Claims
- 1. A method of manufacturing paper cover stock having a textured surface pattern, comprising the steps of:
- (a) forming a wet fibrous web;
- (b) partially dewatering the web to between about 30% and about 60% solids;
- (c) conveying the partially dewatered web on a roll rotating at a surface speed to a compression nip defined by the roll and a fabric material having a textured surface pattern;
- (d) moving said fabric material at a speed of about 10% to about 40% less than the surface speed of said roll;
- (e) compressing said web in said nip by forcing said fabric material against said web on said roll to directly transfer said web from said roll to said fabric material, said fabric material being compressed against said web with a compression force of at least about 5 lbs/linear inch, the average pressure in the compression nip being at least about 20 psi, said fabric material imprinting a textured pattern on a surface of said web, said web being further compressed and textured by the difference in speed between said fabric material and the surface of said roll; and
- (f) drying said web, said dried web having an apparent density greater than about 4 lb ream/caliper pt. in mils.
- 2. The method of claim 1 including the step of imparting to the web a memory factor greater than about 80.
- 3. The method of claim 1 wherein the step of moving the fabric material includes subjecting the fabric material to a tension on opposite sides of the compression nip, the tension on the fabric material entering said nip being greater than the tension on the fabric material exiting said nip.
- 4. The method of claim 1 including the step of applying a vacuum through said fabric material at said compression nip to directly transfer said web from said roll to said fabric material and to generally conform the surface of said web in contact with said fabric material to the textured surface pattern of said fabric material.
- 5. The method of claim 1 wherein the step of compressing said web includes using an average compression pressure in said nip between about 20 psi and about 400 psi.
- 6. The method of claim 1 wherein the step of compressing said web includes heating said web to a temperature achieved by heating said roll to about 150.degree. to about 210.degree. F.
- 7. The method of claim 1 further comprising the step of applying a protective coating to the web.
- 8. The method of claim 1 wherein the conveying step is accomplished by a roll having a surface roughness average value of from about 0.5 microinches to about 125 microinches.
Parent Case Info
This is a division of application Ser. No. 07/693,030, filed Apr. 30, 1991, now U.S. Pat. No. 5,223,092 which was a continuation of application Ser. No. 07/479,207 filed Feb. 14, 1990 abandoned, which was a continuation of application Ser. No. 07/177,785 filed Apr. 5, 1988.
US Referenced Citations (23)
Foreign Referenced Citations (2)
Number |
Date |
Country |
1212473 |
Nov 1970 |
GBX |
1217378 |
Dec 1970 |
GBX |
Divisions (1)
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Number |
Date |
Country |
Parent |
693030 |
Apr 1991 |
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Continuations (2)
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Number |
Date |
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Parent |
479207 |
Feb 1990 |
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Parent |
177785 |
Apr 1988 |
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