Tissue products having enhanced strength
A tissue product containing a multi-layered paper web that has at least one outer layer formed from a blend of pulp fibers and synthetic fibers is provided. A polymer latex is also applied to the outer layer of the tissue product. It is believed that the polymer latex and synthetic fibers can fuse together to have a synergistic effect on the strength of the tissue product. In addition, the resulting tissue product can be soft and produce low levels of lint and slough.
1. A method for forming a tissue product, said method comprising;
forming a multi-layered paper web that includes at least one outer layer, wherein said outer layer comprises a blend of pulp fibers and synthetic fibers in an amount from about 0.1% to about 20% by weight of said layer so that the total amount of synthetic fibers present within said web is from about 0.1% to about 20% by weight;
drying said multi-layered paper web; and
applying a polymer latex to said outer layer;
wherein said multi-layered paper web is uncreped.
2. A method as defined in claim 1 , wherein said polymer latex has a glass transition temperature of from about −25° C. to about 30° C.
3. A method as defined in claim 1 , wherein said polymer latex comprises from about 0.1% to about 10% of the dry weight of said web.
4. A method as defined in claim 1 , wherein said multi-layered web is through-dried.
5. A method as defined in claim 1 , wherein the total amount of synthetic fibers present within said web is from about 0.1% to about 10% by weight.
6. A method as defined in claim 1 , wherein said web is dried at a temperature that is greater than or equal to the melting point of one or more components of said synthetic fibers.
7. A method as defined in claim 1 , wherein said web is dried at a temperature that is less than the melting point of one or more components of said synthetic fibers.
8. A method as defined in claim 1 , wherein the tissue product has a wet-to-dry tensile strength ratio in the cross-direction of about 0.20 or more.
9. A method as defined in claim 1 , wherein the tissue product has a wet-to-dry tensile strength ratio in the cross-direction of about 0.30 or more.
10. A method as defined in claim 1 , wherein the tissue product has a wet-to-dry tensile strength ratio in the cross-direction of about 0.40 or more.
11. A method as defined in claim 1 , wherein the polymer latex is printed onto said outer layer.
12. A method as defined in claim 11 , wherein said polymer latex is cured at a temperature above or equal to the melting point of one or more components of said synthetic fibers.
13. A method as defined in claim 1 , further comprising curing said polymer latex.
14. A method as defined in claim 1 , wherein said synthetic fibers are multicomponent fibers.
15. A method as defined in claim 1 , wherein said polymer latex comprises from about 0.1% to about 7% of the dry weight of said web.
16. A method as defined in claim 1 , wherein said polymer latex is selected from the group consisting of styrene-butadiene copolymers, polyvinyl acetate homopolymers, vinyl-acetate ethylene copolymers, vinyl-acetate acrylic copolymers, ethylene-vinyl chloride copolymers, ethylene-vinyl chloride-vinyl acetate terpolymers, acrylic polyvinyl chloride polymers, acrylic polymers, and nitrile polymers.
17. A method as defined in claim 1 , wherein said paper web further comprises a debonder.
18. A method as defined in claim 1 , wherein said synthetic fibers have a density imbalance of from about −0.2 to about +0.5 grams per cubic centimeter.
19. A method as defined in claim 1 , wherein said synthetic fibers have a density imbalance of from about −0.2 to about +0.4 grams per cubic centimeter.
20. A method as defined in claim 1 , wherein said synthetic fibers have a density imbalance of from about −0.1 to about +0.4 grams per cubic centimeter.
21. A method as defined in claim 1 , wherein said multi-layered web forms a first ply of the tissue product.
22. A method as defined in claim 21 , wherein a second ply is positioned adjacent to said first ply.
23. A method for forming a tissue product, said method comprising;
forming a multi-layered paper web that includes at least one outer layer, wherein said outer layer comprises a blend of pulp fibers and synthetic multicomponent fibers in an amount from about 0.1% to about 20% by weight of said layer so that the total amount of synthetic multicomponent fibers present within said web is from about 0.1% to about 20% by weight, wherein said synthetic multicomponent fibers have a density imbalance of from about −0.2 to about +0.5 grams per cubic centimeter;
through-drying said multi-layered paper web; and
thereafter, printing a polymer latex onto said outer layer, said polymer latex having a glass transition temperature of from about −25° C. to about 30° C.;
wherein said multi-layered paper web is uncreped.
24. A method as defined in claim 23 , wherein said polymer latex comprises from about 0.1% to about 10% of the dry weight of said web.
25. A method as defined in claim 23 , wherein the total amount of synthetic multicomponent fibers present within said web is from about 0.1% to about 10% by weight.
26. A method as defined in claim 23 , wherein said web is dried at a temperature that is greater than or equal to the melting point of one or more components of said synthetic fibers.
27. A method as defined in claim 23 , wherein said web is dried at a temperature that is less than the melting point of one or more components of said synthetic fibers.
28. A method as defined in claim 23 , wherein the tissue product has a wet-to-dry tensile strength ratio in the cross-direction of about 0.20 or more.
29. A method as defined in claim 23 , wherein the tissue product has a wet-to-dry tensile strength ratio in the cross-direction of about 0.30 or more.
30. A method as defined in claim 23 , wherein the tissue product has a wet-to-dry tensile strength ratio in the cross-direction of about 0.40 or more.
31. A method as defined in claim 23 , further comprising curing said polymer latex.
32. A method as defined in claim 31 , wherein said polymer latex is cured at a temperature above or equal to the melting point of one or more components of said synthetic fibers.
33. A method as defined in claim 23 , wherein said synthetic fibers have a density imbalance of from about −0.2 to about +0.4,grams per cubic centimeter.
34. A method as defined in claim 23 , wherein said synthetic fibers have a density imbalance of from about −0.1 to about +0.4 grams per cubic centimeter.
35. A method as defined in claim 23 , wherein said multi-layered web forms a first ply of the tissue product.
36. A method as defined in claim 35 , wherein a second ply is positioned adjacent to said first ply.
37. A method for forming a tissue product, said method comprising;
forming a multi-layered paper web that includes at least one outer layer, wherein said outer layer comprises a blend of pulp fibers and synthetic bicomponent fibers in an amount from about 0.1% to about 10% by weight of said layer so that the total amount of synthetic bicomponent fibers present within said web is from about 0.1% to about 10% by weight, wherein said synthetic bicomponent fibers have a density imbalance of from about −0.2 to about +0.5 grams per cubic centimeter;
through-drying said multi-layered paper web; and
thereafter, applying a polymer latex to said outer layer, said polymer latex having a glass transition temperature of from about −25° C. to about 30° C.;
wherein said multi-layered paper web is uncreped.
38. A method as defined in claim 37 , wherein said web is dried at a temperature that is greater than or equal to the melting point of one or more components of said synthetic fibers.
39. A method as defined in claim 37 , wherein said web is dried at a temperature that is less than the melting point of one or more components of said synthetic fibers.
40. A method as defined in claim 37 , wherein the tissue product has a wet-to-dry tensile strength ratio in the cross-direction of about 0.20 or more.
41. A method as defined in claim 37 , wherein the tissue product has a wet-to-dry tensile strength ratio in the cross-direction of about 0.30 or more.
42. A method as defined in claim 37 , wherein the tissue product has a wet-to-dry tensile strength ratio in the cross-direction of about 0.40 or more.
43. A method as defined in claim 37 , further comprising curing said polymer latex.
44. A method as defined in claim 43 , wherein said polymer latex is cured at a temperature above or equal to the melting point of one or more components of said synthetic fibers.
45. A method as defined in claim 37 , wherein said synthetic fibers have a density imbalance of from about −0.2 to about +0.4 grams per cubic centimeter.
46. A method as defined in claim 37 , wherein said synthetic fibers have a density imbalance of from about −0.1 to about +0.4 grams per cubic centimeter.