Soft bulky multi-ply product and method of making the same
An ultra soft, bulky, multi-ply tissue having low overall sidedness and a geometric mean tensile strength of less than about 800 g/3″ wherein an embossed ply has a TMI sidedness of at least about 0.45 and an embossed area of at least about 2%, which is capable of being made from non-premium furnish, and method for making such products are disclosed. An ultra soft, bulky, multi-ply tissue having low overall sidedness and a geometric mean tensile strength of less than about 35 g/3″ per lb. of basis weight wherein an embossed ply has a TMI sidedness of at least about 0.45 and an embossed area of at least about 2%, which is capable of being made from non-premium furnish, and method for making such products are also disclosed.
1. A method for making an ultra soft high basis weight multi-ply tissue product comprising:
(a) providing a fibrous pulp furnish;
(b) forming a first nascent web from said furnish;
(c) forming a second nascent web from said furnish;
(d) embossing at least one of said webs between a pair of embossing rolls;
(e) combining said first web with said second web to form a multi-ply web;
(f) optionally calendering said embossed multi-ply web; and
wherein steps (a)-(f) are controlled to produce a multi-ply tissue product, the first embossed ply having a TMI sidedness of at least about 0.45 and an embossed area of at least about 2%, wherein the multi-ply tissue product exhibits an overall TMI sidedness of less than about 0.6 and a geometric mean tensile strength of less than about 800 g/3″.
2. The method of claim 1 , wherein the outer surface of said multi-ply web is substantially free of protrusions resulting from said embossing in step (d).
3. The method of claim 1 , wherein said first web further comprises at least about 1 lb of a cationic nitrogenous softener/ton of furnish.
4. The method of claim 3 , wherein the softener is a trivalent cationic organic nitrogen compound incorporating long fatty acid chains, a tetravalent organic nitrogen compound incorporating long fatty acid chains, an imidazoline, an amino acid salt, a linear amine amide, a tetravalent quaternary ammonium salt, a quatenary ammonium salt, an amido amine salt derived from a partially neutralized amine, or any combination thereof.
5. The method of claim 3 , wherein from about 0.5 lb. softener to about 10 lbs. softener/ton of furnish is added.
6. The method of claim 3 , wherein the softener is included in the fibrous pulp furnish prior to web formation or applied to the web after formation, or both.
7. The method of claim 1 , wherein at least one of said plies is biaxially undulatory.
8. The method of claim 1 , wherein said fibrous pulp furnish comprises a coarseness in excess of about 11 grams per hundred meters.
9. The method of claim 1 , wherein said furnish comprises from about 30% to about 85% of a first fiber having a coarseness of about 15 mg/100 m or less and a fiber length of from about 0.8 mm to about 1.8 mm and from about 15% to about 70% of a second fiber having a coarseness of about 35 mg/100 m or less and a fiber length of at least about 2.0 mm.
10. The method of claim 1 , wherein said first fiber comprises a coarseness of about 13.5 mg/100 m or less and a fiber length of from about 0.8 mm to about 1.4 mm and said second fiber comprises a coarseness of not more than about 35 mg/100 m and a fiber length of at least about 2.2 mm.
11. The method of claim 1 , wherein said first fiber comprises a coarseness of about 12 mg/100 m or less and a fiber length of from about 0.8 mm to about 1.2 mm and said second fiber comprises a coarseness of no more than about 25 mg/100 m and a fiber length of at least about 2.5 mm.
12. The method of claim 1 , wherein said first and second webs are combined by knurling.
13. The method of claim 12 , wherein at least one of said plies is biaxially undulatory.
14. The method of claim 1 , wherein said furnish includes a temporary wet strength adjusting agent resulting in a Finch Cup cross-direction wet tensile of at least about 40 g/3 inches.
15. The method of claim 14 , wherein the temporary wet strength agent is an aliphatic aldehyde, aromatic aldehyde, a polymeric reaction product of a monomer or polymer having an aldehyde group and optionally a nitrogen group, or any combination thereof.
16. The method of claim 14 , wherein the temporary wet strength agent is glyoxal, malonic dialdehyde, succinic dialdehyde, glutaraldehyde, dialdehyde starch, a cyclic urea containing an aldehyde moiety, a polyol containing aldehyde moiety, a reaction product of an aldehyde containing monomer or polymer and a vinyl-amide or acrylamide polymer, a glyoxylated acrylamide polymer or glyoxylated vinyl-amide or mixtures thereof.
17. The method of claim 1 , wherein said furnish includes an amount of temporary wet strength adjusting agent resulting in a wet/dry ratio of at least about 10%.
18. The method of claim 1 , wherein the furnish contains at least one of recycled and nonwoody fibers in an amount of less than about 70% of the total furnish.
19. The method of claim 1 , wherein the basis weight of said first nascent web is at least about 10 lbs/3000 sq. ft. ream.
20. The method of claim 1 , wherein the multi-ply tissue has a specific caliper after embossing and optional calendering of from about 2.5 to about 5 mils/8 plies/lb. basis weight.
21. The method of claim 1 , wherein said emboss comprises a micro and macro emboss pattern which covers less than about 30% of the embossed web.
22. The method of claim 1 , wherein said multi-ply tissue has a GM tensile strength of from about 21 g to about 35 g/3″ width per lb. of basis weight.
23. The method of claim 1 , wherein each of said first and second webs are calendered individually.
24. The method of claim 1 , wherein said multi-ply web is calendered.
25. The method of claim 1 , wherein at least one of said first and second nascent webs are stratified.
26. The method of claim 1 , wherein said first and second nascent webs are homogenous.
27. The method of claim 1 , wherein said multi-ply tissue comprises more than two plies.
28. The method of claim 1 , wherein the TMI sidedness of the second ply differs from that of the first by at least about 0.1.
29. The method of claim 1 , wherein the embossed area of the first ply is at least about 4%.
30. The method of claim 1 , wherein the TMI sidedness of the second ply differs from that of the first by at least about 0.15.
31. The method of claim 1 , wherein the embossed area of the first ply is at least about 8%.
32. A method for making an ultra soft high basis weight multi-ply tissue product comprising:
(a) providing a fibrous pulp furnish;
(b) forming a first nascent web from said furnish;
(c) forming a second nascent web from said furnish;
(d) embossing at least one of said webs between a pair of embossing rolls;
(e) combining said first web with said second web to form a multi-ply web;
(f) optionally calendering said embossed multi-ply web; and
wherein steps (a)-(f) are controlled to produce a multi-ply tissue product, the first embossed ply having a TMI sidedness of at least about 0.45 and an embossed area of at least about 2%, wherein the multi-ply tissue product exhibits an overall TMI sidedness of less than about 0.6 and a geometric mean tensile strength of less than about 35 g/3″ per lb. of basis weight.
33. The method of claim 32 , wherein the outer surface of said multi-ply web is substantially free of protrusions resulting from said embossing in step (d).
34. The method of claim 32 , wherein said first web further comprises at least about 1 lb of a cationic nitrogenous softener/ton of furnish.
35. The method of claim 34 , wherein the softener is a trivalent cationic organic nitrogen compound incorporating long fatty acid chains, a tetravalent organic nitrogen compound incorporating long fatty acid chains, an imidazoline, an amino acid salt, a linear amine amide, a tetravalent quaternary ammonium salt, a quatenary ammonium salt, an amido amine salt derived from a partially neutralized amine, or any combination thereof.
36. The method of claim 34 , wherein from about 0.5 lb. softener to about 10 lbs. softener/ton of furnish is added.
37. The method of claim 34 , wherein the softener is included in the fibrous pulp furnish prior to web formation or applied to the web after formation, or both.
38. The method of claim 32 , wherein at least one of said plies is biaxially undulatory.
39. The method of claim 32 , wherein said fibrous pulp furnish comprises a coarseness in excess of about 11 grams per hundred meters.
40. The method of claim 32 , wherein said furnish comprises from about 30% to about 85% of a first fiber having a coarseness of about 15 mg/100 m or less and a fiber length of from about 0.8 mm to about 1.8 mm and from about 15% to about 70% of a second fiber having a coarseness of about 35 mg/100 m or less and a fiber length of at least about 2.0 mm.
41. The method of claim 32 , wherein said first fiber comprises a coarseness of about 13.5 mg/100 m or less and a fiber length of from about 0.8 mm to about 1.4 mm and said second fiber comprises a coarseness of not more than about 35 mg/100 m and a fiber length of at least about 2.2 mm.
42. The method of claim 32 , wherein said first fiber comprises a coarseness of about 12 mg/100 m or less and a fiber length of from about 0.8 mm to about 1.2 mm and said second fiber comprises a coarseness of no more than about 25 mg/100 m and a fiber length of at least about 2.5 mm.
43. The method of claim 32 , wherein said first and second webs are combined by knurling.
44. The method of claim 43 , wherein said knurling comprises embossing together less than about 10% of the web area located at the edges of the first and second webs.
45. The method of claim 32 , wherein said furnish includes a temporary wet strength adjusting agent resulting in a Finch Cup cross-direction wet tensile of at least about 40 g/3 inches.
46. The method of claim 45 , wherein the temporary wet strength agent is an aliphatic aldehyde, aromatic aldehyde, a polymeric reaction product of a monomer or polymer having an aldehyde group and optionally a nitrogen group, or any combination thereof.
47. The method of claim 45 , wherein the temporary wet strength agent is glyoxal, malonic dialdehyde, succinic dialdehyde, glutaraldehyde, dialdehyde starch, a cyclic urea containing an aldehyde moiety, a polyol containing aldehyde moiety, a reaction product of an aldehyde containing monomer or polymer and a vinyl-amide or acrylamide polymer, a glyoxylated acrylamide polymer or glyoxylated vinyl-amide or mixtures thereof.
48. The method of claim 32 , wherein said furnish includes an amount of temporary wet strength adjusting agent resulting in a wet/dry ratio of at least about 10%.
49. The method of claim 32 , wherein the furnish contains at least one of recycled and nonwoody fibers in an amount of less than about 70% of the total furnish.
50. The method of claim 32 , wherein the basis weight of said first nascent web is at least about 10 lbs/3000 sq. ft. ream.
51. The method of claim 32 , wherein the multi-ply tissue has a specific caliper after embossing and optional calendering of from about 2.5 to about 5 mils/8 plies/lb. basis weight.
52. The method of claim 32 , wherein said emboss comprises a micro and macro emboss pattern which covers less than about 30% of the embossed web.
53. The method of claim 32 , wherein said multi-ply tissue has a GM tensile strength of from about 21 g to about 35 g/3″ width per lb. of basis weight.
54. The method of claim 32 , wherein each of said first and second webs are calendered individually.
55. The method of claim 32 , wherein said multi-ply web is calendered.
56. The method of claim 32 , wherein at least one of said first and second nascent webs are stratified.
57. The method of claim 32 , wherein said first and second nascent webs are homogenous.
58. The method of claim 32 , wherein said multi-ply tissue comprises more than two plies.
59. The method of claim 32 , wherein the TMI sidedness of the second ply differs from that of the first by at least about 0.1.
60. The method of claim 32 , wherein the embossed area of the first ply is at least about 4%.
61. The method of claim 32 , wherein the TMI sidedness of the second ply differs from that of the first by at least about 0.15.
62. The method of claim 32 , wherein the embossed area of the first ply is at least about 8%.