EP2088237A1 - Serviette TAD à poids de base élevé préparée à partir d'une composition brute - Google Patents

Serviette TAD à poids de base élevé préparée à partir d'une composition brute Download PDF

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Publication number
EP2088237A1
EP2088237A1 EP09001039A EP09001039A EP2088237A1 EP 2088237 A1 EP2088237 A1 EP 2088237A1 EP 09001039 A EP09001039 A EP 09001039A EP 09001039 A EP09001039 A EP 09001039A EP 2088237 A1 EP2088237 A1 EP 2088237A1
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EP
European Patent Office
Prior art keywords
fiber
web
basis weight
per
weight
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
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EP09001039A
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German (de)
English (en)
Inventor
Frank D. Harper
Mark L. Robinson
Hung Liang Chou
Steven R. Olson
Martin A. Hynnek
Gary L. Worry
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Georgia Pacific Consumer Products LP
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Georgia Pacific Consumer Products LP
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Publication date
Priority claimed from US12/357,524 external-priority patent/US8080130B2/en
Application filed by Georgia Pacific Consumer Products LP filed Critical Georgia Pacific Consumer Products LP
Publication of EP2088237A1 publication Critical patent/EP2088237A1/fr
Withdrawn legal-status Critical Current

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    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21F—PAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
    • D21F11/00—Processes for making continuous lengths of paper, or of cardboard, or of wet web for fibre board production, on paper-making machines
    • D21F11/006—Making patterned paper
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21F—PAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
    • D21F5/00—Dryer section of machines for making continuous webs of paper
    • D21F5/18—Drying webs by hot air
    • D21F5/182—Drying webs by hot air through perforated cylinders
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
    • D21H27/002—Tissue paper; Absorbent paper
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
    • D21H27/30—Multi-ply
    • D21H27/40—Multi-ply at least one of the sheets being non-planar, e.g. crêped

Definitions

  • Paper toweling pervades modem industrial civilizations, being found in almost all kitchens and all but the fanciest of away from home restrooms, its wide use largely attributable to its low cost and ability to rapidly absorb moisture. In most cases, paper toweling is used for a single event, drying the hands, wiping up a spill, cleaning a window - then disposed of. Accordingly, low cost is extremely important for almost all grades. As far as performance goes, absorbency and cross direction wet strength are considered quite important across the spectrum for almost all grades of toweling as absorbency is a measure of how well the toweling will perform its intended function while cross-direction wet strength is a key determinant of the ability of the towel to resist shredding in use.
  • This invention relates to a high-end paper towel which is suitable for use as kitchen roll towel and can be made from a non-premium furnish without use of softeners achieving not only perceived softness which is comparable to toweling made from premium furnishes but also achieves consumer acceptance exceeding that of leading towels made from premium furnish.
  • U. S. Pat. No. 3,812,000 by Salvucci and Yiannos incorporated herein by reference in its entirety, disclose a technique for producing a soft tissue by avoiding mechanical compression of an elastomeric containing furnish until the consistency of the web is at least 80% solids.
  • U. S. No. 3,821,068 by Shaw incorporated herein by reference in its entirety, discloses a papermaking scheme for producing soft tissue by avoiding mechanical compaction until the sheet has been dried to at least 80% solids.
  • Fiber and chemicals can be used to modify the attributes of absorbent paper products.
  • U. S. Pat. No. 5,320,710 by Reeves et al ., and incorporated herein by reference in its entirety describes a new furnish combination extracted from the species Funifera of the genus Hesporaloe in the Agavaceae family. This furnish has fibers which are very long and which have very fine geometrical attributes known to enhance towel and tissue performance.
  • U. S. Pat. No. 3,755,220 by Freimark and Schaftlein incorporated herein by reference in its entirety, describes a debonding scheme for maintaining wet strength while reducing product dry strength - a method said to enhance the handfeel of towel products.
  • Figure 1 is a graph illustrating consumer preference of two products of the present invention as compared to the current market leading brand in a home use test.
  • Figure 2 is a schematic illustrating a paper machine suitable for producing basesheet for toweling of the present invention.
  • Figures 3A and 3B are schematic illustrations of an emboss pattern suitable for toweling of the present invention wherein Figure 3A is the obverse (outer side) side of the towel and Figure 3B is the reverse.
  • Figure 4 presents the SAT absorbent capacity of examples of the present invention relative to their CD wet tensile strength.
  • Figure 5 presents the Sensory Softness of examples of the present invention relative to their CD wet tensile strength.
  • Figures 6 , 7 and 8 demonstrate the surprising effect of embossing and caliper upon absorbency.
  • Toweling of the present invention is both extremely heavy and is perceived as extremely soft when compared to the best of currently available offerings, even though it can be manufactured from distinctly non-premium furnish using high levels of fabric crepe combined with low reel crepe. High levels of absorbency can be maintained as softeners are not required to achieve extreme softness.
  • Figure 1 illustrates the performance of two grades of toweling of the present invention (heavy, soft and heavy, strong) as compared to the current market leading brand designated "B" in home use testing by consumers against a wide variety of toweling. It is considered extremely significant that both embodiments far surpass the current market leading brand in almost every category.
  • Toweling of the present invention can be produced on conventional through-air dried machines incorporating a twin wire former as shown in Figure 2 in which furnish supplied through head box 20 is directed in a jet into the nip formed between forming fabric 24 and transfer fabric 28 as they pass between forming roll 32 and breast roll 36 as forming fabric 24 and transfer fabric 28 translate in continuous loops diverging after passing between forming roll 32 and breast roll 36.
  • transfer fabric 28 passes through dewatering zone 40 in which suction boxes 44 remove moisture from the web and transfer fabric 28 increasing the consistency of the web to perhaps 10 to 25% prior to transfer of the web to through drying fabric 48.
  • low grade fiber may be used to produce toweling of the present invention, the furnish comprising about 20 to 50% by weight of short high freeness cellulosic fiber and up to about 80% of relatively coarse high freeness long fiber having a coarseness (C) of at least about 15.5 mg/100 m.
  • the weight percent of short high freeness cellulosic fiber is preferably from about 30% to 45% and more preferably is about 35% to 45%. It is generally disadvantageous to apply more than light refining to either component of the furnish.
  • the freeness (CSF) of the short fiber component should be at least 500 ml while the freeness of the long fiber component should be above 600 ml.
  • Fiber lengths, and proportions should be controlled such that the weight weighted average fiber length (l z ) of the furnish is at least about 2.2 mm, preferably above 2.3, more preferably above about 2.4, and most preferably above 2.5, with the ratio of coarseness to weight weighted average fiber length (C/l z ) exceeding 5.3, in contrast to current market leading brands having lower C/l z values, typically under 5.0.
  • sheets are ply bonded together using the overall emboss pattern of USP D384,210 shown in Figures 3A and 3B wherein the embodiments set out are used for the opposing sides of the sheets to form nested concentric circles on alternating sides of the two ply web with the element height and penetration being chosen such that the finished product caliper is above 6.2 mils/ 8 sheets per lb/rm of basis weight.
  • a stratified headbox wherein layers enriched in long fiber content are disposed to the exterior of the finished product.
  • the long fiber content of the layers forming the exterior of the product will comprise at least about 50%; more preferably at least about 70%; and most preferably about 80% by weight of long fiber.
  • the creping adhesive used on the Yankee cylinder is capable of cooperating with the web at intermediate moisture to facilitate transfer from the creping fabric to the Yankee and to firmly secure the web to the Yankee cylinder as it is dried to a consistency of 96% or more on the cylinder preferably with a high velocity drying hood.
  • the adhesive is preferably a hygroscopic, re-wettable, substantially non-crosslinking adhesive.
  • preferred adhesives include poly(vinyl alcohol) of the general class described in United States Patent No. 4,528,316 to Soerens et al .
  • Other suitable adhesives are disclosed in co-pending United States Published Patent Application 2005/0006040, January 13, 2005, Boettcher, et al ., Serial No.
  • Suitable adhesives are optionally provided with modifiers and so forth. It is preferred to use crosslinker sparingly or not at all in the adhesive so that in many cases the resin will be substantially non-crosslinked in use.
  • Creping adhesives may comprise and may comprise a thermosetting or non-thermosetting resin, a film-forming semi-crystalline polymer and optionally an inorganic cross-linking agent as well as modifiers.
  • the creping adhesive of the present invention may also include any art-recognized components, including, but not limited to, organic cross linkers, hydrocarbons oils, surfactants, or plasticizers.
  • Creping modifiers which may be used include a quaternary ammonium complex comprising at least one non-cyclic amide.
  • the quaternary ammonium complex may also contain one or several nitrogen atoms (or other atoms) that are capable of reacting with alkylating or quatemizing agents.
  • These alkylating or quatemizing agents may contain zero, one, two, three or four non-cyclic amide containing groups.
  • An amide containing group is represented by the following formula structure: where R 7 and R 8 are non-cyclic molecular chains of organic or inorganic atoms.
  • Preferred non-cyclic bis-amide quaternary ammonium complexes can be of the formula: where R 1 and R 2 can be long chain non-cyclic saturated or unsaturated aliphatic groups; R 3 and R 4 can be long chain non-cyclic saturated or unsaturated aliphatic groups, a halogen, a hydroxide, an alkoxylated fatty acid, an alkoxylated fatty alcohol, a polyethylene oxide group, or an organic alcohol group; and R 5 and R 6 can be long chain non-cyclic saturated or unsaturated aliphatic groups.
  • the modifier is present in the creping adhesive in an amount of from about 0.05% to about 50%, more preferably from about 0.25% to about 20%, and most preferably from about 1% to about 18% based on the total solids of the creping adhesive composition.
  • Modifiers include those obtainable from Goldschmidt Corporation of Essen, Germany, or Process Application Corporation based in Washington Crossing, PA.
  • Appropriate creping modifiers from Goldschmidt Corporation include, but are not limited to, VARISOFT ® 222LM, VARISOFT ® 222, VARISOFT ® 110, VARISOFT ® 222LT, VARISOFT ® 110 DEG, and VARISOFT ® 238.
  • Appropriate creping modifiers from Process Application Corporation include, but are not limited to, PALSOFT 580 FDA or PALSOFT 580C.
  • creping modifiers for use in the present invention include, but are not limited to, those compounds as described in WO/01/85109 , which is incorporated herein by reference in its entirety.
  • Creping adhesives for use according to the present invention include any art recognized thermosetting or non-thermosetting resin.
  • Resins according to the present invention are preferably chosen from thermosetting and non-thermosetting polyamide resins or glyoxylated polyacrylamide resins.
  • Polyamides for use in the present invention can be branched or unbranched, saturated or unsaturated.
  • Polyamide resins for use in the present invention may include polyaminoamide-epichlorohydrin (PAE) resins of the same general type employed as wet strength resins.
  • PAE resins are described, for example, in " Wet-Strength Resins and Their Applications," Ch. 2, H. Espy entitled Alkaline-Curing Polymeric Amine-Epichlorohydrin Resins , which is incorporated herein by reference in its entirety.
  • Preferred PAE resins for use according to the present invention include a water-soluble polymeric reaction product of an epihalohydrin, preferably epichlorohydrin, and a water-soluble polyamide having secondary amine groups derived from a polyalkylene polyamine and a saturated aliphatic dibasic carboxylic acid containing from about 3 to about 10 carbon atoms.
  • non-thermosetting cationic polyamide resins can be found in United States Patent No. 5,338,807, issued to Espy et al . and incorporated herein by reference.
  • the non-thermosetting resin may be synthesized by directly reacting the polyamides of a dicarboxylic acid and methyl bis(3-aminopropyl)amine in an aqueous solution, with epichlorohydrin.
  • the carboxylic acids can include saturated and unsaturated dicarboxylic acids having from about 2 to 12 carbon atoms, including for example, oxalic, malonic, succinic, glutaric, adipic, pilemic, suberic, azelaic, sebacic, maleic, itaconic, phthalic, and terephthalic acids. Adipic and glutaric acids are preferred, with adipic acid being the most preferred.
  • the esters of the aliphatic dicarboxylic acids and aromatic dicarboxylic acids, such as the phathalic acid, may be used, as well as combinations of such dicarboxylic acids or esters.
  • Thermosetting polyamide resins for use in the present invention may be made from the reaction product of an epihalohydrin resin and a polyamide containing secondary amine or tertiary amines.
  • a dibasic carboxylic acid is first reacted with the polyalkylene polyamine, optionally in aqueous solution, under conditions suitable to produce a water-soluble polyamide.
  • the preparation of the resin is completed by reacting the water-soluble amide with an epihalohydrin, particularly epichlorohydrin, to form the water-soluble thermosetting resin.
  • the polyamide resin may be based on DETA instead of a generalized polyamine.
  • Two examples of structures of such a polyamide resin are given below.
  • Structure 1 shows two types of end groups: a di-acid and a mono-acid based group:
  • Structure 2 shows a polymer with one end-group based on a di-acid group and the other end-group based on a nitrogen group:
  • the polyamide resin has a viscosity of from about 80 to about 800 centipoise and a total solids of from about 5% to about 40%.
  • the polyamide resin is present in the creping adhesive according to the present invention in an amount of from about 0% to about 99.5%.
  • the polyamide resin is present in the creping adhesive in an amount of from about 20% to about 80%.
  • the polyamide resin is present in the creping adhesive in an amount of from about 40% to about 60% based on the total solids of the creping adhesive composition.
  • Polyamide resins for use according to the present invention can be obtained from Ondeo-Nalco Corporation, based in Naperville, Illinois, and Hercules Corporation, based in Wilmington, Delaware.
  • Creping adhesive resins for use according to the present invention from Ondeo-Nalco Corporation include, but are not limited to, CREPECCEL ® 675NT, CREPECCEL ® 675P and CREPECCEL ® 690HA.
  • Appropriate creping adhesive resins available from Hercules Corporation include, but are not limited to, HERCULES 82-176, Unisoft 805 and CREPETROL A-6115.
  • polyamide resins for use according to the present invention include, for example, those described in United States Patent Nos. 5,961,782 and 6,133,405 , both of which are incorporated herein by reference.
  • the creping adhesive may also comprise a film-forming semi-crystalline polymer.
  • Film-forming semi-crystalline polymers for use in the present invention can be selected from, for example, hemicellulose, carboxymethyl cellulose, and most preferably includes polyvinyl alcohol (PVOH).
  • Polyvinyl alcohols used in the creping adhesive can have an average molecular weight of about 13,000 to about 124,000 daltons. According to one embodiment, the polyvinyl alcohols have a degree of hydrolysis of from about 80% to about 99.9%. According to another embodiment, polyvinyl alcohols have a degree of hydrolysis of from about 85% to about 95%. In yet another embodiment, polyvinyl alcohols have a degree of hydrolysis of from about 86% to about 90%.
  • polyvinyl alcohols preferably have a viscosity, measured at 20 degree centigrade using a 4% aqueous solution, of from about 2 to about 100 centipoise. According to another embodiment, polyvinyl alcohols have a viscosity of from about 10 to about 70 centipoise. In yet another embodiment, polyvinyl alcohols have a viscosity of from about 20 to about 50 centipoise.
  • polyvinyl alcohol it is present in the creping adhesive in an amount of from about 10% to 90% or 20% to about 80%. In some embodiments, the polyvinyl alcohol is present in the creping adhesive in an amount of from about 40% to about 60%, by weight, based on the total solids of the creping adhesive composition.
  • Polyvinyl alcohols for use according to the present invention include those obtainable from Monsanto Chemical Co. and Celanese Chemical. Appropriate polyvinyl alcohols from Monsanto Chemical Co. include Gelvatols, including, but not limited to, GELVATOL 1-90, GELVATOL 3-60, GELVATOL 20-30, GELVATOL 1-30, GELVATOL 20-90, and GELVATOL 20-60. Regarding the Gelvatols, the first number indicates the percentage residual polyvinyl acetate and the next series of digits when multiplied by 1,000 gives the number corresponding to the average molecular weight.
  • the creping adhesive may also comprise one or more inorganic cross-linking salts or agents.
  • Such additives are believed best used sparingly or not at all in connection with the present invention.
  • a non-exhaustive list of multivalent metal ions includes calcium, barium, titanium, chromium, manganese, iron, cobalt, nickel, zinc, molybdenium, tin, antimony, niobium, vanadium, tungsten, selenium, and zirconium. Mixtures of metal ions can be used.
  • Preferred anions include acetate, formate, hydroxide, carbonate, chloride, bromide, iodide, sulfate, tartrate, and phosphate.
  • zirconium salt for use according to one embodiment of the present invention can be chosen from one or more zirconium compounds having a valence of plus four, such as ammonium zirconium carbonate, zirconium acetylacetonate, zirconium acetate, zirconium carbonate, zirconium sulfate, zirconium phosphate, potassium zirconium carbonate, zirconium sodium phosphate, and sodium zirconium tartrate.
  • Appropriate zirconium compounds include, for example, those described in United States Patent No. 6,207,011 , which is incorporated herein by reference.
  • the inorganic cross-linking salt can be present in the creping adhesive in an amount of from about 0% to about 30%. In another embodiment, the inorganic cross-linking agent can be present in the creping adhesive in an amount of from about 1% to about 20%. In yet another embodiment, the inorganic cross-linking salt can be present in the creping adhesive in an amount of from about 1% to about 10% by weight based on the total solids of the creping adhesive composition.
  • Zirconium compounds for use according to the present invention include those obtainable from EKA Chemicals Co. (previously Hopton Industries) and Magnesium Elektron, Inc. Appropriate commercial zirconium compounds from EKA Chemicals Co. are AZCOTE 5800M and KZCOTE 5000 and from Magnesium Elektron, Inc. are AZC or KZC.
  • the creping adhesive according to the present invention can include any other art recognized components, including, but not limited to, organic cross-linkers, hydrocarbon oils, surfactants, amphoterics, humectants, plasticizers, or other surface treatment agents.
  • organic cross-linkers includes glyoxal, maleic anhydride, bismaleimide, bis acrylamide, and epihalohydrin.
  • the organic cross-linkers can be cyclic or non-cyclic compounds.
  • Plastizers for use in the present invention can include propylene glycol, diethylene glycol, triethylene glycol, dipropylene glycol, and glycerol.
  • the creping adhesive may be applied as a single composition or may be applied in its component parts. More particularly, the polyamide resin may be applied separately from the polyvinyl alcohol (PVOH) and the modifier.
  • PVOH polyvinyl alcohol
  • Basis weight refers to the weight of a 3000 square foot ream of product in pounds.
  • percent or like terminology refers to weight percent on a dry basis, that is to say, with no free water present, which is equivalent to 5% moisture in the fiber.
  • the simple absorbency tester is a particularly useful apparatus for measuring the hydrophilicity and absorbency properties of a sample of tissue, napkins, or towel.
  • a sample of tissue, napkins, or towel 2.0 inches in diameter is mounted between a top flat plastic cover and a bottom grooved sample plate.
  • the tissue, napkin, or towel sample disc is held in place by a 1/8 inch wide circumference flange area.
  • the sample is not compressed by the holder.
  • De-ionized water at 73°F. is introduced to the sample at the center of the bottom sample plate through a 1 mm diameter conduit. This water is at a hydrostatic head of minus 5 mm.
  • Flow is initiated by a pulse introduced at the start of the measurement by the instrument mechanism. Water is thus imbibed by the tissue, napkin, or towel sample from this central entrance point radially outward by capillary action. When the rate of water imbibation decreases below 0.005 gm water per 5 seconds, the test is terminated. The amount of water removed from the reservoir and absorbed by the sample is weighed and reported as grams of water per square meter of sample or grams of water per gram of sheet. In practice, an M/K Systems Inc. Gravimetric Absorbency Testing System is used. This is a commercial system obtainable from M/K Systems Inc., 12 Garden Street, Danvers, Mass., 01923.
  • WAC water absorbent capacity
  • SAT water absorbent capacity
  • WAC is actually determined by the instrument itself
  • WAC is defined as the point where the weight versus time graph has a "zero" slope, i.e., the sample has stopped absorbing.
  • the termination criteria for a test are expressed in maximum change in water weight absorbed over a fixed time period. This is basically an estimate of zero slope on the weight versus time graph.
  • the program uses a change of 0.005 g over a 5 second time interval as termination criteria; unless "Slow SAT" is specified in which case the cut off criteria is 1 mg in 20 seconds.
  • Water absorbency rate is measured in seconds and is the time it takes for a sample to absorb a 0.1 gram droplet of water disposed on its surface by way of an automated syringe.
  • the test specimens are preferably conditioned at 23°C ⁇ 1 °C (73.4°F ⁇ 1.8°F.) at 50% relative humidity.
  • 4 3X3 inch test specimens are prepared. Each specimen is placed in a sample holder such that a high intensity lamp is directed toward the specimen. 0.1 ml of water is deposited on the specimen surface and a stop watch is started. When the water is absorbed, as indicated by lack of further reflection of light from the drop, the stopwatch is stopped and the time recorded to the nearest 0.1 seconds. The procedure is repeated for each specimen and the results averaged for the sample.
  • SAT Rate is determined by graphing the weight of water absorbed by the sample (in grams) against the square root of time (in seconds). The SAT rate is the best fit slope between 10 and 60 percent of the end point (grams of water absorbed).
  • Dry tensile strengths (MD and CD), stretch, ratios thereof, break modulus, stress and strain are measured with a standard Instron test device or other suitable elongation tensile tester which may be configured in various ways, typically using 3 or 1 inch wide strips of tissue or towel, conditioned at 50% relative humidity and 23°C (73.4°F), with the tensile test run at a crosshead speed of 2 in/min for modulus, 10 in/min for tensile.
  • inch wide specimens were pulled at 0.5 inches per minute so that a larger number of data points were available.
  • stretch refers to stretch (elongation) at break. Break modulus is the ratio of peak load to stretch at peak load.
  • Tensile modulus reported in grams per inch per percent strain, is determined by the same procedure used for tensile strength except that the modulus recorded is the geometric mean of the chord slopes of the cross direction and machine direction load-strain curves from a value of 0 to 100 grams, and a sample width of only one inch is used.
  • GMT refers to the geometric mean tensile strength of the CD and MD tensile.
  • Tensile energy absorption (TEA) is measured in accordance with TAPPI test method T494 om-01.
  • Initial MD modulus refers to the maximum MD modulus below 5% strain.
  • the Finch cup method uses a three-inch wide strip of tissue that is folded into a loop, clamped in the Finch Cup, then immersed in a water.
  • the Finch Cup which is available from the Thwing-Albert Instrument Company of Philadelphia, Pa., is mounted onto a tensile tester equipped with a 2.0 pound load cell with the flange of the Finch Cup clamped by the tester's lower jaw and the ends of tissue loop clamped into the upper jaw of the tensile tester.
  • the sample is immersed in water that has been adjusted to a pH of 7.0. ⁇ 0.01 and the tensile is tested after a 5 second immersion time.
  • the indicated load reading should be divided by two to reflect the intrinsic properties of the sheet.
  • wet or dry tensile ratios are simply ratios of the values determined by way of the foregoing methods. Unless otherwise specified, a tensile property is a dry sheet property.
  • the void volume and /or void volume ratio as referred to hereafter, are determined by saturating a sheet with a nonpolar liquid and measuring the amount of liquid absorbed.
  • the volume of liquid absorbed is equivalent to the void volume within the sheet structure.
  • the percent weight increase (PWI) is expressed as grams of liquid absorbed per gram of fiber in the sheet structure times 100, as noted hereinafter. More specifically, for each single-ply sheet sample to be tested, select 8 sheets and cut out a 1 inch by 1 inch square (1 inch in the machine direction and 1 inch in the cross-machine direction). For multi-ply product samples, each ply is measured as a separate entity. Multiple samples should be separated into individual single plies and 8 sheets from each ply position used for testing.
  • the PWI for all eight individual specimens is determined as described above and the average of the eight specimens is the PWI for the sample.
  • the void volume ratio is calculated by dividing the PWI by 1.9 (density of fluid) to express the ratio as a percentage, whereas the void volume (gms/gm or g/g) is simply the weight increase ratio; that is, PWI divided by 100.
  • Fiber lengths and coarseness incorporated herein are determined using the HiRes Fiber Quality Analyzer manufactured by OpTest Equipment, Inc of Hawksbury, Ontario Canada.
  • Subjective product attributes are often best evaluated using test protocols in which a consumer uses and evaluates a product.
  • a consumer will use a single product and evaluate its characteristics using a standard scale.
  • paired comparison tests the consumers are given samples of two different products and asked to rate each vis-à-vis the other for either specific attributes or overall preference.
  • Sensory softness is a subjectively measured tactile property that approximates consumer perception of sheet softness in normal use. Softness is usually measured by 20 trained panelists and includes internal comparison among product samples. The results obtained are statistically converted to a useful comparative scale.
  • Fpm refers to feet per minute while consistency refers to the weight percent fiber of the web.
  • a nascent web of 10 percent consistency is 10 weight percent fiber and 90 weight percent water.
  • Aggregate Crepe Ratio Forming Fabric Speed / Reel Speed
  • Aggregate Crepe , percent Aggregate Crepe Ratio - 1 ⁇ 100 % .
  • the Aggregate Crepe is indicative of the final MD stretch found in sheets made with this process.
  • PLI or pli means pounds force per linear inch.
  • Velocity delta means a difference in speed
  • indentation Pusey and Jones hardness (indentation) is measured in accordance with ASTM D 531, and refers to the indentation number (standard specimen and conditions).
  • Calipers reported herein are 8-sheet calipers unless otherwise indicated.
  • the sheets are stacked and the caliper measurement taken about the central portion of the stack.
  • the test samples are conditioned in an atmosphere of 23° ⁇ 1.0°C (73.4° ⁇ 1.8°F) at 50% relative humidity for at least about 2 hours and then measured with a Thwing-Albert Model 89-II-JR or Progage Electronic Thickness Tester with 2-in (50.8-mm) diameter anvils, 539 ⁇ 10 grams dead weight load, and 0.231 in./sec descent rate.
  • each sheet of product to be tested must have the same number of plies as the product is sold.
  • base sheet testing off of the paper machine reel single plies are used with eight sheets being selected and stacked together. Specific volume is determined from basis weight and caliper.
  • Towel base sheets were produced on a TAD paper machine having the configuration shown in Figure 2 .
  • the base sheets were produced using a furnish containing sixty percent Southern SWK and forty percent Southern HWK.
  • the base sheet also contained broke in amounts ranging from seventeen to twenty-five percent of the total furnish.
  • the sheets were produced using a three-layered head box with the layer that contacted the Yankee dryer comprised of 100% SWK.
  • the sheet was shaped on a Voith 44G TAD fabric having a standard warp and a contact area of eighteen percent. Refining was used to control the dry strength of the base sheets, while wet strength and wet/dry ratio was produced by addition of a polyaminoamide epichlorohydrin permanent wet strength resin and carboxymethylcellulose to the wet end.
  • Hercules Prosoft TQ-456 an imidazolinium-based debonder containing a poly-propylene glycol oleate was added to wet end during manufacture of one of the towel base sheets in the amount of 5.5 lbs/ton.
  • the sheets were creped at a fabric crepe of 18 to 20 percent, while the reel crepe ranged from -0.3 to 0.2 percent.
  • the sheets were creped from the Yankee dryer using a creping blade having a blade of twenty degrees.
  • the base sheets were dried to about 80 percent solids on the through-dryer while the reel moisture was controlled to a value of between 2.0 and 2.5 percent.
  • the physical properties of the base sheets are shown in Tablel-1.
  • the base sheets were converted to finished product by embossing them using the emboss pattern shown in Figures 3A and 3B .
  • the finished product properties are shown in Table 2-2.
  • the physical properties of competitive product "V”, a high-weight double-recreped product are also shown. In consumer tests, this product has received the highest scores for overall performance and for most important attribute ratings of any commercially- available product in our experience.
  • Premium 2-ply TAD towel basesheets were produced having two CD wet strength targets (i.e., 470 g/3" and 740 g/3") with two levels of basis weight (17.7 lb/rm and 19.3 lb/rm).
  • Webs were formed using 60% pine, 40% hardwood plus 30% broke, base sheet strength being altered by changing refining levels (i.e., pine and Yankee side layer furnishes were refined to different levels of freeness).
  • Target GM tensile strength levels for the trial were: 1600 g/3" & 2700 g/3" as set forth in Table 2-1.
  • Table 2-2 gives the detailed process conditions used to make the base sheets. As can be seen from the table, for one of the prototypes, the addition of debonder was required in order to obtain the desired physical properties. No debonder was needed to produce the other base sheets. The base sheet physical properties are shown in Table 2-3. Table 2-2 Paper Machine Process Conditions Used to Make Super Premium TAD Towel Base Sheets Trial Cell ID Q-1 Q-2 Q-3 Q-4 Prototype Description Low str Med wt Low str High wt. High str Med wt.
  • the target GM tensile strength levels for the trial were: 1640 g/3" (Low Tensile Strength) and 2200 g/3" (Medium Tensile Strength).
  • Table 3-1 Super Premium TAD Towel Basesheet Factors Levels Target Furnish 60%-Pine / 40%-Hardwood / 30%-Broke Refining Pine refiner varied to control strength Yankee layer tickler refiner varied to control strength Wet Strength Resin (Amres) ⁇ 13.3 lb/ton Dry Strength Resin (CMC) ⁇ 2.7 lb/ton Wet End Softener (Hercules TQ-456) None. Fabric Crepe Level 16 to 19% TAD Fabric Style Voith 44G, standard warp at 18% contact area TAD Spray Release ⁇ 60 mg/m 2 Post TAD No.
  • Table 3-2 gives the detailed process conditions used to make the four basesheets.
  • Table 3-3 gives the detailed physical property data for the basesheets made during the trial.
  • Table 3-2 Paper Machine Process Conditions Used to Make Super Premium TAD Towel Basesheets Table Trial Cell ID R-1 R-2 R-3 R-4 Prototype Description 16.2 lb/rml Medium Strength 16.2 lb/rm/ Low Strength 17.7 lb/rm/ Medium Strength 19.3 lb/rm/ Medium Strength Rush/Drag, fpm 304 300 300 300 Fabric Crepe, % 16.0 16.0 18.0 18.0 Pine/HardwoodBroke, % 60/40/30 60/40/30 60/40/30 60/40/30 Yankee Layer: Pine/HWBroke, % 100/0/0 100/0/0 100/0/0 100/0/0 Middle Layer: Pine/HWBoke, % 0/9/91 0/9/91 0/9/91 Air Layer: Pine/HWBroke, % 26/
  • the trial prototypes were produced on a commercial towel winder using the nested emboss pattern shown in Figures 3A and 3B . Emboss penetration was adjusted to produce a product having a caliper of approximately 240 mils/8 sheets. The same emboss settings were used to produce all seven trial prototypes. Roll diameter was not controlled; however all trial prototypes had diameters of approximately 5.3 inches. The winding tension was set to deliver rolls having a compression of approximately seven percent. The trial products were produced at a speed of 1000 fpm. The settings for the converting line are shown in Table 4-1.
  • one of the base sheets (Q1) was converted to finished product at a sheet length of 10 inches.
  • the towel products were tested for standard physical properties while sensory softness was measured by a trained panel. The results of these tests are shown in Table 4-2.
  • Prototype base sheets for premium 2-ply TAD towels were prepared having different levels of strength and softness to be used in forming prototype finished premium 2-ply TAD towel having superior softness as well as more easily measured physical attributes (such as thickness, strength and absorbency) for evaluation in home-use testing against Bounty®, a leading competitive TAD product made from a premium furnish having a basis weight of 27.5 lb/rm with 40% eucalyptus.
  • Prototypes were manufactured at 36 lb/rm in low and intermediate strengths. 36 lb/rm prototypes were prepared, at a moderate wet strength level (CDWT ⁇ 550-600 g/3") and a stronger variant at (CDWT ⁇ 650-700 g/3"). After converting the basesheets were used to prepare 56-count ⁇ 5.3" diameter rolls of standard kitchen roll towel width of 11.0".
  • the prototypes were produced using an Albany 44G - standard warp through-drying fabric at 17.9% contact area. The jet-to-wire ratio was adjusted to maintain an MD/CD Tensile Ratio of about 1.0. After the machine was stabilized, the basis weight and refining were adjusted to produce a 19.3 lb/rm basesheet at a strength level of 475 g/3" CDWT. Thereafter, the basis weight and refining were adjusted to produce a 19.3 lb/rm basesheet at a strength level of 560 g/3" CDWT.
  • Polyaminoamide epichlorohydrin permanent wet strength resin and carboxymethylcellulose were added in the wet-end at levels adjusted as needed to achieve the desired basesheet tensile strength and wet/dry ratio targets.
  • Headbox pH was maintained at 7 to 8 while headbox charge was monitored to insure that the charge is between 0 and -0.30 ml of 10-3 N titer/10 ml solution (-0.030 meq per ml) to ensure that wet strength resin retention was acceptable.
  • Hercules TQ-456 an imidazolinium-based debonder containing a poly-propylene glycol oleate was added to the outlet of the middle and air-side blend chest pumps to achieve an improved wet-over-dry tensile level.
  • refining was adjusted to produce a basesheet with a CDWT level of strength approximately 550 g/3".
  • line crepe approximately fabric crepe plus reel crepe
  • the basesheets were dried to about 85% solids on the through-dryer while the reel moisture was maintained at less than about 3.0%.
  • Basesheets having the properties set forth in Table 5-2 were produced: Table 5-2 Base Sheet Physical Properties Base Sheet ID S2 S3 S4 Used in Prototypes W855.1 W856.1 W856.2 W857.1 Basis Weight (lbs/ream) 19.42 19.66 19.54 Caliper (mils/8 sheets) 117.5 116.6 116.5 MD Tensile (g/3") 1631 1936 1754 CD Tensile (g/3") 1718 1958 1693 GM Tensile (g/3") 1673 1945 1722 MD Stretch (%) 28.7 29.6 28.8 CD Stretch (%) 7.4 7.4 7.2 CD Wet Tensile - Finch (g/3") 462 564 544 CD Wet/Dry - Finch (%) 26.9 28.8 32.1 SAT Capacity (g/sq meter) 631 641 598 SAT Capacity (g/g) 10.0 10.0 9.4 SAT Rate (g/sec 0.5 ) 0.32 0.34 0.22 GM Break Modulus (g/%) 115.3 131.4 119.9
  • TAD towel prototypes were produced from three trial base sheets S2, S3 and S4 as described above at 56 sheet count in a sheet length of 10.5 inches.
  • the S3 base sheet was also converted to a product having a sheet length of 11.0 inches.
  • the trial prototypes were produced using the nested Emboss pattern shown in Figures 3A and 3B using new rubber backing and marrying rolls having hardnesses of 60 - 62 Shore A, and 90 - 95 Shore A, respectively.
  • the converting line's feed rolls were set at gaps of 35 mils. Emboss penetration was increased until the targeted caliper of approximately 240 mils/8 sheets was obtained.
  • the emboss settings as shown in Table 5-3 were used to produce finished product rolls at a speed of 1200 fpm. Products produced from the S3 higher-strength base sheet had higher-than-expected wet tensile values, due to lower-than-expected breakdowns during the embossing process.
  • Table 5-3 Emboss Roll Settings Roll Emboss Nip Width (inches) Upper Emboss 1.25 Lower Emboss 1.625 Marrying 0.50
  • Two base sheets were produced in a similar manner to that described in Example 2 from a furnish made up of 70% SWK, 30% HWK that included 30% Broke.
  • the layer next to the Yankee dryer contained 100% SWK; the other base sheet had a Yankee-side layer composed of a 50/50 blend of SWK and HWK.
  • the base sheet physical properties are shown in Table 8-1.
  • Table 8-4 Product Physical Properties Yankee Layer Stratification 100% SWK 50/50 SWK/ HWK Basis Weight (lbs/ream) 37.11 36.40 Caliper (mils/8 sheets) 228.7 227.1 MD Tensile (g/3") 2680 2825 CD Tensile (g/3") 2047 2297 GM Tensile (g/3") 2341 2546 Tensile Ratio 1.31 1.23 MD Stretch (%) 18.6 16.7 CD Stretch (%) 8.0 8.2 CD Wet Tensile - Finch (g/3") 609 638 CD Wet/Dry - Finch (%) 29.8 27.8 Perf Tensile (g/3") 936 1068 SAT Capacity (g/sq meter) 545 520 SAT Capacity (g/g) 9.02 8.78 SAT Rate (g/sec ⁇ 0.5) 0.25 0.23 GM Break Modulus (g/%) 192.0 216.5 GM Tensile Modulus (g/in/%)
  • a towel base sheet was produced on a TAD paper machine in a manner similar to that described in Example 2.
  • the overall furnish was composed of a 70/30 blend of SWK/HWK and included 30% broke.
  • the physical properties of the base sheet are shown in Table 9-1.
  • Table 9-1 Base Sheet Physical Properties Basis Weight (lbs/ream) 19.73 Caliper (mils/8 sheets) 114.2 MD Tensile (g/3") 1602 CD Tensile (g/3") 1694 GM Tensile (g/3") 1645 Tensile Ratio 0.95 MD Stretch (%) 23.3 CD Stretch (%) 6.6 CD Wet Tensile - Finch (g/3") 441 CD Wet/Dry - Finch (%) 26.0 SAT Capacity (g/sq meter) 603 SAT Capacity (g/g) 9.40 SAT Rate (g/sec ⁇ 0.5) 0.26 GM Break Modulus (g/%) 134.1 GM Tensile Modulus (g/in/%) 35.3
  • the base sheet was embossed using the emboss pattern shown in Figures 3A and 3B . Finished products were produced at four levels of emboss, as shown in Table 9-2.
  • Table 9-2 Emboss Nip Widths - Penetration Curve Samples Marrying Roll (all cells) 5/8 inch Condition 1A Upper Embosser 1-13/16 inch Lower Embosser 1-13/16 inch Condition 1B Upper Embosser 1-15/16 inch Lower Embosser 1-15/16 inch Condition 1C Upper Embosser 1-5/8 inch Lower Embosser 1-3/4 inch Condition 1D Upper Embosser 1-1/2 inch Lower Embosser 1-11/16 inch

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US8080130B2 (en) * 2008-02-01 2011-12-20 Georgia-Pacific Consumer Products Lp High basis weight TAD towel prepared from coarse furnish
US8834677B2 (en) * 2013-01-31 2014-09-16 Kimberly-Clark Worldwide, Inc. Tissue having high improved cross-direction stretch
US20150129145A1 (en) * 2013-11-14 2015-05-14 Georgia-Pacific Consumer Products Lp Soft, absorbent sheets having high absorbency and high caliper, and methods of making soft, absorbent sheets
WO2019082031A1 (fr) * 2017-10-27 2019-05-02 Gpcp Ip Holdings Llc Procédés de fabrication de produits cellulosiques perfectionnés faisant appel à de nouveaux feutres de presse et produits fabriqués selon les procédés

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Cited By (17)

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US8080130B2 (en) * 2008-02-01 2011-12-20 Georgia-Pacific Consumer Products Lp High basis weight TAD towel prepared from coarse furnish
US8834677B2 (en) * 2013-01-31 2014-09-16 Kimberly-Clark Worldwide, Inc. Tissue having high improved cross-direction stretch
CN107142778A (zh) * 2013-11-14 2017-09-08 佐治亚-太平洋消费产品有限合伙公司 具有高吸收性和大厚度的软吸收性片材及制造软吸收性片材的方法
US9915032B2 (en) 2013-11-14 2018-03-13 Gpcp Ip Holdings Llc Soft, absorbent sheets having high absorbency and high caliper, and methods of making soft, absorbent sheets
US9303363B2 (en) * 2013-11-14 2016-04-05 Georgia-Pacific Consumer Products Lp Soft, absorbent sheets having high absorbency and high caliper, and methods of making soft, absorbent sheets
US9404224B2 (en) 2013-11-14 2016-08-02 Georgia-Pacific Consumer Products Lp Soft, absorbent sheets having high absorbency and high caliper, and methods of making soft, absorbent sheets
US9574306B2 (en) 2013-11-14 2017-02-21 Georgia-Pacific Consumer Products Lp Soft, absorbent sheets having high absorbency and high caliper, and methods of making soft, absorbent sheets
US9611591B2 (en) 2013-11-14 2017-04-04 Georgia-Pacific Consumer Products Lp Soft, absorbent sheets having high absorbency and high caliper, and methods of making soft, absorbent sheets
US20150129145A1 (en) * 2013-11-14 2015-05-14 Georgia-Pacific Consumer Products Lp Soft, absorbent sheets having high absorbency and high caliper, and methods of making soft, absorbent sheets
WO2015073863A1 (fr) * 2013-11-14 2015-05-21 Georgia-Pacific Consumer Products Lp Feuilles absorbantes douces presentant une absorbance et une epaisseur superieures, et procedes de fabrication de feuilles absorbantes douces
US9957667B2 (en) 2013-11-14 2018-05-01 Gpcp Ip Holdings Llc Absorbent sheets having high absorbency and high caliper, and methods of making soft, absorbent sheets
US9988766B2 (en) 2013-11-14 2018-06-05 Gpcp Ip Holdings Llc Process of determining features of a papermaking fabric based on sizes and locations of knuckles and pockets in the fabric
EA031293B1 (ru) * 2013-11-14 2018-12-28 Джиписипи Айпи Холдингз Элэлси Мягкий абсорбирующий лист, имеющий высокую абсорбирующую способность и большую толщину
US10704203B2 (en) 2013-11-14 2020-07-07 Gpcp Ip Holdings Llc Absorbent sheets having high absorbency and high caliper, and methods of making soft, absorbent sheets
CN107142778B (zh) * 2013-11-14 2019-05-07 Gpcp知识产权控股有限责任公司 具有高吸收性和大厚度的软吸收性片材及制造软吸收性片材的方法
WO2019082031A1 (fr) * 2017-10-27 2019-05-02 Gpcp Ip Holdings Llc Procédés de fabrication de produits cellulosiques perfectionnés faisant appel à de nouveaux feutres de presse et produits fabriqués selon les procédés
US11098450B2 (en) 2017-10-27 2021-08-24 Albany International Corp. Methods for making improved cellulosic products using novel press felts and products made therefrom

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