High basis weight TAD towel prepared from coarse furnish

• US 8,080,130 B2
• Filed: 01/22/2009
• Issued: 12/20/2011
• Est. Priority Date: 02/01/2008
• Status: Active Grant

• Current Assignee: GPCP IP Holdings LLC
• Original Assignee: Georgia-Pacific Consumer Products LP (KOCH Industries Incorporated)
• Inventors: Harper, Frank D., Robinson, Mark L., Chou, Hung Liang, Olson, Steven R., Hynnek, Martin A., Worry, Gary L.
• Primary Examiner(s): Fortuna, Jose A
• Application Number:
  US12/357,524
• Publication Number:
  US 20090194244A1
• Time in Patent Office: 1,062 Days
• Field of Search: 162111-113, 162123-133, 162/141, 162/147, 162/149, 162/158, 162/164.1, 162/164.3, 162/168.1, 162/177, 162/179, 428/153, 428/156, 428/174, 428/340
• US Class Current: 162/123
• CPC Class Codes: D21H 15/02 characterised by configuration
• CPC Class Codes: D21H 25/005 Mechanical treatment D21H25/08, D21H25/18 take precedence
• CPC Class Codes: D21H 27/002 Tissue paper; Absorbent paper D21H21/22, D21H27/02, D21H27/20 take precedence; toilet paper A47K10/00; absorbent pads for physiological fluids A61L15/16; making on paper-making machines D21F11/00
• CPC Class Codes: D21H 27/02 Patterned paper patterned coatings D21H19/66; embossing B31F1/07; prepared on the paper-making machines D21F11/00
• CPC Class Codes: D21H 27/30 Multi-ply for surface covering D21H27/18; making on paper-making machines D21F9/00, D21F11/00
• CPC Class Codes: Y10T 428/24455 Paper
• CPC Class Codes: Y10T 428/24612 Composite web or sheet

Abstract

Kitchen roll toweling having surprising softness, absorbency and bulk is formed from a furnish comprising long cellulosic fiber having: (i) average weight-weighted fiber length of at least 2.5 mm; coarseness at least 15.5 mg/100 mm; and a Canadian Standard freeness of at least 600 ml combined with (ii) short cellulosic fiber having an average weight-weighted fiber length of at most 1.9 mm having a Canadian Standard freeness of at least 500 ml in a weight ratio of short fiber to long fiber of at least 0.25 to 1.0 to form a nascent web having a consistency in the range from about 10% to about 35% which is rush transferred from one fabric to another at a speed differential of at least about 15%; and creping the web from a Yankee dryer while controlling the real crepe to at most 3% and thereafter converting the web to form a two ply product having a basis weight of at least 29 lb/rm and caliper of at least 220 mils/8 sheets.

Claims

1. A method of forming a multi-ply cellulosic web comprising:

a) supplying to a headbox an aqueous stream comprising;

i) a short cellulosic fiber having an average weight-weighted fiber length of at most 1.9 mm; and

ii) a long cellulosic fiber having;

(1) a average weight-weighted fiber length of at least 2.5 mm; and

(2) a coarseness at least 15.5 mg/100 mm

b) with the weight ratio of short fiber to long fiber being at least 0.25 to 1.0 with the short fiber component having a Canadian Standard freeness of at least 500 ml and the long fiber component having a Canadian Standard freeness of at least 600 ml;

c) forming the web on a first moving foraminous fabric;

d) non-compactively dewatering the web deposited on the first moving foraminous fabric to form a nascent web having a consistency in the range from about 10% to about 35%;

e) transferring the nascent web from the first moving foraminous fabric to a second moving foraminous fabric where the first moving foraminous fabric travels at a speed higher than the second moving foraminous fabric so that the fabric crepe level of the nascent web after transfer is at least about 15%;

f) drying the nascent web on the second moving foraminous fabric to at most 95% solids;

g) transferring the web to a cylinder dryer to further dry the web to at most 98.5% solids;

h) creping the web from the cylinder dryer;

i) transferring the nascent web from the cylinder dryer to a reel where the cylinder dryer is operating at a speed such that the reel crepe is at most 3%;

j) converting the nascent web to form a two-ply product having basis weight of at least 32 lb/rm and caliper of at least 220 mils/8 sheets.

2. The method of claim 1 wherein the C/l_z of the furnish is at least about 5.3.

3. The method of claim 1 wherein the amount of softener applied, if any, is controlled to such a level that the SAT absorbency of the product exceeds about 8.5 g/g.

4. The method of claim 1 wherein the amount of softener applied, if any, is controlled to such a level that the SAT absorbency of the product exceeds about 9.0 g/g.

5. The method of claim 1 wherein the amount of softener applied, if any, is controlled to such a level that the SAT absorbency of the product exceeds about 9.5 g/g.

6. The method of claim 1 wherein the average weight-weighted fiber length of the long cellulosic fiber is at least 2.7 mm.

7. The method of claim 1 wherein the average weight-weighted fiber length of the long cellulosic fiber is at least 2.9 mm.

8. The method of claim 1 wherein the average weight-weighted fiber length of the long cellulosic fiber is at least 3.1 mm.

9. The method of claim 1 wherein the weight ratio of short fiber to long fiber is at least 0.5 to 1.

10. The method of claim 1 wherein the weight ratio of short fiber to long fiber is at least 0.67 to 1.

11. The method of claim 1 wherein the amount of softener applied, if any, is controlled to such a level that the SAT absorbency of the product exceeds about 9.0 g/g.

12. The multi-ply cellulosic web formed by the process of claim 1 wherein the amount of softener applied, if any, is controlled to such a level that the SAT absorbency of the base sheet exceeds about 10.0 g/g.

13. The multi-ply cellulosic web formed by the process of claim 1 wherein the sheet is creped from the drying cylinder at a consistency of at least about 96%.

14. The multi-ply cellulosic web formed by the process of claim 1 wherein the sheet is creped from the drying cylinder at a consistency of at least about 97%.

15. The multi-ply cellulosic web formed by the process of claim 1 wherein the sheet exhibits a finished product caliper of at least 6.2 mils/8 sheets per lb/rm of basis weight.

16. The multi-ply cellulosic web formed by the process of claim 1 wherein the sheet exhibits a basis weight of at least about 35 lbs/rm;

a caliper of at least about 235 mils/8 sheets;

a GM tensile strength of no more than 2800 g/3″

;

an MD stretch of at least about 18%;

a CD wet tensile (Finch cup method) of at least about 550 g/3″

;

a SAT capacity of at least about 9.0 and a GM tensile modulus of no more than about 45 g/in/%.

17. A method of forming a cellulosic web comprising:

a) supplying to a headbox an aqueous stream comprising;

i) a cellulosic short fiber having an average weight-weight fiber length of at most 1.9 mm; and

ii) a cellulosic long fiber having;

(1) an average weight-weight fiber length of at least 2.7 mm; and

(2) a coarseness at least 15.5 mg/100 mm

b) with the weight ratio of short fiber to long fiber being at least 0.4 to 1.0 with the short fiber component having a Canadian Standard freeness of at least 500 ml and the long fiber component having a Canadian Standard freeness of at least 600 ml;

c) forming the web on a first moving foraminous fabric;

d) non-compactively dewatering the web deposited on the first moving foraminous fabric to a consistency in the range from about 10% to about 35%;

e) transferring the nascent web from the first moving foraminous fabric to a second moving foraminous fabric where the first moving foraminous fabric travels at a speed higher than the second moving foraminous fabric so that the fabric crepe level of the nascent web after transfer is at least about 18%;

f) drying the nascent web on the second moving foraminous fabric to at most 95% solids;

g) transferring the web to a cylinder dryer to further dry the web to at most 98.5% solids;

h) dry creping the web from the cylinder dryer;

i) transferring the nascent web from the cylinder dryer to a reel where the cylinder dryer is operating at a speed such that the reel crepe is at most 3%; and

j) converting the nascent web to form a two-ply product having basis weight of at least 32 lb/rm and caliper of at least 220 mils/8 sheets

wherein the furnish, fabric creping parameters, dry creping parameters and wet strength resin are controlled such that the base sheet recovered has a conditioned basis weight of at least about 19 lbs/3000 sq ft ream, a tensile ratio of between about 0.9 and 1.1, a CD wet tensile of at least 450 g/3″

, a GM dry tensile of no more than about 1900 g/3″

, and a GM break modulus of no more than 170 g/%.

18. The method of claim 17 wherein the C/l_z of the furnish is at least about 5.3.

19. The method of claim 17 wherein the amount of softener applied, if any, is controlled to such a level that the SAT absorbency of the basesheet exceeds about 10.0 g/g.

20. The method of claim 17 wherein the amount of softener applied, if any, is controlled to such a level that the SAT absorbency of the basesheet exceeds about 10.5 g/g.

21. The method of claim 17 wherein the amount of softener applied, if any, is controlled to such a level that the SAT absorbency of the basesheet exceeds about 10.7 g/g.

22. The method of claim 17 wherein the sheet is creped from the drying cylinder at a consistency of at least about 96%.

23. The method of claim 17 wherein the sheet is creped from the drying cylinder at a consistency of at least about 97%.

24. The method of claim 17 wherein the finished product exhibits a conditioned basis weight of at least about 35 lbs/rm;

a caliper of at least about 235 mils/8 sheets;

an MD tensile of no more than 2800 g/3″

;

an MD stretch of at least about 20%;

a CD wet tensile (Finch cup method) of at least about 550 g/3″

;

a SAT capacity of at least about 9.5 and a GM tensile modulus of no more than about 40 g/in/%.

25. A two-ply towel product having basis weight of at least 32 lb/rm, a geometric dry tensile strength of at most 2500 g/3″

, a thickness of at least 220 mils/8 sheets, said two-ply towel product being made by the process comprising;

a) supplying to a headbox an aqueous stream comprising;

i) a high freeness short fiber having an average weight-weight fiber length of at most 1.9 mm; and

ii) a high freeness long fiber having an average weight-weight fiber length of at least 2.7 mm and having a coarseness at least 15.5 mg/100 mm with the ratio of short fiber to long fiber being at least 0.25 to 1.0

with the short fiber component having a Canadian Standard freeness of at least 500 ml and the long fiber component having a Canadian Standard freeness of at least 600 ml;

b) forming the web on a first foraminous forming fabric;

c) non-compactively dewatering the web deposited on the first moving foraminous fabric to a consistency in the range from about 10% to about 35%;

d) transferring the nascent web from the first foraminous endless forming fabric to a second moving foraminous fabric where the first moving foraminous fabric is operating at a speed higher than the second moving foraminous fabric so that the fabric crepe level is at least about 18%;

e) drying the nascent web on the second moving foraminous fabric to at most 95% solids;

f) transferring the web to a cylinder dryer to further dry the web to at most 98.5% solids;

g) creping the web from the cylinder dryer;

h) transferring the nascent web from the cylinder dryer to a reel where the cylinder dryer is operating at a speed such that the reel crepe is at most 3%;

i) converting the nascent web to form a two-ply product.

26. The two-ply towel product of claim 25 wherein the C/l_z of the furnish is at least about 5.3.

27. The two-ply towel product of claim 25 wherein the amount of softener applied, if any, is controlled to such a level that the SAT absorbency of the product exceeds about 9.0 g/g.

28. The two-ply towel product of claim 25 wherein the amount of softener applied, if any, is controlled to such a level that the SAT absorbency of the product exceeds about 9.5 g/g.

29. The two-ply towel product of claim 25 wherein the amount of softener applied, if any, is controlled to such a level that the SAT absorbency of the product exceeds about 10.0 g/g.

30. The two-ply towel product of claim 25 wherein the amount of softener applied, if any, is controlled to such a level that the SAT absorbency of the base sheet exceeds about 10.5 g/g.

31. The two-ply towel product of claim 25 wherein the sheet is creped from the drying cylinder at a consistency of at least about 96%.

32. The two-ply towel product of claim 25 wherein the sheet is creped from the drying cylinder at a consistency of at least about 97%.

33. The two-ply towel product of claim 25 wherein the sheet exhibits a finished product caliper of at least 6.2 mils/8 sheets per lb/rm of basis weight.

34. The two-ply towel product of claim 25 wherein the finished product exhibits a basis weight of at least about 35 lbs/rm;

a caliper of at least about 235 mils/8 sheets;

a GM tensile strength of no more than 2800 g/3″

;

an MD stretch of at least about 20%;

a CD wet tensile (Finch cup method) of at least about 550 g/3″

;

a SAT capacity of at least about 9.5 and a GM tensile modulus of no more than about 40 g/in/%.

35. A two-ply TAD towel comprising between about 50 to 75 wt. % softwood Kraft fibers having a average weight-weight fiber length of at least 2.7 mm;

and a coarseness at least 20 mg/100 mm and a Canadian Standard freeness of at least 600 ml, and between about 25 and 50 wt. % short fibers having an average weight-weighted fiber length of at most 1.9 mm and a Canadian Standard freeness of at least 500 ml; and

comprising between about 9 and 20 lbs of PAE wet strength resin per ton, and between 2 and 7 lbs of carboxymethyl cellulose per ton, said towel exhibiting;

a) a basis weight of between 34 and 38 lbs/3000 sq ft ream;

b) a geometric mean dry tensile strength of 2000 and 3300 g/3″

;

c) a specific geometric mean dry tensile strength of 60 and 85 g/3″

per lb/rm of basis weight;

d) a caliper of between about 220 and 250 mils per 8 sheets,

e) a specific caliper of between about 6.5 and 7.5 mils per 8 sheets per lb/rm of basis weight;

f) a gross SAT capacity of between about 450 and 650 g/m²;

g) a specific SAT capacity of between about 13 and 17 g/m² per lb of basis weight;

h) a CD wet tensile strength of between 475 and 825 g/3″

;

i) a specific CD wet tensile strength of between 15 and 22 g/3″

per lb of basis weight;

j) a geometric break modulus of between 175 and 225 g/% stretch; and

k) a specific break modulus of between 5.0 and 6.0 g/% stretch per lb/rm of basis weight.

36. A two-ply TAD towel comprising between about 50 to 75 wt. % softwood Kraft fibers having an average weighted-weighted fiber length of at least 2.7 mm;

and a coarseness at least 15.5 mg/100 mm and a Canadian Standard freeness of at least 600 ml, and between about 25 to 50 wt. % short fibers having an average weight-weighted fiber length of at most 1.9 mm and a Canadian Standard freeness of at least 500 ml; and

comprising between about 9 and 20 lbs of wet strength resin per ton, and between 2 and 7 lbs per ton of carboxymethyl cellulose, said towel exhibiting;

a) a basis weight of between 34 and 38 lbs/3000 sq ft ream;

b) a geometric mean dry tensile strength of no more than 2700 g/3″

;

c) a specific geometric mean dry tensile strength of between no more than 80 g/3″

per lb/rm of basis weight;

d) a caliper of at least about 220 mils per 8 sheets,

e) a specific caliper of at least about 6.5 mils per 8 sheets per lb/rm of basis weight;

f) a gross SAT capacity of at least 500 g/m²;

g) a specific SAT capacity of at least about 14 g/m² per lb/rm of basis weight;

h) a CD wet tensile strength of at least about 600 but no more than about 700 g/3″

;

i) a specific CD wet tensile strength of between 15 and 20 g/3″

per lb of basis weight; and

j) an MD stretch of least about 20%.

37. A method of forming a two-ply cellulosic web comprising:

a) supplying to a first layer of a stratified headbox an aqueous stream comprising;

i) a long cellulosic fiber having;

(1) a average weight-weighted fiber length of at least 2.7 mm; and

(2) a coarseness at least 15.5 mg/100 mm; and

ii) a short cellulosic fiber having an average weight-weighted fiber length of at most 1.9 mm;

with the short fiber component having a Canadian Standard freeness of at least 500 ml and the long fiber component having a Canadian Standard freeness of at least 600 ml, with the weight ratio of long fiber to short fiber being from at least 0.25 to 1.0 up to about 0.67 to 1.0;

b) supplying to an second layer of a stratified headbox an aqueous stream comprising;

i) a short cellulosic fiber having an average weight-weighted fiber length of at most 1.9 mm; and

ii) a long cellulosic fiber having;

(1) a average weight-weighted fiber length of at least 2.7 mm; and

(2) a coarseness at least 15.5 mg/100 mm

with the weight ratio of short fiber to long fiber being at least 0.4 to 1.0 with the short fiber component having a Canadian Standard freeness of at least 500 ml and the long fiber component having a Canadian Standard freeness of at least 600 ml;

c) forming the web on a first moving foraminous fabric;

d) non-compactively dewatering the web deposited on the first moving foraminous fabric to form a nascent web having a consistency in the range from about 10% to about 35%;

e) transferring the nascent web from the first moving foraminous fabric to a second moving foraminous fabric where the first moving foraminous fabric travels at a speed higher than the second moving foraminous fabric so that the fabric crepe level of the nascent web after transfer is at least about 18%;

f) drying the nascent web on the second moving foraminous fabric to at most 95% solids;

g) transferring the web to a cylinder dryer to further dry the web to at most 98.5% solids;

h) creping the web from the cylinder dryer;

i) transferring the nascent web from the cylinder dryer to a reel where the cylinder dryer is operating at a speed such that the reel crepe is at most 3%;

j) converting the nascent web to form a two-ply product having a basis weight of at least 32 lb/rm and caliper of at least 220 mils/8 sheets with the surface of the product corresponding to the first layer of said stratified headbox being disposed to the exterior of said two-ply product.

38. The two-ply cellulosic web formed by the process of claim 37 wherein the content of long fiber in said first layer is at least about 70% by weight.

39. The two-ply cellulosic web formed by the process of claim 37 wherein the ratio of long fiber in said first layer is at least about 80% by weight.

40. The two-ply cellulosic web formed by the process of claim 37 wherein the C/l_z of the furnish is at least about 5.3.

41. The two-ply cellulosic web formed by the process of claim 37 wherein the amount of softener applied, if any, is controlled to such a level that the SAT absorbency of the product exceeds about 9.0 g/g.

42. The two-ply cellulosic web formed by the process of claim 37 wherein the amount of softener applied, if any, is controlled to such a level that the SAT absorbency of the product exceeds about 9.5 g/g.

43. The two-ply cellulosic web formed by the process of claim 37 wherein the amount of softener applied, if any, is controlled to such a level that the SAT absorbency of the product exceeds about 10.0 g/g.

44. The two-ply cellulosic web formed by the process of claim 37 wherein the amount of softener applied, if any, is controlled to such a level that the SAT absorbency of the base sheet exceeds about 10.5 g/g.

45. The two-ply cellulosic web formed by the process of claim 37 wherein the sheet is creped from the drying cylinder at a consistency of at least about 96%.

46. The two-ply cellulosic web formed by the process of claim 37 wherein the sheet is creped from the drying cylinder at a consistency of at least about 97%.

47. The two-ply cellulosic web formed by the process of claim 37 wherein the sheet exhibits a finished product caliper of at least 6.2 mils/8 sheets per lb/rm of basis weight.

48. The two-ply cellulosic web formed by the process of claim 37 wherein the sheet exhibits a basis weight of at least about 35 lbs/rm;

a caliper of at least about 235 mils/8 sheets;

a GM tensile strength of no more than 2800 g/3″

;

an MD stretch of at least about 20%;

a CD wet tensile (Finch cup method) of at least about 550 g/3″

;

a SAT capacity of at least about 9.5 and a GM tensile modulus of no more than about 40 g/in/%.

49. A method of forming a multi-ply cellulosic web comprising:

a) supplying to a headbox an aqueous stream comprising;

i) a short cellulosic fiber having an average weight-weighted fiber length of at most 1.9 mm; and

ii) a long cellulosic fiber having;

(1) a average weight-weighted fiber length of at least 2.5 mm; and

(2) a coarseness at least 15.5 mg/100 mm

b) with the weight ratio of short fiber to long fiber being at least 0.25 to 1.0 with the short fiber component having a Canadian Standard freeness of at least 500 ml and the long fiber component having a Canadian Standard freeness of at least 600 ml;

c) forming the web on a first moving foraminous fabric;

d) non-compactively dewatering the web deposited on the first moving foraminous fabric to form a nascent web having a consistency in the range from about 10% to about 35%;

e) transferring the nascent web from the first moving foraminous fabric to a second moving foraminous fabric where the first moving foraminous fabric travels at a speed higher than the second moving foraminous fabric so that the fabric crepe level of the nascent web after transfer is at least about 15%;

f) drying the nascent web on the second moving foraminous fabric to at most 95% solids;

g) transferring the web to a cylinder dryer to further dry the web to at most 98.5% solids;

h) creping the web from the cylinder dryer;

i) transferring the nascent web from the cylinder dryer to a reel where the cylinder dryer is operating at a speed such that the reel crepe is at most 3%;

j) converting the nascent web to form a two-ply product having basis weight of at least 29 lb/rm and caliper of at least 220 mils/8 sheets.

50. The method of claim 49 wherein the C/l_z of the furnish is at least about 5.3.

51. The method of claim 49 wherein the amount of softener applied, if any, is controlled to such a level that the SAT absorbency of the product exceeds about 8.5 g/g.

52. The method of claim 49 wherein the amount of softener applied, if any, is controlled to such a level that the SAT absorbency of the product exceeds about 9.0 g/g.

53. The method of claim 49 wherein the amount of softener applied, if any, is controlled to such a level that the SAT absorbency of the product exceeds about 9.5 g/g.

54. The method of claim 49 wherein the average weight-weighted fiber length of the long cellulosic fiber is at least 2.7 mm.

55. The method of claim 49 wherein the average weight-weighted fiber length of the long cellulosic fiber is at least 2.9 mm.

56. The method of claim 49 wherein the average weight-weighted fiber length of the long cellulosic fiber is at least 3.1 mm.

57. The method of claim 49 wherein the weight ratio of short fiber to long fiber is at least 0.5 to 1.

58. The method of claim 49 wherein the weight ratio of short fiber to long fiber is at least 0.67 to 1.

59. The method of claim 49 wherein the amount of softener applied, if any, is controlled to such a level that the SAT absorbency of the product exceeds about 9.0 g/g.

60. The multi-ply cellulosic web formed by the process of claim 49 wherein the amount of softener applied, if any, is controlled to such a level that the SAT absorbency of the base sheet exceeds about 10.0 g/g.

61. The multi-ply cellulosic web formed by the process of claim 49 wherein the sheet is creped from the drying cylinder at a consistency of at least about 96%.

62. The multi-ply cellulosic web formed by the process of claim 49 wherein the sheet is creped from the drying cylinder at a consistency of at least about 97%.

63. The multi-ply cellulosic web formed by the process of claim 49 wherein the sheet exhibits a finished product caliper of at least 6.2 mils/8 sheets per lb/rm of basis weight.

64. The multi-ply cellulosic web formed by the process of claim 49 wherein the sheet exhibits a basis weight of at least about 35 lbs/rm;

a caliper of at least about 235 mils/8 sheets;

a GM tensile strength of no more than 2800 g/3″

;

an MD stretch of at least about 18%;

a CD wet tensile (Finch cup method) of at least about 550 g/3″

;

a SAT capacity of at least about 9.0 and a GM tensile modulus of no more than about 45 g/in/%.

65. A two-ply TAD towel comprising between about 50 to 75 wt. % softwood Kraft fibers having a average weight-weight fiber length of at least 2.7 mm;

and a coarseness at least 20 mg/100 mm and a Canadian Standard freeness of at least 600 ml, and between about 25 and 50 wt. % short fibers having an average weight-weighted fiber length of at most 1.9 mm and a Canadian Standard freeness of at least 500 ml; and

comprising between about 9 and 20 lbs of PAE wet strength resin per ton, and between 2 and 7 lbs of carboxymethyl cellulose per ton, said towel exhibiting;

a) a basis weight of between 29 and 38 lbs/3000 sq ft ream;

b) a geometric mean dry tensile strength of 2000 and 3300 g/3″

;

c) a specific geometric mean dry tensile strength of 60 and 85 g/3″

per lb/rm of basis weight;

d) a caliper of between about 220 and 250 mils per 8 sheets,

e) a specific caliper of between about 6.5 and 7.5 mils per 8 sheets per lb/rm of basis weight;

f) a gross SAT capacity of between about 450 and 650 g/m²;

g) a specific SAT capacity of between about 13 and 17 g/m² per lb/rm of basis weight;

h) a CD wet tensile strength of between 475 and 825 g/3″

;

i) a specific CD wet tensile strength of between 15 and 22 g/3″

per lb/rm of basis weight;

j) a geometric break modulus of between 175 and 225 g/% stretch; and

k) a specific break modulus of between 5.0 and 6.0 g/% stretch per lb/rm of basis weight.