Sewn and perforated stack of absorbent sheets

Abstract

The invention provides a stack comprising a plurality of absorbent sheets stacked in facing arrangement. The stack is bound along its top edge by at least one line of stitches comprising a plurality of spaced apart stitch holes and a thread disposed therein. Individual sheets further comprise a line of perforations comprising a plurality of spaced apart perforation holes. The line of stitches and the line of perforations are such that there is generally a one-to-one numerical correspondence amongst at least a majority of the plurality of stitch holes and perforation holes.

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         20 . A method of manufacturing a stack of sewn and perforated absorbent sheets comprising the steps of:
 a. providing a plurality of absorbent sheets;   b. stacking the plurality of absorbent sheets in facing arrangement with one another;   c. providing a sewing and perforating apparatus comprising a first tine and a second tine;   
       wherein the first tine is adapted to receive a thread and the first and second tines are adapted to be displaced in the vertical direction by a drive means;
 d. threading the first tine with a thread; 
 e. moving the first and second tines towards and through the stack of sheets, wherein the first tine creates a stitch hole and the thread is threaded through the stitch hole and the second hole creates a perforation hole; and 
 f. moving the sewing and perforating apparatus or the stack of sheets in the horizontal direction and repeating step (e). 
 
     
     
         21 . The method of  claim 20  further comprising the step of cutting the plurality of sheets to size prior to step (b). 
     
     
         22 . The method of  claim 20  wherein the plurality of sheets are stacked in alignment with one another such that the machine directions of the sheets are aligned with one another. 
     
     
         23 . The method of  claim 22  wherein step (f) results in a line of stitch holes and a line of perforations holes aligned substantially perpendicular to the machine direction of the sheets. 
     
     
         24 . The method of  claim 20  further comprising the steps of providing a backing sheet or strip and folding the backing sheet or strip over a first end of the stack. 
     
     
         25 . The method of  claim 20  further comprising the step of half-folding or quarter-folding the absorbent sheets prior to step (b). 
     
     
         26 . The method of  claim 20  wherein the plurality of absorbent sheets have a basis weight greater than about 10 grams per square meter (gsm), a geometric mean tensile strength (GMT) from about 500 to about 3,500 g/3″ and a vertical absorbent capacity greater than about 4.0 g/g. 
     
     
         27 . The method of  claim 20  wherein the first and the second tines each have a cross-sectional shape and the cross-sectional shape is different. 
     
     
         28 . The method of  claim 27  wherein the first tine has a round, semi-circular or oval cross-sectional shape and the second tine has a rectangular, square, diamond, oval, or linear cross-sectional shape. 
     
     
         29 . The method of  claim 24  wherein the backing sheet or strip has a Taber Stiffness greater than the plurality of absorbent sheets.