CN1071825C - 柔软薄页纸制品的制备方法 - Google Patents

柔软薄页纸制品的制备方法 Download PDF

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CN1071825C
CN1071825C CN95103890A CN95103890A CN1071825C CN 1071825 C CN1071825 C CN 1071825C CN 95103890 A CN95103890 A CN 95103890A CN 95103890 A CN95103890 A CN 95103890A CN 1071825 C CN1071825 C CN 1071825C
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CN1120616A (zh
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G·A·文特
赵启发
M·A·布拉津
T·E·发林顿
D·A·希顿
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Kimberly Clark Worldwide Inc
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    • DTEXTILES; PAPER
    • D21PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21FPAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
    • D21F11/00Processes for making continuous lengths of paper, or of cardboard, or of wet web for fibre board production, on paper-making machines
    • D21F11/14Making cellulose wadding, filter or blotting paper
    • D21F11/145Making cellulose wadding, filter or blotting paper including a through-drying process
    • DTEXTILES; PAPER
    • D21PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21FPAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
    • D21F1/00Wet end of machines for making continuous webs of paper
    • D21F1/0027Screen-cloths
    • DTEXTILES; PAPER
    • D21PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21FPAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
    • D21F1/00Wet end of machines for making continuous webs of paper
    • D21F1/0027Screen-cloths
    • D21F1/0036Multi-layer screen-cloths
    • DTEXTILES; PAPER
    • D21PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21FPAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
    • D21F11/00Processes for making continuous lengths of paper, or of cardboard, or of wet web for fibre board production, on paper-making machines
    • D21F11/006Making patterned paper
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    • D21PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21FPAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
    • D21F11/00Processes for making continuous lengths of paper, or of cardboard, or of wet web for fibre board production, on paper-making machines
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Abstract

使用穿透干燥织物制备如搽面纸,浴巾纸和毛巾纸的穿透干燥的薄页纸产品,所述织物具有突在织物平面上面的约5-300个/英寸的MD压节(5-300/6.45cm2)。这些压节在穿透干燥的纸页中产生相应的突起物,这些突起物赋予纸页显著量的CD伸长率。此外,其它的性能如松厚度、吸水能力,吸水速率和柔韧性也得到改善。

Description

柔软薄页纸制品的制备方法
本申请是1994年4月1 2日申请的共同未决美国专利申请US08/266,630的部分继续。在穿透干燥的薄页纸制品如搽面纸、浴巾纸和毛巾纸的制造中,总需要改进最终制品的性能。尽管人们总是十分关注改进柔软度,但是在纸页中的伸长量也是很重要的,特别是制品的耐久性和韧性。当伸长率增加时,薄页纸能在不破裂的情况下更迅速地缓冲拉应力。此外,特别是横向增加的伸长率改进了直接影响纸页柔软度的纸页柔韧性。
通过起皱,容易得到约为15%的改进的纸页柔韧性和纵向伸长率,但是,由于薄页纸制备方法本身的原因,最终的横向伸长率通常局限于约8%或更低。
因此,需要一种在保持或改进其它希望的薄页纸性能的同时,增加穿透干燥薄页纸制品柔韧性和横向伸长率的方法。
业已发现,一定的穿透干燥织物能给最终薄页纸制品大大地提供增加的横向(CD)伸长率,与此同时还提供高松厚度、增加的柔韧性、快速吸水速率和高吸水能力。这些织物具有有许多“压节”的特点,在此“压节”被定义为织物节,在薄页纸制备方法的纵向(MD),它们是细长的,并明显地露在干燥织物平面的上面;当从横向观察这些织物时,它们似乎是部分重叠的。当薄页纸在该织物上进行干燥时,这些压节在纸页中将赋予相应的突起物。在该纸页中形成的突起物的高度、定位和排列提供增加的松厚度、增加的横向伸长率、增加的柔韧性、增加的吸水能力和增加的吸水速率。所有这些性能对于在此总称为薄页纸制品的制品如搽面纸、浴巾纸和毛巾纸等来讲是所希望的。根据本发明制得的薄页纸可以以一层或多层的薄页纸制品来使用。
令人惊奇的是,另外还发现,当部分饱和时,未起皱的穿透干燥与高松厚度织物和临时的湿强度化学处理的结合能产生具有优异物理性能的柔软薄页纸制品。具体的性能包括:湿压松厚度或WCB(下文定义并以CC/gm表示)、载能比率或LER(下文定义并以%表示)和湿回弹或WS(下文定义并以%表示)。由于它们能同时取得所有这三个试验的高的数值,因此,本发明制得的薄页纸是独特的。由于在穿透干燥器织物上建立起了薄页纸的湿强度,因此取得了这些优异的性能,同时该纸页仍处于其希望的立体构型。随后的破坏性起皱的消除保证了在穿透干燥器上建立起的高松厚结构永久地保留,甚至在已发生部分饱和之后。在使用时,由本发明制得的薄页纸在使用期间显示出优异的完整性,并且特别适于与作为后处理的各种水基和非水基化学助剂的掺入,以进一步改进性能和功能。
因此,一方面,本发明涉及薄页纸的制备方法,包括:(a)将浓度约1%或更低的造纸纤维的水悬浮液沉积在成形织物上,形成一湿纸幅;(b)将该湿纸幅脱水至约20%-约30%的浓度;(c)将脱水的纸幅从成形织物传送至运行速度比成形织物慢约10%至约80%的引纸织物上;(d)将该纸幅传送至穿透干燥织物上,该织物每平方英寸(每6.45cm2)有约6至约300个压节。优选每平方英寸有约10至约150个压节,更优选每平方英寸有约25至约75个压节,这些节露出织物平面至少约0.005英寸(0.012cm),其中该纸幅被微观地进行重排,以与穿透干燥织物的表面相一致;和(e)对该纸幅进行穿透干燥。干燥的纸幅可以进行起皱或保持不起皱。此外,形成的纸幅可以进行压光。
另一方面,本发明涉及起皱或不起皱的穿透干燥的薄页纸,该纸的定量为约10-约70g/m2,与穿透干燥织物上的压节相对应,每平方英寸(每6.45cm2)具有约6至约300个突起物,优选每平方英寸有约10至约150个突起物,更优选每平方英寸有约25至约75个突起物,所说的薄页纸的横向伸长率约为9%或更大,优选为约10~25%,更优选为约10~20%。(本文所用的横向“伸长率”是使用Instron抗张强度测定仪时横向断裂的百分伸长率)。当在未起皱和未压光状态进行测量时,相应于薄页纸表面的突起物的高度或Z方向的尺寸可为约0.005英寸(0.013cm)至约0.05英寸(0.13cm),优选为约0.005英寸(0.013cm)至约0.03英寸(0.076cm),更优选为约0.01英寸(0.025cm)至约0.02英寸(0.051cm)。压光将降低突起物的高度,但不会将它们消除。在纵向突起物的长度可为约0.030英寸至约0.425英寸,优选为约0.05英寸至约0.25英寸,更优选为约0.1英寸至约0.2英寸。
另一方面,本发明涉及一种柔软的薄页纸制品,其WCB为约4.5或更大,优选为约5.0或更大;LER为约50%或更高,优选为约55%或更高;以及WS为约50%或更高,优选为约60%或更高。
还有一方面,本发明涉及一种柔软的、未起皱的、穿透干燥的薄页纸制品,其WCB为约4.5或更大,优选为约5.0或更大;LER为约50%或更高,优选为约55%或更高;以及WS为约50%或更高,优选为约60%或更高。
又一方面,本发明涉及柔软薄页纸的制备方法,包括:(a)形成浓度为约20%或更大的造纸纤维的水悬浮液;(b)在用具有每吨干纤维约1马力-天或更大能量输入的外部热源(如蒸汽)提供的约140°F或更高的温度下对该水悬浮液进行机械处理;(c)将该机械处理纤维的水悬浮液稀释至约0.5%或更低的浓度,并将该稀释的悬浮液送至提供两层或多层的层状造薄页纸的网前箱;(d)在所说的一层或多层中含有临时或永久的湿强助剂;(e)将该稀释的水悬浮液沉积在成形织物上,形成一湿纸幅;(f)将该湿纸幅脱水至从约20%至约30%的浓度;(g)将脱水的纸幅从成形织物传送至运行速度比成形织物慢约10%至约80%的引纸织物上;(h)将该纸幅传送至穿透干燥织物上,借此,该织物被微观地重排,以与穿透干燥织物的表面相一致;(i)对该纸幅进行穿透干燥至最终的干度;和(j)随后压光该纸幅,取得希望的最终于纸页的厚度。
此外,这样的薄页纸的吸水速率为约2.5cm/15秒或更大,优选为约2.5至约4cm/15秒,更优选为约3至约3.5cm/15秒。吸水速率是根据ASTM D1776(样品规定)和TAPPI UM451(纸的毛细作用试验)测定的标准参数。该方法包括将试样沿边浸入水浴中,并测量15秒内水行进的垂直虹吸距离。为方便起见,用纸夹压住该试样,并首先将试样在水浴表面以下一英寸进行浸渍。
另外,本发明的薄页纸的松厚度为约12cm3/g或更大,优选为约2~25cm3/g,更优选为约13~20cm3/g。在此所用的纸页松厚度等于单层制品的厚度除以其定量。厚度是根据TAPPI测试法T402“Standard Conditioning and Testing Atmosphere ForPaper,Board,Pulp Handsheets and Related Products”和T411om-89“Thickness(厚度)of Paper,Paperboard,and CombinedBoard。”测量的。执行T411om-89所用的测微计是具有80g/吋2(每6.45cm2)测量头压力(anvil pressure)的Bulk Micrometer(TMI Model49-72-00,Amityville,New York)。
更进一步的,当通过几何平均模数除以几何平均抗张强度(下文参考图5和图6定义)的商测量时,定量在约10~70g/cm2范围的所述薄页纸的柔韧性为约4.25Km/Kg或更小,优选约4Km/Kg或更小,更优选约2-4.25Km/Kg 。
此外,定量在约10~70g/cm2范围的所述薄页纸的MD挺度值(下文定义)为约100Kg-μm1/2或更小,优选约75Kg-μm1/2或更小,更优选约50Kg-μm1/2或更小。
另外,本发明薄页纸的吸水能力(下文定义)为约11g水/g纤维或更大,优选约11~14g/g。该吸水能力是通过将要测试的纸页切成4吋×4吋的20个方块,并将它们的角订在一起以形成20层纸页的垫而测量的。将该垫置于纤维针迹向下(staplepointsdown)金属丝编织筐中,并向下浸入水浴(30℃)中。当该垫完全湿润时,从水浴中取出,并在金属丝筐中脱水30秒钟。30秒钟后留在垫内水的重量就是吸水量。该值除以垫的重量,从而确定吸水能力。
就使用湿强剂而言,有大量常用于造纸工业以赋予纸和纸板湿强度的物质,它们都可用于本发明。作为湿强剂,这些物质在本领域是已知的,并可从许多来源在市场上得到。对于本发明来说,当添加至纸或薄页纸时,能给薄页纸或纸提供湿强度与干强度之比值大于0.1的任何物质都将被称为湿强剂。这些物质通常被称为永久湿强剂或“暂时”湿强剂。为了区分永久湿强度和暂时湿强度,当掺入纸或薄页纸制品中时,在暴露至水中至少5分钟后,那些将提供保留大于其原始湿强度50%的制品的树脂,将被称为永久湿强剂。暂时湿强剂为在暴露至水中5分钟后显示出低于其原始湿强度50%的那些树脂。这两类材料都能在本发明中找到应用。以干重纤维计,添加至纸浆纤维中的湿强剂量可为至少约0.1%(干重)或更大,优选约0.2%(干重)或更大,更优选约0.1~3%(干重)。
永久湿强剂将或多或少地提供长期的结构湿回弹性能。这种结构将在需要长期湿回弹性能的制品如毛巾纸和许多吸水消费制品中找到应用。相反,暂时湿强剂将提供具有低密度和高回弹性能的结构,但是不能提供暴露于水或体液的长期回弹性能的结构。尽管该结构具有良好的初始完整性,但是,在一段时间后,该结构将开始丧失其湿回弹性能。该性能能用作在提供当开始湿润时是高吸收的,但一段时间后将丧失其完整性的材料的某一优点。该性能能用来提供“可冲洗的”制品。只要获得了在纤维/纤维结合点上产生耐水键的主要性能,借助产生湿强度的机理对本发明的制品几乎没有影响。
能用于本发明的永久湿强剂通常是能自交联的(同型交联)或与本纤维的纤维素或其它成份交联的水溶性的、阳离子低聚物或聚合物树脂。为此目的最广泛使用的材料是称为聚酰胺-聚胺-表氯醇(PAE)型树脂的这类聚合物。这些材料已披露于授权给Keim的专利(US3,700,623和US 3,772,076)中,并由Hercules,Inc.Wilmigton,Delaware以Kymene557H销售。相应的材料被HenkelChemical Co.,Charlotte,North Carolina和Georgia-PacificResins,Inc.,Atlanta,Georgia销售。
聚酰胺-表氯醇树脂在本发明中也可用作粘合树脂。由孟山都开发的并以Santo Res商标销售的材料是能用于本发明的碱活化的聚酰胺-表氯醇树脂。这些材料被披露于授权给Petrovich(US3,885,158;US3,899,388;US4,129,528和US4,147,586)和VanEenam(US4,222,921)的专利中。尽管聚乙烯亚胺树脂并不常用于消费制品中,但是,它们也适于固定本发明制品中的结合点。另一类永久湿强剂为通过甲醛和密胺或尿素反应得到的氨基塑料树脂。
能与本发明一起使用的暂时湿强剂包括(但并不局限于):由American Cyanamid开发并以商品名Parez631NC销售(现在可从Cytec Industries,West Paterson,New Jersey得到)的那些树脂。这类树脂以及类似的树脂披露于Coscia等人的US3,556,932和Williams等人的US3,556,933中。能在本发明中找到应用的其它暂时湿强剂包括改性淀粉,如可从National Starch得到并以Co-Bond1000销售的那些改性淀粉。据信,这些淀粉和相应的淀粉被授予Solarek等人的US4,675,394所覆盖。如披露于日本公开特许公报JP03,185,197中的衍生的二醛淀粉也将作为提供暂时湿强度的有用材料而找到应用。另外还预期,如披露于Bjorkquist的US4,981,557、US5,008,344和US5,085,736中的那些暂时湿强材料也能用于本发明。就所列的湿强树脂的种类和类型而言,应明白的是,所列出的是简单提供的例子,这既不意味着排除其它类型的湿强树脂,也不意味着限定本发明的范围。
虽然上述湿强剂与本发明一起使用找到了特殊的优点,但是其它类型的粘合剂也能用来提供所需的湿回弹性能。它们可以在湿端部施加,或在纸幅形成后或在干燥后通过喷淋或印刷等进行施加。
特别适用于本发明的造纸纤维包括低得率化学制浆纤维,如针叶木和阔叶木的硫酸盐法纤维。与高得率浆如机械浆的纤维相比,这些纤维是相对柔韧的。虽然其它的纤维能有益地用来完成本发明的各个方面,但是,当使用低得率浆纤维时,本发明薄页纸的回弹性能是特别惊人的。
用于本发明的干燥器织物具有由高长MD压节或浮经支配的顶平面的特点,在顶平面中没有横向节。平面差,即在由纵向压节(两个平面的较高者)的最高点形成的平面和由横向(shute)节的那些最高点形成的平面之间的距离,是形成压节的经纱单股直径的约30~150%,优选约70~110%。经纱单股直径可以是约0.005英寸(0.013cm)至约0.05英寸(0.13cm),优选约0.005英寸(0.013cm)至约0.035英寸(0.09cm),更优选约0.010英寸(0.025cm)至约0.020英寸(0.051cm)。
通过纬(CD)纱数确定压节的长度,纬纱与形成压节的经纱交叉。纬纱数可为约2~15,优选约3~11,更优选约3~7根纬纱。绝对地说,压节的长度可为约0.030~0.425英寸,优选约0.05~0.25英寸,更优选约0.1~0.2英寸。
当与横向和纵向节的较低的次平面结合时,这些高长压节形成了立体浮雕构型。因此,有时将本发明的织物在此称之为立体织物。该浮雕构型具有跳纱和皱褶缝拢外观的反向图象。当该织物用来干燥薄页纸的湿纸幅时,该薄页纸幅便印上了该织物的轮廓,并显示缝拢状的外观,该外观具有看起来跳纱的高压节的图象和看起来象皱褶区域的次平面的图象。这些节可以这样的方式排列,如菱形状的形状,或更自由流动状的(装饰的)主题如鱼,蝴蝶等,这些形状在视觉上更好。
从织物制造的观点来看,据信到目前为止,市售的织物一直是同平表面(即,经纬节的顶部在同一高度),或者是纬节高的表面。同平表面可通过表面打磨或热定形而获得,在后者的场合,在热定形期间,经线通常被拉直,并往下拉入织物体内,以增加耐伸长性,并且当用于高温如干法造纸中消除织物的皱折。结果,横向节朝着织物的表面突出。相反,由于它们独特的纺织结构,用于本发明的织物的压节甚至在热定形后仍保持在织物平面之上。
在根据本发明有用的织物的各种实施方案中,基础织物可具有任意网目或编织构型。形成高顶平面压节的经线可以是单根纱线或纱线束。成束的纱线的直径可以相同或不同,以产生雕刻的效果。纵向纱线的横截面可是圆的或不圆的(如椭圆形的,扁平的,矩形的或带状的)。这些经线可由聚合材料、金属材料或它们的结合制得。在纺织机上在生产高压节中包含的经线数可以是约5~100/英寸(2.54cm)。在纺织机上在承重层中包含的经线数也可以是约5~100/英寸。
经线的百分覆盖范围被定义为每英寸织物的总经线数乘以经纱单股直径再乘以100。对于本发明中有用的织物,总的经线覆盖范围大于65%,最好为约80~100%。随着经线覆盖范围的增加,在纸机运行条件下每根经纱承受的载荷交小。因此,在织物热定形步骤中,并不需要将承重经线拉直至相同的程度,以实现伸长和机械稳定性。这有助于维持高长压节的折皱。
图1为根据本发明的不起皱薄页纸制备方法的流程简图。
图2是CD伸长率对各种穿透干燥浴薄页纸产品的松厚度的作图,图解说明了本发明未起皱产品获得的CD伸长率。
图3是吸水速率对许多单层毛巾纸松厚度的作图,图解说明了本发明产品获得的吸水速率的增加。
图4是吸水能力对浴巾纸产品松厚度的作图,图解说明了本发明产品的高吸水能力。
图5是薄页纸综合载荷/伸长率的曲线图,用以图解说明几何平均模量的确定。
图6是几何平均模量除以几何平均抗张强度(柔韧性)的商对搽面纸、浴巾纸和厨房用毛巾纸(kitchen towels)的作图,图解说明了本发明产品的高度柔韧性。
图7是根据本发明有用的穿透干燥织物或引纸织物的平面图。
图7A是图7织物的截面图,图解说明了高长压节和平面差。
图7B是图7织物不同的截面图,进一步图解说明了编织图案和平面差。
图8是根据本发明另一有用织物的平面图。
图8A是图8织物的截面图。
图9是根据本发明另一有用织物的平面图。
图9A是图9织物放大的纵截面,图解说明了织物顶表面、中间平面和次平面的位置。
图10是根据本发明另一有用织物的平面图。
图10A是取线10A-10A的图10织物的横截面图。
图11和12是用于本发明目的另外的织物的平面图。
图13-15是显示用于本发明、包含有非圆形经纱的另外织物的、与图7A相似的横截面图。
图16是改良的标准长网编织机的流程图,该编织机引入了控制额外体系的经纱的提花装置,从而将压印经纱部分“针刺绣花”进入另外的常规造纸机织物中。
图17是根据本发明制得的薄页纸横截面的照片。
图18是MD挺度对各种市售搽面纸、浴巾纸和毛巾纸松厚的作图,图解说明了本发明产品的高松厚度和低挺度。
图19的表示本发明若干个实施例以及若干个对比产品的WCB,LER和WS的图表。
参考图1,将更详细地描述实施本发明的方法。所显示的是带有层状造纸网前箱10的双网成形器,网前箱10将造纸纤维的水悬浮液即液流11喷射或沉积在成形织物12上。然后将该纸幅送至织物13上,在该纸幅部分脱水至约10%干重的过程中,织物13用来支承并携带该新形成的湿纸幅向下游传送。在该湿纸幅被该成形织物支承着时,还可对湿纸幅进行另外的脱水,如通过真空吸水。
然后,将该湿纸幅从成形织物传送至运行速度低于该成形织物的引纸织物17上。以便赋予该纸幅以增加的MD伸长率。采用吻合传递以避免湿纸幅的压缩,优选借助真空板18。该引纸织物可以是带有如图7-16所述压节的织物,或可以是如Asten934、937、939、959或Albany94M的更平滑的织物。如果该引纸织物具有在此所述类型的压节,当与也具有该压节的穿透干燥结合时,那么它可用来赋予某些与该穿透干燥织物相同的性能,并能增强该作用。当具有压节的引纸织物用来取得所希望的CD伸长性能时,它提供了可选择地使用不同的穿透干燥织物,如具有装饰编织图案的织物的适应性,以提供其它方式得不到的另外希望的性能。
然后,借助于真空送纸辊20或真空递纸板将纸幅从引纸织物送至穿透干燥织物19上。穿透干燥织物的运行速度可与引纸织物的运行速度大致相同或不同。如果希望的话,穿透干燥织物可以较低的速度运行,以进一步增强MD伸长率。最好在真空的帮助下进行引纸,以保证纸页的变形与穿透干燥织物相一致,于是获得希望的松厚度、柔韧性、CD伸长率和外观。穿透干燥织物最好有图7-16中所述类型的压节。
用于纸幅传递的真空度为约3-15英寸汞柱(约75-380mmHg),最好是约10英寸汞柱(254mmHg),除了利用真空将纸幅吸至下面的织物上以外,可借助在纸幅的正面使用正压将纸幅吹至下面的织物上而补充或替代真空板(负压)。另外还可使用一根或多根真空辊代替单个或多个真空板。
在由穿透干燥织物支承着的同时,纸幅被穿透干燥器21最终干燥至约94%或更好的浓度,然后送至引纸织物22。使用引纸织物22和不是必须的引纸织物25,将干燥的原纸23送至纸轴24上。也可以使用加压转向辊,以有利于纸幅从引纸织物22至织物25的传递。为此,合适的引纸织物是Albany International 84M或94M和Asten959或937,所有这些都是带有精细花纹的相当平滑的织物。尽管在此没有画出,但可使用卷纸压花或随后的机外压花,以改善原纸的平滑度和柔软度。
根据本发明,穿透干燥织物有一个支承浆幅23的顶面和一个面对穿透干燥器21的底面。靠近底面,织物有使用织物完整的承载层,与此同时,当织物通过纸机穿透干燥部时,能提供足够的强度以保持织物的完整性,另外该织物还具有使穿透干燥空气穿过织物的足够的孔,该浆幅由织物导引。织物的顶面有主要由细长压节组成的浮雕层,细长压节显著地突出在承载层和浮雕层之间的次平面上面。这些压节是由沿织物的顶面在纵向进行纺丝的压印纱的暴露部分形成的,并且在其两端在承载层内联锁。压节在织物的横向留有间隙,结果是,雕刻层在压印纱部分之间和在相应的层之间的次平面上面呈现出凹地。
图2是CD伸长率对各种穿透干燥的浴巾纸产品松厚度的作用,绝大多数产品是由字母“C”表示的市售起皱薄页纸产品。“E”是使用如图1的方法但没有使用在此所述的立体(压节)引纸或穿透干燥织物而制得的实验的单层未起皱穿透干燥的浴巾纸。“I1”是使用具有72×40网孔支数的Lindsay Wire T216-3拓扑(topological)织物制得的本发明的浴巾纸产品。MD单股纱直径为0.013英寸,而CD单股纱直径为0.012英寸。在CD方向每直线英寸存在约20个压节,每平方英寸约100个压节,平面差约0.012英寸。I2也是本发明的浴巾纸产品,但是由具有71×61网孔支数的/indsay Wire T116-3拓扑(topological)织物制造的。MD单股纱直径为0.013英寸,CD单股纱直径为0.014英寸。MD纱线是成双的。在CD方向每直线英寸存在约10个压节,每平方英寸约40个压节,平面差约0.012英寸。两个I2产品之间的差别在于,较低松厚度的产品是利用较高网前箱喷射速度制得的,以提供MD/CD强度比为约1.5,而较高松厚度的产品是利用较低网前箱喷射速度制得的,MD/CD的强度比为约3。I6和I7是根据本发明制得的更重度压光的浴巾纸,并在实施例6和7中详细描述了。
如图所示,本发明的产品具有高松厚度和高CD伸长率的结合,并还呈现出很高的CD伸长率。
图3是吸水速率对各种毛巾纸松厚度的作图。与图2一样,市售产品以字母“C”表示,没有用在此所述的立体织物制备的实验的未起皱穿透干燥的毛巾纸产品以字母“E”表示,利用立体穿透干燥织物制得的本发明的毛巾纸产品以字母“I”表示。应注意的是,采用相同方法制得的产品E和产品I之间吸水速率的差别,仅仅是在本发明产品的场合使用了立体穿透干燥织物而有差别。
如图解说明,本发明的产品具有比对比试验产品或市售毛巾纸产品更高的吸水速率。
图4是吸水能力对各种浴巾纸产品松厚度的作图。市售产品由字母“C”表示,没有用在此所述的立体织物制备的实验的未起皱穿透干燥的浴巾纸产品由字母“E”表示,利用在此所述的立体织物制备的本发明的产品由字母“I”表示。I1和I2如图2中所述的。I6和I7是根据本发明制得的更重度压光的浴巾纸,并详细描述于实施例6和7中。如图所示,本发明的产品具有高松厚度和高吸水能力的结合。
图5是薄页纸综合载荷/伸长率的曲线图,图解说明了纵向或横向模量的确定。(几何平均模量是纵向模量和横向模量乘积的平方根)。如图所示,两个点P1和P2表示对3英寸宽(7.6cm)试样施加的70g和157g的载荷。应如此设计抗张测试仪(GeneralApplication Program,版本2.5,Systems Integration TechnologyInc.,Stoughton,MA;MTS Systems Corporation,ResearchTriangle Park,NC的全部),以致于它能计算以Kg/76.2mm试样宽度来表示的P1和P2之间的斜率。该斜率除以定量(用g/m2表示)乘以0.0762的积就是要测试试样方向(MD或CD)的模量(以Km表示)。
图6是几何平均模量(GMM)除以几何平均抗张(GMT)强度(柔韧性)对搽面纸、浴巾纸和厨房用毛巾纸松厚度的作用。市售的搽面纸表示为“F”,市售的浴巾纸表示为“B”,市售的毛巾纸表示为“T”,没使用在此所述立体织物的实验的浴巾纸表示为“E”,本发明的浴巾纸表示为“I”。如前所述,I1和I2是用相同的织物制得的,但低松厚度的I1和MD/CD强度比约为1.5,高松厚度的I2的MD/CD强度比约为3。如图所示,本发明的产品具有很高的松厚度和低的几何平均模量除以几何平均抗张强度的商。I6和I7是根据本发明制得的更重度压光的浴巾纸,并详细描述于实施例6和7。I8和I9是根据本发明制得的压光的两层搽面纸,并详细描述于实施例8和9中。
图7-16图解说明了用于本发明的若干个立体织物。为了易于观察,由黑实线表示突出的压节。
图7,7A和7B图解说明了用于本发明穿透干燥织物的第一实施方案,其中,通过将额外的经纱体系加至简单的1×1基础花纹上而得到高压节。该额外的经纱体系可“针刺绣花”在任何基础织物结构上。基础结构结果变成承载层,并且在次平面处,它用来划定浮雕层的界限。最简单的基础织物是1×1平纹。当然,也可使用任何其它的单层、双层、三层或多层结构作为基础结构。
参考这些图,穿透干燥织物是由参考符号40表明的。在由虚线41表示的次平面下面,织物40包含有承载层42,该层由基础经纱43与纬纱44以1×1平纹交织的平织织物结构组成。在次平面41的上面,通常由参考符号45表示的浮雕层由针刺绣花入平纹承载层42中的压印纱部分46形成。在本例子中,每个压印部分46都是由受控制的以便针刺绣花入承载层的额外经纱体系中的单径形成的。由额外经纱体系的每根经纱构成的压节46以一定的顺序与纵向成直线,如图7所示,该体系的经纱在织物40的宽度上彼此留有间隔。额外经纱体系产生了主要由纵向压节并在次平面41处承载层的顶面组成的主体浮雕层。在该织物结构中,中间平面与次平面重合。经纱压节46和承载层42的织物结构之间的相互关系产生了一平面差,该差值为压印直径的30-150%,优选约70-100%。在图7A的图解说明中,平面差约为纱线46直径的90%。如上所述,经纱直径可从约0.005-0.05吋,例如,如果经纱直径为0.012吋,那么平面差可以是0.10吋。对于非圆形的纱线,其直径为纱线的垂直尺寸,当纱线在织物中取向时,纱线通常用与次平面平行的最宽部进行取向。
在织物40中,构制了平纹承载层,结果是承载的纬纱42和经纱43的最高点是同平面的,并与次平面41重合;额外的经纱体系46的纱线在承载层经纱44之间定位。
图8和8A图解说明了用于本发明的织物40的改良。改良的织物50具有由虚线51表示的次平面,承载层52在次平面51下面,浮雕层55在次平面51上面。在该穿透干燥织物的实施方案中,浮雕层55具有与前述实施方案的浮雕层图案45十分相似的立体图案,它由在织物的纵向排列的并在织物横向留有间隔的一系列压节54′组成。在织物50中,承载层由通常以平纹交织的纬纱53和经纱54形成。
在承载层的编织过程中,某些纬节突在次平面51上面,这些纬节的顶端确定了一中间平面58。在顶平面55和中间平面58之间的平面差至少等于30%的经纱直径。另一方面,浮雕层55是从承载层52拉伸出的、从经纱54′拉出的经纱部分形成。在浮雕层55中的压印纱部分54′是从包括经纱54的经纱体系中挑选出来的。在本例子中,在包括经纱54和54′的经纱体系中,在每4根经纱中的头3根是承载层52的成分,而且不突在中间平面58的上面。然而,第4根经纱54′由沿织物纵向在次平面51上面的浮雕层中延伸的浮经组成。通过在每个浮经的两端在纬纱53下面穿经承载面,而使压印经纱54′织入承载层52。
在织物50中,经纱54′代替其中的一根基础经纱54。当使用该织物作为穿透干燥织物时,在次平面51处,承载层的不平顶面能给纸幅的皱褶区域赋予与由图7所示织物的浮雕层产生的相比多少有点不同的结构。在两者的情况下,由于压节都浮跨7根纬纱并顺序地排列,因此,由压节中凹地构成的跳纱外观基本上是相同的。
图9和9A图解说明了在本发明中使用的织物的另一实施方案。在本实施方案中,穿透干燥织物60具有在61处虚线表示的次平面和在68处表示的中间平面。在次平面61下面,承载层62包含有由纬纱63和经纱64编织的织物。次平面61是由承载层62中最低纬节的至高点(high point)确定,如参考符号63-L所示。中间平面是由承载层62中最高纬节的至高点确定,如参考符号63-H所示。在这两个图中,经纱6 4已顺序地在图9顶端计数,并且这些数已在图9A中用首标64表示。如图所示,偶数的经纱按照1×1平纹图案。在奇数经纱中,每隔三根经纱即经纱1,5和9等利用1×7构型编织,以在浮雕层中提供跨越7根纬纱延伸的压节。余下的奇数经纱即3,7,11等用提供经纱在3根纬纱下浮起的3×1构型进行编织。这种编织排列又背离了是图7织物特征的在次平面处CD和MD节同平面的排列,并在承载层的顶面提供了更大的变更。
在承载层中MD和CD节的顶端落在中间平面68和次平面61之间。这种编织构型提供了在浮雕层中压节较小的急剧阶式升高。在本实施方案中的平面差65,即表示浮雕层有效厚度的、经纱64-1、64-5、64-9等的最高点和承载层顶端中间平面之间的距离约为形成浮雕立体外观的这些经纱的压印纱部份厚度的65%。参看图9的经纱图案可以看出,纬纱63横向跨越许多经纱。然而,这种横向浮经被限制在中间平面68下面的承载层上,而且不通过浮雕层延伸至织物60的顶面。因此,与织物40和50一样,织物60提供了这样的编织结构的承载层,就是没有突出基层至织物顶面的横向节。在每个实施方案中,由浮雕层构成的立体浮雕主要由在次平面上面平行排列的细长的和升高的压节组成,并在压节之间提供凹地。在每种情况下,凹地在纵向整个织物长度上延伸,并具有由次平面处承载层上表面勾划出的流道。
用于本发明的织物并不局限于具有浮雕层这个特征的织物,除了如圣诞树、鱼、蝴燥的复杂图案以外,织物还可通过引入更复杂的压节排列而得到。如图16所示,通过和标准的长网编织机一起使用提花装置,可得到甚至更复杂的图案。利用控制额外经纱体系的提花装置,可以得到不干扰由承载层得到的织物完整性的图案。甚至在没有补充的提花装置下,也能用多综絖的织机产生更复杂的编织图案。在至多24个综絖的织机上可以得到如菱形、十字形或鱼形的图案。
例如图10,10A和10B图解说明了在次平面71下面有承载层72、在次平面71上面有浮雕层75的穿透干燥织物。在图解说明的编织结构中,承载层72的经纱74成对排列,以与纬纱73交织。利用如图73′所示的每隔4根纬纱具有较大直径的纬纱进行编织。层72的编织结构和其经纱压节的联锁(locking-in)突在产生中间平面78的次平面上面的选出的纬节上。如图10所示,为了获得菱形,成对的经纱伸出承载层72,以在作为压节74′的图案层75内浮动,压节74′在次平面71处承载层72的顶面上、在织物的纵向延伸。经纱压节74′,通过与包括在承载面中的并如图所示基本上以斜纹交叉图案排列的经纱相同的纱线而形成。在浮雕层75中的这种压节图案主要由经纱压节组成,没有闯入任何横向节。
在织物70中,在相同的筘齿内成对地操纵经纱74,但希望用不同的图案操纵每对中的各根经纱,以产生所希望的效果。应注意的是,本实施方案中的压节跨越五根纬纱,以提供希望的菱形图案。可以增加压节的长度从而拉长该图案,或减少至只有三根纬纱的长度,从而压缩该菱形图案。通过使用织物在其上编织的具有完美提花能力的特殊织机,织物设计者可以提供出许多有趣的复杂图案。
在图解说明的这些实施方案中,所有的经纱和纬纱具有大体相同的直径,并以单丝表示。可用其它纱线代替这些纱线之一或更多。例如,用来形成经纱压节的压印纱部分可以是一束直径相同或不同的纱线,以产生浮雕致应。它们可以是圆形的或非圆形的,如横截面为椭圆形的、扁平的、长方形的或带状的。
图11图解说明了其中的浮雕层提供了以集结群的形式集结的并在集结群之间和之内形成凹地的经纱压节84′。如图所示,经纱压节84′的长度从3-7根纬纱进行变化。如与前述实施方案一样,包含有纬纱83和经纱84的承载层与次平面处的浮雕层是有差别的,纬节的顶端确定了在浮雕层顶面以下至少为形成经纱节压印纱直径30%的中间层。在图解说明的编织组织中,该平面处于经纱压节直径的85%和100%之间。
图12图解说明了在承载层的纬纱93和经纱94上面的浮雕层中有压印纱部分94′的织物90。经纱压节94′的结合产生了类似于鱼的更复杂的图案。
图13图解说明了织物100,其中压印纱106为扁平纱,在本例中是椭圆形横截面的,在承载层中的经纱104为带状纱。在本例中纬纱103是圆形的。在图13中所示的织物100提供了具有降低厚度而不损失强度的穿透干燥织物。
图14图解说明了穿透干燥织物110,其中压印纱116是圆形的,以提供浮雕层。在承载层中,该织物包含有与圆形纬纱113交织的扁平经纱114。
图15图解说明了包括有与承载层中纬纱123交织的扁平经纱124的织物120。在图案层中,经纱压节由扁平经纱126和圆形经纱126′的组合而形成。
对于熟练的织物设计者来说,通过在织物的经纱中组合扁平的、带状的和圆形的纱线,可得到许多不同的组合那是显而易见的。
图16图解说明了具有“针刺绣花”压纱进入基础织物结构中的提花装置的长网织机,以产生叠加在承载层上的浮雕层。
该图说明了从若干经纱体系至织机提供经纱的后轴150。如本领域是已知的,还可使用另外的后轴。向前拉伸经纱,通过由齿杆、凸轮和/或杠杆控制的许多综絖151,以在穿透干燥织物的承载层中提供希望的编织图案。在综絖151的前面提供了提花装置,以控制不由综絖151控制的另外的经纱。拉伸通过提花综絖的经纱可以从后轴150引出,或者可以从织机后面的粗纱架(未面出)引出。将经纱通过对应安装在筘座上的筘153,以将纬纱对154处所示的织物的织口进行打纬。经过织机的前部并经过胸辊155,取出该织物,送至织物卷取辊156。最好用电子装置控制提花装置152的综絖,以在生产出的穿透干燥织物的浮雕层中提供任何希望的编织图案。提花控制使得织物浮雕层中织物图案的无限选择成为可能。提花装置可以控制浮雕层的压印经纱,从而与由综絖151形成的承载层以任何希望的顺序联锁,或与织机的经纱提供装置所允许的承载层联锁。
尽管在此所述的纺织物的主要特征是存在长的MD突起节,以赋予未起皱穿透干燥纸页以CD伸长率,但应该明白,预期能产生明显突在干燥织物平面上面的相当的伸长MD区域的其它织物制造工艺也能给出类似的纸页特性。它们的例子包括如Johnso等人(US4,514,245)讲授的或“rapid prototyping”工艺(MechanicalEngineering,1991年4月,第34-43页)建议的将紫外固化的聚合物应用到传统织物的表面上。
图17是根据本发明制得的薄页纸的横截面图(放大50倍)。上边的横截面是沿横向观测的,下边的横截面是沿纵向观测的,两者都说明通过在穿透干燥织物中突出的经纱节,在薄页纸中产生了垂直的突起物。如图所示,突起物的高度可在一定的范围内变化,并且不需要全都是同一高度。在该照片中,在相同的薄页纸上,两个横截面具有彼此紧靠着的两个不同的突起物。本发明产品的特点就是纸页的密度是均一的或基本上均一的。除纸页均衡以外,突起物不具有不同的密度。
图18是MD挺度对许多薄页纸产品松厚度的作图。在某些例子中,对于考虑到厚度和多层影响的定量挺度的GMM/GMT,MD挺度值表明是改善了。已知MD挺度值与入对大量产品的挺度的感觉有关,并可以MD斜率(以Kg表示)乘以纸页厚度(μm)除以层数的商的平方根来计算。[MD挺度=(MD斜度)(纸页厚度/层数)1/2]。本发明纸页的特征在于MD挺度值为100Kg-μm1/2或更低。在其将低MD挺度和高松厚度组合的能力上,这些纸页是独特的。
图19是将本发明制得的产品的WCB、LER和WS与若干个竞争产品进行比较。U1、U2、U3和U4为本发明制得的并分别在实施例10-13中详细描述的产品,C1至C6是市售浴巾纸产品。更具体地说,C1-C3为CHARMIN的三个试样,而C4-C6分别为COTTONELLE,QUILTED NORTHERN和ULTRA-CHARMIN。就同时取得高数值的WCB、LER和WS的能力而言,本发明的薄页纸是优异的。 测量WCB、LER和WS的测试方法说明如下。
Instron4502 Universal Testing Machine用于本试验。1KN的测力计安装在横梁的下边。固定地安装2.25英寸直径的Instron压板。下压板被支撑在滚珠轴承上,以能与上压板理想的对准。松开三个用于下压板的定位螺栓,在约50磅载荷时,使上压板与下压板接触,然后拧紧定位螺栓,以将下压板固定在该位置。当上压板与下压板在8-50磅的载荷下接触时,该移距(测得的上压板至参考平面的距离)必须调零。在自由悬挂状态,测力计必须调零。在进行测量之前,必须使Instron和测力计加热一小时。
Instron单元连接至带有IEEE板用于获得数据和计算机操纵的个人计算机上。该计算机装有Instron SeriesⅫ软件(1989发行)和版本2的硬件。
在加热以及测力计和移距调零之后,将上压板升至约0.2英寸的高度,以使试样能插在压板之间。然后将Instron的控制输入计算机中。
通过使用Instron Serieo Cyclic Test软件(版本1.11)建立了仪器顺序。该编程顺序作为参数文件储存。参数文件有由3个“循环程序块”(指令表)组成如下的7个“标记”(离散事件),
标记1:程序块1
标记2:程序块2
标记3:程序块3
标记4:程序块2
标记5:程序块3
标记6:程序块1
标记7:程序块3。
程序块1指示十字光标以0.75吋/分下降,直至加上0.1磅的载荷为止(由于压缩被定义为负力,因此,Instron装置为-0.1磅)。控制是通过位移进行的。当达到标定负载时,将施加的负载降至零。
程序块2控制十字光标的负载从0.05磅至最高8磅,然后以0.2吋/分的速度返回至0.05磅。用Instron软件,控制方式是位移,限定的种类是负载,第一级为-0.05磅,第二级为-8磅,停延时间为零秒,变换数为2(压缩然后放松);对于程序块的末端,确定了“无作用”。
程序块3使用位移控制和限定的种类,从而简易地将十字光标以4英寸/分的速度升高,停延时间为零。其它的Instron软件置位在第一级中为零,在第二级中为0.15英寸,变换1次,在程序块的末端“无作用”。如果未压缩的试样厚度大于0.15英寸,那么必须改进程序块,从而将十字光标升至适当的高度,而且必须记录并注明变更值。
当在上面给出的程序(标记1-7)中进行操纵时,Instron顺序以0.025磅/吋2压缩试样(0.1磅压力),放松然后再压缩至2磅/吋2(8磅压力),解压后,将十字光标升至0.15英寸,然后再将试样压至2磅/吋2,放松然后将十字光标升至0.15英寸,再压至0.025磅/吋2(0.1磅压力),然后升高十字光标。对于程序块2而言,必须以不大于每0.004英寸或0.03磅压力(无论哪个先出现)的间隔进行数据记录,对于程序块1而言,该间隔为不大于0.003磅压力。一旦测试开始,将经过稍少于2分钟的时间直至Instron顺序结束。
集合SeriesⅫ软件的数据输出,以提供在标志1,2,4和6峰值负载(每个均为0.025和2.0磅/吋2)时的移距(厚度),标记2和4(两次压至2.0磅/吋2)的加载能量,两个加载能量的比值(第二个2磅/吋2循环/第一个2磅/吋2循环),以及最终厚度对起始厚度的比值(最后的厚度对第一个0.025磅/吋2压缩时厚度的比值)。
在执行程序块1和2期间,在屏幕上将负载对厚度结果进行作图。
将转化薄页纸试样在(美国)制浆造纸技术协会(TAPPI)调节室(73°F,50%相对湿度)中调节至少24小时。从纸卷上退取一段3孔或4孔的打孔纸,并在这些孔处进行折叠,以形成Z-或W-折叠的纸堆。然后将该纸堆冲切成2.5英寸的方块,方块是从折叠纸堆的中央切取的。然后测量切取方块的质量精确至10mg或更精确。切取试样的质量最好在0.5g左右,并在0.4和0.6g之间;如果不在此范围,在纸堆中的纸页数必须进行调节。(在该研究过程中,已证明每堆纸中含3层或4层纸页适用于所有的操作;在用三层纸页和四层纸页进行试验时,不会出现湿回弹性能结果的明显不同)。
在70-73°F,利用去离子水的精细喷雾均匀地施加水。这可通过使用带有阻止绝大部分喷雾的容器或其它挡板的常规塑料喷雾瓶,只允许外表约20%的喷雾泡-细雾-到达试样上而实现。如果适当地进行操作的话,在喷雾期间试样上不会出现大水滴形成的湿斑,但试样将均匀地被湿润。在进行喷雾期间,喷雾源必须与试样保持至少6英寸的距离。目的是使试样部分饱和至0.9-1.6的水份比率(g水/g纤维)。
在喷雾期间,使用平坦的多孔支架来固定试样,同时防止了在可能浸入试样边缘并出现湿斑的支承表面上形成大水滴。在本研究中,使用开孔的网状发泡材料,但是如吸水性泡沫材料的其它材料也能满足需要。
对于3层纸页的纸堆,3层纸页必须是分离的,并彼此邻接地置于多孔支架上。必须均匀地施加水雾,使用固定的喷雾数(固定次数地操作喷雾瓶),从两个或三个方向连续地喷雾至分离的纸页上,该数是通过逐次逼近法确定的,以获得标定的湿度值。将试样迅速反转并再用固定的喷雾数进行喷雾,以降低纸页Z方向的湿度梯度。按原程序和相应的纸页原始取向重新安装纸堆。以至少10mg的精确度迅速称重重新安装的纸堆,然后放在Instron下压板的中心,随后用计算机启动Instron测试顺序。在试样和水雾首次接触和测试顺序启动之间经历的时间不大于60秒,通常为45秒。
当要用每堆4层纸页时,这些纸页将比3层纸堆的场合更厚,并且,当湿润时将造成增加处理的问题。在湿润期间,不是单独地将每4层一堆进行处理,而是将4层的纸堆分成每两层一堆的两个纸堆,将这两个纸堆并排放在多孔基片上。如上所述进行喷雾,以弄湿纸堆的顶层纸页。然后将这两个纸堆反转,并再喷雾约相同的水量。在该处理过程中,尽管每个纸页只从一面湿润,但是与3层纸页的纸堆相比,在四层纸页的纸堆中,通常通过减小的纸页厚度部分减轻了每张纸页中Z方向湿度梯度的可能性。(用相同纸页的3层和4层纸页的纸堆进行限定的测试时没显示出明显的差别,这表示,在压缩湿回弹性能测量中,纸页中Z方向湿度梯度即使存在也不会是重要的因素)。在加完水份后,如先前3层纸堆的情况所述,将纸堆重新安装,称重并置于Instron装置中进行测试。
Instron测试后,将试样置于105℃的对流烘箱中干燥。当试样完全干燥(至少20分钟后)时,记录干重。(如果不采用热平衡,那么必须在从烘箱取出试样几秒中内称取试样重量,这是因为水份将迅速被试样吸收)保留水份比率在0.9-1.6的试样的数据。实验表明,在该范围WCB、LER和WS的数值将是相当恒定的。
下面来研究湿回弹性的三个测量。第一个测量是试样在第一次压缩循环至2磅/吋2的峰值负载时的松厚度,以后称为“湿压缩松厚度”或WCB。该松厚度是动态取得的,它不同于在2磅/吋2松厚度的静态测量值。第二个测量被称为“湿回弹或WS,它是在测试顺序最后时在0.025磅/吋2时测得的试样厚度与在测试顺序开始时在0.025磅/吋2时测得的试样厚度的比值。第三个测量是“加载能量比值”或LER,它是在单一测试顺序期间,第二次压缩至2磅/吋2的加载能量与第一次这样的压缩的加载能量的比值。对于从没有负载加至2磅/吋2的峰值负载的试样而言,加载能量等于施加的负载对厚度作图的曲线下的面积。加载能量的单位为英寸-磅。如果压缩后材料塌陷,那就损失了松厚度,随后的压缩将需要很少的能量,这将导致低的LER。对于纯弹性材料,弹回或LER是唯一的。在此所述的这三个测量与纸堆的层数相对无关,并用作湿回弹性能的有用的测量。LER和WS都以百分数表示。
典型的浴巾纸和搽面纸具有35-50%的LER值。对于没有永久湿强树脂的湿松厚材料而言,如图19中未起皱的穿透干燥的浴巾纸所示,超过50%的LER值,那是异乎寻常地好。对于典型的薄页纸,湿弹回在40%-50%的范围,当超过50%时,表明具有良好的湿回弹性能。对于没有永久湿强树脂的松厚薄页纸而言,如通过未起皱的穿透干燥的薄页纸取得的超过60%的WS值,那是超乎寻常的。如果该材料原本就紧密或如果在机械压缩前弄湿对原本松散的材料塌陷,那么LER和WS很高,但原始松厚度和WCB将很低。要取得高LER,高WS和高WCB的唯一可能性,那就是该松厚结构是否具有优异的湿回弹性能。松厚但不可压缩的材料也能显示出高的湿回弹性能,但将是非常挺硬,以致不能用作搽面纸或浴巾纸。
实施例1
为了进一步说明本发明,使用基本上如图1所说明的方法生产未起皱的穿透干燥的薄页纸。更具体地说,制得了三层的单层浴巾纸,其中外层包含有分散的、非结合的Cenibra桉树纤维,中间层含有精磨的北方针叶木硫酸盐法纤维。
在成形之前,在10%浓度将桉树纤维制浆15分钟,并脱水至30%浓度。然后将该纸浆送至每吨3.2马力-天(2.6Kw天/吨)功率输出,在160°F(70℃)操作的Maule轴向分散器(shaftdisperser)。分散后,以每吨干纤维15磅Berocell的用量(0.75%,重量)向纸浆中添加软化剂(Berocell596)。
在4%浓度将针叶木纤维制浆30分钟,然后稀释至3.2%浓度,与此同时将分散的、非结合的桉树纤维稀释至2%浓度。在分散的桉树纤维层/精磨的针叶木纤维层/分散的桉树纤维层中,所有成层的纸页的重量分别为35%/30%/35%。将中间层精制至所要求的程度,以取得目标强度值,而外层提供表面柔软度和松厚度。以中间层为基准,以10-13磅(4.5-5.9Kg)/吨纸浆的用量将Parez631NC添加至中间层。
用在网前箱的两个中间层中有精磨北方针叶木硫酸盐浆的四层网前箱形成湿纸幅,从而生产所述的单一中间层的三层产品。使用将堰板切出约3英寸(75mm)切口的产生湍流的板和伸出堰板约6英寸(150mm)的层分配器。另外还使用伸出堰板约6英寸(150mm)的挠性唇板伸出部分,如在Farrington,Jr.的US 5,129,988(1992,7,14)中讲授的,其标题为“Extended Flexible headbox Slicewith Parallel Flexible Lip Extension and Extended InternalDividers”,在此引入作为参考。实际的堰板开口约为0.9英寸(23mm),并且,在所有四个网前箱层中的水流量是可比较的。送至网前箱的浆浓约为0.09%(重量)。
在双网、真空成形辊的成形器上形成最终三层的纸页;该成形器带有分别为Lindsay2164和Asten866织物的成形织物。成形织物的运行速度为11.9m/sec.。在将新形成的纸幅送至以9.1m/sec.(30%急送)运行的引纸织物之前,利用从成形织物下面的真空吸水,将其脱水至约20-27%浓度。引纸织物为Appleton Wire94 M。使用建立起约6-15英寸(150-380mm)汞柱真空度的真空板将纸幅递至引纸织物。
然后将纸幅送至穿透干燥织物(先前图2所述的以及如图9所说明的Lindsay T216-3)。该穿透干燥织物以9.1m/sec.的速度运行。将纸幅穿过控制在约350°F(175℃)的Honeycomb穿透干燥器,并干燥至最终约94-98%的干度。然后在20英寸(51cm)直径的钢辊和20.5英寸(52.1cm)直径的、110P&J Hardmess橡胶包覆的辊之间,以0.040英寸(0.10cm)的固定间隙压光形成的未起皱的薄页纸。橡胶包覆层的厚度为0.725英寸(1.84cm)。
形成的压光薄页纸性能如下:定量,16.98磅/2880英尺2;CD伸长率,8.6%;松厚度,13.18cm3/g;几何平均模量除以几何平均抗张强度,3.86Km/Kg;吸水能力,11.01g水/g纤维;MD挺度,68.5Kg-μm1/2;MD抗张强度,714g/3英寸宽的试样;CD抗张强度,460g/3英寸宽的试样。
实施例2
如实施例1所述制备未起皱的穿透干燥的浴巾纸,所不同的是穿透干燥织物用图2中所述的Lindsay T116-3替换。
形成的薄页纸性能如下:定量,17.99磅/2880英尺2;CD伸长率,8.5%;松厚度,17.57cm3/g;几何平均模量除以几何平均抗张强度,3.15Km/Kg;吸水能力,11.29 g水/g纤维;MD挺度,89.6Kg-μm1/2;MD抗张强度,753g/3英寸宽的试样;CD抗张强度,545g/3英寸宽的试样。
实施例3
如实施例1所述制备单层未起皱的、穿透干燥的浴巾纸,所不同的是该纸页的桉树纤维与针叶木纤维的比为25/75。精制针叶木层,以取得希望的强度值。以25磅/吨的用量将Kymene557LX加至整个配料中。
最终产品的性能如下:定量,13.55磅/2880英尺2;CD伸长率,20.1%;松厚度,24.89cm3/g;MD挺度,74.5Kg-μm1/2;几何平均模量除以几何平均抗张强度,3.13Km/Kg;MD抗张强度,777g/3英寸宽的试样,CD抗张强度,275g/3英寸宽的试样。
实施例4
除未压光外,如实施例2所述制备单层未起皱的、穿透干燥的浴巾纸。形成纸页的性能如下:定量,17.94;CD伸长率13.2%;松厚度22.80cm3/g;MD挺度,120.1Kg-μm1/2;几何平均模量除以几何平均抗张强度,3.35Km/Kg;吸水能力,12.96;MD抗张强度,951g/3英寸宽试样,CD抗张强度,751g/3英寸宽试样。
实施例5
为了进一步说明本发明,除使用不同的成形器以外,利用基本上如图1所述的方法制备单层、未起皱的、穿透干燥的毛巾纸。更具体地说,在成形前,利用浮选和洗涤步骤,将由13%的白色和彩色纸条,37.5%的分选的办公废纸,19.5%的白色复印纸纸条和30%的涂布的白色亚硫酸盐废纸的原料混合物进行脱墨。在形成纸页前,分别以11磅/吨和3.5磅/吨的比例将Kymene557LX和Quasoft206与纤维浆液混合。
在带有Lindsay Wire Pro57B(图1中的织物13)成形织物的平长网网案上,使用单通网前箱形成湿纸幅。成形器的运行速度为6.0m/sec.。然后,在将新形成的纸幅递至以5.5m/sec.(8%急送)运行的引纸织物以前,利用从成形织物下面的真空吸水将其脱水至约20-27%的浓度。引纸织物为Asten920。使用建立起约6-15英寸(150-380mm)汞柱真空的真空板,从而将纸幅递至引纸织物。
然后将纸幅送至穿透干燥织物(Lindsay Wire T-34),该织物如图10中所述,具有72×32的网目支数,CD纱直径为0.014英寸,MD纱直径为0.014英寸(成双经纱),每隔四根CD纱有一直径为0.02的CD纱。该织物的平面差约0.012英寸,并且在横向每直线英寸有10个压节,每平方英寸有45个压节。该穿透干燥织物的运行速度约为5.5m/sec.。将该纸幅穿过控制在约350°F(175℃)的Honeycomb穿透干燥器,并干燥至最终的约94-98%的干度。
然后在两个20英寸的钢辊之间将该未起皱的薄页纸压光至约12-20磅/直线英寸。形成的纸页的性能如下:定量,39.8g/m2;CD伸长率,9.1%;松厚度,11.72cm3/g,吸水速率,2.94cm/15sec.。
实施例6
类似于实施例1制备单层、穿透干燥的浴巾纸,所不同的是具有如下的改变:Lindsay T-124-1穿透干燥织物;Varisoft 3690PG90(得自Witco Corporation)代替Berocell596作为柔软剂;约35%的急送。该纸页具有下列顺序的27%/16%/30%/27%的四层,分散的桉树纤维/分散的桉树纤维/北方针叶硫酸盐纤维/分散的桉树纤维(穿透干燥织物侧)。将卷筒纸的该纸页在橡胶(110P&J)压光辊上用钢辊进行压光,以给出最终的产品。
最终的产品具有如下性能:定量,24.1磅/2880英尺2;CD伸长率,4.9%;松厚度,8.9cm3/g;几何平均模量除以几何平均抗张强度,4.04;吸水能力,8.94g水/g纤维;MD抗张强度,731g/3英寸宽试样,CD抗张强度,493g/3英寸宽纤维;MD挺度,106Kg-μm1/2
实施例7
类似于实施例1制备双层、未起皱穿透干燥的浴巾纸,所不同的是有如下改变:Lindsay T-124-1穿透干燥织物;Varisoft 3690PG90(得自Witco Corporation)代替Berocell596作为柔软剂;约35%的急送。该纸页具有根据如下顺序的40%/40%/20%的三层,分散的桉树纤维/北方针叶木硫酸盐纤维/北方针叶木硫酸盐纤维(穿透干燥织物侧)。将卷筒纸的该纸页在橡胶(110P&J)压光辊上用钢辊进行压光,以给出最终的产品。
最终产品具有如下性能:定量,23.5磅/2880英尺2;CD伸长率,6.8%;松厚度,8.5cm3/g;几何平均模量除以几何平均抗张强度,3.64;吸水能力,11.1g水/g纤维;MD抗张强度,678g/3英寸宽试样,CD抗张强度,541g/3英寸宽;MD挺度,70.4Kg-μm1/2 。实施例8
类似于实施例1制备双层、未起皱穿透干燥的搽面纸,所不同的是有如下改变。使用Lindsay T-216-4穿透干燥织物。在由A/B/C表示的三层中,每层分成40%/40%/20%,B层和C层是北方阔叶木、北方针叶木和桉树纤维的掺混物,A层是纯的分散的桉树纤维。以所有基纸为基准,该纸页含有40%分散的桉树纤维,10%的桉树纤维,15%北方阔叶木纤维和35%北方针叶木纤维。层B&C包括有5Kg/吨的Parez-631NC和2Kg/吨的Kymene557LX。置于穿透干燥织物一测的层A包含有7.5Kg/吨的Tegopren-6920(得自Goldschmidt化学公司)和7.5Kg/吨的Kymene557LX。将卷筒纸的该纸页在橡胶(50P&J)压光辊上用钢辊进行压光,以给出最终的层。用在外面的两个分散的桉树纤维面将两层层合在一起,并进行两次压光(一次是钢辊对钢辊,压力为50磅/直线英寸,一次是钢辊对橡胶辊,压力为30磅/直线英寸),以降低厚度。
最终的产品有如下性能:定量,23.0磅/2880英尺2;CD伸长率,7.3%;松厚度,7.49cm3/g;几何平均模量除以几何平均抗张强度,3.45;吸水能力,12.0 g水/g纤维;MD抗张强度,915g/3英寸宽,CD抗张强度,725g/3英寸宽;MD挺度,79.5Kg-μm1/2
实施例9
类似于实施例8制备双层、未起皱穿透干燥的搽面纸,所不同的是,将形成的层用在外面的分散的桉树纤维侧层合在一起,并再次压光(钢辊对钢辊,压力50磅/直线英寸),以降低厚度。
最终产品具有如下性能:定量,19.3磅/2880英尺2;CD伸长率,7.5%;松厚度,8.93cm3/g;几何平均模量除以几何平均抗张强度,3.99;吸水能力,13.5g水/g纤维;MD抗张强度,867g/3英寸宽;CD抗张强度,706g/3英寸宽;MD挺度,75.6Kg-μm1/2
实施例10
为了说明本发明的优异的湿完整性,利用如图1所述的方法生产未起皱穿透干燥的薄页纸。更具体地说,制备三层的单层浴巾纸,其中外层含有分散的、非结合的Cenibra桉树纤维,中间层含有精磨的北方针叶木硫酸盐纤维。
成形前,先在10%浓度将桉树纤维制浆15分钟,并脱水至30%的浓度。然后将该浆送至功率输出为3.2马力-天/吨(2.6Kw-天/吨),在160°F(70℃)操作的Maule轴向分散器中。分散后,以每吨分散的干纤维7.0Kg分散剂的用量将柔软剂(Varisoft3690PG90)加至该纸浆中。
将针叶木纤维在4%的浓度制浆30分钟,并在成浆后稀释至3.2%的浓度,同时将分散的、非结合的桉树纤维稀释至2%浓度。在分散的桉树纤维层/精磨针叶木纤维层/分散的桉树纤维层中,整个层状纸页重量分成27%/46%/27%。精制中间层至所要求的程度,以取得目标强度值,而外层提供表面柔软度和松厚度。以中间层为准,以4.0Kg/吨纸浆的用量将Parez631NC加至中间层。
使用网前箱的两个中间层中有精磨北方针叶木硫酸盐纸浆的四层网前箱形成湿纸幅,从而生产所述的单一中间层的三层的产品。使用将堰板切出约3英寸(75mm)切口产生湍流的板和伸出堰板约6英寸(150mm)的层分配器。实际的堰板开口约为0.9英寸(23mm),并且在所有四个网前箱层中的水流量是可比较的。送至网前箱的浆浓约为0.09%重量。
在双网,真空成形辊的成形器上形成最终三层的纸页;该成形器带有分别为Lindsay 2164和Asten 866织物的成形织物。成形织物的运行速度为12m/sec.。在将新形成的纸幅送至以9.1m/sec.(30%急送)运行的引纸织物之前,利用从成形织物下面的真空吸水,将其脱水至约20-27%的浓度。引纸织物为Appleton Wire94M。使用建立起约6-15英寸(150-380mm)汞柱真空度的真空板将纸幅递至引纸织物。
然后,将纸幅送至在此所述的立体穿透干燥织物(Lindsay WireT-124-1)。该穿透干燥织物以9.1m/sec.的速度运行。将纸幅穿过控制在约350°F(175℃)的Honeycomb穿透干燥器,并干燥至最终约94-98%的干度。然后,在20英寸(51cm)直径的钢辊和20.5英寸(52.1cm)直径的、110P&J Hardness橡胶包覆的辊之间,以0.040英寸(0.10cm)的固定间隙压光形成的未起皱的薄页纸。橡胶包覆层的厚度为0.725英寸(1.84cm)。
形成的未起皱穿透干燥纸页具有如下性能:定量,20.8磅/2880英尺2;MD抗张强度,713g/3英寸宽;MD伸长率,17.2%;CD抗张强度,527g/3英寸宽;CD伸长率,4.9%;WCB,5.6cm3/g;LER,55.6%;WS,62.9%。
实施例11
除了定量定在24磅/2880英尺2以外,利用基本上如实施例10所述的方法,制备未起皱穿透干燥的薄页纸。
形成的未起皱穿透干燥纸页具有如下性能:定量,24.1磅/2880英尺2;MD抗张强度,713g/3英寸宽;MD伸长率,17.1%;CD抗张强度,493g/3英寸宽;CD伸长率,4.9%;WCB,5.3cm3/g;LER,55.8%;WS,64.4%。
实施例12
利用基本上如实施例10所述的方法,制备未起皱穿透干燥的薄页纸,所不同的是,用分散的、非结合的南方阔叶木纤维代替分散的、非结合的桉树纤维。形成的未起皱穿透干燥纸页具有如下性能:定量,20.3磅/2880英尺2;MD抗张强度,747g/3英寸宽;MD伸长率,17.5%;CD抗张强度,507g/3英寸宽;CD伸长率,5.5%;WCB,5.4cm3/g;LER,53.6%;WS,60.8%。
实施例13
利用基本上如实施例10所述的方法,制备未起皱穿透干燥的薄页纸,所不同的是,定量定在18磅/2880英尺2;使用LindsayT-216-3A穿透干燥织物,Berocell596用作分散剂。进一步对纸页进行机外压光。形成的未起皱穿透干燥的纸页具有如下性能:定量,17.5磅/2880英尺2;MD抗张强度,1139g/3英寸宽;MD伸长率,21.2%;CD抗张强度,1062g/3英寸宽;CD伸长率,6.8%;WCB,5.23cm3/g;LER,53.4%;WS,64.2%。
很显然,前面给出的例子只是说明性的,并不构成对本发明范围的限定,本发明的范围是由下述权利要求以及其所有的等同物确定的。

Claims (13)

1.一种制备薄页纸的方法,包括:
(a)将浓度为1%或更低的造纸纤维的水悬浮液沉积在成形织物上,以形成一湿纸幅;
(b)将该湿纸幅脱水至20-30%的浓度;
(c)将脱水的纸幅从成形织物传送至运行速度比成形织物慢10-80%的引纸织物上;
(d)将纸幅传送至穿透干燥织物上,在穿透干燥织物上,该纸幅被微观地重排,以与穿透干燥织物的表面相一致,所述的穿透干燥织物具有5-300个压节/英寸2,这些压节高出所述织物平面至少0.005英寸;
(e)穿透干燥该纸幅。
2.权利要求1的方法,其中压节数为10-150/英寸2
3.权利要求1的方法,其中压节数为10-75/英寸2
4.权利要求1的方法,其中引纸织物具有5-300个压节/英寸2,所述压节突在该引纸织物平面上0.005英寸或更大。
5.权利要求4的方法,其中引纸织物的压节为10-150/英寸2
6.权利要求4的方法,其中引纸织物的压节为10-75/英寸2
7.权利要求1或4的方法,其中对穿透干燥的纸幅进行压光。
8.权利要求1或4的方法,其中穿透干燥的纸幅是起皱的。
9.权利要求1或4的方法,其中穿透干燥的纸幅是未起皱的。
10.权利要求1的制备薄页纸的方法,包括:
(a)将浓度为1%或更低的造纸纤维的水悬浮液沉积在成形织物上,以形成一湿纸幅;
(b)将该湿纸幅脱水至20-30%的浓度;
(c)将脱水的纸幅从成形织物转送至运行速度比成形织物慢10-80%的引纸织物上,所说的引纸织物具有5-300个压节/英寸2,所述压节高出引纸织物平面至少0.005英寸,在该引纸织物上,该纸幅被微观地重排,以与引纸织物的表面相一致;
(d)将该纸幅转送至穿透干燥织物,并将纸幅进行干燥。
11.权利要求10的方法,其中压节数为10-150英寸2
12.权利要求10的方法,其中压节数为10-75英寸2
13.一种未起皱的、穿透干燥的薄页纸,其定量为10-70g/m2,并有高度为0.005英寸或更高的、5-300/英寸2的突起物,该突起物与穿透干燥织物上的压节相一致,所述薄页纸的横向伸长率为9%或更大。
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US6017417A (en) 2000-01-25
EP0677612B1 (en) 2000-09-13
FR2735155A1 (fr) 1996-12-13
AU1641295A (en) 1995-10-19
DE69518784T3 (de) 2007-03-29
FR2718470B1 (fr) 1997-01-03
FR2718470A1 (fr) 1995-10-13
GB2288614B (en) 1998-10-28
ES2149290T5 (es) 2006-11-16
JPH083890A (ja) 1996-01-09
EP0677612A2 (en) 1995-10-18
CN1120616A (zh) 1996-04-17
FR2735155B1 (fr) 1999-12-24
JP3758702B2 (ja) 2006-03-22
GB9507576D0 (en) 1995-05-31
DE69518784D1 (de) 2000-10-19
EP0677612A3 (en) 1996-02-28
DE69518784T2 (de) 2001-04-12
US5746887A (en) 1998-05-05
CA2142805C (en) 1999-06-01
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ES2149290T3 (es) 2000-11-01
CN1306122A (zh) 2001-08-01
GB2288614A (en) 1995-10-25
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CA2142805A1 (en) 1995-10-13
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