service wipe, the recessed topographical features trap food particles and when the product is another type of cleaning device, such as a floor mop or shop towel, the recessed topographical features pick-up loose particles.

The recessed lower basis weight area of the mat allows fluid to pass through quickly for applications for diapers and feminine hygiene products. As illustrated in Figs. 6 and 7, the recessed topographical features can be text that indicates a logo or the company's name or other type of identifying indicia, such as a slogan or trademark, or additionally, the recessed topographical features can provide aesthetic properties. In yet another embodiment, the deposited fibers do not cover the raised topographical features and therefore, the mat product has openings extending completely therethrough. The openings can be advantageous for seed growth in agriculture applications. Openings in the airlay materials lower the bending resistance by providing hinges to make the mat more flexible; however, a mat with openings therein does have reduced surface area. For example, when a seed mat is produced, the holes result in a reduction of about 10% or greater in surface area of the mat compared to a flat sheet, e. g. , about 20% or greater reduction in surface area.

The following examples illustrate exemplary embodiments of the present invention and are not limiting of the present scope in any way.

Example 1 A plurality of raised letters (raised topographical features) that have varying heights was formed on the base section of the forming wire. A sufficient amount of fiberized wood pulp fibers was deposited on forming wire such that the raised letters were covered. The formed pad (fibrous web) was

removed from the forming wire and observed to have an exact mirror image of the raised letters. The indented letters have basis weights and thickness values inversely proportional to the heights of the letters. One result of forming recessed topographical features in the formed pad is that the surface of the pad has increased surface area. This embodiment is generally shown in Fig. 6.

Example 2 Other sample webs were produced using a forming wire of the general type shown in Fig. 2. The forming wire incorporates bumps or protrusions (nubs) that were made of an air impermeable material. Thus, air flow through the forming wire is restricted in areas covered by the bumps. This effect allows fine control over the deposition of fibers onto the forming wire surface.

A detailed description, including dimensions, and illustration of one exemplary bump are set forth in Fig. 8. In this embodiment, the radius of the bump is 1.5 mm and therefore, the complementary indentation radius is 1.5 mm.

This results in a surface contour area of indentation of about 0.1413 cm and in the exemplary pad, there are 350 indentations per 100 cm2 of airlaid sheet. This results in a 24.7% increase in surface area compared to a conventional flat sheet or pad.

A pad produced on such a forming wire with bumps will have varying thickness and basis weight as well as increased surface area.

Examples 3-15

The following Examples 3-15 can be used in feminine hygiene or cleaning wipe applications. All of these resulting fibrous products (mats) have increased surface area, differential reduced thickness and differential basis weight.

Example 3 Handsheets were formed on a lab airlaid forming device by depositing a blend of 52 gsm cellulose fluff (e. g., Foley Fluffs () and 12 gsm Trevira bicomponent fiber (Merge #1663, 2.2. dtex x 3 mm) on a forming wire with bumps (protrusions) having a height of about 0.85 mm. The base section of the forming wire can be obtained commercially from Voith of Heidenheim, Germany. The resulting product is shown in Fig. 4. The samples were pressed to a target thickness of 1.20 mm.

Example 4 Handsheets were formed on a lab airlaid forming device by depositing the following layers on a forming wire with bumps having a height of 0. 85 mm: (1) layer 1 was a PET fiber (KoSa merge #35391 A, 15 dpf x 6 mm) at 16 gsm sprayed with 5 gsm of Airflex 192 (Air Products, 10% solids emulsion); and (2) layer 2 was a blend of 41 gsm cellulose fluff (Buckeye, Foley Fluffs) and 8 gsm Trevira bicomponent fiber (Merge #1663, 2.2. dtex x 3 mm). Layer 2 was sprayed with 2 gsm of Airflex 192 (Air Products, 10% solids emulsion).

Samples were pressed to a target caliper of 1.30 mm.

Example 5

Handsheets were formed on a lab airlaid forming device by depositing the following layers on a forming wire with bumps having a height of 0.85 mm : (1) blend of 41 gsm cellulose fluff (Buckeye, Foley Fluffs) and 8 gsm Trevira bicomponent fiber (Merge #1663, 2.2 dtex x 3 mm). This layer was sprayed with 2 gsm of Airflex 192 (Air Products, 10% solids emulsion); (2) layer 2 was PET fiber (KoSa merge #35391A. 15 dpf x 6 mm) at 16 gsm sprayed with 5 gsm of Airflex 192 (Air Products, 10% solids emulsion). Samples were pressed together to a target caliper of 1. 30 mm.

Example 6 Handsheets were formed on a lab airlaid forming device by depositing the materials in the recipe below on a forming wire having raised bumps formed as a part thereof (bump height 0. 85 mm). A blend was prepared and was formed of 13 gsm bicomponent fluff (Trevira, merge #1661, 2.0 dpf, 6 mm) and 47.5 gsm cellulose fiber (Buckeye, Foley Fluffs@). The samples were pressed on the forming wire at 15,000 lbs for 5 seconds and sprayed on one side with latex (Airflex-192,10% emulsion) at an add-on of 2.25 gsm. The pad was then cured at 140° C for 10 minutes. The other side was treated with the same latex at the same add-on and cured at 140° C for 5 minutes. The samples were pressed to a final thickness of 1 mm.

Example 7 Handsheets were formed on a lab airlaid forming device by depositing 52 gsm of cellulose fibers (Buckeye, Foley Fluffs) on a forming wire having bumps (height 0. 85 mm). The samples were pressed on the forming wire

at 15,000 Ibs for 5 seconds, sprayed one side with latex (Airflex-192,10% emulsion) at an add-on of 6. 5 gsm. The pad was then cured at 140° C for 5 minutes. The samples were pressed to a final thickness of 1 mm.

Example 8 The material was formed on a forming wire with bumps (height 0.85 mm) on a pilot airlaid machine using two forming heads. A description of the layers is as follows: (1) bottom layer: blend of 28 gsm cellulose fluff (Buckeye, Foley Fluffs@) and 7.25 gsm Trevira bicomponent fiber (Merge #1661, 2.0 dpf, 6 mm). This layer received 2.25 gsm of Airflex 192 (Air Products, 10% solids emulsion, 0. 1% Aerosol OT) in foam form; (2) top layer: blend of 28 gsm cellulose (Buckeye, Foley Fluffs@) and 7.25 gsm Trevira bicomponent fiber (Merge #1661, 2.0 dpf, 6 mm). This layer was sprayed with 2.25 gsm of Airflex 192 (Air Products, 10% solids emulsion). These layers were pressed to a target thickness of 0.85 mm with a flat emboss roll and dried in through air ovens (Moldow, Fleissner) prior to being slit to a 10 inch width and collected on a roll.

Example 9 The sample was formed in the same manner as in Example 8.

However, the recipe and target thickness for the material are different. The recipe is as follows: (1) bottom layer: blend of 27 gsm cellulose fluff (Buckeye, Foley Fluffs ) and 8.25 gsm Trevira bicomponent fiber (Merge #1661, 2.0 dpf, 6 mm).

This layer received 2.25 gsm of Airflex 192 (Air Products, 10% solids emulsion, 0.1% Aerosol OT) in foam form; (2) top layer: blend of 27 gsm cellulose (Buckeye, Foley Fluffs (8)) and 8.25 gsm Trevira bicomponent fiber (Merge #1661, 2.0 dpf, 6 mm). This layer was sprayed with 2.25 gsm of Airflex 192 (Air Products, 10% solids emulsion).

Example 10 This material has the same recipe as in Example 9. It has the same properties except that an aperture roll (pinned (needle) roll) was used to poke openings in the sample after the second oven (Fleissner) and prior to being slit.

Example 11 The material was formed on a forming wire with bumps (height 0.85 mm) on a pilot airlaid machine using two forming heads. A description of the layers is as follows: (1) bottom layer: blend of 39 gsm cellulose fluff (Buckeye, Foley Fluffs) and 9.25 gsm Trevira bicomponent fiber (Merge #1661, 2.0 dpf, 6 mm). This layer received 2.25 gsm of Airflex 192 (Air Products, 10% solids emulsion, 0. 1% Aerosol OT) in foam form; (2) top layer: blend of 12 gsm PET (Wellman, 1.5 dpf x 4 mm) and 12 gsm Trevira bicomponent fiber (Merge #1661, 2.0 dpf, 6 mm). This layer was sprayed with 2.25 gsm of Airflex 192 (Air Products, 10% solids emulsion). These layers were pressed to a target thickness of 0.95 mm with a flat emboss roll and dried in through air ovens (Moldow, Fleissner) prior to being slit to a 10 inch width and collected on a roll.

Example 12

The material was formed on a forming wire with bumps (height 0.85 mm) on a pilot airlaid machine using three forming heads. Its normal drum was replaced with a drum having 4 mm round holes to ease the flow of long fibers through the forming head. The pad consists of a blend of 174 gsm hydromulch fiber (Canfor Ecofibre hydromulch (natural balded), Vancouver, CN) and 6 gsm Trevira bicomponent fiber (Trevira, merge #1661, 2.0 dpf, 6 mm).

The material was minimally compacted in order to meet the caliper target of 3 mm. It was sprayed on both sides with 7.5 gsm Structurecote 1887 starch binder (Vinamul, 10% emulsion, Bridgewater, NJ) by means of a 2-pass process. The binder was rendered green by addition of a hydromulch dye (150 ml pre 200 L of 10% starch solution, Parkway Research, Houston, TX). The material was dried in a through air oven (Moldow) following each pass.

Example 13 This sample is the same as sample 12 except that a scrim (Conwed R04035-049, Minneapolis, MN) was added before forming head three on the first pass.

Example 14 This sample was the same as in Example 11 except that 7.5 gsm of binder was added to only one side.

Example 15 This sample was the same as in Example 12 except that 7.5 gsm binder was added to only one side.

The forming wires according to each of the present embodiments provide for a textured airlaid web that has a differential basis weight and increased surface area. In one embodiment, the airlaid web is a textured airlaid nonwoven wipe that has a basis weight from about 50 gsm (grams per square meter) to about 80 gsm and a bulk density from about 0.03 g/cc to about 0.15 g/cc including (a) from about 40 weight percent to about 90 weight percent of a bulk fiber; (b) optionally, from about 1 weight percent to about 25 weight percent of an emulsion polymer binder ; and (c) from about 5 weight percent to about 30 weight percent bicomponent fiber, wherein the material has at least a 20% increase in surface area on one surface and the basis weight is at least 15% greater in the high basis weight zones defined within the web.

In another embodiment, the resulting web is a textured airlaid nonwoven wipe that has a basis weight from about 50 gsm to about 80 gsm and a bulk density from about 0.03 g/cc to about 0.15 g/cc. The wipe can include at least two distinct strata where the stratum on one surface is textured and the stratum on the opposing surface is composed of high denier synthetic fibers to provide a relatively flat scrubbing surface. The wipe includes (a) from about 40 weight percent to about 90 weight percent of a bulk fiber; (b) optionally from about 1 weight percent to about 25 weight percent of an emulsion polymer binder; (c) from about 5 weight percent to about 30 weight percent of a bicomponent fiber; and (d) from about 10 weight percent to about 40 weight percent PET fiber (>5.5 denier). The wipe is further characterized as having at least a 20% increase in surface area on one surface and the basis weight is at least 15% greater in the high basis weight zones.

In one embodiment, the airlaid nonwoven material produced according to the present embodiments has about 200 or greater recessed features, e. g. , dimples, per 100 cm2 of airlaid sheet. For example, the airlaid nonwoven material can includes from about 200 to about 500 recessed features per 100 cm2 of airlaid sheet. Accordingly, the addition of recessed features to the surfaces of the airlaid nonwoven material can lead to about a 10% or greater increase in surface areas compared to a flat sheet, and preferably, about 15% or greater increase, e. g. , about 20% or greater.

The bulk fibers of the present webs can be natural, synthetic or a mixture thereof. In one embodiment, the fibers can be cellulose-based pulp fibers, one or more synthetic fibers or a mixture thereof. Any cellulose fibers known in the art, including cellulose fibers of any natural origin, such as those derived from wood pulp, can be used in a cellulosic layer. Preferred cellulose fibers include, but are not limited to, digested fibers, such as kraft, prehydrolyzed kraft, soda, sulfite, chemi-thermal mechanical, and thermo-mechanical treated fibers, derived from softwood, hardwood or cotton linters. More preferred cellulose fibers include, but are not limited to, kraft digested fibers, including prehydrolyzed kraft digested fibers. Suitable for use in the present webs are the cellulose fibers derived from softwoods, such as pines, firs and spruces. Other suitable cellulose fibers include those derived from Esparto grass, bagasse, kemp, flax and other lignaceous and cellulosic fiber sources. Suitable cellulose fibers include, but are not limited to, bleached Kraft southern pine fibers sold under the trademark Foley Fluffs commercially available from Buckeye Technologies Inc., Memphis, TN.

In yet another embodiment, bulk fibers suitable for use in the structures of exemplary embodiments can include cellulosic or synthetic fibers or

blends thereof. Wood cellulose is a particularly preferred fiber, while other preferred fibers include cotton linter pulp, chemically modified cellulose, such as crosslinked cellulose fibers and highly purified cellulose fibers, such as Buckeye <BR> <BR> HP, each of which is available from Buckeye Technologies Inc. , Memphis, TN.

The fluff fibers can be blended with synthetic fibers, for example polyester, such as PET, nylon, polyethylene or polypropylene.

In certain embodiments, the bicomponent fibers contain a delustrant. Preferably, the delustrant is titanium dioxide. In one embodiment, the delustrant is present in the sheath of the bicomponent fibers. In another embodiment, the delustrant is present in the core of the bicomponent fibers.

In certain embodiments, the bicomponent fibers also contain an optical brightener. Preferably, the optical brightener is bis (benzoxazolyl) stilbene.

In one embodiment, the optical brightener is present in the sheath of the bicomponent fibers and in another embodiment, the optical brightener is present in the core of the bicomponent fibers.

The materials of the present embodiments can also have two or more distinct strata where the composition of any one stratum is different from at least one adjacent stratum. Preferably, the material has two outer strata and one or more inner strata, and the bulk fiber of the outer strata have a brightness of 85 or greater. In another embodiment, the material has two outer strata and one more inner strata and the weight percent bicomponent fiber of the inner stratum is greater than the weight percent bicomponent fiber in the outer strata.

As previously mentioned, the resulting formed airlaid web can be used as a component of a wide variety of absorbent structures, including but not

limited to diapers, feminine hygiene materials, incontinent devices, surgical drapes and associated materials, as well as wipes and mops.

It will further be understood that the topographical feature, according to yet another embodiment, can also be formed as part of the cord elements that form the base section of the forming wire. In other words, the base section can be formed in a mold or the like and a selected number of cord elements can be formed so that they have raised features formed as a part thereof and the raised features of plural cord elements complement each other so as define zones in the base section where the air flow is eliminated and therefore, the resultant formed web will have varying weight basis as described hereinbefore with reference to earlier embodiments.

While exemplary drawings and specific embodiments of the present invention have been described and illustrated, it is to be understood that the scope of the present invention is not to be limited to the particular embodiments discussed. Thus, the embodiments shall be regarded as illustrative rather than restrictive, and it should be understood that variations may be made in those embodiments by workers skilled in the art without departing from the scope of the present invention as set forth in the claims that follow, and equivalents thereof. In addition, the features of the different claims set forth below may be combined in various ways in further accordance with the present invention.