US 12,331,465 B2
Foam-formed fibrous sheets with crimped staple fibers
Jian Qin, Appleton, WI (US); Deborah J. Calewarts, Winneconne, WI (US); Charles W. Colman, Marietta, GA (US); Donald E. Waldroup, Roswell, GA (US); Cathleen M. Uttecht, Menasha, WI (US); and Peter Wallace, Penzance (GB)
Assigned to Kimberly-Clark Worldwide, Inc., Neenah, WI (US)
Appl. No. 16/608,471
Filed by Kimberly-Clark Worldwide, Inc., Neenah, WI (US)
PCT Filed Apr. 28, 2017, PCT No. PCT/US2017/030038
§ 371(c)(1), (2) Date Oct. 25, 2019,
PCT Pub. No. WO2018/199975, PCT Pub. Date Nov. 1, 2018.
Prior Publication US 2020/0190739 A1, Jun. 18, 2020
Int. Cl. D21H 15/10 (2006.01); D01D 5/22 (2006.01); D21F 11/00 (2006.01); D21H 13/10 (2006.01); D21H 15/04 (2006.01); D21H 27/00 (2006.01)
CPC D21H 15/10 (2013.01) [D01D 5/22 (2013.01); D21F 11/002 (2013.01); D21H 13/10 (2013.01); D21H 15/04 (2013.01); D21H 27/005 (2013.01)] 14 Claims
OG exemplary drawing
 
1. A method for producing a foam-formed substrate, the method comprising:
producing an aqueous-based foam including at least 1% by weight crimped synthetic fibers and at least 1% by weight binder fibers; wherein the crimped synthetic fibers include a polymer having a Tg greater than or equal to 0° C., have a length from 5 mm to 60 mm, and have a diameter of at least 3 dtex;
forming a wet sheet from the aqueous-based foam; and
drying the wet sheet to obtain the foam-formed substrate;
wherein the foam-formed substrate has a dry density between 0.02 g/cc and 0.1 g/cc.