MXPA98010715A - Mechanic softness of foil material - Google Patents

Abstract

Están descritos nuevos y mejorados métodos y productos relativos a la suavidad de los tejidos fibrosos. La suavidad incrementada entre otras cosas, se obtiene mediante el desgastar con rozamiento la superficie del tejido para crear vellosidad de las fibras sobresalientes.

Description

MECHANICAL SOFTENING OF LEAF MATERIAL FIELD OF THE INVENTION This invention relates to the mechanical softening of the material that is in the sheet form, such as the sheets of paper and the methods for making them. More particularly, this invention relates to tissue and towels that have an increased softness.

BACKGROUND OF THE INVENTION The type and amount of fibers that extend from a sheet have been known to affect the perceived softness of that sheet. Although, tissue sheets are mainly discussed here, it should be recognized that this invention is not limited to tissue sheets or products, but can be applied to any type of paper product, as well as to other types of material, such as to woven and non-woven fabrics, wherein the softness or the amount of the loose fibers on the surface of the product is desirable. All other factors remain the same, a tissue sheet that has more loose fibers on its surface, for example, one that is more hairy, should be perceived as being softer than a tissue sheet that has less loose fibers on its surface. By loose fibers as used herein, it is meant that one end of the fiber is not bonded to the other fibers in the tis sheet and protrudes above the bonded surface of the sheet. The desirability of increasing the number of loose fibers on the surface of a sheet to increase the perceived softness has been known. For example, U.S. Pat. No. 3,592,732 to North America describes the use of a brush to lift fibers from the surface of a tissue or towel sheet to increase its softness.

SYNTHESIS OF THE INVENTION This invention is an improvement over the prior art in the type, and the technique, of the mechanical softening and in the product that is obtained. The apparatus and techniques of the present invention provide an improvement in speed production efficiency. In one embodiment, a new tissue product is also provided which has fibers selectively highlighted on only a portion of the sheet surface. Such a tissue product can be obtained by using the apparatus and eroding techniques on a tissue dried through non-creped air, such as those described in U.S. Patent No. 5,607,551 and in the application for copendent patent of the United States of America series number 08 / 310,186 filed on September 21, 1994, the descriptions of which are incorporated herein by reference.

In one embodiment of the invention, it provides a soft tissue product having an increased surface villi formed by abrading a tissue product comprising one or more tissue layers and having a Max tilt in the machine direction of about 10%. 10 or less.

In an alternate embodiment of the invention, it provides a soft tissue product having an increased surface villi formed by abrading a non-creped continuously dried fabric comprising at least about 10 percent by dry weight of fibers. of high performance pulp and a wet geometric head tension: dry ratio of around 0.1 higher.

In an alternate embodiment of the invention s provides a soft tissue sheet comprising: a first surface and a second surface; each surface comprises fibers for making paper; and at least one of the surface has selectively freed areas of fibers for making paper.

In an alternate embodiment of the invention, it provides a soft paper product comprising: a first layer and a second layer, the layers each comprising fibers for making paper; a first and a second surface, the first surface corresponds to the surface of the first cap and the second surface corresponds to the surface of the second layer; and, at least one of the surfaces has the fibers released thereon.

In an alternate embodiment of the invention, it provides a smooth sheet product having a tensile strength in the machine direction of at least about 1,000 grams per 3 inches and a tensile strength in the direction transverse to the machine of at least about 800 grams per 3 inches and comprising: a first surface, a second surface, each surface comprises fibers; and, at least one of the surfaces has the fibers essentially loose thereon.

In an alternate embodiment of the invention, it provides a sheet of paper having an improved d absorbency rate comprising a first sheet surface and a second sheet surface; a layer comprising paper-making fibers; the layer having a surface; the surface of the layer corresponds to a surface of the sheet of paper; The surface of the layer has fibers worn by friction; the absorbency rate of the sheet being greater than a sheet d a similar composition but not having fibers worn away by friction on its surface and the amount of absorbency for the sheet being comparable to a similar sheet without worn out friction.

In an alternate embodiment of the invention, a soft paper product comprising a layer is provided; the layer comprises long papermaking fibers; the layer has a surface; the surface has a PR / EL of more than about 0.72, or greater than about 1, and in which the surface layer has at least about 20 percent of the fields of view having a ratio of PR / EL around 2 or higher.

In a further embodiment of the present invention there is provided a method for making a sheet product having improved softness comprising obtaining a fabric of fibrous material in sheet form by feeding the fabric into a friction wear apparatus comprising: pressure device; a backup roller; a wear roller; and the frictional wear of the surface of the fabric with the roller to wear with friction.

In an alternate embodiment of the invention there is provided a method for treating a paper web comprising: feeding a paper web comprising fibers for making paper into a pressure point formed by a first and a second roller; the pressure point applies pressure to the tissue to hold the tissue against the second roller; the tissue partially envelops and moves around and with the second roller; a third roller that makes contact with the tissue while the tissue is against the second roller and the third roller has a rough surface; and the third roller rotates while in contact with the fabric to release the fibers or the surface of the fabric.

In an alternate embodiment of the invention, it provides a method for treating a paper web comprising: obtaining paper web comprising fibers for making paper; put the tissue paper in contact with a first roller; hold the fabric against the first roller; and tissue partially wraps and moves around and with the first roller; a second roller that makes contact with the fabric while the fabric is in contact against the first roller, the second roller has a rough surface; and, the second roller rotates while in contact with the fabric to release the fibers on the surface of the fabric.

In yet another additional embodiment of the present invention there is provided an apparatus for treating fibrous material fabrics comprising: a first roller; a second roller; a tensioning device; a frame to hold the rollers and the device in a set relationship; the tensioning device placed on one side of the first roller; the second roller positioned near the first roller, and set at a distance of from about 0.006 inches to about 0.008 inches from the first roller; and the second roller has a friction wearing surface of sufficient roughness to release the fibers, only on the surface of the fabric being treated.

Mechanically softening by abrading the surface of a tissue sheet improves the feel of the sheet as perceived by the consumer or the end user. The wear by friction works the surface of the sheet causing a partial disunion of the surface fibers giving rise to ends of loose fibers on its surface but without reducing the central strength of the sheet. Some potential advantages that can be obtained by frictionally abrading a tissue sheet including: 1) improve the perception of the product by the client in the tact and in the use for a given sheet; 2) reduce chemical costs by reducing the amount of chemical debonders required in the tissue and particularly in the outer layer of the multi-layer tissue; 3) reducing fiber costs including a reduction in the use of higher cost fiber processing, such as crimpable fibers; 4) improve the resistance for a given perceived smoothing; ) reducing the sides in a tissue of one layer or other tissues of a layer; 6) reduce calendering loading pressures which will allow less volume reduction of the tissue during fabrication; Y 7) Improve the absorbency rate.

DRAWINGS Figure 1 is a diagram of a friction wear device and the flow process showing the wear roller with friction and the blade moving in the same direction.

Figure 2 is a diagram of an alternate incorporation of a friction wear apparatus and a flow process showing the wear roller with abrasion and a moving blade in opposite directions.

Figure 3 is a diagram of an alternate incorporation of a friction wear apparatus and a flow process to abrade prior to calendering.

Figure 4 is a photograph at a 40x magnification of a contemporary only calendered tissue that has not been softened by the invention, and having an average PR / EL of 0.71.

Figure 5 is a graph representing data in graphic form.

Figure 6 is a graph representing in graphic form data, Figure 7 is a graph representing data in graphic form.

Figure 8 is a graph representing data in graphic form.

Figure 9 is a graph representing graphically data, Figure 10 is a graph representing graphically data, Figure 11 is a graph representing graphically data.

Figure 12 is a graph representing graphically data.

Figure 13 is a graph representing graphically data.

Figure 14 is a graph representing graphically data.

Figure 15 is a graph representing graphically data.

Figure 16 is a graph representing graphically data.

Figure 17 is a graph representing graphically data, Figure 18 is a diagram of an alternate incorporation of a friction wear apparatus and a flow process.

Figure 19 is a schematic of the friction wear unit of Figure 18.

Figure 20 is a photograph at a 40x magnification of a tissue dried through non-creped and mechanically smoothed air that was worn with friction on the air side only at a rate of wear with friction of 1.5, a tissue velocity of 2,200 feet per minute, a gap of 0.006 inches, and a wear roller roughness with friction of 250 Ra, and having an average PR / EL of 2.44.

Figure 21 is a photograph of a 40x amplification of a tissue dried through mechanically smoothed uncreped air that was worn with friction on the air side only at a friction wear ratio of 2.0, a weaving speed of 1,000 feet per minute, a gap of 0.012 inches, and a wear roller roughness with friction of 250 Ra, and having an average PR / EL of 3.60.

DETAILED DESCRIPTION OF THE CURRENTLY PREFERRED INCORPORATIONS OF THE INVENTION Generally, in the apparatus used to mechanically soften a sheet, the sheet was controlled by a back-up assembly having a back-up roll positioned opposite a friction wear roll. This assembly holds the blade while friction wear occurs, thereby reducing stresses in the blade up and down the wear roller with friction. So. the blade remains stable and is restricted while it is being worn with friction so that the force can be brought to the surface of the blade and so that the entry of the blade force is independent of the strength and level of the blade. stretching of the leaf.

Mechanical softening by wear and tear can be done on any type and material of the sheet, such as the sheets of paper that will be used for the facial tissue, for the body tissue, for the towels, the hand towels and cleaning cloths. . In addition, the paper sheet can be made of long paper fibers (soft wood) short paper fibers (hardwood), secondary fibers, synthetic fibers, or any of these or other fibers known to those skilled in the art of making paper to be useful in papermaking. The long papermaking fibers are generally understood to have a length of about 2 millimeters or greater. Especially suitable hardwood fibers include eucalyptus and maple fibers. It is also contemplated that the sheet can have as much as 100 percent secondary fibers.

As used herein, and unless otherwise specified, the term "sheet" generally refers to any type of sheet of paper, eg, of tissue, towel or a heavier, creped or non-creped base weight product. , multiple layer or single layer, and multiple layer or single layer. It is also contemplated that this process can be used to increase the softness and the number of loose fibers over other types of sheet material such as air-laid products and natural woven synthetic products or any other fiber-based sheet material.

Generally, the process for mechanically softening the tissue sheets can run at speeds of up to 3,000 feet per minute, even though higher speeds may be possible. At a rate of 3,000 feet per minute it is generally preferred that a maximum input force to the sheet be about 17 hp for a 104 inch wide sheet of tissue paper. It is also generally preferred for work to be done on the sheet which is uniform throughout the sheet. At these speeds it is generally preferred that the volume variations of the sheet are also controlled and can be at least about 5 percent or less, to obtain the maximum benefit of this process. The blade can be worn with friction either before or after calendering and any one or both sides of the blade can be worn with friction.

Although in the examples set forth herein the abrasion is carried out as an off-machine operation, it is contemplated, and it may be preferred that the abrasion takes place on the paper making machine. Therefore, the abrading apparatus can be located between the layer and the reel of the paper machine. At this point in the process to make paper the sheet will be hot. Additionally, the humidity level will be lower than the environmental humidity levels of around 5-6% that were present in the abrasions of the machine established in the examples. It is speculated that both lower humidity and increased temperature can cause the fiber surfaces to loosen more easily. Also if a waterproof fabric could be used, bringing the sheet to the abrasion pressure point, such as the backrest, instead of or in conjunction with a rubber-backed backing roller., the pressure point with abrasion would no longer be present. The higher abrasion pressure point will give the blade more dwell time and will more likely result in either lower clamping point pressures or lower velocity differences for the same results. Therefore, with a judicious placement of the rolls under the fabric, and an adequate selection of the fabric tension, the pressure point can be extended, further extended by a substantial amount.

In another configuration of the abrasion on the machine, the abrasion apparatus will be located on the reel. In this configuration the abrasion roller will go over the winding cart, with a controlled pressure. The sheet will be placed in a place by virtue of being part of the roll of paper that is forming on the reel. Thus, the reel drum will function as the pressure point roller and the winding roller as the backup roller for the abrasion apparatus. In addition, this configuration can be combined with the configuration where the abrasion apparatus is located between the dryer and the reel. Therefore, allowing both sides of the blade to be worn with friction on the machine.

Preferably the dust levels must also be controlled to maintain acceptable levels of cleanliness and operator health. It is generally preferred that the process be designed so that the operating cost is in the range of about a couple of dollars per ton.

Generally, to obtain the maximum benefits of mechanical smoothing, the sheet before abrasion can have a thickness of at least about 0.010 inches and, a resistance in the machine direction of at least 750 grams / 3 inches. , and a stretch in the machine direction of at least 12 percent. The resistance in the direction of the machine and in the direction transverse to the machine are the resistance to tension, and are reported in grams per 3 inches). It is contemplated that there is no upper or lower maximum limit for the basis weight, and that there is no upper limit for the thickness, strength or stretch of the blade that can be mechanically smoothed by this process.

The tensile strength in the machine direction, the tension stretching in the machine direction, the tensile strength in the transverse direction to the machine and the stretching of tension in the transverse direction to the machine is obtained according to to the test method TAPPI 494 OM-88"Paper and Cardboard Stress Breakdown Properties" are of the following parameters: crosshead speed is 10.0 inches / min (254 mm / min), load d full scale is 4,540 grams, the jaw expansion (the distance between the jaws sometimes referred to as the measuring length) is 50.8 millimeters, the specimen width is 76.2 millimeters. A suitable voltage testing machine is a Sintech, Model CITS-2000 (System Integration Technology Inc., of Stoughton, MA, a division of MTS Systems Corporation, of Research Triangle Park, North Carolina).

A mechanically smoothed sheet will generally have an easily perceptible change in feel, becoming smoother. Loose fibers created by abrasion can be evident to the visual observation on the edge of the sheet when it is kept in the light. They are also evident when seen under a microscope as can be seen in Figures 20 and 21. These two photographs can be compared with Figure 4, which shows a contemporary tissue sheet that has not worn on the surface with friction. It is believed that the leaf's absorbency rate will generally increase, even though the sheet's overall absorbency must remain the same. This change in the absorbency rate may require the use of an additional wet strength resin in certain applications.

The benefits of this invention can be obtained without appreciable reductions in the strength or in the levels of blade stretching. Therefore, it is generally preferred that mechanical smoothing does not reduce the strength by more than 10 percent and that the stretch in the machine direction is by more than 2 percent, even when greater reductions in strength and stretch can occur, while still benefiting from this invention. In addition, it is generally preferred that mechanical smoothing has little effect on the volume of the sheet, although this can improve the roll firmness due to reduced sheet nesting.

Figure 1 shows a schematic drawing of an embodiment of an apparatus for mechanically smoothing a sheet. In this Figure a sheet 3 moves in the direction of arrow 3a. A hard rubber backing roller 1 rotates in the direction of arrow 2 and at the same speed as sheet 3. To help control the tension of the sheet through the face of the backing roller, a pressure point roller covered with rubber is located before the point of abrasion tension 5. The abrasion pressure point 5 is formed by the backing roller 1 and an abrasion roller 6. The abrasion roller rotates in the direction of the arrow 7 and in the same direction as the blade 3. The abrasion roller 6 rotates at a speed d greater than the velocity of the blade causing an abrasion action on the surface of the blade. This abrasion action lifts the fibers on the blade. The abrasion roll 6 can be a steel roll with a tungsten carbide coating. This configuration allows a homogenously controlled surface abrasion and better tissue tension control resulting in less leaf degradation while wearing with friction.

By the tissue the surface roughness of the abrasion pad can be about 125 to 400 or more Ra (average value of micro-inch roughness). For other types of sheet, such as heavier towels, surface roughness as high as 2,000 Ra may be necessary to obtain the desired amount of loose fibers. For very delicate sheets, or in alternate configurations of abrasion apparatus, a surface roughness of less than 125 Ra may be necessary to obtain the desired amount of loose fiber.

To obtain optimum benefits, the spacing between the abrasion roller 6 and the backing roller 1 must be maintained constant across the length of those rollers, for example in the cross machine direction (CD). It is contemplated that the variation in this interface for the tissue should be within 0.002 inches to obtain the optimal benefits of this process. The equipment for obtaining this type of accuracy in a shell between two rolls is known in the art. For example, a variable crown roll, having a radial size change capacity of 0.002 inches, that uses heat to control its size can be used.

Figure 2 shows an alternate incorporation of the apparatus for mechanically smoothing a sheet. In this embodiment, instead of a pressure point roller for holding the blade 3 against the backing roll while wearing with friction, a mechanical device 8 is used to apply tension against the blade to hold it against the backing roller 1. This mechanical device should be made of or have a thin layer of surface of a high friction wear material, and it can be arched to equalize the curve of the backing roller 1. It can also be placed so close to the pressure point with abrasion 5 as possible. In this embodiment shown in Figure 2, the backing roller 1 is rotating in the direction of the arrow 2, the arrow moves in the direction of the arrow 3a and the abrasion roller 6 moves in the direction of the arrow 7 In this embodiment, in which the abrasion roller is rotating in a direction opposite to the movement of the blade, the mechanical device is located on the back side of the pressure point. If the abrasion roller were moving in the same direction as the blade, as shown in the embodiment of Figure 1, the mechanical device would be located on the front side of the pressure point with abrasion.

A vacuum backing roll, a high friction backing roll, an air pressure system for applying air pressure to the sheet, or other devices known to those skilled in the art of papermaking can be used to provide traction to the blade, preventing it from slipping in relation to the backing roller.

Figure 3 shows a further embodiment of a mechanical smoothing apparatus. In this embodiment, the guide rollers 6 and 9 are used to provide the wrapping of the backing roller 7. The tension created in the fabric by running the slower uncoiler 1 and the reel 3 faster than the backing roller 7 maintains the fabric 2 tightly against the backing roller 7, instead, or in addition to a roller or pressure point device 8 of Figure 2. This incorporation has an abrasion roller 8, and the calendering rolls 4 and 5. The fabric 2 is moved in the direction of the arrow 2a. Therefore, the calendering takes place after the abrasion.

The mechanical smoothing process of the present invention obtains many benefits and improvements over the prior art. For example, single-side abrasion (air side) reduces the two-sides of a single stratum fabric and improves the strength / softness curve for a non-creped bath tissue. The process works the layers of the outer surface of any tissue of tissue given to significantly affect the core layers. Two-sided abrasion significantly improves the strength / softness curve for creped bath tissue.

When non-creped air-dried tissues, such as those described in the aforementioned patent and in the patent application, which were incorporated herein by reference, are mechanically smoothed by this process a new and useful tissue is obtained. These softened non-creped tissues have areas of fibers across their surface that are selectively released. These selectively released areas correspond to the raised or protruding areas of the dried tissue in continuous non-creped form. Therefore, to obtain these selected areas of the ends of loose fibers, the separation of the pressure point with abrasion is set to provide abrasion of the raised surfaces of the sheet while not depressing the depressed areas.

Mechanical smoothing results in increasing the number of loose fiber ends on the surface of the fabric as summarized in the data set forth in Table 1. A greater number of long fiber ends on the surface of the sheet are transferred within a greater number of villi and less two sides of the leaf.

A B L A In Table 1, sample 1 was a control sample which was not worn by friction. The sheets for samples 1 to 11 were three layer sheets, around a base weight of 17 pounds / 2,880 square feet with the outer layers consisting primarily of hardwood and each cap being around 25 percent of the sheet, and the inner cap being primarily soft wood and around 50 percent of the leaf. Sample 12 was a commercially available Scottissue® product (count 1000) and sample 13 was a commercially available Charmin® Ultra tissue (count 340). Samples 1, 12 and 13 were not worn with friction. The "abrasion ratio" was the speed of the abrasion roller over the speed of the backing roller. The PR / EL data were achieved by using the following technique. A sample of the tissue was cut and folded along the direction of the machine. Along the edge of the fold, 100 fields of vision showing fibers protruding from the surface of the sheet are then counted and their perimeters measured. The PR / EL value is the sum of the perimeters of the fibers counted divided by the length of the edge on which they were counted. The specific accounts or data points showed the distribution of 100 samples by the PR / EL ratio, which were taken for samples 1 to 13 in Table 1 as established in Table IA.

PR / EL data were obtained using the Quantimet 900 image analysis system, obtained from Leica (formally known as Cambridge Instruments) of Deerfield, Illinois. The samples were wrapped on a spatula having a width of 3-32 inches. This resulted in a soft but small radius of curvature over which the tissue was bent. The sample was then analyzed using the Quantimet 900 and the following program to determine the total circumference of the protruding fibers and the end edge of the tissue on which the total circumference was obtained. For example, referring to Figure 20, the black area corresponds to the tissue that is folded over the spatula, the gray area to the bottom and the white areas the protruding fibers. Therefore, PR / EL is the cumulative perimeter of the white areas divided by the length of the bord (which, as shown in Figure 20, will be at the height of the table in this Figure). The following program written in the Quips language was used in the Quantimet 900 to obtain the PR / E put here.

Cambridge Instruments Quantimet 900 QUIPS / MX: V03.02 USER. ROUTINE; FLDFZ4 DOES = Examine 100 fields of two strips, 2 x 2 inches to obtain PROEREL histograms on TISUES. COND = Reach Olump; 4X Obj.; 1.5X image amplification; low mass condensate; VNDF + fixed on glass; Condensed and field diagram = wide open; nickel spatula taped on the Y movement for the edge examination; 33 -weight gram used for tissue tension. "Meter Specimen Identity Examiner (No. 2 Newvicon LV = 4.82 SENS = 1.50) STANDARD CALL Load shading corrector (pattern-FLDFUZ) Calibrated user specified (calibration value = 3.019 micras per pixel) TOTAL OF FIELDS: 0. TOTAL PROVEL: 0.

For the SAMPLE = 1 to 2 STAGEX: = 5000. STAGEY: = 80000. Move Phase (STAGEX, STAGEY) Examine Phase (X and Origin of Exam 5000. 80000. Field Size 1500. 3000. No. of Fields 50 1) Pause Message PLEASE PLACE THE NEXT SAMPLE Pause 15 Detect 2D (darker than 35 and lighter than 1 PAUSE) For FIELD 20 Image Frame is the standard live frame Live frame is standard image frame Detect 2D (darker than 35 and more clearly than 10) Modify (OPEN by 1 - Horizontally) Modify (OPEN by 1 - Vertically) Measure field - Parameters in PROVEREL field array: - FIELD PERIMETER / 1886.9 30 Distribute ACCOUNT against PROVEREL in GRAPH from 0.00 to 8.00 in 40 bins, differential TOTPROVEL: = TOTPROVEL + PROVEREL 35 TOTFIELDS: = TOTFIELDS + 1 Step of Phase Next FIELD 40 Next STAGEX: = 5000. STAGEY: = 80000. 45 Move Phase (STAGEX, STAGEY) Print "" Print "" Print distribution (GRAPH, differential, 50 bar chart, scale = 1.00) Print "" Print "" Print "AVE PR / EL =", TOTPROVEL / TOTFIELDS, "FOR", TOTFIELDS, "FOR FIELDS AS" Print "" Print "" For LOOPCOUNT = 1 a 5 Print "" Next End of the Program T A B L A YA A B L A ÍA The mechanical smoothing process of the present invention, even when applicable to any type of fibers, has variable results and affects different types and mixtures of fibers. For example, by increasing the level of soft wood in the outer layers, the amount of dust generated by the process is reduced.

Similarly, the process reduced the basis weight of mixing and 100 percent of long-fiber monolayer sheets to a lesser degree than the layered fiber sheets. Even when it is believed that most of the reduction of the base weight occurred during the rolling and calendering process. If abrasion is done on the machine, the losses associated with separate winding, unwinding or re-rolling should not occur.

The extent to which the process can reduce the size of the sheet, however, does not seem to vary with different types of fibers. Even though it is believed that most of the caliber reduction can be attributed to calendering and rolling processes, caliber reduction can occur from abrasion on one side of the sheet (side to sheet air). When it wears with friction the second time next to the fabric of the blade, the process does not significantly decrease the caliber and in some cases can actually increase the caliber against one of the lateral abrasion processes, even after having to run through a second winding process for two-sided abrasion, The type of fiber does not have an effect of the amount of loss of resistance in the machine direction that can occur from the process. This loss of resistance primarily occurs from calendering and the rolling process with minimal loss occurring from blade abrasion. There was a more significant loss in the resistance and direction of the machine when it was worn with friction the second time, which, however, included an additional rolling process. The process produced a minimum loss and resistance in the machine direction by 66 percent hardwood-34 percent softwood in mixed layers and sheet, but indicated a greater loss in strength in the machine direction for 100 percent of the soft wood fibr sheets. It is speculated that this occurred because 100% of the strength of the soft mader fiber sheet accounts for the layers from the side to the exterior as well as for the central layer against a layered sheet, which has s resistance predominantly located in the central layer, with very little resistance of the leaf coming from the hard mader fibers located in the outer layers of the sheet. I theorized that since the process works on the outer surface or the layers on the outside of the sheet, the process is breaking the junctions of the fibers located in the layers on the outside of the sheet.

Similarly, the type of fiber and the composition of the sheet can have an effect on the CD resistance. The process can produce a minimum loss of CD resistance from 66 percent hardwood to 34 percent softwood layered and mixed leaves. A greater loss in CD strength for 100 percent of the softwood fiber sheets occurred.

A loss of resistance in the machine direction can occur but most of the losses can be attributed to the rolling and calendering process. No significant loss in CD stretch occurs from the process.

The process can generate a greater amount of dust when the outer layers of the sheet consist mostly of shorter hardwood fibers. However, based on the data from an 8-layer purity test on the sheet and layers, the loss of total fiber between a cored or non-abraded sheet with friction was not significant as shown in the Table set out below in Table II and Table III and plotted in Figures 6 and 7.

T A B L A II T A B L A III The data from the fiber analysis of the generated dust indicated that about 95 percent of all the powder consisted of short hardwood fibers. When the outer side layer consisted of longer soft wood fibers, the dust generation was significantly lower. It was speculated that this phenomenon can be explained by the bound area as it refers to the fiber length and the amount of free fibers. The long fibers have more bound area and the abrasion process tends to produce loose fiber ends, while the other end, as well as at all times the center, of the fiber was still embedded in the fabric, thus creating a surface hairy The sheet which appeared to produce the least amount of dust tended to be the 100 percent fiber sheet of NB 50 (soft wood spruce pulp). Of the leaves composed of long and short fibers, the leaf with undispersed eucalyptus (short, hardwood fibers) seemed to produce the least amount of dust. The methods and apparatus for handling and controlling dust are well known to those skilled in the art and, if necessary, can be used for a particular application.

The process tends to improve the sheets in layers rather than the sheets mixed with respect to the softness and stiffness against the strength and loss of caliber as shown in the data of Tables IV and V and as graphs are made in the Figures 8 and 9 respectively. (In Figures 8 and 9, the "E" code is calendered only in the layered center line sheet.) The center line sheet as used here is about 17 pounds / 2,880 square feet, a 3-layer sheet , with the outer side layer consisting primarily of hardwood each layer being about 25 percent of the sheet, and the inner layer being primarily soft wood and about 50 percent of the sheet). All other conditions are calendered sheet as specified to fill the gauge specifications and worn with friction on both sides of the layer. A similar loss in GMT with a mixed sheet against a layered one can also be seen. However, when compared using a softness panel rating on hands, the resistance softness curve of the sheets in layer s improved compared to the only calendered sheet dried through air and not creped (Code "E") and mixed in relation to both the softness and the rigidity. The data from the 8-layer purity test for both the layered and mixed centerline sheets are shown in Tables VI and VII and are plotted in Figures 10 and 11 respectively.

T A B L A IV (GMT against Relative Softness) A B L A V (GMT against Relative Stiffness) A B A VI M a d e r a S e a v e M a d e r a r e T A B L A VII M a d e r a S e a v e M e D u r a The mechanical smoothing process tended to work the surfaces from the side to the outside of a given sheet had some small effect. over the center of the leaf depending on the type of leaf used. The process improved the softness and stiffness of the 100 per cent long fiber sheet but affected the strength of those leaves. It is speculated that the mixed or layered long fiber and the short fibr sheets are structured so that the long fibers constitute the largest part of the sheet strength, that the short fibers are used to improve the softness. As such, any sheet comprised 100 percent of equally treated long fibers having the strength evenly divided through the layers of the sheet. Consequently, when a process such as a mechanical smoothing works the outer layers of a sheet, it reduces more significantly the strength of that sheet as shown in the data set forth in Tables IV and V and is put into graphs in FIGS. 9.

The resistance / softness curve for mechanically smoothed sheets shows that these sheets are at a point located above the resistance / softness curve for a sheet that is not only calendered. When it is worn with friction on the air side of the sheet only, such sheet is at a point above the resistance / softness curve. When the sheets are worn with friction on both sides of the sheet, such sheet is at a point above the resistance / softness curve for a calendered sheet only. These results are established in the data set forth in Tables IV and V and plotted in Figures 8, 9 and 12. As used herein, the term "GMT" is equal to the square root of the sum of the resistance in the direction of the machine multiplied by the resistance in the direction transverse to the machine.

Generally between 4 to 7 percent reduction in base weight occurs with only calendering. An additional 2 to 3 percent reduction in base weight occurs from calendering and abrasion on one side. Because the process on a pilot plant was set up, it was only able to abrade one side of the sheet at a time, the roller was turned as a worn roller on one side and wound on the reel. This was then removed and replaced on the unwinder and run through the conversion process and worn with friction a second time. Because the product goes through the furler a second time, it speculates that the blade loses a certain percentage of basis weight, gauge, stretch and resistance due strictly to the same rolling process. These losses do not occur in a commercial process either where the sheet is worn out or outside the machine or where the sheet is worn with friction on the machine, either on one side or both sides. Therefore, when the sheet is worn a second time next to the sheet fabric, the sheet undergoes an additional 1 to 4 percent reduction in the base weight for the 100 percent fiber sheets on the pilot plant. long blended while the layered sheets experienced an additional reduction of 4 to 6 percent of the basis weight. In commercial applications, two-sided abrasion can be conducted simultaneously, thus limiting the second rewinding step.

Changes in the basis weight for the particular types of the leaves are as follows, and are established in the data set forth in Table VIII and plotted in Figure 13 T A B L A VIII Base Weight Comparison (# / 2880 square feet) Undispersed Eucalyptus Layers Sheet - The data indicate a 6.6 percent reduction in base weight with calendering (17.46, # / 2880 square feet to 16.3 # / 2880 square feet) and an additional 2.1 percent calendering and One-side abrasion (16.3 # / 2880 square feet to 15.95 # / 2880 square feet) with an additional 5.0 percent reduction of two-sided abrasion and the second winding process (15.9 # / 2880 square feet to 15.15 # / 2880 square feet), for a total of 3.2 percent reduction in the base weight of the two-sided abrasion sheet (7.46 # / 2880 square feet to 15.15 # / 288 square feet).

Mixed Fiber Sheet - The data indicates a reduction of 4.7 percent in the basis weight with the calender (16.92 # / 2880 square feet to 16.13 # / 2880 square feet) and a 3. additional percent of calendering and one side abrasion (16.3 # / 2880 square feet to 15.59 # / 2880 square feet) with an additional 1.5 percent reduction of a two-sided abrasion and second winding process (15.59 # / 2880 square feet to 15.51 # / 2880 square feet), for a total of 8.3 percent reduction in the basis weight of the two-sided abrasion sheet (16.92 # / 2880 square feet to 15.51 # / 2880 square feet) . 100% (long fiber) of LL Sheet 19 - Data indicates a 3.9 percent reduction in base weight with calendering (17.24 # / 2880 square foot to 16.56 # / 2880 square foot) and an additional 3.0 percent calendering and abrasion from one side (16.56 # / 2880 square feet to 16.06 # / 2880 square feet) with an additional reduction of 4.2 percent from two-sided abrasion and the second winding process (16.06 # / 2880 square feet) 15.38 # / 2880 square foot), for a total of a 10.8 percent reduction in the basis weight of the two-sided abrasion sheet (17.24 # / 2880 square feet to 15.38 # / 2880 square feet).

Central Fiber Layer Sheet in Layers - The data indicate a 4.2 percent reduction in the basis weight with calendering (17.18 # / 2880 square feet to 16.45 # / 2880 square feet) and an additional 3.2 percent calendering and abrasion from one side (16.45 # / 2880 square feet to 15.92 # / 2880 square feet) with an additional reduction of 4.4 percent from a two-sided abrasion and the second winding process (15.9 # / 2880 square feet to 15.22 # / 2880 square feet), for a total of 11.4 percent reduction in the base weight of the two-sided abrasion sheet (17.18 # / 2880 square feet to 15.22 # / 288 square feet). 100% NB50 sheet (long fiber) - The data indicates a 4.3 percent reduction in the basis weight with the calender (17.84 # / 2880 square feet to 17.07 # / 2880 square feet) and an additional 3. percent of calendering and an abrasion of a lad (17.07 # / 2880 square feet to 16.5 # / 2880 square feet) with an additional reduction of 1.3 percent from two side abrasion and the second winding process (16.5 # / 2880 square foot 16.28 # / 2880 square feet), for a total of a reduction of 8. percent in the base weight of the blade to two-side abrasion (17.84 # / 2880 square feet to 16.28 # / 2880 square feet).

Between a reduction of 33 to 44 percent in the caliber occurs only with calendering. An additional reduction of 12 to 21 percent in the caliber occurs and the calendering of the abrasion on one side. Because the process on the pilot plant as configured was only able to abrade one sheet side at a time, the roll was converted to a roll worn with friction on one side and rolled onto the spool. It was then removed and replaced on and unrolled and run through the conversion process and worn with friction a second time. Because the product goes through the furler a second time, it is speculated that the sheet will lose a certain percentage of basis weight, caliber, strength and stretch due strictly to the rolling process itself. Therefore, when the sheet was worn with friction a second time next to the sheet fabric, the sheet experienced an additional reduction of .2 to .7 percent in caliper. In commercial applications the two-sided abrasion can be carried out simultaneously on any outside of the machine or on the machine as thus eliminating one or both rewinding steps.

The changes in the caliber for the particular leaf types are as follows, and are set forth in Figure 14.

Non-Scattered Eucalyptus Layers - Data indicates a 43.8 percent reduction in caliper with calendering (.0224 inches to .0126 inches) and an additional 13.5 percent calendering and one side abrasion (.0126 inches to .0109 inches) with an additional reduction of 2. 8 percent of the abrasion of two sides and the second process of rolling (0.109 inches to .0106 inches). Through the entire process from the sheet to a calendered final product and two-sided abrasion, the sheet gave a 52.7 percent reduction in caliber (.0224 inches to .0106 inches) Mixed Fiber Sheet - Data indicates a reduction of 41.5 percent in caliper with calendering (.024 inches to .0141 inches) and an additional 14.9 percent calendering and one side abrasion (.0141 inches to .01 inches) with an additional reduction of 6.7 percent of the two-side abrasion and the second winding process (0.1 inches to .0112 inches). Through the entire process from the sheet to a calendered final product and the abrasion on both sides, the sheet gave a 53.5 percent reduction in caliper (.0241 inches to .0112 inches).

Leaf LL 19 100% (long fiber) - The data indicates a reduction of 38.4 percent in caliber with the calender (.0242 inches to .0149 inches) and an additional 14.8 percent calendering and one side abrasion (.0149 inch to .0127 inches) with an additional 3.8 percent reduction in abrasion from two sides and the second Rolling process (0.127 inches to .0132 inches). Through the complete process from the sheet to a final calendered product and the abrasion of both sides, the sheet gave a reduction of 45.5 percent in the calibration (.0242 inches to .0132 inches).

Central Fiber Layer Sheet in Layers - The data indicate a reduction of 33.3 percent in caliper with calendering (.0231 inches to .0154 inches) and an additional d 21.4 percent of calendering and one side abrasion (.0154 inches to .0121 inches) with an additional reduction of 4.1 percent of the abrasion of two sides and the second process of winding (0.121 inches to .0116 inches). Through the entire process from the blade to a calendered end product the abrasion of two sides, the blade gave a reduction of 49.8 percent in the caliber (.0231 inches to .0116 inches).

NB50 sheet 100% (long fiber) - The data indicate a reduction of 36.1 percent in caliper with calendering (.023 inches to .0147 inches) and an additional 12.2 percent calendering and one side abrasion (.0147 inches to .0129 inches) with an additional 2.3 percent reduction of two-sided abrasion and the second winding process (0.129 inches to .0132 inches). Through the entire process from the sheet to a calendered final product and two-sided abrasion, the sheet gave a 42.6 percent reduction in caliber (.023 inches to .0132 inches).

Between a reduction of 5.2 to 15.5 percent in resistance in the direction of the machine occurs only with calendering. An additional reduction of .4 to 9.4 percent in the resistance in the machine direction occurs from calendering and abrasion from one side. Because the process on the pilot plant as configured, it was only able to abrade one side of the sheet at a time, the roll was converted as a roll worn on one side and wound on the reel. This was then removed and replaced over and unrolled and run through the conversion process and s worn out with friction a second time. Because the product goes through a reel a second time, it speculates that the sheet will lose a certain percent of the basis weight, caliber, strength and stretch due strictly to the rolling process itself. Therefore, when the blade was worn with friction a second time next to the cloth of the blade, the blade experienced an additional reduction of 1.7 to 6. 6 percent in machine direction resistance for layered fiber sheets and mixed fibr sheets and an additional reduction of 16.3 to 19.9 percent in machine direction direction for fiber sheets 100% long. In commercial applications, wear with two-sided friction can be carried out simultaneously either outside the machine or on the machine, thereby eliminating one or both of the rewinding steps.

The changes in the resistance in the direction of the machine for the particular types of sheets are as follows, and they are also established in the data of Table IX and positions and graphs in Figure 16.

A B L IX Non-Dispersed Eucalyptus Layers Sheet - The data indicate a reduction of 13.9 percent in the resistance in the direction of the machine with calendering (682.7 grams 588 grams). The resistance in the direction of the machine is less after calendering than after an abrasion of one side (588 grams at 638.2 grams). (But, this data may reflect variations in the base sheet). The data indicated a further reduction of 1.7 percent of the two-side abrasion and second winding process (638.2 grams to 627.1 grams) Through the complete process of the sheet to a final produced calender and a two-sided abrasion, the Leaf gave a 8.1 percent reduction in MD resistance (687.2 grams 627.1 grams).

Mixed Fiber Sheet - The data indicate a 5.2 percent reduction in the resistance in the direction of the machine with calendering (714.7 grams at 677.7 grams) and an additional 1.7 percent from the calendering and abrasion of one side (677.7) grams at 666.2 grams) with an additional reduction of 6.2 percent of the abrasion of two sides and the second process of rolling (666.2 grams to 625 grams). Through full process from the sheet to a final produced calendering the abrasion of two sides, the sheet gave a reduction of 12.6 percent in the resistance in the machine direction (714 grams to 625 grams).

Leaf LL 19 100% (long fiber) - The data indicate the reduction in 15.5 percent in the resistance in the direction of the machine with calendering (743.7 grams to 628. grams) and an additional 9.4 percent from the calendering abrasion from one side (628.3 grams to 569.5 grams) with an additional reduction of 19.9 percent from two-sided abrasion and second winding process (569.3 grams to 456.2 grams). Through the entire process from the sheet to the final produced calendering and two-sided abrasion, the sheet gave a 38.7 percent reduction in the machine direction resistance (743.7 grams to 456.2 grams).

Central Fiber Layer Sheet in Layers - The data indicate a 9.1 percent reduction in machine direction resistance with calendering (782.5 grams at 711 grams) and an additional 0.4 percent from calendering the abrasion of a side (711 grams to 707.9 grams) with an additional reduction of 6.6 percent of the abrasion of two sides and the second process of rolling (707.9 grams to 661.4 grams). Through the entire process from the sheet to the final produced calendering and two-sided abrasion, the sheet gave a 15.5 percent reduction in machine direction resistance (782.5 grams to 661.4 grams).

NB50 sheet 100% (long fiber) - The data indicate the reduction in 13.1 percent in the resistance in the direction of the machine with calendering (1023.2 grams to 888.8 grams) and an additional .8 percent from the calendering and abrasion on one side (888.8 grams to 881.8 grams) with an additional reduction of 16.3 percent from two-sided abrasion and second winding process (881.8 grams to 737.8 grams). Through the complete process from the sheet to the final produced calendering and the two-sided abrasion, the sheet gave a reduction of 27.9 percent in the resistance in the machine direction (1023.2 grams to 737.8 grams).

Between 18 to 28 percent reduction in resistance in the cross machine direction occurred only with calendering. An additional reduction of 2.1 to 12.9 percent in cross-machine direction resistance occurs from calendering and one side abrasion. Because the process on the pilot plant as it was set up, it was only able to abrade one side of the sheet at a time, the roll became like a worn roll on one side and rolled up on the reel. This was then removed and replaced on the unwinding and was run through the converter process and worn with friction a second time. Because the product goes through the furler one second time, it is speculated that the sheet will lose a certain percentage of basis weight, caliber and stretch due strictly to the rolling process itself. Therefore, when the sheet was worn with friction a second time next to the cloth of the sheet, the sheet underwent a reduction of 9.7 per cent additional in cross machine direction strength for the layered fiber sheets and a additional reduction from 10.3 to 23.5 percent in cross-machine direction strength for 100 percent long fiber and mixed fiber sheets. In commercial applications, two-sided abrasion can be carried out simultaneously either outside the machine or on the machine, thereby eliminating one or both of the rewinding steps.

The changes in cross machine direction resistance for particular types of sheets are as follows, and are also set forth in the data of Table IX and put into graphs in Figure 16. Table 10 establishes the relative data of the softness and changes in resistance and put in graphs in Figure 15.

A B A X PSP against GMT PSP is a determination of softness that is carried out by people experienced in judging the texture properties of a leaf. The more superior the number is, the more smooth the tissue.

Non-Dispersed Eucalyptus Layers Sheet - The data indicate a 20.4 percent reduction in cross-machine direction resistance with calendering (580 grams at 462.3 grams) and an additional 6.8 percent from calendering and a abrasion from one side (462.3 grams to 431 grams) with an additional reduction of 9.7 percent from the two sided abrasion and the second rolling process (431 grams 389.1 grams). Through the complete process of the sheet to a calendered two-sided abrasion produced final the blade gave a 33 percent reduction in the resistance in the transverse direction to the machine (580.5 grams at 389.1 grams).

Mixed Fiber Sheet - The data indicates an 18 percent reduction in cross machine direction resistance with calendering (563.1 grams at 461.7 grams) and an additional 2.1 percent from calendering and abrasion on one side ( 461.7 grams to 452 grams) with an additional reduction of 12.8 percent from two-sided abrasion and the second rolling process (452 grams to 394.1 grams). Through the entire process from the sheet to a final produced calender and a two-sided abrasion, the sheet gave a 30 percent reduction in cross machine direction resistance (563.1 grams to 394.1 grams).

The LL Sheet 19 100% (long fiber) - The data indicate a reduction of 32.7 percent in the resistance in the cross machine direction with calendering (599.5 grams at 403.2 grams) and an additional 12.9 percent from the calendering and one-sided abrasion (403.2 grams to 351.3 grams) with a further reduction of 23.5 percent from two-sided abrasion and the second rolling process (351.3 grams to 268.6 grams). Through the entire process from the sheet to a final produced calendering and a two-sided abrasion, the sheet gave a 55.2 percent reduction in cross machine direction resistance (599.5 grams to 268.6 grams).

Central Fiber Layer Sheet in Layers - The data indicate a 28 percent reduction in cross direction resistance to the calendered machine (683 grams to 491.8 grams) and an additional 5.1 percent from calendering and abrasion from one side (491.8 grams to 466. grams) with an additional reduction of 9.7 percent from the two-sided abrasion and second winding process (466. grams to 421.6 grams). Through the entire process from the blade to the final produced calendering and two-sided abrasion, the blade gave a 38.3 percent reduction in cross-machine direction resistance (683 grams to 421.6 grams) 100% NB50 sheet (long fiber) - The data indicates a reduction of 22.5 percent in cross-machine direction resistance with calendering (1005.4 grams to 778.9 grams) and an additional 12.6 percent from calendering and abrasion on one side (778.9 grams at 681 grams with an additional reduction of 10.3 percent from the two-sided abrasion and second winding process (681 grams 611.1 grams) Through the complete process from the au calendered final produced leaf and the abrasion on two sides, the blade gave a 39.2 percent reduction in cross-machine direction resistance (1005.4 grams to 611. grams).

Between a reduction of 4.5 to 6.7 percent of the stretch in the machine direction occurs with only the calendering. An additional reduction of .7 to 2.2 percent in the stretch in the machine direction occurs from calendering and abrasion from one side. Because the process on the pilot plant as configured, was only able to abrade one side of the sheet at a time, the roll was turned into a worn roll with a one-sided roll and wound on the reel. Then it was removed and replaced from the unwinding and was run through the conversion process and was worn with chafing a second time. Because the product goes through the wrapping a second time, it is speculated that the sheet will lose a certain percentage of basis weight, caliber resistance and stretching due strictly from the rolling process itself. Therefore, when the sheet was abraded a second time next to the web of the sheet, the sheet experienced an additional reduction of 1.4 to 3.2 percent in the stretch in the machine direction. In commercial applications the friction of two sides can be conducted simultaneously either outside the machine or on the machine, eliminating one or both rewinding steps.

The changes in the stretch in the direction of the machine for the particular types of leaves are as follows, and they are also established in the data of Table XI and put into graphs in Figure 17.

T A B L A XI MD / CD Stretch Undispersed Eucalyptus Layer Sheet - Data indicates a 6.7 percent reduction in machine direction stretch with calendering and an additional 1.3 percent from calendering and one side abrasion with an additional 2.4 reduction percent from the abrasion of two sides and the second process of rolling. Through full process from the sheet to a calendering produced final two-sided abrasion, the sheet gave a reduction of 10.4 percent in the stretch in the machine direction.

Mixed Fiber Sheet - The data indicates a 5.1 percent reduction in machine direction stretch with calendering and an additional 1.6 percent from calendering and one side abrasion with an additional 1.7 percent reduction from the abrasion of two sides and second winding process. Through the complete process from the sheet to a final produced calendering and two-sided abrasion, the sheet gave a 8.4 percent reduction in the machine direction stretch.

Central Fiber Layer Sheet in Layers - The data indicates a 4.5 percent reduction in the machine direction stretch with a calender and an additional 1.8 percent from calendering and abrasion on one side with an additional reduction of 2.7 percent from the abrasion of two sides and the second process of rolling. Through the complete process from the sheet to a final produced calender and a two-sided abrasion, the sheet gave a reduction of 9 percent in the stretch in the machine direction.

NB50 sheet 100% (long fiber) - The data indicate a 6.5 percent reduction in the machine direction stretch with calendering and an additional .75 percent from calendering and one side abrasion with a reduction additional 1.4 percent from the abrasion of two sides and the second process of rolling. Through the complete process from the sheet to a final produced calender and a two-sided abrasion, the sheet gave a 8.6 percent reduction in the stretch in the machine direction.

The established parameters that must be considered for the mechanical smoothing process can be as follows A separation between the abrading roller and the backing roll is preferred-a minimum separation obtained without scaling the fibers on the surface of the sheet. For tissue sheets this should be within a range of about 0.005 inches-a gap of 0.10 inches depending on the configuration of the sheet.

Abrasion Roller Speed - At the speed of the abrasion roller it can be at its maximum. In a pilot plant analysis, the critical speed of the abrasive roller was 4,500 fpm, so that the maximum speed ratio was twice the maximum fabric speed of 2,200 fpm on the pilot plant equit. In the commercial team this limitation should not be present. The effect of speed ratio, for example increasing the ends of loose fibers as the ratio between the abrasion roller and the fabric becomes larger is believed to be explained by the increased contact area that the abrasion roller has with the tissue to increase the speed of the roll in relation to the fabric. Therefore, the abrasion roller works more on the fabric breaking more bonds. In addition, the additional links that are broken appear to be internal to the sheet, resulting in a reduction in stiffness.

Calendering - Abrasion before or after calendering has variable effects on leaf properties It is speculated that this effect may be due to an increased amount of work that is induced to the leaf without calendering. The more rigid calendered sheet creates more strength against abrasion roller. This was also shown by increasing the motor load of the abrasion roller for abrasion against the calendering condition.

The roughness of the abrasion roller-dust surface, the run, and the amount of loose fibr ends are affected by the roughness of the abrasion roller. U coated tungsten carbide roller from "ATCAM, Inc." Part number ATCAM-100-250 can be used. Even when other coatings and the type of abrasive materials can be used. For example, any one from an abrasion roll d type sandpaper to a grooved metal roll, any roll with a textured surface may be employed.

Using these parameters as shown in the data set forth in Table XII and plotted in Figure 5, the process was able to increase hairiness by reducing grit and reducing stiffness. All are attributes for improving the overall smoothness of a given tissue sheet. As used here, the term "GMT" is equal to the square root of the sum of the resistance in the direction of the machine multiplied by the resistance in the direction transverse to the machine.

T A B L A XII Examples 1 to 4 used a mechanical smoothing apparatus which is configured as that shown in Figures 18 and 19. This apparatus has an uncoiler 1, a calender 2 and an abrasion 3 and a rewinder 6 Figure 19 shows a view in detail of an abrasion . The similar numbers correspond to similar structure between these two Figures. The abrasion has a frame 10 which supports a backing roller 4, an abrasion roller 5, a pressure point roller 14 and a control 11. The abrasion also has an apparatus for adjusting the separation between the backing roll and abrasion roll and apparatus (not shown) for imparting a load to the pressure point between the backing and abrasion rolls (and the abrasion pressure point) and the pressure point between the pressure point roll and the backup roller. The backing roll 4 is a covered neoprene d roller of shore "A" hardness of 90 and is driven at a line speed by a motor that is not shown in the Figures. The abrasion roller 15 is mounted below the backing roller 4 and is driven by the web 13 and the motorbike 12. The abrasion roller 5 can be driven in the same direction or opposite to that of the movement of the sheet 7 was configured in Figure 18 and in 19, sheet 7 moved in the direction of arrow 8.

The embodiment shown in Figure 18 is configured to carry out abrasion after calendering. In order to carry out the abrasion before calendering the calender 2 is moved down from the abrasion 3 and is placed between the and the rewinder.

EXAMPLE 1 A sheet having the following properties basis weight of 28 g / m2; 0.026 inch base sheet gauge 3 layers; outer layers 25% (each) of dispersed eucalypt fibers (hardwood); and 50 percent center of spruce fibers (soft wood) were mechanically abraded mechanically on the wear device by mechanical friction at speeds from 500 fmp to 2,200 fmp. These speeds should not be seen as a limit on commercial speeds for this process.

Four different abrasion rollers coated with different tungsten carbide are used: 250 Ra; 250 Ra with silicon; 125 Ra; and 400 Ra. These rollers were flame-coated with a tungsten carbide coating by ATCAM, Inc. The process was run under the following conditions and variations. The gap between the backing roller and the abrasion roller was set to .024 inches to .006 inches. The abrasion roller speed is 1,136 to three times the line speed rotating in the same direction as the blade. The abrasion on one side was used for the air side and the side of the sheet fabric. The two-side abrasion was used against both sides of the blade. The pressure point roller is placed before the abrasion pressure point (shown in Figure 19) and at the outlet of the abrasion pressure point (not shown) and loaded at pressures from 5.0 to 0 pounds per linear inch. Calendering after abrasion is loaded at approximately 20 pounds per linear inch to achieve a finished sheet gauge of .013.014 inches. The calendering before abrasion was loaded at approximately 20 pounds per linear inch to achieve a finished sheet gauge of .012-.013 inches.

Improvements in softness as it relates to gritty, grainy, stiffness and villus characteristics with minimal reduction in machine direction and cross direction and caliper resistance were obtained in both physical panel tests and smoothness. Notable improvements in smoothness between wear with friction after calendering at a 0.006-inch gap and frictional wear before calendering at a 0.008-inch gap are not observable. Abrasion before calendering tends to improve softness but a loss of strength and stretch. The abrasion process after calendering seems to improve a more even lift of fibers over the entire sheet. An accumulation of fibers on the abrasion roller is not an issue for any of the roller coatings tested. The generation of dust increases when the size or separation of the abrasion pressure point is decreased and when the speed of the abrasion roller is increased. A minimum pressure point pressure of 0.8 pounds per linear inch between the pressure point roller and the backing roller is required before the point of abrasion pressure. When only one side is worn with friction, the frictional wear of the air side of the blade greatly reduces the two sides of the finished sheet.

E J E M P L O 2 A non-creped air-dried sheet similar to that used in Example 1 was mechanically smoothed on the surface.

The smoothing was carried out at speeds d around 2,200 fpm, which should not be seen as a limit on commercial speeds for this process, and with the following conditions and variations. The abrasion roller e a Ra 250 coated with tungsten carbide. The smoothing process is run with the separation between the back roll and the abrasion roll seat at .005 inches .009 inches. The speed of the abrasion roller is 1.5 twice the line speed rotating in the same direction as the abrasion sheet is used from one side to the air side of the sheet. The abrasion of two sides was used against both sides of the blade. The pressure point roller was placed before the abrasion pressure point and loaded to 0.8 pound linear inch. The calendering after abrasion was loaded 25 lines per linear inch and 200 pounds per linear inch. E calendered before abrasion was loaded at 25 pounds per linear inch and 200 pounds per linear inch. The abrasion was carried out also without calendering.

The effects of mechanical smoothing greatly improve when preceded by an optimized calendering process. Mechanical softening is capable of delivering a greater advantage when the separation between the abraded roller and the backing roller is minimized. Mechanical smoothing is also capable of delivering a greater advantage when the speed of the abrasion roll relative to the backing roll is increased to its maximum.

E J E M P L O O 3 A sheet dried through creped air having the following properties: basis weight of 15.2 pounds / 2,880 square feet, dry; a 4-layer base sheet with hard wood on the outer layer and soft, broken wood on the inner layers; and a caliber of around 0.007 inches mechanically softened. The percent of the long fibers within the outer layers of this sheet were changed from 0 percent to 25 percent and up to 50 percent.

Mechanical smoothing was conducted at speeds of around 2,200 fpm which should not be seen as a limit on commercial speeds for this process. The abrasion roller is a Ra 250 coated with tungsten carbide. The smoothing process was run with the separation between the backing roller and the abrasion roller at .006 inches. The speed of the abrasion roller is 1.5 and twice the line speed turning in the same direction as the blade.

The softness is improved. However, the improvement in softness is not significant as in Examples 1 and 2. The amount of powder generated during the process was reduced to increasing the level of soft wood fibers in the outer layers.

E J E P L O Four sheets dried through non-creped air having a basis weight of about 17-18 pounds / 2,880 square feet and a gauge of about 0.023-0.24 inches s mechanically smoothed. The first has a fiber distribution, in Figure 11, with 66 percent of eucalypt dispersed and 34 percent of LL 19 fibers mixed across the sheet. The second sheet is 100 percent softwood. The third leaf has fibers not dispersed in the outer layers, having 33 percent of undispersed eucalyptus located in the air side layer, 34 percent of LL 1 fibers located in the central layer and 33 percent of dispersed eucalypt located in the cloth side layer. The fourth blade is a blade mixed with several levels of the C6001 debonder, which is made with itco and is an imidazole d-type debonder.

The mechanical softener is carried out speeds of around 2,200 fpm which should not be seen as a limit of commercial speeds for this process. E abrasion roller is a roll coated with tungsten carbide Ra 250.

The smoothing process was carried out with the separation between the backing roller and the roller of abrasive at .006 inches. The speed of the abrasion roller is twice (4,400 fpm) the line speed (2,200 fpm) rotating in the same direction as the blade. The abrasion is after calendering. The calendering is loaded to achieve a finished sheet gauge of .014-.015 inches (30-35 pounds per linear inch). The abrasion on one side was used against the air side of the sheet. Two-sided abrasion was used against both sides of the blade.

The abrasion of the single side has some improvement in the resistance-softness curve for each sheet. The two-sided abrasion significantly improved the softness resistance curve for each sheet. By layering the fibers inside the sheet, it improves softness with minimal losses of blade strength and stretch. The sheets of 100 percent softwood fiber show strength losses due to the strength of the compressed sheet within the three layers of the sheet against the centerline sheet where the strength was compressed mainly within the core layer . It is speculated that this occurs because the process gives the most work to the outer surfaces of the sheet.

Examples 5 to 59 are illustrative of a number of different variables that can be controlled in this process, and the effect on the final product can have these variables. These Examples, as with Examples 1 to 4, were carried out at room temperature and ambient humidity. The variables that were evaluated include: the size of the separation between the base roller and the abrasion roller; the ratio of the speed between the abrasion roller and the fabric or the sheet; abrasion before calendering or after calendering; the load, both the pressure and the type of apparatus placed on the sheet against the backing roller; and, the different abrasion roller surfaces. Although the optimum conditions for any particular application may vary, and changes in one variable may change the optimum conditions for another variable, these Examples show several general parameters around the mechanical smoothing process.

The number of loose fiber ends on the tissue surface was increased by this process. The overall softness of the blade was improved by this process.

The lower the separation between the rolls, the greater the amount of loose fiber ends. The lower separation collocations make contact with more surface area by raising the loose fiber ends across the entire surface of the fabric rather than just over the spikes. It is speculated that this can be an important factor to improve the softness on the air side of the leaf, because the valleys or low points on the fabric are a higher percentage of the surface area on the air side of the sheet. It is noted, however, that the larger separation, which wears with just friction the peaks of the leaf, gives rise to an important alternate embodiment of the invention.

The loss of resistance in the direction of the machine and the stretching was low. More than one effect on the resistance in the transverse direction and the stretch was noted. The degradation of cogging wear resistance was not significant or severe until the separation reached 0.006 inches before calendering or 0.004 inch after calendering. It is speculated that these separations are reaching the thickness of the sheet at any given point when it is flat, and that the sheet is being broken internally rather than just above the surface. Stretching was also reduced to these separation placements.

The Ra 250 roller seems to produce the best results. The 250 Ra roller with silicone did not provide any additional benefit and the silicone seemed to wear out. The Ra 400 roller appears to be very aggressive and produced large amounts of dust. Roller Ra 125 also produced large amounts of dust possibly in part due to the lack of hollow area between the particles. Even when the accumulation of dust on any of the rollers was not a problem. If there is anything, the silicone-coated roller had the highest accumulation.

The speed ratio, for example, having the abrasion roller moving in the same direction as the backing roller and the blade, seems to provide better results than the speed difference, for example, the abrasion roller moves more slowly than or in the opposite direction of the sheet. It is speculated that the speed ratio produces a constant contact distance with the abrasion roller against the blade when changing the speed of the machine. A negative rate of velocity (slower abrasion roll or flipping away from the fabric) is not optimal. Any woven edge defects can cause the fabric to tear and break at the point of pressure.

A pressure point roller used to hold the fabric against the base roller is more effective than using a brass plate against the fabric. Uneven loading can cause wrinkling of the fabric and a poor gauge profile. Therefore, the fabric should be maintained with even pressure against the base roller through the entire roller car.

The process can generate static electricity if required can be controlled by methods and apparatus known to those skilled in the art.

The frictional wear of the air side of a sheet of a stratum can cause the side to be comparable and smooth to the fabric side by eliminating both sides of that sheet.

These Examples illustrate that favorable conditions for a tissue are generally an abrasive roller with a Ra of 250, a separation between the abrasion roller and the backing roller of 0.006 inches, a co-grinding wear after calendering, and a rate of speed. of 1.5. In addition, there was no noticeable improvement in the smoothness of the abrasion after calendering at a 0.00 inch gap and the abrasion before calendering at a distance of 0. 008 inches The limit for the placement of separation appears to be 0.006 inches before calendering and 0.00 inches after calendering. The 0.006-inch separation for abrasion after calendering provides a more even lift of the loose fiber ends across the entire surface of the fabric, in the valley and above the peaks.

In Examples 5 to 9, a sheet and having the following properties before mechanical softening: base weight of about 17 pounds / 2,880 square feet; 3 layers; the outer layers of about 25/30 percent of wood dispersed (each); The middle layer of around 40/50 percent softwood was used. The leaf gauge was 0.0255 inches. The pressure point roller was loaded at a pressure point of 2.3 pounds per linear inch loading on the base roller. A rubber base roller and a 250 Ra abrasion roller without a silicone release agent were used. Abrasion took place on the air side of the leaf only. The calendering took place after the abrasion and s loaded at 20 pounds per linear inch. The machine hauls for the mechanical smoothing apparatus were as follows: 1. percent of the uncoiler to the abrasion unit; 1.2 percent from the abrasion unit to the calender; and 2.0 percent from the calendering to the reel. With the exception of Example 5, all other Examples were run with the blade and abrasion roller traveling in the same direction. With a baseline, the blade was run through the softening apparatus without wearing down the blade providing the following results: Caliber (one sheet) = 13.0 (0.013 inches) Caliber (10 sheets) = 102 (0.102 inches) MD = 1237 Stretching = 18.6% CD = 983 Stretching = 6.9% As used here the reported data such as M 1237 and CD = 983 are resistances measured in grams / 3 inches E J E M P L O O 5 __ A gap of 0.024 inches was used between the base roller and the abrasion roller. The abrasion roller speed was twice as fast as the tissue velocity with the direction of displacement opposite the fabric. This arrangement caused the fabric to tear and break due to the edge defects on the parent roller that created stress points. high at the pressure point.

E J E M P L O 6 The following conditions were used and the following results were provided: Separation = 0.024 inches Velocity Ratio = 3.0 Fabric Velocity 500 fpm Caliber = 13.6 MD = 1207 Stretch = 19% CD = 943 Stretch 6.5% As used herein, a gauge value such as 13.6 corresponds to 0.0136 inches.

E J E M P L O 7 The ratio of speeds was changed from 3 to 2.5 times the speed of the fabric. All other variables were kept constant. There were notable loose fiber ends generated and the overall appearance of the sheet was better than the speed ratio of 3.0. The following conditions were used and the following results were provided: Separation = 0.024 inches Speed Ratio = 2.5 Fabric Speed 500 fpm Caliber = 13.5 MD = 1196 Stretching = 17.2% CD = 1013 Stretching = 6.6% EXAMPLE The rate of speed was changed 1.5 times the speed of the fabric. All other variables remained constant. No apparent change in the appearance of the blade or the operation of the apparatus was noted for the rate of velocity of 2.5 times. The following conditions will be used and the following results were provided: Separation = 0.024 inches Speed Ratio = 1.5 Fabric Speed 500 fpm Caliber = 13.5 MD = 1224 Stretching = 16.6% CD = 1080 Stretching = 6.5% J E M P L O The speed ratio was adjusted down to 1,136 times the speed of the fabric. No apparent change in condition was noted without abrasion. Less dust was generated than at higher rates of velocity. The following conditions were used and the following results were provided: Separation = 0.024 inches Rate of Speed = 1.136 Fabric Speed 500 fpm Caliber = 12.6 MD = 1246 Stretching = 16.8% CD = 1040 Stretching = 6.4% In Examples 10 to 29, a sheet having a supply similar to that used in Examples 5 to 9 was used. The sheet size before processing was 0.024 inches, the resistance in the machine direction was 1220 and stretch was of 24.4 percent, its stretch in the transverse direction was 1398 and its stretch was 6. percent. The pressure point roller was loaded at a pressure point load of 2.3 pounds per linear inch on the base roll. A rubber base roller and a 250 Ra abrasion roller without silicone release agent were used. The abrasion roller had a diameter of 7.0 inches. Abrasion took place on the air side of the leaf sides of the sheet as indicated in the Examples. The calendering took place after the abrasion and was charged at 20 pounds per linear inch. The pulls of the machine for the mechanical softening apparatus were similar to those for Examples 5 to 9. The blade and the abrasion roller were moving in the same direction. As a baseline, the sheet was run through the smoothing apparatus if the sheet was abraded and the following results were obtained: Caliber (one sheet) = 11.5 MD = 1220 Stretching = 14.2% CD = 1067 Stretching = 5.6% E J E M P L O 10 The separation was reduced to 0.020 inches. There was an increase in the dust generated compared to the largest separation. It also seems that there is a reduction in the two side of the converted product.

Separation = 0.020 inches Velocity Ratio = 1.136 Fabric Velocity 500 fpm Air-to-Air Abrasion Caliber = 11 MD = 1107 Stretching = 12.57% CD = 952 Stretching = 6.2% E J E M P L O 11 The speed ratio was increased to 1.5. The powder generation increased from the conditions of Example 10. The following conditions were used and the following results were provided: Separation = 0.020 inches Speed Ratio = 1.15 Fabric Speed 500 fpm Air Side Abrasion Caliber = 10.3 MD = 1144 Stretching = 15.4% CD = 942 Stretching = 5.9% E J E M P L O 12 The speed ratio was increased to 2.5 times the speed of the base roller. The loose fiber ends generated on the fabric appear to be better than those generated at the rate of 1.5 speed. The following conditions were used and the following results were provided: Separation = 0.020 inches Speed Ratio = 2.5 Fabric Speed 500 fpm Air Side Abrasion Caliber = 10 MD = 1218 Stretching = 12.3: CD = 955 Stretching = 5.8% E J E M P L O 13 The speed ratio was increased to 3.0. The ends of loose fiber on the fabric however seem to be better at the 1.5 speed ratio. The accumulation of dust on the abrasion roller was faster than in the previous conditions. The following conditions were used and the following results were provided: Separation = 0.020 inches Velocity Ratio = 3.0 Fabric Velocity 500 fpm Abrasion from Side to Air Caliber = 12.1 MD = 1280 Stretching = 16.2 'CD = 1089 Stretching = 7.2% E J E P L O 14 The following conditions were used and s. They provided the following results: Separation = 0.016 inches Velocity Ratio = 3.0 Fabric Velocity 500 fpm Abrasion from Side to Air Caliber = 10.8 MD = 1217 Stretching = 13.3% CD = 1129 Stretching = 10.2% E J E M L O 15 The following conditions were used and the following results were provided: Separation = 0.016 inches Speed Ratio = 2.5 Fabric Speed 500 fpm Air Side Abrasion Caliber = 10.9 MD = 1181 Stretching = 12.3% CD = 1129 Stretching = 6.3% E J E M L O 16 The following conditions were used provided the following results: Separation = 0.016 inches Rate Ratio = 1.5 Fabric Speed 500 fpm Air Side Abrasion Caliber = 10.9 MD = 1126 Stretching = 13.5% CD = 1043 Stretching = 6.4% E J E M P L O 17 The following conditions were used and the following results were provided: Separation = 0.016 inches Speed Ratio = 1.136 Fabric Speed 500 fpm Air Side Abrasion Caliber = 10.2 MD = 1189 Stretch 12.8% CD = 973 Stretch 6.2% E J E M P L O 18 The following conditions were used and the following results were provided: Separation = 0.016 inches Speed Ratio = 1.5 Fabric Speed 500 fpm Fabric Side Abrasion Caliber = 10.9 MD = 1235 Stretching = 12.8! CD = 976 Stretching = 6.2% E J E M P L O 19 The following conditions were used, the following results were provided: Separation = 0.020 inches Speed Ratio = 1.5 Fabric Speed 500 fpm Fabric Side Abrasion Caliber = 10.5 MD = 1216 Stretching = 12.9% CD = 1076 Stretching = 6.1% The dust generated at this separation size was distinctly less than at the 0.016 inch separation. - E E M P L O 20 The following conditions were used and the following results were provided: Separation = 0.012 inches Speed Ratio = 1.5 Fabric Speed 500 fpm Air Side Abrasion Caliber = 11.2 MD = 1216 Stretching = 13.4% CD = 993 Stretching = 5.8% E J E L O 21 The following conditions were used and the following results were provided: Separation = 0.012 inches Speed Ratio = 1.5 Fabric Speed 500 fpm Air Side Abrasion Caliber = 13.3 MD = 1198 Stretching = 15.9 'CD = 1100 Stretching = 6.7% Gauge measurements were also taken after each machine section. The caliper after abrasion was only 22.7, after abrasion and calendering it was 14.2. The reduced separation again increased the amount of loose fiber ends.

E J E M P L O 22 The following conditions were used and the following results were provided: Separation = 0.016 inches Speed Ratio = 1.5 Fabric Speed 500 fpm Air Side Abrasion Caliber = 12.7 MD = 1135 Stretching = 15.0 'CD = 999 Stretching = 5.8% E J E M P L O 23 The following conditions were used and the following results were provided: Separation = 0.020 inches Speed Ratio = 1.5 Fabric Speed 500 fpm Air Side Abrasion Caliber = 13.3 MD = 1188 Stretching = 16.3! CD = 1032 Stretching = 5.8% In Examples 24 to 29 the abrasion roll was changed to a roll of 125 Ra and a roll of 400 Ra as indicated in the Examples. These rollers had runs of 0.002 inches on the drive side and 0.001 inches on the operator's side. The roller diameters were 5.85 inches.

E J E M P L O 24 The following conditions were used and the following results were provided: Roller 125 Ra Separation = 0.016 inches Speed Ratio = 1.5 Fabric Speed 1000 fpm Air Side Abrasion Caliber = 13.7 MD = 1022 Stretching = 16.4% CD = 1110 Stretching = 6.4% E M L O 25 The following conditions were used and the following results were provided: Roller 125 Ra Separation = 0.020 inches Speed Ratio = 1.5 Fabric Speed 1000 fpm Air Side Abrasion Caliber = 14.0 MD = 1141 Stretch = 15.7% CD = 1242 Stretch = 6.0% E J E M P L O 26 The following conditions were used provided the following results: Roller 125 Ra Separation = 0.012 inches Speed Ratio = 1.5 Fabric Speed 1000 fpm Air Side Abrasion Caliber = 14.0 MD = 1155 Stretching = 17.1% CD = 1080 Stretching = 6.3% The dust generation for the 125 R roller appeared to be greater than with the 250 Ra roller.

E J E P L O 27 The following conditions were used and the following results were provided: Roller of 400 Ra Separation = 0.012 inches Speed Ratio = 1.5 Fabric Speed 1000 fpm Air Side Abrasion Caliber = 13.6 MD = 1156 Stretching = 16.0% CD = 944 Stretching = 6.5% A larger amount of powder was generated with the 400 Ra roller than with the previous abrasion rollers.

E E M P L O 28 The following conditions were used and the following results were provided: Roller of 400 Ra Separation = 0.016 inches Rate of Speed = 1.5 Speed of the Fabric 1000 fpm Abrasion of Side to the Air Caliber = 12.6 MD = 1118 Stretching = 15.2% CD = 1161 Stretching = 6. 2% E J E M P L O 29 The following conditions were used provided the following results: Roller of 400 Ra Separation = 0.020 inches Rate of Speed = 1.5 Speed of Fabric 1000 fpm Abrasion of Side to Air Caliber = 13.9 MD = 1066 Stretching = 17.2? CD = 1245 Stretching = 5.9% It was observed that the motor load for the motorcycle driving the abrasion roller decreased as the interference with the fabric decreased.

In Examples 30 to 34 a sheet of properties similar to that used in Examples 10 to 29 was employed. The pressure point roll was loaded to a pressure point load of 2.3 pounds per linear inch on the base roll. A rubber base roller was used. An abrasion roller of 250 Ra was used with silicone applied to it. E roller abrasion had a diameter of 7 inches and a corrid of 0.001 inches. The abrasion took place on the air side of the sheet. The calendering took place after the abrasion and s loaded at 20 pounds per linear inch. The hauls for the machine for the mechanical softening apparatus were similar to those for Examples 5 to 9. The blade and abrasion roller were moving in the same direction. As the base line of the sheet runs the softening apparatus without abrasion and without calendering the sheet provided the following results: Caliber (one sheet) = 18.9 MD = 1132 Stretching = 20.6 'CD = 1243 Stretching = 6.2% E J E M L O 30 The following conditions were used provided the following results: 250 Ra (with / silicone) Separation = 0.020 inches Speed Ratio = 1.5 Fabric Speed 1000 fpm Caliber = 12.2 MD = 1115 Stretch 15.9. CD = 1074 Stretching 6.5% Very little dust was generated under these conditions.

E J E M L O 31 The following conditions were used and the following results were provided: 250 Ra (with / silicone) Separation = 0.016 inches Rate Ratio = 1.5 Fabric Speed 1000 fpm Caliber = 12.1 MD = 1159 Stretch = 14.8; CD = 1134 Stretching = 6.2% E E M P L O 32 The following conditions were used and the following results were provided: 250 Ra (with / silicone) Separation = 0.012"Abrasion Roller Current = 6.9 amps Rate Ratio = 1.5 Base Rodill Current = 7.6 amps Fabric Speed 1000 fpm Caliber = 11.4 MD = 1170 Stretching = 13.6% CD = 1106 Stretching = 6.6% The use of the Ra 250 with silicone generated much less dust than the Ra 125 or 400 rolls.

E E M P O 33 The following conditions were used, the following results were provided: 250 Ra (with / silicone) Separation = 0.008 inches Speed Ratio = 1.5 Fabric Speed 1000 fpm Caliber = 11.3 MD = 1103 Stretch = 13.3% CD = 1163 Stretch = 6.2% These conditions provided an increase in loose fiber ends and an improvement in softness compared to the other conditions using silicones on the abrasion roller.

E J E M P L O 34 The following conditions were used, the following results were provided: 250 Ra (with / silicone) Separation = 0.008 inches Speed Ratio = 1.25 Fabric Speed 1000 fpm Caliber = 12.0 MD = 1113 Stretching = 13.9% CD = 1106 Stretching = 5.4% In Example 35 a sheet similar to that used in Examples 5 to 9 was used. The pressure point roll was loaded to a pressure point of 2.3 pounds per linear inch loading onto the base roll. A rubber base roller was used. An abrasion roller of 250 Ra with silicone applied to it was used. The abrasion roller had a diameter of 7 inches and a run of 0.001 inches. The abrasion took place on the air side of the sheet. The calendering took place before abrasion and was loaded at 20 pounds per linear inch. The blade and the abrasion roller were moving in the same direction. As a baseline the sheet was run through softening apparatus without abrasion and the following results were provided: Caliber (one sheet) = 11.7 MD = 1060 Stretching = 13.9% CD = 1184 Stretching = 6.8% E J E M P L O 35 The following conditions were used provided the following results: 250 Ra (with / silicone) Separation = 0.008 inches Speed Ratio = 1.5 Fabric Speed 1000 fpm Caliber = 12.2 MD = 1114 Stretching = 15.0% CD = 1249 Stretching = 5.8% In Examples 36 to 52, a sheet having a supply similar to that used in Examples 5 to 9 was used. The caliper of the sheet before processing was 0.028 inches, its resistance in the machine direction was 970 and stretch was of 16.8 percent, its resistance in the transverse direction was 886 and its stretch was 9.7 percent. The pressure point roller was loaded to a pressure point load of 2.3 pounds per linear inch on the base roll. A rubber base roller was used. An abrasion rod of 250 Ra was used with (w /) and without (wo /) silicon applied to it as noted in the Examples. The abrasion roller had a diameter of 7 inches and a run of 0.00 inches. Abrasion took place on the air side of the sheet web as noted in the Examples. The calendering took place before the abrasion (except for Examples 50 to 52 in which the abrasion took place before calendering) and was loaded at 20 pounds per linear inch. The blade and the abrasion roller moved in the same direction The machine hauls were less -0.5 percent from the uncoiler to the calender, from 1.5 percent of the calender to the abrasion unit, and from 0 from the abrasion unit to the reel. As a baseline the sheet was run through the wear-free softening apparatus with sheet friction and the following results were provided: Caliber = 15.7 MD = 1048 Stretching = 13.8% CD = 784 Stretching = 7.6% E J E M P L O 36 The following conditions were used provided the following results: 250 Ra (with / silicone) Separation = 0.008 inches Speed Ratio = 1.5 Fabric Speed 1000 fpm Air Side Abrasion Caliber = 13.6 MD = 960 Stretching = 12.9% CD = 716 Stretching = 8.8% E J E M P O 37 The following conditions were used and the following results were provided: 250 Ra (with / silicone) Separation = 0.006 inches Speed Ratio = 1.5 Fabric Speed 1000 fpm Air Side Abrasion Caliber = 15.3 MD = 989 Stretching = 13.7% CD = 753 Stretching = 7.1% These conditions resulted in very little dust generation.

E J E M P L O 38 The following conditions were used provided the following results: 250 Ra (with / silicone) Separation = 0.004 inches Speed Ratio = 1.5 Fabric Speed 1000 fpm Air Side Abrasion Caliber = 16.0 MD = 885 Stretching = 14.5% CD = 707 Stretching = 7.5% At this level the separation was making it small enough to appear that it also caused a large degradation of the resistance E J E M P L O 39 The following conditions were used and the following results were provided: 250 Ra (with / silicone) Separation = 0.006 inches Velocity Ratio = 2.0 Fabric Speed 1000 fpm Abrasion from Side to Air Caliber = 15.4 MD = 994 Stretching = 12.8% CD = 756 Stretching = 7.1% It appears that the higher speed ratio resulted in a reduced machine direction stretch.

E J E M P L O 40 The following conditions were used, the following results were provided: 250 Ra (with / silicone) Separation = 0.006 inches Speed Ratio = 1.25 Fabric Speed 1000 fpm Air Side Abrasion Caliber = 17.6 MD = 1086 Stretching = 16.0% CD = 815 Stretching = 7.2% E J E M P L O 41 The following conditions were used and the following results were provided: 250 Ra (with / silicone) Separation = 0.006 inches Speed Ratio = 1.75 Fabric Speed 1000 fpm Air Side Abrasion Caliber = 16.3 MD = 1008 Stretching = 15.1. CD = 736 Stretching = 7.6% E J E M P L O 42 The following conditions were used provided the following results: 250 Ra (without / silicone) Separation = 0.010 inches Speed Ratio = 1.5 Fabric Speed 1000 fpm Air Side Abrasion Caliber = 15.6 MD = 1096 Stretching = 16.8% CD = 865 Stretching = 9.8% E J E M P L O 43 The following conditions were used provided the following results: 250 Ra (without / silicone) Separation = 0.008 inches Speed Ratio = 1.5 Fabric Speed 1000 fpm Air Side Abrasion Caliber = 16.7 MD = 1053 Stretch 15.0% CD = 895 Stretch 9.1% To these conditions a significant amount of dust was generated.

E J E M P L O 44 The following conditions were used and the following results were provided: 250 Ra (without / silicone) Separation = 0.006 inches Speed Ratio = 1.5 Fabric Speed 1000 fpm Air Side Abrasion Caliber = 16.5 MD = 1028 Stretching = 14.5% CD = 806 Stretching = 7.4% E E M P L O 45 The following conditions were used and s provided the following results: 250 Ra (without / silicone) Separation = 0.006 inches Speed Ratio = 1.25 Fabric Speed 1000 fpm Air Side Abrasion Caliber = 16.3 MD = 960 Stretch = 14.7? CD = 854 Stretching = 6.9% E J E M L O 46 The following conditions were used and the following results were provided: 250 Ra (without / silicone). (The remaining Examples are used on a roll of 250 Ra (without / silicone)). Separation = 0.006 inches Velocity Ratio = 2.0 Fabric Velocity 1000 fpm Abrasion from Side to Air Caliber = 14.4 MD = 890 Stretching = 11.9% CD = 731 Stretching = 6.7% E J E M P L O 47 The following conditions were used and the following results were provided: Separation = 0.006 inches Speed Ratio = 1.5 Fabric Speed 1000 fpm Fabric Side Abrasion Caliber = 14.7 MD = 970 Stretching = 13.6% CD = 766 Stretching = 6.6% E J E M P O 48 The following conditions were used and the following results were provided: Separation = 0.008 inches Speed Ratio = 1.5 Fabric Speed 1000 fpm Fabric Side Abrasion Caliber = 15.5 MD = 960 Stretching = 13.0% CD = 735 Stretching = 6.3% E J E M P L O 49 The following conditions were used and the following results were provided: Separation = 0.010 inches Speed Ratio = 1.5 Fabric Speed 1000 fpm Fabric Side Abrasion Caliber = 14.4 MD = 1017 Stretching = 13.6 'CD = 915 Stretching = 10.3' E J E M P L O 50 Calendering before abrasion and the following conditions were used and the following results were provided: Separation = 0.010 inches Speed Ratio = 1.5 Fabric Speed 1000 fpm Fabric Side Abrasion Caliber = 15.2 MD = 992 Stretch 14.0% CD = 833 Stretch 7.0% E J E M P L O 51 Calendering before abrasion and the following conditions were used and the following results were provided: Separation = 0.008 inches Speed Ratio = 1.5 Fabric Speed 1000 fpm Fabric Side Abrasion Caliber = 14.8 MD = 921 Stretching = 12.8% CD = 788 Stretching = 7.5% E J E M L O 52 Calendering before abrasion and the following conditions were used and the following results were provided: Separation = 0.010 inches Speed Ratio = 1.5 Fabric Speed 1000 fpm Fabric Side Abrasion Caliber = 15.3 MD = 944 Stretching = 13.3% CD = 764 Stretching = 7.9% E J E M L O 53 A sheet having properties similar to that used in Examples 36 to 52 was worn with friction on both sides. The calendering took place before the abrasion. The side of the sheet fabric was worn with friction under the same conditions as set forth in Example 49. The open air of the sheet was worn with friction under the following conditions and the following results were provided: Separation = 0.006 inches Speed Ratio = 1.5 Fabric Speed 1000 fpm Caliber = 12.0 MD = 1001 Stretching = 14.7% CD = 820 Stretching = 7.2% E J E M P L O 54 A sheet having properties similar to those used in Examples 36 to 52 was worn with friction on the air side. The load on the pressure point roller was reduced to 1.5 pounds per linear inch. The following conditions were used and the following results were provided: Separation = 0.006 inches Speed Ratio = 1.5 Fabric Speed 1000 fpm Caliber = 17.8 MD = 970 Stretching = 18.9% CD = 733 Stretching = 7.8% The fabric after the abrasion did not wrinkle but showed signs of withdrawal at the outlet of the calendering pressure point.

E J E M P O 55 A sheet having properties similar to that used in Examples 36 to 52 was worn with friction on the air side. The load on the pressure point roller was reduced to 0.8 pounds per linear inch. The following conditions were used and the following results were provided: Separation = 0.006 inches Speed Ratio = 1.5 Fabric Speed 1000 fpm Caliber = 17.7 MD = 930 Stretching = 18% CD = 830 Stretching = 7.5% The fabric handled the same for this pressure point loading as for the load in Example 53.

E J E M P L O 56 A sheet having properties similar to that used in Examples 36 to 52 was worn with friction on the air side with calendering before abrasion. The calendering was charged to 30 pounds per linear inch and the following conditions were used and the following results were provided: Separation = 0.006 inches Speed Ratio = 1.5 Fabric Speed 1000 fpm Caliber = 15.1 MD = 967 Stretching = 17.1% CD = 920 Stretching = 8.1% E J E M L O 57 A sheet having properties similar to that used in Examples 36 to 52 was worn with friction on the air side with calendering before abrasion. The calender was charged at 30 pounds per linear inch and the following conditions were used and the following results were provided: Separation = 0.006 inches Speed Ratio = 1.5 Fabric Speed 1500 fpm Caliber = 17.0 MD = 879 Stretching = 16.9? CD = 792 Stretching = 7.9% The increased dust levels occurred to increase the speed of that used in Example 55.

E J E M P L O 58 A sheet having properties similar to that used in Examples 36 to 52 was worn with friction on the air side with calendering before abrasion. The calender was charged at 30 pounds per linear inch and the following conditions were used and the following results were provided: Separation = 0.006 inches Speed Ratio = 1.5 Fabric Speed 2000 fpm Caliber = 18.4 MD = 945 Stretching = 19.4% CD = 803 Stretching = 7.5% Dust levels increased with speed.

E J E M P L O 59 A sheet having properties similar to that used in Examples 36 to 52 was worn with friction on the air side with calendering before abrasion. The calender was charged at 30 pounds per linear inch and the following conditions were used and the following results were provided: Separation = 0.006 inches Speed Ratio = 1.5 Fabric Speed 2200 fpm Caliber = 18.0 MD = 939 Stretching = 18.5% CD = 776 Stretching = 7.7% The moisture: dry ratio is simply the ratio of the wet tensile strength divided by the dry strength strength. This can be expressed using the tensile strengths in the machine direction (MD), the tensile strengths in the cross machine direction (CD), or the resistance to the geometric main tension (GMT).

The voltage tester is programmed (GAP [General Application Program], version 2.5, of System Integration Technology Inc., of Stoughton, MA, a division of MTS Systems Corporation, (of Research Triangle Park, North Carolina) so that This calculates a linear regression for the points that are sampled from Pl to P2.This calculation was made repeatedly on the curve by adjusting the points P to P2 in a regular way along the curve (described hereinafter) The highest value of these calculations is the Max tilt and when it is carried out on the direction of the specimen machine it is called the Max tilt in the direction of the machine.

The voltage tester program should be set so that five hundred points such as Pl and P2 are taken over two and one half inch (63.5 millimeters) in extension d. This provides a sufficient number of point to essentially exceed any practical specimen elongation. With a crosshead speed of ten inches per minute (254 millimeters / minute), this resulted in a point cad 0.030 seconds. The program calculates inclinations between these points by placing the tenth point as the starting point (for example Pl), counting thirty points to point 40 (for example P2) and carrying out a linear regression on this thirty points. This stores the inclination of this returned in any arrangement. The program then counts up to points until the twentieth point (which becomes Pl) repeats the processing again (counting thirty points to what would be the fiftieth point (which becomes P2), calculating the slope and then storing it in arrangement). This process continues for the complete lengthening of the leaf. The Max tilt is then chosen as the highest value of this arrangement. Max tilt units or kilograms per three inch specimen width. (Tension is then without dimension since the length of extension is divided by the length of the jaw extension.This calculation is taken into account by the test machine program).

Claims (42)

R E I V I N D I C A C I O N S

1. A soft tissue product having an increased surface villus formed by abrading with friction a tissue product comprising one or more tissue layers and having a machine direction inclination Max of about 10 or less.

2. A soft tissue product having an increased surface villi formed by abrading a non-creped continuous dried fabric comprising at least about 10 percent by dry weight of high yielding pulp fibers and a proportion of Humid geometric head tension: dry of around 0.1 or greater.

3. A sheet of soft tissue comprising: a first surface and a second surface; each surface comprises fibers for making paper; and, at least one of the surfaces having selectively loosened areas of the fibers for making paper.

4. The soft tissue sheet as claimed in clause 3 characterized in that the first surface comprises short paper fibers and in which the selectively released areas are located on the first surface.

5. The soft tissue sheet as claimed in clause 3 characterized in that the selectively released areas are located on both the first and second surfaces.

6. The soft tissue sheet as claimed in clause 3 characterized in that the sheet is a single layer sheet.

7. The soft tissue sheet as claimed in clause 3 characterized in that the sheet has a tensile strength in the machine direction of at least about 1,000 grams by 3 inches and a tensile strength in the direction transverse to the machine of at least about 800.

8. The soft tissue sheet as claimed in clause 6 characterized in that the surface of the single layer sheet is essentially of the same smoothness.

9. A soft paper product comprising: a first layer and a second layer, the layers each comprising fibers for making paper; a first and a second surface, the first surface corresponds to the surface d of the first layer and the second surface corresponds to the surface of the second layer; and at least one of the surfaces has fibers released thereon.

10. A soft sheet product having a tensile strength in the machine direction of at least about 1,000 grams by 3 inches and a cross-machine direction tensile strength of at least about 800 grams per 3 inches comprising a first surface and a second surface each surface comprises fibers; and at least one of the surfaces has substantial loose fibers on it

11. The soft sheet product as claimed in clause 10 characterized in that the product d sheet is a nonwoven product.

12. The soft sheet product as claimed in clause 10 characterized in that the fibers comprise fibers for making paper.

13. The soft sheet product as claimed in clause 10 characterized in that the sheet product is a single layer paper product.

14. A sheet of paper has an improved d absorbency rate comprising: a first sheet surface and a second sheet surface; a layer comprising the fibers for making paper; the layer has a surface; the surface of the layer corresponds to a surface of the paper sheet; the surface of the layer has fibers worn with friction; The rate of absorbency of the sheet is greater than a sheet of similar composition but not having fibers worn with friction on its surface and the amount of absorbency for the sheet is comparable to the non-worn sheet with similar friction.

15. The sheet of paper as claimed in clause 14 characterized in that the sheet is a tissue for the bathroom.

16. The sheet of paper as claimed in clause 15 characterized in that the bath tissue has a second layer comprising fibers for making paper.

17. The sheet of paper as claimed in clause 14 characterized in that the sheet is a towel product.

18. The sheet of paper as claimed in clause 17 characterized in that the towel product has a second layer comprising fibers for making paper.

19. The sheet of paper as claimed in clause 14 characterized in that the sheet is a facial tissue.

20. The sheet of paper as claimed in clause 19 characterized in that the facial tissue has a second layer comprising fibers for making paper.

21. The sheet of paper as claimed in clause 14 characterized in that the first and second leaf surfaces have fibers worn with friction thereon.

22. The sheet of paper as claimed in clause 21 characterized in that the first and second leaf surfaces have essentially the same smoothness.

23. A soft paper product comprising a layer; the layer comprises long papermaking fibers; the cap has a surface; the surface has a PR / EL of plus d around 0.72.

24. The paper product as claimed in clause 23 characterized in that the PR / EL is greater than about 1.

The paper product as claimed in clause 24 characterized in that the layer comprises at least about 25 percent of the long papermaking fibers.

26. The paper product as claimed in clauses 23, 24 or 25 characterized in that the surface has at least about 20 percent of the fields of view having a PR / EL ratio of about 2 or greater.

27. A method for making a sheet product having an improved smoothness comprising: (a) obtaining a fabric of fibrous material in the form of a sheet; (b) feeding the tissue into an abrasion apparatus comprising a pressure device; a backup roller; and an abrasion roller; Y (c) abrade the surface of the fabric with friction with the abrasion roller.

28. The method as claimed in clause 27 characterized in that the fabric comprises fibers for making paper.

29. The method as claimed in clause 27 characterized in that the abrasion roller has a surface roughness of from about 125 Ra to about 400 Ra.

30. The method as claimed in clause 28 characterized in that the abrasion roller has a surface roughness of from about 125 Ra to about 400 Ra.

31. The methods as claimed in clause 28 characterized in that the abrasion apparatus is located on the paper machine.

32. The method as claimed in clause 31 characterized in that the spool forms part of the abrasion apparatus.

33. A method for treating a paper fabric comprising: (a) feeding a paper web comprising fibers for making paper into a pressure point formed by a first and a second roller; (b) the pressure point applies pressure to the tissue to hold the tissue against the second roller; (c) the tissue partially envelops and moves around and with the second roller; (d) a third roller making contact with the tissue while the fabric is against the second roller and the third roller having a rough surface; Y (e) the third roller rotates while in contact with the fabric to loosen the fibers on the surface of the fabric.

34. The method as claimed in clause 33 characterized in that the fabric is calendered before contacting the third roller.

35. The method as claimed in clause 33 characterized in that the fabric is calendered after making contact with the third roller.

36. The method as claimed in clause 33 characterized in that the third roller has a roughness of from about 125 Ra to about 400 Ra.

37. A method for treating a paper fabric comprising: (a) obtaining a paper web comprising fibers for making paper; (b) bringing the tissue paper into contact with the first roller; (Or hold the fabric against the first roller; (d) the tissue wrapping partially moving around and with the first roller; (e) a second roller that contacts the fabric while the fabric is in contact against the first roller, the second roller has a rough surface; Y (f) the second roller rotates while in contact with the fabric to release the fibers on the surface of the fabric.

38. The method as claimed in clause 37 characterized in that the fabric is calendered before contacting the second roller.

39. The method as claimed in clause 37 characterized in that the fabric is calendered after contacting the second roller.

40. The method as claimed in clause 37 characterized in that the second roller has a roughness of from about 125 Ra to about 400 Ra.

41. The method as claimed in clause 37 characterized in that the method is carried out on a paper machine.

42. An apparatus for treating fabrics of fibrous material comprising: (a) a first roller; (b) a second roller; (c) a tensioning device; (d) a frame to hold the rollers and device in an established relationship; (e) the tensioning device positioned on the side of the first roller; (f) the second roller positioned closer to the first roller, and set at a distance of from about 0.006 inches to about 0.008 inches from the first roller; Y (g) the second roller has a wear surface of sufficient roughness to release the fibers only on the surface of the fabric being treated. U M E N New and improved methods and products relating to the softness of fibrous tissues are described. The increased softness, among other things, is obtained by abrading the surface of the fabric with friction to create villus of the protruding fibers.