U.S. patent application number 11/848912 was filed with the patent office on 2009-03-05 for spindle and spindle attachments for coreless and flexible core rolled tissue products.
Invention is credited to Benjamin Joseph Kruchoski, Thomas Gerard Shannon.
Application Number | 20090057169 11/848912 |
Document ID | / |
Family ID | 40386745 |
Filed Date | 2009-03-05 |
United States Patent
Application |
20090057169 |
Kind Code |
A1 |
Kruchoski; Benjamin Joseph ;
et al. |
March 5, 2009 |
Spindle and Spindle Attachments for Coreless and Flexible Core
Rolled Tissue Products
Abstract
Spindles attachments and replacement spindles for use with a
coreless tissue roll or a flexible core rolled tissue product are
generally disclosed. In one embodiment, a spindle attachment having
an elongated tube is generally disclosed. Each end portion of the
spindle attachment is tapered at an angle of less than 45.degree..
The elongated tube defines a circular opening that extends through
the center of the elongated tube. In another embodiment, an armed
spindle for use in place of a traditional spindle is generally
disclosed. The armed spindle includes a pair of opposing pegs
connected to at least 4 arms. Each arm has a pair of end portions
that extend away from the center axis of the armed spindle to a
middle portion. Also, a kit is disclosed that includes both a
spindle attachment or an armed spindle and at least one rolled
tissue product.
Inventors: |
Kruchoski; Benjamin Joseph;
(Appleton, WI) ; Shannon; Thomas Gerard; (Neenah,
WI) |
Correspondence
Address: |
DORITY & MANNING, P.A.
POST OFFICE BOX 1449
GREENVILLE
SC
29602-1449
US
|
Family ID: |
40386745 |
Appl. No.: |
11/848912 |
Filed: |
August 31, 2007 |
Current U.S.
Class: |
206/225 ;
242/599; 242/599.1 |
Current CPC
Class: |
A47K 10/40 20130101;
A47K 2010/3206 20130101 |
Class at
Publication: |
206/225 ;
242/599; 242/599.1 |
International
Class: |
A47K 10/38 20060101
A47K010/38; A47K 10/40 20060101 A47K010/40; B65D 71/00 20060101
B65D071/00; B65H 16/06 20060101 B65H016/06 |
Claims
1. A spindle attachment for use with a traditional spindle, the
spindle attachment comprising an elongated tube defining two
opposing end portions separated by a middle portion, wherein each
end portion is tapered at an angle of less than 55.degree. and the
middle portion is substantially cylindrical in shape, and wherein
the elongated tube defines a circular opening that extends through
the center of the elongated tube from one end portion to the
opposition end portion, the opening having an inner diameter of
from about 0.75 inches to about 1.25 inches.
2. A spindle attachment as in claim 1, wherein the middle portion
defines an outer surface having an outer diameter of about 1.25
inches to about 2 inches.
3. A spindle attachment as in claim 2, wherein the outer surface of
the middle portion has an outer diameter of about 1.5 inches to
about 1.75 inches.
4. A spindle attachment as in claim 2, wherein the outer surface of
the middle portion has an outer diameter of about 1.45 inches to
about 1.6 inches.
5. A spindle attachment as in claim 1, wherein each end portion and
the middle portion collectively define an outer surface coated with
an lubricating coating that lowers the coefficient of friction of
the outer surface.
6. A spindle attachment as in claim 1, wherein each end portion and
the middle portion collectively define a grooved outer surface.
7. A spindle attachment as in claim 1, wherein each end portion is
tapered at an angle of about 20.degree. to about 40.degree..
8. A kit comprising the spindle attachment as in claim 1; and at
least one rolled tissue product, the rolled tissue product
comprising a nonwoven tissue web comprising pulp fibers wound about
a flexible core, wherein the flexible core comprises a polymeric
sheet of synthetic polymers, wherein the nonwoven tissue web and
the flexible core are attached to each other at an inner layer of
the nonwoven tissue web by an attachment mechanism, and wherein the
tissue sheet defines a machine direction, the tissue sheet having a
tensile strength in the machine direction that is weaker than the
strength of the flexible core.
9. A kit as in claim 8, wherein the middle portion defines an outer
surface having an outer diameter, and wherein the flexible core
defines an inner diameter that is from about 0.1% to about 5%
greater than the outer diameter of the outer surface of the middle
portion.
10. An armed spindle for use in place of a traditional spindle, the
armed spindle comprising a pair of opposing pegs that define a
center axis of the armed spindle that extends through the center
portion of each opposing peg, and at least 3 arms, each arm being
in contact with each opposing peg, wherein each arm has a pair of
end portions that extend away from the center axis of the armed
spindle to a middle portion; wherein the at least four arms are
configured to rotate about the center axis from a substantially
flat position to a rotating position where the arms are spaced
apart in a substantially equal distance.
11. An armed spindle as in claim 10 having 4 arms, wherein the 4
arms are configured to rotate about the center axis from a
substantially flat position to a cross-like shape.
12. An armed spindle as in claim 10 having 6 arms, wherein the 6
arms are configured to rotate about the center axis from a
substantially flat position to a hexagonal-like shape.
13. An armed spindle as in claim 10, wherein each arm defines a
surface coated with a lubricating coating that lowers the
coefficient of friction of the surface.
14. An armed spindle as in claim 10, wherein oppositely positioned
arms move in concert with each other, but independently from
adjacently positioned arms.
15. A kit comprising the spindle attachment as in claim 10; and at
least one rolled tissue product, the rolled tissue product
comprising a nonwoven tissue web comprising pulp fibers wound about
a flexible core, wherein the flexible core comprises a polymeric
sheet of synthetic polymers, wherein the nonwoven tissue web and
the flexible core are attached to each other at an inner layer of
the nonwoven tissue web by an attachment mechanism, and wherein the
tissue sheet defines a machine direction, the tissue sheet having a
tensile strength in the machine direction that is weaker than the
strength of the flexible core.
16. A kit as in claim 15, wherein the middle portion defines an
outer diameter when in the rotating position, and wherein the
flexible core defines an inner diameter that is from about 0.1% to
about 5% greater than the outer diameter defined by the arms in a
rotating position.
17. An expanding spindle comprising a pair of end portions and a
middle portion, the middle portion having an extended diameter,
wherein the middle portion expands to a compressed diameter from
the extended diameter when the end portions are compressed towards
each other.
18. An expanding spindle as in claim 17, wherein the middle portion
comprises at least two separate pieces, and wherein each end
portion is tapered such that the separate middle portion pieces
expand when the tapered end portions are compressed toward each
other.
19. An expanding spindle as in claim 17, wherein the middle portion
expands during compression of the end portions toward each other
due to an air bladder positioned within the middle portion and
between the end portions.
Description
BACKGROUND OF THE INVENTION
[0001] Commercial and consumer absorbent products such as shop
towels, nonwoven fabrics, wipers, toilet tissue and paper towels
are often packaged, distributed, and dispensed in roll format. Most
products in this format include a cylindrical core at the center of
the roll. Typically, the absorbent product is wrapped about the
core. Most roll format product dispensers require this core to
function properly. The core is usually some type of stiff cardboard
tube, plastic tube, or solid spindle which is glued to the product
so that the product does not separate from the core.
[0002] The absorbent product is normally loaded by mounting the
roll on a spindle in a manner similar to the ubiquitous bathroom
toilet roll dispenser. The spindle passes through or otherwise
penetrates the inner space of the core. Some dispensers include
pegs that penetrate the hollow space within the core for only a
limited extent, as demonstrated in U.S. Pat. Nos. 390,084 and
2,905,404 to Lane and Simmons, respectively.
[0003] Recently, coreless rolls of products such as, for example,
toilet tissue have appeared on the market, primarily in Europe.
These coreless rolls are wound throughout the entire diameter of
the roll. There are advantages and disadvantages associated with
the coreless rolls. Coreless rolls are ecologically superior to
cored rolls because they lack the central core made of plastic,
cardboard or other material. In addition, more product can be
provided in the space that would otherwise have been occupied by
the core. Cored rolls are more expensive to manufacture than
coreless rolls because of the expense of making the cores and
joining the cores to the product.
[0004] On the other hand, coreless roll products have dispensing
problems that are difficult to overcome. Coreless rolls may not
dispense properly on a conventional core roll dispenser.
Conventional dispensers for coreless rolls typically include an
enclosed surface that supports the roll as it turns, and an opening
through which the product is passed. While functional, these
dispensers have some undesirable characteristics, including an
inability to control drag resistance to withdrawal of the product;
the fact that the product actually touches the inside of the
dispenser, which might be considered unsanitary by some consumers;
and an inability to provide 180 degree product access to the
consumer. Some dispensers for coreless rolls have pressure plates
and pins that project into the side of the roll between the layers
of product. It can be difficult to center the roll during loading
of these dispenser without a centering device and the pressure
plate and pins can easily be pried back to release the roll from
the dispenser.
[0005] Accordingly, a need exists for an adapter to convert
conventional cored roll dispensers to handle flexible core tissue
rolls. Additionally, a need exists for a spindle replacement
designed for coreless and flexible core rolls that can be
substituted for a conventional dispenser.
SUMMARY OF THE INVENTION
[0006] In general, the present disclosure is directed to spindles
attachments and replacement spindles for use with a coreless tissue
roll or a flexible core rolled tissue product. For example, in one
embodiment, a spindle attachment having an elongated tube is
generally disclosed. Each end portion of the spindle attachment is
tapered at an angle of less than 45.degree., such as from about
20.degree. to about 40.degree.. The middle portion is substantially
cylindrical in shape. The elongated tube defines a circular opening
that extends through the center of the elongated tube from one end
portion to the opposition end portion. The opening has an inner
diameter of from about 0.75 inches to about 1.25 inches.
[0007] The middle portion defines an outer surface that can have an
outer diameter of about 1.25 inches to about 2 inches, such as from
about 1.5 inches to about 1.75 inches, or from about 1.45 inches to
about 1.6 inches. Each end portion and the middle portion
collectively define an outer surface that can be coated with an
lubricating coating that lowers the coefficient of friction of the
outer surface. Also, each end portion and the middle portion can
collectively define a grooved outer surface.
[0008] In another embodiment, an armed spindle for use in place of
a traditional spindle is generally disclosed. The armed spindle
includes a pair of opposing pegs that define a center axis of the
armed spindle extending through the center portion of each opposing
peg. At least 3 arms (such as at least 4 arms) are each in contact
with each opposing peg. Each arm has a pair of end portions that
extend away from the center axis of the armed spindle to a middle
portion. The arms are configured to rotate about the center axis
from a substantially flat position to a rotating position where the
arms are spaced apart in a substantially equal distance. For
example, when the armed spindle has 4 arms, the arms are configured
to rotate about the center axis from a substantially flat position
to a cross-like shape. Alternatively, when the armed spindle has 6
arms, the arms are configured to rotate about the center axis from
a substantially flat position to a hexagonal-like shape. In one
particular embodiment, oppositely positioned arms move in concert
with each other, but independently from adjacently positioned
arms.
[0009] In yet another embodiment, a kit is disclosed that includes
both a spindle attachment or an armed spindle and at least one
rolled tissue product. The rolled tissue product includes a
nonwoven tissue web comprising pulp fibers wound about a flexible
core. The flexible core comprises a polymeric sheet of synthetic
polymers. The nonwoven tissue web and the flexible core are
attached to each other at an inner layer of the nonwoven tissue web
by an attachment mechanism. The tissue sheet has a tensile strength
in the machine direction that is weaker than the strength of the
flexible core. In a particular embodiment, the flexible core
defines an inner diameter that is from about 0.1% to about 5%
greater than the outer diameter of the middle portion of the
spindle attachment or spindle replacement.
[0010] Other features and aspects of the present invention are
discussed in greater detail below.
DEFINITIONS
[0011] "Roll Bulk" can be calculated by two different methods:
[0012] 1. roll bulk (cc/g)=3.142.times.(Roll Diameter squared
(cm.sup.2)-outer Core Diameter squared (cm.sup.2))/(4.times.Sheet
length (cm).times.sheet count.times.Basis Weight (g/cm.sup.2)) or
[0013] 2. roll bulk (cc/g)=0.785.times.(Roll Diameter squared
(cm.sup.2)-outer Core Diameter squared (cm.sup.2))/(Sheet length
(cm).times.sheet count.times.Basis Weight (g/cm.sup.2)).
[0014] Tissue products can be distinguished from other paper
products in terms of their bulk. For various rolled products of
this invention, the single sheet bulk of the sheet on the roll can
be about 5 cc/g am or greater, such as about 7 cc/g or greater,
such as about 8 cc/g or greater, such as from about 6 cc/g to about
24 cc/g.
[0015] Single sheet bulk is calculated by taking the single sheet
caliper and dividing by the conditioned basis weight of the
product. The term "caliper" as used herein is the thickness of a
single tissue sheet, and may either be measured as the thickness of
a single tissue sheet or as the thickness of a stack of ten tissue
sheets and dividing the ten tissue sheet thickness by ten, where
each sheet within the stack is placed with the same side up.
Caliper is expressed in microns. Caliper is measured in accordance
with TAPPI test methods T402 "Standard Conditioning and Testing
Atmosphere For Paper, Board, Pulp Handsheets and Related Products"
and T411 om-89 "Thickness (caliper) of Paper, Paperboard, and
Combined Board" optionally with Note 3 for stacked tissue sheets.
The micrometer used for carrying out T411 om-89 is a Bulk
Micrometer (TMI Model 49-72-00, Amityville, N.Y.) or equivalent
having an anvil diameter of 4 1/16 inches (103.2 millimeters) and
an anvil pressure of 220 grams/square inch (3.3 g kilo
Pascals).
[0016] The basis weight and bone dry basis weight of the tissue
sheet specimens are determined using TAPPI T410 procedure or a
modified equivalent such as: Tissue samples are conditioned at
23.degree. C.+-.1.degree. C. and 50.+-.2% relative humidity for a
minimum of 4 hours. After conditioning a stack of
16''-3''.times.3'' samples is cut using a die press and associated
die. This represents a tissue sheet sample area of 144 in.sup.2 or
929 cm.sup.2. Examples of suitable die presses are TMI DGD die
press manufactured by Testing Machines, Inc., Islandia, N.Y., or a
Swing Beam testing machine manufactured by USM Corporation,
Wilmington, Mass. Die size tolerances are .+-.0.008 inches in both
directions. The specimen stack is then weighed to the nearest 0.001
gram on a tared analytical balance. The basis weight in grams per
square meter is calculated using the following equation: Basis
weight=stack wt. in grams/0.0929.
[0017] A sheet of tissue can be defined as the material between the
adjacent lines of weakness in the continuous sheet that comprises
the rolled product. The sheet length is defined as the distance
between adjacent lines of weakness and the sheet width as defined
as the edge to edge distance of the sheet perpendicular to the
sheet length. For example, sanitary bath products preferably have
single sheet lengths of from about 3 inches to about 8 inches, such
as from about 3.25 inches to about 7 inches such as from about 3.5
inches to about 6 inches, such as from about 3.75 inches to about 5
inches. The sanitary bath products of the present invention
preferably have sheet widths of from about 3 inches to about 6
inches, such as from about 3.25 inches to about 5 inches such as
from about 3.5 inches to about 4.75 inches.
[0018] The Basis Weight of a sheet is usually expressed in ounces
of material per square yard (osy) or grams per square meter (gsm).
(Note that to convert from osy to gsm, multiply osy by 33.91.)
[0019] A "synthetic polymer" as defined herein refers to a polymer
which is not found as is in nature. The synthetic polymers have
been altered by a processing step to create a polymer having
physical or chemical properties unique to the natural world via
human intervention. Such polymers may or may not be derived from
materials from sustainable resources. Sustainable resources are
resources which can be replenished on an on-going basis.
Sustainable resources include living plants and animals and in
particular those plants and animals grown under agricultural or
domesticated conditions. Most commonly, sustainable materials
typically are sourced from agricultural crops or similar plant
based materials. Cellulose fibers and cotton fibers are not
synthetic polymers, however, rayon derived from cellulose fibers
would be considered a synthetic polymer for the purposes of the
present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] A full and enabling disclosure of the present invention,
including the best mode thereof to one of ordinary skill in the
art, is set forth more particularly in the remainder of the
specification, including reference to the accompanying figures in
which:
[0021] FIG. 1 shows an exemplary spindle attachment for use with a
coreless tissue product or a tissue product having a flexible
core;
[0022] FIGS. 2A and 2B depict an exemplary spindle for use with a
coreless tissue product or a tissue product having a flexible
core;
[0023] FIG. 3 shows a traditional spindle for use with conventional
toilet tissue products;
[0024] FIG. 4 is a prospective view of an exemplary rolled tissue
product having a flexible core;
[0025] FIG. 5 is a prospective view of a stack of exemplary rolled
tissue products having a flexible core;
[0026] FIG. 6 is a side view of a stack of exemplary rolled tissue
products having a flexible core packaged in a packaging
material;
[0027] FIGS. 7A and 7B are different views of another exemplary
rolled tissue product with a flexible core having tabs marking the
core;
[0028] FIG. 8 shows a side view of an exemplary rolled tissue
product having a flexible core;
[0029] FIG. 9 is a schematic diagram of a tissue web forming
machine, illustrating the formation of a stratified tissue web
having multiple layers in accordance with the present
disclosure;
[0030] FIG. 10 is a schematic diagram of one embodiment of a
process for forming uncreped through-dried tissue webs for use in
the present disclosure;
[0031] FIG. 11 is a schematic diagram of one embodiment of a
process for forming wet creped tissue webs for use in the present
disclosure;
[0032] FIG. 12 is a side view of a traditional spindle in use with
a rolled tissue product;
[0033] FIG. 13 is a side view of a traditional spindle in use with
a deformed rolled tissue product;
[0034] FIGS. 14A and 14B are prospective views of an expanding
spindle;
[0035] FIGS. 15A and 15B are prospective views of an expanding
spindle having tapered end portions; and
[0036] FIG. 16 is a side view of an expanding spindle having the
middle portion expanded to give shape definition to the flexible
core rolled tissue product.
[0037] Repeat use of reference characters in the present
specification and drawings is intended to represent same or
analogous features or elements of the present disclosure.
DETAILED DESCRIPTION
[0038] Reference now will be made to the embodiments of the
invention, one or more examples of which are set forth below. Each
example is provided by way of an explanation of the invention, not
as a limitation of the invention. In fact, it will be apparent to
those skilled in the art that various modifications and variations
can be made in the invention without departing from the scope or
spirit of the invention. For instance, features illustrated or
described as one embodiment can be used on another embodiment to
yield still a further embodiment. Thus, it is intended that the
present invention cover such modifications and variations as come
within the scope of the appended claims and their equivalents. It
is to be understood by one of ordinary skill in the art that the
present discussion is a description of exemplary embodiments only,
and is not intended as limiting the broader aspects of the present
invention, which broader aspects are embodied exemplary
constructions. In general, the present disclosure is directed to a
spindle attachment or spindle replacement for use with a coreless
rolled tissue product or a rolled tissue product having a flexible
core.
[0039] A suitable spindle attachment can be included to mount over
a traditional spindle. A traditional spindle 200 is shown in FIG.
3. The traditional spindle has a first tube 202 and a second tube
204 that are configured in a telescopically arrangement.
Specifically, the second tube 204 has a slightly wider inner
diameter so that the first tube 202 can slide within the inner
diameter of the second tube 204. Internally, a spring (not shown)
is provided within the center of the first and second tubes 202,
204 so that the tubes are biased away from each other. Thus, the
length L.sub.t of the traditional spindle can vary, but is
generally designed to fit within a pair of spindle holders (not
shown). The pegs 206, 208 are positioned along the ends of each
tube 202, 204, respectively, to secure the traditional spindle in
the spindle holder.
[0040] However, this traditional spindle 200 presents several
problems when used with a flexible core tissue roll of the present
invention. For example, since the flexible core may not be
perfectly circular (such as shown in FIG. 8), the roll may not spin
well on the spindle. Referring to FIG. 12, a traditional rolled
tissue product 300 is shown having a stiff cardboard core 302. The
traditional rolled tissue product 300 rests on the spindle 304 such
that the axis of rotation is on the spindle, not the center of the
roll. Additionally, when rotating, the axis of rotation of the roll
varies as the roll bounces and moves about the spindle 304. When
the traditional rolled tissue product 300 is flattened, the
deformed core 302 does not rotate smoothly about the spindle 304,
such as shown in FIG. 13.
[0041] This problem is especially present when there is a
significant difference in the outer diameter d.sub.T and the inner
diameter defined by the inner surface of the flexible core of the
rolled tissue product. This difference is present in most
circumstances because the traditional spindle typically has an
outer diameter d.sub.T from about 0.75 inches to about 1 inch while
the inner diameter defined by the inner surface of the flexible
core of the rolled tissue product is typically from about 1.25
inches to about 2 inches, such as from about 1.5 inches to about
1.75 inches.
[0042] Additionally, the traditional spindle can create problems
when mounting the flexible core tissue roll. For instance, the
90.degree. angles formed by the cylindrical shape of both the first
and second tubes 202, 204 and the pins 206, 208 can be difficult to
insert into the flexible core of the rolled tissue product. In some
instances, these sharp edges can tear or otherwise damage the
flexible core member during insertion.
[0043] In order to overcome these problems associated with using
the traditional spindles with the flexible core rolled tissue
products of the present disclosure, the present inventors have
created specially designed spindle attachments and spindles.
I. Spindle Attachments
[0044] First, referring to FIG. 1, a spindle attachment 210 is
shown. In this embodiment, the spindle attachment 210 is designed
for use with a traditional spindle (such as shown in FIG. 3). As
shown, the spindle attachment 210 has an inner opening 212
extending the entire length L.sub.SA of the spindle attachment 210.
This inner opening is designed to accommodate insertion of a
standard bath or towel spindle as well as allow the spindle to fit
the so called j-hook bath tissue dispensers. J-hook dispensers
typically are designed as a rod perpendicularly extending from a
wall. The end of the rod farthest from the wall when
perpendicularly extended is turned upwards or flared slightly. In
normal use, the core is slid over the rod and the roll rotates
about the rod. The upward or flared end prevents the roll from
sliding off the rod during use. The inner opening 212 has an inner
diameter d.sub.I that is larger than the spindle to which it is
desired to be attached. In one embodiment, the inner diameter
d.sub.I of the inner opening 212 ranges from about 0.75 inches to
about 1.25 inches. However, the inner diameter d.sub.I does not
have to closely match the outer diameter d.sub..tau. of the
traditional spindle 200 in order to function properly.
[0045] In use, a flexible core rolled tissue product can be mounted
onto the spindle attachment 210. Each of the ends of the spindle
attachment 210 includes a tapered section 214 that gradually
increases the width of the spindle attachment 210 from the inner
diameter d.sub.I to the outer diameter d.sub.O of the middle
section 216. In one particular embodiment, the tapered sections 214
have an angle of less than about 55.degree. or less than about
45.degree., such as from about 20.degree. to about 40.degree..
These tapered end sections 214 help a user insert the spindle
attachment 210 into the flexible core of a rolled tissue product.
By gradually increasing in diameter, the spindle attachment 210 can
be more easily inserted into the flexible core, when compared to a
traditional spindle. Additionally, the gradual increase in diameter
of the tapered sections 214 can help prevent the spindle attachment
210 from damaging the flexible core of the rolled tissue
product.
[0046] The middle section 216 has an outer diameter d.sub.O that is
configured to closely match the inner diameter defined by the
flexible core of the rolled tissue product (e.g., is less from
about 0.001 inch to about 0.1 inch less than the diameter of the
flexible core). For example, depending on the inner diameter of the
flexible core rolled tissue product, the outer diameter d.sub.O can
range from about 1.25 inches to about 2 inches, such as from about
1.5 inches to about 1.75 inches. In one particular embodiment, the
outer diameter d.sub.O can be from about 1.45 inch to about 1.6
inches. Thus, once mounted onto the spindle attachment 210, the
flexible core rolled tissue product will be shaped to be
substantially round by the middle section 216. As such, the
flexible core rolled tissue product will rotate smoothly and
properly on a traditional spindle.
[0047] Additionally, an outer coating can be applied to the outer
surface of the spindle attachment 210 in order to reduce the
coefficient of friction between the spindle attachment and the
flexible core.
[0048] Alternatively, or additionally, the outer surface can be
grooved to reduce the contact area of the spindle attachment
surface and the flexible core. Thus, less frictional forces are
asserted between the two when the rolled tissue product is mounted
on the spindle attachment.
[0049] After mounting the flexible core rolled tissue product onto
the spindle attachment 210, the spindle attachment 210 can then be
mounted onto a traditional spindle (such as the traditional spindle
200 shown in FIG. 3). The overall length L.sub.SA of the spindle
attachment 210 is less than that of the traditional spindle 200,
such that the spindle attachment 210 can be mounted onto a
traditional spindle while still allowing the traditional spindle to
be mounted onto the mounting brackets.
[0050] In one embodiment, at least one spindle attachment 210 and
at least one flexible core rolled tissue product can be included
within a kit. By packaging the spindle attachment 210 together with
the flexible core rolled tissue product, the outer diameter d.sub.O
of middle section 216 on the spindle attachment 210 can be uniquely
matched to the inner diameter defined by the inner surface of the
flexible core on the rolled tissue product. For example, the outer
diameter d.sub.O of the spindle attachment 210 can from about 0.1%
to about 5% smaller (in diameter) than the inner diameter defined
by the inner surface of the flexible core in the kit.
II. Spindle Replacement
[0051] Although the spindle attachment 210 of FIG. 1 is shown for
use with a traditional spindle, a spindle replacement can be
designed having a similar overall design. For example, the spindle
replacement can have substantially the same outer appearance (e.g.,
tapered ends and a larger middle portion), but can be provided with
outer pegs for use in traditional mounting brackets (instead of
having openings in each end). In this embodiment, the spindle
replacement can be separated into two pieces and telescopically
arranged with a spring internally positioned, as described with
respect to FIG. 3.
[0052] In another embodiment, the flexible core rolled tissue
product can be provided in a kit with a spindle replacement that is
designed to overcome the problems associated with the traditional
spindle 200. For example, referring to FIGS. 2A and 2B, an armed
spindle 220 is shown. The armed spindle 220 can be used in place of
a traditional spindle. The armed spindle 220 is shown having four
arms 222a-222d that are connected on each end by pegs 224a, 224b.
Each arm 222a-222d is tapered on towards the end portions of the
arm. Thus, each arm 222a-222d gradually increases in distance away
from the axis X defined through the center of each peg 224a, 224b.
Due to this tapered increase in diameter (i.e., distance away from
the axis X defined through the center of each peg 224a, 224b), the
armed spindle 220 can be more easily slid into a flexible core of a
rolled tissue product, when compared to a traditional spindle.
[0053] Additionally, the arms 222a-222d of the armed spindle 220
can be configured such that they can be interchanged between a
substantially flat orientation and a rotating position having each
arm spaced apart in a substantially equal distance. For example,
referring to FIG. 2A, the arms 222a-222d can be oriented in a
cross-like shape, such that each arm is substantially equally
spaced apart from each other. This cross-like shape can help give
the flexible core of the rolled tissue product definition during
use. Thus, the rolled tissue product can spin more smoothly once
mounted on the armed spindle 220 and the spindle is oriented in a
cross-like shape.
[0054] On the other hand, the arms 222a-222d of the armed spindle
220 can be laid substantially flat to facilitate the insertion of
the armed spindle 220 into the flexible core of the rolled tissue
product, such as shown in FIG. 2B. In this orientation, the armed
spindle 220 can more closely resemble the substantially linear
shape of the flexible core of the rolled tissue product after it is
removed from its packaging. As such, the arms 222a-222d of the
armed spindle 220 can be more easily inserted into the flexible
core. After being inserted into the flexible core, the arms
222a-222d of the armed spindle 220 can be rotated to the cross-like
orientation shown in FIG. 2A and described above.
[0055] Rotation between the substantially flat orientation and the
cross-like orientation can be accomplished according to any method.
For example, in the shown embodiments, oppositely positioned arms
move in concert with each other but independent of their
neighboring arms. Referring to FIGS. 2A and 2B, arms 222a and 222c
move in concert with each other, but independently from arms 222b
and 222d. The opposite is also true: arms 222b and 222d move in
concert with each other, but independently from arms 222a and
222c.
[0056] Although the embodiment shown in FIGS. 2A and 2B includes 4
arms 222a-222d on the armed spindle 220, any number of arms can be
included within the scope of the present disclosure. For example,
the armed spindle 220 can have from 4 arms to 8 arms. In one
particular embodiment, the armed spindle 220 can have 6 arms.
Likewise, the armed spindle can have as few as 3 arms. Thus, any
reasonable number of arms (at least 3) can be used. Additionally,
the armed spindle can be provided with an outer surface (not shown)
that conceals the inner arms positioned within the construction of
the spindle.
[0057] Alternatively, the spindle replacement can increase its
width upon compression of the ends toward the middle. For example,
referring to FIGS. 14A and 14B, an expanding spindle replacement
310 is generally shown. Upon compression of the end portions 312a,
312b towards each other, the middle portion 314 expands. By
expanding the middle portion 314, the flexible core (and thus the
entire flexible core rolled tissue product) can be given shape
definition. For example, the middle portion 314 can be designed to
expand to within 5% of the inner diameter of the flexible core.
This compression can allow the replacement spindle to be inserted
into the flexible core when expanded to have a smaller diameter
d.sub.Ext, but at the length of the spindle holder L.sub.SH have a
diameter d.sub.Comp that gives shape definition to the flexible
core. In this embodiment, the expanding spindle can rotate with the
rolled tissue product, instead of being stationary on the holder
during use.
[0058] In one embodiment, the expanding spindle can have two
tapered end portions 320a, 320b that are engaged to the expanding
middle pieces 322a, 322b. When compressed towards each other (to
the length of the spindle holder--typically 5 and 1/8 inches), each
tapered end portion moves between the middle pieces 322a, 322b
separating them farther apart. Thus, the expanded middle portions
320a, 320b give shape definition to the flexible core 322. Although
the expanding spindle is shown using tapered end portions in this
embodiment, any method of expanding the middle portion can be
utilized. For example, the middle portion can be expanded using an
air pocket or bladder, a spring loaded system, etc.
III. Kits
[0059] When utilized as a toilet tissue roll spindle, the spindle
replacement or spindle attachment can be utilized with coreless or
flexible core tissue rolls for dispensing purposes. For example,
the flexible core tissue product can be included in a kit along
with the spindle replacement or spindle attachment.
[0060] In one particular embodiment, a rolled tissue product having
a flexible core can be included within a kit having a spindle
attachment or spindle replacement. The flexible core can provide
sufficient strength for the rolled tissue product during storage,
shipment, and use, while remaining flexible primarily for packaging
and storage purposes. As such, the flexible core is constructed
from a synthetic polymeric sheet material that has a greater
tensile strength than that of the tissue product. Additionally, the
synthetic polymeric material of the flexible core can protect the
inner layers of the rolled tissue paper during use, which can allow
these inner layers to be used in the ordinary course without damage
or waste that sometimes occurs with coreless rolled tissue
products.
[0061] FIG. 4 shows an exemplary rolled tissue product 100 having a
flexible core 102. Tissue web 104 is rolled about the flexible core
102. As shown, the rolled tissue product 100 is flattened in one
direction creating an oval-like shape to the rolled tissue product
100. Due to this flat oval-like shape, several rolled tissue
products 100 can be stacked closely together for optimized
packaging and storage purposes. For example, referring to FIG. 5,
four rolled tissue products 100 are shown closely stacked together.
As shown, the flexible core 102 of each of these rolled tissue
products 100 does not have any significant space within the core.
Thus, the stacked rolled tissue products 100 can be packaged
closely together without wasting space, such as shown in FIG. 6.
The package 106 is shown having packaging material 108 tightly
wrapped around the stacked tissue products 100 which have been
flattened into oval-like shapes.
[0062] The flexible core can be attached to the innermost layer of
the tissue web by any method. In one particular embodiment, the
tissue web is adhered to the flexible core through the use of an
adhesive. Any suitable adhesive can be utilized for attaching the
flexible core to the tissue web. Alternatively, the tissue web can
be laminated to the flexible core via thermal bonding (heat and
pressure). No matter the attachment of the tissue web to the
flexible core, the attachment is strong enough to withstand the
winding process during the manufacture of the rolled tissue
product. Particularly, the force in the machine direction exerted
on the attachment between the tissue web and the flexible core when
the winding process begins can create significant strain on the
attachment. If a water-soluble polymer film is used as the flexible
core, the tissue web may be attached to the core by application of
a small amount of water to the sheet at or near the point of
attachment of the tissue sheet with the flexible core.
[0063] The tissue web can be wound onto the roll to create a rolled
tissue product having a wide range of roll bulk. For example, the
roll bulk of the products can be from about 4 cc/g to about 30
cc/g, such as from about 5 cc/g to about 25 cc/g, such as from
about 6 cc/g to about 20 cc/g.
[0064] The flexible core can have tabs or flaps that extend beyond
the edges of the rolled tissue product to allow for the flexible
core to be readily located and separated in anticipation of use.
For example, referring to FIGS. 7A and 7B, the rolled tissue
product 100 is shown having flaps 110A and 110B located on either
side of the flexible core 102. The user can open the core formed by
the flexible core through the use of tabs 110A and 110B in order to
insert a spindle through the flexible core for dispensing purposes.
In an additional embodiment, the flexible core can be colored
(e.g., by the inclusion of a pigment, dye, or other colorant within
or onto the surface of the core) to provide a visual discernment of
the flexible core for the user.
[0065] During use, the rolled tissue product 100 can be shaped back
into a cylindrical shape having a circular orientation when viewed
from the side. For example, referring to FIG. 8, the rolled tissue
product 100 has been formed back into a circular shape when viewed
from the side. Specifically, a user has formed both the tissue
product 104 and the flexible core member 102 into a substantially
circular shape when viewed from the side. As such, the tissue
product 102 can be dispensed off the rolled tissue product 100 by
the use of conventional spindles or particularly designed spindles
(such as disclosed in further detail below).
A. Flexible Core
[0066] Generally speaking, the flexible core is constructed from a
flexible sheet of synthetic fibers in order to provide the required
strength to the web. The flexible sheet can include a nonwoven web
of synthetic fibers, a woven web of synthetic fibers, a polymeric
film, or combinations thereof. The use of the synthetic fibers
allows for added strength to the flexible core, when compared to
the tissue product constructed primarily of pulp fibers. For
example, the flexible core can have a tensile strength that is
greater than the tensile strength of the tissue web in the machine
direction. In one embodiment, the tensile strength of the flexible
core is at least twice that of the tissue web in the machine
direction, such as at least five times stronger.
[0067] The use of a polymeric film allows standard production
equipment to be used in manufacturing of the roll. Polymeric films
can be produced and delivered in form of an open end tube or
sleeve. Such production methods are routinely used to make plastic
bags and are well known in the art. These sleeves can be
manufactured such that any diameter may be created. The sleeve may
or may not have a seam in the longitudinal direction, the seam may
or may not have overlap. In one embodiment, this sleeve can then be
slid over a tissue winding mandrel in the same manner as
traditional cores can be placed on these winding mandrels in the
converting process. Thus, minimal impact on current production
equipment is required.
[0068] The basis weight of the sheet(s) used to form the flexible
core is relatively low to allow for less material needed (reducing
cost and waste) as well as facilitating flushability and general
disposal of the product. Additionally, the relatively low basis
weights of the core can increase the flexibility of the core. For
example, the basis weight of the flexible core can be from about 5
grams per square meter (gsm) to about 150 gsm, such as from about
10 gsm to about 100 gsm. For example, the basis weight of the
sheet(s) used to form the flexible core can have a basis weight of
about 10 gsm to about 75 gsm. The basis weight of the flexible core
can be calculated by measuring the weight of the flexible sheet
material in grams and dividing by the surface area of the outer
part of the flexible core under conditions of 23.degree.
C.+/-1.degree. C. and 50%+/-5% relative humidity for a minimum of 4
hours. The surface area of the outer part of the flexible core can
be determined by taking the circumference of the expanded core
(i.e., .pi. times diameter) and multiplying by the length of the
roll. Alternatively, the flexible core can be cut along a traverse
line and the area of the resulting flat sheet can be measured
(length times width).
[0069] Preferably the flexible core is made from a single ply of
polymeric material. If multiple plies of polymeric material are
used the basis weight of the core is determined using the weight of
all plies that comprise the core. This weight also includes any
binder materials that are used to hold the flexible core together.
The basis weight of the core does not include any adhesives that
are applied to attach the tissue web to the core.
[0070] In one particular embodiment, the flexible core includes a
nonwoven web including synthetic fibers. The nonwoven web can be
made by any number of processes. As a practical matter, however,
the nonwoven fabrics and the fibers that make up nonwoven fabrics
usually will be prepared by a melt-extrusion process and formed
into the nonwoven fabric. The term melt-extrusion process includes,
among others, such well-known processes as meltblowing and
spunbonding. Other methods for preparing nonwoven fabrics are, of
course, known and may be employed. Such methods include air laying,
wet laying, carding, and so forth. In some cases it may be either
desirable or necessary to stabilize the nonwoven fabric by known
means, such as thermal point bonding, through-air bonding, and
hydroentangling. The non-woven web comprising synthetic fibers may
also comprise a binder to provide strength and integrity to the
web. Such binders are well known in the art. Preferably the binders
are water soluble so as to facilitate the breakup of the flexible
core in the web. These binders are included when calculating the
basis weight of the flexible core.
[0071] As stated, the nonwoven web can primarily include synthetic
fibers, particularly synthetic hydrophobic fibers, such as
polyolefin fibers. In one particular embodiment, polypropylene
fibers can be used to form the nonwoven web. The polypropylene
fibers may have a denier per filament of about 1.5 to 2.5, and the
nonwoven web may have a basis weight of about 17 grams per square
meter (0.5 ounce per square yard). Furthermore, the nonwoven fabric
may include bicomponent or other multicomponent fibers. Exemplary
multicomponent nonwoven fabrics are described in U.S. Pat. No.
5,382,400 issued to Pike et al., U.S. Publication no. 2003/0118816
entitled "High Loft Low Density Nonwoven Fabrics Of Crimped
Filaments And Methods Of Making Same" and U.S. Publication No.
2003/0203162 entitled "Methods For Making Nonwoven Materials On A
Surface Having Surface Features And Nonwoven Materials Having
Surface Features" which are hereby incorporated by reference herein
in their entirety.
[0072] Sheath/core bicomponent fibers where the sheath is a
polyolefin such as polyethylene or polypropylene and the core is
polyester such as poly(ethylene terephthalate) or poly(butylene
terephthalate) can also be used to produce carded fabrics or
spunbonded fabrics. The primary role of the polyester core is to
provide resiliency and thus to maintain or recover bulk under/after
load.
[0073] In one embodiment, the nonwoven web can be combined with an
additional sheet layer, such as another nonwoven web or webs, a
film(s), or combinations thereof. When included as part of a
laminate, the nonwoven web generally provides a more cloth-like
feeling to the laminate. For example, a film-web laminate can be
formed from the nonwoven web overlying a film layer. In one
embodiment, for instance, the nonwoven web is thermally laminated
to the film to form the film-web laminate. However, any suitable
technique can be utilized to form the laminate. Suitable techniques
for bonding a film to a nonwoven web are described in U.S. Pat.
Nos. 5,843,057 to McCormack; 5,855,999 to McCormack; 6,002,064 to
Kobylivker, et al.; 6,037,281 to Mathis, et al.; and WO 99/12734,
which are incorporated herein in their entirety by reference
thereto for all purposes.
[0074] In another embodiment, a film can be utilized within the
flexible core, either alone or in combination with another layer,
the film can be formed from a synthetic polymeric material that
provides sufficient strength to the flexible core. For example, the
film layer may be formed from a thin plastic film or other flexible
liquid-impermeable material. In one embodiment, the film layer is
formed from a polyethylene film having a thickness of from about
0.01 mm to about 0.05 mm.
[0075] The film may be formed from a polyolefin polymer, such as
linear, low-density polyethylene (LLDPE) or polypropylene. Examples
of predominately linear polyolefin polymers include, without
limitation, polymers produced from the following monomers:
ethylene, propylene, 1-butene, 4-methyl-pentene, 1-hexene, 1-octene
and higher olefins as well as copolymers and terpolymers of the
foregoing. In addition, copolymers of ethylene and other olefins
including butene, 4-methyl-pentene, hexene, heptene, octene,
decene, etc., are also examples of predominately linear polyolefin
polymers.
[0076] If desired, the film may also contain an elastomeric
polymer. The use of an elastic polymer in the film can provide an
elastic component to the flexible core, which can aid in the
winding process of the rolled tissue product. For example, an
elastic film can absorb some of the forces exerted on the tissue
web and the attachment between the flexible core and the tissue web
during the winding process, particularly at the beginning of the
winding process. Any suitable elastomeric polymer can be included,
such as elastomeric polyesters, elastomeric polyurethanes,
elastomeric polyamides, elastomeric polyolefins, elastomeric
copolymers, and so forth. Examples of elastomeric copolymers
include block copolymers having the general formula A-B-A' or A-B,
wherein A and A' are each a thermoplastic polymer endblock that
contains a styrenic moiety (e.g., poly(vinyl arene)) and wherein B
is an elastomeric polymer midblock, such as a conjugated diene or a
lower alkene polymer (e.g.,
polystyrene-poly(ethylene-butylene)-polystyrene block copolymers).
Also suitable are polymers composed of an A-B-A-B tetrablock
copolymer, such as discussed in U.S. Pat. No. 5,332,613 to Taylor,
et al., which is incorporated herein in its entirety by reference
thereto for all purposes. An example of such a tetrablock copolymer
is a
styrene-poly(ethylene-propylene)-styrene-poly(ethylene-propylene)
("S-EP-S-EP") block copolymer. Commercially available A-B-A' and
A-B-A-B copolymers include several different formulations from
Kraton Polymers of Houston, Tex. under the trade designation
KRATON.RTM.. KRATON.RTM. block copolymers are available in several
different formulations, a number of which are identified in U.S.
Pat. Nos. 4,663,220, 4,323,534, 4,834,738, 5,093,422 and 5,304,599,
which are hereby incorporated in their entirety by reference
thereto for all purposes. Other commercially available block
copolymers include the S-EP-S or
styrene-poly(ethylene-propylene)-styrene elastomeric copolymer
available from Kuraray Company, Ltd. of Okayama, Japan, under the
trade name SEPTON.RTM..
[0077] Examples of elastomeric polyolefins include ultra-low
density elastomeric polypropylenes and polyethylenes, such as those
produced by "single-site" or "metallocene" catalysis methods. Such
elastomeric olefin polymers are commercially available from
ExxonMobil Chemical Co. of Houston, Tex. under the trade
designations ACHIEVE.RTM. (propylene-based), EXACT.RTM.
(ethylene-based), and EXCEED.RTM. (ethylene-based). Elastomeric
olefin polymers are also commercially available from DuPont Dow
Elastomers, LLC (a joint venture between DuPont and the Dow
Chemical Co.) under the trade designation ENGAGE.RTM.
(ethylene-based) and AFFINITY.RTM. (ethylene-based). Examples of
such polymers are also described in U.S. Pat. Nos. 5,278,272 and
5,272,236 to Lai, et al., which are incorporated herein in their
entirety by reference thereto for all purposes. Also useful are
certain elastomeric polypropylenes, such as described in U.S. Pat.
Nos. 5,539,056 to Yang, et al. and 5,596,052 to Resconi, et al.,
which are incorporated herein in their entirety by reference
thereto for all purposes.
[0078] If desired, blends of two or more polymers may also be
utilized to form the film. For example, the film may be formed from
a blend of a high performance elastomer and a lower performance
elastomer. A high performance elastomer is generally an elastomer
having a low level of hysteresis, such as less than about 75%, and
in some embodiments, less than about 60%. Likewise, a low
performance elastomer is generally an elastomer having a high level
of hysteresis, such as greater than about 75%. The hysteresis value
may be determined by first elongating a sample to an ultimate
elongation of 50% and then allowing the sample to retract to an
amount where the amount of resistance is zero. Particularly
suitable high performance elastomers may include styrenic-based
block copolymers, such as described above and commercially
available from Kraton Polymers of Houston, Tex. under the trade
designation KRATON.RTM.. Likewise, particularly suitable low
performance elastomers include elastomeric polyolefins, such as
metallocene-catalyzed polyolefins (e.g., single site
metallocene-catalyzed linear low density polyethylene) commercially
available from DuPont Dow Elastomers, LLC under the trade
designation AFFINITY.RTM.. In some embodiments, the high
performance elastomer may constitute from about 25 wt. % to about
90 wt. % of the polymer component of the film, and the low
performance elastomer may likewise constitute from about 10 wt. %
to about 75 wt. % of the polymer component of the film. Further
examples of such a high performance/low performance elastomer blend
are described in U.S. Pat. No. 6,794,024 to Walton, et al., which
is incorporated herein in its entirety by reference thereto for all
purposes.
[0079] The film may constitute the entire flexible core, or may be
part of a multilayer film, as long as the total basis weight
remains relatively low. Multilayer films may be prepared by cast or
blown film coextrusion of the layers, by extrusion coating, or by
any conventional layering process. In one embodiment, the laminate
is consists only of two layers: a nonwoven web and a film. For
example, a stretched thin polypropylene film having a thickness of
about 0.015 mm may be thermally laminated to a nonwoven web. On the
other hand, in some embodiments, other layers may be included in
the laminate, so long as the resulting laminate provides sufficient
flexibility and strength. When present, the other layer(s) of the
laminate can include, nonwoven webs, films, foams, etc.
[0080] In one particular embodiment, when the rolled tissue product
is used as toilet tissue, the flexible core can be constructed
either in whole or in part from a hydrophilic synthetic polymer(s),
such as water-soluble or water-dispersible synthetic polymers. In
most embodiments, a combination of water-soluble and
water-dispersible polymers can be utilized. For example, the
hydrophilic synthetic polymer can allow the flexible core to
disintegrate when submerged in water for a period of time (e.g., up
to about 5 or 6 hours, such as from about 30 minutes to about an
hour). Thus, in this embodiment, the flexible core can be safely
flushed along with the used toilet tissue.
[0081] Any water soluble polymer may be used within the films
(either in whole or in part), including but not limited to,
polyvinyl alcohol, hydroxy propyl cellulose, methylhydroxypropyl
cellulose, hydroxy ethylcellulose, and copolymers and mixtures
thereof. Examples of suitable water soluble polymeric films include
but is not limited to water soluble packaging films and water
soluble edible films, such as but not limited to M-7031 and MC-1832
films, manufactured and sold by Water-Sol, Inc, Merrillville, Ind.
Another suitable biodegradable polymer is available from BASF under
the name Ecovio L Foam, which consists of BASF's biodegradable
polyester and renewable polylactide.
[0082] In another embodiment, the polymeric film is made at least
in part from a biodegradable thermoplastic preferably made from
sustainable resources. Flexible biodegradable films are well
studied in the field of flexible films; they decompose naturally
avoiding environmental problems once they are thrown in composting
areas as waste. Until recently use of these films has been rather
rare and limited to compounds with low molecular weight and
generally inferior mechanical properties. Recent advances, however,
have significantly increased the availability of products with
improved properties such that biodegradable plastic films are
becoming used widely in products such as food wraps, trash bags and
other products. The biodegradable polymeric films preferably meet
or exceed the "ASTM D6400-99 Standard" according to the
"Specifications for Compostable Plastics". Such biodegradable films
are now readily available. An example of acceptable commercially
available biodegradable films are the starch based films used in
trash bags sold under the trade name BioBag.RTM. sold by
BiogroupUSA.
[0083] Examples of suitable polymers includes, but is not limited
to, polylactic acid, thermoplastic starches, polyhydroxyalkanoate
(PHA), and combinations thereof. Thermoplastic starch or TPS
consists typically consists of amorphous amylose/amylopectin
produced by extrusion in the presence of a plasticizer such as
glycerol to help make the films flexible and ductile. They tend to
be hygroscopic and for some applications may require blending with
a hydrophobic polymer. PLA/TPS blends and co-polymers are also
known in the art and are suitable for purposes of the present
invention. Such co-polymers may be made by reacting PLA with maleic
anhydride and co-extruding with TPS in the presence of a peroxide
catalyst. Other methods for creating such blends are known in the
art.
[0084] In another embodiment, the film may be made from a
combination of a water soluble film such as PVA and a water-soluble
polymer from a natural source. For example, pectin, a biodegradable
polysaccharide can be blended with poly(vinyl alcohol) (PVA), a
synthetic polymer that is not very biodegradable. Both materials
are water soluble and thus the blend is water soluble. As films,
pectin/PVA blends are more flexible than pectin alone and stronger
than PVA alone. A blend of the two increases the biodegradability
of PVA while maintaining its mechanical and solubility properties.
The ratio of pectin to PVA can be controlled to give the strength
and flexibility properties required for the material to serve as
the core material. Such approaches may be preferred as a simpler
alternative to increasing overall biodegradability of the
system.
B. Tissue Web
[0085] The tissue products may include single-ply tissue products
or multiple-ply tissue products. For instance, in one embodiment,
the product may include two plies or three plies. In general, any
suitable tissue web may be processed as a rolled product having a
flexible core in accordance with the present disclosure. For
example, in one embodiment, the base sheet can be a tissue product,
such as a bath tissue, a facial tissue, a paper towel, an
industrial wiper, and the like. Tissue products typically have a
bulk density of at least 3 cc/g. The tissue products can contain
one or more plies and can be made from any suitable types of
fiber.
[0086] Fibers suitable for making tissue webs comprise any natural
or synthetic cellulosic fibers including, but not limited to
nonwoody fibers, such as cotton, abaca, kenaf, sabai grass, flax,
esparto grass, straw, jute hemp, bagasse, milkweed floss fibers,
and pineapple leaf fibers; and woody or pulp fibers such as those
obtained from deciduous and coniferous trees, including softwood
fibers, such as northern and southern softwood kraft fibers;
hardwood fibers, such as eucalyptus, maple, birch, and aspen. Pulp
fibers can be prepared in high-yield or low-yield forms and can be
pulped in any known method, including kraft, sulfite, high-yield
pulping methods and other known pulping methods. Fibers prepared
from organosolv pulping methods can also be used, including the
fibers and methods disclosed in U.S. Pat. No. 4,793,898, issued
Dec. 27, 1988 to Laamanen et al.; U.S. Pat. No. 4,594,130, issued
Jun. 10, 1986 to Chanq et al.; and U.S. Pat. No. 3,585,104. Useful
fibers can also be produced by anthraquinone pulping, exemplified
by U.S. Pat. No. 5,595,628 issued Jan. 21, 1997, to Gordon et
al.
[0087] A portion of the fibers, such as up to 50% or less by dry
weight, or from about 5% to about 30% by dry weight, can be
synthetic fibers such as rayon, polyolefin fibers, polyester
fibers, bicomponent sheath-core fibers, multi-component binder
fibers, and the like. An exemplary polyethylene fiber is
Pulpex.RTM., available from Hercules, Inc. (Wilmington, Del.). Any
known bleaching method can be used. Synthetic cellulose fiber types
include rayon in all its varieties and other fibers derived from
viscose or chemically-modified cellulose.
[0088] Chemically treated natural cellulosic fibers can be used
such as mercerized pulps, chemically stiffened or crosslinked
fibers, or sulfonated fibers. For good mechanical properties in
using papermaking fibers, it can be desirable that the fibers be
relatively undamaged and largely unrefined or only lightly refined.
While recycled fibers can be used, virgin fibers are generally
useful for their mechanical properties and lack of contaminants.
Mercerized fibers, regenerated cellulosic fibers, cellulose
produced by microbes, rayon, and other cellulosic material or
cellulosic derivatives can be used. Suitable papermaking fibers can
also include recycled fibers, virgin fibers, or mixes thereof. In
certain embodiments capable of high bulk and good compressive
properties, the fibers can have a Canadian Standard Freeness of at
least 200, more specifically at least 300, more specifically still
at least 400, and most specifically at least 500.
[0089] Other papermaking fibers that can be used in the present
disclosure include paper broke or recycled fibers and high yield
fibers. High yield pulp fibers are those papermaking fibers
produced by pulping processes providing a yield of about 65% or
greater, more specifically about 75% or greater, and still more
specifically about 75% to about 95%. Yield is the resulting amount
of processed fibers expressed as a percentage of the initial wood
mass. Such pulping processes include bleached chemithermomechanical
pulp (BCTMP), chemithermomechanical pulp (CTMP), pressure/pressure
thermomechanical pulp (PTMP), thermomechanical pulp (TMP),
thermomechanical chemical pulp (TMCP), high yield sulfite pulps,
and high yield Kraft pulps, all of which leave the resulting fibers
with high levels of lignin. High yield fibers are well known for
their stiffness in both dry and wet states relative to typical
chemically pulped fibers.
[0090] In general, any process capable of forming a paper web can
also be utilized in the present disclosure. For example, a
papermaking process of the present disclosure can utilize creping,
wet creping, double creping, embossing, wet pressing, air pressing,
through-air drying, creped through-air drying, uncreped through-air
drying, hydroentangling, air laying, as well as other steps known
in the art.
[0091] Also suitable for products of the present disclosure are
tissue sheets that are pattern densified or imprinted, such as the
tissue sheets disclosed in any of the following U.S. Pat. Nos.
4,514,345 issued on Apr. 30, 1985, to Johnson et al.; 4,528,239
issued on Jul. 9, 1985, to Trokhan; 5,098,522 issued on Mar. 24,
1992; 5,260,171 issued on Nov. 9, 1993, to Smurkoski et al.;
5,275,700 issued on Jan. 4, 1994, to Trokhan; 5,328,565 issued on
Jul. 12, 1994, to Rasch et al.; 5,334,289 issued on Aug. 2, 1994,
to Trokhan et al.; 5,431,786 issued on Jul. 11, 1995, to Rasch et
al.; 5,496,624 issued on Mar. 5, 1996, to Steltjes. Jr. et al.;
5,500,277 issued on Mar. 19, 1996, to Trokhan et al.; 5,514,523
issued on May 7, 1996, to Trokhan et al.; 5,554,467 issued on Sep.
10, 1996, to Trokhan et al.; 5,566,724 issued on Oct. 22, 1996, to
Trokhan et al.; 5,624,790 issued on Apr. 29, 1997, to Trokhan et
al.; and, 5,628,876 issued on May 13, 1997, to Avers et al., the
disclosures of which are incorporated herein by reference to the
extent that they are non-contradictory herewith. Such imprinted
tissue sheets may have a network of densified regions that have
been imprinted against a drum dryer by an imprinting fabric, and
regions that are relatively less densified (e.g., "domes" in the
tissue sheet) corresponding to deflection conduits in the
imprinting fabric, wherein the tissue sheet superposed over the
deflection conduits was deflected by an air pressure differential
across the deflection conduit to form a lower-density pillow-like
region or dome in the tissue sheet.
[0092] The tissue web can also be formed without a substantial
amount of inner fiber-to-fiber bond strength. In this regard, the
fiber furnish used to form the base web can be treated with a
chemical debonding agent. The debonding agent can be added to the
fiber slurry during the pulping process or can be added directly to
the headbox. Suitable debonding agents that may be used in the
present disclosure include cationic debonding agents such as fatty
dialkyl quaternary amine salts, mono fatty alkyl tertiary amine
salts, primary amine salts, imidazoline quaternary salts, silicone
quaternary salt and unsaturated fatty alkyl amine salts. Other
suitable debonding agents are disclosed in U.S. Pat. No. 5,529,665
to Kaun which is incorporated herein by reference. In particular,
Kaun discloses the use of cationic silicone compositions as
debonding agents.
[0093] In one embodiment, the debonding agent used in the process
of the present disclosure is an organic quaternary ammonium
chloride and, particularly, a silicone-based amine salt of a
quaternary ammonium chloride. For example, the debonding agent can
be PROSOFT.RTM. TQ1003, marketed by the Hercules Corporation. The
debonding agent can be added to the fiber slurry in an amount of
from about 1 kg per metric tonne to about 10 kg per metric tonne of
fibers present within the slurry.
[0094] In an alternative embodiment, the debonding agent can be an
imidazoline-based agent. The imidazoline-based debonding agent can
be obtained, for instance, from the Witco Corporation. The
imidazoline-based debonding agent can be added in an amount of
between 2.0 to about 15 kg per metric tonne.
[0095] In one embodiment, the debonding agent can be added to the
fiber furnish according to a process as disclosed in PCT
Application having an International Publication No. WO 99/34057
filed on Dec. 17, 1998 or in PCT Published Application having an
International Publication No. WO 00/66835 filed on Apr. 28, 2000,
which are both incorporated herein by reference. In the above
publications, a process is disclosed in which a chemical additive,
such as a debonding agent, is adsorbed onto cellulosic papermaking
fibers at high levels. The process includes the steps of treating a
fiber slurry with an excess of the chemical additive, allowing
sufficient residence time for adsorption to occur, filtering the
slurry to remove unadsorbed chemical additives, and redispursing
the filtered pulp with fresh water prior to forming a nonwoven
web.
[0096] Optional chemical additives may also be added to the aqueous
papermaking furnish or to the formed embryonic web to impart
additional benefits to the product and process and are not
antagonistic to the intended benefits of the invention. The
following materials are included as examples of additional
chemicals that may be applied to the web along with the additive
composition of the present invention. The chemicals are included as
examples and are not intended to limit the scope of the invention.
Such chemicals may be added at any point in the papermaking
process.
[0097] Additional types of chemicals that may be added to the paper
web include, but is not limited to, absorbency aids usually in the
form of cationic, anionic, or non-ionic surfactants, humectants and
plasticizers such as low molecular weight polyethylene glycols and
polyhydroxy compounds such as glycerin and propylene glycol.
Materials that supply skin health benefits such as mineral oil,
aloe extract, vitamin e, silicone, lotions in general and the like
may also be incorporated into the finished products.
[0098] In general, the products of the present invention can be
used in conjunction with any known materials and chemicals that are
not antagonistic to its intended use. Examples of such materials
include but are not limited to odor control agents, such as odor
absorbents, activated carbon fibers and particles, baby powder,
baking soda, chelating agents, zeolites, perfumes or other
odor-masking agents, cyclodextrin compounds, oxidizers, and the
like. Superabsorbent particles, synthetic fibers, or films may also
be employed. Additional options include cationic dyes, optical
brighteners, humectants, emollients, and the like.
[0099] Tissue webs that may be formed in accordance with the
present disclosure may include a single homogenous layer of fibers
or may include a stratified or layered construction. For instance,
the tissue web ply may include two or three layers of fibers. Each
layer may have a different fiber composition. For example,
referring to FIG. 9, one embodiment of a device for forming a
multi-layered stratified pulp furnish is illustrated. As shown, a
three-layered headbox 10 generally includes an upper head box wall
12 and a lower head box wall 14. Headbox 10 further includes a
first divider 16 and a second divider 18, which separate three
fiber stock layers.
[0100] Each of the fiber layers comprise a dilute aqueous
suspension of papermaking fibers. The particular fibers contained
in each layer generally depends upon the product being formed and
the desired results. For instance, the fiber composition of each
layer may vary depending upon whether a bath tissue product, facial
tissue product or paper towel is being produced. In one embodiment,
for instance, middle layer 20 contains southern softwood kraft
fibers either alone or in combination with other fibers such as
high yield fibers. Outer layers 22 and 24, on the other hand,
contain softwood fibers, such as northern softwood kraft.
[0101] In an alternative embodiment, the middle layer may contain
softwood fibers for strength, while the outer layers may comprise
hardwood fibers, such as eucalyptus fibers, for a perceived
softness.
[0102] An endless traveling forming fabric 26, suitably supported
and driven by rolls 28 and 30, receives the layered papermaking
stock issuing from headbox 10. Once retained on fabric 26, the
layered fiber suspension passes water through the fabric as shown
by the arrows 32. Water removal is achieved by combinations of
gravity, centrifugal force and vacuum suction depending on the
forming configuration.
[0103] Forming multi-layered paper webs is also described and
disclosed in U.S. Pat. No. 5,129,988 to Farrington, Jr., which is
incorporated herein by reference.
[0104] The basis weight of tissue webs made in accordance with the
present disclosure can vary depending upon the final product. For
example, the process may be used to produce bath tissues, facial
tissues, paper towels, industrial wipers, and the like. In general,
the basis weight of the tissue products may vary from about 10 gsm
to about 110 gsm, such as from about 20 gsm to about 90 gsm. For
bath tissue and facial tissues, for instance, the basis weight may
range from about 10 gsm to about 40 gsm. For paper towels, on the
other hand, the basis weight may range from about 25 gsm to about
80 gsm.
[0105] The tissue web bulk may also vary from about 3 cc/g to 20
cc/g, such as from about 5 cc/g to 15 cc/g. The sheet "bulk" is
calculated as the quotient of the caliper of a dry tissue sheet,
expressed in microns, divided by the dry basis weight, expressed in
grams per square meter. The resulting sheet bulk is expressed in
cubic centimeters per gram. More specifically, the caliper is
measured as the total thickness of a stack of ten representative
sheets and dividing the total thickness of the stack by ten, where
each sheet within the stack is placed with the same side up.
Caliper is measured in accordance with TAPPI test method T411 om-89
"Thickness (caliper) of Paper, Paperboard, and Combined Board" with
Note 3 for stacked sheets. The micrometer used for carrying out
T411 om-89 is an Emveco 200-A Tissue Caliper Tester available from
Emveco, Inc., Newberg, Oreg. The micrometer has a load of 2.00
kilo-Pascals (132 grams per square inch), a pressure foot area of
2500 square millimeters, a pressure foot diameter of 56.42
millimeters, a dwell time of 3 seconds and a lowering rate of 0.8
millimeters per second.
[0106] In multiple ply products, the basis weight of each tissue
web present in the product can also vary. In general, the total
basis weight of a multiple ply product will generally be the same
as indicated above, such as from about 20 gsm to about 110 gsm.
Thus, the basis weight of each ply can be from about 10 gsm to
about 60 gsm, such as from about 20 gsm to about 40 gsm.
[0107] Once the aqueous suspension of fibers is formed into a
tissue web, the tissue web may be processed using various
techniques and methods. For example, referring to FIG. 10, shown is
a method for making throughdried tissue sheets. (For simplicity,
the various tensioning rolls schematically used to define the
several fabric runs are shown, but not numbered. It will be
appreciated that variations from the apparatus and method
illustrated in FIG. 10 can be made without departing from the
general process). Shown is a twin wire former having a papermaking
headbox 34, such as a layered headbox, which injects or deposits a
stream 36 of an aqueous suspension of papermaking fibers onto the
forming fabric 38 positioned on a forming roll 39. The forming
fabric serves to support and carry the newly-formed wet web
downstream in the process as the web is partially dewatered to a
consistency of about 10 dry weight percent. Additional dewatering
of the wet web can be carried out, such as by vacuum suction, while
the wet web is supported by the forming fabric.
[0108] The wet web is then transferred from the forming fabric to a
transfer fabric 40. In one embodiment, the transfer fabric can be
traveling at a slower speed than the forming fabric in order to
impart increased stretch into the web. This is commonly referred to
as a "rush" transfer. Preferably the transfer fabric can have a
void volume that is equal to or less than that of the forming
fabric. The relative speed difference between the two fabrics can
be from 0-60 percent, more specifically from about 15-45 percent.
Transfer is preferably carried out with the assistance of a vacuum
shoe 42 such that the forming fabric and the transfer fabric
simultaneously converge and diverge at the leading edge of the
vacuum slot.
[0109] The web is then transferred from the transfer fabric to the
throughdrying fabric 44 with the aid of a vacuum transfer roll 46
or a vacuum transfer shoe, optionally again using a fixed gap
transfer as previously described. The throughdrying fabric can be
traveling at about the same speed or a different speed relative to
the transfer fabric. If desired, the throughdrying fabric can be
run at a slower speed to further enhance stretch. Transfer can be
carried out with vacuum assistance to ensure deformation of the
sheet to conform to the throughdrying fabric, thus yielding desired
bulk and appearance if desired. Suitable throughdrying fabrics are
described in U.S. Pat. No. 5,429,686 issued to Kai F. Chiu et al.
and U.S. Pat. No. 5,672,248 to Wendt, et al. which are incorporated
by reference.
[0110] In one embodiment, the throughdrying fabric contains high
and long impression knuckles. For example, the throughdrying fabric
can have about from about 5 to about 300 impression knuckles per
square inch which are raised at least about 0.005 inches above the
plane of the fabric. During drying, the web can be macroscopically
arranged to conform to the surface of the throughdrying fabric and
form a three-dimensional surface. Flat surfaces, however, can also
be used in the present disclosure.
[0111] The side of the web contacting the throughdrying fabric is
typically referred to as the "fabric side" of the paper web. The
fabric side of the paper web, as described above, may have a shape
that conforms to the surface of the throughdrying fabric after the
fabric is dried in the throughdryer. The opposite side of the paper
web, on the other hand, is typically referred to as the "air side".
The air side of the web is typically smoother than the fabric side
during normal throughdrying processes.
[0112] The level of vacuum used for the web transfers can be from
about 3 to about 15 inches of mercury (75 to about 380 millimeters
of mercury), preferably about 5 inches (125 millimeters) of
mercury. The vacuum shoe (negative pressure) can be supplemented or
replaced by the use of positive pressure from the opposite side of
the web to blow the web onto the next fabric in addition to or as a
replacement for sucking it onto the next fabric with vacuum. Also,
a vacuum roll or rolls can be used to replace the vacuum
shoe(s).
[0113] While supported by the throughdrying fabric, the web is
finally dried to a consistency of about 94 percent or greater by
the throughdryer 48 and thereafter transferred to a carrier fabric
50. The dried basesheet 52 is transported to the reel 54 using
carrier fabric 50 and an optional carrier fabric 56. An optional
pressurized turning roll 58 can be used to facilitate transfer of
the web from carrier fabric 50 to fabric 56. Suitable carrier
fabrics for this purpose are Albany International 84M or 94M and
Asten 959 or 937, all of which are relatively smooth fabrics having
a fine pattern. Although not shown, reel calendering or subsequent
off-line calendering can be used to improve the smoothness and
softness of the basesheet.
[0114] In one embodiment, the reel 54 shown in FIG. 10 can run at a
speed slower than the fabric 56 in a rush transfer process for
building crepe into the paper web 52. For instance, the relative
speed difference between the reel and the fabric can be from about
5% to about 25% and, particularly from about 12% to about 14%. Rush
transfer at the reel can occur either alone or in conjunction with
a rush transfer process upstream, such as between the forming
fabric and the transfer fabric.
[0115] In one embodiment, the paper web 52 is a textured web which
has been dried in a three-dimensional state such that the hydrogen
bonds joining fibers were substantially formed while the web was
not in a flat, planar state. For instance, the web can be formed
while the web is on a highly textured throughdrying fabric or other
three-dimensional substrate. Processes for producing uncreped
throughdried fabrics are, for instance, disclosed in U.S. Pat. No.
5,672,248 to Wendt, et al.; U.S. Pat. No. 5,656,132 to Farrington,
et al.; U.S. Pat. No. 6,120,642 to Lindsay and Burazin; U.S. Pat.
No. 6,096,169 to Hermans, et al.; U.S. Pat. No. 6,197,154 to Chen,
et al.; and U.S. Pat. No. 6,143,135 to Hada, et al., all of which
are herein incorporated by reference in their entireties.
[0116] In FIG. 10, a process is shown for producing uncreped
through-air dried tissue webs. For example, referring to FIG. 11,
one embodiment of a process for forming wet creped tissue webs is
shown. In this embodiment, a headbox 60 emits an aqueous suspension
of fibers onto a forming fabric 62 which is supported and driven by
a plurality of guide rolls 64. A vacuum box 66 is disposed beneath
forming fabric 62 and is adapted to remove water from the fiber
furnish to assist in forming a web. From forming fabric 62, a
formed web 68 is transferred to a second fabric 70, which may be
either a wire or a felt. Fabric 70 is supported for movement around
a continuous path by a plurality of guide rolls 72. Also included
is a pick up roll 74 designed to facilitate transfer of web 68 from
fabric 62 to fabric 70.
[0117] From fabric 70, web 68, in this embodiment, is transferred
to the surface of a rotatable heated dryer drum 76, such as a
Yankee dryer.
[0118] In this embodiment, as web 68 is carried through a portion
of the rotational path of the dryer surface, heat is imparted to
the web causing most of the moisture contained within the web to be
evaporated. Web 68 is then removed from dryer drum 76 by a creping
blade 78. Creping web 78 as it is formed further reduces internal
bonding within the web and increases softness.
[0119] Creping the tissue web as shown in FIG. 10 increases the
softness of the web by breaking apart fiber-to-fiber bonds
contained within the tissue web. Applying the additive composition
to the outside of the paper web, on the other hand, not only
assists in creping the web but also adds dry strength, wet
strength, stretchability and tear resistance to the web.
[0120] According to the process of the current disclosure, numerous
and different tissue products can be formed. For instance, the
tissue products may be single-ply wiper products. The products can
be, for instance, facial tissues, bath tissues, paper towels,
napkins, industrial wipers, and the like. As stated above, the
basis weight can range anywhere from about 10 gsm to about 110
gsm.
[0121] In one embodiment, tissue webs made according to the present
disclosure can be incorporated into multiple-ply products. For
instance, in one embodiment, a tissue web made according to the
present disclosure can be attached to one or more other tissue webs
for forming a wiping product having desired characteristics. The
other webs laminated to the tissue web of the present disclosure
can be, for instance, a wet-creped web, a calendered web, an
embossed web, a through-air dried web, a creped through-air dried
web, an uncreped through-air dried web, an airlaid web, and the
like.
[0122] These and other modifications and variations to the present
invention may be practiced by those of ordinary skill in the art,
without departing from the spirit and scope of the present
invention, which is more particularly set forth in the appended
claims. In addition, it should be understood that aspects of the
various embodiments may be interchanged both in whole or in part.
Furthermore, those of ordinary skill in the art will appreciate
that the foregoing description is by way of example only, and is
not intended to limit the invention so further described in such
appended claims.
* * * * *