CA1146396A - Layered paper having a soft and smooth velutinous surface, and method of making such paper - Google Patents

Abstract

LAYERED PAPER HAVING A SOFT AND SMOOTH
VELUTINOUS SURFACE, AND METHOD OF MAKING SUCH PAPER

Abstract A layered paper and method of making it, which paper is characterized by having a soft, relatively untextured smooth velutinous surface defined by a multiplicity of relatively flaccid papermaking fibers having unbonded free end portions of substantial length, and which surface is subjectively discernible by humans as being extremely soft and smooth. Exemplary embodiments include tissue paper, and tissue paper products comprising one or more plies of such paper. The method includes wet laying a layered web which has a relatively low bond surface layer comprising at least about 60% relatively short papermaking fibers, drying the web without imparting substantial texture thereto, breaking sufficient papermaking bonds in the surface layer to generate a velutinous surface having, an FFE-Index of at least about 60 and preferably at least about 90, and calendering the dried web as required to provide said surface layer with an HTP-Texture of about 1.0 or less, and more preferably about 0.7 or less, and most preferably about 0.1 or less.

Description

J~ 3~

LAYF.RED PAPER ~ IG ~ OFT P~ND S~IOOTH
VELUTINOUS_SURFACE~.n~ O? G~ MAKING SUC~I PAPER
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Description Technical Field This invention relates to paper and papermaking: more particularly, to soft and absorbent wet laid tissue paper for such products as toilet tissue and facial tissue.

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By and large, consumers of tissue paper products prefer such products to feel soft. Sof~ness is a generally qualita-- ti~e, multi-faceted generic term which is-believed to be related to such bulk related physical properties as sprin~iness, resilience, compressibility and flexibility; and surface related physical properties such as flaccidness, surface suppleness, and smoothness; smoothness being the relative absence of texture. To illustrate some of the facets of softness> a pillow n~ay be said to be sof~ because it is sufficiently compressible and resilient to con:~orm to one's head so that zones of hig~ pressure are obviated; or, a flocked inflexible steeI plate may be said to 'nave a soft surface; or, a fur may be said to be soft ~y virtue of comprising a multitude of flaccid, supple hairs which each have one end attaclled to a flexible skin; or, whereas a satin cloth will generally be perceived ;o be smooth, it will generally not be regarded as soft in the velvety sense.
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Subjective softness determinations are considered to be bipolar in nature: that is, dependent on both human somatic sensibility as well as physical properties of the en~ity being evaluated for softness. Also~ surface softness and bulk softness can be considered separately with respect to tissue paper and tissue paper products.

. ' ' 1146396 Human somatic sensibility is discussed at length in Medical Phys'iology by Vernon B. Mountcas~le which was published and copyrighted by C. V. Mosby Company in 1974.
! Mountcastle states, in part, that the human sense of touch S involves such qualities as touch-pressure, pain, warmth, cold, and joint position; and that the usual touch/tactile 'i sensory experiences are amalgams of these. Indeed, it seems that surface softness and bulk softness are such complex amalgams.

' 10 The above assertion that surface softness and bulk softness can be considered separateIy is supported by 'The'Fundamental'Prope'r't'ie's'Of'Pap'er R'e'la'te'd'To'Its'Uses, Yolume'2 which was edited by Frances Bolam, and copyrighted and published in Great Britain in 1976 at The Pitman Press . 15 Bath.' This book contains contributions from W. Gallay, and B. H. Hollmark which provide'further background with respect to the present invention. First, at page 688, Ga-llay reported a general tendency to a relationship between the number of fibres or fibre bun~les protruding from the ' 20 surface of a tissue per unit area, with the subjective softness judgment given by a test panel. He opined that this general tendency was undoubtedly disturbed greatly by the'length of the fibers and the variation in their degree of flexural rigidity. Moreover, Gallay taught directly away from the present invention by asserting that a large proportion of long-fibered softwood should be'used for making soft tissues. Second, Hollmark disclosed a stylus type synthetic fingertip for performing instrumental evaluating of surface softness. He reported, however, that his equipment signal was insufficient to describe surface softness otherwise than to give a very coarse indication - like soft, mediu~, and rough. As described more fully hereinafter, a human-tactile-response texture quantifying system which is useful for evaluating embodiments of the present invention, also uses a stylus albeit of different design, and for generating data of substantially different character.

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Pa~er which is suitable for sanitary products has long ' been made by wet laying an embryonic web of homogeneous furnish; mechanically pressing the web between felts to ' remove water; and final drying. Such paper is generally characterized by smoothness, high density, harsh feel, poor softness, and low absorbency Creping to'break some inter- -fiber bonds, and calendering to reduce creping induced texture are practiced to increase the subjectively perceiv-able softness of such paper.

High bulk, single layer papers which are said to be soft and absorbent are d~sclosed in U.S. Patents ~o. 3,301,746;
No. 3,821,068; and No. 3,812,000 which are described below.
It is believed that the degree of subjectively perceivable softness of these bulked papers is most closeIy related to the'compressibility facet of softness. That is, the greater the bulk, the more easily the paper is compressed and the greater the subjectively perceivable'softness. Gene~ally speakin~, these papers have'high bul~ relative to wet-- pres~ed papers by virtue of being formed and substantially pre-'dried before being subjected to substantial mechanical compression. This obvlates, to some extent, the'formation of rigid interfiber hydrogen bonds which would otherwise I bond the ibers into a relatively dense and inflexible i sheet.

U.S'. Patent No. 3,301,746 which'issued January 31, 1967 to L.H. Sanford and J.B. Sisson (hereinafter the Sanford-Siss~n patent) discloses, briefly, a relatively highly textured, highIy bulked, single'layer absorbent paper and process for forming such paper which process comprises the steps of forming an uncompacted paper web; thermally predrying the uncompacted web to a fiber consistency of about 30~/O to about 80~/o while it is supported on a foraminous imprinting fabric having about 20 to about 60 meshes per inch; imprinting I the knuckle pattern of the fabric in the predried uncompacted j 35 web at a knuckle pressure of about 1000 p.s.i. to about , 12~000 p.s.i.; and final drying which may be followed by .. _ . . ~ . _ . _ . , _ ... . .. . . . .... .

1~46396 creping, ~s stated hereinabove, the subjectively perceivable softness of this paper is believed to be more related to the compressibility of the paper which results from its high bulk structure than to other softness related properties.

U.S. Patent No. 3,821,068 which issued June 28, 1974 to Shaw (hereinafter the Shaw patent) discloses a soft, absorbent, creped single layer paper formed by avoiding mechanical compression of the fiber furnish'until the sheet is at least ~0% dry. As disclosed, the paper is pre-dried without 10' mechanical compression to at least 80% consistency on a foraminous drying fabric. The abstract states that mechanical compression is avo'ided during pre-drying to substantially reduce formation of papermaking bonds which would orm upon compression of the web while wet. Thus, the paper is said to be'soft and low density; soft, apparently, because of the -compressibility of the low 'dens'ity structure.' i~ .. . _.
U.S'. Patent No. 3,812,Q00 which issued May 21, 1974 to : Salvucci et al. (hereinafter the Salvucci et al. patent) discloses a soft, absorbent, fibrous, single layer sheet material formed by avoiding mechanical compression of an elastomer-containing fiber furnish until the sheet is at least 8~% dry. Briefly, the paper made by this process apparently achieves its relative softness from the compressi-bility or springiness derived by inhibiting the formation of relatively rigid hydrogen bonds by avoiding mechanical compression until substantially dried (i.e: at least 80%
dry), and by providing some resilient elastomeric bonds by including an elastomeric material in the furnish.

The background art also discloses layered paper (and concomitant processes) which paper is suitable for sanitary products, and in which paper the layers comprise different fiber make-ups and, perhaps, strength additives of different I types to achieve different properties. Representative patents whi.ch are described more ful]y hereinafter include , ~146396 U.S. Patent No. 2,881,669; British Patent No. 1,117,731;
U.S. Patent No. 3,994,771; British Patent No. 2,006,296A;
Japanese Patent No. SH0 54-46914 which was opened for - publication on April 13, 1979; and U.S. Patent -i~o. 4,166,001.

U.S. Patent No. 2,~81,669 which issued Apri~ 14, 1959 to Thomas et al. discloses and claims paper having long i fibers predominating on opposite sides of a short fiber - zone, and apparatus for making such long-shor~-long fiber paper. By way of background, this patent also conclusionally states that "multi-ply" (multi-layered) paper made on twin ' wire Fourdrinier machines has short fibers distributed on ~ both sides o~ the paper and the long fibers are concentrated in the middle or central zone of the paper.

British Patent No. 1,117,731 which was filed by Wycombe Marsh Paper Mills Limited was published June 26, 1968. It identifies Michael Edward White as the inventor-an~ is hereinafter referred to as the White patent. This patent }- discloses a wet-laid, wet-felt-pressed 2-layer paper which, as disclosed, is believed to have been wet creped from a drying drum, and subsequently finally dried by passing over a pluralit~J of other drying drums. As s~ated in the patent, this paper comprises a soft and absorbent surfaced short fiber layer, and a strong and smooth-surfaced long fiber layer. The long fiber layer is stated to be preferably laid down first and the short fiber layer laid on top of the long ' fiber layer; then, the long fiber layer is disposed adjacent the creping/dryer drum. It is believed that such paper - which has been wet creped from a dryer drum would be relatively ~ dense and textured, and would not feeI particularly soft or ; 30 smooth as compared to present day commercial tissue paper products.

U.S. Patent No. 3,994,771 which issued November 30, 1976 to Morgan et al. discloses and claims a Process For Forming A Layered Paper Web Having Improved Bulk, Tactile .
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~1~a6396 Impression And Absorbency And Paper Thereof. Briefly, in this process, at least one layer of at least two superposed stratified fibrous layers is bulked into the interfila-mentary spaces of a foraminous fabric such as an imprinting fabric mentioned hereinabove with respect to the Sanford-Sisson patent. The resulting paper is relatively highly bulked and textured, and is generally subjectively perceived to be relatively soft. As was stated hereinabove with respect to Sanford-Sisson, it is believed that the perceived softness of this paper is more related to its compressibility then to other softness related properties.

British Patent No. 2,006,296A which was published May

2, 1979 recites a wet-laid, dry creped, bulky absorbent tissue paper web of desirable softness and smoothness characteristics, which paper is produced utilizing a very fine mesh transfer and imprinting fabric having between 4900 and 8100 openinqs per square inch. The paper may be single or two-ply. It is stated to have a relatively high bulk (low density) relative to wet pressed papers by virtue of being pre-dried in the absence of significant pressure until a web consistency of from 40% to 90% is achieved. The pattern of the imprinting fabric is impressed into the pre-dried web, and the web is then final dried and creped. Reference the Sanford-Sisson, Salvucci et al., and Shaw patents described hereinbefore.

Japanese Patent No. SH~ 54-46914 opened for publica-tion on April 13, 1979, discloses a Double Layer Laminate Tissue Product which apparently comprises a predominantly long fibered strength layer which is said to have a soft and smooth outer surface, and a low bond layer; and which is dry creped from a creping surface to which the long fiber layer was adhered. As disclosed and claimed, the paper apparently ~146396 has small creping induced inter-layer voids. When two such sheets of paper are combined to form two-ply products, they are combined so that long fiber layers face outwardly on bo~h sides of the product.

U.S. Patent No. 4,166,001 which issued August 28, 1979 to Dunning et al. is titled Multiple Layer Formation Process For Creped Paper for making a soft and bulky creped tissue which apparently also derives its softness from the compressi-bility due to its bulkiness inasmuch as its out~r layers are strongly bonded fibers which are separated by an intermediate central section of weakly bonded fibers. The softness related bulkiness is apparently induced, at least in part, by two creping operations.

. As compared to the'patents and literature'described and discussed above, the present invention provides a layered tissue paper, and products made therefrom whic~ have a soft surfa~e which is comprised primarily of short-fibered hardwood and is characterized by being both smooth and velutinous:
smoothness being obj'ectively and inversely rel'ated to texture;
and velutinous being objectively related to the relative density of reIativel'y flaccid ibers having unbonded free end portions which constitute the'soft surface. Indeed, the paper embodiments of the present invention have a quasi-flocked appearance and tactility.

D'i's'clo's'ure'O'f The 'In've'nt'i'on In accordance with one aspect of the present invention there is provided an improved tissue paper, and tissue paper products made therefrom, which paper has a smooth velutinous top surface. Such paper has a high degree of subjectively perceivable sotness by virtue of being: multi-layered;
having a top surface layer comprising at least about 60% and preferably about 8570 or more short papermaking fibers;
having an HTR-Texture of the top surface layer of about 1.0 or less, and more preferably about 0.7 or less, and most .. . . . .. . . . .

.' preferably about 0.1 or less; having an FFE-Index of the top j surface of about 60 or more, and preferably about 90 or more. The process for making such paper must include the step of breaking sufficient interfiber bonds ~ 5 between the short papermaking fibers defining i~s top surface i to provide sufficient free end portions thereof to achieve the required FFE-Index of the top surface of the paper.
Such bond breaking is preferably achieved by dry creping the paper from a creping surface to whic'n the top surface layer 10 (short fiber layer) has been adhesively secured, and the creping should be effected at a fiber consistency (dryness) of at l'east about 80% and preferably at least about 95%

3 consistency. Such paper may be made through the use of conventional felts, or foraminous carrier fabrics in vogue 15 today. Such paper may be but is not necessarily of relatively high bulk density.
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. 'Brie'f Descri~t'ion'O'f The'Drawin'gs - While the specification concludes with claims particu- -larly pointing out and distinctly claiming the subject 20 matter regarded as forming the present invention, it is believed the invention will be better understood from the following description taken in conjunction with the accompany-ing drawings in which:

Figure 1 is a quasi sectional view of a line drawing 1 25 schematic representation of a two-layer paper sheet embodi-I ment of the present invention, which sheet has a soft and smooth velutinous top surface.
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. Figure 2 is side elevational, somewhat schematic view of a preferred papermaking machine for manufacturing paper according to and embodying the present invention.

Figure 3 is a graph showing the direct relationship , between softness and percent short fibers in the top surface layer of each of several samples of paper embodying the present in~ention.

g Figures 4 and 5 are graphs of normalized softness v.
HTR-Texture data and normalized softness v. FFE-Index data, respectively, derived from testing samples of paper embody-~ ing the present invention as well as samples of several 7 5 contemporary tissue paper products.

Figures 6 and 7 are graphs of data showing HTR-Texture v. Percent Fiber Consistency When Creped, and FFE-Index v.
Percent Fiber Consistency When Creped, respectively, of paper made by varying doctor blade moisture while making 10 paper by the process of the present invention using a foraminous carrier fabric, and by avoiding substantial compressive force on the'paper prior to transferring the ' paper to a Yankee'dryer/creping drum.

Figures 8 and 9'are graphs of data showing HTR-Texture v. Percent Fiber Consistency When Creped, and FFE-Index v.
Percent Fiber Consistelicy When Creped, respectively, of paper made by the'process of the present invention using a felt carrier fabr;c.' Figure lOa is a graph'of Softness v. Bulk Density data derived from samples of several contemporary tissue paper products.

Figure'lOb is a graph of Softness v. Bulk Density data derived from five examples of paper embodying the present i'nvention.

Figure'll is an enlarged edge-on electron microscope photographic view of a fragmentary creped and calendered twb-layer sheet of paper which'paper sheet is an exemplary embodiment of the present invention.

F'igure t2 is an enlarged edge-on electron microscope photographic view of a non-creped and non-calendered two-layer sheet of paper of the same genesis as the sheet of paper shown in Figure ll~

_ _ . . . _ . ., . . . ... . , .. _ . . . ... . .

3~6 Figures 13 and 14 are electron microscope photographic views of the paper sheets shown in Figures 11 and 12, respec-tively, except Figures 13 and 14 are views of the top surfaces of the samples as viewed from eleva~ed frontal positions at a relatively shallow downward viewing angle of 15 below horizontal.
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Figures 15 and 16 are electron microscope photographic views of the paper sheets shown in Figures 11 and 12, respec-tively, except Figures 15 and 16 are views of the bottom surfaces of the samples as viewed from Iow frontal positions at a relatively slight upward viewing angle of 15 above horizontal.

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Figure 17 is an enlarged scale, fragmentary plan view of the top surface (forming surface) of a 4-shed satin weave forming wire having long surface knuckIes/crossovers which extend in the cross machine direction when the fabric is instailed in a papermaking machine such as shown in Figure 2.

Figure 18 is an enlarged scale, fragmentary plan view of the top surface (imprinting surface) of a 3-shed carrier fabric having two-over, one-under ilaments extending in the machine direction when the fabric is installed in a paper-making machine such as shown in Figure 2.

Figure 19 is, relative to Figure 2, an enlarged scale side elevational view of a fragmentary portion of the papermaking machine shown in Figure 2, which view shows the angular relation of the doctor blade to the Yankee drying cylinder.

Figure 20 is a somewhat schematic, side elevational view of an apparatus for combining 2 rolls of paper in back to back relation to form rolls of 2-ply paper for the purpose of ultimately converting the 2-ply paper into 2-ply paper products.

' 11~63g6 Figure 21 is a partially peeled apart, fragmentary sectional view of a somewhat schematic representation of a 2-ply tissue paper product embodiment of the present invention.

Figure 22 is a somewhat schema~ic block diagram of an instrumentation system for quantitatively determining the average HTR-Texture of paper as described and defined hereinafter.

Figures 23a and 23b ~re X-Y plotted graphs of the spectral distribution of the surface irregularities of the top surfaces of samples of the paper shown in Figures 11, 13, and 15 as determined by an instrumentation system such as that shown in Figure 22.

Figure;24 is a plan view of a fragmentary sheet' of paper embodying the present inventionj and on which represen-tations of two orthogonally rel'ated texture'sample~ are' identified.
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Figure'25 is a fragmentary sectional view of a sampleslide as used to determine texture of paper samples when tested by an apparatus such as shown in F,igure 22.

Figure 26 is a plan view 'of a texture sample slide of the type shown in Figure 25, and on which sample the path traced by a texture tracing stylus is identified.

', Figures 27a through 27d are texture graphs of four different samples taken from one lot of converted paper (Example 3 described hereinafter) embodying the present invention, and which graphs show the relative magnitude of sample-to-sample variance in the top surface (Yankee side) texture of such paper.

Figures 28a and 28b are texture plots of the back surfaces of two representative samples of the same paper from which Yankee-side samples were taken for Figures 27a ¦ through 27d.
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--3~6 Figures 29a and 29b are texture plots of ~he top sur~aces (Ynkee side) of two representatlve samples of calendered and reeled (but no~ combined or converted) paper of the type which was sllbsequen~ly converted to make the paper from which samples were taken for Figures 27a through 27dl and 28a and 28b.

Figures 30a and 30b are texture plo,s of samples of a contemporary, textured and bulked paper of ~he type disclosed and claimed in the Morgan et al. patent ~No. 3,994,771 described hereinbefore.

Figure 31 is a plan v;ew of a ragmentary sheet of paper showing the layout orientation of.a fiber-count (FFE-Index) s~mple wi~h respect to the machine direction of the paper.

Figure 32 is a fragmentary, side elevational view of an . ~ apparatus for brushing paper samples having a velutinous surface to cause the free fiber ends to be oriented more erectly to facilitate ascertaining the relative density of such free f.iber ends, which relative density is hereinafter designated and described as the FFE-Index.

Figure 33 is an enlarged scale, fragmentar~ view of a vertically extending edge of an FFE-Index s~mple sllde.

Figure 34 is a photographic view of a portion of t.he ~op edge of an FFE-Index sample as viewed in the direction of the arrow on Figure 33.

. Figures 35 and 36 are photographic views of relatively sparse and dense free-fi~er-end zones, respectively, of the FFE-Index sample of Figure 34, and which zones are enl.arged about 2.8x with respect to Figure 34.

_ 13 -Figure 37 is a quasi sectional view of a line drawing schematic repxesentation of a 3-layer paper sheet embodiment ~ of the present invention, which sheet has two smooth velutinous i surfaces.
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Figure 38 is a quasi sectional view of a line drawing schematic representation of a 3-layer paper sheet embodiment of the present invention, which sheet has a smooth velutinous top surface and a relatively highly textured bottom surface.

Figure'39 is a quasi sectional view of a line drawing schematic representation of a two-ply tissue paper product wherein each ply is a sheet of paper like that shown in Figure 38, and wherein both outside surfaces of the product are smooth and veIutinous.

Figures 40 and 41 are'fragmentary plan views of the top surfaces of alternate embodiment 4-shed and 5-shed satin weave carrier fabrics, respectively, in which'the 3-over and . 4-over filaments, respectivel'y, extend in the machine direction of the papermaking machine.' , Figures 42 through 47 are somewhat schematic side elevational views of alternate embodiment papermaking machines~.

Figures 48 through 52 are graphs of HTR-Texture v. FFE-i Index data taken from samples of Examples 1 through 5, respectively, which Examples' are described hereinafter.

'Det'ai'led Descrip't'ioh'~'f'The''In'ven'tion A line drawing sectional view of an exemplary paper ' sheet 70 embodying the present invention is shown in Figure 1 to comprise a top layer 71 having a velutinous top surface 72 defined by free fiber ends 73 of relatively short paper-making fibers 74, and a second layer 75 of fibrous papermaking material such as relatively long papermaking fibers 76. The top surfare 72 is also referred to as the Yankee-side of paper 70, and the opposite side is also referred to as the . . 1146396 off-Yankee-side because of their respective orientations ¦ with the Yankee dryer surface when made as described below.
Paper 70, preferably' has a total basis weight of from about 6 to about 40 pounds per 3,000 square feet (about 10 to about 65 grams per square meter), and layer 71 preferably has a basis weight of from about 3 ta about 35 pounds per 3,000 square feet (about 5 to about 57 grams per square . meter), which basis weights are with respect to paper 70 in an uncreped state. More preferably, the total basis weight , 10 of paper 70 is from about 7 to about 25 pounds per 3,000 ; . square feet (about 11 to about 41 gra7ns per square meter) ' and the basis weight of layer 71 is from about 3 to about 20 .. pounds per 3,000 square feet (about 5 to about 33 grams per . square meter) as measured in an uncreped state.' Figure 2 is side elevational view of a papermaking . machine:80 for manufacturing paper:according to the method . of the present invention, and which will be'de-scribed more .~ fully after the ollowing brief descriptions of the invention, . . and the graphs show7n on Figures 3'through lQa and.lOb.
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Brief'ly, the present invention provides a multi-layer tissue'paper sheet which is preferably wet laid and wherein the top layer is constituted and configured to precipitate a ' human-tactile-response'of velvety smoothness and softness . for users of such paper or paper.products'made therefrom:
for instance, f~cial tissue and.toilet tissue:products.
This is provided by constituting the top layer of a relatively low bond furnish comprising at least about 60% of relatively short papermaking fibers having average lengths of from about 0.25 7mn to about 1.5 mm. More preferably, the top ' 30 layer will comprise about 85% or more of such relatively short papermaking' fibers. This layer will have relatively low strength so it is united with at least another layer which is so constituted and configured to provide the ultimate paper sheet and paper products with sufficient wet : 35 and dry strength for their intended purposes. As will also be described more fully hereinafter, paper sheet embodiments ~ of the present invention can comprise.three layers wherein _ . .. ___.. _ . . . . .. .. .. .... .... . . .. .. .: . . . . .
- -114~396 both outside surfaces are velutinous, or wherein one outside layer is relatively highly textured and bulked. When two plies of the latter three-layer paper sheet are united with their velutinous surfaces facing outwardly, the product is both highly bulked, and v'elvety soft and smooth on both outside surfaces.

The method of making such paper embodiments of ~he present invention preferably comprises wet laying suitably constituted furnishes as described above so that the sheet has a relatively low degree of human-tactile-response texture;
that is, texture which is virtually imperceptible to a human through the'sense of touch. Preferably the level of texture will be'no greater than an HTR-Texture of 1.0 as hereinafter define'd; and more preferably an HTR-Texture of no greater 1~ than 0.'7; and most preferably an HTR-Texture'of about 0.1 or even less. Then, when the paper is sufficiently dried to virtually preclude subsequent autogeneous inter-fib'er bonding, a sufficient number of inter-fiber bonds are broken between the'fibers which define the'top surface of the top layer of the'sheet t~ provide a free-fiber-end index (FF~-Index as hereinafter defined) of at least about 60, and more preferably 90 or more. Such bond breaking could of course be'accomplished manually with a micro-pick but can effectively be accomplished by brushing or blading the top surface, or by dry creping the sheet. When the sheet is creped to achieve the desired FFE-Index, it is most effectively done after adhering the top surface (short fiber) of the sheet to a creping surface, and effecting creping after the sheet is dried to a fiber consistency of about 80% or more; and more preferably dried prior to creping to a fiber consistency of about 95% or more. Creping, however, induces increased texture which may then need to be reduced to achieve the required low level of ~TR-Texture. This is most effectively accomplished by calendering the sheet and drawing out the crepe sufficiently to achieve the required level of HTR-Texture. Such calender-ing and crepe drawing may be'accomplished at the dry end of - 16 - .
. . . ..
1 the papermaking machine as illustrated in Figure 2, or as an ¦ adjunct ~o subsequent combining and/or converting operations, I or a combination thereof as more fully described hereinafter.

I Before describing the methods of determining HTR-1 5 Texture and FFE-Index, and describing specific examples of the present invention, Figures' 3 through lOa and lOb (which will also be more fully discussed hereinafter) are referred to briefly to provide a graphical basis for comprehending the following descriptions of the various facets of the present invention. The data plotted in these graphs is also tabulated: reference Table Ia for Figure 3; Table'II for Figures 4 and 5; Table'IIIa for Figures 6 and 7; Table IIIb , for Figures 8 and 9; and Table'IVa for Figure lOa; and Table IVb'for Figure'lOb.

Figure'3 illustrates the'direct rel'ation betw~en the degree of subjective~softness o 2-layer paper made according " to the'process of the present invention as a function of the :~ ~
percent of relatively short papermaking fibers in the top layer of the paper having average lengths of from about 0.25 mm to about 1.5 mm while the'remainder of the top layer was comprised essentially of rel'atively long papermaking fibers:
,, i.e.', cellulosic fibers having average lengths of about 2.0 mm or greater. The'second layers of all of the numbered ' Examples described hereinafter were comprised primarily of such relative b long p-~ermaking f~bers.

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: 1146396 ., . . 'TABLE'la Sotness, Texture and Velutinous Effects of ~ Varying % Short ~iber in Top Layer, ¦Two Layer Paper Having Lon~-Fiber Bottorn ~ayer Layer Puri.ty % Short 'FFE-Index Sample Fibers, Softness, Brushed HTR-D'es'ignator Top Layer '''PSU''' ~es ''No 'T'ex'ture LP-95 95 2.1 124 91 ' 0.07 LP-86 86 1.9 90 50 0.20 . LP-68 68 1.5 72 19 0.04 LP-52 52 1.4 65 34 0.18 LP-17 17 0.9 . 43 Figure 3 ' l . ..........
~ ABLE Ib -~Additional Data, Paper Samples M~de By .~Varying % Short ~ib~r in Top Layer, 'Two Lay'~r'Pap'er'Haiving Lon'g-Fibe'r' B'o't'~om La7'er , Layer . Tensile Purity Bulk Strength,' ~
~ ! .Sample Basis Wt. Caliper, . Density, gms/inch Stretch, : ~ Des"i$~ator'1b'sl'3000f 2' m'il's'/4'pl'i'es' .cm3/gm ' MD' ~D. 'P'e'rcent.
' LP-95 18.6 17.6 7.4 314 193 16 LP-86 :20.3 21.9 8.4. 276 243 23 i LP-68 20.4 22.4 8.5 261 231 14 .1 LP-52 20.0 22.0 8.5 ' 408 273 26 LP-17 19.8 20.6 8.1 338 222 21 .

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~ ~146396 . - 18 -. ..
TABLE II
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Comparative Data, Exemplary Tissue Paper Product Embodiment of Present Invention and . Plurality of Contemporary T~ssue Paper Products . . Softness, PSU, Softness, Normalized PSU, to HTR-Softness, Normalized Texture=
Produc~ PSU, HTR- to FFE-124 FFE-0.07,2-Ply - Desi~nator Plies Raw Data Texture 2-Ply Basis Index Basis ' Present ; Invention:
Example 1 2 2.1 0.07 2.1 124 2.1 Contemporary 3 Products:
CP-l-l 1 1.2 3.01 1.0 180 2.4 CP-1-2 : 1 0.5 1.99 1.6 80 1.4 -'I .
1~ CP-1-3 ~ ~0.42.16 1.5 82 - 1.4 .' 1~ CP-1-4 1 -1.21.11 1.3 37 - -0.6 ~:: CP-1-5 1 -1.40.16 Z.2 16 -1.1 . ~ ' '; .
: ~ CP-2-1 . 2 1.81.18 1.7 130 2.2 : CP-2-2 . 2 1.2 1.13 1.8 90 1.6 CP-2-3 2 0.~ 1.07 1.5 77 0.8 CP-2-4 2 -0.2 0.22 1.8 42 -0.2 CP-2-5 2 0.0 0.04 2.5 29 0.0 ~ '!'. i . CP-2-6 2 -0.3 0.71 2.0 34 -0.1 .~ CP-2-7 2 -0.5 0.24 2.1 27 -0.4 CP-2-8 2 -0.6 0.02 1.8 31 -0.6 Fig~re 4 ~ ~Figore 5 .

-( ~ 1~6396.

' 'T~BLE'II'Ia HTR-Texture & FFE-Index v. ' Percent Fiber Consistency When Creped, , Papexmaking Process Using Foxaminous Fabric ; 'Carr'i'er'And'Blow Through'Pre-Yankee Pre-Drying Fiber Consistency '. I~hen HTR- FFE-Cr'epe'd,'% 'T'e'x't'ure 'In'd'ex ,

4.~ 96 79 0.4 146 88 0.5 160 1.3 142 _ 156 99 1.4 189 igure'6 - ~ t . . Figure'7 .
:. ...............
'~ABLE'II'Ib ' ..
. ~ ' HTR-Texture & FFE-Index v.
.Percent Fiber Consis~ency . ' When Creped, Papermaking Process 'U's'i'n'g'P'r'e'ss'ur'e''On'Fel't'Pr'e'-Yank'ee'-Drye'r D'ew'a't'er'ihg Fiber ; , Consistency l~hen HTR- -FFE-rep'e'd','% 'T'e'x't'u're ' In'~ex , ' i3 4.3 88 77 2.8 111 81 2.5 1~4 '88 2.2 118 1.5 139 98 2.1 165 . ~ Figure 8-Figure 9 . _ . . _ _ _ _ . . , _ . . .

:

11~6396 - TaBLE IVa Trend, Softness v. Bulk Density Contemporary Tissue Paper Products, Reference Figure lOa Contemporary Tissue Bulk Produc~ Product No. of Softness*, Density, ' Designator ''Type 'Pli'es PSU '' ''cm3/gm CP-l-lToilet 1 1.2 .11.1 CP-1-2Toilet 1 0.5 10.9 CP-1-3Toilet 1 0.4 9.6 CP-1-4Toilet 1 -1.2 7.0 CP-1-5Toilet 1 -1.4 5.6 . , CP-2-1' Toilet 2 1.8 11.2 CP-2-2Toilet 2 1.2 10.4 CP-2-3Toilet 2 0.5 9.6 CP-2-4Toilet 2. -0.2 7.2 CP-2-5Facial 2 0.0 5.3 ' ,.
CP-2-6Toilet 2 -0.3 8.1 CP-2-7Toilet 2 -0.5 7.5 CP-2-8 'Facial 2 -0.6 6.3 .' 'T~BLE IVb - Spread, Softness v. Bulk Density,

5 Examples of Present Invention Tissue Paper Products Reference Figure lOb Tissue Bulk Example Product No. of S~ftness*, Density, 'D'es'igna'tor ''Tvp'e' 'Plies PSU ' ''cm3'/gm . Example 1 Facial 2 2.1 7.4 Example 2 Toilet 2 1.5 10.0 Example 3 Facial 2 1.9 8.7 Example 4 Facial 1 1.1 5.5 Example 5 . Facial 2 1.2 8.3 *Because of the subjective nature of softness determinations, the softness units on these two tables may not be equal.

11~6396 Figures 4 and 5 illustrate the inverse relation between softness and HTR-Texture, and the direct relation between softness and FFE-Index, respectively, of a number of tissue paper products which number includes an exemplary two-layer embodiment of the present invention having a relatively low HTR-Texture and a relatively high FFE-Index. These softness data were normali~ed to a common FFE-Index of 124 in Figure 4, and to a common HTR-Texture of 0.07 in Figure 5, according to a least squares regression equation derived from a statistical analysis of the raw data presented in Table II. Also, wh'ereas the above described inverse relation between softness and HTR-Texture, and the direct relation between softness and FFE-Index are believed to be'universal, the curves shown in Figures 4 and S were determined for a specific set of samples-and such'curves could be somewhat different for other sets of samples: that is, their slopes, intercept, and degrees of curvature'could be'somewhat different but none ~ the less evidence'the'universe and direct relations recited'~ above.
.:~ ~
3s ~
- - 20 Figures 6 and 7 illustrate the'improved (lower~ level --of HTR-Texture and increased FFE-lndex, respectively, which results from creping paper made'according to the present invention through the use of a foraminous carrier fabric as a function of increasing fiber consistency when creped.
- 25 Figures 8 and 9 illustrate'the improved (lower) leveI of j HTR-Texture and increased FFE-Index, respective}y which ii results from creping paper made'according to the present invention through the use of a felt carrier fabric as a function of increasing fiber consistency when creped. The paper samples from which the data were'obtained for Figures 6 through 9 were creped but not calendered, cambined, or converted.

Figures lOa'and lOb, considered together, illustrate to some extent the relative independence of paper embodiments of the present invention from the interdependent relation between bulk density and softness which has heretofore been considered virtually axiomatic with respect to tissue paper products. These data are plotted on two graphs hecause of a lack of identity of the softness data units which were .
~_ . _ . ..... . .... . .

114~6396 . precipitated by the data grouping. That is, the data for Figure lOa was obtained from a different set of samples than the data for Figure lOb so the scale factors could be but are not necessarily different because of the subjective i 5 aspect of such testing.

.; Parenthetically, with respect to subjective softness testing to obtain the softness data.reported herein in PSU
(Panel-Score-Units), a number of practiced softness judges are'asked to rate the relative softness of a plurality of paired samples. The data are analyzed by a statistical method known as a paired comparison analysis. I~ this method, pairs of samples are'first itentified as such.
! Then, the pairs of samples are judged one pair at a time by each'judge: one sample'of each pair being designated X and the other Y. Briefly, each X ~ample is graded against its paired.Y sample as follows:

' ' ' 1. a grade of zero is given if X and Y are j~d'ged to be'equally soft;
; - - - - - --~ - . ................... .... . .
. 2. a grade of plus one is given if X is judged to i 20 maybe a little softer than Y, ant a grade of minus one is given if Y is judged to maybe be a little ~ofter than X;

3. a grade of plus two is given if X is judged to i . surely be a little'softer than Y, and a grade of ~, 25 ' minu~ two is given if Y is judged to surely be a j little softer than X;
: .
4. a grade of plus three is given to X if it is judged to be a lot softer than Y, and a grade of minus three is given if Y is judged to be a lot ~ofter than X; and, lastly, 5. a grade of plus four i~ given to X if it is judged to be a whole lot softer.than Y, and a grade of minus 4 is given if Y i~ judged to be a whole lot softer than X.
1- . .

- - - - - - . ' l 114~396 The resulting data from all ~udges and all sample pairs are then pair-averaged and rank ordered according to their grades. Then~ the rank is shifted up or down in value as ,, required to give a zero P'SU value to whichever sample is chosen to be the'~ero-base standard. The other samples then have plus or minus values as determined by their relative grades with respect to the zero base standard. The grade values of the samples reported herein have been proportionally changed to scale the grades in PSU units so that about 0.2 PSU represents a significant difference in subj'ectively perceived softness.

Referring again to ~igure 2, papermaking machine 80 comprises a duplex headbox 8L having a top chamber 82 and a bottom chamber 83, an over and under duplex slice 84, and a Fourdrinier wire 85 which'is looped over and about breast roll 86, deflector 90, vacuum suction boxes 9I,'couch roll 92, and a plurality of turning rolls 94. In operation, one ' papermaking furnish is pumped through'top chamber ~2 while a second furnish is pumped through bottom chamber'83 and ' 20 thence out of'the duplex slice 84 in over and under relation ; onto Fourdrinier wire 85 to form thereon an embryonic web 88 comprising layers 88a ant'88b. Dewatering occurs through the Fourdrinier wire'85 and is assisted by deflector 90 and vacuum boxes 91. As the Fourdrinier wire makes its return run in the direction shown by the arrow, showers 95 clean it - prior to its commencing another pass over breast roll 86.
At web transfer zone'93, the embryonic web 88 is transferred to a foraminous carrier fabric 96 by the action of vacuum transfer box 97. Carrier fabric 96 carries the web from the transfer zone 93 past vacuum dewatering box 98, through blow-through predryers lO0 and past two turning rolls lOl after which the web i9 transferred to a Yankee'dryer 108 by the'action of pressure roll 102. The carrier fabric 96 is ; then cleaned and dewatered as it com~letes its loop by passing over and around additional turning rolls lOl, showers 103, and ~acuum dewatering box 105. The predried paper web is adhesively secured to the cylindrical surface of Yankee dryer 108 by adhesive applied by spray applicator 109.

, .

. 1~46396 Drying is completed on the steam heated Yankee dryer 108 and by hot air which ~s heated and circulated through drying hood L10 by means not shown. The web is then dry creped from the Yankee dryer 108 by doctor blade 111 after which it ¦ 5 is designated paper sheet 70 comprising a Yankee-side layer 71 and an off-Yankee-site layer 75. Paper sheet 70 then ¦ passes between calender rolls 112 and 113, about a circumfer~
ential portion of reel 115, and thence is wound into a roll 116 on a core 117 disposed on shaft 118.

lQ Still referring to Figure 2, the genesis of Yankee-side layer 71 of paper sheet 70 is the furnish pumped through bottom chamber 83 of headbox 81, and which furnish is applied directly to the Fourdrinier wire 85 whereupon it becomes layer 88b of embryonic web 88. Similarly, the genesis of the off-Yankee-side layer 75 of paper sheet 70 is the furnish delivered through top chamber 82 of headbox 81, and which furnish fo D layer 88a on top of layer 88b of embryonic web 88.

Papermaking machine 80 is preferably used to make paper , 20 embodying the present invention by supplying a short-fiber ; furnish through bottom chamber 83 which comprises at least 607o and is preferably comprised essentially of relatively short papermaking fibers having aYerage }engths of from about 0.25 mm to about 1.5 mm; reference Figure 3. These would commonly be hardwood fibers which are identified more ¦ specifically in Examples 1 through 5 which are described hereinafter. Concurrently, a long-fiber furnish is preferably delivered through top chamber 82. Such a long-fiber furnish would commonly comprise softwood fibers having average lengths of about 2.0 mm or more. Thus, the resulting paper sheet 70 comprises a low strength, short fiber layer, and a high strength, long fiber layer. The long fiber layer 75 provides the strength required for sheet 70 to be suitable for its intended purposes ~i.e.: toilet tissue, or facial tissue, or the like) while, when creped and calendered, the outwardly facing surface 72 of the short fiber layer 71 is soft, smooth, and velut~nous; reference Figure 1.

~6396 Furth~r, with respect to making paper sheet 70 embodying the present invention on papermaking machine 80, Figure 2, the Fourdrinier wire 85 must be of a fine mesh having relatively small spans with respect to the average lengths of the fibers constituting the short fiber furnish so that good formation will occur; and the foraminous carrier fabric 96 should have a fine mesh having relatively small opening i spans with respect to the average lengths of the fibers ~ constituting the long fiber furnish to substantially obviate - 10 bulking the fabric side of the embryonic web into the interfilamentary spaces of the fabric 96. Preferably, such carrier fabrics will have mesh counts of greater-than 60 per inch in the cross-machine-direction to precipitate a high ;1 crepe frequency which, in turn, provides a reIatively low degree of texture in the'creped paper. Also, wi'th respect ! to the process conditions for making exemplary paper sheet 70, the paper ~eb should be dried to about 80~ fiber consistency, I and more preferably to about 95% fiber consistency prior to creping: reference Figures 6 and 7 with.respect to~the impact of doctor blade fiber consistency on HTR-Texture and FFE-Index, respectively.

- Figure 11 is an enlarged, edge-on electron microscope ~I photographic view of a creped and calendered exemplary j embodiment of paper sheet 70, Figure 1, which clearly shows ' 25 the'sheet to be loosely structured, and to have upstanding ¦ free (unbonded) fiber ends 73'which corporately define the 3 top surface 72 of paper sheet 70 Figure 12 is an enlarged, edge-on electron mlcroscope photographic view of a non-creped and non-calendered 2-layer sheet of paper 70a of the same genesis as paper sheet ' 70, Figure 12. This illustrates ~hat the sheet 70a, prior to creping and calendering, has a relatively tightly bound structure and few fiber ends upstanding from its top surface.
Thus, the creping and calendering co convert paper sheet .

70a, Figure 12, to paper sheet 70, Figure 11, greatly loosens the structure and precipitates a high count of upstanding unbonded free fiber ends.
., Figures 13 ant 14 which are top oblique photographic views of sheets 70 and 70a, respectively, and Figures 15 and 16 which are bottom oblique photographic views of sheets 70 and 70a, respectively, further clearly illustrate the loose- -' ness (low density, large voids) of the structure of the creped and calendered sheet 70 relative'to the tightly structured, uncreped and uncalendcred sheet 70a.

Figure 17 is a fragmentary plan view of an exemplary ' Fourdrinier wire 85 which, when installed on a papermaking machine such as 80, Figure 2, is suitable for making paper ~, embodying the present invention. Such a Fourdrinier wire 85 preferably has a 110 X 95 or greater mesh (110 machinedirection monofilaments per inch, and 95 cross machine direction monofilaments per inch) and is woven in the'4-shed .~t weave illustrated in Figure'17 so that the long (3-over~ forming-surface crossovers extend in the cross machine direction.

' ~igure 18 is a fragmentary plan view of the outwardly ' facing surface of an exemplary foraminous carrier fabric such as identified by designator 96, Figure 2. For practicing the'present invention, foraminous carrier fabric g6 preferabLy is a semi-twill weave having a 73 X 60 mesh of monofilaments in which the long (2-over) outwardly facing crossovers extend in the machine direction.

Figure 19 is a side elevational view of Yankee dryer 108, Figure 2, having an enlarged-scale doctor blade 111 shown therewith for the purpose of clearly identifying the angular relations and features thereof, to wit: angle B is , designated the bevel angle of the doctor blade 111; angle C
! iS designated the back clearance angle; angle D is designatedthe creping impact angle; and angle A is the supplement to the'creping impact angle D.
I . .

li46396 .

Figure 20 is a side elevat-ional view of a combining ! apparatus 120 for combining two rolls 116 of paper 70, Fip,ure 2, into 2-ply rolls 135 of 2-ply paper 134 which paper is amenable to subsequent converting into 2-ply tissue paper products such as facial tissue and toilet tissue.
Combining apparatus 120 comprises means not shown for synchronously unwinding 2 rolls 116 at predetermined speeds and tension, calender rolls 121 and 122, means not shown for controlling the calendering pressure between calender rolls 121 and 122, turning rolls 123, plybonding wheel 124, reel 127, and means not shown for controlling the speed, and dra~
of the 2-ply paper 134 being forwarded and wound into rolls 135 on cores 136 which are disposed on shaft 13i.

Figure 21 is a fragmentary sectional view of 2-ply paper 134 comprising 2 sheets of paper 70, Figure 1, which have'their long fiber layers 75 juxtaposed and ~hich both have'their ~eIutinous top surfaces 72 facing outwardly.
'....................... .
' HTR'-T'ex't'ure' Figure 22 is an instrumentation system 140 for quanti-tativeIy evaluating the'texture of paper samples in terms of - the population ant amplitude of surface irregularities which - are'corporately referred to as texture. More particularly, the'instrumentation system 140 is operated to provide a -' histogram-graph of the frequency spectrum and amplitude~ of ~'uch'texture irregularities in the most significant range of human tactile'response: namely, in the'frequency range of from 10 to 50 irregularities per lineal inch. The ultimate data is the integrated area of the X-Y plotted graph which lies between 10 and 50 cycles per inch, and above a base amplitude value of 0.1 mil. Because the units of the integrated area are mil-cycles per inch which are cumbersome units, the texture data is simply referred to as HTR-Texture: one unit of HTR-Texture being an integrated area of 1 mil-cycle per inch.- Parenthetically, HTR is an pseudo acronym for human tactile response.

As sh~wn in Figure 22, the texture quantifying instru-mentation system 140 comprises a probe assem~ly 141 having . ~146396 a stylus 142 having a twenty-thousandths-of-one-inch diameter hemispherical tip 143; means 144 for counterbalancing the ¦ stylus to provide a pressure of about 12.4 grams per square centimeter which is in the range of the pressure applied by ! 5 a human who grasps a tissue or cloth between a thumb and forefinger to subjectively evaluate its softness; a sample drive table 145 which comprises means for moving a tissue paper sa~ple 146 back and forth at a predetermined rate in the direction perpendicular to the sheet of paper upon which Figure 22 is drawn; a stylus drive unit 150 for moving the probe assembly 141 left and right at a predetermined rate; a ' surface analyzer control unit 155, a frequency spectrum -~ analyzer 160, an x-y plotter 165, and an optional oscilloscope 166. An x-y graph'of the type generated by the system 140 is designated 167. It is this type of graph'on which the x-axis is: calibrated in cycles per lineal inch of stylus ¦ travel, and the y-axis is calibrated in mils, peak-to-peak vertical displacement of the stylus tip 143 which graph is ~ubsequently measured, wi'thin predetermined boundaries, to integrate the area under the'curve 170 to determine the . average HTR-Texture of a paper sample 146.

The specific texture quantifying instrumentation system-140, Figure 22, which was used to test the texture samples - te~cribed herein comprises: the probe'assembly 141 and the 25: ~tylus trive unit 150 are combinet in a Surfanalyzer 150 Drive No. 21-1410-01 which was procured from Gould Surfanalyzer Equipment, Federal Products, Provitence,' Rhode Island; the stylus. 142 was also obtained fr~m Federal Products as their part number 22-0132-00 for the stylus per se and part number 22-0129-00 which is an extension arm for the stylus per se;
the sample drive table 145 is a ~eiss microscope frame and stage having a DC motor connected directly to the horizontal control shaft, and a rheostat for controlling the drive speed; the surface analyzer control unit 155 is a Surfanalyzer controller number 21-1330-20428 which was also procured from Federal Products; the frequency spectrum analyzer 160 is a Federal Scientific Ubiquitous~Spectrum Analyzer Model UA-500-1 from Federal Scientific Corporation, New York, New York;

, . . 1146396 - 29~-the oscilloscope 166 is a Tektronix Model T921; and the x-y recorder 165 is a Hewlett-Packard number 7044A. When operated, the stylus drive unit drives the stylus laterally at a rate of O.l inches per second ~2.54 mm/second) while 5 the sample 146 is moved orthogonally with respect to the lateral motion of the stylus at a rate of about 0.0025 ~nches per second (about 0.0635 mm/second) for a test period of 8 sweeps-of the frequency analyzer which takes about 200 seconds. Thus, the texture data is derived from a relatively lO Iong zig-zag path across the sample which path has a total length of about 20 inches (about 51 cm).
j Figures 23a and 23b are x-y plot~ of plu9 45 degree and minus 45 degree velutinous-surface (Yankee-surface) samples, res~ectively, of a 2-ply facial tissue product l34 comprising 15 two paper sheets 70, Figure'l, embodying the present invention ~-~ which paper s'amples were taken from Example'l described hereinafter, and which plots were obtained through the use of'instrumentation system 140, Figure'22. The sam~le'graphed - in Figure 23a wa~ determined to have an HTR-Texture'(mils-J 20 cycleR per lineal inch) of 0.0'4; the area under the curve 170 which lieR between the da~hed vertical lines at 10 and ¦ 50' cycles per lineal inch, and above a Rtandard thre~hold I base amplitude value'of 0.1 mils whi'ch is indicated by the '¦ da~hed horizontal line. Similarly, the HTR-Texture'of the 25 8ample graphed in Figure 23b was determined to have an HTR-j Texture of 0.09. As is apparent from Figures 23a and 23b, I the measured texture of different samples of the same paper exhibit some variance. Accordingly, average HTR-Textures are detenmined and reported to characterize the sample.
Thus, the average HTR-Texture for this paper would be 0.07 (rounded to 2 digits). Of course, more samples would normally be run to provide a statistically meaningful average having a reasonably smali mean deviation. Indeed, as reported ' hereinafter, additional samples of Example 1 paper were run to provide~an average HTR-Texture for-Example 1, outside surfaces of finished 2-ply facial tissue product, of 0.07 wieh a standard deviation of 0.02.

.. . __ _ ._ .~ . . .. _ .. _.. . ... .. . . . . . ..

:1146396 . . .

Figure 24 is a fragmentary plan view of a sample of paper sheet 70, Figure 1, on which a plus 45 degree texture sample is designated 146a and on which a minus 45 degree texture sample is designated 146b. As shown, the length dimension of sample 146a is oriented at plus 45 degrees with respect to the machine direction (MD) of the paper 70; and the length dimension of sample 146b is minus 45 degrees with respect to the MD of the paper. Thus, the ~amples 146a and 146b are designated plus and minus 45 degree samples, I0 reSpectively.
Figure 25 is a fragmentary sectional view of a texture sample slide 180 comprising a glass slide 181 to which a paper sample 146 is attached with a double adhesive tape 182. Such a sample'is prepared by scissoring the sample;
placing its top-surface down on a clean table; and lightly pressing an a & esive tape'covered slide 181 onto the back side'o the paper sample. Only light pressure should be e~erted to obviate error inducing changes in the paper sample'l4¢. ~' F~gure'26 is a plan view of a texture sample'slide 180, Figure 25, upon which i8 indicated the zig-zag path 183 of stylus tip 143'when the sample slide 180 is tested in instrumentation system 140, Figure 22. The zig-zag path 183 i5 precipitated by the simultaneous back or forth motion of the sample drive'table 145 in the direction indicated by arr~w 184, and the side-to-side motion imparted by the stylus drive unit 150, Figure 22, which is indicated by arrow 185. The arrows 186 and 187 indicate'the machine direction ~MD) on the plus and minus 45 degree'samples 146, respectively, as described above.

When one-ply tissue products are HTR-Texture tested, samples 146 and 9 lides 180 are prepared so that the textures of both sides are averaged. When two-ply tissue products are HTR-Texture tested, single-ply samples 146 and slides 180 are normally prepared so that the textures of the outside surfaces of both plies are averaged. However, as later ---- --.

discussed with respect to Examples 1 through 5, and Figures ' 48 through 52, both sides of each ply may be measured and j reporeed independently for such purposes as evidencing that the paper samples do indeed have two-sided characters: that . 5 is, for instance, a smooth velutinous. side, and a textured side as shown in Figure 38 which is described more fully : hereinafter.

Figures 27a through 27d are Yankee-side HTR-Texture plots of samples of Example 3 (described hereinafter) paper which had been converted into 2-ply facial tissue, and which plots further illustrate the variance among a plurality of samples of the same paper; namely Example 3 described hereinafter. More specifically, Figures 27a and 27c are plu8 45 degree samples having'HTR-Texture values of 0.02 and 0.3, respectiveIy; and Figures 27b 'and 27d are minus 45 degr.ee'samples having HTR-Texture values of 0.04 and 0.2, respectively.
:~ .
Figures 28a and.28b are HTR-Texture plots of plus and . minus 45 degree,' off-Yankee-side samples, respectively, Example.'3 paper (described hereinafter) which had also been converted into 2-ply facial tissues by combining, stretching, calendering, ply bonding, slitting, U-folding, and transverse cutting. The HTR-Texture'values for Figures 28a and 28b are 1.3 and 0.8, respectiveIy, which'evidence, as compared to HTR-Texture values recited above'for the Yankee-side samples shown in Figures 27a through 27d, that the Yankee-side samples are significantly less textured than the off-Yankee ~. side samples of the same paper.

i Figures 29a and 29b are HTR-Texture plots of plus and : 30 minus 45 degree Yankee-side samples, respectively, of Example 3 paper which had been calendered and reeled at the dry end of the papermachine but which had not been converted into finished 2-ply tissue produc.t. Thus, this paper hat not been subjected to the stretching and calendering of the combining apparatus, Figure 20, and other converting steps not illustrated. The HTR-Texture values for Figures 29a and i . _._ __. , ... _ . .. . .
-. 11463~6 29b are 0.37 and 0.41, respectively, which average somewhat more than the average of o.i4 for the converted samples graphed in Figures 27a through 27d as described above. This evidences the efficacy with respect to reducing texture which is effected by the post papermaking calendering and ¦ stretching of combining and converting the paper to produce ¦ 2-ply facial tissues.

Figures 30a and 30b are HTR-Texture plots of plus and minus 45 degree off-Yankee-side samples, respectively, of a textured, short-long-short fiber 3-layer prior art toilet tissue paper of the type disclosed in the Morgan et al.
' patent which was tescribed hereinbefore. These specific samples have HTR-Texture values of 2.8 and 3.3, respectively.
More'off-Yankee-side samples provided an overall average HTR-Texture of 3.'3; and a plurality of Yankee-side'samples of the same paper provided an HTR-Texture o 2.7. Thus, ~- because the HTR-Texture'for such'a 3-layer, l-ply tissue paper product is the average'of both sides, the average HTR-Texture for this prior art tissue'paper product was determined 20- to be'3Ø

' 'FFE'-In'd'ex Figures 3I, 32, and 33 illustrate the sequence of ' taking a sample 190 from a sheet of paper 70, Figure 31;
attaching the sample to the underside of a sled 191 and pulling the sled in the'direction indicated by arrow 196 to move the'sled across a brushing member 193 secured to a I backing plate 194 of brushing apparatus 200; and making an FFE-Index Sample 201 by U-folding the sample 190 across the top end cf a #1-1/2 glass slide cover 197, and then securing that sub-assembly between two glass microscope slides 198, 198. As indicated in Figure 33, when the FFE-Index Sample -- 201 is viewed in ~he direction indicated by arrow 199, the upstanding, unbonded free-fiber-ends 73 which corporately define'the velutinous top surface 72 of paper 70, Figure 1, can be counted. Such viewing is preferably done through an optical system havin~ an adjustable focus in order to clearly identify each fiber to be counted: otherwise, for instance .

J - _ _ ~ 6396 - 33 ~
as when photographic silhouettes of the types shown in Figures 34-36 are used, some apparent ambiguity may exist with respect to which fiber end portions belong to which j fiber base portions of fibers which cross such as fibers 73 1 5 33 and 73-34, Figure 36. The count is made over a one-half-! inch length ~1.27 cm) of the top edge of the U-folded sample;
j only fibers which have a visible loose (unbonded) free end having a free-end length of 0.1 mm or greater are counted.
Fibers which have no visible free end are not counted;
neither are fibers having free-ends shorter than 0.1 mm -counted. When the free-fiber-ends are counted according to these rules, the resulting number is the FFE-Index.

Figure~ 34 through 36 are fragmentary enlarged photo-, silhouettes of an FFE-Index Sample 201 having an FFE-Index ? 15 of 126. The fiber-ends 73 of this sample have numerical suffixes from 1 through 49 which appear in numerical sequence from left to right in Figures 35 (fiber-ends 73-1 through 73-23) and 36 (fiber-ends 73-24 through'73-49). Figures 35 snd 36 are enlarged portions of Figure 34 which have been s 20 enlarged to better illustrate the nature of the velutinous surface of the paper sample'and to clearly identify the counted f~bers. Also, a one millimeter scale is provided for convenience on Figures 35 and 36. Some of the'fibers of Figures 35 and 36 are also identified on the'smaller scale 25 Figure 34 to facilitate reader orientatio~. It is apparent s from these figures that the'velutinous top surface 72 of the ' sample comprises non-uniform areas w~th respect to fiber i free-end count and lengths. That is, the velutinous surface i of the illustrated sample is not uniform in the nature of a 30 cut pile rug. However, with respect to a human's tactile perceptiveness, such velutinous surfaces do in fact feel uniformly soft, smooth, and velvety. The lengths of the individually identified fibers on Figures 35 and 36 are tabulated for convenience on Tables Va and Vb, respectively.

Parenthetically, the brushing of paper samples 190 prior to assembling FFE-Index Samples 201, Figure 33, is done with a unit pressure of about 5 grams per square centi-- i meter which is a little less than about half of the average . _ .. __ . __ .. . . .. . . .. . . .

. .
- 33a -thumb-forefinger pressure applied by a human who is asked to feel a tissue or cloth to develop a subjective impression of its softness. This brushing sufficiently orients the free-fiber-ends in an upstanding disposition to facilitate counting j 5 them but care must be exerted to avoid breaking substantial numbers of interfiber bonds during the brushing inasmuch as that would precipitate spurious free-fiSer-ends.

.
.

.
, .. .. .. ..

3~

TABLE Va , _ . _ Free (Unbonded) Fiber Ends, Lengths Enlarged FFE-Index Sample Figure 35 Length, mm Unbonded Fiber Upstanding Designators, End Portion Of ~iber 73-1 ~.05 73-2 ~.0 73-3 0.1~
73 4 0~24 73~5 0.02 73~6 0.03 73 7 0.04 . 73-8 0.07 73-9 ~.OS
. 73-10 0.23 73-13 0.13 73~14 0.1 73-15 0.08 ~3-~6 0.03 73-17 0.03 73-18 0.09 73-19 ~.28 73-Z0 0.~8 73~21 0.02 73-22 0.~8 73-23 ~.02 . . ' l~g6396 ~ . - _ .
TABLE Vb Free (Unbonded) Fiber Ends, Lengths ~ Enlarged FEE-lndex Sample ¦ Figure 36 ¦ Length I Unbonded ~, Fiber Upstanding 'iDesignators, Ent Portion 3Figure 36 Of Fiber 73-24 0.13 73-25 0. 31 73-Z6 0.57 , 73-27 0.61 j 73-28 0.69 l 73-29 0.42 i 73-30 0.25 73-31 0; 06 ~ 73 32 0.09 :~ 73-33 0.37 73-34 0.50 73_35 0.20 73-36 0.15 , 73-37 0.45 73-38 0.07 73-39 0.06 73-40 0.38 73-41 0.43 73-42 0.13 73-43 0.24 73-44 0.45 73-45 0.42 73-46 0.25 73-47 0.30 73-48 0.81 73-49 0.08 __,.. _ __ _ .. . . ... . . . ...
. .

114~396 Alternate Paper Embodiments of Present Invention Alternate paper embodiments of the present invention are shown in Figures 37, 38, and 39 and are identified by designators 210, 220, and 230 respectively. The various elements of these alternate embodiment papers which have counterparts in paper sheet 70, Figure 1, are identically designated in order to simplify the descriptions. Alter-nate paper sheet 210, Figure 37, is a 3-layer integrated structure comprising a predominantly long fibered, rela-tively high strength middle layer 75 which is sandwichedbetween and unified with two relatively low strength, smooth and soft outer layers 71 of predominantly flaccid short fibers. The short fibers of layers 71 have free-end-portions 73 which corporately define a velutinous surface 72 on each of the two sides of the paper sheet 210.

Alternate paper sheet 220, Figure 38, is a 3-layer integrated structure wherein the top two layers as illus-trated are, effectively, paper sheet 70, and the bottom layer 221 is a textured layer which preferably is predominantly comprised of relatively short papermaking fibers such as the fibers used to make top layer 71.
However, whereas top layer 71 has a soft and smooth velutinous top surface as described and defined herein-before, bottom layer 221 has a textured outer surface 222; preferably texturized in the manner disclosed in the Morgan et al U.S. Patent 3,994,771.

Alternate paper embodiment 230, Fiqure 39, is in fact a 2-ply tissue paper product comprising two plies of alternate paper 220 as described above and which have been combined in texture-side 222 to texture-side 222 relation so that both outer surfaces of the product are soft, smooth, and velutinous.

., ~ .

' - 37 -Alterna't'e'For'amihous'Carrier Fabri'cs Figures 40 and 41 are fragmentary plan views of 4-shed and 5-shed satin weave carrier fabrics 96a and 96b, respec-ti~ely, which can be used in place of the foraminous carrier fabric 96 on papermaking machine 80, Figure 2, or the herein-after described alternate papermaking machines having a carrier fabric 96 for the purpose'of making paper embodying the present invention or by the process thereof. However, a8 compared to paper made through the use of the semi-twill carrier fabric 96 illustrated on Figure 18, the higher shed count satin weaves progressively precipi~ate highe~ degrees of texture'for identical mesh count~. Therefore, al~ other things being equal, to achieve a predetermined low level of texture, the'4-shed satin weave carrier fabric 96a, Figure 40, would have to have a higher mesh count than the semi-twill carrier fabric 96, Figure'1'8; and the 5-shed satin weave'carrier fabric ~6b, Figure 41, would have to have an even higher mesh count than the f~bric 96a. This texture ~, effect of shed count is beIieved to be'related to the effect i 20- t~e'different crossover patterns and spacing have'on creping frequenc~ and character, all other thlngs being equal.

' ~l'terh'a't'e''P'aper'mak'ih'~'Ma'ch'in'es A number of papermaking machines are shown in side elevational view~ in Figures 42 through 47. While this is ; 25 beIieved to be ~uite a comprehensive showing of alternate papermaking machines for practicing the present invention, it i8 not believed to be an exhaustive showing because of the myriad of papermaking machine configurations which are known ~o those skilled in the~art. To s~mplify the descriptions of the several alternate papermaking machines, the components ~hich have counterparts in papermaking machine 80, Figure 2, are identically designated; and t~e alternate I~achines are described with respect to differences there-between.

.

. . 1~4~3~6 Briefly, alternate papermaking machine 280, Figure 42, is essentially different from papermaking machine 80, Figure . 2, by virtue of having a felt loop 296 in place of foraminous carrier fabric 96; by having two pressure rolls 102 rather 5 than one; and by not having blow through dryers 100. Thus, ehe relatively high degree of pre-Yankee dryer dryn-ess which can be achieved with blow through predrying is not believed to be critical to the present invention. Also, it is not believed to be essential to the present invention to avoid substantial mechanical pressing andlor compaction while rel'atively wet which avoidance'is apparently critical to some'of the prior art processes.

Alternate papermaking machine 380, Figure'43, is like papermaking machine 280, Figure 42, except it further comprises ~ 15 a lower felt loop 297 and wet pressing rolls 298.and 299 and I means not shown for controllabIy biasing rolls 298 and 299 . together. The'lower felt loop 297 is looped about additionaL
.~ turni~g rolls 101 as illustrated. This alternate'papermaking machine'further illustrates that it is not believed to be essential to avoid substantial pressing and/or compaction of the paper web while it is reIatively wet. While wet pressing i8 believed to in fact precipitate more compaction and - hydrogen bonding, subsequent creping, calendering and crepe stretching in accordance with'the present invention pro~ides the'smoothness and velutinous characteristics of paper - ' embodying the present invention.

Alternate papermaking machine 480, Figure 44, is function-! ally similar to papermaking machine 80, Figure 2, except its . headbox 481 has three chambers designated 482, 483 and 484 for adapting the machine 480 to make 2-layer or 3-layer paper; it : further comprises an intermediate carrier fabric 496, an intermediate vacuum transfer box 497, additional vacuum dewatering boxes 498, and additional turning rolls 101 for guiding ant supporting the loop of fabric 496. When operated to produce a 2-layer paper sheet having a predominantly ~hort fiber layer on its Yankee-side, and a predominantly ii~6~6 . ~ .

long fiber layer on its off-Yankee-side, a predominantly short fiber furnish is delivered from chamber 482, and a predominantly long fiber furnish is delivered simultaneously ' from chambers 483 and 484 which effectively causes headbox 481 to be a quasi 2-chamber headbox. Thus, the long fiber furnish is first on the Fourdrinier wire 85 and the short fiber furnish is delivered on top of the long fiber furnish.
For a given Fourdrinier wire mesh, this provides a smoother embryonic fiber web than machine 80, Figure 2, wherein the short fiber furnish is delivered onto the Fourdrinier wire in order for the Yankee-side of the paper to be the short fiber layer. Also, the embryonic web formed on the Fourdrinier wire of machine 480 undergoes two intermed$ate'transfers prior to being transferred to the'Yankee dryer 108: a first intermediate transfer precipitated by vacuum transfer box 49'7; and a second intermediate transfer precipitated by vacuum transfer box 97.
~ .
~ Alternate papermaking machine'580, Figure 45,-is -~ substantially identical to papermaking machine 480, Figure - 20 44, except that machine'580 has a fel't loop 296 in place of ' the'foraminous carrier fabric 96 of machine 480, and machine 580 has no blow through predryers 100. Thus, machine'580 will normally deliver a relatively wetter web to its Yankee dryer 108 as compared to machine 480.

Alternate papermaking machine 680, Figure 46, is of the ' general type shown in Figure }7 of the Morgan et al. patent referenced hereinbefore which, when fitted with appropriate fine mesh fabrics and wires and when operated in accordance with the present invention is suitable for making 3-layer paper 210, Figure 37, as described hereinbefore. As compared to machine 480, Figure 44, machine 680 further comprises a twin wire former in the lower left corner of Figure 46.
Briefly, papermaking machine 680 comprise~ a single chamber headbox 681 for discretely forming a layer 71 which ultimately becomes the off-Yankee-side of the paper 210, and a twin , ~463~6 wire fonmer 685 comprising a twin headbox 682, carrier fabric 496 and Fourdrinier wire 696 for forming a 2-layer ¦ embryonic web comprising another layer 71 and a layer 75.
The twin headbox is divided into two chambers 683 and 684.
Optional steam or air jets 690 are provided to assist vacuum ~ 5 transfer boxes 497 and 697 to cause the discrete layer 71 to .~ transfer from Fourdrinier wire 85 onto the 2-layer embryonic I web, and for the 2-layer embr~onic web. to be forwarded on "~ carrier fabric 496 from vacuum transfer box 697 to vacuum transfer box 97. Then, as the 2-layer embryonic web passes 10 over vacuum transfer box 497, the discrete layer 71 is transferred onto the smooth upper surface of -layer 75 from ' Fourdrinier wire 85. The'3-layer web is then predried, ;! transferred to the Yankee dryer and so forth'as previously described. This order of formation places the twin-wire ~ 15 formed layer 71 against the Yankee dr~er surface so that it : wi'll most effectively have its interfiber bonds broken by the'action of doctor blade'lll. Subsequent calendering and stretching must be contralled suficiently to proYid'e the required smooth and velutinous c~aracter for top surface 72 of layer 71. Fourdrinier wire~ 85 and 696 are preferably 4-.~ shed satin weaves having 110 X 95 meshes per inch and .' conftgured as shown in Figure 17; and preferably carrier ' fabric~' 96 and 496 are 3-shed semi-twill weaves having 73 X
fi0 meshes per inch and configured as shown in Figure 18 although it i9 not intended to thereby limit the scope of the'present invention.

~l Alternate papermachine 780, Figure 47, is a representa-! tive machine for making 3-layer paper 220, Figure 38, hsvinga textured bottom.layer 221 and a smwoth velutinous ~op layer 71. Machine 780 is simiIar to machine 680, Figure 46, except for setting up the twin wire section to form an embryonic web having a short fiber layer 221 having discrete area3 par~ially deflected into the interfilamentary spaces of carrier fabric 496, and a substantially flat, untextured long fiber layer 75. Fourdrinier wires 85 and 696 of papermaking machine 780 are preferably 4-shed satin weaves 114639t;

hav~ng 110 X 95 meshes per inch and configured as shown in Figure 17; and preferably, to enable texturizing the pre-dominantly short fiber layer 221, carrier fabric 496 has a 5-shed satin weave h~ving about 31 X 25'meshes per inch and configured as shown in Figure 41 although it is not intended to thereby limit the scope of the present invention.

~ 'E'xamp'le' 1 - A 2-layer paper sheet of the configuration shown in F.igure 1 was produced in accordance with the hereinbefore described process on a papermaking machine'of the general configuration shown in F~gure'44 and identified thereon as . papermaking machine 480. Briefly, a first fibrous slurry ' comprised primarily of short papermaking fibers was pumped through'headbox chamber 482 and, simultaneously, a second fibrous slurry comprised primarily of long papermaking - fibers was pumped through headbox chambers 483 and 484 and deIivered in superposed relation onto the Fourdrinier wire - 85 whereupon dewatering commenced whereby a 2-layer embryonic . web 'was formed which comprised a short. fiber la~er on top of and integral with'a long fiber layer. The first slurry had a fiber consistency of about 0.12% and its fibrous content c'omprised 25% by weight of ~orthern Hardwood Sulfite and 75%
by wefght of Eucalyptus Hardwood, the fibers of both of which have'average lengths of about 0.8 mm. The first..slurry also comprised about O.lZ b~ weight of fibers of Parez.631 ~C wet strength additive which was procured from American.Cyanamid.
The'second slurry had a fiber consistency of about 0.044%
and its fibrous content was all Northern Softwood Kraft produced by the Buckeye Cellulose Company and having a~erage fiber lengths of about 2.5 mm. Additionally, the second slurry also comprised about 1.5% by weight of fibers of Pare~ 531 NC, the above identified wet strength additive-from American Cyanamid. The resulting paper web comprised a predominantly short fiber layer which constituted about 57%
of the total basis weight of the web, and a long fiber layer . i l 4 639 6 -.42 -which constituted about 43% of the total basis weight of the .~ web. The purity of the short fiber layer upon which the I ultimate benefits of the present invention depend greatly was determined to be 957O; not lOOZ because of the inability ! 5 to totally preclude inter-slurry mixing in the superimposed headbox discharge streams and on the Fourdrinier wire 85.
The other principal machine and process conditions comprised:
Fourdrinier wire 85 was of the 47shed, satin weave configura-' tion shown on Figure 17, and had 110 machine direction and '. 10 95 cross-machine-direction monofilaments.per inch, respec-tively; the fiber consistency was about'8% when transferred fsom the Fourdrinier wire'B'5; the intenmediate carrier . fabric was also of'the 4-shed,. satin weave configuration shown in Figure 17 and also had 110 X 95 (MD X CD) mono-~ '15 filaments per inch; the fiber consistency was increased to ... . about 22% prior to transfer.to the'foraminous carrier . fabric 9'6; fabric 96 was of the monofilament polyester type ~: . ~ of the'configuration shown in Figure 18 having a'3-shedsemi-twill weave'and 73'X 60 (MD X CD) monofilaments per inch;' the diagonal free span of the foraminous' carrier fabrlc 96 was 0.28 mm which is considerably less than the ,~ average long fiber length'of 2.5 mm in the layer of the web ti8posed on the fabric 96 which substantially obviated ' displacing or bulking of the fibers of that layer intQ the : ~ 25 interfilamentary spaces of the fabrIc 96; the'fiber consistency was increased to a BPD '(before predsyer) value of about 29%
~ust before the blow-thsough'predryers 100 and, by the .l action of the predryers loO, to an APD '(-fter' ~redryer) vaIue of about 52% prior to transfer onto the Yankee dryer 108; the transfer roll 102 was rubber covered having a P~J
hardness value of 45 and was biased towards the Yankee dryer . 108 at 440 pounds per lineal inch (pli); creping adhesive comprising a 0.25% aqueous solution of polyvinyl alcohol was spray applied by applicators 109 at a rate of O.OOlZ ml per . 35 square centimeter of the Yankee dryer surfacej the fiber consistency was increased to 98~5/o before dry creping the web with doctor blade 111; doctor blade 111 had a bevel .... ,_~ . . . . ... __ ... _ . .. .
.~ .

3~

angle of 30 degrees and was positio~ed with respect to the Yankee dryer to provide a~-~im~act angle of about 90 degrees;
the Yankee dryer was operated at about 80C fp~ (feQt pPr minute) (about 244 meters per minute); the top calender roll 112 was steel and the bottom calender roll 113 was rubber co~ered having a P&J hardness value of 30; calender rolls 112 and 113 were biased together at 90 pli and operated at surface speeds of 617 fpm (about 188 meters per minute);
and the paper was reeled a~ 641 fpm (about 19~ meters per minute) to provide a draw o about 4% which resulted in a residual crepe of about 20%. This paper ~as subsequently - combined and converted into 2-ply paper of the configuration shown in Figure 21 through the use of a com~ining apparatus such as 120, Figure 20. The top ealender roll 121 was steel a~d the bottom calender roll 122 Wa3 rubber covered h~ving a P~J hardness value of 95; and calender rolls 121 and 122 ~ere biased together at 100 pli a~d operated at surface speeds of about 350 fpm tabout 107 meters per minute).O The . 2-ply paper was reeled with a 1% draw. The physical properties of the 2 layer paper and the 2-ply paper product made therefro~ are tabulated in Table VI~

. .

i J ~
~146396 ..

Example 1: Physical Properties of a 2-Layer/2-Ply Facial Tissue and the Paper From Which it was Produced Paper Finished i : Machine Product ¦ Parameter - Reel SamPle Sample BasisUnits 8asis Weight 19.0 18.6 2-Plr lbs/3M f~2 I
Callper ' 22.1 17.6 4-Ply mlls , 8ulk Density 9.i 7.4 2-Plr cm3/gm j Tensile: MD . 300 314 2-Ply I gm/in ~1. CD 211 193 2-Ply gm~in ., ~ Total . 511 507 2-Ply gm/in ~' ~ ' 'Stretch:' MD 21.1 15.5 2-Ply gm/in CD 5.5 5 9 2-Plr gm/in Surface Purity:
., ~ Of-Yankee Slde 11 11 -% short fi~er ~,~ ~ank~e S~lde 9S 95 -Z short fiber f: ~ . HTR-Texture Index:
; ~ . Off-Yankee Side : 0.40. 0.18 - per inch ~ aD}ee Side 0.14 0.07 - mil-c~cles i,' ~ per inch Pree'Fiber End Inde~:
Off-Yankee Side 8rushed : 47 55 - ' None Off-Yankee Side Unbrushed 41 31 - None ~ Yankee Side Brushed 130 124 None : ~ Yankee Side UDbrushed~ 111 91 ~ - None ~oft~ess (E~pert Panel) - ~2.1 A Contemr P.S.U.
, por y 2-plr 3 ~ facial tissue ' . _ _ _ .. . . _ _ .. ... . . . . . ... ... . .

' 11463~6 , - 45 -Example 2 A 2-layer paper sheet of the configuration shown in Figure 1 was produced in accordance with the hereinbefore described process on a papermaking machine of the general configuration sho~n in Figure 44 and identified thereon as papermaking machine 480 except the paper was reeled without being calendered between calender rolls 112 and 113. Thus, as compared to reeled paper of Example 1, the reeled paper of Example 2 has relatively high HTR-Texture values. As compared to Example 1 which is well suited for facial tissue, the paper produced by Example 2 is well suited for,use in toilet tissue products. Briefly, a first fibrouQ slurry ' compri~ed primarily of short papermaking fibers was pumped through headbox chamber 482 and, simultaneously, a second fibrous slurry comprised primarily of long papermaking fibers was pumped through headbox chambers 483 and 484 and delivered in superposed relation onto the Fourdrinier wire 85 whereupon dewatering commenced whereby a 2-layer embryonic we~ wa~ formet which comprised a shor~ fiber layer on top of and integral with a long fiber layer. The first slurry had a fiber consistency of about 0.15% and its fibrous content wa~ EucalyptuQ Hardwood, the'fibers of which have average lengths' of about 0.8 mm. The irst slurry also comprised about 0.4% by weight of fibers of Accostrength 514, a dry ~trength additive supplied by American Cyanamid. The second slusry had a fiber consistency of about 0.063% and its fibrous content was all ~.~orthern Softwood Kraft produced by the Buckeye Cellulose Company and having average fiber lengths of about 2.5 mm. Additionally, the second slurry al3o compris~d about 0.4% and 1.6%'by weight of fibers of Accostre~gth 98 a~d Accostrength 514, respectively, which are dry strength additives from American Cyanamid. The resulting paper web comprised a predominantly short fiber layer which constituted about 5~% of the total basis weight of the web, and a long fiber layer which cons~ituted about 45~ of the total basis weight of the web. The purity of the short fiber layer upon which the ultimate benefits of the ~ 1146396 ' - 46 -present invention depend greatly was determined to be 97%.
. The other principal machine and process conditions comprised:
Fourdrinier wire 85 was of the 4-shed, satin weave configura-: tion shown on Figure 17, and had 78 machine direction and 62 cross-machine-direction monofiIaments per inch, respectively;
! the fiber consistency wa~ about 8% when transferred from the I Fourdrinier wire 85; the intermediate carrier fabric was ,~ - also of the 4-shed, satin weave configuration shown in .. ' Figure 17 and also had 78 X 62 ~D ~Y CD); monofilaments per inch;' the fiber consistency was increased to about 19% prior to transfer to the foraminous carrier fabric 96; fabric 96 was of the monofilament polyester t~pe of the configuration sho'wn ~n Figure 41 having a 5-shed satin weave and 84 X 76 oMD X CD) filaments per inch;' the'diagonal free ~pan of the oraminous' carrier fabric 96 was 0.24 mm which is consider-- ably les's than the average'long fiber length of.2.5 mm in the'layer of the web 'disposed on the fabric 96 which ~ubstantialIy obviated tisplacing or bulking of the fibers ' of that layer into the interfi:lamentary space~ of the fabric . ~ 20 9'6; the fiber con~istency wa~ increased.to a BPD value of about 3270 ~ust before the bIow-through predryers 100 and, by '' the action of the predryers 100, to an APD value of about 53% prior to transfer onto the Yankee dryer 108; the transfer roll 102 was rubber covered having a P&J value of 45 and was biased towards the'Yankee'dryer 108 at 430 pounds per lineal i'nch'(pli); creping athesive' comprising a 0.25Z aqueous solution of polyvinyl alcohol was spray applied by applicators . 109 at a rate of 0.00076 ml per square centimeter of the , Yankee'dryer surface; the fiber consistency was increased to 98.5% before dry creping the web with doctor bIade 111;
doctor blade 111 had a bevel angle of 30.degree~ and wa~
pasitioned with re~pect to the Yankee dryer to provide an impact angle of about 90 degrees; the Yankee dryer was operated at about 800 fpm (feet per minute) (about 244 meters per minute); and the paper was reeled at 675 fpm (about 205 meters per minute) to provide about 16% crepe.

__. .. . , , _ . _ _ . . . . . ... . . .

^ 11~6396 This paper was subsequently combined into 2-ply paper of the configuration shown in Figure 21 through the use of a combin-j ing apparatus such as 120, Figure 20. However, the calender ¦ rolls 121 and 122 were not biased together. The 2-ply paper S was reeled at about 200 fpm (about 61 meters per minute~
with a 3% draw. The physical properties of the 2-layer paper and the 2-ply paper product made therefrom are tabula~ed in Table VII.

~11 . .

1~6396 TABLE VII
¦ Example 2: Physical Properties of a 2-Layer/2-Ply Toilet Ti~sue and the Paper From Which it was Produced Paper Finished ~ , Machlne Product - ~ Parameter Reel SamPle SampleBasis Uni~s Basis ~eight 20.3 20.5 2-Ply lbs/3M ft2 ' Caliper 14.5 13.2 2-Ply mils Bulk Density 11.1 10.0 2-Ply cm3/g~
Tenslle: MD 327 311 2-Ply gm/ln CD 274 258 2-Ely gm/in Total 601 569 2-Ply gm/ln jStretch: MD 20.9 2009 2-Ply Z
CD 5.5 5.7 2-Ply 2 , ' Surface Purity:
,- Off-Yankee Side 6 6 - - 2 ~hort fiber Yankee Side 97 97 - 2 short fiber - HTR-Texture Intex: --- Off-Yankee Slde 1.33 1.14 - - mil-cycles - per lnch Yankee Slde 0.31 0.31 mll-cycles per inch Free Flber End Index:
Off-Yankee S~de Bru~hed 77 60 - - None Off-Yankee Slde Unbrushet 40 30 ~ - None ! Yarkee Slte Brushet122 115 - ~ None Yankee Side Unbrushet 106 79 - - None Softnes~ ~Expert Panel) - - +1.0 A Contem- P.S.U.
porary 2-Ply i facial ti~sue . I .

.

_ _~_._ . _ . ..... . . .... .. . .
-.

- 11463~6 j - Example' 3 A 2-layer paper sheet of the configuration shown in Figure 1 was produced in accordance with the hereinbefore de.2cribed process on a single-felt-loop papermaking machine of the general configuration shown in Figure 45 and identified thereon as papermaking machine 580 except the paper was not calendered between calender rolls 112 and 113. Thus, relative to the reeled Example 1 paper, the reeled Example 3 paper i9 more highly textured. Briefly, a first fibrous slurry comprised primarily of short papermaking fibers was pumped through the top headbox chamber and, simultaneously, a ~econd fibrous slurry comprised primarily of lon~ papermaking f~bers was pumped through the'other two headbox chambers and delivered in superposed relation onto the Fourdrinier wire 85 whereupon dewatering commenced whereby a 2-layer embryonic web' was formed which'comprised a short fiber layer on top of and integral with a long fiber layer. The first slurry had a fiber consistency of about 0.11% and its fibrous content was Eucalyptus Hardwood Kraft-, the'fibers of whic~ have average lengths of.about 0.8 mm. The second slurry had a iber consistency of about 0;047% and its fibrous content was all Northern Softwood Kraft produced by the 8uckeye CeIlulose.Cbmpany and having average fiber length.~ of about 2.5 mm. Additionally, the second slurry also comprised about 1.1% by weight of fibers of Parez 631 ~C, a wet streng~h additive procured from American Cyanamid. The resulting paper web comprised a predominantly short fiber layer which ; constituted about 55% of the total basis weight of the web, ant a long fiber layer which constituted about 45% of the total basis weight of the web. The purity of the short flber layer upon which the ultimate benefits of the present invention depend greatly was determined to be 94%. The other principal machine and process conditions comprised:
Fourdrinier wire 85 was of the 4-shed, satin weave configuration shown on Figure 17, and had 110 machine direction and 95 cross-machine-direction monofilaments per inch, respectively;

' ~ 11463g6 :

the fiber consistency was about 8% when transferred from the 1 Fourdrinier wire 85; the intermediate carrier fabric was I also of the 4-shed, satin weave configuration shown in ~ Figure 17 and also had 110 X 95 (MD X CD) monofilaments per ¦ 5 inch; the fiber consistency was increased to about 16-/o prior to transfer to the batt-on-mesh drying felt loop 296; the fiber consistency was increased to about 22% prior to transfer onto the Yankee dryer 108; the'transfer roll 102 was ru~ber covered having a P&J value of 45 and was biased towards the Yankee dryer 108 at 480 pounds per lineal inch (pli); creping athesive comprising a 0.27% aqueous solution of polyvinyl alcohol was spray applied by applicators 109 at a rate of 0.00079 ml per square centimeter of the Yankee dryer surface;
¦ the fiber consistency was increased to about 94Z before dry creping the web with'doctor blade'll'l; doctor blade 111 had ' a bevel angle of 30 degrees and was positioned with respect to the Yankee'dryer to provide an impact angle of about 90 degrees; the Yankee dryer was operated at about 499 fpm (feet per minute) (about 152 meters per minute); and the paper was reeled at 389 fpm (about 119 meters per minute) to provide about 2270 crepe. This paper was subsequently combined and converted into 2-ply paper of the configuration sho'wn in Figure'21 through the'use o~ a ccmbining apparatus such as 120, Figure'20. The'top calender roll 121 was steel and the bottom calender roll 122 was rubber covered having a - P&J value of 50; and calender rolls 121 and 122 were biased together at 90 pli and operated at surface speeds of about - 200 fpm (about 61 meters per minute). The 2-ply paper was reeIed with a 3% draw. The physical properties of the 2-layer paper and the 2-ply paper product made therefrom are tabulated in Table VIII.

. .

~146396 - TABLE VIII
Example 3: Physical Properties of a 2-Layerl2-Ply Conventional Facial Tissue and the PaPer From Which it was Produced PaperFinished Machine Product Parameter . Reel Sample SamPle BasisUnits I Ba~sIs Weight 17.8 .18.6 2-Plylbs/3M ft2 - Caliper 24.4 20.7 4-Ply~il8 - Bulk Denslty 10.6 8.7 2-Plycm3/g~
~, Tensile: MD 465 441 2-Plygm/in CD 209 195 2-Plygm/in Tot-l 674 636 2-Plygm/in - Stretch: MD 24.-1 17.3 2-Ply 2 CD 6.7 6.3 2-Ply Surace Purity:
:~ Off-YaDkee Side 10 10 - ~ short fiber :~ ~ Y~ e Site 94 94 -2 short fiber HTR-Texture Index:
3 - Of-Yankee Slde1.89 1.03 - - mll-cycles Yankee Side 0.40 0.10 - mil-cycles per inch . Free Fiber End Intex:
Off-YaDkee SIde Brushet 32 22 None . Of-Yankee Side Unbrushet 14 8 - None I ~ankee Side Brushed 168 179 - ~ None , Ya~kee Slde Unbru~hed 110 128. ~ - None :I Softness (Expert Panel) - ~1.7 A Conto~ P.S.U.
porary 2-Ply facial tlssu~

- ' .

f .
. . ~

~ r 1146396 'Exampl'e 4 A 3-layer paper sheet of the configuration shown in Fi~ure 37 was produced in accordance with the hereinbefore described process on a papermaking machine of the general configuration shown in Figure 44 ant identified thereon as ' papermaking-machine 480. Briefly, a first fibrous slurry comprised primarily of short paperma~ing fibers was pumped through headbox chambers 482 and 484 and, simultaneously, a second fibrous slurry comprised primarily of long papermaking 10 fibers was pumped through headbox chamber 483 and delivered ' in superposed relation onto the Fourdrinier wire 85 whereupon' dewatering commenced whereby a 3-layer embryonic web was ~' formed whi'ch comprised short fiber layers on top of and beneath and integral with a long fiber layer. The first 15 slurry had a fiber consistency of about 0.11% and its fibrous ; content Eucalyptus Hardwood Kraft, the fibers of which have average length~ of about 0.8 mm. The second slurry had a fiber consistency of about 0.15% and ~ts fibrous content was all Northern Softwood Krat produced by the Buckeye Cellulose 20 Company and having average'fiber lengths of about 2.5 mm.
Additional}y, the'second slurry also comprised about 0.4% by we'ight of fibers of Parez 631 ~C,' which was procured from A~erican Cyanamid. The'resulting paper web comprised a predominantly short iber top layer (Yankee-side) which 25 constituted about 3070 of the total basi-~ weight of the web, a long fiber middle layer which'constituted about 40% of the total basis weight of the web, and a short fiber bottom layer (off-Yankee-side) which constituted about 30% of the total basis weight of the web. The short fiber purity of 30 the top and bottom short fiber layers upon which the ultimate benefits of the present invent~on depend greatly was determined to be 99% and 98%, respectively. The other principal machine and process conditions comprised: Fourdrinier wire 85 was of the 4-shed, satin weave configuration shown on Figure 17, and had 110 machine direction and 95 cross-machine-direction monofilaments per inch, respectively; the fiber consistency was estimated to be about 870 when transferred from the Fourdrinier wire 85; the intermediate carrier fabric was 11463~6 - s3 -'¦ also of the 4-shed, satin weave configuration shown in Figure 17 and also had 110 X 95 (MD X CD) monofilaments per ' in~h; the fiber consistency was estimated to have increased to about 22% prior to transfer to the foraminous carrier fabric 96; fabric 96 was of the monofilament polyester type of the configuration shown in Figure 40 having a 4-shed satin weave and 110 X 95 ~MD X CD) monofilaments per inch;
the diagonal free span of the foraminous carrier fabric 96 was 0.17 mm.which is considerably less than the average : 10 short fiber length of 0.8 mm in the layer of the web disposed on the'fabric 96 which substantially obviated displacing or ; bulking of the fibers of that layer into the interfilamentary spaces of the fabric 96; the fiber consistency was increased to a~ estimated BPD value of about 27% just before the blow-- 15 through'predrrers 100 and, by the'action of the predryers }00, to an estimated APD value'of about 60% prior to transfer onto the'Yankee dryer 10'8; the'transfer roll 102 was rubber co~ered having a P&J value'of 45 and was biased towards the :~ Yankee'dryer 108 at 450 pounds per lineal inch (pli); creping adhesive comprising a 0.25Z aqueous solution of polyvinyl - alcohol ~as spray applied by applicators 109 at a rate of '. 0.'.00082 ml per square centimeter of the Yankee dryer surface;
the'fiber consistency was increased to an est~mated 99%
before try creping the web with'doctor blade'lll; doctor blade'lll had a bevel angle of 30 degrees and was positioned with'respect to the Yankee.'dryer to provide an imp'act angle . of about 90 degrees; the Yankee'dryer was operated at about 800 fpm (feet per minute) (about 244 meters per minute)-; the top calender roll 112 was steel and the bottom calender roll 113 was rubber covered having a P W value of about 5'0;
calender roll~ 112 and 113 were biased together at 90 pli and operated at surface speeds of 659 fpm (about 200 meters ' per minute); and the paper was reeled at 670 fpm (about 204 meters per minute) which resulted in a residual crepe of about 16.3Z. This paper was subsequently further stretched, ' calendered, and con~erted into finished l-ply, 3-layer facial tissue during which it was calendered at 190 pli at . 200 fpm (about 61 meters per minute) ant about 3% draw. The physical properties of the 3-layer paper and the l-ply paper product made therefr~m are tabulated in Table IX.

_ ~ . . . . .
.

. ~ 6 i TABLE IX
Example 4: Physical Properties of a 3-Layer/l-Ply Facial Tissue and the Pape~ From Which it was Produced . Paper Finished Machine Product Parameter Reel Sa~ple Sample Basis Units Basls Welght 16.9 16.8 2-Ply lb~/3M ft~
Caliper 13.3 11.7 2-Ply ~lls Bulk Density 6.2 5G5 l-Ply cm3/gm Tensile: MD 370 368 2-Ply gm/in CD 203 228 2-Ply gm/in Total 573 596 2-Ply gm/in Stretch: MD 23 o 5 19 o 1 2-Ply %
CD 4O~ 4O4 2-Ply Surface Purity:
Off-Yankee Side 98 ~8 ~ ~ % ~hort fiber =~ ~arkee Side 99 99 ~ - ~ short fiber HT~-Texture Inde~: -O~f-Ya~kee! Side 0~0g 0.06 - m~l cycle~
per inch Ya~kee Sid.e 0~06 0~04 - - mil-cycles per inch Free Fiber End Indexo Off-Yankee~ Side Bru~hed 135 137 o~ None Off-Yankee Side Unbrushed 91 8g -~ Ns~e Yankee Side Brushed 147 154 ~ - None Yankee Side Uubxushed 131 g6 ~ None Softnes~ (E~pert Panel) ~ ~ ~0~3 A Contem- P.S.UO
por~ry 2-Ply f~cial ~issue 63g6'''-'" ' '--^' ' Example 5 A 2-layer facial tissue paper sheet of the c~nfiguration shown in Figure 1 was produced in accordance with the herein before described process on a papermaking machine of the - 5 general configuration shown in Figure 2 and identified thereon as papermaking machine 80. ~riefly, a first fibrous slurry comprised primarily of short papermaking fibers was pumped through headbox chamber 82 and, s~multaneously, a second fibrous slurry comprised primarily of long papermaking fibers was pumped through headbox chamber 83 and deIivered in superposed relation onto the Fourdrinier wire 85 whereupon dewatering commencet whereby a 2-layer embryonic web was formed which comprised a short fiber layer on top of and integral with a long fiber layer. The first slurry had a fiber consistency of about 0.13% and its fibrous conten~
comprised 50% by weight of ~orthern Hardwood Sulfite and 50%
by weight of Eucalyptus Hardwood Kraft, the fibers of both having average lengths of about 0.8 mm. The first slur~y also com~rised about 0.15% of its fiber weight of Parez 631 NC, a wet strength additive which was procured from American CyanamidD Also, the first slurry contained about 0.25% by weight of fibers of Accostrength 514, a potentiating agent which was also procured from American Cyanamid. The second 81urry had a fiber consistency of about 0.14% and its fibrous content was all ~orthern Softwood Kraft produced by the Buckeye Cellulose Company and having average fiber lengths of about 2.5 ~m. Additionally, the second slurry also compriset about 0.24% by weight of fibers of Parez 631 NC, the above identified wet strength additive from American Cyanamid. The resulting paper web comprised a predominantly short fiber layer which constituted about 55% of the total basis weight of the web, and a long fiber layer which consti-tuted about 457O of the total basis weight of the web. The purity of the short fiber layer upon which the ultimate benefits of the present invention depend greatly was determined to be 91%. The other principal machine and process conditions comprised: Fourdrinier wire 85 was of the 4-shed, satin weave configuration shown on Figure 17, and had 110 machine direc~ion and 95 cross-machine-direction monofilamen~s per inch, respectively; the fi~er consistency was estimated to .

be about 15 to 18~ when transferred from the Fourdrinier wire 85 to the foraminous carrier fabric 96; fabric 96 was of the monofilament polyester-type of the configuration shown in Figure 18 having a 3-shed semi-twill weave and 73 X
60 (MD X CD) monofilament.s per inch; the diagonal free span of the foraminous carrier fabric 96 was 0.28 mm which is considerably less than the average long fiber length of 2.5 mm in the layer of the web disposed on the fabric 96 which substantially obviated displacing or bulking of the fibers Of that layer in~o the interfilamentary spaces of the fabric 96; the fiber consistency was increa~ed to a BPD value of about 23% ~ust before the blow-through predryers lO0 and, by the action of the predryers lO0, to an APD value of about 59% prior to transfer onto the Yankee'dryer 108; the transfer roll 102 was rubber covered having a P W value of 41 and was biased towards the'Yan~ee'dryer 108 at 490 pounds per lineal inchl(pli); creping adhesive'comprising a 0.53% aqueous solut~on of 40% polyvinyl a}cohol and 60% Peter Cooper LX
animal base glue was spray applied by~applicators 109 at a rate of 0.00048 ml per square'centimeter of the Yankee dryer surface; the'fiber consistency was increased to 96.8% before dry creping the web with doctor blate 111; toctor blade 111 had a bevel angle of 27 degrees and was positioned with respect to the Yankee dryer to provide an impact angle of about 81 degrees; the Yankee dryer was operated at about 2600 fpm (feet per minute) (about 791 meters per minute);
the top calender roll 112 was steel and the bottom calender roll 113 was rubber covered having a P&J value of 47;
calender rolls 112 and 113 were biased together at 65 pli and operated at surface ~peeds of 1996 fpm (about 607 meters per minute); and the paper was reeled at 2083 fpm (about 634 meters per minute) to provide a residual crepe of about 20%.
Thi~ paper wa~ ~ubsequently combined and converted into 2-ply paper of the configuration shown in Figure 21 through the use of a combining apparatus such as 120, Figure 20.
The top calender roll 121 was steel and the bottom calender roll 122 was rubber covered having a P&J value of 95; and ~. .

~.. __ _ _ . . ... . _ . .. . . . . .... . .

. ~1463~6 - s7 -calender rolls 121 and 122 were biased together at 100 pli ¦ and operated at surface speeds of about 350 fpm (about 107 meters per minute). The 2-ply paper was reeled with a 4%
- draw. The physical properties of the 2-layer paper and the ' 5 2-ply paper product made therefrom are tabulated in Table X~

While the papermaking machine 80, Figure 2, was only involved in making Example 5, it is believed that the benefits of the present invention can be reali~ed most efficiently and economically on such a machine although it is not intended to thereby limit the scope of the present invention.

.- :

ii46396 l TABLE X
', Example 5: Physical Properties of a 2-Layer/2-Ply Facial Tissue and the Paper From Which it ~as Produced Paper Finished Machine Product Parameter Reel Sample Sample Basis Units Basis Weight 19.4 18.6 2-Plylbs/3M f~2 Cal~per 25.8 19.6 4-Ply mil~
Bulk Denslty . 10.4 8.3 2-Ply cm3/gm Tensile: MD 339 310 2-Ply, gm/in CD 197 196 2-Ply gm/in ~otal : 536 506 2-Ply gm/in Stretch: MD 28.3 16.6 2-Ply %
, CD 7.3 7.0 2-Ply i Surface Purity:
Off-Yankee Side 14 1~ - % short fiber Yankee Side 91 91 ~ hort fiber .~ . . _ .
HTR-Te~ture Index:
Off-Yankee Site 0.95 0.22 - mll-cycles : per inch Yankee Slde 0.65 0.30 - - mil-cycle8 per inch Free Fiber End Index:
Off-Yankee Side Brushed 52 53 ~ - None - Off-Yankee Side Unbrushed 35 29 - - None Yankee Slte Brushed 78 71 - ~ None ~aDkee Side Unbrushed 52 . 47 None So~tness (Expert Panel) - +0.5 A Contem- P.S.~.
porary 2-Ply facial ti~ue ___ . , , . _ _. , _ .. . ... . _ .. . .. :
-. 1146396 . For convenience, the HTR-Texture v. FFE-Index dat~ for ' Ex~mples 1 through 5 are plotted on Figures 48 through 52, ~ respectively, and tabulated together in Table XIa. Each of the data point designators comprises two numbers separated by a hyphen: the number to the left of the hyphen is the E'xample number (i.e., 1, 2, 3, 4, or 5); and, the numbers to the'right of the hyphen were assigned according to the key listed in Table XIb. Briefly, in general, the graphs indicate: the two-sided nature of the two-layer Examples 1, 2, 3, and 5 of paper 70: that is, that their Yankee-sides are substantially different from their off-Yankee sides inasmuch as, in general, their Yankee-sides have'substantially ' higher FFE-Index values and lower HTR-Texture values than -. ' their off-Yankee-sides; and that both the Yankee-side and the off-Yankee side of the 3-layer Example 4, Figure 37, have reIatively high FFE-Index values and low HTR-values which'indicate that.both outer surfaces of such paper and the products made'therefrom are smooth, soft and .velu'tinous:
'' the haIlmarks of paper embodying the present invention.

__ ._ .~ .. _ . ...... .

I ~ ~

TABLE XIa . . . _ HTR-Texture v. FFE-Index 5 Examples of Present Invention Tissue Paper & Products Reference Figures 48-52 , - _ ............ . r . . ,, Yan ~YL~ _ Off-Yankee Side ., . FFE-I ldex FFE-Index : Example Reeled or HTR- Not HTR- NotNumber Converted Texture Brushed Brushed Texture Brushed Brushed . . _ . ._ ___ .
1, _Reeled 0.14 130 111 0.40 47 41 2 layer C~verted, . . . .
: 2-p~ 0.07 124 91 0.18 55 31 ._ _ ... _ .__ : . .
2, Reeled 0.31 122 106 1.33 77 40 2 layer Con~erted, . . _ . . . _ ! 2 ply 0.31 115 79 1.14 60 30 ,,_ _ _ : _ 3, Reeled ', 0.40 168 110 1.89 32 14 ~ 2 layer Converted, .. .
; ' . 2-ply 0.10 17g 128 1.03 22 8 : ' . -- _-: : .. .-4, Reeled 0.06 147 131 0.09 135 91 2 layer Converted, . . __ _ .
. l-ply 0.04 154 96 0.06 137 89 .! ' . . . _ _ . .____ - _ . __ . __ _ . . ._ ,., . 5, Reeled 0.65 78 52 0.95 ~2 35 2 layer Converted~ _ ._ . ........ ~ ...
. . 2-ply 0.30 71 47 . 0.22 53 29 . , . ..........
TABEE ~Ib Rey: Designator Sufi~eg. .... .... .
' Eo~re~ture v.'FFE-Index Data Polnt-~,'Flgures 48-52 Sample Surface:
Paper: Sample Surface: Brushed or De~igDator Suffix, Reeled or Yankee 51de o~ Unbrushed For . Figures 48-52 Converted Off-Yankee SideFFE-Index -1 Reelet Off-Yankee SideBrushed -2 ' Reeled Of~-Yaukee SideUnbrushed , -3 Reeled Yankee Side Brushet . -4 ~eeled Yankee Side Unbrushed -S Converted Off-Yankee SideBru~hed

-6 Converted Off-Yankee SideUnbrushed

-7 Converted Yankee Sid~ Brushed

-8 Converted Y _ kee SideUnbrushPd . I .

, _ , . . .... ,_ . .. . , . _ _ . .

~f . . 1146396 While particular embodiments of the present invention . have been illustrated and described, it would be obvious to I tho~e skilled in the art that various other changes and modifications can be made without departing from the spir~t and scope of the invention. Therefore, it is intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.

What is claimed is-:
I

J
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~ .
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~ _ .. _.__ _ _ . ... ..... . . .

Claims (35)

Claims

1. A tissue paper sheet having a substantially flat velutinous top surface, said sheet comprising a first layer comprising papermaking fibers and a second layer comprising substrate means for supporting said first layer and for providing said product with sufficient tensile strength for its intended purpose, said first layer comprising a primary filamentary constituent of about 60% or more by weight of relatively short papermaking fibers having average lengths of from about 0.25 mm to about 1.50 mm, said velutinous top surface being the outwardly facing surface of said first layer which surface is defined by substantially unbonded free end portions of a multiplicity of said short fibers, said sheet having an average top surface human-tactile-response texture (HTR-Texture) of about 1.0 or less, and said velutinous top surface having an average free-fiber-end index (FFE-Index) of at least about sixty (60).

2. The paper sheet of Claim 1 wherein said first layer comprises about 85% or more by weight of said primary filamentary constituent.

3. The paper sheet of Claim 1 wherein said sheet has an average HTR-Texture of about 0.7 or less.

4. The paper sheet of Claim 3 wherein said HTR-Texture is a vestigial remnant of creping.

S. The paper sheet of Claim 1 wherein said velutinous top surface has an average FFE-Index of at least about ninety (90).

6. The paper sheet of Claim 1 wherein said first layer further comprises a remainder filamentary constituent of relatively long papermaking fiber having average lengths of about 2.0 mm or more.

7. The paper sheet of Claim 6 wherein said long papermaking fibers are substantially as flaccid as said short papermaking fibers.

8. The paper sheet of Claim 1 wherein said second layer comprises primarily fibrous material.

9. The paper sheet of Claim 8 wherein said second layer comprises about 40% or more by weight of relatively long papermaking fibers having average lengths of about 2.0 mm or more.

10. The paper sheet of Claim 1 wherein said sheet has a basis weight of from about 6 to about 40 pounds per 3,000 square feet (about 10 to about 65 grams per square meter), and said first layer has a basis weight of from about 3 to about 35 pounds per 3,000-square feet (about 5 to about 57 grams per square meter), said basis weights being as measured in an uncreped state.

11. The paper sheet of Claim 10 wherein said sheet has a basis weight of from about 7 to about 25 pounds per 3,000 square feet (about 11 to about 41 grams per square meter), and said first layer has a basis weight of from about 3 to about 20 pounds per 3,000 square feet (about 5 to about 33 grams per square meter), said basis weights being as measured in an uncreped state.

12. The paper sheet of Claim 1, further comprising a third layer comprising papermaking fibers, said third layer being juxtaposed the opposite side of said second layer from said first layer, said third layer comprising a principal filamentary constituent of about 6070 or more by weight of relatively short papermaking fibers and having a velutinous outside surface, said sheet further having an average HTR-Texture on its third layer side of about 1.0 or less, and said velutinous outside surface having an average FFE-Index of about sixty (60) or more.

13. The paper sheet of Claim 2, 3 or 5 further compris-ing a third layer comprising papermaking fibers, said third layer being juxtaposed the opposite side of said second layer from said first layer, said third layer comprising a principal filamentary constituent of about 60% or more by weight of relatively short papermaking fibers and having a velutinous outside surface, said sheet further having an average HTR-Texture on its third layer side of about 1.0 or less, and said velutinous outside surface having an average FFE-Index of about sixty (60) or more.

14. The paper sheet of Claim 12 wherein said third layer is substantially identical to said first layer in composition, average HTR-Texture, and average FFE-Index.

15. The paper sheet of Claim 1, wherein said sheet further comprises a relatively highly bulked and textured third layer of papermaking fibers which third layer is disposed on the opposite side of said second layer from said first layer.

16. The paper sheet of Claim 2, 3 or 5, wherein said sheet further comprises a relatively highly bulked and textured third layer of papermaking fibers which third layer is disposed on the opposite side of said second layer from said first layer.

17. The paper sheet of Claim 15 wherein said third layer is comprised primarily of relatively short papermaking fibers which are partially displaced outwardly from the general plane of said sheet in small discrete deflected areas, said deflected areas numbering from about 15 to about 560 per square cm.

18. A two-ply sheet type tissue paper product having a substantially flat velutinous top surface, said product comprising a first ply of tissue paper and a second ply of tissue paper in juxtaposed relation, said first ply being a two-layer tissue paper sheet comprising a first layer and a second layer, said first layer comprising a primary filamentary constituent of about 60% or more by weight of relatively short papermaking fibers having average lengths of from about 0.25 mm to about 1.5 mm, said velutinous top surface being the outwardly facing surface of said first layer which surface is defined by substantially unbonded free end portions of a multi-plicity of said short fibers, said sheet having an average HTR-Texture of about 1.0 or less, and said velutinous surface having an average FFE-Index of at least about sixty (60).

19. The two-ply sheet type tissue paper product of Claim 18 wherein said second ply comprises an upper layer of papermaking fibers and a lower layer comprising substrate means for supporting said first layer and for providing said second ply with sufficient tensile strength for its intended purpose.

said upper layer comprising a first filamentary constituent of about 60% or more by weight of relatively short papermaking fibers having average lengths of from about 0.25 mm to about 1.5 mm, said upper layer further having an outwardly facing velutinous surface defined by substantially unbonded free end portions of a multiplicity of said short fibers, said second ply having an average upper layer HTR-Texture of about 1.0 or less, and said velutinous surface of said upper layer having an average FFE-Index of about sixty (60) or more, said first and second plies being associated with said second layer of said first ply being juxtaposed said lower layer of said second ply whereby both outwardly facing surfaces of said product are velutinous surfaces.

20. The two-ply sheet type tissue paper product of Claim 18 wherein each said ply having a velutinous surface further comprises a relatively highly bulked and textured third layer disposed to face oppositely from each said ply's respective said velutinous surface.

21. The two-ply sheet type tissue paper product of Claim 20 wherein said third layer is comprised primarily of relatively short papermaking fibers which are partially displaced outwardly from the general plane of said sheet in small discrete deflected areas, said deflected areas numbering from about 15 to about 560 per square cm.

22. The two-ply sheet type tissue paper product of Claim 18, 19 or 20 further comprising means for providing said product with substantial wet strength whereby said product is adapted to be a facial tissue or a paper towel.

23. The two-ply sheet type tissue paper product of Claim 18, 19 or 20 further comprising means for providing said product with relatively low wet strength whereby said product is adapted to be a toilet tissue.

24. A method of making a multi-layer wet-laid tissue paper sheet having a substantially flat and smooth velutinous top surface which velutinous top surface comprises a primary filamentary constituent of about 60% or more by weight of relatively short papermaking fibers having average lengths of about 1.5 mm or less and which velutinous top surface is characterized by an average free-fiber-end index (FFE-Index) of about 60 or greater and an average human-tactile-response texture (HTR-Texture) of about 1.0 or less, said method comprising the steps of:
depositing a first fibrous slurry comprising about 60% or more of said relativelay short papermak-ing fibers onto a first forming surface which is sufficiently smooth to provide a paper web formed thereon from said first slurry with an average HTR-Texture of about 1.0 or less;

depositing a second fibrous slurry onto a second forming surface, said slurry comprising rela-tively long papermaking fibers as a primary constituent;
dewatering and associating said slurries suffic-iently to form a multi-layer embryonic web comprising at least two layers in juxtaposed relation; and, breaking sufficient bonds intermediate said multi-plicity of short papermaking fibers defining said top surface of said web to provide a predetermined average FFE-Index of about 60 or greater.

25. The method of Claim 24 wherein a 2-layer embryonic web is formed.

26. The method of Claim 25 wherein said second forming surface is a relatively smooth foraminous surface of a papermaking machine member, and said first forming surface is the outwardly facing surface of said web layer formed from said second slurry.

27. The method of Claim 25 wherein said first forming surface is a relatively smooth foraminous surface of a papermaking machine member, and said second forming surface is the outwardly facing surface of said web layer formed from said first slurry.

28. The method of Claim 25, 26 or 27 further comprising the steps of forming a third embryonic layer from a third fibrous slurry comprised primarily of relatively short papermaking fibers having average lengths of about 1.5 mm or less so the layer formed from said second slurry is sandwiched between the layers formed from said first slurry and said third slurry, and breaking sufficient interfiber bonds intermediate fibers defining the outer surface of said third layer to provide said surface with a predetermined average FFE-Index of at least about 60.

29. The method of Claim 25, 26 or 27 further comprising the steps of forming a third embryonic layer from a third fibrous slurry comprised primarily of relatively short papermaking fibers having average lengths of about 1.5 mm or less to form a third embryonic layer so that the layer formed from said second slurry is sandwiched between the layers formed from said first slurry and said third slurry, and dewatering said third embryonic layer with a differential fluid pressure while said third embryonic layer is juxtaposed a carrier member having sufficiently large mesh openings to enable a substantial portion of the short fibers of said third layer to be displaced into said mesh openings to textur-ize said third layer to an average HTR-Texture of greater than 1Ø

30. A method of making a 3-layer wet-laid tissue paper sheet having a substantially flat and smooth velutinous top surface and a substantially textured bottom surface, said velutinous top surface comprising a primary filamentary constituent of about 60% or more by weight of relatively short papermaking fibers having average lengths of about 1.5 mm or less and which velutinous top surface is characterized by an average free-fiber-end index (FFE-Index) of about 60 or greater and an average human-tactile-response texture (HTR-Texture) of about 1.0 or less, said method comprising the steps of:
wet forming a first embryonic layer of paper having a top surface from a first fibrous slurry com-prising about 60% or more of said relatively short papermaking fibers on a first forming surface which is sufficiently smooth to provide a paper web formed thereon from said first slurry with an average HTR-Texture of about 1.0 or less;

wet forming a 2-layer web having a substantially planar long fiber layer having a smooth outer surface and a predominantly short fiber bottom layer having a substantially textured outer surface by deflecting discrete portions of the short fiber layer into the interfilamentary spaces of a foraminous carrier fabric;

dewatering and associating said first layer with said 2-layer web so that said first layer is juxtaposed said smooth outer surface to form a unified 3-layer embryonic web, and drying said embryonic web without imparting substantial texture thereto whereby said papermaking fibers become bonded together in a relatively smooth unified web, said unified web having a top surface defined primarily by a multiplicity of inter-fiber-bonded short papermaking fibers from said first slurry; and breaking sufficient bonds intermediate said multi-plicity of short papermaking fibers defining said top surface of said first layer of said 3-layer web to provide said top surface with a predeter-mined average FFE-Index of about 60 or greater.

31. The method of Claim 24, wherein said breaking of sufficient bonds is enabled by adhering said web to a creping surface and effected by creping said web from said creping surface at a fiber consistency of about 80%
or more, and said method further comprises the step of calendering and drawing said web sufficiently to assure an average top surface HTR-Texture of about 1.0 or less.

32. The method of Claim 26, 27 or 30, wherein said breaking of sufficient bonds is enabled by adhering said web to a creping surface and effected by creping said web from said creping surface at a fiber consistency of about 80% or more, and said method further comprises the step of calendering and drawing said web sufficiently to assure an average top surface HTR-Texture of about 1.0 or less.

33 The method of Claim 31 wherein said creping is effected at a fiber consistency of about 95% or more.

34 The method of Claim 31 wherein said creping is effected to a sufficient degree to impart an average HTR-Texture to said top surface of said web of greater than 1.0, and an average FFE-Index to said top surface of about 90 or more.

35. The method of Claim 31 wherein said top surface of said web is the surface of said web which is adhered to said creping surface.