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WO2025240701A1 - Procédé et système de gaufrage pour augmentation de volume - Google Patents

Procédé et système de gaufrage pour augmentation de volume

Info

Publication number
WO2025240701A1
WO2025240701A1 PCT/US2025/029502 US2025029502W WO2025240701A1 WO 2025240701 A1 WO2025240701 A1 WO 2025240701A1 US 2025029502 W US2025029502 W US 2025029502W WO 2025240701 A1 WO2025240701 A1 WO 2025240701A1
Authority
WO
WIPO (PCT)
Prior art keywords
embossing
tissue
ply
tissue ply
roll
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/US2025/029502
Other languages
English (en)
Inventor
Ludovic ACOSTA
Massimo CAGNONE
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Kimberly Clark Worldwide Inc
Kimberly Clark Corp
Original Assignee
Kimberly Clark Worldwide Inc
Kimberly Clark Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Kimberly Clark Worldwide Inc, Kimberly Clark Corp filed Critical Kimberly Clark Worldwide Inc
Publication of WO2025240701A1 publication Critical patent/WO2025240701A1/fr
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

Links

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
    • D21F11/12—Making corrugated paper or board
    • 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
    • B31F1/07—Embossing, i.e. producing impressions formed by locally deep-drawing, e.g. using rolls provided with complementary profiles
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
    • D21H27/30—Multi-ply
    • D21H27/40—Multi-ply at least one of the sheets being non-planar, e.g. crêped
    • 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
    • B31F2201/00—Mechanical deformation of paper or cardboard without removing material
    • B31F2201/07—Embossing
    • B31F2201/0707—Embossing by tools working continuously
    • B31F2201/0715—The tools being rollers
    • 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
    • B31F2201/00—Mechanical deformation of paper or cardboard without removing material
    • B31F2201/07—Embossing
    • B31F2201/0758—Characteristics of the embossed product
    • B31F2201/0761—Multi-layered
    • B31F2201/0766—Multi-layered the layers being superposed tip to tip
    • 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
    • B31F2201/00—Mechanical deformation of paper or cardboard without removing material
    • B31F2201/07—Embossing
    • B31F2201/0784—Auxiliary operations
    • B31F2201/0787—Applying adhesive

Definitions

  • Consumer tissue products such as facial tissue, bath tissue and paper wipers are generally used to absorb liquids and fluids.
  • Such paper products are predominantly formed of cellulosic papermaking fibers by manufacturing techniques designed specifically to produce several important properties.
  • the products should have good bulk, a soft feel, and should be highly absorbent.
  • the products should also have a pleasant aesthetic appearance and should be resilient against delamination in the environment in which they are used.
  • a decorative paper product has been created by embossing a pattern onto one or both sides of the paper web during manufacturing.
  • This standard mechanical embossing resulted in the deformation or breaking of fibers in an attempt to physically press the pattern into the web.
  • the resulting embossed patterns were not well-defined and faded as the paper product aged.
  • embossing patterns into tissue webs typically reduce the strength of the web.
  • embossing to increase the thickness of the tissue product, particularly bath tissue.
  • embossing patterns have been used in order to increase the thickness of multi-ply products in order to improve softness, tactile feel, and roll bulk.
  • Conventional embossing technologies including double embossed random lamination (DERL) or double embosser synchronized lamination (DESL) have limits on the ability to generate volume at acceptable levels of basesheet degradation.
  • the present disclosure is directed to a process and system for producing multi-layer embossed tissue products having enhanced bulk, a soft feel, and various other properties.
  • the present disclosure is also directed to tissue products made from the process.
  • the present disclosure is directed to a method of producing an embossed multi-ply tissue product.
  • the method includes conveying a first tissue ply through a first heated embossing nip. A first surface of the first tissue ply contacts a first embossing roll while in the nip.
  • the first embossing roll defines a pattern of male embossing elements that form an embossed pattern in the first tissue ply.
  • the embossed pattern comprises a pattern of protrusions that extend from a second surface of the first tissue ply.
  • a second tissue ply is conveyed through a second heated embossing nip.
  • a first surface of the second tissue ply contacts a second embossing roll while in the nip.
  • the second embossing roll defines a pattern of male embossing elements that form an embossing pattern in the second tissue ply.
  • the embossing pattern comprises a pattern of protrusions that extend from a second surface of the second tissue ply.
  • the method further includes conveying the first and second embossed tissue plies through a pinch point, such as a heated gap, that is formed between the first embossing roll and the second embossing roll.
  • a pinch point such as a heated gap
  • an open nip refers to a nip in which the two opposing rollers do not make contact and form a gap therebetween.
  • the first tissue ply is laminated to the second tissue ply to form a multi-ply tissue product.
  • the first and second embossed tissue plies can be conveyed through the pinch point such that the second surface of the first tissue ply faces the second surface of the second tissue ply.
  • At least some of the protrusions on the second surface of the first tissue ply are in alignment with at least some of the protrusions on the second surface of the second tissue ply when the two tissue plies are conveyed through the pinch point. For instance, greater than about 25%, such as greater than about 50%, such as greater than about 70%, such as greater than about 80%, such as greater than about 90% of the protrusions on the second surface of the first tissue ply remain in alignment with the protrusions on the second surface of the second tissue ply when the two plies are brought together to form the multi-ply product.
  • the male embossing elements on the first embossing roll are in alignment with the male embossing elements on the second embossing roll in order to form the pinch point.
  • the pattern of male embossing elements on the first embossing roll can be identical to the pattern of male embossing elements on the second embossing roll.
  • the first embossing roll and the second embossing roll can be positioned in a spaced apart relationship to form the pinch point.
  • the pinch point can define a gap between the first embossing roll and the second embossing roll. The gap can have a distance that is less than the total thickness of the first tissue ply and the second tissue ply.
  • the first tissue ply prior to entering the first nip, can be prewetted with a prewetting solution comprising water.
  • the second tissue ply prior to entering the second nip, can be prewetted with a prewetting solution also comprising water.
  • the prewetting solution applied to the first tissue ply and applied to the second tissue ply can comprise water in an amount greater than about 70% by weight, such as greater than about 95% by weight, such as in an amount greater than about 98% by weight, and, in one embodiment, can comprise only water.
  • the prewetting solution can contain any suitable adjuvant that enhances at least one property of the tissue product.
  • the prewetting solution can be heated prior to application to the first tissue ply or the second tissue ply.
  • the prewetting solution can be heated to a temperature of from about 60°C to about 95°C, such as from about 60°C to about 80°C.
  • the prewetting solution can be sprayed onto a surface of the first tissue ply and can be sprayed onto a surface of the second tissue ply.
  • the prewetting solution can be applied to the first tissue ply and to the second tissue ply in an amount from about 1% to about 10% by weight, such as in an amount from about 2% to about 6% by weight.
  • the method can further include the step of applying a bonding solution to at least one of the tissue plies prior to conveying the first and second tissue plies through the pinch point.
  • the bonding solution can comprise an adhesive or can be adhesive-free.
  • the bonding solution can comprise water that is adhesive-free.
  • the bonding solution can be applied, for instance, using a roll applicator.
  • the bonding solution is applied to the second surface of the first tissue ply by a roll applicator while the first tissue ply is in contact with the first embossing roll but prior to entering the pinch point between the first embossing roll and the second embossing roll.
  • the male embossing elements on the first embossing roll and on the second embossing roll can comprise discrete shapes.
  • the male embossing elements can have a diameter of from about 0.2 mm to about 2 mm, such as from about 0.3 mm to about 0.8 mm.
  • the diameter of the discrete shapes can be the same on each roll or, alternatively, the embossing elements on one roll can be larger (but still in alignment) with the embossing elements on an opposite roll.
  • the diameter of the male embossing elements is determined by drawing a best fit circle around the perimeter of the embossing element and measuring the diameter.
  • the male embossing elements can generally have a height of from about 0.4 mm to about 4 mm, such as from about 1 mm to about 2 mm.
  • the male embossing elements on an embossing roll can have the same height or can have different heights.
  • the first embossing roll and the second embossing roll can be heated.
  • the embossing rolls for instance, can each independently be heated to a temperature of from about 70°C to about 190°C.
  • a third tissue ply can be fed into the process.
  • a third tissue ply can be conveyed from an unwind station and fed between the first tissue ply and the second tissue ply prior to being fed into the pinch point.
  • the process can be used to make tissue products having more that 3 plies, such as 4 plies, 5 plies, or 6 plies. All different types of tissue webs can be incorporated into products made in accordance with the present disclosure.
  • the first tissue ply and/or the second tissue ply can comprise a creped tissue web, an uncreped tissue web, a through-air dried tissue web, or the like.
  • Each tissue ply can generally have a basis weight of from about 10 gsm to about 60 gsm, such as from about 12 gsm to about 28 gsm.
  • the multi-ply product made in accordance with the present disclosure can have a relatively high bulk, such as greater than about 9 cm 3 /g, such as greater than about 10 cm 3 /g, such as greater than about 11 cm 3 /g, such as greater than about 12 cm 3 /g.
  • Tissue products made in accordance with the present disclosure can be spirally wound into rolls with periodic lines of perforation for producing bath tissues and paper towels. Alternatively, the tissue product can be cut into individual sheets and marketed as interfolded stacks, such facial tissues.
  • the present disclosure is also directed to an embossing system for producing multi-ply tissue products.
  • the embossing system includes a first heated embossing nip for receiving a first tissue ply.
  • the first heated embossing nip can be formed between a first embossing roll and an opposing roll.
  • the first embossing roll defines a pattern of male embossing elements that form an embossing pattern into the first tissue ply.
  • the system further includes a second heated embossing nip formed between a second embossing roll and an opposing roll.
  • the second embossing roll defines a pattern of male embossing elements that form an embossing pattern in the second tissue ply.
  • the opposing rolls can have a smooth surface or a textured surface.
  • the system further includes a heated pinch point formed between the first embossing roll and the second embossing roll.
  • the heated pinch point can be defined by a gap between the opposing rolls and can be positioned to receive the first tissue ply after being embossed and the second tissue ply after being embossed for laminating the two tissue plies together.
  • the pattern of male embossing elements on the first embossing roll are placed in alignment with the pattern of male embossing elements on the second embossing roll. In this manner, embossments formed on the first tissue ply can be registered or placed in alignment with embossments formed into the second tissue ply.
  • Figure 1 is a cross-sectional view of one embodiment of an embossing process in accordance with the present disclosure
  • Figure 2 is a cross-sectional view of one embodiment of a multi-ply tissue product made in accordance with the present disclosure
  • Figure 3 is a cross-sectional view of another embodiment of an embossing process in accordance with the present disclosure
  • Figure 4 is a cross-sectional view of another embodiment of a multi-ply tissue product made in accordance with the present disclosure.
  • Figure 5 is a perspective view of one embodiment of a spirally wound roll of tissue product made in accordance with the present disclosure.
  • Figure 6 is a side view of an interfolded stack of individual sheets of a tissue product made in accordance with the present disclosure.
  • machine direction generally refers to the direction in which a tissue web or product is produced.
  • cross-machine direction or “CD” refers to the direction perpendicular to the machine direction.
  • Fibrous Structure refers to a structure comprising a plurality of elongated particulate having a length to diameter ratio greater than about 10 such as, for example, papermaking fibers and more particularly pulp fibers, including both wood and non-wood pulp fibers, and synthetic staple fibers.
  • a non-limiting example of a fibrous structure is a tissue web comprising pulp fibers.
  • tissue Web or “Tissue Ply” refers to a fibrous structure provided in sheet form and being suitable for forming a tissue product.
  • Tissue Product refers to products made from tissue webs and includes, bath tissues, facial tissues, paper towels, industrial wipers, foodservice wipers, napkins, medical pads, and other similar products. Tissue products may comprise one, two, three or more plies.
  • the term “Pattern” generally refers to the arrangement of one or more design elements. Within a given pattern the design elements may be the same or may be different, further the design elements may be the same relative size or may be different sizes. For example, in one embodiment, a single design element may be repeated in a pattern, but the size of the design element may be different from one design element to the next within the pattern.
  • the term “Embossing Pattern or Design” generally refers to a decorative shape disposed across at least one dimension of a fibrous structure surface, the pattern may comprise a line element, discrete elements or other shapes.
  • the embossing pattern comprises a portion of the fibrous structure lying out of plane with the surface plane of the fibrous structure.
  • the embossing pattern results from embossing the fibrous structure resulting in protrusions having a z- directional elevation on one side of the fibrous structure and raised areas on the opposite side of the fibrous structure.
  • Discrete Elements or Shapes refers to an element, such as an embossing element, disposed on a fibrous structure that does not extend continuously in any dimension of the fibrous structure.
  • Basis Weight generally refers to the bone dry weight per unit area of a tissue and is generally expressed as grams per square meter (gsm). Basis weight is measured using TAPPI test method T-220. While basis weight may be varied, tissue products prepared according to the present invention generally have a basis weight greater than about 10 gsm, such as from about 10 to about 80 gsm and more preferably from about 30 to about 60 gsm.
  • the term “caliper” is the representative thickness of a single sheet (caliper of tissue products comprising two or more plies is the thickness of a single sheet of tissue product comprising all plies) measured in accordance with TAPPI test method T402 using a ProGage 500 Thickness Tester (Thwing-Albert Instrument Company, West Berlin, N.J.). The micrometer has an anvil diameter of 2.22 inches (56.4 mm) and an anvil pressure of 132 grams per square inch (per 6.45 square centimeters) (2.0 kPa).
  • Sheet Bulk refers to the quotient of the caliper (generally having units of pm) divided by the bone dry basis weight (generally having units of gsm). The resulting sheet bulk is expressed in cubic centimeters per gram (cc/g). While sheet bulk may vary depending on any one of a number of factors, tissue products prepared according to the present invention may have a sheet bulk greater than about 10.0 cc/g.
  • dot embossment or “dot emboss element” means an embossment or an embossing element that exhibits an aspect ratio of about 1 :1 .25 or less, such as an aspect ratio from about 1 .0 to about 1.25.
  • dot embossments are embossments having a circular, oval, square, or triangular cross-sectional shape.
  • the present disclosure is directed to an embossing process and system for producing multi-ply tissue products with excellent bulk.
  • the process and system of the present disclosure can increase the caliper of individual tissue plies and then combine them together that produces a significant amount of bulk in the final product.
  • Multi-ply tissue products are produced in accordance with the present disclosure using a hot embossing process where opposing tissue plies are embossed with the same or similar patterns. The two tissue plies are then brought together such that protrusions caused by embossing on one tissue ply are registered or placed in alignment with protrusions caused by embossing on the opposing ply. In this manner, tissue products are made with substantial void volume and bulk which leads to superior liquid absorbency properties.
  • a first tissue ply is optionally prewetted and then fed to a first heated embossing nip.
  • the first embossing nip can be formed between an embossing roll and a backing roll.
  • a second tissue ply can be optionally prewetted and fed to a second heated embossing nip.
  • the second embossing nip can be formed between a second embossing roll and a backing roll.
  • Each embossing roll includes a pattern of raised male embossing elements that can comprise discrete shapes and arranged on the embossing roll in a desired pattern.
  • the first embossed tissue ply and the second embossed tissue ply are fed through a heated pinch point.
  • the pinch point is formed between the first embossing roll and the second embossing roll.
  • the first tissue ply is brought together and attached to the second tissue ply to form a multi-ply tissue product.
  • the male embossing elements on the first embossing roll are positioned in alignment with at least some of the male embossing elements on the second embossing roll. In this manner, the embossing protrusions on the first tissue ply are aligned with and attached to the embossing protrusions on the second tissue ply in producing the multi-ply tissue product.
  • the multi-ply tissue products are produced that have extremely high bulk values.
  • the multi-ply tissue products can have a bulk greater than about 6 cm 3 /g, such as greater than about 8 cm 3 /g, such as greater than about 9 cm 3 /g, such as greater than about 10 cm 3 /g, such as even greater than about 12 cm 3 /g while minimizing strength degradation.
  • Tissue products made according to the present disclosure can display a bulk of up to about 20 cm 3 /g.
  • any suitable tissue ply can be embossed in accordance with the present disclosure.
  • the tissue ply for instance, can comprise any suitable nonwoven material that can be made through a wetlaid process, air-laying process, or through a foam forming process.
  • the tissue ply generally contains cellulose fibers, particularly cellulose pulp fibers.
  • the tissue ply can contain greater than about 40% by weight, such as greater than about 50% by weight, such as greater than about 60% by weight, such as greater than about 70% by weight cellulose pulp fibers.
  • the multi-ply products in accordance with the present disclosure can be used to produce numerous products including bath tissue, facial tissue, table napkins, paper towels, and the like.
  • the tissue product can contain at least two tissue plies, such as three tissue plies or four tissue plies.
  • the multi-ply embossed tissue products of the present invention generally have a total product basis weight of at least about 20 gsm, such as at least about 25 gsm, such as at least about 30 gsm, such as at least about 35 gsm, such as at least about 40 gsm, such as at least about 45 gsm and less than about 120 gsm.
  • the product basis weight may range from about 20 gsm to about 70 gsm, such as from about 30 gsm to about 65 gsm, such as about 40 gsm to about 60 gsm.
  • the multi-ply embossed tissue products may comprise two, three or four tissue plies where the basis weight of each individual tissue ply is less than about 40 gsm, such as from about 10 gsm to about 25 gsm, such as from about 12 gsm to about 20 gsm.
  • the multi-ply products of the present invention are embossed and comprise two or more tissue plies bonded together along a plurality of bonded areas.
  • the bonded areas may correspond to the embossments disposed on the one or more tissue plies.
  • the first tissue ply and the second tissue ply can be bonded together using an adhesive.
  • the bonded areas can be formed without using an adhesive such that the tissue product is substantially free or completely free from adhesives.
  • the tissue plies can be bonded together using a bonding solution that comprises primarily or only water.
  • the embossed area, relative to the total area of the ply surface, and in-turn the bonded area may range from about 2% to about 80%, such as from about 2% to about 30%, such as from about 2% to about 20%.
  • a process and system 10 that may be used to produce multi-ply tissue products 12 in accordance with the present disclosure is illustrated.
  • a first tissue ply 14 and a second tissue ply 16 are fed into the process in order to produce the multi-ply product 12.
  • the first tissue ply 14 and the second tissue ply 16 can be prewetted with a prewetting solution.
  • a prewetting solution can be applied to the first tissue ply 14 by the prewetting station 18 and the second tissue ply 16 can be prewetted with a prewetting solution by a prewetting station 20.
  • the prewetting solution applied to the first tissue ply 14 and to the second tissue ply 16 can comprise water in an amount greater than about 70% by weight, such as in an amount greater than about 90% by weight, such as in an amount greater than about 94% by weight, such as in an amount greater than about 96% by weight, such as in an amount greater than about 98% by weight, and, in one embodiment, can comprise only water.
  • the prewetting solution can comprise an aqueous solution containing water in combination with an adjuvant that improves or enhances at least one property of the tissue product.
  • the prewetting solution may be applied to each tissue ply by any suitable means.
  • Any contact or contactless application means suitable for applying a prewetting solution to a tissue basesheet or ply can be used, such as spraying, dipping, padding, printing, slot extruding, rotogravure printing, flexographic printing, offset printing, screen printing, and mixtures thereof.
  • noncontact printing methods such as ink jet printing, digital printing, spraying, and topical application using a WEKO fluid application system (commercially available from Weitmann & Konrad GmbH & Co., Leinfelden-Echterdingen, Germany) may be used to apply the prewetting solution to the web prior to embossing.
  • the prewetting solution is applied without direct contact between the ply and the applicator, such as by a liquid applicator comprising a nozzle system to spray the prewetting solution onto the outer surface of the tissue ply as it is conveyed past the applicator.
  • the prewetting solution is applied to the surface of the tissue ply during the converting process by spraying at least one surface of the tissue ply with a prewetting solution and then simultaneously drying and embossing the wetted tissue ply by conveying it through a heated embossing nip.
  • the embossed tissue web may then be attached to the second tissue web.
  • the prewetting solution can be applied by a single device or multiple devices.
  • the one or more application devices may apply the same prewetting solution or may be configured to apply different prewetting solutions. In those instances where the process employs a single device it may be configured to apply two or more different prewetting solutions by providing the device with two or more chambers capable of separately delivering the different solutions.
  • the prewetting applicator can be configured and arranged to apply a prewetting solution to the tissue plies immediately prior to the plies being conveyed to an embossing unit or may be configured to apply the prewetting solution while the ply is engaged by one of the embossing rolls. Regardless, it is generally preferred that the wetted ply does not have sufficient time to dry before embossments are imparted to the web by the heated embossing roll.
  • the applicator unit may be configured to apply the prewetting solution to only a portion of the tissue ply surface.
  • the applicator may be configured such that only the embossed portion of the ply is treated.
  • the applicator unit may be configured such that the prewetting solution covers at least about 90% of the surface area, such as at least about 92% of the surface area, such as at least about 95% of the surface area, such as about 100% of the surface area of the ply.
  • the prewetting solution may be applied in a pattern or may be applied randomly.
  • the applicator unit may be configured to provide a controlled amount of aqueous composition to the tissue ply such that the basis weight of the tissue ply is increased in the range from about 1 % to about 10%, such as from about 2% to about 8%.
  • the prewetting solution can be applied to the first tissue ply 14 and to the second tissue ply 16 in an amount greater than about 3% by weight and in an amount less than about 7% by weight, such as in an amount less than about 6% by weight, such as in an amount less than about 5% by weight.
  • the wetted tissue ply is dried as it is brought into contact with the heated embossing roll. In this manner, the embossed tissue ply may have a basis weight substantially similar to the unembossed tissue ply prior to application of the prewetting solution.
  • the temperature of the prewetting solution being applied to the tissue ply may be about 50°C or greater, such as about 55°C or greater, such as about 60°C or greater, such as about 65°C or greater, such as about 70°C or greater.
  • the temperature of the prewetting solution may range from about 50°C to about 80°C, such as from about 60°C to about 75°C, such as from about 65°C to about 70°C.
  • the first tissue ply 14 is fed into a first heated embossing nip 22.
  • the embossing nip 22 is formed between a first embossing roll 24 and an opposing roll 26.
  • the opposing roll 26 can comprise any suitable backing roll.
  • the opposing roll 26 can comprise a roll having a surface made from a rubber or rubber-like material.
  • the opposing roll 26 can comprise a roll having a smooth surface or a textured surface.
  • the first embossing roll 24 and/or the opposing roll 26 can be heated.
  • the first embossing roll 24 includes a pattern of male embossing elements 28 that emboss a pattern into the first tissue ply 14.
  • the first tissue ply 14 is heated to a temperature sufficient to evaporate the prewetting solution or water and dried.
  • the first tissue ply 14 is fed around guide rolls 30 and fed into the first heated nip 22.
  • the guide rolls 30 are positioned to prevent contact with the opposing roll 26.
  • the first tissue ply 14 can be placed in contact with the opposing roll 26 and wrapped around the opposing roll as the first tissue ply 14 is fed into the nip 22.
  • the nip 22 can be heated using any suitable heating means.
  • the embossing roll 24 can be heated, the backing roll 26 can be heated, or both rolls can be heated.
  • the embossing roll 24 is heated.
  • the nip 22 or the surface of the embossing roll 24, for instance, can be heated to a temperature of greater than about 70°C, such as greater than about 80°C, such as greater than about 90°C, such as greater than about 100°C, such as greater than about 110°C, such as greater than about 120°C, such as greater than about 130°C, such as greater than about 140°C, and less than about 220°C, such as less than about 200°C, such as less than about 190°C, such as less than about 180°C, such as less than about 170°C.
  • the embossing roll 24 can be combined with a heating device that can be housed within the roll for heating by conduction.
  • the embossing roll 24 can be heated by radiation and/or convection.
  • the nip 22 formed between the embossing roll 24 and the backing roll 26 is heated for heating the tissue ply 14 as the tissue ply is embossed.
  • the wetted tissue ply remains in contact with the heated embossing roll for a sufficiently long time to allow the drying of the ply itself, but without reducing the processing speed of the tissue product.
  • the duration of contact can be influenced by the temperature of the embossing roll, the size of the roll and the degree to which the wetted tissue ply wraps the roll. Generally, it is preferred to optimize the conditions not only to improve embossing clarity and ply attachment, but also to maintain sufficient processing speed and to maintain the efficiency of the drying process of the wet paper ply just embossed.
  • the first tissue ply 14 can be wrapped around the embossing roll greater than about 90°, such as greater than about 100°, such as greater than about 120°, such as greater than about 130°, and less than about 350°, such as less than about 330°, such as less than about 320° in order to apply sufficient heat to the tissue ply.
  • the embossing roll 24 is generally a hard and non-deformable roll, such as a steel roll.
  • the backing roll 26 can be a substantially smooth roll or a textured roll that, in one embodiment, can include a covering made of natural or synthetic rubber.
  • the natural or synthetic rubber for instance, can be polybutadiene or copolymers of ethylene and propylene or the like.
  • the backing roll 26 has a hardness of greater than about 40 Shore A, such as from about 40 Shore A to about 100 Shore A including all increments of 1 Shore A therebetween.
  • the hardness of the backing roll 26 can be from about 50 Shore A to about 70 Shore A.
  • the first tissue ply 14 enters the heated nip 22 and is embossed by the embossing roll 24 by the pattern of male embossing elements 28. Not only is the first tissue ply 14 heated in the nip 22 but is also subjected to pressure against the embossing roll 24 by the opposing roll 26 for forming an embossed pattern into the first tissue ply 14.
  • the second tissue ply 16 is also embossed in a similar manner. As shown in FIG. 1 , the second tissue ply 16 is optionally fed around guide rolls 32 and fed into a second heated nip 34. The second heated nip 34 is formed between a second embossing roll 36 opposite an opposing roll 38. The second embossing roll 36 includes a pattern of male embossing elements 40 that emboss a pattern into the second tissue ply 16.
  • the second heated embossing nip 34 can be heated using any suitable means.
  • the second embossing roll 36, the opposing roll 38, or both rolls can be heated.
  • the nip 34 or the surface of the embossing roll 36 can be heated to a temperature of greater than about 70°C, such as greater than about 80°C, such as greater than about 90°C, such as greater than about 100°C, such as greater than about 110°C, such as greater than about 120°C, such as greater than about 130°C, such as greater than about 140°C, and less than about 220°C, such as less than about 200°C, such as less than about 190°C, such as less than about 180°C, such as less than about 170°C.
  • the prewetted second tissue ply 16 can remain in contact with the second heated embossing roll 36 for a sufficiently long time to allow the drying of the ply.
  • the duration of contact can be influenced by the temperature of the embossing roll, the size of the roll, and the degree to which the wetted tissue ply wraps the roll.
  • the second tissue ply 16, for instance, can be wrapped around the second embossing roll 36 greater than about 90°, such as greater than about 100°, such as greater than about 120°, such as greater than about 130°, and less than about 350°, such as less than about 330°, such as less than about 320°.
  • the second embossing roll 36 is generally a hard and non-deformable roll, such as a steel roll.
  • the opposing roll or backing roll 38 can be a substantially smooth roll or textured roll that can include a covering made of natural or synthetic rubber.
  • the opposing roll 38 for instance, can have a hardness of greater than about 40 Shore A, such as from about 40 Shore A to about 100 Shore A, including all increments of 1 Shore A therebetween.
  • the hardness of the opposing roll 38 can be from about 50 Shore A to about 70 Shore A.
  • the first embossing roll 24 includes a pattern of male embossing elements 28, while the second embossing roll 36 includes a pattern of male embossing elements 40.
  • the pattern of male embossing elements 28 on the first embossing roll 24 can be very similar to the pattern of male embossing elements 40 on the second embossing roll 36.
  • the pattern of male embossing elements 28 on the first embossing roll 24 are identical to the pattern of male embossing elements 40 on the second embossing roll 36.
  • the patterns can match such that all of the male embossing elements on one of the embossing rolls includes a corresponding and identical male embossing element on the opposing embossing roll.
  • one of the embossing rolls may include a lesser amount of male embossing elements than the other embossing roll.
  • the pattern containing a smaller number of male embossing elements can at least partially align with a corresponding male embossing element in the pattern applied to the other embossing roll.
  • the pattern of male embossing elements on the first embossing roll can be placed in alignment and be registered with the pattern of male embossing elements on the second embossing roll.
  • the pattern of male embossing elements appearing on the first embossing roll 24 and appearing on the second embossing roll 36 can vary depending upon the particular application.
  • the male embossing elements comprise discrete shapes.
  • the top surface of each male embossing element can be circular, oval, triangular, rectangular, or can have an irregular shape.
  • the male embossing elements can be positioned on the surface of each embossing roll in a random pattern or in a more discernible repeating pattern.
  • the male embossing elements are positioned on each embossing roll so as to form rows and/or columns.
  • the male embossing elements for instance, can be equally spaced within each row, equally spaced within each column, or can be uniformly populated over the surface of the embossing roll.
  • the male embossing elements can form discontinuous line structures on the embossing roll.
  • the male embossing elements can form wave-like discontinuous line structures over the surface of the embossing roll. Each wave-like line structure can be spaced from an adjacent wave-like line structure.
  • each male embossing element may comprise a discrete shape.
  • the size of the top surface of each male embossing element can vary. In one aspect, the top surface of each male embossing element can have the same size or, alternatively, can have different sizes within the pattern.
  • each male embossing element when applying a best fit circle around the top surface of each male embossing element, can have a diameter of generally greater than about 0.2 mm, such as greater than about 0.25 mm, such as greater than about 0.3 mm, such as greater than about 0.35 mm, such as greater than about 0.4 mm, and less than about 2 mm, such as less than about 1 .5 mm, such as less than about 1 .2 mm, such as less than about 1 mm, such as less than about 0.8 mm, such as less than about 0.6 mm.
  • the male embossing elements on one embossing roll can be the same size or can have a different size than the male embossing elements on an opposing embossing roll.
  • the embossing elements on one roll can be larger or have a larger diameter than the corresponding embossing elements on the opposing roll.
  • the height of the male embossing elements can also vary.
  • the male embossing elements have a height of greater than about 0.4 mm, such as greater than about 0.6 mm, such as greater than about 0.8 mm, such as greater than about 1 mm.
  • the height of the male embossing elements can be less than about 4 mm, such as less than about 3.5 mm, such as less than about 3 mm, such as less than about 2.5 mm, such as less than about 2 mm.
  • the height of the male embossing elements on one embossing roll can be the same or different.
  • the embossing patterns on the embossing rolls can also include other embossing elements.
  • one or both of the embossing rolls can include continuous line elements.
  • the line elements can form figures or other fanciful shapes into the tissue plies that are embossed.
  • the two tissue plies are brought together in a heated pinch point 42.
  • the heated pinch point 42 is formed between the first embossing roll 24 and the second embossing roll 36.
  • the first tissue ply 14 is attached or laminated to the second tissue ply 16 to form the multi-ply tissue product 12.
  • a bonding solution can be applied to at least one of the tissue plies that can facilitate forming a bond between the first tissue ply 14 and the second tissue ply 16.
  • a bonding solution applicator 48 is placed in association with a surface of the first tissue ply 14.
  • the bonding solution applicator 48 in one aspect, can comprise a supply roll 50 in communication with an applicator roll 52.
  • the applicator roll 52 receives a bonding solution from the supply roll 50 and applies it to a surface of the first tissue ply 14.
  • the bonding solution can comprise an adhesive Alternatively, the lamination process can be carried out without the use of an adhesive.
  • a bonding solution comprising an aqueous composition, preferably free from any adhesives, is applied to one of the tissue plies just prior to the lamination step such that the ply does not prematurely dry prior to being joined with the opposing ply.
  • the resulting multi-ply product 12 can also be free of adhesives.
  • multi-ply tissue products can be made in accordance with the present disclosure that do not contain a starch, a methylcellulose, or a polymer adhesive containing polypropylene, polyisobutylene, a polyurethane, a polyacrylate, a polyvinyl acetate, an ethylene vinyl acetate, or a polyvinyl alcohol. Without having to use an adhesive, the softness of the tissue product 12 can be enhanced.
  • the bonding solution applied to the first tissue ply can contain water in an amount greater than about 50% by weight, such as in an amount greater than about 70% by weight, such as in an amount greater than about 80% by weight, such as in an amount greater than about 90% by weight, such as in an amount greater than about 95% by weight, such as in an amount greater than about 97% by weight, such as in an amount greater than about 99% by weight.
  • the bonding solution only comprises water.
  • the bonding solution applicator 48 represents merely one way of applying the bonding solution to the first tissue ply 14.
  • Various other techniques and methods can be used to apply the bonding solution to the first tissue ply 14.
  • the bonding solution can be applied to the tissue ply using a gravure roll, through a digital printer, using a knife blade, or spraying the bonding solution onto the tissue ply 14.
  • the bonding solution is heated prior to being applied to the tissue ply 14.
  • the bonding solution can be heated to a temperature of from about 60°C to about 90°C, including all increments of 1 °C therebetween.
  • the bonding solution can be heated to a temperature of greater than about 65°C, such as greater than about 70°C, such as greater than about 75°C, and less than about 85°C.
  • the bonding solution is generally applied to the first tissue ply 14 in an amount less than about 6% by weight, such as in an amount less than about 5% by weight, such as in an amount less than about 4% by weight, such as in an amount less than about 3% by weight, such as in an amount less than about 2% by weight, such as in an amount less than about 1% by weight.
  • the bonding solution is applied to the first tissue ply 14 in an amount greater than about 0.1% by weight, such as in an amount greater than about 0.5% by weight, such as in an amount greater than about 1% by weight, such as in an amount greater than about 1 .5% by weight, such as in an amount greater than about 2% by weight.
  • the first tissue ply 14 is attached to the second tissue ply 16 within the heated pinch point 42.
  • the first embossing roll 24 and the second embossing roll 36 are positioned in alignment with each other such that at least some of the male embossing elements 28 on the first embossing roll 24 are in registration or alignment with the pattern of male embossing elements 40 on the second embossing roll 36.
  • the pattern of male embossing elements on the first embossing roll 24 can be identical to the pattern of male embossing elements on the second embossing roll 36.
  • the male embossing elements on the respective embossing rolls form protrusions that extend from the surface of each tissue ply.
  • the multi-ply tissue product 12 is illustrated.
  • the tissue product 12 includes the first tissue ply 14 attached to the second tissue ply 16.
  • the tissue ply 14 includes a pattern of protrusions 44 that were formed into the tissue ply by the male embossing elements 28 on the first embossing roll 24.
  • the second tissue ply 16 includes a pattern of protrusions 46 that were formed into the tissue ply by the male embossing elements 40 of the second embossing roll 36.
  • the tissue product 12 is formed in which the pattern of protrusions 44 remained in alignment with the pattern of protrusions 46. As shown in FIG. 2, the result produces a tissue product 12 that has a significant amount of void space and therefore has enhanced bulk, excellent softness properties, and dramatically improved liquid absorption properties.
  • the first tissue ply 14 is bonded to the second tissue ply 16 primarily only where the protrusions 44 and 46 appear.
  • the top surface of the protrusions 44 and 46 form bonded areas that correspond to the embossments formed into the tissue plies by the embossing rolls 24 and 36.
  • the bonding areas or embossed areas of each tissue ply relative to the total area of the ply surface can vary depending upon the particular application.
  • the embossed area or bonded area of the tissue plies relative to the total area of the ply surface can range from about 2% to about 90%.
  • the embossed area or bonded area can be greater than about 4%, such as greater than about 6%, such as greater than about 8%, such as greater than about 10%, such as greater than about 12%, such as greater than about 14%, such as greater than about 16%, such as greater than about 18%, such as greater than about 20%, such as greater than about 22%, such as greater than about 24%, such as greater than about 26%, such as greater than about 28% of the total area of the ply surface.
  • the embossed areas or bonded areas can generally be less than about 50%, such as less than about 45%, such as less than about 40%, such as less than about 35%, such as less than about 30%, such as less than about 26%, such as less than about 24%, such as less than about 20% of the total area of the ply surface.
  • the first and second tissue plies 14 and 16 fed into the process can be planar or can include three-dimensional characteristics prior to being conveyed through the heated embossing nips 22 and 34.
  • one or both of the tissue plies can be micro-embossed prior to being conveyed into the heated embossing nips 22 and 34.
  • one or more of the tissue plies can include dot embossments prior to being fed into the process illustrated in FIG. 1 .
  • the first and second tissue plies 14 and 16 can be embossed as single ply webs or can include two or more plies that are brought together and fed through the embossing nips. In this manner, the final product can include 2 plies, 3 plies, 4 plies, 5 plies, 6 plies and so forth.
  • the tissue plies 14 and 16 are subjected to heat and pressure for forming an embossing pattern into the plies.
  • the heated pinch point 42 on the other hand, the tissue plies 14 and 16 are brought into contact with each other for laminating the plies together without deteriorating the embossing patterns that have been formed into the tissue plies.
  • the heated pinch point 42 in one embodiment, may only apply light pressure to the tissue plies 14 and 16.
  • the first embossing roll 24 may be spaced from the second embossing roll 36 to form a gap through which the tissue plies 14 and 16 are fed.
  • the gap can have a distance that is shorter than the total width of the two tissue plies.
  • the gap for instance, may have a distance of less than about 2 mm, such as less than about 0.8 mm, such as less than about 0.6 mm, such as less than about 0.5 mm, and greater than about 0.1 mm, such as greater than about 0.2 mm, such as greater than about 0.3 mm.
  • FIG. 3 another embodiment of a process and system for embossing tissue webs and forming a multi-ply product is shown. Like reference numerals have been used to indicate similar elements.
  • the process illustrated in FIG. 3 is very similar to the process illustrated in FIG. 1 except that a third tissue ply 60 is fed into the process for being positioned between the first tissue ply 14 and the second tissue ply 16.
  • the first tissue ply 14 is optionally prewetted and then fed into a first heated nip 22 positioned between a first embossing roll 24 and an opposing roll or backing roll 26.
  • a second tissue ply 16 can also be prewetted and then fed into a second heated nip 34 formed between a second embossing roll 36 and an opposing roll 38.
  • the embossed first tissue ply 14 and the embossed tissue ply 16 are then fed into a heated pinch point 42 formed between the first embossing roll 24 and the second embossing roll 36.
  • an unwind station unwinds a third tissue ply 60, which can be fed into the heated pinch point 42 for laminating to the first tissue ply 14 and the second tissue ply 16.
  • the third tissue ply 60 can be fed into the process anywhere upstream from the heated pinch point 42. In the embodiment illustrated in FIG.
  • the third tissue ply 60 is fed in between the applicator roll 52 of the applicator 48 and the first embossing roll 24.
  • the bonding solution therefore, is applied to a surface of the third tissue ply for bonding to the second tissue ply 16.
  • a bonding solution can be applied to opposite surfaces of the third tissue ply or can be applied to a surface of the first tissue ply 14 and to a surface of the second tissue ply 16.
  • the third tissue ply 60 in this embodiment, is not embossed and is laminated to the first tissue ply 12 and the second tissue ply 16 for forming a multi-ply tissue product 12.
  • the tissue product 12 is illustrated in FIG. 4. As shown, in this embodiment, the protrusions 44 on the first tissue ply 14 remain in alignment with the protrusions 46 on the second tissue ply 16.
  • the third tissue ply 60 is positioned between the two tissue plies 14 and 16 and can, in one embodiment, comprise a relatively flat planar tissue web. Adding the third tissue ply 60 to the product 12 may further increase the liquid absorption properties of the overall product. In other embodiments, further plies can be incorporated into the product for forming tissue products with more than 3 plies.
  • any suitable tissue web can be embossed in accordance with the present disclosure and incorporated into the tissue product 12.
  • Bath tissue, facial tissue, paper towels, industrial wipers, and the like can be formed in accordance with the present disclosure.
  • the tissue product 12 can be packaged as individual sheets contained in a dispenser or can be offered to consumers in the form of a spirally wound roll.
  • Fibers suitable for making tissue webs comprise any natural or synthetic cellulosic fibers including, but not limited to nonwoody fibers, such as cotton, abaca, kenaf, sabai grass, flax, esparto grass, straw, jute hemp, bagasse, milkweed floss fibers, and pineapple leaf fibers; and woody or pulp fibers such as those obtained from deciduous and coniferous trees, including softwood fibers, such as northern and southern softwood kraft fibers; hardwood fibers, such as eucalyptus, maple, birch, and aspen.
  • nonwoody fibers such as cotton, abaca, kenaf, sabai grass, flax, esparto grass, straw, jute hemp, bagasse, milkweed floss fibers, and pineapple leaf fibers
  • woody or pulp fibers such as those obtained from deciduous and coniferous trees, including softwood fibers, such as northern and southern softwood kraft fibers; hardwood fibers, such as
  • Pulp fibers can be prepared in high-yield or low-yield forms and can be pulped in any known method, including kraft, sulfite, high-yield pulping methods and other known pulping methods. Fibers prepared from organosolv pulping methods can also be used, including the fibers and methods disclosed in U.S. Pat. No. 4,793,898, issued Dec. 27, 1988 to Laamanen et al.; U.S. Pat. No.
  • Useful fibers can also be produced by anthraquinone pulping, exemplified by U.S. Pat. No. 5,595,628 issued Jan. 21 , 1997, to Gordon et al.
  • a portion of the fibers can be synthetic fibers such as rayon, polyolefin fibers, polyester fibers, bicomponent sheath-core fibers, multi-component binder fibers, and the like.
  • An exemplary polyethylene fiber is Pulpex®, available from Hercules, Inc. (Wilmington, Del.). Any known bleaching method can be used.
  • Synthetic cellulose fiber types include rayon in all its varieties and other fibers derived from viscose or chemically-modified cellulose.
  • Chemically treated natural cellulosic fibers can be used such as mercerized pulps, chemically stiffened or crosslinked fibers, or sulfonated fibers.
  • the fibers For good mechanical properties in using papermaking fibers, it can be desirable that the fibers be relatively undamaged and largely unrefined or only lightly refined. While recycled fibers can be used, virgin fibers are generally useful for their mechanical properties and lack of contaminants. Mercerized fibers, regenerated cellulosic fibers, cellulose produced by microbes, rayon, and other cellulosic material or cellulosic derivatives can be used.
  • Suitable papermaking fibers can also include recycled fibers, virgin fibers, or mixes thereof. In certain embodiments capable of high bulk and good compressive properties, the fibers can have a Canadian Standard Freeness of at least 200, more specifically at least 300, more specifically still at least 400, and most specifically at least 500.
  • High yield pulp fibers are those papermaking fibers produced by pulping processes providing a yield of about 65% or greater, more specifically about 75% or greater, and still more specifically about 75% to about 95%. Yield is the resulting amount of processed fibers expressed as a percentage of the initial wood mass.
  • pulping processes include bleached chemithermomechanical pulp (BCTMP), chemithermomechanical pulp (CTMP), pressure/pressure thermomechanical pulp (PTMP), thermomechanical pulp (TMP), thermomechanical chemical pulp (TMCP), high yield sulfite pulps, and high yield Kraft pulps, all of which leave the resulting fibers with high levels of lignin.
  • High yield fibers are well known for their stiffness in both dry and wet states relative to typical chemically pulped fibers.
  • any process capable of forming a paper web can also be utilized in the present disclosure.
  • a papermaking process of the present disclosure can utilize creping, wet creping, double creping, embossing, wet pressing, air pressing, through-air drying, creped through-air drying, uncreped through-air drying, hydroentangling, air laying, as well as other steps known in the art.
  • the tissue web may be formed from a fiber furnish containing pulp fibers in an amount of at least about 50% by weight, such as at least about 60% by weight, such as at least about 70% by weight, such as at least about 80% by weight, such as at least about 90% by weight, such as 100% by weight.
  • the tissue web can also be formed without a substantial amount of inner fiber-to-fiber bond strength.
  • the fiber furnish used to form the base web can be treated with a chemical debonding agent.
  • the debonding agent can be added to the fiber slurry during the pulping process or can be added directly to the headbox.
  • Suitable debonding agents include cationic debonding agents such as fatty dialkyl quaternary amine salts, mono fatty alkyl tertiary amine salts, primary amine salts, imidazoline quaternary salts, silicone quaternary salt and unsaturated fatty alkyl amine salts.
  • Other suitable debonding agents are disclosed in U.S. Pat. No. 5,529,665 to Kaun which is incorporated herein by reference. In particular, Kaun discloses the use of cationic silicone compositions as debonding agents.
  • the debonding agent used in the process of the present disclosure is an organic quaternary ammonium chloride and, particularly, a silicone-based amine salt of a quaternary ammonium chloride.
  • the debonding agent can be PROSOFT® TQ1003, marketed by the Hercules Corporation.
  • the debonding agent can be added to the fiber slurry in an amount of from about 1 kg per metric tonne to about 10 kg per metric tonne of fibers present within the slurry.
  • the debonding agent can be an imidazoline-based agent.
  • the imidazoline-based debonding agent can be obtained, for instance, from the Witco Corporation.
  • the imidazoline-based debonding agent can be added in an amount of between 2.0 to about 15 kg per metric tonne.
  • the debonding agent can be added to the fiber furnish according to a process as disclosed in PCT Application having an International Publication No. WO 99/34057 filed on Dec. 17, 1998 or in PCT Published Application having an International Publication No. WO 00/66835 filed on Apr. 28, 2000, which are both incorporated herein by reference.
  • a process is disclosed in which a chemical additive, such as a debonding agent, is adsorbed onto cellulosic papermaking fibers at high levels.
  • the process includes the steps of treating a fiber slurry with an excess of the chemical additive, allowing sufficient residence time for adsorption to occur, filtering the slurry to remove unadsorbed chemical additives, and redispersing the filtered pulp with fresh water prior to forming a nonwoven web.
  • Optional chemical additives may also be added to the aqueous papermaking furnish or to the formed embryonic web to impart additional benefits to the product and process and are not antagonistic to the intended benefits of the invention.
  • additional chemicals may be applied to the web along with the additive composition of the present invention.
  • the chemicals are included as examples and are not intended to limit the scope of the invention. Such chemicals may be added at any point in the papermaking process, including being added simultaneously with the additive composition in the pulp making process, wherein said additive or additives are blended directly with the additive composition.
  • Additional types of chemicals that may be added to the paper web include, but is not limited to, absorbency aids usually in the form of cationic, anionic, or non-ionic surfactants, humectants and plasticizers such as low molecular weight polyethylene glycols and polyhydroxy compounds such as glycerin and propylene glycol.
  • absorbency aids usually in the form of cationic, anionic, or non-ionic surfactants
  • humectants and plasticizers such as low molecular weight polyethylene glycols and polyhydroxy compounds such as glycerin and propylene glycol.
  • Materials that supply skin health benefits such as mineral oil, aloe extract, vitamin e, silicone, lotions in general and the like may also be incorporated into the finished products.
  • the products of the present disclosure can be used in conjunction with any known materials and chemicals that are not antagonistic to its intended use.
  • materials include but are not limited to odor control agents, such as odor absorbents, activated carbon fibers and particles, baby powder, baking soda, chelating agents, zeolites, perfumes or other odor-masking agents, cyclodextrin compounds, oxidizers, and the like.
  • odor control agents such as odor absorbents, activated carbon fibers and particles, baby powder, baking soda, chelating agents, zeolites, perfumes or other odor-masking agents, cyclodextrin compounds, oxidizers, and the like.
  • Superabsorbent particles, synthetic fibers, or films may also be employed. Additional options include cationic dyes, optical brighteners, humectants, emollients, and the like.
  • Tissue webs that may be treated in accordance with the present disclosure may include a single homogenous layer of fibers or may include a stratified or layered construction.
  • the tissue web ply may include two or three layers of fibers.
  • the basis weight of tissue webs made in accordance with the present disclosure can vary depending upon the final product.
  • the process may be used to produce bath tissues, facial tissues, paper towels, industrial wipers, and the like.
  • the basis weight of the tissue products may vary from about 10 gsm to about 120 gsm, such as from about 20 gsm to about 90 gsm.
  • the basis weight may range from about 10 gsm to about 40 gsm.
  • the basis weight may range from about 25 gsm to about 80 gsm.
  • the basis weight of each tissue web present in the product can also vary.
  • the total basis weight of a multiple ply product will generally be the same as indicated above, such as from about 20 gsm to about 120 gsm.
  • the basis weight of each ply can be from about 10 gsm to about 60 gsm, such as from about 12 gsm to about 40 gsm.
  • the tissue product 12 of the present disclosure can be used to produce a spirally wound roll 200 as shown in FIG. 5.
  • the spirally wound roll 200 for instance, can comprise a bath tissue.
  • the spirally wound roll of the tissue product 12 can be periodically perforated for allowing a user to tear off individual sheets.
  • the tissue product 12 can be formed into a spirally wound roll that comprises a paper towel or industrial wiper.
  • the tissue product 12 of the present disclosure can be cut into individual sheets and formed into a stack 300 as shown in FIG. 6.
  • the stack of individual sheets 300 can be interfolded if desired.
  • the stack of individual sheets 300 can comprise a facial tissue product.

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Abstract

Selon l'invention, des produits en tissu multicouche sont formés avec des caractéristiques de volume élevées. Une première couche de tissu est gaufrée dans une première ligne de contact de gaufrage chauffée et une seconde couche de tissu est gaufrée dans une seconde ligne de contact de gaufrage chauffée. Les deux couches de tissu sont ensuite réunies en un point de pincement chauffé qui est formé entre les rouleaux de gaufrage chauffés qui sont utilisés pour initialement gaufrer les couches de tissu. Les rouleaux de gaufrage possèdent des éléments de gaufrage mâles qui sont maintenus en alignement lorsque les couches de tissu sont réunies.
PCT/US2025/029502 2024-05-16 2025-05-15 Procédé et système de gaufrage pour augmentation de volume Pending WO2025240701A1 (fr)

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US63/648,399 2024-05-16

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6309731B1 (en) * 1997-03-10 2001-10-30 Uni-Charm Corporation Wiping sheet
EP2121322B1 (fr) * 2007-02-14 2016-06-01 3A Composites GmbH Panneau stratifie gonflant a plis gaufres et procede de fabrication associe
US20230265617A1 (en) * 2020-07-03 2023-08-24 Essity Hygiene And Health Aktiebolag Coreless Rolls of a Tissue Paper Product and Methods of Manufacturing Coreless Rolls
US20230295880A1 (en) * 2020-07-03 2023-09-21 Essity Hygiene And Health Aktiebolag Tissue paper products, rolls and stacks of tissue paper products, and manufacturing methods

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6309731B1 (en) * 1997-03-10 2001-10-30 Uni-Charm Corporation Wiping sheet
EP2121322B1 (fr) * 2007-02-14 2016-06-01 3A Composites GmbH Panneau stratifie gonflant a plis gaufres et procede de fabrication associe
US20230265617A1 (en) * 2020-07-03 2023-08-24 Essity Hygiene And Health Aktiebolag Coreless Rolls of a Tissue Paper Product and Methods of Manufacturing Coreless Rolls
US20230295880A1 (en) * 2020-07-03 2023-09-21 Essity Hygiene And Health Aktiebolag Tissue paper products, rolls and stacks of tissue paper products, and manufacturing methods

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