Patent Description:
While the foregoing formulations have been successfully employed in the manufacture of tissue products, they leave much to be desired. For example, their application often requires complex and expensive off-line processes such as rotogravure printing, flexographic printing or spraying. These methods are not only complex and expensive, they generally treat more of the tissue surface than is necessary to achieve the desired user benefit. Accordingly, there remains a need in the art for a low cost, in-line process for selectively treating a tissue product with a lotion.

A low-cost, in-line process for treating a fibrous web with a lotion has now been discovered. The inventive process is particularly useful in treating fibrous webs, particularly textured tissue webs, with a lotion. In certain instances, the method may be used to selectively dispose lotion on only a portion of the structure's surface.

In one aspect, the present invention provides a textured fibrous web having a first side to be contacted by a user in-use, the first side having an uppermost surface lying in a first surface plane and second surface lying in a second surface plane, the second surface plane lying below the first surface plane, and a lotion selectively disposed on the uppermost surface in an amount ranging from about <NUM> to about <NUM> grams per square meter of textured fibrous web, wherein the lotion has a penetration hardness as measured by the method defined herein ranging from <NUM> to <NUM>.

In another aspect, the present invention provides a method of manufacturing a lotion treated web comprising the steps of: providing a lotion composition having a penetration hardness as measured by the method defined herein ranging from about <NUM> to about <NUM>; providing a nip between a transfer surface and a second surface; applying the lotion to the transfer surface; conveying a web through the nip whereby one outwardly facing surface of the web is contacted by the transfer surface resulting in a transfer of the lotion to the surface of the web; and wherein the web has a first side with an uppermost surface lying in a first surface plane and a second surface lying in a second surface plane, the second surface plane lying below the first surface plane and wherein the lotion is selectively disposed on the uppermost surface.

In certain instances, the amount of lotion transfer to the web may be less than about <NUM> grams per square meter (gsm) of fibrous web and more preferably less than about <NUM> gsm and still more preferably less than about <NUM> gsm, such as from about <NUM> to about <NUM> gsm, such as from about <NUM> to about <NUM> gsm.

As used herein the term "fibrous structure" refers to a structure comprising a plurality of elongated particulate having a length to diameter ratio greater than about <NUM> such as, for example, papermaking fibers and more particularly pulp fibers, including both wood and non-wood pulp fibers, and synthetic staple fibers. A non-limiting example of a fibrous structure is a tissue web comprising pulp fibers.

As used herein the term "basesheet" refers to a fibrous structure provided in sheet form that has been formed by any one of the papermaking processes described herein but has not been subjected to further processing to convert the sheet into a finished product, such as subtractive texturing, embossing, calendering, perforating, plying, folding, or rolling into individual rolled products.

As used herein the term "tissue web" refers to a fibrous structure provided in sheet form and being suitable for forming a tissue product.

As used herein the term "tissue product" refers to products made from tissue webs and includes, bath tissues, facial tissues, paper towels, industrial wipers, foodservice wipers, napkins, medical pads, and other similar products. Tissue products may comprise one, two, three or more plies.

As used herein the term "ply" refers to a discrete tissue web used to form a tissue product. Individual plies may be arranged in juxtaposition to each other.

As used herein the term "layer" refers to a plurality of strata of fibers, chemical treatments, or the like, within a ply.

As used herein, the term "papermaking fabric" means any woven fabric used for making a tissue sheet, either by a wet-laid process or an air-laid process. Specific papermaking fabrics within the scope of this invention include wet-laid through-air drying fabrics and air-laid forming fabrics.

As used herein, the term "textured" generally refers the three-dimensional topography of a first or a second side of a fibrous structure. Generally, a textured structure will have a first side with first and second surfaces lying in first and second surface planes where there is some non-zero z-direction height difference between the first and second surface planes. For example, in one-embodiment, a textured tissue web may comprise a plurality of elevated elements having an upper surface lying in a first surface plane separated from one another by land areas lying in a second surface plane.

As used herein, the term "surface plane" generally refers to the plane formed by the upper most surface of an element disposed on one side of a fibrous structure. A surface plane may be determined by well-known imaging techniques such as, for example, using a VHX-<NUM> Digital Microscope (manufactured by Keyence Corporation of Osaka, Japan) equipped with VHX-H3M application software or other suitable image analysis software.

As used herein, the term "design element" means a decorative figure, icon or shape such as a line element, a flower, heart, puppy, logo, trademark, word(s) and the like. A design element may comprise a portion of the fibrous structure surface that lies out of plane with the land or background areas.

As used herein the term "line element" refers to an element, such as a design element, in the shape of a line, which may be continuous, discrete, interrupted, and/or a partial line with respect to a fibrous structure on which it is present. The line element may be of any suitable shape such as straight, bent, kinked, curled, curvilinear, serpentine, sinusoidal, and mixtures thereof, that may form regular or irregular periodic or non-periodic lattice work or structures wherein the line element exhibits a length along its path of at least <NUM>. In one example, the line element may comprise a plurality of discrete elements, such as dots and/or dashes for example, that are oriented together to form a line element.

As used herein the term "continuous element" refers to an element, such as a design element, disposed on a fibrous structure that extends without interruption throughout one dimension of the fibrous structure.

As used herein the term "discrete element" refers to an element, such as a design element, disposed on a fibrous structure that does not extend continuously in any dimension of the fibrous structure.

As used herein the term "basis weight" generally refers to the bone-dry weight per unit area of a tissue and is generally expressed as grams per square meter (gsm). Basis weight is measured using TAPPI test method T-<NUM>. While basis weight may be varied, tissue products prepared according to the present invention generally have a basis weight greater than about <NUM> gsm, such as from about <NUM> to about <NUM> gsm and more preferably from about <NUM> to about <NUM> gsm.

As used herein the term "caliper" is the representative thickness of a single sheet (caliper of tissue products comprising two or more plies is the thickness of a single sheet of tissue product comprising all plies) measured in accordance with TAPPI test method T402 using an EMVECO <NUM>-A Microgage automated micrometer (EMVECO, Inc. , Newberg, OR). The micrometer has an anvil diameter of <NUM> inches (<NUM>) and an anvil pressure of <NUM> grams per square inch (per <NUM> square centimeters) (<NUM> kPa). The caliper of a tissue product may vary depending on a variety of manufacturing processes and the number of plies in the product, however, tissue products prepared according to the present invention generally have a caliper greater than about <NUM>, more preferably greater than about <NUM> and still more preferably greater than about <NUM>, such as from about <NUM> to about <NUM>,<NUM> and more preferably from about <NUM> to about <NUM>,<NUM>.

As used herein the term "sheet bulk" refers to the quotient of the caliper (generally having units of µm) divided by the bone-dry basis weight (generally having units of gsm). The resulting sheet bulk is expressed in cubic centimeters per gram (cc/g). While sheet bulk may vary depending on any one of a number of factors, tissue products prepared according to the present invention may have a sheet bulk greater than about <NUM> cc/g, more preferably greater than about <NUM> cc/g and still more preferably greater than about <NUM> cc/g, such as from about <NUM> to about <NUM> cc/g.

As used herein, the terms "geometric mean tensile" and "GMT" refer to the square root of the product of the machine direction tensile strength and the cross-machine direction tensile strength of the tissue product. While the GMT may vary, tissue products prepared according to the present invention may have a GMT greater than about <NUM>/<NUM>" (g/<NUM>), more preferably greater than about <NUM>/<NUM>" (g/<NUM>) and still more preferably greater than about <NUM>,<NUM>/<NUM>" (g/<NUM>).

The present invention provides a variety of novel lotion treated fibrous structures and methods of producing the same. For example, the present invention provides tissue products, particularly products having three-dimensional surface topography, where a lotion is selectively applied to only a portion of the tissue surface.

While any fibrous structure may be treated with a lotion according to the present invention, in certain instances it may be preferable to treat a fibrous structure having a three-dimensional topography with portions of the structure upper surface lying in first and second surface planes. In certain preferred embodiments the first surface plane lies above the second surface plane and forms the upper most structure surface and is selectively treated with lotion. The second surface, which lies below the first surface, is generally free from lotion. In this manner, the surface of the structure may be selectively treated with lotion such that the surface first brought into contact with the user's skin in-use is selectively treated with lotion. In this manner, the amount of lotion added to the tissue may be reduced without negatively affecting user's perception of softness and comfort. Further, by reducing the amount of lotion and selectively applying it to only a portion of the structure, other important properties such as absorbency, strength and bulk may be preserved.

In certain embodiments the textured surface may comprise a first side having peaks or ridges lying in a first surface plane and valleys lying in a second surface plane below the first surface plane. In other embodiments the first side may comprise a first surface plane and a design element lying in a second surface plane below the first surface plane where the design element provides the fibrous structure with a visually discernable design which users may find aesthetically pleasing. Regardless of the shape and arrangement of elements the structures of the present invention generally have a first side having at least two different surface planes where the upper most surface is preferentially treated with a lotion.

Textured fibrous structures useful in the present invention may be created using any number of well-known techniques, such as wet molding or embossing. In certain preferred embodiments, texture is imparted to the fibrous structure during the manufacturing process such as by wet texturing, molding using a drying fabric or by embossing. Generally, the texture is not the result of printing.

Accordingly, in one embodiment, the fibrous structure is a wet-laid tissue web having a textured surface formed during the manufacturing process by molding the web using an endless belt having a corresponding textured surface. For example, the wet-laid tissue web may be manufactured using an endless belt which comprises a continuous three-dimensional element (also referred to herein as a continuous line element) and a reinforcing structure (also referred to herein as a carrier structure or fabric). The reinforcing structure comprises a pair of opposed major surfaces - a web contacting surface from which the continuous line elements extend and a machine contacting surface. Machinery employed in a typical papermaking operation is well known in the art and may include, for example, vacuum pickup shoes, rollers, and drying cylinders. In one embodiment the belt comprises a through-air drying fabric useful for transporting an embryonic tissue web across drying cylinders during the tissue manufacturing process. In such embodiments the web contacting surface supports the embryonic tissue web, while the opposite surface, the machine contacting surface, contacts the through-air dryer.

In certain embodiments a plurality of continuous line elements may be disposed on the web-contacting surface for cooperating with, and structuring of, the wet fibrous web during manufacturing. In a particularly preferred embodiment the web contacting surface comprises a plurality of spaced apart three-dimensional elements distributed across the web-contacting surface of the carrier structure and together constituting from at least about <NUM> percent of the web-contacting surface, such as from about <NUM> to about <NUM> percent, more preferably from about <NUM> to about <NUM> percent, and still more preferably from about <NUM> to about <NUM> percent of the web-contacting surface.

Now with reference to <FIG>, one embodiment of a fibrous structure <NUM> prepared according to the present invention is illustrated. The fibrous structure <NUM> has two principle dimensions - a machine direction ("MD"), which is the direction substantially parallel to the principal direction of travel of the tissue web during manufacture and a cross-machine direction ("CD"), which is generally orthogonal to the machine direction. The fibrous structure generally has a textured first side <NUM> comprising a plurality of continuous elevated line elements <NUM>, also referred to herein as ridges, and a plurality of valleys <NUM>, also referred to herein as land areas, there-between.

The line elements <NUM> lie in a first surface plane <NUM> and the valleys lie in a second surface plane <NUM> and together form the surface of the first side <NUM>. Opposite the first side <NUM> is the second side <NUM>, lying in a bottom surface plane <NUM>. While the instant fibrous structure is illustrated as having alternating ridges and valleys which define both the first and second sides and provide both with a textured surface, the invention is not so limited. For example, in an alternative embodiment the fibrous structure may comprise only one textured side. Moreover, while the illustrated line elements <NUM> and valleys <NUM> are both continuous the invention is not so limited, as will be discussed in further detail below.

With continued reference to <FIG> the fibrous structure <NUM> comprises a lotion <NUM> selectively deposited on the ridges <NUM>. In this manner the lotion <NUM> lies in the first surface plane <NUM> and is registered with the upper-most surface of the fibrous structure <NUM> such that it is the first surface to contact a user's skin in-use.

Turning now to <FIG>, another embodiment of a fibrous structure <NUM> prepared according to the present invention is illustrated. The fibrous structure <NUM> comprises a plurality of discrete design elements <NUM> that form a portion of the first side <NUM> of the structure <NUM>. The design elements <NUM> have an upper surface lying in a first surface plane <NUM>. The design elements <NUM> are separated from one another by land areas <NUM>, which have an upper surface lying in a second surface plane <NUM>. The first surface plane <NUM> lies above the second surface plane <NUM> and together the discrete design elements <NUM> and the land areas <NUM> form the first side <NUM> of the structure. Opposite the first side <NUM> is a second side <NUM> that forms the bottom of the structure <NUM> and lies in a bottom surface plane <NUM>.

A lotion <NUM> is selectively disposed on, in registration with, the discrete design elements <NUM>. As such, the lotion <NUM> is selectively disposed on the upper most surface of the structure <NUM>, while the land areas <NUM> are substantially free from lotion.

With reference now to <FIG>, another embodiment of a fibrous structure <NUM> according to the present invention is provided. The first side <NUM> comprises continuous line elements <NUM>, which are similarly sized and have generally straight, parallel spaced apart sidewalls that provide the continuous elements <NUM> with a width, and a height. The width and the height may be varied depending on the desired physical properties of the fibrous structure, such as sheet bulk and cross-machine direction stretch. In certain embodiments the height of the sidewalls is such that the resulting tissue structure has a caliper greater than about <NUM>, such as from about <NUM> to about <NUM>,<NUM>. The height is generally measured as the distance between the first surface plane <NUM> and the bottom surface plane <NUM>.

The spacing and arrangement of the continuous line elements may vary depending on the desired tissue product properties and appearance. In one embodiment a plurality of line elements extend continuously throughout one dimension of the fibrous structure and each element in the plurality is spaced apart from the adjacent element. Thus, the elements may be spaced apart across the entire cross-machine direction of the fibrous structure or may run diagonally relative to the machine and cross-machine directions. Of course, the directions of the line elements alignments (machine direction, cross-machine direction, or diagonal) discussed above refer to the principal alignment of the elements. Within each alignment, the elements may have segments aligned at other directions, but aggregate to yield the particular alignment of the entire elements.

In addition to varying the spacing and arrangement of the elements, the shape of the element may also be varied. For example, in one embodiment, the elements are substantially sinusoidal and are arranged substantially parallel to one another such that none of the elements intersect one-another. As such the adjacent sidewalls of individual elements are equally spaced apart from one another. In such embodiments, the spacing of elements may be from about <NUM> to about <NUM>, and more preferably from about <NUM> to about <NUM> apart. The foregoing spacing may be optimized to maximum caliper of the fibrous structure, or provide a fibrous structure having a three-dimensional surface topography, yet relatively uniform density. Further, while in certain embodiments the elements are continuous the invention is not so limited. In other embodiments the elements may be discrete.

Further, while the elements are illustrated as having a square horizontal and lateral (relative to the upper surface plane) cross-sectional shape the invention is not so limited, and the elements may have any number of different horizontal and lateral cross-sectional shapes. A particularly preferred element is a line element having substantially planar sidewalls which are generally perpendicular to the upper surface plane. Further, while the uppermost surface of the element <NUM> is illustrated as being planar and defining a first surface plane <NUM>, the invention is not so limited. For example, the element's upper surface may be non-planar, such as having further depressions in the form of lines or dots disposed thereon. Where the element's upper surface is non-planar the design element plane is generally defined by a line drawn tangent to the upper most point of the design element and parallel to the x-axis of the fibrous structure.

The individual elements, also referred to herein as design elements, may be arranged in any number of different manners to create a decorative pattern. In one particular embodiment design elements are spaced and arranged in a non-random pattern so as to create a wave-like design. Landing areas may be interspaced between adjacent individual design elements so as to provide a visually distinctive interruption to the decorative pattern formed by the individual spaced apart design elements. In this manner, despite being discrete elements, the design elements are spaced apart so as to form a visually distinctive curvilinear decorative element that extends substantially in the machine direction. In this manner, taken as a whole, the discrete elements may form a decorative pattern, such as a wave-like pattern.

In other embodiments the design elements may be spaced and arranged so as to form a decorative figure, icon or shape such as a flower, heart, puppy, logo, trademark, word(s) and the like. Generally, the design elements are spaced about the fibrous structure and can be equally spaced or may be varied such that the density and the spacing distance may be varied amongst the design elements. For example, the density of the design elements can be varied to provide a relatively large or relatively small number of design elements on the web. In a particularly preferred embodiment the design element density, measured as the percentage of one surface of the fibrous structure covered by a design element, is from about <NUM> to about <NUM> percent and more preferably from about <NUM> to about <NUM> percent. Similarly, the spacing of the design elements can also be varied, for example, the design elements can be arranged in spaced apart rows. In addition, the distance between spaced apart rows and/or between the design elements within a single row can also be varied.

Fibrous structures having textured surfaces which may be imparted with a design element of the present invention may be formed using any one of several well-known manufacturing processes. For example, in certain embodiments, fibrous structures may be produced by a through-air drying (TAD) manufacturing process, an advanced tissue molding system (ATMOS) manufacturing process, a structured tissue technology (STT) manufacturing process, or belt creped. In particularly preferred embodiments the fibrous structure is manufactured by a creped through-air dried (CTAD) process or uncreped through-air dried (UCTAD) process.

In one embodiment, tissue webs useful in the present invention are formed by the UCTAD process of: (a) depositing an aqueous suspension of papermaking fibers (furnish) onto an endless forming fabric to form a wet web; (b) dewatering or drying the web; (c) transferring the web to a transfer fabric; (d) transferring the web to a TAD fabric of the present invention having a pattern thereon; (e) deflecting the web wherein the web is macroscopically rearranged to substantially conform the web to the textured background pattern of the TAD fabric; and (f) through-air drying the web. In the foregoing process the web is not subject to creping but may be further processed as described below to impart a design pattern to the web.

After the basesheet is formed and dried it may be subjected to various converting process before final packaging. Prior to, or during this converting process, in accordance with the present invention, the basesheet is subjected to treatment with a lotion, which is preferably provided in solid form and transferred to a first surface of the basesheet by a transfer surface and more preferably a heated transfer surface.

In a particularly preferred embodiment, the transfer surface is a calender roll. In this manner a calendering-coating process may be used to selectively deposit a lotion on the surface of the web. This calendering-coating process may compress the web as it applies lotion to the upper most surface, effectively breaking some bonds formed between the fibers of the basesheet while selectively applying a lotion to its surface. The perceived softness of the basesheet is increased without significantly sacrificing tensile strength or any other characteristic thereof.

Referring now to <FIG>, one embodiment of a roll-gap apparatus useful for calendering-coating a fibrous structure according to the present invention is illustrated. In general, roll-gap calendering involves two calendering rolls <NUM> and <NUM> that compress the web <NUM>, which may be textured in certain preferred embodiments. The surfaces <NUM>, <NUM> of calendering rolls <NUM>, <NUM> contacting the web <NUM> may comprise a variety of materials including, for example, metal such as steel or cast iron, or a polymeric material such as polyurethane, natural rubber (hard or soft), synthetic rubber, an elastomeric material, and the like. Furthermore, the roll surfaces can be smooth, roughened, or etched. In one embodiment, a first calendering roll <NUM> has a surface <NUM> comprising a polymer material and the second calendering roll <NUM> has a smooth metal surface <NUM>.

The calendering-coating of the fibrous structure is achieved through compression of the fibrous structure in a nip <NUM> between the first and second calendering rolls <NUM> and <NUM>. The two calendering rolls <NUM> and <NUM> are arranged to provide nip load, commonly having units of pounds per linear inch (pli) ranging from about <NUM> to about <NUM> pli (<NUM> to about <NUM> N/mm), such as from about <NUM> to about <NUM> pli (<NUM> to about <NUM> N/mm). While the embodiment illustrated in <FIG> relies upon a constant gap between the calendering rolls <NUM> and <NUM>, the invention is not so limited, and the invention may be implemented using a calendering apparatus where the surfaces of the two rolls can be pressed together to form a pressure between the surfaces that compresses the base web at a higher pressure than the gap. However, depending on the load settings and the z-direction properties of the fibrous structure, it is possible to run the nipped mode at the same or even less pressure than the gap mode.

Both calendering rolls <NUM>, <NUM> rotate so their respective surfaces <NUM>, <NUM> move in the same direction as the web <NUM>. In the embodiment illustrated in <FIG>, the first calendering roll <NUM> is rotating counter-clockwise and the second calendering roll <NUM> is rotating clockwise. In certain instances, the fibrous structure moves from an unwind roll through a roll-gap calendering apparatus and is rewound onto a roll.

In a particularly preferred embodiment at least one of the calender rolls, particularly the roll to which the lotion is applied, is a roll having a metal surface and more preferably a heated steel roll with a substantially smooth surface. For example, with continued reference to <FIG>, the lotion <NUM>, which is provided in a solid state and has a penetration hardness greater than about <NUM>, such as from about <NUM> to about <NUM> (measured pursuant to the Hardness Method set forth below) is urged against the surface <NUM> of a second calendering roll <NUM>, which preferably has a metal surface and is heated. The second calender roll may be heated such that its surface temperature is at least about <NUM>, such as from about <NUM> to about <NUM> and more preferably from about <NUM> to about <NUM>. The degree to which the second calender roll is heated may depend on the composition of the lotion and the desired lotion add-on.

With reference now to <FIG>, the calendering-coating apparatus may be provided with an applicator <NUM> for retaining a solid lotion <NUM>, having a thickness (t), and urging the lotion against the surface <NUM> of a calender roll <NUM>. In certain non-limiting instances, the lotion thickness (t) may range from about <NUM> to about <NUM>. Further, as discussed in more detail below, the lotion thickness (t) may be varied along with one or more process variables to control the amount of lotion added to the web. As the lotion <NUM> is urged against the calender surface <NUM> a coating of lotion <NUM> is applied. The lotion <NUM> may then be transferred to the surface of a web <NUM> as it passes through the nip <NUM>.

The speed of the web <NUM> as it passes through the nip <NUM> may be varied to control the amount of lotion added to the web. In certain non-limiting instances, the web speed may range from about <NUM> to about <NUM> meters per minute, such as from about <NUM> to about <NUM> meters per minute.

The applicator <NUM> may comprise a holder <NUM> and an automatic indexing mechanism <NUM> for automatically advancing the solid lotion <NUM> towards the roll surface <NUM>. The automatic indexing mechanism may include a pressure sensor for measuring and monitoring the pressure applied to the solid lotion as it is urged against the calender roll surface and a means for advancing the solid lotion towards the roll surface. In other embodiments the lotion applicator may comprise a holder and a mechanical means, such as a spring, to maintain the desired pressure against the solid lotion and urge it against the roll surface.

In certain preferred embodiments the automatic indexing mechanism <NUM> may advance the solid lotion <NUM> towards the roll surface <NUM> at a predetermined feed rate (FR) to achieve the desired add-on. For example, the feed rate may be varied from about <NUM> to about <NUM> per second to achieve an add-on from about <NUM> to about <NUM> grams per square meter (gsm) of web. In certain instances the desired add-on (having units of grams per square meter of web) may be achieved by controlling the thickness of the solid lotion (having units of mm or the like), the lotion feed rate (FR, having units of mm per second or the like), the penetration hardness of the lotion (measured as described herein and having units of mm) and the speed of the web (having units of meters per minute or the like) as it passes through the nip. For example, the desired lotion add-on may be related to lotion thickness, feed rate, penetration hardness and web speed by Equation <NUM>, below.

For carrying out the calendering-coating process the solid lotion <NUM> is urged against the second calender roll <NUM> and a portion of the lotion is transferred to the roll surface <NUM>. The lotion coated roll surface <NUM> is then brought into contact with the first side <NUM> of the web <NUM> in the calender nip <NUM>. Within the nip, the lotion is transferred from the roll surface to the upper most surface of the first side <NUM> of the textured fibrous structure. After leaving the calender nip, the roll surface may be substantially free from lotion however, in certain instances it is possible that a lotion residue remains on the surface. Lotion residue on the leading rotating sector of the second calender roll <NUM> may be stripped from the outer surface thereof with the help of a doctor blade (shown in <FIG>) or other stripping device.

After leaving the calender nip, the textured fibrous structure has been treated with the lotion, with the lotion oriented on the first side <NUM> and more particularly on the upper most surface of the first side <NUM>. The lotion treated fibrous structure may be subjected to further processing, such as drying, to ensure that the lotion treatment retains its size, shape, configuration, or registration on the first side <NUM> of the structure as it was applied. It will be recognized by those skilled in the art that the particular configuration of the calender rolls <NUM>, <NUM> and applicator <NUM> as shown in <FIG> is merely exemplary, and other configurations and set up of the apparatus may be used.

The total add-on amount of the lotion to the fibrous structure may be less than about <NUM> grams per square meter (gsm) of fibrous web and more preferably less than about <NUM> gsm and still more preferably less than about <NUM> gsm, such as from about <NUM> to about <NUM> gsm. In other instances, the lotion add-on may be expressed in terms as a percentage of the weight of the fibrous structure and may be less than about <NUM> percent, by weight of the web, such as from about <NUM> to about <NUM> percent and more preferably from about <NUM> to about <NUM> percent. The lotion add-on amount will depend upon the desired effect of the composition on the product attributes and the specific composition of the lotion.

Preferably the lotion is a solid at room temperature and is melted during the application process after which it re-solidifies to form a distribution, preferably a uniform distribution, of solid deposits on the upper most surface of a textured fibrous structure. Because the composition is a solid at room temperature and rapidly solidifies after deposition, it has less tendency to penetrate and migrate into the sheet. Compared to fibrous structures treated with liquid formulations, this leaves a greater percentage of the additive composition on the surface of the tissue where it can contact and transfer to the user's skin to provide enhanced skin health benefits. Furthermore, a lower add-on amount can be used to deliver the same benefit at a lower cost because of the efficient placement of the composition substantially at the surface of the product.

Solid lotions useful in the present invention may be provided with a range of different product forms. One of these is a so-called "stick" which is usually a bar of an apparently firm solid material held within an applicator and which retains its structural integrity and shape while being urged against a calender roll. When a portion of the stick is drawn across the surface of a calender roll a film of the stick composition is transferred to the roll surface. Although the stick has the appearance of a solid article capable of retaining its own shape for a period of time, the material usually has a structured liquid phase so that a film of the composition is readily transferred from the stick to roll surface upon contact.

Lotion compositions useful in the present invention may be provided as solids that are characterized by their retaining their shape without lateral support under the influence of the Earth's gravity, at temperatures up to at least <NUM>. The hardness of the solid lotions can be measured in a needle penetration test. Pursuant to this test, as the solid lotions become softer, their needle penetration hardness values increase, with higher hardness values being indicative of a softer lotion composition. The lotion compositions have a penetration hardness from <NUM> to <NUM>, more particularly from <NUM> to <NUM>, more particularly from <NUM> to <NUM>, and still more particularly from <NUM> to <NUM> measured pursuant to the Hardness Method set forth below. Hardness values within these ranges are indicative of self-supporting solid lotions having a somewhat soft feel but are well suited for indirect application to a tissue web via a conventional calendering apparatus.

In particularly preferred embodiments lotions useful in the present invention are formulated as hydrophobic compositions. The hydrophobic lotions of the present invention preferably do not comprise added water, which could require an additional drying step. However, minor or trace quantities of water in the lotion that are picked as a result of, for example, ambient humidity can be tolerated without adverse effect. Typically, hydrophobic lotions useful in the present invention are provided as a solid stick having a penetration hardness ranging from <NUM> to <NUM> and contain about <NUM> percent or less water, preferably about <NUM> percent or less water, most preferably about <NUM> percent or less water.

In certain instances, the solid lotion composition may be hydrophobic and comprise one or more oils. The amount of oil in the composition can be from about <NUM> to about <NUM> weight percent, more specifically from about <NUM> to about <NUM> weight percent, and still more specifically from about <NUM> to about <NUM> weight percent. Suitable oils include, but are not limited to, the following classes of oils: petroleum or mineral oils, such as mineral oil and petrolatum; or animal oils, such as mink oil and lanolin oil.

Particularly preferred oils are mineral oils such as petroleum derivatives comprising a mixture of paraffinic and naphthenic (cyclic) hydrocarbons. These include both "light" and "heavy" mineral oils, which are differentiated on the basis of the average molecular weight of the hydrocarbons included. The mineral oils useful herein have the following properties: viscosity of from about <NUM> centistokes (about <NUM><NUM>/s) to about <NUM> centistokes (about <NUM><NUM>/s) at <NUM>; density between about <NUM> and about <NUM>/cm<NUM> at <NUM>; flash point between about <NUM> and about <NUM>; and carbon chain length between about <NUM> and about <NUM> carbons.

In other instances, lotions useful in the present invention may comprise a wax. The amount of wax in the composition can be from about <NUM> to about <NUM> weight percent, more specifically from about <NUM> to about <NUM> weight percent, and still more specifically from about <NUM> to about <NUM> weight percent. Suitable waxes include, but are not limited to, the following classes: natural waxes, such as beeswax and carnauba wax; petroleum waxes, such as paraffin and ceresine wax; silicone waxes, such as alkyl methyl siloxanes; or synthetic waxes, such as synthetic beeswax and synthetic sperm wax.

In still other instances, lotions useful in the present invention may comprise one or more fatty alcohol, which may be present in amounts ranging from about <NUM> to about <NUM> weight percent, and more specifically from about <NUM> to about <NUM> weight percent. Suitable fatty alcohols include alcohols having a carbon chain length of C<NUM>-C<NUM>, including acetyl alcohol, stearyl alcohol, behenyl alcohol, and dodecyl alcohol.

In particularly preferred embodiments lotions useful in the present invention may be provided as a solid stick having a penetration hardness ranging from <NUM> to <NUM> and comprising from about <NUM> to about <NUM> weight percent oil, and from about <NUM> to about <NUM> weight percent wax, preferably also containing from about <NUM> to about <NUM> weight percent fatty alcohol.

In other embodiments lotions useful in the present invention may be provided as a solid stick having a penetration hardness ranging from <NUM> to <NUM> and comprising from about <NUM> to about <NUM> weight percent mineral oil and from about <NUM> to about <NUM> weight percent ceresin wax having a melting point from <NUM> to <NUM> and from about <NUM> to about <NUM> weight percent fatty alcohol selected from the group consisting of cetyl alcohol, stearyl alcohol, behenyl alcohol, and dodecyl alcohol.

In order to better enhance the benefits to a user, additional ingredients may optionally be included in a lotion useful in the present invention. Optional ingredients and their corresponding benefits include, without limitation, C<NUM> or greater fatty alcohols (lubricity, body, opacity), fatty esters (lubricity, feel modification), vitamins (topical medicinal benefits), dimethicone (skin protection), powders (lubricity, oil absorption, skin protection), preservatives and antioxidants (product integrity), ethoxylated fatty alcohols (wetability, process aids), fragrance (consumer appeal), lanolin derivatives (skin moisturization), colorants, optical brighteners, sunscreens, alpha hydroxy acids, natural herbal extracts, and the like. In a particularly preferred embodiment, the lotion comprises one or more oils selected from the group consisting of plant oils, such as aloe extract, sunflower oil and avocado oil, and silicone oils, such as dimethicone and alkyl methylsilicones.

While in certain instances lotions useful in the present invention may be provided in hydrophobic forms, the invention is not so limited. In other instances, the lotion may be hydrophilic and comprise water. Preferably hydrophilic lotions are provided as a solid stick having a penetration hardness ranging from about <NUM> to about <NUM> and comprise from <NUM> to <NUM> weight percent hydrophilic solvent. Suitable hydrophilic solvents include, but are not limited to, the following materials: water, propylene glycol, polyethylene glycol, methoxyisopropanol, PPG-<NUM> propyl ether, PPG-<NUM> butyl ether, PPG-<NUM> methyl ether, PPG-<NUM> methyl ether, dipropylene glycol propyl ether, dipropylene glycol butyl ether, dipropylene glycol, methyl propanediol, propylene carbonate, water soluble/dispersible polypropylene glycols, ethoxylated polypropylene glycol, glycerin, sorbitol, hydrogenated starch hydrolysate, and silicone glycols.

Particularly preferred hydrophilic solvents are high molecular weight polyethylene glycols. As used herein "high molecular weight polyethylene glycols," generally refer to polyethylene glycols having an average molecular weight of <NUM> or greater, such as <NUM> or greater, such as <NUM> or greater. Particularly preferred are high molecular weight polyethylene glycols that are not liquid at room temperature, such as polyethylene glycols having an average molecular weight from about <NUM> to about <NUM>,<NUM>, such as from about <NUM> to about <NUM>,<NUM>, such as from about <NUM> to about <NUM>,<NUM>. The solid hydrophilic lotion may comprise from <NUM> to <NUM> weight percent weight percent high molecular weight polyethylene glycol and has a penetration hardness ranging from <NUM> to <NUM>.

In other embodiments, the solid hydrophilic lotion may comprise propylene glycol, glycerin and a fatty alcohol. For example, the hydrophilic lotion may comprise from about <NUM> to about <NUM> weight percent propylene glycol, from about <NUM> to about <NUM> weight percent glycerin and from about <NUM> to about <NUM> weight percent of a fatty alcohol. Suitable fatty alcohols include, but are not limited to, alcohols having a carbon chain length of C<NUM>-C<NUM>, including cetyl alcohol, stearyl alcohol, arachidyl alcohol, and behenyl alcohol.

In certain instances, the hydrophilic lotion composition may comprise water, such as from about <NUM> to about <NUM> weight percent, more specifically from about <NUM> to about <NUM> weight percent, more specifically from about <NUM> to about <NUM> weight percent.

Tissue webs and products produced according to the present invention not only comprise a lotion that may be readily available for transfer to the user's skin to protect the skin from or prevent further irritation and redness, they may also have favorable physical properties, such as sufficient strength to withstand use without being stiff or rough. Accordingly, in one embodiment of the present invention a tissue product has a basis weight from about <NUM> to about <NUM> gsm, and more preferably from about <NUM> to about <NUM> gsm and a sheet bulk greater than about <NUM> cc/g, such as from about <NUM> to about <NUM> cc/g and more preferably greater than about <NUM> cc/g, such as from about <NUM> to about <NUM> cc/g.

In addition to having the foregoing basis weights and sheet bulks, tissue webs and products prepared according to the present invention may have a geometric mean tensile (GMT) greater than about <NUM>/<NUM>" (g/<NUM>), such as from about <NUM> to about <NUM>,<NUM>/<NUM>" (g/<NUM>), and more preferably from about <NUM> to about <NUM>,<NUM>/<NUM>" (g/<NUM>). At these tensile strengths the tissue webs and products have relatively low geometric mean modulus, expressed as GM Slope, so as to not overly stiffen the tissue product. Accordingly, in certain embodiments, tissue webs and products may have GM Slope less than about <NUM>, and more preferably less than about <NUM> and still more preferably less than about <NUM>.

In one particularly preferred embodiment the present invention provides a lotion rolled bath tissue product having a basis weight from about <NUM> to about <NUM> gsm, a GMT from about <NUM> to about <NUM>,<NUM>/<NUM>" (g/<NUM>), a GM Slope less than about <NUM>, such as from about <NUM> to about <NUM>, and a GM Stretch greater than about <NUM> percent, such as from about <NUM> to about <NUM> percent. The foregoing rolled bath tissue product preferably comprises at least one textured tissue web having a first side with first and second surfaces lying in first and second surface planes. The z-directional height difference between the first and second surface planes may be from about <NUM> to about <NUM> and more preferably from about <NUM> to about <NUM>.

The inventive single ply tissue webs may be plied together with other single ply webs prepared according to the present disclosure or with single ply webs of the prior art to form multi-ply tissue products using any ply attachment means known in the art, such as mechanical crimping or adhesive.

When two or more inventive tissue webs are joined together the resulting multi-ply tissue product may have a basis weight greater than about <NUM> gsm, such as from about <NUM> to about <NUM> gsm, and more preferably from about <NUM> to about <NUM> gsm. At these basis weights the tissue products generally have calipers greater than about <NUM>, such as from about <NUM> to about <NUM>,<NUM>, and more preferably from about <NUM> to about <NUM>,<NUM>. The tissue products further have sheet bulks greater than about <NUM> cc/g, such as from about <NUM> to about <NUM> cc/g and more preferably from about <NUM> to about <NUM> cc/g.

The inventive tissue products may also have relatively low modulus so as not to be overly stiff. For example, in certain embodiments the present invention provides lotion treated tissue products having a GMT greater than about <NUM>/<NUM>" (g/<NUM>), such as from about <NUM> to about <NUM>,<NUM>/<NUM>" (g/<NUM>), and geometric means slopes (GM Slopes) less than about <NUM> and more preferably less than about <NUM>, such as from about <NUM> to about <NUM>, such as from about <NUM> to about <NUM>, such as from about <NUM> to about <NUM>. At the foregoing strengths, inventive tissue products may have a Stiffness index less than about <NUM>, such as from about <NUM> to about <NUM>, such as from about <NUM> to about <NUM>.

The hardness and rigidity of a composition, such as a lotion useful in the present invention, which is a firm solid can be determined by penetrometry. If the composition is a softer solid, this will be observed as a substantial lack of any resistance to the penetrometer probe.

A suitable procedure for measuring penetration hardness utilizes Precision Scientific Model No. <NUM> penetrometer equipped with a C521 needle (weight <NUM> grams) which has a cone angle at the point of the needle specified to be <NUM>° <NUM>' ±<NUM>'. A <NUM> weight is added to the plunger rod (<NUM>) for a combined testing load of approximately <NUM>. Tests were conduct at approximately <NUM>.

A sample of the composition with a flat upper surface is placed on the base of the penetrometer. The height of the mechanism head is adjusted so that the point of the penetrometer needle is brought exactly into contact with the surface of the sample. With the instrument zeroed, the test rod is released allowing the needle to descend into the sample. The release lever is depressed (held open) for a period of <NUM> seconds after which it is then released (closed). The depth gauge rod is then pressed down gently as far as it will go and the penetration depth is read from the gauge. Desirably the test is carried out at five (<NUM>) points on each sample and the results are averaged.

Utilizing a test of this nature, an appropriate hardness of a lotion for use in the present invention has a penetration of less than <NUM> in this test, for example in a range from <NUM> to <NUM>, more particularly from <NUM> to <NUM>, more particularly from <NUM> to <NUM>, and still more particularly from <NUM> to <NUM>.

Lotion add-on was determined gravimetrically. A lotion treated web was cut off of the treated roll shortly after its manufacture and then die cut with a <NUM> x <NUM> die. Six stacks comprising <NUM> die cut sheets each were collected and then weighed on a scale to the nearest <NUM>. The basis weight (gsm) of the treated sample was calculated by dividing the mass of the sample by its area (<NUM><NUM>). An untreated tissue sample (control), run under the same process conditions, was sampled and its basis weight measured similarly. The treatment add-on (gsm) is the difference between the basis weights of the treated and untreated samples.

Samples for tensile strength testing are prepared by cutting a <NUM> inches (<NUM>) x <NUM> inches (<NUM>) long strip in either the machine direction (MD) or cross-machine direction (CD) orientation using a JDC Precision Sample Cutter (Thwing-Albert Instrument Company, Philadelphia, PA, Model No. JDC <NUM>-<NUM>, Ser. No. <NUM>). The instrument used for measuring tensile strengths is an MTS Systems Sintech <NUM>, Serial No. <NUM>. The data acquisition software is MTS TestWorks™ for Windows Ver. <NUM> (MTS Systems Corp. , Research Triangle Park, NC). The load cell is selected from either a <NUM> or <NUM> Newton maximum, depending on the strength of the sample being tested, such that the majority of peak load values fall between <NUM> and <NUM> percent of the load cell's full-scale value. The gauge length between jaws is <NUM> ± <NUM> inches. The jaws are operated using pneumatic-action and are rubber coated. The minimum grip face width is <NUM> inches (<NUM>), and the approximate height of a jaw is <NUM> inches (<NUM>). The crosshead speed is <NUM> ± <NUM> inches/min (<NUM> ± <NUM>/min), and the break sensitivity is set at <NUM> percent. The sample is placed in the jaws of the instrument, centered both vertically and horizontally. The test is then started and ends when the specimen breaks. The peak load is recorded as either the "MD tensile strength" or the "CD tensile strength" of the specimen depending on the sample being tested. At least six representative specimens are tested for each product, taken "as is," and the arithmetic average of all individual specimen tests is either the MD or CD tensile strength for the product.

The various surface planes and z-directional height differences may be measured using well-known microscopy techniques. For example, the cross-section image of a fibrous structure, web or tissue product, may be taken using a VHX-<NUM> Digital Microscope (Keyence Corporation of Osaka, Japan) equipped with VHX-H3M application software. Using the application software, a first line may be drawn approximately along the top surface plane of structure with the line tangent to two adjacent elevated elements. A second line is drawn approximately along the bottom surface plane of the structure with the line tangent to two adjacent land areas. With the two lines drawn, each corresponding to a surface plane of the structure, the application software can be instructed to calculate the distances between the planes.

A single-ply tissue product was produced using a through-air dried papermaking process commonly referred to as "uncreped through-air dried" ("UCTAD") and generally described in <CIT>, the contents of which are incorporated herein in a manner consistent with the present disclosure.

Tissue basesheets were produced from a furnish comprising northern softwood kraft and eucalyptus kraft using a layered headbox fed by three stock chests such that the webs having three layers (two outer layers and a middle layer) were formed. The two outer layers comprised eucalyptus and the middle layer comprised softwood. The <NUM>-layered structure had a furnish split of <NUM>% EHWK/<NUM>% NBSK/<NUM>% EHWK, all on a weight percent basis.

The tissue web was formed on a Voith Fabrics TissueForm V forming fabric, vacuum dewatered to approximately <NUM> percent consistency and then subjected to rush transfer when transferred to the transfer fabric. The transfer fabric was the fabric described as "Fred" in <CIT> (commercially available from Voith Fabrics, Appleton, WI).

The web was then transferred to a through-air drying fabric. The through-air drying fabric was a silicone printed fabric described previously in co-pending PCT Appl. Transfer to the through-drying fabric was done using vacuum levels of greater than <NUM> bars (<NUM> kPa) at the transfer. The web was then dried to approximately <NUM> percent solids before winding.

A hydrophobic lotion composition (Lotion Reference Code <NUM>) was prepared by adding mineral oil (<NUM>) to a stainless-steel beaker equipped with a hot plate and overhead stirrer. The mineral oil was heated with agitation to <NUM>. Once heated, dimethicone (<NUM>) and isopropyl palmitate (<NUM>) were mixed with the mineral oil. Ceresin wax (<NUM>) was then mixed with agitation and heating to <NUM>. After the wax was completely melted stearyl alcohol (<NUM>) was added, followed by the aloe extract (<NUM>) and vitamin E acetate (<NUM>). The composition was mixed for <NUM> minutes and then a UV optical brightening agent, Tinopal OB (<NUM>) and the visual colorant, Black Ink Exp R3989-<NUM> (<NUM>) was added. The entire mixture was poured into a pan and allowed to cool overnight. The hardness of the resulting cake was measured as described above.

A hydrophilic lotion comprising propylene glycol and glycerin (Lotion Reference Code <NUM>) was prepared by mixing propylene glycol (<NUM>) and glycerin (<NUM>) in a large beaker and the mixture was heated to <NUM> with good mixing but no air entrainment. Once at temperature and uniformly mixed, sodium stearate (<NUM>) was added and mixed until dissolved. A UV optical brightening agent, Tinopal OB (<NUM>), and a visual colorant, blue liquid dye (<NUM>), were added and mixed until uniform. The mixture was stirred and allowed to cool to <NUM>, then poured into a pan and allowed to cool overnight. Total batch weight was <NUM>. The hardness of the resulting cake was measured as described above.

A hydrophobic lotion comprising polyethylene glycol (Lotion Reference Code <NUM>) was prepared by mixing PEG <NUM> (<NUM>) and PEG <NUM> (<NUM>) in a large beaker and heating to <NUM>. Once the PEGs were completely mixed, a UV optical brightening agent, Tinopal OB (<NUM>), and a visual colorant, blue liquid dye (<NUM>) were added and mixed until uniform. The mixture was allowed to cool slightly and poured into a pan and allowed to cool overnight. Total batch weight was <NUM>. The hardness of the resulting cake was measured as described above.

The basesheet was calendered-coated using an apparatus substantially similar to that illustrated in <FIG>. The solid lotion was applied to a steel calender roll opposed to a conventional <NUM> P&J roll. In certain instances the steel calender roll was heated. The calender linear nip load ranged from about <NUM> to about <NUM> pli (about <NUM> to about <NUM> N/mm). The process conditions used to produce each of the inventive samples are set forth in Table <NUM>, below.

The lotion treated tissue web was converted to a finished rolled tissue product and subjected to physical testing. The results of the physical testing are summarized in Table <NUM>, below.

Claim 1:
A textured fibrous web having a first side to be contacted by a user in-use, the first side having an uppermost surface lying in a first surface plane and a second surface lying in a second surface plane, the second surface plane lying below the first surface plane, and a lotion selectively disposed on the uppermost surface in an amount ranging from about <NUM> to about <NUM> grams per square meter of textured fibrous web, wherein the lotion has a penetration hardness as measured by the method defined herein ranging from <NUM> to <NUM>.