CA1222406A - Wet-microcontracted paper and concomitant process - Google Patents
Wet-microcontracted paper and concomitant processInfo
- Publication number
- CA1222406A CA1222406A CA000423570A CA423570A CA1222406A CA 1222406 A CA1222406 A CA 1222406A CA 000423570 A CA000423570 A CA 000423570A CA 423570 A CA423570 A CA 423570A CA 1222406 A CA1222406 A CA 1222406A
- Authority
- CA
- Canada
- Prior art keywords
- web
- fabric
- transfer
- paper
- velocity
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Classifications
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21F—PAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
- D21F11/00—Processes for making continuous lengths of paper, or of cardboard, or of wet web for fibre board production, on paper-making machines
- D21F11/006—Making patterned paper
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21F—PAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
- D21F11/00—Processes for making continuous lengths of paper, or of cardboard, or of wet web for fibre board production, on paper-making machines
- D21F11/14—Making cellulose wadding, filter or blotting paper
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21F—PAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
- D21F2/00—Transferring webs from wet ends to press sections
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24355—Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
- Y10T428/24446—Wrinkled, creased, crinkled or creped
- Y10T428/24455—Paper
- Y10T428/24463—Plural paper components
Abstract
WET-MICROCONTRACTED PAPER
AND CONCOMITANT PROCESS
Edward R. Wells and Thomas A. Hensler ABSTRACT
High bulk, absorbent piper having a relatively high MD elongation at rupture, and a substantially greater stress/strain modulus in the lowest one-third of its range of MD extensibility -- preferably when wet -- than equally machine-direction-stretchable, purely dry-foreshortened (e.g., dry-creped) paper having substantially identical MD elongation at rup-ture. The process includes a differential velocity transfer of a wet-laid embryonic web having relatively low fiber consistency from a carrier to a substantially slower moving, open-mesh transfer fabric having a substantial void volume; and thereafter drying the web while precluding substantial macroscopic rearrangement of the fibers in the plane of the web. The differ-ential velocity transfer is effected without sub-stantial compaction of the web by avoiding substantial mechanical pressing, centrifugal slinging, air blast-ing, and the like. The MD stress-strain property of the paper when wet is directly related to the magnitude of the differential velocity at transfer; to the magnitude of the wet-strength property of the paper;
and to the topography of the transfer fabric.
AND CONCOMITANT PROCESS
Edward R. Wells and Thomas A. Hensler ABSTRACT
High bulk, absorbent piper having a relatively high MD elongation at rupture, and a substantially greater stress/strain modulus in the lowest one-third of its range of MD extensibility -- preferably when wet -- than equally machine-direction-stretchable, purely dry-foreshortened (e.g., dry-creped) paper having substantially identical MD elongation at rup-ture. The process includes a differential velocity transfer of a wet-laid embryonic web having relatively low fiber consistency from a carrier to a substantially slower moving, open-mesh transfer fabric having a substantial void volume; and thereafter drying the web while precluding substantial macroscopic rearrangement of the fibers in the plane of the web. The differ-ential velocity transfer is effected without sub-stantial compaction of the web by avoiding substantial mechanical pressing, centrifugal slinging, air blast-ing, and the like. The MD stress-strain property of the paper when wet is directly related to the magnitude of the differential velocity at transfer; to the magnitude of the wet-strength property of the paper;
and to the topography of the transfer fabric.
Description
I~T-MICROCONTRACTED PAPER
AND CONCOMIT~NT PROCESS
Edward R. Wells and Thomas A. ~ensler DESCRIPTION
Technical Field This invention pertains to tissue paper having high bulk, high liquid absorbency, and high machine direction extensibility; and to methods of making such paper. More specific~ll~ this invention pertains to such tissue paper which, rel`ative to dry-creped tissue paper, has a substantiàlly higher machine direction stress/strain modulus through its low range of machine direction extensibility; and a process for makin~ such tissue paper which process includes substantially foreshortening a wet- laid paper web in the wet end o~
a papermaking machine under such conditions that the foreshortening does not precipitate substantial com-paction or d~nsification of the web.
Background Art Tissue paper having h~gh bulk (i.eO, low density),high liquid absorbenc~, and high machine direction (MD?
ex~ensibility is disclosed in U.S. Patent 3,301,746 which issued January 31, 1967 to L. H. Sanord and J.
B. Sisson. Briefly, their invention involves predrying an uncompacted paper web, and then imprinting a knuckle pattern from an imprinting fabric into the paper web under high pressure. Thus, portions of ~he web are co~pacted by the high pressure and the remainder of the '~
4~
web remains uncompacted. The compacted portions con-tribute strength; and the uncompac~ed portions preserve bulk. The MD extensibility is, predominantly, pre-cipitated by dry creping. Such dry-creped paper manifests a very low MD stress/strain modulus until a high percentage of its MD extensibi.lity is pull~d out.
Thus, when it is desi~able to retain a substantial portion of dry creping induced MD extensibility, control of the web do~nst~eam of the creping blade is very difficult because substantial tensioning of the web to facilitate its control is virtually precluded:
especially with respect to low strength tissue paper at high machine speeds (e.g., greater than three-thousand-feet-per-minute) (about 914 m/min). U.S. Patent 15- 3,994,771~whi~ch issued ~ovember 30,~ 1976 to~George Morgan, Jr. and Thomas F. Rich extended this technology to layered paper, the title of ~he patent being Process For Forming A Layered Paper ~eb Having Improved Bulk, Tactile Impression And Absorbency And Paper Thereof.
A Method And Apparatus For Shrinking A Traveling Web Of Fiberous Mate~i~l in the wet end of a paper-making machine is disclosed in U.S. Patent 4,072,S57 which issued Februa~y 7, 1978 to Christian Schiel. The Schiel invention is apparently presented as an al-ternative to dry-creping and the like for webs having insufficient strength to undergo dry creping and the like; andl or a way of achieving a shrunken web from a given furnish in such a way that the web has a higher MD tensile streng~h than were equal shrinkage pre-cipitated by dry-creping or the like. Basically, the Schiel invention involves transferring a wet paper web from a porous carrier fabric to a slower moving trans-fer fabric by passin~ them in juxtaposed relation ~ ~ 2 2 ~ ~ ~
across a centrifugal force inducing transfer head, and applying a differen~ial pressure across them and the transfer head. Inferentially, it is believed that paper produced by practicing the Schiel invention would not have high bulk, and its MD stress/strain property is not elucidated. That is, the Schiel patent focuses on achieving a shrunken web of high ultimate strength rather than achieving a hi~h bulk tissue having high MD
extensibility and a relatively high stress/strain modulus through its low and in~ermedia~e ranges of extensibili~y than dry-creped paper as is provided by the present invention.
A ~ethod For ManufacturingiCn A ~aper Machine ~
'' Paper Whi'ch Has`Good Fri'ction Characteristics ~n'd/'~r'" ' '`
Which Is Stretchable is disclosed in Canadian Patent 879,436 which issued August 31, 1971, and British Patent 1,212,473 which published November 18, 1970 which patents ~ere both apparently deri~ed from a common Finnish patent application having a priority date o Mar~h 1, 1968. These patents also disclose a papermaking process which includes a wet-end differ-ential velocity transer which, as a rule, is effected at less thar~ a seven percent velocity diferential.
Successive differential velocity transfers are dis cussed as a means of makin~ it possible to short~n the paper web to a high degree: presumably substantially greater than seven percent. Achieving stretchable paper having a high coefficient of fri~tion is a pri-mary objective of the invention whereas achieving high bulk is apparently not inasmuch as all of the figures disclose wet press sections downstream fro~ the dif-ferential velocity transfer zone.
AND CONCOMIT~NT PROCESS
Edward R. Wells and Thomas A. ~ensler DESCRIPTION
Technical Field This invention pertains to tissue paper having high bulk, high liquid absorbency, and high machine direction extensibility; and to methods of making such paper. More specific~ll~ this invention pertains to such tissue paper which, rel`ative to dry-creped tissue paper, has a substantiàlly higher machine direction stress/strain modulus through its low range of machine direction extensibility; and a process for makin~ such tissue paper which process includes substantially foreshortening a wet- laid paper web in the wet end o~
a papermaking machine under such conditions that the foreshortening does not precipitate substantial com-paction or d~nsification of the web.
Background Art Tissue paper having h~gh bulk (i.eO, low density),high liquid absorbenc~, and high machine direction (MD?
ex~ensibility is disclosed in U.S. Patent 3,301,746 which issued January 31, 1967 to L. H. Sanord and J.
B. Sisson. Briefly, their invention involves predrying an uncompacted paper web, and then imprinting a knuckle pattern from an imprinting fabric into the paper web under high pressure. Thus, portions of ~he web are co~pacted by the high pressure and the remainder of the '~
4~
web remains uncompacted. The compacted portions con-tribute strength; and the uncompac~ed portions preserve bulk. The MD extensibility is, predominantly, pre-cipitated by dry creping. Such dry-creped paper manifests a very low MD stress/strain modulus until a high percentage of its MD extensibi.lity is pull~d out.
Thus, when it is desi~able to retain a substantial portion of dry creping induced MD extensibility, control of the web do~nst~eam of the creping blade is very difficult because substantial tensioning of the web to facilitate its control is virtually precluded:
especially with respect to low strength tissue paper at high machine speeds (e.g., greater than three-thousand-feet-per-minute) (about 914 m/min). U.S. Patent 15- 3,994,771~whi~ch issued ~ovember 30,~ 1976 to~George Morgan, Jr. and Thomas F. Rich extended this technology to layered paper, the title of ~he patent being Process For Forming A Layered Paper ~eb Having Improved Bulk, Tactile Impression And Absorbency And Paper Thereof.
A Method And Apparatus For Shrinking A Traveling Web Of Fiberous Mate~i~l in the wet end of a paper-making machine is disclosed in U.S. Patent 4,072,S57 which issued Februa~y 7, 1978 to Christian Schiel. The Schiel invention is apparently presented as an al-ternative to dry-creping and the like for webs having insufficient strength to undergo dry creping and the like; andl or a way of achieving a shrunken web from a given furnish in such a way that the web has a higher MD tensile streng~h than were equal shrinkage pre-cipitated by dry-creping or the like. Basically, the Schiel invention involves transferring a wet paper web from a porous carrier fabric to a slower moving trans-fer fabric by passin~ them in juxtaposed relation ~ ~ 2 2 ~ ~ ~
across a centrifugal force inducing transfer head, and applying a differen~ial pressure across them and the transfer head. Inferentially, it is believed that paper produced by practicing the Schiel invention would not have high bulk, and its MD stress/strain property is not elucidated. That is, the Schiel patent focuses on achieving a shrunken web of high ultimate strength rather than achieving a hi~h bulk tissue having high MD
extensibility and a relatively high stress/strain modulus through its low and in~ermedia~e ranges of extensibili~y than dry-creped paper as is provided by the present invention.
A ~ethod For ManufacturingiCn A ~aper Machine ~
'' Paper Whi'ch Has`Good Fri'ction Characteristics ~n'd/'~r'" ' '`
Which Is Stretchable is disclosed in Canadian Patent 879,436 which issued August 31, 1971, and British Patent 1,212,473 which published November 18, 1970 which patents ~ere both apparently deri~ed from a common Finnish patent application having a priority date o Mar~h 1, 1968. These patents also disclose a papermaking process which includes a wet-end differ-ential velocity transer which, as a rule, is effected at less thar~ a seven percent velocity diferential.
Successive differential velocity transfers are dis cussed as a means of makin~ it possible to short~n the paper web to a high degree: presumably substantially greater than seven percent. Achieving stretchable paper having a high coefficient of fri~tion is a pri-mary objective of the invention whereas achieving high bulk is apparently not inasmuch as all of the figures disclose wet press sections downstream fro~ the dif-ferential velocity transfer zone.
2~ 36 As compared to the background art described above, the present invention provides MD-stretch-able tissue paper having high bulk and, relative to equally MD foreshortened dry-creped tissue pape~
made from the same fu~nish, a substantially higher stress/strain modulus in the low range o~ its MD
extensibility albeit a somewhat reduced MD tensile rupture strength. Such paper is produced by a method which includes a differential velocity transfer of a web in the ~et end of a papermaking machine that avoids substantial compaction of the web. Through such a substantially non-compacting transfer onto a transfer fabric having a substantial void volume, the web is said to be wet-microcontracted: that means, substan-tially fores~ortened -- preferably from a~out ~en percent to about forty percent -- in the machine direction without substantially increasing the web density. The process also includes drying the paper after the wet-end fo~eshortening without overall com-paction and without substantially altering the ~iberarrangement in the plane of the web. However, the process may include afte~ the post-wet-microcontracting step, pattern lmprinting in accordance with U.S. Patent
made from the same fu~nish, a substantially higher stress/strain modulus in the low range o~ its MD
extensibility albeit a somewhat reduced MD tensile rupture strength. Such paper is produced by a method which includes a differential velocity transfer of a web in the ~et end of a papermaking machine that avoids substantial compaction of the web. Through such a substantially non-compacting transfer onto a transfer fabric having a substantial void volume, the web is said to be wet-microcontracted: that means, substan-tially fores~ortened -- preferably from a~out ~en percent to about forty percent -- in the machine direction without substantially increasing the web density. The process also includes drying the paper after the wet-end fo~eshortening without overall com-paction and without substantially altering the ~iberarrangement in the plane of the web. However, the process may include afte~ the post-wet-microcontracting step, pattern lmprinting in accordance with U.S. Patent
3,301,746 tc~ improve its tensile strength; and some degree of dry-creping to achie~e a product having a hybrid stress/strain modulus: i.e., a stress/strain modulus between those of a purely wet-microcontracted web and a purely dry-creped web having the same overall ~ID foreshortening, and made from the same furnlsh in essentially the same way albeit the different manners of precipitating the MD foreshortening. Such paper is substantially easier to control (e.g., reel) in the dry end of a papermaking machine, and is especially useful in multi-ply ~issue paper products wherein the plies `~ ~ 22 ~
have substantially different stress/strain properties:
particularly wherein the stress/strain properties are sufficiently different to have different characters but which have sufflciently matched elongations at rupture that the multi-ply products have monomodal stress/-strain characters. By way of defining stress/strain properties of different characters, a stress/strain property which, if plotted on a graph, is upwardly concave (i.e., concave as viewed from above) is hereby defined to have a different character than a sub-stantially linear plot or a reversely curved plot:
i.e,, a stress/strain property which when graphed produces an upwardly convex plot.
Disclosure Of The Invention . _w In accordance with one aspect of the invention, a process is provided for making high bulk, MD-extensible tissue paper having an MD stress/strain property sub-stantially different from comparably extensible dry-creped paper; that is, different by virtue o~ having a substantially greater MD stress/strain modulus through its low and moderate ranges of MD extensibility This is achieved by forming an embryonic web from an aqueous fibrous papermaking furnish, and non-compressively removing sufficient water therefrom prior to its reaching a transfer zone on a carrier fabric that it has a predetermined fiber consistency at the transfer zone. The consistency prior to the transfer is prefer-ably from about ten to about thirty percent fibers by weight and, more preferably, from about ten to about twenty percent fibers by weight and, most preferably, from abou~ ten to about fifteen percent fibers by weight.
Dry and/or ~et strength additives may be included in the furnish or applied to the web after its formation to im-part a predetermined level of streng~h to the ~7eb. At the 2~
transfer zone, ~he back side of a transfer ~l.e., receiving) fabri~ traverses a convexly curved transfer head. While the transfer fabric is so traversing the transfer head, the carrîer fabric is caused to converge and then diverge therewith at sufficiently small acute angles that compaction of the web therebetween is substantially obviated. The transfer fabric has a substantial void volume, and is for~arded at a pre-determined lesser velocity than the carrier abric;
preferably the lesser velocity is from about ten to about forty percent slower and, more preferably, from about fifteen percent to about thirty percent slower than the velocity of the carrier fabric. Preferably, the transfer fabric has a sufficient void volume by virtue of being an open weave and ha~ing a mesh count of from about four to about thirty ~ilaments per centi-meter in both ~he machine direction and the cross-machine direction and, mo~e preferably, from about six to about twenty-six ilaments per centlme~er in both directions and, most preferably, from about six to about ifteen filaments per centlmeter in both direc-tions. At the transfer zone, only a sufficient di-fferential gaseous pressure -- pre~erably vacuum applied through the transfer head -- is applied to the web to cause it to tr~nsfer to the transer fabric without substantial compaction: i.e., ~ithout a sub-stantial increase in its density. The web is there-after dried without overall compaction thereof and without su~stantially altering ~he macroscopic fiber arrangement in the plane of the web. Preferabl~, however, the web is imprin~ed with the knuckle pattern of the transfer fabric under high pressure to precipi-tate tensile strength bonds, and the web preferably is suficientl~ dry-creped to substantially reduce any harshness which might otherwise be precipitated by such imprinting, The web may then be lightly calend~red for ~ caliper control and reeled or directly~ ~ to `' paper products. The calender or the reel may be operated at such a speed relative to the dry-creping velocity of the web that the finished paper has a predetermined ~esidual degree of dry crepe or virtually none at the papermaker's option or as desired from the paper properties viewpoint.
Brief Description Of The Dxawings .
While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter regarded as forming the present invention, it is believed the invention will be better understood from the following description taken in coniuction with the accompanying drawings in which identical designators in the se~eral views refer to substantially identical entities such as papermaking machine components, and in which:
Figure ~ is a fragmentary, side elevational ~iew of a transfer zone of an exemplary papermaking machine through the use of which the method of the present invention may be practlced.
Figure 2 is a some~hat schematic side ele-vational view of a papermaking machine in which a transfer zone such as shown in Figure 1 is incorporated and through the use of which the present invention may be practiced.
Figures 3 and 4 are fragmentary plan views of an exemplary forming wire/carrier fabric and an exemplary transfer/imprinting abric, respectively, for use in th~ papermaking machine shown in Figure 2.
Figure 5 is a fragmentary, enlarged scale, side elevational view o the creping-dryin~ cylinder and creping blade portion of the papermaking machine shown in Figure 2.
Figures 6 through 8 a~e graphical representations of parametric relationships pertaining to the present invention as practiced in a papermaking machine of the configuration shown ~in Figure 2.
~ . . . .. . . . . .
Figure 9 is a somewhat schematic, side elevational view of a 3-loop, twin-wire-fo~mer (TWF) type paper- -making machine in which the me~hod of the presentinvention may be practiced.
Figures 10 and 11 are mixed graphical representa-tions of parametric relationships pertaining to the present invention as practiced in papermakin~ machines of the configurations shown in Fi~ures 2 and g.
Figures 12 through 15 are graphs o~ parametric relationships pertaining ~o the present invention as practiced in a papermaking machine of the configuration shown in Figure 9.
Figure 16 is a somewhat schematic, side eleva-tional view of another papermaking machine in which the method of the present invention may be practiced.
t~
. 9 _.
Figures 17 and 18 are graphs of stress/strain relationships of tissue paper embodiments of the present invention which paper was made through the use of a papermaking making machine o the configuration shown in Figure 16.
Detailed_~ sc__ption Of The Invention Figure 1 shows a differen~ial-velocity ~ransfer zone ZO of an exemplary papermaking machine 21, Figure 2, with which the method of the present invention may be practiced, and through the use of which papermaking machine paper embodiments o ~he present invention may be produced.
.
Briefly, the method of the present invention involves the formation of a paper web from an aqueous slurry of papermaking ~ibers; for~arding the web at a low ~iber consistency on a ~o~a~inous member to a differential velocity transfer zone where the web is ~ransferred to a slo~er mo~ing member such as a loop of open weave f~bric to achieve wet-microcontraction o 20 the web in the machine directicn without precipitating substantial macrofolding (deined hereinafter3 or compaction of the web; and, subsequent to the dif-erential velocity transfe~, drying the web without overall compaction and without further material re-arrangement ~f the fibers o the web in the planethereof. The paper may be pattern com2acted by im-printing a fabric knuckle pattern into it prior to final drying; and the paper may be creped after being dried. Also, primarily for product caliper control t the paper may be lightly calendered after being dried.
A primary facet of the invention is to achieve the differential velocity transfer without precipitating ~;~2~
- 10 ~
substantial compaction (i.e., densification) of the web. Thus, the web is said to b~ wet-microcontracted as opposed to being wet compacted or macro-folded or the like.
The principal process parameters which determine the ultimate density, and stress/strain modulus and character o~ paper embodiments of the present invention include: the percentage velocity differPnce between the carrier fabric and the transfer fabric; the fiber consistency of the web when undergoing the differential velocity transfer; the void volume and topography of the transfer fabric; thc geometry of the transfer zone;
strength additives; creping angle i creped; and ~ ` degree~of residual crepe i~ dry-creped.
1~ Referring again to Fi~ure 1, transfer zone 20 is seen to comprise couch roll 23, re~urn roll 24, trans-fer head 25, carri~.r f~b~ic 26 looped abou~ rolls 23 and 24 and across the convex facing surface ~7 of transfer head 25, transfer ~abric 28 which is lead across transfer head 25 intermediate surface 27 and the carrier fabric 26 and thence across vacuum box 29. As shown in Figure 1, ~eb 30 is forwarded at velocity V
to transfer zone 20 on carrier fabric 26 and is for-warded at velocity V2 from the ~ransfer zone 20 on transfer fabric 28. A sufficient level o vacuum to ef~ect transfer from carrier fabric 26 to transer fabric 28 is applied through modulator means not shown to the web 30 via port 32 in transfer head 25. This vacuum also effects some water removal from web 30 after which the web is subjected to additional vacuum applied through ports 33, 34 and 35 on vacuum box 29 to achieve further dewatering of the web. The vacu~m applied ~o ports 33, 34, and 35 may be individually ~ ~22~6 modulated or modulated by a common means not show~.
While not intending to thereby rigidly limit the present invention to such stated values, the angles of convergence C and divergence D of carrier fabric 26 and transfer ~abric 28 are pre~erably in the order of about fifteen degrees or 50, and the angular change 38 in the direction of carrier fabric 26 over surface 27 is preferably about ten degrees so that a vacuum seal is maintained across the slot in surface 27 of transfer head 25, and so that web 30 is not substantially compressively compacted in the transer zone. Also, surface 27 is convexly curved downstream (i.e., in the direction fabric 28 traverses surface 27) with a rela-tively large radius (e.g., 8 inch radius or larger) to preclude high levels of paper ~eb compressio~ due to hoop stress induced by tension in fabric 26, and so disposed to obviate centri~ugal force on web 30 as web 30 is forwarded past the transfer head 25.
Figure 2 shows, in somewhat schematic form, an exemplary papermaking machine 21 or prac~icing the present invention. Papermaking machin~ 21 comprises transfer zone 20 as described hereinabove and, ad-ditionally: a orming sec~ion 41, an intermediate carrie~ section 42,a pre-dryer/ lmprintin~ section 43, a drying/crepin~ section 44, a calender asse~bly 45, and reeling means 46.
The forming section 41, Flg~re 2, of papermaking machine 21 comprises a headb~x S0; a loop of fine mesh forming wire or fabric 51 which is looped abou~ a vacuum breast roll 52, ove~ vacuum box 53, about rolls 55 through 59, and under showe~s 60. Intermedia~e rolls 56 and 57, ~orming wire 51 is deflected from a ~2;~ 6 straight run by a separation roll 62. Biasing means not shown are provided for moving roll 58 as indicated by the adjacent arrow to maintain fabric 51 in a slack-obviating tensioned state.
Intermediate carrier section 42, Figure 2, com-prises a loop of carrier fabric 26 which is looped about rolls 62 through 69 and about an arcuate portion of roll 56. The loop of fabric 26 also pass~s over vacuum box 70, and transfer head 25; and under showers 71. Biasing means are also provided to move roll 65 to obviate slack in fabric 26 as was discussed above with respect to obviating slack in fabric 51. As is clearly indicated in ~igure 2, Juxtaposed psrtions of fabrics 51 and 26 extend about an arcuate portion of roll 56, across vacuum box 70, and separate a~ter passing over an arcuate portion of separation roll 62. Preferabl~, fabric 26 is identical to fabric 51 but for thei~
lengths.
The pre-dr~er/imprinting section 43, Figure 2, o 20 papermaking lilachine 21 comprises a loop of transer fabric 28 which is alternatively referred to as an imprintin~ fabric~ Fabric 28 is looped about rolls 77 through 86; passes across trans~er head 25 and vacuum box 29; through a blow-through p~e-dryer 88; and u~der showers 89. Additionally, means no~ shown are provided for biasing roll 79 towards the adjacent dryingfc~eping cylinder 91 with a predetermined force per lineal inch (pli) to effect imprinting the knuckle pattern of fabric 28 in web 30 in the manner o~ and for the purpose disclosed in the hereinbefore referenced Sanford and Sisson patent; and biasing means not shown are provided or moving roll 85 as indicated by the ~l~2~4 adjacent arrow to obviate slaclc in fabric 28.
The drying/creping section 44, Figure 2, of papermaking machine 21 comprises drying/creping cylin der 91 which is hereinafter alternatively referred to 5 as ~ankee 91, adhesive applicator means 92, and doctor blade 93. This portion of pape~making machine is shown in somewhat larger scale in Figure 5 in order to clearly define certain angles with respect to the doctor blade 93 and its relation to Yankee 91. Accord-10 ingly, drying~creping section 44 is described morefully hereinafter concomitantl~ with discussin~ Figure 5.
S~ill referring to papermaking ~achine 21, Figure 2) it fur her comprises means not shown for independ~
15 ently controlling the velocites Vl (of carrier fabric 26), Y2 ~of transfer fabric 28 and Yankee 91), V3 (of calender 45)> and V~ (of reeling means 46) in order to independently control the degree of wet-microcontrac-tion precipitated in the transfer zone 20> the degree 20 of dry-crepe, and the degree of residual dry-crepe as is more fully deseribed hereinafter.
Figure 3 is an enlarged scale frag~entary plan view of an exempla~y carr~er fabric 26 and, preferably, of the for~ing fabric 51 o~ papermaking machine 21, 25 Figure 2. The specific fabric 26 shown in Figure 3 comprises machine direction filamen~s 95 and cross-machine-direc~ion ilaments 96 which are wo~en together in a 5-shed satin weave using a non-numerically-con-secutive warp plck sequence. This forms an open weave 30 fabric havin~ apertures 98. Such a fabric weave is described in U.S. Patent 4,239,065 and shown in Figure 8 thereof. ~ilamPnts 95 and 96 are preferably poly-ester monofilaments. A typical papermaking fiber 97 having an approximate length of about two ~m is shown superimposed on an exemplary fabric 26 having a mesh count of eighty-four machine direction filaments per S inch (about 33 MD filaments per centimeter) and se~enty-six cross-machine direction filaments per inch (about 30 CD filaments per centimeter). All of the filaments of the exemplary fabric 26 have nominal diameters o about seventeen-hundredths ~m. Thus, papermaking fibers tend to lie substantially 1at on such a fine mesh fabric w~len it is used as either a forming fabric or an intermediate carrier fabric; and apertures 98 facilitate water draina~e as well as water removal via vacuum means.
Figure 4 is a fragmentary plan view of an ex-emplary ~ransfer/imprinting fabric 28 of papermaking machine 21, Figu~e 2. The scale of Figure 4 is about the same as for Figure 3 in order to clearly illustrate the relati~ely large apertures 102 (vo~d spaces~ of ~ fabric 28 compared to the size of papermaking fiber 97, and thus mal~;e it réadily apparent that such flbers can be deflected into the voids of such a coarse mesh, open weave transfer fabric. Fo~ instance, as shown, trans-fer fabric ~8 has a mesh count of about twenty-our machine direction filaments 100 per inch (about 9~5 ~D
filaments per centimeter) and about twenty cross-machine direction filaments 101 per inch (about 7.9 CD
filaments per centimete~. The filaments 100 and lOl of the exemplary transfer fabric 28 are preferably poly-ester, and ha~e diamete~s o~ absut six-tenths of a milli~eter. As sho~n, transfer fabric 28 is also an open, 5-shed satin weave generated by using a non-numerically-consecutive warp pick sequence (e.g., 1, 3, 5, 2, 4) as described in U.S. Patent 4,239,065; and the top surface of fabric 28 has been sanded to provide flat eliptical-shape imprinting knuckles designated 103 and 104.
Figure 5 is an enlarged scale view of the creping section of papermaking machine 21 in which the impact angle between ~ankee ~1 and doctor blade 93 is desig-nated angle I, the bevel angle o~ doctor blade 93 is designated angle B, and the back clearance angle be-tween Yankee 91 and doctor blade 93 is designate angle CL. Means not shown are provided for adjusting angle I. In general, creping of a paper web tends to disrupt ~onds in the ~eb. This causes the web to be.softer but .
of lower tensile strength than were it not creped.
These effects of creping can be alte~ed somewhat by adjusting angle 1: that is, increasing angle I will generally lessen the softenin~ induced by creping and will ~enerally lessen the creping induced reduction of tensile strength. Thus, i~creasing angle I will generally precipitate a p~per web having grea~er tensile str~ngth but less softness and dry end sheet control as compared to the paper web being p~oduced prior to so increasing angle I. The optimum value for an~le I will therefore depend on which is the more desirable product attribute: softness or tensile strength. This is particularly significant with respect to the present invention inasmuch as wet-microcsntracting generally precipitates lower tensile strength and less softness but better dry end sheet 3~ control than dry-creping to achieve equally MD foreo shortened paper ~ebs, all other factors being equal.
Indeed) substantially be~ter dry-end sheet control can be achieved in hybrid pape~ wherein MD foreshortening ~24 is precipitated by a combination of wet-microcon-tracting and dry-creping as more fully described hereinafter with respect to discussing Figures 6 and 12.
A papermaking machine o~ the general coniguration shown in Figure 2 and designated therein as papermaking machine 21 was run under the following conditions in accordance with the present invention to produce paper embodiments of the present invention, as well as purPly dry-creped paper. The forming fabric and the carrier fabric were polyester fabrics ha~ing mesh counts o seventy-eight by sixty MD/CD filaments per inch (about . . 30 7. x ~3.6 ~il.aments.per cen~timeter), and.were.~oven in four shed sa~in ~eaves wherein the warps (i.e., ~he machine direction filaments) alternately cross o~er one shute and under three shu~es, and wherein the shutes alternately cross over ~hree warps and under one warp.
The curvature of surface 27 of transfer head ~5 was a~
eight (8) inch (about 20 cm.) radius. The transfer~im-printing fabric 28 ~s of the mesh count and weavedescribed h~reinbefore with respect to ~abric 28, Figure 4: i.e., a 5-shed satin weave which had been woven with a non-numerically-consecutive ~arp pick sequence, and having a ~esh count of twenty-four MD by twenty CD ilaments per inc~ (about 9.4 x 7.9 ilaments per centimeter). The furnish comprised ifty percent (50%) northern softwood kra~t (~SK) (i.e., long paper-making ~ibers) and fity percent (50%~ hardwood sulfite (i.e., short papermaking fibers). A strength additive -- namely Parez 631 NC --was added to the furnish at a rate of about 16.8 pounds per ton (abou~ 8.4 gms/kg).
Parez is a registered trademark of American Cyanamid.
Polyvinyl alcohol creping adhesi~e was used and an impact angle I of eighty-nine ~8~) degrees was main-tained. A fiber consistency o about twelve-and-two-tenths percen~ (12.2%) ~as Tnaintained at the couch roll 23 and a before-pre-dryer (hereinafter BPD) fiber consistency of about twenty-five percent (25%) was maintained. During the run, a constant yelocity Vl o about six hundred ~600) feet per minute (about 183 meters per minute) was maintained for fabrics 51 and 26; a constant reel yelocity V4 of about four-hundred-fifty (450) feet per minu~e (about 137 meters perminute) was main~ained; and no calendering was ef-fected. The principal parameter varied during the run was V2: the linear velocity of the transfer fabric 28 and the surface velocity of Yankee 91. V2 was varied from Vl to less ~han V4: l.e., from six-hundred feet per minu~e (about 183 meters per minute) to our-hundred-twenty feet per minute (about 128 meters per minute). Also, the pape~ web was dried in the p~e-dryer 88 to a fiber consistency of from about seventy to about seventy-five percent after the p~e-dryer (hereinafter APD~, and final dried on the Yankee to about ninety-eight or ninety-nine percent. The re-sulting paper had a basis weight of from about twenty-three-and-ninP-tenths (23.9) to about twenty five-and-six-tenths (25.6) pounds per three-thousand square feet (from about 3~ to about 42 g~ams per square meter), and a dry caliper of from about nineteen-and-eight-tenths (19.8) mils (about 0.5 n~) to about twenty-three-and-four-tenths (23.4) mils (about 0.6 mm).
Figu~e 6 is a graph of stressls~rain data obtained from five dry samples of pape~ produced during the above described run of papermaking machine 21, Figure ~22 2. The values of Vl, V2 and V4 are tabulated in Table I for each designated curve on Figure 2. The percent wet-microcontraction (~MC) listed in Table I was co~-puted by dividing the difference between Vl and V2 by S Vl; the percent dry crepe was computed by dividing the difference between V2 and V4 by V2. The overall MD
foreshortenin~ was computed by dividing the difference between Vl and V4 by Vl.
IABLE I
Overall MD Fore-VELOCITT.ES Dry- Sh~r~-Curv~ Nos. Feet/~inute (meters/minute) WMC Crepe ening Figs 6&7 Vl V2 Y4 lllllllW 600(183~ 630(183)450(137) -O- 25% 25%
112~112W 600(183~ 510(155)450(137) 15~ 13% 25 113/113W 600(1~3) 4~0(146)450(137) 20~ 7% 25~
114/114W 600~183) 450(137)450(137) 25% 0 25%
115/115N G00~183) 420(128)4501137) 30% -7% 25 Parenthetically, ~he stressjstrain data and resultin~ moduli presented in Figures 6-8, lZ-15, 17 and 18, and as used herein were obtained by testing samples having gage len~ths of four inches (about 10 cm) and which were o~e inch (2.54 cm.) wide by applying and recording tensile force in the machine-direction (MD) of the samples in an apparatus which stretched the samples at a rate of about four inches per minute (about 10 cm. per minute). Thus, whereas stress per se is force per unit of cross-sectional area, the graphed stress data are presented in grams force per unit of sample width. ~lso these stress/strain graphs were derived from testing sever~l replicate samples --generally four -- and averaging the data therefrom.
Therefore, data poin~s per se are nst indicated on the graphs.
Still referring to Figure 6, curve 111 was derived from 25% purely d~y-creped paper, and curve 111 is highly upwardly concave which reflects the relative ease (low tensile values) of pulling out dry-crepe induced stretch until the available stretch in the paper is largely removed after which ~he slope of curve 111 increases sharply. By way of contrast, the curves 112 through 115 have distinctly different characters:
i.e., shapes. That is, curve 112 has a generally linear cha~acter and cu~ves 113 through 115 are re-versely curved compared to curve 111. Thus, the hybrid paper samples of curves 112 and 113 -- paper which has been both wet-microcontracted and dry-creped -- as well as the purely wet-mic~cont~acted samples of curves 114 and 115 have distinctly diferent characters rom ~he purely dry-creped paper of Cu~ve 111~ Thes~ character differences are believed to be relatively great due to the relatively low ~iber consistency of the paper web at the time it was transferred ~rom carrier fabric 25 to transfer fab~ic 28: i.e., twelve-and-~wo-tenths percent (12.2%) fibers by weight measured at couch 23.
Still referring to Figure 6, the higher stress/-strain values through the low and/or moderate ranges of elongation of curves 112 th~ough llS as compared to curve 111 manifest why better sheet control can be maintained while reeling andlo~ converting the pure and hybrid WMC paper webs than purely dry-creped webs because higher tension can be maintained on them with-out substantially vitiating their ~D stretch.
Figure 7 is a graph of MD stress/strain data obtained from wet samples of paper which were produced as stated above and described in conjunction with describing Figure 6. That is, curves lllW through 115W
are, respectively, derived from wet samples of the paper which precipitated curves 111 through 115 in Figure 6, above. The hybrid samples have stress/strain curves (112W and 113W) which are substantially less concave upwardly than curve lllW the curve for dry-creped paper. Also, the cu~ves for the purely wet-microcontracted samples (curves 114W and ll5W~ are of a different character ~rom curve lllW: that îs, curve lllW is upwardly concave ~hereas curves 114W and llSW
are upw~rdly convex. Such differences in the relative values and characters of the wet stress/strain curves of hybrid and pure we~-microcont~acted paper (here-inaft~r WMC paper) as compared to purely dry crPped paper makes such WMC paper especially useful as a ply of multi-ply tissue p~oduc~s wherein the plys have substantially identical elongations at rupture, but substantially non-identical stress/s~rain curves. Such paper products wherein the plies are discontinuously adhered together manifest monomodal st~Pss/strain characters due to their matched elongations at rupture;
mani~est additive ply strengths ~hroughout their strain domains; and have high liquid absorbency. For example, consider a discontinuously bonded two-ply product comprising a ply o WMC paper and a ply of purely dry-creped papPr. If an uncons~ained dr~-creped tissue is wetted, crepe induced stresses are relieved and the creped tis~ue elon~ates in the plane o~ the paper as some o the crepe folds are floa~ed out. However, when such a creped ~issue is a pl~ o~ a multi-ply product in which another ply constrains unadhered portions of the ~z~
creped ply from being elongated in the plane o the paper when wetted, but does not otherwise constrain such portions of ~he creped ply, at least some of those portions of the creped ply ~ill pucker. This assumes that such product remains substantially unstressed as wetting thereof is effected. Such puckering enhances the wet bulk and caliper of the product as well as its overall liquid absorbency. In general, ~MC tissue paper will ac~ as such a constrainer for dry-creped 10 tissue paper when they are discon~inuously adhered or bonded together to make a multi-ply product. Also, WMC
paper having zero dry-crepe can be such a constrainer for hybrid WMC/dry-creped paper; and hybrid ~MC/dry-~- creped paper can be such a constrainer for pu~ely dry-creped paper ~i.e., dry-creped paper having no degree ~ WMC), Additional ~xamples of makin~ paper embodiments of the present invention (~.e., pure and hybrid ~C paper~
have been made and are hereinater described to illus-trate, for instance, the fact that the present in-vention may be practiced on a wide variety of paper-making machines, and to illustrate a variety of control parameters with which the level~ and shape of the stress/strain modulus of WMC paper can be tailored to 25 provide parametrically optimized end products: e.g., a WMC paper web having such a stress/strain modulus that, when incorporated in a 2-ply tissue paper product along with a purely dry-creped ply, the product manifests good absorbency and a monomodal stresslstrain property.
30 Note: as used herein, a monomodal stress/strain property is defined as a stresslstr~in curve ha~ing only one peak whereas a product comprising discon-tinuously adhered plies having substantial strengths albeit unmatched ultimate elongations at rupture will have stress/strain curves having two or more peaks.
Note also that pure ~MC paper web and hybrid WMC paper web can also have matched elongations at rupture yet have sufficiently different stress/strain properties Lhat they can be co~bined to form a product which will also pucker when wetted (and thus have high liquid absorbency), and manifest a strength efficient mono-modal stresslstrain property. This is, howe~er, not intended to lmply that a monomodal stress/strain property is required Lo achieve the puckering pre-cipitated absorbency benefit. Rather, matching the plies to achieve a monomodal stressl strain property precipitates strength and energy absorption efficiency i~ such`multi-ply tissue p~per prGducts in additlon to ~ -providing ~he puckering absorbency benefit.
Figure ~ comprises graphed stress/strain dataderived from ~esting additional wet samples o~ r,~MC
paper produc-~d on a papermaking machine of the geometry shown in Flgure 2 to illustrate the transfer fabric mesh count impact on the stressl strain property of the WMC paper. ~ssentially, two runs were made under substantially identical conditions but for the mesh of the transfer[imprinting fabrlc 28, to wit: curve 117 was derived from paper made ~hile a transfer fabric 28 having ~ mesh count of thirt~-six MD filaments per inch (about 14/cm) by thirty-two CD filaments per inch (about 12.6lc~) was on papermaking machine 21; and curve 118 was deri~ed ~ro~ paper made while a transfer fabric 28 having a mesh count of sixty-four MD Eila-ments per inch (about 25.2~cm) by fifty-four CD fila-ments per inch (about 21.3/cm) was on the papermaking machine. Both were of the weave shown in Figure 4.
Thus, all other things being equal, the stress/strain modulus of WMC paper is directly related to the mesh count o the transfer fabric: i.e., a finer mesh precipitates a higher stress/strain modulus and vice versa. It is, however, not intended to thereby imply that finer ~esh fabrics precipitate the best results fro~ the present invention. What is best depends on what product att~ibutes are important. Indeed, while the fine-mesh-fabric curve 118 is higher than the coarse-mesh-abric curve 117 in Figure 8, the 118 paper had a substantially smaller caliper ~i.e., 10.9 ~0.277]
v. 14.1 [0.358] mils ~mmJ for the 117 paper) and thus lower bulk. Accordingly, bulk is enhanced by using - ~coarser transfer fabrics whereas strength is enhanc~d - by using finer transe~ labr~cs. - -15Still referring to Figure 8, the paper samples were made using a fu~nish comprised solely of northern softwood kraft (~elati~ely long papermaking ~ibers).
The papermaki~g machine was run with a velocity Vl of six-hundred feet per minute (about 183 meters per minute) and transfer abric velocity V2-of four-hundred-eighty feet per minute (about 146 meters per minute) to achie~e twency pe~cent (20%) ~MC. The couch consis-tency was about sixteen-and-one-half percent ~or the 117 curve paper 7 and about thirteen~and-nine-tenths percent for the 118 cur~e paper. As the paper was being forwarded on fabric 28, Figure 2, from the pre-dryer 88 to the Yankee 91, the zones of the paper juxtaposed the knuckles of fabric ~8 were im~regnated with a latex binder material by a rotogravure-type applicator, not sho~ in Figure 2. The quantities of latex solids ~or the papers o~ curves 117 and 118 were forty-fou~-hundredths and sixty-hundredths pounds, respectively, per three-thousand-square feet (about 0.72 gms. and 0.98 gms. per s~uare meter). The paper produced had a basis weight ~hen reeled in the range of about seventeen to about eighteen pounds per three-thousand-square-feet (from about 27.6 to about 29~3 grams per square meter), and was lightly calendered at about twelve pounds pe~ lineal inch (pli) (about 2.15 kg per lineal centimeter~. Although the paper was parted from the ~ankee ~1 with a doctor blade 93 set at an impact angle I of eighty-four degrees, the paper had 10 no substantial degree of residual dry-crepe because it was reeled at the same velocity as the velocity of the Yankee 91: i.e., V4-V2.
Figure 9 shows a twin-wire-former (TWF) type papermaking maGhine 121 with which the present process invention can be practiced to produce paper embodiments of the present invention. As compared to paper~aking machine 21, Figure 2, papermaking machine 121 comprises a twin-wire-forme~ sectio~ 12~ rather than a fixed roof former. Insofar as the present invention is concerned, the transfer zone 20 of both machines are preferably identical, as are their pre-dryer/imprinting sections 43, theix dr~inglcreping sections 44, their calender sections 45, and their reeling sections 46. Thus, these sections and their corresponding coFponents are identically numbered albeit some of the components numbered in Figure 2 are not numbered in Figure 9 to avoid undue redundancy.
The twin-wire-former section 122 of papermaking machine 121, Figure 9, comprises an endless foraminous forming fabric 127 which is looped about a plurality of guide rolls 125; and an endless, foraminous carrier fa~ric 26 which is looped abou~ the forming roll 126 and through the transfer zone 20 as shown. Essentially, fabrics 26 and 127 synchronously con~erge ad;acent a headbox 123 from which a jet o aqueous papermaking furnish issues. Primary dewatering occurs through the portion of fabric 127 wrapped about forming roll 126, and subsequent dewatering is assisted by trans~er 5 vacuum box 70 and vacuum box 153 to provide a pre-determined fiber consistency of the web 30 as it is orwarded on fabric 26 to ~he transfer zone 20. In-sofar as the present invention i5 concerned, paper-making machine l~l is operated like papermaking machine 21, Figure 2, and is primarily presented in Figure 9 because it was used to make paper samples from which data were derived and plotted on the graphs presented in Figures lO through 15, inclusive. It is not in-tended, however, to thereby imply that the present in~ention is limited to papermaking machines having identical transfer ~ones.
Figure 10 is a graph comprising curves 131, 132 and 133 of dr~ density data versus percent WMC of a mix of paper samples produced on papermaking machines of the configurations shown in Figures 2 and 9. The samples fro~ which cur~e 131 was deri~ed were purely wet-microcontracted albeit remoYed from the Yankee 91 by doctor 93. That ~s, any dry-crepe which was induced in the webs by doctor 93 was pulled out of the webs by running the reel at the ~ankee velocity: i.e., V4 -V2. These samples had nominal basis weights of about eighteen (18) pounds per three-thousand (3000) square feet (about 29.3 gmslsq. meter); and were made using a transfer fabric 28 o~ the wea~e shown in Figure 4 and a mesh count of twen~y-our MD filaments per inch (about 9.4/cm) by twenty (20) CD filaments per inch (about 7.9/cm), all of the ilaments having a diameter of about six-tenths (0.6) mm. The rise of cur~e 13L at values of I~MC is excess of twenty-five (25) percent is believed to be a manifestation of the fibers o~ the web overcrowding the voids of fabric 28 and precipita~ing some macrofolding of the web lnasmuch as a significant 5 degree of undeslrable mac~oolding induced hard ridges were visible in paper samples made at thirty (30) percent ~MC: l.e., (Vl - V~)IVl - 0.3.
Macrofolding is hereby defined as causing a low-fiber-consistency web to fold in such a manner that 10 adjacent machine direction spaced portions of the web become stacked on each o~her in the Z-direction of the web, whereas we~-microcontracting as defined herein is intended to be wet-end machine-direction-foreshortening which is effected in such a manner that macroolding is 15 substantially precluded.
Still referring to Figure 10, curves 132 and 133 were dcrived f~om families o saFples which families were machine-direction foreshortened twenty percent and twenty-five percent, respectively, and which had basis 20 weights of about eighteen and twenty-five pounds per three-thousand-square feet, respectively, (about 29.3 grams and 40.7 grams per square meter, respectively).
For example, to make a sample for curve 132 having twenty percent machine-direction foreshortening (i.e., 25 (Vl-V4)/V1~20%) which was wet-microcontracted only ten pe~cent (i.e., (Vl-~2)/Vl=10%), it had to be dry-creped to provide the o~her ~en percen~ machine-directio~
foreshortening. Thus, to make the family o samples from which curve 132 was de~ived, V4 ~as maintained 30 constant at eighty percent o~ the value o Vl. and V2 was incremented from Yl to V4. Similarly, for cur~e 133, V4 was maintained cons~ant at seventy-five percent of the value of a constant value of Vl (e.g., 600 feet per minute), and V2 was varied from the value of Vl to the value of V4.
Signiicantly all of the paper samples fr~m which curves 131, 132 and 133 of Figure 10 were derived 5 manifest low density (hlgh bulk) as compared to con-ventional wet-felt-pressed papers. Moreover, curve 131 (purely W~C paper) manifests a decreasing dry density up to about twenty-five percent foreshortening after which the density increase is believed to be a mani-10 festation of macrofolding, whereas curve 132 (sampleshavin~ the same basis weight as for curve 131) mani-fests a slightly increasing dry density as the I~MC
portion of the constant oyerall twen~y-percen~ machine direction oreshortening is increased. Also, curve 133 15 which was derived from samples of heavier basis weight and greater machine direction ~o~eshortening (i.e., 25%) than for cur~e 132 manifests a substantially constant d~y density as the WMC portion of the total twenty-five percent machine direction ~oreshor~ening is 20 varied from zer~ to the full twenty-five percent.
Referri.lg now to Figure 11, curves 131W, 132W, and 133W were derived from we~ samples of the same re-spective paper samples f~om which curves 131, 132, and 133 of Figure 10 were deri~ed. Curves 131W, 132W, and 25 133W all manifest relatively low wet densitles and, very importantly with respect to -the present invention, all manifest an inverse relationship o~ wet density to percent WMC at leas~ up to the nadir o curve 131W at which the foregoing descrlbed macrofolding phenomenon 30 became manifest.
~Z2 Figures 12 and 13 are dry and wet density curves, respectively, derived from data obtained from families of samples which were substantially identically made as the samples from which the curves of Figures 6 and 7 5 were derived except for their basis weight, and for their percent fibe~ consistencies by weight at the point of their differential velocity transfers. For Figures 6 and 7, the fiber consistency at couch 63 was maintained at abou~ twelv~-and-two-tenths percent 10 (12.2V/o), and for Figures 12 and 13 it was maintained at about twenty-one-and-one-half percent (21.5%).
The basis weigh~s for Figures 6 and 7 were about twenty--f~ve po~nds per thre~-thousand s~uare feet (about 40.7 grams per squà~e meter~ and for Figures I2 15 and 13 were about eighteen pounds per three-thousand square feet (about 29.3 grams per square meter). These comparative data manifest much greater differences between WMC paper and purely dry creped paper for the Figure ~ and 7 samples deri~ed at the lower fiber 20 consistency (12.2%) than for the Flgu~e 12 and 13 samples derilred at the higher fiber consistency (21.5%) at transfer. Albeit the pre~erred range of fiber consistency at transfer is f~om about ~en to about thirty percent, the more p~eferred ran~e is rom abou~
25 ten to about twent~ percent, and the most preferred range is from about ten to about fifteen parcent.
Velocity and MD foreshortening data ~or the samples from which the cu~ves of Figures 12 and 13 were derived are presented in T~ble II. These data also 30 indicate tha~ some WMC can be pulled out of the samples by reeling the paper faster at a velocity V4 which is greater than the Yankee ~elocity V2; it does no~ shift the stress/strain further upward and to the l~ft as was the case at the lower level of fiber consistency at transfer. That is, compare the displacement of curve 115 relative to curve 114, Figure 6, to the virtual 5 non-displacement of curve 139 relative to curve 138, Figure 1~.
TABL~ II
Overall ~ Fore-VELOCITIES Dry- Short-Cu~ve Nos. Feet/minute (mete~s/minute) ~MC Crep~ ening Figs. 12&13 Vl 2 ~4 ; 135/135W 8~Q~244) 800~(244~. 560(171) -O- 30~ 30%
` ~ 136/I36W 8~0(244~' 705(215) ' 560`(I71) I2 -21 30%-137/137~ 800(244) 620(18g) 560(171) 22 10 30%
13~/138W 8QO(2h4) 560~171) 560(171~ 30% -0- 30%
139/13~W 800(244) 520(158~ 560(171) 35% -8% 307, Figures 14 and 15 a~e graphs upon ~hich the curves ~ere derived xom dry and ~et samples, re-spectively, having different levels of wet-microcon--traction ranging rom fifteen to thirty percent in five percent (5%) incremen~s. Briefly, the samples from which these data ~ere de~iyed were run to lllustrate how the ~1Ongation a~ rupture o~ WMC pap~r can be tailored by controlling the degree o WMC. The data tabulated in Table III taken in coniunction ~ith that graphed in Figures 14 aRd 15 clearly indicate that the elongation at rupture (i.e., the percent strain at which a sample brea~s and thus the end point o ea h of - 30 the curves) is directly reIated to ~he degree of WMC.
~2~
TABLE III
Ove~all MD For~-VELOCITIES Dry- Short-5Curve Nos. FDet/minute (meters/minute) ~IC Crepe ening Figs. 14&15 Vl V2 V4 141/l~lW ~00(244) 680~207) 680(207) 15~ -0- 15%
142/142W 800(244~ 640(19S) 640(195) 20% -0- 20%
143/143W 800(244) 600(183) 600(183) 25% -0- ~5%
lQ 144/144W 800(244) 560(171) 560(171) 30% -0- 30%
Figure 16 is a side elevational view of another papermaking machine 221 in which the present inven~ion may be practiced, and in which the corresponding elements are identicaLly designate~ tc the elements o paper-ma~ing machine 21, Figure 2 Insofar as the presentinvention is concerned, papermaking machine 221 is operated in the same manne~ as papermaking machine 21:
that îs, the paper web 30 unde~oes a differential velocity, relatively n~n-compacting trans~er ~rom fabric 26 to fabric 28 while the fiber consistency of the web is relatively low. The low fiber consistency and the relative absence o compacting forces enables substantial machine-direction ~oreshortening of the web without substantial compaction o~ the web. A principal purpose of showing papermaking machine 221 is because the data plo~ted on the graphs of F~gures 17 and 18 were obtained ~rom tissue paper samples which were made on a papermaking machin~. of that geometry.
Figures 17 and 18 are graphs upon which the curves were deri~ed from dry and wet samples, respec-tively, which were made on a papermaking machine 221, Figure 16. Briefly, these samples were run to derive exemplary data to illustrate how the stress at rupture (i.e., the breaking-poi~t stress for each sample) can be tailored in WMC paper by the inclusion of strength addi.tives in the furnish. All of the samples were made rom a urnish wherein the fibers were northern soft-wood kraft; fo~med at eight-hundred feet per minute (about 244 meters pe~ minute) on a forming ~abric 26 having a mesh count of eighty-four by seventy-six filaments per inch (abou~ 33 X 30 per centimeter) and of the weave shown in Figu~e 3; transferred to an imprinting fabric 28 traveling at about six-hundred feet per minute (about 183 meters per minute), and having a mesh count of thirty-six by thirty-two fila-ments per inch (about 14 X 13 per centimeter), and of the weave shown in Figure 4; so transferred at a fiber consistency of from about eighteen to about twenty-one percent; and reeled at the same velocity as the im-printing fabric 28. Parez was added ~o the furnish in the following quantities: curve 251, zero; curve 252, two-and-nine-tenths (2.93 pounds per ton of fibers (about 1.45 grams pe~ kilog~am); curve 253, seven-and-one-~enth pounds per ton o iber (about 3.55 grams per kilogram); and for curve 254, about fifteen pounds per ton of fibers ~about 7.5~grams per kilogram).
By way of recap~ing, the data included herein manifests: the bul~ -- especiall~ wet bulk -- of WMC
paper is directly rel ted to the void volume of the transfer (receiving) abrlc and thus is inversely rela~ed to the mesh count o~ the transfer fabric albeit the strength is directly related to the mesh count o~
the transfer fabric; the st~ain at rupture of WMC
paper is directly related to the degree of ~MC; the st~ess at ~up~ure o~ WMC paper is directly related to the strength properti~s of the furnish (albeit this is not intended to preclude providing additional strength by applyin~ strengthen:ing materials to the webs per se); the~ character o~ the stress/strain property of WMC
~ 2 paper is directly related to the portion of machine-direction foreshortening which is imparted by wet-microcontracting per se and upon the fiber consistency of the web when it undergoes the differential velocity transfer; and, in general, evidences that the present invention can be used to make high bulk/low density ~C
paper o~er a broad spectrum o~ process conditions. It is, however, not intended to thereb~ limit the scope o~
the present invention. Moreover, although all of the presented data we~e obtained through the use of paper~aking machines havin~ creping means, it is also no~ lntended to thereby limit the scope of the present invention.
While particular em~odiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing f-~om the spirit and scope o the invention.
It is intended to cover in the append~d claims all such changes and modifications ~hat are wi~hln the scope of this invention.
What is claimed is:
have substantially different stress/strain properties:
particularly wherein the stress/strain properties are sufficiently different to have different characters but which have sufflciently matched elongations at rupture that the multi-ply products have monomodal stress/-strain characters. By way of defining stress/strain properties of different characters, a stress/strain property which, if plotted on a graph, is upwardly concave (i.e., concave as viewed from above) is hereby defined to have a different character than a sub-stantially linear plot or a reversely curved plot:
i.e,, a stress/strain property which when graphed produces an upwardly convex plot.
Disclosure Of The Invention . _w In accordance with one aspect of the invention, a process is provided for making high bulk, MD-extensible tissue paper having an MD stress/strain property sub-stantially different from comparably extensible dry-creped paper; that is, different by virtue o~ having a substantially greater MD stress/strain modulus through its low and moderate ranges of MD extensibility This is achieved by forming an embryonic web from an aqueous fibrous papermaking furnish, and non-compressively removing sufficient water therefrom prior to its reaching a transfer zone on a carrier fabric that it has a predetermined fiber consistency at the transfer zone. The consistency prior to the transfer is prefer-ably from about ten to about thirty percent fibers by weight and, more preferably, from about ten to about twenty percent fibers by weight and, most preferably, from abou~ ten to about fifteen percent fibers by weight.
Dry and/or ~et strength additives may be included in the furnish or applied to the web after its formation to im-part a predetermined level of streng~h to the ~7eb. At the 2~
transfer zone, ~he back side of a transfer ~l.e., receiving) fabri~ traverses a convexly curved transfer head. While the transfer fabric is so traversing the transfer head, the carrîer fabric is caused to converge and then diverge therewith at sufficiently small acute angles that compaction of the web therebetween is substantially obviated. The transfer fabric has a substantial void volume, and is for~arded at a pre-determined lesser velocity than the carrier abric;
preferably the lesser velocity is from about ten to about forty percent slower and, more preferably, from about fifteen percent to about thirty percent slower than the velocity of the carrier fabric. Preferably, the transfer fabric has a sufficient void volume by virtue of being an open weave and ha~ing a mesh count of from about four to about thirty ~ilaments per centi-meter in both ~he machine direction and the cross-machine direction and, mo~e preferably, from about six to about twenty-six ilaments per centlme~er in both directions and, most preferably, from about six to about ifteen filaments per centlmeter in both direc-tions. At the transfer zone, only a sufficient di-fferential gaseous pressure -- pre~erably vacuum applied through the transfer head -- is applied to the web to cause it to tr~nsfer to the transer fabric without substantial compaction: i.e., ~ithout a sub-stantial increase in its density. The web is there-after dried without overall compaction thereof and without su~stantially altering ~he macroscopic fiber arrangement in the plane of the web. Preferabl~, however, the web is imprin~ed with the knuckle pattern of the transfer fabric under high pressure to precipi-tate tensile strength bonds, and the web preferably is suficientl~ dry-creped to substantially reduce any harshness which might otherwise be precipitated by such imprinting, The web may then be lightly calend~red for ~ caliper control and reeled or directly~ ~ to `' paper products. The calender or the reel may be operated at such a speed relative to the dry-creping velocity of the web that the finished paper has a predetermined ~esidual degree of dry crepe or virtually none at the papermaker's option or as desired from the paper properties viewpoint.
Brief Description Of The Dxawings .
While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter regarded as forming the present invention, it is believed the invention will be better understood from the following description taken in coniuction with the accompanying drawings in which identical designators in the se~eral views refer to substantially identical entities such as papermaking machine components, and in which:
Figure ~ is a fragmentary, side elevational ~iew of a transfer zone of an exemplary papermaking machine through the use of which the method of the present invention may be practlced.
Figure 2 is a some~hat schematic side ele-vational view of a papermaking machine in which a transfer zone such as shown in Figure 1 is incorporated and through the use of which the present invention may be practiced.
Figures 3 and 4 are fragmentary plan views of an exemplary forming wire/carrier fabric and an exemplary transfer/imprinting abric, respectively, for use in th~ papermaking machine shown in Figure 2.
Figure 5 is a fragmentary, enlarged scale, side elevational view o the creping-dryin~ cylinder and creping blade portion of the papermaking machine shown in Figure 2.
Figures 6 through 8 a~e graphical representations of parametric relationships pertaining to the present invention as practiced in a papermaking machine of the configuration shown ~in Figure 2.
~ . . . .. . . . . .
Figure 9 is a somewhat schematic, side elevational view of a 3-loop, twin-wire-fo~mer (TWF) type paper- -making machine in which the me~hod of the presentinvention may be practiced.
Figures 10 and 11 are mixed graphical representa-tions of parametric relationships pertaining to the present invention as practiced in papermakin~ machines of the configurations shown in Fi~ures 2 and g.
Figures 12 through 15 are graphs o~ parametric relationships pertaining ~o the present invention as practiced in a papermaking machine of the configuration shown in Figure 9.
Figure 16 is a somewhat schematic, side eleva-tional view of another papermaking machine in which the method of the present invention may be practiced.
t~
. 9 _.
Figures 17 and 18 are graphs of stress/strain relationships of tissue paper embodiments of the present invention which paper was made through the use of a papermaking making machine o the configuration shown in Figure 16.
Detailed_~ sc__ption Of The Invention Figure 1 shows a differen~ial-velocity ~ransfer zone ZO of an exemplary papermaking machine 21, Figure 2, with which the method of the present invention may be practiced, and through the use of which papermaking machine paper embodiments o ~he present invention may be produced.
.
Briefly, the method of the present invention involves the formation of a paper web from an aqueous slurry of papermaking ~ibers; for~arding the web at a low ~iber consistency on a ~o~a~inous member to a differential velocity transfer zone where the web is ~ransferred to a slo~er mo~ing member such as a loop of open weave f~bric to achieve wet-microcontraction o 20 the web in the machine directicn without precipitating substantial macrofolding (deined hereinafter3 or compaction of the web; and, subsequent to the dif-erential velocity transfe~, drying the web without overall compaction and without further material re-arrangement ~f the fibers o the web in the planethereof. The paper may be pattern com2acted by im-printing a fabric knuckle pattern into it prior to final drying; and the paper may be creped after being dried. Also, primarily for product caliper control t the paper may be lightly calendered after being dried.
A primary facet of the invention is to achieve the differential velocity transfer without precipitating ~;~2~
- 10 ~
substantial compaction (i.e., densification) of the web. Thus, the web is said to b~ wet-microcontracted as opposed to being wet compacted or macro-folded or the like.
The principal process parameters which determine the ultimate density, and stress/strain modulus and character o~ paper embodiments of the present invention include: the percentage velocity differPnce between the carrier fabric and the transfer fabric; the fiber consistency of the web when undergoing the differential velocity transfer; the void volume and topography of the transfer fabric; thc geometry of the transfer zone;
strength additives; creping angle i creped; and ~ ` degree~of residual crepe i~ dry-creped.
1~ Referring again to Fi~ure 1, transfer zone 20 is seen to comprise couch roll 23, re~urn roll 24, trans-fer head 25, carri~.r f~b~ic 26 looped abou~ rolls 23 and 24 and across the convex facing surface ~7 of transfer head 25, transfer ~abric 28 which is lead across transfer head 25 intermediate surface 27 and the carrier fabric 26 and thence across vacuum box 29. As shown in Figure 1, ~eb 30 is forwarded at velocity V
to transfer zone 20 on carrier fabric 26 and is for-warded at velocity V2 from the ~ransfer zone 20 on transfer fabric 28. A sufficient level o vacuum to ef~ect transfer from carrier fabric 26 to transer fabric 28 is applied through modulator means not shown to the web 30 via port 32 in transfer head 25. This vacuum also effects some water removal from web 30 after which the web is subjected to additional vacuum applied through ports 33, 34 and 35 on vacuum box 29 to achieve further dewatering of the web. The vacu~m applied ~o ports 33, 34, and 35 may be individually ~ ~22~6 modulated or modulated by a common means not show~.
While not intending to thereby rigidly limit the present invention to such stated values, the angles of convergence C and divergence D of carrier fabric 26 and transfer ~abric 28 are pre~erably in the order of about fifteen degrees or 50, and the angular change 38 in the direction of carrier fabric 26 over surface 27 is preferably about ten degrees so that a vacuum seal is maintained across the slot in surface 27 of transfer head 25, and so that web 30 is not substantially compressively compacted in the transer zone. Also, surface 27 is convexly curved downstream (i.e., in the direction fabric 28 traverses surface 27) with a rela-tively large radius (e.g., 8 inch radius or larger) to preclude high levels of paper ~eb compressio~ due to hoop stress induced by tension in fabric 26, and so disposed to obviate centri~ugal force on web 30 as web 30 is forwarded past the transfer head 25.
Figure 2 shows, in somewhat schematic form, an exemplary papermaking machine 21 or prac~icing the present invention. Papermaking machin~ 21 comprises transfer zone 20 as described hereinabove and, ad-ditionally: a orming sec~ion 41, an intermediate carrie~ section 42,a pre-dryer/ lmprintin~ section 43, a drying/crepin~ section 44, a calender asse~bly 45, and reeling means 46.
The forming section 41, Flg~re 2, of papermaking machine 21 comprises a headb~x S0; a loop of fine mesh forming wire or fabric 51 which is looped abou~ a vacuum breast roll 52, ove~ vacuum box 53, about rolls 55 through 59, and under showe~s 60. Intermedia~e rolls 56 and 57, ~orming wire 51 is deflected from a ~2;~ 6 straight run by a separation roll 62. Biasing means not shown are provided for moving roll 58 as indicated by the adjacent arrow to maintain fabric 51 in a slack-obviating tensioned state.
Intermediate carrier section 42, Figure 2, com-prises a loop of carrier fabric 26 which is looped about rolls 62 through 69 and about an arcuate portion of roll 56. The loop of fabric 26 also pass~s over vacuum box 70, and transfer head 25; and under showers 71. Biasing means are also provided to move roll 65 to obviate slack in fabric 26 as was discussed above with respect to obviating slack in fabric 51. As is clearly indicated in ~igure 2, Juxtaposed psrtions of fabrics 51 and 26 extend about an arcuate portion of roll 56, across vacuum box 70, and separate a~ter passing over an arcuate portion of separation roll 62. Preferabl~, fabric 26 is identical to fabric 51 but for thei~
lengths.
The pre-dr~er/imprinting section 43, Figure 2, o 20 papermaking lilachine 21 comprises a loop of transer fabric 28 which is alternatively referred to as an imprintin~ fabric~ Fabric 28 is looped about rolls 77 through 86; passes across trans~er head 25 and vacuum box 29; through a blow-through p~e-dryer 88; and u~der showers 89. Additionally, means no~ shown are provided for biasing roll 79 towards the adjacent dryingfc~eping cylinder 91 with a predetermined force per lineal inch (pli) to effect imprinting the knuckle pattern of fabric 28 in web 30 in the manner o~ and for the purpose disclosed in the hereinbefore referenced Sanford and Sisson patent; and biasing means not shown are provided or moving roll 85 as indicated by the ~l~2~4 adjacent arrow to obviate slaclc in fabric 28.
The drying/creping section 44, Figure 2, of papermaking machine 21 comprises drying/creping cylin der 91 which is hereinafter alternatively referred to 5 as ~ankee 91, adhesive applicator means 92, and doctor blade 93. This portion of pape~making machine is shown in somewhat larger scale in Figure 5 in order to clearly define certain angles with respect to the doctor blade 93 and its relation to Yankee 91. Accord-10 ingly, drying~creping section 44 is described morefully hereinafter concomitantl~ with discussin~ Figure 5.
S~ill referring to papermaking ~achine 21, Figure 2) it fur her comprises means not shown for independ~
15 ently controlling the velocites Vl (of carrier fabric 26), Y2 ~of transfer fabric 28 and Yankee 91), V3 (of calender 45)> and V~ (of reeling means 46) in order to independently control the degree of wet-microcontrac-tion precipitated in the transfer zone 20> the degree 20 of dry-crepe, and the degree of residual dry-crepe as is more fully deseribed hereinafter.
Figure 3 is an enlarged scale frag~entary plan view of an exempla~y carr~er fabric 26 and, preferably, of the for~ing fabric 51 o~ papermaking machine 21, 25 Figure 2. The specific fabric 26 shown in Figure 3 comprises machine direction filamen~s 95 and cross-machine-direc~ion ilaments 96 which are wo~en together in a 5-shed satin weave using a non-numerically-con-secutive warp plck sequence. This forms an open weave 30 fabric havin~ apertures 98. Such a fabric weave is described in U.S. Patent 4,239,065 and shown in Figure 8 thereof. ~ilamPnts 95 and 96 are preferably poly-ester monofilaments. A typical papermaking fiber 97 having an approximate length of about two ~m is shown superimposed on an exemplary fabric 26 having a mesh count of eighty-four machine direction filaments per S inch (about 33 MD filaments per centimeter) and se~enty-six cross-machine direction filaments per inch (about 30 CD filaments per centimeter). All of the filaments of the exemplary fabric 26 have nominal diameters o about seventeen-hundredths ~m. Thus, papermaking fibers tend to lie substantially 1at on such a fine mesh fabric w~len it is used as either a forming fabric or an intermediate carrier fabric; and apertures 98 facilitate water draina~e as well as water removal via vacuum means.
Figure 4 is a fragmentary plan view of an ex-emplary ~ransfer/imprinting fabric 28 of papermaking machine 21, Figu~e 2. The scale of Figure 4 is about the same as for Figure 3 in order to clearly illustrate the relati~ely large apertures 102 (vo~d spaces~ of ~ fabric 28 compared to the size of papermaking fiber 97, and thus mal~;e it réadily apparent that such flbers can be deflected into the voids of such a coarse mesh, open weave transfer fabric. Fo~ instance, as shown, trans-fer fabric ~8 has a mesh count of about twenty-our machine direction filaments 100 per inch (about 9~5 ~D
filaments per centimeter) and about twenty cross-machine direction filaments 101 per inch (about 7.9 CD
filaments per centimete~. The filaments 100 and lOl of the exemplary transfer fabric 28 are preferably poly-ester, and ha~e diamete~s o~ absut six-tenths of a milli~eter. As sho~n, transfer fabric 28 is also an open, 5-shed satin weave generated by using a non-numerically-consecutive warp pick sequence (e.g., 1, 3, 5, 2, 4) as described in U.S. Patent 4,239,065; and the top surface of fabric 28 has been sanded to provide flat eliptical-shape imprinting knuckles designated 103 and 104.
Figure 5 is an enlarged scale view of the creping section of papermaking machine 21 in which the impact angle between ~ankee ~1 and doctor blade 93 is desig-nated angle I, the bevel angle o~ doctor blade 93 is designated angle B, and the back clearance angle be-tween Yankee 91 and doctor blade 93 is designate angle CL. Means not shown are provided for adjusting angle I. In general, creping of a paper web tends to disrupt ~onds in the ~eb. This causes the web to be.softer but .
of lower tensile strength than were it not creped.
These effects of creping can be alte~ed somewhat by adjusting angle 1: that is, increasing angle I will generally lessen the softenin~ induced by creping and will ~enerally lessen the creping induced reduction of tensile strength. Thus, i~creasing angle I will generally precipitate a p~per web having grea~er tensile str~ngth but less softness and dry end sheet control as compared to the paper web being p~oduced prior to so increasing angle I. The optimum value for an~le I will therefore depend on which is the more desirable product attribute: softness or tensile strength. This is particularly significant with respect to the present invention inasmuch as wet-microcsntracting generally precipitates lower tensile strength and less softness but better dry end sheet 3~ control than dry-creping to achieve equally MD foreo shortened paper ~ebs, all other factors being equal.
Indeed) substantially be~ter dry-end sheet control can be achieved in hybrid pape~ wherein MD foreshortening ~24 is precipitated by a combination of wet-microcon-tracting and dry-creping as more fully described hereinafter with respect to discussing Figures 6 and 12.
A papermaking machine o~ the general coniguration shown in Figure 2 and designated therein as papermaking machine 21 was run under the following conditions in accordance with the present invention to produce paper embodiments of the present invention, as well as purPly dry-creped paper. The forming fabric and the carrier fabric were polyester fabrics ha~ing mesh counts o seventy-eight by sixty MD/CD filaments per inch (about . . 30 7. x ~3.6 ~il.aments.per cen~timeter), and.were.~oven in four shed sa~in ~eaves wherein the warps (i.e., ~he machine direction filaments) alternately cross o~er one shute and under three shu~es, and wherein the shutes alternately cross over ~hree warps and under one warp.
The curvature of surface 27 of transfer head ~5 was a~
eight (8) inch (about 20 cm.) radius. The transfer~im-printing fabric 28 ~s of the mesh count and weavedescribed h~reinbefore with respect to ~abric 28, Figure 4: i.e., a 5-shed satin weave which had been woven with a non-numerically-consecutive ~arp pick sequence, and having a ~esh count of twenty-four MD by twenty CD ilaments per inc~ (about 9.4 x 7.9 ilaments per centimeter). The furnish comprised ifty percent (50%) northern softwood kra~t (~SK) (i.e., long paper-making ~ibers) and fity percent (50%~ hardwood sulfite (i.e., short papermaking fibers). A strength additive -- namely Parez 631 NC --was added to the furnish at a rate of about 16.8 pounds per ton (abou~ 8.4 gms/kg).
Parez is a registered trademark of American Cyanamid.
Polyvinyl alcohol creping adhesi~e was used and an impact angle I of eighty-nine ~8~) degrees was main-tained. A fiber consistency o about twelve-and-two-tenths percen~ (12.2%) ~as Tnaintained at the couch roll 23 and a before-pre-dryer (hereinafter BPD) fiber consistency of about twenty-five percent (25%) was maintained. During the run, a constant yelocity Vl o about six hundred ~600) feet per minute (about 183 meters per minute) was maintained for fabrics 51 and 26; a constant reel yelocity V4 of about four-hundred-fifty (450) feet per minu~e (about 137 meters perminute) was main~ained; and no calendering was ef-fected. The principal parameter varied during the run was V2: the linear velocity of the transfer fabric 28 and the surface velocity of Yankee 91. V2 was varied from Vl to less ~han V4: l.e., from six-hundred feet per minu~e (about 183 meters per minute) to our-hundred-twenty feet per minute (about 128 meters per minute). Also, the pape~ web was dried in the p~e-dryer 88 to a fiber consistency of from about seventy to about seventy-five percent after the p~e-dryer (hereinafter APD~, and final dried on the Yankee to about ninety-eight or ninety-nine percent. The re-sulting paper had a basis weight of from about twenty-three-and-ninP-tenths (23.9) to about twenty five-and-six-tenths (25.6) pounds per three-thousand square feet (from about 3~ to about 42 g~ams per square meter), and a dry caliper of from about nineteen-and-eight-tenths (19.8) mils (about 0.5 n~) to about twenty-three-and-four-tenths (23.4) mils (about 0.6 mm).
Figu~e 6 is a graph of stressls~rain data obtained from five dry samples of pape~ produced during the above described run of papermaking machine 21, Figure ~22 2. The values of Vl, V2 and V4 are tabulated in Table I for each designated curve on Figure 2. The percent wet-microcontraction (~MC) listed in Table I was co~-puted by dividing the difference between Vl and V2 by S Vl; the percent dry crepe was computed by dividing the difference between V2 and V4 by V2. The overall MD
foreshortenin~ was computed by dividing the difference between Vl and V4 by Vl.
IABLE I
Overall MD Fore-VELOCITT.ES Dry- Sh~r~-Curv~ Nos. Feet/~inute (meters/minute) WMC Crepe ening Figs 6&7 Vl V2 Y4 lllllllW 600(183~ 630(183)450(137) -O- 25% 25%
112~112W 600(183~ 510(155)450(137) 15~ 13% 25 113/113W 600(1~3) 4~0(146)450(137) 20~ 7% 25~
114/114W 600~183) 450(137)450(137) 25% 0 25%
115/115N G00~183) 420(128)4501137) 30% -7% 25 Parenthetically, ~he stressjstrain data and resultin~ moduli presented in Figures 6-8, lZ-15, 17 and 18, and as used herein were obtained by testing samples having gage len~ths of four inches (about 10 cm) and which were o~e inch (2.54 cm.) wide by applying and recording tensile force in the machine-direction (MD) of the samples in an apparatus which stretched the samples at a rate of about four inches per minute (about 10 cm. per minute). Thus, whereas stress per se is force per unit of cross-sectional area, the graphed stress data are presented in grams force per unit of sample width. ~lso these stress/strain graphs were derived from testing sever~l replicate samples --generally four -- and averaging the data therefrom.
Therefore, data poin~s per se are nst indicated on the graphs.
Still referring to Figure 6, curve 111 was derived from 25% purely d~y-creped paper, and curve 111 is highly upwardly concave which reflects the relative ease (low tensile values) of pulling out dry-crepe induced stretch until the available stretch in the paper is largely removed after which ~he slope of curve 111 increases sharply. By way of contrast, the curves 112 through 115 have distinctly different characters:
i.e., shapes. That is, curve 112 has a generally linear cha~acter and cu~ves 113 through 115 are re-versely curved compared to curve 111. Thus, the hybrid paper samples of curves 112 and 113 -- paper which has been both wet-microcontracted and dry-creped -- as well as the purely wet-mic~cont~acted samples of curves 114 and 115 have distinctly diferent characters rom ~he purely dry-creped paper of Cu~ve 111~ Thes~ character differences are believed to be relatively great due to the relatively low ~iber consistency of the paper web at the time it was transferred ~rom carrier fabric 25 to transfer fab~ic 28: i.e., twelve-and-~wo-tenths percent (12.2%) fibers by weight measured at couch 23.
Still referring to Figure 6, the higher stress/-strain values through the low and/or moderate ranges of elongation of curves 112 th~ough llS as compared to curve 111 manifest why better sheet control can be maintained while reeling andlo~ converting the pure and hybrid WMC paper webs than purely dry-creped webs because higher tension can be maintained on them with-out substantially vitiating their ~D stretch.
Figure 7 is a graph of MD stress/strain data obtained from wet samples of paper which were produced as stated above and described in conjunction with describing Figure 6. That is, curves lllW through 115W
are, respectively, derived from wet samples of the paper which precipitated curves 111 through 115 in Figure 6, above. The hybrid samples have stress/strain curves (112W and 113W) which are substantially less concave upwardly than curve lllW the curve for dry-creped paper. Also, the cu~ves for the purely wet-microcontracted samples (curves 114W and ll5W~ are of a different character ~rom curve lllW: that îs, curve lllW is upwardly concave ~hereas curves 114W and llSW
are upw~rdly convex. Such differences in the relative values and characters of the wet stress/strain curves of hybrid and pure we~-microcont~acted paper (here-inaft~r WMC paper) as compared to purely dry crPped paper makes such WMC paper especially useful as a ply of multi-ply tissue p~oduc~s wherein the plys have substantially identical elongations at rupture, but substantially non-identical stress/s~rain curves. Such paper products wherein the plies are discontinuously adhered together manifest monomodal st~Pss/strain characters due to their matched elongations at rupture;
mani~est additive ply strengths ~hroughout their strain domains; and have high liquid absorbency. For example, consider a discontinuously bonded two-ply product comprising a ply o WMC paper and a ply of purely dry-creped papPr. If an uncons~ained dr~-creped tissue is wetted, crepe induced stresses are relieved and the creped tis~ue elon~ates in the plane o~ the paper as some o the crepe folds are floa~ed out. However, when such a creped ~issue is a pl~ o~ a multi-ply product in which another ply constrains unadhered portions of the ~z~
creped ply from being elongated in the plane o the paper when wetted, but does not otherwise constrain such portions of ~he creped ply, at least some of those portions of the creped ply ~ill pucker. This assumes that such product remains substantially unstressed as wetting thereof is effected. Such puckering enhances the wet bulk and caliper of the product as well as its overall liquid absorbency. In general, ~MC tissue paper will ac~ as such a constrainer for dry-creped 10 tissue paper when they are discon~inuously adhered or bonded together to make a multi-ply product. Also, WMC
paper having zero dry-crepe can be such a constrainer for hybrid WMC/dry-creped paper; and hybrid ~MC/dry-~- creped paper can be such a constrainer for pu~ely dry-creped paper ~i.e., dry-creped paper having no degree ~ WMC), Additional ~xamples of makin~ paper embodiments of the present invention (~.e., pure and hybrid ~C paper~
have been made and are hereinater described to illus-trate, for instance, the fact that the present in-vention may be practiced on a wide variety of paper-making machines, and to illustrate a variety of control parameters with which the level~ and shape of the stress/strain modulus of WMC paper can be tailored to 25 provide parametrically optimized end products: e.g., a WMC paper web having such a stress/strain modulus that, when incorporated in a 2-ply tissue paper product along with a purely dry-creped ply, the product manifests good absorbency and a monomodal stresslstrain property.
30 Note: as used herein, a monomodal stress/strain property is defined as a stresslstr~in curve ha~ing only one peak whereas a product comprising discon-tinuously adhered plies having substantial strengths albeit unmatched ultimate elongations at rupture will have stress/strain curves having two or more peaks.
Note also that pure ~MC paper web and hybrid WMC paper web can also have matched elongations at rupture yet have sufficiently different stress/strain properties Lhat they can be co~bined to form a product which will also pucker when wetted (and thus have high liquid absorbency), and manifest a strength efficient mono-modal stresslstrain property. This is, howe~er, not intended to lmply that a monomodal stress/strain property is required Lo achieve the puckering pre-cipitated absorbency benefit. Rather, matching the plies to achieve a monomodal stressl strain property precipitates strength and energy absorption efficiency i~ such`multi-ply tissue p~per prGducts in additlon to ~ -providing ~he puckering absorbency benefit.
Figure ~ comprises graphed stress/strain dataderived from ~esting additional wet samples o~ r,~MC
paper produc-~d on a papermaking machine of the geometry shown in Flgure 2 to illustrate the transfer fabric mesh count impact on the stressl strain property of the WMC paper. ~ssentially, two runs were made under substantially identical conditions but for the mesh of the transfer[imprinting fabrlc 28, to wit: curve 117 was derived from paper made ~hile a transfer fabric 28 having ~ mesh count of thirt~-six MD filaments per inch (about 14/cm) by thirty-two CD filaments per inch (about 12.6lc~) was on papermaking machine 21; and curve 118 was deri~ed ~ro~ paper made while a transfer fabric 28 having a mesh count of sixty-four MD Eila-ments per inch (about 25.2~cm) by fifty-four CD fila-ments per inch (about 21.3/cm) was on the papermaking machine. Both were of the weave shown in Figure 4.
Thus, all other things being equal, the stress/strain modulus of WMC paper is directly related to the mesh count o the transfer fabric: i.e., a finer mesh precipitates a higher stress/strain modulus and vice versa. It is, however, not intended to thereby imply that finer ~esh fabrics precipitate the best results fro~ the present invention. What is best depends on what product att~ibutes are important. Indeed, while the fine-mesh-fabric curve 118 is higher than the coarse-mesh-abric curve 117 in Figure 8, the 118 paper had a substantially smaller caliper ~i.e., 10.9 ~0.277]
v. 14.1 [0.358] mils ~mmJ for the 117 paper) and thus lower bulk. Accordingly, bulk is enhanced by using - ~coarser transfer fabrics whereas strength is enhanc~d - by using finer transe~ labr~cs. - -15Still referring to Figure 8, the paper samples were made using a fu~nish comprised solely of northern softwood kraft (~elati~ely long papermaking ~ibers).
The papermaki~g machine was run with a velocity Vl of six-hundred feet per minute (about 183 meters per minute) and transfer abric velocity V2-of four-hundred-eighty feet per minute (about 146 meters per minute) to achie~e twency pe~cent (20%) ~MC. The couch consis-tency was about sixteen-and-one-half percent ~or the 117 curve paper 7 and about thirteen~and-nine-tenths percent for the 118 cur~e paper. As the paper was being forwarded on fabric 28, Figure 2, from the pre-dryer 88 to the Yankee 91, the zones of the paper juxtaposed the knuckles of fabric ~8 were im~regnated with a latex binder material by a rotogravure-type applicator, not sho~ in Figure 2. The quantities of latex solids ~or the papers o~ curves 117 and 118 were forty-fou~-hundredths and sixty-hundredths pounds, respectively, per three-thousand-square feet (about 0.72 gms. and 0.98 gms. per s~uare meter). The paper produced had a basis weight ~hen reeled in the range of about seventeen to about eighteen pounds per three-thousand-square-feet (from about 27.6 to about 29~3 grams per square meter), and was lightly calendered at about twelve pounds pe~ lineal inch (pli) (about 2.15 kg per lineal centimeter~. Although the paper was parted from the ~ankee ~1 with a doctor blade 93 set at an impact angle I of eighty-four degrees, the paper had 10 no substantial degree of residual dry-crepe because it was reeled at the same velocity as the velocity of the Yankee 91: i.e., V4-V2.
Figure 9 shows a twin-wire-former (TWF) type papermaking maGhine 121 with which the present process invention can be practiced to produce paper embodiments of the present invention. As compared to paper~aking machine 21, Figure 2, papermaking machine 121 comprises a twin-wire-forme~ sectio~ 12~ rather than a fixed roof former. Insofar as the present invention is concerned, the transfer zone 20 of both machines are preferably identical, as are their pre-dryer/imprinting sections 43, theix dr~inglcreping sections 44, their calender sections 45, and their reeling sections 46. Thus, these sections and their corresponding coFponents are identically numbered albeit some of the components numbered in Figure 2 are not numbered in Figure 9 to avoid undue redundancy.
The twin-wire-former section 122 of papermaking machine 121, Figure 9, comprises an endless foraminous forming fabric 127 which is looped about a plurality of guide rolls 125; and an endless, foraminous carrier fa~ric 26 which is looped abou~ the forming roll 126 and through the transfer zone 20 as shown. Essentially, fabrics 26 and 127 synchronously con~erge ad;acent a headbox 123 from which a jet o aqueous papermaking furnish issues. Primary dewatering occurs through the portion of fabric 127 wrapped about forming roll 126, and subsequent dewatering is assisted by trans~er 5 vacuum box 70 and vacuum box 153 to provide a pre-determined fiber consistency of the web 30 as it is orwarded on fabric 26 to ~he transfer zone 20. In-sofar as the present invention i5 concerned, paper-making machine l~l is operated like papermaking machine 21, Figure 2, and is primarily presented in Figure 9 because it was used to make paper samples from which data were derived and plotted on the graphs presented in Figures lO through 15, inclusive. It is not in-tended, however, to thereby imply that the present in~ention is limited to papermaking machines having identical transfer ~ones.
Figure 10 is a graph comprising curves 131, 132 and 133 of dr~ density data versus percent WMC of a mix of paper samples produced on papermaking machines of the configurations shown in Figures 2 and 9. The samples fro~ which cur~e 131 was deri~ed were purely wet-microcontracted albeit remoYed from the Yankee 91 by doctor 93. That ~s, any dry-crepe which was induced in the webs by doctor 93 was pulled out of the webs by running the reel at the ~ankee velocity: i.e., V4 -V2. These samples had nominal basis weights of about eighteen (18) pounds per three-thousand (3000) square feet (about 29.3 gmslsq. meter); and were made using a transfer fabric 28 o~ the wea~e shown in Figure 4 and a mesh count of twen~y-our MD filaments per inch (about 9.4/cm) by twenty (20) CD filaments per inch (about 7.9/cm), all of the ilaments having a diameter of about six-tenths (0.6) mm. The rise of cur~e 13L at values of I~MC is excess of twenty-five (25) percent is believed to be a manifestation of the fibers o~ the web overcrowding the voids of fabric 28 and precipita~ing some macrofolding of the web lnasmuch as a significant 5 degree of undeslrable mac~oolding induced hard ridges were visible in paper samples made at thirty (30) percent ~MC: l.e., (Vl - V~)IVl - 0.3.
Macrofolding is hereby defined as causing a low-fiber-consistency web to fold in such a manner that 10 adjacent machine direction spaced portions of the web become stacked on each o~her in the Z-direction of the web, whereas we~-microcontracting as defined herein is intended to be wet-end machine-direction-foreshortening which is effected in such a manner that macroolding is 15 substantially precluded.
Still referring to Figure 10, curves 132 and 133 were dcrived f~om families o saFples which families were machine-direction foreshortened twenty percent and twenty-five percent, respectively, and which had basis 20 weights of about eighteen and twenty-five pounds per three-thousand-square feet, respectively, (about 29.3 grams and 40.7 grams per square meter, respectively).
For example, to make a sample for curve 132 having twenty percent machine-direction foreshortening (i.e., 25 (Vl-V4)/V1~20%) which was wet-microcontracted only ten pe~cent (i.e., (Vl-~2)/Vl=10%), it had to be dry-creped to provide the o~her ~en percen~ machine-directio~
foreshortening. Thus, to make the family o samples from which curve 132 was de~ived, V4 ~as maintained 30 constant at eighty percent o~ the value o Vl. and V2 was incremented from Yl to V4. Similarly, for cur~e 133, V4 was maintained cons~ant at seventy-five percent of the value of a constant value of Vl (e.g., 600 feet per minute), and V2 was varied from the value of Vl to the value of V4.
Signiicantly all of the paper samples fr~m which curves 131, 132 and 133 of Figure 10 were derived 5 manifest low density (hlgh bulk) as compared to con-ventional wet-felt-pressed papers. Moreover, curve 131 (purely W~C paper) manifests a decreasing dry density up to about twenty-five percent foreshortening after which the density increase is believed to be a mani-10 festation of macrofolding, whereas curve 132 (sampleshavin~ the same basis weight as for curve 131) mani-fests a slightly increasing dry density as the I~MC
portion of the constant oyerall twen~y-percen~ machine direction oreshortening is increased. Also, curve 133 15 which was derived from samples of heavier basis weight and greater machine direction ~o~eshortening (i.e., 25%) than for cur~e 132 manifests a substantially constant d~y density as the WMC portion of the total twenty-five percent machine direction ~oreshor~ening is 20 varied from zer~ to the full twenty-five percent.
Referri.lg now to Figure 11, curves 131W, 132W, and 133W were derived from we~ samples of the same re-spective paper samples f~om which curves 131, 132, and 133 of Figure 10 were deri~ed. Curves 131W, 132W, and 25 133W all manifest relatively low wet densitles and, very importantly with respect to -the present invention, all manifest an inverse relationship o~ wet density to percent WMC at leas~ up to the nadir o curve 131W at which the foregoing descrlbed macrofolding phenomenon 30 became manifest.
~Z2 Figures 12 and 13 are dry and wet density curves, respectively, derived from data obtained from families of samples which were substantially identically made as the samples from which the curves of Figures 6 and 7 5 were derived except for their basis weight, and for their percent fibe~ consistencies by weight at the point of their differential velocity transfers. For Figures 6 and 7, the fiber consistency at couch 63 was maintained at abou~ twelv~-and-two-tenths percent 10 (12.2V/o), and for Figures 12 and 13 it was maintained at about twenty-one-and-one-half percent (21.5%).
The basis weigh~s for Figures 6 and 7 were about twenty--f~ve po~nds per thre~-thousand s~uare feet (about 40.7 grams per squà~e meter~ and for Figures I2 15 and 13 were about eighteen pounds per three-thousand square feet (about 29.3 grams per square meter). These comparative data manifest much greater differences between WMC paper and purely dry creped paper for the Figure ~ and 7 samples deri~ed at the lower fiber 20 consistency (12.2%) than for the Flgu~e 12 and 13 samples derilred at the higher fiber consistency (21.5%) at transfer. Albeit the pre~erred range of fiber consistency at transfer is f~om about ~en to about thirty percent, the more p~eferred ran~e is rom abou~
25 ten to about twent~ percent, and the most preferred range is from about ten to about fifteen parcent.
Velocity and MD foreshortening data ~or the samples from which the cu~ves of Figures 12 and 13 were derived are presented in T~ble II. These data also 30 indicate tha~ some WMC can be pulled out of the samples by reeling the paper faster at a velocity V4 which is greater than the Yankee ~elocity V2; it does no~ shift the stress/strain further upward and to the l~ft as was the case at the lower level of fiber consistency at transfer. That is, compare the displacement of curve 115 relative to curve 114, Figure 6, to the virtual 5 non-displacement of curve 139 relative to curve 138, Figure 1~.
TABL~ II
Overall ~ Fore-VELOCITIES Dry- Short-Cu~ve Nos. Feet/minute (mete~s/minute) ~MC Crep~ ening Figs. 12&13 Vl 2 ~4 ; 135/135W 8~Q~244) 800~(244~. 560(171) -O- 30~ 30%
` ~ 136/I36W 8~0(244~' 705(215) ' 560`(I71) I2 -21 30%-137/137~ 800(244) 620(18g) 560(171) 22 10 30%
13~/138W 8QO(2h4) 560~171) 560(171~ 30% -0- 30%
139/13~W 800(244) 520(158~ 560(171) 35% -8% 307, Figures 14 and 15 a~e graphs upon ~hich the curves ~ere derived xom dry and ~et samples, re-spectively, having different levels of wet-microcon--traction ranging rom fifteen to thirty percent in five percent (5%) incremen~s. Briefly, the samples from which these data ~ere de~iyed were run to lllustrate how the ~1Ongation a~ rupture o~ WMC pap~r can be tailored by controlling the degree o WMC. The data tabulated in Table III taken in coniunction ~ith that graphed in Figures 14 aRd 15 clearly indicate that the elongation at rupture (i.e., the percent strain at which a sample brea~s and thus the end point o ea h of - 30 the curves) is directly reIated to ~he degree of WMC.
~2~
TABLE III
Ove~all MD For~-VELOCITIES Dry- Short-5Curve Nos. FDet/minute (meters/minute) ~IC Crepe ening Figs. 14&15 Vl V2 V4 141/l~lW ~00(244) 680~207) 680(207) 15~ -0- 15%
142/142W 800(244~ 640(19S) 640(195) 20% -0- 20%
143/143W 800(244) 600(183) 600(183) 25% -0- ~5%
lQ 144/144W 800(244) 560(171) 560(171) 30% -0- 30%
Figure 16 is a side elevational view of another papermaking machine 221 in which the present inven~ion may be practiced, and in which the corresponding elements are identicaLly designate~ tc the elements o paper-ma~ing machine 21, Figure 2 Insofar as the presentinvention is concerned, papermaking machine 221 is operated in the same manne~ as papermaking machine 21:
that îs, the paper web 30 unde~oes a differential velocity, relatively n~n-compacting trans~er ~rom fabric 26 to fabric 28 while the fiber consistency of the web is relatively low. The low fiber consistency and the relative absence o compacting forces enables substantial machine-direction ~oreshortening of the web without substantial compaction o~ the web. A principal purpose of showing papermaking machine 221 is because the data plo~ted on the graphs of F~gures 17 and 18 were obtained ~rom tissue paper samples which were made on a papermaking machin~. of that geometry.
Figures 17 and 18 are graphs upon which the curves were deri~ed from dry and wet samples, respec-tively, which were made on a papermaking machine 221, Figure 16. Briefly, these samples were run to derive exemplary data to illustrate how the stress at rupture (i.e., the breaking-poi~t stress for each sample) can be tailored in WMC paper by the inclusion of strength addi.tives in the furnish. All of the samples were made rom a urnish wherein the fibers were northern soft-wood kraft; fo~med at eight-hundred feet per minute (about 244 meters pe~ minute) on a forming ~abric 26 having a mesh count of eighty-four by seventy-six filaments per inch (abou~ 33 X 30 per centimeter) and of the weave shown in Figu~e 3; transferred to an imprinting fabric 28 traveling at about six-hundred feet per minute (about 183 meters per minute), and having a mesh count of thirty-six by thirty-two fila-ments per inch (about 14 X 13 per centimeter), and of the weave shown in Figure 4; so transferred at a fiber consistency of from about eighteen to about twenty-one percent; and reeled at the same velocity as the im-printing fabric 28. Parez was added ~o the furnish in the following quantities: curve 251, zero; curve 252, two-and-nine-tenths (2.93 pounds per ton of fibers (about 1.45 grams pe~ kilog~am); curve 253, seven-and-one-~enth pounds per ton o iber (about 3.55 grams per kilogram); and for curve 254, about fifteen pounds per ton of fibers ~about 7.5~grams per kilogram).
By way of recap~ing, the data included herein manifests: the bul~ -- especiall~ wet bulk -- of WMC
paper is directly rel ted to the void volume of the transfer (receiving) abrlc and thus is inversely rela~ed to the mesh count o~ the transfer fabric albeit the strength is directly related to the mesh count o~
the transfer fabric; the st~ain at rupture of WMC
paper is directly related to the degree of ~MC; the st~ess at ~up~ure o~ WMC paper is directly related to the strength properti~s of the furnish (albeit this is not intended to preclude providing additional strength by applyin~ strengthen:ing materials to the webs per se); the~ character o~ the stress/strain property of WMC
~ 2 paper is directly related to the portion of machine-direction foreshortening which is imparted by wet-microcontracting per se and upon the fiber consistency of the web when it undergoes the differential velocity transfer; and, in general, evidences that the present invention can be used to make high bulk/low density ~C
paper o~er a broad spectrum o~ process conditions. It is, however, not intended to thereb~ limit the scope o~
the present invention. Moreover, although all of the presented data we~e obtained through the use of paper~aking machines havin~ creping means, it is also no~ lntended to thereby limit the scope of the present invention.
While particular em~odiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing f-~om the spirit and scope o the invention.
It is intended to cover in the append~d claims all such changes and modifications ~hat are wi~hln the scope of this invention.
What is claimed is:
Claims (22)
1. A process for making high bulk, MD-extensible tissue paper having a predetermined MD stress/strain modulus substantially different from comparably ex-tensible dry-creped paper, said MD stress/strain modulus being substantially greater than for said comparably extensible dry-creped paper through their lowest one-third ranges of MD extensibility, said process comprising the steps of:
forming an embryonic paper web from an aqueous fibrous papermaking furnish;
forwarding said embryonic web at a first velocity on an endless carrier fabric to a transfer zone;
non-compressively removing sufficient water from said embryonic web-prior to its reaching said transfer zone to enable said embryonic web to be transferred to an endless foraminous transfer fabric at said transfer zone, said transfer fabric having a substantially greater void volume than said carrier fabric;
forwarding at a second velocity said endless foraminous transfer fabric along a looped path in contacting relation with a transfer head disposed at said transfer zone, said transfer head having a convex fabric-contacting surface, said second velocity being substantially less than said first velocity;
guiding said carrier fabric and said transfer fabric to cause them to converge and then diverge at acute angles while traversing said convex surface, said acute angles being sufficiently small and the curvature of said convex surface being sufficiently large to substantially obviate fabric-tension-induced compaction of said embryonic web as it passes through said transfer zone;
applying only a sufficient level of differential gaseous pressure across said embryonic web at said transfer zone to cause said embryonic web to trans-fer to said transfer fabric in said transfer zone without precipitating substantial compaction of said embryonic web; and completing the papermaking-machine drying of said embryonic web while maintaining a macroscopic inter-fiber relationship therein in the plane of the web and without overall mechanical compaction of the web.
forming an embryonic paper web from an aqueous fibrous papermaking furnish;
forwarding said embryonic web at a first velocity on an endless carrier fabric to a transfer zone;
non-compressively removing sufficient water from said embryonic web-prior to its reaching said transfer zone to enable said embryonic web to be transferred to an endless foraminous transfer fabric at said transfer zone, said transfer fabric having a substantially greater void volume than said carrier fabric;
forwarding at a second velocity said endless foraminous transfer fabric along a looped path in contacting relation with a transfer head disposed at said transfer zone, said transfer head having a convex fabric-contacting surface, said second velocity being substantially less than said first velocity;
guiding said carrier fabric and said transfer fabric to cause them to converge and then diverge at acute angles while traversing said convex surface, said acute angles being sufficiently small and the curvature of said convex surface being sufficiently large to substantially obviate fabric-tension-induced compaction of said embryonic web as it passes through said transfer zone;
applying only a sufficient level of differential gaseous pressure across said embryonic web at said transfer zone to cause said embryonic web to trans-fer to said transfer fabric in said transfer zone without precipitating substantial compaction of said embryonic web; and completing the papermaking-machine drying of said embryonic web while maintaining a macroscopic inter-fiber relationship therein in the plane of the web and without overall mechanical compaction of the web.
2. The process for making high bulk, MD-extensible tissue paper of claim 1 wherein the fiber consistency of said embryonic web is from about ten (10) to about thirty (30) percent immediately prior to said transfer.
3. The process for making high hulk, MD-extensible tissue paper of claim 2 wherein the fiber consistency is in the range of from about ten (10) to about twenty (20) percent immediately prior to said transfer.
4. The process for making high bulk, MD-extensible tissue paper of claim 2 wherein said fiber consistency is in the range of from about ten (10) to about fifteen (15) percent immediately prior to said transfer.
5. The process for making high bulk, MD-extensible tissue paper of Claim 1 wherein said transfer fabric is of the open weave type and has a mesh count of from about four (4) to about thirty (30) filaments per centimeter in both the machine-direction (MD) and the cross-machine-direction (CD) of said fabric.
6. The process for making high bulk, MD-extensible tissue paper of Claim 5 wherein said mesh count is from about six (6) to about fifteen (15) filaments per centimeter in both the MD and CD directions of said fabric.
7. The process far making high bulk, MD-extensible tissue paper of Claim 1 wherein the velocity of said transfer fabric is from about ten (10) to about forty (40) percent slower than said predetermined velocity of said carrier fabric.
8. The process for making high bulk, MD-extensible tissue paper of Claim 1 wherein the velocity of said transfer fabric is from about fifteen (15) to about thirty (30) percent slower than said predetermined velocity of said carrier fabric.
9. The process of Claim 1, further com-prising the step of adding sufficient wet strength material for said web to be an effective and durable spill wipe-up article.
10. The process of Claim 9 wherein at least a sub-stantial portion of said wet strength material is included in the furnish from which said web is formed.
11. The process of Claim 9 wherein at least a sub-stantial portion of said wet strength material is discontinuously applied to said web after its formation.
12. The process of Claim 1, further comprising the steps of:
adhesively securing said web to a creping cylinder having a surface velocity substantially equal to the velocity of said transfer fabric; and dry-creping said web from said creping cylinder with a doctor blade.
adhesively securing said web to a creping cylinder having a surface velocity substantially equal to the velocity of said transfer fabric; and dry-creping said web from said creping cylinder with a doctor blade.
13. The process of Claim 12 further comprising the step of reeling said web at a velocity at least about equal to the surface velocity of said creping cylinder to substantially remove dry-creping induced exten-sibility therefrom.
14. The process of Claim 12 further comprising the step of reeling said web at a sufficiently slower velocity than the surface velocity of said creping cylinder that said web has a predetermined degree of residual dry-crepe whereby a hybrid stress-strain modulus is imparted to said web which is manifested by the web acting somewhat like a dry-creped web at low stress levels when wet, and the web having a substan-tially higher stress/strain modulus through its middle one-third range of MD extensibility than a purely dry-creped web which is otherwise substantially identical and has substantially equal ultimate MD extensibility.
15. The process of Claim 12 further comprising the step of adding sufficient wet strength material for said web to be an effective and durable spill wipe-up article.
16. The process of Claim 15 wherein at least a sub-stantial portion of said wet strength material is included in the furnish from which said web is formed.
17. The process of Claim 15 wherein at least a sub-stantial portion of said wet strength material is discontinuously applied to said web after its formation.
18. The process of Claim l wherein said embryonic web is dewatered to a fiber consistency of from about ten (10) to about twenty (20) percent immediately prior to being transferred to said transfer fabric, said transfer fabric having a mesh count of from about six (6) to about fifteen (15) filaments per centimeter in both the machine direction and the cross-machine direction, said transfer fabric having a velocity of from about fifteen (15) to about thirty (30) percent slower than said carrier fabric, said gaseous pressure being precipi-tated by a vacuum source, and wherein sufficient wet strength material is incorporated in said web that said web is a durable and effective spill wipe-up article.
19. The process of Claim 18 further comprising the steps of:
adhesively securing said web to a creping cylinder having a surface velocity substantially equal to the velocity of said transfer fabric; and dry-creping said web from said creping cylinder with a doctor blade.
adhesively securing said web to a creping cylinder having a surface velocity substantially equal to the velocity of said transfer fabric; and dry-creping said web from said creping cylinder with a doctor blade.
20. The process of Claim 19 further comprising the step of reeling said web at a velocity at least about equal to the surface velocity of said creping cylinder to substan-tially remove dry-creping induced extensibility therefrom.
21. The process of Claim 19 further comprising the step of reeling said web at a sufficiently slower velocity than the surface velocity of said creping cylinder that said web has a predetermined degree of residual dry-crepe whereby a hybrid stress-strain modulus is imparted to said web which is manifested by the web acting somewhat like a dry-creped web at low stress levels when wet, and the web having a substantially higher stress/strain modulus through its middle one-third range of MD extensibility than a purely dry-creped web which is otherwise substan-tially identical and has substantially equal ultimate MD
extensibility.
extensibility.
22. The process of Claim 1, 18, or 19 wherein said form-ing of said embryonic web comprises forming a multi-layer embryonic web from a plurality of paper-making furnishes.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US358,500 | 1982-03-15 | ||
US06/358,500 US4440597A (en) | 1982-03-15 | 1982-03-15 | Wet-microcontracted paper and concomitant process |
Publications (1)
Publication Number | Publication Date |
---|---|
CA1222406A true CA1222406A (en) | 1987-06-02 |
Family
ID=23409908
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
CA000423570A Expired CA1222406A (en) | 1982-03-15 | 1983-03-14 | Wet-microcontracted paper and concomitant process |
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US (1) | US4440597A (en) |
CA (1) | CA1222406A (en) |
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-
1982
- 1982-03-15 US US06/358,500 patent/US4440597A/en not_active Expired - Lifetime
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1983
- 1983-03-14 CA CA000423570A patent/CA1222406A/en not_active Expired
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