CN109477309A - 柔软的低毛屑的热风穿透干燥纸巾及其形成方法 - Google Patents

柔软的低毛屑的热风穿透干燥纸巾及其形成方法 Download PDF

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CN109477309A
CN109477309A CN201780026499.5A CN201780026499A CN109477309A CN 109477309 A CN109477309 A CN 109477309A CN 201780026499 A CN201780026499 A CN 201780026499A CN 109477309 A CN109477309 A CN 109477309A
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paper handkerchief
structuring
paper
wet end
additive
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B·T·米勒四世
J·E·西利二世
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High-Quality Paper Handkerchief Co Ltd
First Quality Tissue LLC
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Abstract

本发明涉及一种具有小于10TS7的层积柔软度和5.0或更低的毛屑值的多层热风穿透干燥的结构化纸巾。该纸巾的各个层具有第一外层、内层和第二外层，该第一外层包含量为大约0.25kg/ton的湿部临时湿强度添加剂和量为大约0.25kg/ton的湿部干强度添加剂；该内层包含含有离子表面活性剂的第一湿部添加剂和含有非离子表面活性剂的第二湿部添加剂。

Description

柔软的低毛屑的热风穿透干燥纸巾及其形成方法
相关申请
该美国非临时专利申请根据35 U.S.C.§119(e)要求于2016年4月27日提交的美国临时专利申请系列号62/328,350，题为“柔软的低毛屑的热风穿透干燥纸巾及其形成方法”的优先权，其内容在此通过引用以其全文并入本文作为参考。
技术领域
本发明涉及纸巾，特别涉及包含湿部添加剂的多层纸巾。
发明背景
在全球范围内，对一次性纸制品如卫生纸和面巾纸的需求巨大。在北美市场，对以合理价格点提供的更高品质产品的需求与日俱增。对于一次性卫生纸的消费者而言，最重要的品质属性是柔软性和强度。消费者所需的另一属性是低毛屑(lint)，这是指在使用期间从产品中释放的纤维量。
织物绉纱(crepe)是在使织物成形与结构化之间使用速度差以便于用纤维填充结构化织物的谷部，并在Z方向上折叠网幅以产生厚度并影响表面形貌的方法。常规起绉是使用刮刀除去粘附在涂有粘合剂化学品的蒸汽加热圆筒(杨克式烘缸，yankee dryer)上的网幅，并结合杨克式烘缸与卷纸缸之间的速度差以便在Z方向上折叠网幅并产生厚度、褶皱和影响网幅的表面形貌。在圆筒之间压制网幅的压光过程也将影响表面形貌。该表面形貌还可能受网幅中使用的纤维的粗糙度与刚度、纤维精制程度以及转化过程中的压花的影响。添加的化学软化剂和洗涤剂也可以通过产生光滑的表面涂层(其降低了网幅与消费者皮肤之间的摩擦)来影响平滑感。
毛屑，或在使用期间从网幅中释放的纤维量，可能受许多因素的影响，如网幅的整体强度、混入的天然或合成粘合剂(尤其在与消费者直接接触的网幅外表面中的)、网幅外表面的光滑度、纤维的尺寸或纤维在整个网幅中的成层、以及用于将来自杨克式烘缸的片材起绉的起绉刮刀的几何形状。
发明内容
本发明的一个目的是提供一种纸巾制造方法，其采用热风穿透干燥来制造具有优异的柔软度与低毛屑的纸巾。
本发明的一个示例性实施方案的多层热风穿透干燥纸巾包含第一外层、内层和第二外层。该内层包括含有离子表面活性剂的第一湿部添加剂和含有非离子表面活性剂的第二湿部添加剂。
本发明的另一示例性实施方案的多层热风穿透干燥纸巾包含基本由硬木纤维组成的第一外层，基本由软木纤维组成的内层和基本由硬木纤维组成的第二外层。该内层包括含有离子表面活性剂的第一湿部添加剂和含有非离子表面活性剂的第二湿部添加剂。
在至少一个示例性实施方案中，该第一外层进一步包含湿部临时湿强度添加剂。
在至少一个示例性实施方案中，该第一外层进一步包含湿部干强度添加剂。
在至少一个示例性实施方案中，该第二外层进一步包含湿部干强度添加剂。
在至少一个示例性实施方案中，该第二湿部添加剂包含乙氧基化植物油。
在至少一个示例性实施方案中，该第二湿部添加剂包含乙氧基化植物油的组合。
在至少一个示例性实施方案中，该纸巾中第二湿部添加剂与第一湿部添加剂的重量比为至少八比一。
在至少一个示例性实施方案中，该第一内层中第二湿部添加剂与第一湿部添加剂的重量比为至多九十比一。
在至少一个示例性实施方案中，该离子表面活性剂包含解胶剂。
在至少一个示例性实施方案中，该纸巾网幅的双层层压体(2-ply laminate)具有至少91HF的柔软度(手感)。
在至少一个示例性实施方案中，该纸巾网幅的双层层压体具有小于10TS7的层积柔软度(bulk softness)。
在至少一个示例性实施方案中，该湿部临时湿强度添加剂包含乙二醛化聚丙烯酰胺。
在至少一个示例性实施方案中，该湿部干强度添加剂包含两性淀粉。
在至少一个示例性实施方案中，该第一外层进一步包含干强度添加剂。
在至少一个示例性实施方案中，该第一和第二外层基本不含任何表面沉积的软化剂或洗涤剂。
在至少一个示例性实施方案中，该第一或第二外层中的至少一个包含表面沉积的软化剂或洗涤剂。
在至少一个示例性实施方案中，该非离子表面活性剂具有小于10和优选小于8.5的亲水-亲油平衡值。
在至少一个示例性实施方案中，该第一外层包含至少20重量％的软木纤维。
在至少一个示例性实施方案中，该内层包含至少75重量％的软木纤维。
本发明的一个示例性实施方案的结构化纸巾包含：多层热风穿透干燥纸巾的至少两层的层压体，该结构化纸巾具有小于10 TS7的层积柔软度和5.0或更小的毛屑值。
在至少一个示例性实施方案中，该结构化纸巾具有91.0HF或更大的柔软度值。
本发明的实施方案的其它特征和优点将通过以下详述，附图和所附权利要求变得显而易见。
附图概述
将参照附图描述本发明的示例性实施方案，其中：
图1是本发明的一个示例性实施方案的三层纸巾的示意图；
图2是制造本发明的示例性实施方案的多层纸巾的单个层的系统的框图；
图3是由本发明的示例性实施方案的单层纸巾制造多层纸巾的系统的框图；
图4描绘了常规的起绉刮刀；
图5描绘了本发明的示例性实施方案的起绉刮刀的实例；和
图6描绘了本发明的另一示例性实施方案的起绉刮刀的实例。
发明详述
一次性纸制品的制造商长期以来已经认识到消费者对既柔软又牢固的纸巾如卫生纸和面巾纸的强烈需要。柔软度是指使用该纸巾时消费者感知的触感或“手感”。强度是纸幅在使用过程中保持其物理完整性的能力。在制造既柔软又牢固的纸巾时，通常在强度与柔软度之间进行权衡。例如，制造商可以通过添加更多硬木(由于木材中纤维更短，其往往更柔软)令纸巾更柔软，但是这降低了纸张强度。
虽然消费者往往喜欢更柔软的纸巾，但是消费者对通常在使用期间从柔软的纸巾上放出(释放)并以残留物形式留在使用者的皮肤或衣物上的毛屑敏感。用于减少毛屑的常规技术也使纸巾明显不那么柔软。例如，向纸巾中添加干强度添加剂或临时湿强度添加剂或是增加用于制造该纸巾的长纤维软木的量减少了毛屑，但是令纸巾不那么柔软。因此，期望进一步减少从柔软且牢固的纸巾中释放的毛屑的量。
通过控制表面纤维粘合以防止使用该纸巾时表面纤维脱落，在本发明中实现了毛屑的减少。如本文中进一步详细描述的那样，例如通过在多层流浆箱处供应添加剂或通过片材成型过程中的聚合物/纤维的迁移来控制表面纤维粘合。所得纸巾满足了喜欢具有极低毛屑水平的柔软但牢固的纸巾的消费者。
本发明涉及用湿部添加的离子表面活性剂与湿部添加的非离子表面活性剂的组合制得的柔软的结构化纸巾。术语“结构化纸巾”是指使用结构化织物来制得的任何纸巾产品，其具有在造纸过程(例如TAD、UCTAD、ATMOS、NTT或ETAD)中在纸巾网幅中形成的图案。该纸巾可以由多个层构成，包括外层和内层。在至少一个示例性实施方案中，用于各纸巾层的纸浆混合料单独制备。
图1显示了本发明的示例性实施方案的三层纸巾，通常用附图标记1表示。纸巾1的一般结构和制造方法描述在美国专利号8,968,517(转让给申请人)中，其内容在此通过引用以其全文并入本文作为参考。该纸巾1具有外部层2和4以及内部芯层3。外部层2主要由硬木纤维20组成，而外部层4和芯层3由硬木纤维20与软木纤维21的组合组成。该内部芯层3包括充当解胶剂5的离子表面活性剂和充当软化剂6的非离子表面活性剂。如下文中进一步详细解释的那样，外部层2和4还包括在纸巾1的成形过程中由内部芯层3迁移的非离子表面活性剂。外部层2进一步包括干强度添加剂7。外部层4进一步包括干强度添加剂7与临时湿强度添加剂8。
用主要为硬木纤维的混合物制备用于纸巾的外层的纸浆混合料。例如，用于至少一个外层的纸浆混合料是含有相对于构成该混合物的纤维的总百分比为大约70％或更高的硬木纤维的混合物。作为进一步的实例，用于至少一个外层的纸浆混合料是含有相对于构成该混合物的纤维的总百分比为大约80％的硬木纤维的混合物。
用主要为软木纤维的混合物制备用于该纸巾内层的纸浆混合料。例如，用于该内层的纸浆混合料是含有相对于构成该混合物的纤维的总百分比为大约70％或更高的软木纤维的混合物。作为进一步的实例，用于该内层的纸浆混合料是含有相对于构成该混合物的纤维的总百分比为大约90-100％的软木纤维的混合物。
如本领域已知的那样，对纸浆混合料施以稀释阶段，在该阶段中向该混合料中加入水以形成浆料。在稀释阶段之后但是在到达流浆箱之前，将各纸浆混合料脱水以获得含有大约95％的水的浓浆。在本发明的一个示例性实施方案中，将湿部添加剂引入到至少该内层的浓浆纸浆混合料中。在一个示例性实施方案中，将非离子表面活性剂与离子表面活性剂添加到用于该内层的纸浆混合料中。合适的非离子表面活性剂具有小于10、优选小于或等于8.5的亲水亲油平衡值。一种示例性非离子表面活性剂是乙氧基化植物油或两种或更多种乙氧基化植物油的组合。其它示例性非离子表面活性剂包括脂肪醇的环氧乙烷、环氧丙烷加合物；烷基糖苷酯和烷基乙氧基化酯。
合适的离子表面活性剂包括但不限于季胺和阳离子磷脂。示例性的离子表面活性剂是1，2-二(十七烷基)-3-甲基-4，5-二氢咪唑-3-鎓甲基硫酸盐。其它示例性离子表面活性剂包括(2-羟乙基)甲基双[2-[(1-氧代十八烷基)氧基]乙基]铵甲基硫酸盐、脂肪二烷基胺季盐、单脂肪烷基叔胺盐、不饱和的脂肪烷基胺盐、直链烷基磺酸盐、烷基-苯磺酸盐和三甲基-3-[(1-氧代十八烷基)氨基]丙基铵甲基硫酸盐。
在一个示例性实施方案中，该离子表面活性剂可以充当解胶剂，而该非离子表面活性剂充当软化剂。通常，解胶剂通过破坏纤维之间的键合起作用以提供柔韧性，但是不想要的副作用是过度暴露于解胶剂可能会降低该纸巾的整体强度。典型的解胶剂是季胺化合物如三甲基椰油基氯化铵、三甲基油基氯化铵、二甲基二(氢化牛油基)氯化铵和三甲基硬脂基氯化铵。
在添加到内层中之后，该非离子表面活性剂(充当软化剂)迁移穿过该纸巾的其它层，而该离子表面活性剂(充当解胶剂)在该内层中保持相对固定。由于解胶剂基本上保留在该纸巾的内层中，更柔软的硬木纤维(如果用解胶剂处理的话，其可能缺乏足够的抗张强度)可用于该外层。此外，由于仅处理该纸巾的内部，与使用解胶剂处理整个纸巾时相比，其需要更少的解胶剂。
在一个示例性实施方案中，添加到用于该纸巾内层的纸浆混合料中的离子表面活性剂与非离子表面活性剂的比为1∶4至1∶90重量份，优选大约1∶8重量份。特别地，当该离子表面活性剂是季胺解胶剂时，降低相对于非离子表面活性剂的量的浓度可以获得改善的纸巾。过量的解胶剂，特别是作为湿部添加剂引入时，可能削弱该纸巾，而不足量的解胶剂可能无法提供具有足够柔韧性的纸巾。由于非离子表面活性剂迁移到该纸巾的外层，在实际的纸巾中，与纸浆混合料相比，芯层中离子表面活性剂与非离子表面活性剂的比可能显著更低。
在一个示例性实施方案中，向用于至少一个外层的浓浆混合料中添加干强度添加剂。该干强度添加剂可以是例如两性淀粉，其以大约1至40千克/吨加入。在另一示例性实施方案中，向用于至少一个外层的浓浆混合料中添加湿强度添加剂。该湿强度添加剂可以是例如乙二醛化聚丙烯酰胺，通常称为GPAM，其以大约0.25至5千克/吨加入。在又一示例性实施方案中，向外层的一个中加入干强度添加剂(优选两性淀粉)和湿强度添加剂(优选GPAM)。不受理论的束缚，据信当作为湿部添加剂添加时，在单一层中两性淀粉与GPAM的组合在成品纸巾减少毛屑的强度方面提供了协同效应。其它示例性的临时湿强度添加剂包括与任何上述化合物组合使用的醛官能化的阳离子淀粉、醛官能化的聚丙烯酰胺、丙烯醛共聚物和顺式-羟基多糖(瓜尔胶和刺槐豆胶)。
除了两性淀粉之外，合适的干强度添加剂可以包括但不限于乙二醛化聚丙烯酰胺、阳离子淀粉、羧甲基纤维素、瓜尔胶、刺槐豆胶、阳离子聚丙烯酰胺、聚乙烯醇、阴离子聚丙烯酰胺或其组合。
图2是本发明的示例性实施方案的用于制造纸巾的系统的框图，通常标记为附图标记100。该系统100包括第一外层冲浆泵102、芯层冲浆泵104、第二外层冲浆泵106、流浆箱108、成形工段110、干燥工段112和压光工段114。第一和第二外层冲浆泵102、106将第一和第二外部层2、4的纸浆混合料输送至流浆箱108，芯层冲浆泵104将芯层3的纸浆混合料输送至流浆箱108。如本领域已知的那样，流浆箱将纸浆的湿纸幅输送到成形工段110中的成形网上。该湿纸幅铺设在成形网上，且芯层3安设置在第一与第二外部层2、4之间。
在成形工段110中成形后，将部分脱水的纸幅传送至干燥工段112。在干燥工段112中，可以使用常规的热风穿透干燥法干燥本发明的纸巾。在一个示例性实施方案中，使用由Helsinki，Finland的Metso Corporation制造的热风穿透干燥机将本发明的纸巾干燥至大约7至20％的湿度。在本发明的另一示例性实施方案中，串联使用两个或更多个热风穿透干燥阶段。不受理论的束缚，据信使用多个干燥阶段改善了纸巾中的均匀性，由此减少了撕裂。
在一个示例性实施方案中，在热风穿透干燥工艺过程中将本发明的纸巾图案化。此类图案化可以通过使用TAD织物，如G-编织(Prolux 003)或M-编织(Prolux 005)TAD织物来实现。
在热风穿透干燥阶段后，本发明的纸巾可以在第二阶段中使用杨克式干燥鼓进一步干燥。在一个示例性实施方案中，在该纸巾接触该鼓之前将起绉粘合剂施加到该鼓上。将该纸巾粘附到该鼓上，并随后用具有0.5毫米或更小的起绉架(shelf)的耐磨涂覆起绉刮刀将其移除。该起绉刮刀设置角度优选为10至35度，刮刀斜面优选为55至80度。
为了进一步说明起绉过程，图4显示了常规起绉刮刀应用，其中将起绉刮刀401压向蒸汽加热的鼓403以使纸巾纸幅402起绉。该刮刀401可以在刮刀尖端处具有耐磨材料404。刮刀上可用于与纸幅接触的可用距离被称为起绉架的距离或起绉架距离。在显示常规起绉刮刀应用的图4中，起绉架的距离415与起绉刮刀的厚度414相同。
在用于本发明的示例性实施方案的起绉过程中，如图5中所示，起绉架的距离515已经通过倾斜刮刀512的非接触面降低至0.5毫米或更小。选择斜面的角度b以获得所需的起绉架距离。已经发现，起绉架的距离515可以影响纸幅性质，包括拉伸、体积和毛屑，因为该起绉架的距离直接影响刮刀512与纸幅502之间的接触时间，并由此影响该刮刀赋予该纸幅的力。例如，已经观察到，当起绉架距离减小时，在刮刀处存在更少的拉伸破坏以及更高的体积膨胀(bulk generation)。
在另一示例性实施方案中，如图6中所示，采用25度的刮刀设置角度c(其由刮刀尖端与鼓之间的接触点处的法线到起绉刮刀的面605测量)、耐磨材料涂覆的尖端刮刀、80度的刮刀斜面角度d和0.5毫米的起绉架距离615。
该耐磨材料合适地为陶瓷材料、金属陶瓷材料或碳化物材料。例如，该耐磨材料可以选自金属氧化物、陶瓷材料、硅酸盐、碳化物、硼化物、氮化物及其混合物。合适的耐磨材料的特定实例是氧化铝、氧化铬、氧化锆、碳化钨、碳化铬、碳化锆、碳化钽、碳化钛及其混合物。该耐磨材料通过热喷涂、物理气相沉积或化学气相沉积来施加。
该纸巾随后可以在后继阶段中在压光工段114中进行压光。根据一个示例性实施方案，可以使用多个压光辊(未显示)实施压光，所述压光辊输送0-100磅/线性英寸(PLI)的压光压力。通常，提高的压光压力与降低的厚度(caliper)和更光滑的纸巾表面相关。
根据本发明的一个示例性实施方案，陶瓷涂覆的起绉刮刀用于从杨克式干燥鼓上移除该纸巾。陶瓷涂覆的起绉刮刀可以获得减少的粘合剂累积，并有助于实现更高的运行速度。不被理论束缚，据信起绉刮刀的陶瓷涂层与金属起绉刮刀相比提供粘性更低的表面，并更耐受边缘磨损(这会导致粘合剂积累的局部斑点)。陶瓷起绉刮刀允许使用更大量的起绉粘合剂，这反过来又提供了改善的片材完整性和更快的运行速度。
除了使用湿部添加剂之外，还可以用局部或表面沉积的添加剂来处理本发明的纸巾。表面沉积添加剂的实例包括用于提高纤维柔软度的软化剂和皮肤洗涤剂。局部软化剂的实例包括但不限于季铵化合物，包括但不限于二烷基二甲基铵盐(例如二牛油基二甲基氯化铵、二牛油基二甲基甲基硫酸铵、二(氢化牛油基)二甲基氯化铵等等)。另一类化学软化剂包括公知的有机反应性聚二甲基硅氧烷成分(包括氨基官能的聚二甲基硅氧烷)、硬脂酸锌、硬脂酸铝、硬脂酸钠、硬脂酸钙、硬脂酸镁、鲸蜡和甾醇油。
在制得纸巾基片后，使用水性粘合剂将两个纸幅/层组成的层压体以面对面的关系层压在一起。用于层压吸收结构的层的粘合剂可以是水溶性的，包括聚乙烯醇、聚乙酸乙烯酯、基于淀粉的粘合剂，或其混合物。该混合物包含1重量％至10重量％的粘合剂。此外，该混合物可以含有至多10重量％的水溶性阳离子树脂，其选自聚酰胺-表氯醇树脂、乙二醛化聚丙烯酰胺树脂、聚乙烯亚胺树脂、聚乙烯亚胺树脂，或其混合物。该混合物的剩余部分由水组成。将混合物加热并保持在90°F至150°F、优选120°F的温度。
使用绝热的不锈钢罐将粘合剂加热并保持在该温度下，所述不锈钢罐具有遍布内部加热表面均匀分布的加热元件。大量被加热的表面积提供了由可调节恒温器控制的均匀加热。该罐设计具有搅拌器以确保适当的混合和传热。
使用涂布辊施加粘合剂，所述涂布辊以轴向平行排列的方式排列，两个压花辊中的一个与其形成辊隙，使得粘合剂涂布辊在两个压花辊之间形成的辊隙的上游。该粘合剂涂布辊在压花突起的顶端将粘合剂转移至压花辊上的压花纸幅。该压花突起的顶端通常在其间形成的辊隙处不接触相对辊的周边，需要增加结合辊以施加用于层压的压力。在两个压花辊之间形成的辊隙下游，该结合辊与和粘合剂涂布辊构成辊隙的同一压花辊形成辊隙。
根据本发明的一个示例性实施方案，在压花工段之前，可以用电晕放电来处理在加工生产线上的纸幅。该处理可以施加到顶层和/或底层上。可以在电晕处理后立即用鼓风机系统将纳米纤维素纤维(NCF)、纳米结晶纤维素(NCC)、微纤化纤维素(MCF)和其它成型的天然与合成纤维吹到该纸幅上。这使得纳米纤维能够通过静电相互作用吸附到该纸幅上。
如所讨论的那样，根据本发明的一个示例性实施方案，将解胶剂添加到至少该内层中作为湿部添加剂。该解胶剂向成品纸巾产品提供柔韧性。但是，解胶剂也降低了该纸巾纸幅的强度，这在制造过程中有时可能会导致断纸。该纸巾纸幅的相对柔软性导致了在重新卷绕过程(必须进行该过程以纠正断纸)中的低效率。因此，如图2中所示，在本发明的示例性实施方案中，使用转换阀120控制作为湿部添加剂的解胶剂向该内层的输送。特别地，当使用例如常规断纸检测传感器检测到断纸时，可以控制该转换阀120以防止进一步输送解胶剂。这使待再卷绕的该部分纸巾幅材具有较低的柔韧性和提高的强度，由此能够进行更有效的再卷绕过程。一旦再卷绕过程完成，该转换阀可以打开以继续输送解胶剂。
除了使用断纸检测传感器之外，还可以在换卷过程中控制该转换阀120，由此可以将纸巾幅材从一个卷转移至另一个卷。该换卷过程可以在该纸巾幅材上产生比正常操作更高的应力，由此提高了断纸机会。在换卷前将该转换阀120关闭，由此提高该纸巾幅材的强度。在该纸巾幅材已经开始在新卷上卷绕时，再次打开该转换阀120。所得基底片材的卷由此在该卷的中心处具有一段更高强度的纸巾幅材，并可以在该卷的外侧具有一段更高强度的纸巾。在精整过程中，更高强度纸巾的外部段被去除和循环。更高强度纸巾的内部段不用于制造成品纸巾。因此，仅将含有解胶剂的基片纸巾的卷部分用于制造成品纸巾。
使用以下测试程序测定本发明的纸巾的基重、钢球破裂强度、MD和CD拉伸和抗张强度、厚度、毛屑和柔软度的下述值：
柔软度测试
使用可获自Leipzig，Germany的EMTEC Electronic GmbH的纸巾柔软度分析仪(TSA)来测定2层纸巾纸幅的柔软度。该TSA包括具有垂直叶片的转子，所述垂直叶片在试样上旋转以施加限定的接触压力。垂直叶片与试样之间的接触产生振动，由振动传感器感测该振动。该传感器随后将信号发送至PC进行处理和显示。大约200至1000Hz范围内的频率分析显示试样的表面光滑度或织构，并被称为TS750值。在6至7kHz之间的频率范围内的另一峰值显示试样的层积柔软度，并被称为TS7值。TS7与TS750值均表示为dB V2rms。当该装置测量在限定负荷下样品的变形时还计算样品的刚度。刚度值(D)表示为mm/N。该装置还计算手感(HF)数，该值对应于用手触摸纸巾样品时感觉到的柔软度(该HF数越高，柔软度越高)。该HF数是通过TSA测量并用算法(该算法还需要样品的厚度和基重)计算的样品的TS750、TS7与刚度的组合。对不同的面巾纸、卫生纸和厨房纸产品可以选择不同的算法。在测试前，应使用日期为2016-05-10的可获自EMTECH的“TSA Leaflet Collection No.9”进行校准检查。如果校准检查显示需要校准，则遵循日期为2015-09-09的可获自EMTECH的“TSALeaflet Collection No.10”作为校准程序。
使用冲头从该纸幅中切出五个100cm2的圆形样品。将样品之一装载到TSA中，夹持就位(面向外或压花层向上)并从TSA所显示的可用柔软度测试算法列表中选择TPII算法。在输入样品参数(包括厚度和基重)后，运行TSA测量程序。对剩余样品重复测试过程，并对所有样品的结果取平均值，记录平均HF数。
钢球破裂强度试验
使用钢球破裂头和保持器，使用可获自Leipzig，Germany的EMTEC ElectronicGmbH的纸巾柔软度分析仪(TSA)来测定2层纸巾纸幅的钢球破裂强度。使用冲头从该纸幅中切出五个100cm2的圆形样品。将样品之一装载到TSA中，在夹持器上压花表面向下，并用环夹持就位。从TSA所显示的可用柔软度测试算法列表中选择钢球破裂算法。随后，通过EMTECH推动钢球破裂头穿过样品，直到纸幅破裂并计算发生破裂所需的克力。对剩余样品重复测试过程，并对所有样品的结果取平均值。
拉伸&MD、CD和湿CD抗张强度测试
由Norwood，MA的Instron制造的Instron 3343拉力试验机(具有100牛顿测力传感器和25.4毫米橡胶涂覆的夹片面)用于抗张强度测量。在测量前，将该Instron 3343拉力试验机校准。在校准后，提供各自为1英寸×4英寸的8个2层产品的条带作为用于各测试的样品。将样品条带之一放置在上夹片面与夹具之间，随后放置在下夹片面与夹具之间，夹具之间的间隙为2英寸。对样品条带进行测试以获得抗张强度和拉伸。重复测试程序，直到所有样品均进行测试。将对八个样品条带获得的值取平均以确定该纸巾的抗张强度。当测试CD湿抗张强度时，将条带放置在105℃的烘箱中5分钟并在临拉动样品之前用75微升去离子水饱和。
毛屑测试
用Sutherland Rub Tester测定由纸巾产品产生的毛屑量。该测试仪使用马达在静止的纸巾上摩擦经称重的毡5次。在摩擦试验之前和之后测量Hunter色彩L值。这两种Hunter色彩L值之间的差值计算为毛屑值。
毛屑测试-样品准备：
在毛屑摩擦测试之前，应按照Tappi Method#T402OM-88对待测试的纸张样品进行调理。这里，在10％至35％的相对湿度水平下和在22℃至40℃的温度范围内将样品预调理24小时。在该预调理步骤之后，应在48至52％的相对湿度下和在22℃至24℃的温度范围内调理该样品24小时。这种摩擦测试还应该在恒温和恒湿的室内进行。
该Sutherland Rub Tester可获自Testing Machines，Inc.(Amityville，N.Y.11701)。首先，通过去除和丢弃可能已经在处理过程中(例如在辊的外侧上)被擦伤的任何产品来准备该纸巾。对多层成品而言，将多层产品的各层含有两片的三个部分移除并放置在工作台上。对于单层产品，将单层产品的各层含有两片的六个部分移除并放置在工作台上。随后将各样品对折，以使折痕沿着纸巾样品的横向(CD)延伸。对于多层产品，确保在折叠样品后朝外的一侧是同一侧朝外。换句话说，不要将所述层彼此撕开，并在产品内侧上摩擦测试彼此相对的侧面。对于单层产品，制造3个远离杨克式烘缸一侧向外的样品，3个杨克式烘缸一侧向外的样品。记录哪些样品是杨克式烘缸一侧向外，哪些样品是远离杨克式烘缸一侧向外。
从Cordage Inc.(800E.Ross Road，Cincinnati，Ohio，45217)获得30″×40″的Crescent#300纸板试片。用裁纸刀裁出六片尺寸为2.5″×6″的纸板。通过在SutherlandRub试验机的固定销上用力压纸板，在六个纸板的每一个中冲压两个孔。
如果使用单层成品，将每个2.5″×6″纸板片居中并小心地放置在六个先前折叠的样品的顶部。确保纸板的6″尺寸平行于每个纸巾样品的纵向(MD)。如果使用多层成品，仅需要三片2.5″×6″的纸板。将每个纸板片居中并小心地放置在三个先前折叠的样品的顶部。再次确保纸板的6″尺寸平行于每个纸巾样品的纵向(MD)。
将纸巾样品的暴露部分的一个边缘折叠到纸板的后面。用获自3M Inc.(3/4″宽的Scotch Brand，St.Paul，Minn.)的胶带将该边缘固定到纸板上。小心地抓住另一伸出的纸巾边缘并将其整齐地折叠到纸板的后面。在保持纸张紧密贴合到纸板上的同时，将该第二边缘用胶带粘贴到纸板后面。对每个样品重复该程序。
翻转每个样品并将纸巾纸的横向边缘粘贴到纸板上。胶带的一半应该接触该纸巾纸，同时另一半粘贴到纸板上。对每个样品重复该程序。如果在样品制备程序的过程中的任何时候该纸巾样品断裂、撕裂或产生磨损，将其丢弃并用新的纸巾样品条带制造新样品。
如果使用多层加工产品，目前在纸板上有三个样品。对于单层成品，目前在纸板上有三个远离杨克式烘缸一侧向外的样品和三个杨克式烘缸一侧向外的样品。
毛屑测试-毡制备
从Cordage Inc.(800E.Ross Road，Cincinnati，Ohio，45217)获得30″×40″的一片Crescent#300纸板。用裁纸刀切割出六片尺寸为2.25″×7.25″的纸板。在纸板的白色侧面上画两条平行于短尺寸并距顶部和底部最大边缘1.125″的线。用直尺作为导向装置，用刀片小心划出线的长度。划至整个片材厚度的大约一半的深度。这种划线使纸板/毡组合能够紧密贴合在Sutherland Rub试验机的砝码周围。在该纸板的划线侧上绘制平行于纸板的长尺寸延伸的箭头。
将六片黑色毡(F-55或等价物，来自550BroadStreet，Bristol，Conn.06010的NewEngland Gasket)切割至2.25″×8.5″×0.0625的尺寸。将毡放置在纸板的未划线的绿色侧面顶部上，以使毡与纸板二者的长边缘平行并对准。确保毡的绒毛侧朝上。也允许大约0.5″伸出到纸板的顶部和底部的最大边缘外。用Scotch牌胶带将两个伸出的毡边缘整齐地折叠到纸板的背侧。制备总计六个毡/纸板组合。
为了最好的再现性，所有样品应当用同一批毡制作。显然，存在着单批毡完全用光的情况。在必须获得新一批毡的那些情况下，应该对新一批毡确定修正因子。为了确定该修正因子，获得代表性的单个相关纸巾样品和足够的毡以组成24个用于新一批和旧一批的纸板/毡样品。
如下所述并且在进行任何摩擦之前，对新一批和旧一批毡的24个纸板/毡样品中的每一个获得Hunter L读数。计算旧一批的24个纸板/毡样品与新一批的24个纸板/毡样品的平均值。
接着，如下所述摩擦测试新一批的24个纸板/毡板和旧一批的24个纸板/毡板。确保对于旧一批和新一批的24个样品中的每一个均使用同一纸巾批号。另外，在制备纸板/薄纸样品过程中必须进行纤维网的取样，以使新一批毡与旧一批毡暴露，以尽可能代表纸巾样品。对单层纸巾产品的情况，丢弃任何可能已经损坏或擦伤的产品。接着，得到48个纸巾条带，各自为两个可用单位(也称为片材)长。将前两个可用单位条带放置在实验室工作台的最左侧，并将48个样品的最后一个放置在工作台的最右侧。在样品角落的1cm×1 cm面积内将最左侧的样品标记数字“1”。继续将样品连续标记至48，使得最右侧的最后一个样品编号为48。
对新毡采用24个奇数编号的样品，对旧毡采用24个偶数编号的样品。按从最低到最高的顺序排列奇数样品。按从最低到最高的顺序排列偶数样品。现在，用字母“Y”标记每批的最小号码。用字母“O”标记下一个最大号码。继续以这种交替的“Y”/“O”模式标记样品。对于杨克式烘缸一侧向外的毛屑分析采用“Y”样品，对于远离杨克式烘缸一侧向外的毛屑分析采用“O”样品。对于单层产品，目前新一批毡和旧一批毡的样品总数为24个。在这24个样品中，十二个用于杨克式烘缸一侧向外的毛屑分析，十二个用于远离杨克式烘缸一侧向外的毛屑分析。
如下所述对旧毡的所有24个样品进行摩擦并测量Hunter Color L值。记录旧毡的12个杨克式烘缸一侧的Hunter Color L值。对12个值取平均。记录旧毡的12个远离杨克式烘缸一侧向外的Hunter Color L值。对12个值取平均。从杨克式烘缸一侧的摩擦样品的平均Hunter Color L读数中减去平均初始未摩擦毡的Hunter Color L读数。这是杨克式烘缸一侧样品的Δ平均差值。从远离杨克式烘缸一侧的摩擦样品的平均Hunter Color L读数中减去平均初始未摩擦毡的Hunter Color L读数。这是远离杨克式烘缸一侧的样品的Δ平均差值。计算杨克式烘缸一侧的Δ平均差值和远离杨克式烘缸一侧的Δ平均差值之和并将该和除以2。这是旧毡的未修正的毛屑值。如果对于旧毡存在着一个通用的毡修正因子，则将它加到旧毡的未修正的毛屑值上。该值为旧毡的修正毛屑值。
如下所述对新毡的所有24个样品进行摩擦并测量Hunter Color L值。记录新毡的12个杨克式烘缸一侧的Hunter Color L值。对12个值取平均。记录新毡的12个远离杨克式烘缸一侧的Hunter Color L值。对12个值取平均。从杨克式烘缸一侧的摩擦样品的平均Hunter Color L读数中减去平均初始未摩擦毡的Hunter Color L读数。这是杨克式烘缸一侧样品的Δ平均差值。从远离杨克式烘缸一侧的摩擦样品的平均Hunter Color L读数中减去平均初始未摩擦毡的Hunter Color L读数。这是远离杨克式烘缸一侧的样品的Δ平均差值。计算杨克式烘缸一侧的Δ平均差值和远离杨克式烘缸一侧的Δ平均差值之和并将该和除以2。这是新毡的未修正的毛屑值。
取旧毡的修正毛屑值和新毡的未修正的毛屑值之间的差值。该差值是新一批毡的毡修正因子。
将该毡修正因子加到新毡的未修正毛屑值上应当与旧毡的修正的毛屑值相等。
同类程序应用于双层纸巾产品，其中24个样品用于旧毡，24个用于新毡。但是，仅摩擦测试该层的消费者使用的外侧层。如上所述，确保准备样品以获得旧毡和新毡的代表性样品。
毛屑测试-4磅砝码的保养
四磅砝码具有四平方英寸的有效接触区域，提供每平方英寸一磅的接触压力。由于接触压力可以通过更换安装在砝码表面上的橡胶垫而改变，重要的是仅使用由制造商(Brown Inc.，Mechanical Services Department，Kalamazoo，Mich.)供应的橡胶垫。如果这些垫变硬、磨损或碎裂，则必须进行更换。
当不使用时，必须定位该砝码以使该垫不支撑砝码的总重量。该砝码最好侧放保存。
毛屑测试-摩擦试验机仪器校准
在使用之前首先必须校准Sutherland Rub Tester。首先，通过将试验机开关移动到“cont”位置开启Sutherland Rub Tester。当试验机悬臂处在与使用者最近的位置时，将试验机的开关旋到“auto”位置。通过将大刻度盘上的指针臂移动到“five”位置设定，将试验机设定为运行5个行程。一个行程是砝码的一次和完全的前进和倒退运动。在每次试验的开始和结束时，摩擦块的末端应该处在与操作者最近的位置。
如上所述在纸板样品上准备一张纸巾纸。此外，如上所述在纸板样品上准备毡。这两种样品将用于仪器的校准并且将不用于采集实际样品的数据。
通过将纸板中的孔滑到固定销上将该校准纸巾样品放置在试验机的底板上。固定销防止样品在测试期间移动。将校准毡/纸板样品夹紧到四磅砝码上，其中纸板侧接触砝码垫。确保纸板/毡组合物平靠着砝码。将这个砝码钩吊到试验机悬臂上并轻轻地将纸巾样品放在砝码/毡组合物的下面。砝码最靠近操作者的末端必须在纸巾样品的纸板上而不是纸巾样品本身上。毡必须平靠在纸巾样品上并且必须100％与纸巾表面接触。按下“push”按钮启动试验机。
记录行程数目并观察和留意覆盖砝码的毡相对于样品的开始和停止位置。如果行程总数为五，并且如果最接近操作者的覆盖砝码的毡的末端在本试验开始和结束时是在纸巾样品的纸板上，则试验机是校准的，可随时使用。如果行程总数不为五，或者如果最接近操作者的覆盖砝码的毡的末端在本试验或是开始或是结束时是在实际纸巾样品上，则重复此校准程序直到数到5个行程在试验的开始和结束时最接近操作者的覆盖砝码的毡的末端均位于纸板的上方为止。
在样品的实际测试期间，监控和观察行程数和覆盖砝码的毡的开始和停止点。必要时重新校准。
毛屑测试-HUNTER COLOR METER校准
根据仪器的操作手册中的所述程序以黑色和白色标准板调节该Hunter ColorDifference Meter。也要进行标准化的稳定性检查以及日常稳定性检查，如果在过去的八小时内还没有这么做的话。此外，必须检查零反射，并且如果需要的话进行重新调节。
将白色标准板放在仪器孔下面的样品台上。松开样品台并使样品板能够被升高到样品孔的下面。
使用“L-Y”、“a-X”和“b-Z”校准旋钮调节仪器以在依次压下“L”、“a”和“b”按钮时读出“L”、“a”和“b”的白色标准板值。
毛屑测试-样品的测量
毛屑测量中的第一步骤是在纸巾上进行摩擦之前测量黑毡/纸板样品的Hunter色值。该测量的第一步骤是从Hunter测色仪的仪器孔下降低白色标准板。在标准板顶部，使覆盖纸板的毡居中，箭头指向色差计的背侧。松开样品台，使覆盖纸板的毡能够升高到样品孔下。
因为毡宽度仅略大于视区直径，要确保毡完全覆盖视区。在确认完全覆盖之后，按下L按钮并等待读数稳定。读取并记录该L值，精确至0.1单位。
如果使用D25D2A头，则降低覆盖纸板的毡和板，将覆盖纸板的毡旋转90°，以使箭头指向测色仪的右侧。接着，松开样品台并再一次检查以确保视区完全被毡覆盖。按下L按钮。读取并记录该值，精确至0.1单位。对于D25D2M单元，记录的值为Hunter Color L值。对于还记录旋转样品读数的D25D2A头，Hunter Color L值是两个记录值的平均值。
对于所有覆盖纸板的毡采用该技术测量Hunter Color L值。如果所有HunterColor L值彼此相差不到0.3单位，则取平均值得到初始L读数。如果Hunter Color L值相差超过0.3个单位，则废弃那些超出界限之外的毡/纸板组合。准备新的样品并重复HunterColor L测量，直到所有的样品彼此相差不到0.3个单位为止。
对于实际的纸巾纸/纸板组合的测量，通过将纸板上的孔滑到固定销上来将纸巾样品/纸板组合放置在试验机的底板上。固定销防止样品在测试期间移动。将校准毡/纸板样品夹紧到四磅砝码上，其中纸板侧接触砝码的垫。确保纸板/毡组合平靠在砝码上。将这个砝码吊在试验机臂上并轻轻地将纸巾样品放在砝码/毡组合的下方。砝码最靠近操作者的末端必须在纸巾样品的纸板上而不是纸巾样品本身上。毡必须平放在纸巾样品上并且必须100％与纸巾表面接触。
接着，按下“push”按钮启动试验机。在五次行程结束时，试验机将自动停止。注意覆盖砝码的毡相对于样品的停止位置。如果覆盖砝码的毡朝向操作者的末端是在纸板上，则试验机运行正常。如果覆盖砝码的毡朝向操作者的末端是在样品上，将这次测量作废并如Sutherland Rub Tester Calibration部分所述重新校准。
将砝码从覆盖纸板的毡上移除。检查纸巾样品。如果被撕裂，则丢弃毡和纸巾样品并重新开始。如果纸巾样品完整无损，则从砝码上移除覆盖纸板的毡。对于毛坯毡，如上所述在覆盖纸板的毡上确定Hunter Color L值。摩擦后记录毡的Hunter Color L读数。摩擦、测量和记录所有剩余样品的Hunter Color L值。
在测量所有纸巾试样后，移除并丢弃所有的毡。毡条不会再次使用。使用纸板直到它们弯曲、撕裂、变软或不再具有光滑表面。
毛屑测试-计算
从样品的远离杨克式烘缸一侧和杨克式烘缸一侧的各实测值中减去未使用毡的平均初始L读数，由此确定ΔL值。回想一下，多层产品仅摩擦纸张的一侧。由此，对多层产品将获得三个ΔL值。对三个ΔL值取平均，并从最终平均值中减去毡因子。最终结果称为双层产品的织物一侧的毛屑值。
对于其中获得杨克式烘缸一侧和远离杨克式烘缸一侧测量的单层产品，从三个杨克式烘缸一侧的L读数中的每一个和三个远离杨克式烘缸一侧的L读数中的每一个中减去未使用毡的平均初始L读数。对三个杨克式烘缸一侧的值计算平均Δ。对三个织物一侧的值计算平均Δ。从这些平均值的每一个中减去毡因子。最终结果被称为单层产品的织物一侧的毛屑值和杨克式烘缸一侧的毛屑值。通过取这两个值的平均值，可以获得整个单层产品的最终毛屑值。
基重
使用染料和压机，从双层产品上切下六个76.2mm×76.2mm正方形样品，小心地避免任何纸幅穿孔。该样品放置在105℃下的烘箱中5分钟，随后在分析天平上称重至小数点后四位。以克为单位的样品重量除以(0.0762米)2以测定以克/平方米为单位的基重。
厚度测试
由West Berlin，NJ的Thwing Albert制造的Thwing-Albert ProGage100Thickness Tester用于厚度测试。从双层产品上切割八个100mm×100mm正方形样品。样品随后单独测试，结果取平均以获得基片的厚度结果。
下面两个实施例描述了本发明的优点。
实施例
HF＞91.0且毛屑值＜5.0的双层层压纸巾
将两个热风穿透干燥纸巾的纸幅层压以制造一卷双层卫生(浴室)纸，其具有190个片材，各自为4.0英寸长和4.0英寸宽。该层压体在直径121毫米的辊上进行辊压。该双层纸巾具有下列产品属性：基重为37.8g/m2，厚度为0.517mm，MD抗张强度为150N/m，CD抗张强度为83N/m，钢球破裂强度为195克力，毛屑值为4.86，MD拉伸为13.4％，CD拉伸为6.4％，CD湿抗张强度为9N/m，HF为91.9，TS7为8.26。
各纸巾纸幅是多层的，单独选择和制备各个层的纤维和化学成分，以最大化产品品质属性的柔软度与强度。该第一外层(其是与杨克式烘缸接触的层)使用80％桉树与0.25千克/吨两性淀粉Redibond 2038(Corn Products，10Finderne Avenue，Bridgewater，NewJersey 08807)(用于毛屑控制)和0.25千克/吨乙二醛化聚丙烯酰胺Hercobond 1194(Ashland，500Hercules Road，Wilmington DE，19808)(用于湿润时的强度和用于毛屑控制)制备。该第一外层的剩余20％是北方漂白软木牛皮纸纤维。该内层包含40％北方漂白软木牛皮纸纤维、60％桉树纤维和1.0千克/吨的T526软化剂/解胶剂(EKA Chemicals Inc.，1775West Oak Commons Court，Marietta，GA，30062)。该第二外层包含20％北方漂白软木牛皮纸纤维、80％桉树纤维和3.0千克/吨Redibond 2038(限制精制并提供Z方向强度)。软木纤维以115千瓦时/吨精制以提供必要的抗张强度。
将纤维和化学品混合物稀释至0.5％稠度的固体并进料到单独的冲浆泵中，该冲浆泵将浆料输送到三层流浆箱中。通过向进料到冲浆泵的浓浆中添加苛性碱，将流浆箱pH控制为7.0。流浆箱将浆料沉积到由成形辊、外成形网和内成形网构成的辊隙中。通过具有Asten Johnson(4399Corporate Rd，Charleston，SC USA)的KT194-P设计的外成形网排出浆料，以帮助排水、纤维支撑和纸幅成形。当织物分离时，纸幅遵循内成形网并用一系列真空箱和蒸汽箱干燥至约25％固体。
然后借助于真空箱将纸幅转移到结构化织物上以促进纤维渗透到结构化织物中，增强层积柔软度和纸幅压印。使用的结构化织物是由Albany(216Airport DriveRochester，NH USA)提供的Prolux 005设计，其具有5个梭口设计，经线序列为1、3、5、2、4，17.8乘11.1纱线/cm目数，0.35毫米经线单丝，0.50毫米纬线单丝，1.02毫米厚度，渗透率值为640立方英尺空气/分钟(cfm)，将转向节表面打磨以提供与杨克式烘缸的27％的接触面积。在转移至杨克式烘缸之前，借助两个TAD热空气冲击鼓干燥该纸幅至85％的水分。
使用粘合剂涂层化学品使纸幅与杨克式鼓表面紧密接触。杨克式烘缸具有3.0巴的蒸汽，而杨克式烘缸上安装的热空气冲击罩吹送高达450℃的加热空气。根据本发明的示例性实施方案，使用具有耐磨氧化铬-二氧化钛材料的刮刀，以20度的设置角度，0.50毫米的起绉架距离和80度的刮刀斜角以10％的绉纱(杨克式烘缸与卷筒之间的速度差)将该纸幅从杨克式烘缸上起绉。在替代实施方案中，可以使用陶瓷刮刀以90度的袋角度将纸幅从杨克式烘缸上以10％的绉纱起绉。在通过压光机之前，纸幅厚度为大约375微米(单层)，通过压光机后体积减小至275微米(单层)。使用10,000psi的高压水流将纸幅切成两个相等宽度的纸幅，并将其卷成两个大小相等的母卷并输送到加工过程。
在加工过程中，使用机械层粘合或DEKO构造的轻压花将两个纤维网层合在一起(仅将顶层压花，胶水在来自压花的高点处施加到顶层内侧，粘合剂由cliché辊提供)，各纸幅的第二外层彼此面对。顶层的压花覆盖率为4％。将产物以121毫米卷绕为190片计数卷。
还进行了替代方法，其中在上述加工之前，纸幅在造纸机上未经压光。在这种情况下，将纸幅以121毫米卷绕成176片计数产品，其具有与前述大致相同的物理性质。
对比例
HF＞91.0且毛屑值＜6.1的双层层压纸巾
将两个热风穿透干燥纸巾的纸幅层压以制造一卷双层卫生(浴室)纸，其具有190个片材，各自为4.0英寸长和4.0英寸宽。该层压体在直径121毫米的辊上进行辊压。该双层纸巾具有下列产品属性：基重为38.2g/m2，厚度为0.525mm，MD抗张强度为155N/m，CD抗张强度为82N/m，钢球破裂强度为222克力，毛屑值为6.04，MD拉伸为11.9％，CD拉伸为7.2％，CD湿抗张强度为8.7N/m，HF为92.2，TS7为8.5。
各纸巾纸幅是多层的，单独选择和制备各个层的纤维和化学成分，以最大化产品品质属性的柔软度和强度。该第一外层(其接触杨克式烘缸)使用95％桉树与0.25千克/吨两性淀粉Redibond 2038(Com Products，10 Finderne Avenue，Bridgewater，New Jersey08807)(用于毛屑控制)和0.25千克/吨乙二醛化聚丙烯酰胺Hercobond 1194(Ashland，500Hercules Road，Wilmington DE，19808)(用于湿润时的强度和用于毛屑控制)制备。该第一外层的剩余5％是北方漂白软木牛皮纸纤维。该内层包含40％北方漂白软木牛皮纸纤维、60％桉树纤维和1.5千克/吨T526软化剂/解胶剂(来自EKA Chemicals Inc.，1775 WestOak Commons Court，Marietta，GA USA)。该第二外层包含20％北方漂白软木牛皮纸纤维、80％桉树纤维和3.0千克/吨Redibond 2038(限制精制并提供Z方向强度)。软木纤维以135千瓦时/吨精制以提供必要的抗张强度。
将纤维和化学品混合物稀释至0.5％稠度的固体并进料到单独的冲浆泵中，该冲浆泵将浆料输送到三层流浆箱中。通过向进料到冲浆泵的浓浆中添加苛性碱，将流浆箱pH控制为7.0。流浆箱将浆料沉积到由成形辊、外成形网和内成形网构成的辊隙中。通过具有Asten Johnson(4399Corporate Rd，Charleston，SC USA)的KT194-P设计的外成形网排出浆料，以帮助排水、纤维支撑和纸幅成形。当织物分离时，纸幅遵循内成形网并用一系列真空箱和蒸汽箱干燥至约25％固体。
然后借助于真空箱将纸幅转移到结构化织物上以促进纤维渗透到结构化织物中，增强层积柔软度和纸幅压印。使用的结构化织物是由Albany(216Airport DriveRochester，NH USA)提供的Prolux 005设计，其具有5个梭口设计，经线序列为1、3、5、2、4，17.8乘11.1纱线/cm目数，0.35毫米经线单丝，0.50毫米纬线单丝，1.02毫米厚度，渗透率值为640立方英尺空气/分钟(cfm)，转向节表面打磨至提供与杨克式烘缸的27％的接触面积。在转移至杨克式烘缸之前，借助两个TAD热空气冲击鼓干燥该纸幅至85％的水分。
使用粘合剂涂层化学品使纸幅与杨克式鼓表面紧密接触。杨克式烘缸具有3.0巴的蒸汽，而杨克式烘缸上安装的热空气冲击罩吹送高达450℃的加热空气。根据本发明的示例性实施方案，使用具有耐磨氧化铬-二氧化钛材料的刮刀以20度的设置角度，1.2毫米的起绉架距离和80度的刮刀斜角以10％的绉纱(杨克式烘缸与卷筒之间的速度差)将该纸幅从杨克式烘缸上起绉。在替代实施方案中，可以使用陶瓷刮刀以90度的袋角度将纸幅从杨克式烘缸上以10％的绉纱起绉。在通过压光机之前，纸幅厚度为大约375微米(单层)，通过压光机后体积减小至275微米(单层)。使用10,000psi的高压水流将纸幅切成两个相等宽度的纸幅，并将其卷成两个大小相等的母卷并输送到加工过程。
在加工过程中，使用机械层粘合或DEKO构造的轻压花将两个纤维网层合在一起(仅将顶层压花，胶水在来自压花的高点处施加到顶层内侧，粘合剂由cliché辊提供)，各纸幅的第二外层彼此面对。顶层的压花覆盖率为4％。将产物以121毫米卷绕成190片计数卷。
还进行了替代方法，其中在上述加工之前，纸幅在造纸机上未经压光。在这种情况下，将纸幅以121毫米卷绕成176片计数产品，其具有与前述大致相同的物理性质。
市售产品的比较测试结果
表1显示了对各种市售产品进行的类似测试的对比测试结果。对基重、体积、干MD和CD抗张强度与拉伸、CD湿抗张强度、性能、几何平均抗张(GMT)强度、钢球破裂强度、HF和毛屑值显示了测试结果。
测试证实本发明是有利的，因为所有其它测试产品都没有表现出相同水平的高柔软度和低毛屑。例如，与实施例相比，所有市售产品都表现出更低的柔软度(即更低的HF值)；并且在一些情况下，与实施例相比，所有市售产品都表现出更高的毛屑值与更低的柔软度的组合。
表1-竞争对手产品质量属性(6个受试样品，在测试时对每个月取平均值)
现在已经显示和详细描述了本发明的实施方案，对其进行各种修改和改进对于本领域技术人员来说将变得显而易见。因此，本发明的精神和范围应被广义地解释，且不受前述说明书的限制。

Claims (28)

1.一种结构化纸巾，其包括：
多层热风穿透干燥纸巾的至少两层的层压体，所述结构化纸巾具有小于10TS7的层积柔软度和5.0或更低的毛屑值。
2.根据权利要求1所述的结构化纸巾，其中所述纸巾具有91.0HF或更大的柔软度值。
3.根据权利要求1所述的结构化纸巾，其中所述多层热风穿透干燥纸巾的各个层包括：
第一外层，其包含量为大约0.25kg/ton的湿部临时湿强度添加剂和量为大约0.25kg/ton的湿部干强度添加剂；
内层，其包含含有离子表面活性剂的第一湿部添加剂和含有非离子表面活性剂的第二湿部添加剂；和
第二外层。
4.根据权利要求3所述的结构化纸巾，其中所述第一外层进一步包含至少75重量％的硬木纤维。
5.根据权利要求4所述的结构化纸巾，其中所述第一外层进一步包含至少20重量％的软木纤维。
6.根据权利要求4所述的结构化纸巾，其中所述内层进一步包含至少40重量％的软木纤维。
7.根据权利要求3所述的结构化纸巾，其中所述第二湿部添加剂包含一种或多种乙氧基化植物油。
8.根据权利要求3所述的结构化纸巾，其中所述纸巾的内层中的第二湿部添加剂与第一湿部添加剂的重量比为至少八比一。
9.根据权利要求3所述的结构化纸巾，其中所述内层中的第二湿部添加剂与第一湿部添加剂的重量比为至多九十比一。
10.根据权利要求3所述的结构化纸巾，其中所述离子表面活性剂包含解胶剂。
11.根据权利要求3所述的结构化纸巾，其中所述湿部临时湿强度添加剂包含乙二醛化聚丙烯酰胺。
12.根据权利要求11所述的结构化纸巾，其中所述湿部干强度添加剂包含两性淀粉。
13.根据权利要求3所述的结构化纸巾，其中所述第二外层包含湿部干强度添加剂。
14.根据权利要求13所述的结构化纸巾，其中所述湿部干强度添加剂包含两性淀粉。
15.根据权利要求3所述的结构化纸巾，其中所述内层包括至少75重量％的软木纤维。
16.根据权利要求3所述的结构化纸巾，其中所述第二外层进一步包含湿部干强度添加剂。
17.根据权利要求3所述的结构化纸巾，其中所述第二外层进一步包含临时湿强度添加剂。
18.根据权利要求3所述的结构化纸巾，其中所述第二外层进一步包含干强度添加剂。
19.根据权利要求3所述的结构化纸巾，其中所述第一外层进一步包含干强度添加剂。
20.根据权利要求3所述的结构化纸巾，其具有至少35N/m的MD抗张强度和CD抗张强度，并且具有小于40gsm的基重。
21.根据权利要求3所述的结构化纸巾，其具有至少35N/m的MD抗张强度和CD抗张强度以及小于650微米的厚度。
22.根据权利要求3所述的结构化纸巾，其中所述第一和第二外层基本不含任何表面沉积的软化剂或洗涤剂。
23.根据权利要求3所述的结构化纸巾，其中所述第一或第二外层中的至少一个包含表面沉积的软化剂或洗涤剂。
24.根据权利要求3所述的结构化纸巾，其中所述非离子表面活性剂具有小于10的亲水-亲油平衡值。
25.根据权利要求3所述的结构化纸巾，其中至少两个层的每一个包含压花区域，其中所述压花区域占该层表面的总表面积的大约3至15％。
26.根据权利要求1所述的结构化纸巾，其中所述纸巾是卫生纸、浴室纸或面巾纸中的一种。
27.根据权利要求1所述的结构化纸巾，其中所述结构化纸巾具有至少500微米的厚度。
28.根据权利要求1所述的结构化纸巾，其中所述结构化纸巾具有500微米至650微米的厚度。
CN201780026499.5A 2016-04-27 2017-04-27 柔软的低毛屑的热风穿透干燥纸巾及其形成方法 Pending CN109477309A (zh)

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