Process and apparatus for making foreshortened cellulsic structure

A process for making a foreshortened single lamina fibrous web comprising fibers and having at least a first plurality of micro-regions comprising said fibers interconnected with a fiber-binding substance in said first plurality of micro-regions, and a second plurality of micro-regions comprising said fibers not interconnected with said fiber-binding substance in said second plurality of micro-regions, said process comprising the steps of:

• (a) providing said fibers;
• (b) providing a macroscopically monoplanar papermaking belt having a web-side surface defining an X-Y plane, a backside surface opposite said web-side surface, and a Z-direction perpendicular to said X-Y plane;
• (c) providing said fiber-binding substance;
• (d) depositing said fibers and said fiber-binding substance to said webside surface of said papermaking belt to form a fibrous web comprising said fiber-binding substance;
• (e) heating at least selected portions of said fibrous web to cause softening of said fiber-binding substance in said selected portions;
• (f) applying pressure to said selected portions of said fibrous web in said Z-direction, thereby densifying said selected portions of said fibrous web and causing said fiber-binding substance in said selected portions to flow and interconnect said fibers which are mutually juxtaposed in said selected portions;
• and
• (g) immobilizing said fiber-binding substance and creating fiber-bonds in said selected portions between said fibers which are interconnected in said selected portions thereby forming said first plurality of micro-regions from said selected portions;
• (h) foreshortening said web comprising said fiber-bonds formed in said first plurality of micro-regions.

A yankeeless process for making a foreshortened single lamina fibrous web having at least a first plurality of micro-regions comprising fibers interconnected with a fiber-binding substance in said first plurality of micro-regions, and a second plurality of micro-regions comprising said fibers not interconnected with said fiber-binding substance in said second plurality of micro-regions, said process comprising the steps of:

• (a) providing a macroscopically monoplanar papermaking belt having a web-side surface defining an X-Y plane, a backside surface opposite to said web-side surface, and a Z-direction perpendicular to said X-Y plane;
• (b) providing said fiber-binding substance;
• (c) depositing said fibers and said fiber-binding substance to said webside surface of said papermaking belt to form a fibrous web comprising said fiber-binding substance;
• (d) providing a first press surface and a second press surface, said press surfaces being mutually parallel and configured to receive therebetween said belt having said fibrous web thereon such that said first press surface contacts said web and said second press surface contacts said belt, at least one of said web-side surface of said belt and said first press surface comprising a patterned framework extending in said Z-direction;
• (e) heating said first press surface to cause softening of said fiber-binding substance in said web;
• (f) impressing said web and said belt between said first and second press surfaces, thereby densifying said selected portions of said web in said Z-direction and causing said fiber-binding substance in said selected portions to flow and interconnect said fibers which are mutually juxtaposed in said selected portions;
• (g) immobilizing said fiber-binding substance and creating fiber-bonds in said selected portions between said fibers which are interconnected in said selected portions, thereby forming said first plurality of micro-regions from said selected portions;
• (h) adhering said web to said first press surface;
• and
• (i) creping said web off said first surface with a creping blade.