EP3556937B1 - Paper sheet and method for manufacturing paper sheet - Google Patents
Paper sheet and method for manufacturing paper sheet Download PDFInfo
- Publication number
- EP3556937B1 EP3556937B1 EP17881628.6A EP17881628A EP3556937B1 EP 3556937 B1 EP3556937 B1 EP 3556937B1 EP 17881628 A EP17881628 A EP 17881628A EP 3556937 B1 EP3556937 B1 EP 3556937B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- paper sheet
- flow direction
- sheet
- paper
- fibers
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- 235000019504 cigarettes Nutrition 0.000 claims description 40
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- 239000000463 material Substances 0.000 claims description 13
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- 125000003178 carboxy group Chemical group [H]OC(*)=O 0.000 claims description 12
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- DPXJVFZANSGRMM-UHFFFAOYSA-N acetic acid;2,3,4,5,6-pentahydroxyhexanal;sodium Chemical compound [Na].CC(O)=O.OCC(O)C(O)C(O)C(O)C=O DPXJVFZANSGRMM-UHFFFAOYSA-N 0.000 description 3
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- 229920000742 Cotton Polymers 0.000 description 2
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- KIUKXJAPPMFGSW-DNGZLQJQSA-N (2S,3S,4S,5R,6R)-6-[(2S,3R,4R,5S,6R)-3-Acetamido-2-[(2S,3S,4R,5R,6R)-6-[(2R,3R,4R,5S,6R)-3-acetamido-2,5-dihydroxy-6-(hydroxymethyl)oxan-4-yl]oxy-2-carboxy-4,5-dihydroxyoxan-3-yl]oxy-5-hydroxy-6-(hydroxymethyl)oxan-4-yl]oxy-3,4,5-trihydroxyoxane-2-carboxylic acid Chemical compound CC(=O)N[C@H]1[C@H](O)O[C@H](CO)[C@@H](O)[C@@H]1O[C@H]1[C@H](O)[C@@H](O)[C@H](O[C@H]2[C@@H]([C@@H](O[C@H]3[C@@H]([C@@H](O)[C@H](O)[C@H](O3)C(O)=O)O)[C@H](O)[C@@H](CO)O2)NC(C)=O)[C@@H](C(O)=O)O1 KIUKXJAPPMFGSW-DNGZLQJQSA-N 0.000 description 1
- 239000002028 Biomass Substances 0.000 description 1
- 241000196324 Embryophyta Species 0.000 description 1
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- LSNNMFCWUKXFEE-UHFFFAOYSA-N Sulfurous acid Chemical compound OS(O)=O LSNNMFCWUKXFEE-UHFFFAOYSA-N 0.000 description 1
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Images
Classifications
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H13/00—Pulp or paper, comprising synthetic cellulose or non-cellulose fibres or web-forming material
- D21H13/02—Synthetic cellulose fibres
- D21H13/06—Cellulose esters
-
- A—HUMAN NECESSITIES
- A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
- A24D—CIGARS; CIGARETTES; TOBACCO SMOKE FILTERS; MOUTHPIECES FOR CIGARS OR CIGARETTES; MANUFACTURE OF TOBACCO SMOKE FILTERS OR MOUTHPIECES
- A24D3/00—Tobacco smoke filters, e.g. filter-tips, filtering inserts; Filters specially adapted for simulated smoking devices; Mouthpieces for cigars or cigarettes
- A24D3/06—Use of materials for tobacco smoke filters
- A24D3/062—Use of materials for tobacco smoke filters characterised by structural features
-
- A—HUMAN NECESSITIES
- A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
- A24D—CIGARS; CIGARETTES; TOBACCO SMOKE FILTERS; MOUTHPIECES FOR CIGARS OR CIGARETTES; MANUFACTURE OF TOBACCO SMOKE FILTERS OR MOUTHPIECES
- A24D3/00—Tobacco smoke filters, e.g. filter-tips, filtering inserts; Filters specially adapted for simulated smoking devices; Mouthpieces for cigars or cigarettes
- A24D3/06—Use of materials for tobacco smoke filters
- A24D3/08—Use of materials for tobacco smoke filters of organic materials as carrier or major constituent
- A24D3/10—Use of materials for tobacco smoke filters of organic materials as carrier or major constituent of cellulose or cellulose derivatives
-
- A—HUMAN NECESSITIES
- A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
- A24D—CIGARS; CIGARETTES; TOBACCO SMOKE FILTERS; MOUTHPIECES FOR CIGARS OR CIGARETTES; MANUFACTURE OF TOBACCO SMOKE FILTERS OR MOUTHPIECES
- A24D3/00—Tobacco smoke filters, e.g. filter-tips, filtering inserts; Filters specially adapted for simulated smoking devices; Mouthpieces for cigars or cigarettes
- A24D3/06—Use of materials for tobacco smoke filters
- A24D3/14—Use of materials for tobacco smoke filters of organic materials as additive
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
- D21H17/20—Macromolecular organic compounds
- D21H17/33—Synthetic macromolecular compounds
- D21H17/34—Synthetic macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D21H17/37—Polymers of unsaturated acids or derivatives thereof, e.g. polyacrylates
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
- D21H27/30—Multi-ply
- D21H27/40—Multi-ply at least one of the sheets being non-planar, e.g. crêped
Definitions
- the present invention relates to a paper sheet having excellent processability, the paper sheet realizing excellent production efficiency of processed products made thereof, and also relates to a method of producing the paper sheet.
- Cellulose ester compounds typically represented by cellulose acetate are excellent natural polymer compounds that are safe and highly processable.
- Cellulose ester compounds are widely utilized for clothing fibers, various plastics, cigarette filters, etc.
- cellulose ester compounds are made from cellulose obtained from plant resources (biomass) that are produced in the greatest quantity on earth, such as wood pulp and cotton. Therefore, such environmental-friendly cellulose ester compounds are regarded as suitable raw materials for a recycling-oriented society, and the expansion of the use of cellulose ester compounds instead of chemical fibers and plastics that are made from petroleum is expected.
- Patent Literature 1 discloses a technique for producing a paper sheet containing cellulose ester staple fibers, pulp fibers, and a binder. Such a paper sheet is, for example, usable as the material of a processed product, such as a cigarette filter, as disclosed in Patent Literatures 2 and 3.
- the paper sheet is, for example, produced in a continuous belt-like shape by using a wet paper machine.
- the continuous belt-shaped paper sheet is subjected to slitting to have a required width, and is then wound into a roll.
- the wound paper sheet is drawn from the roll and subjected to continuous processing while being fed at a predetermined feeding speed.
- EP2862456 discloses a paper sheet comprising a cellulose ester staple fiber, a pulp, and an alkali metal salt of a water-soluble anionic polymer, wherein the paper sheet has an alkali metal content of 2 to 100 ⁇ mol per gram of the paper sheet.
- EP0709037 discloses a tobacco filter material in the form of a sheet having a web structure and comprising a cellulose ester short staple.
- the wound paper sheet When the wound paper sheet is drawn from the roll to continuously produce processed products by using the paper sheet, if tension is exerted on the paper sheet in the feeding direction to a certain degree or greater, the paper sheet may become damaged. As a result, the processability of the paper sheet may be lowered. Consequently, it may become difficult to improve the production efficiency of the processed products by increasing the feeding speed of the paper sheet.
- an objective of the present invention is to, in the case of producing processed products by using a paper sheet containing cellulose ester staple fibers, make it possible to prevent damage to the paper sheet and improve production efficiency of the processed products.
- a paper sheet includes: cellulose ester staple fibers; pulp fibers; and a binder, wherein a plurality of creped portions are formed on the paper sheet, such that the creped portions are arranged in a flow direction of the cellulose ester staple fibers and the pulp fibers and extend in an orthogonal direction orthogonal to the flow direction.
- the plurality of creped portions (continuous or non-continuous wrinkles), which are arranged in the flow direction of the cellulose ester staple fibers and the pulp fibers and extend in the orthogonal direction orthogonal to the flow direction, are formed on the paper sheet. Accordingly, when producing processed products by using the paper sheet while feeding the paper sheet in the flow direction, if tension is exerted on the paper sheet in the flow direction, the paper sheet stretches in the flow direction. This makes it possible to prevent damage to the paper sheet and prevent the processability of the paper sheet from being lowered. Since damage to the paper sheet due to the tension being exerted on the paper sheet in the flow direction is prevented, the feeding speed of the paper sheet in a processing machine can be increased, and thereby the production efficiency of the processed products can be improved.
- the paper sheet may be formed in a belt-like shape, such that a longitudinal direction of the paper sheet is the flow direction. Accordingly, when the paper sheet that has been wound into a roll is drawn from the roll and fed in order to be continuously processed by a processing machine, even if tension is exerted on the paper sheet in the longitudinal direction (feeding direction), damage to the paper sheet is less likely to occur, which makes it possible to further improve the production efficiency of the processed products.
- a crepe ratio of the paper sheet may be set to a value within a range of not less than 5% and not greater than 35%. Since the crepe ratio is set to such a value, when tension is exerted on the paper sheet in the flow direction, the paper sheet stretches in the flow direction, and thereby damage to the paper sheet can be suitably prevented.
- a breaking elongation of the paper sheet in the flow direction may be set to a value within a range of not less than 10% and not greater than 70%. Since the breaking elongation is set to such a value, when tension is exerted on the paper sheet in the flow direction, damage to the paper sheet can be favorably prevented.
- a tensile strength of the paper sheet in the flow direction may be set to a value within a range of not less than 1.5 N/25 mm width and less than 40 N/25 mm width. Accordingly, when reeling in the paper sheet in the flow direction, the paper sheet can be prevented from breaking due to the tension exerted on the paper sheet in the flow direction, and also, the processability of the paper sheet can be suitably kept.
- the binder may be an alkali salt of a polysaccharide containing a carboxyl group.
- the use of the binder of this kind makes it possible to efficiently produce a processed product having high water disintegrability by using the paper sheet.
- the paper sheet may be a filter material of a cigarette filter. Since the plurality of creped portions, which are arranged in the flow direction and extend more in the orthogonal direction than in the flow direction, are formed on the paper sheet, the paper sheet has a large area. Accordingly, by using the paper sheet as a filter material of the cigarette filter, plenty of fine spaces can be uniformly formed inside the cigarette filter. As a result of the fine spaces being uniformly formed, a cigarette filter having a beautiful cross section with no unevenness can be produced.
- a method of producing a paper sheet according to another aspect of the present invention includes: a sheet body forming step of forming a sheet body containing cellulose ester staple fibers, pulp fibers, and a binder; and a creping step of forming a plurality of creped portions on the sheet body, such that the creped portions are arranged in a flow direction of the cellulose ester staple fibers and the pulp fibers and extend in an orthogonal direction orthogonal to the flow direction.
- the sheet body forming step may include forming the sheet body in a belt-like shape, such that a longitudinal direction of the sheet body is the flow direction.
- a crepe ratio of the paper sheet may be set to a value within a range of not less than 5% and not greater than 35%.
- a tensile elongation of the paper sheet in the flow direction may be set to a value within a range of not less than 10% and not greater than 70%.
- a tensile strength of the paper sheet in the flow direction may be set to a value within a range of not less than 1.5 N/25 mm width and less than 40 N/25 mm width by adjusting at least one of a blending ratio of the cellulose ester staple fibers, the pulp fibers, and the binder, a basis weight of the paper sheet, a beating degree of the cellulose ester staple fibers and the pulp fibers, and a crepe ratio of the paper sheet.
- an alkali salt of a polysaccharide containing a carboxyl group may be used as the binder.
- Each of the above aspects of the present invention makes it possible to, in the case of producing processed products by using a paper sheet containing cellulose ester staple fibers, prevent damage to the paper sheet and improve the production efficiency of the processed products.
- FIG. 1 shows a paper sheet 1 according to an embodiment of the present invention.
- the paper sheet 1 contains cellulose ester staple fibers, pulp fibers, and a binder.
- the paper sheet 1 is produced in a belt-like shape by a paper machine 10 (see FIG. 2 ), and wound into a roll.
- FIG. 1 schematically shows, in an enlarged manner, creped portions 1a formed on the paper sheet 1.
- the roll of the paper sheet 1 is subjected to slitting to have a required width in the subsequent processes, and drawn from the roll continuously for producing processed products.
- the cellulose ester is cellulose acetate, which is a typical cellulose ester.
- the cellulose ester staple fibers may be crimped.
- the cellulose ester staple fibers are preferably non-crimped fibers (uncrimped fibers).
- the definition of the non-crimped fibers herein includes not only fully straight fibers but also slightly curved fibers.
- the non-crimped fibers can be obtained by a general chemical fiber spinning technique (e.g., dry spinning, wet spinning, or melt spinning).
- the non-crimped fibers can be obtained by applying tension to crimped fibers whose crimps have previously been formed in a spinning process while heating the crimped fibers by heating means such as heated steam, thereby fully removing the crimps and stretching the fibers.
- the cellulose ester staple fibers can be obtained from a filament fiber bundle that is obtained in the aforementioned spinning process.
- the process of turning cellulose ester fibers into the staple fibers by means of the guillotine equipment or the rotary cutter equipment may be performed continuously with the spinning process.
- the average fiber length of the cellulose ester staple fibers (in the case of crimped fibers, the average value of the end-to-end distances of the crimped fibers in a natural state) can be set to, for example, a value within the range of not less than 1 mm and not greater than 6 mm, preferably a value within the range of not less than 1.5 mm and not greater than 5.0 mm, and more preferably a value within the range of not less than 2.0 mm and not greater than 4.5 mm.
- the average fiber diameter of the cellulose ester staple fibers can be set to, for example, a value within the range of not less than 1.5 denier and not greater than 8.0 denier, preferably a value within the range of not less than 2.0 denier and not greater than 7.0 denier, and more preferably a value within the range of not less than 2.5 denier and not greater than 6.0 denier.
- Each of the cellulose ester staple fibers has, for example, a Y-shaped cross section. However, the cross-sectional shape of the cellulose ester staple fibers is not limited to a Y shape.
- the crimpability, the average fiber length, the average fiber diameter, and the cross-sectional shape of the cellulose ester staple fibers can be confirmed by disintegrating the paper sheet 1 in water and observing the resulting water-disintegrated product with a microscope.
- the paper sheet 1 may also contain other fibers (synthetic fibers, recycled fibers, etc.) different from the cellulose ester fibers and the pulp fibers.
- the pulp fibers are entangled with the cellulose ester staple fibers, and thereby the pulp fibers and the cellulose ester staple fibers are bonded to each other.
- the mechanical strength of the paper sheet 1 can be improved.
- the gaps between the fibers can be adjusted by adjusting the amount of pulp fibers, the amount of cellulose ester staple fibers, and the blending ratio of the pulp fibers and the cellulose ester staple fibers, and thereby a required filtration rate of, for example, smoke components can be adjusted.
- the pulp can be made from natural fibers, such as wood and cotton linter.
- the wood may be either softwood or hardwood.
- a suitable pulping process to be adopted is a chemical pulping process, such as a sulfite process or kraft process.
- chemical pulping process such as a sulfite process or kraft process.
- kraft pulp is superior to the other pulps in terms of obtaining higher strength of the paper sheet 1 with the same composition ratio.
- the pulp may be any of bleached pulp, unbleached pulp, and a mixture of bleached pulp and unbleached pulp. The pulp is beaten by a common beater or disintegrator, and thus prepared for use.
- the weight ratio of the weight of the cellulose ester staple fibers contained in the paper sheet 1 to the weight of the pulp fibers contained in the paper sheet 1 is suitably adjustable in accordance with, for example, a processed product that is produced by using the paper sheet 1.
- the weight ratio is adjusted in accordance with required smoke filtration performance of the cigarette filter.
- the weight ratio of the weight of the cellulose ester staple fibers contained in the paper sheet 1 to the weight of the pulp fibers contained in the paper sheet 1 can be adjusted such that the weight ratio M1/M2 of the weight M1 of the cellulose ester staple fibers contained in the cigarette filter to the weight M2 of the pulp fibers contained in the cigarette filter is, for example, 30/70 to 95/5, preferably 40/60 to 80/20, and more preferably 50/50 to 70/30.
- the binder causes the cellulose ester staple fibers and the pulp fibers to be bonded to each other.
- a predetermined amount of water-soluble polymer may be used as the binder of the paper sheet 1, and thereby both strength of the paper sheet 1 in a dry state and water disintegrability of the paper sheet 1 can be realized.
- a binder capable of imparting water disintegrability to the paper sheet 1 is used as the binder of the present embodiment.
- the binder of the present embodiment is an alkali metal salt of a water-soluble anionic polymer.
- the water-soluble anionic polymer include polysaccharides (e.g., a polysaccharide containing a carboxyl group, for example, carboxymethyl cellulose, carboxymethyl C 2-3 alkyl cellulose such as carboxymethylethyl cellulose, carboxymethyl starch, or alginic acid; and a polysaccharide containing a sulfo group, for example, pectin, carageenan, hyaluronic acid, or chondroitin sulfuric acid) and polyacrylic acid.
- the binder of the present embodiment is an alkali salt of a polysaccharide containing a carboxyl group.
- the alkali metal salt of the water-soluble anionic polymer is contained in a predetermined amount in the paper sheet 1 as a binder, the bonding force between the cellulose ester staple fibers, the bonding force between the pulp fibers, and the bonding force between these two kinds of fibers when the paper sheet 1 is in a dry state are increased by the binder, and thereby the strength of the paper sheet 1 can be improved.
- the acidic group (such as the carboxyl group or the sulfo group) of the water-soluble anionic polymer forms a salt with an alkali metal.
- alkali metal include lithium, sodium, and potassium. Among these alkali metals, sodium is preferred. A single kind or two or more kinds of alkali metals may be used.
- the average substitution degree of the carboxyl group (e.g., carboxymethyl group) forming the alkali metal salt can be set to, for example, a value within the range of not less than 0.4 and not greater than 2.5, preferably a value within the range of not less than 0.55 and not greater than 2.0, and more preferably a value within the range of not less than 0.65 and not greater than 1.5.
- the alkali metal content in the paper sheet 1 can be set to, for example, a value within the range of not less than 2 ⁇ mol and not greater than 100 ⁇ mol per gram of the paper sheet 1, preferably a value within the range of not less than 2 ⁇ mol and not greater than 90 ⁇ mol, more preferably a value within the range of not less than 2 ⁇ mol and not greater than 87 ⁇ mol, and particularly preferably a value within the range of not less than 3 ⁇ mol and not greater than 75 ⁇ mol.
- the water-soluble anionic polymer alkali metal salt content (molar quantity of anionic group) in the paper sheet 1 may be the same as the alkali metal content (molar quantity) in the paper sheet 1.
- the water-soluble anionic polymer alkali metal salt content (molar quantity of anionic group) in the paper sheet 1 can be set, per gram of the cigarette filter, to a value within the same range as that mentioned above (e.g., to a value within the range of not less than 2 ⁇ mol and not greater than 100 ⁇ mol).
- the binder may be different from an alkali metal salt of a water-soluble anionic polymer.
- the basis weight of the paper sheet can be set to, for example, a value within the range of not less than 10 g/m 2 and not great than 60g/m 2 , and preferably a value within the range of not less than 15 g/m 2 and not greater than 50 g/m 2 .
- the basis weight of the paper sheet 1 of the present embodiment is set to a value within the range of not less than 21 g/m 2 and not greater than 40 g/m 2 .
- the paper sheet 1 may contain at least one kind of additive agent.
- the additive agent is, for example, at least one of a sizing agent, a stabilizer, a colorant, an oil solution, a retention aid, a defoaming agent, and activated carbon.
- the additive agent is not limited to these examples.
- a plurality of creped portions are formed such that the creped portions are arranged in a flow direction of the cellulose acetate staple fibers and the pulp fibers (hereinafter, this direction may be simply referred to as “the flow direction”) and extend in an orthogonal direction orthogonal to the flow direction (hereinafter, this direction may be simply referred to as “the orthogonal direction”).
- the plurality of creped portions 1a extend parallel to the orthogonal direction.
- the flow direction herein is the substantial orientation direction of the cellulose acetate staple fibers and the pulp fibers (i.e., the grain direction).
- these fibers are oriented in the orientation direction, because the speed of the flow of a composition that is the raw material of the paper sheet 1 when the composition is fed to a wire mesh 21 of the paper machine 10 is lower than the feeding speed of the wire mesh 21 (see FIG. 2 ). Accordingly, the fibers in the composition are deposited such that they are oriented more in the flow direction than in the other directions. That is, the flow direction coincides with the direction in which the composition is fed to the next process.
- the strength and elongation of the paper sheet 1 in the flow direction differ from those of the paper sheet 1 in the orthogonal direction.
- the tensile strength of the paper sheet is greatest in the flow direction. Therefore, the flow direction of the paper sheet 1 and the orthogonal direction thereto can be confirmed by observing the tensile strength difference in the paper sheet 1 between two different directions, or by observing the fiber orientation in the paper sheet 1 with a microscope.
- the paper sheet 1 is formed in a belt-like shape, and the longitudinal direction thereof is the flow direction. As a result of the plurality of creped portions 1a being formed on the paper sheet 1, stretchability is imparted to the paper sheet 1 such that the paper sheet 1 is stretchable in the flow direction, and also, the surface area of the paper sheet 1 per unit length in the flow direction is increased.
- orthogonal direction orthogonal to the flow direction is not limited to the direction that is exactly orthogonal to the flow direction, but includes, for example, directions that are each shifted from the exactly orthogonal direction by an angular value within the range of 10°.
- the crepe ratio R of the paper sheet 1 is set to a value within the range of not less than 5% and not greater than 35%.
- V1 is the peripheral speed of a heating roller 26 of the paper machine 10 when producing the paper sheet 1
- V2 is the peripheral speed of a winding reel 28 of the paper machine 10 when producing the paper sheet 1 (see FIG. 2 ).
- the breaking elongation of the paper sheet 1 in the flow direction is set to a value within the range of not less than 10% and not greater than 70%.
- the tensile strength (N/25 mm width) of the paper sheet 1 can be set to, for example, a value within the range of not less than 1.0 N/25 mm width and not greater than 80 N/25 mm width, and preferably a value within the range of not less than 1.5 N/25 mm width and not greater than 40 N/25 mm width.
- the tensile strength of the paper sheet 1 in the flow direction is set to a value within the range of not less than 1.5 N/25 mm width and less than 40 N/25 mm width.
- the tensile strength of the paper sheet 1 can be measured, for example, in conformity with the method of JIS P8113.
- the plurality of creped portions 1a which are arranged in the flow direction and extend in the orthogonal direction orthogonal to the flow direction, are formed on the paper sheet 1. Accordingly, when producing processed products by using the paper sheet 1 while feeding the paper sheet 1 in the flow direction, if tension is exerted on the paper sheet 1 in the flow direction, the paper sheet 1 stretches in the flow direction. This makes it possible to prevent damage to the paper sheet 1 and prevent the processability of the paper sheet 1 from being lowered.
- the feeding speed of the paper sheet in a processing machine can be increased to improve the production efficiency of the processed products, and thereby secondary processability of the paper sheet 1 can be improved.
- the paper sheet 1 can be made less likely to tear, the paper sheet 1 can be subjected to, for example, three-dimensional processing using a mold, and thereby the paper sheet 1 can be processed to have a fine three-dimensional structure. Accordingly, for example, a face mask having a three-dimensional structure can be favorably produced by using the paper sheet 1.
- the paper sheet 1 is formed in a belt-like shape, such that the longitudinal direction thereof is the flow direction. Accordingly, when the paper sheet 1 that has been wound into a roll is drawn from the roll and fed to be continuously subjected to processing by a processing machine, even if tension is exerted on the paper sheet 1 in the longitudinal direction (feeding direction), damage to the paper sheet 1 is less likely to occur, which makes it possible to further improve the production efficiency of the processed products.
- the crepe ratio R of the paper sheet 1 is set to a value within the range of not less than 5% and not greater than 35%. Accordingly, when tension is exerted on the paper sheet 1 in the flow direction, the paper sheet 1 stretches in the flow direction, and thereby damage to the paper sheet 1 can be suitably prevented.
- the breaking elongation of the paper sheet 1 in the flow direction is set to a value within the range of not less than 10% and not greater than 70%. Accordingly, when tension is exerted on the paper sheet 1 in the flow direction, damage to the paper sheet 1 can be favorably prevented.
- the tensile strength of the paper sheet 1 in the flow direction is set to a value within the range of not less than 1.5 N/25 mm width and less than 40 N/25 mm width. Accordingly, when reeling in the paper sheet 1 in the flow direction, the paper sheet 1 can be prevented from breaking due to the tension exerted on the paper sheet 1 in the flow direction, and also, the processability of the paper sheet 1 can be suitably kept.
- the binder is an alkali salt of a polysaccharide containing a carboxyl group. This makes it possible to produce a processed product having high water disintegrability by using the paper sheet 1.
- the processed product produced by using the paper sheet 1 is a makeup removing sheet (nonwoven fabric). Owing to the plurality of creped portions 1a, the makeup removing sheet has a larger surface area, and therefore exerts a better makeup removing effect than makeup removing sheets having a flat surface.
- the cellulose ester staple fibers used in the makeup removing sheet have higher lipophilicity than, for example, rayon fibers that are an existing fiber material. Therefore, even if makeup agents contain oil components, a high makeup removing effect can be obtained with the makeup removing sheet. Owing to the plurality of creped portions 1a, the makeup removing sheet also has improved softness. Therefore, the makeup removing sheet easily deforms when coming into contact with the skin, thereby realizing favorable texture and low irritation to the skin, and thus excellent feeling of use can be expected.
- a cleaning sheet nonwoven fabric
- the cleaning sheet Owing to the plurality of creped portions 1a, the cleaning sheet has a larger surface area and the bulkiness of the cleaning sheet is not easily lost. Therefore, the cleaning sheet is capable of adsorbing dirt and extraneous matter present on a cleaning object, thereby making it possible to readily wipe them off the cleaning object.
- the cleaning sheet does not easily tear since the cleaning sheet is highly stretchable, and also, the cleaning sheet is capable of following the shape of the surface of the cleaning object. Therefore, the cleaning work can be performed efficiently with the cleaning sheet.
- the paper sheet 1 having water disintegrability is produced by using, as a binder, an alkali salt of a polysaccharide containing a carboxyl group, then the processed product produced by using the paper sheet 1, such as a cleaning sheet, can be disintegrated in water for disposal after use.
- Cellulose esters are natural compounds containing cellulose, as a base material, which is the same cellulose as that of pulp. Accordingly, it is known that when such a cellulose ester is dispersed in water, the cellulose ester is decomposed by microorganisms with a relatively long period of time. Thus, the cleaning sheet produced by using the paper sheet 1 is degradable in a natural environment.
- the processed product produced by using the paper sheet 1 is a cigarette filter.
- the cigarette filter is produced in the following manner: form the paper sheet 1 into a columnar shape; wrap rolling paper around the outside of the columnar paper sheet 1; and cut it to have a predetermined length.
- the paper sheet 1 is used as a filter material of the cigarette filter.
- the paper sheet 1 Since the plurality of creped portions 1a are formed on the paper sheet 1, the paper sheet 1 has a large surface area. Accordingly, by using the paper sheet 1 as a filter material of the cigarette filter, plenty of fine spaces can be uniformly formed inside the cigarette filter. As a result of the fine spaces being uniformly formed, a columnar cigarette filter having a beautiful cross section with no unevenness can be produced. Thus, by using the paper sheet 1, a cigarette filter with less pressure drop (PD), which is easy to smoke and capable of efficiently capturing smoke particles, can be obtained with stable quality.
- PD pressure drop
- the cigarette filter can be favorably produced while suppressing increase in the pressure drop and adjusting the packing weight of the paper sheet 1.
- the paper sheet 1 with the plurality of creped portions 1a formed thereon may be additionally subjected to three-dimensional processing to form, for example, raised and recessed portions on the paper sheet 1, such that the raised and recessed portions extend in a direction crossing the plurality of creped portions la. In this manner, the pressure drop of the cigarette filter can be adjusted more finely.
- the paper sheet 1 is highly acceptable for consumers as a cigarette filter material.
- the cigarette filter produced by using the paper sheet 1 is capable of causing phenols and the like that are harmful compounds contained in the smoke components to be efficiently adsorbed by the cellulose acetate fibers, and also, capable of causing water to be efficiently adsorbed by the pulp fibers.
- the cigarette filter can be disintegrated in water in a natural environment for disposal after smoking.
- the processed product produced by using the paper sheet 1 include sanitary products such as a disposable diaper, a sanitary napkin, and a sanitary mask.
- sanitary products such as a disposable diaper, a sanitary napkin, and a sanitary mask.
- the paper sheet 1 since the paper sheet 1 has high air permeability, when the user wears the sanitary product, uncomfortable stuffiness and stickiness are reduced , which realizes excellent wearing feeling. Therefore, the paper sheet 1 is also suitable as the material of such a sanitary product.
- FIG. 2 is a schematic diagram of the paper machine 10 according to the embodiment.
- the paper machine 10 is a fourdrinier paper machine.
- the paper machine 10 includes a composition preparation part 11, a wire part 12, a press part 13, a dryer part 14, and the winding reel 28.
- Each of the composition preparation part 11, the wire part 12, the press part 13, and the dryer part 14 has a known configuration.
- the terms "preceding” and “subsequent” in the description below mean “preceding something else” and “subsequent to something else” in the paper machine 10 in the feeding direction of a composition, a sheet body 30, and a paper sheet 1.
- the composition preparation part 11 is, in the paper machine 10, disposed at a position preceding the wire part 12, the press part 13, the dryer part 14, and the winding reel 28.
- the composition preparation part 11 prepares a liquid composition (slurry) that is the raw material of the paper sheet 1.
- the composition preparation part 11 includes a reservoir 20, which stores the composition.
- the wire part 12 is disposed at a position subsequent to the composition preparation part 11.
- the wire part 12 spreads the composition fed from the reservoir 20 into a sheet-like shape to dewater the composition, and feeds the resulting sheet-shaped composition in the feeding direction.
- the wire part 12 includes the wire mesh 21 and a plurality of feeding rollers 22.
- the wire mesh 21 is configured by forming a wire net made of a plurality of wires into an endless belt.
- the plurality of feeding rollers 22 rotate the wire mesh 21.
- at least one of the fiber concentration in the composition fed from the reservoir 20 to the wire part 12, the feeding speed of the composition fed from the reservoir 20 to the wire part 12, and the feeding speed of the composition fed by the wire mesh 21 is adjusted, and thereby the basis weight of the paper sheet 1 is adjusted.
- the composition that has been fed from the reservoir 20 to the wire part 12 is referred to as the sheet body 30.
- the press part 13 is disposed at a position subsequent to the wire part 12.
- the press part 13 further dewaters the sheet body 30 having passed through the wire part 12 while feeding the sheet body 30 in the feeding direction.
- the press part 13 includes: a plurality of felt bodies 23; a plurality of feeding rollers 24; and at least one press roller 25.
- Each of the felt bodies 23 is configured by forming a belt-shaped felt material into an endless belt.
- the plurality of feeding rollers 24 rotate the felt bodies 23.
- the press roller 25 is pivotally supported at a position where the press roller 25 faces the peripheral surfaces of the feeding rollers 24 via the felt bodies 23.
- the dryer part 14 is disposed at a position subsequent to the press part 13.
- the dryer part 14 dries the sheet body 30 having passed through the press part 13 while feeding the sheet body 30 in the feeding direction.
- the dryer part 14 includes at least one heating roller (such as a yankee dryer) 26.
- the heating roller 26 rotates at the peripheral speed V1.
- the winding reel 28 is disposed at a position subsequent to the dryer part 14.
- the winding reel 28 reels in the paper sheet 1 into a roll when the paper sheet 1 is obtained by being separated from the peripheral surface of the heating roller 26.
- the heating roller 26 rotates at the peripheral speed V2.
- the paper machine 10 is of course not limited to a fourdrinier paper machine, but may be a different type of machine.
- the paper machine 10 may be a cylinder paper machine.
- FIG. 3 is a production process chart that shows processes for producing the paper sheet 1 according to the embodiment.
- a raw material preparing process S1 a wire process S2, a pressing process S3, a drying process S4, a creping process S5, a reeling process S6, and a slitting process S7 are performed sequentially.
- processes S1 to S6 are performed sequentially by using the paper machine 10.
- the cellulose ester staple fibers, the pulp fibers, and the binder are uniformly dispersed in water, and thereby the composition is prepared.
- the prepared composition is temporarily stored in the reservoir 20.
- the raw material preparing process S1 may include a beating process for adjusting the entanglement of the fibers.
- a beating process for example, a known refiner is used to mechanically beat the fibers contained in the composition in the presence of water, thereby grinding the fibers.
- the fibers are cut and torn into small pieces. Consequently, the fibers are disintegrated, and also, the fibers become highly hydrated and swollen, which results in increased entanglement of the fibers after the paper is formed.
- the composition stored in the reservoir 20 is spread over the wire mesh 21 of the wire part 12, and thereby the sheet body 30 is formed. Also, the plurality of feeding rollers 22 are rotated to feed the sheet body 30 in the feeding direction together with the wire mesh 21. Part of the water in the sheet body 30 penetrates through the gaps of the wire mesh 21, and is thereby removed from the sheet body 30. In this manner, the sheet body 30 is dewatered to some extent.
- the sheet body 30 having passed through the wire part 12 is placed on the felt bodies 23, and the plurality of feeding rollers 24 are rotated to feed the sheet body 30 in the feeding direction together with the felt bodies 23. Part of the water in the sheet body 30 is absorbed by the surface of the felt bodies 23. In this manner, the sheet body 30 is further dewatered. Then, the sheet body 30 is passed between the press roller 25 and the felt bodies 23 to press the sheet body 30 in the thickness direction, thereby further dewatering the sheet body 30.
- the pressing process S3 only one pair of felt bodies 23 may be used, or two or more pairs of felt bodies 23 arranged continuously in the feeding direction may be used.
- a press machine for pressing the sheet body 30, or suction dewatering equipment for forcibly dewatering the sheet body 30, may be used.
- the sheet body 30 having passed through the press part 13 is fed in the feeding direction while being in contact with the peripheral surface of the heating roller 26. At the time, heat from the peripheral surface of the heating roller 26 is transferred to the sheet body 30, and thereby the sheet body 30 is heated and dried.
- a heating device such as a hot air hood, may be used together with the heating roller 26.
- a doctor blade 27 is used to separate the sheet body 30 from the peripheral surface of the heating roller 26.
- a plurality of creped portions 1a which are arranged in the flow direction and extend in the orthogonal direction orthogonal to the flow direction, are formed on the sheet body 30 when the sheet body 30 passes through the dryer part 14.
- the longitudinal direction of the doctor blade 27 coincides with the axial direction of the heating roller 26.
- the plurality of creped portions 1a arranged in the flow direction and extending in the orthogonal direction are formed on the sheet body 30.
- the crepe ratio R of the paper sheet 1 to be produced is set to, for example, a value within the range of not less than 5% and not greater than 35%. Also, by setting the crepe ratio R to such a value, the breaking elongation of the paper sheet 1 to be produced in the flow direction is set to a value within the range of not less than 10% and not greater than 70%.
- the tensile strength of the paper sheet 1 in the flow direction is set to a predetermined value by at least one of the following methods: a method of adjusting the blending ratio of a plurality of kinds of fibers in the raw material preparing process S1; a method of adjusting the entanglement of the fibers by adjusting the beating degree; a method of adjusting the basis weight (total fiber amount) in the wire process S2; and a method of adjusting the crepe ratio R in the creping process S5.
- the tensile strength of the paper sheet 1 in the flow direction is set to a value within the range of not less than 1.5 N/25 mm width and less than 40 N/25 mm width.
- the belt-shaped paper sheet 1 whose longitudinal direction (feeding direction) is the flow direction is obtained.
- the paper sheet 1 is wound into a roll by the winding reel 28.
- the slitting process S7 the paper sheet 1 previously wound into the roll is subjected to unwinding and slitting (cutting) to have a constant width, and then wound again. In this manner, the paper sheet 1 is obtained as a roll-shaped product.
- the method of producing the paper sheet 1 includes: a sheet body forming process (sheet body forming step) of forming the sheet body 30 containing the cellulose ester staple fibers, the pulp fibers, and the binder; and the creping process (creping step) S5 of forming the plurality of creped portions 1a on the sheet body 30, such that the plurality of creped portions 1a are arranged in the flow direction and extend in the orthogonal direction orthogonal to the flow direction.
- the sheet body forming process includes the raw material preparing process S1, the wire process S2, the pressing process S3, and the drying process S4.
- the sheet body 30 is formed in a belt-like shape, such that the longitudinal direction (feeding direction) of the sheet body 30 is the flow direction.
- the crepe ratio R of the paper sheet 1 is set to a value within the range of not less than 5% and not greater than 35%.
- the tensile elongation of the paper sheet 1 in the flow direction is set to a value within the range of not less than 10% and not greater than 70%.
- the tensile strength of the paper sheet 1 in the flow direction is set to a value within the range of not less than 1.5 N/25 mm width and less than 40 N/25 mm width by adjusting at least one of the blending ratio of the cellulose ester staple fibers, the pulp fibers, and the binder, the basis weight of the paper sheet 1, the beating degree of the cellulose ester staple fibers and the pulp fibers, and the crepe ratio of the paper sheet 1.
- an alkali salt of a polysaccharide containing a carboxyl group is used as the binder.
- the binder adding process can be performed separately from the raw material preparing process S1.
- a liquid containing the binder may be sprayed over or applied to the sheet body, or the sheet body may be immersed in the liquid containing the binder.
- a paper sheet was produced by using cellulose acetate staple fibers, softwood kraft pulp fibers, and carboxymethyl cellulose sodium salt (with an esterification degree of 0.86; CMC1220 available from Daicel Corporation).
- the weight ratio of the cellulose acetate staple fibers, the softwood kraft pulp fibers, and the carboxymethyl cellulose sodium salt was set to 49.5 : 49.5 : 1.0.
- creped portions were formed on each of a plurality of sheet bodies, and the crepe ratio R was varied among the plurality of sheet bodies.
- paper sheets of Comparative Examples 1, 2, and Examples 1 to 17 were produced, such that the value of the basis weight of each paper sheet was set to any of 21, 25, 35, and 40 g/m 2 .
- a flow-direction breaking elongation (tensile elongation at break) test (conforming with the method of JIS P8113), a flow-direction tensile strength test (conforming with the method of JIS P8113), a water disintegrability test (conforming with the method of JIS P4501), and an air resistance (air permeance) test (conforming with the method of JIS P8117) were performed on each of the paper sheets of Comparative Examples 1, 2, and Examples 1 to 17.
- the width of a test piece of each paper sheet (the width in the orthogonal direction orthogonal to the flow direction) was set to 25 mm width ⁇ 0.1 mm. Also, the maximum thickness dimension of each of the paper sheets of Comparative Examples 1, 2, and Examples 1 to 17 in a natural state (i.e., a state where no tension is applied to the paper sheet) was measured by a thickness meter (dial thickness gauge).
- each of the pair of shaping rollers used herein is provided with a plurality of raised and recessed portions formed on the peripheral surface thereof, such that the raised and recessed portions extend in the circumferential direction of each shaping roller.
- the pair of shaping rollers was disposed such that the peripheral surfaces of the respective shaping rollers meshed with each other.
- Each paper sheet was passed between the pair of shaping rollers in the flow direction to subject the paper sheet to three-dimensional processing, and at the time, whether or not cracks were formed in the paper sheet was checked. Also, each paper sheet was fed at a feeding speed of 100/min, and whether or not the paper sheet was able to be rewound without breaking was checked.
- FIG. 4 is a graph showing a relationship between the breaking elongation and the tensile strength of each of the paper sheets of Comparative Examples 1, 2, and Examples 1 to 17.
- FIG. 5 is a graph showing a relationship between the crepe ratio R and the tensile strength of each of the paper sheets of Comparative Examples 1, 2, and Examples 1 to 17.
- FIG. 6 is a graph showing a relationship between the crepe ratio R and the breaking elongation of each of the paper sheets of Comparative Examples 1, 2, and Examples 1 to 17.
- FIG. 7 is a graph showing a relationship between the crepe ratio R and the air resistance of each of the paper sheets of Comparative Examples 1, 2, and Examples 1 to 17.
- the higher the crepe ratio R the more the paper sheet tends to stretch in the flow direction and the breaking elongation increases.
- the tensile strength decreases in accordance with increase in the crepe ratio R.
- the decrease in the tensile strength is due to the basis weight (fiber amount) of the sheet body being small in processes S2 to S4, which are the processes performed before the creped portions are formed on the sheet body, i.e., due to the basis weight (fiber amount) of the extended sheet body being small.
- each of the paper sheets of Examples 1 to 17 exhibits a higher breaking elongation and better formability than the paper sheets of Comparative Examples 1 and 2.
- the reason for this is considered that since the plurality of creped portions extending in the orthogonal direction orthogonal to the flow direction are formed on each of the paper sheets of Examples 1 to 17, when tension in the flow direction is exerted on each of these paper sheets, the paper sheet can stretch in the flow direction, and is less likely to be damaged.
- Example 7 the crepe ratio R was 35%. In Example 8, the crepe ratio R was 40%. Accordingly, each of Examples 7 and 8 exhibited a high and favorable breaking elongation, but the formability thereof was relatively low. Specifically, in each of Examples 7 and 8, no major cracks were found in the paper sheet when it was subjected to the three-dimensional processing. However, at the time of rewinding the paper sheet, when the rotational speed of the rewinding roller was increased, breaking of the paper sheet slightly occurred.
- a filter product such as a cigarette filter
- the pressure drop can be reduced while keeping suitable processability into the filter product.
- FIG. 4 It is considered from the results shown in FIG. 4 that, for example, by setting the crepe ratio R of the paper sheet to a value within the range of not less than 5% and not greater than 35%, a cigarette filter having excellent appearance properties, i.e., not easily dented or bent, and having a suitable pressure drop can be produced.
- the crepe ratio R by setting the crepe ratio R to such a value, the tensile elongation of the paper sheet in the flow direction is set to a value within the range of not less than 10% and not greater than 70%.
- the processed product when producing a makeup removing nonwoven fabric or a cleaning sheet by using the paper sheet 1 of the embodiment, by suitably increasing the crepe ratio R, the processed product can be made bulky, and the makeup removing effect or wiping-off effect of the processed product can be increased.
- the crepe ratio R is too low, it is less likely that sufficient stretchability is imparted to the paper sheet.
- the crepe ratio R is too high, there are risks that the sheet body or paper sheet loosens while being fed due to excessive stretching (i.e., tension exerted on the sheet body or paper sheet to feed the sheet body or paper sheet cannot be sufficiently kept) and that the strength is lowered, causing a difficulty in stably producing the paper sheet or processed product.
- the crepe ratio R of the paper sheet by taking into account, for example, the type of the processed product to be produced by using the paper sheet, the processing conditions of the paper sheet, and the tension in the feeding direction exerted on the sheet body or paper sheet fed in the paper machine or processing machine.
- each aspect of the present invention has an excellent advantageous effect of being able to, in the case of producing processed products by using a paper sheet containing cellulose ester staple fibers, prevent damage to the paper sheet and improve the production efficiency of the processed products. Therefore, the present invention is useful when widely applied as a paper sheet, and a paper sheet producing method, that make it possible to exert the above advantageous effect meaningfully.
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Also Published As
Publication number | Publication date |
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JP6496705B2 (ja) | 2019-04-03 |
CN110073055B (zh) | 2021-11-09 |
EP3556937A1 (en) | 2019-10-23 |
KR20190067198A (ko) | 2019-06-14 |
WO2018110059A1 (ja) | 2018-06-21 |
KR102193242B1 (ko) | 2020-12-22 |
JP2018096010A (ja) | 2018-06-21 |
LT3556937T (lt) | 2021-04-12 |
CN110073055A (zh) | 2019-07-30 |
ES2861724T3 (es) | 2021-10-06 |
EP3556937A4 (en) | 2020-01-15 |
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