CN1194019A - 多层纸制品 - Google Patents

多层纸制品 Download PDF

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CN1194019A
CN1194019A CN96196486A CN96196486A CN1194019A CN 1194019 A CN1194019 A CN 1194019A CN 96196486 A CN96196486 A CN 96196486A CN 96196486 A CN96196486 A CN 96196486A CN 1194019 A CN1194019 A CN 1194019A
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乔治·V·韦格勒
蒂莫西·J·洛伦兹
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Abstract

本发明公开了一种多层纸制品。这些层的一层或两层具有朝其它层突出并接触该层的压花。各层用粘合剂连接在一起,优选是在这些压花处。粘合剂选自一种组合物,该组合物可有利地提供落在特别理想的范围内的最小湿层合强度和干层合强度。

Description

多层纸制品
本发明涉及纤维素纤维结构如纸制品，本发明特别涉及具有连接在一起的多层的纸制品。
纸制品是日常生活中公知的。纸制品通常是指薄页纸，并用作纸贴、擦面纸和浴纸。
薄页纸可含有一单层，但通常含有两层或多层。本文所用的“层”(“ply”)指从成形网或其相当物上取下的单层纸层，并且在没有加入其它纤维的情况下干燥。
当然，一层可以用不同纤维素纤维来分层。分层提供了这样的好处，即中央层可含有较强的纤维以赋予薄页纸产品强度。中央层的外面可以是赋予使用者柔软的触感的较短纤维。分层可以根据普通转让的USP 3,994,771(1976年11月30日授予Morgan，Jr.等人)有利地完成，该专利引入本文作为参考。
通常将两层或多层连接在一起来制备纸制品。将多层连接在一起提供了这样的好处，即所得的层压制品比具有相同厚度的单层的弯曲模量低。这也提供了这样的好处，即柔软的触感被使用者所感觉到。吸收性和厚度通常也有所提高。并且，将三层连接在一起使纸产品具有不同的层压制品的中央层和外层，分别提供强度和柔软性。
多层薄页纸制品通常是纤维素性的。这里所用的“纤维素性的”指一种纸制品，它含有至少约50％重量或至少约50％体积纤维素纤维，包括(但不限于)棉短绒、人造丝和蔗渣，更优选是木浆，如软木(裸子植物或针叶树)或硬木(被子植物或阔叶树)，这些纤维可以被循环。纤维的余量可以是合成纤维，如聚烯烃或聚酯。
纤维素层通常使用粘合剂连接在一起。采用粘合剂将纤维素层接合在一起在普通转让的USP 5,143,776(1992年9月1日授予Givens)中作了有用的描述，将该专利引入本文作为参考。
但是，用粘合剂将纸制品中的多个纤维素层连接在一起可以并已经导致了令人不满意的性能。特别是，用作纸巾、擦面纸和浴纸的纸制品必须具有合适的层合(ply bond)强度。本文所用的“层合强度”是指如下所述的将两个相邻层彼此分开所必需的力。
薄页纸制品，特别是纸巾，在使用时常常被润湿。如果湿层合强度不充分，各层在使用时分开并且破坏了纸制品。尽管看上去简单提高湿层合强度是一件容易的事情，但是干层合强度与湿层合强度直接相关。在现有技术中，当湿层合强度提高到合适的程度时，干层合强度将变得太大。当干层合强度太大时，通常将降低柔软性和吸收性。
因此，本发明的一个目的是提供一多层纸制品。本发明的另一个目的是提供一种多层纸制品，该纸制品具有足够的湿层合强度而同时没有太大的干层合强度。本发明的最后一个目的是提供这样的纸制品，它是纤维素性的并具有用粘合剂连接在一起的多层结构。
本发明包括一多层纤维素纸制品，该纸制品含有至少两层以面对面的关系接合在一起的宏观单平面层。纸制品的湿层合强度至少为4.5克/英寸，优选为至少5.0克/英寸。纸制品的干层合强度为至少4.0～20.0克/英寸，优选为5.0～15.0克/英寸。可以对一层或多层纸制品进行压花。纸制品可以含有两层、三层或多层。因此，本发明的纸制品与现有技术相反，具有彼此无关的湿层合强度和干层合强度。
本发明包括两层或多层宏观单平面状的层，如上所述，这些层是纤维素性的，并可根据相同的制法或不同的制法制备。
每层可具有许多压花，这些压花从一层的平面朝另一层向外突出。类似地，相邻的层可具有朝第一层突出的相对突起。如果想得到三层纸制品，中央层可具有从两个方向向外伸出的压花，尽管没有压花或单向压花的中央层也是可行的。
各层可以根据普通转让的美国专利4,637,859(1987年1月20日授予Trokhan)或4,191,609(1980年3月4日授予Trokhan)，将这两个专利引入本文作为参考。另外，这些层可使用毛毯进行常规干燥。
对本发明来说，每层的定量是约8～30磅，优选11～18磅/3,000英尺2，优选具有根据本领域公知的任何方法生产的硬木和/或软木的组合物。
当完成制备各层的造纸过程后，可以对两层或各层进行压花。可以根据下列方法完成压花，即节对节(knob-to-knob)的压花法，该压花法在作普通转让的USP 3,414,459(1968年12月3日授予Wells)中作了描述；嵌套压花法(nested embossing process)，该压花法在1971年1月19日授予Nystrand的USP 3,556,907中作了描述；或双层压花法(dual ply process)，该压花法在1994年3月15日授予McNeil的作普通转让的USP 5,294,475中作了描述，将所有这些专利引入本文作为参考。
对本发明描述和要求保护的实施方案来说，这些压花可以预先设置在0.05～0.70英寸的间距上，并且可预先在远端的面积设置为0.001～0.100英寸2。每个压花可预先在一个具有许多节(knob)的辊上制备，每个节伸出辊的平面0～0.120英寸。这些压花可以是圆形的、鹅卵形的或不规则形的。
各层最好用粘合剂连接在一起。合适的粘合剂利用完全水解的聚乙烯醇粘合剂和热固性阳离子树脂。该树脂可以是聚酰胺树脂。聚乙烯醇粘合剂和阳离子树脂以89～95％水溶液、优选以约92～95％水溶液(即92～95％水)。在上面所述的粘合剂组合物中的5～11％总固体量中，2～6％的总固体量可含聚乙烯醇粘合剂固体。至少1％的总固体含有热固性阳离子树脂固体。
特别优选的聚乙烯醇是Evanol 71-30，由Du PontCorporation(Wilmington，Delaware)供应。特别优选的热固性阳离子聚酰胺树脂是Kymene 557H，由Hercules Corporation(Wilmingon，Delaware)供应，尽管Kymene LX和其它热塑性阳离子树脂可能也是合适的。
通过非限制性的实施例，粘合剂组合物可包括含10％固体物的聚乙烯醇溶液和含有12.5％固体物的Kymene 557H溶液。也提供以室温供应的自来水。然后依据40份聚乙烯醇粘合剂、8份Kymene 557H和52份水的顺序制备粘合剂。将这些组分以该顺序一起加入到合适的容器中；并采用推进式搅拌器大致搅拌10分钟。优选的混合物的pH是至少7.0以生成合适的固化率。
该实施例提供了含有5％总固体量的粘合剂组合物，其中1％是Kymene、4％是聚乙烯醇粘合剂。该粘合剂可以以3～85克/3,000尺2、4～48克/3,000英尺2、更优选6～20克/3,000英尺2的总固体量施用到一层上。对于含有恒定量总固体物的粘合剂组合物来说，当占恒定固体物总量的热固性阳离子表面活性剂的量增加时，可应用到该层上的粘合剂组合物的量通常将减少。另外说明，对相对聚乙烯醇粘合剂为恒定百分数的热固性阳离子树脂来说，当粘合剂组合物中的总固体物的量增加时，施用到该层上的总固体物的量通常增加。
可以采用三辊式粘合剂应用系统应用粘合剂。采用该系统，将粘合剂作为膜送到给胶辊的表面上。然后将粘合剂膜分散在给胶辊和长度计量辊之间的压区(nip)间，留在长度计量辊的膜部分又输送到一个施用辊上，此处粘合剂膜被再次分裂。留在施用辊上的膜被施用到该层的压花上。然后将该层的压花与另一层接触。这些层在常规的配合辊(marrying rolls)的压区用粘合剂接合在一起。
当然，粘合剂可以用任何本领域公知的其它合适的方式应用到压花上，并通常也用作嵌套式或节对节的压花法。合适的粘合剂施用系统包括橡胶版轮转印刷术、喷洒系统、照相凹版制版法以及上述的三辊系统等。
当突起的间隔和尺寸降低时，可以将更大量的粘合剂应用到所述的实施方案的每个突起上。粘合剂的量可以通过将粘合剂组合物中相对较多的粘合剂固体量，或较大量的粘合剂组合物应用到该层上而增加。
本发明的所得纸制品包括两层或多层的层压制品。本发明的纸制品的湿层合强度为至少4.5克/英寸，更优选至少为5.0克/英寸。
优选的是，根据本发明的纸制品还具有至少4.5的碱性湿层合强度，更优选至少为5.0克/英寸。碱性湿层合强度提供了这样的好处，即如果本发明的纸制品与某些市场上可买到的清洁产品一起使用，各层将保持作为一个整体的层压制品连接在一起。
所得的纸制品还具有4.0～20.0克/英寸、更优选5.0～15.0克/英寸的干层合强度。如下测定湿和干层合强度。干层合强度
提供四个纸成品的样品。从样品的中心切下一沿样品的全长走向的三英寸的条。沿机器方向切取两个条，沿垂直机器方向切下另两个条(即，在机器方向的孔之间或垂直机器方向的边缘)。沿着3英寸边缘中的一个稍作分离，从而可得到彼此独立的各层。手工分离各层直到样品的计量长度为2英寸。
将各层放在拉伸机的夹片(jaw)内。合适的拉伸试验机Model 1451-24，由Thwing/Albert公司(Philadelphia，Pennsylvania)。滑块的分离速度设置在20英寸/分钟，并从初始的2.0英寸的间隔运行7.5英寸。仅记录滑块运行的最后6英寸的数据。测试所有四个拉伸中的样品。然后将四个数据平均以得到一种代表切取四个样品的该产品的单一的层合强度。
必须注意将被拉伸机分离的样品部分不接触拉伸机的较低的夹片或较低的滑块。如果这样的接触发生，它将在测力计上显示并给出一个错误的较高的读数。类似地，必须注意即将要分离的样品部分不接触各层早已被拉伸测试计分离的样品部分。如果这样的接触发生，将错误地增加明显的层合强度。如果上述任一种接触发生，将舍去数据点并测试新样品。湿层合强度
提供一纸制品的单一样品。该样品在转变后至少老化两周，以便使粘合剂组合物有充分的固化时间。
从样品中心沿机器方向切下一3英寸的条。该条经过样品的机器方向的全长(如，在各孔之间)。
沿样品的一个3英寸的边缘分离各层。将仍未分离的样品部分，即未放在拉伸机的夹片内的部分浸渍在蒸馏水中。浸渍后，将样品立即从水中取出并使它在一沥水架上沥水60秒钟。沥水架上配有一尼龙线方筛。形成筛的线的直径为0.015英寸，间隔为0.25英寸。干燥架相对于水平面以45°的角放置。当在干燥架上干燥样品时，样品的放置应使得样品的较长边缘向下与干燥架的斜率对准。在干燥架上将该层的分开的边缘放回到一起从而样品应尽可能地光滑，样品适当地沥去多余的水。在已经从这种方式制备样品后，在拉伸机上测试样品的干层合强度。
下面将描述根据本发明制备的一种纸制品的非限定性的实施例。纸制品由两层纤维素纤维制备，如通常用于由The Procter & GambleCompany(Cincinnati，Ohio)和本发明的受让人销售的Bounty牌纸巾的那种。每层由65％北方软木牛皮浆和35％CTMP(预浸预热木片磨木浆)，其定量为14磅/3000英尺2。每层通过嵌套压花法压成许多椭圆形的突起，其远端的主轴为0.076英寸、副轴为0.038英寸、突起高度为0.070英寸。突起分布在2/3互补的同心钻石形内，45°的间距为0.118英寸。突起占每层面积的约10％。制备互补的两层，并在零间隔配合压区上将两层连接在一起，从而制成每层具有42±3突起/英寸2的整体的层压制品。
将如上述制备的粘合剂组合物应用到一层的突起上。采用三辊系统以约8克/3,000英寸2的量将粘合剂组合物的整个固体物应用到纸制品上。所得的纸制品的湿层合强度为5.4克/英寸和干层合强度为9.1克/英寸。
表I将本发明的纸制品与其它市售的纸巾进行了比较。
使用5％的总固体量粘合剂组合物制备本发明的该样品并在转化后老化两周。本发明的第二个样品利用一6％总固体组合物并在转化后老化三周。
                   表I
牌号           公司/工厂        湿层合强度     干层合强度
本发明          受让人             5.4             9.1
本发明          受让人             6.0            11.7
Bounty          受让人             3.7            14.7
Brawny          James River        3.1            10.1
Sparkle         Georgia Pacific    3.0             7.0
Mardis Grras    Ft.Howard          3.4             7.6
Viva 2-ply      Scott              3.0             4.4
Hi-Dri          Kimberly Clark     3.4             5.5
表I中的每个湿和干层合强度代表5个样品的平均值。当然，对于干层合强度测试来说，五个样品中的每一个代表四个测试试样的平均值。
该公开的结构中各种变化都是可行的。例如，预言其中一层可以被压花，另一层不可以被压花。另一方面，任何一层都可以不被压花。在该实施方案中，通常离散的或连续的粘合剂沉积物将两层连接在一起。每层的用粘合剂连接的区域和未被粘合剂连接的区域都位于该层的平面内。
对本领域普通技术人员来说，其它实施方案和执行方案是可行的，所有这些都属于所附的权利要求范围。

Claims (9)

1.一种多层纤维素纸制品，所述的多层纸制品包括至少两层以面对面的关系连接在一起的宏观单平面层，至少一个所述的层上有压花，所述的压花从所述的层的平面朝所述相对的层向外延伸并接触该相对层，所述的层在所述的压花处彼此连接在一起，所述层制品的湿层合强度至少为4.5克/英寸、干层合强度为4.0～20.0克/英寸，优选湿层合强度至少为5.0克/英寸、更优选干层合强度为5.0～15.0克/英寸。
2.一种权利要求1的纸制品，其特征在于所述各层采用89～89％水性粘合剂组合物连接在一起，其中该粘合剂组合物优选还含有一热固性树脂，更优选该粘合剂含有6～20克/3,000英尺2的总固体物。
3.权利要求1～2中任一项的纸制品，其特征在于每个所述的层具有向所述的其它层突出并接触该层的压花。
4.权利要求1～3的纸制品，含有施用到一层的压花上的粘合剂。
5.权利要求1～4中任一项的纸制品，其特征在于每个所述的层与所述其它的层互补而制备。
6.权利要求1～5中任一项的纸制品，含有两个以面对面的关系连接在一起的层。
7.一种多层纤维素纸制品，所述的多层纸制品含有至少两层以面对面的关系连接在一起的宏观单平面的层，所述纸制品的湿层合强度为至少4.5克/英寸、干层合强度为4.0～20.0克/英寸，和优选湿层合强度至少为5.0克/英寸，更优选干层合强度为5.0～15.0克/英寸。
8.权利要求1～7中任一项的纸制品，含有三个以面对面的关系连接在一起的层。
9.权利要求8的纸制品，其特征在于所述的三层含有一个中央层和两个外层，每个所述的外层具有朝所述的中央层突起并接触该层的压花。
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