US3812000A - Soft,absorbent,fibrous,sheet material formed by avoiding mechanical compression of the elastomer containing fiber furnished until the sheet is at least 80%dry - Google Patents
Soft,absorbent,fibrous,sheet material formed by avoiding mechanical compression of the elastomer containing fiber furnished until the sheet is at least 80%dry Download PDFInfo
- Publication number
- US3812000A US3812000A US00156282A US15628271A US3812000A US 3812000 A US3812000 A US 3812000A US 00156282 A US00156282 A US 00156282A US 15628271 A US15628271 A US 15628271A US 3812000 A US3812000 A US 3812000A
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- United States
- Prior art keywords
- web
- creping
- bonding material
- sheet
- dry
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- Expired - Lifetime
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Images
Classifications
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21F—PAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
- D21F11/00—Processes for making continuous lengths of paper, or of cardboard, or of wet web for fibre board production, on paper-making machines
- D21F11/14—Making cellulose wadding, filter or blotting paper
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31F1/00—Mechanical deformation without removing material, e.g. in combination with laminating
- B31F1/12—Crêping
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24355—Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
- Y10T428/24446—Wrinkled, creased, crinkled or creped
Definitions
- a fibrous web or sheet material formed by deposition from an aqueous slurry and characterized by unusually high bulk and softness, achieved at least in part by the addition of an elastomeric bonding material to the aqueous slurry and by the avoidance of mechanical compression of the web until it is at least 80% dry, so that the elastomeric bonding material creates many of the interfiber bonds within the sheet material.
- the web is subjected to differential creping techniques by adhering it in a printed pattern to the creping surface.
- additional elastomeric bonding material is added in the printed pattern.
- the unusually high bulk of the web is demonstrated by very low average calculated density through its thickness under no load of less than 0.300 grams per cubic centimeter.
- Another significant feature indicative of the bulk and softness of the web is demonstrated by its relatively high TEA-to-stiffness ratio of greater than 1.50
- a method for forming such webs or sheet material is also disclosed, in which lignocellulosic fibers are mixed with water and with an elastomeric bonding material into a fiber furnish, which furnish is formed into a Web. Water is removed from the web without mechanical compression of the web and, when the web is at least 80% dry, it is adhered to a creping surface and creped therefrom.
- This invention relates to soft, fibrous sheet materials and to a method for forming them. Such sheet materials are useful for sanitary paper products such as tissues, towels and the like. More particularly, the present invention relates to a soft, absorbent, fibrous sheet material, characterized by unusually high bulk, that is, low density, as measured by a calculated average density through its thickness under no load, and by a high TEA-to-stiffness ratio, stemming at least in part from the use of an elastomeric bonding material to supply much of the interfiber bonding strength of the sheet material, and from a unique method for making such sheet material. The present invention also relates to the method of making a web which has the above-mentioned characteristics.
- breakinginterfiber bonds in a previously formed web imparts substantial softness primarily upon the surface of such webs due to loose fiber ends extending therefrom, it does nothing to increase the bulk, compressibility, and flexibility of the product or to lower the density of the product, all of which are characteristics which also subjectively indicate softness to a person, without substantially decreasing the strength of the material. This undesired result becomes more pronounced as efforts to soften the web increase.
- paper webs When paper webs are formed by conventional papermaking techniques, they are generally pressed between two opposed surfaces, at least one of which is porous, so that water is removed from the web. It is common to press such Webs on the Fourdrinier wire or other forming surface, as by a pickup roll, or in a press section on a felt between two press rolls, or onto the hard surface of a cast iron Yankee drying drum, which is steam heated to remove moisture from the web and which provides a surface from which the web may be creped. To insure rapid drying of the web, it has been shown to be important for uniform contact to be provided between the Yankee dryer surface and the web.
- the web lacks the desired amount of strength, due to the reduced amount of interfiber bonding resulting from the lack of compression during formation.
- the interfiber bonds which are present are of a hard brittle nature, i.e. hydrogen or hydrate bonds, and deleteriously effect the softness of the web.
- the pressures generated by the knuckle pattern of the woven wire are so high as to create hard portions of the web which give a feeling of harshness to the resulting product.
- even this form of pressing of the web prior to its being at least dry results in a loss of bulk in the web, and an increase in density of the web, all of which is undesirable in a sanitary paper product requiring softness and absorbency.
- the toughness of the sheet is the toughness of the sheet. In essence, this is representative of a combination of the tensile strength of the sheet and the ability of the sheet to stretch. Obviously, if the sheet can absorb some work imposed upon it by stretching so as to avoid firmly resisting thefull force applied, the resulting web' is tougher. It has long been known to crepe webs in various ways to create stretch and, accordingly, to impart toughness. However, even webs which have been creped in one direction, or in several different directions so as to impart universal or isotropic stretch, are weakened by the creping, and accordingly, do not have as much strength as desirable, especiallyif they have relatively low basis weight such as sanitary papers do.
- the field ofnonwoven webs which generally include substantial amounts of fibers having a length greater than /,4 inch
- bonding material vto spaced portions of the web so that fibers in at least portions, and perhaps in a network across the web, become bonded together to impart strength to the web.
- the fibers in such nonwoven webs are sufiiciently longto enable small amounts of adhesive to impart substantial strength to the web since any two adjacent areas of adhesive application can be quite far apart and yet be, able to bond one fiber into a network.
- fibrous webs can be formed which have unusually high softness and bulk and yet which have an elastomeric adhesive uniformly distributed at interfiber contact points throughout the web. This is accomplished by. adding the elastomeric patern of bonding material by means of which the web is initially formed, and by substantially drying the web before subjecting it to any mechanical compression so as to create and preserve bulk.
- Such a Web is even further improved by successive imprinting of such a web with a pattern of bonding material by means of which the web is adhered to a creping surface so that it can be differentially creped to provide even further bulk and softness.
- a principal object and advantage of the present invention is to provide uniquely soft, absorbent, creped fibrous webs.
- a further object and advantages of the presentinvention is to enable such webs to be made on a modified papermaking machine which can operate at high speed.
- the present invention is a soft, absorbent, creped, fibrous web formed by deposition from an aqueous slurry.
- the web comprises randomly arranged, contacting lignocellulosic fibers, and an elastomeric bonding material at substantially uniformly distributed contact points between the fibers generally throughout the web so as to impart structural integrity to the web.
- the web is characterized by having a basis weight of from about 10 to about 30 pounds per 2880 ft a TEA-to-stitfness ratio greater than 1.S0 10-*, and an average calculated density throughout its thickness of no load of less than 0.300 grams per cubic centimeter.
- the web is formed from fibers which have been treated with a debonding agent in order to reduce their natural interfiber bonding capacity.
- Some embodiments of the web contain additional amounts of an elastomeric bonding material in a predetermined pattern so as to create higher strength web segments spaced apart by lower strength web segments.
- More preferred embodiments of the fibrous web of the invention has a TEA-to-stiifness ratio greater than 2.0 10
- the present invention also is a method for forming the above-described soft, absorbent, creped, fibrous webs or sheet material.
- a fiber furnish is mixed from lignocellulosic fibers, an elastomeric bonding material and water.
- a web is formed from the fiber furnish by introductoin of the fiber funrish into a drainage zone in which it contacts at least one foraminous support surface which permits the removal of water thereform. Additional water is removed from the web without employing mechanical compression until the web is at least 80% dry.
- the web is then adhered to a creping surface and removed therefrom by a creping blade.
- the web is adhered with an adhesive to the creping surface.
- the method also includes in some instances the steps of applying an adhesive to selected areas of the web such as by printing, and pressing the web into engagement with the creping surface so that only selected areas of the web are adhered to the creping surface.
- FIG. 1 is a side elevation view of one form of apparatus for forming the fibrous web of the present invention in accordance with the method of the present invention
- FIG. 2 is a side elevation view of a portion of one'form of apparatus for carrying out one form of the method of the present invention
- FIG. 3 is a side elevation view of a portion ofan alternative form of apparatus for carrying out one 'form'of the method of the present invention
- FIG. 4 is a graph illustrating the manner in which the dryness of a web when pressed effects the caliper of the web after pressing
- FIG. 5 is a photomicrograph, having a linear magnification of 75, of a cross-section of one type of prior art web, formed as described in Example I, and having an outline drawn thereover according to the procedure described for determining its calculated density;
- FIG. 6 is a photomicrograph, having a linear magnification of 75, of a cross-section of another type of prior art web, formed as described in Example I, and having an outline drawn thereover according to the procedure described for determining its calculated density;
- FIG. 7 is a photomicrograph, having a linear magnification of 75, of a cross-section of a web of the present invention, formed as described in Example I, and having an outline drawn thereover according to the procedure described for determining its calculated density;
- FIG. 8 is a photomicrograph, having a linear magnification of 75, of a cross-section of a web of the present invention, formed as described in Example II, and having an outline drawn thereover according to the procedure described for determining its calculated density.
- FIG. 1 illustrates one type of papermaking machine which is capable of forming the soft, absorbent, fibrous sheet materials of the present invention and in accordance with the method of the present invention.
- the papermaking machine has a stock distribution means associated therewith, and indicated generally by reference numeral 10, for delivering an aqueous papermaking slurry or fiber furnish to a Fourdrinier wire 16.
- the stock distribution means includes a tapered manifold or header 11 which is connected to a source (not shown) of an aqueous papermaking slurry or fiber furnish.
- a number of branch tubes or laterals 12 connect the tapered manifold 11 to a blending chamber 13 defined by generally parallel upper and lower walls, 14 and 15, respectively.
- the stock distribution system may be similar to that disclosed in U.S. Pat. 3,298,905, issued on Jan. 17, 1967, to A. C. Spengos et al.
- the Fourdrinier wire 16 is carried over a suction breast roll 17 and over a plurality of table rolls 18 after which it passes around a wire turning roll 20 and is threaded past three guide rolls 21, 22, and 23, respectively, back to the suction breast roll 17.
- the assembly of wire 16 and its supporting rolls is driven by drive means (not shown) connected to the wire turning roll 20.
- One or more vacuum boxes, hydrofoils or other dewatering or formation assisting devices may be employed in conjunction with the Fourdrinier wire 16.
- the configuration of the papermaking machine may vary widely from that described above without having any effect upon the present invention. It is important, however, that the web thus formed on the Fourdrinier wire 16 be maintained free from any mechanical compression or compaction until it is at least 80% dry for reasons set forth subsequently.
- the web formed is transferred substantially free from any compaction or mechanical compression from the upper surface of the Fourdrinier wire 16 to the suface of a foraminous drying fabric 24, which may comprise a woven sheet material, such as made of wire or other filamentary materials, or perforated or foraminous base.
- the drying fabric 24 is advanced past a position closely adjacent the portion of the Fourdrinier wire 16 running between the wire turning roll 20 and the first guide roll 22. In doing so, it passes over a rotating suction pickup roll 25 or stationary suction pickup shoe and transfer thereto may be assisted if desired by a steam or air jet such as might issue from a header 26, as shown in phantom line in FIG. 1, disposed opposite the Fourdrinier wire 16 and the suction pickup roll 25.
- the drying fabric 24 carrying the web moves from the suction pickup roll into a drying means, indicated generally by reference numeral 27, and then is carried about guide rolls 28 and 30, and about a pressure roll 31 which presses the Web into engagement with the surface of a creping drum 32.
- One or more vacuum boxes may be disposed behind drying fabric 24 following the pickup roll 25 to 6 remove additional entrained water from the web without compression.
- the drying fabric 24 continues on about a further guide roll 33 and then returns to the transfer point adjacent pickup roll 25.
- the drying means 27 may comprise any means for drying the Web to a point where it has a moisture content of less than 20% by weight, that is, so that it is more than dry. It is important that no mechanical compression or compaction of the web occur prior to its obtaining this dryness level and, therefore, the traditional Yankee drying techniques, wherein the paper web is firmly pressed against the surface of a steam-heated Yankee drying drum, must be avoided when it has a moisture content above 20%.
- various other techniques for drying the web may be employed such as radiant heat lamps, tunnel dryers, or transpiration dryers wherein an preferably heated, is passed through the web. FIG.
- FIGS. 2 and 3 illustrate alternative methods for applying adhesive to the web in order to adhere it to the creping drum 32.
- FIG. 2 illustrates a glue application roll 40 which picks up adhesive from a reservoir 41 and transmits it to the surface of the web immediately prior to the web contacting the creping drum 32.
- FIG. 3 shows and application roll 42 which picks up adhesive from a reservoir 43 and applies it directly to the creping drum 32 after which the web is pressed into contact therewith and adhered.
- FIGS. 2 and 3 are particularly useful in the practice of the method of the invention where only predetermined portions of the web are adhered to the creping surface in order to obtain differential or patterned creping of the web in order to further increase bulk, softness and strength.
- the adhesive which is printed onto the web as shown in FIG. 2 or onto the creping drum as shown in FIG. 3 contains an elastomeric bonding material which accomplishes further interfiber bonding in the portions of the web to which it is applied. The benefits of this will become apparent subsequently.
- the method of the present invention comprises a series of steps which result in the formation of the new sheet materials of the present invention.
- the method includes mixing a fiber furnish from lignocellulosic fibers, an elastomeric bonding material, and water.
- a web is then formed from the fiber furnish in accordance with any one of a number of different techniques, most of which are standard techniques employed in papermaking.
- the web is then subjected to treatment to remove water therefrom without mechanically compressing the web. It is important that enough water be removed from the Web in this manner so that it is at least 80% dry before being mechanically compressed.
- the web is then adhered to the creping surface and creped from the surface with a creping blade.
- the mixing step is normally performed in a headbox preceding the flow distribution equipment employed with the papermaking machine.
- the fibers in the furnish preferably comprise largely relatively short fibers, i.e. those having a length of less than A" and predominately shorter, and substantially all of the fibers are lignocellulosic fibers; that is, those coming from some natural wood fiber source such as wood pulp, so that they form hydrogen bonds of the type associated with papermaking.
- the elastomeric bonding materials which may be employed in the present invention are basically any materials which are capable of at least 75% elongation at rupture. Such materials generally should have an initial Youngs modulus by stretching which is less than 25,000 p.s.i.
- Typical materials may be of the butadiene acrylonitrile type, or other natural or synthetic rubber latices or dispersions thereof with elastomeric properties, such as butadiene-styrene, neoprene, acrylic copolymers, polyvinyl chloride, vinyl copolymers, or nylon.
- Elastomeric properties may be obtained by the addition of suitable plasticizers to polymers such as polyvinyl alcohol or carboxy-methyl-cellulose.
- webs of the present invention may be formed with advantages in a wide range of basis weight, for purposes of forming sanitary paper products, it is preferred that the basis weight be from about to about 30 pounds per ream of 2880 ft. Sheet. products in this particular range of basis weight benefit most from the the method of the present invention since they largely find use in areas where softness and bulk are important. For example, where the product is a wiper, both softness and bulk are important as well as fiuid absorbency and strength. This range of basis weight is one where it is very diflicult to impart to a product the combination of properties achieved by the present invention.
- the web may be formed by any technique which accomplishes deposition and drainage of the fibrous slurry on a foraminous condenser such as a Fourdrinier wire and, of course, the speed of formation of such webs may vary from several hundred feet per minute to over 5,000 feet per minute.
- the steps of the method, in which the web is formed and partially dried without being compressed in any way, are extremely important to the present invention in achieving the formation of a web which has the desired characteristics of high bulk and softness and unusually low density. It has been found from extensive experimentation that when a web is formed by deposition of a fibrous slurry onto a Fourdrinier wire and is dried to at least '80% dry before it is subjected to any mechanical compression such as between two surfaces in a felt or roll nip, that subsequent compression has only a minimal effect upon the subsequent properties such as bulk or caliper unless such compression is sutficiently harsh to cause the breakage of bonds or the chemical transformation of the lignocellulosic material, such as often occurs in an embossing or calendering nip.
- FIG. 4 of the drawings graphically illustrates the results of experimentation in this area.
- a fiber furnish consisting of 50% Western softwood sulfite pulp and 50% Southern gum craft pulp was formed into hand sheets having a basis weight of 10 pounds per ream of 2880 ft.
- One of the hand sheets was not subjected to any pressure and was dried. Its caliper was measured and found to be of a level shown in broken line on the graph. Additional hand sheets were dried to give levels of web dryness as indicated by the reference points on the graph. They were then subjected to pressure between surfaces at a level of 40 p.s.i.g. The samples were then dried until they were 95% dry and their caliper was measured.
- caliper and basis weight reported herein were determined by the following procedures. Basis weight was measured in accordance with TAPPI Standard T410- 05-61. Caliper, or the thickness of one sheet, was measured with a Federal Micrometer Gauge, Model No. D815, in accordance with TAPPI Standard T-411 M-44. A face area of 1 square inch (pressure of 0.5 p.s.i.) was employed when testing 28 pound per ream sheets instead of the standard 0.25 square inch face area (pressure of 7 to 9 p.s.i.). Caliper is indicated in mils.
- the web at this point has fewer hydrogen bonds than would normally be present in a web which is of the same basis weight but which had been subjected to compression prior to being rendered at least 80% dry. This paucity of hydrogen bonds results in unusual softness and compressibility to the web and, of course, the web has greater bulk (lower density) due to the fact that it was not pressed when wet or bonded in the compressed condition.
- a more preferred embodiment of the present invention results from an even further reduction in the number of hydrogen bonds of the type used between fibers in papermaking. It is well-known that such bonds are typically quite hard and inelastic and unfortunately impart these same general properties to the resulting web.
- a chemical debonding agent as by adding such a debonder to the fibrous slurry in the headbox, the number of bonding sites along the individual fibers is reduced so that the fibers are less susceptible to interfiber bonding by hydrogen bonding.
- Debonding agents which may be used for this purpose include, for example, the cationic debonding agents disclosed in U.S. Pat. No. 3,395,708, issued Aug.
- Hervey et al. that is, substances within the class of long chain cationic surfactants, preferably with at least twelve carbon atoms in at least one alkyl chain, such as fatty dialkyl quaternary amine salts, mono fatty alkyl tertiary amine salts, primary amine salts, and unsaturated fatty alkyl amine salts; the cation-active tertiary amine oxides disclosed in U.S. Pat. No. 2,432,- 126, issued Dec. 9, 1947, to Schlosser et al.; and the cation-active amino compounds disclosed in U.S. Pat. No. 2,432,127, issued Dec. 9, 1947, to Schlosser et al.
- the elastomeric bonding material which is also added to the fibrous slurry at the headbox substitutes its bonding ability for that of the hydrogen bonding which is prevented by the debonder, and provides sufficient interfiber bonding to give the web structural integrity.
- the bonds formed by such elastomeric bonding materials are quite soft and resilient and impart further softness to the web without lessening its absorptivity or its bulk, that is, without increasing its density.
- the apparatus shown in FIGS. 2 and 3 may be utilized to apply adhesive to the web or to the creping surface in order to enhance the bonding of the web to the creping surface so as to promote better dry creping and a softer product.
- This is particularly important where the moisture content of the web being applied to the creping surface is less than 10%, for example, when the web is dry.
- the creping adhesive makes up for the lack of moisture which ordinarily is used to attach the web to the dryer surface.
- the mechanism shown in FIGS. 2 and 3 are utilized to print bonding material in predetermined patterns on the web or alternatively on the creping surface in order to selectively adhere the web to the creping surface.
- the pattern of bonding material applied to the web can be in any form which leaves a substantial portion of the surface of the web free from extra amounts of bonding material other than that applied during web formation. Most preferably the pattern comprises less than about 35% of the total surface area of the web so as to leave about 65% or more of the surface of the web free from additional bonding material, at least when printed.
- any of the patterns taught by US. Pats. 3,047,444; 3,009,- 822; 3,059,313; and 3,009,823 may be advantageously employed for the rolls 40 or 42 which comprise, in this instance, gravure rolls.
- Some migration of bonding material occurs after printing. Thus, the bonding material penetrates at least partially through the web and in all directions in the plane of the web. However, preferably migration in all directions in the plane of the web is minimized so as to leave areas comprising a substantial portion of the web free from any additional bonding material, other than that applied by the headbox, for purposes which will become apparent subsequently.
- papermaking fibers generally have a length less than about 4 inch and normally have a predominant fiber length less than about inch in length. Therefore, when additional strength is to be imparted to the sheet by a bonding material, in addition to that added at the headbox, as in this embodiment of the present invention, it is important that there be a continuous interconnection of at least some of the fibers by the additional bonding material throughout the entire web.
- the web will lack the additional strength desired beyond that provided by the bonding material added in the headbox, unless such discrete areas are spaced apart by distances less than average fiber lengths or, typically, less than about ,4 inch.
- the pattern of adhesive is reticular or net-like in configuration
- the interconnected lines of bonding material application provide a network of strength even where substantial areas, in many cases much larger than inch in every direction, are defined between the lines of bonding material application as web portions have a lower amount of interfiber bonding.
- the creping drum 32 may in some instances comprise a heated pressure vessel such as a Yankee dryer, or in other instances may be a smaller roll and may be unheated. It is characterized by an extremely smooth, polished surface to which the bonding material, applied to the web, adheres. The significance of heating depends upon both the characteristics of the particular bonding material employed and the moisture level in the web. Thus, the bonding material may require drying or curing by heating in which case the creping drum 32 may provide a convenient means to accomplish this. Or, the moisture level of the web being fed to the creping drum 32 may be higher than ultimately desired, and the creping drum 32 may be heated to evaporate some of this moisture.
- the web is carried on the surface of the creping drum 32 for a distance and then removed therefrom by the action of a creping doctor blade 38.
- the doctor blade 38 performs a conventional creping operation on the additionally bonded portions of the web, that is, it imparts a series of fine fold lines to portions of the web which are adhered to the creping surface 32.
- the creping blade 38 causes the lesser bonded web portions, which are not attached to the creping drum 32, to puff and arch up to form shaped web portions having excellent softness characteristics.
- the bonding material utilized in the above-described embodiment of the present invention must be capable of several functions, one being the ability to bond fibers in the web to one another and the other being the ability to adhere the additionally bonded portions of the web to the surface of the creping drum 32. In general, any material having these two capabilities may be utilized as the bonding material, if the material can be dried or cured to set it.
- the bonding materials which are capable of accomplishing both of these functions and which can be successfully used are acrylate latex rubber emulsion, useful on an unheated creping surface; emulsions of resins such as acrylates, vinyl acetates, vinyl chlorides, and methacrylates, all of which are useful on a heated creping surface; and water soluble resins such as carboxy methyl cellulose, polyvinylalcohol, and polyacrylamide.
- the bonding material may comprise a mixture of several materials, one having the ability to accomplish interfiber bonding and the other being utilized to create adherence of the web to the creping surface.
- the materials are preferably applied as an integral mixture to the same areas of the web.
- Such materials may comprise any of the materials listed above mixed with a low molecular weight starch, such as dextrin, or a low molecular weight polymer such as carboxymethyl-cellulose or polyvinylalcohol.
- a low molecular weight starch such as dextrin
- a low molecular weight polymer such as carboxymethyl-cellulose or polyvinylalcohol.
- compatible wet strength additives may be used with any of the above materials in order to impart additional wet tensile strength to the resulting sheet material.
- the sheet materials of the present invention resulting from treatment with an elastomeric bonding material of webs which are formed by deposition from an aqueous slurry of fibers, water, and preferably, a debonding agent, having been found to be superior, in terms of such properties as softness and wiping ability, to any other prior art sheet material so formed but not subjected to such treatment.
- These properties may be characterized in many different ways when applied to sheet material used in sanitary paper products such as tissues, towels and the like. This is due to the fact that softness and wiping ability in large measure are subjective impressions one gets from handling the sheet material, and involve an assessment of the combination of thickness or bulk, density, resistance to bending and compression, and other physical properties susceptible to tactile observation.
- the TEA-to-stiffness ratio is obtained by first measuring the TEA (tensile energy absorption) of a given specimen of sheet material in accordance with TAPPI Test, T494 su-64, in both the machine direction (M.D.) and the cross-machine direction (C.D.) in kilogram meters per square meter, with the exception that a jaw sparing of 2 inches rather than the 8 inches recommended by TAPPI is used because of the particular nature of the products, some of which have lines of perforations which must be avoided.
- This test method is not a TAPPI standard but is suggested by TAPPI as the most suitable method to date.
- the stiffness of the product is then measured by subjecting the specimen to the test set forth in TAPPI Standard Test, T451 m-60, in both the machine direction and the cross-machine direction, to determine its effective overhanging length (critical length) denoted as L in centimeters.
- the stiffness of the product is proportional to the cube of the effective overhanging length and is therefore expressed herein as L
- the TEA of a product is obtained by clamping a 100010.005 in. (25410.01 cm.) wide specimen in two spaced sets of jaws when they are 2 in. (5.08 cm.) apart, with any noticeable slack being pulled out of the strip before clamping.
- Strain is applied to the specimen by moving the jaws further apart at a constant rate of 1.001001 in./min. (2.541002 cm./min.) while recording the elongation with an accuracy of 12% of the actual value and the load in either pounds or kilograms with an accuracy of 10.5% until breakage of the specimen.
- the area under the load-elongation curve is then measured by a planimeter or integrator with an accuracy of 12%
- the TEA is then calculated using the equation:
- TEA 100A /LW with units of kilogram-meters per square meter
- A area under load-elongation curve in kilogram-centimeters
- L initial span between clamp lines in centimeters
- W initial width of specimen in centimeters.
- the stiffness of a product is obtained with a Clark softness Tester by placing the end of a 15 to 50 mm. /3 to 2 inches) wide specimen with parallel edges and of convenient length between the jaws or rollers comprising a clamp mounted on a rotatable spindle.
- the spindle can be rotated about a horizontal axis parallel to the long axis of the jaws or rollers and perpendicular to the long axis of the paper strip.
- the overhanging length of the specimen is adjusted by resetting the jaws or turning the rollers until, when the spindle is slowly rotated back and forth through 90", the specimen just falls over at each of the end points of rotation.
- the overhanging or critical length L is then measured from the line where the edges of the jaws or the rollers grip the specimen to the end of the strip.
- the stiffness is indicated by the cube of L.
- specimens for each test are taken in both the machine direction (M.D.) and the cross-machine direction (C.D.).
- M.D. machine direction
- C.D. cross-machine direction
- several tests are made with each and the results averaged in order to eliminate errors due to measurement or to formation.
- the resulting values are then combined in ratio form as follows:
- the average calculated density throughout the thickness of the sheet material under no load is determined by the following procedure.
- An approximately one inch long specimen of the product is oven dried to eliminate moisture therein.
- the dried specimen is inserted in a small container and is slowly immersed at atmospheric pressure in a solution of butyl methacrylate monomer therein containing a small amount of benzoyl peroxide as a catalyst.
- the container and the immersed specimen are placed in an oven having an interior temperature of 55 C. for a period of about 16 hours to cause polymerization of the monomer.
- a small amount of volumetric shrinkage occurs which is insignificant because it is constant for each sample.
- Cross-sections are cut from the resulting embedded sample using a microtome, the sections having a thickness of 10-l2 microns.
- Each section is placed on a glass slide, and covered with mineral oil and a glass cover slip.
- the section of the specimen is now photographed by transmitted light through a microscope having a 24 mm. objective lens and an eye piece of 125x.
- the bellows extension is 50 cm.
- the resulting linear magnification is and the magnified picture is printed in a 5" x 7" format.
- the resulting photomicrograph is mounted on a board, and a transparent paper is placed over the photomicrograph.
- the outline of the resulting cross-section shown in the photomicrograph is now traced onto the transparent paper, care being taken to follow the basic curves and undulations of the cross-sectional outline to an extent sufficient to get inside the outline at least or more of the cross-sectional area including any stray fibers. Certain stray fibers deviating from the outline of the cross-section should be left outside the area in order to obtain truer density values.
- a planimeter is then used to measure the area within the inside edge of the line defining the crosssectional outline in square inches.
- the actual thickness of the sample was obtained by dividing the area by the length of the cross-section outlined and by the linear magnification of 75.
- the calcula ed density under no load in grams per cubic centimeter was obtained by the equation:
- TEA-to-stiffness ratio Basis weight g./m. Actual tm (in.) 2.54 om. 10,000 cm.
- All of the sheet materials of this improved form of the invention comprises a web of randomly arranged lignocellulosic fibers, and an elastomeric bonding material, such as that mentioned previously, at some of the contact points between said fibers to impart structural integrity to the sheet material or web.
- the lignocellulosic fibers may be any of the wood pulp fibers normally used in papermaking.
- the elastomeric bonding material may form bonded web segments spaced apart by unbonded web segments.
- the bonding material is present in the web in a continuous, predetermined reticular pattern which defines a discontinuous predetermined intermittent pattern of discrete unbonded web segments.
- Breaking length 200,000p/3r and is equivalent to the length in meters of a uniformly wide strip of paper which, if held at one end (e.g., freely suspending a coil of that paper by its tab end), would just cause the strip to break under its own weight.
- the web was formed on a conventional Fourdrinier-type papermaking machine and was transferred by a felt run to the surface of a Yankee Dryer. The web was creped from the Yankee Dryer when it was about 65% dry, that is, when it contained only about 35% moisture by weight. The web was further dried in an after-dryer section in the form of heated drums until it was more than about 92% dry.
- the resultant sheet material was one which is typically used in sanitary paper products, such as wet creped bathroom tissue, and possessed the following general properties:
- This first web was subjected to the tests described above and was found to have a TEA-to-stiffness ratio of 0.12 l0 and an average calculated density throughout the thickness of the web under no load of 0.441 grams per cubic centimeter.
- a typical cross-section of this first web photographed with a linear magnification of 75 as described above for determining the average calculated density is shown in FIG. 5.
- the very appearance of the sheet indicates the closely-packed disposition of the fibers and the relative harshness of the sheet even after creping has occurred.
- An outline of the crosssection has also been drawn on the photograph to illustrate the manner in which this is done for purposes of determining the area and the average thickness of the cross-section.
- EXAMPLE II As another illustration of the prior art, a second web was formed from a fiber furnish consisting of water and the following papermaking pulps:
- the web was formed on a conventional Fourdriniertype papermaking machine and was transferred by a felt run to the surface of a Yankee Dryer. The web was creped from the Yankee Dryer when it was about 94% dry, that is, when it contained only about 6% moisture by weight.
- the resultant sheet material was one which is typically used in sanitary paper products, such as dry creped bathroom tissue, and possessed the following general properties:
- This second web was subjected to the tests described above and was found to have a TEA-to-stiffness ratio of 0.527 10- and an average calculated density throughout the thickness of the web under no load of 0.466 grams per cubic centimeter.
- a typical cross-section of this second web photographed with a linear magnification of as described above for determining the average calculated density is shown in FIG. 6.
- the very appearance of the sheet indicates the closely-packed disposition of the fibers and the relative harshness of the sheet even after creping has occurred.
- An outline of the cross-section has also been drawn on the photograph to illustrate the manner in which this is done for purposes of determining the area and the average thickness of the cross-section.
- Rhoplex P339-an anionic acrylic latex used as an elastomeric bonding material.
- the web was further dried on the fabric by passing heated air at 260 F. through the web while conveying it on the fabric through a tunnel dryer.
- the tunnel dryer had sufiicient thermal capacity to reduce the moisture content of the web to less than 10% by weight of the wet web, so that the web was now more than 90% dry.
- the conveyed web was then transferred from the fabric to the surface of a creping dryer of 20 inch diameter by means of a press nip formed against the dryer surface by a inch diameter elastomeric roll having a neoprene cover /2 inch thick and having a hardness of 55 Shore A.
- a 1.5% solution of Peter Cooper T6220 creping adhesive was sprayed into the press nip between the web and the creping dryer surface.
- the amount of adhesive present in the web after spraying is approximately .1% by weight of the web.
- the nip pressure between the elastomeric roll and creping dryer was maintained at 60 p.s.i.
- the creping dryer contained electrical heating coils of suflicient capacity to maintain a surface temperature of 200 F., this being sufficient drying to reduce the moisture content of the sprayed web to approximately 6% by weight at the creping blade at a crepting dryer speed of 30 ft./min.
- the web was creped from the surface of the drying drum by a conventional creping doctor blade set at a creping angle of 5 above the radial line at the point of contact.
- the creped web or sheet material was wound at a speed of 26 ft./min. resulting in a foreshortening of the web in the machine direction of 15%, that is, the formation of 15% crepe in the resultant sheet material.
- the web possessed the following general properties:
- T220 m-60 Stretch (MD) 18.6% (TAPPI Standard, T220 m-60) TEA (MD) 1.286 kg.-m./m. (TAPPI Test, T494 su-64) Tensile (CD) 5.4 oz./in. (TAPPI Standard, T220 m-60) Stretch (CD) 10.5% (TAPPI Standard T220 m-60) TEA (CD) 0.537 kg.-m./m. (TAPPI Test, T494 su-64) Lo (MD) 3.8 cm. (Critical length-TAPPI Standard,
- This sheet material was subjected to the tests described above and was found to have a TEA-to-stitfness ratio of 1.55 10- and an average calculated density throughout the thickness of the sheet under no load of 0.180 grams per cubic centimeter.
- a typical cross-section of this third web photographed with a linear magnification of 75 as described above for determining the average calculated density is shown in FIG. 7. It is readily apparent from the appearance of this sheet that the fibers are loosely arranged so as to provide low density and high bulk, both of which are key factors in the softness of a web. An outline of the cross-section has also been drawn on the photograph to indicate the manner in which this is done for purposes of determining the area and the average thickness of the cross-section.
- a fourth web was formed from an unrefined fiber furnish consisting of water and the following conventional papermaking pulps:
- Quaker 2000 a debonding agent manufactured by Quaker Chemical Company, Conshohocken, Pa., used to reduce interfiber bonding capacity
- Rhoplex P339-an anionic acrylic latex used as an elastomeric bonding material.
- the web was formed on a conventional Fourdrinier-type papermaking machine and transferred to a synthetic twill fabric of 72 x 60 mesh by means of a suction pickup shoe at a point where the web is carried on a stretch of the Fourdrinier wire running between two support rolls. While being conveyed on the fabric, the web was subjected to vacuum applied to the underside of the fabric of 10-11 inches mercury for a duration of 15 milliseconds. This reduced the moisture content of the wet web to approximately 70% by weight of the wet web. The web was further dried on the fabric by passing heated air at 260 F. through the web while conveying it on the fabric through a tunnel dryer.
- the tunnel dryer had sufficient thermal capacity to reduce the moisture content of the web to less than 10% by weight of the wet web, so that the web was now more than dry.
- the web was then fed through apparatus similar to that shown in FIG. 2. Thus, it was printed in a nip formed by a patterned gravure roll having a diameter of 5" and an elastomeric roll having a diameter of 5" and a neoprene cover /2" thick and having a hardness of 65 Shore A durometer.
- the gravure roll had a reticular pattern of interconnected distorted hexagons having two sides perpendicular to the machine direction and a pattern repeat length of 0.040". The distance from apex to apex in the cross direction was 0.080".
- the engraved lines of the pattern were 180-190 microns wide and approximately 46 microns deep.
- the engraved lines of the pattern comprised approximately 27% of the overall surface area.
- the bonding material which was applied to the web by the gravure roll comprised an elastomeric bonding material consisting of a mixture of 70% Celanese 6308 and 30% Celanese 5269 by weight.
- This bonding material is an aqueous emulsion with a solids content of 45% and a viscosity of 250 centipoise at 25 C. as measured on a Brookfield RFV viscometer spindle #3 at 20 r.p.m.
- the pressure in the printing nip was controlled at p.s.i. average and the average basis weight of the sheet was increased during printing by 12.0%.
- the printed web was then applied to the surface of a cast iron creping dryer having a diameter of 15 inches by means of the elastomeric roll described above and with an average nip pressure of p.s.i.
- the creping dryer was oil heated to a surface temperature of F. and the drum surface speed was 20 ft./min. As the web was pressed to the dryer the average dryness was 84%, and upon leaving the drum, the web had an average dryness of about 94%.
- the web was creped from the surface of the drying drum by a conventional creping doctor blade set at an angle of 6 below the radial line at the point of contact.
- the creped web or sheet material was wound at a speed of 16.6 ft./min. resulting in a foreshortening in the machine direction of 20%, that is, the formation of 20% crepe in the resultant sheet material.
- the sheet material possessed the following general properties:
- the sheet material was subjected to the tests described above and was found to have a TEA-to-stitfness ratio of 4.9l and an average calculated density throughout the thickness of the sheet under no load of 0.139 grams per cubic centimeter.
- a typical cross-section of this third web photographed with a linear magnification of 75 as described above for determining the average calculated density is shown in FIG. 8. It is readily apparent from the appearance of this sheet that the fibers are loosely arranged so as to provide low density and high bulk, both of which are key factors in the softness of a web. An outline of the cross-section has also been drawn on the photograph to indicate the manner in which this is done for purposes of determining the area and the average thickness of the cross-section.
- the present invention provides a new and improved form of sheet material which has. a combination of properties heretofore not obtainable in paper Webs.
- the sheet materials of the present invention are quite strong as a result of the elastorneric bonding material incorporated therein, but also are extremely soft and bulky as evidenced by the high TEA-tostilfness ratio and the low density.
- the sheet material of the present invention has substantial stretch in all directions in its own plane stemming from the elastomeric bonds and, in the instances where differential or patterned creping is employed, from the structure thus formed.
- One of the surprising features of the method of the present invention is the simplicity by which the products of the invention are formed, especially in view of some of the alternative methods utilized in the past to achieve some of these features individually.
- the composition of the bonding material may vary quiet widely as may also the pattern in which the bonding material is applied to the web.
- the particular apparatus utilized to accomplish the method of the invention is not significant.
- a wide variety ofdiiferent means can be used for drying the web, creping the web, and applying bonding material to the web. Therefore, the invention is not to be limited to the specific details of the method and products described herein except as may be required by the following claims.
- a method for making a soft, absorbent, creped fibrous sheet material comprising the steps of mixing a fiber furnish from lignocellulosic fibers, an
- a method according to clam 2 wherein said creping surface is heated, and including the step of adding moisture to said web immediately before adhering it to said creping surface to render it less than dry, and :vaporating said moisture by heat from said creping surace.
- a method according to claim 1 including the steps of promoting formation of said web and water removal therefrom by applying a partial vacuum to one surface of said web prior to adhering said web toa creping'surface.
- a method according to claim 1 including applying a partial vacuum to one surface of said web while it is disposed in said drainage zone to remove water therefrom, and applying a partial vacuum to the opposite surface of said web to remove it from contact with said foraminous support surface.
- said adhesive includes an elastomeric bonding agent which bonds fibers together in said selected areas of said web to a greater degree than in other areas of said web.
- an amount which when added to the amount of elasto-' meric bonding agent applied to selected areas of the web is about 7% of the total dry web weight.
- said adhesive includes an elastomeric bonding agent which bonds fibers together in areas of said web which contact said selected areas of said creping surface to a greater degree than in other areas of said web.
- a method according to claim 1 including initially an amount of debonding agent to said fiber furnish which is sufiicient to reduce the breaking length of a flat sheet consisting essentially of such fibers to less than800 meters.
- a method according to claim 1 including mixing a fiber furnish from lignocellulosic fibers, an elastomeric bonding material in the amount of about 5% of the amount of lignocellulosic fibers in said fiber furnish, and water.
- a soft, absorbent, creped fibrous web formed by deposition from an aqueous slurry, said web comprising randomly arranged, contacting lignocellulosic fibers,
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Priority Applications (10)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US00156282A US3812000A (en) | 1971-06-24 | 1971-06-24 | Soft,absorbent,fibrous,sheet material formed by avoiding mechanical compression of the elastomer containing fiber furnished until the sheet is at least 80%dry |
GB2634772A GB1365230A (en) | 1971-06-24 | 1972-06-06 | Soft absorbent fibrous sheet material and a method for making same |
AU43345/72A AU472562B2 (en) | 1971-06-24 | 1972-06-13 | A soft absorbent, fibrous sheet material anda method andan apparatus for making same |
CA145,329A CA972599A (en) | 1971-06-24 | 1972-06-21 | Soft absorbent, fibrous sheet material and a method and an apparatus for making same |
IT51078/72A IT965845B (it) | 1971-06-24 | 1972-06-22 | Materiale laminare fibroso assor bente soffice e metodo ed appa recchiatura per produrre il medesimo |
BE785231A BE785231A (fr) | 1971-06-24 | 1972-06-22 | Matiere en feuille fibreuse, douce et absorbante, et procede etappareilpour la fabriquer |
FR727222881A FR2143424B1 (de) | 1971-06-24 | 1972-06-23 | |
BR4098/72A BR7204098D0 (pt) | 1971-06-24 | 1972-06-23 | Processo para produzir material em forma de folhas fibrosas absorventes e macias e a folha resultante |
DE2231645A DE2231645C2 (de) | 1971-06-24 | 1972-06-23 | Verfahren zur Herstellung einer weichen, absorbierenden, gekreppten Faserbahn |
JP6312872A JPS5517839B1 (de) | 1971-06-24 | 1972-06-23 |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US00156282A US3812000A (en) | 1971-06-24 | 1971-06-24 | Soft,absorbent,fibrous,sheet material formed by avoiding mechanical compression of the elastomer containing fiber furnished until the sheet is at least 80%dry |
Publications (1)
Publication Number | Publication Date |
---|---|
US3812000A true US3812000A (en) | 1974-05-21 |
Family
ID=22558903
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US00156282A Expired - Lifetime US3812000A (en) | 1971-06-24 | 1971-06-24 | Soft,absorbent,fibrous,sheet material formed by avoiding mechanical compression of the elastomer containing fiber furnished until the sheet is at least 80%dry |
Country Status (10)
Country | Link |
---|---|
US (1) | US3812000A (de) |
JP (1) | JPS5517839B1 (de) |
AU (1) | AU472562B2 (de) |
BE (1) | BE785231A (de) |
BR (1) | BR7204098D0 (de) |
CA (1) | CA972599A (de) |
DE (1) | DE2231645C2 (de) |
FR (1) | FR2143424B1 (de) |
GB (1) | GB1365230A (de) |
IT (1) | IT965845B (de) |
Cited By (108)
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US3905863A (en) * | 1973-06-08 | 1975-09-16 | Procter & Gamble | Process for forming absorbent paper by imprinting a semi-twill fabric knuckle pattern thereon prior to final drying and paper thereof |
US3926716A (en) * | 1974-03-19 | 1975-12-16 | Procter & Gamble | Transfer and adherence of relatively dry paper web to a rotating cylindrical surface |
US3974025A (en) * | 1974-04-01 | 1976-08-10 | The Procter & Gamble Company | Absorbent paper having imprinted thereon a semi-twill, fabric knuckle pattern prior to final drying |
US3994771A (en) * | 1975-05-30 | 1976-11-30 | The Procter & Gamble Company | Process for forming a layered paper web having improved bulk, tactile impression and absorbency and paper thereof |
US4003783A (en) * | 1973-09-07 | 1977-01-18 | Clupak, Inc. | Method for compacting a nonwoven fabric impregnated with a thermoplastic binder |
US4036684A (en) * | 1975-08-04 | 1977-07-19 | Beloit Corporation | High bulk tissue forming and drying apparatus |
US4064213A (en) * | 1976-02-09 | 1977-12-20 | Scott Paper Company | Creping process using two-position adhesive application |
US4063995A (en) * | 1975-10-28 | 1977-12-20 | Scott Paper Company | Fibrous webs with improved bonder and creping adhesive |
US4125659A (en) * | 1976-06-01 | 1978-11-14 | American Can Company | Patterned creping of fibrous products |
US4157938A (en) * | 1977-04-21 | 1979-06-12 | The Procter & Gamble Company | Method and apparatus for continuously expelling an atomized stream of water from a moving fibrous web |
US4196045A (en) * | 1978-04-03 | 1980-04-01 | Beloit Corporation | Method and apparatus for texturizing and softening non-woven webs |
WO1981002704A1 (en) * | 1980-03-18 | 1981-10-01 | Valmet Oy | Procedure and paper machine for manufacturing creped paper web |
US4304625A (en) * | 1979-11-13 | 1981-12-08 | Kimberly-Clark Corporation | Creping adhesives for through-dried tissue |
US4448638A (en) * | 1980-08-29 | 1984-05-15 | James River-Dixie/Northern, Inc. | Paper webs having high bulk and absorbency and process and apparatus for producing the same |
US4464224A (en) * | 1982-06-30 | 1984-08-07 | Cip Inc. | Process for manufacture of high bulk paper |
US4940513A (en) * | 1988-12-05 | 1990-07-10 | The Procter & Gamble Company | Process for preparing soft tissue paper treated with noncationic surfactant |
US4959125A (en) * | 1988-12-05 | 1990-09-25 | The Procter & Gamble Company | Soft tissue paper containing noncationic surfactant |
US5048589A (en) * | 1988-05-18 | 1991-09-17 | Kimberly-Clark Corporation | Non-creped hand or wiper towel |
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- 1972-06-23 JP JP6312872A patent/JPS5517839B1/ja active Pending
- 1972-06-23 BR BR4098/72A patent/BR7204098D0/pt unknown
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Also Published As
Publication number | Publication date |
---|---|
BR7204098D0 (pt) | 1973-05-31 |
CA972599A (en) | 1975-08-12 |
BE785231A (fr) | 1972-12-22 |
IT965845B (it) | 1974-02-11 |
AU4334572A (en) | 1973-12-20 |
FR2143424B1 (de) | 1973-07-13 |
AU472562B2 (en) | 1973-12-20 |
JPS5517839B1 (de) | 1980-05-14 |
GB1365230A (en) | 1974-08-29 |
DE2231645C2 (de) | 1982-12-16 |
FR2143424A1 (de) | 1973-02-02 |
DE2231645A1 (de) | 1972-12-28 |
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