Method of producing absorbent sheet with increased wet/dry CD tensile ratio

• US 7,951,266 B2
• Filed: 07/30/2009
• Issued: 05/31/2011
• Est. Priority Date: 10/10/2006
• Status: Active Grant

• Current Assignee: GPCP IP Holdings LLC
• Original Assignee: Georgia-Pacific Consumer Products LP (KOCH Industries Incorporated)
• Inventors: Kokko, Bruce J., Edwards, Steven L.
• Primary Examiner(s): FORTUNA, JOSE A
• Application Number:
  US12/462,136
• Publication Number:
  US 20100006249A1
• Time in Patent Office: 670 Days
• Field of Search: 162/109, 162111-113, 162/183, 162/185, 162/158, 162/164.1, 162/168.1, 162/179, 162/141, 162/149, 162/147, 162/182
• US Class Current: 162/183
• CPC Class Codes: D21F 11/14 Making cellulose wadding, filter or blotting paper
• CPC Class Codes: D21H 21/18 Reinforcing agents
• CPC Class Codes: D21H 21/20 Wet strength agents
• CPC Class Codes: D21H 25/005 Mechanical treatment D21H25/08, D21H25/18 take precedence
• CPC Class Codes: Y02W 30/64 Paper recycling

Abstract

A method of making absorbent cellulosic sheet with increased wet/dry CD tensile ratio includes treating the fiber at high consistency with debonder in a pulper, for example. The process enables the use of large amounts of debonder in a wet-press process in order to achieve wet/dry CD tensile ratios of greater than 30%.

Claims

1. A method of making absorbent cellulosic sheet with increased wet/dry CD tensile ratio comprising:

a) preparing an aqueous furnish consisting essentially of cellulosic papermaking fibers in aqueous suspension having a consistency of 3 percent or more;

b) treating the aqueous furnish at 3 percent or more consistency with debonder;

c) adding a permanent wet strength resin to the aqueous furnish in an amount of from about 5 lbs of permanent wet strength per ton of papermaking fiber to about 50 lbs of permanent wet strength resin per ton of papermaking fiber, the step of adding a permanent wet strength agent to the aqueous furnish being carried out subsequent to the step of treating the aqueous furnish with debonder;

d) diluting the aqueous furnish to a consistency of less than the consistency at which the furnish was treated with debonder;

e) depositing the diluted aqueous furnish onto a foraminous support traveling in a machine direction at a wire speed by way of a jet of the diluted aqueous furnish having a jet velocity in the machine direction;

f) dewatering the furnish on the foraminous support to form a nascent web;

g) wet-pressing the nascent web onto a rotating cylinder; and

h) drying the web to produce the cellulosic sheet;

wherein the steps of dewatering, wet-pressing and drying the web as well as the jet to wire velocity delta are controlled and the furnish, debonder, and permanent wet strength resin are selected and utilized in amounts such that the absorbent cellulosic sheet has a wet/dry CD tensile ratio of greater than 30 percent and an MD/CD dry tensile ratio of less than 1.5.

2. The method according to claim 1, wherein the papermaking fiber includes Kraft softwood fiber in an amount of at least 25 percent by weight of fiber.

3. The method according to claim 2, wherein the steps of dewatering, wet-pressing and drying the web as well as the jet to wire velocity delta are controlled and the furnish, debonder, and permanent wet strength resin are selected and utilized in amounts such that the absorbent cellulosic sheet has a wet/dry CD tensile ratio of greater than 30 percent and an MD/CD dry tensile ratio of less than 1.

4. The method according to claim 2, wherein the aqueous furnish is treated with debonder at a consistency between about 3 and about 8 percent.

5. The method according to claim 2, further comprising adding a dry strength agent to the furnish prior to diluting the furnish.

6. A method of making absorbent cellulosic sheet with increased wet/dry CD tensile ratio comprising:

a) preparing an aqueous furnish consisting essentially of cellulosic papermaking fibers in aqueous suspension having a consistency of 3 percent or more;

b) treating the aqueous furnish at 3 percent or more consistency with debonder;

c) subsequent to the step of treating the aqueous furnish at 3 percent or more consistency with debonder, adding a permanent wet strength resin to the aqueous furnish in an amount of from about 5 lbs of permanent wet strength per ton of papermaking fiber to about 50 lbs of permanent wet strength resin per ton of papermaking fiber;

d) diluting the aqueous furnish to a consistency of less than the consistency at which the furnish was treated with debonder;

e) depositing the diluted aqueous furnish onto a foraminous support traveling in a machine direction at a wire speed by way of a jet of the diluted aqueous furnish having a jet velocity in the machine direction;

f) compactively dewatering the furnish to form a nascent web having an apparently random distribution of papermaking fiber;

g) applying the dewatered web having the apparently random fiber distribution to a translating transfer surface moving at first speed;

h) belt-creping the web from the transfer surface at a consistency of from about 30 percent to about 60 percent utilizing a patterned creping belt, the creping step occurring under pressure in a belt creping nip defined between the transfer surface and the creping belt wherein the belt is traveling at a second speed slower than the speed of said transfer surface, the belt pattern, nip parameters, velocity delta and web consistency being selected such that the web is creped from the transfer surface and redistributed on the creping belt to form a web with a reticulum having a plurality of interconnected regions of different local basis weights including at least (I) a plurality of fiber-enriched pileated regions of high local basis weight, as well as (II) a plurality of regions of compressed papermaking fibers, the compressed regions having relatively low local basis weight; and

i) drying the web to produce the cellulosic sheet;

wherein the steps of dewatering and applying the web to the transfer surface, belt creping, wet-pressing, and drying the web as well as the jet to wire velocity delta are controlled and the furnish, debonder, and permanent wet strength resin are selected and utilized in amounts such that the absorbent cellulosic sheet has a wet/dry CD tensile ratio of greater than 30 percent and an MD/CD dry tensile ratio of less than 1.5.

7. The method according to claim 6, wherein the papermaking fiber includes Kraft softwood fiber in an amount of at least 25 percent by weight of fiber.

8. The method according to claim 7, wherein the steps of dewatering, wet-pressing and drying the web as well as the jet to wire velocity delta are controlled and the furnish, debonder, and permanent wet strength resin are selected and utilized in amounts such that the absorbent cellulosic sheet has a wet/dry CD tensile ratio of greater than 30 percent and an MD/CD dry tensile ratio of less than 1.

9. The method according to claim 7, wherein the aqueous furnish is treated with debonder at a consistency between about 3 and about 8 percent.

10. The method according to claim 7, further comprising the step of adding a dry strength agent to the furnish, which is carried out prior to diluting the furnish.

11. A method of making absorbent cellulosic sheet with increased wet/dry CD tensile ratio comprising:

a) preparing an aqueous furnish consisting essentially of cellulosic papermaking fibers in aqueous suspension having a consistency of 3 percent or more, the papermaking fiber including at least about 40 percent by weight Kraft softwood fiber;

b) treating the aqueous furnish at 3 percent or more consistency with debonder;

c) subsequent to the step of treating the aqueous furnish at 3 percent or more consistency with debonder, adding a permanent wet strength resin to the aqueous furnish in an amount of from about 5 lbs of permanent wet strength resin per ton of papermaking fiber to about 50 lbs of permanent wet strength resin per ton of papermaking fiber;

d) thereafter diluting the aqueous furnish to a consistency of less than the consistency at which the furnish was treated with debonder and less than the consistency at which permanent wet strength resin was added;

e) depositing the diluted aqueous furnish onto a foraminous support traveling in a machine direction at a wire speed by way of a jet of the diluted aqueous furnish having a jet velocity in the machine direction;

f) dewatering the furnish to form a web; and

g) drying the web to produce the cellulosic sheet;

wherein the steps of dewatering and drying the web are controlled and the furnish, debonder, and permanent wet strength resin are selected and utilized in amounts such that the absorbent cellulosic sheet has a wet/dry CD tensile ratio of greater than 30 percent and an MD/CD dry tensile ratio of less than 1.5.

12. The method according to claim 11, wherein the step of preparing the aqueous furnish comprises pulping the fiber in a pulping vessel and wherein the furnish is treated with debonder in the pulping vessel.

13. The method according to claim 11, further comprising the step of refining at least a portion of the papermaking fiber.

14. The method according to claim 11, further comprising the step of blending the debonder-treated aqueous furnish with another aqueous furnish containing papermaking fiber.

15. The method according to claim 14, wherein at least 50 percent by weight of the papermaking fiber in the sheet is pretreated with debonder.

16. The method according to claim 14, wherein at least 75 percent by weight of the papermaking fiber in the sheet is pretreated with debonder.

17. The method according to claim 14, wherein at least 90 percent by weight of the papermaking fiber in the sheet is pretreated with debonder.

18. The method according to claim 11, wherein the papermaking furnish also comprises recycle fiber.