U.S. patent application number 10/094491 was filed with the patent office on 2002-07-11 for method for adding an adsorbable chemical additive to pulp during the pulp processing and products made by said method.
Invention is credited to Burns, Barbara Jean, Coe, Louise Cynthia Ellis, Goulet, Mike Thomas, Rekoske, Michael John.
Application Number | 20020088582 10/094491 |
Document ID | / |
Family ID | 24048489 |
Filed Date | 2002-07-11 |
United States Patent
Application |
20020088582 |
Kind Code |
A1 |
Burns, Barbara Jean ; et
al. |
July 11, 2002 |
Method for adding an adsorbable chemical additive to pulp during
the pulp processing and products made by said method
Abstract
Pulp fibers can be treated with adsorbable chemicals with a
minimal amount of unadsorbed chemical additives present later in
the papermaking process water. A method for adding an adsorbable
chemical to pulp includes mixing pulp fibers that have never been
dried with water to form a fiber slurry. An adsorbable chemical
additive is added to the fiber slurry. The fiber slurry having the
adsorbable chemical additive is transported to a web-forming
apparatus where a wet fibrous web is formed. The wet fibrous web
may be dried to a predetermined consistency thereby forming a dried
fibrous web having from between about 10 to about 100 percent
retention of the adsorbable chemical additive. The dried fibrous
web is transported to a paper machine where the dried fibrous web
is mixed with water to form a wet slurry. In other embodiments, the
fiber slurry can be processed to provide crumb fibers or wet lap
fibers. The wet slurry containing the fibers having the adsorbable
chemical additive adhered thereto is transported through the paper
machine to form a finished paper or tissue product having enhanced
quality due to the retention of the adsorbable chemical additive on
the pulp fibers.
Inventors: |
Burns, Barbara Jean;
(Appleton, WI) ; Coe, Louise Cynthia Ellis;
(Appleton, WI) ; Goulet, Mike Thomas; (Neenah,
WI) ; Rekoske, Michael John; (Appleton, WI) |
Correspondence
Address: |
KIMBERLY-CLARK WORLDWIDE, INC.
401 NORTH LAKE STREET
NEENAH
WI
54956
|
Family ID: |
24048489 |
Appl. No.: |
10/094491 |
Filed: |
March 7, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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|
10094491 |
Mar 7, 2002 |
|
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|
09514740 |
Feb 28, 2000 |
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6379498 |
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Current U.S.
Class: |
162/158 ;
162/202; 162/207 |
Current CPC
Class: |
D21H 17/70 20130101 |
Class at
Publication: |
162/158 ;
162/202; 162/207 |
International
Class: |
D21H 021/00; D21F
001/00; D21F 005/00 |
Claims
We claim:
1. A method for preparing pulp comprising: a) creating a fiber
slurry comprising water, pulp fibers that have never been dried and
an adsorbable chemical additive; b) transporting said fiber slurry
having said adsorbable chemical additive to a web-forming apparatus
and forming a wet fibrous web; and, c) drying said wet fibrous web
to a predetermined consistency thereby forming a dried fibrous web
having from between about 10 to about 100 percent retention of said
adsorbable chemical additive.
2. The method of claim 1, wherein said method further comprises
transporting said dried fibrous web to a paper machine and mixing
said dried fibrous web with water to form a wet slurry, said wet
slurry containing fibers having said adsorbable chemical additive
secured thereto.
3. The method of claim 2, wherein said method further comprises
producing a finished paper or tissue product having enhanced
quality due to the retention of said adsorbable chemical additive
on said fibers.
4. The method of claim 1, 2, or 3, wherein said adsorbable chemical
additive is selected from the group comprising softening agents,
dry strength agents, wet strength agents, opacifying agents, dyes,
and mixtures thereof.
5. The method of claim 1, 2, or 3, wherein said softener is
selected from the group consisting of quaternary ammonium
compounds, quaternized protein compounds, phospholipids, silicone
quaternaries, quaternized, hydrolyzed wheat protein/dimethicone
phosphocopolyol copolymer, organoreactive polysiloxanes, and
silicone gylcols.
6. The method of claim 1, 2, or 3, wherein said adsorbable chemical
additive is a softener.
7. The method of claim 1, 2, or 3, wherein said adsorbable chemical
additive is a bonding agent.
8. The method of claim 1, wherein creating a fiber slurry comprises
adding said adsorbable chemical additive to an aqueous solution
comprising said water and said pulp fibers.
9. The method of claim 1, wherein said adsorbable chemical additive
is added to said slurry of water and pulp fibers in an amount of
about 0.1 kilograms per metric ton or greater.
10. The method of claim 1, wherein said dried fibrous web has a
consistency ranging from about 45 percent to about 100 percent.
11. The method of claim 1, wherein said dried fibrous web has a
consistency ranging from about 85 percent to about 95 percent.
12. The method of claim 1, wherein sufficient residence time is
provided after said adsorbable chemical additive is added to allow
for absorption of said adsorbable chemical additive onto said pulp
fiber.
13. The method of claim 1, further comprising forming a paper or
tissue product from said dried fibrous web.
14. A paper or tissue product made using the method of claim 1.
15. The paper or tissue product of claim 14, wherein the amount of
said chemical additive added to said pulp fibers is about 0.1
kilogram per metric ton or greater.
16. A method for adding an adsorbable chemical to pulp, said method
comprising: a) mixing pulp fibers that have never been dried with
water to form a fiber slurry; b) adding an adsorbable chemical
additive to said fiber slurry; c) transporting said fiber slurry
having said adsorbable chemical additive to a web-forming apparatus
and forming a wet fibrous web; d) drying said wet fibrous web to a
predetermined consistency thereby forming a dried fibrous web
having from between about 10 to about 100 percent retention of said
adsorbable chemical additive; e) transporting said dried fibrous
web to a paper machine and mixing said dried fibrous web with water
to form a wet slurry, said wet slurry containing fibers having said
adsorbable chemical additive adhered thereto; and, f) transporting
said wet slurry through said paper machine to form a finished paper
or tissue product having enhanced quality due to the retention of
said adsorbable chemical additive on said pulp fibers.
17. The fiber slurry of claim 16, wherein the amount of said
chemical additive adsorbed onto said pulp fibers is about 0.1
kilogram per metric ton or greater, and the amount of unadsorbed
said chemical additive in said water is between 0 and about 90
percent of the amount of said chemical additive added to said pulp
fibers.
18. The fiber slurry of claim 16, wherein the amount of said
chemical additive added to said pulp fibers is about 1 kilograms
per metric ton or greater.
19. The fiber slurry of claim 16, wherein the amount of said
chemical additive added to said pulp fibers is about 3 kilograms
per metric ton or greater.
20. The fiber slurry of claim 16, wherein the amount of said
chemical additive added to said pulp fibers is about 5 kilograms
per metric ton or greater.
21. The fiber slurry of claim 16, wherein said chemical additive is
selected from the group comprising softening agents, debonding
agents, dry strength agents, wet strength agents and opacifying
agents.
22. A paper or tissue product made from said fiber slurry of claim
16.
23. A method for adding an adsorbable chemical additive to pulp
fiber, said method comprising: a) creating a fiber slurry
comprising water, pulp fibers that have never been dried and at
least a first adsorbable chemical additive and a second adsorbable
chemical additive; b) transporting said fiber slurry having at
least said first and second adsorbable chemical additives to a
web-forming apparatus and forming a wet fibrous web; and, c) drying
said wet fibrous web to a predetermined consistency thereby forming
a dried fibrous web having from between about 10 to about 100
percent retention of at least said first and second adsorbable
chemical additives.
24. The method of claim 23, wherein said method further comprises
transporting said dried fibrous web to a paper machine and mixing
said dried fibrous web with water to form a wet slurry, said wet
slurry containing fibers having said adsorbable chemical additive
secured thereto.
25. The method of claim 24, wherein said method further comprises
producing a finished paper or tissue product having enhanced
quality due to the retention of said adsorbable chemical additive
on said fibers.
26. The method of claim 23, 24, or 25, wherein said first
adsorbable chemical additive is selected from the group comprising
softening agents, dry strength agents, wet strength agents,
opacifying agents, dyes, and mixtures thereof.
27. The method of claim 26, wherein said softening agent is
selected from the group consisting of quaternary ammonium
compounds, quaternized protein compounds, phospholipids, silicone
quaternaries, quaternized, hydrolyzed wheat protein/dimethicone
phosphocopolyol copolymer, organoreactive polysiloxanes, and
silicone gylcols.
28. The method of claim 23, 24, or 25, wherein said second
adsorbable chemical additive is selected from the group comprising
softening agents, dry strength agents, wet strength agents,
opacifying agents, dyes, and mixtures thereof.
29. The method of claim 28, wherein said softening agent is
selected from the group consisting of quaternary ammonium
compounds, quaternized protein compounds, phospholipids, silicone
quaternaries, quaternized, hydrolyzed wheat protein/dimethicone
phosphocopolyol copolymer, organoreactive polysiloxanes, and
silicone gylcols.
30. The method of claim 23, wherein creating a fiber slurry
comprises adding said first and second adsorbable chemical
additives to an aqueous solution comprising said water and said
pulp fibers.
31. The method of claim 23, wherein said first adsorbable chemical
additive is added to a slurry of water and pulp fibers in an amount
of about 0.1 kilograms per metric ton or greater.
32. The method of claim 23, wherein said second adsorbable chemical
additive is added to a slurry of water and pulp fibers in an amount
of about 0.1 kilogram per metric ton or greater.
33. The method of claim 23, wherein said dried fibrous web has a
consistency ranging from about 45 percent to about 100 percent.
34. The method of claim 23, wherein said dried fibrous web has a
consistency ranging from about 85 percent to about 95 percent.
35. The method of claim 23, wherein sufficient residence time is
provided after said first adsorbable chemical additive is added to
allow for absorption of said first adsorbable chemical additive
onto said pulp fiber.
36. The method of claim 23, wherein sufficient residence time is
provided after said second adsorbable chemical additive is added to
allow for absorption of said second adsorbable chemical additive
onto said pulp fiber.
37. A paper or tissue product made using the method of claim
23.
38. A method for adding an adsorbable chemical to pulp, said method
comprising: a) mixing pulp fibers that have never been dried with
water to form a fiber slurry; b) adding a first adsorbable chemical
additive to said fiber slurry; c) adding at least a second
adsorbable chemical additive to said fiber slurry; d) transporting
said fiber slurry having at least said first and second adsorbable
chemical additives to a web-forming apparatus and forming a wet
fibrous web; e) drying said wet fibrous web to a predetermined
consistency thereby forming a dried fibrous web having from between
about 10 to about 100 percent retention of at least said first and
second adsorbable chemical additives; f) transporting said dried
fibrous web to a paper machine and mixing said dried fibrous web
with water to form a wet slurry, said wet slurry containing fibers
having at least said first and second adsorbable chemical additives
adhered thereto; and, g) transporting said wet slurry through said
paper machine to form a finished paper or tissue product having
enhanced quality due to the retention of at least said first and
second adsorbable chemical additives on said fibers.
39. A fiber slurry produced using the method described in claim 38,
wherein the amount of said first chemical additive adsorbed onto
said pulp fibers is about 0.1 kilogram per metric ton or greater,
and the amount of unadsorbed said first chemical additive in said
water is between 0 and about 90 percent of the amount of said first
chemical additive added to said pulp fibers.
40. A fiber slurry produced using the method described in claim 38,
wherein the amount of said second chemical additive adsorbed onto
said pulp fibers is about 0.1 kilogram per metric ton or greater,
and the amount of unadsorbed said second chemical additive in said
water is between 0 and about 90 percent of the amount of said
second chemical additive adsorbed onto said pulp fibers.
41. A fiber slurry produced using the method described in claim 38,
wherein the amount of said first chemical additive adsorbed onto
said pulp fibers is about 0.1 kilograms per metric ton or greater,
and the amount of unadsorbed said first chemical additive in said
water is between 0 and about 90 percent of the amount of said first
chemical additive added to said pulp fibers and wherein the amount
of said second chemical additive adsorbed onto said pulp fibers is
about 0.1 kilogram per metric ton or greater, and the amount of
unadsorbed said second chemical additive in said water is between 0
and about 90 percent of the amount of said second chemical additive
adsorbed onto said pulp fibers.
42. The fiber slurry of claim 39, 40, or 41, wherein the amount of
said first chemical additive added to said pulp fibers is about 1
kilogram per metric ton or greater.
43. The fiber slurry of claim 39, 40, or 41, wherein the amount of
said second chemical additive added to said pulp fibers is about 1
kilogram per metric ton or greater.
44. The fiber slurry of claim 39, 40, or 41, wherein the amount of
said first chemical additive added to said pulp fibers is about 3
kilograms per metric ton or greater.
45. The fiber slurry of claim 39, 40, or 41, wherein the amount of
said second chemical additive added to said pulp fibers is about 3
kilograms per metric ton or greater.
46. The fiber slurry of claim 39, 40, or 41, wherein the amount of
said first chemical additive added to said pulp fibers is about 5
kilograms per metric ton or greater.
47. The fiber slurry of claim 39, 40, or 41, wherein the amount of
said second chemical additive added to said pulp fibers is about 5
kilograms per metric ton or greater.
48. The fiber slurry of claim 39, 40, or 41, wherein said first
chemical additive is selected from the group comprising softening
agents, debonding agents, dry strength agents, wet strength agents
and opacifying agents.
49. The fiber slurry of claim 39, 40, or 41, wherein said second
chemical additive is selected from the group comprising softening
agents, debonding agents, dry strength agents, wet strength agents
and opacifying agents.
50. A paper or tissue product made from said fiber slurry of claim
39, 40, or 41.
51. A paper or tissue product made using the method of claim
38.
52. A method for preparing pulp comprising: a) creating a fiber
slurry comprising water, pulp fibers that have never been dried and
an adsorbable chemical additive; and, b) transporting said fiber
slurry having said adsorbable chemical additive to a web-forming
apparatus and forming a wet fibrous web, thereby forming a wet
fibrous web having from between about 10 to about 100 percent
retention of said adsorbable chemical additive.
53. A method for adding an adsorbable chemical additive to pulp,
said method comprising: a) mixing pulp fibers that have never been
dried with water to form a fiber slurry; b) adding an adsorbable
chemical additive to said fiber slurry; c) transporting said fiber
slurry having said adsorbable chemical additive to a web-forming
apparatus and forming a wet fibrous web; d) transporting said wet
fibrous web to a paper machine and mixing said wet fibrous web with
water to form a wet slurry, said wet slurry containing fibers
having said adsorbable chemical additive adhered thereto; and, e)
transporting said wet slurry through said paper machine to form a
finished paper or tissue product having enhanced quality due to the
retention of said adsorbable chemical additive on said fibers.
54. A method for adding an adsorbable chemical additive to pulp,
said method comprising: a) mixing pulp fibers that have never been
dried with water to form a fiber slurry; b) adding an adsorbable
chemical additive to said fiber slurry; c) transporting said fiber
slurry having said adsorbable chemical additive to a web-forming
apparatus and forming a crumb pulp; d) transporting said crumb pulp
to a paper machine and mixing said crumb pulp with water to form a
wet slurry, said wet slurry containing fibers having said
adsorbable chemical additive adhered thereto; and, e) transporting
said wet slurry through said paper machine to form a finished paper
or tissue product having enhanced quality due to the retention of
said adsorbable chemical additive on said fibers.
55. A method for adding an adsorbable chemical to pulp, said method
comprising: a) creating a fiber slurry comprising water, pulp
fibers that have never been dried and at least a first adsorbable
chemical additive and a second adsorbable chemical additive; and,
b) transporting said fiber slurry having at least said first and
second adsorbable chemical additives to a web-forming apparatus and
forming a wet fibrous web, thereby forming a wet fibrous web having
from between about 10 to about 100 percent retention of at least
said first and second adsorbable chemical additives.
56. A method for adding an adsorbable chemical to pulp, said method
comprising: a) mixing pulp fibers that have never been dried with
water to form a fiber slurry; b) adding a first adsorbable chemical
additive to said fiber slurry; c) adding at least a second
adsorbable chemical additive to said fiber slurry; d) transporting
said fiber slurry having at least said first and second adsorbable
chemical additives to a web-forming apparatus thereby forming a wet
fibrous web having from between about 10 to about 100 percent
retention of at least said first and second adsorbable chemical
additives; e) transporting said wet fibrous web to a paper machine
and mixing said wet fibrous web with water to form a wet slurry,
said wet slurry containing fibers having at least said first and
second adsorbable chemical additives adhered thereto; and, f)
transporting said wet slurry through said paper machine to form a
finished paper or tissue product having enhanced quality due to the
retention of at least said first and second adsorbable chemical
additives on said fibers.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to paper or tissue
products. More particularly, the invention concerns methods for
applying adsorbable chemical additives to the fibers of pulps
during the pulp processing and the paper products that can be
obtained by the methods.
[0002] In the manufacture of paper products, it is often desirable
to enhance physical and/or optical properties by the addition of
chemical additives. Typically, chemicals such as softeners,
colorants, brighteners, strength agents, etc. are added to the
fiber slurry upstream of the headbox in a paper making machine
during the manufacturing or converting stages of production to
impart certain attributes to the finished product. These chemicals
are usually mixed in a stock chest or stock line where the fiber
slurry has a fiber consistency of from between about 0.15 to about
5 percent or spraying the wet or dry paper or tissue during
production.
[0003] One disadvantage of adding a chemical at each paper machine
is that the manufacturer has to install equipment on each paper
machine to accomplish the chemical addition. This, in many cases,
is a costly proposition. In addition, the uniformity of the
finished product coming off of each paper machine may vary
depending upon how the chemical was added, variations in chemical
uniformity and concentrations, the exact point of chemical
introduction, water chemistry differences among the paper machines
as well as personnel and operational differences of each paper
machine.
[0004] Another difficulty associated with wet end chemical addition
is that the water soluble or water dispersible chemical additives
are suspended in water and are not completely adsorbed onto the
fibers prior to formation of the wet mat. To improve adsorption of
wet end additives, chemical additives are often modified with
functional groups to impart an electrical charge when in water. The
electrokinetic attraction between charged additives and the
anionically charged fiber surfaces aids in the deposition and
retention of chemical additives onto the fibers. Nevertheless, the
amount of chemical additive that can be retained in the paper
machine wet end generally follows an adsorption curve exhibiting
diminishing incremental adsorption with increasing concentration,
similar to that described by Langmuir. As a result, the adsorption
of water soluble or water dispersible chemical additives may be
significantly less than 100 percent, particularly when trying to
achieve high chemical additive loading levels.
[0005] Consequently, at any chemical addition level, and
particularly at high addition levels, a fraction of the chemical
additive is retained on the fiber surface. The remaining fraction
of the chemical additive remains dissolved or dispersed in the
suspending water phase. These unadsorbed chemical additives can
cause a number of problems in the papermaking process. The exact
nature of the chemical additive will determine the specific
problems that may arise, but a partial list of problems that may
result from unadsorbed chemical additives includes: foam, deposits,
contamination of other fiber streams, poor fiber retention on the
machine, compromised chemical layer purity in multi-layer products,
dissolved solids build-up in the water system, interactions with
other process chemicals, felt or fabric plugging, excessive
adhesion or release on dryer surfaces, physical property
variability in the finished product.
[0006] Therefore, what is lacking and needed in the art is a method
for applying adsorbable chemical additives onto pulp fiber surfaces
in the initial or primary pulp processing, providing more uniform
chemical additions to the pulp fiber and a reduction or elimination
of unadsorbed chemical additives in the process water on a paper
machine. The method minimizes the associated manufacturing and
finished product quality problems that would otherwise occur with
conventional wet end chemical addition at the paper machine.
SUMMARY OF THE INVENTION
[0007] It has now been discovered that adsorbable chemical
additives can be adsorbed onto pulp fibers that have never been
dried at high and/or uniform levels with at most a minimal amount
of unadsorbed chemical additives present in the papermaking process
water after the treated pulp fiber has been redispersed in water.
This is accomplished by treating a fiber slurry comprising pulp
fiber and water with an excess of the adsorbable chemical additive,
allowing sufficient residence time for adsorption to occur, and
filtering or otherwise dewatering the fiber slurry to remove water
and unadsorbed chemical additives.
[0008] Hence in one aspect, the invention resides in a method for
applying adsorbable chemical additives to the pulp fibers. The
method comprises creating a fiber slurry comprising water, pulp
fibers that have never been dried, and an adsorbable chemical
additive. The fiber slurry having the chemical additive may be
formed into a wet fibrous web using a web forming apparatus. The
wet fibrous web is dried to a predetermined consistency. In other
embodiments of the present invention, the process may include
further dewatering thereby forming a crumb-form. The dried fibrous
web may have retained from between about 10 to about 100 percent of
the adsorbable chemical additive.
[0009] According to another embodiment of the present invention is
a method for adding an adsorbable chemical to the pulp fiber during
the pulp processing prior to the drying stage. During the pulp
processing, upstream of a paper machine, one can obtain chemically
treated pulp fiber that is essentially homogeneous in chemical
adsorption. Furthermore, the chemically treated pulp fiber can be
transported to several different paper machines that may be located
at various sites, and the quality of the finished product from each
paper machine will be more consistent. Also, by chemically treating
the pulp fiber before the pulp fiber is available for use on
multiple paper machines or multiple runs on a paper machine, the
need to install equipment at each paper machine for the adsorbable
chemical addition can be eliminated.
[0010] This method for processing pulp fibers also enables higher
and more uniform concentrations of adsorbable chemical additives to
be adsorbed by the pulp fibers while at the same time maintaining
significantly lower levels of unadsorbed chemical additive in the
water phase of a papermaking machine compared to paper machine wet
end chemical additions.
[0011] The term "adsorbable" is used herein to refer to a chemical
additive that can be assimilated by the surface of a pulp fiber, in
the absence of any chemical reaction involving the chemical
additive and the fiber. Once the chemical additive is adsorbed, it
may or may not be absorbed into the pulp fiber. The term
"unadsorbed" refers to any portion of the adsorbable chemical
additive that is not adsorbed by the pulp fiber and thus remains
suspended in the process water. The term "web-forming apparatus"
includes fourdrinier former, twin wire former, cylinder machine,
press former, crescent former, and the like known to those skilled
in the art.
[0012] The consistency of the fiber slurry is from about 0.5 to
about 15 percent. In other embodiments, the consistency of the
fiber slurry is from about 2 to about 10 percent or from about 3 to
about 5 percent. The consistency of the dried fibrous web is from
about 45 to about 100 percent. In other embodiments, the
consistency of the dried fibrous web is from about 60 to about 100
percent or from about 85 to about 95 percent. The consistency of
the wet fibrous web is from about 30 to about 45 percent. In other
embodiments, the consistency of the wet fibrous web is from about
35 to about 45 percent or from about 40 to about 45 percent. The
consistency of the crumb form is from about 50 to about 85 percent.
In other embodiments, the consistency of the crumb form is from
about 60 to about 85 percent or from about 80 to about 85
percent.
[0013] The present method allows for the production of pulp fibers
that are useful for making paper products. This results in a pulp
fiber, which after drying, has different mechanical properties than
if the chemical treatment is carried out on pulp fiber in the once
dried state. One aspect of the present invention is a more
uniformly chemically treated pulp fiber, replacing the need for
costly and variable chemical treatments at one or more paper
machines. Another aspect of the invention resides in a pulp fiber
that has a higher chemical additive loading than could otherwise be
achieved in combination with no or a relatively low level of
unadsorbed chemical additive in the process water on a paper
machine. This is because chemical additive loading via wet end
addition is often limited by the level of unadsorbed chemical
and/or contact time, as well as its associated processing
difficulties such as foam, deposits, chemical interactions, felt
plugging, excessive dryer adhesion or release or a variety of paper
physical property control issues caused by the presence of
unadsorbed chemical in the process water on the paper machines.
[0014] In another embodiment, a fiber slurry of the present
invention comprises water, pulp fibers having an adsorbable
chemical additive adsorbed onto the fiber surface. The amount of
chemical additive adsorbed onto the pulp fibers is about 0.1
kilogram per metric ton or greater, and the amount of unadsorbed
chemical additive in the water is between 0 and about 90 percent of
the amount of adsorbable chemical additive added to the pulp
fibers. In particularly desirable embodiments, the amount of
adsorbed chemical additive is about 0.5 kg/metric ton or greater,
particularly about 1 kg/metric ton or greater, and more
particularly about 2 kg/metric ton or greater. Once the wet or
dried fibrous wet is redispersed at the paper machine, the amount
of unadsorbed chemical additive in the water phase is between 0 and
about 15 percent, particularly between 0 and about 10 percent, and
more particularly between 0 and about 7 percent, of the amount of
adsorbed chemical additive.
[0015] According to one embodiment of the present invention, the
method for adding an adsorbable chemical additive to pulp fiber
comprises creating a fiber slurry. The fiber slurry comprises
water, pulp fibers that have never been dried, and an adsorbable
chemical additive. The fiber slurry having the adsorbable chemical
additive is passed to a web-forming apparatus where a wet fibrous
web is formed from the fiber slurry. The wet fibrous web is dried
to a predetermined consistency. The resulting dried fibrous web may
have from between about 10 to about 100 percent retention of the
adsorbable chemical additive on the fibers. The dried fibrous web
may be transported to a paper machine. The dried fibrous web is
mixed with water to form a wet slurry. The wet slurry contains the
fibers having the adsorbable chemical additive secured thereto. A
finished product having enhanced quality due to the retention of
the adsorbable chemical additive on the fibers may be produced from
the wet slurry.
[0016] Another aspect of the present invention resides in a method
for making chemically treated paper products. The method comprising
mixing pulp fibers that have never been dried with water to form a
fiber slurry. An adsorbable chemical additive is added to the fiber
slurry. The fiber slurry, containing the adsorbable chemical
additive is formed into a wet fibrous web. This may be accomplished
in a web-forming apparatus. The wet fibrous web may be dried to a
predetermined consistency. The resulting dried fibrous web may have
from about 10 to about 100 percent retention of the chemical
additive. The pulp fibers, as a dried fibrous web, may be
transported or otherwise delivered to one or more paper machines.
The pulp fiber, as a dried fibrous web, is mixed with water to form
a wet slurry. The wet slurry contains the pulp fibers having the
adsorbable chemical additive secured thereto. A finished product
having enchanced qualities due to the retention of the adsorbable
chemical additive on the fibers may be produced.
[0017] Another aspect of the present invention resides in a method
for making chemically treated finished paper or tissue products.
The method comprising mixing pulp fibers that have never been dried
with water to form a fiber slurry. An adsorbable chemical additive
is added to the fiber slurry. The fiber slurry, containing the
adsorbable chemical additive is formed into a wet fibrous web. This
may be accomplished in a web-forming apparatus. The wet fibrous web
may be dewatered to a predetermined consistency. In other
embodiments, the pulp fiber may be processed to a wet lap or
processed to a crumb form. The resulting pulp fiber may have from
about 10 to about 100 percent retention of the adsorbable chemical
additive. The pulp fibers, once treated with the adsorbable
chemical additive, may be transported or otherwise delivered to one
or more paper machines in the form of a wet fibrous web, a dried
fibrous web, a wet lap, or a crumb form. The pulp fiber, as a wet
fibrous web, a wet lap, or a crumb form, is mixed with water to
form a wet slurry. The wet slurry contains the pulp fibers having
the adsorbable chemical additive secured thereto. A finished
product having enhanced qualities due to the retention of the
adsorbable chemical additive on the fibers is produced.
[0018] Another aspect of the present invention resides in a method
for making chemically treated paper products. The method comprises
creating a fiber slurry comprising water, pulp fibers that have
never been dried, and a first adsorbable chemical additive. At
least a second adsorbable chemical additive may be added to the
fiber slurry, thereby forming a multi-treated fiber slurry. The
additional adsorbable chemical additives may be added
simultaneously with the first adsorbable chemical additives or at
different times or points of the pulp processing. The additional
adsorbable chemical additives may be added simultaneously or at
different times or points of the pulp processing. The multi-treated
fiber slurry, containing the adsorbable chemical additives, is
formed into a wet fibrous web. This may be accomplished in a
web-forming apparatus. The wet fibrous web may be dried to a
predetermined consistency. The resulting dried fibrous web may have
from about 10 to about 100 percent retention of the adsorbable
chemical additives. The pulp fibers, as a multi-treated dried
fibrous web, is transported or otherwise delivered to one or more
paper machines. The pulp fiber, as a multi-treated dried fibrous
web, is mixed with water to form a wet slurry. The wet slurry
contains the pulp fibers having the adsorbable chemical additives
secured thereto. A finished product having enhanced qualities due
to the retention of the adsorbable chemical additives on the fibers
may be produced.
[0019] In other aspects of the present invention reside a method
for making chemically treated paper products. The method comprises
creating a fiber slurry comprising water, pulp fibers that have
never been dried, and a first adsorbable chemical additive. At
least a second adsorbable chemical additive may be added to the
fiber slurry, thereby forming a multi-treated fiber slurry. The
second or additional adsorbable chemical additives may be added
simultaneously with the first adsorbable chemical additive or at
different times or points of the pulp processing. The additional
adsorbable chemical additives may be added simultaneously or at
different times or points of the pulp processing. The multi-treated
fiber slurry, containing the adsorbable chemical additives, is
formed into a wet fibrous web. This may be accomplished in a
web-forming apparatus. The wet fibrous web may be dried to a
predetermined consistency. In other embodiments, the pulp fiber may
be processed to a wet lap or processed to a crumb form. The
resulting pulp fiber may have from about 10 to about 100 percent
retention of the adsorbable chemical additives. The pulp fibers,
once treated with the adsorbable chemical additives, may be
transported or otherwise delivered to one or more paper machines in
the form of a wet fibrous web, a wet lap, or a crumb form. The pulp
fiber, as a multi-treated wet fibrous web, a wet lap, or a crumb
form, is mixed with water to form a wet slurry. The wet slurry
contains the pulp fibers having the adsorbable chemical additives
secured thereto. A finished product having enhanced qualities due
to the retention of the adsorbable chemical additives on the fibers
may be produced.
[0020] The present invention is particularly useful for adding
adsorbable chemical additives such as softening agents to the pulp
fibers, allowing for the less problematic and lower cost production
of finished products having enhanced qualities provided by the
retained adsorbable chemical additives.
[0021] Hence, another aspect of the present invention resides in
paper products formed from pulp fibers that have been chemically
treated prior to a drying phase to minimize the amount of residual,
unadsorbed chemical additives in the process water on a paper
machine. The term "paper" is used herein to broadly include
writing, printing, wrapping, sanitary, and industrial papers,
newsprint, linerboard, tissue, bath tissue, facial tissue, napkins,
wipers, wet wipes, towels, absorbent pads, intake webs in absorbent
articles such as diapers, bed pads, meat and poultry pads, feminine
care pads, and the like made in accordance with any conventional
process for the production of such products. With regard to the use
of the term "paper" as used herein includes any web containing
cellulosic fibers alone or in combination with other fibers,
natural or synthetic. It can be layered or unlayered, creped or
uncreped, and can consist of a single ply or multiple plies. In
addition, the paper or tissue web can contain reinforcing fibers
for integrity and strength.
[0022] The adsorbable chemical additives that can be used in
conjunction with the present invention include: dry strength aids,
wet strength aids, softening agents, adsorbency aids, sizing
agents, dyes, optical brighteners, chemical tracers, opacifiers,
dryer adhesive chemicals, and the like. Additional forms of
adsorbable chemical additives may include: pigments, emollients,
humectants, viricides, bactericides, buffers, waxes,
fluoropolymers, odor control materials and deodorants, zeolites,
perfumes, vegetable and mineral oils, humectants, sizing agents,
surfactants, moisturizers, UV blockers, antibiotic agents, lotions,
fungicides, preservatives, aloevera extract, vitamin E, or the
like. Suitable adsorbable chemical additives are adsorbable by the
papermaking fibers and are water soluble or water dispersible.
[0023] The term "softening agent" refers to any adsorbable chemical
additive that can be incorporated into paper products such as
tissue to provide improved tactile feel and reduce paper stiffness.
A softening agent may be selected from the group consisting of
quaternary ammonium compounds, quaternized protein compounds,
phospholipids, silicone quaternaries, quaternized, hydrolyzed wheat
protein/dimethicone phosphocopolyol copolymer, organoreactive
polysiloxanes, and silicone glycols. These adsorbable chemical
additives can also act to reduce paper stiffness or can act solely
to improve the surface characteristics of tissue, such as by
reducing the coefficient of friction between the tissue surface and
the hand.
[0024] The term "dye" refers to any adsorbable chemical that can be
incorporated into paper products, such as bathroom tissue, facial
tissue, paper towels, and napkins, to impart a color. Depending on
the nature of the adsorbable chemical, dyes may be classified as
acid dyes, basic dyes, direct dyes, cellulose reactive dyes, or
pigments. All classifications are suitable for use in conjunction
with the present invention.
[0025] The term "water soluble" refers to solids or liquids that
will form a solution in water, and the term "water dispersible"
refers to solids or liquids of colloidal size or larger that can be
dispersed into an aqueous medium.
[0026] The method for applying adsorbable chemical additives to the
pulp fibers may be used in a wide variety of pulp finishing
processing, including dry lap pulp, wet lap pulp, crumb pulp, and
flash dried pulp operations. By way of illustration, various pulp
finishing processes (also referred to as pulp processing) are
disclosed in Pulp and Paper Manufacture: The Pulping of Wood,
2.sup.nd Ed., Volume 1, Chapter 12. Ronald G. MacDonald, editor,
which is incorporated by reference.
[0027] In addition, in situations where more than one adsorbable
chemical additive is to be employed, the adsorbable chemical
additives may be added to the fiber slurry in sequence to reduce
interactions between the adsorbable chemical additives. In other
situations, the adsorbable chemical additives may be removed from
the fiber slurry after another adsorbable chemical additive has
been added to facilitate the removal process.
[0028] Many fiber types may be used for the present invention
including hardwood or softwoods, straw, flax, milkweed seed floss
fibers, abaca, hemp, kenaf, bagasse, cotton, reed, and the like.
All known papermaking fibers may be used, including bleached and
unbleached fibers, fibers of natural origin (including wood fiber
and other cellulose fibers, cellulose derivatives, and chemically
stiffened or crosslinked fibers), some component portion of
synthetic fiber (synthetic papermaking fibers include certain forms
of fibers made from polypropylene, acrylic, aramids, acetates, and
the like), virgin and recovered or recycled fibers, hardwood and
softwood, and fibers that have been mechanically pulped (e.g.,
groundwood), chemically pulped (including but not limited to the
kraft and sulfite pulp processings), thermomechanically pulped,
chemithermomechanically pulped, and the like. Mixtures of any
subset of the above mentioned or related fiber classes may be used.
The pulp fibers can be prepared in a multiplicity of ways known to
be advantageous in the art. Useful methods of preparing fibers
include dispersion to impart curl and improved drying properties,
such as disclosed in U.S. Pat. No. 5,348,620 issued Sep. 20, 1994
and U.S. Pat. No. 5,501,768 issued Mar. 26, 1996, both to M. A.
Hermans et al. and U.S. Pat. No. 5,656,132 issued Aug. 12, 1997 to
Farrington, Jr. et al.
[0029] According to the present invention, the adsorbable chemical
treatment of the pulp fibers occurs prior to the drying phase of
the pulp processing. The two generally accepted methods of drying
include flash drying and can drying. Flash drying is most common
with bleached, chemi-thermo-mechanical pulp (BCTMP). The present
invention may also be applied to wet lap pulp processes without the
use of can or flash dryers.
[0030] Numerous features and advantages of the present invention
will appear from the following description. In the description,
reference is made to the accompanying drawings which illustrate
preferred embodiments of the invention. Such embodiments do not
represent the full scope of the invention. Reference should
therefore be made to the claims herein for interpreting the full
scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] FIG. 1 depicts a schematic process flow diagram of a method
according to the present invention for treating pulp fibers with
adsorbable chemical additives.
[0032] FIG. 2 depicts a schematic process flow diagram of a method
according to the present invention for treating pulp fibers with
multiple adsorbable chemical additives.
[0033] FIG. 3 depicts a schematic process flow diagram of a method
of making a creped tissue sheet.
DETAILED DESCRIPTION
[0034] The invention will now be described in greater detail with
reference to the Figures. A variety of conventional pulping
apparatuses and operations can be used with respect to the pulping
phase, pulp processing, and drying of pulp. Nevertheless,
particular conventional components are illustrated for purposes of
providing the context in which the various embodiments of the
invention can be used.
[0035] FIG. 1 depicts pulp processing preparation equipment used to
apply adsorbable chemical additives to pulp fibers according to one
embodiment of the present invention. The pulp processing equipment
comprises a (high density) storage tank 12 where the bleached and
never dried pulp fiber is held in the form of a fiber slurry 10
comprised of the pulp fiber and water. The consistency of the fiber
slurry 10 when contained in the storage tank 12 may range from
about 10 to about 12 percent fiber. In other embodiments, the
consistency of the fiber slurry 10 in the storage tank 12 may range
from about 8 to about 15 percent fiber.
[0036] The fiber slurry 10 is diluted and transferred from the
storage tank 12 through suitable conduits 13 to the blend chest 14
where the fiber slurry 10 is subjected to agitation using a mixing
blade, rotor, recirculation pump, or other suitable device 16,
thereby reducing variations in the fiber slurry 10. The consistency
of the fiber slurry 10 in the blend chest 14 may be from about 0.5
to about 15 percent fiber. In other embodiments, the consistency of
the fiber slurry 10 in the blend chest 14 may be from about 2 to
about 10 percent fiber or from about 3 to about 5 percent
fiber.
[0037] The fiber slurry 10 is transferred from the blend chest 14
through suitable conduits 15 to a machine chest 18. The consistency
of the fiber slurry 10 in the machine chest 18 may be from about
0.5 to about 15 percent fiber. In other embodiments, the
consistency of the fiber slurry 10 in the machine chest 18 may be
from about 2 to about 10 percent fiber or from about 3 to about 5
percent fiber.
[0038] One or more adsorbable chemical additives 24 are supplied
from a reservoir 22 and added to the fiber slurry 10 in the conduit
15 prior to the machine chest 18. The amount of adsorbable chemical
additive 24 is suitably about 0.1 kg./metric ton of pulp fiber or
greater. In particular embodiments, the adsorbable chemical
additive 24 comprises a softening agent and is added in an amount
from about 0.1 kg./metric ton of pulp fiber or greater. The fiber
slurry 10 and the adsorbable chemical additive 24 are desirably
allowed to remain together in the machine chest 18 under agitation
for a residence time sufficient to allow the pulp fibers to adsorb
a substantial portion of the adsorbable chemical additive 24. A
residence time of at least about 10 minutes, for instance may be
sufficient. In other embodiments, the residence time may range from
about 10 seconds to about 30 minutes or from about 2 minutes to
about 15 minutes.
[0039] The fiber slurry 10 is thereafter transferred from the
machine chest 18 through suitable conduits 19 and a fan pump 20 to
the screen device 26 where contaminates are removed based on size.
The consistency of the fiber slurry 10 is typically decreased at
some point during the transfer from the machine chest 18 to the fan
pump 20. One example of the screen device 26 is a slotted screen or
a pressure screen. The fiber slurry 10 may also be subjected to a
series of centricleaners (not shown) to remove heavy particles from
the fiber slurry 10 and an atenuator (not shown) to reduce the
variability of the pressure going into the headbox 28.
[0040] The fiber slurry 10 is thereafter transferred through
suitable conduits 27 to the headbox 28 where the fiber slurry 10 is
injected or deposited into a fourdrinier section 30 thereby forming
a wet fibrous web 32. The wet fibrous web 32 may be subjected to
mechanical pressure to remove water and unadsorbed chemical
additive 24. In the illustrated embodiment, the fourdrinier section
30 precedes a press section 44, although alternative dewatering
devices such as a nip thickening device, or the like may be used.
The fiber slurry 10 is deposited onto a foraminous fabric 46 such
that the fourdrinier section filtrate 48 is removed from the wet
fibrous web 32. The fourdrinier section filtrate 48 comprises a
portion of the process water in addition to the unabsorbed chemical
additive 24 in the water. The press section 44 or other dewatering
device suitably increases the fiber consistency of the wet fibrous
web 32 to about 30 percent or greater, and particularly about 40
percent or greater. The water and unadsorbed chemical additive 24
removed as fourdrinier section filtrate 48 during the web forming
step may be used as dilution water for dilution stages in the pulp
processing, as the dilution water base for the adsorbable chemical
additive 24, or discarded. But, importantly, the fourdrinier
section filtrate 48 containing the unadsorbed chemical additive 24
is not sent forward with the pulp fiber into the papermaking
process.
[0041] The wet fibrous web 32 may be transferred to a dryer section
34 where evaporative drying is carried out on the wet fibrous web
32 to an airdry consistency, thereby forming a dried fibrous web
36. The dried fibrous web 36 is thereafter slit, cut into sheets,
and baled for delivery to paper machines 38. At the paper machines
38, the dried fibrous web 36 is mixed with water to form a wet
slurry 40. The wet slurry 40 contains the pulp fiber having the
adsorbable chemical additive 24 adhered to the individual fibers.
The wet slurry 40 is passed through the papermaking machine and
processed to form a finished product 42. By way of illustration,
various paper or tissue making processes are disclosed in U.S. Pat.
No. 5,667,636 issued Sep. 16, 1997 to Engel et al.; U.S. Pat. No.
5,607,551 issued Mar. 4, 1997 to Farrington, Jr. et al.; U.S. Pat.
No. 5,672,248 issued Sep. 30, 1997 to Wendt et al.; and, U.S. Pat.
No. 5,494,554 issued Feb. 27, 1996 to Edwards et al., which are
incorporated herein by reference. The finished product 42 has
enhanced qualities due to the retention of the adsorbable chemical
additive 24 onto the pulp fibers during the pulp processing.
[0042] In other embodiments of the present invention, the
adsorbable chemical additives 24 may be added to the fiber slurry
10 at a variety of positions in the pulp processing apparatus. In
the alternative, the adsorbable chemical additives 24 may be added
to the fiber slurry 10 at the storage tank 12, the blend chest 14,
the machine chest 18, the fan pump 20, the screen device 26, or any
of the conduits 13, 15, and 19 through which the fiber slurry 10 is
transferred. To enhance the absorption of the adsorbable chemical
additives 24 onto the pulp fibers of the fiber slurry 10, agitation
devices 16 may be utilized. In the conduits 13, 15, and 19, the
agitation devices 16 may include static mixers such as baffles, or
kinetic mixers such as pumps.
[0043] In another embodiment, a second machine chest 21 may be
included in the pulp processing apparatus. (See FIG. 2.) The second
machine chest 21 may be disposed between the first machine chest 18
and the fan pump 20.
[0044] FIG. 2 depicts an alternative embodiment of the present
invention in which sequential addition of adsorbable chemical
additives 24 and 25 are added to the fiber slurry 10. The pulp
processing equipment comprises a (high density) storage tank 12
where the bleached and never dried pulp fiber is held in the form
of a fiber slurry 10 comprised of the pulp fiber and water. The
consistency of the fiber slurry 10 when contained in the storage
tank 12 may range from about 10 to about 12 percent fiber. In other
embodiments, the consistency of the fiber slurry 10 in the storage
tank 12 may range from about 8 to about 15 percent fiber.
[0045] The fiber slurry 10 is diluted and transferred from the
storage tank 12 through suitable conduits 13 to the blend chest 14
where the fiber slurry 10 is subjected to agitation using a mixing
blade, rotor, recirculation pump, or other suitable device 16,
thereby reducing variations in the fiber slurry 10. The consistency
of the fiber slurry 10 in the blend chest 14 may be from about 0.5
to about 15 percent fiber. In other embodiments, the consistency of
the fiber slurry 10 in the blend chest 14 may be from about 2 to
about 10 percent fiber or from about 3 to about 5 percent
fiber.
[0046] The fiber slurry 10 is transferred from the blend chest 14
through suitable conduits 15 to the machine chest 18. The
consistency of the fiber slurry 10 in the machine chest 18 may be
from about 0.5 to about 15 percent fiber. In other embodiments, the
consistency of the fiber slurry 10 in the machine chest 18 may be
from about 2 to about 10 percent fiber or from about 3 to about 5
percent fiber.
[0047] A first adsorbable chemical additive 24, comprising one or
more adsorbable chemical components, is supplied from a reservoir
22 and added to the fiber slurry 10 in a suitable conduit 15 prior
to the machine chest 18. The amount of first adsorbable chemical
additive 24 is suitably about 0.1 kg./metric ton of pulp fiber or
greater. In particular embodiments, wherein the first adsorbable
chemical additive 24 is a softening agent and is added in an amount
from about 0.1 kg./metric ton of pulp fiber or greater. The fiber
slurry 10 and the first adsorbable chemical additive 24 are
desirably allowed to remain together in the machine chest 18 under
agitation for a residence time sufficient to allow the pulp fibers
to adsorb a substantial portion of the first adsorbable chemical
additive 24. A residence time of at least about 10 minutes, for
instance may be sufficient. In other embodiments, the residence
time may range from about 10 seconds to about 30 minutes or from
about 2 minutes to about 15 minutes.
[0048] The fiber slurry 10 containing the first adsorbable chemical
additive 24 is transferred from the machine chest 18 through
suitable conduits 17 to the second machine chest 21. A second
adsorbable chemical additive 25, comprising one or adsorbable
chemical additives, is supplied from a second reservoir 23 and
added to the fiber slurry 10 in a suitable conduit 17 prior to the
second machine chest 21. The amount of the second adsorbable
chemical additive 25 is suitably about 0.1 kg./metric ton of pulp
fiber or greater. In particular embodiments, wherein the second
adsorbable chemical additive 25 is a softening agent and is added
in an amount from about 0.1 kg./metric ton of pulp fiber or
greater. The fiber slurry 10 and the second adsorbable chemical
additive 25 are desirably allowed to remain together in the second
machine chest 21 under agitation for a residence time sufficient to
allow the pulp fibers to adsorb a substantial portion of the second
adsorbable chemical additive 25. A residence time of at least about
10 minutes, for instance may be sufficient. In other embodiments,
the residence time may range from about 10 seconds to about 30
minutes or from about 2 minutes to about 15 minutes.
[0049] The fiber slurry 10 containing the first and second
adsorbable chemical additives 24 and 25 is thereafter transferred
from the second machine chest 21 through suitable conduits 19 and a
fan pump 20 to the screen device 26 where contaminates are removed
based on size. One example of the screen device 26 is a slotted
screen or pressure screen. The fiber slurry 10 may also be
subjected to a series of centricleaners (not shown) to remove heavy
particles from the fiber slurry 10 and an atenuator (not
shown).
[0050] The fiber slurry 10 is thereafter transferred through
suitable conduits 27 to the headbox 28 where the fiber slurry 10 is
injected or deposited into a fourdrinier section 30 thereby forming
a wet fibrous web 32. The wet fibrous web 32 may be subjected to
mechanical pressure to remove water and unadsorbed chemical
additive 24.
[0051] The wet fibrous web 32 may be transferred to a dryer section
34 where evaporative drying is carried out on the wet fibrous web
32, thereby forming a dried fibrous web 36. The dried fibrous web
36 is thereafter slit, cut into sheets, and baled for delivery to
paper machines 38. At the paper machines 38, the dried fibrous web
36 is mixed with water to form a wet slurry 40. The wet slurry 40
contains the pulp fiber having the first and second adsorbable
chemical additives 24 and 25 adhered to the individual fibers. The
wet slurry 40 is passed through the paper machine and processed to
form a finished product 42. The finished product 42 has enhanced
qualities due to the retention of the first and second adsorbable
chemical additives 24 and 25 onto the pulp fibers during the pulp
processing.
[0052] In other embodiments of the present invention, each of the
first and second adsorbable chemical additives 24 and 25 may be
added to the fiber slurry 10 at a variety of positions in the pulp
processing apparatus. In alternative embodiments, the first and
second adsorbable chemical additives 24 and 25 may be added to the
fiber slurry 10 at the storage tank 12, the blend chest 14, the
first or second machine chests 18 and 21, the fan pump 20, the
screen device 26, or any of the conduits 13, 15, 17, and 19 through
which the fiber slurry 10 is transferred. In addition, the first
and second adsorbable chemical additives 24 and 25 may be added to
the same piece of pulp processing equipment at different times,
such as the addition of the second adsorbable chemical additive 25
to the blend chest 14 after a sufficient residence time has elapsed
after the addition of the first adsorbable chemical additive 24 to
the blend chest 14. To enhance the uniformity of the absorption of
the first and second adsorbable chemical additives 24 and 25 onto
the pulp fibers of the fiber slurry 10, agitation devices 16 may be
utilized. In the conduits 13, 15, and 19, the agitation devices 16
may include static mixers such as baffles, or kinetic mixers such
as pumps.
[0053] In other embodiments of the present invention, one batch of
pulp fibers may be treated with a first chemical additive according
to the method of the present invention as discussed above while a
second batch of pulp fibers may be treated with a second chemical
additive according to the present invention. During the papermaking
process, different pulp fibers or pulp fibers having different
treatments may be processed into a layered paper or tissue product
as disclosed in the U.S. Pat. No. 5,730,839 issued Mar. 24, 1998 to
Wendt et al., which is incorporated herein by reference.
[0054] Referring to the FIG. 3, a tissue web 64 is formed using a
2-layer headbox 50 between a forming fabric 52 and a conventional
wet press papermaking (or carrier) felt 56 which wraps at least
partially about a forming roll 54 and a press roll 58. The tissue
web 64 is then transferred from the papermaking felt 56 to the
Yankee dryer 60 applying the vacuum press roll 58. An adhesive
mixture is typically sprayed using a spray boom 59 onto the surface
of the Yankee dryer 60 just before the application of the tissue
web to the Yankee dryer 60 by the press roll 58. A natural gas
heated hood (not shown) may partially surround the Yankee dryer 60,
assisting in drying the tissue web 64. Two tissue webs 64 may be
plied together and calendered. The resulting 2-ply tissue product
can be wound onto a hard roll.
EXAMPLES
Example 1
[0055] This example will describe how to produce chemically
modified pulp as described according to the present invention.
Referencing FIG. 1, the fully bleached eucalyptus pulp fiber slurry
having about 10% solids was diluted to about 2.5% solids in the
conduit as the fiber slurry was pumped out of the high density
storage tank. The fiber slurry was then pumped to the blend chest.
As the fiber slurry was transferred from the blend chest to the
machine chest through a conduit, a 1 percent dispersion of an
imidazoline softening agent (methyl-1-oleyl amidoethyl-2-oleyl
imidazolinium methylsulfate identified as Mackernium DC-183,
commercially available from McIntyre Ltd., located in University
Park, Illinois), was mixed into the fiber slurry.
[0056] The dosage of the chemical softener was 3 kilograms per
tonne of eucalyptus pulp fiber in the fiber slurry. The chemical
softener was mixed with the fiber slurry in the machine chest for
about 10 minutes. The fiber slurry was then diluted to about 0.6%
solids and used to form a wet fibrous web on the wet end of a dry
lap machine.
[0057] During the formation of the wet fibrous web, a substantial
portion of the chemical softener remained attached to the pulp
fiber in the fiber slurry. The unadsorbed chemical softener
remained in the water phase, which was drained as filtrate from the
pulp fiber. The wet fibrous web was pressed in a press section and
dried in a dryer section, thereby forming a dried fibrous web
having 90% solids. As treated, the pulp fiber was now in the form
to be used as a raw material in the tissue papermaking process.
[0058] The filtrate removed during the drainage step was recycled
back in the process and used for the dilution of the fiber slurry
in the conduits. Recycling of the filtrate containing the
unadsorbed Mackernium DC-183 chemical softener provided additional
opportunities for adsorption of the chemical softener by the pulp
fiber of the fiber slurry.
Example 2
[0059] A layered soft tissue product was made using the pulp fiber
produced according to the process disclosed in Example 1. The
tissue product was made using the overall process shown in FIG. 3.
The first stock layer contained the chemically treated Eucalyptus
hardwood pulp fiber produced as described in Example 1, which made
up about 65 percent of the tissue web by weight. This first stock
layer was the first layer to come into contact with the forming
fabric and was also the layer that came into contact with the
drying surface of the Yankee dryer. The second stock layer
contained northern softwood kraft pulp fiber. The second stock
layer made up about 35 percent of the tissue web by weight. A
modified polyacrylamide dry strength agent, Hercobond 1366
commercially available from Hercules Inc. located in Wilmington,
Del., was added to the pulp fiber of the softwood layer. The
Hercobond 1366 was added to the thick stock, that was at about 1.9%
solids, at an addition level of about 0.3% of the pulp fiber in the
entire tissue web. A polyamide epichlorohydrin wet strength agent,
Kymene 557LX commercially available from the Hercules, Inc., was
added to both the Eucalyptus and northern softwood kraft furnishes
at an addition level of about 0.2% based on the pulp fiber in the
entire tissue web.
[0060] Referring to the FIG. 3, the tissue web was formed using a
2-layer headbox between an Albany P-621 forming fabric commercially
available from Albany International Corp., located in Menasha,
Wis., and a conventional wet press papermaking (or carrier) felt
(Weavex M1C commercially available from Weavex located in Wake
Forest, N.C.) which wraps at least partially about a forming roll
and a press roll. The basis weight of the tissue web was about 7.3
pounds per 2880 square feet of air dried tissue web.
[0061] The tissue web was then transferred from the papermaking
felt to the Yankee dryer by the vacuum press roll. The water
content of the tissue web on the papermaking felt just prior to
transfer of the tissue web to the Yankee dryer was about 87
percent. The moisture content of the tissue web after the
application of the press roll was about 55 percent. An adhesive
mixture was sprayed using a spray boom onto the surface of the
Yankee dryer just before the application of the tissue web by the
press roll. The adhesive mixture consisted of about 40% polyvinyl
alcohol, about 40% polyamide resin and about 20% quaternized
polyamido amine as disclosed in U.S. Pat. No. 5,730,839 issued to
Wendt et al. which is herein incorporated by reference. The
application rate of the adhesive mixture was about 5.5 pounds of
dry adhesive per tonne of dry pulp fiber in the tissue web. A
natural gas heated hood (not shown) partially surrounding the
Yankee dryer had a supply air temperature of about 680.degree. F.
to assist in drying the tissue web. The temperature of the tissue
web after the application of the creping doctor was about
240.degree. F. as measured with a handheld infrared temperature
gun. The machine speed of the 24 inch wide tissue web was about
3000 feet per minute. The crepe ratio was about 1.30 or about
30%.
[0062] Two tissue webs were unwound from two soft rolls (or parent
rolls) and plied together and calendered with two steel rolls at 90
pounds per lineal inch. The 2-ply tissue product was constructed
such that the first stock layer containing the chemically treated
Eucalyptus pulp fiber disclosed in Example 1 was plied to the
outside of the 2-ply tissue product which was wound onto a hard
roll. The hard roll is converted into finished product, such as
facial tissue and the like. The finished basis weight of the 2-ply
tissue product at standard TAPPI standard temperature and humidity
was about 17.1 pounds per 2880 square feet. The MD tensile was
about 951 grams per 3 inches and the CD tensile was about 449 grams
per 3 inches. The thickness of one 2-ply tissue product was about
0.0097 inches. The MD stretch in the finished tissue product was
about 23.3 percent. All tensile tests were conducted at standard
TAPPI conditions.
[0063] While the invention has been described in conjunction with a
specific embodiment, it is to be understood that many alternatives,
modifications and variations will be apparent to those skilled in
the art in light of the aforegoing description. Accordingly, this
invention is intended to embrace all such alternatives,
modifications and variations which fall within the spirit and scope
of the appended claims.
* * * * *