CN1048060C - 柔软薄页纸及其制备方法 - Google Patents

柔软薄页纸及其制备方法 Download PDF

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CN1048060C
CN1048060C CN94193014A CN94193014A CN1048060C CN 1048060 C CN1048060 C CN 1048060C CN 94193014 A CN94193014 A CN 94193014A CN 94193014 A CN94193014 A CN 94193014A CN 1048060 C CN1048060 C CN 1048060C
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小·T·E·发林顿
J·S·巴曼
M·A·布拉辛
F·-J·陈
K·A·格尔格
M·A·赫曼斯
R·J·马科林
M·J·雷科斯克
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Abstract

在不用单烘缸的情况下，能制造柔软至足以用作优质浴巾纸的柔软穿透干燥薄页纸。分别通过湿部急速递纸和穿透干燥合成网的设计，而替代了通常的单烘缸的纵向和横向伸长率的作用。特别有益的是，在至少一层中用化学机械处理过的纤维来形成薄页纸。最终的薄页纸具有高松厚度(约6cm3/g或更大)和低挺度。

Description

柔软薄页纸及其制备方法
                   发明背景
在薄页纸产品如浴巾纸的制造过程中，必须注意大量的产品特性，以便提供适宜于产品预定用途的、具有适当的特性的混和的最终产品。在这些不同的特性中，对于优质产品而言，改善柔软度一直是主要目标。柔软度的主要组成包括挺度和松厚度(密度)，具有较低的挺度和较高的松厚度(较低的密度)，通常能改善所能感觉的柔软度。
传统的薄页纸产品一直是用湿压法进行制造的，其中，在最终干燥前，通过从纸幅中压榨或挤出水而从湿抄纸幅中除去大量的水。特别是，当纸幅被吸水造纸毛毯支承时，在将它送至单烘缸表面进行最终干燥时，利用压辊将该纸幅在毛毯和旋转加热烘缸(单烘缸)的表面之间挤压。然后，用刮刀刀片(起皱)从单烘缸上取出干燥纸幅，该刀片通过破坏在该方法的湿压阶段预先形成的许多键，而用来部分地使干燥纸幅剥离。起皱通常改善了纸幅的柔软度，但要以大量的强度损失为代价。
近年来，穿透干燥已日益成为干燥薄页纸纸幅的普通的方法。通过将热空气穿过纸幅直至其干燥，穿透干燥提供了从纸幅中除去水的相对不压缩的方法。更具体地说，将湿抄纸幅从成形网送至粗糙的、高度可渗透的穿透干燥合成网上，并留在穿透干燥合成网上直至其干燥。由于形成了更少的造纸键又由于该纸幅更为不致密，因此，最终的干燥纸幅比湿压不起皱干燥纸更柔软、更松厚。尽管随后仍要将纸幅送至用于起皱的单烘缸，以进行最终干燥和/或使最终的薄页纸柔软，但省去了从湿纸幅中挤水。
尽管有消除单烘缸并生产不起皱的穿透干燥薄页纸这样的生产动机，但当与它们的起皱对应物相比时，迄今为止，不用单烘缸(不起皱)的各种尝试所生产的穿透干燥薄页纸均缺乏适当的柔软度。由于没有起皱，在该过程中没有机械剥离作用，因此部分是由于不起皱纸页固有的高挺度和高强度之故。由于挺度是柔软度的主要组成，因此，不起皱穿透干燥纸页的使用一直局限于高强度是最重要的应用行业，如工业用擦试纸和毛巾纸，而不是应用于需要柔软度的场合，如消费市场的浴巾纸，优质家用毛巾纸，以及搽面纸。
                        本发明概要
现已发现，在适当的方法中，使用某些预处理的造纸纤维，能制造出具有特别适宜用作浴巾纸性能的薄页纸。优选这样一种穿透干燥薄页纸的制造方法，其中薄页纸幅不贴在单烘缸上，因此是不起皱的。与市售起皱浴巾纸产品、特别是与先前的不起皱的穿透干燥产品相比，本发明得到的薄页纸的特征在于，具有高松厚度和低挺度的独特的结合。
通过薄页纸纵向(MD)负载/伸长率曲线的最大斜率(后面称之为“MD最大斜率”)，或进一步计及薄页纸厚度和产品层数的MD挺度因子(后面定义)，能客观地表示本发明产品的挺度。根据本发明，通过克服不起皱穿透干燥纸页固有的高挺度，能生产出高松厚度和低挺度的可接受的柔软薄页纸。此外，本发明产品具有提供使用耐久性的约10％或更大的高程度伸长率。至今，还从没抄造出这种高松厚度且柔软、强韧和可伸长的薄页纸产品。尽管本发明特别适用于浴巾纸，但也可用作柔软度为主要特征的其它纸产品，如搽面纸和家用毛巾纸。因此，本发明一方面涉及松厚度(后面定义)约9cm3/g或更大、MD最大斜率约10或更小的柔软薄页纸。
本发明的另一方面涉及包含一层或多层不起皱穿透干燥层的柔软薄页纸，其MD最大斜率约为10或更小，优选还具有约6cm3/g或更大的松厚度。
本发明的另一方面涉及松厚度约9cm3/g或更大，MD挺度因子约150或更小的柔软薄页纸。
本发明的另一方面涉及包含一层或多层不起皱穿透干燥层的柔软薄页纸，其MD挺度因子约150或更小，优选还具有约6cm3/g或更大的松厚度。
本发明的再一方面涉及一种柔软薄页纸页的制造方法：该方法包含(a)形成浓度约为20％或更大的造纸纤维的水悬浮液；(b)通过外部热源如蒸汽，并利用约1马力-日/吨干纤维或更大的功率输入，在140°F或更高的温度下对该水悬浮液进行机械处理，从而使纤维卷曲；(c)将卷曲纤维的水悬浮液浓度稀释至约0.5％或更小，并将该稀释的悬浮液送至抄造薄页纸的网前箱；(d)将稀释的水悬浮液沉积至成形网上，以形成湿纸幅；(e)将湿纸幅脱水至约20-30％的浓度；(f)将该脱水的纸幅从成形网送至运行速度比成形网低约10-80％的递纸织物上；(g)将纸幅送至穿透干燥合成网，借此将该纸幅进行宏观重排，从而与穿透干燥合成网的表面相一致；和(h)将该纸幅穿透干燥至最终干度。
以厚度(后面定义，以微米(μm)表示)除以定量(以g/m2表示)的商来计算本发明产品的松厚度。所得到的松厚度表示为cm3/g。对于本发明的产品而言，松厚度可为约6cm3/g或更大，优选约9cm3/g或更大，合适约9-20cm3/g，更具体地说约10-15cm3/g。相对于上述的本发明产品的松厚度是根据由薄页造纸机生产的没经后处理如压花的原纸得到的。不过，如果需要，可对本发明的原纸进行压花以产生甚至更大的松厚度或更美观，或可不压花。此外，如果需要或必需满足现有产品的规格，可对本发明原纸进行压光，以改善平滑度或降低松厚度。
本发明产品的MD最大斜率可为约1O或更小，优选约5或更小，合适为约3-6。如何确定MD最大斜率，将结合图6在后面进行描述。MD最大斜率是薄页纸的MD负载/伸长率曲线的最大斜率。MD最大斜率的单位为kg/3吋(7.62cm)，但为方便起见，后面所述的MD最大斜率值没有单位。
本发明产品的MD挺度因子可以为约150或更小，优选约100或更小，合适为约50-100。通过将MD最大斜率乘以厚度除以层数商的平方根来计算MD挺度因子。MD挺度因子的单位为(kg/3吋)-μm0.5，但为简便起见，后面所述的MD挺度因子没有单位。
在此所用的厚度是单页纸的厚度，但以10片纸页堆积的厚度进行测量，并将10片纸页的厚度除以10，在纸堆中的每页纸均以相同的面向上而放置。厚度以μm表示。它是根据TAPPI测试方法T402“纸、纸板、纸浆抄片和相应产品的标准状态和测试气氛”和T41lom-89“纸、纸板以及复合板的厚度”，并根据堆积纸页的附注3而测量的。用来执行T41l om-89的厚度计是支承直径(anvildiameter)为
Figure C9419301400081
吋(103.2毫米)。支承压力(anvil pressure)为220g/吋2(3.39千帕)的松厚度计(TMI型49-72-00，Amityville，New York)。测完厚度后，将相同的成堆的10片纸页用来确定其平均定量。
本发明的产品可是单层产品，或多层产品，如两层、三层、四层或更多层。尽管单层产品由于其较低的制造成本而是有利的，但许多消费者仍优选多层产品。对于多层产品而言，无需每层产品都相同，只要至少一层是根据本发明的就行。
本发明产品的定量可以为约5-70g/m2(gsm)，优选约10-40g/m2，更优选约20-30g/m2。对于单层浴巾纸，优选定量约为25g/m2。对于双层薄页纸，优选每层纸页的定量约为20g/m2。对于三层薄页纸，优选每层纸页的定量约为15g/m2。
另外，本发明的薄页纸还具有相当高的MD伸长率的特征。MD伸长率的数量可以约为10％或更大，合适的约15-25或30％。横向(CD)伸长率约为3％或更大，合适的约7-10％。在将纸幅从成形网送至递纸织物时，和/或从递纸织物送至另一递纸织物时，和/或从递纸织物送至穿透干燥合成网时，可将MD伸长率赋予纸页。CD伸长率是由穿透干燥合成网的设计来支配的。
为适于用作浴巾纸，优选MD抗张强度约为600g/3吋(7.62cm)宽或更大，更合适的约700-1500g。优选CD抗张强度约为300g/3吋(7.62cm)宽或更大，更合适的约400-600g。
根据TAPPI测试法494 OM-88“纸和纸板的抗张性能”，使用下述参数，可得到MD抗张强度，MD伸长率，CD抗张强度和CD伸长率；十字头速度为10.0吋/分(254mm/min)，全刻度(full scale)负荷为10磅(1b)(4.540g)，夹板间距(jaw span)(夹板之间的距离，有时称之为校正长度)为2.0吋(50.8mm)，试样宽度3吋(76.2mm)。抗张测试器为Sintech，CITS-2000型(SystemsIntegration Technology Inc.，Stoughton，MA；MTS SystemsCorporation的分部，Research Triangle Park，NC)。
用于本发明目的的造纸纤维包括已知用于造纸的任何的纤维素纤维，特别是用于制造密度相对较低的纸如搽面纸，浴巾纸，毛巾纸，薄餐巾纸等的那些纤维。合适的纤维包括，未用过的针叶木和阔叶木纤维，以及二次或回用纤维素纤维，以及它们的混合物。特别合适的阔叶木纤维包括桉树属和械树属纤维。在此所用的“二次纤维”意指任何这样的纤维素纤维，即先前已通过物理、化学或机械手段从其原始母体中分离开来，并进一步形成纤维纸幅，干燥至约10％(重量)或更低的水分含量；然后通过某些物理、化学或机械手段从其纸幅母体中再次分离出来的纤维。
薄页纸柔软度的关键组成是纸页的挺度或耐折性能。以前的方法是，通过起皱，层合，构成图案与单烘缸接触，或它们的某种组合来降低挺度。在不起皱穿透干燥方法中，第一种或最后一种方法都是不可能的。因而，期望层合能在所需的总抗张强度时，对降低纸页挺度起关键作用。理论上，能在已处理过的从而给出很高强度或模量(或许通过精浆或化学作用)的很薄的层(对于低挺度)中承载所希望的总的强度。余下的各层可包含已处理过的从而大大降低其强度(模量)的纤维。因此，在所需总强度下实现低挺度的关键为：以使各种层间的强度(模量)差最大化的方式来处理或改性纤维。对非强韧(weaker)层的理想的改性是同时降低抗张强度和增加松厚度，而模量将最大程度的降低。
对于相对不强韧层而言，生产柔软纤维的改性方法包括机械改性、化学改性，以及机械改性和化学改性的结合。借助通过机械作用而使纤维永久变形的方法，可实现机械改性。这些机械改性方法将卷曲，扭结和微压缩引入到纤维中，这将降低纤维对纤维的结合，降低纸页的抗张强度，并增加纸页的松厚度，伸长率，孔隙率和柔软度。合适的机械改性方法的例子包括，闪击干燥，干纤维化和高浓湿卷曲。尽管能使纤维卷曲的任何方法和机械装置均能增加纸页的柔软度，但在水中能产生更为卷曲或更挺硬卷曲或更永久卷曲的方法或机械装置将更大程度地增加纸页的柔软度，因此是优选的。此外，可将柔软度增加剂在机械改性之前或之后添加至机械改性的纤维中，从而产生优于单独的机械处理或湿部化学剂添加的柔软度的增加。用于本发明目的的纤维的优选改性方法是使纤维通过轴向磨浆机，该磨浆机是在高温处理纤维(给予高剪切力和纤维内高摩擦力)的高浓湿法卷曲装置。已通过轴向磨浆机(本文有时称作“磨浆(disperging)”的纤维被称之为“磨过的纤维”。由于它们的松厚度建立能力和它们的柔软度，这些纤维具有某些使它们特别适于制造不起皱穿透干燥薄页纸的性能。
进行磨浆处理的纤维水悬浮液的浓度必须高至足以提供显著的纤维对纤维的接触，或高至足以进行将改变处理过纤维的表面性能的处理。具体地说，该浓度可以至少为约20，更优选约20-约60，最优选约30至约50％(干重)。该浓度主要受用来处理纤维的机器的种类所支配。对某些旋转轴向磨浆机而言，例如在浓度超过约40％(干重)时，就有堵塞机器的危险。对于其它种类的磨浆机，如Bivis磨浆机(可从Clextral Company，Firminy Cedex，France购得)，可使用大于50的浓度而不堵塞。这种装置通常可被称为加压的双螺旋轴向磨浆机，每个轴均有若干沿物料流动方向取向的螺旋片(screwflights)，随后有若干沿相反方向取向的螺旋片，以产生反压。螺旋片是带槽的，从而使物料通过这些槽从一排螺旋片流至另一排。为了最大程度地使纤维对纤维进行接触，对于所用的特定磨浆机而言，希望使用尽可能高的浓度。
磨浆期间纤维悬浮液的温度约为140°F或更高，优选约150°F或更高，更优选约210°F或更高，最优选约220°F或更高。由于不可能将常压操作的、装置内的纤维水悬浮液加热超过水的沸点，因此，温度的上限是由该装置是否加压而确定的。有意思的是，据信纤维卷曲的程度和耐久性主要受被磨浆处理的纤维中木素含量影响，对于高木素含量的纤维而言，可得到更大程度的影响。因此，在将先前认为是不适宜地柔软的纤维转变成适宜的柔软纤维中，高木素含量的高得率浆是特别有利的。以依次降低的木素含量的高得率浆的排序为：磨木浆，热磨机械浆(TMP)，化学机械浆(CMP)，和漂白的化学热磨机械浆(BCTMP)。这些纸浆的木素含量约为15％或更高，而化学浆(硫酸盐纸浆和亚硫酸盐纸浆)为木素含量约为5％或更低的低得率浆。
在磨浆期间对纤维悬浮液施加的功率也对纤维性能产生影响。通常，随着功率输入的增加将增加纤维的卷曲。然而，另外还发现，功率输入达到约2马力-日/吨干纤维(悬浮液中)(HPD/T)(1.6千瓦-日/吨)时，纤维卷曲达到最大值。优选的功率输入范围为约1-3HPD/T(0.8-约2.5千瓦-日/吨)，更优选约2HPD/T(1.6千瓦-日/吨)或更大。
在对纤维进行磨浆处理期间，必需使纤维经受主要是纤维对纤维的磨擦或剪切，以及纤维与用来处理纤维的机械装置的表面的磨擦或剪力。将纤维压成独立纤维的某种压缩也是希望的，以增强或扩大对纤维的磨擦或剪切作用。所用的适当的剪切量和压缩量取决于在最终薄页纸中取得高松厚度和低挺度的最终结果。若干台造纸工业中已知的轴向磨浆机或等效的机械装置能用来实现所希望的各种结果。合适的轴向磨浆机非限定性的包括不加压的轴向磨浆机和加压的轴向磨浆机，如上述的Bivis磨浆机。轴向磨浆机的特征在于其相当高的体积：内表面积的比率，并主要依靠纤维对纤维的接触，以产生纤维的改性。这与主要依靠金属表面对纤维的接触而不是纤维对纤维接触的圆盘精磨机或圆盘磨浆机相反。尽管对于柔软层纤维而言，磨浆是降低模量的优选的方法，但这并不意味着用以这种方式处理的纤维来限制本发明。可使用机械或化学方法来降低这些纤维的强度和模量，并且与强韧层一同用来直接降低纸页的挺度。
可使用柔软剂、有时称之为脱粘剂，以增加薄页纸产品的柔软度，这些柔软剂可在磨浆之前、之中或之后与纤维混合。还可将这些柔软剂喷在或印在成形后仍是湿的纸幅上，或在成形前添加至薄页纸机的湿部。合适的柔软剂非限定性的包括，脂肪酸、蜡、季铵盐类、二甲基二氢化脂氯化铵、硫酸甲酯季铵盐、羧基化聚乙烯、柯卡酰胺(cocamide)、二乙醇胺、椰子甜菜碱(coco betaine)、月桂基肌氨酸钠、部分乙氧基化的季铵盐、二硬脂酰(distearyl)二甲基氯化铵、聚硅氧烷等。合适的市售化学柔软剂的例子非限定性的包括，Eka Nobel Inc.制造的Berocell 596和584(季铵化合物)，Sherex Chemical Company制造的Adogen 442(二甲基二氢化脂氯化铵)，Quaker Chemical Company制造的Quasoft 203(季铵盐)，和AKzo Chemical Company制造的Arquad 2HT-75(二(氢化脂)二甲基氯化铵)。柔软剂合适的用量将随所选的种类和所希望的结果而大大地改变。以纤维重量为准，非限定性的用量可约为0.05-1％(重量)，更具体地说约为0.25-0.75％(重量)，特别是约0.5％(重量)。
现在，参见本发明的薄页纸制造方法，成形方法和装置可以是造纸工业中熟知的常规方法和装置。这些成形方法包括，长网造纸机、roof成形器(如真空胸辊)、以及间隙成形器(如双网成形器，新月形(crescent)成形器)，等等。对于较高运行速度而言，优选双网成形器。成形网也是常规的，即优选带较大纤维支承的细织纹以产生较平滑的纸页，粗织纹提供较大的松厚度。用来将纤维沉积至成形网上的网前箱可以成层或不成层的，但由于薄页纸的性能可通过改变各层的组成而精细调整，所以成层的网前箱是有利的。
更具体地说，对于单层产品，优选提供在薄页纸的“空气面”和“网面”有研磨纤维的三层薄页纸。(“空气面”指的是在干燥期间不与干燥网接触的薄页纸面，而“网面”指的是在干燥期间与穿透干燥合成网接触的薄页纸面)。在薄页纸的中间优选含有没经研磨的普通的针叶木纤维或二次纤维，以给予薄页纸以足够的强度。然而，在所有的层中均包括有研磨的纤维同样在本发明的范围内。对于双层产品，优选在薄页纸页的网面上提供研磨的纤维，并将两层薄页纸层合在一起，结果是，研磨纤维层成为产品的外表面层。不过，取决于产品希望的纸页性能，研磨的纤维(未用过的纤维或二次纤维)可存在于任一或所有的层中。在所有场合，只要有研磨的纤维存在就能增加松厚度并降低挺度。在任一层中研磨纤维的用量可为1-100％(重量)，更具体地说为约20％(重量)或更高，约50％(重量)或更高，或约80％(重量)或更高。优选用在此所述的脱粘剂处理研磨的纤维，以进一步增加松厚度并降低挺度。
在本发明薄页纸的制造中，优选包括有递纸织物，以改善纸页的平滑度和/或赋予足够的伸长率。在此所用的“递纸织物”是置于纸幅制造过程的成形区和干燥部之间的织物。该织物可具有相对平滑的表面以赋予纸幅以平滑度，但必须有足够的织物密度，从而在急速递纸期间能抓住纸幅并保持接触。优选用“固定间隙”递纸或“吻合”递纸将纸幅从成形网送至递纸织物，其中在两织物之间基本上不压缩纸幅，以便保存薄页纸页的厚度或松厚度和/或使织物最小程度的磨损。
递纸织物包括单层、多层或复合可渗透的结构。优选的织物至少有下列之一的特征：(1)在与湿纸幅接触的递纸织物的面上(顶面)，每吋的MD纱线数(目数)为10-200(4-80/cm)，每英寸的CD纱线数(支数)也为10-200。纱线直径通常小于0.050吋(1.3mm)：和(2)在顶面上，MD节的最高点与CD节的最高点之间的距离约为0.001-约0.02或0.03吋(0.025-约0.5或0.75mm)。在这两个最高点之间，可由MD纱或CD纱来形成节，以给出三维特性的构形。例如，特别合适的递纸织物包括，由Asten Forming Fabrics，Inc.，Appleton，Wisconsin制造的并称为934，937，939和959号的织物，以及由Albany International，Appleton Wire Division，制造的Albany 94M。
为了给薄页纸提供伸长率，在织物之间在湿纸幅传递的一个或多个位置提供速度差。以速度较低的递纸织物为准，成形网和递纸织物之间的速度差可约为5-75％或更大，优选约10-35％，更优选约15-25％。最佳速度差将取决于包括被制造的产品的特定种类的各种因素。如前所述，赋予纸幅的伸长率的增加与速度差成正比。对于定量约为25g/m2的单层不起皱穿透干燥的浴巾纸而言，例如，在成形网和单一递纸织物之间约20-25％的速度差将使最终产品产生约15-25％的伸长率。在干燥前，利用单一差速递纸或两个或多个差速递纸，能给予纸幅以伸长率。因此，可有一个或多个递纸织物。因此，赋予纸幅的伸长率可在一个、两个、三个或多个差速递纸中分配。优选在真空的帮助下将纸幅送至最后的织物(穿透干燥合成网)上进行最终的干燥，以保证纸幅的宏观重排，从而给出希望的松厚度和外观。使用独立的递纸织物和穿透干燥合成网能提供出优于现有技术的显著的改进，这是由于它能特定地设计这两种织物，以独立地提出关键的产品要求之故。例如，通常使递纸织物最佳化，以使高急速递纸值能有效地转化成高MD伸长率，并改进纸页的平滑度，与此同时，将穿透干燥合成网设计成产生松厚度和CD伸长率。因此，有益的是，递纸织物是相当细密和相对平整的，而穿透干燥合成网相当粗糙并且有最优化的三维构型。结果是，相对平滑的纸页离开递纸区，然后进行宏观重排(借助于真空)，从而给出高松厚度，高CD伸长率以及穿透干燥合成网的表面构形。没有可见的(至少没有宏观肉眼可见的)递纸织物的痕迹留在最终产品中。纸页构形在从递纸织物送至穿透干燥合成网时被完全改变，纤维被宏观重排，包括明显的纤维-纤维的移动。
干燥方法可是趋于保存湿纸幅松厚度或厚度的非压缩性干燥方法，非限定性的例子包括，穿透干燥，红外辐照，微波干燥等。由于其工业有效性和实用性，因此穿透干燥是熟知的，并且是用于本发明对纸幅进行非压缩干燥的优选方法。合适的穿透干燥合成网非限定性的包括，Asten 920A和937A以及Velostar P800和103A。优选在穿透干燥合成网上将纸幅干燥至最终干度，而不压在单烘缸表面上，和不在随后进行起皱。与通过将由穿透干燥合成网或另外织物支承的湿纸幅压在单烘缸上的方法制得的产品相比，或与点结合空气沉降产品相比，上述的穿透干燥法能提供密度相对均匀的产品。尽管最终产品的外观和松厚度由穿透干燥合成网设的设计来确定，但纸幅的MD伸长率主要由递纸织物提供，因此，本发明的方法具有更大的处理灵活性。
                      附图的简要说明
图1是说明根据本发明的不起皱穿透干燥纸页制造方法的流程示意图。
图2是利用轴向磨浆机处理纤维的本发明纤维处理方法的流程示意图。
图3是图2的轴向磨浆机的局部(cut-away)透视图。
图4是使用一对串联的Bivis轴向磨浆机的本发明的另一种方法的流程示意图。
图5是薄页纸负荷/伸长率曲线的综合的曲线图，用来说明如何确定MD最大斜率。
图6为根据本发明制得的浴巾纸和市售起皱的浴巾纸的松厚度对平板挺度(通过排成序列的灵敏板测定的挺度)的图表，用来说明本发明产品显示出的高松厚度和低挺度。
图7为根据本发明制得的浴巾纸和市售浴巾纸的平板挺度对MD最大斜率的图表，用来说明平板挺度与MD最大斜率的关系。
图8为根据本发明制得的浴巾纸和市售浴巾纸的松厚度对MD最大斜率的图表，进一步说明本发明产品显示出的高松厚度和低挺度。
图9为类似于图8的图表，所不同的是平板挺度对MD挺度因子，用来说明平板挺度与MD挺度因子的关系。
图10为类似于图9的图表，所不同的是松厚度对MD挺度因子，进一步说明本发明产品的高松厚度和低挺度。
               本发明的详细说明
直接参考附图，对本发明作更详细的描述。
图1说明了进行本发明方法的装置。(为简单起见，画出了用来示意限定若干织物运行的各种松紧辊，但没标号。应明白的是，在不违背本发明的范围下，能对图1所示的装置和方法作出各种变更)。图1示出了带有成层造纸网前箱10的双网成形器，网前箱10将造纸纤维的水悬浮液流11注射或沉积到成形网13上，在纸幅部分脱水至约10％干重的浓度的过程中，成形网13用来支承并携带新形成的湿纸幅。在湿纸幅被成形网支承时，如通过真空吸水可另外使湿纸幅脱水。
然后，将湿纸幅从成形网送至运行速度比成形网慢的递纸织物17上，以便给予纸幅以增加的伸长率。优选借助真空板18以及成形网和递纸织物间的固定间隙或间距进行递纸，或借助吻合递纸而进行递纸，以避免对湿纸幅的压缩。
然后借助真空递纸辊20或真空递纸板，再次使用或不使用前述的固定间隙递纸，将纸幅从递纸织物送至穿透干燥合成网19。相对于递纸织物而言，穿透干燥合成网的运行速度可与之大约相同或不同。如果需要的话，穿透干燥合成网可以更慢的速度运行，从而进一步增加伸长率。优选借助真空进行递纸，以保证纸页的变形，从而与穿透干燥合成网相一致，于是得到希望的松厚度和外观。
用于纸幅递纸的真空度可以为约3-15英寸汞柱(75-约380mmHg)，优选约5英寸汞柱(125mmHg)。除了用真空将纸幅吸至下一个织物上以外，可通过在纸幅的反面使用正压来补偿或替代真空板(负压)以将纸幅吹至下一个织物上。另外还可使用一根或多根真空辊来替代真空板。
在由穿透干燥合成网支承的同时，该纸幅被穿透干燥器21最终干燥至约94％或更大的浓度，然后送至引纸织物22。使用引纸织物22和可有可无的引纸织物25将干燥的原纸23送至纸轴24上。可使用任选加压的转向辊26，以有利于纸幅从引纸织物22递至织物25上。用于此目的的合适的引纸织物有Albany International84M或94M以及Asten 959或937，所有这些均是带细小花纹的相当平滑的织物。尽管没有画出，但能对卷筒纸进行压光或随后的离线压光，以改善原纸的平滑度和柔软度。
图2是说明为磨浆准备的用于处理二次造纸纤维的整个处理步骤的方块流程图。(对于未使用过的纤维，可用水将纤维制成希望浓度的浆液，并直接引入磨浆机)。图2示出了将待处理的造纸配料40在外加稀释水42时送至高浓碎浆机41(ST6C-W型，Bird EscherWyss，Mansfield，MA)，以达到约15％的浓度。在泵出碎浆机之前，将浆料稀释至约6％的浓度，在外加稀释水下将成浆纤维送至粗筛43(Fiberizer Model FT-E，Bird Escher Wyss)，以便除去大的杂质。粗筛的进口浓度约4％。粗筛的粗筛废料送至废物处理44。粗筛的合格品被送至高浓除渣器45(Cyclone Model 7 inch size，Bird Escher Wyss)，以便除去从粗筛逃脱的重质杂质。高浓除渣器的粗筛废料送至废物处理。高浓除渣器的合格品送至细筛46A(Centrisorter Model 200，Bird Escher Wyss)，以进一步除去更小的杂质。将稀释水加至细筛的给料液流中，以使给料浓度达到约2％。细筛的粗筛废物送至第二细筛46B(Axiguard，1型，BirdEscher Wyss)，以除去另外的杂质。合格品循环至细筛46A的给料液流中，并将粗筛废料送至废物处理。然后将在外加稀释水而达到约1％浓度的细筛的合格品顺序通过四个浮选池47，48，49和50(Aerator Model CF1，Bird Escher Wyss)，以除去油墨颗粒和胶粘物。每个浮选池的废弃物送至废物处理。最后一个浮选池的合格品送至洗浆机51(Double Nip Thickener Model 100，BlackClawson Co.，Middletown，OH)，以除去很小的油墨颗粒，并增浓至约10％。洗浆机的废弃物送至废物处理。洗浆机的合格品送至带式压榨机52(Arus-Andritz Belt Filter Press Model CPF 20inches，Andritz-Ruthner Inc.，Arlingtor，TX)，以使水含量降至约30％。带式压榨机的废弃物送至废物处理。然后将得到的部分脱水的纤维材料送至在图4中将详细描述的轴向磨浆机53(GR11，Tng. S. Maule & C.S.P.A.，Torino，Italy)，以便根据本发明对纤维进行处理，从而改善它们的性能。将蒸汽54送至磨浆机的给料液流中，以升高给料材料的温度。得到的处理过的纤维55可直接用作造纸原料，或如希望的话进行进一步的处理。
图3是如图2所述，根据本发明对纤维进行处理的优选装置的局部透视图。该特殊装置是由Ing.S.Maule & C.S.P.A.，Torino，Italy制造的GRII型轴向磨浆机。图3示出了上圆柱外壳61和下圆柱外壳62，当它们闭合时，它们将包住带有许多浆叶64的旋转轴63。上外壳含有两排隆起的指状物65和三个检查部分66。上外壳的一端是入口67。在旋转轴的入口端是用来使轴旋转的驱动电机68。在旋转轴的出口端是支承旋转轴的轴承外壳69。旋转轴的入口端含有直接置于入口下的螺旋进料区70，该区用来将进料推进并通过磨浆机。磨浆机的出口71含有绞折板72，该板带有手柄73，当磨浆机闭合时，手柄被安装在上外壳上的液压气囊74接合。气囊提供了可控的耐绞折板的旋转性，因此提供了一种在磨浆机内反压的控制机构。当增加反压时，对纤维处理的程度也将增加。当操作期间，隆起的指状物与旋转轴的浆叶交叉成指交叉状，从而在它们之间对进料进行处理。
图4是使用一对双轴磨浆机(Bivis磨浆机)的本发明另一方法的方块流程图。如图所示，以约50％的浓度将造纸纸浆送至螺旋给料器。螺旋给料器计量地将原浆送至串联的两台Bivis磨浆机的第一台中。每台Bivis磨浆机均含有三个压缩/膨胀区。将蒸汽通入第一台Bivis磨浆机中，以使纤维的温度升至约212°F(100℃)。将处理过的纸浆送至第二台Bivis磨浆机，并在与第一台Bivis磨浆机相同的条件下进行操作。通过将取自第二台磨浆机的处理过的纸浆放入冷水浴中而使之骤冷，然后脱水至合适的浓度。
下面将结合实施例来讨论图5-10。
                         实施例实施例1-20：为了说明本发明，用基本上如图1所述的方法生产大量的不起皱穿透干燥薄页纸。更具体地说，实施例1-19均为带三层的、单片浴巾纸，其中外层包括研磨过的、脱粘的桉树属纤维，中间层包括精制的北方针叶木硫酸盐纤维。实施例20为双片浴巾纸，其中每片均为如前所述实施例那样分层的。将Cenebra桉树属纤维在10％的浓度打浆15分钟，然后脱水至30％浓度。然后将纸浆送至如图3所述的Maule轴向磨浆机。该磨浆机在160°F(70℃)操作。其功率输入为2.2HPD/T(1.8Kw-日/吨)。研磨后，将柔软剂(Berocell 584)添加至纸浆中，添加量为每吨干纤维10磅Berocell(0.5％重量)。
成形前，将针叶木纤维在2.5％浓度打浆30分钟，同时将研磨过的、脱粘的桉树纤维稀释至2％浓度。在研磨过的桉树层/精制针叶木层/研磨过的桉树层中，整个的层间纸页重量分布为37.5％/25％/37.5％。将中间层精磨至达到目标强度值所需的程度，外层提供柔软度和松厚度。
这些实施例使用了四层的Beloit Concept III网前箱。在网前箱的两个中间层中使用精制的北方针叶木硫酸盐浆，以产生用于所述三层产品的单一中间层。使用从堰板凹进约三吋(75mm)的档板和伸出堰板约6吋(150mm)的层间隔板产生的湍流。还使用伸出堰板约6吋(150mm)的挠性唇板伸出部分，如授于Farrington，Jr.的US5129988(1992.7.14)所述，该专利的题目为“带有平行挠性唇板伸出部分和延长的内隔板的延长的挠性网前箱堰板”，在此将它引入作为参考。堰板的净开口约为0.9吋(23mm)，在四个网前箱层中的水流不相上下。送至网前箱的浆料浓度为约0.09％重量。
在双网、真空成形辊成形区上形成最终的三层的纸页，其中成形网(图1中12和13)分别是空隙体积分别为约64.5％和61％的Asten 866网和Asten 856A网。成形网的运行速度为12.1m/s。然后，在将新形成的纸幅送至以9.7m/s运行的(25％的急速递纸)递纸织物之前，在成形网下面使用真空吸水将纸幅脱水至约20-27％的浓度。所使用的递纸织物包括Asten 934和Albany 94M。使用能产生约6-15吋汞柱(150-380mmHg)真空度的真空板，将纸幅递至递纸织物上。
然后，将纸幅送至以约9.7m/s速度运行的穿透干燥合成网上。使用Velostar 800和Asten 934穿透干燥合成网。将纸幅导引通过在约350°F(175℃)温度下操作的Honeycomb穿透干燥器，并干燥至约94-98％浓度的最终干度。
为了说明本发明，表1给出了实施例1-20更详细的处理条件以及最终的薄页纸性能的描述。如表1和下表2中使用的栏头具有下列意义：“TAD织物”指的是穿透干燥合成网(穿透干燥合成网的标记“W”或“S”指的是哪一网面对着纸幅。“W”表示由经节支配的面，“S”表示由纬节(shute knuckles)支配的面。)；“#1Trans Vac”是用来将纸幅从成形网递至递纸织物的真空度，以mmHg表示；“#2 Trans Vac”是用来将纸幅从递纸织物递至穿透干燥合成网的真空度，以mmHg表示；“Cons @ #1 Trans”是在从成形网至递纸织物的这一位置纸幅的浓度，以百分固含量表示；“Cons @#2 Trans”是在从递纸织物至穿透干燥合成网的这一位置纸幅的浓度，以百分固含量表示；“MD Tensile Strength”为纵向抗张强度，以g/3吋宽(7.62cm)试样表示；“MD Tensile Stretch”为纵向伸长率，以试样裂断时的百分伸长率表示；“MD Max Slope”如前定义，以kg/3吋宽(7.62cm)试样表示；“CD Tensile Strength”是横向抗张强度，以g/3吋宽(7.62cm)试样表示；“CD TensileStretch”为横向伸长率，以试样裂断时的百分伸长率表示；“GMT”为几何平均抗张强度，以g/3吋宽(7.62cm)试样表示；“BasisWt”为成品的定量，以g/m2表示；“Caliper”如前所述，为10页纸厚度除以10的值，以μm表示；“Bulk”为如上所定义的松厚度，以cm3/g表示；“Panel Stiff”为纸页的挺度，当将纸页放在手中时，通过感受折叠的相对锐度的顺序排列的灵敏板来确定，以1-14的数来表示，数值越大，挺度越大(市售浴巾纸通常在约3-约8)；“MD Stiff Factor”为如上定义的纵向挺度因子，以(kg/3吋)-μm0.5表示。
                                  表1实施例TRANSFER        TAD           #1     #2      CONS     COMS     MO          MO        MO
   FABRIC         FABRIC        TRANS  TRANS   @#1      @#2      TENSILE     TENSILE   MAX
                                VAC    VAC     TRANS    TRANS    STRENGTH    STRETCH   SLOPE1     ALBANY 94M W   VELOSTAR      380    200     20-22    22-24    775         19.2      5.0872     ASTEN 934 W    ASTEN 934     380    100     20-22    27-29    721         19.3      4.6363     ASTEN 934 W    ASTEN 934     150    100     20-22    22-24    712         18.9      4.8154     ALBANY 94M S   VELOSTAR      150    200     20-22    27-29    799         19.2      5.1495     ALBANY 94M S   VELOSTAR      380    100     20-22    27-29    834         22.0      5.2236     ALBANY 94M S   ASTEN 934     380    100     20-22    27-29    897         20.2      5.6217     ALBANY 94M S   VELOSTAR      150    100     20-22    22-24    815         19.1      5.5438     ALBANY 94M W   VELOSTAR      150    100     25-27    27-29    843         21.7      5.6989     ALBANY 94M W   VELOSTAR      380    100     20-22    27-29    867         20.0      5.69610     ASTEN 934 W    ASTEN 934     380    200     20-22    22-24    721         20.6      4.70911     ALBANY 94M S   VELOSTAR      380    200     25-27    27-29    819         20.2      5.44112     ASTEN 934 W    ASTEN 934     150    200     20-22    27-29    709         20.2      4.91313     ALBANY 94M W   VELOSTAR      380    200     25-27    27-29    531         20.1      3.49614     ASTEN 934 W    ASTEN 934     380    200     25-27    27-29    472         19.5      3.24415     ALBANY 94M S   VELOSTAR      380    200     25-27    27-29    631         21.4      4.03616     ASTEN 937 S    ASTEN 934     380    200     25-27    27-29    535         20.9      3.93317     VELOSTAR 800W  ASTEN 934     380    200     25-27    27-29    427         16.3      3.90118     ASTEN 934 S    ASTEN 934     380    200     25-27    27-29    530         21.3      4.20619     ALBANY 94M S   VELOSTAR      380    200     25-27    27-29    600         20.8      4.75420     ALBANT 94M S   VELOSTAR      380    200     25-27    27-29    708         18.7      5.970
                             表1(续)CD          CD                                       PAHEL    MOTENSILE     TENSILE     ·          BASIS  CALIPER  BULK   STIFF   STIFFSTRENGTH    STRETCH    GHT    WT                             FACTOR557         8.5        657    29.2    287     9.8     4.1    86529         5.4        618    28.7    323     11.2    4.0    83563         5.0        633    28.8    323     11.2    4.1    86534         8.2        654    28.9    305     10.5    4.6    90629         6.9        725    30.2    305     10.1    4.7    91632         3.9        753    29.3    287     9.8     4.5    95571         6.9        682    28.9    297     10.3    4.5    96623         6.4        724    28.7    292     10.2    4.7    97638         7.2        744    29.7    297     10.0    4.6    98511         5.3        607    28.3    361     12.7    3.5    89577         7.9        687    29.1    312     10.7    4.2    96503         5.2        598    28.9    348     12.0    4.0    92428         8.3        477    20.7    249     12.0    3.5    55324         6.0        391    19.6    315     16.0    3.4    58356         11.2       474    19.8    269     13.5    3.4    66383         5.8        453    20.1    325     16.1    3.8    71306         14.8       362    19.6    330     16.8    3.4    71299         9.4        398    19.9    335     16.8    3.2    77415         4.5        499    20.0    287     14.3    3.8    81494         8.6        591    38.0    388     10.1    3.2    83
现在参考图5-10，将对本发明各方面进行更详细的描述。
图5为薄页纸负载/伸长率综合曲线，用来说明如何确定MD MaxSlope。如图5所示，选择在负载/伸长率曲线上的两点P1和P2，为说明起见，两点间的距离被放大。设定抗张测试仪的程序(GAP[普通的应用程序]，2.5版本，Systems Integration TechnologyInc.，Stoughton，MA；MTS Systems Corporation的分部，ResearchTriangle Park，NC)，以便计算取样的点P1-P2的线性回归。通过沿曲线进行有规律的调整点P1和P2，在曲线上重复做这种计算(后面描述)。这些计算的最高值即最大斜率，并且，当在样品的纵向进行计算时，被称为MD最大斜率。
应设置抗张测试仪程序，以便在伸长2吋半(63.5mm)的间距上能取500个如P1和P2的点。这提供了足以基本上超过试样实际伸长的点数。当利用10吋/分(2.54mm/min)的十字速度时，每0.030秒将转换成一个点。通过设定第10个点为起始点(例如P1)，计数30个点至第40个点(例如P2)，并对这三十个点进行线性回归，该程序计算这些点中的斜率。该程序以阵列(array)的形式存储该回归的斜率。然后该程序往上数10个点至第20个点(即为P1)，并再以重复上述步骤(计数30个点至第50个点(P2)，计算斜率并也以阵列形式存储斜率)。在纸页整个伸长过程中连续执行该过程。然后从该阵列中选出最高值作为最大斜率。最大斜率的单位是Kg/3吋试样宽。(由于伸长的长度除以夹板间距的长度，因此，应力当然是无单位的。该计算是由测试仪程序实现的。)。
图6为根据本发明制得的浴巾纸(分别以点a-t作图的实施例1-20)和许多市售起皱浴巾纸的松厚度对平板挺度的图表；市售产品以表示单层产品的“1”，表示双层产品的“2”和表示三层产品的“3”来作图。该图表表明，本发明产品具有独特的高松厚度和低挺度的结合。
图7是对同样的产品的平板挺度对MD最大斜率的图表，用来说明MD最大斜率与由顺序排列的灵敏板测得的挺度的关系。该图表表明，MD最大斜率是平板挺度的客观量度。
图8是对同样的产品的松厚度对MD最大斜率的图表，用来说明本发明产品显示出高松厚度和低挺度(由MD最大斜率测量的)的结合。
图9是类似于图7的图表，所不同的是，用平板挺度对MD挺度因子而不是MD最大斜率进行作图，它是用来说明，MD挺度因子也是挺度的有效量度。
图10是类似于图8、用松厚度对MD挺度因子进行作图的图表，用来说明，本发明产品显示出高松厚度和低挺度(由MD挺度因子测得)的结合。
应该明白的是，前述的实施例只是用来解释本发明，而不应理解为对本发明范围的限定，本发明的范围由下面的权利要求书及其所有的等同物来限定。

Claims (40)

1.一种柔软薄页纸产品，它包含一层或多层薄页纸层，并且具有约9cm3/g或更大的松厚度，MD最大斜率约为10或更小。
2.权利要求1的产品，其松厚度为约9-20cm3/g 。
3.权利要求1的产品，其松厚度为约10-15cm3/g。
4.权利要求1的产品，其MD最大斜率为约5或更小。
5.权利要求1的产品，其MD最大斜率为约3-6。
6.一种柔软薄页纸产品，它包含一层或多层不起皱穿透干燥薄页纸层，并具有约10或更小的MD最大斜率。
7.权利要求6的产品，其松厚度为约6cm3/g或更大。
8.权利要求6的产品，其纵向伸长率为约10％或更大。
9.权利要求6的产品，其纵向伸长率为约15-25％。
10.权利要求6的产品，其有一层不起皱穿透干燥层。
11.权利要求6的产品，有两层不起皱穿透干燥层。
12.权利要求6的产品，有三层不起皱穿透干燥层。
13.权利要求6的产品，有四层不起皱穿透干燥层。
14.权利要求6的产品，其中所说的层中具有两层或多层，至少一层为面朝外的层，并含约20％或更多的卷曲纤维。
15.权利要求6的产品，其中所说的层中具有两层或多层，至少一层为面朝外的层，并含约80％或更多的卷曲纤维。
16.一种柔软薄页纸产品，含一层或多层薄页纸层，并具有约9cm3/g或更大的松厚度，MD挺度因子约为150或更小。
17.权利要求16的产品，其松厚度为约9-20cm3/g。
18.权利要求16的产品，其松厚度为约10-15cm3/g。
19.权利要求16的产品，其MD挺度因子为约100或更小。
20.权利要求16的产品，其MD挺度因子为约50至100。
21.一种柔软薄页纸产品，它包含一层或多层不起皱穿透干燥薄页纸层，并具有约150或更小的MD挺度因子。
22.权利要求21的产品，其松厚度为约6cm3/g或更大。
23.权利要求21的产品，其纵向伸长率为约10％或更大。
24.权利要求21的产品，纵向伸长率为约15-25％。
25.权利要求21的产品，含一层不起皱穿透干燥层。
26.权利要求21的产品，含两层不起皱穿透干燥层。
27.权利要求21的产品，含三层不起皱穿透干燥层。
28.权利要求21的产品，含四层不起皱穿透干燥层。
29.权利要求21的产品，其中所述的层有两层或多层，至少一层为面朝外的层，并含约20％或更多的卷曲纤维。
30.权利要求21的产品，其中所述的层有两层或多层，至少一层为面朝外的层，并含约80％或更多卷曲的纤维。
31.一种柔软的单层浴巾纸，它包含有成层的、不起皱的、穿透干燥薄页纸，该纸页有含约80％(重量)或更多卷曲桉树属纤维的空气面层，以及含约80％(重量)或更多卷曲桉树属纤维的织物面层，所述的薄页纸的松厚度为约9-20cm3/g，MD挺度因子为约50-100，纵向伸长率为约10-25％。
32.一种柔软薄页纸产品的制备方法，该方法包括
(a)形成约20％或更高浓度的造纸纤维的水悬浮液；
(b)在约140°F或更高温度下，利用约1马力-日/吨干纤维或更大的功率输入对所述水悬浮液进行机械处理，从而使纤维卷曲；
(c)将卷曲纤维的水悬浮液稀释至约0.5％或更低的浓度，并将该稀释的悬浮液送至制造薄页纸的网前箱；
(d)将该稀释的造纸纤维水悬浮液沉积在成形网上，以形成湿纸幅；
(e)将湿纸幅脱水至约20-30％的浓度；
(f)将脱水的纸幅从成形网递至运行速度比成形网慢约10-80％的递纸织物上；
(g)将纸幅递至穿透干燥合成网上，借此，将纸幅宏观重排，以与穿透干燥合成网的表面相一致；和
(h)将纸幅穿透干燥至最终干度。
33.权利要求32的方法，其中，在纤维通过磨浆机时，通过机械处理而使之卷曲。
34.权利要求32的方法，其中，用化学柔软剂对纤维进行表面处理。
35.权利要求32的方法，其中，卷曲的纤维为桉树属纤维。
36.权利要求32的方法，其中以多层纸幅的一层或两层，将卷曲的纤维沉积在成形网上。
37.权利要求36的方法，其中，纸幅含一内层和两个外层，至少一外层含卷曲纤维。
38.权利要求37的方法，其中，两外层均含卷曲纤维。
39.权利要求32的方法，其中，纸幅中的所有纤维均经如步骤(b)所述的机械处理。
40.权利要求32的方法，其中将卷曲的纤维作为纸幅的空气面层和织物面层而沉积在成形网上。
CN94193014A 1993-06-24 1994-05-27 柔软薄页纸及其制备方法 Expired - Lifetime CN1048060C (zh)

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CA2103342A1 (en) 1994-12-25
AU696805B2 (en) 1998-09-17
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AU7243894A (en) 1995-01-17
DE69406502T2 (de) 1998-03-26
AU4517897A (en) 1998-02-12
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US5932068A (en) 1999-08-03
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US20030089475A1 (en) 2003-05-15
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US7156954B2 (en) 2007-01-02
CA2103342C (en) 2006-10-03
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